Case 21E 121E 221E 321E SERIES 3 TIER 3 Compact Wheel Loader Operator's Manual 87682102 - PDF DOWNLO

OPERATOR’S MANUAL COMPACT WHEEL LOADER

21E 121E 221E 321E SERIES 3 TIER 3

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Bur • Issued 01May 08 Printed in U.S.A. • Book/Form Number 87682102 NA Copyright © 2008. 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 This unit first became available 05-2008 REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01May 08

21E, 121E, 221E, 321E Series 3 Tier 3 Compact Wheel Loader

87682102 NA

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

INDEX SECTION 1 INTRODUCTION, SAFETY, PLATES AND DECALS ................................................................................. 1-1 FOREWORD.............................................................................................................................................. 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 PRECAUTIONS 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 ...................................................................................................................................... 1-28

SECTION 2 CONTROLS AND INSTRUMENTS .............................................................................................................. 2-1 CONTROLS AND INSTRUMENTS ........................................................................................................... 2-1 INSTRUMENT CLUSTER AND LAMPS.................................................................................................... 2-5 CAB............................................................................................................................................................ 2-8 OPERATOR’S COMPARTMENT CONTROLS ....................................................................................... 2-13 STARTER SWITCH KEY...................................................................................................................... 2-13 HEATING .............................................................................................................................................. 2-13 AIR CONDITIONING (OPTIONAL)....................................................................................................... 2-14 TURN SIGNAL LIGHTS, MAIN BEAMS, WINDSCREEN WIPER/WASHER AND HORN CONTROL LEVER ........................................................................................................... 2-15 TRAVEL AND WORK CONTROL LEVER............................................................................................ 2-18 BUCKET CONTROL LEVER ................................................................................................................ 2-18 CONTROL LEVER ADDITIONAL FUNCTION ..................................................................................... 2-20 4 x 1 BUCKET (OPTIONAL) ................................................................................................................. 2-20 LOCKING THE CONTROL LEVERS.................................................................................................... 2-20 RETURN TO DIG (OPTIONAL) ............................................................................................................ 2-20 BRAKING AND STOPPING ................................................................................................................. 2-21 STEERING COLUMN - ADJUSTMENT................................................................................................ 2-22 OPERATOR’S SEAT ............................................................................................................................... 2-23 SEAT BELT.............................................................................................................................................. 2-25 OPTIONAL CONTROLS.......................................................................................................................... 2-26 FRONT AND REAR WORK LIGHTS.................................................................................................... 2-26 ROTARY LIGHT ................................................................................................................................... 2-26 REVERSE ACOUSTIC SIGNAL ........................................................................................................... 2-27 LOAD STABILIZATION SYSTEM......................................................................................................... 2-27 BATTERY MASTER SWITCH .............................................................................................................. 2-28

INDEX SECTION 3 OPERATING THE MACHINE....................................................................................................................... 3-1 GENERAL INSTRUCTIONS...................................................................................................................... 3-1 BEFORE OPERATING THE MACHINE ................................................................................................. 3-1 OPERATING THE MACHINE ................................................................................................................. 3-1 RUNNING-IN PERIOD ........................................................................................................................... 3-2 AFTER DAILY OPERATION - MACHINE PARKING ............................................................................. 3-3 START-UP ................................................................................................................................................. 3-4 ENGINE STOP .......................................................................................................................................... 3-7 TRAVEL ..................................................................................................................................................... 3-8 BEFORE STARTING THE TRAVEL....................................................................................................... 3-8 STARTING.............................................................................................................................................. 3-8 WORKING SPEED - CREEP SPEED (INCHING).................................................................................. 3-9 “HIGH SPEED” (OPTIONAL)................................................................................................................ 3-10 ROAD TRAVEL........................................................................................................................................ 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 ATTACHMENT...................................................................................................................... 3-19 QUICK TOOL COUPLER ..................................................................................................................... 3-20 BUCKET TEETH - REPLACEMENT .................................................................................................... 3-22

SECTION 4 SUPPLIES AND MAINTENANCE CHART .................................................................................................. 4-1 SUPPLY SUMMARIZING CHART............................................................................................................. 4-1 FUEL....................................................................................................................................................... 4-2 HYDRAULIC OIL .................................................................................................................................... 4-3 SAFETY INSTRUCTIONS ......................................................................................................................... 4-4 MAINTENANCE INTERVALS CHART ...................................................................................................... 4-6 HOURMETER......................................................................................................................................... 4-8 CHECKS BEFORE START-UP AND BEFORE EACH WORKING SHIFT (10 HOURS)............................................................................................................................................... 4-9 MACHINE GENERAL INSPECTION ...................................................................................................... 4-9 SERVICE AND PARKING BRAKES....................................................................................................... 4-9 LIGHTS................................................................................................................................................... 4-9 CONTROLS AND LAMPS OPERATION ................................................................................................ 4-9 ENGINE OIL - LEVEL........................................................................................................................... 4-10 COOLING SYSTEM LIQUID - LEVEL .................................................................................................. 4-10 HYDRAULIC OIL TANK - LEVEL ......................................................................................................... 4-11 FUEL TANK - LEVEL............................................................................................................................ 4-12 AIR CONDITIONING REFRIGERATING AGENT - LEVEL .................................................................. 4-13 SCREEN WASHER LIQUID - LEVEL................................................................................................... 4-13 WEEKLY SERVICE (50 HOURS)............................................................................................................ 4-14 CAB AIR FILTER - CLEANING ............................................................................................................ 4-14 AIR FILTER - CLEANING ..................................................................................................................... 4-15 DRIVE BELT - CHECK ......................................................................................................................... 4-18 FRONT AXLE - LEVEL CHECK ........................................................................................................... 4-19 REAR AXLE - LEVEL CHECK.............................................................................................................. 4-20

INDEX TYRES - PRESSURE CHECK ............................................................................................................. 4-21 WHEELS - NUTS TIGHTENING........................................................................................................... 4-23 GREASE NIPPLES - GREASING ........................................................................................................ 4-24 ELECTRICAL SYSTEM - VOLTAGE AND CONTINUITY CHECK....................................................... 4-26 MONTHLY SERVICE (250 HOURS) ....................................................................................................... 4-27 REAR AXLE - GREASING ................................................................................................................... 4-27 HEATING AND AIR CONDITIONING SYSTEM ................................................................................... 4-28 SERVICE AFTER 500 HOURS ............................................................................................................... 4-29 ENGINE OIL - CHANGE....................................................................................................................... 4-29 ENGINE OIL FILTER - REPLACEMENT.............................................................................................. 4-31 FUEL FILTER - REPLACEMENT ......................................................................................................... 4-32 SERVICE AFTER 1000 HOURS ............................................................................................................. 4-33 CAB AIR FILTER - REPLACEMENT .................................................................................................... 4-33 ENGINE VALVE CLEARANCE - CHECK AND ADJUSTMENT ........................................................... 4-34 AIR INTAKE SYSTEM LINES - CHECK ............................................................................................... 4-34 AIR FILTER - REPLACEMENT ............................................................................................................ 4-35 HYDRAULIC SYSTEM RETURN OIL FILTER - CHANGE................................................................... 4-37 HYDRAULIC SYSTEM BREATHER FILTER - REPLACEMENT ......................................................... 4-38 BRAKE - PRESSURE CHECK ............................................................................................................. 4-38 ACCUMULATOR - PRESSURE CHECK.............................................................................................. 4-40 BATTERIES - LEVEL CHECK AND TERMINAL CHARGE CHECK .................................................... 4-42 HEATING SYSTEM FILTER - REPLACEMENT................................................................................... 4-44 FRONT AXLE - OIL CHANGE .............................................................................................................. 4-44 REAR AXLE - OIL CHANGE ................................................................................................................ 4-45 SERVICE AFTER 3000 HOURS ............................................................................................................. 4-47 FUEL TANK - CLEANING .................................................................................................................... 4-47 HYDRAULIC OIL TANK - CLEANING AND OIL CHANGE .................................................................. 4-48 DIESEL ENGINE - CLEANING................................................................................................................ 4-50 SERVICE IF NECESSARY...................................................................................................................... 4-51 COOLERS - CLEANING....................................................................................................................... 4-51 TYRES - REPLACEMENT.................................................................................................................... 4-52 CONNECTORS AND LINES - REPLACEMENT .................................................................................. 4-53 FUSES .................................................................................................................................................. 4-54 RELAYS................................................................................................................................................ 4-55 BULBS - REPLACEMENT .................................................................................................................... 4-56 ROTARY LIGHT ................................................................................................................................... 4-59 BRAKE SYSTEM - AIR BLEEDING...................................................................................................... 4-60 BATTERIES - REPLACEMENT............................................................................................................ 4-61 DRIVE BELT - REPLACEMENT........................................................................................................... 4-62 BUCKET TEETH - REPLACEMENT .................................................................................................... 4-63

SECTION 5 TROUBLESHOOTING ................................................................................................................................. 5-1 FAULTS INDICATED BY GAUGES........................................................................................................... 5-2 NO CURRENT / BATTERY .................................................................................................................... 5-2 ENGINE OIL PRESSURE ...................................................................................................................... 5-3 BRAKE PRESSURE ............................................................................................................................... 5-3 ENGINE OIL TEMPERATURE ............................................................................................................... 5-4 HYDRAULIC OIL TEMPERATURE ........................................................................................................ 5-4 AIR FILTER CLOGGED ......................................................................................................................... 5-4 ENGINE WATER TEMPERATURE ........................................................................................................ 5-5

INDEX ENGINE ..................................................................................................................................................... 5-6 STEERING SYSTEM............................................................................................................................... 5-11 BRAKE SYSTEM ..................................................................................................................................... 5-12 HYDRAULIC SYSTEM ............................................................................................................................ 5-14 ELECTRICAL SYSTEM ........................................................................................................................... 5-15 AXLES ..................................................................................................................................................... 5-16 AXLES COMPONENTS ....................................................................................................................... 5-19 TRANSMISSION...................................................................................................................................... 5-21 WORKING ATTACHMENT...................................................................................................................... 5-23 HEATING AND AIR CONDITIONING SYSTEM ...................................................................................... 5-24 AIR CONDITIONING ............................................................................................................................ 5-25 COOLER............................................................................................................................................... 5-26 HEATING .............................................................................................................................................. 5-27

SECTION 6 STORAGE .................................................................................................................................................... 6-1 MACHINE STORAGE............................................................................................................................. 6-1 STORING THE ENGINE ........................................................................................................................ 6-1 BATTERY STORAGE............................................................................................................................. 6-2 MACHINE RECOMMISSIONING ........................................................................................................... 6-2

SECTION 7 ACCESSORIES............................................................................................................................................ 7-1 4 x 1 (BOTTOM-DUMP) BUCKET (OPTIONAL) ....................................................................................... 7-1 FORKS ...................................................................................................................................................... 7-2

SECTION 8 DATA AND TECHNICAL SPECIFICATIONS .............................................................................................. 8-1 DIMENSIONS AND PERFORMANCE (WITH STANDARD BUCKET)...................................................... 8-1 DIMENSIONS AND PERFORMANCE (WITH FORKS)............................................................................. 8-2 NOISE........................................................................................................................................................ 8-3 WEIGHTS .................................................................................................................................................. 8-3 DIESEL ENGINE ....................................................................................................................................... 8-3 TIGHTENING TORQUES ....................................................................................................................... 8-4 BRAKE SYSTEM ....................................................................................................................................... 8-5 BRAKE PEDAL VALVE .......................................................................................................................... 8-5 PRESSURE SWITCHES ........................................................................................................................ 8-5 ACCUMULATORS.................................................................................................................................. 8-6 STEERING SYSTEM................................................................................................................................. 8-7 POWER STEERING ............................................................................................................................... 8-7 STEERING CYLINDER .......................................................................................................................... 8-7 HYDRAULIC SYSTEM .............................................................................................................................. 8-8 PRESSURE ADJUSTMENT ................................................................................................................... 8-8 VARIABLE-DISPLACEMENT PUMP...................................................................................................... 8-8 GEAR PUMP .......................................................................................................................................... 8-9 HYDRAULIC CYLINDERS ..................................................................................................................... 8-9 TRAVEL MOTOR ................................................................................................................................. 8-10 ELECTRICAL SYSTEM ........................................................................................................................... 8-10 BUCKETS ................................................................................................................................................ 8-10

INDEX AXLES ..................................................................................................................................................... 8-11 FRONT AXLE ....................................................................................................................................... 8-11 “HIGH SPEED” FRONT AXLE.............................................................................................................. 8-11 REAR AXLE.......................................................................................................................................... 8-12 “HIGH SPEED” REAR AXLE ................................................................................................................ 8-12 TIGHTENING TORQUES ........................................................................................................................ 8-13

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

INDEX

SECTION 1 INTRODUCTION, SAFETY, PLATES AND DECALS FOREWORD 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 cab 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.

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 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 keywords (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. 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 this Manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine.

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

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

This machine is designed for excavating, loading, transporting and dumping materials such as soil, rocks and other bulk materials.

Using other attachments, the machine 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.

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

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 the environment conditions make it necessary, the following personal safety equipment should be at hand: - respirators (or dustproof masks);

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- ear plugs or acoustic ears protections; - 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.

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 TRAVEL 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 This machine is designed for excavating, loading, transporting and dumping soil or other bulk materials.

Using the machine 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 starter switch key even for stops of short duration.

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

When entering or leaving the operator’s compartment, it is essential that the working attachment controls are 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 on or off 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 bucket completely raised.

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

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SECTION 1 CAB 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.

Two cab versions are available: - with heated and ventilated air; - with air conditioning.

The cab is an essential part of the machine structure. The cab structure cannot be modified. It is therefore forbidden to perform boring, welding and anyway to connect the cab with a device that could impair the job for which it has been intended.

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 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, 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 (16.40 ft).

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

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 attachment to the ground, stop the engine, remove the starter switch 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 parking the machine, some precautions are necessary.

Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

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Place some wedges under the wheels so as to prevent the machine from moving.

Make sure that the door and the engine guard are 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 compliance with the relevant 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 safety equipment and suitable clothing to perform maintenance operations on the machine.

During maintenance operations, apply a warning plate.

11 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 raised bucket 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, place it in a safe position.

Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Lock the articulated joint.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake lever.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Place some wedges under the wheels so as to prevent the machine from moving.

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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.

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.

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 re-fuelling.

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

Use a non-inflammable product for cleaning parts.

16 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.

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The engine exhaust pipe 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.

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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.

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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.

Never touch the battery terminals with your hands.

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

20 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.

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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.

Make sure that machine and attachment are suitable for the type of work to be carried out.

Make sure the machine is in good condition and that the maintenance 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 ISO7096 standard.

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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

INTRODUCTION, SAFETY, PLATES AND DECALS PRECAUTIONS 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: - hydraulic oil;

23

- brake system oil; - coolant mixture, condensation rests and pure antifreeze; - diesel oil; - oil and diesel oil filter elements; - engine and air conditioning air filter 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

24 ENGINE The plate is applied on the crankcase side.

1. Model

25

1-14

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

1. Model 2. Serial number

26 PUMP The plate is applied on the pump body.

1. Model 2. Serial number

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

1. Model 2. Serial number

28 1-15

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

1. Type 2. Serial number

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

1. Serial number

30

1-16

INTRODUCTION, SAFETY, PLATES AND DECALS

MAIN COMPONENTS

31 1. Bucket

9. Hydraulic pumps

2. Dumping cylinder

10. Battery

3. Lifting cylinder

11. Rear axle

4. Fuel tank

12. Transmission

5. Cab

13. Steering cylinder

6. Hydraulic oil tank

14. Front axle

7. Air filter

15. Wheel loader attachment

8. Diesel 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

32

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. 21E and 121E models: 99 dB(A) 221E and 321E models: 100 dB(A)

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

All models: 75 dB(A) LOW SULFUR FUEL DECAL (21E) This decal indicates the type of fuel.

34 1-18

INTRODUCTION, SAFETY, PLATES AND DECALS POSITION OF DECALS

35

1-19

SECTION 1 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 Glass breaking This decal shows how and where to brake the glass in case of need.

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

3

38 4

39

1-20

INTRODUCTION, SAFETY, PLATES AND DECALS 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.

Opening of the engine guard To open the engine guard use the starter switch key.

Before opening the engine guard, stop the engine and remove the starter switch key.

Explosion hazard Read carefully this manual to avoid dangerous explosions.

Slinging 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.

5

40 6

41 7

42 8

43 9

44

1-21

SECTION 1 Fire extinguisher Ensure the extinguisher fitted, complies with local regulations and is fully serviceable.

Parking brake This decal shows the location of the parking brake.

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

10

45 11

46 12

47 Frontal stay dangerous Nobody must stay in front of machine during the working stages.

13

48

1-22

INTRODUCTION, SAFETY, PLATES AND DECALS 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.

Quick coupler pin Be careful during assembly and disassembly of quick coupler pin.

14

49 15

50 16

51

1-23

SECTION 1 Engine fan danger Be careful engine fan could entangle hands and cause injuries.

17

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

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

18

53 19

54

1-24

INTRODUCTION, SAFETY, PLATES AND DECALS 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.

20

55 21

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

22

57

1-25

SECTION 1 Engine start During the engine start the transmission must be disengaged.

23

58 Operator’s Manual This decal suggests to read this manual carefully before operating the machine.

24

59 Danger of oil tank under pressure This decal shows that the operator must be careful because the oil tank is under pressure.

25

60 1-26

INTRODUCTION, SAFETY, PLATES AND DECALS Danger of hot liquid under pressure This decal shows the presence of hot liquid under pressure.

26

61

1-27

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 during reverse travel, without seeking the assistance of a flag man. Make perfectly sure that you and the signalman understand the signals to be used. The flag man must always keep out from the machine working area.

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

MOVE AWAY FROM ME

START THE ENGINE

62

65 GO THIS FAR

STOP THE ENGINE

63 STOP ALL AND HOLD

COME TO ME

64

1-28

66

67

INTRODUCTION, SAFETY, PLATES AND DECALS STOP

LOWER LOAD OR BUCKET

68 EMERGENCY STOP

71 RAISE LOAD OR BUCKET SLOWLY

69 RAISE LOAD OR BUCKET

72 LOWER LOAD OR BUCKET SLOWLY

70

73

1-29

SECTION 1 TURN MACHINE LEFT

DUMP THE BUCKET

74 TURN MACHINE RIGHT

75 FILL THE BUCKET

76

1-30

77

SECTION 2 CONTROLS AND INSTRUMENTS CONTROLS AND INSTRUMENTS

1 2-1

SECTION 2

Ref.

Description

Operation

Operation

1

Control lever

2

Pedal

Service brake and inching

3

Lever

Steering column

Adjusts the steering column.

4

Pedal

Accelerator

Controls the travelling speed.

