Case 21E 121E 221E 321E Compact Wheel Loader Operator's Manual 87647835 - PDF DOWNLOAD

OPERATOR’S MANUAL COMPACT WHEEL LOADER

21E 121E 221E 321E

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Bur • Issued 11-2006 (Revised 03-2007) Printed in U.S.A. • Book/Form Number 87647835 NA Copyright © 2007. CNH America, LLC. All Rights Reserved.

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

11-2006

21E, 121E, 221E, 321E

87612154 NA

Revision 1

03-2007

21E, 121E, 221E, 321E

87647835 NA

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 that, if not avoided, will result in death or serious injury.

The color associated with Danger is RED. · WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or 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. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: · The first panel indicates the nature of the hazard. · The second panel indicates the appropriate avoidance of the hazard. · Background color is YELLOW · Prohibition symbols such as and STOP if used, are RED.

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 instructions on machine operation and maintenance.

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine.

Contact your Dealer for assistance in obtaining the manuals for your machine. Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and maintenance records.

Always give the Machine Name, Model, and P. I.N. (Product Identification Number) or S. N. (Serial Number) of your machine so your Dealer can provide the correct manuals for your machine.

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America, LLC. Racine, WI 53403 U.S.A..

SAFETY INFORMATIONS

S

This warning symbol points out important messages involving your safety.

Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and to safeguard your safety and personal integrity.

In this manual you will find this symbol together with the following key-words:

S WARNING S This symbol warns about the possibility of potential damages to the machine that can involve the operator’s safety.

S DANGER S With specific warnings about potential dangers for the operator’s or other persons integrity directly or indirectly involved.

The non compliance with the warning preceded by the above mentioned key-words (WARNING and DANGER) can cause serious accidents or even the death of the persons involved.

Moreover in the present Manual have been given some instructions with texts in italics, preceded by the words NOTE and CAUTION, with following meanings to protect the machine: NOTE: it emphasizes and underlines to the operator the correct technique or correct procedure to follow.

S CAUTION S It warns the operator of a possible hazard of machine damage in case he does not follow a determined procedure.

INDEX SECTION 1 INTRODUCTION, SAFETY, PLATES AND DECALS ................................................................................. 1-1 INTRODUCTION ....................................................................................................................................... 1-1 SAFETY INSTRUCTIONS ......................................................................................................................... 1-2 GENERAL SAFETY INSTRUCTIONS.................................................................................................... 1-2 BEFORE OPERATING THE MACHINE ................................................................................................. 1-3 OPERATING THE MACHINE ................................................................................................................. 1-5 PARKING THE MACHINE ...................................................................................................................... 1-8 MAINTENANCE AND ADJUSTMENTS.................................................................................................. 1-8 PREVENTION OF FIRE OR EXPLOSIONS......................................................................................... 1-10 PREVENTION OF BURNS ................................................................................................................... 1-11 PREVENTION OF RISKS ASSOCIATED WITH VIBRATIONS............................................................ 1-12 PRECAUTION FOR WASTE DISPOSAL ............................................................................................. 1-13 COMPONENTS IDENTIFICATION PLATES........................................................................................... 1-14 MAIN COMPONENTS ............................................................................................................................. 1-17 DECALS................................................................................................................................................... 1-18 NOISE LEVEL DECAL ......................................................................................................................... 1-18 POSITION OF DECALS ....................................................................................................................... 1-19 HAND SIGNALS ...................................................................................................................................... 1-26

SECTION 2 CONTROLS AND INSTRUMENTS .............................................................................................................. 2-1 CONTROLS AND INSTRUMENTS ........................................................................................................... 2-1 INSTRUMENTS AND PILOT LAMPS..................................................................................................... 2-4 CAB............................................................................................................................................................ 2-6 OPERATOR’S COMPARTMENT CONTROLS ....................................................................................... 2-11 IGNITION KEY...................................................................................................................................... 2-11 HEATING .............................................................................................................................................. 2-11 AIR CONDITIONING (OPTIONAL)....................................................................................................... 2-12 TURN SIGNALS, MAIN BEAMS, FRONT SCREEN WIPER/WASHER CONTROL LEVERS AND HORN ........................................................................................................................... 2-13 TRAVEL/WORK CONTROL LEVER .................................................................................................... 2-16 BUCKET CONTROL LEVER ................................................................................................................ 2-16 BRAKING AND STOPPING ................................................................................................................. 2-18 STEERING COLUMN - ADJUSTMENT................................................................................................ 2-19 OPERATOR’S SEAT ............................................................................................................................... 2-20 SEAT BELT.............................................................................................................................................. 2-22 OPTIONAL CONTROLS.......................................................................................................................... 2-23 FRONT/REAR WORKING FLOODLAMP............................................................................................ 2-23 ROTARY BEACON............................................................................................................................... 2-23 REVERSING ACOUSTIC SIGNAL ....................................................................................................... 2-24 LOAD STABILIZATION SYSTEM......................................................................................................... 2-24 BATTERY MAIN SWITCH .................................................................................................................... 2-25

SECTION 3 OPERATING THE MACHINE....................................................................................................................... 3-1 GENERAL INSTRUCTIONS...................................................................................................................... 3-1 BEFORE OPERATING THE MACHINE ................................................................................................. 3-1

INDEX OPERATING THE MACHINE ................................................................................................................. 3-1 RUNNING-IN PERIOD ........................................................................................................................... 3-2 AFTER DAILY OPERATION - PARKING ............................................................................................... 3-3 STARTING................................................................................................................................................. 3-4 TRAVEL ..................................................................................................................................................... 3-8 BEFORE STARTING THE TRAVEL....................................................................................................... 3-8 START UP .............................................................................................................................................. 3-8 WORKING SPEED - CREEP SPEED .................................................................................................... 3-9 OVERDRIVE (OPTIONAL) ................................................................................................................... 3-10 TRAVEL ON PUBLIC HIGHWAY ............................................................................................................ 3-11 MACHINE OUTFIT FOR TRAVEL ON PUBLIC HIGHWAYS............................................................... 3-12 OPERATING THE MACHINE WITH COLD WEATHER.......................................................................... 3-13 OPERATING THE MACHINE WITH HOT WEATHER ............................................................................ 3-14 TOWING .................................................................................................................................................. 3-15 TRANSPORT........................................................................................................................................... 3-17 WORKING EQUIPMENT ......................................................................................................................... 3-19 QUICK COUPLER ................................................................................................................................ 3-20 BUCKETS TEETH - CHANGE ............................................................................................................. 3-22

SECTION 4 REFILLINGS AND SERVICING ................................................................................................................... 4-1 REFILLING QUANTITIES TABLE ............................................................................................................. 4-1 FUEL....................................................................................................................................................... 4-2 HYDRAULIC OIL .................................................................................................................................... 4-3 SAFETY INSTRUCTIONS ......................................................................................................................... 4-4 SERVICING INTERVALS CHART............................................................................................................. 4-9 HOURMETER....................................................................................................................................... 4-11 CHECKS BEFORE START-UP AND BEFORE EACH WORKING SHIFT (10 HOURS) ........................ 4-12 MACHINE GENERAL INSPECTION .................................................................................................... 4-12 SERVICE AND PARKING BRAKES..................................................................................................... 4-12 LIGHTS................................................................................................................................................. 4-12 CONTROLS AND PILOT LIGHTS OPERATION.................................................................................. 4-12 ENGINE OIL - LEVEL........................................................................................................................... 4-13 HYDRAULIC OIL RESERVOIR - LEVEL.............................................................................................. 4-13 FUEL TANK - LEVEL............................................................................................................................ 4-14 COOLANT - LEVEL .............................................................................................................................. 4-15 SCREEN WASHER LIQUID - LEVEL................................................................................................... 4-16 WEEKLY SERVICE (50 HOURS)............................................................................................................ 4-17 CAB BREATHER FILTER - CLEANING ............................................................................................... 4-17 AIR FILTER - CLEANING..................................................................................................................... 4-17 DRIVE BELT - CHECK ......................................................................................................................... 4-21 HYDRAULIC SYSTEM RETURN OIL FILTER - PRESSURE CHECK................................................. 4-22 FRONT AND REAR AXLE - OIL LEVEL CHECK ................................................................................. 4-22 TYRES - PRESSURE CHECK ............................................................................................................. 4-24 WHEELS - NUTS TIGHTENING .......................................................................................................... 4-28 GREASE NIPPLES - GREASING ........................................................................................................ 4-28 ELECTRICAL SYSTEM - VOLTAGE AND CONTINUITY CHECK ...................................................... 4-31 MONTHLY SERVICE (250 HOURS) ....................................................................................................... 4-32 REAR AXLE - GREASING ................................................................................................................... 4-32 HEATING/AIR CONDITIONING SYSTEM ........................................................................................... 4-33

INDEX SERVICE AFTER 1000 HOURS ............................................................................................................. 4-35 CAB BREATHER FILTER - CHANGE .................................................................................................. 4-35 ENGINE OIL - CHANGE....................................................................................................................... 4-36 ENGINE OIL FILTER - CHANGE ......................................................................................................... 4-37 ENGINE VALVES CLEARANCE - CHECK/ADJUSTMENT ................................................................. 4-38 FUEL FILTER - CHANGE..................................................................................................................... 4-40 AIR INTAKE SYSTEM - CHECK .......................................................................................................... 4-41 AIR FILTER - CHANGE ........................................................................................................................ 4-41 HYDRAULIC SYSTEM RETURN OIL FILTER - CHANGE................................................................... 4-43 HYDRAULIC SYSTEM BREATHER FILTER - CHANGE..................................................................... 4-44 BRAKE - PRESSURE CHECK ............................................................................................................. 4-44 ACCUMULATOR - PRESSURE CHECK.............................................................................................. 4-46 AXLES - DISCS THICKNESS CHECK ................................................................................................. 4-48 BATTERIES - LEVEL CHECK - CLAMPS CHARGE CHECK .............................................................. 4-49 HEATING SYSTEM FILTER - CHANGE .............................................................................................. 4-50 FRONT AXLE - OIL CHANGE .............................................................................................................. 4-51 REAR AXLE - OIL CHANGE ................................................................................................................ 4-51 SERVICE AFTER 3000 HOURS ............................................................................................................. 4-53 FUEL TANK - CLEANING .................................................................................................................... 4-53 HYDRAULIC OIL RESERVOIR - CLEANING AND OIL CHANGE....................................................... 4-54 DIESEL ENGINE - CLEANING................................................................................................................ 4-55 SERVICE IF NECESSARY...................................................................................................................... 4-56 TYRES - CHANGE ............................................................................................................................... 4-56 CONNECTORS AND HYDRAULIC HOSES - CHANGE...................................................................... 4-57 FUSES .................................................................................................................................................. 4-58 RELAYS................................................................................................................................................ 4-60 BULBS - REPLACEMENT .................................................................................................................... 4-61 ROTARY BEACON............................................................................................................................... 4-64 BRAKES SYSTEM - AIR BLEEDING ................................................................................................... 4-65 BATTERIES - REPLACEMENT............................................................................................................ 4-66 INJECTORS - REPLACEMENT ........................................................................................................... 4-67 BUCKETS TEETH - CHANGE.............................................................................................................. 4-67

SECTION 5 TROUBLESHOOTING ................................................................................................................................. 5-1 FAULTS INDICATED BY THE INSTRUMENT .......................................................................................... 5-2 NO ELECTRIC POWER SUPPLY / ALTERNATOR............................................................................... 5-2 ENGINE OIL PRESSURE ...................................................................................................................... 5-2 BRAKES PRESSURE ............................................................................................................................ 5-3 ENGINE OIL TEMPERATURE ............................................................................................................... 5-3 HYDRAULIC OIL TEMPERATURE ........................................................................................................ 5-4 AIR FILTER ............................................................................................................................................ 5-4 ENGINE ..................................................................................................................................................... 5-5 STEERING SYSTEM................................................................................................................................. 5-8 BRAKES SYSTEM..................................................................................................................................... 5-9 HYDRAULIC SYSTEM ............................................................................................................................ 5-11 ELECTRICAL SYSTEM ........................................................................................................................... 5-12 AXLES ..................................................................................................................................................... 5-13 AXLES COMPONENTS ....................................................................................................................... 5-16 TRANSMISSION...................................................................................................................................... 5-18

INDEX WORKING EQUIPMENT ......................................................................................................................... 5-20 HEATING AND AIR CONDITIONING SYSTEM ...................................................................................... 5-21 AIR CONDITIONER.............................................................................................................................. 5-22 TRANSMISSION COOLER .................................................................................................................. 5-23 HEATING .............................................................................................................................................. 5-24

SECTION 6 STORAGE .................................................................................................................................................... 6-1 MACHINE STORAGE............................................................................................................................. 6-1 ENGINE STORAGE ............................................................................................................................... 6-1 BATTERIES STORAGE ......................................................................................................................... 6-2 MACHINE RECOMMISSIONING ........................................................................................................... 6-2

SECTION 7 EQUIPMENT................................................................................................................................................. 7-1 BOTTOM-DUMP BUCKET (OPTIONAL)................................................................................................... 7-1 LIFTING FORKS........................................................................................................................................ 7-2

SECTION 8 DATA AND TECHNICAL FEATURES ......................................................................................................... 8-1 SIZES AND PERFORMANCE ................................................................................................................... 8-1 PERFORMANCES ................................................................................................................................. 8-2 NOISE........................................................................................................................................................ 8-2 WEIGHTS .................................................................................................................................................. 8-3 DIESEL ENGINE ....................................................................................................................................... 8-3 TIGHTENING TORQUES ....................................................................................................................... 8-4 BRAKES SYSTEM..................................................................................................................................... 8-5 BRAKE PEDAL VALVE .......................................................................................................................... 8-5 PRESSURE SWITCHES ........................................................................................................................ 8-5 ACCUMULATORS.................................................................................................................................. 8-5 STEERING SYSTEM................................................................................................................................. 8-6 POWER STEERING ............................................................................................................................... 8-6 STEERING CYLINDER .......................................................................................................................... 8-6 HYDRAULIC SYSTEM .............................................................................................................................. 8-7 PRESSURES ADJUSTMENT ................................................................................................................ 8-7 PUMP AT VARIABLE DELIVERY .......................................................................................................... 8-7 DOUBLE GEAR PUMP .......................................................................................................................... 8-8 HYDRAULIC CYLINDERS ..................................................................................................................... 8-8 HYDRAULIC MOTOR............................................................................................................................. 8-9 ELECTRICAL SYSTEM ............................................................................................................................. 8-9 BUCKETS .................................................................................................................................................. 8-9 AXLES ..................................................................................................................................................... 8-10 FRONT AXLES ..................................................................................................................................... 8-10 REAR AXLES ....................................................................................................................................... 8-10 REAR AXLE WITH SPEED GEARBOX (HIGH SPEED) ...................................................................... 8-11 TIGHTENING TORQUES ..................................................................................................................... 8-11

SECTION 9 ALPHABETICAL INDEX .............................................................................................................................. 9-1

SECTION 1 INTRODUCTION, SAFETY, PLATES AND DECALS INTRODUCTION The current Operator’s Manual is the user’s guide for correct run-in, use and maintenance of the machine.

Carefully read this Operator’s Manual and store it in the cabin for quick location and reference.

Instructions concerning safety, operation and maintenance have been developed to permit safe service and operation of this machine.

In the event of queries or suggestions relevant to your machine do not hesitate to address to your Dealer. Dealers have qualified and trained personnel at disposal as well as Original Spares, means and equipment suitable to carry out all necessary maintenance.

Do not use this machine for any applications or purposes other than those described in this Manual. If you use this machine for duties involving the use of attachments, accessories, or special tools, consult your Dealer to make sure that the adaptations or modifications carried out are in conformity with the machine’s technical specifications and with current regulations on safety.

SPARE PARTS The “non-genuine” spare parts have not been controlled and authorized by the Manufacturer. The assembly and/or use of such products may have negative effects on the machine design features and could impair its operation safety. The Manufacturer is not liable for any damage caused by “nongenuine” spare parts or accessories.

WARRANTY This machine is under warranty according to the regulations in force in Your Country and in compliance with the sales agreement drawn up with the Dealer. The warranty, however, expires if the operation and maintenance instruction for this machine and contained in this manual, have not been followed.

Any modifications or adaptations which are not approved by the Manufacturer may invalidate the machine’s original conformity with safety requirements.

Before entrusting this machine to an operator, make sure that: - the operator has received necessary training on how to operate the machine correctly and safely in one of our Training Centres or from an approved organization; - the operator has read and fully understood the instructions given in this Manual.

Consult your Dealer to obtain extra manuals or manuals in other languages.

Your Dealer is at your disposal for any further information.

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SECTION 1

SAFETY INSTRUCTIONS GENERAL SAFETY INSTRUCTIONS Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and to safeguard your safety and personal integrity.

In this manual you will find the following indications:

S WARNING S This symbol warns about the possibility of potential damages to the machine that can involve the operator’s safety.

S DANGER S With specific warnings about potential dangers for the operator’s or other persons integrity directly or indirectly involved.

The non compliance with the warning preceded by the above mentioned key-words (WARNING and DANGER) can cause serious accidents or even the death of the persons involved.

Moreover in the present Manual have been given some instructions with texts in italics, preceded by the words NOTE and CAUTION, with following meanings to protect the machine: NOTE: it emphasizes and underlines to the operator the correct technique or correct procedure to follow.

S CAUTION S It warns the operator of a possible hazard of machine damage in case he does not follow a determined procedure.

Your safety and that of people around you depends on you. It is essential that you understand this manual for the correct operation, inspection, lubrication and maintenance of this machine.

Read this manual carefully and check that: - you understand fully the symbols on the controls and the safety signs used in this manual and on the machine; - you understand fully the speed, stability, braking and steering characteristics of the machine. If you are in any doubt, consult your Dealer.

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The safety messages in this section concern situations which may arise during normal machine operation and servicing. These safety messages also indicate the different ways of coping with these situations. Other safety messages are used throughout the manual to indicate specific dangers.

Whatever type of work is concerned, the safety arrangements applicable to private or public job sites are those which correspond to the regulations in force in the country and in the trade concerned (example, mining, quarries, underground work).

The information given in this chapter is a summary of the basic rules to respect at all times and does not exempt you from observing traffic regulations or the requirements of insurance companies.

Always keep this manual in the storage compartment provided for it. Make sure that it is always complete and in good condition. Consult your Dealer to obtain extra manuals.

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.

Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

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

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

INTRODUCTION, SAFETY, PLATES AND DECALS BEFORE OPERATING THE MACHINE Read and assimilate the instructions and warnings shown in this manual before operating the machine.

The presence of grease, oil, mud or (in winter) ice on the steps and access handles can cause accidents. Make sure they are always clean.

Remove anything which might hinder visibility.

Clean the windshield, windows and rear view mirrors.

Before travelling or working at night, check that the lighting and signalling systems are operating correctly.

Make sure the doors and the engine guard are correctly fastened before undertaking any travel.

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Make sure that no loose object or tool is left on the machine or in the operator’s compartment.

The operator should be the only person on the machine. Make sure there is nobody on or near the machine.

When mounting or dismounting from the machine always face the machine and use the steps and access handles on the left-hand side of the machine.

Wear close fitting clothing and safety equipment appropriate for the job: - safety helmet; - safety shoes; - heavy gloves; - reflective clothing; - wet weather clothing.

If environment condition require it following personal safety equipment should be at hand: - respirators (or dustproof masks); - ear plugs or acoustic ears protections;

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- goggles with lateral shield or masks for eyes protection.

Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get caught into moving parts.

Make sure that you fully understand the location and function of each control. Operating the controls wrongly can cause serious physical injury.

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SECTION 1 Be prepared for emergencies. Always keep a first aid kit and a fire extinguisher close at hand on the machine. Make sure that the fire extinguisher is serviced in accordance with the manufacturer’s instructions.

Make sure that you fully understand the location and function of each control. An incorrect manipulation of the controls can cause serious physical injury.

Check the machine at least once per working shift for obvious damage and defects. Report any changes (relevant to operation) immediately. If necessary, stop the machine immediately and lock it.

3 Always fasten your seat belt before starting the engine. The seat belt will protect you efficiently if you attach it correctly and if you always wear it. The seat belt should not be too loose. It must not be twisted or caught in the seat. Check the condition and pressure of the tyres regularly.

ROAD OPERATION Check that the cab door is closed correctly before undertaking any road travel.

Before undertaking any travel on public highway, lock the working attachments and install the safety systems required by regulations.

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ON JOB SITES Operating the machine requires your full attention.

Caution on the part of the operator can prevent accidents. Make sure you know the capabilities and limits of the machine and the space needed for it to operate. There are areas of poor visibility in the machine’s working range. Have someone guide you for all jobs which have poor visibility.

Check all around the machine every day to ensure there are no oil leaks or hydraulic fluid leaks.

Tighten unions as necessary and replace any parts as required.

Make sure you know the hand signals used on your job site so that you can be guided when making delicate manoeuvres or for work where direct visibility is not available.

Check that all the controls and all the safety devices operate correctly in a safe, clear area before beginning work.

Keep away from dangerous areas such as ditches, over-hangs, soft areas, etc.

Walk around the work site before using the machine and look for hazards.

Inspect and note all possible risks before driving the machine into a new working area. Holes, obstacles, debris and other hazards in the working area can cause serious physical injury.

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INTRODUCTION, SAFETY, PLATES AND DECALS OPERATING THE MACHINE The wheel loader is designed for excavating, loading, transporting and dumping soil or other bulk materials.

Using the wheel loader for purposes other than or extending beyond those stated above, for instance: - 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 the personnel or may cause injury or extensive damage.

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Do not allow anyone to climb onto the machine. A passenger can fall or cause an accident.

Never operate any of the machine controls unless you are seated correctly in the operator’s seat.

Adapt your driving style to suit the conditions of work (sloping ground or rough ground), the state of the road and weather conditions.

Use all the controls gradually so that the machine works smoothly.

Stop the engine and remove the ignition key even for stops of short duration.

Never alight from the operator’s compartment leaving the engine running.

When mounting on or off the operator’s compartment, the loader attachment controls must compulsory be locked. Never try to by-pass this basic safety requirement.

Dust, smoke or fog can reduce visibility and cause an accident. Stop the machine or slow down until visibility returns to normal.

Never jump down from the machine. When dismounting from the machine always face the machine and use the steps and access handles.

Whenever parking the machine on sloping ground, use the wheel chocks to immobilize the machine.

Never travel at full speed with the loader attachment completely raised.

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Never travel at high speed if the loader bucket hinders visibility. You could drive into a hidden object.

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SECTION 1 CAB AND CANOPY The cab has been designed for the operator’s comfort. The walls, the roof and machine platform are insulated so as to reduce noise to minimum level.

Three cab versions are available: - with heated and ventilated air; - with air conditioning; - BLU CAB only with air conditioning.

The cab and canopy are an essential part of the machine structure. The cab and canopy structure cannot be modified. It is therefore forbidden to perform boring, welding and anyway to connect them with a device that could jeopardize its intended operation.

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Any damage due to accidents, fires, hits and corrosion to original structure may cause the inefficiency of the same and decrease its safety.

The evaluation of a damage should therefore be carried out by skilled personnel and the damaged parts should if possible be replaced.

All cab internal components as the operator’s seat as well as seat belts must be checked carefully and must not be damaged.

The cab and canopy must be replaced in case of overturning.

All damaged parts must be replaced.

S WARNING S IN CASE OF OVERTURNING, DO NOT TRY TO REPAIR, WELD OR STRAIGHTEN THE CAB AND CANOPY, but address to skilled personnel at your Dealer.

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INTRODUCTION, SAFETY, PLATES AND DECALS ON JOB SITES On job sites on the public highway, use regulation signals, taking into account the working range of the machine. The national or local regulations define the quantity, type and location of signals.

Avoid running the engine in an enclosed space. If this cannot be avoided, ensure good ventilation under all circumstances.

Do not work close to live overhead electric lines without first making sure that the minimum distances are observed: 5 metres (16 ft 5 in).

If your machine comes into contact with electric lines: - do not leave the machine; - drive the machine out of the hazard area. Warn others against approaching and touching the machine; - have the live wire deenergized; - do not leave the machine until the damaged line has been safely deenergized.

Make sure you know the location of pipes and cables before starting work. Electrical cables, gas pipes, water pipes or other underground installations can cause serious physical injury.

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Do not allow anyone to stand in the machine working area. If the operator carries out a wrong manoeuvre, this could cause an accident. Stop all movement until the person has moved away.

Any uncontrolled movement of the machine can cause an accident.

In case of any operational problem or damage, lower the loader attachment to the ground, stop the engine, remove the ignition key and raise the parking brake lever. Find the cause of the defect or inform responsible personnel. Take measures to prevent the use of the machine.

When the machine is being lifted, nobody must be allowed to remain in the area surrounding the machine.

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SECTION 1 PARKING THE MACHINE When you park the machine, proceed in the following manner: - park the machine on a flat, level surface away from any soft ground, excavations or poorly shored cavity; - lower the loader bucket until it is pressing on the ground; - place the direction of travel and gear change levers in the neutral position; - immobilize the machine by means of the parking brake; - shut down the engine and remove the ignition key;

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- release the hydraulic pressure by operating the control levers in both directions; - make sure that the door and the engine guard is correctly fastened and lock the operator’s compartment door; - check that no part of the machine is protruding onto the public highway. If this cannot be avoided, install signs in accordance with regulations.

