Case 580 Super R 590 Super R & 695 Super R Series 2 Operator's Manual 6-86452 - PDF DOWNLOAD

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Loader Backhoes 580 Super R, 590 Super R and 695 Super R Series 2

Operator’s Manual Lep 6-86452 EN

Loader Backhoes 580 Super R, 590 Super R and 695 Super R Series 2

Operator’s Manual

Lep 6-86452 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 Lep 6-86452 EN Copyright © 2006 CNH France S.A.

Issued 05-2006

OPERATOR’S MANUAL 580 Super R 590 Super R 695 Super R Series 2

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QUICK REFERENCE SECTION GUIDE Shown are the Sections contained within this manual.

1 - To the owner 2 - Identification numbers/Machine components 3 - Safety/Decals/Hands signals 4 - Controls/Instruments/Accessories 5 - Operating Instructions 6 - Job site and road instructions 7 - Servicing intervals 8 - Lubrication/Filters/Fluids 9 - Maintenance/Adjustments 10 - Electrical system 11 - Storage 12 - Specifications 13 - Alphabetical index

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TABLE OF CONTENTS SECTION 1 TO THE OWNER........................................................................................................................1-1 580 Super R, 590 Super R and 695 Super R Series 2 LOADER BACKHOES ...........................................1-1 RIGHT, LEFT, FRONT AND REAR OF THE MACHINE.............................................................................1-3 SECTION 2 IDENTIFICATION NUMBERS/MACHINE COMPONENTS .......................................................2-1 TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE ......................................2-1 IDENTIFICATION OF MAIN COMPONENTS .............................................................................................2-5 SECTION 3 SAFETY/DECALS/HANDS SIGNALS .......................................................................................3-1 DECALS ......................................................................................................................................................3-7 HAND SIGNALS........................................................................................................................................3-14 SECTION 4 CONTROLS/INSTRUMENTS/ACCESSORIES .........................................................................4-1 CAB DOORS ...............................................................................................................................................4-1 STEPS AND ACCESS HANDLES ..............................................................................................................4-1 FRONT INSTRUMENT PANEL (580 Super R - 590 Super R)....................................................................4-3 FRONT INSTRUMENT PANEL (695 Super R) ...........................................................................................4-5 SIDE MOUNTED INSTRUMENT PANEL....................................................................................................4-7 INSTRUMENT PANEL ................................................................................................................................4-9 OPERATOR’S COMPARTMENT CONTROLS .........................................................................................4-12 OPERATOR’S SEAT.................................................................................................................................4-36 LOADER ATTACHMENT CONTROLS .....................................................................................................4-40 BACKHOE ATTACHMENT MECHANICAL CONTROLS VERSION.........................................................4-45 BACKHOE ATTACHMENT HYDRAULIC CONTROLS VERSION ...........................................................4-55 HEATING AND AIR CONDITIONING CONTROLS ..................................................................................4-62 CAB AIR FILTER.......................................................................................................................................4-65 BRAKE FLUID RESERVOIR.....................................................................................................................4-65 FIRE EXTINGUISHER ..............................................................................................................................4-65 OPERATOR’S COMPARTMENT WINDOWS...........................................................................................4-66 LOADER ATTACHMENT SAFETY STRUT ..............................................................................................4-67 ENGINE GUARD.......................................................................................................................................4-69 FUEL TANK...............................................................................................................................................4-69 HYDRAULIC RESERVOIR........................................................................................................................4-70 BATTERY AND TOOL BOX ......................................................................................................................4-70 MACHINE TOOLING.................................................................................................................................4-70 REAR VIEW MIRRORS ............................................................................................................................4-71 HEATER CONTROL VALVE.....................................................................................................................4-71 REVERSIBLE STABILIZER PADS (Centre pivot backhoe version)..........................................................4-71 LOADER BUCKET QUICK COUPLER .....................................................................................................4-72 ROTATING BEACON................................................................................................................................4-72 ATTACHMENT SAFETY VALVES ............................................................................................................4-73 BACKHOE BUCKET MECHANICAL QUICK COUPLER ..........................................................................4-74