5

Instrument cluster

Lamps and gauges

6

Lamp

Exhaust gas recirculation (only 321E models)

7

Lamp

Emergency steering

8

Lamp

“High speed” (Optional)

This lamp lights up by engagement of the high speed.

9

Switch

“High speed” (Optional)

High speed engagement/disengagement.

Symbol

Horn, turn signal lights, tail lights/low beams/main beams, front windscreen wiper/washer.

Depress pedal - machine is braked gently.

Depress pedal fully - machine is braked with service brake.

Indicates the wrong emission of exhaust gas.

Emergency steering system check.

Turns on when detecting emergency steering pressure.

Activates and deactivates the hazard lights.

10

Switch

Hazard lights

11

Push-button

Creep speed (only on models without “return to dig”)

Engagement and disengagement of slow speed when the feature “return to dig” is not installed.

12

Switch

Travel

Engage the travel gears: forward - idle - reverse.

13

Lever

Control of working attachment

Lifting and lowering - Bucket dumping.

14

Knob

Control lever lock

Performs the locking and unlocking of the control levers.

2-2

It flashes when the hazard warning lights are activated.

F N R

CONTROLS AND INSTRUMENTS Ref. 15

16

Description

Operation

Socket

Lever

Operation

Symbol

Auxiliary socket 12 V. Additional hydraulic operation (optional)

Activates an additional hydraulic function (clamshell bucket, sweeper).

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

17

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 windscreen wiper - press the symbol face of the switch.

18

Switch

Rear windscreen wiper and washer

To activate the windscreen washer - press again the symbol face of the switch.

To deactivate the windscreen wiper - press the switch face without symbol.

To activate the work lights - depress symbol face of switch.

Switch

Front and rear work lights (optional)

20

Switch

Low speed (only on models with, “return to dig”)

Engagement and disengagement of slow speed when the feature “return to dig” is not installed.

21

Switch

Quick tool coupler

Enable to hydraulic system of the quick tool coupler.

22

Starter switch key

Activates and deactivates the electrical system

Activates and deactivates the electrical system.

23

Switch

Air conditioning (optional)

Activation and deactivation of the air conditioning system.

24

Switch

“Return to dig” (optional)

Engagement and disengagement of the “return to dig” system.

25

Switch

Load sensing system (optional)

Activation and deactivation of the load sensing system.

26

Switch

Reverse acoustic alarm (optional)

Activation and deactivation of acoustic reversing alarm.

19

To deactivate the work lights - depress switch face without symbol.

Engine starting and stopping.

2-3

SECTION 2 Ref.

Description

Operation

27

Switch

Rotary light (Optional)

28

Knob

Heating

Adjusts the heating power.

29

Knob

Fan speed

Adjusts the fan speed.

2-4

Operation Rotary light ON - depress symbol face of switch.

Rotary light OFF - depress switch face without symbol.

Symbol

CONTROLS AND INSTRUMENTS

INSTRUMENT CLUSTER AND LAMPS STANDARD INSTRUMENT CLUSTER

2 “HIGH SPEED” CLUSTER

3

2-5

SECTION 2

Ref.

Description

Operation

Operation

1

Lamp

Battery

Lights up when the battery is discharged.

2

Lamp

Engine oil pressure

Lights up when the engine oil pressure is too low.

3

Lamp

Oil brake pressure

Lights up when the brake oil pressure is too low.

4

Lamp

Preheating

Lights up during the engine preheating phase.

5

Lamp

Parking brake

Lights up when the parking brake is engaged.

6

Lamp

Engine water temperature

Lights up when the engine water temperature is too high.

7

Lamp

Hydraulic oil temperature

Lights up when the hydraulic oil temperature is too high.

8

Lamp

Air filter

Lights up when the air filter is restricted.

9

Lamp

Main beams

Lights up when the main beams are lit.

10

Lamp

Turn signal lights

It flashes when the turn signal lights are connected.

11

Lamp

Forward

It lights up when forward travel is selected.

12

Lamp

Creep speed

Lights up when creep speed is activated.

13

Lamp

Reverse travel

It lights up when reverse travel is selected.

14

Gauge

Fuel level

Indicates the fuel level.

2-6

Symbol

CONTROLS AND INSTRUMENTS Ref.

Description

Operation

Operation

15

Hourmeter

Working hours

Indicates the machine working hours.

16

Gauge

Engine water temperature

Indicates the engine oil temperature.

17

Gauge

Travel speed (“high speed” models)

Indicates the travel speed in km/h and mph.

Symbol

2-7

SECTION 2

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

Always face the machine when climbing or dismounting.

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).

4

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

DOOR OPENING Unlock the door with the starter switch key.

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

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

5 DOOR LOCKING The door can be locked completely open.

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

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

6

2-8

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.

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

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

8 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.

9

2-9

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 as it cannot be blocked in fully open position.

This can damage the window or cause injuries to persons.

10

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

11 In the front outer part of the storage box there are the first-aid kit (1) and the rotary light (2).

The storage box contains a warning triangle (3).

12

2-10

CONTROLS AND INSTRUMENTS SUNBLIND The sunblind (1) is applied over the front screen.

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

13 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.

14

FIRE EXTINGUISHER The fire extinguisher (1) is located in the front left, close to the accelerator pedal.

15 AUXILIARY SOCKET The 12 V socket (1) can be used, for instance, for the connection of a hand lamp.

16 2-11

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

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

It is possible to slightly change the outlet slat orientation according to operator’s needs.

17

18 Air filter The air filter (4) is located on the right side of the machine, below the side window, and it is accessible after the opening of the side cover (5).

Keep the intake ports clean.

19

2-12

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.

STARTER SWITCH KEY The starter switch key (1) is placed right of the operator’s seat and can be set to several positions.

0 = Stop 1 = Electrical system activation To perform the start-up operation, turn starter switch key to position 1; when the buzzer stops sounding, you can further turn the key to symbol position and when the engine starts, release the key, which thanks to a spring returns to position 1.

20

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 knob (1).

The rotary knob (1) has two stages: - 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 allow the engine oil to mix with the heating oil.

By means of rotary knob (2) the blower speed for heating or ventilation is switched on and adjusted.

Rotary knob (2) has four stages:

21

= blower off •

= low speed

• = middle speed

•

= high speed

2-13

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

Activate by pushing switch (A).

By means of rotary knob (B) the blower speed for ventilation is switched on and adjusted.

22 AIR TEMPERATURE ADJUSTMENT The temperature of the air blown into the cab can be steplessly adjusted with rotary knob (B). To increase the cooling capacity, turn the rotary knob to the right.

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, evaporator exchanger fins must be cleaned;

and

heat

- keep cab door and windows closed.

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

The refrigerating 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 coolant can cause frostbite.

If coolant 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 °F), cover loosely with a bandage to protect against infection and consult a doctor immediately.

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

2-14

CONTROLS AND INSTRUMENTS TURN SIGNAL LIGHTS, MAIN BEAMS, WINDSCREEN WIPER/WASHER AND HORN CONTROL LEVER With the activation of this lever (A) following functions are active.

23 Position

Operation

Symbol

Remarks

1

Acoustic signal

Press lever button to position 1.

2

Left turn signal light

Pull lever to position 3. Lamp (10) lights up.

3

Right turn signal light

Push lever to position 2. Lamp (10) lights up.

4

Main beams

Push lever to position 4. Main beams activate with low beams on. Lamp (9) turns on.

24

2-15

SECTION 2 WINDSCREEN WIPER AND WASHER The rotary handle of the lever selects the following functions: 0 = Windscreen wiper off J = Windscreen wiper inching I

= Windscreen wiper on

Windscreen wiper on Rotary knob to position J (intermittent wiping).

Rotary knob to position I (windscreen wiper).

Windscreen wiper off Rotary knob to position 0.

Windscreen washer on Bring lever (A) to position 6 and lock it.

Activate the windscreen wiper to position I. Windscreen washer off Release lever (A).

Windscreen wiper to position 0.

25 The fluid reservoir (B) for the windscreen washer is located outside of the cab frontally on the left side.

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

In winter, add antifreeze to the water.

26

2-16

CONTROLS AND INSTRUMENTS MAIN BEAMS, LOW 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 low beams Press symbol face of switch (1) up to the second notch.

27 Switching off of low beams and tail lights Depress blank face of switch (1).

To switch on the main beams Main beams switch on by lever (A).

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

Lamp (9) turns on.

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

28 To switch off the main beams Bring lever (A) to position 4 and release it.

29 REAR WINDSCREEN WIPER AND WASHER To switch on the windscreen wiper Press symbol face of switch (1) up to the first notch.

Activation of windscreen washer Press symbol face of switch (1) further down and hold.

Switch off Depress blank face of switch (1).

30

2-17

SECTION 2 TRAVEL AND WORK CONTROL LEVER The machine 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.

Lamps (11) and (13) are off.

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

Lamp (11) lit.

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

Lamp (13) lit.

31

As long as the parking brake is engaged, 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.

When the creep speed is engaged, lamp (12) is on.

When the creep speed is active, the machine movement is limited to the maximum speed allowed by this gear. This is important for work requiring low working speeds.

32

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 33

2-18

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 to position 2a.

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

Lower the bucket to the ground. Bring control lever (A) to 2a position and lock it. The bucket now rests on the ground by its own weight and can move freely. After setting back the control lever to position 2, the floating position function is cancelled.

34

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, e.g. 1/4, 2/3 or 2/4, the two movements of the bucket will be performed simultaneously depending on the loading of the hydraulic systems 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.

35

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 systems 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 0 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 from the working wall.

2-19

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

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

4 x 1 BUCKET (OPTIONAL)

36

Control lever (1) initiates the following working movements: - control lever (1) forwards - 4 x 1 bucket opening; - control lever (1) backwards - 4 x 1 bucket closing.

LOCKING THE CONTROL LEVERS

37

Control levers (1) and (2) have a common mechanical locking device. With which the working hydraulic functions can be locked, e.g. 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.

RETURN TO DIG (OPTIONAL)

38

The “return to dig” function brings the bucket back from position (B) to working position (A). Only the boom must be lowered back manually.

39

2-20

CONTROLS AND INSTRUMENTS Select the “return to dig” function by depressing symbol face of switch (1). The lamp on the switch turns on.

To deactivate the function press the blank face of switch (1). The indicator lamp will go out.

40 Push-button (2) on control lever is deactivated if the function “return to dig” is disabled.

If the machine is equipped with forks the function “return to dig” should be disabled.

BRAKING AND STOPPING

41

To brake the machine during the travel, simply take off the foot from the accelerator pedal (2). The hydrostatic transmission reduces the travel speed.

To stop the machine, depress the brake pedal (1). In this way the brake discs apply to the front axle and, at the same time, the transmission power decreases, even if the pedal (2) is not released.

42

2-21

SECTION 2 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; - place the working equipment on the ground; - place travel lever to “0”; - apply the parking brake.

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

Press lever (1) to move the steering column forward.

43

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.

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

Lamp (5) is off when parking brake is deactivated.

45

2-22

CONTROLS AND INSTRUMENTS

OPERATOR’S SEAT For a correct use of the machine with full performance and comfort, check that the operator’s seat and controls are in good condition; then adjust the seat to suit the operator’s height.

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 place the machine in a safe condition.

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

46

Once locked, the 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 weight to be adjusted can be read by the indicator (2).

47

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.

48

2-23

SECTION 2 FORE-AND-AFT ADJUSTMENT The fore-and-aft adjustment of the seat is performed by 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.

49

BACKREST ADJUSTMENT The backrest inclination is adjusted by lever (5).

Sit on seat and lean back lightly against backrest.

Pull lever (5) upwards in arrow direction.

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

When the required position is achieved, release the lever.

50

2-24

CONTROLS AND INSTRUMENTS

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.

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

The belt rolls in automatically.

52

2-25

SECTION 2

OPTIONAL CONTROLS FRONT AND REAR WORK LIGHTS The switch for front and rear work lights is installed in the cab at the seat’s right side.

Switch (1) front lights on Press on symbol to middle position of switch.

Switch (1) front and rear lights on Press on symbol to last position of switch.

Switch (1) lights off Press on blank side to first position of switch.

53

ROTARY LIGHT The rotary light is fixed by means of a magnetic socket into an area marked (A) in front of the canopy or cab.

A socket (1) is installed in the front left, below the cab.

54 Switch on Press symbol face of switch (2).

Switch off Depress blank face of switch (2).

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

2-26

55

CONTROLS AND INSTRUMENTS REVERSE ACOUSTIC SIGNAL On demand, the machine can be equipped with a reverse acoustic signal which may be deactivated.

Activation Press symbol face of switch (1).

Deactivation Depress blank face of switch (1).

56

LOAD STABILIZATION SYSTEM

S CAUTION S The load sensing system cannot be activated together if the machine is equipped with the pipe break option.

The load sensing option is an hydraulic cushioning system of the bucket loading and lifting device.

The system helps relieving the bearings, axles and tyres during machine travel over rough ground and bumpy roads.

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

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

57

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

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

58

2-27

SECTION 2 BATTERY MASTER SWITCH The battery master switch (1) is located in the engine compartment, on the right under the battery.

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

The battery master switch (1) cuts out completely the electrical system from the battery.

If the switch is set to vertical position (ON) the battery is connected.

If the switch is turned to 90° (OFF) the battery is disconnected.

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

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59

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.

Before starting to work with the machine, take following precautions.

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.

Regularly consult the hourmeter to ensure maintenance intervals are observed.

Walk around the machine, look for any leaks and inspect the hoses. Perform tightening and replacement as necessary.

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

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

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

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

Check the condition of the tyres and the tyre pressure.

Clean the steps and access handles. 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 hood 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.

Do not work close to live overhead electric lines without first making sure that the minimum distances are observed: 5 metres (16.40 ft).

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

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 a trailer, observe the following. See chapter “Transport”.

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

3-1

SECTION 3 During the towing of the machine. See chapter “Towing”.

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 working attachment to the ground, engage 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.

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).

When stopping the engine take account of weather conditions. See chapter “Engine stop”.

To ensure an adequate lubrication, let the engine run at idle speed for 1 minute at 1000 rpm before increasing the rpm.

To park the machine. See chapter “Machine parking”.

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 inspection and maintenance operations must be carried out in addition to the operations scheduled by the maintenance section: 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 working attachment.

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 maintenance recommended by the Manufacturer.

3-2

OPERATING THE MACHINE AFTER DAILY OPERATION - MACHINE PARKING Place the machine in a safe condition.

Carry out daily service operations.

Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket 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.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

1

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Place some wedges under the wheels so as to prevent the machine from moving.

Remove gross dirt from machine.

Perform a visual check of the hydraulic system hose tightness.

Perform a visual check of machine condition, tyres and working attachment.

Protect the machine against unauthorized starting.

Close windows.

Lock the cab door and the engine guard with the starter switch key.

WEDGES The wedges are located in the front side of the machine and are fixed to the frame.

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

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

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

2

3-3

SECTION 3

START-UP To perform a correct start-up procedure, observe following precautions.

Adjust the seat and fasten the seat belt.

Activate the parking brake.

Place the direction-of-travel lever in neutral position.

Deactivate the immobilizer (option).

Turn the starter switch key (1) to position I. All warning lamps will switch on shortly (self-test).

After the self-test, the battery lamp (2) and the engine oil pressure lamp (3) will remain on.

When the temperature is low, the preheating lamp (5) turns on.

3

When the brake pressure is too low, lamp (4) turns on.

When the parking brake is applied, lamp (6) turns on.

Turn again the starter switch key (1) to

.

Hold key in position until the preheating lamp (5) and the brake pressure lamp (4) go out and the engine starts.

Release the key, it will return to position 1. Increase the engine speed slightly by depressing the accelerator pedal.

The battery lamp (2) and the engine oil pressure lamp (3) will turn off.

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

The lamp of the parking brake (6) continues to be lit up.

S WARNING S If the warning and lamps do not go out, stop the engine immediately. Detect the cause of a fault and remedy. Only then restart the engine.

3-4

4

OPERATING THE MACHINE 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.

Set the starter switch key to position “0” and restart.

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

The engine cannot be started when the machine is being towed as the wheels are blocked by the hydrostatic travel drive.

ASSISTED STARTING A high current flows on connection of the ground cable. Sparks occurring at the contact point may ignite gases at the discharged battery.

Connect the ground cable to the frame as far as possible away from the discharged battery.

During assisted starting operations (by means of an external battery), do not lean over the batteries.

Wear goggles.

Never try to start the machine when the batteries are defective or frozen.

Only connect batteries (battery assemblies) with the same voltage.

Only use 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.

When performing assisted starting, never use power supplies creating an overvoltage, such as, for example, two or three batteries in series or devices generating voltages above 12 V. Never use welding generators or welding transformers as power sources.

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

3-5

SECTION 3 Check whether the battery of the receiving machine (discharged battery) is in working order: - switch off electrical accessories (lights, fans); - insert the key into the cylinder, the warning lamps for the engine check must turn on; - if warning lamps do not turn on, the battery is faulty (discharged or with a 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.

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

ENGINE START Start the engine of the supplying machine.

Increase rpm.

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

Activate some of the accessories with high current absorption, such as complete lighting and air conditioning. This prevents voltage peaks, which might damage electronic modules, from occurring when the jumper cables are disconnected.

Connect battery jumper cables, as described in the previous paragraph.

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 STOP Rest the bucket on the ground.

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

Shift control lever (2) to position 0.

6 Activate the parking brake.

Lamp (5) turns on.

Set the starter switch key to position “0”. The engine stops.

Remove starter switch key.

Secure the machine against inadvertent movements and unauthorized starting.

7

3-7

SECTION 3

TRAVEL BEFORE STARTING THE TRAVEL Raise the working attachment 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.

If the machine is equipped with seat belt, fasten it.

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.

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

Run the engine at full load only if warm.

STARTING 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 (3) on control lever (1) and, if necessary, shift into the other gear with button (2).

8

3-8

OPERATING THE MACHINE WORKING SPEED - CREEP SPEED (INCHING) 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 pressure on pedal is increased, the machine is braked by the disc brakes of 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 (creep speed), the travel needs less power than with normal travel. More power is therefore available to the working hydraulics.

With switch (2), 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 “HIGH SPEED” (OPTIONAL) The machine model with “high speed”-feature is designed to travel at a maximum speed of 35 km/h (21.74 mph). If this speed is exceeded the machine can be damaged.

If the maximum travel speed of 35 km/h (21.74 mph) is exceeded (red range of speedometer), release the accelerator to reduce the 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 (21.74 mph) also on level terrain, contact the After-sales service to have the hydrostatic travel drive readjusted.

HIGH SPEED ENGAGEMENT Stop the machine.

Press brake pedal until lamp (1) turns on.

Now press the symbol face of switch (1).

Lamp (2) turns on.

Now the “high speed” function is active.

HIGH SPEED DISENGAGEMENT The machine is running with “high speed” function engaged.