MAINTENANCE AND ADJUSTMENTS Do not carry out any service operation until you have read and understood the instructions and warnings given in this manual.

Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including information on the replacement of parts and equipment as this service concerns exclusively the qualified personnel.

Wear suitable clothing when servicing the machine.

During the service work apply a warning plate.

12 Always wear eye protection when using a tool which might project metal particles. Use a hammer with a soft face, such as copper, for installing pins.

Incorrectly performed maintenance or adjustments can cause serious injury. If you do not understand a maintenance or adjustment procedure, consult your Dealer.

A wheel loader raised or an unexpected movement of the machine with no operator on board can cause serious injuries.

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INTRODUCTION, SAFETY, PLATES AND DECALS Before carrying out any maintenance on this machine, proceed in the following manner: - park the machine on flat, level ground; - lower the bucket until it rests on the ground; - shut down the engine and remove the ignition key; - raise the parking brake lever; - block the wheels to prevent any machine movement.

Unauthorized modifications of the machine can cause serious injuries. Do not carry out any modification on this machine without obtaining prior authorization from your Dealer. Any modification carried out must be in conformity with the machine’s technical specifications and must conform to current safety regulations.

Do not carry out any welding operation on the machine without prior authorization from your Dealer.

Some of the machine’s components are subject to type approvals. It is mandatory when replacing those components to ensure that they are in conformity with regulations.

Hydraulic fluid or grease under pressure which penetrates the skin can cause serious injury. Take the necessary safety precautions (protective clothing and face and hand protection) to prevent all such risks. In addition, before handling these products, read the manufacturer’s specific instructions for their use. If hydraulic fluid penetrates the skin a doctor must be called immediately.

When carrying out a welding operation on the machine, as authorized by the Manufacturer and in accordance with his specifications, disconnect the alternator plug and connect the welding set earth lead to the component on which the welding is to be carried out. Never connect the earth lead to a hydraulic system component.

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A burst tyre can cause serious injury. Regularly check the condition of tyres and always observe the inflation pressures defined in accordance with the type of tyre and ground concerned.

When checking tyre pressures or during an inflation operation, never stay facing the tyre but always facing the tread surface. Always use an inflation cage when the wheel is removed from the machine. Keep all other persons away from the area.

Never weld near a tyre. It is essential to remove the tyre before any welding operation.

Take the necessary safety measures to protect your face when using compressed air.

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SECTION 1 PREVENTION OF FIRE OR EXPLOSIONS Engine fuel can cause an explosion or a fire.

- Never refuel when the engine is running.

- Do not smoke during refuelling.

- Take all the necessary safety measures when welding, grinding or when working near a naked flame.

Use a non-inflammable product for cleaning parts.

17 A spark or flame can cause the hydrogen in a battery to explode. To prevent any risk of explosion, observe the following instructions: - when disconnecting the battery cables, always disconnect the negative (-) cable first; - to reconnect the battery cables, always connect the negative (-) cable last; - never short-circuit the battery clamps with metal objects; - do not weld, grind or smoke near a battery.

Always store batteries in a safe place, out of the reach of children.

18

The electrical system or the engine exhaust may produce sparks. Before using the machine in an area which may contain inflammable vapours, ensure that there is good ventilation.

Always keep a fire extinguisher available on the machine. Make sure that it is properly maintained in conformity with the manufacturer’s instructions.

Clean the machine regularly, remove all debris and material which may catch fire.

Check for leaks. Replace damaged hoses, pipes and unions. Clean the machine after any repair work before operating it.

19

1-10

INTRODUCTION, SAFETY, PLATES AND DECALS PREVENTION OF BURNS Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid any contact with the skin, eyes or clothing.

Antidote: - EXTERNAL: rinse well with water, removing any soiled clothing.

- INTERNAL: avoid vomiting. Drink water to rinse your mouth. Consult a doctor.

- EYES: rinse abundantly with water for 15 minutes and consult a doctor.

- When the electrolyte of a battery is frozen, it can explode if you attempt to charge the battery or if you try to start the engine using a booster battery.

Always keep the battery charged to prevent the electrolyte freezing.

20

Batteries generate explosive gases. Keep all flames, sparks and cigarettes away. Provide good ventilation when changing a battery or using a battery in an enclosed space. Always protect your eyes when working near a battery.

21 Never touch the battery terminals with your hands.

This can induce a state of electrolysis and impair the main organs of the body.

Boiling coolant solution can spray out if the radiator cap is removed while the system is still hot. To remove the cap: allow the system to cool down, turn the cap to the first notch and wait until there is no more pressure. Then remove the cap.

22

1-11

SECTION 1 PREVENTION OF RISKS ASSOCIATED WITH VIBRATIONS Machine vibrations cause discomfort to the operator and in some cases his health and safety may be at risk. To reduce these risks to a minimum: - make sure that machine and equipment are suitable for the type of work to be carried out; - make sure the machine is in good condition and that the service interval work has been carried out correctly; - check the tyres pressure, the steering and brake system; - check that the operator’s seat and adjustment controls are in good condition and then adjust the seat to suit the operator’s size and weight. The seat complies with ISO 7096 standard.

ON JOB SITES Operate all controls progressively so the machine works smoothly.

Modify your driving to suit working conditions.

During travel, adjust your speed and slow down if necessary.

Make sure the machine is working on firm ground, with no holes or obstacles.

1-12

23

INTRODUCTION, SAFETY, PLATES AND DECALS PRECAUTION FOR WASTE DISPOSAL Improperly disposing of waste can threaten the environment.

Each country has its own Regulations on this subject. It is therefore advisable to prepare suitable containers to collect and store momentarily all solid and fluid materials that must not be scattered in the environment to avoid pollution.

At preset intervals these products will be delivered to disposal stations legally recognized and present in this Country.

Hereunder are listed some products of the machine requiring disposal: - lube oil;

24

- brakes system oil; - refrigerant mixture, condensation rests and antifreeze; - diesel oil; - oil and diesel oil cartridges; - engine and air conditioning air filters elements; - battery.

Also polluting rags, paper, sawdust and gloves must be disposed in compliance with the same procedures.

Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service centre to recover and recycle used air conditioning refrigerants. Obtain information on the proper way to recycle or dispose of waste from your local environmental or recycling centre, or from your Dealer.

1-13

SECTION 1

COMPONENTS IDENTIFICATION PLATES When ordering parts, requesting information or assistance, always give your Dealer the type and serial number of your machine and component concerned.

MACHINE The plate is applied on the machine frame.

1. Machine type 2. Serial number

25 ENGINE The plate is applied on the crankcase side.

1. Model 2. Serial number

26

1-14

INTRODUCTION, SAFETY, PLATES AND DECALS AXLES The plate is applied on the axle body.

1. Model 2. Serial number

27 PUMP The plate is applied on the pump body.

1. Model 2. Serial number

28 TRAVEL MOTOR The plate is applied on the engine body.

1. Model 2. Serial number

29 1-15

SECTION 1 EQUIPMENT Each working equipment carries a plate for identification.

1. Type 2. Serial number

30 CAB The cab plate is located inside left under the seat.

1. Serial number

31

1-16

INTRODUCTION, SAFETY, PLATES AND DECALS

MAIN COMPONENTS

32 1. Wheel loader bucket

9. Pump

2. Dumping cylinder

10. Battery

3. Lifting cylinder

11. Rear axle

4. Fuel tank

12. Transmission

5. Cab

13. Steering cylinder

6. Hydraulic oil reservoir

14. Front axle

7. Air filter

15. Wheel loader

8. Engine

16. Quick tool coupler

MACHINE SIDES The terms “right”, “left”, “front” and “rear”, when used in this manual, indicate the sides of the machine as seen from the operator’s seat.

1. Front side - forward 2. Rear side - backward 3. Right side 4. Left side

33 1-17

SECTION 1

DECALS

S WARNING S An illegible or missing decal can have far-reaching consequences. Check them everyday.

S WARNING S Make sure that all decals are perfectly legible.

Clean them regularly, replace them with new decals if they are damaged, missing or painted over. If there is a decal on a part that is replaced, make sure you install a new decal on the new part.

NOTE: when you clean the decals, use only a cloth, water and soap. Do not use solvents, petrol, etc.

NOISE LEVEL DECAL EXTERNAL NOISE LEVEL This decal (1) shows the value in decibel of the external noise level LWA of machine as guaranteed by the Manufacturer. As per European Directive 2000/14/EC. Models 21E: 98 dB(A) Models 121E, 221E and 321E: 99 dB(A)

34

INTERNAL NOISE LEVEL No relevant decal applied on the machine. It is the noise pressure level LpA inside of the cabin.

All models: 77 dB(A)

1-18

INTRODUCTION, SAFETY, PLATES AND DECALS POSITION OF DECALS

35 Fuel tank Make sure that the tank bearing this decal contains fuel only.

Battery This decal shows that you have to refer to the Operator’s Manual.

1

36 2

37

1-19

SECTION 1 Explosion hazard Read carefully this manual to avoid dangerous explosions.

3

38 Emergency exit This decal shows the location of a possible emergency exit.

Danger of staying behind This decal shows that the operator must not allow anyone to stay in the back of the machine when the engine is running.

Engine stop Remove the ignition key if the engine comes to a stop.

4

39 5

40 6

41

1-20

INTRODUCTION, SAFETY, PLATES AND DECALS Ether output hazard Beware because in the shown area there could be a release of ether.

7

42 Suspension points This decal shows the slinging points for machine handling. Never use any other slinging points than those shown on this decal.

Operator’s Manual This decal shows the manual location. Read the manual carefully to ensure you operate the machine correctly.

8

43 9

44 Fire extinguisher Ensure the extinguisher fitted, complies with local regulations and is fully serviceable.

10

45

1-21

SECTION 1 Articulated joint dangerous stay Nobody must stay in the articulated joint area of loader during the working stages.

11

46 Frontal stay dangerous Nobody must stay in front of machine during the working stage.

Bucket transport position This decal shows the correct position of the bucket during transport.

Quick tool coupler This decal shows the presence of a quick tool coupler. Read this manual to understand its operation.

12

47 13

48 14

49

1-22

INTRODUCTION, SAFETY, PLATES AND DECALS Quick tool coupler pin Be careful during assembly and disassembly of quick tool coupler pin.

15

50 Engine fan danger Be careful engine fan could entangle your hands and cause injuries.

16

51 Drive belt danger Be careful, the drive belt could entangle your hands and cause injuries.

Suspension points This decal shows the useful suspension points for machine lifting. Do not use other points.

17

52 18

53

1-23

SECTION 1 Oil tank Read this manual carefully to avoid the risk of oil under pressure inside of the tank in case of service.

19

54 Seat belt This decal reminds to wear your safety belt at all times to avoid all risk of being ejected in the event of the machine turning over.

20

55 Brake accumulator pressure danger Be careful for possible overpressure of the brakes system accumulator.

Articulated joint danger Caution is required in case of articulated joint lock.

21

56 22

57

1-24

INTRODUCTION, SAFETY, PLATES AND DECALS Crush hazard Observe safety distance from the machine during the working stages.

23

58 Engine start-up During the engine start-up the transmission must be disengaged.

24

59 Explosion hazard Read carefully this manual to avoid dangerous explosions.

25

60

1-25

SECTION 1

HAND SIGNALS When operating the machine, never attempt to carry out tasks calling for fine control or to work in areas where visibility is poor or impaired without seeking the assistance of a flagman. Make perfectly sure that you and the flagman understand the signals to be used. The flagman must always keep out from the machine working area.

The operator must always keep visual contact with the flagman; stop machine immediately if the contact is lost.

START THE ENGINE

MOVE AWAY FROM ME

61

64 GO THIS FAR

STOP THE ENGINE

62 COME TO ME

STOP ALL AND HOLD

63

1-26

65

66

INTRODUCTION, SAFETY, PLATES AND DECALS LOWER LOAD OR BUCKET

STOP

67

70 RAISE LOAD OR BUCKET SLOWLY

EMERGENCY STOP

68

71 LOWER LOAD OR BUCKET SLOWLY

RAISE LOAD OR BUCKET

69

72

1-27

SECTION 1 DUMP THE BUCKET

TURN MACHINE LEFT

73 TURN MACHINE RIGHT

74 FILL THE BUCKET

75

1-28

76

SECTION 2 CONTROLS AND INSTRUMENTS CONTROLS AND INSTRUMENTS

1 2-1

SECTION 2

Ref.

Description

Function

1

Control lever

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

2

Pilot light

Overdrive (Optional)

Overdrive visualization.

3

Pilot light

Emergency steering (Optional)

Emergency steering system check.

4

Switch

Overdrive (Optional)

Overdrive selection.

Symbol

Tail lights ON - depress switch down to 1st notch.

5

3-stage switch

Lights

Dipped beams ON - press symbol side of switch up to second click.

Tail lights / dipped beam OFF - depress switch face without symbol.

To activate the wiper - depress symbol side of switch.

6

Switch

Wiper, washer rear

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

To deactivate the wiper - depress switch face without symbol.

To activate the floodlamps - depress symbol face of switch.

Switch

Front working floodlamps (Optional)

8

Switch

Rear working floodlamps (Optional)

9

Switch

Enable Quick tool coupler

Enable to hydraulic circuit of the quick tool coupler.

10

Switch

Load stabilization system

Activation and deactivation of the load stabilization system.

11

Switch

Acoustic reversing signal (Optional)

Activation and deactivation of acoustic reversing signal.

Switch

Rotary beacon To switch off Acoustic reversing signal (Optional)

7

12

2-2

To deactivate the floodlamps - depress switch face without symbol.

To activate the floodlamps - depress symbol face of switch.

To deactivate the floodlamps - depress switch face without symbol.

Rotary beacon ON - depress symbol face of switch.

Rotary beacon OFF - depress switch face without symbol.

R

CONTROLS AND INSTRUMENTS Ref.

Description

Function

13

Optional

14

Switch

Air conditioning system (Optional)

15

Block

Road travel

16

Socket

12 V

17

Lever

Steering column lock

18

Service brake and inching

19

Accelerator pedal

20

3-stage switch

Travel/Working

It powers the travel operation: forward - idling - reversing.

21

Control lever

Working

Lifting/lowering - bucket dumping.

22

Switch

Work/Creep speed

Two-speed switch-over.

23

Lever

Auxiliary hydraulic function

Activates an additional hydraulic function (bottomdump bucket, sweeper, etc.).

24

3-stage blower switch

Symbol

Activation and deactivation of the air conditioning system.

Adjusts the steering column.

Depress pedal - machine is braked gently.

Depress pedal fully - machine is braked with service brake.

Controls the travelling speed.

1, 2, 3 = speed power stages 0 = OFF.

F N R

1 2 3

25

Knob

Heating

26

Switch/Pilot light

Hazard warning signals

Key Switch

Ignition lock Electrical system

27

Controls the heating power.

Activates and deactivates the hazard warning signals.

It flashes when hazard warning signals are active.

Activates and deactivates the electrical system.

Starting/Stopping the engine.

2-3

SECTION 2 INSTRUMENTS AND PILOT LAMPS

2 Ref.

Function

1

Pilot light

Alternator

Lights up when the battery is not charged.

2

Pilot light

Engine oil pressure

Lights up when the engine oil pressure is too low.

3

Pilot light

Oil brake pressure

4

Preheating

5

Pilot light

Parking brake

Pilot light

Engine oil temperature

6

2-4

Description

Shut off the engine and rectify the fault.

Lights up when the brake pressure is too low.

Stop the machine immediately and rectify the fault.

Lights up during automatic preheating.

Lights up when the parking brake is applied.

Lights up when the engine oil temperature is too high.

Shut off the engine and rectify the fault.

Symbol

CONTROLS AND INSTRUMENTS Ref. 7

Description Pilot light

Function Hydraulic oil temperature

Symbol

Lights up when the hydraulic oil temperature is too high.

Shut off the engine and rectify the fault.

8

Pilot light

Air filter

Lights up when the air filter is contaminated.

9

Pilot light

Main beams

Lights up when the headlamps are on main beam.

10

Pilot light

Turn signal light

When connected it flashes.

11

Pilot light

Forward

It lights up when forward travel is selected.

12

Pilot light

Creep speed

Lights up when creep speed is activated.

13

Pilot light

Reverse

It lights up when reverse travel is selected.

14

Fuel gauge

15

Speedometer

(Optional)

It shows the speed km/h and mph (with additional gear option only).

16

Temperature

Engine oil

It indicates the engine oil temperature.

17

Hourmeter

Service hours

It shows the machine service hours.

It shows the fuel tank level. km/h mph

2-5

SECTION 2

CAB ENTRY AND EXIT To mount on and off the cabin always use steps (1) and handles (2) duly fitted on machine.

Always face the machine when entering or leaving it.

S WARNING S Never use the steering wheel or the control levers to help yourself entering or leaving the operator’s compartment.

S WARNING S Clean the steps and access handles and remove all traces of grease, oil, mud and ice (winter).

3

S WARNING S Never jump down from the machine. When dismounting from the operator’s compartment always face the machine and use the steps and access handles.

DOOR OPENING Unlock door with key.

Depress lock button (1) and swing door open sideways with handle (2).

4 DOOR LOCKING The cab door engages in its limit position.

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

To open the door from inside, push lever (3) downwards.

S WARNING S Make sure that the doors are correctly closed before any travel.

5

2-6

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

Push the catch (1) forward.

Swing the window open into blocking position.

6 CAB WINDOW (OPTIONAL) Window opening Pull retainer forward (1).

Open the cab window, until it locks at stroke end.

7 Window closing To unlock the window, pull handle (3) or keep the release button (2) pressed. Now the window can be closed.

To close the window completely, catch the retainer (1) in the guide pin and than press it downwards.

8

2-7

SECTION 2 EMERGENCY EXIT If the cab door is unusable, get out through the side window.

Open the window as described.

Pull retainer (1) and unlock it.

The window can now be opened completely.

S CAUTION S Open the window completely only in an emergency case as it cannot be blocked in fully open position.

This can damage the window or cause injuries to persons.

9

DOCUMENTS STORAGE BOX/FIRST-AID KIT/ WARNING TRIANGLE HOLDER Left, near the operator’s seat is located a storing compartment for documents (1) (Operator’s Manual and possible other documents).

10 In the front of compartment, there is the prearrangement for the first-aid kit (1) and the rotary beacon (2).

The compartment can also contain a warning triangle (3).

11

2-8

CONTROLS AND INSTRUMENTS SUN VISOR The sun visor (1) is applied over the front screen.

This can be adjusted according to the operator’s needs.

12 CAB LIGHTING The cab interior lighting is switched on and off directly at the lamp (1).

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

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

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

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

13

FIRE EXTINGUISHER The fire extinguisher (1) is located frontally right, near the accelerator pedal.

14 AUXILIARY SOCKET The socket outlet 12 V (1) can be used for hand lamp connection, for instance.

15 2-9

SECTION 2 VENTILATION The cab is ventilated through the right side window or by activating the fan, introducing fresh air in the cabin.

The outlets swinging fins (1), (2) and (3) deflect the air flow to the front and rear glass, to the lateral glasses and to the feet area.

16

17 Air filter The air is sucked into the cab through the air filter (4).

Keep the suction ports clean.

The cleaner is located on the right side of the vehicle, below the side window, and is accessible after opening the right service door (5).

18

2-10

CONTROLS AND INSTRUMENTS

OPERATOR’S COMPARTMENT CONTROLS

S WARNING S Before starting the engine, make sure you are fully aware of the location and the function of each control. Operating the controls wrongly can cause serious physical injury.

IGNITION KEY It is placed right of the operator’s seat and has four stages.

0

= Stop

I

= Contact

II

= Preheating

III

= Ignition

19

HEATING The heating efficiency depends on the temperature of the engine. Full heating performance is therefore available only after the engine has reached its operating temperature.

The heating intensity is controlled by means of rotary switch (1).

The rotary switch (1) is 2-stage: - turn right to switch off heating; - turn left to switch on heating.

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

The blower for heating and/or ventilation is switched on with rotary switch (2).

Rotary switch (2) is 4-stage:

20

= blower off 1

= low speed

2

= middle speed

3

= high speed

2-11

SECTION 2 AIR CONDITIONING (OPTIONAL) AIR CONDITIONING ACTIVATION Start engine.

Activate the air conditioning with switch (A).

Bring blower (B) to level 1 or higher.

21 AIR TEMPERATURE ADJUSTMENT The temperature of the air blown into the cab can be steplessly adjusted with rotary switch (B).

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

Prerequisites for good cooling performance: - the suction opening for fresh air on the right side of the cab must not be covered up or soiled; - filter, cooler/heater and the fins of the evaporator and the heat exchanger must be cleaned; - keep door and windows of cab closed.

REFRIGERATING AGENT R 134a If handled in a wrong manner refrigerant R 134a can be dangerous. Therefore it is important the following warning and directions are adhered to.

The refrigerant agent R 134a has a boiling point of 12 °C (53.6 °F).

Never expose any part of the air conditioning system to flames or excessive heat, because of the risk of fire or explosion and the production of phosgene gas.

Never disconnect or disassemble any part of the air conditioning system as escaping refrigerant can cause frostbite.

If refrigerant comes into contact with your skin, use the same treatment as for frostbite.

Warm the exposed area of skin with your hand or lukewarm water 32 °C (89.6 °F), cover loosely with a bandage to protect against infection and consult a doctor immediately.

If refrigerant comes into contact with your eyes, rinse them immediately with cold water for at least 5 minutes and consult a doctor immediately.

2-12

CONTROLS AND INSTRUMENTS TURN SIGNALS, MAIN BEAMS, FRONT SCREEN WIPER/WASHER CONTROL LEVERS AND HORN With the activation of this lever (A) following functions are active.

22 Position

Function

Symbol

Remarks

1

Horn

Press lever button to position 1.

2

Left turn signal light

Pull lever to position 3. Pilot lamp (10) lights up.

3

Right turn signal light

Push lever to position 2. Pilot light (10) lights up.

4

Main beams

Push lever to position 4. Main beams activate with dipped beams on. Pilot light (9) lights up.

23

2-13

SECTION 2 SCREEN WASHER/WIPER The rotary handle of the lever selects the following functions: 0

= Screen wiper off

J

= Screen wiper inching

I

= Screen wiper on

To switch on the screen wiper: - turn rotary handle to position J (inching); - turn knob to position I (wiper).

To switch off the screen wiper: - turn rotary handle to position 0.

To switch on the screen washer: - bring lever (A) to position 6 and lock it; - set screen wiper to position I. To switch off the screen washer: - release lever (A); - set screen wiper to position 0.

24 The fluid reservoir (B) for the screen wiper system is located in the engine compartment.

After opening the engine guard, the reservoir is accessible in the right sidewall.

To top up reservoir, remove cap (C) and add water.

In winter, add antifreeze to the water.

25

2-14

CONTROLS AND INSTRUMENTS MAIN BEAMS, DIPPED BEAMS AND TAIL LIGHTS The lights can be switched on and off with switch (1).

To switch on the tail lights: - press symbol face of switch (1) up to the first notch.

To switch on the dipped beams: - press symbol face of switch (1) up to the second notch.

To switch off dipped beams / tail lights: - depress blank face of switch (1).

26

To switch on the main beams: - main beams activate with lever (A).

Bring lever (A) to position 4 and release it.

Pilot light (9) lights up.

The main beams can be switched on only if the dipped beams are already on.

To switch off the main beams: - bring lever (A) to position 4 and release it.

27

28 REAR SCREEN WASHER/WIPER To switch on the screen wiper: - press symbol face of switch (1) down to the first notch.

To switch on the screen washer: - press symbol face of switch (1) further down and hold.

Switch off: - press blank face of switch (1).

29

2-15

SECTION 2 TRAVEL/WORK CONTROL LEVER The wheel loader is equipped with a control lever (1) for travel and working operations control.

Switch (2) selects the travel direction - forward or reverse with the following positions: - Switch (2) in central position (N) - travel direction disengaged.

Pilot lamps (11) and (13) are off.

- Switch (2) to forward position (F) - forward travel engaged.

Pilot lamp (11) lit.

- Switch (2) to reverse position (R) - reversing engaged.

Pilot lamp (13) lit.

30

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

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

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

With switch (3) you can switch-over from creep speed to work speed and vice versa.

If you engage the creep speed, pilot lamp (12) lights up.

When engaging the creep speed the wheel loader movement is restricted to maximum speed allowed by this gear. This is important for work requiring low working speeds.

31

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

BUCKET CONTROL LEVER With control lever (A) you can carry out following operation.

Controls layout: 0

= Stop

1

= Lifting

2

= Lowering

2a = Floating 3

= Back-tipping

4

= Dumping

2-16

32

CONTROLS AND INSTRUMENTS FLOATING POSITION OF BUCKET

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

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

Position 2a allows the floating at ground level during reversing.

Place the bucket on the ground. Bring control lever (A) to 2a position and lock it. The bucket now rests freely on the ground, loaded only by its own weight.

After setting back the control lever to position 2, the floating position function is cancelled.

33

Pull the control lever by hand back from position 2a to position 2.

Set to other position the control lever returns automatically to 0.

USING COMBINED FUNCTIONS To combine two functions: 1/4

Lifting and dumping

2/4

Lowering and dumping

2/3

Lowering and back-tipping

If two functions are combined, for instance 1/4, 2/3 or 2/4, the two movements of the bucket will be performed simultaneously depending on the loading of the hydraulic circuits lifting / lowering and back-tipping / dumping.