TABLE OF CONTENTS

SECTION 5 OPERATING INSTRUCTIONS ..................................................................................................5-1 BEFORE OPERATING THE MACHINE......................................................................................................5-1 OPERATING THE MACHINE......................................................................................................................5-2 RUNNING-IN PERIOD ................................................................................................................................5-3 STARTING THE ENGINE ...........................................................................................................................5-4 STARTING THE ENGINE IN COLD WEATHER WITH AN AIR INTAKE HEATER (GRID HEATER)..........................................................................................................................................5-6 STOPPING THE ENGINE ...........................................................................................................................5-7 CODED ANTI-THEFT SYSTEM..................................................................................................................5-9 OPERATING THE MACHINE IN COLD WEATHER .................................................................................5-10 OPERATING THE MACHINE IN HOT WEATHER ...................................................................................5-10 SETTING THE BACKHOE ATTACHMENT IN WORKING POSITION .....................................................5-11 LOCKING OR UNLOCKING THE BACKHOE ATTACHMENT .................................................................5-13 BACKHOE ATTACHMENT SIDESHIFT (Sideshift backhoe version) .......................................................5-14 SETTING THE BACKHOE ATTACHMENT IN THE ROAD TRAVEL POSITION .....................................5-15 ON ROAD TRAVEL REQUIREMENTS.....................................................................................................5-16 REPLACING A BACKHOE BUCKET ........................................................................................................5-18 REPLACING A LOADER BUCKET ...........................................................................................................5-19 DIFFERENTIAL LOCK ..............................................................................................................................5-21 LOADER BUCKET MOUNTED FORKS....................................................................................................5-23 HYDRAULIC SPEED CONTROL ..............................................................................................................5-25 STEER PHASING (4WS) ..........................................................................................................................5-25 BACKHOE ATTACHMENT AUXILIARY HYDRAULIC TOOLS.................................................................5-28 HAND-HELD AUXILIARY HYDRAULIC TOOLS.......................................................................................5-29 TWO OR FOUR WHEEL DRIVE...............................................................................................................5-30 LIFTING AND CRANING LOADS WITH THE LOADER ATTACHMENT..................................................5-31 LOADER ATTACHMENT MAXIMUM LIFTING LOADS............................................................................5-32 MAXIMUM LIFTING LOADS USING BUCKET MOUNTED PALLET FORKS ..........................................5-33 LIFTING LOADS WITH THE BACKHOE ATTACHMENT .........................................................................5-34 MAXIMUM WORKING LOADS WITH BACKHOE ATTACHMENT ...........................................................5-36 BACKHOE ATTACHMENT MAXIMUM LIFTING LOADS .........................................................................5-37 TRANSPORTING THE MACHINE ............................................................................................................5-38 LIFTING THE MACHINE ...........................................................................................................................5-39 TOWING THE MACHINE ..........................................................................................................................5-40 OPERATING THE MACHINE IN WATER .................................................................................................5-42 PARKING THE MACHINE.........................................................................................................................5-42 SECTION 6 JOB SITE AND ROAD INSTRUCTIONS ...................................................................................6-1 INSTRUCTIONS FOR USE.........................................................................................................................6-1 ROAD TRAVEL ...........................................................................................................................................6-2

TABLE OF CONTENTS

Job site and road instructions (continued) JOB SITE TRAVEL......................................................................................................................................6-7 LOADER ATTACHMENT OPERATING INSTRUCTIONS ..........................................................................6-9 BACKHOE ATTACHMENT OPERATING INSTRUCTIONS .....................................................................6-14 BALLASTING AND TYRES.......................................................................................................................6-20 SECTION 7 SERVICING INTERVALS ..........................................................................................................7-1 SERVICING INSTRUCTIONS.....................................................................................................................7-1 HOURMETER .............................................................................................................................................7-2 INTERVALS.................................................................................................................................................7-3 SECTION 8 LUBRICATION/FILTERS/FLUIDS.............................................................................................8-1 FLUIDS AND LUBRICANTS .......................................................................................................................8-1 FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS ..............................................................8-2 GREASE POINTS .......................................................................................................................................8-3 LEVELS .......................................................................................................................................................8-9 ENGINE.....................................................................................................................................................8-13 COOLING SYSTEM ..................................................................................................................................8-16 FUEL SYSTEM..........................................................................................................................................8-18 RELEASING THE PRESSURE IN THE HYDRAULIC SYSTEM...............................................................8-21 HYDRAULIC SYSTEM ..............................................................................................................................8-22 AIR FILTER ...............................................................................................................................................8-27 TRANSMISSION (POWERSHUTTLE)......................................................................................................8-31 TRANSMISSION (POWERSHIFT)............................................................................................................8-34 FRONT DRIVE AXLE ................................................................................................................................8-37 REAR AXLE ..............................................................................................................................................8-40 SECTION 9 MAINTENANCE/ADJUSTMENTS .............................................................................................9-1 WHEELS AND TYRES................................................................................................................................9-1 LOADER BUCKET MECHANICAL/HYDRAULIC SELF LEVELLING/RETURN TO DIG ADJUSTMENT ...............................................................................................................................9-3 RADIATOR, COOLANT AND AIR CONDITIONING CONDENSER ...........................................................9-4 ENGINE ALTERNATOR AND FAN BELT...................................................................................................9-5 TURBOCHARGER ......................................................................................................................................9-6 ENGINE ROCKER ARM CLEARANCE ADJUSTMENT .............................................................................9-7 MACHINE INSPECTION AND CLEANING .................................................................................................9-7 CYLINDER LEAK INSPECTION .................................................................................................................9-8 AIR CONDITIONING ...................................................................................................................................9-8 DRAINING THE TELESCOPIC DIPPER.....................................................................................................9-9 CAB FILTERS ...........................................................................................................................................9-10 HEATER UNIT AND AIR CONDITIONING COOLER ...............................................................................9-11