To slow down and stop the machine, depress and hold the brake pedal.

Press the blank face of switch (1) to disengage the “high speed” function.

Lamp (2) turns on.

Release the brake pedal and start the machine slowly (slow or working speed).

3-10

11

OPERATING THE MACHINE

ROAD TRAVEL 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 Always fasten your seat belt before travelling on the road.

Check that the lighting and signalling systems are operating correctly before travelling on the road.

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

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 machine starts swinging up and down due to road conditions, the travel speed must be reduced by braking.

Continue to travel 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 light (4).

Lock the control lever (1) of the working attachment and the auxiliary functions against accidental activation.

Switch off the work lights (8).

Switch off the load sensing system (option).

Check that the steering column is locked.

Close the cab door (10).

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

12

Fasten seat belt.

Adjust mirrors (9).

POSITION THE WORKING ATTACHMENT The working attachment 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 attachment to transport position the distance (X) must be minimum 370 mm (1.21 in).

13 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!

14

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 (35.6 °F)) use a low temperature fuel or mix a protective fluid with your fuel.

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

Increase oil change frequency when operating below -10 °C (50 °F).

ENGINE OIL The engine oil must have a viscosity corresponding to the ambient temperature.

COOLANT It must have characteristics corresponding to the ambient temperature.

BATTERY Efficient cold starting requires that battery is wellcharged.

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

15 Observe the following recommendations: - maintain the correct coolant level in the coolant reservoir; - check the condition of the cooler plug before starting. Replace the plug if necessary; - carefully clean the cooler and the engine; - check the condition of the alternator belt and engine fan belt; - use lubricants with the recommended degree of viscosity; - use an appropriate coolant.

3-14

OPERATING THE MACHINE

TOWING Towing is delicate job, always performed at user’s risk. The Manufacturer warranty does not cover damages or accidents caused during the towing. As far as possible, carry out the repair on the spot, without towing the machine.

The machine must be towed only at the low speed of approximately 2 km/h (1.24 mph) and over a maximum distance of 0.5 km (0.31 mph).

Otherwise the travel motor would get damaged because of overheat.

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 must be dimensioned in compliance with standard ISO 10532; therefore, the pin is able to withstand a load of 9 t. (12760 lb).

The towing vehicle must have sufficient tractive power.

Nobody must stay 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 caps (1) from the valves for forward (3) or reverse travel (2) control.

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

Hold the nut with a wrench and with an Allen wrench turn down setscrew (4) or (5), until it is flush with nut (6) or (7). Tighten the 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 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 machine on a low bed trailer.

16

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.

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

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

19

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 the machine with appropriate means (lifting tackle, wire cables, chains, tensioners, wedges).

20

LOADING BY CRANE Loading by crane requires suitable loading gear.

Lock articulated joint.

21

3-17

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

22 When the pin (3) is not used, it must be inserted into its support (4) and blocked by means of the clamp (5).

23

3-18

OPERATING THE MACHINE

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

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

Attachments from other manufacturers may be assembled and put into operation only if in compliance with Machinery Directive 89/392 EEC and only if the Manufacturer’s Declaration of Conformity of the attachment as well as the Manufacturer’s 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, 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 attachment.

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, a training course must be organized, held 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 the attachment 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 attachment or component which is to be mounted or disassembled, 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 service pressure at the quick tool coupler or at the hydraulic ports for the fitted attachments is 230 ± 10 bar (3335 ± 145 psi).

3-19

SECTION 3 QUICK TOOL 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.

Non approved equipment, according to the situation, could not be able to cope with the lifting or tensile force applied by the machine, this can of course damage the same and its attachments.

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

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

The quick tool coupler is activated by means of the switch installed on the cab console at the right of the seat. This switch has two positions, quick coupler open (lamp on) and quick coupler locked (lamp off).

In the locked position, the switch is secured by a mechanical lock against a possible accidental activation. To set the switch to open position, pull slightly the lock towards the operator 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 tool coupler locks open (lamp on) or close (lamp off), according to previous switch setting.

The hydraulic system of the quick tool coupler is equipped with accumulator, during normal operation the accumulator creates a continuous hydraulic preload of the quick coupler cylinders.

3-20

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 system receives an oil feed sufficient to enable the activation of the quick tool coupler.

However, when the accumulator is discharged, the cylinder motion is performed obviously more slowly.

During operation the accumulator preload holds the working equipment constantly under load.

If, due to a long term inactivity of the machine, the accumulator is discharged, the safe locking of the quick tool coupler is always active thanks to the hydraulic locking valves.

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 by quickly retracting the working equipment to stroke end (for instance by fully tipping back the bucket), in this way the main relief valve inside the control valve can activate (sound similar to a whistle).

When the accumulator of the quick coupler is completely charged, the coupler gets open without any problem.

OPERATING THE MACHINE ASSEMBLY Rest the bucket on the ground in vertical position.

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

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

25 Move the machine until the upper support (4) of the quick coupler 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 (lamp off). The hook (7) fits into the housing (6). The bucket is now locked (3) (lamp off).

26 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 plate slots (2).

27

3-21

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

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

28 Slightly lower the lifting arm so that support (4) and hooks (7) can protrude from the bucket housing.

During reverse travel, the boom remains free.

29

BUCKET TEETH - REPLACEMENT

S WARNING S Nobody must stay in the way of the tooth or tooth safety latch that has to be extracted.

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 safety pin (1) using a piece of smooth metal or of hard wood (2).

30

3-22

OPERATING THE MACHINE Drive out the tooth (3) from the tooth holder (4) using a piece of smooth metal or of hard wood (2).

31 Clean the inside of the housing and remove dirt and corrosion.

Fit new tooth (3) into the housing (4).

32 The tooth (3) must be in contact with the point indicated by the arrow.

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.

33

3-23

SECTION 3 NOTES:

3-24

SECTION 4 SUPPLIES AND MAINTENANCE CHART SUPPLY SUMMARIZING CHART Component to refill Suggested product Screen washer tank Cooling system

Fuel system

Engine (without filter)

Brake system

Oil tank Hydraulic system

Front axle: - differential - side gearboxes Rear axle: - differential - side gearboxes - gear box

Air conditioning system: - coolant - oil (compressor) Greasing of grease nipples

CASE standard

International Viscosity standard

Quantity (litres) (gal) 21E

121E

221E

Water and alcohol

-

-

-

2.2 (0.60)

AKCELA Premium Anti-freeze antifreeze 50% water 50%

MS 1710

CUNA NC 956-16

-

24 (6.30)

Decanted and filtered diesel fuel

-

-

-

100 (26.40)

SAE 15W40

15 (3.90)

-

Oil AKCELA ENGINE or oil AKCELA N. 1 ENGINE

MS 1120

API CF-4 MIL-L-2104 F LEVEL

321E

MS 1121

API CF-4/CH-4 ACEA E7/E5

see Hydraulic system

-

-

-

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

MS 1216

ISO VG 68 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)

AKCELA HYDRAULIC EXCAVATORS FLUID BIO biodegradable oil (special equipment)

MS 1216

ISO VG 46 DIN 51524

-

56 (14.8)

67 (17.7)

67 (17.7)

74 (19.5)

7.5 (1.98) 2x0.7 (2x0.18)

8 (2.11) 2x0.6 (2x0.16)

8 (2.11) 2x0.6 (2x0.16)

(2.11) 2x0.6 (2x0.16)

7.5 (1.98) 2x0.7 (2x0.18) 0.75 (0.20)

8 (2.11) 2x0.7 (2x0.18) 0.75 (0.20)

8 (2.11) 2x0.7 (2x0.18) 0.75 (0.20)

8 (2.11) 2x0.7 (2x0.18) 0.75 (0.20)

AKCELA GEAR 135 H EP LS Oil

-

API GL5

SAE 80W-90

R 134a PAG SP 20

-

-

-

1.1 (0.29) -

AKCELA MULTIPURPOSE GREASE 251H EP Multi purpose grease

-

NLGI2

-

-

8

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 fuels 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 (59 °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 (68 °F).

- At temperatures below -15 °C (59 °F) to -20 °C (68 °F), petroleum 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% petroleum can be added (see diagram).

In most cases, adequate resistance to cold can also be obtained by adding a fluidizing additive for winter operation: Legend: I

Summer-grade diesel fuel

II

Winter-grade diesel fuel

A

Outer temperature

B

Percentage of petroleum

S CAUTION S Diesel fuels must never be mixed with gasoline.

1

4-2

SUPPLIES AND MAINTENANCE CHART HYDRAULIC OIL For the first refilling the HYDROSYSTEM 68 oil.

Manufacturer uses

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 “HYDROSYSTEM 46 BIO-S” 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 HYDROSYSTEM 46 BIO-S is restricted only to hydraulic systems. Do not mix this hydraulic oil with oils of other makes; this kind of mixture will decrease 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.

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

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 maintenance operations.

Before performing any operation on the machine, wear tight clothes and personal safety devices appropriate for the operation to be carried out: - safety helmet; - safety shoes; - heavy gloves; - reflective clothing; - wet weather clothing.

If the environment conditions make it necessary, the following personal safety equipment should be at hand: - respirators (or dustproof masks); - ear plugs or acoustic ears protections; - goggles with lateral shield or masks for eyes protection.

Before performing any maintenance operation, wait for the engine and all hydraulic systems and components to cool down.

Clean the grease fittings before lubrication.

Before filling oil, clean the area around plugs and necks.

Carefully prevent that dust or dirt enter the hydraulic systems or components.

4-4

3

SUPPLIES AND MAINTENANCE CHART MACHINE SAFETY Before carrying out any service or repair work the machine must be secured as follows.

Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Block the articulated joint.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

4

Place some wedges under the wheels so as to prevent the machine from moving.

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.

4-5

SECTION 4

MAINTENANCE INTERVALS CHART Cleaning

Oil change

Pressure check

Level check and top-up

Check

Water draining

Greasing

Replacement

Air bleeding

Maintenance

Before Every 250 starting Every 50 h h work Every Every Every 10 week month h

Every 500 h Every month

Every 1000 h

Every 3000 h

When necessary

Page

General checks General inspection

4-9

Cab Controls and lamps

4-9

Windscreen washer liquid

4-13

Air filter

4-14/4-33

Diesel engine and fuel system Diesel engine Engine oil

4-50 4-10/4-29

Engine oil filter

4-31

Drive belt

4-18

Valve clearance

4-34

Fuel filter

4-32

Water trap

4-14

Fuel tank

4-9/4-47

Cooling system Coolant

4-10

Cooler

4-51

Air intake system Air filter - main filter element

4-35

Air filter - safety element

4-17/4-35

Air filter - dust discharge valve

4-15

System lines

4-34

Hydraulic system Hydraulic oil tank

4-11/4-48

Return filter

4-37

Breather filter

4-38

Connectors and hoses

4-53

4-6

SUPPLIES AND MAINTENANCE CHART

Maintenance

Before Every 250 starting Every 50 h h work Every Every Every 10 week month h

Every 500 h Every month

Every 1000 h

Every 3000 h

When necessary

Page

Transmission components Front axle

4-19/4-44

Rear axle

4-20/ 4-27/4-45

Tyres

4-52

Tyres - Pressure

4-21

Tyres - Tightening

4-23

Brake system Brake system

4-9/4-60

Service brake

4-9

Brake - Pressure

4-38

Brake accumulator

4-40

Parking brake

4-9

Electrical system Lights - Bulbs

4-9/4-56

Rotary light

4-9

Relays and fuses

4-55

Voltage and continuity

4-26

Battery

4-61

Battery - Electrolyte

4-43

Battery - Charged

4-43

Battery - Clamps

4-43

Heating - Air conditioning Heating filter

4-44

Evaporator

4-28

Compressor belt

4-28

Condenser

4-28

Coolant

4-13

Attachment Buckets - Teeth

4-63

Forks

4-50

Greasing Various grease nipples

4-24

4-7

SECTION 4 HOURMETER The hourmeter (1) allows to schedule the maintenance operations. It works in the same way as a clock when the engine is running and adds up the service hours.

Maintenance intervals are properly calculated to guarantee safe and efficient machine operation.

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

5

4-8

SUPPLIES AND MAINTENANCE CHART

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

Check

Cleaning

Level check and top-up

Replacement

Machine - General inspection Service brake - Parking brake Lights Controls and lamps Engine oil - Level Cooling system liquid - Level Hydraulic oil tank - 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.

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 build-up during the work.

SERVICE AND PARKING BRAKES Before starting the machine, check the proper operation of the service and parking brakes.

The braking pressure must be reduced before performing any work on the braking system: - place the bucket on the ground;

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 parking brake lever reaches the 4th notch. When the braking efficiency diminishes, check the lining thickness of the brake plates 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 LAMPS OPERATION Before starting the machine, check the correct operation of all controls and instruments and of the lamps installed in the operator’s compartment.

Should faults be noticed, stop the engine and locate the trouble.

- stop the engine and remove the starter switch key; - apply the parking brake; - depress brake pedal 10-15 times.

4-9

SECTION 4 ENGINE OIL - LEVEL Move the machine to a level and firm ground and park it safely.

Activate the parking brake.

Engine oil and operating temperature.

Stop the engine and remove the starter switch key.

Open the engine guard.

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

Wipe the dipstick (1) with a clean cloth and reinsert it into the engine.

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

7

COOLING SYSTEM LIQUID - LEVEL Move the machine to a level and firm ground and park it safely.

Activate the parking brake.

Stop the engine and remove the starter switch key.

Open the engine guard.

The cooling liquid reservoir (1) is placed above the cooler on the left side of the machine.

Check the liquid level thanks to the transparence of the reservoir (1).

If necessary, top up with new liquid by removing the plug (2).

S WARNING S Boiling liquid could splash out from the reservoir, if the cap is removed while the system is still hot.

Before removing the cap, let the system cool down completely.

4-10

8

SUPPLIES AND MAINTENANCE CHART HYDRAULIC OIL TANK - LEVEL Move the machine to a level and firm ground and park it safely.

Activate the parking brake.

Stop the engine and remove the starter switch key.

Relieve the pressure from 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 firm working clothing. Skin contact with hydraulic oils is a health hazard.

9 Open the engine guard.

Check the oil level.

The level gauge (1) is installed on the left side of the machine, close to the battery.

If the oil level is close to or under the reference mark (red), top up oil.

In order to perform this operation, unscrew and remove the filler plug (2) and fill with new and clean oil by means of a funnel.

10

4-11

SECTION 4 FUEL TANK - LEVEL Use normally available 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 Never smoke or bring open flames close to the fuel tank.

Fuel may be irritant on skin; wear gloves or apply some protective cream.

Never remove the plug or refill with the engine running.

Before filling the tank, clean the area around the filler plug in order to prevent that foreign bodies enter the tank. After filling, screw in and tighten the plug again.

Do not spill fuel and do not let it be absorbed by the ground, as it represents a danger of environmental pollution.

Immediately absorb fuel spillovers with rags or binding substances, then dispose of them according to the environmental legislation.

Move the machine to a level and firm ground and park it safely.

Activate the parking brake.

Stop the engine and remove the starter switch key.

Check the fuel level on the instrument cluster by means of gauge (14).

If the level is close to the red field, fuel must be filled in.

11 Unscrew and remove the filler plug (1) and refuel.

12 4-12

SUPPLIES AND MAINTENANCE CHART AIR CONDITIONING REFRIGERATING AGENT - LEVEL

S CAUTION S The HFC 134a refrigerating agent has safety features: this means that it is non-flammable, non-explosive, non-toxic, non-irritating, tasteless and colourless.

Nevertheless, it is necessary to take some precautions.

Avoid any contact with the refrigerant. In case of skin contact with the refrigerant, immediately treat the skin.

Wear safety goggles to protect your eyes. If, despite these, some refrigerant comes in contact with the eyes, immediately consult a doctor.

13

Empty the system before carrying out repairs on it.

Do not let the refrigerant release in the surrounding areas. To suck it, only use duly approved aspirators.

Regardless of the system being full of refrigerant or empty, heat determines a remarkable overpressure, which could not only damage the system, but also cause explosions.

Therefore, avoid weldings, heat sources or open flames.

Empty refrigerant cylinders must not be discarded.

When full, refrigerant cylinders must not be exposed to sun rays or other heat sources for a long time. The maximum admissible temperature of a full coolant bottle must not exceed 45 °C (113 °F).

With the engine running and the system connected, the refrigerant inside the tank (1) must reach the top of the dryer (2), without showing any bubble. 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.

SCREEN WASHER LIQUID - LEVEL The liquid reservoir (1) for the windscreen washer is located outside the cab on the rear left side.

The liquid level can be checked visually as its reservoir (1) is transparent.

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

In winter, add antifreeze to the water.

14

4-13

SECTION 4

WEEKLY SERVICE (50 HOURS) SERVICE POINTS

Check

Pressure check

Level check and top-up

Cleaning

Greasing

Water draining

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

CAB AIR FILTER - CLEANING To access the air filter, it is necessary to leave the operator’s seat and exit the cab, going to the right side.

Under the right window there is a door (1) which is opened by means of the starter switch key.

To remove the filter (2), open the door (1), then loosen the winged screw (3) and remove the grid (4).

Now it is possible to remove the filter (2) and to clean it.

Clean the filter (2) in water with a suitable detergent (consult your Dealer). Instructions for using the detergent are printed on the detergent packaging.

Shake off the excess water and allow to dry naturally.

The filter (2) must be completely dry before reinstallation.

4-14

15

SUPPLIES AND MAINTENANCE CHART AIR FILTER - CLEANING

S WARNING S Never leave the engine on when components 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 air cleaner restriction indicator is not suitable for pressurized water. Protector from pressurized water.

The machine is equipped with a dry-air filter, including a main and a safety filter element. The air filter is installed under the engine guard on the back of the cab on the right side.

Replace or clean the main filter element, when 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.

16

DUST DISCHARGE VALVE - CLEANING 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.

17

MAIN FILTER ELEMENT - DISASSEMBLY Unscrew the clamps (2) and remove the cover (3).

18

4-15

SECTION 4 Remove the main filter element (4) with caution.

19

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

After three 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 re-used immediately.

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

20

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

Finally blow compressed air inside the filter 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.

21

4-16

SUPPLIES AND MAINTENANCE CHART MAIN FILTER ELEMENT - ASSEMBLY 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.

During the assembly of the cover, pay attention to the “TOP” mark.

Turn the cover (3) slightly to the right or left so that the dowel pin can engage in the filter body.

At this point lock the clamps (2).

22 SAFETY ELEMENT - REPLACEMENT If, after the maintenance of the main filter element, the lamp turns on immediately, replace the safety element.

S CAUTION S After 5 cleaning cycles of the main filter element, and anyway at least every two years, the safety filter element must be replaced.

Carefully remove the cover (3) after unlocking the clamps (2).