Thus, it is possible in position 1/4 to raise the lifting frame during dumping; this is above all useful when loading material on vehicles.

34

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

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

It is possible to pass from the lifting position directly to the back-tipping position without going back to neutral first. The lifting function is then not active.

After switching back to lifting, the function is reactivated. The above described switching mode (priority switching) facilitates loading of material at the working face.

2-17

SECTION 2 CONTROL LEVER ADDITIONAL FUNCTION Control lever (1) can be used switching additional hydraulic functions, for instance hydraulic quick tool coupler, bottom-dump bucket, sweeper attachment.

In the foremost position, control lever (1) has a lock facility, useful for sweeper operation.

35 BOTTOM-DUMP BUCKET (OPTIONAL) Control lever (1) initiates the following working movements: - control lever (1) forwards - bottom-dump bucket open; - control lever (1) backwards - bottom-dump bucket closed.

36 LOCKING THE CONTROL LEVERS Control levers (1) and (2) have a common mechanical locking device. With which the working hydraulic functions can be locked, for instance for road travel.

Turn knob (3) counterclockwise until the marking aligns with the “Locked” symbol.

Turn knob (3) clockwise until the marking aligns with the “Unlocked” symbol.

37

BRAKING AND STOPPING To brake the machine during travelling, it is generally sufficient to take the foot off the accelerator pedal (2). In this case, the driving speed is efficiently reduced by the hydrostatic travel transmission.

To stop the wheel loader completely, depress brake pedal (1). The disk brake on the front axle is applied, the power output of the transmission is automatically decreased at the same time, even if pedal (2) is not released.

38 2-18

CONTROLS AND INSTRUMENTS STEERING COLUMN - ADJUSTMENT Do not adjust the steering column during travel.

Concentrate on the road to avoid accidents.

Before adjusting the steering column: - stop the machine; - stand working equipment on the ground; - travel direction to “0”; - apply the parking brake.

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

- Press lever (1) downwards; the steering column moves into front position.

39

- Pull steering column back into the desired position.

- Release the lever to lock the steering column.

PARKING BRAKE To activate the parking brake pull lever (1) upwards.

Lower the lever to release the parking brake.

40 With the parking brake engaged pilot lamp (5) lights up.

Pilot lamp (5) is off when parking brake is deactivated.

41

2-19

SECTION 2

OPERATOR’S SEAT To operate the machine correctly with maximum efficiency and comfort, the seat should be correctly adjusted to suit the weight and height of the operator.

S WARNING S Before using the controls, make sure that the seat is adjusted and positioned correctly.

Never adjust the seat while driving. The operator could lose concentration - danger of accidents.

Before adjusting the seat: - stop the machine; - move the gearshift 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.

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

42

HEIGHT ADJUSTMENT The height can be adjusted in several stages.

Raise operator’s seat (3) as far as required until engagement is audible. If the seat is raised beyond the last stage, it drops back to the lowest position.

43

2-20

CONTROLS AND INSTRUMENTS FORE-AND-AFT ADJUSTMENT The fore-and-after adjustment is performed with the locking lever (4).

Lift lever upwards in direction of arrow, move seat to required position and release lever. Release the lever. The locking lever must engage in the required position. Once locked, the operator’s seat must not be movable into another position.

44 BACKREST ADJUSTMENT The backrest inclination can be adjusted with the locking lever (5).

Sit on seat and lean back lightly against backrest.

Pull locking lever (5) upwards in direction of arrow.

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

When backrest is in required position release locking lever.

45

2-21

SECTION 2

SEAT BELT

S WARNING S Always fasten your seat belt before starting the engine. The machine is equipped with a roll over protection system (ROPS) which ensures your safety. The seat belt will protect you efficiently if you attach it correctly and if you always wear it. The seat belt must not be too loose. It must not be twisted or caught in the seat.

Check periodically the seat belt and all its securing elements. If you notice that the seat belt and its securing elements are damaged or some of them missing, perform immediately repair or replacement of parts. Seat belts damaged or worn because of an accident, they have to be replaced.

The seat belt buckle must not be clogged, for instance from paper or other objects, otherwise the hooking tongue does not lock. Never run belt over rigid or fragile objects such as bunches of keys or spectacles. In this way your body could get injured in case of accident. The operator’s seat is fitted with a lap-type seat belt. The belt tensioning roller is incorporated on the left side of the seat.

FASTEN SEAT BELT Insert the hooking tongue (2) in the buckle (1). Pull the tongue against the buckle to check if the seat belt is well secured.

The belt should not be entangled or rolled.

46 RELEASE SEAT BELT Press the lock (3) of the buckle (1) and take out the hooking tongue.

The belt rolls in automatically.

47

2-22

CONTROLS AND INSTRUMENTS

OPTIONAL CONTROLS FRONT/REAR WORKING FLOODLAMP The front (1) and rear (2) working floodlamps are installed on the cab right and left side.

Switch ON: - press symbol face of switch (1) and (2).

Switch OFF: - depress switch face without symbol (1) and (2).

48

ROTARY BEACON The rotary beacon is placed with its magnetic base in the area marked (A) in front of the cab roof.

A socket outlet (1) is located in front at the left, below the cab.

49 Switch ON: - press symbol face of switch (2).

Switch OFF: - depress blank face of switch (2).

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

2-23

SECTION 2 REVERSING ACOUSTIC SIGNAL During driving on the public highway, the acoustic reversing signal must be deactivated.

Connection: - press symbol face of switch (1).

Disconnection: - depress blank face of switch (1).

S WARNING S On public highways the acoustic signal for reversing must be disconnected.

51

LOAD STABILIZATION SYSTEM

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

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

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

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

52

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

The system is switched on and off with switch (1).

- When the load stabilization system is active, pilot lamp (1) is on.

The load stabilization system is deactivated when a factory-adjusted lifting height on the sensor is exceeded (2).

53

2-24

CONTROLS AND INSTRUMENTS BATTERY MAIN SWITCH The battery main switch (1) is located under the engine guard, on the right near the battery.

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

The battery main switch (1) serves the purpose of disconnecting the electrical system as a whole from the battery. The switch positions shown in figure have the following meaning:

54

I = ON II = OFF In the OFF position, the battery main switch (1) prevents: - unauthorized starting of the engine; - unintentional discharging of the battery.

2-25

SECTION 2 NOTES:

2-26

SECTION 3 OPERATING THE MACHINE GENERAL INSTRUCTIONS BEFORE OPERATING THE MACHINE

OPERATING THE MACHINE

S WARNING S

S WARNING S

Read and assimilate the instructions and warnings shown in this manual before operating the machine.

Check that all the controls and all the safety devices operate correctly in a safe, clear area before beginning work.

Before operating the machine, observe the following instructions:

When operating the machine the following instructions must be observed:

- Check the levels (engine oil, hydraulic fluid and coolant fluid) and make sure that the various fluids correspond to the conditions of use.

- Start the engine taking into account weather conditions.

- Carry out the daily maintenance operations.

- Walk around the machine, look for any leaks and inspect the hoses.

- Before undertaking any road travel, lock the equipment, and connect the safety systems required by regulations.

- Before any road travel or job site work at night, check that the lighting and signalling systems are operating correctly.

- Check the condition of the tyres and the tyre pressure.

- Clean the steps and access handles and your shoes. The presence of oil, mud or ice (winter) can cause accidents. Make sure they are always clean.

- Clean or replace safety decals which are no longer legible.

- Make sure that the engine guard is closed and latched correctly.

- Check that the cab door is closed correctly.

- Remove anything which might hinder visibility.

Clean the windshield windows and rear view mirrors.

- Make sure that no objects or tools are left on the machine or in the operator’s compartment.

- Make sure to know the escape manoeuvres from machine (emergency exit).

- Make sure that nobody is under or on the machine. The operator should be the only person on the machine.

- Make sure that nobody is within the working range of the machine.

- Regularly consult the hourmeter to ensure Servicing Intervals are observed.

- If you use the machine under particularly severe conditions (dusty or corrosive atmosphere, etc.), the Servicing Intervals should be reduced.

- Make sure that you know the location of pipes and cables before beginning work.

- Do not work near overhead high-voltage electrical cables without checking beforehand that all necessary measures have been taken to respect the minimum distances: 5 metres (16 ft 5 in).

- On job sites on the public highway, use regulation signals, taking into account the working range of the machine. Local regulations define the number, type and location of reflective strips.

- Make sure that the operator’s seat is correctly adjusted and positioned.

- Never operate any control or driving component unless you are seated correctly in the operator’s seat with the seat belt adjusted and attached correctly.

- Adapt your operating style to the type and conditions of work.

- Do not allow anyone to stand in the machine working area. Stop all movement until the person has moved away.

- Operate all controls progressively so the machine works smoothly.

- When loading the machine onto the trailer of an articulated vehicle, see “Transporting the machine”.

- When towing the machine, see “Towing the machine”.

3-1

SECTION 3 - Avoid running the engine in an enclosed space. If necessary, ensure good ventilation under all circumstances.

- Dust, smoke or fog can reduce visibility and cause an accident. Stop or slow down the machine until normal visibility is restored.

- If there is any operating problem, immediately lower the loader equipment to the ground, apply the parking brake and stop the engine. Find the cause or inform responsible persons and take the necessary measures to forbid the use of the machine.

- When stopping the engine take account of weather conditions.

- When parking the machine, see “Parking the machine”.

RUNNING-IN PERIOD Your machine will last longer and give better and more economical performance if you pay particular attention to the engine during the first twenty hours of operation.

During this period: Keep a close watch on the instrument panel.

Operate the machine at normal speeds. Do not run the engine too much at stalling speeds (with the wheels turning slowly or stopped and the engine at full speed).

To ensure adequate lubrication, idle the engine at 1000 rev/min. for one minute before increasing the rpm.

Maintain the engine at the normal operating temperature.

Do not run the engine at idle speed for long periods.

During the running-in period, the following inspections and maintenance operations must be carried out in addition to the operations shown in the Maintenance Programme: Every ten hours or daily Check the engine oil and coolant levels.

Check the transmission and rear axle oil levels.

Check the greasing of the front equipment.

After the first 10 operating hours Check the tightness of the wheel nuts.

After the first 50 operating hours After the first 50 operating hours, consult your Dealer for the 50 hour servicing operations recommended by the Manufacturer.

3-2

OPERATING THE MACHINE AFTER DAILY OPERATION - PARKING Secure the machine: - Carry out daily service operations.

- Change equipment.

- Park the machine.

- Park machine on dry and level ground. Place the working equipment on a stand or on the ground.

- To stop the machine on a grade: park the machine with face downhill and with the teeth of the bucket pushed firmly into the ground.

- Secure the machine with the wheel chocks (1).

- Apply the parking brake.

1

- Set control levers and gear levers to position 0.

- Switch off engine.

- Remove gross dirt from machine.

- Visual check - verify hydraulic system for leaks.

- Visual check - machine condition, wheels and equipment.

- Protect the machine against unauthorized starting.

- Remove ignition key.

- Close windows.

- Lock cab door and engine guard.

CHOCK The chock is located below the cab door.

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

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

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

2

3-3

SECTION 3

STARTING Apply parking brake.

Shift to neutral.

Deactivate the immobilizer (optional).

Turn key in key switch to position I. All warning and pilot lights switch on briefly (selftest).

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

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

When the brake pressure is too low, pilot light (3) is on.

3

When the parking brake is applied, pilot light (5) is on.

Turn key to position II. Hold key in position II until the preheating indicator (4) and the brake pressure pilot light (3) go out.

Turn key to position III against the spring pressure.

The engine starts up.

Release the key, it will return to position II. Increase the engine speed slightly by depressing the accelerator pedal.

The alternator (1) and engine oil pressure (2) pilot lights go out.

If the machine is started after a downtime, it may take up to 45 seconds until the emergency steering accumulator (optional) is charged and the pilot light goes out.

The pilot light of the parking brake (5) continues to be lit up.

S WARNING S If the warning and pilot lights do not go out, shut off the engine immediately. Detect the cause of a fault and remedy. Only then restart the engine.

If the engine does not start, repeat the starting procedure. If the engine does not start after 10 seconds of uninterrupted starting, turn the key switch back to position I and wait one minute.

Turn key switch to position 0 and start again.

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

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

3-4

4

OPERATING THE MACHINE ASSISTED STARTING

S CAUTION S A high current flows on connection of the earthing cable. Sparks occurring at the contact point may ignite gases at the discharged battery.

The ground clamp should therefore be connected as far as possible from the discharged battery.

Never lean over the batteries when jump-starting a vehicle. Wear goggles.

Never use assisted starting when the batteries are defective or frozen.

Never connect batteries (battery sets) 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, for instance two or three batteries or booster units connected in series and generating voltages in excess of 12 V. 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.

Check whether the battery of the receiving machine (discharged battery) is in working order.

- Switch off electrical consumers (headlamps, fan).

- Insert the key in the cylinder, the pilot lights for engine check must light up.

- If pilot lamps do not light up, the battery is faulty (discharged or with short-circuit inside).

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

Install a functional battery before jump-starting.

Switch off all electrical consumers in receiving machine and turn key switch to 0.

Switch off all consumers in supplying machine (booster battery) and shut off engine.

3-5

SECTION 3 Connect the red jumper cable to the positive clamp of the discharged battery (1) and then to the positive clamp of the booster battery (2).

Connect the black jumper cable first to the negative clamp of the booster battery (3) and then to a brightmetal point on the receiving machine (4), near the negative clamp of the discharged battery.

5 Starting the engine 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 restarting.

Once the engine has started up, proceed as follows: - switch on some high consumption units, for instance 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.

Connect battery jumper cables in this way: - negative terminal on receiving machine (4); - negative terminal on supplying machine (3); - positive terminal on supplying machine (2); - positive terminal on receiving machine (1); - disconnect high consumption units; - run the engine at moderate speed for about half an hour. The batteries recharge partially.

Have the electrical system of the machine checked, to determine why the batteries were discharged.

3-6

OPERATING THE MACHINE Engine shut off Place the working equipment on the ground.

Disconnect translation by setting switch (1) to central position. Pilot lights (6) and (7) must switch off.

Shift control lever (2) to position 0.

Apply the parking brake with lever.

Pilot light (5) lights up.

Turn the key to position 0.

The engine shuts off.

Withdraw the key.

Secure the machine against inadvertent movements and unauthorized starting.

6

7

3-7

SECTION 3

TRAVEL BEFORE STARTING THE TRAVEL Raise the working equipment only to such an extent that the machine can pass under overhead power lines without risk.

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

The machine is equipped with seat belt for the operator. Fasten seat belt.

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

Never travel across slopes.

Take the utmost care on slippery and greasy ground.

Check for correct tyre pressure.

Make sure the wheels have adequate grip; only then are the steering and braking properties assured.

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

Give the engine 2 to 3 minutes time to warm up before setting off.

Run the engine at full load only if warm.

START UP Check that the steering column is locked.

Raise the working equipment slightly.

Release the parking brake.

Give a signal with the horn.

Select the travel direction with switch (2) of control lever (1) and, if desired, shift into the other gear with button (3).

8

3-8

OPERATING THE MACHINE WORKING SPEED - CREEP SPEED The functions can be engaged under load, that is the machine must not be stationary before switching the function. Switching over to opposite driving direction - even in position N - should, however be avoided, as the machine is then braked abruptly.

Reduce speed beforehand.

The brake pedal (1) fulfils two functions.

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

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

9

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

During inching (slow travel), the travel needs less power than with normal travel. More power is therefore available to the working hydraulics.

With switch (3), the machine can be switched between normal working speed and creep speed.

With creep speed, the travelling speed is limited.

The creep speed is particularly useful for precision work such as levelling or sweeping operations.

10

3-9

SECTION 3 OVERDRIVE (OPTIONAL) The wheel loader with overdrive option is designed for a maximum speed of 35 km/h (21.748 mph).

Exceeding the maximum speed may cause damage.

If the maximum speed of 35 km/h (21.748 mph) is exceeded during travelling (red range of speedometer), release the accelerator pedal to reduce the travel speed. During downhill travel, brake the machine with the brake pedal to bring the machine back into the admissible range.

If the machine reaches a speed of more than 35 km/h (21.748 mph) also on level terrain, contact the Aftersales service to have the hydrostatic travel drive readjusted.

OVERDRIVE CONNECTION Switch on or start the machine.

The engine is running, working or creep speed is engaged.

Preselect the overdrive gear with switch (1) by bringing it to central position.

Press brake pedal fully down until pilot light (2) is ON. The machine must absolutely stop.

Press symbol face of switch (1) down.

11 Pilot light (12) is OFF. Pilot light (3) lights up.

Release the brake pedal. Pilot light (2) is OFF. Bring the switch (1) to OFF. Overdrive remains active.

Set off slowly.

OVERDRIVE DISCONNECTION The machine is running with overdrive function on.

The machine must be stationary.

Bring switch (1) to central position.

Press brake pedal strongly until pilot light (2) is ON. Press symbol face of switch (1).

Pilot light (3) is OFF. When creep speed is active, pilot light (12) is ON. Release the brake pedal. Pilot light (2) is OFF. Bring the switch (1) to OFF. The overdrive function is deactivated when the machine is shut off (engine off) and the working speed is engaged.

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

3-10

12

OPERATING THE MACHINE

TRAVEL ON PUBLIC HIGHWAY ABROAD Observe the highway code and the safety regulations in force in the country of use.

GERMANY In Germany the machine can be approved with an EBE (Individual operation permission) for special equipment types.

S CAUTION S When travelling on public roads, the loader must be equipped with a first-aid kit, a warning triangle, a fire extinguisher and a warning beacon.

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

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

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

Some tyre types and treads are not suited for public highway travel.

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

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

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

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

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

Continue to travel with at creep speed.

3-11

SECTION 3 MACHINE OUTFIT FOR TRAVEL ON PUBLIC HIGHWAYS Cover up the front edge of the bucket with a guard strip (7).

Check brakes, steering and tyres.

Check headlights (3), license plate light (5) and rear lights (6).

Install rotary beacon (4).

Protect with locking mechanism (1) the control lever for bucket and auxiliary function against inadvertent activation.

Switch off the working floodlamps (8).

Switch off the load stabilization system (optional).

Check that the steering column is locked.

13

Close the door (10) of the cabin.

Check the settings and locks of the operator’s seat.

Attach the seat belt.

Adjust mirrors (9).

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

Empty the bucket and tip it fully backwards. Bring loading equipment into transport position the distance (X) must be minimum 370 mm (1 ft 3 in).

14 Both edges (A) and (B) must be placed in such a way to result, at least visually, as parallel.

NOTE: the procedures described herein may differ depending on the traffic standards in force in each country. Observe all adaptations and modifications.

15

3-12

OPERATING THE MACHINE

OPERATING THE MACHINE WITH COLD WEATHER FUEL Refill the fuel tank after each working day to prevent the formation of condensation and the entry of water into the fuel system.

To prevent the formation of crystals (-2 °C (28.4 °F)) use a low temperature fuel or mix a protective fluid with your fuel.

LUBE OIL Select oil viscosity (SAE grade) according to ambient temperature before starting engine.

Increase oil change frequency when operating below -10 °C (14 °F).

BATTERY Efficient cold starting requires that battery is wellcharged.

Starting limit temperatures can be lowered by 4 or 5 °C (39.2 °F or 41 °F) by heating batteries up to about +20 °C (68 °F) (to do so, remove batteries and store in warm place).

COLD START ASSISTANCE To start the engine at temperatures near 0 °C (32 °F) use glow plugs if necessary.

This not only lowers starting limit temperature, but provides easier starting at temperatures normally not requiring a starting aid.

3-13

SECTION 3

OPERATING THE MACHINE WITH HOT WEATHER Air density decreases as altitude or ambient temperature increases. As a result of this, the engine’s maximum output, quality of exhaust gas, temperature level and, in extreme cases, starting behaviour, are impaired. Engine can be used at altitudes up to 1000 metres (3280 ft 11 in) and temperatures up to 30 °C (86 °F) for mobile operations. If the engine is to operate under more severe conditions (at higher altitudes or temperatures), it will be necessary to reduce the injected fuel quantity and thus engine power.

16 Observe the following recommendations: - Maintain the correct level of coolant solution in the coolant reservoir.

- Check the condition of the radiator cap before starting. Replace the cap if necessary.

- Clean the radiator, the oil cooler and the engine carefully.

- Check the condition of the alternator and fan belt.

- Use lubricants with the recommended degree of viscosity.

- Use an appropriate coolant solution.

3-14

OPERATING THE MACHINE

TOWING The machine must be towed only with a low speed of approximately 2 km/h (1.243 mph) and over a maximum distance of 0.5 km (0.31 mi).

Otherwise the travel motor would get damaged because of overheat.

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

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

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 5800 kg (12760 lbs).

The towing vehicle must have sufficient tractive power.

Nobody must stand near the towing rod or rope.

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

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

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

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

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

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

After machine towing, loosen hex nut (6) or (7).

Unscrew setscrew (4) or (5) completely and retighten hex nut (6) or (7).

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

17

3-15

SECTION 3 TOWING LUG The towing lug (1) is located at the rear of the machine.

Never use the towing lug to tow trailers.

18 Unlocking Lift catch (2). The pin (3) can be pulled up.

19 Locking Lower pin (3). The catch (2) locks automatically.

20

3-16

OPERATING THE MACHINE

TRANSPORT 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.

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

Ensure that lashing gear has sufficient strength.

TRANSPORT ON TRUCK Place the machine on the truck and lower the equipment.

Lock articulated joint.

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

21

LOADING BY CRANE Loading by crane requires suitable loading gear.

Lock articulated joint.

22

3-17

SECTION 3 ARTICULATED JOINT LOCKING Drive loader into such a position that the boreholes of the holders (1) and (2) are aligned one above the other. Then secure with the pin (3). The pin is located in a support (4) on the frame.

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

24

3-18

OPERATING THE MACHINE

WORKING EQUIPMENT The machine can be equipped with various working equipments. The components of the equipments are assembled with hydraulic cylinders and connectors. Components can be combined in various ways for optimum adaptation of the equipment to the specific application.

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

Equipments from other manufacturers may be assembled and put into operation only if in compliance with Machine Directive 89/392 EEC and only if the Manufacturer Declaration of Conformity of equipment as well as the Manufacturer Declaration of Compatibility of the machine are available.

Special equipment such as bucket for light-weight material with a bulk density of less than to 1.4 t/m3, (87.4 pound/foot3) could obstruct the operator’s field of vision. In this case, work must either be carried out with the assistance of a flagman or the working range must be blocked off.

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

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

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

If such know-how is lacking, meticulous instruction must be given by experienced personnel.

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 cause life threatening situations.

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

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

At the end of work, place 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, block off the joints.

Remove the blocks on finishing work.

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

S WARNING S The maximum operating pressure at the quick tool coupler i.e. at the hydraulic ports for the fitted equipments is 230 ± 10 bar (3335 ± 145 psi).

3-19

SECTION 3 QUICK COUPLER The machine is equipped with a universal quick coupler in compliance with SAE J2513 / ISO 24410 standard. On the machine can be installed different working equipment, even those of other machines unless provided with quick tool coupler. But this is not the allowed and approved use for this machine.

Use approved equipment only, delivered by a CASE authorized Dealer.

During operation, the accumulator is loaded and reloaded by the pressure of the working hydraulic line. The oil stored in the accumulator activates also the cylinders during the equipment change.

Also when the accumulator is unloaded, the hydraulic line receives an oil feed sufficient to enable the activation of the quick tool coupler.

Non approved equipment, according to the situation, cannot bear the lifting or tensile force of the wheel loader, this can of course damage the loader and its equipment.

However, when the accumulator is unloaded, the locking movement of the cylinders is performed obviously much slowly. During operation the accumulator preload holds the working equipment constantly under load.

Damaged equipment represents a real danger for the operator and the persons in the machine vicinity and can cause accidents or serious injuries or even death.

If, due to a longterm inactivity of the machine, the accumulator is unloaded, the safe locking of the quick coupler is always active thanks to the hydraulic locking valves.

S WARNING S Use approved equipment only, delivered by Case authorized Dealer. The non compliance with this instruction can cause accidents with serious injuries or even death.

The quick coupler is activated by means of switch installed on the right console. This switch has two positions, quick coupling OPEN (pilot lamp on) and quick coupling LOCKED (pilot lamp off).

In the LOCKED position, the switch is secured through a mechanical lock against a possible unexpected activation. To set the switch to OPEN position, pull slightly the lock towards the operator (arrow direction) and by pressing on the symbol, lower the switch.

With activation disconnected, the quick coupler is always locked. If the activation is disconnected with quick coupler open, this locks automatically.

As soon as the activation is enabled, the quick coupler locks set/shift to either position OPEN (pilot lamp on) or CLOSED (pilot lamp off) previously set on the switch.

The quick coupler is equipped with an accumulator, which during normal operation, feeds continuously the quick coupler cylinders with an hydraulic preload.

3-20

It can however happen that the quick coupler hooks get jammed, hindering in this way the RELEASING of the locking system. In such a case, the accumulator has to be manually charged. This is possible be recalling the working equipment up to stroke end (for instance tipping back the bucket fully), in this way the main relief valve inside of control valve can activate (sound similar to a whistle).

When the accumulator of the quick coupler is completely loaded, the coupler gets OPEN without any problem.

