Case 340 Articulated Truck Operator's Manual 6-84771 EN - PDF DOWNLOAD

340 Articulated Truck

Operator’s Manual Lep 6-84771 EN Replaces Lep 6-84770 EN

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.

The words Danger, Warning or Caution used on the safety decals have the following significance: • DANGER: Indicates an immediate hazardous situation that, if not avoided, could result in serious injury or even death. The colour associated with Danger is RED. • WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in serious injury. The colour associated with Warning is ORANGE. • CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in minor injury. It may also be used to alert against unsafe practices. The colour associated with Caution is YELLOW. Certain decals, in conformity with the ISO standard are in several parts. They must be interpreted as follows: • • • •

The upper panel indicates the nature of the danger.

The lower panel indicates appropriate avoidance of the danger.

Background colour is YELLOW. Prohibition symbols such as if used, are RED.

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

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

• Reads and understands ALL Safety Decals on the machine.

• Clears the area of other persons.

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

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

Reproduction or translation, even partial, is prohibited without written authorization from CNH France S.A. Company Copyright © 2005 CNH France S.A.

Lep 6-84771 EN Issued October 2004 (revised January 2005)

OPERATOR’S MANUAL 340

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QUICK REFERENCE SECTION GUIDE The Sections in this book are shown below.

1 - To the owner/Safety 2 - Controls/Instruments/Accessories 3 - Operating instructions 4 - Servicing intervals/Lubrication/Fluids 5 - Maintenance/Adjustments 6 - Electrical system 7 - Storage 8 - Specifications 9 - Alphabetical index

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TABLE OF CONTENTS

SECTION 1 - TO THE OWNER/SAFETY ................................................................................................... 1-1 340 Articulated Truck ............................................................................................................................... 1-1 Legal documents ...................................................................................................................................... 1-2 Right, left, front and rear of the machine .................................................................................................. 1-3 Type, serial number and year of manufacture ......................................................................................... 1-4 Position of identification data on main component groups ....................................................................... 1-5 Identification of the main components of the machine ............................................................................. 1-8 Safety rules ............................................................................................................................................ 1-11 Prevention of fires .................................................................................................................................. 1-12 Overturning accidents ............................................................................................................................ 1-12 Instructions for use ................................................................................................................................. 1-13 Maintenance instructions ....................................................................................................................... 1-16 Decals and plates ................................................................................................................................... 1-19 Hand signals .......................................................................................................................................... 1-30 SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES .................................................................... 2-1 Accessing the cab .................................................................................................................................... 2-1 Door ......................................................................................................................................................... 2-2 Location of controls, instruments and accessories .................................................................................. 2-4 Driver’s seat (Standard) ......................................................................................................................... 2-10 Driver’s seat (Electro-pneumatic) ........................................................................................................... 2-11 Folding seat ............................................................................................................................................ 2-12 Seat belts ............................................................................................................................................... 2-12 Accessory functions ............................................................................................................................... 2-13 SECTION 3 - OPERATING INSTRUCTIONS ............................................................................................. 3-1 Before operating the machine .................................................................................................................. 3-1 Operating the machine ............................................................................................................................. 3-1 Run-in period ............................................................................................................................................ 3-2 Filling the fuel tank ................................................................................................................................... 3-3 Starting and stopping the engine ............................................................................................................. 3-4 Multifunctional display ............................................................................................................................ 3-11 Starting the vehicle ................................................................................................................................. 3-35 Stopping and parking the vehicle ........................................................................................................... 3-36 Driving the vehicle .................................................................................................................................. 3-38 Using the automatic transmission .......................................................................................................... 3-39 Using the Integrated IRCM auxiliary brake control ................................................................................. 3-43 Using the differential lock ....................................................................................................................... 3-44 Working with the vehicle ........................................................................................................................ 3-45 Emergency stopping .............................................................................................................................. 3-52 Emergency steering ............................................................................................................................... 3-53

TABLE OF CONTENTS

Operating instructions (continued) Replacing a complete wheel ...................................................................................................................3-54 In the event of overturning ......................................................................................................................3-57 Climate control system operation ...........................................................................................................3-58 Overturning accidents .............................................................................................................................3-63 Rescuing the vehicle ..............................................................................................................................3-64 Towing the vehicle ..................................................................................................................................3-64 Transporting the vehicle .........................................................................................................................3-67 SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS .............................................................. 4-1 Servicing instructions ................................................................................................................................4-1 Location of main components used for maintenance ...............................................................................4-4 Preliminary operations ..............................................................................................................................4-6 Scheduled maintenance program in hours .............................................................................................4-16 Lubrication and scheduled replacement chart ........................................................................................4-18 Daily operations ......................................................................................................................................4-20 Engine ....................................................................................................................................................4-23 Fuel supply system .................................................................................................................................4-27 Air intake system ....................................................................................................................................4-31 Cooling system .......................................................................................................................................4-35 Automatic transmission ..........................................................................................................................4-38 Drive line shaft support ...........................................................................................................................4-42 Front differential ......................................................................................................................................4-43 Front and rear hubs ................................................................................................................................4-44 Rear tandem Axles .................................................................................................................................4-45 Hydraulic system ....................................................................................................................................4-49 Brake cooling circuit ...............................................................................................................................4-53 Hood opening/cab tipping system ..........................................................................................................4-57 Greasing .................................................................................................................................................4-57 SECTION 5 - MAINTENANCE/ADJUSTMENTS ........................................................................................ 5-1 Suspension ...............................................................................................................................................5-1 Braking circuit ...........................................................................................................................................5-5 Braking circuit ...........................................................................................................................................5-5 Tires and wheels ......................................................................................................................................5-6 Air conditioning system ...........................................................................................................................5-10 Compressed air system ..........................................................................................................................5-12 Bodywork ................................................................................................................................................5-13

TABLE OF CONTENTS

SECTION 6 - ELECTRICAL SYSTEM ........................................................................................................ 6-1 Precautions .............................................................................................................................................. 6-1 Battery maintenance (not sealed) ............................................................................................................ 6-4 Interconnection control unit ...................................................................................................................... 6-6 Lighting system ...................................................................................................................................... 6-12 SECTION 7 - STORAGE ............................................................................................................................. 7-1 Storing the vehicle .................................................................................................................................... 7-1 SECTION 8 - SPECIFICATIONS ................................................................................................................ 8-1 Main groups ............................................................................................................................................. 8-1 Dimensions .............................................................................................................................................. 8-2 Weights .................................................................................................................................................... 8-4 Center of gravity (horizontal position) ...................................................................................................... 8-5 Performance ............................................................................................................................................. 8-6 Main group characteristics ....................................................................................................................... 8-7 Tightening torque ................................................................................................................................... 8-11 Capacities .............................................................................................................................................. 8-12 SECTION 9 - ALPHABETICAL INDEX ...................................................................................................... 9-1

TABLE OF CONTENTS

NOTES

SECTION 1

32

TO THE OWNER/SAFETY 340 ARTICULATED TRUCK

269ROM01

1

Dealer’s Stamp

CNH France S.A. Rue des Meuniers 60330 LE PLESSIS BELLEVILLE FRANCE

1-1

SECTION 1 - TO THE OWNER/SAFETY

Your machine has been designed and built to the highest standards of quality. It conforms to all current safety regulations. However, the risk of accidents can never be completely excluded. That is why it is essential to observe elementary safety rules and precautions. Hazard control and accident prevention are dependent upon the awareness, concern and prudence of the operator. Personnel involved in the operation, transport, maintenance and storage of equipment must be suitably trained.

This manual contains important information concerning safety in operation, adjustment and maintenance of your machine. Use the detailed alphabetical index at the end of the manual to find what you are looking for.

Use this manual as a guide; your machine is a working tool and you will always be able to count on it, as long as it is correctly maintained.

Do not use the machine and prevent anyone else using or servicing the machine before (you yourself or other people) are fully aware of the instructions given in this manual concerning safety, operation and maintenance. Only use operators who have proved their ability to operate and maintain this machine in a correct, safe manner.

This machine was designed and made for the following use: 1. to haul excavated material in general; 2. to haul material coming from industrial or civil engineering construction sites in general; 3. to haul material required to build infrastructures and/or civil engineering constructions.

Do not use this machine for applications other than those shown in this manual. Consult your Dealer for any information concerning changes, additions or modifications which have to be carried out on this machine to ensure that these are in compliance with the regulations and safety rules of various countries.

Any unauthorized modification could cause serious or fatal injury. Any person carrying out such modifications is entirely responsible for the consequences.

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This operator’s manual must be kept in the "manual" compartment provided for that purpose on this machine. Make sure that the manual is in good condition. To obtain additional manuals or to obtain other information concerning this machine, consult your Dealer. Your Dealer can provide you with genuine parts and has specially trained technicians who know the best methods for repair and maintenance of your machine.

LEGAL DOCUMENTS A declaration defining the weight shown on the manufacturer’s identification plate - Shows that the weight shown on the manufacturer’s plate is a value covering the heaviest configuration and which does not necessarily correspond with the configuration that is being transported.

A "CE" certificate of conformity - For a new construction equipment machine, series produced as per the type approved model, designed and manufactured in conformity with the requirements of European Directive 98/37/CE, concerning machine safety and mainly concerning: 1 - The following Directives: - CE 89/336: Electromagnetic compatibility - CE 2000/14: Noise emission 2 - The following European Standards: - EN 474-1: Safety-General requirements - EN 474-6: Specific requirements for dumper IMPORTANT: An original of this "CE" conformity certificate is supplied with each machine and must be kept carefully by the owner.

IMPORTANT: The official documents supplied with the machine must be kept by the owner in order to present them to any inspecting authority which may request them.

SECTION 1 - TO THE OWNER/SAFETY

RIGHT, LEFT, FRONT AND REAR OF THE MACHINE As used in this manual, the terms "right", "left", "front" and "rear" indicate the sides of the machine as seen from the operator’s seat.

A. B. C. D.

A

FRONT REAR RIGHT-HAND SIDE LEFT-HAND SIDE

D

174MN10CA

C

B 2

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SECTION 1 - TO THE OWNER/SAFETY

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE When ordering parts, requesting information or assistance, always give your Dealer the type, serial number and year of manufacture of your machine.

In the spaces below, write the type, serial number and year of manufacture of your machine.

MACHINE Type................................................................................

Serial number.................................................................

Year of manufacturer .....................................................

CS01F537

3

CS01F537A

4

1-4

SECTION 1 - TO THE OWNER/SAFETY

POSITION OF IDENTIFICATION DATA ON MAIN COMPONENT GROUPS All the main vehicle component groups are identified with a serial number to be found on the actual group, in the positions shown below.

!

WARNING

!

The component group identification number is always to be indicated when ordering parts.

CAB The cab number is indicated on a plate in the cab on the right.

269NM0D1

5 CHASSIS The chassis number is stamped on the right side of the vehicle.

CS01F539

6 ENGINE The type of engine and the serial number are indicated on a plate on the engine.

269NM0D3

7

1-5

SECTION 1 - TO THE OWNER/SAFETY

TRANSMISSION The type of transmission and the serial number are indicated on a plate on the transmission.

269NM0D4

8 DRIVE AXLES The type of axle and the serial number are indicated on a plate on the axle housing.

269DT0E1

9

1-6

SECTION 1 - TO THE OWNER/SAFETY

DUMP CYLINDER AND STEERING CYLINDER The type and serial number are indicated on a plate on the cylinder barrel.

CS01F543

10 FRONT SUSPENSION CYLINDER The type and serial number are indicated on a plate on the cylinder barrel.

CS01F544

11

1-7

SECTION 1 - TO THE OWNER/SAFETY

IDENTIFICATION OF THE MAIN COMPONENTS OF THE MACHINE

269CU001

12 1. Engine hood 2. Front light clusters 3. Front fastening points 5. Cab 8. Battery disconnect access door 10. Dump 11. Front axle 12. Intermediate axle 13. Rear axle

1-8

SECTION 1 - TO THE OWNER/SAFETY

269CU002

13 4. Rear fastening points 6. Door 7. Cab ladder 9. Fuel tank 10. Dump 12. Intermediate axle 13. Rear axle 14. Articulation/oscillation joint 15. Rear light clusters 16. Joint lock 17. Tipped body lock

1-9

SECTION 1 - TO THE OWNER/SAFETY

CAB - INTERIOR

269NU091

14 1. Sun visor 2. Steering wheel 3. Instrument dashboard 4. Climate control system controls 5. Pedal controls 6. Seat belts 7. Driver’s seat 8. Control dashboard 9. Camera monitor 10. Radio

1-10

SECTION 1 - TO THE OWNER/SAFETY

SAFETY RULES

6.

The instructions and warnings given in this Operator’s Manual illustrate the fundamental safety principles for operating construction site articulated trucks.

The vehicle must only be driven by qualified personnel, who are authorized to do so by prevailing legislation.

7.

Drivers must be in a suitable psychological and physical state (no tiredness, effect of alcohol, drugs, etc.).

8.

The procedures are not comprehensive. The Manufacturer cannot account for all the possible methods of use and operation, nor evaluate all the possible consequences.

Furthermore, drivers must be familiar with the position and operation of all controls, instruments, gauges and warning lights in the vehicle. The driver must also be able to evaluate possible failures which may occur and take the required precautions.

9.

Do not allow unqualified or unsuitable personnel to use the vehicle.

Consequently, operators must be responsible and careful at all times, to prevent hazardous situations for themselves and others.

10. Maintenance and repair operations must be carried out by qualified personnel, who are familiar with the arrangement and operation of assemblies and workshop tools.

These instructions are not comprehensive. They do not illustrate all the potential hazards which may arise.

Operators must be aware of all the procedures described in this Operator’s Manual. The procedures advise against adopting work methods which could cause injuries and/or affect safe use of the vehicle.

Use of the vehicle is subject to the respect of the specifications contained in this manual and safety regulations laid down by law in the country where the vehicle is used. Knowledge of local legislation is mandatory for all vehicle users.

Read this manual carefully. Contact an expert or call the Manufacturer if in doubt.

SAFETY INFORMATION

11. Do not allow unqualified personnel to carry out maintenance or repair operations on the vehicle.

12. Do not wear rings, wristwatches or loose and hanging clothes when carrying out maintenance and repair operations on the vehicle.

13. Do not use radio or personal stereo headphones during operations to avoid distraction.

Always read the safety related decals.

14. Personnel must use the vehicle safety features (seat belts) and personal protection devices during vehicle use and maintenance.

Replace the labels if they are damaged.

15. Safety equipment:

Always follow the recommended safety instructions.

GENERAL INSTRUCTIONS 1.

Make sure there is a first aid kit in the vehicle.

Check and replenish regularly.

2.

Make sure there is a list of emergency telephone numbers. Keep it up-to-date.

3.

Vehicle personnel should be aware of basic first aid procedures to be applied in the event of an accident or casualty.

4.

Keep children away from the vehicle, the equipment and the materials used.

5.

Keep unauthorized personnel away from the vehicle, the equipment and the materials used.

1.

2.

3.

4.

5.

6.

Hard hat Safety glasses or face mask Protective earphones Thick gloves Suitable clothes Safety boots

1-11

SECTION 1 - TO THE OWNER/SAFETY

PREVENTION OF FIRES 1.

Keep a suitably sized fire extinguisher in the vehicle. Check it regularly.

18. Stay away from the vehicle if a small fire occurs in the brake or tire areas. The tires could explode.

2.

The portable fire extinguisher should only be used by skilled personnel.

19. Never stand in front of the tire wall. Keep a safety distance of at least 15 meters from the tread.

3.

Vehicle personnel must be familiar with the basic techniques for dealing with fire.

4.

Fuel and most lubricants and fluids are flammable.

20. Stay away from the vehicle for a few hours after putting out a fire to allow the tires time to cool down.

5.

Do not smoke while refueling or adding fluids. Do not refuel or add more fluid near open flames. Do not handle fuel.

OVERTURNING ACCIDENTS Prevention 1.

Always check the limits for height and width during all stages of loading/unloading, and make sure they are within the prescribed limits.

2.

Keep the wheels perpendicular to the slope when driving up or down a gradient.

3.

Do not make a U-turn on a gradient, to prevent turning over.

battery

4.

Respect the transverse gradient permitted for the vehicle when loaded and unloaded.

10. Do not store flammable substances in places which are not suitable for the purpose. Do not pierce or burn pressurized containers or cylinders. Do not pile up materials soaked in flammable substances.

5.

Respect the values for maximum negotiation when unloaded and loaded.

6.

Check that the hammer for breaking the specially treated glass is always kept in the cab.

6.

Stop the engine before refueling. Do not refuel in enclosed places.

7.

Check for leakage or residues of fuel, lubricants and fluids which could cause minor fires before starting the engine.

8.

Short circuits can cause fires.

9.

Regularly check the condition of terminals, wiring and electrical devices.

11. Be careful where you leave rags and/or replaced materials which may contain flammable residues.

In the event of overturning 1.

Make sure that the personnel trained to use the vehicle know where the emergency exits are and the location of the special glass breaking tool.

2.

The following emergency exits can be used to abandon the vehicle:

12. Put out all smouldering materials and open lights before starting any maintenance operation.

13. Do not smoke during maintenance operations.

14. Do not use fuel, solvents or other flammable or toxic fluids to clean mechanical parts. Use nonflammable, non-toxic, type-approved products on the market.

15. Do not weld near tanks, pipes, reservoirs, electric wires or flammable materials in general. Always disconnect batteries prior to welding on vehicle.

16. Protect flammable parts with suitable guards when welding.

17. Stay away from the vehicle and call a fire-fighting expert team in the event of a large-scale fire.

1-12

slope

1. door (open), 2. front right window (smash).

3.

Use the special tool, located at the bottom of the window to break the specially treated glass.

SECTION 1 - TO THE OWNER/SAFETY

INSTRUCTIONS FOR USE CAB

STARTING AND STOPPING

1.

Use the steps and handles to get on and off.

1.

2.

Keep the steps and handles clean to avoid slipping.

Before starting, check the vehicle exterior for problems, such as flat tires, fluid leakage or broken parts.

3.

Do not use flexible parts or controls such as handles. They could break or get damaged.

2.

Make sure no one is near the vehicle when starting the engine.

4.

Face the vehicle while you are getting on and off.

Have three points of contact (steps and handles) at all times.

3.

Sound the horn before starting the engine.

4.

Start the engine while you are sitting in the driver’s seat.

5.

Do not start the engine by short-circuiting the starter motor wires.

6.

Two people are required to start the engine with a battery charger or auxiliary battery: one person must sit in the driver’s seat and the other person must stand near the battery charger or auxiliary battery.

7.

Do not carry out this operation if the battery is frozen. It could explode.

8.

Be aware of cable connection procedure and polarity to prevent the risk of the batteries exploding or projecting electrolyte.

9.

Always wear gloves and eye protection when approaching batteries.

5.

Do not jump on or off the vehicle.

6.

Do not get on or off while the vehicle is moving.

7.

Keep the floor clear of objects, tools or other items which could interfere with the pedals.

8.

Keep the pedals clean (mud or grease).

9.

Eliminate anything which can reduce visibility or distract the driver.

10. Keep windows and rear view mirrors clean.

11. With the vehicle stationary and the parking brake applied, before starting up, check the position of the seat, the steering wheel and the rear view mirrors to ensure maximum driving comfort and control accessibility.

12. Make these adjustments each time the driver is changed.

10. Do not smoke or use open lights or flames near batteries.

13. Drivers should be able to press the pedals down fully and operate the controls correctly without removing their backs from the backrest.

11. In the event of contact with electrolyte, wash the affected area for at least 15 minutes and call a doctor.

14. Do not adjust the seat, the steering wheel or the rear view mirrors while driving or in any other way than specified.

12. Do not run the engine in closed areas without a suitable ventilation system for disposing of harmful exhaust in the air.

15. Always wear seat belts.

13. Never leave the vehicle with the engine running.

16. The belt must not be twisted. The belt should wrapped around your hips, not your abdomen, to prevent the risk of slipping forwards.

14. Do not park with the parking brake applied and a gear engaged, even if you are sitting in the driver’s seat.

17. Replace a seat belt that was being worn during a serious accident, even if it does not appear damaged.

15. Before leaving the vehicle parked in a suitable area where it is not a hindrance, make sure that the parking brake is applied and that the keys have been removed from the control panel.

18. Do not make changes liable to decrease the effectiveness of the seat belt.

1-13

SECTION 1 - TO THE OWNER/SAFETY

16. Always apply the parking brake in the following cases: 1. When the vehicle is parked for a long or short time;

16. Do not use the vehicle if the parking brake is not working properly.

WORKING THE VEHICLE 1.

Do not use the vehicle for purposes other than those described by the Manufacturer.

2.

Always check height and width during the various loading/unloading operations. Make sure they fall within the specified limits.

3.

Beware of overhead obstacles, such as bridges, cables and wires. Make sure that the load does not hit them.

4.

Keep the wheels facing to the slope when driving up or down a gradient.

5.

Do not make a U-turn on a gradient to prevent rolling over.

6.

Respect the transverse gradient, permitted for a laden and unladen vehicle.

7.

Respect the maximum possible gradient for a laden and unladen vehicle.

8.

Look out for people when reversing and changing direction.

9.

Ideally, a second person should be asked to signal when reversing. This person will be able to observe the approach from a more favorable position with respect to the driver.

2. When loading/unloading the vehicle.

DRIVING THE VEHICLE 1.

Make all the necessary adjustments (seat, steering wheel, rear view mirrors) before starting up.

2.

Check that the engine warning lights are giving the correct indications.

3.

Sound the horn before driving off.

4.

Check that no one is driving near the vehicle before driving off.

5.

Be very careful when steering: the front part of the vehicle can move also when the vehicle is stationary. This can be very dangerous for people standing near the vehicle.

6.

Check the ground surrounding the vehicle before reversing to make sure there are no people or obstacles.

7.

Do not transport people in the cab or in other parts of the vehicle, with the exception of the folding seat.

8.

Pay attention to signs, especially speed limits.

Never exceed the speed limit.

9.

Never drive at speeds which are forbidden and dangerous for yourself or others.

10. Do not exceed the maximum speed allowed.

11. Switch the lights on at night and when visibility is poor (dust, fog, rain). Slow down.

12. Never travel with the transmission in neutral.

13. Do not use the parking brake for slowing down or stopping the vehicle.

14. Select the gearbox manual mode and use the low gears (2nd and 3rd) to slow the vehicle down.

Use all the vehicle’s auxiliary brakes (retarder, exhaust brake).

15. If the brakes overheat, select the gearbox manual mode and use the low gears (2nd and 3rd) to slow the vehicle down. Do not use the parking brake to slow or stop the vehicle when it is moving. This should be done only in the event of an emergency after sufficiently reducing the speed with other methods.

1-14

10. Do not move the vehicle to loading position while the loading machine bucket or excavator is moving overhead.

11. Stay inside the cab while loading the vehicle.

12. Make sure that the maximum capacity of the vehicle is not exceeded during loading operations.

13. Make sure that the load is properly spread and will not fall out of the dumper during transportation.

14. Check the area before unloading. Look out for hazardous points: loose terrain, ditches, humps and fencing.

15. Beware of icy ground; it may become treacherous and slippery when the temperature rises.

16. Avoid loading and unloading on steep slopes; the vehicle could roll over.

17. Be very careful of throwing the vehicle out of balance by the movement of material out of the dumper during unloading operations.

SECTION 1 - TO THE OWNER/SAFETY

18. Check that the dump body is in the correct position before driving off after unloading.

19. No one should ever stand in the loading and unloading area of the vehicle.

20. When unloading using the external control, the operator must never leave the control, which is located in a safe position and must wear all the required personal protection devices.

21. Never start off during loading or unloading operations.

22. Do not get on or off the vehicle during loading and unloading operations.

23. When passing another vehicle, the unladen vehicle should give way to the loaded vehicle and a vehicle driving downhill should give way to a vehicle driving uphill.

24. If other vehicles and/or other machines are used in the working area, appoint a person in charge of signaling and use signals which can be understood by all drivers. In this case, all personnel must follow the instructions provided.

REPLACING A WHEEL Wheel replacement operations require the utmost care. They must be carried out by at least two experts, using a hoist or a crane to handle the wheel. If possible, stop the unladen vehicle in a flat area, apply the parking brake and remove the key from the control panel. Make sure that the ground is firm enough for the load to be supported. If in doubt, use plates and platforms to prevent the vehicle from sinking.

1.

Only use the lifting points shown.

2.

Make sure that the lifting device is suitable to carry out the operation and follow all safety requirements.

3.

Do not use wheels or fasteners other than those originally provided.

4.

Excessive tightening may be dangerous. Do not use tubes or extensions other than those provided to tighten the wheel nuts.

5.

Check that the wheel nuts are tight after two or three hours of vehicle operation.

6.

Check wheel nut tightness regularly.

TOWING THE VEHICLE 1.

Use the specific hitch points specifically provided for towing the vehicle.

2.

Do not use cables, belts or chains for towing the vehicle or to tow another vehicle; they could break.

3.

Do not use cables, belts or chains for towing the vehicle or to tow another vehicle if the braking system of the vehicle being towed does not work.

4.

Always use a stiff, suitably dimensioned bar.

5.

An operator must always be aboard the vehicle being towed.

6.

Do not stand near vehicles being towed.

7.

The parking brake will not work if the drive shaft is removed from the rear transmission and/or the planetary gears and/or the drive axles.

8.

In this case, install suitable chocks under the wheels in both directions of travel to prevent uncontrolled vehicle movement.

1-15

SECTION 1 - TO THE OWNER/SAFETY

MAINTENANCE INSTRUCTIONS INTRODUCTION

PREVENTING INJURIES

Personnel in charge of repairs must be aware of all the procedures described in this Operator’s Manual.

The procedures advise against adopting work methods which could cause injuries and/or affect the safety of the vehicle.

1.

Use the steps and handles provided for getting on and off the front platforms.

2.

Use the steps and handles provided for getting on and off the side platform.

3.

Keep the steps and handles clean to avoid slipping. Do not use flexible parts or controls such as handles. They could break or get damaged.

4.

Face the vehicle while your are getting on and off.

Have three points of contact (steps and handles) at all times.

5.

Do not jump on or off the vehicle.

6.

Do not get on or off while the vehicle is moving.

7.

Checking, bleeding, topping-off, maintenance and replacement operations must be carried out with the vehicle stationary, on level ground, in a well lit and ventilated area. Apply the parking brake, install chocks under the wheels and remove the keys from the starter switch, unless otherwise specified in the Operator’s Manual.

8.

Make sure that no one is sitting in the driver’s seat unless otherwise specified in this manual.

9.

Use portable lamps when the lighting is not adequate to illuminate working areas which cannot easily be accessed otherwise.