TABLE OF CONTENTS

Maintenance/adjustments (continued) PARKING BRAKE ADJUSTMENT ............................................................................................................9-11 BRAKE FLUID ...........................................................................................................................................9-12 CHECKING AND ADJUSTING STABILIZER PLAY (Sideshift backhoe version) .....................................9-13 BACKHOE BUCKET EXCAVATION POSITION .......................................................................................9-13 TELESCOPIC DIPPER .............................................................................................................................9-14 FRONT WHEEL ADJUSTMENTS (2WS)..................................................................................................9-15 FRONT WHEEL ADJUSTMENTS (4WS)..................................................................................................9-16 ROPS/FOPS CAB (Or protective frame) ...................................................................................................9-17 TROUBLESHOOTING ..............................................................................................................................9-19 SECTION 10 ELECTRICAL SYSTEM .........................................................................................................10-1 FUSES AND RELAYS...............................................................................................................................10-1 BATTERY ..................................................................................................................................................10-6 CONNECTING A BOOSTER BATTERY...................................................................................................10-8 ALTERNATOR ..........................................................................................................................................10-9 STARTER MOTOR ...................................................................................................................................10-9 BULBS.....................................................................................................................................................10-10 REPLACING A BULB ..............................................................................................................................10-10 SECTION 11 STORAGE..............................................................................................................................11-1 SECTION 12 SPECIFICATIONS .................................................................................................................12-1 ENGINE - 95 HP / 71 KW (580 Super R Models)......................................................................................12-1 ENGINE - 110 HP / 82 KW (590 Super R and 695 Super R Models) .......................................................12-1 COOLING SYSTEM ..................................................................................................................................12-1 FUEL SYSTEM..........................................................................................................................................12-2 TRANSMISSION (580 Super R and 590 Super R Models).......................................................................12-2 TRANSMISSION (695 Super R Models) ...................................................................................................12-2 ELECTRICAL SYSTEM.............................................................................................................................12-2 BRAKES ....................................................................................................................................................12-2 STEERING ................................................................................................................................................12-2 REAR AXLE ..............................................................................................................................................12-3 HYDRAULIC SYSTEM ..............................................................................................................................12-3 MAXIMUM SLOPE WHEN USING THE MACHINE ..................................................................................12-3 FRONT COUNTERWEIGHT .....................................................................................................................12-3 RADIATOR COOLANTS ...........................................................................................................................12-3 NOISE LEVEL ...........................................................................................................................................12-3 VIBRATION LEVEL INSIDE THE CAB .....................................................................................................12-3 TYRES.......................................................................................................................................................12-4

TABLE OF CONTENTS

Specifications (continued) FOUR WHEEL DRIVE TYRE COMBINATIONS .......................................................................................12-4 TYRES PRESSURES ...............................................................................................................................12-4 TRAVEL SPEED (580 Super R and 590 Super R Models) .......................................................................12-5 TRAVEL SPEED (695 Super R Models) ...................................................................................................12-5 MODELS 580 Super R and 590 Super R LOADER ATTACHMENT - DIMENSIONS AND PERFORMANCE ....................................................................................................12-6 MODEL 695 Super R (Sideshift version) LOADER ATTACHMENT - DIMENSIONS AND PERFORMANCE ....................................................................................................12-8 MODEL 695 Super R (Centre pivot version) LOADER ATTACHMENT - DIMENSIONS AND PERFORMANCE ..................................................................................................12-10 MODELS 580 Super R and 590 Super R BACKHOE ATTACHMENT - DIMENSIONS AND PERFORMANCE ..................................................................................................12-12 MODEL 695 Super R (Sideshift version) BACKHOE ATTACHMENT - DIMENSIONS AND PERFORMANCE ..................................................................................................12-14 MODEL 695 Super R (Centre pivot version) BACKHOE ATTACHMENT - DIMENSIONS AND PERFORMANCE ..................................................................................................12-16 MODELS 580 Super R AND 590 Super R LIFTING CAPACITIES .........................................................12-18 MODEL 695 Super R (Sideshift version) LIFTING CAPACITIES............................................................12-19 MODEL 695 Super R (Centre pivot version) LIFTING CAPACITIES ......................................................12-20 SECTION 13 ALPHABETICAL INDEX........................................................................................................13-1

TABLE OF CONTENTS

NOTES

SECTION 1 TO THE OWNER 580 Super R, 590 Super R and 695 Super R Series 2 LOADER BACKHOES

1 Type shown: 590 Super R Serie 2

Dealer’s Stamp

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

1-1

SECTION 1 - TO THE OWNER You are the owner of a machine that has been designed and built with quality constantly in mind. It conforms to current labour safety regulations and all national highway and road regulations. See “Official documents”. However, this does not exclude all risk of accidents; that is why it is essential to observe elementary safety rules and precautions.

Read this manual carefully before operating the machine. Instructions concerning safety, operation and maintenance have been developed to permit safe service and operation of this machine.

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

The standard attachments and equipment of this machine are intended for general earthmoving purposes and re-handling. If the machine is to be used for lifting loads (tubing, concrete pipe sections, shoring material, etc.) then make sure the machine is suitably equipped for this type of work.

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

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

For certain applications, the machine must undergo regular inspection. Consult your Dealer.

Before entrusting this machine to an operator, make sure that: 1. The operator has received necessary training on how to operate the machine correctly and safely in one of our Training Centres or from an approved organization.

2. The operator has read and fully understood the instructions given in this manual.

1-2

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

Your Dealer is at your disposal for any further information. He will also provide any after-sales service you may require and genuine spare parts, your guarantee of quality, match and conformity with official regulations.

OFFICIAL DOCUMENTS A certificate defining the weight shown on the manufacturer’s plate - Indicates that the weight shown on the manufacturer’s plate is a value based on the heaviest configuration and does not always correspond to the configuration being carried.

Standard test certificate - Noise level (2000/14/EC) (copy provided in separate form or on the back of the “EC” certificate of conformity) A “EC” certificate of conformity - For a new construction equipment machine, series produced to a type approved design, designed and manufactured in accordance with the requirements of European directive 98/37/EC, concerning machine safety and mainly: 1. The following directives: - 2000/14/EC: Noise level - 89/336/EC: Electromagnetic compatibility 2. The following European standards: - EN 474-1: Safety - General requirements - EN 474-4: Safety Loader Backhoes equipped for load lifting IMPORTANT: An original of this “EC” certificate is supplied with each machine and must be kept carefully by the owner. (Only a photocopy can be supplied subsequently on request).

IMPORTANT: The official documents supplied with the machine must be kept by the owner so that he may show them to the control authorities if requested to do so.