OPERATING THE MACHINE ASSEMBLY The bucket lays upright on the ground.

By moving the machine forward, bring the lifting frame (1) and the bucket (2) to assembly position.

25 Unlock switch (3) from mechanical lock and press the symbol face of switch (pilot lamp on).

26 Move the wheel loader until the upper support (4) of the lifting frame can fit into the bucket housing (5).

Lift the bucket and tip it back to enable the support to fit into the housing (5).

Set switch (3) to LOCKED position (pilot lamp off).

The lower hook (7) fits into the housing (6). The bucket is now locked (3) (pilot lamp off).

27 LOCKING CHECK Lift and tip back the bucket to enable the check of the locking system (visual check).

Hooks (1) must protrude out of the housings (2).

28

3-21

SECTION 3 DISASSEMBLY Slightly tilt back the bucket and lay it on the ground.

Unlock switch (3) from mechanical lock and press the symbol face of switch at the same time.

29 Slightly lower the lifting frame so that hooks (4) and (7) can protrude from the bucket housing. By reversing the wheel loader, the lifting frame is then released.

30

BUCKETS TEETH - CHANGE

S WARNING S Nobody must stand in the direction of the ejected safety latch and tooth.

The safety latch or the tooth can suddenly be ejected when driven out and hit persons.

Metal splinters may cause injury.

Wear your personal protective equipment and goggles.

Drive out tooth safety latch (1) using a piece of smooth metal or of hard wood (2).

31

3-22

OPERATING THE MACHINE To drive out the tooth (3) from housing (4), cover the same with a piece of smooth metal or of hard wood (2).

32 Clean inside of housing and remove dirt and corrosion.

Insert new tooth (3) into housing (4). The tooth must be in contact with the housing (arrow).

33 Drive in new safety latch (1) into the port (5) of the housing (4). The latch can be driven into the housing from either side.

34

3-23

SECTION 3 NOTES:

3-24

SECTION 4 REFILLINGS AND SERVICING REFILLING QUANTITIES TABLE Component to Refill Suggested Product Screen washer tank Fuel tank Fuel system Engine (with filter) and cooling system

Brakes System

Hydraulic system

Case International Standard Standard

Viscosity

Water and alcohol

-

-

-

Decanted and filtered diesel fuel

-

-

-

Oil AKCELA ENGINE or oil AKCELA N. 1 ENGINE

Quantity (litres, gal) 21E

121E

221E

321E

2.2 (0.60) 90 (23.77) 100 (26.40)

API CF-4 MS 1120 MIL-L-2104 F LEVEL SAE 15W40 API CF-4/CH-4 MS 1121 ACEA E7/E5

15 (3.90)

see Hydraulic system

-

-

-

AKCELA AW HYDRAULIC FLUID 68 HV (-30 to +40 °C) (-22 to +104 °F)

MS 1216

ISO VG 46 DIN 51524

-

56 (14.8)

67 (17.7)

67 (17.7)

74 (19.5)

AKCELA HYDRAULIC EXCAVATORS FLUID (-10 to +50 °C) (14 to +122 °F)

MS 1216

ISO VG 46 DIN 51524

-

56 (14.8)

67 (17.7)

67 (17.7)

74 (19.5)

MS 1216

ISO VG 46 DIN 51524

-

56 (14.8)

67 (17.7)

67 (17.7)

74 (19.5)

7.5 (1.98)

8 (2.11)

8 (2.11)

8 (2.11)

AKCELA HYDRAULIC EXCAVATORS FLUID BIO Biodegradable Oil

-

(special equipment)

Front axle: - differential

- side reduction gears Rear axle: - differential

2x0.7 2x0.6 2x0.6 2x0.6 (2x0.18) (2x0.16) (2x0.16) (2x0.16) AKCELA GEAR 135 H EP LS Oil

-

API GL5

SAE 80W-90

- side reduction gears

Greasing of grease nipples

8 (2.11)

8 (2.11)

8 (2.11)

2x0.7 2x0.7 2x0.7 2x0.7 (2x0.18) (2x0.18) (2x0.18) (2x0.18)

- gear box Air Conditioning System: - coolant - oil (compressor)

7.5 (1.98)

0.75 (0.20)

0.75 (0.20)

0.75 (0.20)

R 134a PAG SP 20

-

-

-

1.1 (0.29) -

AKCELA MULTIPURPOSE GREASE 251H EP Multi purpose grease

-

NLGI2

-

-

0.75 (0.20)

4-1

SECTION 4 FUEL Use commercially available diesel fuel with less than 0.5% sulphur content. If the sulphur content is higher, oil change intervals should be reduced. The following fuel specifications/standards are approved: - DIN EN 590 - BS 2869 - ASTM D 975-96; 1-D and 2-D - NATO Code F-54 / F-34 / F-44 and XF 63 Exhaust emission values which may be determined in the case of type approval tests always refer to the reference fuel prescribed by the authorities for the type approval test.

WINTER-GRADE FUEL Waxing may occur at low temperatures, clogging the fuel system and reducing engine efficiency. If the ambient temperature is less than 0 °C (32 °F), winter-grade fuel, suitable down to -15 °C (5 °F), should be used; this fuel is usually available from filling stations well in advance of the cold months. Diesel fuel containing additives (Super diesel) is often on sale as well, for use down to -20 °C (-4 °F).

- At temperatures below -15 °C to -20 °C (5 °F to 4 °F), kerosene should be added to the diesel fuel.

The relevant percentages are given in the adjacent diagram.

If summer-grade diesel fuel must be used at temperatures below 0 °C (32 °F), up to 60% kerosene can be added (see diagram).

In most cases, adequate resistance to cold can also be obtained by adding a flow improver (additive).

Legend: I

Summer-grade diesel fuel

II

Winter-grade diesel fuel

A

Outer temperature

B

Percentage of kerosene added

S CAUTION S Diesel fuels must never be mixed with gasoline (Normal and Super grades).

1

4-2

REFILLINGS AND SERVICING HYDRAULIC OIL For the first refill, Manufacturer uses AKCELA AW HYDRAULIC FLUID 68 HV oil.

Hydraulic oil is not soluble in water; this can generate condensate water in the hydraulic oil tank.

Therefore drain condensate water periodically, particularly after a long downtime period. Dispose of drained liquid as used oil.

VISCOSITY Generally, multi-grade oils shall be used. In closed heated rooms at temperatures > 5 °C (41 °F), also single-grade oils can be used. As the viscosity of lube oil is dependent on temperature, the choice of SAE grade should be governed by the ambient temperature prevailing at the engine operating site.

Optimum operating behaviour will be attained if you take the accompanying oil viscosity diagram as a guide. Should the temperature fall temporarily below the limits of the SAE grade selected, cold starting may be affected but the engine will not be damaged.

The application of a certain oil at higher temperatures than those indicated in the chart, should be as far as possible limited, in order to keep wear to a minimum.

Synthetic lube oils feature an improved temperature and oxidation stability.

ENVIRONMENTALLY COMPATIBLE HYDRAULIC OIL The hydraulic system of this machine can be filled at with environmentally compatible, synthetic hydraulic fluid too (special equipment). Stickers with corresponding instructions are then attached to the machine.

This synthetic hydraulic fluid “AKCELA HYDRAULIC EXCAVATORS FLUID BIO” has been tested by the Manufacturer and approved for application on the machines.

2

A change from mineral hydraulic oil to this synthetic hydraulic fluid can, however, be made also at a later date. Environmentally compatible hydraulic fluid must not be simply poured away as normal waste. It must be disposed of in the same way as any used oil!

If hydraulic fluid seeps into the ground, the machine Owner and the Competent Authorities must be informed. The use of AKCELA HYDRAULIC EXCAVATORS FLUID BIO is restricted only to hydraulic systems.

Do not mix this hydraulic liquid with other oils of other makes; this kind of mixture decreases the oil biodegradability.

4-3

SECTION 4

SAFETY INSTRUCTIONS No inspection and servicing work may be carried out until the Operator’s Manual has been read and understood.

S CAUTION S There is a risk of serious injury if maintenance or repairs are not performed correctly. If you do not understand the maintenance procedures, consult your Dealer.

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization. Consult your Dealer.

Respect the maintenance intervals prescribed by this Manual carefully.

IMPORTANT: if you use the machine under particularly severe conditions (dusty or corrosive atmosphere, etc.) reduce the intervals between servicing operations.

MACHINE SAFETY Before carrying out any servicing or repair work the machine must be secured as follows: - park machine on level and firm ground; - place the working equipment on the ground; - lock the articulated joint; - stop the engine; - apply the parking brake; - remove ignition key; - secure machine with wheel chocks to avoid its rolling or overturning.

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, for instance by a specialist fitter or by attending a training course.

4-4

3

REFILLINGS AND SERVICING EQUIPMENT Wear closely fitting 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.

WORKING EQUIPMENT Place 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, block off the joints.

Remove the blocks on finishing work.

4

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

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.

CLEANING Clean the units within the working range before starting work.

Select the cleaning agent according to the material the parts to be cleaned are made.

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

5

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

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

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

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

Wear gloves.

Observe the instructions on the packaging.

4-5

SECTION 4 FLAMMABLE LIQUIDS When handling flammable liquids: - do not smoke; - keep away from unshielded light sources and naked flames.

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

Never attempt to extinguish burning liquids with water. Use: - dry powder; - with carbon dioxide; - with foam.

Water used for extinguishing purposes would vaporize 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.

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.

Always store hydraulic oil in the original containers.

Use a respiratory mask for protection to avoid inhaling dust from brake linings.

Swallowing hydraulic oil is a severe health hazard.

When hydraulic oil has been swallowed, avoid vomiting, but consult a doctor or go to a hospital.

If oil has splashed into the eyes, rinse immediately with plenty of clear water and consult a doctor.

Never let hydraulic oils come into contact with the skin. Wear rubber gloves and firm protective clothing. Skin contact with hydraulic oils is a severe health hazard.

If contact with the skin cannot be avoided, protect the skin with a barrier cream.

Contact with the skin should be as brief as possible.

Wash with water and soap sufficiently.

Never let hydraulic oil penetrate into the ground; it contaminates the ground water.

Collect escaping hydraulic oil and dispose of it separately from other wastes and without polluting the environment. Never mix with used oil.

4-6

6

REFILLINGS AND SERVICING VISIBLE OIL LEAKS Have any visible leakage repaired immediately.

Escaping oil pollutes the environment.

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

Repair any leakages in the piping and hose system immediately or have them repaired.

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

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

7

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

Never repair damaged piping; always replace it.

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

ENVIRONMENTALLY COMPATIBLE DISPOSAL Oils, greases, brake fluids, cleaning agents, solvents and oily components, for instance filters, cleaning rags, replaced wear parts and unserviceable machine parts, must be disposed of separately in the interest of environmental protection.

Never dispose of such substances with standard household refuse.

Empty substances into the containers provided for this purposes.

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

8

Never allow oils and oily waste to get into the soil or into water; they pollute the environment!

EXHAUST GASES Exhaust gases are a health hazard, do not inhale.

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

4-7

SECTION 4 BATTERIES Batteries give off explosive gases.

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

Battery acid is toxic and corrosive.

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

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

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

9

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 watchstraps 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.

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, then the positive clamp.

After work, connect first the positive clamp then the negative.

10

4-8

REFILLINGS AND SERVICING

SERVICING INTERVALS CHART Cleaning

Oil change

Pressure check

Level check and topping-up

Check

Draining the water

Greasing

Replacement

Air bleeding

Service

Before starting work Every 10 hours

Every 50 Every 250 hours hours Every Every week month

Every 1000 hours

Every 3000 hours

When necessary

Page

General checks General inspection

4-12

Cab Controls and pilot lights functionality

4-12

Screen washer liquid

4-16

Filter

4-17/4-35

Diesel motor and fuel system Diesel motor Engine oil

4-55 4-13/4-36

Engine oil filter

4-37

Drive belt

4-21

Valve clearance

4-38

Fuel filter

4-40

Injection nozzles

4-67

Water trap

4-17

Fuel tank

4-12/4-53

Air intake system Air filter - main filter element

19-42

Air filter - safety element

4-20/4-42

Air filter - dust discharge valve

4-18

Hoses, pipes and sleeves

4-41

Hydraulic system Hydraulic oil reservoir

4-13/4-54

Return filter

4-22/4-43

Breather filter

4-44

Hoses, pipes and connectors

4-57

4-9

SECTION 4

Service

Before starting work Every 10 hours

Every 50 Every 250 hours hours Every Every week month

Every 1000 hours

Every 3000 hours

When necessary

Page

Transmission components Front axle

4-22/4-51

Rear axle

4-22/4-32/ 4-51

Tyres

4-56

Tyres - Pressure

4-24

Tyres - Tightening

4-28

Brake system Brakes System

4-12/4-65

Service brake

4-12

Brake - Pressure

4-44

Brake accumulator

4-46

Brake discs - Thickness

4-48

Parking brake

4-12

Electrical system Lights - Bulbs

4-12/4-61

Rotary beacon

4-12

Relays and fuses

4-60

Voltage and continuity

4-31

Battery

4-66

Battery - Electrolyte

4-49

Battery - Loaded

4-50

Battery - Clamps

4-50

Heating - Air conditioning Heating filter

4-50

Evaporator

4-33

Compressor belt

4-33

Condenser

4-34

Coolant

4-15

Equipment Buckets - Teeth

4-67

Lifting forks

4-55

Greasing Various grease nipples

4-10

4-28

REFILLINGS AND SERVICING HOURMETER The hourmeter (1) allows to schedule the servicing operations. It works in the same way as a clock when the engine is running and adds up the service hours.

Servicing Intervals are properly calculated to guarantee safe and efficient machine operation.

Be sure to carry out all the servicing operations properly, as defined in this manual.

11

4-11

SECTION 4

CHECKS BEFORE START-UP AND BEFORE EACH WORKING SHIFT (10 HOURS) SERVICE POINTS

Check

Cleaning

Level check and topping- Replacement up

Machine - General inspection Service brake - Parking brake Lights Controls and pilot lights functionality Engine oil - Level Hydraulic oil reservoir - Level Fuel tank - Level Coolant - Level Screen washer liquid - Level

MACHINE GENERAL INSPECTION Before operating the machine it is advisable to carry out a general inspection of: - Check visually the machine and working equipment for possible breaks or damages to components or to the machine structure. Should problems be noticed, address to an authorized workshop to have the necessary repairs done.

Replace all the damaged or worn parts with original spares.

- Check for leaks; and if present, rectify them.

- Keep the machine clean daily from the dirt buildup during the work.

SERVICE AND PARKING BRAKES Before starting the machine, check the proper operation of:

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

PARKING BRAKE The parking brake requires virtually no maintenance and is applied when the hand brake lever reaches the 4th notch. When the braking efficiency diminishes, check the lining thickness of the brake disks and contact the After-sales service.

LIGHTS Before operating the machine it is advisable to carry out again a general cleaning and operation check of all lights.

CONTROLS AND PILOT LIGHTS OPERATION

- parking brake.

Before starting the machine, check the proper operation of all controls and instruments and pilot lights of the control dashboard.

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

Should faults be noticed, shut off the engine and locate the trouble.

- service brake;

- Place the working equipment on the ground.

- Switch off engine.

- Apply parking brake.

- Depress brake pedal 10-15 times.

4-12

REFILLINGS AND SERVICING ENGINE OIL - LEVEL Park the machine on level ground and protect against inadvertent movements.

Engine oil and operating temperature.

Switch off engine.

Wait one minute and pull out the dipstick (1).

Wipe dipstick (1) clean with a lint-free cloth and reinsert.

12 Pull out dipstick again. The oil level should lie between the marks. If the oil level is at the “min” mark or below, top up engine oil through the filler neck (2).

13

HYDRAULIC OIL RESERVOIR - LEVEL Park the machine on a flat surface and place the working equipment on the ground.

Apply parking brake. Switch off engine.

Depressurize the hydraulic system. To do so, move the control levers of the working equipment with the engine off, until the working equipment stops making movements. Secure the machine.

Avoid skin contact with hydraulic oils. Wear gloves and firm working clothing. Skin contact with hydraulic oils is a health hazard.

The oil level should reach the middle of the inspection glass (1). If it is below the lower edge of the inspection glass, top up oil. To do so, unscrew the cap (2) of the breather filter and top up hydraulic oil.

14

4-13

SECTION 4 FUEL TANK - LEVEL Use commercial-grade diesel fuels with a sulphur content of less than 0.5%.

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

S WARNING S Do not smoke and do not use open flames.

Diesel fuel may be harmful to the skin, wear protective gloves or use a barrier cream.

Switch off engine.

Never take off the cap or refuel when the engine is running. While you refuel keep the control of refuelling gun.

Before refuelling, clean the seat of the filler neck to avoid the introduction of foreign bodies in the tank.

After refuelling, retighten the cap firmly.

Do not spill fuel and do not let it penetrate into the ground: environmental pollution hazard.

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

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

Open the tank lock.

Unlock the tank cap (1) by turning the key 90° counterclockwise and remove the cap.

Fill in fuel through the filler neck.

If possible, use a microfilter in the filling line.

15

4-14

REFILLINGS AND SERVICING COOLANT - LEVEL

S CAUTION S Refrigerating agent R 134a used is known as a safety coolant.

This means that this coolant is non-combustible, non-explosive, non-toxic, non-irritating, odourless and tasteless. Nevertheless, the following points must be observed: Avoid any contact with liquid coolant. Treat parts of the skin that have come in contact with this agent as frostbite.

Wear goggles to protect your eyes. In case coolant gets into contact with the eyes, seek medical advice immediately.

Before carrying out repairs on the air conditioner, the system must be emptied. Don’t let coolant escape. For sucking coolant use only approved evacuation equipment.

It is strictly forbidden to carry out welding work on parts of the closed system or in the vicinity thereof.

Whether the system is filled with coolant or not, heating always produces high overpressure which may cause damage to the unit or even explosions.

Full coolant bottles must not be thrown and exposed for prolonged periods to sunlight or other sources of heat. The maximum admissible temperature of a full coolant bottle must not exceed 45 °C (113 °F).

It is essential to keep the cooling system free from chlorine or chlorine-containing substances and from oils and greases. Evacuating and filling equipment should be used exclusively for R 134a.

Check the coolant level.

With the engine running and the unit switched on, the coolant visible in the inspection glass must reach the top of the container (arrow) and be free of bubbles. Bubbles in the inspection glass are a sign of coolant low level in the system. The system must be checked for leaks and refilled by a specialized workshop.

16

4-15

SECTION 4 SCREEN WASHER LIQUID - LEVEL The liquid reservoir (1) for the screen wiper system is located in the engine compartment.

After opening the engine guard, the reservoir is accessible in the right sidewall.

To top up, remove cap (2) and fill in with water.

In winter, add antifreeze to the water.

17

4-16

REFILLINGS AND SERVICING

WEEKLY SERVICE (50 HOURS) SERVICE POINTS

Check

Pressure check

Level check and topping-up

Cleaning

Greasing

Draining the water

Breather filter - Cab Air filter: dust discharge valve Main filter element - Safety element Drive belt Water trap - Fuel system Hydraulic system return oil filter Front axle Rear axle Tyres Wheels - Nuts tightening Various grease nipples Electrical system - Voltage and continuity

CAB BREATHER FILTER - CLEANING The filter is accessible after opening of the service door (1).

Remove the wing nuts of the filter frame and detach the frame (2).

Remove the filter element (3) and check if it is clean.

If necessary, clean it.

Install the filter element (3).

Assemble the frame (2) of the filter.

Close the service door (1).

18

AIR FILTER - CLEANING

S WARNING S Never leave the engine on when parts of the air intake system have been removed. Engine damage may occur if the air intake system is allowed to draw in unfiltered air.

The wheel-loader is equipped with a dry-air filter comprising a main filter and a safety filter element.

The dry-air filter is located under the engine guard.

Replace or clean the main filter element, when pilot lamp (8) lights up. In this case, the main filter element must be cleaned or replaced even if the change interval has not been reached.

19

4-17

SECTION 4 DUST DISCHARGE VALVE Check that the discharge slot of the valve (1) is not clogged up with dust. If necessary, remove the dust accumulated by pressing apart lips of discharge slot as indicated by arrows.

Clean discharge slot from time to time.

Remove any caked dirt by pressing together upper section of valve.

20

MAIN FILTER ELEMENT Loosen the clamps (2) and remove the dust collector (3).

21 Remove the main filter element (4) carefully.

22

4-18

REFILLINGS AND SERVICING MAIN FILTER ELEMENT - CLEANING Never clean filter elements by beating them against hard objects.

After 3 cleaning cycles or after one year of operation at the latest, the main filter element must be replaced.

Never clean filters with petrol and flammable or hot liquids.

Cleaning with compressed air is suitable if the filter element is to be reused immediately.

The air pressure at the nozzle must not exceed 5 bars (73 psi).

23

Start cleaning the filter surface by blowing dry compressed air diagonally from outside into the filter element.

Continue cleaning by blowing compressed air from inside against the element.

Cleaning is finished when all visible dust has been removed from the element.

CHECKS Checks before installation of the main filter element: - check the filter paper with the help of a lamp bulb.

Filter damage is indicated where the light shines brightly through the paper. If damaged, replace the main filter element immediately.

24 Check the seal (5) visually. If the seal is damaged, replace the main filter element immediately.

25

4-19

SECTION 4 MAIN FILTER ELEMENT REASSEMBLY Before reassembly of a new main filter element, apply a thin layer of oil, Vaseline or similar lubricant on the sealing face of the element. The cleaned or the new filter element is installed in reverse order.

When installing the dust collector, pay attention to the “TOP” marking.

Turn the dust collector (3) slightly to the right or left so that the dowel pin can engage in the filter housing. At this point close all clamps (2).

26 SAFETY ELEMENT If the pilot lamp lights up again immediately after servicing, the safety filter has to be replaced.

S CAUTION S After 5 cleaning cycles of the main filter element, but after 2 years at the latest, the safety filter has to be replaced by a new one.

Loosen the clamps (2) and remove the dust collector (3) carefully.

27 Remove the main filter element (4) carefully.

28 The safety filter element (6) can be withdrawn thereafter.

Replace safety filter element.

Before installing a new safety filter element, apply a thin layer of oil, Vaseline or similar lubricant on the sealing face of the element.

29

4-20

REFILLINGS AND SERVICING DRIVE BELT - CHECK Visually inspect entire belt for damage.

Replace damaged belt.

After replacing the belt, make an adjustment after 15 minutes of operation.

To check the belt tension, use suitable tension gauge.

- Place indicator arm (1) into gauge.

- Position guide (3) on belt (2), midway between pulleys, with stop against edge of belt.

30 - Push slowly on black pad (4) at right angles to belt, until spring is heard or felt to trigger.

- Carefully remove gauge without altering position of indicator arm (1).

- Read off value where black indicator arm (1) intersects scale (5) (arrow). For adjustment values see manual.

- If necessary, retension belt and measure again.

31 DRIVE BELT TENSION Loosen screws (1), (2) and (3).

Adjust alternator (4) in direction of arrow by turning screw (3), until correct belt (5) tension is achieved.

Retighten screws (1), (2) and (3).

S WARNING S Check, tension and change belt only with engine off. Reassemble belt guard, if provided.

32 DRIVE BELT REPLACEMENT Loosen screws (1), (2) and (3).

Adjust alternator (4) in direction of arrow by turning screw (3).

Remove the belt and insert a new one.

Adjust alternator (4) against direction of arrow by turning screw (3), until correct belt tension is achieved.

Retighten screws (1), (2) and (3).

33

4-21

SECTION 4 HYDRAULIC SYSTEM RETURN OIL FILTER - PRESSURE CHECK The hydraulic system is equipped with a return flow filter (1).

A built-in by-pass valve protects the return flow filter against overpressure.

When the by-pass is open, the filter is no longer in the circuit. The filter cartridge should therefore be replaced in time.

To check the return flow pressure with pressure gauge (2), the engine must be run at full speed. To this aim set the travel direction selector to 0, by applying the parking brake and by bringing the engine with the accelerator to maximum speed. A second person can now read the pressure gauge.

34

Should the return pressure lie in the red range of the pressure gauge, the filter cartridge must be replaced even if the schedule change interval has not yet elapsed.

FRONT AND REAR AXLE - OIL LEVEL CHECK Park the machine on a flat surface and lower the equipment to the ground.

Shut off the engine and apply the parking brake.

Secure the machine by placing chocks under the wheels to prevent inadvertent movements.

Secure the machine against unauthorized starting.

Before working on axles or gearboxes, bleed axles and gearboxes.

Risk of scalding from hot oil.

Collect escaping oil and discard without polluting the environment.

FRONT AXLE Activate the breather valve (1).

Unscrew the level and filling plug (2). Oil level should be flush with the hole.

If this is not the case, fill in oil through the hole until it comes out from the hole.

Clean and retighten the level plug (1).

Repeat the check after 10 minutes and top up again, if necessary.

35

4-22

REFILLINGS AND SERVICING REAR AXLE Activate the breather valve (1).

Unscrew the level and filling plug (2). Oil level should be flush with the hole.

If this is not the case, fill in oil through the hole until it comes out from the hole.

Clean and retighten the level plug (2).

Repeat the check after 10 minutes and top up again, if necessary.

36

WHEELS REDUCTION GEAR Park the machine on a flat surface. Wait 10 minutes until the oil level in the axles is balanced before beginning the check.