The procedures are not comprehensive. The manufacturer cannot account for and evaluate all the possible methods of operation or the possible consequences.

1.

Keep the place of work clean and dry. Do not smoke during maintenance operations. Wear all the required personal protection devices before starting maintenance operations.

2.

Carry out maintenance operations as scheduled.

3.

Carry out all operations which are required for the correct and safe use of the vehicle.

4.

Always install signs warning that operations are being carried out on the vehicle.

5.

Do not allow unqualified personnel to carry out maintenance or repair operations on the vehicle.

6.

Carry out maintenance and repair operations with the utmost care.

7.

Only use the specific tools or wrenches expressly specified for replacement, checking and maintenance operations.

8.

Never tamper with valves, regulators or other devices, unless specified in the Operator’s Manual, to prevent damage to vehicle components and consequent hazards for personnel.

9.

Always lock the articulation joint, unless otherwise specified. See "Preliminary operations" in Section 4.

10. Always lock the dump body when operating in such conditions. See "Preliminary operations" in Section 4.

11. Make absolutely sure that the electrical power is disconnected before working directly or indirectly on electrical system parts by throwing the battery disconnect switch.

1-16

10. Use a ladder or platform with steps complying with safety regulations to carry out repairs and maintenance operations in areas which cannot be reached from the ground.

11. Keep hands and clothes away from moving parts when carrying out operations with the engine running.

12. Do not put your head or other parts of your body (feet, hands) near shafts or parts in motion when the engine is running.

13. Warn people who are near the vehicle before starting the engine (e.g; for a test).

SECTION 1 - TO THE OWNER/SAFETY

14. Wait for at least four hours after stopping the vehicle before conducting maintenance operations to avoid contact with hot parts. Be very careful of the cooling fan which could start up suddenly.

15. Do not work over or under a vehicle propped up on jacks or other lifting devices which are not suitable to ensure safety.

16. Unload the vehicle before jacking it up. Only use the lifting points shown.

17. Make sure that the lifting device is suitable to carry out the operations and meet safety requirements.

18. After jacking up the vehicle, prop it up before carrying out any operations underneath.

19. Fully deflate the tire before carrying out any type of operation on tires or rims.

20. Never stand in front of the tire wall while your are inflating a tire.

21. Never weld rims with tires fitted, to prevent explosions and fire.

22. Only use the expressly specified tools for inflating accumulators with nitrogen.

23. Pressurized hydraulic system. Before you replace the hydraulic filter or service the hydraulic system, wear face protection and slowly loosen the hydraulic reservoir fill cap to relieve the air pressure. If you do not follow these instructions, you can be injured.

PREVENTING INTOXICATION AND CONTAMINATION 1.

Do not run the engine in closed areas without a suitable ventilation system for evacuating harmful gas in the air.

2.

Avoid prolonged, repeated contacts of fuel, lubricant and fluids with the skin to prevent skin problems and other syndromes.

3.

Do not swallow fuel, lubricant or fluids. In the event of accidental contact with the eyes, wash the area thoroughly with water and contact a doctor.

4.

Be very careful: drained oil and fluids, as well as filters and surrounding parts, can be very hot.

5.

Ensure adequate ventilation to prevent the accumulation of toxic vapors while cleaning and replacing filters.

6.

Do not weld in closed areas or areas which are not suitably ventilated.

7.

Do not weld on or near painted surfaces to prevent developing toxic vapors.

8.

Remove the paint with suitable products, wash the surfaces and leave to dry.

9.

Do not breathe in dust and toxic residues while grinding and sand-blasting. Protect your face with a mask and safety glasses.

10. Use a suitable vacuum cleaner to remove dusty residues from the vehicle or place of work.

11. Do not play with compressed air. Keep compressed air gun nozzles away from people.

12. Wear protective glasses with side guards and a mask when using compressed air to clean filters, to prevent injury caused by particles of dust. You are advised to carry out the cleaning operations in a ventilated area.

13. Be very careful before removing caps or covers from reservoirs, radiators or cylinders: turn the part slowly to discharge any residual pressure.

14. Stand to one side during bleeding operations and always wear protective glasses. Loosen the bleeder slowly a few turns to let out condensation and fluid.

15. Discharge pressure from the circuits before carrying out operations.

16. Never use your hands to detect leakage of pressurized fluid.

17. Pressurized fluid leakage can penetrate the skin and the eyes, causing very severe injuries.

18. Never use open lights or flames to detect leakage from the air conditioning system. It could generate phosgene, a very dangerous gas.

1-17

SECTION 1 - TO THE OWNER/SAFETY

PREVENTING BURNS AND ELECTROCUTION 1.

Be very careful of all parts of the vehicle which can reach high operating temperatures: engine, radiators, heat exchangers, exhaust pipe, transmission, axles, brake discs, hubs).

2.

Do not loosen the radiator cap when the engine is hot. Let the coolant cool down before removing the cap. In any event, remove the cap very carefully. Loosen the cap slowly to release the pressure and then remove it.

3.

Do not place sources of heat near pressurized fluid tubes, to prevent sudden failures.

4.

Protect hoses and electrical wires with suitable guards when welding.

5.

Batteries contain sulphuric acid: always wear gloves and eye protection when approaching the batteries.

6.

In the event of contact with electrolyte, wash the affected area for at least 15 minutes and call a doctor.

7.

Do not charge a frozen battery. It could explode.

8.

Be aware of battery cable connection procedure and polarity to prevent the risk of the batteries exploding or projecting electrolyte.

9.

Do not smoke or use open lights or flames near the batteries.

10. Ensure adequate ventilation to prevent the accumulation of explosive gas while recharging the battery.

11. Do not charge batteries near the workshop air compressor intake.

12. Install the air compressor away from the area where paint, fuel and batteries are stored to prevent taking in vapors.

13. Do not open the camera box or the monitor. Live electrical parts inside.

14. All operations must be carried out by skilled, suitably equipped personnel.

1-18

SECTION 1 - TO THE OWNER/SAFETY

DECALS AND PLATES

!

WARNING

!

An illegible or missing decal or plate can have serious consequences. Check them every day.

Make sure that the decals or plates are perfectly legible, clean them regularly and replace all decals or plates that are destroyed, lost, painted over or no longer legible with new ones. When parts bearing decals or plates are replaced, make sure to put a new decal or plate on each new part.

When cleaning decals, use a cloth, water and soap.

Never use solvents, fuel, etc.

POSITION OF DECALS When replacing a decal or plate, make sure it is located as shown in the illustration below.

10

8

1 13 12

9

14

11 15 7 5

4

3

2

6

2

11 1 2 3

4

269DT201A

15 This chapter only covers decals or plates relating to safety, machine operation and servicing. Part numbers are given in the Parts catalogue.

You can obtain new decals or plates from your Dealer.

1-19

SECTION 1 - TO THE OWNER/SAFETY

HOT SURFACES

1

CS01K541

16 CRUSH HAZARD

2

CS01K544

17 CRUSH HAZARD

3

CS01K543

18

1-20

SECTION 1 - TO THE OWNER/SAFETY

KEEP CLEAR OF DRIVE SHAFT

4

CS01K542C

19 TIPPING ENGINE HOOD

5

CS01K542A

20 CRUSH HAZARD

6

CS01K546

21 SLIP HAZARD

7

CS01K545

22

1-21

SECTION 1 - TO THE OWNER/SAFETY

CRUSH HAZARD

8

CS01K548

23 SEAT BELT

9

Inside cab.

CS01K552

24 MISCELLANEOUS HAZARDS Inside cab.

10

CS01K553

25 PRESSURIZED SYSTEM HAZARD

11

CS01K553C

26

1-22

SECTION 1 - TO THE OWNER/SAFETY

ENTANGLEMENT HAZARD Inside engine hood.

12

CS01K549A

27 STARTING HAZARD Inside engine hood.

13

CS01K550

28 DANGER OF BURNS Inside engine hood.

14

CS01K551A

29 BATTERY MASTER SWITCH Inside engine hood.

15

CS01K540A

30

1-23

SECTION 1 - TO THE OWNER/SAFETY

16

19

19

17

18 18 18

19

19

18 20

18 18

21 20

269DT200B

31 EMERGENCY EXIT Inside cab.

16

CS01K536A

32

1-24

SECTION 1 - TO THE OWNER/SAFETY

VOLTAGE RATING Inside cab.

17

500400259A

33 VEHICLE TIE-DOWN

18

500404117

34 TOWING EYE

19

CS01K513A

35 CENTRALIZED LUBRICATING POINT

20

CS01K528A

36

1-25

SECTION 1 - TO THE OWNER/SAFETY

HYDRAULIC OIL FILLER

21

CS01K521A

37

24

23

25

22

29

26

30

27 28

269DT201C

38 HOIST CONTROL Inside cab.

22

CS01K534A

39

1-26

SECTION 1 - TO THE OWNER/SAFETY

TIRE INFLATION PRESSURE

23

Inside cab.

CS01G502B

40 PARKING BRAKE CONTROL Inside cab.

24

CS01K539A

41 GEAR SELECTION Inside cab.

25

500401346A

42

1-27

SECTION 1 - TO THE OWNER/SAFETY

TEST POINT

26

Inside engine hood.

CS01K529A

43 MAINTENANCE CHART

27

500409427

44

1-28

SECTION 1 - TO THE OWNER/SAFETY

FLUID AND LUBRICANTS

28

CS01G502

45 INTERNAL NOISE LEVEL This decal shows the value in decibels of the noise level inside the cab.

29

CS01G500A

46 EXTERNAL NOISE LEVEL This decal shows the value in decibels of the noise level outside the machine.

30

CS01G500B

47

1-29

SECTION 1 - TO THE OWNER/SAFETY

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

START THE ENGINE

COME TO ME Wave hands back and forth (palms inwards).

PDE0002A

SHUT DOWN THE ENGINE

48

PDE0003A

50 MOVE AWAY FROM ME Wave hands back and forth (palms outwards).

PDE0002

49 PDE0003

51

1-30

SECTION 1 - TO THE OWNER/SAFETY

GO THIS FAR

EMERGENCY STOP Wave hands back and forth.

PDE0004A

52 ALL STOP AND HOLD

PDE0005

55 TURN THE MACHINE TO THE LEFT To stop movement, stop moving hand and clench fist.

PDE0004

53 STOP Wave hand back and forth.

PDE0008A

56 TURN MACHINE RIGHT To stop movement, stop moving hand and clench fist.

PDE0005A

54 PDE0008

57

1-31

SECTION 1 - TO THE OWNER/SAFETY

NOTES

1-32

SECTION 2

32

CONTROLS/INSTRUMENTS/ACCESSORIES ACCESSING THE CAB 1.

Always use the grips and steps which have been specifically designed to ensure good accessibility when getting on and off the vehicle. Maintain a 3point contact when getting on or off the machine.

269NS131

1 2.

Use the specific steps and handles for getting on and off the side of operators platform.

3.

Keep the steps and handles clean to avoid slipping. Do not use flexible parts or controls as handles. They could break or get damaged.

4.

Face the vehicle while you are getting on and off.

Maintain three points of contact (steps and handles) at all times.

5.

Do not jump on or off the vehicle.

6.

Do not get on or off while the vehicle is moving.

269NS132

2

2-1

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES DOOR The door handle has a lock. To lock the door; turn the key clockwise (1). To unlock the door; turn the key counterclockwise (2). To open the door from the outside press the button on the handle.

269NU082

3 To open the door from the inside; lower the lever on the lock. The following controls are arranged on the inner side of the door: 1. Door opening lever; 2. Door closing handle; 3. Sliding window release levers.

269NU083

4

2-2

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

This page is intentionally left blank

2-3

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES LOCATION OF CONTROLS, INSTRUMENTS AND ACCESSORIES

!

WARNING

!

Before starting the engine, make sure that you are fully aware of the location and function of each control.

Incorrect operation of the controls could cause serious bodily injury.

269NU112

5

2-4

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES 1. External lights/headlight control

17. Automatic transmission lever

2. Front working lights control

18. Cigar lighter

3. Rotating beacon control

19. Rear axle/longitudinal lock control

4. Not used

20. Central longitudinal lock control

5. Hazard light control

21. Ashtray

6. Instrument panel and warning lamps 7. Not used

22. Windscreen wiper, management control

8. Rear view mirrors heating control (if equipped)

23. Accelerator pedal

9. Side window wiper control

24. Brake pedal

washer

and

10. Side window washer control

25. Ignition key switch

11. Battery disconnect switch (for operation, see "Electrical power disconnection" in Section 3)

26. Steering wheel

12. Integrated IRCM (engine brake + retarder) auxiliary brake control

28. Direction indicators and horn control

13. Driven mirror adjustment control (if equipped)

30. Climate control system controls

display

27. Steering column slant adjustment lever 29. Headlight and daytime flashing control

14. Parking brake 15. 12V power socket 16. Dump body control and parking brake (hold) button

2-5

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES INSTRUMENT PANEL AND WARNING LAMPS

269NU135

6 WARNING LAMP PANEL 1. Engine rpm gauge

11. Dump body and parking brake (hold) applied

2. Automatic transmission oil temperature gauge and hot oil temperature warning light

12. Engine brake applied

3. Engine coolant temperature gauge and overheating engine coolant warning lamp

14. TCU transmission control unit failure

4. Fuel level gauge and reserve warning light 5. Multi functional display 6. Hour meter 7. Central differential lock on 8. Axle differential lock on 9. Tipped body 10. Parking brake on

2-6

13. Transmission retarder on 15. Generic failure 16. Severe failure 17. EDC engine control unit failure 18. Direction indicators/hazard lights on 19. Low generator charge 20. Main beam headlights on

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES INDICATOR

269NU136A

7 1. The rev counter shows the engine speed.

!

WARNING

!

The optimal engine speed is in the range from 1300 to 1800 rpm. Do not exceed the maximum speed of 2300 rpm (green sector) while travelling in manual mode.

A speed of 2500 rpm (orange sector) may be reached for a short time only in exceptional circumstances.

NEVER exceed the maximum engine speed of 2500 rpm (red sector).

2. The automatic transmission oil temperature gauge shows the oil temperature at converter output. The warning light indicates that the alarm threshold has been reached.

!

WARNING

!

.Automatic transmission oil temperature: must be in specified range in normal working conditions: 80 < T < 100 °C If the warning light comes on, select manual mode and engage a shorter gear to prevent torque converter slipping. If this is not sufficient, stop the vehicle and verify the causes.

3. The engine coolant gauge shows the engine temperature. The warning light indicates that the alarm threshold has been reached.

!

WARNING

!

.The engine coolant temperature in normal running conditions must be in the following range: 80 < T < 100 °C. If the warning light comes on, stop the vehicle, stop the engine and locate the causes of the problem.

4. The fuel gauge shows the level of fuel in the tank. The warning light shows that reserve level has been reached.

IMPORTANT: The indication is only approximate: it may not be correct in certain conditions (up/downhill, braking, etc.).

5. The hour meter shows the hours and tenths of hours for which the engine has been operated. It also enables servicing operations to be scheduled.

2-7

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES WARNING LIGHT

269NU133

8 1. Central differential lock on.

Orange. Indicates that the central differential is on 2. Axle differential lock on.

Orange. Indicates that the axle differential is on.

3. Body not down.

Orange. This indicates that the dump body is not in down position.

4. Parking brake on.

Red. This indicates that the parking brake is applied.

5. Tipping park brake (hold) applied.

Red. This indicates that the tipping parking brake is engaged.

6. Engine brake applied.

Orange. This indicates that the engine brake (first integrated brake level position) is on.

7. Retarder on.

Orange. This indicates that the retarder (second integrated brake level position) is on.

8. TCU transmission control unit problem.

Red. This indicates that the TCU automatic transmission control unit has detected a functional anomaly in the system.

IMPORTANT: The anomaly warning light will come on when one or more messages appear on the display. Refer to the MULTIFUNCTIONAL DISPLAY chapter for more info.

2-8

9. Generic failure.

Yellow. This indicates that the vehicle control system (BODY COMPUTER) has detected a functional anomaly which does not affect vehicle integrity and/or the driver’s safety.

!

WARNING

!

Verify the cause of the anomaly as soon as possible when the warning light comes on.

IMPORTANT: The anomaly warning light will come on when one or more messages appear on the display.

10. Severe problem.

Red. This indicates that the vehicle control system (BODY COMPUTER) has detected a functional anomaly which affects vehicle integrity and/or the driver’s safety.

!

WARNING

!

STOP THE VEHICLE IMMEDIATELY and verify the cause of the anomaly when the warning light comes on.

IMPORTANT: The anomaly warning light will come on when one or more messages appear on the display.

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES 11. EDC engine control unit problem.

Red. This indicates that the EDC engine control unit has detected a functional anomaly in the system.

IMPORTANT: The warning light will come on when the engine is started until the brake pedal is pressed for the first time.

The anomaly warning light will come on when one or more messages appear on the display. Refer to the MULTIFUNCTIONAL DISPLAY chapter for more info.

12. Directional indicators/hazard lights on.

Green. This indicates that the vehicle direction indicators or hazard lights are on.

IMPORTANT: The hazard lights will be operated while the off-vehicle warm-up procedure is in progress.

13. Low generator charge.

Red. This warning light comes on when the ignition switch is in position (1). It goes out as soon as the engine is started.

!

WARNING

!

In other conditions, the warning light will come on to indicate that the alternator is not charging.

IMPORTANT: The anomaly warning light will come on when one or more messages appear on the display.

14. Main beams on.

Blue. This indicates that the main beam headlights are on.

2-9

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES DRIVER’S SEAT (STANDARD) Check and adjust the position of the seat if required before starting the engine and adjust it, if required, to ensure maximum driving comfort and accessibility to controls.

!

WARNING

!

The vehicle must be stationary to carry out this operation and the engine turned off.

WEIGHT ADJUSTMENT This adjustment is obtained manually by turning the specific control (1) either clockwise or counterclockwise to allow for increased or decreased weight on the seat and the seat height.

CUSHION ANGLE ADJUSTMENT The front and rear parts of the cushion can be adjusted separately; adjust the cushion angle by means of the levers (2) and (3), respectively.

BACKREST ANGLE ADJUSTMENT Rest your back firmly against the backrest and adjust the angle by means of the lever (4).

FORE/AFT POSITION ADJUSTMENT Lift the lever (5) and slide the seat to the required position. Make sure that the mechanism is locked after adjusting the seat position.

ARMREST POSITION ADJUSTMENT Turn control (6) clockwise or anticlockwise to increase or decrease armrest height.

HEAD REST ADJUSTMENT The head rest height and angle can be adjusted.

174NU04

9

2-10

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES DRIVER’S SEAT (ELECTRO-PNEUMATIC) Check and adjust the position of the seat if required before starting the engine and adjust it, if required, to ensure maximum driving comfort and accessibility to controls.

!

WARNING

!

The vehicle must be stationary to carry out this operation and the engine turned off.

(A) SEAT HEATING Use the switch to turn the heating ON/OFF. NOTE: The warning light built into the switch will light up when the device is on.

(B) WEIGHT ADJUSTMENT To adjust the reaction to the driver’s weight use the button: + for heavier weight - for lighter weight.

(C) LUMBAR ADJUSTMENT To adjust the seat’s lumbar support use the button.

(D) BACK SUPPORT ADJUSTMENT To adjust the seat’s back support use the button.

CUSHION ANGLE ADJUSTMENT The front and rear parts of the cushion can be adjusted separately; adjust the cushion slant by means of the levers (2) and (3), respectively.

BACKREST ANGLE ADJUSTMENT Rest your back firmly against the backrest and adjust the slant by means of the lever (4).

FORE/AFT POSITION ADJUSTMENT Lift the lever (5) and slide the seat to the required position. Make sure that the mechanism is locked after adjusting the seat position.

174NU82

10

ARMREST POSITION ADJUSTMENT Turn control (6) clockwise or counterclockwise to increase or decrease armrest height.

HEAD REST ADJUSTMENT The head rest height and angle can be adjusted.

2-11

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES FOLDING SEAT A folding seat is provided.

Proceed as follows to use the seat: 1.

Operate the lever and slide the driver’s seat laterally to the right.

2.

Lower the trainer’s seat.

3.

When there is no passenger reposition the driver’s seat.

!

WARNING

!

The vehicle must be stationary to carry out this operation and the engine off.

174NU05

11

SEAT BELTS The vehicle is equipped with two-point seat belts complete with automatic retractor.

The seat belt does not require manual adjustment: the belt will automatically adjust to the most suitable length for the driver allowing freedom of movement as long as movements are not sudden.

The mechanism is sensitive to changes in vehicle movement.

Consequently, the belt may lock in the following cases: - braking or sudden acceleration; - vehicle on grade; - vehicle cornering.

174NU06

12

To fasten the seat belt, take the tab and insert it in the buckle until it clicks.

174NU07

13

2-12

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES To release the seat belt, press the button provided on the upper side of the buckle.

NOTE: The passenger seat belt requires adjusting the length for prosper fit to the person’s size.

!

WARNING

!

The vehicle must be stationary to carry out this operation and the engine off.

174NU08

14

ACCESSORY FUNCTIONS ADJUSTING THE STEERING WHEEL POSITION Proceed as follows: 1.

Release the lever (1) by pulling it upwards.

2.

Adjust the height and tilt of the steering wheel (2).

3.

Lock the lever by pushing it downwards.

!

WARNING

!

The vehicle must be stationary to carry out this operation and the engine off.

269NU0D4

15 REAR VIEW MIRRORS The right and left rear view mirrors can be adjusted manually or by means of the rear view mirror power control. Adjust the mirrors so that in his normal driving/ operating position the operator has complete visibility along and throughout both sides of the truck.

Adjust to ensure the best lateral and rear view.

!

WARNING

!

The vehicle must be stationary to carry out this operation.

269NU241

16

2-13

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES SIDE WINDOWS 1.

Pull and turn the lever (1) to release;

2.

Push the lever inwards as far as required: this position will be held automatically.

Proceed as follows to close the window: 1.

Pull the lever and push if forwards (2) to fasten.

!

WARNING

!

This procedure refers to both windows (on door side and on right dashboard side).

269NU0D5

17 SUNSHADES Pull tab (a) to lower the sunshade.

Pull cord (b) to lift the sunshade: the sunshade will automatically roll itself up.

CS03B003

18 POSITION LIGHT AND HEADLIGHT CONTROL The control has three positions: Position 0: OFF Position 1: position lights ON Position 2: headlights ON

269NU214

19

2-14

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES HEADLIGHT CONTROL The control has two positions: Position 1: low-beam headlights Position 2: high-beam headlights Press the button on the control lever (arrow) to flash the headlights during daytime.

269NU212A

20 TURN INDICATOR AND HORN CONTROL The control has three positions: Position 0: OFF Position 1 (up): right turn indicators Position 2 (down): left turn indicators Press the button on the control lever (arrow) to operate the horn.

269NU213

21 WINDSHIELD WIPER/WASHER CONTROL The control has four positions: Position 0: OFF Position 1: intermittent wipe Position 2: slow wipe Position 3: fast wipe Press the button (arrow) on the control lever to operate the windshield washer.

269NU231B

22

2-15

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES REAR VIEW MIRROR POWER CONTROL The rear view mirror switch has two positions: Position 1: right mirror Position 2: left mirror Press button in the required direction to adjust the mirror: -

Arrow upwards: mirror upwards Arrow downwards: mirror downwards Arrow rightwards: mirror rightwards Arrow leftwards: mirror leftwards 269NU242A

!

WARNING

23

!

The vehicle must be stationary to carry out this operation.

HEATED REAR VIEW MIRROR CONTROL The control has two positions: Position 0: OFF Position 1: ON

269NU244

24 SIDE WINDOW WIPER CONTROL The control has two positions: Position 0: OFF Position 1: ON

269NU234

25

2-16

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES SIDE WINDOW WASHER CONTROL The windshield washer will operate when this switch is pressed and held down. When the switch is released, the windshield washer ceases to operate.

269NU235

26 ROTATING BEACON CONTROL The control has two positions: Position 0: OFF Position 1: ON

269NU225

27 REAR WORK LIGHT CONTROL The control has two positions: Position 0: OFF Position 1: ON

269NU226

28

2-17

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES PARKING BRAKE The control has two positions: Position 0: OFF Position 1: ON To engage the parking brake, move lever to position 1 (vehicle with brake on).

To release the parking brake, lift the knob, and the lever will automatically return to position 0 (vehicle with brake off).

269NU271C

29

!

WARNING

!

The specific warning lamp (1) on the instrument panel lights up when the parking brake is engaged.

IMPORTANT: Always apply the parking brake in the following cases: When the vehicle is parked for a long or short time.

Loading/unloading the vehicle.

269NU272

30 SUPPLEMENTARY PARKING BRAKE (HOLD) To apply the supplementary parking brake: Press the button on the side of the body tipping lever.

To release the supplementary parking brake: Press the button on the side of the body tipping lever or operate the gear lever.

!

WARNING

!

The specific warning lamp (2) on the instrument panel lights up when the parking brake (hold) is engaged.

269NU273

31

!

WARNING

!

The supplementary parking brake (hold) can only be applied when the vehicle is stationary. It cannot therefore be used as a service brake even in an emergency.

IMPORTANT: The supplementary parking brake (hold) is applied automatically when shifting to neutral, REGARDLESS of the position of the lever.

The supplementary parking brake (hold) does not need to be applied.

2-18

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES MULTIFUNCTIONAL DISPLAY CONTROLS “ESC” press the button (1) to quit the menu and go back to the home page.

“ENTER” press the button (2) to access the menu or confirm a selection.

269NU141

32 “SCROLL” press + (forwards) or - (backwards) to scroll the menu.

!

WARNING

!

This button is used to adjust brightness on the home page.

269NU142

33 The display comes on: With the battery switch on and ignition switch in “MAR” position.

Engine running.

In these conditions this display home page appears.

For more information see "Multifunctional display" in Section 3.

269NU143

34

2-19

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES HAZARD LIGHT CONTROL The control has two positions: Position 0: OFF Position 1: ON

269NU224

35 DOME LIGHT/MAP READING LIGHT CONTROL Dome light (a) can be switched on by pressing the switch as indicated: Position A: OFF Position B: ON Map reading light (b) can be switched on by pressing the switch as indicated: Position A: OFF Position C: ON NOTE: A dome light will come on automatically when the door is opened.

174NU79A

36 ENGINE STARTER SWITCH The starter switch has three positions: Position 0: all off, key can be removed Position 1: run/prepare starting, electrical power on, key cannot be removed Position 2: engine starting

269NU251B

37

2-20

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES SOUND SYSTEM INSTALLATION The sound system is installed in the upper right-hand side of the cab.

174NM87

38 CB TRANSCEIVER SET The CB transceiver set can be installed in a special compartment located in the upper left-hand side of the cab.