23 Remove the main filter element (4) carefully.

24 The safety filter element (5) 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.

25

4-17

SECTION 4 DRIVE BELT - CHECK

S WARNING S Danger of injuries caused by engine components and by moving belts.

Risk of burns, caused by hot components of the engine or cooler: start the maintenance and repair works only after the cooling down of these components.

Place the machine in a safe condition.

Stop the engine and remove the starter switch key.

Open the engine guard.

Perform a visual inspection of the belt.

26

Check the belt for cracks crossing over. Transversal cracks (1), parallel to the belt width are allowed.

Cracks parallel to the belt length (2), crossing the transversal ones (1) are not allowed.

In this case the belt has to be replaced. The belt must be replaced also in case of frayed edges or if it is losing pieces.

Check that the belts have no shiny or worn out spots. In this case the belt is loose or it slips.

CHECK OF BELT TENSION 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.

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).

If necessary, retension belt and measure again.

4-18

27

SUPPLIES AND MAINTENANCE CHART FRONT AXLE - LEVEL CHECK Move the machine to a level and firm ground.

Rest the bucket on the ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Place some wedges under the wheels to prevent the machine from moving.

Secure the machine against unauthorized starting.

Risk of scalding from hot oil.

Collect escaping oil and discard without polluting the environment.

Wait 10 minutes until the oil level in the axles is balanced before beginning the level check.

28

Activate the breather valve (1) to bleed air.

Unscrew and remove the level and filler 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 plug (2).

After 10 minutes, repeat the level check and top up again, if necessary.

4-19

SECTION 4 REAR AXLE - LEVEL CHECK Move the machine to a level and firm ground.

Rest the bucket on the ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Place some wedges under the wheels to prevent the machine from moving.

Secure the machine against unauthorized starting.

Risk of scalding from hot oil.

Collect escaping oil and discard without polluting the environment.

Wait 10 minutes until the oil level in the axles is balanced before beginning the level check.

29

Activate the breather valve (1) to bleed air.

Unscrew and remove the level and filler 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 plug (2).

After 10 minutes, repeat the level check and top up again, if necessary.

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

Unscrew plug (1) partially to release internal pressure.

30 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 (1).

After 10 minutes, repeat the level check and top up again, if necessary.

31

4-20

SUPPLIES AND MAINTENANCE CHART TYRES - PRESSURE CHECK

S CAUTION S A burst tyre can cause serious injury. Regularly check the conditions of the tyres and always observe the inflating pressure.

Before inflating, check that the tyres, rims and their components are not damaged, that they do not present foreign bodies and that they are securely fastened.

Check pressure only with cold tyres; when tyres are warm, the pressure values detected are higher.

Inflate tyres only with normal compressed air.

Never use flammable gas: danger of explosions!

When inflating tyres, stay at due distance and constantly observe the pressure gauge of the inflating device, in order not to exceed the prescribed pressure.

While inflating, make sure nobody stays close to the tyre. If available, place a protection cage around the tyre.

Always inflate the tyres to the prescribed pressure.

A too low pressure can make the machine unstable and can overheat excessively the tyres by causing: - tyre breaks; - tread damage; - inner damage; - uneven wear and short life.

An overinflation of the tyres determines a higher sensitivity to breaks in case of bumps and, under extreme conditions, the rim can get deformed and the tyre can burst.

32

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

4-21

SECTION 4 INFLATION PROCEDURE Move the machine to a level and firm ground.

Rest the bucket on the ground.

Activate the parking brake.

Stop the engine and remove the starter switch key.

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.

33

RECOMMENDED PRESSURES 21E Front axle with working equipment

Rear axle

Forks and other equipment

Dumping and loading bucket

(bar) (psi)

(bar) (psi)

(bar) (psi)

3.5 (51)

3.0 (44)

2.0 (29)

335/80 R20 EM BRIDGESTONE

x

x

x

365/70 R18 EM SP T 9 DUNLOP

2.75 (40)

3.25 (47)

1.75 (25)

x

x

x

Tyre

335/80 R18 EM SP 9 DUNLOP

12.5-20 MPT GOODYEAR

121E Front axle with working equipment

Rear axle

Forks and other equipment

Dumping and loading bucket

(bar) (psi)

(bar) (psi)

(bar) (psi)

12.5-20 MPT GOODYEAR

x

x

x

14.5-20 MPT 04 MITAS

x

x

x

365/80 R20 EM SP T 9 DUNLOP

3.5 (51)

2.75 (40)

2.0 (29)

365/80 R20 EM VUT BRIDGESTONE

3.5 (51)

3.3 (48)

3.3 (48)

375/75 R20 MPT XM27 MITAS

3.5 (51)

2.5 (36)

1.5 (22)

405/70 R20 EM SP T 9 DUNLOP

3.0 (44)

2.5 (36)

1.5 (22)

Tyre

4-22

SUPPLIES AND MAINTENANCE CHART

221E Front axle with working equipment

Rear axle

Forks and other equipment

Dumping and loading bucket

(bar) (psi)

(bar) (psi)

(bar) (psi)

x

x

x

365/80 R20 EM SP T 9 DUNLOP

3.5 (51)

2.75 (40)

2.0 (29)

365/80 R20 EM VUT BRIDGESTONE

3.5 (51)

3.3 (48)

3.3 (48)

375/75 R20 MPT XM27 MITAS

3.5 (51)

2.5 (36)

1.5 (22)

405/70 R20 EM SP T 9 DUNLOP

3.0 (44)

2.5 (36)

1.5 (22)

Tyre

14.5-20 MPT 04 MITAS

321E Front axle with working equipment

Rear axle

Forks and other equipment

Dumping and loading bucket

(bar) (psi)

(bar) (psi)

(bar) (psi)

14.5-20 MPT 04 MITAS

x

x

x

405/70 R20 EM VUT BRIDGESTONE

x

x

x

405/70 R20 MPT XM27 MITAS

3.5 (51)

3.5 (51)

1.5 (22)

405/70 R20 EM SP T 9 DUNLOP

3.5 (51)

3.0 (44)

2.0 (29)

Tyre

WHEELS - NUTS TIGHTENING Move the machine to a level and firm ground.

Rest the bucket on the ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Place some wedges under the wheels so as to prevent the machine from moving.

Check if nuts (1) are tighten. Tighten to prescribed torque 550 Nm (405 lbf•ft).

34

4-23

SECTION 4 GREASE NIPPLES - GREASING Move the machine to a level and firm ground.

Rest the bucket on the ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Place some wedges under the wheels to prevent the machine from moving.

Remove the protective cap from the grease nipple.

Clean the grease nipple.

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

35

Now add grease until the waste grease comes out from the support joints.

Wipe off used grease with cleaning rags.

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

Position

Greasing location

Quantity

Hydraulic system 1

Tilt dumping cylinder

2

2

Lifting cylinder

2

Frame 3

Articulated joint

2

Lifting equipment 4

Boom

2

5

Levers

2

6

Connecting rods

1

7

Quick tool coupler

2

Attachment 8

Bottom-dump bucket

2x2

9

Bottom-dump bucket cylinder

2x2

Cardan shaft 10

Yoke

2

Intermediate bearing

1

Cab 11

4-24

Door hinges

2x2

SUPPLIES AND MAINTENANCE CHART

36

4-25

SECTION 4 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 terminal (-), then the positive terminal (+).

After work, connect first the positive terminal (+), then the negative one (-).

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

This creates a short circuit with consequent damage of the battery or of the electronic system.

At engine start-up, the battery is controlled (preexcited) by an electronic circuit, whose task is to have the battery supply power.

The circuit is an integral part of the electronic unit.

A lamp (1) on the instrument panel, indicates the correct operation of the battery. As soon as the starter switch key is inserted, lamp (1) must turn on and it must turn off as soon as the engine starts.

If this is not the case, there is a fault in the battery electric system or in the instrument cluster.

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

37

4-26

SUPPLIES AND MAINTENANCE CHART

MONTHLY SERVICE (250 HOURS) SERVICE POINTS

Check

Cleaning

Greasing

Replacement

Rear axle Evaporator - Air conditioning system Compressor - Air conditioning system Compressor belt - Tension Condenser

REAR AXLE - GREASING Move the machine to a level and firm ground.

Rest the bucket on the ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Place some wedges under the wheels to prevent the machine from moving.

Remove plug from relevant grease nipple.

Clean the grease nipples (1).

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

Insert clean grease that by means of the hoses (2) reaches the pin (3) of rear axle floating.

38

Wipe off used grease with clean rags.

After the greasing, apply protective plug on grease nipples again.

39

4-27

SECTION 4 HEATING AND 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.

Main components: - fan (1); - heat exchanger (2); - evaporator (3); - heating filter (4);

40

- heating valve (5).

These components are accessible after removal of the cover. The heat exchanger, the evaporator and the blower require no servicing.

COMPRESSOR BELT Replace defective belt.

If the belt (1) tension is not correct, tension the belt again.

If the compressor (2) is not safely fastened, check and tighten the loose screws.

FILTER If the filter (4) is dirty, remove the cover first and then the filter and clean it with air jets.

EVAPORATOR If the evaporator (3) is dirty and the fins deformed, blow away the dirt and straighten the fins.

41

When the antifreeze protection sensor on the evaporator is bent or leaking, repair or replace it.

CONDENSER A contaminated condenser (1) has a bad condensing performance. Clean by blowing out or wash with water (do not use high-pressure jet cleaners).

Deformed fins can be repaired by straightening.

42

4-28

SUPPLIES AND MAINTENANCE CHART

SERVICE AFTER 500 HOURS SERVICE POINTS

Check

Pressure check

Checking the level

Oil change

Replacement

Engine oil Engine oil filter Fuel filter

ENGINE OIL - CHANGE

S CAUTION S Risk of scalding from hot oil.

Collect escaping oil and discard it without polluting the environment.

Bring engine to operating temperature.

Move the machine to a level and firm ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

The drain plug (2) is located at the rear of the machine, under the same.

Remove the plastic cover (1) to make the plug (2) accessible.

Place a collecting container below the drain plug.

For capacity, refer to the table of refilling quantities in this manual.

43 The engine is equipped with drain sleeve (3) and exhaust pipe (4).

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

Unscrew the blanking cover (5) from plug (3).

Unscrew the blanking cover (6) from exhaust pipe (4).

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

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

Retighten the plastic cover (6) on the exhaust pipe (4).

44

Retighten the blanking cover (5) on the exhaust pipe (3).

4-29

SECTION 4 Fill with engine oil.

Loosen and remove the plug (7) of the filler neck.

Pour the engine oil into the filler neck trying to reach the maximum level.

Tighten the plug (7) again.

Start the engine and let it run for about 2 minutes at idle speed.

45 Stop the engine and after some minutes pull out the dipstick (8).

Wipe the dipstick (8) with a clean cloth and reinsert it into the engine.

Pull out the dipstick again. The oil level must be flush with the mark “MAX”.

If this is not the case, top up with other engine oil and repeat the check.

46

4-30

SUPPLIES AND MAINTENANCE CHART ENGINE OIL FILTER - REPLACEMENT

S WARNING S Risk of scalding from hot oil.

Collect escaping oil and discard it without polluting the environment.

Move the machine to a level and firm ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Open the engine guard.

Clean filter support (1).

Place a container under the filter, to collect the draining oil.

Loosen and unscrew the oil filter cartridge (2).

Clean the seal face of the filter support (1).

Apply a light coat of oil on the gasket (3) of new oil filter cartridge.

47

Tighten manually the new cartridge (2) until gasket is flush.

Tighten the cartridge (2) by another half turn.

Check the oil level and pressure.

Check tightness of new cartridge gasket (3).

4-31

SECTION 4 FUEL FILTER - REPLACEMENT

S WARNING S For this kind of replacement stop the engine and wait until it is cool.

Collect fuel, rags and old filters and discard them without polluting the environment.

Move the machine to a level and firm ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Open the engine guard.

Clean fuel filter support (1).

Place a container under the filter, to collect the draining fuel.

Loosen and unscrew the fuel filter cartridge (2).

Clean the seal face of the filter support (1).

Apply a small amount of diesel fuel on the gasket (3) of the new cartridge (2).

Tighten manually the new cartridge (2) until gasket is flush.

Tighten the cartridge (2) by another half turn.

Bleed air from the fuel system.

Check tightness of new cartridge gaskets (3).

4-32

48

SUPPLIES AND MAINTENANCE CHART

SERVICE AFTER 1000 HOURS SERVICE POINTS

Check

Pressure check

Checking the level

Oil change

Replacement

Cab air filter Engine valve clearance Air intake system - Lines Air filter Hydraulic oil return filter Hydraulic system breather filter Brake Accumulator Battery - Electrolyte Battery - Charged Battery - Clamps Heating system filter Front axle Rear axle

CAB AIR FILTER - REPLACEMENT To access the air filter, it is necessary to leave the operator’s seat and exit the cab, going to the right side.

Under the right window there is a door (1) which is opened by means of the starter switch key.

To remove the filter (2), open the door (1), then loosen the winged screw (3) and remove the grid (4).

Now it is possible to remove the filter (2) and replace it with a new one.

49

4-33

SECTION 4 ENGINE VALVE CLEARANCE - CHECK AND ADJUSTMENT NOTE: consult your Dealer.

For Tier III engines, because of the presence of the additional lobe for the internal E.G.R., it is not possible to use the valve clearance adjustment procedure, according to which the adjustment of the clearance of all valves is to be carried out by performing only two positionings of the drive shaft.

S WARNING S Each cylinder must be checked by taking it to the T.D.C. (top dead centre) at compression end and by checking the clearance of both valves exclusively on the examined cylinder.

Adjust the clearance between the rockers and the valves by means of the Allen wrench (1), the wrench (2) and the thickness gauge (3).

The clearance is: - suction valves 0.25 ÷ 0.05 mm (0.009 ÷ 0.001 in) - exhaust valves 0.50 ÷ 0.05 mm (0.01 ÷ 0.001 in)

AIR INTAKE SYSTEM LINES - CHECK Hoses and tubes for air intake damaged or leaking, influence enormously the performance and life of the engine.

Dirt or pieces of the intake air can reach the engine and damage it heavily.

The engine must not be allowed to draw in unfiltered air, therefore: - check all hoses and pipes for tightness; - check that all clamps are correctly in place and tightened.

Remove immediately possible damages replace at once the damaged components.

4-34

and

50

SUPPLIES AND MAINTENANCE CHART AIR FILTER - REPLACEMENT

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; - lamp (8) comes on after the cleaning.

The replacement of the safety element is also necessary when: - after replacement of main element (8) lamp comes on; - after cleaning the main filter element for the 5th time.

51

FILTER ELEMENTS - REPLACEMENT Carefully remove the cover (1) after unlocking the clamps (2).

52 Remove the main filter element (3).

53

4-35

SECTION 4 The safety filter element (4) can be withdrawn thereafter.

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

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.

Assemble the new safety filter element (4).

Assemble the new main filter element (3).

Reassemble the cover (1) and lock it with the clamps (2).

4-36

SUPPLIES AND MAINTENANCE CHART HYDRAULIC SYSTEM RETURN OIL FILTER - CHANGE

S CAUTION S Before starting working on the hydraulic system, make sure that it is not under pressure and relieve any residual pressure from it.

Avoid skin contact with the hydraulic oil, as it could be dangerous for your health.

Collect the used hydraulic oil, old filters and rags and dispose of them according to the environmental legislation.

Move the machine to a level and firm ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Open the engine guard.

Unscrew and remove the plug (1).

55 Pay attention to the gasket (2) and to the spring (3) and check their conditions.

56 Extract the filter body (4) with the filter element (5).

Remove the filter element (5) from the body (4), then dispose of it according to the environmental legislation.

Drain the residual oil from the filter body (4) into a container for used oil. Clean the filter body (4) with white spirit or diesel oil. Check the gasket (6) and replace it, if damaged.

Insert the new filter element (5) into the filter body (4).

Assemble the complete filter body (4) into the tank, then install the spring (3).

Tighten the plug (1) again.

57

4-37

SECTION 4 HYDRAULIC SYSTEM BREATHER FILTER - REPLACEMENT The breather filter (1) ensures aeration and bleeding of the hydraulic tank in case of variations of the hydraulic oil level.

The breather filter (1) contains a filter element (2) which prevents dust and dirt from penetrating and oil from spraying out. Replacing or cleaning is not possible.

Change the breather filter (1) completely.

During the assembly phase of the new filter, tighten the screws crosswise and continuously.

58

BRAKE - PRESSURE CHECK

S CAUTION S Repair operations on the brakes must be performed only by personnel specially trained to carry out operations on the braking system.

Move the machine to a level and firm ground.

Stop the engine and remove the starter switch key.

Place some wedges under the wheels to prevent the machine from moving.

Block 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.

Remove the plug (1) from the joint (2) of the brake valve (3) and connect the pressure gauge (4).

(Measuring range up to 200 bar (2900 psi)).

59

Check that the parking brake is activated and that the travel lever is in neutral position.

Start the engine and wait until the required minimum braking pressure is achieved, that is when 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 (797 ± 73 psi).

Contact the After-sales service in case the following conditions occur: - 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).

4-38

60

SUPPLIES AND MAINTENANCE CHART PRESSURE ADJUSTMENT The adjustment of the brake pressure is carried out by means of the setscrew (7), located in the lower part of the brake valve.

Connect a pressure gauge (range 250 bars (3625 psi)) to the brake line. Then depress the brake pedal.

To decrease the brake pressure, tighten setscrew (7).

To increase the brake pressure, unscrew the setscrew (7).

After that, the setscrew must be secured with the locknut (6).

61

4-39

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 after the machine and the articulated joint have been secured. In the hydraulic system, the accumulators contain nitrogen under very 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; - before carrying out any inspection and maintenance job, relieve pressure from the hydraulic side of the system; - before disassembling an accumulator, wear goggles and gloves; - fill the accumulator with nitrogen only, and never use compressed air or oxygen; - immediately report any defects or damage to the After-sales service.

Move the machine to a level and firm ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Place some wedges under the wheels to prevent the machine from moving.

Block the articulated joint.

Relieve the braking pressure.

To this purpose, depress brake pedal 10-15 times.

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

Remove the plug (1) from the coupler (2) of the joint (3).

Screw in the pressure gauge (4) (measuring range up to 200 bar (2900 psi)) on the coupler (2).

4-40

62

SUPPLIES AND MAINTENANCE CHART Start the engine and wait until the accumulator pressure is reached, the lamp (5) turns off and the acoustic warning signal stops sounding.

Check the braking pressure.

The pressure 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.

After the accumulator has reached the charging pressure, stop the engine and leave the starter switch key in position 1.

Depress the brake pedal repeatedly to limit stop and observe the pressure gauge.

63

Each time the brake pedal is pressed, the pressure drops.

When the acoustic warning signal is not heard and the lamp (5) does not turn on, despite a repeated activation of the brake pedal (minimum 3 times), the accumulator pressure is sufficient.