Turn the wheels until plug (1) is in position (A).

Unscrew plug (1) partially to release internal pressure.

37 Turn the wheels until plug (1) is in position (B).

Unscrew plug (1).

Oil level should be flush with the hole. If this is not the case, fill in oil through the hole until it comes out from the hole.

Clean and retighten the plug.

Repeat the check after 10 minutes and top up again, if necessary.

38

4-23

SECTION 4 TYRES - PRESSURE CHECK

S CAUTION S Before inflating the tyres, check the tyres, rims and rim parts for damage, penetrated foreign objects and proper fitting.

Check the tyre inflation pressure only when the tyres are cold, as when they are warm, the pressures indicated are higher than usual.

Use inflation equipment with long filling hose, selffixing nozzle and pressure gauge.

Inflate the tyres only with compressed ambient air.

Never use inflammable gases: risk of explosion!

During tyre inflation, do not stand near the tyre and always in the plane of the tyre tread.

Watch the tyre and the pressure gauge of the inflating equipment permanently during the inflation and never exceed the prescribed tyre pressures.

If available, place a safety cage around the wheel.

Make sure that nobody is standing near the tyre when it is being inflated.

Always inflate tyres to the prescribed pressure: - excessive tyres pressure means poor handling properties off the road and a risk of bursting tyres; - insufficient pressure means increased wear on the tyres and inadequate stability of the machine.

Apply the right tyre pressure for each axle and foreseen application.

Do not keep tyres pressure lower than the values due, so as not to overheat the tyres, because this could cause: - tyre breaks; - tread damage; - inner damage; - uneven wear and short life.

Do not overinflate the tyres, because if bumped they can break easily and under extreme conditions the rim can get deformed and the tyre can burst.

S CAUTION S The tyres inflating pressure varies according to the load applied to axles.

4-24

39

REFILLINGS AND SERVICING Park the machine on level and firm ground with sufficient strength.

Place the working equipment on the ground.

Apply the parking brake.

Switch off engine.

Attach the self-locking nozzle of the inflating equipment to the tyre filling valve (1).

The device is equipped with a pressure gauge (2), that when connected, allows to check the pressure value.

If the pressure results to be lower than expected, proceed to the inflation.

40

ADVICED PRESSURES 21E Front axle with working equipment

Rear axle

Forks and other equipment

Bottom-dump and loading bucket

in bar (psi)

in bar (psi)

in bar (psi)

10.5/80-18 EM TG 42 DU

x

3.25 (47)

2.5 (36)

12.5-18 MPT E 91-2 DU

x

2.5 (36)

1.75 (25.4)

12.5-20 MPT TG 32 DU

3.5 (51)

3.0 (43.5)

1.5 (21.8)

12.5-R20 MPT SP PG 8 DU

3.5 (51)

3.0 (43.5)

2.0 (29)

5.5/55 R18 MPT SP PG 7 DU

4.0 (58)

3.0 (43.5)

2.0 (29)

335/80 R18 MPT XM27 MI

3.5 (51)

2.5 (36)

1.5 (21.8)

335/80 R18 EM SP 9 DU

3.5 (51)

3.0 (43.5)

2.0 (29)

335/80 R20 MPT SP T 9 DU

3.0 (43.5)

2.5 (36)

1.5 (21.8)

335/80 R20 EM SP T 9 DU

3.25 (47)

2.75 (40)

1.75 (25.4)

335/80 R20 EM VUT L2 BS

3.5 (51)

3.3 (48)

2.9 (42)

335/80 R20 MPT XM27 MI

3.0 (43.5)

2.0 (29)

1.5 (21.8)

366/70 R18 EM SP T 9 DU

3.25 (47)

2.75 (40)

1.75 (25.4)

Tyre type

4-25

SECTION 4

121E Front axle with working equipment

Rear axle

Forks and other equipment

Bottom-dump and loading bucket

in bar (psi)

in bar (psi)

in bar (psi)

x

3.5 (51)

2.5 (36)

14.5-20 MPT E 91 DU

3.5 (51)

2.5 (36)

1.5 (21.8)

14.5-R20 SP PG 8 DU

3.5 (51)

3.0 (43.5)

2.0 (29)

335/80 R20 EM SP T 9 DU

x

3.0 (43.5)

1.5 (21.8)

335/80 R20 MPT XM27 MI

x

3.0 (43.5)

1.5 (21.8)

365/80 R20 EM SP T 9 DU

3.5 (51)

2.75 (40)

2.0 (29)

365/80 R20 EM VUT L2 BS

3.5 (51)

3.3 (48)

3.3 (48)

375/75 R20 MPT XM27 MI

3.5 (51)

2.5 (36)

1.5 (21.8)

405/70 R20 MPT XM27 MI

3.5 (51)

2.5 (36)

1.5 (21.8)

16/17-20 EM E 91-2 DU

2.75 (40)

2.25 (32.6)

1.5 (21.8)

405/70 R20 EM PG 75 R DU

3.25 (47)

2.75 (25.4)

1.75 (25.4)

405/70 R20 EM SP T 9 DU

3.0 (43.5)

2.5 (36)

1.5 (21.8)

Tyre type

12.5-R20 MPT SP PG 8 DU

221E Front axle with working equipment

Rear axle

Forks and other equipment

Bottom-dump and loading bucket

in bar (psi)

in bar (psi)

in bar (psi)

x

4.0 (58)

2.5 (36)

14.5-20 MPT E 91 DU

3.5 (51)

2.75 (40)

1.75 (25.4)

14.5-R20 MPT SP PG 8 DU

4.0 (58)

3.5 (51)

2.0 (29)

335/80 R20 EM SP T 9 DU

x

3.25 (47)

1.75 (25.4)

335/80 R20 MPT XM27 MI

x

3.0 (43.5)

1.5 (21.8)

365/80 R20 EM SP T 9 DU

3.5 (51)

3.0 (43.5)

2.0 (29)

365/80 R20 EM VUT L2 BS

4.0 (58)

3.5 (51)

3.5 (51)

375/75 R20 MPT XM27 MI

3.5 (51)

2.5 (36)

1.5 (21.8)

405/70 R20 MPT XM27 MI

3.5 (51)

2.5 (36)

1.5 (21.8)

3.0 (43.5)

2.5 (36)

1.5 (21.8)

3.5 (51)

3.0 (43.5)

2.0 (29)

3.25 (47)

2.75 (40)

1.75 (25.4)

Tyre type

12.5-R20 MPT SP PG 8 DU

16/17-20 EM E 91-2 DU 405/70 R20 EM PG 75 R DU 405/70 R20 EM SP T 9 DU

4-26

REFILLINGS AND SERVICING

321E Front axle with working equipment

Rear axle

Forks and other equipment

Bottom-dump and loading bucket

in bar (psi)

in bar (psi)

in bar (psi)

x

4.0 (58)

2.5 (36)

14.5-20 MPT E 91 DU

3.5 (51)

3.0 (43.5)

2.0 (29)

14.5-R20 MPT SP PG 8 DU

4.0 (58)

3.5 (51)

2.0 (29)

335/80 R20 EM SP T 9 DU

x

3.75 (54.4)

2.0 (29)

335/80 R20 MPT XM27 MI

x

3.8 (55)

2.0 (29)

365/80 R20 EM SP T 9 DU

3.5 (51)

3.0 (43.5)

2.0 (29)

375/75 R20 MPT XM27 MI

3.5 (51)

2.5 (36)

1.5 (21.8)

405/70 R20 MPT XM27 MI

3.5 (51)

3.5 (51)

1.5 (21.8)

3.25 (47)

2.75 (40)

1.75 (25.4)

3.75 (54.4)

3.25 (47)

2.25 (32.6)

405/70 R20 EM SP T 9 DU

3.5 (51)

3.0 (43.5)

2.0 (29)

405/70 R20 EM VUT L2 DU

4.0 (58)

3.5 (51)

3.5 (51)

Tyre type

12.5-R20 MPT SP PG 8 DU

16/17-20 EM E 91-2 DU 405/70 R20 EM PG 75 R DU

4-27

SECTION 4 WHEELS - NUTS TIGHTENING Park the machine on a flat surface and lower the equipment to the ground.

Switch off engine.

Apply parking brake.

Secure the machine by placing chocks under the wheels to prevent inadvertent movements.

Check if nuts (1) are tighten. Tightening torque 550 Nm (405.6 lbf·ft).

41

GREASE NIPPLES - GREASING Before beginning greasing work: - park the machine on a level surface; - place the working equipment on the ground in dumping position; - secure the machine; - shut off the engine.

42 Remove the protective cap from the grease nipple.

Clean the grease nipple.

Press the nozzle of the grease gun on the grease nipple.

Inject grease until the fresh grease squeezes the used grease out of the bearing joints.

Wipe off used grease with cleaning rags.

After greasing, put protective cap back onto the grease nipple.

4-28

REFILLINGS AND SERVICING

43

4-29

SECTION 4

Position

Greasing location

Quantity

Hydraulic system 1

Dumping cylinder

2

2

Lifting cylinder

2

Frame 3

Articulated joint

2

Lifting frame 4

Lifting arms

2

5

Draw bar

2

6

Toggle lever

1

7

Quick tool coupler

2

Equipment 8

Bottom-dump bucket

2x2

9

Bottom-dump bucket cylinder

2x2

Cardan shaft 10

Normal operation

2

Intermediate bearing

1

(Overdrive option)

Cab 11

4-30

Hinges

2x2

REFILLINGS AND SERVICING ELECTRICAL SYSTEM - VOLTAGE AND CONTINUITY CHECK 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 clamp.

After work, connect first the positive clamp then the negative.

Use only measuring instrument for voltage and continuity testing: - never use a test lamps; - never “tap against ground”.

This causes a short circuit with consequent damage to the alternator or to the electronics of PMS. To start up the engine, the alternator is controlled (pre-excited) by an electronic circuit, whose task consists in enabling the alternator to supply power.

The circuit is an integral part of the central electronic system in the control console.

A warning lamp in the control console (alternator) indicates that the alternator is functioning correctly.

This LED must light up when the key switch is switched on; it is extinguished when the engine is running.

If this is not the case, there is a fault in the alternator circuit or in the control console.

To prevent further damage, the cause of the fault must be traced and eliminated as quickly as possible.

Address to After-sales Service.

4-31

SECTION 4

MONTHLY SERVICE (250 HOURS) SERVICE POINTS

Check

Cleaning

Greasing

Replacement

Rear axle Heating and air conditioning system: filter Evaporator - Air conditioning system Compressor - Air conditioning system Compressor belt - Tension Condenser

REAR AXLE - GREASING Park the machine on a flat surface and lower the working equipment to the ground.

Switch off engine.

Secure the machine with wheel chocks, so that it cannot move.

Remove plug from relevant grease nipple.

Clean the grease nipples (1).

Press the nozzle of the grease gun on the grease nipples.

Inject grease until the fresh grease squeezes the used grease out of the bearing joints.

Wipe off used grease with clean rags.

After the greasing apply protective plug on grease nipple.

4-32

44

REFILLINGS AND SERVICING HEATING/AIR CONDITIONING SYSTEM The visual checks should be performed even in case the air conditioning is not used.

The air conditioning should moreover be switched on once a month for 10 to 15 minutes. To prevent drying out and embrittlement of the shaft seal in the compressor. This measure also ensures regular lubrication of the compressor components.

The heater / air conditioner is installed in the driver’s cab on the right side of the operator’s seat.

- Blower (1) - Heat exchanger (2)

45

- Evaporator (3) - Heating filter (4) - Heating valve (5) These components are accessible after removal of the cover. The heat exchanger, the evaporator and the blower require no servicing.

FILTER If the filter (4) is contaminated, remove the cover first and then the filter.

Clean the filter with water jets.

EVAPORATOR When the evaporator (3) is soiled and the ribs deformed.

- Blow out dirt and remove by suction, straighten deformed ribs.

When the antifreeze protection sensor on evaporator is kinked or leaking.

- Have sensor repaired.

COMPRESSOR BELT When the compressor belt (1) is damaged.

- Replace defective belt.

When the belt tension is not correct.

- Readjust, if necessary.

When the compressor (2) is not safely fastened.

- Tighten loosened screws.

46

4-33

SECTION 4 CONDENSER When condenser (1) is contaminated.

- Contaminated condensers have a bad condensing performance. Clean by blowing out or wash with water (do not use high-pressure jet cleaners).

Deformed ribs can be repaired by straightening.

47

4-34

REFILLINGS AND SERVICING

SERVICE AFTER 1000 HOURS SERVICE POINTS

Check

Pressure check

Checking the level

Oil change Replacement

Cab breather filter Engine oil Engine oil filter Engine valves clearance Fuel filter Air intake system - Lines Air filter Hydraulic oil return filter Hydraulic system breather filter Brake Accumulator Brake discs thickness Battery - Electrolyte Battery - Loaded Battery - Clamps Heating system filter Front axle Rear axle

CAB BREATHER FILTER - CHANGE The filter is accessible after opening of the service door (1).

Remove the wing nuts of the filter frame and detach the frame (2).

Remove the filter element (3).

Install the new filter element (3).

Assemble the frame (2) of the filter.

Close the service door (1).

48

4-35

SECTION 4 ENGINE OIL - CHANGE

S CAUTION S Risk of scalding from hot oil.

Collect escaping oil and discard without polluting the environment.

Bring engine to operating temperature.

Park the machine on level ground and protect against inadvertent movements.

Switch off engine.

To reach the drain plug, remove the grid under the machine at the rear.

Remove screw (1), push grid (2) towards the rear and swing downwards before removing.

Place a collecting recipient below the drain plug.

The recipient capacity can be determined by means of the relevant table in this manual.

49 Engine, hydraulic oil reservoir and gearboxes may be equipped with special oil drain plugs (3) with drain hose (4).

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

Unscrew blanking plug (5) from cap (3).

Unscrew blanking plug (6) from drain hose (4).

Screw draining hose (4) onto the plug; the plug opens and the oil drains away.

After the oil has drained away, unscrew the oil draining hose (4); the plug closes automatically.

Screw up again the blanking plug (6).

50

When the engine oil has drained away: - fill in engine oil into filler neck (7) until the oil level reaches the “MAX” mark; - start the engine and let it run for about 2 minutes at idling speed; - check the oil level and, if necessary, top up with oil to the “MAX” mark; - after the work, reassemble grid to the frame with screw.

51

4-36

REFILLINGS AND SERVICING ENGINE OIL FILTER - CHANGE

S WARNING S Risk of scalding from hot oil.

Collect escaping oil and discard without polluting the environment.

The oil filter is equipped with a valve and a special tube preventing the reflow of oil.

Use only original oil filter cartridges.

Clean filter head (1).

Loosen and unscrew oil filter cartridge (2) using commercial tool.

Catch any escaping oil.

Clean any dirt from filter carrier sealing surface.

Apply a light film of oil to rubber gasket (3) of new fuel filter cartridge.

Manually screw in new cartridge until gasket is flush.

Tighten oil filter cartridge (2) with final half-turn.

Check oil level.

52

Check oil pressure.

Check oil filter cartridge gasket (3) for leaks.

4-37

SECTION 4 ENGINE VALVES CLEARANCE - CHECK/ ADJUSTMENT Remove cylinder head cover.

Position crankshaft as per schematic.

Before adjusting valve clearance, allow engine to cool down for at least 30 minutes: oil temperature should be below 80 °C (176 °F).

Check valve clearance (1) between rocker arm / tappet contact face (2) and valve stem (3) with feeler gauge (6) (there should be only slight resistance when feeler blade is inserted).

Valve clearance Load

Engine F4M2011 BF4M2011

mm in mm in

0.3 +0.1 -0 0.011 +0.003 -0 0.3 +0.1 -0 0.011 +0.003 -0

Drain 0.5 +0.1

53

-0 0.019 +0.003 -0 0.5 +0.1 -0 0.019 +0.003 -0

Adjust valve clearance if necessary: - loosen locknut (4); - use Allen key (7) to turn setscrew (5) so that correct valve clearance is attained after locknut (4) has been tightened.

Check and adjust valve clearance on all cylinders.

Reinstall cylinder head cover, with new gasket if necessary.

54

4-38

REFILLINGS AND SERVICING VALVE CLEARANCE ADJUSTMENT SCHEMATIC

55 Crankshaft Position (1): Turn crankshaft until both valves in cylinder (1) overlap (exhaust valve about to close, inlet valve about to open).

Adjust clearance of valves marked in black on schematic. Mark respective rocker arm with chalk to show that adjustment has been carried out.

Crankshaft Position (2): Turn crankshaft one full revolution (360°).

Adjust clearance of valves marked in black on schematic.

4-39

SECTION 4 FUEL FILTER - CHANGE

S CAUTION S During work on the fuel system: - stop the engine; - keep away open flames; - do not smoke.

Collect escaping fuel and discard without polluting the environment. Discard used filter cartridges without polluting the environment. Fuel may cause skin injuries. Wear gloves and suitable working clothing.

FUEL FILTER Clean the outside of the fuel filter carefully.

Loosen and unscrew the filter cartridge (1).

56 Collect escaping fuel.

Clean the filter carrier surface (2) accurately.

Apply a small amount of diesel fuel on the gasket (3) of the new filter cartridge.

Screw the cartridge by hand until it seats on the gasket.

Tighten the fuel filter cartridge by another half turn.

Bleed the fuel system.

Check filter for leaks.

57

4-40

REFILLINGS AND SERVICING AIR INTAKE SYSTEM - CHECK The engine must not be allowed to draw in unfiltered air, therefore: - check all hoses and pipes for leaking; - check that all clamps are in place and tight.

AIR FILTER - CHANGE

S WARNING S Never leave the engine on when parts of the air intake system have been removed.

Engine damage may occur if the air intake system is allowed to draw in unfiltered air.

The replacement of the main filter element is necessary when: - the cleaning reveals that the filter is damaged; - pilot light (8) comes on after the cleaning.

The replacement of the safety element is also necessary when: - after replacement of main element (8) pilot light comes on; - after cleaning the main filter element for the 5th time.

58

4-41

SECTION 4 FILTER ELEMENT CHANGE Loosen the clamps (2) and remove the dust collector (1) carefully.

59 Remove the main filter element (3) carefully.

60 The safety filter element (4) can be withdrawn thereafter.

Before installing a new safety filter element, apply a thin layer of oil, Vaseline or similar lubricant on the sealing face of the element.

61 Before installing a new safety filter element, check the discharge nozzle at the filter housing and the accessible part of the intake line with your fingers. If dust is detected in the intake line to the engine, contact immediately the After-sales service.

Install the new safety element (4). Install the new main filter element (3). Reinstall dust collector (1) locking the clamps (2).

4-42

REFILLINGS AND SERVICING HYDRAULIC SYSTEM RETURN OIL FILTER - CHANGE

S CAUTION S Park the machine on a flat surface and place the working equipment on the ground.

Apply parking brake.

Switch off engine.

Depressurize the hydraulic system. To do so, move the control levers of the working equipment with the engine off, until the working equipment stops making movements. Avoid skin contact with hydraulic oils. Wear gloves and suitable working clothing.

Skin contact with hydraulic oils is a health hazard.

Unscrew plug (1).

62 Pay attention to gasket (2) and spring (3).

63 Withdraw filter pot (4) with filter cartridge (6).

Remove filter cartridge (6) by turning and pulling at the same time from filter pot (4) and discard without polluting the environment.

Pour the oil remaining in filter pot (4) into a recipient for used oils. Clean filter pot (4) with white spirit or diesel fuel. Check gasket (5) and replace, if damaged.

Assemble the filter in reverse order.

64

4-43

SECTION 4 HYDRAULIC SYSTEM BREATHER FILTER - CHANGE The breather filter ensures aeration and bleeding of the hydraulic reservoir when the hydraulic oil level varies.

The breather filter is equipped with a filter element which prevents dust and dirt from getting into and oil splashes from getting out of the reservoir. Replacing or cleaning is not possible.

Change breather filter completely.

65

BRAKE - PRESSURE CHECK

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

If in doubt, have the work done by the After-sales service.

Never do repair work on brakes unless the machine is secured.

When working on brakes, block the articulated joint.

Park the machine on a flat surface and lower the working equipment to the ground.

Secure the machine and the articulated joint.

Relieve the braking pressure.

To remove the braking pressure, depress the brake pedal 10-15 times. The brake system is depressurized when the pedal can be depressed without resistance.

Unscrew the cap (1) from measuring port (2) on brake valve (3) and connect gauge (4) to the port.

(Measuring range up to 200 bar (2900 psi)).

66 Check that the parking brake is applied and that the travel selector lever is set to 0.

Start the engine and wait until the required minimum braking pressure is achieved, that is when pilot lamp (5) goes out and when the acoustic warning signal stops sounding.

Check the braking pressure.

The pressure gauge (4) must indicate a pressure of 55 + 5 bar (798 + 72 psi).

In the event this value is not achieved, please contact our After-sales service.

67

4-44

REFILLINGS AND SERVICING

S CAUTION S When: - pilot lamp does not go out; - the acoustic warning signal continues to sound; - the braking pressure is below 55 bar (797 psi) or higher than 60 bar (870 psi). the brake system is defective.

Contact the After-sales service.

PRESSURE ADJUSTMENT The adjustment of the brake pressure is carried out by means of setscrew (7), placed in the lower section of the brake pedal valve.

Install a pressure gauge (with a scale of 250 bar (3626 psi)) to the brake line. Then activate the brake.

To decrease the brake pressure, tighten setscrew (7).

To increase the brake pressure, unscrew the setscrew (7).

After that the setscrew has to be locked with locknut (6).

68

4-45

SECTION 4 ACCUMULATOR - PRESSURE CHECK

S CAUTION S Never do repair work on brakes unless you are qualified to work on brake systems. In case of doubts contact the After-sales service.

Carry out service work only if the machine and articulated joint have been secured beforehand.

Accumulators are installed in the hydraulic system containing nitrogen under high pressure.

Even if the hydraulic pressure in the system is eliminated, the nitrogen in the accumulator remains under pressure. The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

Therefore: - never perform mechanical work on accumulators, never weld or solder them; - testing and servicing work must be carried out by reliable personnel only; - prior to any testing and servicing work, depressurize the hydraulic part of the system; - before disassembly of an accumulator, always wear goggles and working gloves; - fill accumulators with nitrogen only, never with compressed air or oxygen; - report any defects or damage to the After-sales service 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.

Park the machine on a flat surface and lower the working equipment to the ground.

Secure the machine and the articulated joint.

Relieve the braking pressure.

To this purpose, depress brake pedal 10-15 times.

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

Unscrew the cap (1) from measuring port (2) (M16 x 2) of connector (3).

69

4-46

REFILLINGS AND SERVICING Connect a pressure gauge (4) (measuring range up to 200 bar (2900 psi)) on measuring port (2).

Start the engine and wait until the required minimum braking pressure is achieved. The acoustic warning signal stops sounding and pilot lamp (5) goes out.

The gauge must indicate a pressure of 150 - 10 bar (2175 - 145 psi). In the event this value is not achieved, please contact our After-sales service.

When the accumulator pressure is achieved, SHUT OFF the engine, while the ignition must be activated.

Depress the brake pedal repeatedly to limit stop and observe the pressure gauge.

70

Each time the brake pedal is pressed, the pressure drops.

When the acoustic warning signal is not heard and the pilot light (5) does not light up, although the repeated activation of the brake pedal (minimum 3 times), the accumulator pressure is too low.

In the event this value is not achieved, please contact our After-sales service.

At work shift end: - relieve the braking pressure; - unscrew pressure gauge (4); - screw cap (1) on measuring port (2).

4-47

SECTION 4 AXLES - DISCS THICKNESS CHECK DIFFERENTIAL DISCS THICKNESS

New counterdisc thickness = 1.5±0.03 mm (0.05±0.001 in) Worn counterdisc minimum thickness = 1.4 mm (0.055 in) Reference disc CA110643 - quantity 10

New friction disc thickness = 1.6±0.03 mm (0.06±0.001 in) Worn disc minimum thickness = 1.45 mm (0.057 in) Reference disc CA110644 - quantity 8

New friction disc thickness = 2.8±0.03 mm (0.11±0.001 in) Worn disc minimum thickness = 1.45 mm (0.057 in) Reference disc CA110642 - quantity 2.7

71 DISCS THICKNESS ON BRAKE UNIT

New friction disc thickness = 10±0.1 mm (0.39±0.003 in) Worn disc minimum thickness = 8.8 mm (0.34 in) Reference disc CA119682 - quantity 1

New counterdisc thickness = 11.7±0.05 mm (0.46±0.002 in) Reference disc CA125584 - quantity 1

72

4-48

REFILLINGS AND SERVICING BATTERIES - LEVEL CHECK - CLAMPS CHARGE CHECK

S CAUTION S Batteries give off explosive gases.

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

Battery acid is toxic and corrosive.

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

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

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

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

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.

The battery is located on the righthand side of the wheel loader in the rear frame.

Opening the engine guard gives access to the battery.

73 CHECKING THE ELECTROLYTE LEVEL Remove the caps (1).

When undercaps (2) are present: - electrolyte level should reach base of these.

Without undercaps: - electrolyte level should be 10 - 15 mm (0.39 - 0.59 in) above top of plates.

If necessary, top up with distilled water.

Retighten the caps (1).

74

4-49

SECTION 4 CHARGE CHECK Unscrew caps (1) and undercaps (2) if installed.