NOTE: The CB set should be installed by the Customer.

Remove the lining corresponding to the shape of the set to access the compartment.

The compartment houses the set’s power supply cables.

269NU2C1

39 CLOSED CIRCUIT CAMERA The vehicle is equipped with a closed circuit camera for monitoring the area behind the vehicle.

Press button (1) to switch the camera power supply on (camera in stand-by).

IMPORTANT: Keep the camera normally in stand-by unless the vehicle is to remain stationary for some time.

Press button (2) to switch the camera on (camera in operation, image displayed).

IMPORTANT: The camera is automatically set in operation when the Reverse gear is selected. The camera is automatically put into stand-by when the Neutral or Forward gear is selected.

269NU2A1

40

2-21

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES STEERING Steering is controlled by means of the steering wheel.

Turn the steering wheel in the required direction according to the required steering radius. Turn the steering wheel in the opposite direction to straighten the vehicle or steer in the opposite direction.

IMPORTANT: The steering wheel is without any return effect while cornering.

Consequently, the vehicle will continue to follow the set cornering line when the steering wheel is released.

269NU252A

41

!

WARNING

!

A buzzer will be operated (continuous tone) if the emergency pump automatically starts up following a steering circuit pressure reduction.

The buzzer will beep to indicate that the emergency pump fuse has blown and consequently that the pump will not work in an emergency.

269NU383

42 ACCELERATOR The accelerator is controlled by means of a pedal on the floor to be operated by the driver’s right foot. Press the pedal to increase the engine speed proportionally to the position of the pedal.

174NU26

43

2-22

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES SERVICE BRAKE The service brake is controlled by means of a pedal on the floor to be operated by the driver’s right foot.

Press the pedal to obtain a braking effect in proportion to the exerted pressure.

174NU27

44 INTEGRATED IRCM AUXILIARY BRAKE CONTROL Position 0: OFF Position 1: engine brake ON Position 2: engine brake + transmission retarder ON. IMPORTANT: The integrated auxiliary brake in position 2 will generate maximum braking effect compatibly with the operative conditions of the vehicle by means of the retarder.

269NU264

45 AUTOMATIC TRANSMISSION The vehicle is equipped with an automatic transmission with six forward gears and three reverse gears, plus a torque converter.

The gearshift lever has three positions: Position N (Neutral) is used for: - starting/stopping the engine - vehicle stationary and engine running Position F (Forward) is used for: - forward movement of the vehicle Position R (Reverse) is used for: - reverse movement of the vehicle NOTE: An external buzzer will sound when the R position is selected.

174NU31A

46

2-23

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES To shift from position (N) to position (F) or (R), keep the button on the top of the lever pressed.

The transmission can also be operated manually. (a) Lever pushed leftwards (towards the driver): to select a lower gear (shift down). (b) Lever pushed rightwards (towards the side): to select a higher gear (shift up).

For more information see "Using the automatic transmission" in Section 3.

269NU281B

47

2-24

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES LONGITUDINAL DIFFERENTIAL LOCK CONTROL IMPORTANT: The vehicle is equipped with transversal self-locking differentials on all axles.

These differentials are locked automatically to ensure correct adherence grip of each wheel.

!

WARNING

!

Only use the differential lock when needed and disengage it as soon as working conditions make it no longer necessary. Stop the machine before engaging either differential lock.

Control switches positions: Position 0: OFF Position 1: longitudinal lock between axles engaged

269NU294

48 Position 0: OFF Position 1: central differential lock engaged For more information see "Using the differential lock" in Section 3.

269NU295

49

2-25

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES BODY HOIST CAB CONTROL The control has three positions: Position 0: OFF Position 1: dumper raise Position 2: dumper lower For more information see "Working with the vehicle" in Section 3.

269NU293A

50 HEATING AND VENTILATION OR AIR CONDITIONING CONTROLS Manual climate control Knob (1): regulates heater temperature.

Turn clockwise to increase heating Turn counter-clockwise to decrease heating (position D: OFF) Button (2): controls entry of outside air into the cab.

Pressed: flap closed, internal air recirculation Not pressed: flap open, air enters from outside Knob (3): air conditioner adjustment thermostat.

Turn clockwise to increase cooling Turn counter-clockwise to decrease cooling (position D: OFF) Knob (4): regulates fan speed.

Turn clockwise to increase speed Turn counter-clockwise to decrease speed (position D: OFF).

- For operation see "Climate control system operation" in Section 3.

269NU2D2

51

2-26

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES Automatic climate control

269NU2D1

52 1. Automatic

7. External temperature display

2. Automatic on warning light

8. Ventilation

3. Air conditioning

9. Ventilation on warning light

4. Air conditioning on warning light

10. Temperature

5. Air recycling

11. Display screen

6. Air recycling on warning light - For operation see "Climate control system operation" in Section 3.

2-27

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES EXTERNAL CONTROLS Opening the side access doors The side access doors open in the direction opposite that of travel.

To open the access door, place your hand in the gap and pull outwards.

269NU053

53 To close the access door, accompany it to closure, rest it on the catch and push fully.

269NU054

54

2-28

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

269NU052

55 1. Battery disconnect switch 2. Off-vehicle engine starting/stopping control or Off-vehicle engine starting/stopping and warmup control

4. Manual engine hood and cab tipping preselection control or Electric operated hydraulic engine hood and cab tipping pre-selection control

3. Emergency battery disconnect switch

5. Emergency engine hood opening control

BATTERY DISCONNECT SWITCH Press the button (1) to power the electrical utilities.

Press the button (2) to disconnect electrical power.

1

-For operation see "Electrical power disconnection" in Section 3.

269NS0F6

56

2-29

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES OFF-VEHICLE WARM-UP CONTROL The control reverses the currently active function each time it is operated.

2

Press to start the engine.

Press to stop the engine.

Or, alternatively

269NU063A

57 OFF-VEHICLE ENGINE STARTING AND WARMUP CONTROL

3

The control reverses the currently active function each time it is operated.

Press the upper part of the button (1) to start the engine.

Press the upper part of the button again to stop the engine.

Press the lower part of the button (2) to start the offvehicle warm-up procedure.

Press the lower part of the button again to stop the offvehicle warm-up procedure.

269NU064

58

IMPORTANT: The warm-up procedure will only work when the engine is running.

EMERGENCY BATTERY DISCONNECT SWITCH Open the protective cover and push the switch underneath to disconnect electrical power to utilities.

- For operation see "Electrical power disconnection" in Section 3.

269NS102

59

2-30

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES ENGINE HOOD AND CAB TIPPING PRE-SELECTION CONTROL

5

Position 1: engine hood pre-selection.

Position 2: cab pre-selection.

269NU073

60 HYDRAULIC ENGINE HOOD AND CAB TIPPING CONTROL (where fitted)

5

Press the button (1) to tip the hood.

Press the button (2) to tip the cab.

269NU074

61

2-31

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

NOTES

2-32

SECTION 3

68

OPERATING INSTRUCTIONS BEFORE OPERATING THE MACHINE

!

WARNING

!

Do not operate this machine until you read and understand the instructions and warnings shown in this manual.

Observe the operating instructions shown in this chapter, since any other use without the prior agreement of the manufacturer is considered to be forbidden.

Before operating the machine, observe the following instructions: 1.

Check the levels (engine oil, hydraulic fluid and cooling system) and make sure that the various fluids correspond to the conditions of use. See "Fluids and lubricants" in Section 4.

2.

Carry out the daily maintenance operations. See Section 4.

3.

Check around the machine, identify any leaks and inspect the hoses. Tighten or replace where necessary. See Section 5.

4.

Before carrying out any work in the hours of darkness, check that the lighting and signalling systems are operating correctly.

14. Make yourself aware of work site safety measures and hand signals.

15. Holes, obstacles, debris and other dangers on the work site can cause serious bodily injury.

Inspect and identify all possible risks before driving the machine into a new working area.

16. Before starting the engine, give warning of your presence by sounding the horn.

17. Never start the engine in any other manner than that shown in this manual.

18. Avoid loose fitting clothing, loose or uncovered long hair, and jewelry.

19. Different jobs will require different protective equipment. Items such as hard hats, protective shoes, heavy gloves, reflector type vests, respirators, ear protection, and eye protection can be required. Before you start the job, determine what protective equipment is required. Use this equipment at all times.

OPERATING THE MACHINE

!

WARNING

!

5.

Check the correct operation of the windshield wipers.

Check the correct operation of all the controls and all the safety devices in a safe, unobstructed area before starting work.

6.

Check the condition and pressure of the tires.

See "Tires and wheels" in Section 5.

When operating the machine observe the following instructions:

7.

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

1.

Start the engine, taking into account the weather conditions. See "Starting the engine".

2.

If the machine is used under particularly severe conditions (dusty or corrosive environment, etc.) reduce the length of the servicing intervals.

3.

If this machine is new or if the engine has been reconditioned, see "Run-in period".

4.

When operating on a work site on a public highway, use the regulation traffic signs, taking into account the operating range of the machine.

Local regulations define the number, type and location of reflective strips.

8.

Clean or change safety decals which are no longer legible.

9.

Make sure that the engine hood is closed and locked correctly.

10. Make sure that the cab door is closed correctly.

11. Remove anything which can obstruct visibility.

Clean the windows and rear view mirrors.

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

13. Make sure that no one is under or on the machine. The operator must be alone on the machine.

3-1

SECTION 3 - OPERATING INSTRUCTIONS 5.

Be vigilant, make yourself aware of places where other people are working close to your working area. Keep all other people away from the machine. Non-observance of these instructions can cause serious bodily injury.

6.

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

7.

Never operate a control or driving component without being correctly seated in the operator’s seat with the seat belt fastened.

8.

9.

Always make allowance for working conditions (sloping or rough ground), the conditions of the ground and weather conditions.

Never allow any other person within the working range of the machine. Stop all movement until the person has moved away.

10. Use all the controls gradually so that the machine operates smoothly.

11. Before moving in reverse, make sure that there is no one behind the machine.

12. Never work with the engine hood open.

13. When towing the machine, see "Towing the machine". In this Section.

14. Avoid running the engine in a confined space. If this cannot be avoided, provide good ventilation in all circumstances.

15. Dust, smoke or mist can reduce visibility and cause an accident. Stop or slow down the machine until normal visibility is regained.

16. In the event of an operating problem or damage, move the machine to a safe place, shut down the engine and remove the key. Identify or report the defect and, if necessary, take measures to prevent the machine being operated.

3-2

RUN-IN PERIOD Longer engine life, improved characteristics and more economic operation can be obtained by taking great care with the engine during the first thirty operating hours.

During this period: Warm the engine up before using it under load.

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

Check the warning and indicator lamps and indicators and gauges frequently.

Check the oil levels and coolant solution levels frequently.

IMPORTANT: During the run-in period a certain number of operations have to be carried out after the first 100 and then 250 hours. See "Scheduled maintenance program" in Section 4.

SECTION 3 - OPERATING INSTRUCTIONS FILLING THE FUEL TANK IMPORTANT: Put out all flames while refuelling. Do not smoke.

IMPORTANT: Keep the fuel tank as full as possible.

Refuel when the minimum fuel level is reached.

Use fuels of the specified types supplied by petroleum companies. Do not use other than specified fuels. Use of other than specified fuels can cause severe engine damage.

1.

Open the left side access door.

2.

Clean the filler area, open the filler cap and refuel with fuel of the specified type.

3.

Close the cap carefully and close access door.

269NU314

1 FUEL SPECIFICATIONS Specification for acceptable No. 2 diesel fuel API gravity, minimum ...................................................................................................................................... 34 Flash point, minimum .................................................................................................................. 60 °C (140 °F) Cloud point, maximum (was appearance point) ............................................................................-20 °C (-5 °F) Pour point, maximum...................................................................................................................-26 °C (-15 °F) Distillation temperature, 90% point...................................................................... 282 to 338 °C (540 to 640 °F) Viscosity, at 38 °C (100 °F) Cent is tokes ..................................................................................................................................... 2.0 to 4.3 Cetane number, minimum ....................................................................43 (45 to 55 for winter or high altitudes) Water and sediment, by volume, maximum.............................................................................................. 0.05%

3-3

SECTION 3 - OPERATING INSTRUCTIONS STARTING AND STOPPING THE ENGINE

!

WARNING

!

Exhaust gases are toxic. Do not start the engine in a closed room unless suitably ventilated.

Sound the horn before starting the engine.

PRELIMINARY OPERATION IMPORTANT: It is advisable to perform daily checks before starting the vehicle.

Refer to the following chapters for additional details.

Top up the levels and eliminate any faults, if required.

Power the electrical utilities to start the engine.

General electrical utilities Open right side access door.

- or

269NS0F5

2 Get into the cab.

269NS0F2

3

3-4

SECTION 3 - OPERATING INSTRUCTIONS Press the button to power the electrical utilities.

269NS0F6A

4 STARTING THE ENGINE FROM THE DRIVER’S CAB IMPORTANT: Starting the engine from the cab is possible in the following conditions: Parking brake set.

Gear lever in neutral position.

Key inserted in ignition switch.

Turn the ignition key to position (1).

The vehicle is fitted with an electronic intake air preheating device for cold starting (glow plug). The system is activated when the temperature is under a predetermined value (approximately 10°C).

269NU331

5 This condition is shown on the display.

The engine can be started when the pre-heating procedure is over.

IMPORTANT: The pre-heating device will be switched off to avoid discharging the batteries if the engine is not started in a few seconds.

In this case to start the vehicle the above procedure has to be repeated.

269NU335

6

3-5

SECTION 3 - OPERATING INSTRUCTIONS Turn the ignition switch to position (2) and release it as soon as the engine starts.

!

WARNING

!

Do not run the starter motor for longer than 15 seconds if the engine does not start immediately.

If the engine does not start, wait for at least ten seconds before attempting again to let the starter motor cool down.

269NU334

7 With the engine running check that the EDC warning light is off.

IMPORTANT: With the ignition switch turned to position (1), the EDC light goes off the first time the brake pedal is pressed.

The EDC warning light will stay on or blink if the engine control unit detects a malfunction.

A message will appear on the display when this occurs.

269NS0F4

8 WARMING THE ENGINE After starting the cold engine, drive off slowly for a distance to warm the engine (as soon as the automatic transmission control unit enables this). Run the engine at medium to low rpm.

Do not stress the braking system while the engine is warming up.

!

WARNING

!

Do not idle the engine for a long time, when cold or hot.

After starting the hot engine, let it idle for a few seconds before increasing the rpm to allow correct lubrication of the turbo charger.

3-6

269NU341

9

SECTION 3 - OPERATING INSTRUCTIONS STOPPING THE ENGINE FROM THE DRIVER’S CAB 1.

Idle the engine for a 2-3 minutes to balance the temperature and lubricate the turbo charger.

2.

Turn the ignition key to position (0).

269NU341

10 STARTING AND STOPPING THE ENGINE FROM OFF THE VEHICLE IMPORTANT: Starting the engine from off the vehicle is possible in the following conditions: Gear lever in neutral position.

Parking brake applied.

Ignition switch in position 0.

Open right side access door.

269NU374

11

3-7

SECTION 3 - OPERATING INSTRUCTIONS Hold the button pressed until the engine starts.

!

WARNING

!

The pre-heating device enables the started motor after a certain time according to the engine temperature.

Hold the button pressed until the starter motor is engaged and until the engine has started.

!

WARNING

!

Do not run the starter motor for longer than 15 seconds if the engine does not start immediately.

If the engine does not start, wait for at least ten seconds before attempting again to let the starter motor cool down.

269NU063A

12

To stop the engine, open the right side access door and press the button - or

269NU367

13 Turn the ignition switch to position 1 and back to position 0.

!

WARNING

!

Do not switch the ignition switch to position 2 to avoid DAMAGING THE STARTER MOTOR. After starting the engine off the vehicle: The engine can be accelerated; The parking brake can be released; Transmission cannot shift into gear and remains in neutral.

To start operating the vehicle proceed as follows: Turn the ignition switch to position 1.

3-8

269NU365

14

SECTION 3 - OPERATING INSTRUCTIONS

!

WARNING

!

Do not switch the ignition switch to position 2 to avoid DAMAGING THE STARTER MOTOR BEYOND REPAIR Proceed as shown in the following chapters.

OFF-VEHICLE WARM-UP PROCEDURE The automatic warm-up procedure is used to gradually warm the engine, the automatic transmission and the hydraulic systems of the vehicle, without needing to move the vehicle and without supervision.

The system after running the engine at idling speed for 30 seconds will accelerate to approximately 10001200 rpm according to ambient temperature conditions and will apply the retarder to create an engine load.

The system stops the retarder and returns the engine to idling speed when the required temperatures are reached.

The vehicle can be run in these conditions as long as required and will remain warm.

IMPORTANT: The off-vehicle warm-up procedure is possible in the following conditions: Engine started off-vehicle.

Gear lever in neutral position.

Parking brake applied.

Ignition switch in position 0.

Open right side access door.

269NU374

15

3-9

SECTION 3 - OPERATING INSTRUCTIONS Press the button and release it: the control system will run the automatic engine warm-up procedure.

IMPORTANT: The hazard lights will blink while the procedure is in progress.

The blinking will stop when the vehicle has been warmed up.

Proceed as follows to stop the warm-up procedure: Press the button again - or Turn the ignition switch to position 1.

269NU375

!

WARNING

!

Do not switch the ignition switch to position 2 to avoid DAMAGING THE STARTER MOTOR BEYOND REPAIR - or Release the parking brake - or Operate the automatic transmission selector lever.

To start the vehicle proceed as follows: Turn the ignition switch to position 1.

!

WARNING

!

Do not switch the ignition switch to position 2 to avoid DAMAGING THE STARTER MOTOR BEYOND REPAIR Proceed as shown in the following chapters.

3-10

16

SECTION 3 - OPERATING INSTRUCTIONS MULTIFUNCTIONAL DISPLAY The vehicle is equipped with a multifunctional display for: Viewing vehicle operation and use parameters.

Programming vehicle operative options.

NOTE: The figure shows the home page with British Units.

269NU151

17 The home page is split into the following various sections: 1. Vehicle speed.

8. Hydraulic system fluid temperature.

2. Cold start device warning light.

9. Current date and time.

3. Climate control warning light.

4. Odometer.

5. Brake coolant temperature.

6 Selected gear and automatic transmission operative mode.

NOTE: The date and time sector may be used for showing diagnostic messages.

NOTE: Press ENTER to go to the main menu.

7. Running time.

NOTE: The hours refer to the selected mode (see paragraphs below).

3-11

SECTION 3 - OPERATING INSTRUCTIONS DIAGNOSTIC MESSAGES Three types of diagnostic messages may appear in the event of an anomaly EDC engine control unit problem: a two-digit numeric code will appear and either warning lights in flashing or fixed mode will come on according to the severity of the anomaly.

269NS0F4

18 TCU automatic transmission control system problem: a two-character alphanumeric code will appear and either warning lights will come on.

269N4153

19 Body computer (vehicle) control system problem: a message will appear and either warning light (1) or lights (1) and (2) will come on according to the severity of the anomaly.

NOTE: Call your Dealer for more information on anomaly codes and messages.

1

2

269NU383

20

3-12

SECTION 3 - OPERATING INSTRUCTIONS MAIN MENU The main menu presents a set of options whose meaning is explained below.

VEHICLE MANAGEMENT: A number of vehicle operation functional modes (body, automatic transmission) can be programmed.

TRIP COMPUTER: The method for counting time, distance and averages can be defined.

ENGINE TEST: A selection of operating parameters can be read.

TRANSMISSION TEST: A selection of operating parameters can be read.

269NU155

21

SETUP: The date, time, language and unit of measure can be set.

TEST BODY: The body angle potentiometer can be calibrated.

Proceed as follows: Press “SCROLL” + (forwards) or - (backwards) to select an option.

269NU142

22 Press “ENTER” (2) to go to the selected option.

Press “ESC” (1) to go to the home page.

NOTE: Press “SCROLL” to go to the next (+) or previous (-) option on the page.

Press “ENTER” to confirm the selected option and forward by one page at a time to the last option.

Press “ESC” to go back by one page one at a time to the home page.

269NU141

23

3-13

SECTION 3 - OPERATING INSTRUCTIONS VEHICLE MANAGEMENT Available option sequence

269NU161A

24 NOTE: LEVELS CHECK option is not available.

269NU161

25

3-14

SECTION 3 - OPERATING INSTRUCTIONS BODY CONTROL Available option sequence

269NU171A

26 Meaning of the options.

BODY CONTROL

269NU171

27 3-15

SECTION 3 - OPERATING INSTRUCTIONS LEVER SELECTION: defines the operating mode of the body tip lever.

AUTOMATIC MODE Shift the lever in the required direction and release it to tip the body. The operation will be completed to end of stroke.

Move the lever again in one of the two directions to stop the movement.

MANUAL MODE Move the lever in the required direction and hold it there until the movement stops.

Release the lever to stop the movement (dead-man control)

269NU172

28

ENGINE SELECTION: defines the operating mode of the engine while the body is being tipped.

AUTOMATIC MODE The engine is accelerated automatically for the entire movement after operating the body tipping lever.

The engine returns to idling speed when the movement stops.

MANUAL MODE The engine can be accelerated by the driver pressing the accelerator pedal for the entire movement after operating the body tipping lever.

The engine returns to normal idling speed when the accelerator pedal is released.

3-16

269NU173

29

SECTION 3 - OPERATING INSTRUCTIONS TM PROGRAM SELECTION Available option sequence

269NU181A

30 Meaning of the options.

TM PROGRAM SELECTION ECO PROGRAM: the TCU transmission control unit establishes the shift points according to travelling conditions privileging fuel saving.

POWER PROGRAM: the TCU transmission control unit establishes the shift points according to travelling conditions privileging maximum vehicle performance.

269NU161

31

3-17

SECTION 3 - OPERATING INSTRUCTIONS AEB REQUEST Available option sequence

269NU191A

32 Meaning of the options.

AEB REQUEST: the TCU transmission control unit runs the AEB internal check and calibration procedure.

!

WARNING

!

Respect the following conditions for running the AEB sequence correctly: - Gearshift lever in Neutral position.

- Engine idling.

- Parking brake applied.

- Automatic transmission warm (80 - 90 °C).

269NU191

33

NOTE: The system will not run the procedure if any one of these conditions is not respected.

NOTE: Advancement will be shown on the display while the procedure is in progress.

269NU192

34

3-18

SECTION 3 - OPERATING INSTRUCTIONS TRIP COMPUTER Available option sequence

269NU201A

35 Trip Computer resetting follows the rules below: - Trip default: reset every solar day.

- Trip 100 hours: reset every 100 hours of operation or following manual reset (reset trip 100 hours).

- Trip 500 hours: reset every 500 hours of operation or following manual reset (reset trip 500 hours).

- Trip overall: cannot be reset (the reading are stored from when the engine was first started).

269NU201

36 3-19

SECTION 3 - OPERATING INSTRUCTIONS TRIP DEFAULT Available option sequence

269NU202A

37 Meaning of the options.

ANALYSIS: For showing operative parameters: Instantaneous consumption.

Average consumption (average according to trip computer settings).

Distance covered.

Time elapsed.

Number of tipping operations.

Autonomy in hours (calculated according to average current values).

269NU202

38 ANALYSIS BETWEEN TWO OVERTURNS: For showing typical working cycle parameters: Average consumption (average according to trip computer settings).

Distance covered.

Average time elapsed.

269NU203

39

3-20

SECTION 3 - OPERATING INSTRUCTIONS TRIP 100 HOURS Available option sequence

269NU204A

40 Meaning of the options.

ANALYSIS: For showing operative parameters: Instantaneous consumption.

Average consumption (average according to trip computer settings).

Distance covered.

Time elapsed.

Number of tipping operations.

Autonomy in hours (calculated according to average current values).

269NU204

41 TRIP 500 HOURS Similar to trip 100 hours except for basic time.

TRIP OVERALL Similar to trip 100 hours except for basic time.

NOTE: The trip overall cannot be reset.

3-21

SECTION 3 - OPERATING INSTRUCTIONS RESET TRIP 100 HOURS Available option sequence

269NU205A

42 Meaning of the options.

RESET TRIP 100 HOURS The trip 100 hour counter is reset.

269NU205

43 RESET TRIP 100 HOURS Available option sequence

269NU206A

44 Meaning of the options.

RESET TRIP 500 HOURS The trip 500 hour counter is reset.

269NU206

45

3-22

SECTION 3 - OPERATING INSTRUCTIONS ENGINE TEST Available option sequence

269NU211A

46 Meaning of the options.

ENGINE TEST PAGE 1: For showing operative parameters: Engine operative mode.

NOTE: The operative mode is identified by a code.

Engine speed.

Engine output load (% respect to maximum).

Accelerator pedal position (% respect to maximum).

Instantaneous fuel consumption.

Engine coolant temperature.

269NU211

47 ENGINE TEST PAGE 2: For showing operative parameter: Engine oil pressure.

Engine oil temperature.

Inlet air temperature (after intercooler).

Inlet air pressure (after intercooler).

Fuel temperature.

Hours of operation.

269NU212

48

3-23

SECTION 3 - OPERATING INSTRUCTIONS AUTOMATIC TRANSMISSION TEST Available option sequence

269NU221A

49 Meaning of the options.

TRANSMISSION TEST PAGE 1: For showing operative parameters: Selected gear.

Automatic transmission operative mode.

Selected program.

Converter pump speed (the same as engine speed).

Brake input load (% respect to maximum).

Retarder braking torque (% respect to maximum).

269NU221B

50 TRANSMISSION TEST PAGE 2: For showing operative parameter: Converter output oil temperature.

Oil sump temperature.

Hours of operation.

269NU222A

51

3-24

SECTION 3 - OPERATING INSTRUCTIONS SETTINGS Available option sequence

269NU231A

52

269NU231

53 3-25

SECTION 3 - OPERATING INSTRUCTIONS DATE SET Available option sequence

269NU241A

54 Meaning of the options.

DATE SET

269NU241B

55 3-26

SECTION 3 - OPERATING INSTRUCTIONS CHANGE YEAR: to set the year: the year is identified by the last two digits (e.g.: 04 = 2004).

269NU242

56 CHANGE MONTH: to set the month: the month is identified by two digits out of 12 (e.g.: 05 = May).

269NU243

57 CHANGE DAY: to set the day: the day is identified by two digits out of 31 (e.g.: 12 = twelfth day of the current month).

269NU244

58

3-27

SECTION 3 - OPERATING INSTRUCTIONS TIME SET Available option sequence

269NU251A

59 Meaning of the options.

TIME SET

269NU251

60

3-28

SECTION 3 - OPERATING INSTRUCTIONS CHANGE HOURS: to set the hour: the hour is identified by two digits out of 24 (e.g. 14 = fourteen hundred hours, 2 o’clock p.m.).