SECTION 1 - TO THE OWNER PRESENTATION The loader backhoes are hydraulic digging machines. They consist of travel components, an engine, hydraulic assemblies and an operator’s compartment. When the operator operates the controls, the pump, driven by the engine, sends hydraulic fluid to the control valves. The control valves distribute the hydraulic fluid to the various components. A cooling system including an oil cooler maintains the hydraulic fluid at a normal operating temperature.

The 695 Super R loader backhoes exist in two different versions: sideshift backhoe version (sideshift backhoe attachment) or centre pivot backhoe version (fixed backhoe attachment).

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

OPERATOR AND SEAT ATTACHMENT POSITION 1.

2.

3.

4.

IN

LOADER

FRONT REAR RIGHT-HAND SIDE LEFT-HAND SIDE

2 OPERATOR AND SEAT ATTACHMENT POSITION 1.

2.

3.

4.

IN

BACKHOE

FRONT REAR RIGHT-HAND SIDE LEFT-HAND SIDE

3

1-3

SECTION 1 - TO THE OWNER

NOTES

1-4

SECTION 2 IDENTIFICATION NUMBERS/MACHINE COMPONENTS TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE When ordering parts, requesting information or assistance, always give your Dealer the type and serial number of your machine.

Write the type, serial number and year of manufacture of your machine and the serial numbers on the various hydraulic and mechanical components in the spaces provided below.

MACHINE (A) With CE mark (1) Type....................................................................

(2) Serial number .....................................................

(3) Year of manufacture ...........................................

(B) Without CE mark (1) Type....................................................................

(2) Serial number .....................................................

Rue des Meuniers

CNH FRANCE 60330 LE PLESSIS-BELLEVILLE FRANCE YEAR

Type

Homologation n.

kW Serial number Total permissible mass

kg

Permissible front axle load

kg

Permissible rear axle load

kg

Permissible towable mass

kg

Rue des Meuniers

CNH FRANCE

MODEL/TECHTYPE ENGINE 4WD AXLE

60330 LE PLESSIS-BELLEVILLE FRANCE

UNIT SERIAL NUMBER TRANSMISSION REAR AXLE

1

2-1

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS ENGINE Make and type ......................................................... .................................................................................

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

2 FOUR WHEEL DRIVE Axle type ..................................................................

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

Rotation....................................................................

Ratio.........................................................................

3 TRANSMISSION - 4x4 POWERSHUTTLE Model number ..........................................................

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

4

2-2

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS TRANSMISSION - 4x2 POWERSHIFT Model number..........................................................

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

5 REAR AXLE Model number..........................................................

Date .........................................................................

6 REAR AXLE - (695 Super R) Model number..........................................................

Date .........................................................................

7

2-3

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS CAB Model number ..........................................................

Date .........................................................................

Rue des Meuniers

CNH FRANCE 60330 LE PLESSIS-BELLEVILLE FRANCE PROTECTIVE STRUCTURE FOR MODELS

MASS. max Kg.

L bs.

INTERNATIONAL STANDARD SERIAL N ˚

PART. N

DATE

8 PROTECTIVE STRUCTURE (ROPS) Model number ..........................................................

Date .........................................................................

Rue des Meuniers

CNH FRANCE 60330 LE PLESSIS-BELLEVILLE FRANCE PROTECTIVE STRUCTURE FOR MODELS 580 SR

MASS. max kg.

L bs.

INTERNATIONAL STANDARD SERIAL N ˚

PART. N

DATE

9

2-4

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS IDENTIFICATION OF MAIN COMPONENTS SIDESHIFT BACKHOE VERSION

10

11 1.

2.

3.

4.

5.

6.

7.

8.

Loader bucket Loader arm Front axle Fuel tank Rear axle Operator’s compartment Engine guard Backhoe boom

9.

10.

11.

12.

13.

14.

15.

Backhoe dipper or telescopic dipper Backhoe bucket Backhoe attachment sideshift carriage Stabilizers Battery box Hydraulic tank Swing cylinder

2-5

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS CENTRE PIVOT BACKHOE VERSION (695 Super R)

12

13 1.

2.

3.

4.

5.

6.

7.

2-6

Loader bucket Loader arm Front axle Fuel tank Rear axle Operator’s compartment Engine guard

8.

9.

10.

11.

12.

13.

14.

Backhoe boom Backhoe dipper or telescopic dipper Backhoe bucket Stabilizers Battery box Hydraulic tank Swing cylinders

SECTION 3 SAFETY/DECALS/HANDS SIGNALS SAFETY INSTRUCTIONS

BEFORE USING THE MACHINE

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

ON ROAD AND JOB SITE

Read this manual carefully and check that: - You understand fully the symbols on the controls and the safety signs used in this manual and on the machine.

- You understand fully the speed, stability, braking and steering characteristics of the machine. If you are in any doubt, consult your Dealer.

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

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

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

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

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

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

3. Remove anything which might hinder visibility.

Clean the windshield, windows and rear view mirrors.

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

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

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

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

8. When mounting or dismounting from the machine always face the machine and use the steps and access handles on the left-hand side of the machine. The right-hand door is to be used only in case of emergency.

9. Make sure you know the position and function of every control. Operating the controls wrongly can cause serious physical injury.

10. Before operating the machine, check the backhoe attachment control pattern currently in use on the machine. Failure to comply with these instructions can cause unexpected machine movements, death or serious injury.