Measure electrolyte density of individual cells with commercial hydrometer (3).

Hydrometer reading (see table on following page) indicates battery’s state of charge.

During measurement, temperature of electrolyte should preferably be +20 °C (68 °F).

Electrolyte density in kg/dm3 (lb/foot3)

Charge

Normal

Tropical

1.28 (80)

1.23 (77)

correct

1.20 (75)

1.12 (70)

low: charge

1.12 (70)

1.08 (67)

discharged: recharge immediately

75

CLAMPS CHECK Keep battery clean and dry.

Disconnect dirty clamps.

Clean battery poles (+) and (-) and clamps and grease with acid-free and acid resistant grease.

When reassembling, ensure that clamps make good contact. Tighten the wheel nuts by hand.

HEATING SYSTEM FILTER - CHANGE

76

The air conditioner/heater is installed in the cab on the right side of the operator’s seat.

- Remove the cover (1).

- Remove and replace the filter (2).

77

4-50

REFILLINGS AND SERVICING FRONT AXLE - OIL CHANGE Activate the breather valve (1).

Place a collecting recipient under the front axle. The recipient capacity can be determined by means of the relevant table in this manual.

Unscrew the drain plug (2). After complete draining, clean drain plug (2) and screw back in place.

78 Unscrew the level plug (3).

Fill in oil. Oil level should be flush with the hole, fill in fresh oil until it comes out from the hole.

Clean and retighten the level plug (3).

After 10 minutes check oil level and top up if necessary.

REAR AXLE - OIL CHANGE

79

Activate the breather valve (1).

Place a collecting recipient under the rear axle. The recipient capacity can be determined by means of the relevant table in this manual.

Unscrew the drain plug (2), collect the used oil and discard without polluting the environment. After complete draining, clean drain plug (2) and screw back in place.

Unscrew the level and filling plug (3).

Pour in oil. Oil level should be flush with the hole, fill in fresh oil until it comes out from the hole.

80 Clean and retighten the level and filling plug (3).

After 10 minutes check oil level and top up if necessary.

81

4-51

SECTION 4 TRANSMISSION Activate the breather valve (1).

Place a collecting recipient under the front axle. The recipient capacity can be determined by means of the relevant table in this manual.

Unscrew the drain plug (2). After complete draining, clean drain plug (2) and screw back in place.

Unscrew the level and filling plug (3).

Pour in oil. Oil level should be flush with the hole, fill in fresh oil until it comes out from the hole.

Clean and screw back the plug (3).

After 10 minutes check oil level and top up if necessary.

82

WHEEL HUB REDUCTION GEARS Park the machine on a flat surface. Wait 10 minutes until the oil level is balanced.

Turn the wheels until plug (1) is in lower position (A).

Place a collecting recipient under the front axle. The recipient capacity can be determined by means of the relevant table in this manual.

Unscrew plug (1) and let the oil come out.

Clean and screw back the plug (1).

83 Turn the wheels until plug (1) is positioned horizontally (B).

Unscrew plug (1).

Pour in oil. Oil level should be flush with the hole, fill in fresh oil until it comes out from the hole.

Clean and screw back the plug (1).

After 10 minutes check oil level and top up if necessary.

84

4-52

REFILLINGS AND SERVICING

SERVICE AFTER 3000 HOURS SERVICE POINTS

Check

Cleaning

Oil change

Replacement

Fuel tank Oil tank Brakes accumulator Equipment - Forks Diesel motor

FUEL TANK - CLEANING

S CAUTION S Do not use petrol, paraffin oil or other solvents.

Use diesel fuel for cleaning and flushing instead.

Empty the tank beforehand by using up as much fuel as possible.

Unscrew the drain plug (1) below the fuel tank and drain the remaining fuel into a suitable container.

Filter the remaining fuel for reuse or discard without polluting the environment.

Rinse the tank with fresh fuel.

Screw drain plug (1) back in place and fill in fuel through the filler neck.

Bleed the fuel system.

Check filter for leaks.

85

4-53

SECTION 4 HYDRAULIC OIL RESERVOIR CLEANING AND OIL CHANGE

S CAUTION S Risk of scalding from hot engine oil.

Collect escaping hydraulic oil and discard without polluting the environment.

Never start the engine while the hydraulic oil reservoir is empty.

Secure the machine against unauthorized starting.

Park the machine on a flat surface.

Lower the equipment to the ground.

Shut off the engine, apply the parking brake.

For draining, unscrew the plug of the radiator.

Place a collecting recipient under the hydraulic reservoir. The reservoir capacity can be determined by means of the relevant table in this manual.

Unscrew the cover (1) of the return flow filter and withdraw the filter pot (3) and cartridge (4). Clean the bottom and the inside of the reservoir through the opening with hydraulic or flushing oil.

86 Unscrew the breather filter (2). Fill in new hydraulic oil through a strainer equipped funnel using a hand pump or an oil can until the oil level reaches the upper area of the inspection glass. Screw cover (1) back in place and bleed the whole system.

87

4-54

REFILLINGS AND SERVICING

DIESEL ENGINE - CLEANING

S WARNING S Clean the engine only when the engine is switched off.

Preparation: - Switch off engine.

- Remove engine covers and cooling air hood.

Replace them after cleaning and before test run.

- Cover electrical / electronic components and connections (for instance alternator, starter, governor, solenoid).

Using compressed air: - Blow air through engine, taking particular care not to damage cooler and cooling fins (begin to blow through air from exhaust side). Remove dirt which has blown into interior space.

Using cold cleaning detergent: - Spray engine with commercial cold cleaning detergent and allow to react for approximately 10 minutes.

- Clean the engine with strong water jets. Repeat operation if necessary.

- Allow engine to run warm so that remaining water evaporates.

Using high-pressure device: - Clean engine with steam jets (maximum spray pressure of 60 bar (870 psi), maximum steam temperature of 90 °C (194 °F)).

- Allow engine to run warm so that remaining water evaporates.

4-55

SECTION 4

SERVICE IF NECESSARY SERVICE POINTS

Replacement

Greasing

Air bleeding

Check

Tyres Connectors and hoses Fuses and relays Lights / Headlamps - Bulbs Rotary beacon - Reflectors Brakes System Battery Injection nozzles Buckets teeth

TYRES - CHANGE DISASSEMBLY

ASSEMBLY

Park the machine on firm and level ground.

Inflate the tyre to approximately 1 bar (14.5 psi).

Secure the articulated joint.

Do not damage the threads of the wheel studs.

Apply parking brake.

Tighten the wheel nuts by hand.

Shut down the engine and remove the ignition key.

Remove the supports under the raised axle and lower the axle.

Loosen the wheel nuts of the wheel to be changed by approximately 1 full turn.

Raise the axle with the defective wheel slightly until the wheels come clear of the ground.

- Front axle: by means of bucket raise the wheel loader upward.

- Rear axle: raise the wheel loader with a jack or a winch.

Place supports on both sides under the raised axle to prevent it from lowering.

Secure the machine as described in the chapter.

Release the air from tyre.

Unscrew the wheel nuts and remove the wheel making sure not to damage the wheel studs.

Do not lose the centering rings, spring washers and wheel nuts, because they will be reused by reassembly.

4-56

Tighten the wheel nuts crosswise to prescribed torque 450 Nm (332 lbf·ft).

Inflate the tyre with the correct pressure. (See page 4-25)

REFILLINGS AND SERVICING Position of tyre tread When fitting the wheels pay attention to the direction of the tyre tread. Figure shows the tread position offering the best traction during forward travel under normal conditions.

In special cases, another tread position may be of advantage. In such cases, contact the After-sales service.

88

CONNECTORS AND HYDRAULIC HOSES - CHANGE Before detaching hydraulic hoses, depressurize the hydraulic system.

Replace damaged and leaking hydraulic hoses by new ones.

Use original spares only, they are coordinated with the respective function.

Do not reuse used hoses and connectors.

Dispose of leaked oil and oily wastes without polluting the environment. Oil and oily wastes must be prevented from seeping into the ground or water.

Hydraulic hoses should be replaced after a six-year period of use. To prevent an increased risk of failure.

Tighten connectors to specified torque.

4-57

SECTION 4 FUSES FUSES IN THE CAB The fuses are accessible after opening the service door (1) on the right-hand side of the cab.

89

F1

7.5A

Emergency steering system

F2

7.5A

Load stabilization system

F3

7.5A

Switch 2nd gear

F4

5A

Right parking light, rear left light, license plate light

F5

15A

Socket outlet, switch illumination

F6

7.5A

Multifunction lever, creep speed solenoid

F7

7.5A

Gauge cluster, parking brake

F8

7.5A

Solenoid valve forward and reverse

F9

7.5A

Main beam left

F10

7.5A

Reversing light, reversing alarm

F11

7.5A

Engine stop solenoid

F12

15A

Backup

F13

10A

Flashing lights, hazard warning signals

F14

10A

Socket outlet, rotary beacon

F15

10A

Cab light, radio +30

F16

7.5A

Wiper, washer rear

F17

5A

Floating position

F18

10A

Backup

F19

5A

Left parking light, rear left light, panel backlight

F20

10A

Stop light, hazard warning signals

F21

15A

Wiper/washer front, radio +15

F22

15A

Rear working floodlamp

F23

7.5A

Dipped beam left

4-58

90

REFILLINGS AND SERVICING F24

7.5A

Dipped beam right

F25

7.5A

Main beam right

F26

7.5A

Preheating control input

F27

15A

Front working floodlamp

F28

15A

Horn

F29

15A

Backup

F30

15A

Immobilizer

F31

30A

Blower

FUSES IN RELAY COMPARTMENT The fuse of the preheating control is located under the engine guard in front at the right.

F1.1

50A

Immobilizer

91

FUSES REPLACEMENT Remove the defective fuse and insert a new one with the same load rating.

4-59

SECTION 4 RELAYS RELAYS IN THE CAB The fuses are accessible after opening the service door on the right-hand side of the cab.

Optional relay K1

Speed change relay

K2

Brake pressure relay

K3

High speed relay

K4

Load stabilizer relay

K5

Backup relay

K6

Backup relay

K7

Backup relay

K21

Air conditioner relay

K22

Diodes box

Standard relay K8

Creep speed relay

K9

Parking brake relay

K10

Dipped beams relay

K11

Main beams relay

K12

Electromagnetic deflector

K13

Brake pressure relay / unlock translation

K14

Reversing light / back-up alarm

K15

Reverse speed relay

K16

Front screen wiper relay

K17

Forward speed solenoid relay

K18

Start lock relay

K19

Signal relay / horn

K20

Blower relay

RELAY IN THE ENGINE BAY The fuse of the preheating control is located under the engine guard in front at the right.

K1.3 Preheating check relay K1.5 Starter relay

RELAY CHANGE Remove the defective fuse and insert a new one with the same load rating.

4-60

92

REFILLINGS AND SERVICING BULBS - REPLACEMENT Before replacing a bulb, shut off the engine and remove ignition key.

Burnt bulbs have to be replaced with bulbs of same power.

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.

1. Headlight 2. Turn signal light 3. Rear light, stop light, turn signal and reversing light 4. Front working floodlamp 5. Rear working floodlamp (optional) 6. Flashing light (optional)

93 HEADLIGHT Loosen the 4 screws at the rear (3).

Remove the plug (4) and the rubber hood (5).

Remove the bulb (1) from holder (2) and install new bulb.

Reassemble in reverse order.

94

4-61

SECTION 4 TURN SIGNAL LIGHT Loosen the 2 screws at the rear (1).

Remove front cover (3).

Replace defective bulb (2).

Reassemble in reverse order.

95 WORKING FLOODLAMP Unscrew screws (1) and remove the headlight glass (2) carefully.

96 Shift the safety bracket (3).

97 Remove defective bulb (5) from holder (4) and install new bulb.

98 Reassemble in reverse order.

4-62

REFILLINGS AND SERVICING REAR STOP LIGHT/TURN SIGNAL LIGHT Unscrew protections from spotlights (A) and (B).

Now are the bulbs accessible.

1. Tail light 2. Stop light 3. Turn signal light 4. Reversing light

99 Replace defective bulb.

A. Tail light bulb B. Stop light bulb C. Turn signal light bulb D. Reversing light bulb

100 Reassemble in the reverse order.

INTERIOR LIGHT Remove cover (1).

Replace defective bulb.

101 Reassemble in reverse order.

4-63

SECTION 4 ROTARY BEACON Bulb replacement Depress catch (1) and take off cover (2).

102 Take out bulb (3) and replace by a new one.

103 Place back cover (2). Press lever (1) and insert cover (2) with snap-lock.

Reflector replacement Remove cover (2) as already described. Withdraw clip (4) using small pincers. The reflector can then be completely withdrawn together with motor (5).

104 Install new reflector with motor (5). Insert clip (4) and put on cover (2).

4-64

REFILLINGS AND SERVICING BRAKES SYSTEM - AIR BLEEDING The system must be bled when air has penetrated into the line system, this happens when brake lines are being loosened or when parts of the brake system are being replaced or detached.

Bleeding requires two persons.

- Right bleeding valve (2) on the front axle (only with overdrive option).

- Left bleeding valve (2) on the front axle (only with overdrive option).

- Bleeding valve (1) on the disk brake.

105 For bleeding, connect a hose (3) to the respective bleeding valve and hold the other end into a recipient filled with some hydraulic oil.

While the first person depresses the brake pedal and holds it depressed with the engine running, the second person opens the bleeding valve (4) by approximately 1/2 turn and closes it only after the hydraulic oil flowing into the recipient is free from bubbles. Only then can the first person release the brake pedal.

To make sure all the air has been removed from the system, perform this procedure at least twice.

106

4-65

SECTION 4 BATTERIES - REPLACEMENT

S WARNING S Shut off the engine before removing batteries to prevent damage to the alternator and regulator or to electronic modules.

Remove ignition key.

Detach and attach the clamps in the given sequence.

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

Detach clamp from battery negative pole.

Detach clamp from battery positive pole.

Insulate clamps.

Unscrew battery holder (1).

Remove battery (2) from holder.

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

Install the new battery (2).

Screw battery holder (1) in place.

Connect pole terminal to positive pole of battery.

Tighten terminals nuts.

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

Connect negative clamp to battery negative pole.

Grease battery poles and clamps with grease of non-corrosive Vaseline.

Loose or corroded clamps overload the alternator and regulator.

4-66

107

REFILLINGS AND SERVICING INJECTORS - REPLACEMENT

S CAUTION S Consult a doctor immediately, if your skin has come into contact with fuel under high pressure.

Keep away from moving parts when the engine is running. Some of the moving parts are not directly visible when the engine is on.

The injection nozzles do not require regular servicing. The nozzles should be replaced and not cleaned. Replacement is, however, not necessary unless an injection nozzle is defective. The main signs indicating that it may be necessary to replace a nozzle are: - the engine does not start at all or starts only with difficulty; - insufficient engine performance; - the engine has ignition failure or runs irregularly; - high fuel consumption; - emission of black smoke; - engine knocking or vibrating; - engine overheats.

To find out which of the injection nozzles is defective, let the engine run at high idling speed. (See page 5-6)

BUCKETS TEETH - CHANGE

S WARNING S Park the machine safely.

Nobody must stand in the direction of the ejected safety latch and tooth.

The safety latch and tooth can be suddenly ejected during the extraction and cause injuries.

Metal splinters may cause injury.

Wear protective clothing and goggles.

4-67

SECTION 4 Drive out safety pin (1) using a piece of smooth metal or of hard wood (2).

108 Drive tooth (3) out of housing (4) using a piece of smooth metal or of hard wood.

109 Clean the housing and remove rust, if present.

Insert new tooth (3) into the housing (4).

110 The tooth (3) must stay in contact with housing (4); insert new safety pin (1).

The safety pin (1) can be inserted in the housing from both ends.

111

4-68

SECTION 5 TROUBLESHOOTING Faults are often due to the machine not having been operated or serviced properly.

When dealing with faults, it is therefore necessary to read the corresponding chapter of the operating instructions once again.

If you cannot find the cause of a fault or rectify it, contact the After-sales service.

Describe the fault and the accompanying circumstances as precisely as possible when contacting our After-sales service. Exact information helps to locate and to rectify faults as fast as possible.

Never do work for which you are not qualified.

The present fault table lists the faults reported to date, their possible causes and the remedial action.

In exceptional cases, a described fault may also have another cause.

FAULT The fault is described as a result of an observation or of a preceding activity.

Observe the machine carefully.

Examine the problem thoroughly.

Ask yourself the following questions: - Which warning signs preceded the fault?

- Which repair and servicing work had been performed beforehand?

- Has this defect already been noticed in the past?

- Are we faced with one or with several defects occurring at the same time?

POSSIBLE CAUSES This column describes the possible causes of the fault observed. The causes are listed in the order of their probability of occurrence, the possible cause applying in most of the cases is mentioned in first place.

CORRECTION This column informs about how to detect the causes of faults and how to remedy them.

5-1

SECTION 5

FAULTS INDICATED BY THE INSTRUMENT Watch the pilot lights during travel.

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

1. Pilot light indicating a lack of current 2. Engine oil low pressure light 3. Brakes low pressure light 4. Engine oil high temperature light 5. Hydraulic oil high temperature light 6. Air filter restriction light 7. Engine oil temperature light Stop the wheel loader immediately when a pilot light lights up and acoustic warning signal is heard.

1

If necessary, shut off the engine, locate the cause and rectify or contact the After-sales service.

NO ELECTRIC POWER SUPPLY / ALTERNATOR In the event of an alternator malfunction only pilot light (1) lights up.

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

ENGINE OIL PRESSURE

2

When the engine oil pressure is too low, pilot light (2) lights up and a warning signal is heard.

Stop the wheel loader, shut off the engine, locate the cause and rectify or contact the After-sales service.

3

5-2

TROUBLESHOOTING BRAKES PRESSURE If the brake pressure drops sharply during the travel, the wheel loader will be stopped immediately.

At the same time, pilot light (3) lights up and the acoustic warning signal is heard.

Secure the machine.

Locate the cause of the pressure drop and rectify or contact the After-sales service. Only then set the loader back into operation.

4 OVERDRIVE (OPTIONAL) When the brake pressure drops sharply during driving, the wheel loader will be stopped immediately if the loader speed is less than 5 km/h (3.107 mph).

At the same time, pilot light (3) lights up and the acoustic warning signal is heard.

If the speed is higher than or equal to 5 km/h (3.107 mph), only pilot light (3) is lit up and the acoustic warning signal is heard.

Secure the machine.

Locate the cause of the pressure drop and rectify or contact the After-sales service. Only then set the loader back into operation.

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

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

The maximum admissible temperature is approximately 135 °C (275 °F).

The engine oil temperature is monitored by a gauge indicator (7).

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

When the oil temperature indicator (7) is in the red range, pilot light (4) is lit up and an acoustic signal is heard, the engine oil temperature is too high.

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

If the pilot light (4) continues to be on after several minutes of idling and if the oil temperature indicator (7) remains in the red range and if the acoustic warning is still sounding. Switch off engine.

5

Secure the machine, locate the cause and rectify or contact the After-sales service.

5-3

SECTION 5 HYDRAULIC OIL TEMPERATURE When the hydraulic oil temperature is too high, pilot light (5) lights up and a warning signal is heard.

Stop the wheel loader, shut off the engine, locate the cause and rectify or contact the After-sales service.

AIR FILTER

6

When the air filter is contaminated, pilot light (6) lights up and a warning signal is heard. When pilot light (6) is on, the filter must be cleaned or replaced even if the maintenance interval has not yet elapsed.

7

5-4

TROUBLESHOOTING

ENGINE FAULT

POSSIBLE CAUSE

The engine does start at all or Improper starting procedure. starts only with difficulty.

CORRECTION Revise the starting procedure.

Fuel low or missing.

Verify the fuel level.

Air in the feeding system.

Bleed the feeding system.

Incorrect viscosity engine oil.

Use oil with correct viscosity.

Fuel not suitable for operating temperature.

Use correct type of fuel for temperature conditions.

Feeding system contaminated.

Clean the system.

Fuel filter clogged.

Replace the filter element.

Fuel injector(s) faulty.

Consult your Dealer.

Fuel system contaminated.

Clean the system.

Fuel injector(s) faulty.

Consult your Dealer.

Engine overloaded.

Engage a lower speed or decrease the load.

Air filter clogged.

Perform maintenance of air filter.

Fuel not suitable.

Use the correct fuel.

Engine working temperature.

Check the thermostat.

Equipment not correctly adjusted.

See equipment instruction manual.

Equipment not correctly adjusted.

See equipment instruction manual.

Wrong valves clearance.

Check and adjust.

Engine maximum idle with no load too low.

Consult your Dealer.

Oil level low.

Top up oil level.

Oil pressure low.

Consult your Dealer.

Engine working temperature low.

Thermostat faulty.

Replace thermostat.

Oil pressure low.

Oil level low.

Top up oil in correct quantity.

Oil of wrong quality and viscosity.

Drain and refill oil with correct quality and viscosity.

The engine runs irregularly or fails.

The engine does not develop full power.

The engine does not develop full power (continuously).

Engine knocking.

5-5

SECTION 5 FAULT Oil consumption excessive.

Excessive fuel consumption.

The engine does not run with all cylinders.

Exhaust smoke: blue

5-6

POSSIBLE CAUSE

CORRECTION

Engine oil level too high.

Decrease oil level.

Oil viscosity unsuitable.

Use oil with correct viscosity.

Oil leaks.

Repair leaks.

Breather hose filter clogged.

Replace breather filter.

Radiator core clogged.

Clean.

Engine load excessive.

Engage a lower speed or decrease the load.

Engine oil level low.

Top up oil level.

Coolant level low.

Restore the liquid level in the recovery tank. Check for possible system leaks.

Radiator cap faulty.

Replace the cap.

Fan belt loose or worn.

Check belt tensioner. Replace the belt if worn.

Cooling system clogged.

Wash cooling system.

Thermostat faulty.

Check the thermostat.

Leaks in the hoses connectors.

Tighten the hoses connectors.

Fault in the temperature indicator or gauge.

Consult your Dealer.

Fuel not suitable.

Use suitable fuel.

Air filter dirty or clogged.

Carry out the cleaning of the air filter.

Engine overloaded.

Engage a lower speed or decrease the load.

Wrong valves clearance.

Check and adjust.

Equipment not correctly adjusted.

Consult the manual of the equipment for a proper operation.

Engine temperature low.

Check the thermostat.

Fuel injectors clogged.

Have maintenance carried out by Dealer.

Oil level too high.

Top up oil level.

Injection line leaks.

Check for leaks and rectify.

Defective injector.

Replace.

Oil level too high.

Top up oil level.

Excessive inclination of engine.

Revise position.

TROUBLESHOOTING FAULT Exhaust smoke: white

Exhaust smoke: black

Engine stalls.

POSSIBLE CAUSE

CORRECTION

Starting temperature too low.

Engine preheating.

Oil level too high.

Top up oil level.

Excessive inclination of engine.

Revise position.

Fuel unsuitable.

Replace with suitable fuel.

Wrong valves clearance.

Adjust or replace.

Defective injector.

Replace.

Air filter clogged.

Clean and if necessary replace.

Switch and/or air filter clogged indicator.

Check and replace.

Charge-air line leaking.

Check for leaks and rectify.

Wrong valves clearance.

Adjust and/or replace valve.

Defective injector.

Replace.

Contaminated fuel.

Drain and clean fuel system.

Fuel filter clogged.

Replace.

5-7

SECTION 5

STEERING SYSTEM FAULT

POSSIBLE CAUSE

CORRECTION

Steering wheel hard.

Pump drive coupling defective.

Consult your Dealer.

Steering wheel hard to turn when travelling on level ground.

Oil level too low.

Refill.

Pressure too low.

Consult your Dealer.

Limited-slip differential or steering mechanics sluggish.

Consult your Dealer.

Air in hydraulic system.

Purge system of air.

Internal leaks in steering valve.

Repair or replace.

Steering wheel easy to turn at limit stop.

Internal leaks in steering valve.

Repair or replace.

During fast steering action, wheel turns fast for a short time (steering catching up).

Air in hydraulic system.

Purge system of air.

Internal leaks in steering valve.

Repair or replace.

Oil supply rate insufficient.

Consult your Dealer.

Steering valve jams.

Consult your Dealer.

Steering wobbly, permanent tread correction necessary.

The steering wheel when released still turns.

5-8

TROUBLESHOOTING

BRAKES SYSTEM FAULT

POSSIBLE CAUSE

CORRECTION

Abrupt braking.

Pressure wrongly adjusted.

Decrease pressure by handling on the setscrew under the pedal.

During work, pressure has to be checked with a pressure gauge.

Low braking effect.

Pressure wrongly adjusted.

Increase the pressure by handling on the setscrew under the pedal.

During work, pressure has to be checked with a pressure gauge.

WARNING: the admissible pressures for the brakes have not to be exceeded.

Braking effect delayed and brake opens.

Insufficient supply and release speed Make sure that section of pipes of of the brakes. braking system in not low in relation to their length and to oil delivery.

Brakes remain engaged.

Hydraulic oil viscosity too high.

Carry out the filling of the system with hydraulic oil at prescribed viscosity.

Release of braking system not correct.

The system does not release completely and remaining pressure acts on the brakes.

Pedal does not return to stroke begin. Check that the limit screw of pedal leaves a little gap between the return guide of pedal and activation piston.