269NU252

61 CHANGE MINUTES: to set the minutes: minutes are identified by two digits out of 60 (e.g.: 32 = thirty-two minutes).

269NU253

62

3-29

SECTION 3 - OPERATING INSTRUCTIONS MEASURE UNITS SET Available option sequence

269NU261A

63 Meaning of the options.

MEASURE UNITS SET METRIC MODE: shows all measurements using metric units (EEC).

ANGLO-SAXON MODE: shows all measurements using imperial units.

269NU261

64

3-30

SECTION 3 - OPERATING INSTRUCTIONS LANGUAGE SET Available option sequence

269NU271B

65 Meaning of the options.

LANGUAGE SET ITALIAN: selects Italian language on the display.

ENGLISH: selects English language on the display.

269NU271

66

3-31

SECTION 3 - OPERATING INSTRUCTIONS TIME FORMAT Available option sequence

269NU281A

67 Meaning of the options.

TIME FORMAT 12-24 TIME FORMAT 12h: set the time in a.m./p.m. mode (e.g.: 6 a.m. = six o’clock in the morning, 6 p.m. = six o’clock in the afternoon).

TIME FORMAT 24h: set the time in 24h mode (e.g.: 6 = six o’clock in the morning; 18 = six o’clock in the afternoon).

269NU281

68

3-32

SECTION 3 - OPERATING INSTRUCTIONS CALIBRATE BODY ANGLE Available option sequence

269NU291A

69 Meaning of the options.

CALIBRATE BODY ANGLE: for calibrating the body angle position sensor.

269NU291

70 CALIBRATE MINIMUM ANGLE: to define the sensor down stroke end position.

269NU292

71

3-33

SECTION 3 - OPERATING INSTRUCTIONS CALIBRATE MAXIMUM ANGLE: to determine the sensor up stroke end position.

269NU293

72

3-34

SECTION 3 - OPERATING INSTRUCTIONS STARTING THE VEHICLE

!

WARNING

!

Make sure that the area around the vehicle is clear of personnel and obstructions before moving the machine. Sound the horn before starting the vehicle.

IMPORTANT: The camera is automatically set in operation when the reverse gear is selected.

1.

Check that all warning lights are off and all indications on the display are correct.

!

WARNING

!

The warning lights will both remain on until the hydraulic braking circuit reaches the specified pressure.

A message will appear on the display when this occurs.

2.

Check that the dump body is in the down position.

269NU383

73 3.

Release the parking brake and press the brake pedal.

174NU27

74 4.

Operate the selecting lever as needed.

269NU382

75

3-35

SECTION 3 - OPERATING INSTRUCTIONS 5.

Release the brake pedal and press the accelerator pedal: the vehicle will start to move in the selected direction.

!

WARNING

!

The TCU control unit will prevent shifting gears from Neutral position when the automatic transmission oil temperature is less than -12°C. A message will appear on the display when this occurs.

Warm the transmission up (possibly by using the off-vehicle warm-up procedure) to restore normal operation.

174NU26

76

STOPPING AND PARKING THE VEHICLE STOPPING 1.

Release the accelerator pedal and press the brake pedal.

STANDING STILL 1.

Press the brake pedal to stop the vehicle.

IMPORTANT: The vehicle can be kept stationary by pressing the brake pedal with the gearshift lever in Forward/Reverse.

Avoid holding brake a long time with transmission in gear since it may cause transmission oil overheating.

174NU27

77 2.

Place the transmission in Neutral.

269NU392

78

3-36

SECTION 3 - OPERATING INSTRUCTIONS 3.

Apply the parking brake. Release the brake pedal.

!

WARNING

!

The warning light in the switch will only indicate that the switch position has been changed. The instrument panel warning light will indicate whether the parking brake is on. Wait for a few seconds before releasing the brake pedal after applying the parking brake.

4.

Stop the engine for prolonged stops and remove the key from the starter switch.

!

WARNING

269NU433

79

!

Do not leave the vehicle with the engine running.

PARKING Take the following precautions when parking the vehicle for a long time: 1.

Fill the fuel tank to prevent the formation of condensation.

2.

Park the vehicle straight the front and rear chassis aligned.

3.

Park the vehicle as far as possible on flat ground, in a suitable area where it is not a hindrance.

4.

Place the transmission in Neutral, apply the parking brake, stop the engine and remove the key from the starter switch.

5.

Inspect the vehicle to check for any damage or leaks.

3-37

SECTION 3 - OPERATING INSTRUCTIONS DRIVING THE VEHICLE PRECAUTIONS DURING THE INITIAL PERIOD OF USE New vehicles require a short run-in period of at least 150/200 hours. Take the following precautions during this time: - Do not demand maximum engine power.

- After starting the engine, warm it up slowly, without demanding an excessively high engine speed too soon.

- Do not over stress the brakes.

- Check the engine oil level and the transmission oil level daily.

- Check the auxiliary drive belt tension weekly.

- Check the tightness of all wheel nuts daily.

Adopt similar precautions (for the concerned parts) following the replacement or overhauling of major components (engine, transmission, axle, brakes, etc.)

NORMAL RUNNING Check the following parameters by means of the instruments while travelling: 1.

The battery warning lamp (1) must be off.

2.

Alarm warning lamps (2) must be off.

3.

Engine coolant temperature (3) in normal working conditions must be in the specified range 80 to 100 °C.

!

WARNING

!

If the pressure is lower than the minimum level (the alarm warning lamp is on), stop the vehicle, stop the engine and investigate the causes.

4.

The automatic transmission oil temperature (4) in normal working conditions must be in the specified range: 80 to 100 °C.

!

WARNING

!

If the temperature is excessively high, select manual mode and engage a lower gear to prevent torque converter slipping. If this is not sufficient, stop the vehicle and investigate the causes.

3-38

269NU.A33

80

SECTION 3 - OPERATING INSTRUCTIONS Do not drain the fuel tank as this will cause the formation of air bubbles in the hoses and deposits of impurities which can reach the injection system from the bottom of the tank.

Never travel with the transmission in Neutral.

Select automatic mode.

Use the transmission in manual mode to prevent driving for long stretches with the torque converter working. If this happens, select a lower gear. Extended use of the torque converter will increase fuel consumption and oil temperature.

Do not exceed maximum engine speed, especially downhill.

Use the auxiliary integrated brake when driving long distances downhill to slow the vehicle down using the brakes less and, consequently, reducing brake overheating.

USING THE AUTOMATIC TRANSMISSION AUTOMATIC/MANUAL OPERATION The automatic transmission modes are shown on the display 1.

Engaged/selected gear, specifically: N = Neutral F1>>>6 = Forward 1st gear >>> 6th gear R1>>>3 = Reverse 1st gear >>> 3rd gear LF>>>LR = Limp home function activated

2.

Mode POWER = POWER program ECO = ECO program

3.

Lock-up Off = engaged (converter locked) On = released (converter turning)

4.

269NU3B4

81

Mode A = Automatic M = Manual

3-39

SECTION 3 - OPERATING INSTRUCTIONS The transmission is switched to automatic mode when the engine is started.

Press the button and shift the lever to engage a gear: Forward/reverse (holds AUTOMATIC mode).

269NU3B5

82 Side (switches to MANUAL mode).

After the first operate, the system will switch from AUTOMATIC on top of the control to MANUAL and vice versa each time the button is pressed.

To switch from AUTOMATIC to MANUAL mode: - Press the button or - Tip the lever to the side.

To switch from MANUAL to AUTOMATIC mode: - Press the button.

Select automatic mode in normal vehicle conditions.

Select manual mode: - In particularly difficult conditions, such as steep hills or slippery terrain.

- To avoid continuous gear shifts (“gear hunting”).

3-40

269NU3B6

83

SECTION 3 - OPERATING INSTRUCTIONS FORWARD/REVERSE SELECTION The gearshift lever has three positions.

Position N (Neutral) is used for: - starting/stopping the engine; - vehicle stationary and engine running.

Position F (Forward) is used for: - forward movement of the vehicle.

Position R (Reverse) is used for: - reverse movement of the vehicle.

!

WARNING

!

269NU3B3

84

Stop the vehicle completely before selecting reverse from a forward gear or vice versa.

NOTE: It is not possible to shift from position N to position F or R if the parking brake is applied.

NOTE: An external audible warning device will sound when Reverse is selected.

NOTE: When Reverse is selected, the transmission automatically switches to manual mode.

AUTOMATIC MODE GEAR SELECTION The automatic transmission control system selects the most suitable gear in relation to engine speed and load.

The system governs automatic torque converter lock-up clutch engagement according to engine speed and load.

The two operating modes of the control system can be set on the display: ECO PROGRAM with shift points that maximize fuel saving.

POWER PROGRAM with shift points that provide top performance.

Starting from a standstill will take place automatically in second gear.

NOTE: The automatic transmission may keep shifting down and up when travelling uphill ("gear hunting").

In this case, it is advisable to manually select the lower gear and reduce speed.

NOTE: .The control system tends to shift to higher gears to decrease engine load when travelling downhill. This decreases the engine braking effect and increases speed.

Switch to manual mode and select a gear suitable to avoid increasing speed in this situation.

3-41

SECTION 3 - OPERATING INSTRUCTIONS MANUAL GEAR SELECTION Move the lever to the side to shift gear: a. Lever pushed left (towards the driver): selects a lower gear (shift down). b. Lever pushed rightwards (away from driver): selects a higher gear (shift up).

Each movement to the side will correspond to one gear shift.

Specifically, push the lever laterally: - In Forward position to select forward gears.

- In Reverse position to select reverse gears.

NOTE: Select an appropriate gear for starting off. The vehicle will start off in the last selected gear if the vehicle is stopped without shifting.

The optimal engine speed is in the range from 1300 to 1800 rpm.

Shift up when the engine speed reaches 2300 rpm.

Shift down if the engine speed drops until 1200 rpm and the lock-up is released (converter phase): the warning light will come on to indicate this condition.

!

WARNING

174NU31A

85

!

Prolonged running with engaged converter (lockup disengaged) results in automatic increased transmission oil temperature, which is shown by the gauge set on the dashboard.

A message will appear on the display when this occurs.

In this case, shift down to a lower gear to engage the lock-up clutch and travel in this manner until the oil temperature returns to normal.

NOTE: The control system will prevent gearshifts which are not compatible with the vehicle and engine speeds.

NOTE: The system will automatically apply the retarder if the engine speed reaches the maximum setting limit when travelling downhill.

3-42

269NU3C3

86

SECTION 3 - OPERATING INSTRUCTIONS USING THE INTEGRATED IRCM AUXILIARY BRAKE CONTROL The control has three positions Position 0: OFF Position 1: engine brake ON Position 2: engine brake + retarder ON. IMPORTANT: The integrated auxiliary brake in position 2 will automatically generate maximum braking effect by the engine and transmission by electronic control of the retarder.

Shift the lever to the required braking position to activate the braking device.

Move the lever back to position 0 to disconnect the braking device.

269NU264

87 The engine brake warning light (1) will light up with the control in position 1 and lifting off the accelerator.

The retarder warning light (2) will light up with the control in position 2 and lifting off the accelerator.

IMPORTANT: Press the accelerator pedal to deactivate the auxiliary integrated brake.

269NU3F2

88

!

WARNING

!

Use the integrated auxiliary brake to reduce vehicle speed when cornering or going downhill and to avoid using the service brakes overheating.

Continuous use of the retarder (position 2) will increase transmission oil temperature shown by the gauge.

To avoid oil overheating, disengage the retarder (position 2) for short periods.

269NU3C3

89

3-43

SECTION 3 - OPERATING INSTRUCTIONS USING THE DIFFERENTIAL LOCK The vehicle is equipped with transversal limited slip differentials on all axles.

These differentials are locked automatically according to the adherence of each wheel.

The vehicle is equipped with a rear longitudinal lock and central longitudinal lock in the automatic transmission. Both can be independently locked using the specific control switch.

See "Longitudinal differential lock control" in Section 2.

The respective warning light will come on when the lock is applied.

221NU76

90 To lock: - Stop the vehicle with the wheels straight.

- Don’t accelerate the engine.

- Press the switch to the required position and start moving again.

!

WARNING

!

Move the vehicle slightly if engagement is difficult.

IMPORTANT: The locks will not be applied if the vehicle speed exceeds 3 km/h.

221NU77

91 With locked inserted central lock engaged it is possible to engage only the first two gears.

To disengage the lock: - Stop the vehicle with the wheels straight.

- Press the switch to the position (0) and start off again.

!

WARNING

!

Only use the longitudinal drive line locks when needed and disengage it as soon as conditions improve.

Engage the locks BEFORE facing slippery terrain.

Do not engage the locks if one wheel is slipping, to prevent damaging the mechanism: stop the vehicle before engaging the lock.

Do not steer the vehicle with the central differential lock engaged (except if stuck in mud or sand) to prevent causing severe damage to the transmission. Do not drive on terrain where traction is good with the rear differential lock engaged, to prevent causing severe damage to the transmission and to the tires.

3-44

221NU78

92

SECTION 3 - OPERATING INSTRUCTIONS WORKING WITH THE VEHICLE The typical working cycle of the vehicle, regardless of the type of job, can be divided into four phases: Loading, hauling, dumping and empty return.

LOADING The most common methods of loading are with hydraulic excavators and front end loaders.

The vehicle can be loaded equally well from the rear or the side. The truck driver must facilitate loading operations for maximum loading speed. The shorter the distance the loading unit has to travel, the more loading cycles it can make in a given period and the quicker the truck will be ready to move off.

Waiting vehicles should stay about two vehicle lengths behind the vehicle being loaded to avoid any spillage from the loading vehicle or truck.

HAULING When travelling on the haul road, keep to a safe speed for the haul road conditions and grades.

Adjust your speed to the load size you are hauling if road conditions are good. Braking distance is longer and steering reaction faster when the vehicle is fully loaded.

While travelling, consider that the front and rear end of the vehicle pivot both on the vertical and on the horizontal axis: this will reduce the driver’s perception of the behaviour of the rear end of the vehicle.

!

WARNING

!

The specific features of the chassis pivot and of the steering tend to cause oversteering when cornering at medium-to-high speed (i.e. the front of the vehicle tends to go straight).

This is particularly the case on slippery terrain and/or when the vehicle is fully loaded.

For some jobs, the loading vehicle may work more efficiently when trucks are positioned on both sides.

Thus, while one vehicle is being loaded, the other vehicle can move into position on the opposite side.

Since the vehicle is usually backed into the loading position with this method, the operator must be alert and careful while backing, especially when not assisted by flag man.

NOTE: The truck may roll over if abrupt steering movements are made at high speeds, especially at full load when the centre of gravity is high. Slow the truck down when approaching a turn.

Keep the vehicle braked by selecting Neutral or applying the supplementary parking brake during loading operations.

When approaching or encountering soft or slippery terrain, stop the machine and engage the longitudinal drive line locks in time to prevent getting stuck.

Where possible, the vehicle should be positioned downwind of the loader especially when dusty material is being loaded and/or on a windy day.

To lock: Stop the vehicle with the wheels straight.

Do not accelerate the engine.

Press the switch to the required position and start moving again.

A cleanup dozer or small loader is often used in conjunction with the main loader to keep the area clear of bucket spillage. The truck driver must always be alert to the position of these machines to prevent accidents and congestion.

The following precautions should be observed when approaching the loading area:

Turn the locks off as soon as the conditions return to normal.

Avoid rocks or other spillage which can damage the vehicle and particularly the tires.

- Avoid rocks and other spillage which can damage the vehicle or the tires.

Keep a safe distance from the vehicle ahead, particularly on slippery ground or in bad weather conditions.

- Allow the cleanup machine sufficient time to clear debris.

Observe the rules relating to braking distances and speed on the site.

- Do not approach the loading vehicle when the bucket is swinging overhead, to avoid being hit by falling material.

3-45

SECTION 3 - OPERATING INSTRUCTIONS Driving uphill Check the traction capacity according to load, gradient and road surface before driving up a steep hill.

Set automatic transmission POWER PROGRAM mode on the display.

The automatic transmission may keep shifting down and up when travelling uphill (“gear hunting”).

In this case, it is advisable to manually select the lower gear and reduce speed. Select the most suitable gear to avoid converter slipping.

Driving downhill IMPORTANT: The transmission control system tends to shift to higher gears to decrease engine load when travelling downhill. This decreases the engine braking effect and increases speed.

Switch to MANUAL mode and select a gear suitable to avoid speeding up in this situation.

As a general rule travelling downhill use the same gear selection when travelling uphill on the same road.

Never coast downhill in NEUTRAL even for short distances.

Never exceed (2300 rpm).

the

maximum

engine

speed

Use the auxiliary engine and transmission brake to slow the vehicle down.

If the speed tends to increase, also with the auxiliary brakes applied, press the brake pedal to slow the vehicle down to reach an engine speed suitable for shifting the transmission to a lower gear then release the brakes.

Do not apply the brake pedal continuously for long periods to avoid overheating.

Driving on planed terrain and poor grip If in doubt about the conditions of the planed route, walk on it to determine whether it is okay to use and not get stuck.

When approaching or encountering soft or slippery conditions, stop the machine and engage the longitudinal drive line locks in time to prevent getting stuck.

Remove the locks as soon as grip conditions improve.

Avoid travelling in deep ruts if possible.

Choose a slightly different course each time if there is enough room to do so to avoid making deep ruts.

3-46

SECTION 3 - OPERATING INSTRUCTIONS How to avoid getting stuck in mud or sand The following actions can be taken to avoid the risk of getting stuck in mud or sand.

1.

Reduce the load size (lighter)

2.

Zig-zag Select Forward position and accelerate without making the wheels slip.

Steer fully to the right and to the left. Proceed until the vehicle nearly stops, then steer rapidly in the opposite direction and so on.

269NU471

93 The vehicle should get unstuck following three or four manoeuvres of this kind. Otherwise attempt the following manoeuvres.

3.

Drive forwards and backwards Engage all differential locks when the vehicle is stationary.

Select Forward and accelerate.

Brake, select Reverse and accelerate.

Brake, select Forward and accelerate.

Repeat until the vehicle gets unstuck.

If you are unsuccessful rescue the vehicle. See “Rescuing and towing the machine”.

269NU472

94 DUMPING The dumping operation usually depends on the type of material being hauled.

Prior to dumping, be aware of overhead wires. If electrical wires are contacted, remain in cab to prevent electrocution.

Spoil and waste material is either dumped or piled up in reverse.

In this case, the operation should be supervised and directed by flag man on the ground.

3-47

SECTION 3 - OPERATING INSTRUCTIONS While backing to dump, the vehicle driver must watch the person on the ground and obey his instructions while remaining seated.

When dumping into a hopper, avoid hitting into the protective rail with the tires or scraping them against the guides.

When dumping material over a spoil bank, the driver must know how close the vehicle can approach the edge under all weather conditions.

Before dumping, make sure that the wheels are well supported by compact, flat ground.

Never dump on unstable ground.

EMPTY RETURN The precautions illustrated for hauling a load apply to an unloaded vehicle also.

Specifically, the fact that the vehicle is lighter does not authorise you to handle it carelessly. Maintain a speed to avoid sudden manoeuvres.

Set automatic transmission ECO PROGRAM mode on the display.

3-48

SECTION 3 - OPERATING INSTRUCTIONS TIPPING THE BODY IMPORTANT: The four operating modes of the control system can be set on the display: - AUTOMATIC LEVER for operating by tipping the lever without needing to hold it in position.

- MANUAL LEVER for operating by tipping the lever and holding it in the desired position.

- AUTOMATIC ENGINE for automatically increasing engine speed during the operation.

- MANUAL ENGINE for accelerating manually during the operation.

Standard tipping Carry out the dumping operation preferably in the following conditions (recommended but not mandatory): - Vehicle stationary, on level ground; - Gearshift lever in Neutral position; - Parking brake applied.

1.

Place the dumper control in position (1).

2.

Wait for the cylinders to extend completely.

IMPORTANT: Either move (AUTOMATIC LEVER) or release (MANUAL LEVER) the control to stop the operation in progress.

The respective warning light on the dashboard will come on.

Slow travel speed is allowed during tipping operation.

Only 1st and 2nd Forward gear and 1st Reverse gear can be selected.

After dumping proceed as follows: 1.

Place the control in position (2).

2.

Wait for the body to return to the chassis

IMPORTANT: Either move (AUTOMATIC LEVER) or release (MANUAL LEVER) the control to stop the operation in progress.

The warning light on the dashboard will go out when the body has reached the chassis.

!

WARNING

269NU293A

95

!

Travel only with the dumper down, fully resting on the chassis.

3-49

SECTION 3 - OPERATING INSTRUCTIONS Quick tipping The vehicle is equipped with a supplementary parking brake for use during dumping operations only.

Carry out the dumping operation in the following conditions (mandatory): - Vehicle stationary, on level ground; IMPORTANT: Do not move the vehicle while tipping the body up.

1.

Press the side button.

IMPORTANT: The system will automatically select Neutral and the rear parking brakes will be applied.

2.

Release the brake pedal.

269NU273

96 3.

Place the dumper control in position (1).

4.

Wait for the cylinders to extend completely.

IMPORTANT: Either move (AUTOMATIC LEVER) or release (MANUAL LEVER) the control to stop the body movement.

The respective warning light on the dashboard will come on.

After dumping proceed as follows: 1.

Place the control in position (2).

2.

Wait for the operation to end and release the control.

IMPORTANT: Either tip (AUTOMATIC LEVER) or release (MANUAL LEVER) the control to stop the operation in progress.

The warning light on the dashboard will go out when the operation is finished.

3-50

269NU293A

97

SECTION 3 - OPERATING INSTRUCTIONS Press the side button again to hold the previous gear/ mode selection or Select neutral and then the required gear/mode.

IMPORTANT: The system will automatically release the rear parking brakes.

!

WARNING

!

Travel only with the dumper down, fully resting on the chassis.

269NU273

98

3-51

SECTION 3 - OPERATING INSTRUCTIONS EMERGENCY STOPPING The vehicle can be stopped in one of the following ways if braking efficiency using the brake pedal is low or missing: 1.

Apply the auxiliary integrated brake by selecting position 2.

269NU264

99 2.

Move the transmission lever left to shift down.

IMPORTANT: The control system will prevent gearshifts which are not compatible with the vehicle and engine speeds.

269NU434

100 3.

Apply the parking brake.

!

WARNING

!

Apply the parking brake carefully especially when the vehicle is loaded to avoid locking the rear wheels and causing damage to the drive line components.

269NU433

101

3-52

SECTION 3 - OPERATING INSTRUCTIONS EMERGENCY STEERING The emergency steering pump will automatically engage, if there is a pressure drop in the steering circuit. This will not take place if the vehicle is stationary.

!

WARNING

!

A buzzer will sound if the emergency steering pump starts operating.

3-53

SECTION 3 - OPERATING INSTRUCTIONS REPLACING A COMPLETE WHEEL

!

WARNING

!

The wheel replacement operation requires the utmost care. The operation must be carried out by at least two people using a hoist or a crane to handle the wheel.

!

WARNING

!

ALWAYS MAKE SURE that the wheel being replaced is completely flat before proceeding.

!

WARNING

!

Exploding tires and/or rim parts can cause injury or death. Keep yourself and others out of the DANGER AREA. Stand on the tread side of the tire. Always use the correct air pressure and follow the instructions in this manual for adding air or servicing the tires

!

WARNING

!

Explosive separation of the tire and/or rim parts can cause injury or death. When tire service is necessary, have a qualified tire mechanic service the tire.

!

WARNING

!

DO NOT weld to wheel or rim when a tire is installed. Welding will cause an explosive air/gas mixture that will be ignited with high temperatures.

This can happen to tires inflated or deflated.

Removing air or breaking bead is not adequate.

Tire MUST be completely removed from the rim prior to welding.

3-54

SECTION 3 - OPERATING INSTRUCTIONS REMOVAL 1.

If possible, stop the unloaded vehicle in a flat area, stop the engine and apply the parking brake.

2.

Remove the cap and the valve stem to make sure that the wheel to be replaced is completely deflated.

269NM2A1

102 3.

Loosen the fastening nuts on the wheel to be removed without removing the nuts.

!

WARNING

!

ALWAYS lock the articulation in the safety position before lifting the vehicle.

4.

Raise the vehicle to lift the wheel from the ground. Then place suitable safety blocks under the axle.

!

WARNING

!

269NU492

103

The vehicle can be lifted by a gantry crane or using suitable steel cables positioned not to damage any of the components or tubes while lifting.

5.

Fasten the wheel to a crane or other lifting device and place a workshop jack under the wheel.

6.

Fully remove the fastening nuts.

7.

Then remove the wheel being careful not to damage the wheel studs. Position it safely on the workshop jack and remove it.

174NU62

104 3-55

SECTION 3 - OPERATING INSTRUCTIONS FITTING Clean the wheel stud and nut threads. Clean the rim and hub resting surfaces.

Fit the new wheel, bringing it up to the wheel studs with a workshop jack and lifting it with a crane. Be careful not to damage the stud threads.

Tighten the nuts slightly until the wheel is correctly positioned on the hub.

Inflate the tire to a pressure of approximately 1.5 bar.

See "Tires and wheels" in Section 5.

174NU63A

105 Lower the vehicle and tighten the nuts to the specified torque using the sequence shown.

Inflate to the specified pressure. See "Tires and wheels" in Section 5.

269NU4A1

106

3-56

SECTION 3 - OPERATING INSTRUCTIONS IN THE EVENT OF OVERTURNING Make sure that the personnel trained to use the vehicle know where the emergency exits are and the location of the special glass breaking tool.

The following emergency exits can be used to abandon the vehicle: - door (open); - front right window (smash).

269NS073

107 Use the special tool, located at the bottom of the window to break the specially treated glass.

IMPORTANT: Check that the hammer for breaking the specially treated glass is always kept in the cab.

174NS08

108

3-57

SECTION 3 - OPERATING INSTRUCTIONS CLIMATE CONTROL SYSTEM OPERATION MANUAL CLIMATE CONTROL A. Only heater Start engine.

Regulate fan speed with knob (4).

Regulate temperature as desired with knob (1).

B. Only air conditioner Start engine.

Regulate fan speed with knob (4).

NOTE: The air conditioner will not come on if knob (4) is in the off position.

Regulate the temperature as desired with knob (3).

C. Heater and air conditioner Start engine.

Regulate fan speed with knob (4).

NOTE: The air conditioner will not come on if knob (4) is in the off position.

Regulate the temperature as desired with knob (1) (warm air) and knob (3) (cold air).

D. Recirculation enable Press button (2).

269NU2D2

109 AUTO MODE 1.

Start the engine.

2.

Set the required temperature (1). The set value will appear on the display.