Once check is complete, relieve the brake pressure.

Remove the pressure gauge (4) and tighten the plug (1) again.

4-41

SECTION 4 BATTERIES - LEVEL CHECK AND TERMINAL CHARGE CHECK

S WARNING S 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 thoroughly with water for 15 minutes and get prompt medical attention.

When working with batteries, always wear gloves, protection goggles and suitable clothes.

S WARNING S Never touch the battery terminals with your hands.

This could generate an electrolysis inside the human body and damage the body’s vital organs.

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.

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

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 right rear side of the machine.

Opening the engine guard gives access to the battery.

The battery is located to the right of the engine.

64

4-42

SUPPLIES AND MAINTENANCE CHART CHECKING THE ELECTROLYTE LEVEL Remove the caps (1).

When the 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).

65 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/in3)

Charge

Normal

Tropical

1.28 (0.05)

1.23 (0.04)

correct

1.20 (0.04

1.12 (0.04)

low: charge

1.12 (0.04)

1.08 (0.03)

discharged: recharge immediately

66

TERMINAL CHECK Keep battery clean and dry.

Disconnect any dirty terminals.

Clean the battery poles (+) and (-) and the terminals, then grease then with neutral and acid-resistant grease.

When assembling, make sure that the terminal surfaces make good contact.

Tighten the terminal nuts by hand.

67

4-43

SECTION 4 HEATING SYSTEM FILTER - REPLACEMENT Open the door (1), loosen the winged screw (3), remove the grid (4) and finally remove the filter (2).

68

FRONT AXLE - OIL CHANGE Move the machine to a level and firm ground.

Place the bucket on the ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Place some wedges under the wheels to prevent the machine from moving.

Risk of scalding from hot oil.

Activate the breather valve (1) to bleed air.

Place a collecting container under the front axle.

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

69

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.

Loosen the level and filler plug (3).

Fill in oil. Oil level should be flush with the hole, so fill in new oil until oil comes out of the hole.

Clean and retighten the level and filler plug (3).

After 10 minutes, check the level again and top up if necessary.

70

4-44

SUPPLIES AND MAINTENANCE CHART REAR AXLE - OIL CHANGE Move the machine to a level and firm ground.

Place the bucket on the ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Place some wedges under the wheels to prevent the machine from moving.

Risk of scalding from hot oil.

Activate the breather valve (1) to bleed air.

Place a collecting container under the rear axle. The recipient capacity can be determined by means of the relevant table in this manual.

71

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. Loosen the level and filler 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 and filler plug (3).

After 10 minutes, check the level and top up, if necessary.

TRANSMISSION

72

Activate the breather valve (1) to bleed air.

Place a collecting container under the front 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.

Loosen the level and filler plug (3).

Fill in oil. Oil level should be flush with the hole, so fill in new oil until oil comes out of the hole.

Clean and retighten the level and filler plug (3).

73

After 10 minutes check oil level and top up if necessary.

4-45

SECTION 4 WHEEL GEARBOXES Turn the wheels until plug (1) is in lower position (A).

Place a collecting container 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 retighten the plug (1).

74 Turn the wheels until plug (1) is positioned horizontally (B).

Unscrew plug (1).

Fill in oil. Oil level should be flush with the hole, so fill in new oil until oil comes out of the hole.

Clean and retighten the plug (1).

75 After 10 minutes check oil level and top up if necessary.

4-46

SUPPLIES AND MAINTENANCE CHART

SERVICE AFTER 3000 HOURS SERVICE POINTS

Check

Cleaning

Oil change

Replacement

Fuel tank Oil tank Brakes accumulator Equipment - Forks Diesel engine

FUEL TANK - CLEANING

S CAUTION S Never smoke or bring open flames close to the fuel tank.

Fuel may be irritant on skin; wear gloves or apply some protective cream.

Never remove the tank plug or refuel with the engine running.

To clean and rinse, never use fuel and do not use petrol, petroleum or other solvents.

Before filling the tank, clean the area around the filler plug in order to prevent that foreign bodies enter the tank. After filling, screw in and tighten the plug again.

Do not spill fuel and do not let it be absorbed by the ground, as it represents a danger of environmental pollution.

Immediately absorb fuel spillovers with rags or binding substances, then dispose of them according to the environmental legislation.

Empty the tank beforehand by using up as much fuel as possible.

Move the machine to a level and firm ground.

Stop the engine and remove the starter switch key.

Place some wedges under the wheels to prevent the machine from moving.

Unscrew the drain plug (1) located below the machine under the 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.

76

Screw in the drain plug (1) again.

4-47

SECTION 4 Loosen the plug (2) of the filler neck and refill.

Tighten the plug (2) again.

Bleed the fuel system, check for possible leaks and eliminate them.

77

HYDRAULIC OIL TANK - CLEANING AND OIL CHANGE

S CAUTION S Before starting working on the hydraulic system, make sure that it is not under pressure and relieve any residual pressure from it.

Risk of scalding from hot oil.

Never start the machine with an empty tank.

Avoid skin contact with hydraulic oils, as it could be dangerous for your health.

Collect the used hydraulic oil, old filters and dirty rags and dispose of them according to the environmental legislation.

78

Move the machine to a level and firm ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Go under the machine to loosen and remove the screws (1) and disassemble the lower cover (2).

Thus it is possible to access the drain plug (3) in the lower part of the tank.

Place a collecting container under the oil tank. For its capacity, refer to the table of refilling quantities.

79

4-48

SUPPLIES AND MAINTENANCE CHART Open the engine guard.

Loosen and remove cover (4) of the return filter.

Now, from under the machine, loosen and remove the drain plug (3) of the oil tank and let oil completely flow out.

80 Remove the filter body (7) together with the filter element (6).

Through the opening, clean the inside and the bottom of the tank by using clean hydraulic oil or washing oil.

Unscrew and remove the breather filter (5).

81 Screw in the drain plug (3) and reinstall the cover (2) by fixing it with screws (1).

Using a funnel equipped with filter and a manual pump or a manual oiler, fill up through the hole of the breather filter (5) until you reach the upper edge of the level indicator (8).

82 Reassemble the breather filter (5), install the filter body (7) with the (clean or new) filter element (6) and screw in the cover (4) again.

Bleed the hydraulic system.

4-49

SECTION 4

DIESEL ENGINE - CLEANING

S WARNING S Clean the engine only when the engine is switched off.

Preparation: Stop the engine.

Clean.

Open the engine guard.

Cover electrical and electronic components as well as connections (for example alternator, starter motor, 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.

4-50

SUPPLIES AND MAINTENANCE CHART

SERVICE IF NECESSARY SERVICE POINTS

Replacement

Cleaning

Air bleeding

Check

Coolers Tyres Connectors and hoses Fuses and relays Lights / Headlamps - Bulbs Rotary light - Reflectors Brake system Battery Drive belt Bucket teeth

COOLERS - CLEANING Move the machine to a level and firm ground.

Place the bucket on the ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Place some wedges under the wheels to prevent the machine from moving.

Wait for the cooling system to cool down.

Open the engine guard.

83 Clean the coolers.

For this operation you can employ a vacuum cleaner or a high-pressure jet cleaner.

S WARNING S During the cleaning operation with water jets, always wear a face shield to avoid serious injuries or even death.

Pay attention not to bend or to damage the fins during the cleaning. To this aim, take following precautions: - never exceed a pressure of 7000 kPa (999 psi);

84

- minimum distance between nozzle and coolers 300 ÷ 500 mm (11.81 ÷ 19.68 in); - the water jet must be held vertically with respect to the fins, in order to reduce the pressure on them and to improve the cleaning.

4-51

SECTION 4 TYRES - REPLACEMENT DISASSEMBLY Move the machine to a level and firm ground.

Place the bucket on the ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Place some wedges under the wheels to prevent the machine from moving.

Block the articulated joint.

Loosen the wheel nuts of the wheel to be changed by approximately one full turn.

Raise the axle with the defective wheel slightly until the wheels come clear of the ground.

85

Front axle: using the bucket, lift the machine.

Rear axle: lift the machine with a winch or a jack.

Support the raised axle with wood blocks to prevent it from lowering.

Release the air from tyre.

Loosen the nuts (1) of the wheel (2). Remove the wheel (2) without damaging the pin thread.

Do not lose the centring rings, spring washers and wheel nuts, because they will be reused by reassembly.

86

ASSEMBLY Inflate the tyre to approximately 1 bar.

Do not damage the threads of the wheel studs.

Tighten the nuts hand-tight.

Remove the wood blocks previously set under the raised axle and lower it.

Tighten the nuts crosswise to the prescribed torque 450 Nm (331 lbf•ft).

Inflate the tyre with the correct pressure.

4-52

SUPPLIES AND MAINTENANCE CHART Position of tyre tread When fitting the wheels pay attention to the direction of the tyre tread. Define the position offering the maximum traction force during forward travel under normal conditions.

In special cases, another tread position may be of advantage. In such cases, contact the After-sales service.

87

CONNECTORS AND LINES REPLACEMENT Before replacing hydraulic lines and fittings, relieve the pressure from the hydraulic system.

Always use original spare parts and never reuse used lines or fittings.

Dispose of drained oil and oily waste 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.

Check for the presence of leaks in the hydraulic system lines.

Quickly repair any hydraulic oil leaks in order to prevent waste, possible damage and dirt from entering the system. Search for hydraulic leaks with the engine running and let it run at a speed between 1200 and 1500 rpm.

Immediately replace the hoses showing signs of damage, cuts, scratches, swellings or leaks at fittings.

IMPORTANT: while replacing or assembling a pipe or hose, make sure that all elements are perfectly clean and free from any trace of dirt.

In order to guarantee the gasket seal, it is important that the fittings are not overtightened or undertightened.

After replacing a hose or a fitting, bleed the system.

4-53

SECTION 4 FUSES FUSES IN THE CAB Fuses (2) can be accessed after opening the door (1) located outside the cab on the right side under the window.

FUSE REPLACEMENT Extract the faulty fuse and insert a new fuse with the same charge.

88

F1

7.5A

Emergency steering

F2

7.5A

Load stabilization, return to dig

F3

7.5A

2nd gear switch

F4

5A

Right parking light, rear left light, license plate light

F5

15A

Power outlet, switch lighting, switch lighting

F6

7.5A

Control lever, creep speed

F7

7.5A

Instrument cluster, parking brake

F8

7.5A

Forward and reverse travel

F9

7.5A

Left main beam

F10

7.5A

Reverse travel light, back-up alarm

F11

7.5A

Engine stop solenoid

F12

7.5A

Available

F13

10A

Hazard warning lights, turn signal lights

F14

10A

Rotary beacon

F15

10A

Radio +30, cigarette lighter

F16

7.5A

Rear windscreen wiper and washer

F17

5A

Quick coupler

F18

5A

Engine control unit, diagnostics, main valve releasing relay

F19

5A

Left parking light, rear right light, instrument cluster backlighting

F20

10A

Brake light, hazard warning

F21

15A

Front windscreen wiper and washer, radio +15

F22

15A

Rear work lights

F23

7.5A

Low beam left

F24

7.5A

Low beam right

F25

7.5A

Right main beam

F26

5A

Power supply

F27

15A

Front work lights

F28

15A

Horn

F29

5A

Engine control unit

F30

10A

Anti-theft device

4-54

SUPPLIES AND MAINTENANCE CHART RELAYS RELAYS IN THE CAB Relays (2) can be accessed by opening the door (1) located outside the cab on the right side under the window.

Optional relays K1

2nd gear relay

K2

Brake pressure monitoring relay

K3

High speed releasing relay

K4

“Ride control” relay

K5

Available

K6

Front work lights

K7

Main valve releasing relay

K21

A/C relay

K22

Diode box

89

Standard relay K8

Relay creep gear

K9

Parking brake relay

K10

Low beam relay

K11

Main beam relay

K12

Flasher relay

K13

Low brake pressure relay

K14

Reversing light relay, back-up alarm relay

K15

Reverse solenoid relay

K16

Relay front windscreen wiper

K17

Forward speed relay

K18

Start interlock relay

K19

Horn relay

K20

Blower relay

RELAY IN THE ENGINE COMPARTMENT The starting relay and the preheating control relay are located on the front right side, under the engine guard.

K1.3 Preheating interrupting relay K1.4 “Grid heater” relay K1.5 Starting relay

For relay replacement, remove the defective fuse and insert a new one of the same type.

90 4-55

SECTION 4 BULBS - REPLACEMENT Before replacing a bulb, stop the engine and remove the starter switch 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. Front light 2. Turn signal light 3. Rear light, stop light, turn signal and reversing light 4. Front work light (optional) 5. Rear work light (optional) 6. Rotary light (optional)

91

FRONT LIGHT 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.

92

4-56

SUPPLIES AND MAINTENANCE CHART TURN SIGNAL LIGHT Loosen the two rear screws (1).

Remove the front cover (3).

Replace the defective bulb (2).

Reassemble in reverse order.

93 FRONT WORK LIGHT (OPTIONAL) Unscrew the screws (1) and remove the headlight glass (2) carefully.

94 Shift the safety bracket (3).

95 Extract the defective bulb (5) from the bulb holder (4) and insert a new bulb.

Reassemble in reverse order.

96

4-57

SECTION 4 REAR STOP LIGHT AND TURN SIGNAL LIGHT Unscrew and remove the covers (A) and (B).

Now the bulbs are accessible.

1. Tail light 2. Stop light 3. Turn signal light 4. Reversing light

97 Replace the defective bulb.

A. Tail light bulb B. Stop light bulb C. Turn signal light bulb D. Reversing light bulb

98 CAB LIGHT Remove the cover (1).

Replace the defective bulb.

99

4-58

SUPPLIES AND MAINTENANCE CHART ROTARY LIGHT Bulb replacement Depress the catch (1) and take off the cover (2).

100 Extract the bulb (3) and insert a new one.

101 Place the back cover (2). Press the lever (1) and insert the cover (2) with snap-lock.

Reflector replacement Remove the cover (2). Withdraw the clip (4) using small pincers. The reflector can then be completely withdrawn together with motor (5).

102 Fit new reflector with motor (5). Insert the clip (4) and put on the cover (2).

4-59

SECTION 4 BRAKE 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.

Bleeding valve (1) on the disc brake.

Right bleeding valve (2) on the front axle (only on “high speed” models).

Left bleeding valve (2) on the front axle (only on “high speed” models).

103

PROCEDURE Start the engine.

Perform 3-4 cycles to move all cylinders (boom, arm, steering) up to stroke end from both sides.

Stop the engine.

Disconnect the parking brake cable from the caliper.

(Do not use the parking brake during the bleeding procedure).

Remove the plug from the bleeding valve (1) on the caliper. Connect a hose and a little container to the valve.

Start the engine and then stop it (after 3-4 cycles).

Press down 3-4 times and hold the brake pedal.

Loosen the bleeding valve (1) to release the air.

Tighten bleeding valve (1) and release the pedal.

If the machine is equipped with oil-bath disc brake in the front axle (version “high speed”), repeat the same bleeding procedure both with the left and right brake, using the bleeding valves (2) installed in the front axle.

Reconnect the cable of the parking brake.

4-60

104

SUPPLIES AND MAINTENANCE CHART BATTERIES - REPLACEMENT Move the machine to a level and firm ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Place some wedges under the wheels to prevent the machine from moving.

S WARNING S Never exchange the battery terminals. Connect the positive cable to the positive terminal (+) and the negative cable to the negative terminal (-).

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 terminals with metal objects.

Never touch the battery terminals with your hands.

This could generate an electrolysis inside the human body and damage the body’s vital organs.

Open the engine guard.

Place the battery switch in the OFF position.

Loosen and remove the screw (1), disassemble the battery bracket (2).

Remove the battery (3).

Before installing the new battery, thoroughly clean the contact surfaces of the battery poles and clamps.

Install the new battery (3) and fasten it with the battery bracket (2) by tightening the screw (1).

Connect the positive cable to the positive terminal and the negative cable to the negative terminal.

105

Do not overtighten the terminal nuts, to prevent damaging them.

Grease battery poles and clamps with appropriate grease or neutral vaseline.

4-61

SECTION 4 DRIVE BELT - REPLACEMENT

S CAUTION S Danger of injuries caused by engine components and by moving belts.

Risk of burns caused by engine or cooler hot components.

Start maintenance and repair operations only after the engine and the cooler have cooled down.

Always replace the damaged belt.

Place the machine in a safe condition.

Stop the engine and remove the starter switch key.

Open the engine guard.

Loosen the screw (2).

Push the alternator (1) towards the engine, thus loosening the belt tension.

Now release the belt (3) from the various pulleys and remove it.

Assemble the new transmission belt (3).

Tension the belt by moving the alternator (1) outwards.

Check the belt tension.

This check must be repeated after a few hours of operation; if necessary, repeat the tension adjustment.

4-62

106

SUPPLIES AND MAINTENANCE CHART BUCKET TEETH - REPLACEMENT

S WARNING S Nobody must stay in the way of the tooth or tooth safety latch that has to be extracted.

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

Metal splinters may cause injury.

Always wear your personal protective clothing and devices, as well as protective goggles.

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

107 Drive out the tooth (3) from the tooth holder (4) using a piece of smooth metal or of hard wood (2).

108 Clean the inside of the housing and remove dirt and corrosion.

Fit new tooth (3) into the housing (4).

109

4-63

SECTION 4 The tooth (3) must be in contact with the point indicated by the arrow.

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.

110

4-64

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.

In case it is not possible to find the cause of the fault or to eliminate 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.

These following tables are reported for your guidance only. If any repairs are required beyond routine maintenance, your machine must be returned to your Dealer who has the correct tools, facilities and knowledge to perform repairs to the correct specification and safety standards.

These tables describe the failures already occurred, their possible causes and the remedies to be adopted. In exceptional cases, a failure described 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.

ACTION This column informs about how to detect the causes of faults and how to remedy them.

5-1

SECTION 5

FAULTS INDICATED BY GAUGES Watch the lamps during travel.

The machine works troublefree as long as no lamp is on and no acoustic warning signal is heard.

1. Lamp indicating a lack of current 2. Lamp indicating low engine oil pressure 3. Lamp indicating low brake pressure 4. Lamp indicating engine oil high temperature 5. Lamp indicating hydraulic oil high temperature 6. Lamp indicating air filter restriction 7. Engine water temperature indicator When a lamp turns on and an acoustic warning signal is heard, immediately stop the machine.

1

If necessary, stop the engine, locate the cause and eliminate the fault or contact the After-sales service.

NO CURRENT / BATTERY In case of battery failure, only lamp (1) turns on.

If the lamp (1) does not turn off after increasing the engine rpm, stop the engine, locate and eliminate the cause of the fault or contact the After-sales service.

2

5-2

TROUBLESHOOTING ENGINE OIL PRESSURE When the engine oil pressure is too low, lamp (2) lights up and a warning signal is heard.