Remove foreign bodies from underneath the pedal.

The pilot lamp on the control panel does not light up or it remains permanently lit.

Check the registration of the pressure Set on the pressure gauge, placed on gauge. the load valve, a value that, although under the minimum pressure of accumulator, is sufficiently high to ensure 3 or 4 braking from pilot lighting.

Uneven brake pressure.

The minimum pressure off the accumulator is lower the brake maximum pressure.

Check the correct adjustment of accumulator pressure. If necessary, handle on the setscrew of accumulator loading valve.

5-9

SECTION 5 FAULT

POSSIBLE CAUSE

CORRECTION

Continuous recharge of accumulators.

Too much or too low nitrogen in the accumulators.

After draining oil from accumulators, with a suitable instrument check the nitrogen pressure in the same. Carry out again the filling following carefully the Manufacturer’s instruction. The nitrogen pressure can be detected when reading the pressure of the last quantity of oil spilled out.

Feeding pump always under pressure.

Pump worn.

Repair or replace pump.

Valve contaminated.

Check carefully the valve (gliding of components, gaskets kit condition and connectors tightness).

The accumulators cannot be filled.

A foreign body clogs the priority valve.

Check the sliding of all parts, in detail of the charging accumulator input valve. Check hydraulic connection.

After checking the accumulator load valve, check that the piston stop ring seats properly, placed before the load connection. Bleed air from the feeding pump circuit.

Shocks felt on pedal.

Pressure floating abruptly on discharge side.

Discharge flow of brake is too high.

Increase the section of the discharge line.

Smooth braking (Inching) not possible.

Valve adjustment (Inching) wrong.

Adjust valves.

Valve operation wrong.

Replace.

Braking noisy.

Brake plates, discs and linings worn. Check and replace.

Unsuitable oil

5-10

Change to proper oil.

TROUBLESHOOTING

HYDRAULIC SYSTEM FAULT Hydraulic system does not operate regularly.

Hydraulic oil overheated.

The equipment control does not activate.

POSSIBLE CAUSE

CORRECTION

Oil level low.

Top up system.

Hydraulic filter clogged.

Replace hydraulic filter.

Hydraulic system faulty.

Consult your Dealer.

Oil level high or low.

Top up oil level.

Oil filter element clogged.

Replace filter.

Delivery control wrongly adjusted.

Adjust delivery control for lower delivery.

Hoses not correctly connected.

Connect hoses correctly.

Check the oil flow in the half-joints.

Activate control levers. If problem still continues replace male half-joints.

The load exceeds the system capacity.

Decrease the load or use a suitable cylinder.

The equipment does not move Lines not correctly connected. when control lever is activated.

Excessive load on equipment coupling.

Connect correctly lines of equipment coupling cylinders.

Decrease the load.

5-11

SECTION 5

ELECTRICAL SYSTEM FAULT Electrical system is inoperative.

Starter speed low and engine cranks slowly.

Starter inoperative.

POSSIBLE CAUSE Loosen or oxidised battery connections.

Clean and tighten connections.

Battery faulty.

Check battery open circuit voltage for 12.6 V minimum. Check electrolyte density.

Battery switch to “OFF”.

Set battery switch to “ON”.

Low battery output.

Check battery open circuit voltage for 12.6 V minimum. Check electrolyte density.

Incorrect viscosity engine oil.

Use correct viscosity oil for temperature conditions.

Loosen or oxidised battery connections.

Clean and tighten connections.

Defective battery.

Charge or replace batteries.

Charge indicator lamp stays on Low engine idle speed. with engine running.

Batteries will not charge.

Charge indicator flashing indicating excessive charging voltage.

5-12

CORRECTION

Increase idle speed.

Loose belt.

Check belt tension.

Malfunctioning battery.

Check battery open circuit voltage for 12.6 V minimum. Check electrolyte density.

Alternator malfunctioning.

Have the alternator checked by your Dealer.

Loosen or oxidised battery connections.

Clean and tighten connections.

Battery faulty.

Check battery open circuit voltage for 12.6 V minimum. Check electrolyte density.

Loose or worn belt.

Check belt tension. Replace belt if required.

Alternator malfunctioning.

Have the alternator checked by your Dealer.

TROUBLESHOOTING

AXLES FAULT Noise during travel.

Noise during idling.

Intermittent noise.

Constant noise.

POSSIBLE CAUSE

CORRECTION

Excessive backlash between ring gear and pinion.

Adjust.

Pinion and ring gear worn.

Replace.

Bearings and pinion worn.

Replace.

Loosen pinion bearings.

Adjust.

Excessive pinion axial backlash.

Adjust.

Differential bearings worn.

Replace.

Pinion bearings loosen.

Adjust.

Ring gear excessively offset.

Replace.

Lube level low.

Top up.

Lube grade poor or wrong.

Replace.

Axle beam bent.

Replace.

Noises emitted by the axle when Adjust or replace (see above). machine is moving are heard usually during idling, even if not too loud.

Wrong backlash between pinion and ring gear (the noise heard while decelerating disappears when speed is increased).

Adjust.

Pinion spline or input flange worn.

Replace.

Damaged ring gear.

Replace bevel gear.

Differential box screws loosen.

Replace both.

Ring gear teeth or pinion teeth damaged.

Replace bevel gear.

Worn bearings.

Replace.

Pinion splines worn.

Replace.

Axle beam bent.

Replace.

5-13

SECTION 5 FAULT Noise while bending.

Wheels vibrate.

Steering faulty.

Differential does not operate; jams while steering.

Vibrations during forward run.

5-14

POSSIBLE CAUSE

CORRECTION

Differential planetary gears damaged. Replace.

Differential box and/or pins worn.

Replace.

Differential bearings worn.

Replace.

Axle beam splines worn.

Replace.

Axle installation incorrect.

Reinstall.

Axle faulty.

Replace axle.

Axle overload, load displacement wrong.

Remove excessive load and displace it again.

Different tyres rotation radius.

Replace tyre or deflate one of them.

Axle beam bent.

Replace axle beam.

Wrong use.

Consult Instruction Manual.

Axle installation incorrect.

Reinstall.

Axle faulty.

Replace axle.

Axle overload, load displacement wrong.

Remove excessive load and displace it again.

Axle beam broken.

Replace axle beam.

Wrong use.

Consult Instruction Manual.

Axle installation incorrect.

Reinstall.

Axle beam broken.

Replace axle beam.

Axle beam bent.

Replace axle beam.

Wrong use.

Consult Instruction Manual.

Axle installation incorrect.

Reinstall.

Axle faulty.

Replace axle.

Axle overload, load displacement wrong.

Remove excessive load and displace it again.

Different tyres rotation radius.

Replace tyre or deflate one of them.

Axle beam bent.

Replace axle beam.

TROUBLESHOOTING FAULT Irregular wear of tyre.

POSSIBLE CAUSE

CORRECTION

Axle installation incorrect.

Reinstall.

Axle faulty.

Replace axle.

Axle overload, load displacement wrong.

Remove excessive load and displace it again.

Different tyres rotation radius.

Replace tyre or deflate one of them.

Axle beam broken.

Replace axle beam.

Axle beam bent.

Replace axle beam.

Differential locked.

Check differential installation and if necessary remove and check components.

Wheels are not correctly aligned.

Check structure integrity and wheel hub bearings.

Wrong use.

Consult Operator’s Manual.

5-15

SECTION 5 AXLES COMPONENTS FAULT Outer tip of ring gear tooth is broken.

Inner tip of ring gear tooth is broken.

POSSIBLE CAUSE

CORRECTION

Excessive gear load compared to the Recheck backlash between pinion one expected. and ring gear.

Gear adjustment wrong (excessive backlash).

Recheck backlash between pinion and ring gear.

Pinion nut loosen.

Tighten nut.

Crash load.

Replace bevel gear.

Gear adjustment wrong (insufficient backlash).

Recheck backlash between pinion and ring gear.

Pinion nut loosen.

Tighten nut.

Ring gear teeth or pinion teeth Insufficient lubrication. damaged or scored.

Contaminated lubricant.

Use correct lubricant.

Use correct lubricant.

Incorrect lubrication or poor additives. Use correct lubricant.

Worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring gear.

Ring gear teeth or pinion teeth Prolonged operation at high overheated. Check if gear temperature. teeth have faded.

Drive pinion teeth pitted.

Axle beam body bent.

Bearings worn or pitted.

5-16

Replace worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring gear.

Replace bevel gear.

Unsuitable lubricant.

Use correct lubricant.

Low oil level.

Refill.

Contaminated lubricant.

Use correct lubricant.

Extremely intense use.

Replace bevel gear.

Insufficient lubrication.

Use correct lubricant.

Machine overloaded.

Replace beam body.

Damaged vehicle.

Replace beam body.

Crash load.

Replace beam body.

Insufficient lubrication.

Use correct lubricant.

Contaminated lubricant.

Use correct lubricant.

Extremely intense use.

Replace bearings.

Pinion nut loosen.

Tighten nut.

TROUBLESHOOTING FAULT Gaskets leak oil.

POSSIBLE CAUSE

Prolonged operation at excessive oil Replace gaskets. temperature.

Oil gasket wrongly installed.

Reinstall.

Gasket edge cut or scored.

Replace gaskets.

Contaminated lubricant.

Use correct lubricant.

Excessive wear of input flange Intense use. spline.

Replace flange.

Pinion nut loosen.

Tighten nut.

Pinion axial backlash.

Recheck backlash between pinion and ring gear.

Intense use.

Pinion gear tooth fatigue break. Check if the fracture line is with wavy or clearly delineated (stop line).

Break of pinion and ring gear teeth.

CORRECTION

Replace flange.

Continuous overload.

Replace flange.

Crash load of differential components.

Replace bevel gear.

Splines of planetary gear worn Intense use. (excessive backlash).

Replace differential gear group.

Replace axle beam, if necessary.

Surfaces of bearing worn or scratched.

Insufficient lubrication.

Use lubricant and replace bearings.

Lubrication wrong.

Use lubricant and replace bearings.

Contaminated lubricant.

Use lubricant and replace bearings.

Inner diameter of pinion Intense use. tapered roller bearing worn out.

Replace bearing and check pinion axial backlash.

Excessive pinion axial backlash.

Replace bearing and check pinion axial backlash.

Unsuitable lubrication.

Use correct lubricant.

Contaminated lubricant.

Use correct lubricant.

Broken or bent axle beam.

Intense vehicle operation, overload.

Replace axle beam.

Broken axle beam at wheel flange.

Wheel support loosen.

Replace axle beam.

Axle beam body bent.

Check bending of axle beam body.

5-17

SECTION 5

TRANSMISSION FAULT

POSSIBLE CAUSE

CORRECTION

Hydraulics of steering and Transmission coupling faulty. working system does not react.

Replace.

Machine does not move.

Hydraulic oil level too low.

Refill.

Engine does not come under load.

Operation faults in the pressure control circuit of travel pump.

Consult your Dealer.

Travel motor not connected with rear Recheck installation of travel motor. axle.

Engine under load.

Parking brake still applied.

Release parking brake.

Parking brake switch still stuck in opening position.

Replace.

Travel direction lever faulty.

Replace.

Rear axle locked.

Check axle.

Brake locked.

Release brake.

Machine does not move either Travel direction valve faulty. forward or back.

Replace.

Travel direction lever faulty.

Replace.

Supply filter contaminated.

Clean or replace.

On a flat surface the machine starts only with high engine speed.

Insufficient acceleration in both Supply filter contaminated. travelling directions.

Clean and if necessary replace.

Unsuitable oil.

Replace with correct oil.

Oil temperature too high.

Check and try to lower the temperature.

Friction loss in the axle traction.

Consult your Dealer.

Operation faults in the pressure control circuit of travel pump.

Consult your Dealer.

Operation faults in the high pressure Consult your Dealer. circuit of transmission.

Operation faults in the pressure supply circuit of travel pump.

5-18

Consult your Dealer.

TROUBLESHOOTING FAULT

POSSIBLE CAUSE

Maximum travelling speed not Supply filter contaminated. reached.

CORRECTION Clean and if necessary replace.

Unsuitable oil.

Replace with correct oil.

Oil temperature too high.

Check and try to lower the temperature.

Friction loss in the axle traction.

Consult your Dealer.

Operation faults in the pressure control circuit of travel pump.

Consult your Dealer.

Operation faults in the high pressure Consult your Dealer. circuit of transmission.

Operation faults in the pressure supply circuit of travel pump.

Consult your Dealer.

5-19

SECTION 5

WORKING EQUIPMENT FAULT

POSSIBLE CAUSE

Lifting, dumping not functional. Low hydraulic oil level.

Pump drive coupling defective.

CORRECTION Refill.

Replace.

Kinematics fault (working equipment Consult your Dealer. components deformed).

Operating kinematics at control valve Consult your Dealer. defective.

Control lever of bucket equipment does not hold locking in floating position.

Operating kinematics at control valve Consult your Dealer. defective.

Control piston locking in control valve Consult your Dealer. defective.

Dumping or lifting time too long.

Primary pressure setting too low.

Adjust primary pressure.

Maximum engine speed too low.

Raise engine speed.

Pump delivery rate too low.

Consult your Dealer.

Operating kinematics at control valve Consult your Dealer. defective.

Internal leaks in control valve or in cylinders.

Find and rectify leak.

Travel of control valve piston insufficient.

Consult your Dealer.

Lowering time too long.

Operating kinematics at control valve Consult your Dealer. defective.

Lifting force insufficient.

Primary pressure setting too low.

Consult your Dealer.

Internal leaks in control valve or in cylinders.

Find and rectify leak.

Primary pressure setting too low.

Adjust primary pressure.

Secondary pressure setting too low.

Secondary pressure setting.

Internal leaks in control valve or in cylinders.

Find and rectify leak.

Dumping force insufficient.

5-20

TROUBLESHOOTING

HEATING AND AIR CONDITIONING SYSTEM FAULT System very noisy.

POSSIBLE CAUSE

CORRECTION

Belt loose or worn.

Retension belt or replace.

Clutch noisy.

Repair clutch.

Compressor supporting bracket loose Repair bracket, replace compressor. or internal compressor parts worn out.

Blower motor excessively worn.

Replace blower.

System overfilled.

Evacuate coolant until the high pressure reading is normal again.

Not enough coolant in the system.

Check for leaks, refill the system.

5-21

SECTION 5 AIR CONDITIONER FAULT Blower does not operate.

POSSIBLE CAUSE Fuse blown or loose.

CORRECTION Check fuse contact, if necessary plug in correctly.

Replace defective fuse.

Reappearance of the defect after a short time indicates a short-circuit.

Check blower for blocking or other faults.

Eliminate the cause.

Connector loose.

Check that connectors at the bottom of the unit are firmly in place and correct, if necessary.

Check connections at blower switch.

Open the unit and check the electrical connections inside.

Connecting cable damaged or ripped Replace cable, observing correct off. cable run and connection.

Electrical connections interchanged.

Check connecting cables and reconnect properly, if necessary.

Blower switch defective.

Replace by new Original Spare.

Blower unit locked.

Eliminate the cause of the blockage, for instance by removing foreign object from rotor.

If necessary, install a new blower.

Blower motor defective.

Replace blower.

Blower cannot be switched off. Bridge the blower switch.

Replace blower switch.

Reduced blower performance. Rated supply voltage incorrect.

Rated voltage of conditioner and of vehicle system must be identical.

Replace blower.

Dirty clamps.

Clean connector contacts.

Proceed with care to avoid shortcircuits.

Insufficient cross-section of electrical Lay cables with the recommended cables. cross-sections.

5-22

Heat exchanger heavily contaminated.

Clean carefully to avoid causing damage to the exchanger which might result in consequential leaks.

Blower ducts obstructed.

Check air ducts and outlets for obstructions and remove any foreign objects.

Remove trouble.

TROUBLESHOOTING TRANSMISSION COOLER FAULT Compressor not working.

POSSIBLE CAUSE

CORRECTION

Open circuit in compressor solenoid. Check power supply to the clutch.

Faulty thermostat.

Replace thermostat.

Belt loose or broken.

Adjust belt tension, replace belt.

Belt pulley not turning although magnetic clutch is engaged.

Check compressor and replace, if necessary.

Compressor clutch slipping.

Repair clutch or replace compressor.

Evaporator flooded.

Expansion valve jammed or stuck in open position.

Replace expansion valve.

Evaporator frozen.

Thermostat sensor in wrong position. Install sensor in another place.

Evaporator clogged up.

Cooling ribs dirty.

Clean evaporator.

Coolant leaking.

Refrigerant line defective.

Check all lines for defects caused by external influences or chafing.

Leaks in the system.

Evacuate the system, refill, check for leaks and repair.

Air filter clogged up.

Clean air filter or replace.

Air filter.

5-23

SECTION 5 HEATING FAULT Heating does not work.

POSSIBLE CAUSE Heating liquid still cold.

Wait until the engine has reached operating temperature.

Heating valve closed.

Open the valve.

Heating performance reduced. Heat exchanger or filter heavily contaminated.

Heating cannot be switched off.

Clean carefully, to avoid causing damage which might result in consequential leaks.

Adjustment of tie-rod cable controlling the heating valve inappropriate.

Readjust the tie-rod cable.

Air in heat exchanger.

The radiator is self-venting. Wait until the radiator has finished self-venting.

Unit under-dimensioned.

Consider installing an additional heating or more powerful unit.

Adjustment of tie-rod cable controlling the heating valve inappropriate.

Readjust the tie-rod cable.

Control element or tie-rod cable defective.

Check control element or tie-rod cable and replace, if necessary.

Air distribution flaps cannot be Flap hinges sluggish. adjusted.

5-24

CORRECTION

Check flap and lubricate, if necessary.

Flap deformed.

Check flap.

Flap clogged.

Check flap and remove foreign object, if any.

SECTION 6 STORAGE MACHINE STORAGE

ENGINE STORAGE

If the loader is to be set out of operation for longer periods, the following measures are recommended:

If the engine is to remain idle for an extended period of time, it is necessary to take protective measures to prevent rusting. The preservative measures described here will protect the engine for up to 6 months.

- Secure the articulated joint.

- Place the machine on supports to lift the tyres clear of the ground.

- Release parking brake.

The procedure will have to be reversed before the engine is recommissioned.

- Lower working equipment on the ground.

Anti-corrosion oils to specification:

- Set control lever to position 0 (idling).

- MIL-L-21260B.

- Apply grease on bright-metal parts of the machine.

- TL 9150-037/2.

- Carry out preservation of the engine.

- Set battery main switch to OFF.

- Nato Code C 640 / 642.

Anti-corrosion media for exterior protection only to specification: - Nato Code C 632.

Recommended cleaning agent to remove preservatives: - Petroleum benzine (hazardous materials class A3).

- Clean engine with high-pressure equipment.

- Run engine up to operating temperature, then switch off.

- Drain engine oil and fill with anticorrosion oil.

- Drain fuel from tank.

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

- Run engine for approximately 10 minutes.

- Switch off engine.

- Race engine repeatedly by hand for cylinder and combustion chamber preservation.

- Dismantle belts and store in packaged form.

- Spray pulley grooves with anti-corrosion agent.

- Close intake and exhaust ports.

6-1

SECTION 6 BATTERIES STORAGE

MACHINE RECOMMISSIONING

For extended machine downtime periods, remove batteries and store on dry, well ventilated premises at about 20 °C (68 °F).

Observe the following points:

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

- Clean battery.

- Check acid density and battery fluid level once a fortnight.

- Charge batteries when acid density has fallen to 1.23 kg/dm3 (77 lb/foot3) or earlier.

- Keep batteries clean and dry externally.

- Remove engine preservation. Fill in new engine oil.

- Check battery charge condition.

- Install battery and reconnect to the electrical system.

- Set battery main switch to ON. - Check tyre pressure.

- Degrease piston rods of hydraulic cylinders.

- Put loader back on its wheels.

- Check operation of the electrical system.

- Remove articulated joint blocking mechanism.

- Check operation of braking and steering systems.

- Bring machine into driving position and apply parking brake.

- Bleed hydraulic system.

Remove engine preservation - Remove anti-corrosion agent from the grooves of the pulley.

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

- Remove closures from intake and exhaust ports.

- Commission engine.

6-2

SECTION 7 EQUIPMENT BOTTOM-DUMP BUCKET (OPTIONAL) ASSEMBLY Assemble the bucket with the same procedure of standard bucket.

Shut off the engine and depressurize the hydraulic system by actuating control levers (1) and (2), until the equipment cannot move.

1 Connect the hydraulic hoses (3) and (4).

2 The hydraulic hoses must be connected in such a way that the following working movements are initiated when control lever (2) is actuated.

Control lever (2) forward - bucket opens.

Control lever (2) backward - bucket closes.

If this is not the case, exchange the hydraulic hoses (3) and (4).

DISASSEMBLY Place the bucket on the ground. Shut off the engine and depressurize the hydraulic system. Actuate control lever (1) and (2) until the equipment stops performing working movements. Loosen the hydraulic hoses (3) and (4). Close hydraulic hoses and connectors with caps.

Proceed as per “Standard bucket” disassembly.

7-1

SECTION 7

LIFTING FORKS Always take up the load with both fork prongs.

Check the prongs by permanent visual inspections and put them out of operation immediately if damage is detected.

Fork prongs are not designed to withstand lateral forces. Avoid driving the prongs diagonally under the load or pushing the load with the side.

Do not let loads fall on fork prongs.

The transport of molten or fused material is forbidden.

The transport of persons on fork prongs is forbidden.

Do not lift loads with the tip of the prongs. Risk of overloading.

Have legally prescribed checks performed regularly by qualified personnel or by the After-sales service.

The rules and regulations in force in the country of use must be observed.

Perform regular measurements of prong wear.

FORKS TYPES Standard forks (1).

3 Collapsible forks (2).

Keep the forks folded in absence of loads it reduces the risk of incidents. Forks must not be removed to couple some type of equipment.

4

7-2

EQUIPMENT DISASSEMBLY AND ASSEMBLY Place carrier (1) with lifting forks (2) on the ground and attach as described.

Assembly and disassembly of lifting forks are similar to a bucket assembly/disassembly procedure.

5

6

7

7-3

SECTION 7 WORKING WITH LIFTING FORKS Taking up loads To take up loads, drive the loader slowly in front of the load. Hold the lifting forks in horizontal position and raise or lower to the respective height. Drive the lifting forks under the load or into the pallet. Then, lift the load, tilt the forks backwards and bring load up or down to transport height. The transport height is the distance between the ground and the lower edge of the lifting forks. This distance should not be greater than 30 cm (0.98 ft).

Load transport During load transport, the lifting forks must always be tilted backwards. Pull lever (A) into position 3 (back-tipping). When driving up and down a hill, the load must always be carried on the uphill side.

8

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

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

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

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

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

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

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

Centre-of-gravity distances of more than 500 mm (1 ft 8 in) reduce the payload.

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

1. Carrying capacity kg / piece 2. Centre-of-gravity of the load / mm 3. Material 4. Week of manufacture 5. Year of manufacture 6. Material code 7. Serial number

7-4

9

EQUIPMENT FORKS - CHECK Inspections have to be performed regularly.

ISO 5057 prescribes an inspection at least every 12 months. Depending on the conditions of use, for instance multi-shift work or severe operating conditions, the inspections are to be performed more frequently. Moreover, the operator is obliged to perform regular visual checks.

The following points must be checked: - wear - cracking in the bent area - cracking in welding seams - deformations and warping - functioning of the arresters - damage of fork hook and fork tip - general condition Cracking test

S CAUTION S Cracking tests must be performed by specially qualified experts.

In the event of positive cracking test results, both prongs must be replaced immediately.

Critical zones are the fork bending point and the welds at the suspensions.

The usual methods of testing applied are the magnetic powder test or the dye penetration test.

Principle of destruction-free testing for cracks by means of the dye penetration method.

1. Clean the zone to be tested thoroughly.

2. Spray red penetrant on the test zone.

3. Remove red penetrant.

4. Spray developer on the test zone.

Cracks are now visible.

10

7-5

SECTION 7 Deformation check

S CAUTION S If the bending angle of the prongs is greater than 91° or less than 88°, both fork prongs must be replaced immediately.

Fork prongs are delivered with a bending angle of 90°.

They are designed in such a way that they can withstand even twice the nominal load without any remaining deformation.

In practice, permanent deformation may, however, occur by overloading, misuse or unilateral loading.

11

Measurement: Make a mark at the vertical and horizontal distance of 500 mm (1 ft 8 in).

Measure diagonal distance d.

The diagonal distance may be 695 to 713 mm (2 ft 3 in to 2 ft 4 in).

If the measured distance is less than 695 mm (2 ft 3 in) or greater than 713 mm (2 ft 4 in), both fork prongs must be replaced immediately.

12 Wear check

S CAUTION S When a wear of 10% is exceeded, both fork prongs must be replaced immediately.

Fork prong wear occurs most often in the outer bending area.

Starting point of the wear measurement is the original nominal thickness n of the fork prong.

At a nominal thickness of, for instance, 40 mm (0.13 ft), the wear limit is 36 mm (0.12 ft).

When a wear of 10% is exceeded, both fork prongs must be replaced immediately.