NOTE: The value will change by 1 °C each time the button is pressed.

The message LO will appear if the temperature is set to less than 18 °C. The message HI will appear if the temperature is set to more than 30°C. NOTE: The display will blink if an excessively low temperature is set without switching the A/C system on.

3-58

269NU2F1

110

SECTION 3 - OPERATING INSTRUCTIONS 3.

Press the A/C on button (1) the respective warning light will come on.

NOTE: The system will provide all automatic functions, except for cooling to less than the outside air temperature, if the A/C system is not switched on.

269NU2F2

111 4.

Press the AUTO button (1) the respective warning light will come on.

The climate control system will keep the required temperature and set the correct fan speed.

NOTE: The system will provide all automatic functions except for the fan if the fan speed is set manually.

269NU2F3

112 Press the button (1) to switch the recirculation function on if the outside air is heavily polluted (dust, fumes): the respective warning light will come on.

IMPORTANT: It is advisable not to keep the system in recirculation position for a long time. It will make the air stale in the cab.

The system will automatically let fresh air into the cab at predetermined times.

The recirculation function will be switched on automatically when the ambient temperature is warmer than 27°C. To switch the system off: Set fan speed to zero.

269NU2F4

113

3-59

SECTION 3 - OPERATING INSTRUCTIONS MANUAL MODE 1.

Start the engine.

2.

Switch AUTO function off where applicable: the respective warning light will go out.

3.

Set the required temperature (1). The set value will appear on the display.

NOTE: The display will blink if an excessively low temperature is set without switching the A/C system on.

269NU2F1

114 4.

Switch the A/C system on (1) if required.

NOTE: The A/C system can be switched to dry air in the cab in the event of high humidity at temperatures no lower than 4-5 °C also while the system is warming up.

269NU2F2

115 5.

Set the required fan speed (1).

6.

Switch on recirculation, if required.

269NU303

116

3-60

SECTION 3 - OPERATING INSTRUCTIONS OUTSIDE TEMPERATURE READING Press the temperature reading button (1). The temperature will appear on the display for a few seconds.

NOTE: The display will blink regularly when the outside temperature approaches zero to warn of the possible formation of ice.

269NU304

117 GENERAL INSTRUCTIONS To get the greatest degree of efficiency and safe operation from the system the practical rules given below should be followed: 1.

Make sure the windows are closed to maximize A/C system efficacy.

2.

When starting after the vehicle has been standing in the sun, set to maximum cooling and open all the windows for a few minutes to cool the cab.

3.

Avoid directing the flow of cold air towards the occupants by adjusting the air outlets.

4.

Any leakage of water from under the vehicle is due to normal drainage of condensation produced by the treated air dehumidifier.

3-61

SECTION 3 - OPERATING INSTRUCTIONS CONTROL SYSTEM AIR VENTS

1

4 4 2

2

3

269NU2E1

118 1 Central vents directing air to windscreen.

2 Adjustable front vent directing air to driver.

3 Lower vents directing air to feet.

4 Side vents directing air to driver.

The air vents allow the circulation and direction of air to be controlled. The air vents are opened and controlled manually.

IMPORTANT: The air vents must always be open when the air conditioning is in use.

IMPORTANT: Air from all vents is conditioned.

3-62

SECTION 3 - OPERATING INSTRUCTIONS OVERTURNING ACCIDENTS PREVENTION Always check the limits for height and width during all stages of loading/unloading, and make sure they are within the prescribed limits.

Keep the wheels perpendicular to the slope when driving up or down a gradient.

Do not make a U-turn on a gradient, to prevent turning over.

Respect the transverse gradient permitted for the loaded and unloaded vehicle.

Do not turn at high speeds on flat ground.

156NS19

119 Respect the values for maximum slopes when unloaded and loaded. See section 8.

156NS20

120

3-63

SECTION 3 - OPERATING INSTRUCTIONS RESCUING THE VEHICLE The vehicle can be rescued using steel rope and/or chains suitable for this purpose.

Use the attaching points provided for this purpose: - Front hitching points.

269NU493

121 - Rear hitching points.

The rescue procedure is used to tow or load the vehicle onto a semi trailer.

!

WARNING

!

The rescue operation must be done with extreme caution: it must be carried out by very skilled personnel using of safety precautions.

269NU494

122

TOWING THE VEHICLE Use the specific hitches provided for this purpose to tow the vehicle: - Front hitching points.

269NU493

123 3-64

SECTION 3 - OPERATING INSTRUCTIONS - Rear hitching points.

269NU494

124 Always use a suitably fastened rigid towing bar.

Never use straps, cables or chains.

!

WARNING

!

Maximum speed of the vehicles: 5 km/h.

The towing vehicle must have: 1.

A total weight comparable to that of the vehicle being towed.

2.

Traction power sufficient to tow the vehicle up any hills along the way.

3.

156NS24

125

Braking power sufficient to slow or stop the vehicles on hills along the way.

If possible, the engine should be kept running to lubricate the transmission correctly and to ensure hydraulically assisted steering and braking.

Select Neutral position.

If the engine will not start, proceed as follows to avoid turning the transmission: - Disconnect the propeller shaft (1) from the intermediate axle and fasten it temporarily to the chassis.

- Disconnect both front drive shafts (2) from the hubs and temporarily fasten them to the chassis (contact your Dealer for more information).

269NU495

126

3-65

SECTION 3 - OPERATING INSTRUCTIONS RELEASING PARKING BRAKE CALLIPERS If compressed air is not available to release the parking brake applied, the vehicle will be braked automatically by the spring accumulator cylinder. The brake must be released to tow the vehicle by a mechanical release tool. Use the screw provided for this purpose.

1.

Check the wheels to prevent machine movement.

269NU4D2

127 2.

Engage the screw and turn it by 90° to lock it in the slot.

269NU4D3

128 3.

Turn the nut clockwise to release the brake pads.

!

WARNING

!

After installation of the parking brake emergency release device, the vehicle must only be towed the vehicle must not be operated with the brake release tool installed.

Before using the vehicle move the parking brake release tool.

269NU4D4

129

3-66

SECTION 3 - OPERATING INSTRUCTIONS TRANSPORTING THE VEHICLE Preparatory operations are required to prepare the vehicle for transport. These depend on the vehicle outfit and typology.

The following procedures are in common for all vehicles AFTER they are loaded onto the transporter.

1.

Select Neutral and apply the parking brake.

2.

Close all windows.

3.

Close the door and all access doors.

4.

Remove battery power by operating the battery disconnect switch.

5.

Lock the articulation safety joint.

Then tie down the vehicle to the trailer transport using the attaching points provided.

!

WARNING

!

Contact the person in charge of the transport for information on tie down requirements.

269NU4E1

130

3-67

SECTION 3 - OPERATING INSTRUCTIONS

NOTES

3-68

SECTION 4

62

SERVICING INTERVALS/LUBRICATION/FLUIDS SERVICING INSTRUCTIONS 1.

2.

Operators are authorized to carry out the following operations while respecting general precautions: - Checking levels and adding fluids, if required; - Checking tire pressure and correcting, if required.

- Air cleaner replacement.

- Grease application.

Read this chapter carefully before carrying out maintenance operation, repair operations, refuelling or carrying out any other operation on the vehicle.

3.

Never allow unauthorized personnel to repair the vehicle, replace vehicle parts or carry out maintenance operations.

4.

Keep the work area clean and dry.

5.

Do not smoke operations.

6.

Wear all the required personal protection devices before starting maintenance operations.

7.

Carry out all maintenance operation with care.

8.

Use portable lamps when the lighting is not adequate and to illuminate working areas which cannot easily be accessed otherwise.

9.

Use a ladder or platform with steps that comply with safety regulations to carry out repairs and maintenance operations in areas which cannot be reached from the ground.

during

the

maintenance

10. All checking, bleeding, adding of fluids, maintenance and replacement operations must be carried out with the vehicle stationary, on level ground, in a well lit and ventilated area. Apply the parking brake, install chocks under the wheels and remove the key from the starter switch.

11. Keep hands and clothes away from moving parts when carrying out operations with the engine running.

15. Do not run the engine in enclosed areas without a suitable ventilation system for evacuating the harmful gas in the air.

16. Avoid prolonged, repeated contact between fuel, lubricant and fluids and the skin, to prevent problems and other syndromes.

17. Be very careful before removing caps or covers from reservoirs, radiators or cylinders: turn the part slowly to discharge any residual pressure.

18. Do not loosen the radiator cap when the engine is hot.

19. Let the coolant cool down before removing the cap. In any event, remove the cap very carefully.

Loosen the cap slowly to release the pressure and remove it.

20. Discharge pressure from circuits before carrying out any operations.

21. Never use your hands or other body parts to detect leakage of pressurized fluid.

22. Pressurized fluid leakage can penetrate the skin and the eyes, causing very severe injuries.

23. If hydraulic fluid penetrates the skin, call a doctor immediately. Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin and can cause serious injury and possibly death if proper medical treatment by a physician familiar with this type of injury is not received immediately. Keep body and hands away from pin holes or nozzles which eject hydraulic fluid under high pressure and use paper or cardboard and NOT HANDS to search for leaks.

24. Do not work over or under a vehicle propped up on jacks or other lifting devices which are not suitable to ensure safety.

25. Unload the vehicle before jacking it up. Only use the lifting points shown.

12. Do not put your head or other parts of your body (feet, hands) near shafts or turning parts when the engine is running.

26. Make sure that the lifting device is suitable to carry out the operations and meet safety requirements.

13. Fully deflate the tire before carrying out any type of operation on tires or rims.

27. After jacking up the vehicle, block it up firmly before carrying out any operations underneath.

14. Warn people who are near the vehicle before starting the engine (e.g. for a test).

4-1

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 28. Never tamper with valves, regulators or other devices, unless specified in the Operator’s Manual, to prevent damage to vehicle components and hazards for people.

29. Wear safety glasses with side guards and a mask when using compressed air to clean filters, to prevent injury caused by particles of dust or debris. You are advised to carry out the cleaning operations in a ventilated area.

30. Batteries contain sulphuric acid: always wear gloves and safety glasses when approaching batteries. Do not expose the battery to sparks or flames.

31. Check all fluid levels with the vehicle on level ground, the wheels straight and the parking brake applied.

32. Wait a few minutes for the level to stabilize before checking.

33. Observe scrupulous cleanness of oil and fluid containers when refilling.

34. Use the same oil and fluid type specified for the assemblies when adding more.

35. Never change the injection pump calibration, to prevent damaging the engine and the transmission.

!

WARNING

!

Properly dispose of replaced material (brake pads, filters, etc.;) and fluids resulting from maintenance operations and repairs (material soaked in fuel, oil, powder, etc.) according to the laws and local regulations.

Collect and dispose of used lubricants and fluids, according to the local regulation.

Collect and dispose of used batteries according to the local regulation.

Drain and recharge the air-conditioning system using the specified devices, according to the local regulation.

4-2

IMPORTANT: Scheduled service intervals are based on normal working conditions. The intervals may change in relation to use, road conditions and environmental conditions. Vehicles used in high ambient temperatures or in extremely dusty conditions will require more frequent maintenance. Contact your Dealer if in doubt or in the event of failures which cannot be solved by applying normal maintenance procedures.

!

WARNING

!

Carry out maintenance interventions when the indication appears on the display or at the specified frequency, as applicable.

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS

This page is intentionally left blank

4-3

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS LOCATION OF MAIN COMPONENTS USED FOR MAINTENANCE

269NM063A3

1 1.

Engine oil dipstick

10. Engine coolant reservoir

2.

Engine oil filler

11. Automatic transmission oil dipstick-filler

3.

Engine oil drainage cap

12. Automatic transmission oil drain cap

4.

Engine oil filter (2)

13. Automatic transmission oil filter (2)

5.

Accessory belt (2)

14. Front differential

6.

VGT circuit air filter

15. Front hubs

7.

Fuel pre-filter

16. Intermediate axle

8.

Fuel filter

17. Rear axle

9.

Engine air filter (main and secondary)

4-4

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS

269NM064A3

2 18. Front suspensions (2)

27. Steering-tipping circuit pressurized circuit

19. Compressed air dryer filter

28. Hood/cab tipper system reservoir

20. Brake cooling circuit fluid reservoir

29. Automatic grease dispenser reservoir

21. Hydraulic system oil reservoir

30. Climate control compressor

22. Brake cooling circuit mesh filter

31. Climate control air filter

23. Steering-tipping circuit mesh filter

32. Propeller shaft mount

24. Braking circuit mesh filter

33. Windscreen washer fluid reservoir (2)

25. Brake cooling circuit pressurized filter

34. Batteries

26. Brake circuit pressurized filter

35. Fuel tank

4-5

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS PRELIMINARY OPERATIONS VEHICLE CONDITIONING Prepare the vehicle as follows before starting scheduled or extra maintenance operations.

1.

Wash the outside of the vehicle.

2.

Store the vehicle in a sheltered place. The floor must be flat, clean and aligned.

3.

Ensure adequate lighting.

4.

Position chocks in front of and behind the front or rear wheels.

5.

Attach a “DO NOT OPERATE” tag on the steering wheel.

6.

Procure the necessary equipment and tools are available.

7.

Procure suitable containers.

8.

Procure the specified consumable materials.

!

spare

WARNING

parts

and

!

Make sure the vehicle is operating correctly after maintenance or repairs are complete.

ELECTRICAL POWER CUT-OFF Battery disconnect switch Make sure that the electrical power is disconnected before working directly or indirectly on electrical system parts by operating the battery disconnect switch. See "Precautions" in Section 6.

4-6

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS ARTICULATION SAFETY LOCK IMPORTANT: Always lock the articulation in safety position unless otherwise specified.

1.

Align the vehicle (front and rear chassis) and remove the pin (1).

2.

Turn the tie-rod forwards (2).

3.

Insert the pin in the slot on the front chassis (3) and install the retaining pin.

269NS111

3

4-7

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS RAISED DUMPER SAFETY LOCK IMPORTANT: Always lock the raised body for servicing operations. Ensure that the dumper body is empty prior to raising the dumper body and installing the safety lock.

1.

Place the transmission in park position, apply the parking brake and turn off the engine.

2.

Fully raise the dumper and remove the pin (1).

3.

Turn the tie-rod forwards (2).

4.

Insert the pin in the slot on the rear chassis (3) and install the retaining pin.

269NS121

4

4-8

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS MANUAL TIPPING ENGINE HOOD 1.

Open the left side access door.

2.

Take the lever from the tool kit; use one end of the lever to turn the pawl clockwise (1).

269NM091

5 3.

Press the button to activate hood tip.

269NU073

6 4.

Place the lever (1) in the pump actuator (2), then work the lever up and down to completely tip the hood.

Proceed as follows to close the hood.

1.

Use one end of the lever to turn the pawl counter clockwise (2).

2.

Insert the lever in the pump actuator then operate it up and down to close the hood completely.

3.

Remove the lever and close the side access door.

4.

Return the lever to the tool box.

269NM093

7

4-9

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS Proceed as follows in the event of a failure to the hydraulic release system: 1.

Open the left side access door.

2.

Pull the emergency release handle to open the hood latch.

3.

Proceed as shown above to tip the hood.

269NM094

8 ELECTRO-HYDRAULIC TIPPING ENGINE HOOD IMPORTANT: This operation is NOT POSSIBLE if the system is not electrically powered.

1.

Open the left side access door.

2.

Take the lever from the tool box; use one end of the lever to turn the pawl clockwise (1).

269NM091

9 3.

Press the button until the hood is completely tipped open.

Proceed as follows to close the hood.

1.

Use one end of the lever to turn the pawl counter clockwise (2).

2.

Press the button until the hood is completely closed.

3.

Remove the lever and close the side access door.

269NU074

10

4-10

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS TIPPING THE CAB IMPORTANT: This operation is NOT POSSIBLE if the system is not electrically powered.

!

WARNING

!

Before tipping the cab: - Remove any loose objects from cab.

- Close the door.

- Open both mudguards.

- Tip the engine hood open.

!

WARNING

!

The cab will be tipped towards the left-hand side of the vehicle.

1.

Disconnect the exhaust pipe by loosening the clamp.

269NM0A1

11 2.

Disconnect the steering column from the steering box.

269NM0A6

12

4-11

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 3.

Remove the snap ring (1) of both pins (2) on the right-hand side.

!

WARNING

!

Contact your Dealer for more information on the tipping procedure.

269NM0A3

13 Manual tipping Proceed as follows to tip the cab.

1.

Check that the pawl is turned completely clockwise (1).

269NM091

14 2.

Press the button to cab tip.

269NM0A7

15

4-12

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 3.

Insert the lever (1) in the pump actuator (2), then work the lever up and down to tip the cab completely.

Proceed as follows to close the cab.

1.

Use one end of the lever to turn the pawl counter clockwise (2).

2.

Insert the lever in the pump actuator and operate it up and down to close the cab completely.

269NM093

16 Electro-hydraulic tipping Proceed as follows to tip the cab.

1.

Check that the pawl is turned clockwise (1).

269NM091

17 2.

Press the button until the cab is completely tipped.

Proceed as follows to close the cab.

1.

Use one end of the lever to turn the pawl counter clockwise (2).

2.

Press the button until the cab is completely closed.

3.

Install the pins and secure them with the snap rings.

4.

Connect the steering column to the steering box.

5.

Connect the exhaust pipe and fasten it with the clamp.

269NM0A8

18

4-13

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS OPENING THE MUDGUARDS NOTE: Close the cab door before opening the left mudguard.

1.

Remove the mounting bolts (1).

2.

Remove the stop pin from its seat (2).

269NM0B1

19 3.

Turn the mudguard towards the rear of the vehicle.

269NM0B2

20

4-14

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 4.

Re-insert the stop pin into its hole and into the slot in the mudguard to keep the mudguard open.

!

WARNING

!

Be careful once the mudguard is open.

Do not operate the machine with the mudguard open.

5.

Reverse the operation to close the mudguard.

269NM0B3

21 OPENING/REMOVING LOWER GUARDS Proceed as follows to open the guards: 1.

Support the guard.

2.

Remove both mounting bolts and lower the guard slowly until it is completely open.

To close the cover proceed as above in reverse order.

IMPORTANT: Do not move the vehicle with the guards open to prevent damage.

Proceed as follows to remove the guards: 1.

Open the guard.

2.

Remove both mounting bolts and the guard on the opposite side and remove it.

269NM0C1

22

To close the guards proceed as above in reverse order.

IMPORTANT: Do not move the vehicle without the guards to prevent damage.

269NM0C2

23

4-15

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS SCHEDULED MAINTENANCE PROGRAM IN HOURS

Check engine oil level (5)

X

Check engine coolant level (5)

X

Check tyre pressure / wear / conditions (5)

X

Check accessory / climate control system belts (5)

X

Check lights and warning lights (5)

X

Check windshield wiper (5)

X

Check windshield washer level (5)

X

Check brake cooling circuit fluid level (5)

X

Check hydraulic fluid level (5)

X

Check automatic transmission oil level

X

Fuel pre-filter water drain

X

Check front suspension element height

X

Check engine coolant connections

X

Check efficiency of parking brake

X

Check efficiency of emergency steering pump control

X

Clean conditioner condenser

X

Check accessory / climate control system belt tension

X

Check front hub oil level

X

Check axle oil level

X

Clean engine oil breather

X

Battery maintenance (unsealed batteries)

X

Check oil dryer function / visual inspection of reservoirs

X

Bleed fuel tank condensation water

X

Check hood / cab tipper oil level

X

Check intake system tightness

X

Automatic transmission TCU AEB procedure

X

Check accumulator pressure

X

Clean brake cooling circuit mesh filter

X

Clean hydraulic system circuit mesh filters (2 filters)

Year

4000 hours

2000 hours

1000 hours

500 hours

100 hours

SERVICE POINTS

10 hours

Checking, adjusting and cleaning operations

X

Clean the radiator/intercooler surface

X

Check heat exchanger tightness

X

Check antifreeze concentration

X

4-16

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS

Fill automatic grease dispenser

Year

3000 hours

2000 hours

1000 hours

500 hours

250 hours

SERVICE POINTS

100 hours

Lubrication and replacement operations

X

Replace fuel pre-filter

X

Change engine oil

X

Replace engine oil filter

X

Replace fuel filter

X

Replace climate control system air cleaner (*)

X

X

Replace air cleaner main element

X

Change automatic transmission oil (3)

X

Replace automatic transmission oil filter (3)

X

Change differential and front hub oil (4)

X

Change intermediate and rear axle oil (4)

X

Replace compressed air dryer filter (*)

X

Change brake cooling circuit fluid

X

Replace brake cooling circuit filter (1)

X

Recharge climate control system (*)

X

X

Change engine coolant (**)

X

Change hydraulic system oil

X

Replace hydraulic system filter (2 filters) (1)

X

Change front suspension oil / gas

X

Replace secondary air cleaner filter element (2)

X

Replace accessory belts (all)

X

NOTE: The table indicates the time interval between two consecutive operations.

The frequency shown in the table refer to all operations checked using on board vehicle diagnostic systems.

(1) (2) (3) (4) (5)

Or when indication appears on display.

Or every three main filter replacements.

First change/replacement when unit is new or serviced after 100 hours.

First change/replacement when unit is new or serviced after 200 hours.

Every 10 hours of operation or once each day, whichever comes first.

(*) yearly for periods of use less than envisaged interval (**) every two years for periods of use less than envisaged interval

4-17

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS LUBRICATION AND SCHEDULED REPLACEMENT CHART

269DT0F5

24

4-18

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS LUBRICATION AND SCHEDULED REPLACEMENT CHART KEY 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

Engine oil Engine oil filter Fuel pre-filter Fuel filter Main air/secondary air cleaner (1) (*) Turbo VGT air filter Engine coolant (**) Not used Automatic transmission oil (2) Automatic transmission oil filter (2) Front differential/hub/axle oil (3) Accumulator pressure check Hydraulic system oil Hydraulic system mesh filters (2 filters) Hydraulic/steering/tipping system fluid filter Hydraulic/braking system fluid filter Automatic grease lubricant Centralized front/fear grease lubricant Brake cooling circuit fluid Climate control system fluid (recharge) Climate control system dehumidifier Tire pressure / wheel tightening check Brake cooling circuit fluid filter Brake cooling circuit mesh filter cleaning Compressed air dryer filter (*)

NOTE: Service frequency is expressed in hours.

(1) Or every three main filter replacements (2) First change/replacement when unit is new or serviced after 100 hours (3) First change/replacement when unit is new or serviced after 200 hours (*) yearly for periods of use less than 1000 hours interval (**) every two years for periods of use less than 2000 hours interval

4-19

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS DAILY OPERATIONS IMPORTANT: Check the levels with the vehicle on level ground.

CHECKING ENGINE OIL LEVEL 1.

Open the right-hand access door.

2.

With the engine off and cold, remove the oil dipstick and check the level. The oil level must be between the references on the dipstick. Install the dipstick.

IMPORTANT: If the engine is warm, stop the engine and wait for ten minutes for the oil to drain back into the sump.

!

WARNING

!

Do not use the vehicle if the oil level is either under or over the limits.

Lack of lubricant or excessive lubricant can damage the engine.

3.

269NM103A

25

If required, add extra oil using oil of the same type contained in the oil sump.

156NM11

26

4-20

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS CHECKING ENGINE COOLANT LEVEL 1.

Open the engine hood.

2.

With the engine off and cold, check that the fluid level is at the specified distance 60 mm below cap seat.

3.

Add extra coolant, if required, of the same type contained in the circuit.

269NM102

27 CHECKING AUTOMATIC TRANSMISSION OIL LEVEL

!

WARNING

!

This procedure is applicable when the automatic transmission is cold only.

1.

Start the engine and idle it with the gearshift in Neutral position for approximately one minute.

2.

Clean the fill cap area, loosen the handle by two or three turns and remove the dipstick built into the fill cap. Check that the oil level in the transmission is not under the COLD “MIN” mark (minimum level).

3.

Fill if required, then insert the dipstick and tighten the grip.

4.

Check the oil level when the transmission oil is hot, soon after the engine is stopped.

269NM201

28

CHECKING HYDRAULIC FLUID LEVEL (a) Hydraulic system (b) Brake cooling circuit

!

WARNING

!

Check the level with the dump body in the down position.

1.

With the engine stopped, check that the level is between the maximum (arrow) and minimum marks in both reservoirs.

2.

Oil level must be above the lower sight glass or no higher then the bottom of the top sight glass.

3.

Add extra fluid if required, using fluid of the same type contained in the reservoir.

4.

Visually check the main hydraulic system components for any signs of leakage daily.

269NM111

29

4-21

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS PERFORM THE FOLLOWING CHECKS BEFORE USING THE VEHICLE: 1.

Fuel level in tank.

2.

Tire conditions and air pressure.

3.

Operation of lights and warning lamps on instrument panel.

4.

Service and parking brake operation.

5.

Windshield wipers.

6.

Operation of lights, headlights and rotating beacon (if equipped).

7.

Check for loose or missing fasteners.

8.

Check for fluid leaks.

!

WARNING

!

Visually inspect the vehicle, checking working conditions and for damage/problems which may cause damage to the vehicle or injury to operators.

4-22

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS ENGINE ENGINE OIL CHANGE

!

WARNING

!

Collect and dispose of used lubricants and fluids, according to local regulations.

1.

Stop the warm engine and wait for the coolant temperature to drop to 60°C.

2.

Open the engine hood up.

3.

Remove the lower guards.

4.

Have ready a container of a suitable capacity and remove the dipstick.

5.

Clean the plug area, loosen the drain plug and drain all the oil.

!

WARNING

!

Do not remove the rear cap: this will prevent complete drainage of the sump.

6.

Clean the heading, install the drain plug.

269NM123

30 7.

Clean the fill cap area and pour in the specific amount of lubricant through the filler.

8.

Close the fill cap and install the dipstick in the housing.

9.

Start the engine and warm it up. Stop the engine and wait for a few minutes.

269NM122

31

4-23

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 10. Remove the oil dipstick and check that the level is between the marks on the dipstick. Add extra oil, if required.

!

WARNING

!

Do not use the vehicle if the oil level is either under or over the limits.

Lack of lubricant or excessive lubricant can damage the engine.

156NM11

32 ENGINE OIL FILTERS REPLACEMENT

!

WARNING

!

Collect and dispose of used lubricants and fluids, according to local regulations.

!

WARNING

!

Replace the oil filters at the frequency specified. If the filters are obstructed, the bypass valve will permit lubrication of the engine, but the circulating lubricant will not be filtered.

1.

Stop the warm engine and wait for the coolant temperature to drop to 60°C.

2.

Open the engine hood.

3.

Loosen and remove the filtering cartridges using an oil filter wrench. Carefully clean the housing.

269NM131

33

4-24

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 4.