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

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

3-1

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS 13. Always fasten your seat belt before starting the engine. The machine is equipped with a roll over protection system (ROPS) which ensures your safety. The seat belt will protect you efficiently if you attach it correctly and if you always wear it. The seat belt should not be too loose. It must not be twisted or caught in the seat.

14. Make sure you know ways of getting out of the machine (emergency exit via the right hand door) in case the machine falls over or if access via the left-hand door is not possible. Make sure that the right-hand door is not locked.

15. Check the condition and pressure of the tyres regularly.

ROAD OPERATION 1. (695 Super R) Before undertaking any road travel, select the 2 wheel steer position and install the flip over cover to lock the switch in that position.

2. Check that both the cab doors are closed correctly before undertaking any road travel.

3. Before undertaking any road travel, lock the working attachments and install the safety systems required by regulations. Raise the stabilizers completely and lock them mechanically.

4. Before travelling on the road, make sure that the load on each axle, depending on the machine configuration, conforms to the road traffic regulations of the country concerned.

ON THE JOB SITE 1. Operating the machine requires your full attention. Caution on the part of the operator can prevent accidents. Make sure you know the capabilities and limits of the machine and the space needed for it to operate. There are areas of poor visibility in the machine’s working range.

Have someone guide you for all jobs which have poor visibility.

2. Check all around the machine every day to ensure there are no oil leaks or hydraulic fluid leaks. Tighten unions as necessary and replace any parts as required.

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

3-2

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

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

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

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

PREVENTION OF RISKS ASSOCIATED WITH VIBRATIONS Machine vibrations cause discomfort to the operator and in some cases his health and safety may be at risk. To reduce these risks to a minimum: 1. Make sure the machine, attachment and tool are suitable for doing the type of work to be carried out.

2. Make sure the machine is in good condition and that the service interval work has been carried out correctly.

3. Check the tyre pressure, the steering and braking systems and the play in the attachment linkage.

4. Check that the operator’s seat and adjustment controls are in good condition and then adjust the seat to suit the operator’s size and weight.

The seat is in conformance with ISO 7096, 2000 Class EM5.

On the job site: 1. Operate all controls progressively so the machine works smoothly.

2. Modify your driving to suit working conditions.

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

4. Use the glide ride system.

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

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS OPERATING THE MACHINE

ON THE JOB SITE

ON ROAD AND JOB SITE

1. On job sites on the public highway, use regulation signals, taking into account the working range of the machine. National or local regulations define the number, type and location of reflector strips.

1. Do not allow anyone to climb onto the machine.

A passenger can fall or cause an accident.

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

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

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

5. Stop the engine and remove the starter switch key even for stops of short duration.

6. Never leave the operator’s compartment when the engine is running.

7. When entering or leaving the operator’s compartment, it is essential that the loader attachment controls are locked. Never try to by-pass this basic safety requirement.

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

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

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

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

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

ROAD OPERATION 1. It is mandatory to make sure that the brake pedals are locked together before any road travel or travel in third or fourth gear. If this instruction is not observed an accident may occur.

2. Avoid running the engine in an enclosed space.

If it cannot be avoided, ensure good ventilation under all circumstances.

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

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

5. Do not allow anyone to stand in the machine working area. If the operator uses the swing or attachment controls wrongly, this could cause an accident. Stop all movement until the person has moved away.

6. Before moving the stabilizers make sure that no person is within the working range of the stabilizers.

7. When moving the machine onto a trailer, place the gear change lever in first gear. Keep the loader bucket 20 cm from the ground.

8. Load lifting must be carried out in accordance with the instructions shown in this manual and in accordance with current regulations.

9. Before using the backhoe attachment make sure that the machine is clear of the ground by means of the stabilizers and the loader attachment.

10. Any uncontrolled movement of the machine can cause an accident. Before turning the operator’s seat to the backhoe attachment working position, it is essential to place the direction of travel control lever and the gear change lever in the neutral position and immobilize the machine by means of the parking brake lever.

2. (695 Super R) Before undertaking any road travel, select the 2 wheel steer position and install the flip over cover to lock the switch in that position.

3-3

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS 11. If you are using the backhoe attachment or if you are carrying out maintenance operations, use the engine throttle lever. The use of the lever for any other operations can cause accidents.

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

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

PARKING THE MACHINE When you park the machine, proceed in the following manner: 1. Park the machine on a flat, level surface away from any soft ground, excavations or poorly shored cavity.

2. Lower the loader bucket until it is pressing on the ground.

3. Place the backhoe attachment in the road travel position.

4. Place the direction of travel and gear change levers in the neutral position.

5. Immobilize the machine by means of the parking brake.

6. Raise the stabilizers completely and immobilize them mechanically.

7. Stop the engine and remove the starter switch key.

8. Release the hydraulic pressure by operating the control levers in both directions. On pilot controlled machines turn key “ON” and release pressure.

9. Make sure that the doors and the engine guard is correctly fastened and lock the operator’s compartment doors.

10.Check that no part of the machine is protruding onto the public highway. If this cannot be avoided, install signs in accordance with regulations.

3-4

MAINTENANCE AND ADJUSTMENTS 1. Do not carry out any maintenance operations until you have read and understood the instructions and warnings given in this manual.

2. Wear suitable clothing when servicing the machine.

3. When servicing the machine, place one “Do not start up” label on the instrument panel.

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

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

6. If the attachment is raised or the machine moves when there is no operator, serious injury can result. Before carrying out any maintenance on this machine, proceed in the following manner: 1. Park the machine on flat, level ground.