Stop the machine, stop the engine, locate and eliminate the cause of the fault or contact the After-sales service.

3

BRAKE PRESSURE If the brake pressure drops sharply during travel, the machine stops immediately.

At the same time, lamp (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 machine back into operation.

4 “HIGH SPEED” MODELS When the brake pressure drops sharply during travel, the machine stops immediately if speed is lower than 5 km/h (3.10 mph).

At the same time, lamp (3) turns on and the acoustic signal is heard.

If the speed is higher than or equal to 5 km/h (3.10 mph), only lamp (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 machine back into operation.

5-3

SECTION 5 ENGINE OIL TEMPERATURE The circulation of the engine oil is controlled by a thermostat.

The maximum admissible temperature is approximately 135 °C (275 °F).

If the lamp (4) turns on and the acoustic warning signal is heard, it means that the temperature is too high.

Immediately stop the machine and let the engine run at idle speed to let the oil cool down.

If, after several minutes at idle speed, the lamp (4) does not turn off and the acoustic warning signal does not stop, stop the engine.

Secure the machine, locate the cause and rectify or contact the After-sales service.

5

HYDRAULIC OIL TEMPERATURE When the hydraulic oil temperature is too high, lamp (5) lights up and a warning signal is heard.

Stop the machine, stop the engine, locate and eliminate the cause of the fault or contact the After-sales service.

6

AIR FILTER CLOGGED When the air filter is clogged, the lamp (6) turns on and an acoustic warning signal is heard. When lamp (6) turns on, the filter must be cleaned or replaced, even if the maintenance interval has not yet elapsed.

7

5-4

TROUBLESHOOTING ENGINE WATER TEMPERATURE If the engine water temperature indicator (7) remains in the green area, the machine is operating correctly.

If the indicator (7) reaches the red area, the water temperature is too high.

Stop the machine, stop the engine, locate and eliminate the cause of the fault or contact the After-sales service.

8

5-5

SECTION 5

ENGINE FAULT Engine does not start.

POSSIBLE CAUSE

ACTION

Discharged or damaged battery.

Check and recharge the battery and, if necessary, replace it.

Corroded or loose connections to battery terminals.

Clean, check and tighten the battery terminal nuts. Replace the terminals and the nuts, if excessively corroded.

Wrong timing of the injection pump.

Check and correctly time the injection pump.

Deposits or water in the fuel tank.

Disconnect the hoses and clean them with a jet of compressed air.

Disassemble and clean the injection pump. Eliminate water from the fuel tank and refill the tank.

Insufficient fuel reserve.

Refuel.

No supply.

Overhaul or replace the supply or transfer pumps.

Air bubbles in the fuel passage hoses Check the lines to find out the cause or in the injection pump. of the presence of air, and check the supply pump; eliminate the air from inside the injection pump by loosening the appropriate plug and manually operating the supply pump.

Defective starter motor.

The engine does not start at low temperatures.

Replace the fuel with a different fuel Supply system clogged because of the formation of paraffin crystals due suitable for low temperatures.

Replace fuel filters. to the use of incorrect fuel.

Device for cold advance variation malfunctioning.

5-6

Repair or replace the starter motor.

Have the supply pump overhauled by the After-sales service or replace the pump.

TROUBLESHOOTING FAULT The engine stops.

POSSIBLE CAUSE

ACTION

Idle speed too low.

Adjust by means of the adjusting screw.

Irregular delivery of the injection pump.

Adjust delivery.

Dirt or water in the fuel hoses.

Disconnect the hoses and clean them with a jet of compressed air.

Disassemble and clean the injection pump. Eliminate water from the fuel tank and refill the tank.

Fuel filter clogged.

Clean the fuel filter and, if necessary, replace it.

Presence of air in the supply and injection system.

Check the hoses for cracks or their connections for looseness.

Replace worn parts, then eliminate air from the hoses and bleed the injection pump and the fuel filter by loosening the appropriate plugs and manually operating the priming pump.

Broken injection pump controls.

Replace the injection pump.

Anomalous play between timing shaft Adjust play. eccentrics and tappets.

The engine overheats.

Burnt, corroded or cracked valves.

Replace the valves, rectify or replace the seats on the cylinder head.

Defective water pump.

Check the assy and replace it, if necessary; replace the gasket.

Faulty thermostat.

Replace.

Scales in coolant passage compartments in the cylinder head and assy.

Carefully wash. Follow the rules for the type of scales remover used.

Insufficient tension of water pump control belt.

Check and adjust belt tension.

Too low coolant level.

Refill with coolant.

Wrong engine timing.

Check timing and correctly time.

Incorrectly calibrated injection pump both in excess and in defect.

Correct pump delivery on a workbench so that injection occurs according to the prescribed delivery.

Air filter clogged.

Clean the air filter and, if necessary, replace it.

5-7

SECTION 5 FAULT

POSSIBLE CAUSE

The engine lacks power and its Wrong timing of the injection pump. operation is irregular.

ACTION Check timing and correctly set the pump.

Defective automatic advance variator.

Check the operation on the injection pump workbench; if the detected values do not match the prescribed values, replace the variator spring.

Defective automatic cold advance device.

Adjust or replace the injection pump.

Excessive wear of the piston.

Overhaul the engine and replace the worn parts.

Incorrect calibration of the speed adjuster.

Check and correctly calibrate the adjuster.

The engine lacks power and its Partial clogging of the nozzles or operation is irregular. malfunction of the injectors.

Dirt or water in the supply and injection system.

Clean the holes of the injectors using the appropriate tools for the full overhaul of the injectors.

Carefully clean and refuel.

Anomalous play between timing shaft Check the play and correctly adjust. eccentrics and tappets.

Defective turbocharger.

Replace the complete assembly.

Air filter clogged.

Clean the air filter or replace it.

Defective supply device.

Check that the membrane does not have holes, that the contrast spring is correct and is correctly loaded (check on workbench).

Check that there is a correct air pressure inside the suction manifold with respect to the revolution speed of the engine at full load.

Control tie rods between throttle pedal and adjuster lever incorrectly adjusted.

5-8

Adjust the tie rods so that the control lever can be taken to the maximum displacement position.

TROUBLESHOOTING FAULT The engine has anomalous knocks.

The engine has anomalous knocks.

POSSIBLE CAUSE

ACTION

Malfunctioning injectors.

Replace the injectors.

Clogged fuel lines.

Disassemble the lines, clean them and replace the severely dented ones.

Incorrect setting of the injection pump.

Correct the pump setting so that injection occurs according to the prescribed advance angle.

Grind the drive shaft pins and Excessive play of one or more assemble smaller bearings. Replace crankshaft bearings or big end bearings or excessive shoulder play. the thrust half-rings.

Unbalanced drive shaft.

Check the alignment of the drive shaft.

Loosening of the flywheel fastening screws.

Replace the loose screws and tighten all screws to the prescribed torque.

Misaligned connecting rods.

Replace the connecting rods.

Replace the piston pin and/or the Piston pin noise due to excessive play in the piston hubs in the big end piston and the big end bushing. bushing.

Anomalous engine smoke.

Free bushings in the seat on the connecting rod.

Replace the bushings with new ones.

Noisy timing.

Adjust the play between the timing shaft eccentrics and tappets and check that there are no broken springs, no excessive play between valve rods and guides, tappets and seats.

Excessive maximum pump delivery.

Disconnect the pump and adjust its delivery according to the data contained in the calibration table.

Black or dark grey smoke.

Starting device incorrectly adjusted or Adjust the injection pump or replace malfunctioning. it.

The injection pump is excessively delayed (or the advance variator is defective).

Correct the setting, check the variator.

5-9

SECTION 5 FAULT Anomalous engine smoke.

Black or dark grey smoke.

POSSIBLE CAUSE The injection pump is excessively advanced.

ACTION Correct the setting.

The holes of the injectors (or of some Replace the injectors with a set of of them) are partially or fully clogged. new injectors or clean and recondition the original ones by using the proper tools.

Blue, greyish-blue or greyishwhite smoke.

Air filter clogged or deteriorated.

Clean or replace the filter element.

Compression loss in the engine due to: stuck or worn elastic rings; cylinder liner wear; deteriorated or incorrectly adjusted valves.

Overhaul the engine or limit interventions on parts.

Incorrect injector type, different injectors of different types or incorrectly calibrated injectors.

Replace the injectors.

Injection lines with incorrect internal diameter, crushed line ends due to repeated blockages.

Check the conditions of the ends or of the connections, replace the lines if necessary.

Excessive injection delay.

Correct the pump setting.

Defective automatic cold advance device.

Calibrate the injection pump or replace the device.

Defective injectors.

Replace the injectors.

Oil passage from piston rings caused Overhaul the engine. by stuck or worn rings or by liner wall wear.

5-10

Engine oil passing through the suction valve guides because of guide or valve rod wear.

Recondition the cylinder head.

Too cold engine (blocked or inefficient thermostat).

Replace the thermostat.

TROUBLESHOOTING

STEERING SYSTEM FAULT

POSSIBLE CAUSE

ACTION

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 with oil.

Pressure too low.

Consult your Dealer.

Limited-slip differential or steering mechanics sluggish.

Consult your Dealer.

Steering wobbly, permanent tread correction necessary.

Air in hydraulic system.

Purge system of air.

Internal leak in power steering.

Repair or replace.

Steering wheel easy to turn at stopper.

Internal leak in power steering.

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 leak in power steering.

Repair or replace.

Oil supply rate insufficient.

Consult your Dealer.

The power steering blocks.

Consult your Dealer.

The steering wheel when released still turns.

5-11

SECTION 5

BRAKE SYSTEM FAULT

POSSIBLE CAUSE

ACTION

Abrupt braking.

Pressure setting incorrect.

Decrease pressure by handling on the setscrew under the pedal.

During operation, pressure must be checked with a pressure gauge.

Insufficient braking action.

Pressure setting incorrect.

Increase the pressure with the setscrew under the pedal.

During operation, pressure must be checked with a pressure gauge.

WARNING: the admissible braking pressures must not be exceeded.

Delayed braking action and release of brake.

Insufficient charging and discharging Make sure the diameter of the lines in speed of the brakes. the brake system is not too small with respect to their length and the oil volume.

Viscosity of hydraulic oil too high.

Fill the system with hydraulic oil of prescribed viscosity.

Incorrect discharging of the brake system.

The system is not completely released and the residual pressure continues to act on the brakes.

Brake pedal does not return to original position.

Check that the stop screw of the pedal leaves some clearance between pedal return and actuating piston.

Remove foreign bodies from underneath the pedal.

The lamp on the instrument does not turn on or remains always on.

Check the pressure switch setting.

Adjust the pressure switch on the charging valve to a value which, although remaining below the minimum pressure of the accumulator, is high enough to ensure 3 or 4 braking cycles after the lamp has turned on.

Inconstant brake pressure.

The minimum pressure of the accumulator is lower than the brake maximum pressure.

Check the correct setting of accumulator pressure. If necessary, correct the value on the setscrew of the accumulator charging valve.

Brakes remain engaged.

5-12

TROUBLESHOOTING FAULT

POSSIBLE CAUSE

ACTION

Accumulators are permanently Not enough or too much nitrogen in recharged. accumulators.

After removing the oil from the accumulators, check the nitrogen pressure in the accumulators with a suitable instrument. Refill the accumulators in strict observance of the manufacturer’s operating instructions. The nitrogen pressure can be checked by measuring the pressure of the residual oil ejected.

Feeding pump always under pressure.

Pump worn out.

Repair or replace pump.

Valve contaminated.

Check carefully the valve (gliding of components, gaskets kit condition and connectors tightness).

The accumulators do not recharge.

A foreign body clogs the priority valve.

Check all parts for proper movement, especially the valve at the inlet.

Check the hydraulic connection. After checking the accumulator charging valve, check that the piston stop ring seats properly, placed before the load connection. Bleed the feed pump circuit.

Knocks are felt at pedal.

Abrupt pressure variations on the release side.

Discharge flow of brake too high.

Choose a larger diameter for the discharge lines.

Smooth braking (Inching) not possible.

Valve adjustment (Inching) wrong.

Adjust the valve.

Wrong valve operation.

Replace.

Braking noisy.

Brake plates, discs and linings worn. Check and replace.

Unsuitable oil

Change to proper oil.

5-13

SECTION 5

HYDRAULIC SYSTEM FAULT Hydraulic system does not operate regularly.

Hydraulic oil overheated.

The equipment control does not activate.

POSSIBLE CAUSE 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 the 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 the attachment.

5-14

ACTION

Correctly connect the lines.

Decrease the load.

TROUBLESHOOTING

ELECTRICAL SYSTEM FAULT Electrical system is inoperative.

Insufficient starter motor speed, the engine cranks slowly.

The starter motor does not operate.

The battery lamp remains on with the engine running.

Batteries will not charge.

POSSIBLE CAUSE

ACTION

Loose or oxidised battery connections.

Clean and tighten connections.

Battery faulty.

Check battery open circuit voltage for 12.6 volts minimum.

Check the electrolyte level and density.

Battery switch to OFF.

Set battery switch to ON.

Low battery output.

Check battery open circuit voltage for 12.6 volts minimum.

Check the electrolyte level and density.

Incorrect viscosity engine oil.

Use correct viscosity oil for temperature conditions.

Loose or oxidised battery connections.

Clean and tighten connections.

Defective battery.

Charge or replace batteries.

Low engine idle speed.

Increase idle speed.

Loose belt.

Check belt tension.

Malfunctioning battery.

Check battery open circuit voltage for 12.6 volts minimum.

Check the electrolyte level and density.

Alternator malfunctioning.

Have the alternator checked by your Dealer.

Loose or oxidised battery connections.

Clean and tighten connections.

Battery faulty.

Check battery open circuit voltage for 12.6 volts minimum.

Check the electrolyte level and density.

Loose or worn belt.

Check belt tension. Replace belt if required.

Alternator malfunctioning.

The battery lamp flashes, indicating an excessive charge voltage.

Have the alternator checked by your Dealer.

5-15

SECTION 5

AXLES FAULT Noise during travel.

Noise at idle speed.

POSSIBLE CAUSE

ACTION

Excessive play between ring gear and pinion.

Adjust the play.

Worn pinion and ring gear.

Replace pinion and ring gear.

Bearings and pinion worn.

Replace bearings.

Loosen pinion bearings.

Check bearing fastening.

Excessive pinion end play.

Adjust the end play.

Differential bearings worn out.

Replace bearings.

Loose differential bearings.

Adjust bearing play.

Ring gear excessively off-set.

Replace the ring gear.

Oil level low.

Check and refill with oil.

Poor or incorrect oil grade.

Replace the oil.

Axle beam bent.

Replace the axle beam.

The noises coming from the axle when the machine is moving are usually heard at idle speed, even if they are not very loud

Adjust or replace.

Wrong backlash between pinion and Adjust the play between the pinion and the ring gear. ring gear (the noise heard while decelerating disappears when speed is increased).

Intermittent noise.

Constant noise.

5-16

Pinion spline or input flange worn.

Replace the pinion.

Damaged ring gear.

Replace pinion and ring gear.

Loose differential box screws.

Tighten or replace the screws.

Ring gear teeth or pinion teeth damaged.

Replace pinion and ring gear.

Worn bearings.

Replace the bearings.

Pinion splines worn.

Replace the pinion.

Axle beam bent.

Replace the axle beam.

TROUBLESHOOTING FAULT Noise while bending.

Wheels vibrate.

Steering faulty.

Differential does not operate; jams while steering.

Vibrations during forward run.

POSSIBLE CAUSE

ACTION

Worn differential gears.

Replace the gears.

Worn differential assy and/or differential pins.

Replace the differential assy.

Worn differential shims.

Replace the shims.

Axle beam splines worn.

Replace the axle beam.

Axle installation incorrect.

Reinstall.

Axle faulty.

Replace axle.

Axle overload, load displacement wrong.

Remove excessive load and displace the weight differently.

Different tyres rotation radius.

Replace tyre or deflate one of them.

Axle beam bent.

Replace the axle beam.

Wrong use.

Consult the manual again.

Axle installation incorrect.

Reinstall.

Axle faulty.

Replace axle.

Axle overload, load displacement wrong.

Remove excessive load and displace the weight differently.

Axle beam broken.

Replace the axle beam.

Wrong use.

Consult the manual again.

Axle installation incorrect.

Reinstall.

Axle beam broken.

Replace the axle beam.

Axle beam bent.

Replace the axle beam.

Wrong use.

Consult the manual again.

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 the axle beam.

5-17

SECTION 5 FAULT Irregular wear of tyre.

5-18

POSSIBLE CAUSE

ACTION

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 the axle beam.

Axle beam bent.

Replace the 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 the manual again.

TROUBLESHOOTING AXLES COMPONENTS FAULT Break towards the external end of the ring gear tooth.

POSSIBLE CAUSE

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 loose.

Tighten the nut.

Break towards the internal end Crash load. of the ring gear tooth.

Gear adjustment wrong (insufficient backlash).

Pinion teeth or ring gear teeth worn or scored.

Bent central axle body.

Bearings worn or pitted.

Replace the ring gear.

Recheck backlash between pinion and ring gear.

Pinion nut loose.

Tighten the nut.

Insufficient oil.

Top up.

Contaminated oil.

Use clean or new oil.

Incorrect oil with poor additives.

Use correct oil.

Worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring gear.

Replace 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 temperature. overheated. Check if gear teeth have faded.

Unsuitable oil.

Drive pinion teeth pitted.

ACTION

Replace pinion and ring gear.

Use correct oil.

Oil level low.

Top up.

Contaminated oil.

Use clean or new oil.

Extremely intense use.

Replace the pinion.

Insufficient oil.

Top up.

Machine overloaded.

Replace the central axle body.

Damaged vehicle.

Replace the central axle body.

Crash load.

Replace the central axle body.

Insufficient oil.

Top up.

Contaminated oil.

Use clean or new oil.

Extremely intense use.

Replace the bearings.

Pinion nut loose.

Tighten nut.

5-19

SECTION 5 FAULT Gaskets leak oil.

POSSIBLE CAUSE

ACTION

Prolonged operation at excessive oil Replace gaskets. temperature.

Oil gasket wrongly installed.

Reinstall.

Gasket edge cut or scored.

Replace gaskets.

Contaminated oil.

Use clean or new oil.

Excessive wear of input flange Intense use. spline.

Pinion nut loose.

Replace flange.

Tighten nut.

Pinion axial backlash.

Recheck backlash between pinion and ring gear.

Pinion gear tooth fatigue break. Check if the fracture line is with wavy or clearly delineated (stop line).

Intense use.

Replace flange.

Continuous overload.

Replace flange.

Break of pinion and ring gear teeth.

Crash load of differential components.

Replace pinion and ring gear.

Splines of planetary gear worn Intense use. (excessive backlash).

Replace the differential assy.