Fill the new cartridges with the specified lubricant and apply the same lubricant to the seals.

156NM25

34 5.

Install the new cartridges and tighten by hand until the seal comes into contact with the housing, then turn another 3/4 of a turn.

!

WARNING

!

Do not over tighten the cartridge. This could damage the seal.

6.

Start the engine for a few minutes and check for any signs of lubricant leakage.

7.

Check engine oil level and add extra oil, if required.

156NM42

35

ACCESSORY DRIVE BELTS The engine is equipped with one alternator drive belt (1) and one climate control compressor drive belt (2), tensioned by means of an adjustable device and that do not require adjustment.

238NM01

36

4-25

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS Check 1.

Open the engine hood.

2.

Remove the belt protective guard.

3.

When the engine off and cold, check that the belt is not frayed or cracked (small crosswise cracks are allowed).

4.

Manually press the longest stretch and check the tensioner is functioning properly.

5.

Reassemble the belt protective guard.

156NM15

37 Replacing the drive belts 1.

Open the engine hood.

2.

Remove the belt protective guard.

3.

With the engine switched off and cold, use a square wrench to turn the tensioner in direction indicated and loosen the belt.

Alternator drive belt (1).

Climate control compressor drive belt (2).

!

WARNING

!

Do not turn the tensioner in the wrong direction to prevent damaging the internal load spring.

4.

Remove the belt.

5.

Fit the new belt and release the tensioner.

238NM02

38

!

WARNING

!

Do not turn the belt on the pulley to make it fit in the groove. Do not use a tool (e.g. a screwdriver) as a lever, to prevent damaging the belt.

The belts must not touch the bottom of the grooves or rub against surrounding parts.

6.

Run the engine for ten minutes, stop it and wait for it to cool down. Then check belt tension.

7.

Reassemble the belt protective guard.

4-26

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS FUEL SUPPLY SYSTEM DRAINING FUEL FILTER (SEDIMENT) 1.

Open the left side access door.

2.

With the engine stopped, loosen the plug and drain the soiled fuel.

3.

Tighten the plug without forcing it when sediment free fuel flows out.

269NM161

39 DRAIN FUEL TANK CONDENSATION (WATER) 1.

Loosen the drain plug and let a little fuel out to drain the residues and water which normally form in the tank.

2.

Clean the drain plug. Check that the threading is in good condition and install it.

!

WARNING

!

Keep the fuel tank as full as possible.

Use fuels of the specified types. See “Fuel specifications” in section 3.

Do not use other than specified fuels. Use of other than specified fuels can cause engine damage.

269NM162

40

4-27

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS BLEEDING FUEL FEED CIRCUIT AIR

269NM173

41 1.

Open the engine hood.

2.

Attach suitable pipes to the indicated bleed screws and allow them to drain into a suitable recipient.

3.

Loosen the bleed valve (2) by a few turns.

Pre-filter 4.

Operate the fuel pump manual control (1) until the fuel runs out without air bubbles.

5.

Tighten the screw.

Filter 6.

Repeat the operation for screw (2).

Cylinder head bleed screw 7.

Remove the soundproofing cover.

8.

Repeat the operation for screw (3).

!

WARNING

!

Never spill fuel on the alternator belt with fuel to prevent damaging it.

4-28

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS FUEL FILTER REPLACEMENT The vehicle is equipped with: - Separator pre-filter cartridge mounted on the chassis at the side of the engine.

269NM181

42 - One filter cartridge unit mounted on the engine.

1.

Open the engine hood.

2.

With the engine switched off, loosen and remove the filter cartridge by means of an oil filter wrench and carefully clean the support and engine.

269NM182

43 3.

Fill the new cartridge with the specified fuel and apply the engine oil lubricant to the seal.

269NM183

44

4-29

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 4.

Install the new cartridge and tighten by hand until the seal comes into contact with the housing, then turn another 3/4 of a turn.

!

WARNING

!

Do not over tighten the cartridge. This could damage the seal.

5.

Bleed the air out of the filters. See “Bleeding fuel feed circuit air”.

6.

Run the engine for a few minutes and check for any signs of fuel leakage.

156NM42

45

4-30

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS AIR INTAKE SYSTEM CHECK INTAKE SYSTEM TIGHTNESS 1.

Open the engine hood.

2.

Check tightness of intake system seals and clamps.

3.

Eliminate any leakage in the sections between the air cleaner intake manifold and the turbocharger, to prevent the risk of taking foreign bodies into the turbocharger and the engine.

4.

Eliminate any leakage in the section between the turbocharger and the engine, to prevent engine damage.

269NM191

46 CHECKING TURBOCHARGER LUBRICATION 1.

Open the engine hood.

2.

Inspect the oil supply (1) and return pipes (2) to check for any signs of leaks or problems which could decrease the flow of lubricant.

!

WARNING

!

Considering the high operating speed of the turbocharger, any reduction in oil supply would cause turbo failures.

269NM193

47

Cleaning the outside of the intercooler Clean the outside of the radiator with compressed air to remove debris (leaves, insects).

If the debris will not blow off, brush the radiator surface with a solution of detergent and water, then use a pressure washer to remove the residual. Do not use pressure that will damage the cooling fins.

4-31

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS MAIN AIR FILTERING ELEMENT CLEANING/REPLACEMENT

!

WARNING

!

Clean the filtering element when the respective warning lamp comes on.

Do not clean the filtering element every day.

Follow the specified frequencies.

The main filtering element can be cleaned up to six times, then it must be replaced.

1.

Release the clips and remove the cover; empty and clean it carefully.

269NM1A1

48 2.

Remove the primary cartridge and clean using the most appropriate of the following methods.

269NM1A2

49 Clean by blowing compressed air at a maximum pressure of 3 bar, blowing air from the inside of the filtering element outwards.

!

WARNING

!

Keep the jet of air a few centimetres away from the element to prevent damaging it. Never clean the filtering element by knocking it on a hard surface.

If the filtering element is deformed in any way, replace it.

156NM52

50

4-32

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS Carry out the following checks before refitting the filtering element: Check conditions of O-rings and plastic tabs. Replace the filtering element, if required.

Check the condition of the filtering element by placing a source of light inside; light will filter from the smallest cracks, indicating that the filter must be replaced.

!

WARNING

!

Make sure the temperature of light source heat (e.g. a lamp bulb) does not exceed 60°C.

156NM53

51 Cleaning the rubber dust ejector Clean the rubber dust ejector, check its condition and replace it if required. It must be flexible and free of cracks.

269NM1B1

52

4-33

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS SECONDARY AIR FILTER ELEMENT REPLACEMENT

!

WARNING

!

The secondary element must not be cleaned. It must only be replaced.

Remove the element.

Insert the new element, then replace the main filtering element as shown.

269NM1B2

53 REPLACING THE VARIABLE GEOMETRY TURBINE AIR CONTROL PIPE FILTERING ELEMENT 1.

Open the engine hood.

2.

With the engine switched off, loosen and remove the filter cartridge by means of an oil filter wrench and carefully clean the support and engine.

3.

Install the new cartridge and tighten by hand until the seal comes into contact with the housing, then turn another 3/4 of a turn.

!

WARNING

!

Do not tighten the cartridge excessively. This could damage the seal.

269NM1B3

54

4-34

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS COOLING SYSTEM Change the engine coolant and clean the system.

!

WARNING

!

Collect and dispose of used lubricants and fluids, according to local regulations.

DRAINING 1.

With the engine stopped and cold, turn the heater control valve to maximum.

2.

Open the engine hood and remove the concerned guards.

3.

Open the fill cap on the reservoir.

269NM102

55 4.

Have a container of a suitable capacity ready and remove the line from the heat exchanger to the pump intake. Drain the coolant.

5.

Wait for all the coolant to drain out and reconnect the line. Tighten the clamp.

269NM103B

56

4-35

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS CLEANING 1.

Prepare a mixture of water and coolant system detergent. Pour the mixture slowly through the fill cap to reach the level and close the cap.

!

WARNING

!

Respect the proportions specified by the supplier.

Excessive concentration could damage the engine.

!

WARNING

!

Detergents do not contain antifreeze. Do not leave cleaning solution in the vehicle in cold temperatures, if the coolant circuit contains a mixture of these products.

2.

Start the engine and let it run for the recommended time (approx. one hour).

3.

Stop the engine and let it cool down. Drain the mixture as shown above.

4.

Fill the system with clean water. Run the engine until the thermostat fully opens.

5.

Stop the engine and let it cool. Drain the circuit as explained above. If the drained water is still very dirty, repeat the cleaning operation with detergent.

269NM102

57

FILLING 1.

Prepare a mixture of water and specific antifreeze proportion, see “Antifreeze concentration in engine coolant” in section 8. Pour the mixture slowly through the fill cap. Do not close the cap.

2.

Start the engine and leave it run at low idle. At the same time, monitor and add mixture until all the air has been eliminated from the system. Continue to monitor for at least 15 minutes;

3.

Close the fill cap.

4.

Run the engine at a 1500 - 1800 rpm until the thermostat has fully opened.

5.

Check for presence of foam or air bubbles in the reservoir.

6.

Stop the engine and let cool down. Check level and top up, if required.

!

WARNING

!

Check that the pressure check valve built into the cap is working. Replace the cap if necessary.

4-36

269NM102

58

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS ANTIFREEZE CONCENTRATION CHECK The minimum concentration of antifreeze depends on the ambient temperature where the vehicle is in use.

See “Antifreeze concentration in engine coolant” in section 8.

Check the concentration of antifreeze in engine coolant by using a refractometer.

Use the refractometer to check that the percentage of antifreeze in the engine coolant is within the specified range.

NOTE: Always respect the supplier’s mixing specifications if particular additives are used.

RADIATOR SURFACE CLEANING Clean the outside of the radiator with compressed air to remove accumulated debris (dirt, leaves, insects).

If air pressure will not remove the dirt, brush the radiator surface with a solution of detergent and water, then use a pressure washer to remove the residual dirt.

COOLANT-TRANSMISSION OIL HEAT EXCHANGER TIGHTNESS Visually check tightness of hose clamp at heat exchanger and all other coolant connections.

4-37

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS AUTOMATIC TRANSMISSION OIL LEVEL CHECK

!

WARNING

!

Correct oil level is essential for the correct operation of the transmission. Insufficient oil can cause irregular operation and damage the converter.

Excess oil can cause the formation of emulsion and overheat the transmission.

Cold check 15 - 45°C 1.

Start the engine and let it idle with the gearshift in Neutral position for approximately one minute.

Apply parking brake.

2.

Clean the fill/dipstick area, loosen the handle two or three turns and remove the dipstick built into the fill cap. Check that the oil level in the transmission is not below the COLD mark (minimum level).

269NM201

59 3.

Add extra oil, if required. Do not drain oil if level is too high, insert the dipstick by re-fastening the handle.

4.

Carry out a hot check as soon as possible.

Hot check 80 - 90°C 1.

Run the machine a certain distance to warm up the transmission.

2.

Let the engine idle with the gearshift in Neutral position. Apply parking brake.

3.

Clean the fill/dipstick area, loosen the handle two or three turns and remove the dipstick built into the fill cap. Check that the oil level in the transmission is not within the HOT range.

4.

Either add extra oil or drain the oil to reach the specified level and install the dipstick by re-fastening the handle.

4-38

269NM202

60

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 5.

Check that breather is clean and working.

269NM202A

61 TRANSMISSION OIL CHANGE

!

WARNING

!

Collect and dispose of used lubricants and fluids, according to local regulations.

!

WARNING

!

Replace filters when changing the oil.

1.

Remove the concerned guards.

2.

Have a container of a suitable capacity ready, clean the fill/dipstick area, loosen the handle two or three turns and remove the dipstick.

3.

Remove both drain plug and drain the oil.

4.

Clean the drain plug. Check that the threads are in good condition. Apply sealant to both plugs and tighten them to the specified torque.

5.

Remove transmission oil filter and replace with new filter. See "Transmission oil filters replacement".

6.

Pour in the specified amount of lubricant through the fill and insert the dipstick by re-fastening the handle.

7.

Check the level again after a test drive (see checking the transmission oil level).

269NM211

62

4-39

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS

!

WARNING

!

At the end of the oil change operations, carry out the self-learning procedure (AEB procedure) to ensure self-adaptation of solenoid valve control parameters by the TCU (Contact the dealership for additional information).

AEB PROCEDURE It is advisable to run the AEB internal control and selfcalibration procedure after changing the oil or if gear shifts become rough.

Respect the following conditions for running the AEB sequence correctly: - Gear lever in neutral position; - Engine idling; - Parking brake applied; - Automatic transmission at 80 - 90°C. Proceed as follows: - Called up AEB REQUEST mode on the display; - Press ENTER to enable; - Wait for the procedure to end on the display.

TRANSMISSION OIL FILTERS REPLACEMENT

!

WARNING

!

Replace filters when changing the oil.

1.

Open the engine hood.

2.

With the engine cold, loosen and remove the filter cartridges using the tool and carefully clean the housing and engine.

269NM212

63

4-40

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 3.

Fill the new cartridges with the specified lubricant and apply the same lubricant to seals.

156NM25

64 4.

Install the new cartridge and tighten the cartridge by hand until the seal comes in contact with the housing, then turn another 3/4 of a turn.

5.

Run the engine for a few minutes and check for any signs of leakage.

6.

Check transmission oil level and add extra oil, if required.

156NM42

65

4-41

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS DRIVE LINE SHAFT SUPPORT OIL LEVEL CHECK 1.

Clean the cap area, open the level cap (1) and the filler cap (2).

2.

Fill with the specified lubricant through the filler cap (2) until it flows out of the level cap hole (1).

3.

Clean both caps, replace the O-ring and close it.

OIL CHANGE

!

WARNING

!

Collect and dispose of used lubricants and fluids, according to local regulations.

269NM213

1.

Arrange a container of suitable capacity, clean the cap area, open the level cap (1) and the filler cap (2).

2.

Remove drain cap (1) and drain the oil.

3.

Clean the drain cap. Check that the threads are in good condition, replace the O-ring and close it.

66

269NM214

67 4.

Fill with the specified lubricant through the filler cap (2) until it flows out of the level cap hole (1).

5.

Clean both caps, replace the O-rings and close it.

6.

Run a road test, check the oil level (1).

7.

If required, top up oil of the specified type, repeat the road test and check the level again

269NM213

68

4-42

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS FRONT DIFFERENTIAL OIL LEVEL CHECK 1.

Clean the cap area and open the cap (1). Lubricant should drip out of the hole.

2.

If necessary, add oil as indicated in the next paragraph.

3.

Close the fill/level cap and tighten it to at the specified torque.

OIL CHANGE

!

WARNING

!

Collect and dispose of used lubricants and fluids, according to local regulations.

1.

Have a container of a suitable capacity ready, clean the plug areas and remove the plug (1).

2.

Remove the drain plug (2) and drain all the lubricant.

3.

Clean the plug (2), check that the threads are in good conditions. Replace the seal and apply sealant to the plug and tighten it to the specified torque.

4.

Fill with the specified lubricant until it overflows from the cap hole (1).

5.

Replace the seal and apply sealant to the plug (1) and tighten it to the specified torque.

6.

Run a road test, check the level (1). If required fill with the specified lubricant until it overflows from the cap hole (1). Repeat the road test and check the level.

269NM221

69

269NM221

70

4-43

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS FRONT AND REAR HUBS NOTE: The procedures described below refers to both front hubs.

OIL LEVEL CHECK 1.

Move the reference mark of a hub to the horizontal position.

2.

Clean the cap area and open the cap (1).

Lubricant should drip out of the hole.

3.

If necessary, add oil as indicated in the next paragraph.

4.

Close the level cap and tighten it to at the specified torque.

OIL CHANGE

!

WARNING

!

Collect and dispose of used lubricants and fluids, according to local regulations.

1.

Move the drain plug on one hub to the lowest position.

2.

Have a container of a suitable capacity ready, clean the plug areas, remove the level plug (2) and the drain plug (1) and drain all the lubricant.

269NM231

71

269NM234

72 3.

Move the reference mark of a hub to the horizontal position.

4.

Fill with the specified lubricant until it overflows from the cap hole (1).

5.

Replace the seal and apply sealant to the plug (1) and tighten it to the specified torque.

6.

Run a road test, check the level (1). If required fill with the specified lubricant until it overflows from the cap hole (2). Repeat the road test and check the level.

269NM235

73

4-44

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS REAR TANDEM AXLES OIL LEVEL CHECK NOTE: The procedures described below refer to both axles.

1.

Move the reference mark of a hub to the horizontal position.

2.

Clean the cap area and open the cap (1).

Lubricant should drip out of the hole.

3.

If necessary, add oil as indicated in the next paragraph.

4.

Close the level cap and tighten it to at the specified torque.

NOTE: All planetary hubs oil level must be checked.

Check the breather (arranged on the chassis on top of the breather tube). It must be clean and in working order.

269NM231

OIL CHANGE

74

!

WARNING

!

Collect and dispose of used lubricants and fluids, according to local regulations.

1.

Move the drain plug on one hub to the lowest position.

2.

Have a container of a suitable capacity ready, clean the plug areas, remove the level plug (1).

Drain the lubricant.

3.

Clean the plug (2), check that the threads are in good conditions. Replace the seal and apply sealant to the plug and tighten it to the specified torque.

269NM232

75

4-45

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 4.

Move the reference mark of a hub to the horizontal position.

5.

Fill with the specified lubricant until it overflows from the cap hole (1).

6.

Replace the seal and apply sealant to the plug (1) and tighten it to the specified torque.

7.

Run a road test, check the level (1). If required fill with the specified lubricant until it overflows from the cap hole (1). Repeat the road test and check the level.

8.

Repeat the procedure on the other hubs.

9.

Have a container of a suitable capacity ready, clean the plug areas, remove plugs (1) and (2) and drain all the lubricant.

269NM231

76

269NM252

77 10. Have a container of a suitable capacity ready, clean the plug areas, remove plugs (1) and (2) and drain all the lubricant.

11. Clean the plug (2), check that the threading is in good conditions. Replace the seal and apply sealant to the plug and tighten it to the specified torque.

269NM253

78

4-46

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 12. Fill with approximately 1.5 litres specified lubricant through the cap hole (1).

13. Replace the seal and apply sealant to the plug (1) and tighten it to the specified torque.

269NM262

79 14. Fill with specified lubricant until it overflows from the cap hole (1).

15. Replace the seal and apply sealant to the plug (1) and tighten it to the specified torque.

16. Run a road test, check the level (1). If required fill with the specified lubricant until it overflows from the cap hole (1). Repeat the road test and check the level.

269NM263

80 17. Have a container of a suitable capacity ready, clean the plug areas, remove plugs (1) and (2) and drain all the lubricant.

18. Clean the plug (2), check that the threading is in good conditions. Replace the seal and apply sealant to the plug and tighten it to the specified torque.

269NM254

81

4-47

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 19. Fill with specified lubricant until the fluid spills out of the hole in the cap hole (1).

20. Replace the seal and apply sealant to the plug (1) and tighten it to the specified torque.

269NM264

82 21. Run a road test, check the level (1). If required fill with the specified lubricant until it overflows from the cap hole (1). Repeat the road test and check the level.

269NM263

83

4-48

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS HYDRAULIC SYSTEM FITTING AND HOSE TIGHTNESS CHECK Visually check for system leaks and tightness of line connections.

!

WARNING

!

In the event of defects or leakage from any of the circuits, repairs must be carried out before using the vehicle.

HYDRAULIC OIL CHANGE

!

WARNING

!

Collect and dispose of used lubricants and fluids, according to local regulations.

1.

Wait for the fluid temperature to reach 40°C.

2.

Open the engine hood.

3.

Have a container of a suitable capacity ready, clean the fill plug and drain plug areas and remove the fill plug.

269NM301

84 4.

Remove the drain plug and drain the fluid.

5.

Clean the drain plugs. Check that the threads are in good conditions. Replace the drain plug and tighten them to the specified torque.

6.

Pour in the specified amount of fluid through the filler and close it.

269NM302

85

4-49

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS REPLACING THE PRESSURIZED BRAKE ACTUATOR FILTER IMPORTANT: Replace the filter when you change the hydraulic fluid.

1.

Open the engine hood.

2.

With the engine stopped, loosen and remove the filter cartridge with a hexagonal wrench and carefully clean the housing.

269NM311

86 3.

Check integrity of the seals (1) on the cartridge, replace if required.

4.

Replace the filter element by inserting in the cartridge.

5.

Check that the seal (2) is correctly positioned.

269NM312

87 6.

Fill the new cartridge with the specified fluid and apply the same fluid to the seals.

7.

Install the filter and tighten by hand until the seal comes into contact with the housing, then tighten another 3/4 of a turn.

!

WARNING

!

Do not fasten the cartridge excessively. This could damage the seal.

8.

Run the engine for a few minutes and check for leakage.

269NM183

88

4-50

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS Cleaning the suction filter IMPORTANT: Clean the filter when you change the hydraulic fluid when the reservoir is empty.

1.

Disconnect the hoses (1).

2.

Remove the flange (2) and remove the cartridge (3) from its housing.

3.

Clean the cartridge with detergent and insert it on the flange.

4.

Apply sealant and install the flange.

5.

Connect the hoses.

6.

Fill the reservoir.

7.

Check for leaks.

269NM313

89 REPLACING THE STEERING/TIPPING PRESSURIZED FILTER IMPORTANT: Replace the filter when you change the hydraulic fluid.

1.

Open the right mudguard.

2.

With the engine stopped, loosen and remove the filter cartridge housing with a hexagonal wrench and carefully clean the housing.

269NM321

90 3.

Check condition of the seals (1) on the cartridge, housing replace if required.

4.

Replace the filter element by inserting in the cartridge housing.

5.

Check that the seal (2) is correctly positioned.

269NM312

91

4-51

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 6.

Fill the new cartridge housing with the specified fluid and apply the same fluid to the seals.

7.

Install the filter and tighten by hand until the seal comes into contact with the housing, then tighten another 3/4 of a turn.

!

WARNING

!

Do not fasten the cartridge excessively. This could damage the seal.

8.

Run the engine for a few minutes and check for leakage.

269NM183

92 Cleaning the suction filter IMPORTANT: Clean the filter when you change the hydraulic fluid when the reservoir is empty.

1.

Disconnect the hose (1).

2.

Remove the flange (2) and remove the cartridge (3) from its housing.

3.

Clean the cartridge with detergent and insert it on the flange.

4.

Apply sealant and install the flange.

5.

Connect the hose.

6.

Fill the reservoir.

7.

Check for leaks.

269NM324

93

4-52

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS BRAKE COOLING CIRCUIT FITTING AND HOSE TIGHTNESS CHECK Visually check for the system leaks and tightness of respective lines.

!

WARNING

!

If there are faults or leaks in the circuit, repairs must be carried out before using the vehicle.

HYDRAULIC OIL CHANGE

!

WARNING

!

Collect and dispose of used lubricants and fluids, according to local regulations.

1.

Wait for the fluid temperature to reach 40°C.

2.

Open the engine hood.

3.

Have a container of a suitable capacity ready, clean the fill plug and drain plug areas and remove the fill plug.

269NM331

94 4.

Remove both drain plugs and drain the fluid.

269NM332

95

4-53

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 5.

Loosen and remove the filter cartridge with a hexagonal wrench to make the circuit draining operation easier.

269NM341

96 6.

Have a container of a suitable capacity ready, clean the drain cap areas on the brake units remove the caps and drain the fluid.

7.

Clean the drain caps and remove any metallic residues. Check that the threads are in good condition, replace the seal and install it.

8.

Add the specified amount of fluid through the fill and install it.

9.

Replace the pressurized filter as shown in the respective paragraph.

10. Close the engine hood.

269NM333

97

4-54

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS PRESSURIZED FILTER REPLACEMENT IMPORTANT: Replace the filter when you change the brake cooling fluid.

1.

With the engine stopped, loosen and remove the filter cartridge housing with a hexagonal wrench and carefully clean the housing.

269NM341

98 2.

Check condition of the seals (1) on the cartridge housing, replace if required.

3.

Replace the filter element by inserting in the cartridge.

4.

Check that the seal (2) is correctly positioned.

269NM312

99 5.

Fill the new cartridge with the specified fluid and apply the same fluid to the seals.

6.

Install the filter and tighten by hand until the seal comes into contact with the housing, then tighten another 3/4 of a turn.

!

WARNING

!

Do not fasten the cartridge excessively. This could damage the seal.

7.

Run the engine for a few minutes and check for leakage.

269NM183

100

4-55

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS Cleaning the internal suction filter IMPORTANT: Clean the filter when you change the brake cooling fluid when the reservoir is empty.

1.

Disconnect the hoses (1).

2.

Remove the flange (2) and remove the cartridge (3) from the flange.

3.

Clean the cartridge with detergent and insert it on the flange

4.

Apply sealant and install the flange.

5.

Connect the hoses.

6.

Fill the reservoir.

7.

Check for leaks.

269NM342

101

4-56

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS HOOD OPENING/CAB TIPPING SYSTEM OIL LEVEL CHECK 1.

Open the left side access door.

2.

Check that the oil level is as specified, when the hood is lowered, through the cap. Add extra oil, if required. cap-level distance: 10 mm - 15 mm.

3.

Close the cap and the access door.

FLUID CHANGE

!

WARNING

!

Collect and dispose of used lubricants and fluids, according to local regulations.

1.

Open the left side access door.

2.

Clean the fill cap area and remove it.

3.

Use a syringe and suitable extension to suck all the fluid from the reservoir.

4.

Fill with the specified amount of fluid and install the cap.

5.

Close the access door.

269NM3E1

102

GREASING CENTRALIZED GREASE DISPENSERS The vehicle is equipped with two centralized grease dispensers for the front and rear chassis components, respectively.

Use a manual grease dispenser only. Never use a high pressure grease dispenser.

1.

Clean the grease fitting.

2.

Inject grease of the specific type in the centralized front fitting.

269NM3F2

103

4-57

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 3.

Inject grease of the specific type in the centralised rear fitting.

!

WARNING

!

Inject lubricant until it is visible at the lubricated points to ensure efficient lubrication.

269NM3F3

104 4.

Check that grease dispensers are functional when applying grease.

269NM3F4

105 RESTORING GREASE DISPENSER FUNCTIONALITY Grease application will not work if one of the grease lines or greased point (joint) is obstructed.

Restore operation of the dispenser is very important in this case.

1.

Locate the obstructed grease point from which no grease is being let out.

5.

Inject pressurized lubricant in the fitting until it pours out of the grease point.

2.

Check that the grease point or tube are not damaged; replace if required.

6.

Reconnect the fitting to the point.

7.

3.

Locate the fitting on the point.

Apply grease and check that lubricant pours out of all grease points.

4.

Disconnect the located fitting from the point.