2. Lower the loader and backhoe attachments until they are resting on the ground.

3. Stop the engine and remove the starter switch key.

4. Raise the parking brake lever.

5. Block the wheels to prevent any machine movement.

6. If a servicing operation requires the loader attachment to be raised (working on the engine), install the loader attachment support strut.

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

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS 8. Do not carry out any welding operation on the machine without prior authorization from your Dealer.

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

10. Hydraulic fluid or grease under pressure which penetrates the skin can cause serious injury.

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

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

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

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

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

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

- Never re-fuel when the engine is running.

- Do not smoke during re-fuelling.

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

2. Use a non-inflammable product for cleaning parts.

3. A spark or flame can cause the hydrogen in a battery to explode. To prevent any risk of explosion, observe the following instructions: - When disconnecting the battery cables, always disconnect the negative (-) cable first.

- To reconnect the battery cables, always connect the negative (-) cable last.

- Never short-circuit the battery terminals with metal objects.

- Do not weld, grind or smoke near a battery.

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

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

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

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

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

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

16. The machine’s structure is in conformity with the “FOPS” and “ROPS” protection standards. Any modification (drilling, welding, etc.) may cause that conformity to be invalidated.

3-5

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS PREVENTION OF BURNS 1. Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid any contact with the skin, eyes or clothing.

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

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

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

2. When the electrolyte of a battery is frozen, it can explode if you attempt to charge the battery or if you try to start the engine using a booster battery. Always keep the battery charged to prevent the electrolyte freezing.

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

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

Then remove the cap.

3. If you operate this machine without a ROPS/ FOPS cab (or frame) and the machine rolls over, you can be seriously injured or killed.

Remove the ROPS/FOPS cab only for service or replacement. Do not operate the machine with the ROPS/FOPS cab (or frame) removed.

4. Do not install accessories (fixed or otherwise) which can increase the weight of the machine.

This could cause serious accidents. Do not exceed the maximum weight shown on the ROPS/FOPS cab (or frame) identification plate.

5. Improper ROPS/FOPS cab (or frame) inspection or maintenance can cause serious injury.

Carry out the recommended ROPS/FOPS cab (or frame) inspection procedure shown in this manual. If it is necessary to replace ROPS/ FOPS parts or the ROPS/FOPS cab (or frame), use only the replacement parts shown in the Parts Catalogue for your machine.

GLIDE RIDE SYSTEM (Optional) 1. Never operate the glide ride lever when the loader arms and the loader bucket are maintaining the machine in a raised position. The machine could fall to the ground and cause serious or fatal injury.

5. Never touch the battery terminals with your hands. This can induce a state of electrolysis and impair the main organs of the body.

2. If the glide ride lever is operated when the starter switch key is in the “ON” position, the loader arms may rise or lower slightly due to the effect of the hydraulic accumulator.

ROPS/FOPS CAB (Or protective frame)

3. Never use the glide ride system during precise levelling operations or when using the backhoe attachment.

1. Do not try to weld or straighten the ROPS/FOPS cab (or frame).

2. Do not modify the ROPS/FOPS cab (or frame) in any manner. Unauthorized modification, such as welding, drilling, cutting and adding attachments, as well as any damage resulting from collisions or the machine rolling over, could weaken the structure and reduce your protection. Replace the ROPS/FOPS cab (or frame) if subjected to roll over or damage. Do not attempt to repair it.

3-6

4. Never use the glide ride control system during handling and loading operations, since this could damage the accumulator.

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS DECALS

!

WARNING

!

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

!

WARNING

!

Make sure that all decals are perfectly legible.

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

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

NOTE: This chapter only covers decals relating to safety and machine operation and servicing. For information on all decals on the machine, consult the spare parts catalogue.

EXTERNAL NOISE LEVEL This decal shows the value in decibels of the external noise level of the machine, as guaranteed by the manufacturer. As per European Directive 2000/14/ EC - Stage II. Model: 580 Super R Part number: 87346382

1 Models: 590 Super R and 695 Super R Part number: 87346214

2

3-7

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS POSITION OF DECALS For the decal functions, see “Decal illustrations”.

When replacing decals, be sure to install them in the locations shown.

x1 000

3

3-8

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS

85828053

4

3-9

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS DECAL ILLUSTRATIONS Brake oil Part number: 85807870 This decal indicates the operator should check the brake oil level and that the operator should consult the Operator’s Manual for oil specification and fill volume.

5 Fire extinguisher Part number: 85804337 Ensure the extinguisher fitted, complies with local regulations and is fully serviceable.

6 Safety belt Part number: 85804335 This decal reminds to wear your safety belt at all times to avoid all risk of being ejected in the event of the machine turning over.

7 Safety hat Part number: 85804334 Wear a safety hat for your own protection.

8 Operator’s manual Part number: 85804333 This decal shows where the Operator’s Manual is kept. Read the manual carefully to ensure you operate the machine correctly.

9

3-10

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS Overhead electric lines Part number: 85804327 Do not work near live overhead electric lines without first making sure that the minimum distances will be respected.

10 Warning Part number: 85804400 Ensure when the machine is left unattended it is safe and secure.

11 First aid kit Part number: 85804339 Make sure there is nothing missing in the First Aid kit and regularly check the expiry date of pharmaceutical products.

12 Backhoe boom height (Specific to certain countries) Part number: 85805829 Always remember to take the height of the backhoe boom into consideration when travelling with or transporting the machine. The maximum height must be 3.9 metres above ground level. When transporting the machine, be sure to know the distance between the ground and the highest point of the machine.

13

Keep clear of the working area Part number: 85804331 This adhesive reminds the operator not to permit anyone to remain within the working range of the machine when the engine is running.