Replace axle beam, if necessary.

Surface of spherical washers worn or scratched.

Insufficient oil.

Top up and replace the washers.

Unsuitable oil.

Use correct oil and replace the washers.

Contaminated oil.

Use clean or new oil.

Internal diameter of the pinion Intense use. bearing worn.

Replace bearing and check pinion axial backlash.

Excessive pinion end play.

Replace bearing and check pinion axial backlash.

Unsuitable oil.

Use correct oil.

Contaminated oil.

Use clean or new oil.

Broken or bent axle beam.

Intense vehicle operation, overload.

Replace the axle beam.

Broken axle beam at wheel flange.

Wheel support loosen.

Replace the axle beam.

Central axle body distorted.

Check the distortion of the central axle body.

5-20

TROUBLESHOOTING

TRANSMISSION FAULT

POSSIBLE CAUSE

ACTION

The steering does not respond.

Transmission coupling faulty.

Replace the coupler.

Machine does not move.

Hydraulic oil level too low.

Top up with new oil.

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 the switch.

Travel direction lever faulty.

Replace the lever.

Rear axle locked.

Check axle.

Brake locked.

Release brake.

Machine does not move either Travel direction valve faulty. forward or back.

Travel direction lever faulty.

Replace the solenoid valve.

Replace the lever.

Supply filter contaminated.

Clean or replace the filter, if necessary.

Insufficient acceleration in both Supply filter contaminated. travelling directions.

Clean or replace the filter, if necessary.

On a flat surface the machine starts only with high engine speed.

Unsuitable oil.

Use 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 control pressure system of the travel pump.

Consult your Dealer.

Operation faults in the high-pressure Consult your Dealer. system of the transmission.

Operation faults in the supply pressure system of the travel pump.

Consult your Dealer.

5-21

SECTION 5 FAULT

POSSIBLE CAUSE

Maximum travelling speed not Supply filter contaminated. reached.

ACTION Clean or replace the filter, if necessary.

Unsuitable oil.

Use 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 control pressure system of the travel pump.

Consult your Dealer.

Operation faults in the high-pressure Consult your Dealer. system of the transmission.

Operation faults in the supply pressure system of the travel pump.

5-22

Consult your Dealer.

TROUBLESHOOTING

WORKING ATTACHMENT FAULT

POSSIBLE CAUSE

Lifting, dumping not functional. Low oil level.

Pump drive coupling defective.

ACTION Top up with new oil.

Replace the coupler.

Kinematics fault (working equipment Consult your Dealer. components deformed).

Defective kinematics in the control valve section.

Consult your Dealer.

Control lever of bucket equipment does not hold locking in floating position.

Defective kinematics in the control valve section.

Consult your Dealer.

Defect of control piston block in control valve section.

Consult your Dealer.

Dumping or lifting time too long.

Primary pressure setting too low.

Adjust primary pressure.

Maximum engine speed too low.

Adjust.

Pump delivery rate too low.

Consult your Dealer.

Defective kinematics in the control valve section.

Consult your Dealer.

Internal leaks in control valve section Find and eliminate the leak. or in cylinders.

Travel of control valve section piston Consult your Dealer. too short.

Lowering time too long.

Defective kinematics in the control valve section.

Consult your Dealer.

Lifting force insufficient.

Primary pressure setting too low.

Consult your Dealer.

Internal leaks in control valve section Find and eliminate the leak. or in cylinders.

Dumping force insufficient.

Primary pressure setting too low.

Adjust primary pressure.

Secondary pressure setting too low.

Secondary pressure setting.

Internal leaks in control valve section Find and eliminate the leak. or in cylinders.

5-23

SECTION 5

HEATING AND AIR CONDITIONING SYSTEM FAULT System very noisy.

5-24

POSSIBLE CAUSE

ACTION

Belt loose or worn.

Adjust the tension of the belt or replace it.

Clutch noisy.

Fasten the clutch.

Compressor supporting bracket loose or internal compressor parts worn out.

Repair bracket, replace compressor.

Fan 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 and refill the system.

TROUBLESHOOTING AIR CONDITIONING FAULT Fan does not operate.

POSSIBLE CAUSE

ACTION

Fuse blown or loose.

Check fuse contact, if necessary plug in correctly. Replace defective fuse.

Reappearance of the defect after a short time indicates a short-circuit.

Connector loose.

Check that connectors at the bottom of the unit are firmly in place and correct, if necessary.

Check connections at blower switch.

Fan cannot be switched off.

Connecting cable damaged or broken.

Replace the cable, observing the correct cable path and the connection.

Electrical connections interchanged.

Check connecting cables and reconnect properly, if necessary.

Fan switch defective.

Replace switch.

Fan unit locked.

Eliminate the cause of the blockage, e.g. by removing foreign object from rotor. If necessary, install a new blower.

Fan motor defective.

Replace blower.

Bridge the blower switch.

Replace blower switch.

Reduced blower performance. Rated supply voltage incorrect.

Dirty clamps.

Rated voltage of conditioner and of vehicle system must be identical.

Replace blower.

Clean connector contacts. Proceed with care to avoid short-circuits.

Insufficient cross-section of electrical Lay cables with the recommended cables. cross-sections.

Heat exchanger heavily contaminated.

Clean carefully to avoid causing damage to the exchanger which might result in consequential leaks.

Fan ducts obstructed.

Check air ducts and outlets for obstructions and remove any foreign objects. Remove trouble.

5-25

SECTION 5 COOLER FAULT Compressor not working.

POSSIBLE CAUSE

ACTION

Open circuit in compressor solenoid. Check power supply to the clutch.

Faulty thermostat.

Replace the 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.

Clean or replace the air filter.

Air filter.

5-26

TROUBLESHOOTING 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.

ACTION

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.

Check flap and lubricate, if necessary.

Flap deformed.

Check the flap and replace it.

Flap clogged.

Check flap and remove foreign object, if any.

5-27

SECTION 5 NOTES:

5-28

SECTION 6 STORAGE MACHINE STORAGE

STORING THE ENGINE

If the machine is to remain unused for a period exceeding 30 days, store it under cover or cover it with a waterproof tarpaulin.

If the engine is to be left unused for a long time, it is necessary to conserve it by means of specific products against rust formation.

Clean the machine completely. Paint all surfaces of the machine where the paintwork is damaged, to avoid rust.

Clean the engine with a high-pressure device.

Take the engine to the operating pressure, then stop it.

Check the machine for worn or damaged parts and replace as necessary.

Drain the engine oil and fill in anti-corrosive oil.

Lubricate the machine and drain oil from transmission, oil tank, axles and engine; refill with recommended oil.

Produce a mixture of 90% diesel fuel and 10% anticorrosive oil and fill the tank with it.

Drain fuel from the tank.

Check the radiator coolant level. If the machine is within 100 hours before the scheduled maintenance after 3000 hours, or within 2 months before the maintenance scheduled after 2 years, perform the prescribed maintenance operations.

Let the engine run for approximately 10 minutes.

Operate the working attachment so that all its cylinders are in fully retracted position and rest the bucket on a block of wood.

Disassemble the belts and store them packed.

Stop the engine and operate the control levers to release all residual pressure from the hydraulic systems.

Close the suction and the drain openings.

Check that the parking brake is disengaged.

Take the main battery switch to the OFF position.

Block the articulated joint by means of the appropriate pin.

Coat the exposed portions of the cylinder rods and control valve sections with anti-corrosive grease.

Remove the battery from the machine and store it.

Place blocks under the axles to remove the weight from the tyres.

Cover the exhaust pipe opening.

Perform the engine protection operations.

Stop the engine.

Manually rotate the engine several times for cylinder and combustion chamber preservation.

Spray some anti-corrosive grease in the pulley races.

Before operating the engine again, it is necessary to remove the preservation products.

Products Anti-corrosive oil according to specification: - MIL-L-21260B; - TL 9150-037/2; - Nato Code C 640 / 642.

Anti-corrosive product for external preservation according to specification: - Nato Code C 632.

Recommended detergent for preservation product removal: - Petrol solvent (danger class A3).

6-1

SECTION 6 BATTERY STORAGE

MACHINE RECOMMISSIONING

Remove the batteries from the machine. Store them on a wooden table in a dry, cool, well ventilated room, if possible at a temperature above 0 °C (32 °F) (optimum temperature 20 °C (68°F)).

To take the machine back to service after a long storage period, it is necessary to take some precautions.

Perform the following operations: - clean the battery; - check the acid concentration and the electrolyte level every two weeks; - recharge the battery when the acid density is lower than 1.23 kg/dm3 (3 lb/in3) or earlier; - keep the outside of the batteries clean and dry.

Eliminate all engine protections. Fill in engine oil.

Fill the fuel tank.

Reassemble and connect the batteries. Check the charge and the electrolyte level.

Place the main battery switch in the ON position.

Check all oil levels.

Check the level of the coolant solution.

Check the condition of the tyres and the tyre pressure.

Remove the blocks from under the axles.

Unlock the articulated joint.

Remove the cover from the exhaust pipe opening.

Remove the anti-corrosive grease from the cylinder rods and the other coated areas.

Check the operation of the electrical system.

Bleed air from the hydraulic system.

Check the operation of the steering system and braking system.

Remove the engine protections Remove the anti-corrosive grease from the pulley races.

Assemble the belts and adjust the tension after brief operation.

Reopen the suction and drain lines.

Operate the engine.

S WARNING S Check the machine for leaks and for broken, defective or missing parts.

S WARNING S Before starting the engine, make sure all the controls are in the neutral position. This will prevent any unexpected movement of the machine and of any electrical equipment.

S WARNING S Avoid running the engine in an enclosed space.

Ensure adequate ventilation at all times.

6-2

SECTION 7 ACCESSORIES 4 x 1 (BOTTOM-DUMP) BUCKET (OPTIONAL) ASSEMBLY Assemble the bucket with the same procedure of standard bucket.

Stop the engine and depressurize the hydraulic system by actuating control levers (1) and (2), until the equipment cannot move.

1 Connect the hoses (3) and (4).

2 Connect the hoses so that the following movements are initiated by means of the control lever (2).

Control lever (2) forward - bucket opens.

Control lever (2) backward - bucket closes.

If this is not the case, exchange the hoses (3) and (4).

DISASSEMBLY Lower the bucket to the ground. Stop the engine and depressurize the hydraulic system. Actuate control levers (1) and (2) until the attachment stops moving.

Loosen the hoses (3) and (4). Close the hose and the hydraulic connectors with appropriate protective covers.

Proceed as for “Standard bucket”.

7-1

SECTION 7

FORKS Always lift the load by using both forks.

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 the forks, as they could be damaged.

The transport of molten or fused material is forbidden.

Do not transport any person on forks, as it could be dangerous.

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 fork wear.

Drive with folded forks with no load, as this reduces the risk of accidents. It is not necessary to remove the forks to connect certain types of attachment.

FORK TYPES Standard forks (1).

3 Collapsible forks (2).

4

7-2

ACCESSORIES DISASSEMBLY AND ASSEMBLY Place the tool (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 (11.81 in).

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 operations, the machine must always 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 and the load and deposit. After reversing, lower the forks again.

PLATE The machine’s total overturning load 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 (19.68 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

ACCESSORIES 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 a distance of 500 mm (19.70 in) both in vertical and in horizontal direction.

Measure the diagonal distance (d).

The diagonal must be between 695 mm (27.36 in) and 713 mm (28.07 in).

If the measured value is lower than 695 mm (27.36 in) or higher than 713 mm (28.07 in), immediately replace both forks.

12 Wear check

S CAUTION S When wear exceeds 10%, immediately replace both forks.

Fork prong wear occurs most often in the outer bending area.

Start measuring wear from the original nominal thickness (n).

With a nominal thickness of 40 mm (1.57 in), the wear limit is 36 mm (1.41 in).

When wear exceeds 10%, immediately replace both forks.

13

7-6

SECTION 8 DATA AND TECHNICAL SPECIFICATIONS DIMENSIONS AND PERFORMANCE (WITH STANDARD BUCKET)

1

BUCKET - DIMENSIONS

21E

121E

221E

321E

5490 (217)

5590 (220)

5650 (222)

A Total length

mm (in)

5360 (211)

B Cab height

mm (in)

2710 (106)

C Bucket width

mm (in)

D Wheel width

2790 (114.17) 2790 (109.84)

2790 (109.84)

1900 (74.80)

2050 (80.70)

2100 (82.70)

2100 (82.70)

mm (in)

1841 (73.11)

1910 (75.19)

1910 (75.19)

1963 (77.28)

E Dumping height

mm (in)

2525 (99.40)

2530 (99.60) 2600 (102.36)

2640 (104)

F Dumping reach

mm (in)

825 (34.44)

785 (30.90)

890 (35.03)

G Maximum height of bucket pin

mm (in) 3250 (127.95)

H Dumping depth

mm (in)

105 (4.133)

110 (4.33)

117 (4.606)

116 (4.56)

I

mm (in)

2182 (85.90)

2250 (88.59)

2350 (92.51)

2350 (92.51)

J Track

mm (in)

1480 (58.26)

1526 (60.08)

1526 (60.10)

1570 (61.81)

K Clearance from ground to axle

mm (in)

330 (13)

330 (13)

330 (13)

330 (13)

L Rear overhang

mm (in)

1203 (47.36)

1267 (50)

1267 (50)

1267 (50)

W Clearance from ground to drive shaft mm (in)

400 (15.74)

415 (16.33)

415 (16.33)

415 (16.33)

4615 (10153)

4920 (10824)

5430 (11946)

5770 (12695)

21E

121E

221E

321E

0.7 (24.72)

0.8 (28.25)

1 (35.31)

1.1 (38.85)

Wheel base

Operating weight (with standard bucket)

kg (lb)

BUCKET - PERFORMANCE

845 (33.26)

3250 (127.9) 3350 (131.88)

4430 (174.40)

Standard bucket capacity

m3 (ft3)

Tensile force

kg (lb) 3800 (8360) 4550 (7990) 4410 (9702) 5100 (12220)

Dumping load - ISO axis

kg (lb) 3345 (7359) 3495 (7689) 4245 (9359)

4420 (9724)

Dumping load - turned by 40° ISO

kg (lb) 2945 (6480) 3100 (6820) 3630 (7986)

3755 (8261)

Bucket width

mm (in) 1900 (74.80) 2050 (80.70) 2100 (82.68) 2100 (82.68)

Lifting capacity at ground

mm (in) 4260 (168)

5520 (218)

4410 (174)

6060 (234)

8-1

SECTION 8

DIMENSIONS AND PERFORMANCE (WITH FORKS)

1

BUCKET WITH FORKS - DIMENSIONS

21E

121E

221E

321E

Total length with forks

mm (in) 1200 (47.24) 1200 (47.24) 1200 (47.24) 1200 (47.24)

Width of fork support

mm (in) 1450 (57.08) 1450 (57.08) 1450 (57.08) 1450 (57.08)

Fork weight

kg (lb)

370 (814)

370 (814)

370 (814)

370 (814)

A Clearance from ground

mm (in)

100 (3.94)

100 (3.94)

100 (3.94)

100 (3.94)

B Height with maximum outreach

mm (in) 1300 (51.18) 1330 (52.36) 1388 (54.64) 1388 (54.64)

C

Maximum height

mm (in)

2960 (116.53)

2982 (117.40) 945 (37.20)

3080 (121.25)

3157 (124.30)

D Outreach at ground

mm (in) 980 (38.58)

E Maximum outreach

mm (in) 1335 (52.55) 1315 (51.77) 1340 (52.75) 1390 (54.72)

F Outreach at maximum height

mm (in) 600 (23.62)

580 (22.83)

G Outreach of coupler pin of bucket with mm (in) 1630 (21.85) 1630 (21.85) forks H Coupler pin switch and centre of gravity

mm (in) 340 (13.40)

340 (13.40)

945 (37.20) 1010 (39.76) 610 (24.01)

587 (23.11)

1650 (65)

1700 (67)

340 (13.40)

340 (13.40)

Payload on level ground

kg (lb)

1640 (3608) 1780 (3916) 2120 (4664) 2215 (4873)

Payload on rough ground

kg (lb)

1230 (2706) 1335 (2937) 1590 (3498) 1660 (3652)

Operating weight

kg (lb)

LIFTING LOADS

4655 (10214)

4895 (10770)

5370 (11814)

5690 (12518)

21E

121E

221E

321E

At L1 = 500 mm (19.68 in)

kg (lb)

1600 (3520)

1700 (3740)

1950 (4290)

2250 (4950)

At L2 = 800 mm (31.49 in)

kg (lb)

1400 (3080)

1500 (3300)

1550 (3410)

1550 (3410)

At L3 = 1000 mm (39.37 in)

kg (lb)

1250 (2750)

1250 (2750)

1250 (2750)

1250 (2750)

At L4 = 1200 mm (47.24 in)

kg (lb)

1000 (2200)

1000 (3520)

1000 (3520)

1000 (3520)

8-2

DATA AND TECHNICAL SPECIFICATIONS

NOISE 21E External noise level LWA

121E

221E

99 dB(A)

321E

100 dB(A)

Internal noise level LpA

75 dB(A)

WEIGHTS 21E Engine

kg (lb)

Front axle

kg (lb)

230 (506)

Rear axle (gearbox included) kg (lb) and travel motor

312 (686)

Cab

121E

221E

321E

300 (660) 318 (700) 251 (473)

kg (lb)

315 (694)

470 (1034)

Variable-displacement pump kg (lb)

30 (66)

Hydraulic motor

kg (lb)

35 (77)

Lifting equipment

kg (lb)

Lifting cylinder

kg (lb)

Cylinder for quick coupler

kg (lb)

Counterweight

kg (lb)

420 (924)

600 (1320) 30 (66) 12 (26)

393 (865)

415 (913)

676 (1488)

786 (1730)

DIESEL ENGINE

Iveco model

21E

121E

221E

321E

F5C E9454 B* A003

F5C E9454 C* A001

F5C E9454 E* A004

F5C E9454 G* A001

Operation

4-stroke diesel engine

Number of cylinders

4

Bore

mm (in)

99 (3.90)

Stroke

mm (in)

104 (4.09)

Total displacement

3

3

Power ISO 9249 Rated rpm

kW/CV rpm

Ignition order

220 (162)

260 (192)

275 (203)

310 (228)

40 / 54

48 / 64

55 / 74

61 / 82

2300

2300

2500

2500

1,3,4,2

Compression ratio Weight

3202 (195.400)

cm (in )

Maximum torque (at 1400 Nm (lbf•ft) rpm)

17 ± 0.5 : 1 kg (lb)

300 (660)

8-3

SECTION 8 TIGHTENING TORQUES Component

Tightening torque (Nm) (lbf•ft)

Oil pan plug

50 (36.90)

1/8 G plug (crankcase)

40 (29.50)

3/8 G plug (crankcase)

15 (11.06)

Water drain plug (crankcase)

40 (29.50)

Inspection covers

25 (18.43)

Timing gearbox cover

25 (18.43)

Timing gearbox

25 (18.43)

Flywheel case (M8)

35 (25.81)

Flywheel case (M12)

120 (88.50)

Cylinder head - 1st phase (M12)

65 (48)

Cylinder head - 2nd phase (M12)

90 (66.40)

Cylinder head - 3rd phase (M12)

60 (44.25)

Rocker shaft assy

25 (18.43)

Head cover

25 (18.43)

Valve adjusting nut

20 (14.75)

Suction manifold

25 (18.43)

Exhaust manifold

15 (11.06)

Heat exchanger

25 (18.43)

Drive shaft pulley

350 (258)

Flywheel

30 (22.12)

Injectors (screw)

25 (18.43)

Injectors (nut)

30 (22.12)

Fuel filter

25 (18.43)

Oil filter

25 (18.43)

Oil pump

25 (18.43)

Water pump

25 (18.43)

Alternator

50 (36.90)

Fuel pump

25 (18.43)

Sensors (oil pressure, water temperature, etc.)