4-58

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS FRONT GREASE DISPENSER SYSTEM DISTRIBUTOR

269NM3F5

106 Circuit

Grease application point

Circuit

Grease application point

A1

Oscillation bearing

A7

Oscillation bearing

A2

Right suspension cylinder upper joint

A8

Left suspension cylinder lower joint

A3

Oscillation bearing

A9

Oscillation bearing

A4

Right suspension cylinder lower joint

A10

Reaction rod joint

A5

Oscillation bearing

A11

Oscillation bearing

A6

Left suspension cylinder upper joint

A12

Central fork joint

REAR GREASE DISPENSER SYSTEM DISTRIBUTOR

269NM3F6

107 Circuit

Grease application point

Circuit

Grease application point

B1

Rear suspension right rocker arm

B8

Left tip cylinder lower joint

B2

Rear suspension left rocker arm

B9

Right steering cylinder rear joint

B3

Right tip cylinder lower joint

B10

Left steering cylinder rear joint

B4

Left tip cylinder upper joint

B11

Right body pivot pin

B5

Upper articulation hinge

B12

Lower articulation hinge

B6

Left body pivot pin

B13

Right tip cylinder upper joint

B7

Right steering cylinder front joint

B14

Left steering cylinder front joint

4-59

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS AUTOMATIC GREASE DISPENSING SYSTEM Filling the reservoir The vehicle is equipped with a centralized grease dispensing system.

The system does not required specific maintenance.

1.

Clean the filler grease fitting (1).

2.

Connect the dispenser to the fitting and fill the reservoir to the “MAX” line.

3.

Disconnect the dispenser and clean the fitting.

NOTE: All drive shafts are equipped maintenance-free CV joints and sliding joints.

!

WARNING

with

!

Full functionality will be restore after approximately 10 minutes of operation following removal or emptying procedures.

269NM3F7

!

WARNING

108

!

Lubricant will flow out of the overflow valve (2) if the system is obstructed or clogged up.

Proceed as shown above to restore operation.

Adjusting the automatic grease dispensing system timer A lubrication cycle consists of a pause and a working cycle.

The pause determines the time between two lubrication dispensing operations: it decreases as the pause time decreases.

The working time determines the time of the dispensing phase: this increases as the working time increases.

The lubrication cycle is repeated constantly after starting the engine.

The times can be adjusted by means of two switches which can be reached after removing the cover:

269NM3F8

109 4-60

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS Pause time, BLUE switch (1).

Working time, RED switch (2).

The pause and working times according to the position of the respective switch is shown in the following table. Proceed as follows to control the lubrication cycle times: Remove the cover.

Turn the BLUE switch to the required position to adjust the time elapsing between two dispensing operations.

Turn the RED switch to the required position to adjust the duration of the dispensing operation (and consequently the amount of dispensed lubricant).

269NM3F9

110

Reposition the cover.

Factory set timing is: Pause 2 hours (BLUE switch position 2).

Working 12 minutes (RED switch position 6).

2

Switch position

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

Pause time (hours) BLUE switch

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Working time (minutes) RED switch

2

4

6

8

10

12

14

16

18

20

22

24

26

28

30

4-61

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS

NOTES

4-62

SECTION 5

14

MAINTENANCE/ADJUSTMENTS SUSPENSION

!

WARNING

!

The following operations must be carried out by suitably equipped, experienced personnel. Use the equipment specifically required to carry out suspension inflating operations.

NOTE: Carry out the following operations on both suspension cylinders in parallel.

FRONT SUSPENSION CYLINDER INFLATING DEVICE B. Inflating device C. Copper seal D. Copper seal E. Pressure gauge 0 - 50 bar F. Hose G. Transparent tube H. Hose I. Nitrogen cylinder fitting L. Hose fitting

269NM271

1 EQUIPMENT CONNECTION DIAGRAM a. Suspension cylinder b. Nitrogen supply cylinder B. Inflating device E. Pressure gauge 0 - 50 bar IN. Nitrogen into suspension knob (control) OUT. Nitrogen suspension breather knob (control) Contact your Dealer for more information.

269NM272

2

5-1

SECTION 5 - MAINTENANCE/ADJUSTMENTS SUSPENSION CYLINDER HEIGHT CHECK

!

WARNING

!

Carry out the check after parking the empty vehicle on flat ground for at least one hour.

1.

Check that position x shown in the figure is within the specified range for both elements.

Control position: 82 - 86 mm.

2.

Check inflation pressure as follows if the measurements are not correct.

269NM281

3 SUSPENSION CYLINDER PRESSURE CHECK

!

WARNING

!

Carry out the check after parking the empty vehicle on flat ground for at least one hour.

1.

Raise the vehicle wheels off the ground with suitable lifting devices to fully extend the suspension.

2.

Remove the protective cap on the cylinder.

269NM282

4

5-2

SECTION 5 - MAINTENANCE/ADJUSTMENTS 3.

Check that the inlet knob IN and the breather knob OUT on the inflation tool (B) are closed.

4.

Connect the inflation tool (Fig. 2, ref. B) to the quick coupling.

5.

Check that the pressure on the gauge (E) is in the specified range.

Suspension pressure = 35 bar.

6.

Otherwise inflate or deflate as shown below.

7.

Remove all the equipment and install the protective cap.

SUSPENSION ELEMENT INFLATION 1.

Open the nitrogen supply cylinder knob (b) and the inlet knob IN to let nitrogen into the suspension element (a).

2.

Let in nitrogen at a pressure of approximately 38 bar, then close the inlet knob IN and the cylinder knob.

3.

Adjust the suspension element pressure to the specific value by means of the breather knob OUT.

4.

Close the OUT breather, disconnect the inflation tool, remove all equipment and install the protective cap.

269NM272

5

SUSPENSION ELEMENT DEFLATION 1.

Release gas by means of the OUT breather valve knob to reach the required pressure.

2.

Close the OUT breather, disconnect the inflation tool, remove all equipment and install the protective cap.

5-3

SECTION 5 - MAINTENANCE/ADJUSTMENTS SUSPENSION FLUID ELEMENT CHANGE

!

WARNING

!

Collect and dispose of used lubricants and fluids, according to local regulations.

1.

Lift the front end of the vehicle with suitable lifting means to fully extend the suspension against the mechanical stops.

2.

Release ALL pressure from the suspension cylinders as shown above.

3.

Arrange a container of suitable capacity, remove the filler cap (1) and drain cap (2) and drain the fluid completely.

4.

Clean the drain cap. Check that the threads are in good condition. Replace the O-ring and close it.

5.

Pour 1.7 litres of the specified fluid through the filler cap.

6.

Close the filler cap and inflate the suspension as shown previously.

269NM283

6 7.

Check that position x is within the specific range after travelling a short distance.

Check position: 82 - 86 mm.

269NM281

7

5-4

SECTION 5 - MAINTENANCE/ADJUSTMENTS BRAKING CIRCUIT CHECKING PARKING BRAKE EFFICIENCY 1.

Position the vehicle on a flat surface that is wide enough to allow small movements.

2.

Switch the engine off turn switch to the ON position, move the selector lever to Neutral and engage the parking brake, the parking brake warning lamp should light up.

3.

With the engine off turn switch to the ON position, disengage the parking brake, the parking brake warning lamp should go out.

4.

Repeatedly engage and disengage the parking brake until the warning lamp remains lit when the control is disengaged.

5.

Start the engine and wait for the parking brake warning lamp to go out.

6.

Select manual, first gear forward, let the vehicle move forward very slowly, then engage the parking brake: the warning lamp should light up and the vehicle should stop immediately (the gearbox automatically goes into Neutral).

CHECKING PARKING BRAKE EFFICIENCY 1.

Switch the engine off turn switch to the ON position, move the selector lever to Neutral and engage the parking brake.

2.

Operate the parking brake five times. Check that no alarm warning lights come on.

269NU383

8

BRAKING CIRCUIT CHECKING EMERGENCY PUMP CONTROL EFFICIENCY 1.

Switch the engine off, move the selector lever to Neutral and engage the parking brake.

2.

Turn the ignition switch to position 1 (ON).

3.

Move the selector to the Forward position.

In this condition, the alarm warnings lights should come on and the message should appear on the display. A buzzer should start sounding (continuously)

5-5

SECTION 5 - MAINTENANCE/ADJUSTMENTS TIRES AND WHEELS

!

WARNING

!

Exploding tires and/or rim parts can cause injury or death. Keep yourself and others out of the DANGER AREA. Stand on the tread side of the tire. Always use the correct air pressure and follow the instructions in this manual for adding air or servicing the tires.

!

WARNING

!

Explosive separation of the tire and/or rim parts can cause injury or death. When tire service is necessary, have a qualified tire mechanic service the tire.

!

WARNING

!

DO NOT weld to wheel or rim when a tire is installed. Welding will cause an explosive air/gas mixture that will be ignited with high temperatures.

This can happen to tires inflated or deflated.

Removing air or breaking bead is not adequate.

Tire MUST be completely removed from the rim prior to welding.

5-6

SECTION 5 - MAINTENANCE/ADJUSTMENTS

B910410J

9 The above illustration show danger areas caused by exploding tires and/or rim parts. KEEP YOURSELF AND OTHERS OUT OF THESE DANGER AREAS.

The next page shows the correct methods that you MUST use when adding air or servicing a tire.

5-7

SECTION 5 - MAINTENANCE/ADJUSTMENTS ADDING AIR TO THE TIRES This procedure is only for adding air to the tire. If the tire has lost most or all of the air, do the following: 1.

Before you add air, have the wheel correctly installed on the machine or put the wheel in a restraining device (tire inflation cage).

2.

Use an air hose with remote shutoff valve and a self-locking air chuck.

3.

Stand BEHIND the tread of the tire and make sure ALL persons are away from the side of the tire before you start to add air.

4.

Inflate the tire to the recommended air pressure.

DO NOT inflate the tire more than the recommended pressure given on the following page.

B790490R

10 TIRE OR RIM SERVICE Always have a qualified tire mechanic service the tires and rims for this machine. It is recommended that you have the mechanic inflate the tires. To prevent accidents, use a restraining device (tire inflation cage), correct equipment and correct procedure. Explosive separation of the tire (single piece rim) or the tire and/ or rim parts (multi-piece rim) can cause serious injury or death.

5-8

SECTION 5 - MAINTENANCE/ADJUSTMENTS TIRE AND WHEEL CHECK 1.

Remove the protective cap and connect the inflation device fitting to the valve.

2.

Check that the tire inflation pressure is within the specified range.

3.

Restore pressure if required as shown below.

4.

Disconnect the fitting and install the protective cap.

NOTE: Check pressure and inflate the tires when cold.

5.

Check the condition of the rims.

6.

Check that all bolts are tightened to the specified torque.

7.

Check tire wear.

8.

Check tires for cuts or other damage; check the tires do not touch the vehicle.

269NM2A1

11

TIRE INFLATION 1.

Remove the protective cap and connect the inflation device fitting to the valve.

2.

Adjust specified pressure.

3.

Disconnect the fitting and install the protective cap.

269NM2A1

12

5-9

SECTION 5 - MAINTENANCE/ADJUSTMENTS AIR CONDITIONING SYSTEM CONDENSER CLEANING 1.

Open the engine hood.

2.

Inspect and clean the condenser with compressed air, maximum 5 bar, then close the engine hood.

NOTE: The system is equipped with a maintenancefree dryer filter integrated in the condenser.

CAB AIR FILTER CLEANING/REPLACEMENT 1.

Release and remove the rubber stops from the left side cover.

269NM401

13 2.

Remove the filter.

3.

Replace the filter or clean in with compressed air, maximum 5 bar. Install and fasten the screws.

4.

Fasten the side cover with the hooks.

IMPORTANT: The filter must be mounted with the arrows pointing towards the passenger compartment.

If there is no mark, mark one to facilitate reassembly.

269NM402

14

5-10

SECTION 5 - MAINTENANCE/ADJUSTMENTS SYSTEM CHECKING AND RECHARGING Check the system charge once a year or when reduced cooling is noticed (see your Dealer).

!

WARNING

!

The checking and recharging operations must be carried out by experienced personnel.

R134a (tetrafluoroethane) coolant is used. This coolant is classified as an environmentally-friendly product.

For reasons of incompatibility between compressor oil and fluid, do not use R12 in systems designed to use R134a.

!

WARNING

!

Do not discharge R134a into the atmosphere.

Although the product has a zero ozone depletion potential it has a global warming potential.

Recovery and recycling procedures are governed by local and regional laws.

Always use type-approved coolant recovery and recharging devices.

Do not mix different coolants in the same device.

269NM411

15 1.

High pressure circuit valve.

2.

Low pressure circuit valve.

3.

System inspection and charging device.

5-11

SECTION 5 - MAINTENANCE/ADJUSTMENTS COMPRESSED AIR SYSTEM VISUAL INSPECTION OF THE TANK 1.

Open the engine hood.

2.

Visually check the external conditions of the reservoirs.

!

WARNING

!

Under no circumstances should any form of heat treatment or welding be carried out on the outside of the tank.

If the reservoir is dented or cracked, have it replaced.

The tank is only designed for use with compressed air systems.

AIR DRYER FUNCTIONALITY CHECK 1.

Open the engine hood.

2.

Operate the bleeding valve on both reservoirs to check correct operation of the air dryer.

The air should come out of the tank with no traces of condensation/moisture.

As soon as a small amount of moisture is noticed, increase of inspections at shorter intervals to check whether the moisture is due to temporary overloading of the dryer or whether its efficiency is permanently impaired.

The condensation should disappear as soon as the granulate is operating again.

If this is not so, replace the cartridge.

5-12

269NM3D1

16

SECTION 5 - MAINTENANCE/ADJUSTMENTS DRYER FILTER REPLACEMENT 1.

Open the engine hood.

2.

Remove the triangular cover by loosening the mounting screws.

269NM3D2

17 3.

Remove the filter cartridge by loosening it by hand.

4.

Tighten the new cartridge by hand until the seal comes into contact with the housing, then turn by another 3/4th of a turn.

!

WARNING

!

Do not fasten the cartridge excessively. This could damage the seal.

5.

Install the triangular cover.

269NM3D3

18

BODYWORK FRONT WINDSHIELD WIPER BLADE REPLACEMENT 1.

Lift the arm and blade.

2.

Loosen the screws mounting the blade and remove it.

3.

Fit the new blade and install the screws.

174NM40

19

5-13

SECTION 5 - MAINTENANCE/ADJUSTMENTS SIDE WINDSHIELD WIPER BLADE REPLACEMENT 1.

Lift the arm and blade.

2.

Push the blade backwards, disengage it from the stop and remove it.

3.

Fit the correct adapter on the new blade and bring the blade up to the clip to fasten it in the adapter.

4.

Pull the blade to fasten the adapter clip.

174NM41

20 WINDSHIELD WASHER FLUID RESERVOIR 1.

Open the engine hood.

2.

Check whether the fluid level in the reservoir is adequate.

3.

If required, fill with a mixture of water and detergent in the specified proportions.

IMPORTANT: When the ambient temperature decreases to 0 °C (32 °F) and below, always use an antifreeze type washer solution.

4.

Install the cap and close the hood.

269NM423

NOTE: Follow the detergent recommended by the supplier.

proportions

CLEANING Wash the vehicle regularly with mild products and water to eliminate any traces of corrosive agents (salt, sand, etc.).

Dry carefully with compressed air to avoid any accumulations.

Do not use products containing aromatic solvents, methanol or hydrocarbons for cleaning paint work.

Do not use a pressure washer or steam to clean the inside of the cab.

Alternatively, use specific products, carefully observing the instructions provided by the manufacturer.

When cleaning plastic parts do not use gasoline, kerosene, paint solvents, etc. Use soap and water and a clean cloth only.

The use of gasoline, paraffin, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

Ensure good ventilation in the cab until the products have dried. Never use chloride solvents (trichlorethylene, hyperchloride, etc.).

Wash seat belts with warm water and mild soap.

Rinse and let dry in the shade. Never use strong detergents, bleach or dies. Avoid any chemical substance which could weaken the fibers.

5-14

21

SECTION 6

16

ELECTRICAL SYSTEM PRECAUTIONS Make sure that the electrical power is disconnected before working directly or indirectly on electrical system parts by turning off the battery master switch.

BATTERY MASTER SWITCH 1.

Open right side access door.

269NS0F5

1 or 1.

Get into the cab.

269NS0F2

2 2.

Press the button (1) to power the electrical utilities, the upper part of the switch will illuminate (green icon).

3.

Press the button (2) to disconnect electrical power, the lower part of the switch will illuminate (red icon).

269NS0F6

3

6-1

SECTION 6 - ELECTRICAL SYSTEM To disconnect electrical power: 1.

Stop the engine.

2.

Wait for approximately 10 seconds before disconnecting the electrical power.

IMPORTANT: The EDC engine control unit must run a number of diagnostic procedures which require electrical power for a few seconds after stopping the engine. Consequently, you must wait for approximately 10 seconds after stopping the engine to disconnect electrical power.

EMERGENCY SWITCH

!

WARNING

!

The emergency switch disconnects electrical power to all utilities, none excluded.

This can cause considerable functional problems to the engine control system. For this reason, the switch must only be used when absolutely necessary.

IMPORTANT: The engine cannot be started again after tripping the switch 5 consecutive times. Contact your Dealer to have the function restored.

1.

Open right side access door.

269NS103

4 2.

Raise the protective cover and push the switch.

Observe the following rules of good practice to prevent damaging beyond repair the electronic control unit fitted in the vehicle: 1.

Disconnect the battery master switch before carrying out arc welding operations on the chassis. Remove the control unit to weld near the control unit.

2.

After a service operation requiring battery disconnection, make sure that the terminals are well connected.

269NS102

5 6-2

SECTION 6 - ELECTRICAL SYSTEM 3.

Do not use a battery charger to start the engine.

4.

Disconnect the batteries to recharge them.

5.

Do not disconnect the control unit connectors when the engine is running or the control units are under power.

6.

Do not disconnect the batteries when the engine is running.

!

WARNING

!

The vehicle electrical system should work even if the battery is dead.

7.

when electrical arc welding on the chassis is required, disconnect the positive and negative battery wires, short-circuit them and disconnect all ground wires.

8.

Remove the control unit to weld near the device.

!

WARNING

!

Contact your Dealer for more information on arc welding procedures.

9.

Remove the transmission control unit in the event of operations at temperatures exceeding 80°C (oven painting, etc.).

6-3

SECTION 6 - ELECTRICAL SYSTEM BATTERY MAINTENANCE (NOT SEALED) IMPORTANT: Sealed batteries (maintenance free) do not require addition of water in normal working conditions and mild climates. The electrolyte should be checked approximately once a year in tropical climates.

1.

Tip the engine hood up. Remove the battery compartment cover.

2.

Carefully clean the batteries, the cables and the case, removing corrosion rust and dirt, which can cause voltage drops.

269NM541

6 3.

Check through the caps that the distance between the electrolyte and the upper edge of the plate of each element is as specified: Level-plate distance 8 - 15 mm.

4.

If required, top off with distilled water when the batteries are cold and at rest, through the fill holes.

5.

Check the battery charge with a hydrometer or battery load tester.

Temperature ambient air

Electrolyte density (100% of charge)

°C

g/dm3

40

1.265

20

1.285

0

1.300

-20

1.365

!

WARNING

!

The presence of some electrical devices which must always be electrically powered causes a slight current consumption, also when the battery disconnect switch is off.

It may be difficult to start the engine after a long stop (one month or longer) due to partial discharging of the batteries. To avoid this problem, start and warm the engine up (possibly by travelling a short distance) once a month.

6-4

269NM452

7

SECTION 6 - ELECTRICAL SYSTEM RECHARGING BATTERY WITH EXTERNAL DEVICES Batteries should normally be removed from the vehicle to be recharged.

If this is not possible, the batteries can also be recharged using an external source (battery charger) connected directly to the battery terminals.

NOTE: The vehicle is equipped with a 24 volt electrical system with negative (-) ground. Disconnect the batteries from the vehicle’s electrical system.

1.

Lay the cables on the ground ensuring that the terminals do not touch metal parts or each other.

Connect the red cable (A) to the POSITIVE (+) terminal of the dead battery.

2.

Connect the black cable (B) to the NEGATIVE (-) terminal of the dead battery.

3.

Set the recharge time. Start recharging.

!

WARNING

!

Respect the instructions provided by the battery charger supplier. Respect the sequence of operations. DO NOT reverse the polarity when making the connection.

174NM44

8

6-5

SECTION 6 - ELECTRICAL SYSTEM INTERCONNECTION CONTROL UNIT FUSE AND RELAY BOX The fuses protecting electrical system devices and the relays are arranged in a specific compartment in the lower part of the cab.

NOTE: Seek the cause of the failure in the electrical system if a fuse blows repeatedly. Never install a fuse that has a higher Amperage rating than the original.

269DT0F1

9 6-6

SECTION 6 - ELECTRICAL SYSTEM RELAYS

269DT0F2

10 Code

Type

Description

E1

-

-

E2

N

Headlight circuit relay

E3

F

Utility cut-off during cranking relay

E4

N

Flasher relay

E5

-

-

E6

N

Brake light relay

E7

-

-

E8

-

-

E9

X

Windscreen wiper flick

E10

N

Dipped-beam/main-beam headlight relay

E11

N

Work light relay

E12

N

Horn relay

E13

-

-

E14A

-

-

E14B

-

-

E13

-

-

6-7

SECTION 6 - ELECTRICAL SYSTEM DUMP RELAYS

269DT0F2

11 Code

Type

E17

H

Transmission in neutral for cranking relay (K1)

E18

H

Reverse relay (K2)

E19

-

-

E21

H

Camera relay

E22

H

Climate control relay

E23

H

Automatic grease dispenser relay

E24

H

Battery disconnect relay

E25

H

Left side window wiper relay

E26

H

Right side window wiper relay

E27

H

Side window washer pump relay

E28

H

Fuel heater

E29

-

-

E30

-

-

E31

-

-

E32

-

-

E33

-

-

E34

-

-

E35

-

-

E36

-

-

E37

H

Engine brake relay

E38

H

Brake pedal relay

E39

H

Engine limiting relay

6-8

Description

SECTION 6 - ELECTRICAL SYSTEM DUMP RELAYS, RESISTORS AND DIODES

269DT0F2

12 Code

Type

Description

D1

G

Off-vehicle ignition diodes

D2

G

Battery disconnect master switch diodes

D3

-

-

D4

-

-

D5

-

-

D6

-

-

R1

R

Engine control

R2

R

Engine brake

GA

L

Ignition switch powered utilities

GB

-

-

GC

L

Main relay

GD

L

Hood/cab tipping

GE

L

Start-up

FUSE BOX COMPONENT WIRING DIAGRAM

269DT0F6

13 Type: (F) - 50A relay

Type: (N) - 20 A NO relay

Type: (G) - Diode block

Type: (R) - Resistors

Type: (H) - 10/20 A exchange micro relay

Type: (X) - Windscreen wiper flick

Type: (L) - 40 A NO relay 6-9

SECTION 6 - ELECTRICAL SYSTEM FUSE OVERVIEW

269DT0F3

14 Fuse Rating No.

Circuit

Fuse Rating No.

Circuit

1

7.5 A Clearance light, dashboard light

13

3A

Shut-off solenoid valve

2

7.5 A Clearance lights, warning light

14

5A

Dashboard power

3

3A

Main beam switch, dipped beam switch-off with main beam switch-on

15

7.5 A Windscreen wiper-washer

16

10 A

4

5A

LH dipped, beam headlights

17

7.5 A Reverse, camera stand-by

5

5A

RH dipped, beam headlight

18

7.5 A Brake lights

5A

LH main-beam headlight, warning light

19

7.5 A Air dryer

6 7

7.5 A RH main-beam headlight

8

20 A

Front work lights

9

10 A

Heated electro-pneumatic seat

10

-

11

10 A

Horns

12

5A

Heated motorised mirror, main beam circuit, relay E28

6-10

-

Grease dispensing device

20

3A

Ceiling lights

21

10 A

Climate control compressor

22

5A

Blinkers

23

20 A

Fuel heater

24

15 A

Climate control fan

SECTION 6 - ELECTRICAL SYSTEM DUMP FUSES

1

2

3

269DT0F4

15 Colour code

(1) WHITE

(2) BLACK

(3) RED

Fuse No.

Rating

31

5A

Utility/engine warning light power from main relay

32

20 A

Engine ECU power from main relay

33

5A

Power +30 - 30 pin diagnostic socket

34

5A

Power +15 - ECU engine

35

5A

Power +15 - alternator/engine brake switch/retarder switch

36

25 A

Hood/cab tipping pump

41

7.5 A

LH side windscreen wiper

42

7.5 A

RH side windscreen wiper - washer

43

15 A

12V power socket - 12V cigar lighter

44

20 A

24-12 V voltage reducer

45

10 A

Transmission ECU power (+15) - relay E17/E21

46

7.5 A

Transmission ECU power (+30 memory)

51

3A

HEAD power

52

10 A

I/O HEAD power

53

3A

MIDAC_1, MIDAC_2, MIDAC_3

54

7.5 A

I/O MIDAC_1 power

55

10A

I/O MIDAC_2 power

56

7.5 A

I/O MIDAC_3 power

Circuit

6-11

SECTION 6 - ELECTRICAL SYSTEM LIGHTING SYSTEM LIST OF BULBS Function

Power (w)

Type

Quantity

5

BA15s

2

55/70

H4

2

Tipping main beam

70

H1

2

Cab ceiling light

5

-

1

Cab map reading light

5

-

1

Front direction indicator

21

BA15s

2

Side direction indicator

21

BA15s

2

Working lights

5

BA15s

4

Marker

5

BA15s

2

Direction

21

BA15s

2

Brake lights

21

BA15s

2

Reversing light

21

BA15s

1

Front Marker Dipped beam/main beam

Rear

6-12

SECTION 6 - ELECTRICAL SYSTEM HEADLIGHT BULB REPLACEMENT Headlights: High-beam headlights, headlights, front position light.

low-beam

1.

Tip the engine hood.

2.

Loosen the mounting screw (1) and turn the complete light cluster outwards.

269NM471

16 3.

Remove the affected protective cover: (1) Dipped-beam headlight/marker lights (2) Main-beam headlights

4.

Disconnect the concerned electrical connection.

5.

Release the bulb holder clip and remove the halogen bulb or remove the position light bulb.

6.

Replace by following the above procedure in reverse.

IMPORTANT: Do not touch a halogen bulb with your fingers. This could effect correct operation.

DIRECTION INDICATOR BULB REPLACEMENT

269NM472

17 1.

Loosen the hitching screw (1) and turn the complete light cluster outwards.

269NM471

18

6-13

SECTION 6 - ELECTRICAL SYSTEM 2.

Loosen the hitching ring.