14

3-11

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS Danger of being crushed Part number: 85804332 This decal warns you to keep a minimum safety distance between your feet and the stabilizers when they moving.

15 Danger of being crushed Part number: 85804329 This decal warns you to keep a minimum safety distance between your hands and all moving parts.

16 Danger of being burnt Part number: 85804326 This decal reminds you that engine parts are hot after it has been running. Allow the engine to cool down completely before undertaking any maintenance work.

17 Battery Part number: 85804330 This decal reminds you it is necessary to see “Battery” in Section 10.

18 Engine Part number: 85804324 This decal warns that certain components in the engine compartment can trap your hand, cut or burn you. Before removing the engine guard, shut down the engine, remove the starter switch key and consult the manual.

19 3-12

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS Hydraulic reservoir Part number: 85804341 Make sure that you only fill a reservoir bearing this symbol with hydraulic fluid. See “Fluids and lubricants” in Section 8.

20 Loader attachment upper position Part number: 85804325 This decal warns that it is mandatory to install the safety strut when carrying out any operation requiring the loader attachment to be in raised position.

21 Fuel tank Part number: 85804338 Make sure that you only fill a tank bearing this symbol with fuel. See “Fluids and lubricants” in Section 8.

22 Slinging points Part number: 85804336 This decal shows the slinging points to be used when lifting the machine. Never use any other slinging points than those shown on this decal.

23

3-13

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS HAND SIGNALS When operating the machine, never attempt to carry out tasks calling for fine control or to work in areas where visibility is poor or impaired without seeking the assistance of a signalman. Make perfectly sure that you and the signalman understand the signals to be used.

START THE ENGINE

MOVE AWAY FROM ME Wave hands forward and backward (palms out).

24 STOP THE ENGINE

27 GO THIS FAR

25 COME TO ME

28

Wave hands forward and backward (palms in).

ALL STOP AND HOLD

26

3-14

29

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS STOP

LOWER LOAD OR BUCKET

Wave one hand back and forth.

33 30

RAISE LOAD OR BUCKET SLOWLY

EMERGENCY STOP Wave both hands back and forth.

34 LOWER LOAD OR BUCKET SLOWLY 31 RAISE LOAD OR BUCKET

35 32

3-15

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS DUMP LOADER BUCKET

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

39 RAISE BACKHOE BOOM 36 TURN MACHINE RIGHT To stop movement, stop moving hand and clench fist.

40 LOWER BACKHOE BOOM

37 ROLL BACK LOADER BUCKET

41

38

3-16

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS BACKHOE DIPPER IN

BACKHOE BUCKET DUMP

42 BACKHOE DIPPER OUT

45 RETRACT TELESCOPIC DIPPER (If fitted)

43 BACKHOE BUCKET DIG

46 EXTEND TELESCOPIC DIPPER (If fitted)

44

47

3-17

SECTION 3 - SAFETY/DECALS/HANDS SIGNALS

NOTES

3-18

SECTION 4 CONTROLS/INSTRUMENTS/ACCESSORIES CAB DOORS To open the right-hand and left-hand doors from the outside, push the lock inwards and pull the handle (1).

1 Lift the latch (2) to open the right-hand and left-hand doors from the inside.

IMPORTANT: Use the left-hand door for entering or leaving the operator’s compartment. The right-hand door is only for use in emergency.

!

WARNING

!

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

NOTE: To lock the doors, use the starter switch key.

2

STEPS AND ACCESS HANDLES Use the steps and access handles when entering or leaving the operator’s compartment.

580 Super R and 590 Super R

3

4-1

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 695 Super R

4

!

WARNING

!

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

!

WARNING

!

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

4-2

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FRONT INSTRUMENT PANEL (580 Super R - 590 Super R)

==

5 1. 2/4 WHEEL DRIVE SWITCH This switch is used to engage or disengage four wheel drive.

The switch has three positions: OFF = front axle drive disengaged, with braking on all 4 wheels.

ON, 2nd position = the switch lamp goes out and the front axle drive is disengaged (2 wheel drive operation).

ON, 3rd position = the switch lamp lights up and the front axle drive is engaged (4 wheel drive operation).

See “2 or 4 wheel drive” in Section 5.

NOTE: When the four wheel drive switch is in the “OFF” position and both brake pedals are operated together the four wheel drive, will automatically be engaged (above 3 Km/h) to give four wheel drive braking and disengage with brake pedals released.

2. HAND-HELD AUXILIARY HYDRAULIC TOOL CONTROLS (Optional) For instructions on how to use these controls, see “Hand-held auxiliary hydraulic tools” in Section 5.

3. LOADER ATTACHMENT LOCKING SWITCH (Optional) When operated, this switch is for preventing any movement of the loader attachment during travel.

4. SWITCH FOR OPTIONAL EQUIPMENT 5. ROTATING BEACON SWITCH This switch is used to turn the rotating beacon on or off.

6. HYDRAULIC SPEED CONTROL SWITCH See “Hydraulic speed control” in Section 5 for use during operation.

4-3

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

==

6 7. GLIDE RIDE SYSTEM CONTROL SWITCH (Optional) The glide ride system control improves the machine behaviour during travel, regardless of the type of terrain and with the loader bucket full or empty. It reduces forward and rearward pitching when moving to the rear or forwards and when carrying loads, at the same time increasing productivity and operator comfort. It also minimises impact forces to which the machine may be subjected.

!

WARNING

!