25 (18.43)

8-4

DATA AND TECHNICAL SPECIFICATIONS

BRAKE SYSTEM BRAKE PEDAL VALVE Allowable service pressure ................................................................................................... 175 bar (2537 psi) Adjusted pressure ..................................................................................................................... 55 bar (797 psi) Pressure of brake on disc ......................................................................................................... 55 bar (797 psi) ACCUMULATOR CHARGING VALVE Preloading pressure.............................................................................................................. 175 bar (2537 psi) “Cut-in” pressure ................................................................................................................... 120 bar (1740 psi) “Cut-off” pressure .................................................................................................................. 150 bar (2175 psi)

PRESSURE SWITCHES STOP LIGHT PRESSURE SWITCH Infeed pressure .......................................................................................................................... 3.5 bar (51 psi) Function .........................................................................................................................................when closing BRAKE ACCUMULATOR CHARGE PRESSURE SWITCH Infeed pressure ........................................................................................................................80 bar (1160 psi) Function .......................................................................................................................................... bidirectional GEARBOX PRESSURE SWITCH (HIGH SPEED ONLY) Infeed pressure ......................................................................................................................... 40 bar (580 psi) Function .........................................................................................................................................when closing

8-5

SECTION 8 ACCUMULATORS BRAKE ACCUMULATOR Capacity ..............................................................................................................................0.32 litres (0.10 gal) Maximum pressure ............................................................................................................... 210 bar (3045 psi) Service temperature........................................................................................ -10 °C / +80 °C (-50 °F/+176 °F) Filling gas.............................................................................................................................................. nitrogen Filling gas overpressure.............................................................................................. 16 ± 1 bar (232 ± 15 psi) Weight............................................................................................................................................. 1.3 kg (3 lb) QUICK COUPLER CYLINDER ACCUMULATOR Capacity ................................................................................................................................0.6 litres (0.20 gal) Maximum pressure ............................................................................................................... 330 bar (4784 psi) Service temperature........................................................................................ -10 °C / +80 °C (-50 °F/+176 °F) Filling gas.............................................................................................................................................. nitrogen Preloading pressure.................................................................................................... 50 ± 1 bar (725 ± 15 psi) Weight............................................................................................................................................. 3.3 kg (7 lb) LOAD STABILIZATION ACCUMULATOR Capacity ..............................................................................................................................0.75 litres (0.20 gal) Maximum pressure ............................................................................................................... 330 bar (4784 psi) Service temperature........................................................................................ -10 °C / +80 °C (-50 °F/+176 °F) Filling gas.............................................................................................................................................. nitrogen Filling gas overpressure.............................................................................................. 25 ± 1 bar (362 ± 15 psi) Weight................................................................................................................................................ 4 kg (9 lb)

8-6

DATA AND TECHNICAL SPECIFICATIONS

STEERING SYSTEM System pressure .................................................................................................................................... 175 bar

POWER STEERING 21E - 121E - 221E

321E

OSPC200LS

OSPC315LS

Model Displacement

cm3/rev (in3/rev)

200 (12.20)

315 (19.22)

Rated oil flow

litre/min (gal/min)

20 (5.30)

32 (8.40)

kg (lb)

5.8 (13)

6.2 (14)

bar (psi)

240 (3480)

240 (3480)

Weight Relief valve adjustment TIGHTENING TORQUES Component

Tightening torque (Nm) (lbf•ft)

Steering wheel nut

55 (40.56)

Steering column bracket

23 (17)

End cover

30 (22.12)

Connector

45 (33.20)

Adaptors

55 (40.56)

Check valve

30 (22.12)

STEERING CYLINDER 21E

121E

Quantity

221E

321E

1

Ø rod

mm (in)

32 (1.25)

40 (1.57)

Ø piston

mm (in)

70 (2.75)

80 (3.14)

Stroke

mm (in)

300 (11.81)

300 (11.81)

8-7

SECTION 8

HYDRAULIC SYSTEM PRESSURE ADJUSTMENT WORKING ATTACHMENT Primary safety pressure ........................................................................................................ 250 bar (3625 psi) Secondary safety pressure - tilt dumping cylinder bottom side............................................. 280 bar (4060 psi) Secondary safety pressure - tilt dumping cylinder rod side .................................................. 250 bar (3625 psi) Secondary safety pressure - lifting cylinder bottom side....................................................... 280 bar (4060 psi)

VARIABLE-DISPLACEMENT PUMP 21E System

Power

221E

321E

Pump with adjustment depending on engine rpm AV4VG40DA1D A4VG56DA1D2 A4VG56DA1D2 A4VG71DA1D2 2 / 32R / 32R / 32R / 32R

Model Displacement

121E

cm3/rev (in3/rev) kW

40 (2.44)

56.0 (3.41)

56.0 (3.41)

71.0 (4.33)

35.7

38.0

48.3

49.0

Transmission through

diesel engine direct drive, i = 1.0

Service revolutions (= engine rated speed)

rpm

2300

2300

2500

2500

Maximum oil delivery

rpm

92.00

128.8

140.0

177.5

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 1100 rpm)

Adjustment end

bar (psi)

400 (5800) (at 1800 rpm)

400 (5800) (at 1900 rpm)

400 (5800) (at 1900 rpm)

400 (5800) (at 1900 rpm)

Pressure cut-off

bar (psi)

430 (6234)

High-pressure relief valves bar (psi) opening -

465 (6742)

467 (6771)

467 (6771)

467 (6771)

Hydraulic motor adjustment start

245 (3552)

190 (2755)

245 (3552) (190 “high speed” models)

215 (3117)

Voltage

8-8

bar (psi) V

12

DATA AND TECHNICAL SPECIFICATIONS GEAR PUMP

Model Displacement Maximum pressure

(cm3/rev) (in3/rev)

21E

121E

221E

321E

022R0020KB

032R0020KB

028R0020KB

032R0020KB

22.5 (1.37)

32 (1.39)

28 (1.70)

32 (1.95)

bar (psi)

270 (3914)

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 (3.94)

100 (3.94)

110 (4.33)

Stroke

mm (in)

721(28.38)

728 (28.66)

718 (28.26)

730 (28.74)

Tilt dumping cylinder Quantity

1

Ø rod

mm (in)

50 (1.97)

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 (19.30)

490 (19.30)

Quick coupler cylinder Quantity

1

Ø rod

mm (in)

25 (0.99)

25 (0.99)

25 (0.99)

25 (0.99)

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)

8-9

SECTION 8 TRAVEL MOTOR 21E

121E

Type

221E

321E

A6VM80HA1U1 / 63W

Displacement Qmax / Qmin

cm3 (in3)

Maximum speed

80 / 18.8 (4.88/ 80 / 23.7 (4.88/ 80 / 29.2 (4.48/ 80 / 32.5 (4.48/ 1.47) 1.44) 1.78) 1.98)

rpm

4352

5289

4770

-

Delivery pressure

bar (psi)

25 (362)

25 (362)

25 (362)

25 (362)

Service pressure

bar (psi)

245 (3552)

190 (2755)

190 (2755)

200 (2900)

Pressure increasing spring

bar (psi)

10 (145)

10 (145)

10 (145)

10 (145)

Voltage

V

12

ELECTRICAL SYSTEM Service voltage ........................................................................................................................................... 12 V Battery: Capacity (20 h).......................................................................................................................................... 95 Ah Critical current........................................................................................................................................... 900 A Weight............................................................................................................................................ 25 kg (55 lb)

BUCKETS 21E 3

121E

221E

321E

SAE capacity

m 0.65 0.70 3 (22.95) (24.72) (ft )

0.80 (28.25)

0.80 (28.25)

0.90 (31.78)

0.90 (31.78)

1.00 (35.31)

1.00 (35.31)

1.10 (38.84)

1.20 (42.37)

Width

mm 1800 1900 (in) (70.86) (74.80)

1900 (74.80)

2050 (80.70)

2050 (80.70)

2050 (80.70)

2100 (82.67)

2100 (82.67)

2100 (82.67)

2100 (82.67)

Weight

kg (lb)

295 (650)

315 (693)

335 (781)

335 (781)

365 (803)

365 (803)

370 (814)

410 (902)

8-10

250 (550)

265 (583)

DATA AND TECHNICAL SPECIFICATIONS

AXLES FRONT AXLE

Model

21E

121E - 221E - 321E

28.16 (CA147195)

28.25 (CA150144)

Differential type

limited slip

Bevel gear reduction ratio

2.90 / 1

3.66 / 1

Reduction gear ratio

6.00 / 1

6.00 / 1

Total reduction ratio

17.45 / 1

22.00 / 1

Input rotation direction

clockwise

Bevel gear play

0.17 ÷ 0.24 mm ( 0.66 ÷ 0.94 in)

Pinion bearing preload (measured on D = 34.5 mm (1.35 in) without seal rings) Ring gear-pinion bearing total preload (measured on D = 34.5 mm (1.35 in) without seal rings)

P = 9.2 ÷ 13.7 daN (20.64 ÷ 30.79 lbf) T= (P+3.1)+(P+4.7) daN T= (P+2.5)+(P+3.8) daN (P+6.97)+(P+10.56) lbf (P+5.62)+(P+5.54) lbf

Dynamic load Static load

55000 Nm (40565 lbf•ft) 137500 Nm (101415 lbf•ft)

Service brake torque

980 Nm (723 lbf•ft)

Parking brake torque

780 Nm (576 lbf•ft)

Maximum service pressure

55 bar (797 psi)

“HIGH SPEED” FRONT AXLE 121E - 221E - 321E Model Differential type

28.25 (CA147188) limited slip

Bevel gear reduction ratio

3.66 /1

Reduction gear ratio

6.00 / 1

Total reduction ratio

22.00 / 1

Input rotation direction

clockwise

Bevel gear play

0.17 ÷ 0.24 mm (0.0066 ÷ 0.0094 in)

Pinion bearing preload (measured on D = 34.5 mm (1.35 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.64 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.5 mm (1.35 in) without seal rings)

T= (P+2.5)+(P+3.8) daN (P+5.62)+(P+8.54) lbf

Maximum service pressure

55 bar (797 psi)

8-11

SECTION 8 REAR AXLE 21E

121E - 221E

321E

Model

CA147194+CA150145 CA147189+CA150146 CA147186+CA150147 28.16 + TB150 28.20 + TB150 28.20 + TB150

Differential type

CA147194: standard CA147189: standard CA147186: standard CA150145: limited slip CA150146: limited slip CA150147: limited slip

Bevel gear reduction ratio

2.91 / 1

3.66 / 1

3.66 / 1

Reduction gear ratio

6.00 / 1

6.00 / 1

6.00 / 1

Transmission box reduction gear

2.257 / 1

2.257 / 1

2.053 / 1

Total reduction ratio

39.38 / 1

49.65 / 1

45.156 / 1

Input rotation direction Bevel gear play

counterclockwise 0.18 ÷ 0.23 mm (0.007 ÷ 0.009 in)

Pinion bearing preload (measured on D = 34.8 mm (1.37 in) without seal rings) Ring gear-pinion bearing total preload (measured on D = 34.8 mm (1.37 in) without seal rings)

0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf) T= (P+3.1)+(P+4.7) daN T= (P+6.96+P+10.56 lbf)

T= (P+2.5)+(P+3.8) daN (P+5.62+P+8.54 lbf)

“HIGH SPEED” REAR AXLE 121E - 221E - 321E Model Differential type Dry weight

CA147187 28.20 + TB138.5 limited slip /

Bevel gear reduction ratio

3.66 /1

Reduction gear ratio

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 direction Bevel gear play

counterclockwise 0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in)

Pinion bearing preload (measured on D = 34.8 mm (1.37 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.8 mm (1.37 in) without seal rings)

T= (P+2.5)+(P+3.8) daN (P+5.62)+(P+8.54) lbf

8-12

DATA AND TECHNICAL SPECIFICATIONS

TIGHTENING TORQUES Component

Tightening torque (Nm) (lbf•ft)

Wheels nuts

550 (405)

Cardan shaft

34 (25)

Front axle fastening Front axle fastening (pin retainer)

350 (258) 79 (58)

Rear axle fastening

350 (258)

Fastening of variable-displacement pump to engine

250 (184)

Fastening of travel motor to transmission

725 (535)

Counterweight

390 (288)

Engine supports

140 (103)

Cab elastic supports

240 (177)

8-13

SECTION 8 NOTES:

8-14

SECTION 9 ALPHABETICAL INDEX Symbols “EC” Declaration of conformity ...........................1-1 “High speed” front axle .....................................8-11 “High speed” rear axle .....................................8-12

D Dimensions and performance ............................ 8-1 Documents storage box ................................... 2-10 Drive belt .................................................4-18, 4-62

Numerics 4 x 1 (bottom-dump) bucket ...............................7-1 4 x 1 bucket ......................................................2-20

E Electrical system ........................... 4-26, 5-15, 8-10 Emergency exit .......................................1-20, 2-10 Emergency steering ......................................... 4-54 Engine ............................................... 4-50, 5-6, 8-3 Engine oil ...................................... 3-13, 4-10, 4-29 Engine oil filter ................................................. 4-31 Engine stop ........................................................3-7 Engine storage ................................................... 6-1 Engine valve clearance .................................... 4-34 Engine water temperature .................................. 5-5 Evaporator ....................................................... 4-28

A Accessories ........................................................7-1 Accumulator .....................................................4-40 Acoustic signal .................................................2-27 Adjusting the air temperature ...........................2-14 Air conditioning ............................. 2-14, 4-28, 5-25 Air conditioning filter .........................................4-28 Air filter ............................................ 4-15, 4-35, 5-4 Air intake system lines .....................................4-34 Attachment .................................... 1-16, 3-19, 5-23 Auxiliary socket ................................................2-11 B Batteries storage ................................................6-2 Battery .................................. 1-20, 3-13, 4-42, 4-61 Battery master switch .......................................2-28 Beam .......................................................4-56, 4-57 Brake system ..........................................4-60, 5-12 Bucket control lever .........................................2-18 Bucket teeth ............................................3-22, 4-63 Buckets ............................................................8-10 Bulbs ................................................................4-56

F Fire extinguisher .............................................. 2-11 Forks ...........................................................7-2, 7-5 Front axle ...................................... 4-19, 4-44, 8-11 Front/rear work lights .......................................2-26 Fuel .................................................................... 4-2 Fuel filter .......................................................... 4-32 Fuel tank .................................................4-12, 4-47 Fuses ............................................................... 4-54 G Gearbox ........................................................... 4-29

C Cab ................................................... 1-6, 1-16, 2-8 Cab air filter ......................................................4-33 Cab breather filter ............................................4-14 Cab lighting ......................................................2-11 Compressor belt ...............................................4-28 Condenser .......................................................4-28 Control lever additional function .......................2-20 Coolant .............................................................3-13 Coolers .............................................................4-51 Cooling system ................................................4-10

H Heating ....................................................2-13, 5-27 Heating system ................................................ 4-28 Heating system filter ........................................ 4-44 High speed ....................................................... 3-10 Horn control lever ............................................. 2-15 Hourmeter ..........................................................4-8 Hydraulic oil ....................................................... 4-3 Hydraulic oil tank .....................................4-11, 4-48 Hydraulic system .......................................5-14, 8-5 Hydraulic system breather filter ....................... 4-38 Hydraulic system return oil filter ....................... 4-37

D Decals ..............................................................1-18

I Identification plates .......................................... 1-14 9-1

SECTION 9 I Instruments ........................................................ 2-1 J Jump-starting ..................................................... 3-5 L Lamps ................................................................ 2-5 Lights ................................................................. 4-9 Load stabilization system ................................. 2-27 Low beams ....................................................... 2-17 Lubricating oil ................................................... 3-13 M Machine storage ................................................ 6-1 Main beams ..................................................... 2-17 Main beams control lever ................................. 2-15 Maintenance intervals chart ............................... 4-6 N Noise emissions ............................................... 1-18 O Operator’s compartment controls ..................... 2-13 Operator’s seat ................................................ 2-23 P Parking brake ............................................2-22, 4-9 Pump ...........................................................8-8, 8-9 Q Quick tool coupler ............................................ 3-20 R Rear axle .............................. 4-20, 4-27, 4-45, 8-12 Rear stop light .................................................. 4-58 Rear turn signal light ........................................ 4-58 Rear windscreen washer/wiper ........................ 2-17 Relays .............................................................. 4-55 Return to dig .................................................... 2-20 Road travel ....................................................... 3-11 Rotary light ..............................................2-26, 4-59 S Seat belt ........................................................... 2-25 Service brake ..................................................... 4-9 Slinging points .........................................1-21, 1-26 Starter switch key ............................................. 2-13 Start-up .............................................................. 3-4 9-2

S Steering column ............................................... 2-22 Steering system ............................................... 5-11 Sunblind ........................................................... 2-11 Supply summarizing chart .................................. 4-1 T Tail lights .......................................................... 2-17 Towing ............................................................. 3-15 Transmission ...........................................4-45, 5-21 Transport .......................................................... 3-17 Travel ................................................................. 3-8 Travel motor ..................................................... 8-10 Travel/work control lever .................................. 2-18 Turn signal light ................................................ 4-57 Turn signal light control lever ........................... 2-15 Tyres .......................................................4-21, 4-52 W Warranty ............................................................ 1-1 Weights .............................................................. 8-3 Wheels ............................................................. 4-23 Windscreen washer liquid ................................ 4-13 Windscreen washer/wiper ................................ 2-16 Windscreen washer/wiper control lever ........... 2-15

CNH ITALIA S.p.A. - Viale delle Nazioni, 55 - 41100 MODENA - Italy TECHNICAL SUPPORT - Technical Information Print No. 87682102 - 05-2008

PRINTED IN ITALY

Z

COPYRIGHT BY CNH ITALIA S.p.A. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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.