13

7-6

SECTION 8 DATA AND TECHNICAL FEATURES SIZES AND PERFORMANCE

1

MULTI-FUNCTIONAL BUCKET A

Total length

B

Cab height

C

Bucket length

D

Distance between wheels outer edges

E

Dumping height

F

Dumping reach

G

Maximum height from bucket pin

H

Dumping depth

I

Wheelbase

J

Tread

K

Gap from ground to disc brake

Operating load (with additional counterweight)

mm ft mm ft mm ft mm ft mm ft mm ft mm ft mm ft mm ft mm ft mm ft kg lb

21E 5250 17.2 2680 8.5 1900 6.2 1850 6.1 2550 8.4 820 2.7 3250 10.7 80 0.26 2200 7.2 1480 4.8 330 1.1 4730 10427

121E 5250 17.2 2800 9.1 2050 6.7 1910 6.3 2600 8.5 780 2.6 3300 10.5 50 0.16 2250 7.4 1520 4.9 330 1.1 5045 11122

221E 5600 18.4 2800 9.1 2050 6.7 1910 6.3 2600 8.5 840 2.7 3400 11.4 85 0.29 2350 7.7 1520 4.9 330 1.1 5545 1224

321E 5750 18.9 2800 9.1 2100 6.9 1980 6.5 2650 8.7 890 2.9 3450 11.3 90 0.29 2350 7.7 1520 4.9 330 1.1 5894 12994

8-1

SECTION 8

PALLET FORKS mm ft mm ft kg lb mm ft mm ft mm ft mm ft mm ft kg lb kg lb kg lb

Total length Width of the forks support Forks weight L

Height with maximum outreach

M

Maximum height

N

Outreach at ground

O

Maximum outreach

P

Outreach at maximum height

Payload on flat ground (80%) - articulated Payload on rough ground (60%) - articulated Operating load (with additional counterweight)

21E 1200 3.9 1450 4.8 370 819 1370 4.5 3040 10 850 2.8 1330 4.4 590 1.93 1640 2712 1230 2706 4780 10538

121E 1200 3.9 1450 4.7 370 816 1440 4.7 3100 10.1 750 2.5 1270 4.2 530 1.7 1780 2954 1340 2948 5045 11122

221E 1200 3.9 1450 4.7 370 816 1490 4.9 3180 10.4 750 2.5 1300 4.3 570 1.9 2120 3505 1590 3498 5545 12224

321E 1200 3.9 1450 4.7 370 816 1490 4.9 3260 10.7 820 2.7 1350 4.4 560 1.8 2220 3660 1660 3652 5845 12886

21E

121E

221E

321E

0.7

0.8

0.9

1.1

PERFORMANCES MULTI-FUNCTIONAL BUCKET m

Standard bucket capacity (density 1.8)

3

3

ft daN lbf kg lb kg lb mm ft daN lbf

Tensile force Dumping load - ISO line Dumping load - joint at 40° ISO Bucket length Lifting capacity at ground (hydraulic)

24.7

28.2

31.8

38.8

5400 12140 3350 7385 2950 6504 1900 6.2 4260 9577

5900 13264 3500 7716 3100 6834 2050 6.7 5050 11353

5800 13039 4270 9414 3650 8047 2050 6.7 5500 12364

7500 16861 4420 9744 3750 8267 2100 6.8 6050 13601

NOISE 21E External noise level LWA Internal noise level LpA

8-2

98 dB(A)

121E

221E 99 dB(A)

77 dB(A)

321E

DATA AND TECHNICAL FEATURES

WEIGHTS 21E Engine

kg (lb)

Front axle

kg (lb)

230 (507)

Rear axle (speed gearbox kg (lb) included) and hydraulic motor

312 (688)

121E

221E

321E

250 (550) 318 (701) 251 (553)

Cab

kg (lb)

470 (1036)

Pump at variable delivery

kg (lb)

30 (66)

Hydraulic motor

kg (lb)

Lifting frame

kg (lb)

Lifting cylinder

kg (lb)

30 (66)

Cylinder for quick coupler

kg (lb)

12 (26)

Counterweight

kg (lb)

315 (694)

35 (77) 420 (926)

393 (866)

600 (1322)

415 (915)

676 (1490)

786 (1733)

221E

321E

DIESEL ENGINE 21E

121E Deutz F4M 2011

Manufacturer and type Operation

4-stroke diesel engine

Combustion system

Naturally aspirated engine with direct injection

Cylinders number

Vertical, in line

Boring

mm (in)

Stroke

mm (in)

Power DIN 70 020 (at rated rpm)

cm3

94 (0.30) 112 (0.37)

(ft3)

kW/CV (hp)

Rated rpm (at full load)

1/min

Rpm at no load

1/min

Maximum rpm with no load

1/min

3108 (0.109) 40.4 / 55.0 (54.1)

44.0 / 59.9 (59)

45.0 / 61.2 (60.3)

56.0 / 76.2 (75)

2300

2400

2500

2300

2580+100

2390+100

900 ± 50 2390

+100

2530

+100

Ignition order

1,3,4,2

Rotation direction

leftwards in relation to flywheel position

Compression ratio

19 : 1

17,5 : 1

Oil pressure (at 900 rpm)

bar (psi)

1.4 (20.3)

Oil pressure (at 1800 rpm)

bar (psi)

2.2 (31.9)

Oil pressure (at 2800 rpm)

bar (psi)

3.0 (43.5)

Weight

Turbocharged engine at direct injection

4

Cylinders arrangement

Displacement

Deutz BF4M 2011

kg (lb)

256 (564)

257 (565)

8-3

SECTION 8 TIGHTENING TORQUES Position

Tightening Nm

lbf·ft

Head cover

8.5

6.3

Cylinder head cover

8.5

6.3

Rocker arm adjustment screw

21

15.5

Intake manifold

8.5

6.3

Foot Rigid suspension

45

33.2

Foot Elastic suspension

106

78.2

Air intake pipe

21

15.5

Exhaust manifold

22

16.2

Oil drain plug

55

40.6

Oil pan (sheet metal)

21

15.5

Oil pan (cast)

31

22.9

Ignition hoses fastening

30

22.1

Injection valves attachment

21

15.5

Lube oil filter cartridge

27

19.9

Fittings

4

2.9

8-4

DATA AND TECHNICAL FEATURES

BRAKES SYSTEM BRAKE PEDAL VALVE Allowable working pressure ................................................................................................ 150 bar (2175 lbf·ft) Adjusted pressure ................................................................................................................... 55 bar (797 lbf·ft) Pressure of brake on disc ....................................................................................................... 55 bar (797 lbf·ft) ACCUMULATOR LOADING VALVE Infeed pressure ................................................................................................................... 100 bar (1450 lbf·ft) Outfeed pressure ................................................................................................................ 150 bar (2175 lbf·ft) Allowable pressure.............................................................................................................. 150 bar (2175 lbf·ft)

PRESSURE SWITCHES STOP LIGHT PRESSURE SWITCH Infeed pressure ........................................................................................................................ 3.5 bar (51 lbf·ft) Function .........................................................................................................................................when closing PRESSURE SWITCH ACCUMULATOR LOADING Infeed pressure ..................................................................................................................... 80 bar (1160 lbf·ft) Function .......................................................................................................................................... bidirectional GEARBOX PRESSURE SWITCH (HIGH SPEED ONLY) Infeed pressure ....................................................................................................................... 40 bar (580 lbf·ft) Function .........................................................................................................................................when closing

ACCUMULATORS BRAKE ACCUMULATOR Capacity ..............................................................................................................................0.32 litres (0.10 gal) Allowable service overpressure .......................................................................................... 210 bar (3045 lbf·ft) Allowable service temperature.................................................................... -10 °C at + 80 °C (14 °F at 176 °F) Filling gas ............................................................................................................................................. nitrogen Filling gas overpressure.............................................................................................. 20 ± 1 bar (290 ± 15 psi) Weight ............................................................................................................................................1.3 kg (3 lbs) PUMP ACCUMULATOR Capacity ..............................................................................................................................0.16 litres (0.04 gal) Allowable service overpressure .......................................................................................... 210 bar (3045 lbf·ft) Allowable service temperature................................................................... -30 °C at + 80 °C (-22 °F at 176 °F) Filling gas ............................................................................................................................................. nitrogen Filling gas overpressure.............................................................................................. 25 ± 1 bar (362 ± 15 psi) Weight ............................................................................................................................................0.8 kg (2 lbs)

8-5

SECTION 8

STEERING SYSTEM Primary safety pressure ........................................................................................................ 175 bar (2537 psi) Secondary safety pressure ................................................................................................... 240 bar (3480 psi)

POWER STEERING 21E - 121E - 221E

321E

OSPC200LS

OSPC315LS

Model Displacement

cm3/rev (in3/rev)

200 (12.2)

315 (19.2)

Rated oil flow

litre/min (gal/min)

20 (5.3)

32 (8.4)

kg (lb)

5.8 (13)

6.2 (14)

Relief valve adjusting

bar (psi)

170 (2465)

170 (2465)

Shock valve adjusting

bar (psi)

215 (3117)

225 (3262)

Weight

TIGHTENING TORQUES Tightening

Position

Nm

lbf·ft

Steering wheel nut

55

40

Power steering to steering column bracket

23

17

Power steering end cover

30

22

Power steering end pipe connection

45

33

Power steering pipe adaptors

55

40

Check valve

30

22

Shock valve

30

22

STEERING CYLINDER 21E

121E

Quantity

221E

321E

1

Ø rod

mm (in)

32 (1.2)

32 (1.2)

32 (1.2)

40 (1.6)

Ø piston

mm (in)

70 (2.7)

70 (2.7)

70 (2.7)

80 (3.15)

Stroke

mm (in)

300 (0.9)

300 (0.9)

300 (0.9)

300 (0.9)

8-6

DATA AND TECHNICAL FEATURES

HYDRAULIC SYSTEM PRESSURES ADJUSTMENT WORKING EQUIPMENT Primary safety pressure ........................................................................................................ 230 bar (3335 psi) Secondary safety pressure - side dumping cylinder bottom ................................................. 250 bar (3625 psi) Secondary safety pressure - side dumping cylinder rod ....................................................... 280 bar (4061 psi) Secondary safety pressure - side lifting cylinder bottom....................................................... 280 bar (4061 psi) TRANSMISSION 21E

121E

221E

321E

25 (362)

27 (391)

27 (391)

27 (391)

Supply pressure (loading platform)

bar (psi)

Adjustment start

bar (psi)

50 (725)

Adjustment end

bar (psi)

400 (5801)

Pressure cut off

bar (psi)

Maximum pressure valve opening

bar (psi) 465 (6744)

467 (6773)

430 (6236) 467 (6773)

467 (6773)

Hydraulic motor adjustment start

bar (psi) 255 (3698)

200 (2900)

200 (2900)

200 (2900)

PUMP AT VARIABLE DELIVERY 21E System

121E

221E

321E

Pump with adjustment depending on engine speed AV4VG40DA1D2 A4VG56DA1D2 A4VG56DA1D2 A4VG71DA1D2 / 32R / 32R / 32R / 32R

Type Volumetric delivery

cm3/rev (in3/rev)

40 (2.44)

56.0 (3.41)

56.0 (3.41)

71.0 (4.33)

Useful power

kW (hp)

34.4 (46.1)

38.0 (51)

38.5 (51.6)

49.0 (65.7)

Transmission through Service revolutions (= engine rated speed)

diesel engine direct drive i = 1.0 1/min

2300

2400

2500

2300

Maximum oil delivery

bar (psi)

88.9 (1289)

131.3 (1904)

136.9 (1986)

159.3 (2310)

Supply pressure (rotation speed at full load)

bar (psi)

25 (362)

27 (391)

27 (391)

27 (391)

Adjustment start

bar (psi)

50 (725) (at 1100 rpm)

50 (725) (at 1100 rpm)

50 (725) (at 1100 rpm)

50 (725) (at 1150 rpm)

Adjustment end

bar (psi)

400 (5801) (at 1900 rpm)

400 (5801) (at 2100 rpm)

400 (5801) (at 2100 rpm)

400 (5801) (at 1800 rpm)

Pressure cut off

bar (psi)

High pressure limiting valves - opening -

bar (psi)

Hydraulic motor adjustment bar (psi) start Voltage

V

430 (6234) 465 (6744)

467 (6773)

467 (6773)

467 (6773)

255 (3698) (at 2100 rpm)

200 (2900) (at 2300 rpm)

200 (2900) (at 2300 rpm)

210 (3045) (at 2000 rpm)

12

8-7

SECTION 8 DOUBLE GEAR PUMP 21E

121E

21E

Working and steering equipment

Function

121E

Blower and service brake

Type Delivery

221E

321E

Working and steering equipment

221E

321E

Blower and service brake

Gear pump cm3/rev (in3/rev)

22.5 (1.37)

28 (1.7)

11 (0.67)

Transmission

28 (1.7)

32 (1.95)

11 (0.67)

14 (0.85)

2500

2300

primary until through-shaft, i = 1.0

Service revolutions

1/min

Operating pressure

bar (psi)

Oil supply

l/min (gal/min)

2300

2400

2300

270 (3914) 50 (13.2)

2400

2500

150 (2175)

67 (17.7)

25 (6.6)

2300 270 (3914)

26 (6.9)

70 (18.5)

73 (19.3)

150 (2175) 27 (7.1)

32 (8.4)

HYDRAULIC CYLINDERS 21E

121E

221E

321E

Lifting cylinder Quantity

1

Ø rod

mm (in)

50 (1.96)

55 (2.16)

55 (2.16)

60 (2.36)

Ø piston

mm (in)

90 (3.54)

100 (3.93)

100 (3.93)

110 (4.33)

Stroke

mm (in)

721 (28.38)

728 (28.66)

728 (28.66)

730 (28.74)

Dumping cylinder Quantity

1

Ø rod

mm (in)

50 (1.96)

55 (2.16)

55 (2.16)

60 (2.36)

Ø piston

mm (in)

90 (3.54)

100 (3.93)

100 (3.93)

110 (4.33)

Stroke

mm (in)

459 (18.07)

454 (17.87)

490 (19.29)

490 (19.29)

Quick coupler cylinder Quantity

1

Ø rod

mm (in)

25 (0.98)

25 (0.98)

25 (0.98)

25 (0.98)

Ø piston

mm (in)

40 (1.57)

40 (1.57)

40 (1.57)

40 (1.57)

Stroke

mm (in)

60 (2.36)

60 (2.36)

60 (2.36)

60 (2.36)

21E

121E

221E

321E

STROKE TIMES With bucket empty Lifting

sec

6.0 ± 0.5

5.7 ± 0.5

5.5 ± 0.5

6.3 ± 0.5

Lowering

sec

3.0 ± 0.5

3.0 ± 0.5

3.2 ± 0.5

3.2 ± 0.5

Lifting

sec

1.0 ± 0.5

1.0 ± 0.5

1.2 ± 0.5

1.2 ± 0.5

8-8

DATA AND TECHNICAL FEATURES HYDRAULIC MOTOR 21E Type

121E

221E

321E A6VM107HA1U1 / 63W

A6VM80HA1U1 / 63W

Displacement Qmax / Qmin

cm3 (in3)

80 / 18.8 (4.88 / 1.15)

80 / 23.7 (4.88 / 1.44)

80 / 24.8 (4.88 / 1.51)

107 / 31.5 (6.53 / 1.92)

Maximum service revolutions

rpm

4362

5289

5292

4811

Delivery pressure

bar (psi)

25 (362)

25 (362)

25 (362)

25 (362)

Operating pressure

bar (psi)

245 (3552)

190 (2755)

185 (2682)

200 (2900)

Pressure increasing spring

bar (psi)

20 (290)

10 (145)

10 (145)

10 (145)

Voltage

V

12

ELECTRICAL SYSTEM Service voltage ........................................................................................................................................... 12 V Battery: - Capacity (20 h)....................................................................................................................................... 92 Ah - Critical current........................................................................................................................................ 900 A Alternator................................................................................................................................................... 55 A

BUCKETS 21E

121E

221E

321E

SAE capacity

m3 (ft3)

Width

mm 1800 (ft) (5.9)

1900 (6.2)

1900 (6.2)

2050 (6.7)

2050 (6.7)

2050 2100 2100 (6.7) (6.900) (6.9)

2100 (6.9)

2100 (6.9)

Weight

kg (lb)

265 (584)

295 (650)

315 (694)

335 (738)

335 (738)

370 (816)

410 (904)

0.65 (23)

250 (551)

0.70 0.80 0.80 0.90 0.90 1.00 1.00 1.10 1.20 (24.7) (28.2) (28.2) (31.8) (31.8) (35.3) (35.3) (38.8) (42.4)

365 (805)

365 (805)

8-9

SECTION 8

AXLES FRONT AXLES Model

21E

121E - 221E - 321E

28.16 (CA147195)

28.25 (CA150144)

Differential type Dry weight

limited slip 230 kg (507 lb)

318 kg (701 lb)

Bevel gear reduction

2.90 / 1

3.667 / 1

Epicyclical gear reduction

6.00 / 1

6.00 / 1

Total reduction

17.45 / 1

21.000 / 1

Input rotation

clockwise

Bevel gear coupling clearance

0.17 ÷ 0.24 mm (0.0066 ÷ 0.0094 in)

Bevel pinion bearings preload (measured on D = 34.5 mm (1.35 in) without sealing rings)

P = 9.2 ÷ 13.7 daN (20.6 ÷ 30.8 lbf)

Pinion-ring gear bearings total preload (measured on D = 34.5 mm (1.35 in) without sealing rings)

T= (P+3.1)+(P+4.7) daN T=(P+6.9)+(P+10.5) lbf

Maximum operating pressure

T= (P+2.5)+(P+3.8) daN T=(P+5.6)+(P+8.5) lbf

55 bar (797)

REAR AXLES 21E

121E - 221E - 321E

Model

CA147194+CA150145 28.16 + TB150

CA147189+CA150146 28.20 + TB150

Differential type

CA147194: standard CA150145: limited slip

CA147189: standard CA150146: limited slip

255 kg (562 lb)

276 kg (608 lb)

Bevel gear reduction

2.91 / 1

3.66 / 1

Epicyclical gear reduction

6.00 / 1

6.00 / 1

Transmission box reduction gear

2.257 / 1

2.257 / 1

Total reduction

39.38 / 1

49.65 / 1

Dry weight

Input rotation Bevel gear coupling clearance Bevel pinion bearings preload (measured on D = 34.8 mm (1.37 in) without sealing rings) Pinion-ring gear bearings total preload (measured on D = 34.8 mm (1.37 in) without sealing rings)

8-10

counterclockwise 0.18 ÷ 0.23 mm (0.0070 ÷ 0.0090 in)

0.17 ÷ 0.24 mm (0.0066 ÷ 0.0094 in)

P = 9.2 ÷ 13.7 daN (20.6 ÷ 30.8 lbf) T= (P+3.1)+(P+4.7) daN T=(P+6.9)+(P+10.5) lbf

T= (P+2.5)+(P+3.8) daN T=(P+5.6)+(P+8.5) lbf

DATA AND TECHNICAL FEATURES REAR AXLE WITH SPEED GEARBOX (HIGH SPEED) 121E - 221E - 321E CA147187 28.20 + TB138.5

Model Differential type

limited slip

Dry weight

/

Bevel gear reduction

3.66 / 1

Epicyclical gear reduction

6.00 / 1

Transmission box reduction gear (1°)

2.75 / 1

Total reduction (1°)

60.5 / 1

Transmission box reduction gear (2°)

1.163 / 1

Total reduction (2°)

25.28 / 1

Input rotation

counterclockwise

Bevel gear coupling clearance

0.17 ÷ 0.24 mm (0.0066 ÷ 0.0094 in)

Bevel pinion bearings preload (measured on D = 34.8 mm (1.37 in) without sealing rings)

P = 9.2 ÷ 13.7 daN (20.6 ÷ 30.8 lbf)

Pinion-ring gear bearings total preload (measured on D = 34.8 mm (1.37 in) without sealing rings)

T= (P+2.5)+(P+3.8) daN T=(P+5.6) + (P+8.5) lbf

TIGHTENING TORQUES Position

Tightening Nm

lbf·ft

Wheels nuts

550

406

Cardan shaft

34

25

Front axle fastening

350

258

Front axle fastening (pin retainer)

79

58

Pump at variable delivery fastening

250

184

Speed change gearbox fastening

71

52

Counterweight

390

288

Engine supports

140

103

8-11

SECTION 8 NOTES:

8-12

SECTION 9 ALPHABETICAL INDEX A Accumulator .....................................................4-46 Adjusting the air temperature ...........................2-12 Air conditioner ............................... 2-12, 4-33, 5-22 Air conditioning filter .........................................4-33 Air filter ............................................ 4-17, 4-41, 5-4 Air intake system ..............................................4-41 Assisted starting .................................................3-5 Auxiliary socket ..................................................2-9 B Batteries storage ................................................6-2 Battery ........................... 1-19, 3-13, 4-8, 4-49, 4-66 Battery main switch ..........................................2-25 Bottom-dump bucket .................................2-18, 7-1 Brakes System ..........................................4-65, 5-9 Bucket control lever .........................................2-16 Buckets ..............................................................8-9 Buckets teeth ..........................................3-22, 4-67 Bulbs ................................................................4-61 C Cab ................................................... 1-6, 1-16, 2-6 Cab breather filter ...................................4-17, 4-35 Cab lighting ........................................................2-9 Compressor belt ...............................................4-33 Condenser .......................................................4-34 Control lever additional function .......................2-18 Coolant .............................................................3-13 D Decals ..............................................................1-18 Dipped beams ..................................................2-15 Documents storage box .....................................2-8 Drive belt ..........................................................4-21 E Electrical system ...................... 4-8, 4-31, 5-12, 8-9 Emergency exit .........................................1-20, 2-8 Engine ............................................... 4-55, 5-5, 8-3 Engine oil ................................................4-13, 4-36 Engine oil filter .................................................4-37 Engine shut off ...................................................3-7 Engine storage ...................................................6-1 Engine valves clearance ..................................4-38

E Equipment ....................... 1-16, 3-19, 4-5, 5-20, 7-1 Evaporator ....................................................... 4-33 Explosion hazard ............................................. 1-20 F Fire extinguisher ................................................2-9 Front axle .........................................................8-10 Front drive axle .......................................4-22, 4-51 Front/rear working floodlamp ........................... 2-23 Fuel .................................................................... 4-2 Fuel filter .......................................................... 4-40 Fuel tank .................................................4-14, 4-53 Fuses ...............................................................4-58 H Headlight .................................................4-61, 4-62 Heating ....................................................2-11, 5-24 Heating system ................................................ 4-33 Heating system filter ........................................4-50 High-speed .......................................................3-10 Horn .................................................................2-24 Horn control lever ............................................. 2-13 Hourmeter ........................................................4-11 Hydraulic motor .................................................. 8-9 Hydraulic oil ....................................................... 4-3 Hydraulic oil reservoir .............................4-13, 4-54 Hydraulic system .......................................5-11, 8-5 Hydraulic system breather filter ....................... 4-44 Hydraulic system return oil filter ..............4-22, 4-43 I Identification plates .......................................... 1-14 Ignition key .......................................................2-11 Injection nozzles .............................................. 4-67 Instruments ........................................................2-1 L Lifting forks ..................................................7-2, 7-5 Lights ............................................................... 4-12 Load stabilization system ................................. 2-24 Lube oil ............................................................ 3-13

9-1

SECTION 9 M Machine storage ................................................ 6-1 Main beams ..................................................... 2-15 Main beams control lever ................................. 2-13 N Noise emissions ............................................... 1-18 O Operator’s compartment controls ..................... 2-11 Operator’s seat ................................................ 2-20 P Parking brake ..........................................2-19, 4-12 Pilot lights ........................................................... 2-4 Pump ...........................................................8-7, 8-8 Q Quick coupler ................................................... 3-20 R Rear axle ....................................... 4-23, 4-32, 4-51 Rear axle with gear speed gearbox (High Speed) .....................................................8-11 Rear axle with speed gearbox (standard) ........ 8-10 Rear screen washer/wiper ............................... 2-15 Rear stop light .................................................. 4-63 Rear turn signal light ........................................ 4-63 Refilling quantities table ..................................... 4-1 Relays .............................................................. 4-60 Rotary beacon .........................................2-23, 4-64 S Safety instructions .............................................. 1-2 Screen washer liquid ........................................ 4-16 Screen washer/wiper ....................................... 2-14 Screen washer/wiper control lever ................... 2-13 Seat belt ..................................................1-24, 2-22 Service brake ................................................... 4-12 Servicing intervals chart ..................................... 4-9 Sizes and performances .................................... 8-1 Speed-change gearbox .................................... 4-36 Start up .............................................................. 3-4 Steering control adjustment ............................. 2-19 Steering system ................................................. 5-8 Sun visor ............................................................ 2-9 Suspension points ...................................1-21, 1-23

9-2

T Tail lights .......................................................... 2-15 Towing ............................................................. 3-15 Transmission ...........................................4-52, 5-18 Transport .......................................................... 3-17 Travel ................................................................. 3-8 Travel on public highway ................................. 3-11 Travel/work control lever .................................. 2-16 Turn signal light ................................................ 4-62 Turn signals control lever ................................. 2-13 Tyres .......................................................4-24, 4-56 W Warranty ............................................................ 1-1 Weights .............................................................. 8-3 Wheels ............................................................. 4-28

Print No. 6559919 - 4-2007

PRINTED IN ITALY

Z

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CASE policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE Dealer.