3.

Remove the direction indicator bulb.

4.

Replace by following the above procedure in reverse.

269NM473

19 REAR WARNING LIGHT BULB REPLACEMENT Rear marker lights, brake lights, turn indicators.

1.

Remove the protective grid by loosening the mounting screws.

2.

Remove the lens and replace the position light bulb (1), the direction indicator light bulb (2), the brake light bulb (3).

3.

Replace by following the above procedure in reverse.

269NM481

20 REVERSE LIGHT BULB REPLACEMENT 1.

Remove the lens by loosening the fastening screws and replace the bulb.

2.

Replace by following the above procedure in reverse.

269NM482

21

6-14

SECTION 6 - ELECTRICAL SYSTEM WORK HEADLIGHT BULB REPLACEMENT 1.

Remove the complete light cluster by loosening the mounting screws and disconnecting the electrical connector.

2.

Remove the cover.

3.

Release the clip and remove the bulb.

4.

Replace by following the above procedure in reverse.

!

WARNING

!

174NM61

Do not touch a halogen bulb with your fingers.

This could effect its operation.

22

REPLACING THE MAP READING LIGHT/DOME LIGHT BULB 1.

Using a screwdriver, extract the transparent cover (1) off and replace the bulb.

2.

Unscrew the map light (2) and replace the bulb.

3.

Refit by reversing the removal sequence.

269NM484

23 DIRECTING THE HEADLIGHTS The headlights must be redirected after complete removal of headlights. You are advised to use appropriate equipment to carry out this operation.

In any case, adequately correct setting can be obtained as follows: 1.

Position the unladen vehicle, with tires inflated at the specified pressure, on flat ground in front of a light colored wall.

2.

Draw two crosses on the wall corresponding to the center points of each headlight.

6-15

SECTION 6 - ELECTRICAL SYSTEM 3.

Back the vehicle 10 m and switch on the lowbeams. The distance between the crosses and the reference points P-P should be 10% of the height between the middle of the crosses and the ground (tolerance 1%).

174NM48

24 4.

Turn the adjustment screws, if required: (1) vertical adjustment (2) horizontal adjustment

269NM491

25

6-16

SECTION 7

2

STORAGE STORING THE VEHICLE The following service operations are required in the event of long storage (parking for longer than three months) to protect functionality of units and vehicle operation.

Disregarding these operations may necessitate overhauling when the vehicle returns to use.

CLEANING Wash the vehicle to remove mud and dirt. Remove stones which may be jammed between the tires or the suspension units and remove deposits from the containers and cab floor.

Wash the external parts with a pressure washer and detergent. Be careful not to direct the jet directly onto the most exposed parts of the electrical system.

Do not use the pressure washer to clean inside the cab.

MAINTENANCE Change the following: 1.

2.

3.

4.

Engine oil.

Transmission oil.

Engine coolant.

Hydraulic fluid.

Furthermore: 1.

2.

3.

Fill the reservoirs (fuel, hydraulic oil) to prevent the formation of condensation.

Lubricate the entire vehicle in the specified greasing points.

Apply rustproof protection to all mechanical parts subject to corrosion.

Remove the battery from the vehicle and store in a dry, ventilated place.

!

CHECKS AND REPAIRS

WARNING

!

Inspect and test the vehicle. Complete all the repairs required.

Do not stack batteries, to avoid damaging the ones underneath.

Repair fluid leakage by replacing sleeves, caps or seals which are not perfectly tight.

Batteries will discharge when not in use: on an average, a battery will lose half its charge in 60 days.

Proceed as follows for correct battery conservation:

Apply paint where the paint is scuffed but not rusted.

Where required, remove all traces of corrosion and rust by means of suitable mechanical devices. Clean the affected parts, apply rustproof protection and paint.

Protect centralized lubricators from paint.

1.

2.

3.

Clean the outside very carefully.

Regularly check the electrolyte level.

Charge the battery every 30 days.

!

WARNING

!

Used batteries must be not be stored for longer than six months: alternatively, fit the batteries in other vehicles.

7-1

SECTION 7 - STORAGE STORAGE Store the vehicle in a sheltered, clean, dry place.

Lift the vehicle using suitable lifting devices and arrange it on stands to raise the tires off the ground.

Remove all traces of oil and grease from the tires.

Inflate the tires to a pressure of approximately 1 bar and protect from direct light with a suitable cover.

RETURN TO SERVICE The following checks are required to make the vehicle operational when resuming service.

Change the following: 1.

Engine oil (only for storage exceeding one year)

2.

Transmission oil (only for storage exceeding one year).

3.

Engine coolant (only for storage exceeding two years).

4.

Hydraulic fluid (only for storage exceeding two years).

Lubricate the entire vehicle at the specified greasing points.

Charge the batteries as described above. Check the charge after one day: replace the battery if the charge drops, even partially.

Fit the batteries on the vehicle and apply pure Vaseline to the terminals.

Inflate the tires to the specified pressure. Furthermore, check that the tires are not damaged or cracked.

Inspect and test the vehicle. Complete the repairs required. Specifically, eliminate any traces of rust and paint the concerned parts. Eliminate any leakage of fluids.

7-2

SECTION 8

12

SPECIFICATIONS MAIN GROUPS Engine .......................................................................................................................... IVECO F3B (Cursor 13) Transmission .................................................................................................................................ZF 6 WG 310 Front axle..............................................................................................................................................ZF RP17 Intermediate axle ........................................................................................................................... ZF MTD3105 Rear axle ....................................................................................................................................... ZF MTD3105

8-1

SECTION 8 - SPECIFICATIONS DIMENSIONS

269DT041

1

8-2

SECTION 8 - SPECIFICATIONS (A) Wheel base...................................................................................................................................... 4.300 m (B) Front track........................................................................................................................................ 2.596 m (C) Rear track ........................................................................................................................................ 2.596 m (D) Front overhang ................................................................................................................................ 3.000 m (E) Rear overhang ................................................................................................................................. 1.512 m (F) Overall length................................................................................................................................. 10.782 m (G) Maximum width (excluding mirrors)................................................................................................. 3.340 m (H) Maximum height (empty vehicle)..................................................................................................... 3.835 m (I) Ground clearance (empty vehicle) ................................................................................................... 0.577 m (J) Distance between tandem axles ...................................................................................................... 1.970 m (L) Loading height (empty vehicle) ........................................................................................................ 3.110 m (M) Maximum height of body (empty vehicle)........................................................................................ 6.910 m (N) Maximum tipping angle (degrees) ...........................................................................................................70° (R) Ground clearance (empty vehicle)................................................................................................... 0.980 m - Internal steering circle ......................................................................................................................... 4.164 m - External steering circle ........................................................................................................................ 8.685 m - Loading capacity to the brim (SAE 1:1)...................................................................................................13 m3 - Full loading capacity (SAE 2:1) ............................................................................................................16.8 m3 Dimensional tolerance: 3%

8-3

SECTION 8 - SPECIFICATIONS WEIGHTS

269DT061

2 Empty vehicle

kg

Total

29 000

FW

Front axle

14 000

RW1

First tandem axle

7500

RW2

Second tandem axle

7500

Loaded vehicle

kg

GVW max.

Total

65 000

FW

Front axle

19 000

RW1

First tandem axle

23 000

RW2

Second tandem axle

23 000

Q (load)

Capacity

36 000

Dimensional toleance : 3% GVW (Gross Vehicle Weight)

8-4

SECTION 8 - SPECIFICATIONS CENTER OF GRAVITY (horizontal position)

269DT071

3 Empty vehicle

mm

Loaded vehicle

mm

S

Front distance

2734

S

Front distance

3740

T

Rear distance

2551

T

Rear distance

1545

Dimensional toleance : 3%

8-5

SECTION 8 - SPECIFICATIONS PERFORMANCE Type of tires

29.5 R 25

Axle reduction ratio Gear

1 : 22.24

Lock-up (%)

Gearbox ratio

Total ratio

Speed km/h (*)

Max. gradient (**)

First gear

1 : 5.350

118.984

5.9

33.7

Second gear

1 : 3.455

76.839

9.1

20.5

Third gear

1 : 2.206

49.061

14.3

12.4

Fourth gear

1 : 1.421

31.603

22.2

7.4

Fifth gear

1 : 0.969

21.551

32.6

4.5

Sixth gear

1 : 0.624

13.878

50.6

2.2

First Reverse gear

1 : 5.350

118.984

5.9

33.7

Second Reverse gear

1 : 2.206

49.061

14.3

12.4

Third Reverse gear

1 : 0.969

21.551

32.6

4.5

(*) Speed that can be reached with engine running at 2100 tr/mn (rpm) and tire rolling circumference of 5.575 m (**) Full load Minimum speed at maximum torque in first gear .................................................................................. 3.1 km/h Max. speed (calculated)...................................................................................................................... 50.6 km/h Maximum gradient in first gear (calculated, locked up).............................................................................33.7% Maximum gradient in first gear (calculated, using converter) ...................................................................46.3% Unladen transversal gradeability (minimum adherence ratio 0.6)................................................................60% Full load transversal gradeability (minimum adherence ratio 0.6) ...............................................................40%

8-6

SECTION 8 - SPECIFICATIONS MAIN GROUP CHARACTERISTICS ENGINE IVECO F3B - Cursor 13 Four-stoke diesel, supercharged with variable geometry exhaust gas turbo compressor.

Electronically controlled injector-pump injection system with fuel pre-filter and filter and pump in tank.

Forced lubrication with gear pump and double oil filter.

Water cooled with centrifuge pump. Radiator fan hydraulic system with pump driven by engine.

Compressed air system driven by engine.

Main characteristics Number of cylinders ..................................................................................................................................... 6 Bore................................................................................................................................................... 135 mm Stroke ................................................................................................................................................ 150 mm Displacement ...............................................................................................................................12.882 cm3 Compression ratio .............................................................................................................................. 16.5 : 1 Injection order .............................................................................................................................. 1-4-2-6-3-5 Maximum performance Maximum power ..................................................................................................................340 kW 455 BHP Power ratio ..................................................................................................................................... 2.000 rpm Maximum torque .............................................................................................................................2.000 Nm Torque ratio .................................................................................................................................... 1.200 rpm AUTOMATIC TRANSMISSION ZF 6WG310 Automatic transmission with 6 forward gears and 3 reverse.

Single stage hydrodynamic torque converter.

Stall ratio.................................................................................................................................................. 1 :1.84 Lock-up clutch in all gears.

Incorporated third differential with central splitter between front, intermediate and lockable rear axles.

Transmission ratios: Normal First ....................................................................................................................................................... 5.350 Second .................................................................................................................................................. 3.455 Third ...................................................................................................................................................... 2.206 Fourth .................................................................................................................................................... 1.421 Fifth ....................................................................................................................................................... 0.969 Sixth ...................................................................................................................................................... 0.624 First RG ................................................................................................................................................. 5.350 Second RG............................................................................................................................................ 2.206 Third RG................................................................................................................................................ 0.969 RG = Reverse gear FRONT DRIVE AXLE Type: semi-independent with automatic transmission integrated differential, and ZF RP17 hubs.

Limited slip differential forming single block with automatic transmission, pivoting drive axles with double CV joint, wheel hubs with planetary reductions.

Pivoting axle hinged to chassis, transversal stabilizer.

Total reduction ratios: Central bevel gear pair ....................................................................................................................3.50 (35/10) Planetary reduction gear set........................................................................................................................ 6.35 Total reduction ........................................................................................................................................... 22.24

8-7

SECTION 8 - SPECIFICATIONS INTERMEDIATE AND REAR DRIVE AXLES Type: ZF AP17 Rigid type axle with planetary reduction gears on hubs; limited slip differential.

Splitter arranged between intermediate axle and lockable rear axle.

Total reduction ratios: Central bevel gear pair.................................................................................................................... 3.50 (35/10) Planetary reduction gear set ........................................................................................................................6.35 Total reduction............................................................................................................................................22.24 BRAKES Service brake Wet multiple plate disc brake unit, hydraulically controlled on each wheel.

Parking brake Plate and spring applied, pneumatically released calliper acting on drive shaft between gearbox and intermediate axle.

Additional parking brake Can be applied when the vehicle is stationary, acts on tandem axle brake units.

WHEELS AND TIRES Steel rims on six wheels Type

Rims

Tires

Standard

25.00 - 25“

29.5 R 25

Optional

25.00 - 25“

850/65 R 25

Optional

24.00 - 29“

800/65 R 29

TIRE PRESSURE TABLE Pressure Tires

Front (F)

Rear (R)

Bar

Bar

29.5 R 25

3.00

3.50

850/65 R 25

3.00

3.50

800/65 R 29

3.50

3.50

269DT0F7

SUSPENSION Front: Two hydro-pneumatic cylinders (nitrogen/oil) for variable flexibility and damping.

Rear: Rigid double rocker arm, load splitter on intermediate and rear axles with reaction bar.

8-8

4

SECTION 8 - SPECIFICATIONS HYDRAULIC SYSTEM Independent reservoir. Oil-water heat exchanger.

Steering-tipping circuit: suction and delivery filter. Pump operated mechanically by the automatic transmission.

Braking circuit: suction and delivery filter. Pump operated mechanically by the engine.

Steering Hydraulically controlled, two dual action hydraulic cylinders acting on articulation joint hinged between chassis.

Emergency pump, operated by the automatic transmission.

Tipper Two dual acting multistage hydraulic cylinders fitted on ball joints inside the chassis.

Assisted return stroke.

Brake Independent front and rear wheel braking system. Hydraulic pressure accumulators.

Oil cooling system with pump and heat exchanger.

BRAKE COOLING SYSTEM Independent reservoir. Oil-water heat exchanger. Suction and delivery filter.

Hydraulically operated pump with proportional temperature control.

ELECTRICAL SYSTEM Multiplex electrical system.

Connection between ECUs on CAN line.

Nominal voltage...........................................................................................................................................24 V Starter motor....................................................................................................................................24 V 5.5 kW Alternator ............................................................................................................................................ 28 V 90 A Batteries: 2, connected in series ........................................................12 V 140 Ah, 1200 A (SAE), 750 A (IEC) CHASSIS High-resistant steel (Hardox 400) structure with welded boxing and plates.

Articulated, two independent structures, connected by means of oscillation bearing and taper roller bearings for demanding use ensuring rotation and pivoting between the two chassis.

DRIVE CAB Steel structure conforming to ROPS/FOPS specifications. Flexible support pads.

Can be tipped by hydraulic system. Tippable engine hood.

Electronically controlled climate control system.

BODY Structure with flat steel bottom with boxed parts strengthening subframes and flexible support pads. Walls and bottom in high abrasion resistance steel (Hardox 400).

Can be tipped on hydraulic cylinders.

Body bottom heated by passage of exhaust gas (optional).

8-9

SECTION 8 - SPECIFICATIONS ANTIFREEZE CONCENTRATION IN ENGINE COOLANT Ambient temperature Antifreeze

Water

50%

50%

°C -35<

ANTIFREEZE CONCENTRATION IN WINDSHIELD WASHER FLUID Ambient temperature Antifreeze

Water

-35

1

0

-20

1

1

-10

1

2

0

1

6

Above freeze point

1

10

°C

BATTERY ELECTROLYTE DENSITY TABLE

8-10

Ambient temperature

Electrolyte density (100% of charge)

°C

g/dm3

40

1.265

20

1.285

0

1.300

-20

1.365

SECTION 8 - SPECIFICATIONS TIGHTENING TORQUE Components

Tightening torque Nm

Notes

Automatic transmission Oil drainage cap

140

Hubs/Axles Hub oil drainage/level cap

150

Differential casing oil drainage cap

150

Differential cylindrical reducer oil drainage cap

70

Socket head

Central differential oil drainage cap

70

Socket head

Differential casing oil level cap

150

Differential cylindrical reducer oil level cap

150

Socket head

Central differential oil level cap

150

Socket head

Hydraulic system Tank drainage cap (both)

20

Steering and wheels Wheel fastening nuts

590

Steering column fastening bolt

45

8-11

SECTION 8 - SPECIFICATIONS CAPACITIES Components

Capacity

Specifications

L

Kg

30.5

--------

SAE 15W40 / API CH4 ACEA E5 / MS 1121

50

--------

CUNA 956-16 / MS 1710 (ethylene glycol)

440

--------

ASTM 0-975 #2 diesel fuel

35.5

--------

SAE 15W40 / API CH4 ACEA E5 / MS 1121

1.8

--------

SAE 85W140 / API GL5 MIL-L-2105 D / MS 1316

14.0

--------

9.0 x 2

--------

Intermediate axle/ planetary

34.0

--------

Rear axle/planetary

33.0

--------

1.6 x 2

--------

ATF DEXRON II

300

--------

ISO VG 46 DIN 51524 Part 2 HV MS 1230

100

--------

MAT 3525

2.0

--------

ATF DEXRON II

--------

2.0

NLGI No.2

--------

1.2

R134a

--------

--------

Water/methanol mixture

Engine oil sump Akcela No.1 Engine Oil Engine coolant radiator Akcela Premium Anti-freeze Fuel tank Diesel Automatic transmission Akcela No.1 Engine Oil Rear drive shaft support Akcela Gear 135H EPl Axles/differentials/planetary hubs Front differential Akcela Gear 135H EP

Front hub

SAE 85W140 / API GL5 MIL-L-2105 D / MS 1316

Suspension CASE Trans XHD Hydraulic circuit Akcela Hydraulic Excavators Fluid Brake cooling circuit Akcela Nexplore Engine hood / Cab tipping circuit CASE Trans XHD Greasing system Akcela Premium Grease EP2 Climate control system Refrigerant fluid R134a Windshield washer Windshield washer fluid

8-12

SECTION 9

5

ALPHABETICAL INDEX A

D

Accelerator........................................................ 2-22 Accessing the cab ............................................... 2-1 Accessory drive belts ........................................ 4-25 Accessory functions .......................................... 2-13 Adding air to the tires .......................................... 5-8 Adjusting the steering wheel position................. 2-13 Air conditioning system ..................................... 5-10 Air intake system............................................... 4-31 Antifreeze concentration check ......................... 4-37 Antifreeze concentration in engine coolant ........ 8-10 Antifreeze concentration in windscreen washer fluid................................................... 8-10 Articulation safety lock......................................... 4-7 Automatic transmission ............................ 2-23, 4-38

Daily operations................................................. 4-20 Decals and plates .............................................. 1-19 Dimensions ......................................................... 8-2 Directing the headlights ..................................... 6-15 Direction indicator bulb replacement.................. 6-13 Dome light/map reading light control.................. 2-20 Door .................................................................... 2-2 Drain fuel tank condensation ............................. 4-27 Draining fuel filter............................................... 4-27 Drive line shaft support ...................................... 4-42 Driver’s seat (electro-pneumatic) ....................... 2-11 Driver’s seat (standard) ..................................... 2-10 Driving the vehicle ............................................. 3-38 Dump fuses ....................................................... 6-11 Dump relays ........................................................ 6-8 Dump relays, resistors and diodes....................... 6-9

B Battery electrolyte density table......................... 8-10 Battery maintenance ........................................... 6-4 Battery master switch .......................................... 6-1 Before operating the machine ............................. 3-1 Bleeding fuel feed circuit air .............................. 4-28 Body hoist cab control ....................................... 2-26 Bodywork .......................................................... 5-13 Brake cooling circuit .......................................... 4-53 Braking circuit...................................................... 5-5 C Cab air filter cleaning/replacement .................... 5-10 Capacities ......................................................... 8-12 CB transceiver set............................................. 2-21 Center of gravity.................................................. 8-5 Checking and replacing the system................... 5-11 Checking automatic transmission oil level ......... 4-21 Checking engine coolant level........................... 4-21 Checking engine oil level................................... 4-20 Checking hydraulic fluid level ............................ 4-21 Checking turbocharger lubrication ..................... 4-31 Climate control system operation ...................... 3-58 Closed circuit camera........................................ 2-21 Compressed air system..................................... 5-12 Condenser cleaning .......................................... 5-10 Controls/Instruments/Accessories ....................... 2-1 Coolant-transmission oil heat exchanger tightness ....................................................... 4-37 Cooling system.................................................. 4-35

E Electrical power cut-off ........................................ 4-6 Electrical system.................................................. 6-1 Electro-hydraulic tipping engine hood ................ 4-10 Emergency battery disconnect switch................ 2-30 Emergency steering........................................... 3-53 Emergency stopping.......................................... 3-52 Emergency switch ............................................... 6-2 Engine............................................................... 4-23 Engine oil change .............................................. 4-23 Engine oil filters replacement............................. 4-24 Engine starter switch ......................................... 2-20 Equipment connection diagram ........................... 5-1 External controls................................................ 2-28 F Filling the fuel tank............................................... 3-3 Folding seat....................................................... 2-12 Front and rear hubs ........................................... 4-44 Front differential................................................. 4-43 Front suspension cylinder inflating device............ 5-1 Front windshield wiper blade replacement ......... 5-13 Front work light control ...................................... 2-17 Fuel filter replacement ....................................... 4-29 Fuel specifications ............................................... 3-3 Fuel supply system............................................ 4-27 Fusebox component wiring diagram .................... 6-9 Fuses ................................................................ 6-10

9-1

SECTION 9 - ALPHABETICAL INDEX G

P

Greasing............................................................ 4-57

Parking brake .................................................... 2-18 Performance........................................................ 8-6 Position light and headlight control .................... 2-14 Position of identification data on main component groups .......................................... 1-5 Preliminary operation........................................... 3-4 Preliminary operations......................................... 4-6 Prevention of fires.............................................. 1-12

H Hand signals...................................................... 1-30 Hazard light control............................................ 2-20 Headlight bulb replacement ............................... 6-13 Headlight control................................................ 2-15 Heated rear view mirror control.......................... 2-16 Heating and ventilation or air conditioning controls ......................................................... 2-26 Hood opening/cab tipping system...................... 4-57 Hydraulic system ............................................... 4-49 I Identification of the main components of the machine................................................. 1-8 Instructions for use ............................................ 1-13 Instrument panel and warning lamps ................... 2-6 Integrated IRCM auxiliary brake control ............. 2-23 Interconnection control unit.................................. 6-6 L Legal documents ................................................. 1-2 Lighting system.................................................. 6-12 Location of controls, instruments and accessories .............................................. 2-4 Location of main components used f or maintenance ............................................... 4-4 Longitudinal differential lock control ................... 2-25 Lubrication and scheduled replacement chart.... 4-18 M Main air filtering element cleaning/replacement . 4-32 Main group characteristics ................................... 8-7 Main groups......................................................... 8-1 Maintenance instructions ................................... 1-16 Maintenance/Adjustments ................................... 5-1 Manually tipping engine hood .............................. 4-9 Multifunctional display........................................ 3-11 Multifunctional display controls .......................... 2-19 O Opening the mudguards .................................... 4-14 Opening/removing lower guards ........................ 4-15 Operating instructions.......................................... 3-1 Operating the machine ........................................ 3-1 Overturning accidents...............................1-12, 3-63

9-2

R Radiator surface cleaning .................................. 4-37 Raised dumper safety lock .................................. 4-8 Rear tandem axles ............................................ 4-45 Rear view mirror power control .......................... 2-16 Rear view mirrors .............................................. 2-13 Rear warning light bulb replacement.................. 6-14 Recharging battery with external devices ............ 6-5 Relays ................................................................. 6-7 Replacing a complete wheel.............................. 3-54 Replacing the map reading light/dome light bulb ....................................................... 6-15 Replacing the pressurised brake actuator filter ................................................. 4-50 Replacing the steering-tipping pressurised filter............................................ 4-51 Replacing the variable geometry turbine air control pipe filtering element..................... 4-34 Rescuing the vehicle ......................................... 3-64 Reverse light bulb replacement ......................... 6-14 Right, left, front and rear of the machine .............. 1-3 Rotating beacon control..................................... 2-17 Run-in period....................................................... 3-2 S Safety rules ....................................................... 1-11 Scheduled maintenance program in hours ........ 4-16 Seat belts .......................................................... 2-12 Secondary air filter element replacement........... 4-34 Service brake .................................................... 2-23 Servicing instructions........................................... 4-1 Servicing intervals/Lubrication/Fluids................... 4-1 Side window washer control .............................. 2-17 Side window wiper control ................................. 2-16 Side windows .................................................... 2-14 Side windshield wiper blade replacement .......... 5-14 Sound system installation .................................. 2-21 Specifications ...................................................... 8-1 Starting and stopping the engine ......................... 3-4

SECTION 9 - ALPHABETICAL INDEX S

U

Steering ............................................................ 2-22 Stopping and parking the vehicle....................... 3-36 Storage ............................................................... 7-1 Storing the vehicle............................................... 7-1 Sunshades ........................................................ 2-14 Supplementary parking brake............................ 2-18 Suspension ......................................................... 5-1 Suspension cylinder pressure check ................... 5-2 Suspension element deflation ............................. 5-3 Suspension element inflation............................... 5-3 Suspension fluid element change........................ 5-4

Using the automatic transmission ...................... 3-39 Using the differential lock................................... 3-44 Using the integrated IRCM auxiliary brake control ................................................. 3-43

T Tightening torque .............................................. 8-11 Tipping the body................................................ 3-49 Tipping the cab.................................................. 4-11 Tire and wheel check .......................................... 5-9 Tire inflation......................................................... 5-9 Tire or rim service ............................................... 5-8 Tire pressure table .............................................. 8-8 Tires and wheels ................................................. 5-6 To the owner/Safety ............................................ 1-1 Towing the vehicle ............................................ 3-64 Transmission oil change.................................... 4-39 Transmission oil filters replacement................... 4-40 Transporting the vehicle .................................... 3-67 Turn indicator and horn control.......................... 2-15 Type, serial number and year of manufacture ..... 1-4

V Vehicle conditioning............................................. 4-6 W Weights ............................................................... 8-4 Wheels and tires.................................................. 8-8 Windshield washer fluid reservoir ...................... 5-14 Windshield wiper/washer control ....................... 2-15 Work headlight bulb replacement ...................... 6-15 Working with the vehicle .................................... 3-45

9-3

SECTION 9 - ALPHABETICAL INDEX

NOTE: CNH France S.A. Company reserves the right to make changes in the specification and design of the machine without prior notice and without incurring any obligation to modify units previously sold.

The description of the models shown in this manual has been made in accordance with the technical specifications known as of the date of design of this document.

9-4

CASE TECHNICAL MANUALS You can obtain manuals on the operation, maintenance and repair of your machine from your CASE Dealer.

To ensure quick and efficient service, consult your CASE Dealer for assistance in ordering the correct manuals for your machine.

Your CASE Dealer can deal with orders for operator’s manuals, parts catalogues and service manuals.

Always give the type and serial number of your machine so that your CASE Dealer can supply you with the right manuals for your machine.

Printed in France