Never operate the glide ride system control when the loader arm and loader bucket are maintaining the front of the machine raised off the ground. The machine could fall and cause serious or fatal injury.

!

WARNING

!

Never use the Ride Control system during handling and loading operations, since this could damage the accumulator.

4-4

8. MANUAL MODE SELECTION SWITCH (Powershift transmission) In situations where a MANUAL gear change (up or downshift) is required the powershift auto change can be overridden by selection of this console mounted switch.

NOTE: Changing gears up or down must always be done using the Powershift transmission lever. See “Powershift transmission control lever”.

When manual mode is no longer required, place the control in “OFF” position to return to automatic gear shifting.

9. WARNING HORN BUTTON (Powershift) This hold-down switch operates the warning horn.

10. HAZARD LIGHT SWITCH Press the control down to locked position. The direction indicators and the control will flash simultaneously.

Press down again for the direction indicators and control lamp to go out.

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FRONT INSTRUMENT PANEL (695 Super R)

7 1. 2/4 WHEEL DRIVE SWITCH This switch is used to engage or disengage four wheel drive.

The switch has three positions: OFF = front axle drive disengaged, with braking on all 4 wheels.

ON, 2nd position = the switch lamp goes out and the front axle drive is disengaged (2 wheel drive operation).

ON, 3rd position = the switch lamp lights up and the front axle drive is engaged (4 wheel drive operation).

See “2 or 4 wheel drive” in Section 5.

NOTE: When the four wheel drive switch is in the “OFF” position and both brake pedals are operated together the four wheel drive, will automatically be engaged (above 3 Km/h) to give four wheel drive braking and disengage with brake pedals released.

2. HAND-HELD AUXILIARY HYDRAULIC TOOL CONTROLS (Optional) For instructions on how to use these controls, see “Hand-held auxiliary hydraulic tools” in Section 5.

3. LOADER ATTACHMENT LOCKING SWITCH (Optional) When operated, this switch is for preventing any movement of the loader attachment during travel.

4. STEER MODE SWITCH This switch has a locking cover and is used to select “Road”, “4WS” or “Crab steer”. See “4 wheel steer phasing” in Section 5.

This switch has 3 positions: Position (a) = “Road” Position (b) = “4WS” Position (c) = “Crab steer” IMPORTANT: Before undertaking any road travel, select “Road” mode and fold back the cover to lock the switch in this position.

5. ROTATING BEACON SWITCH This switch is used to turn the rotating beacon on or off.

4-5

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

8 6. HYDRAULIC SPEED CONTROL SWITCH See “Hydraulic speed control” in Section 5 for use during operation.

7. GLIDE RIDE SYSTEM CONTROL SWITCH (Optional) The glide ride system control improves the machine behaviour during travel, regardless of the type of terrain and with the loader bucket full or empty. It reduces forward and rearward pitching when moving to the rear or forwards and when carrying loads, at the same time increasing productivity and operator comfort. It also minimises impact forces to which the machine may be subjected.

!

WARNING

!

Never operate the glide ride system control when the loader arm and loader bucket are maintaining the front of the machine raised off the ground. The machine could fall and cause serious or fatal injury.

!

WARNING

!

Never use the Ride Control system during handling and loading operations, since this could damage the accumulator.

4-6

8. MANUAL MODE SELECTION SWITCH (Powershift transmission) In situations where a MANUAL gear change (up or downshift) is required the powershift auto change can be overridden by selection of this console mounted switch.

NOTE: Changing gears up or down must always be done using the Powershift transmission lever. See “Powershift transmission control lever”.

When manual mode is no longer required, place the control in “OFF” position to return to automatic gear shifting.

9. WARNING HORN BUTTON (Powershift) This hold-down switch operates the warning horn.

10. HAZARD LIGHT SWITCH Press the control down to locked position. The direction indicators and the control will flash simultaneously.

Press down again for the direction indicators and control lamp to go out.

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SIDE MOUNTED INSTRUMENT PANEL

9 1. FRONT WORK LIGHTS SWITCH This switch has 3 positions: 1st position = “OFF” 2nd position = the two frontal outer working lights turn on.

3rd position = the two front inner working lights turn on.

The lights switch turns on only in the second and third position.

3. BACKHOE ATTACHMENT SIDESHIFT CARRIAGE LOCKING AND UNLOCKING SWITCH (Sideshift backhoe version) This switch has 2 positions: The switch is used to lock or unlock the backhoe attachment sideshift carriage to allow lateral shifting.

For sideshifting, see “Backhoe attachment sideshift” in Section 5.

2. LIGHT SWITCH The switch has three positions: - the first position is “OFF”, - the second position powers the gauge cluster, the parking lights, with heading indicator lamp and the rear red lateral lights.

The third position powers the beam lights and the main beam indicator lamp.

4. BACKHOE ATTACHMENT LOCKING SWITCH (695 Super R) This switch has 2 positions: The switch is used to lock or unlock the backhoe attachment locking plate in preparation for road travel.

See “Locking or unlocking the backhoe attachment” in Section 5.

4-7

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

10 5. REAR WORK LIGHTS SWITCH This switch has 3 positions: 1st position = “OFF” 2nd position = the two rear outer working lights turn on.

3rd position = the two rear inner working lights turn on.

The lights switch turns on only in the second and third position.

NOTE: Never use the working lights during road travel.

6. INSTRUMENT PANEL See “Instrument panel”.

4-8

7. REAR WINDSHIELD WIPER SWITCH This switch is used to operate the windshield wiper. It will continue to operate until the switch returns to “OFF” position.

8. REAR WINDSHIELD WASHER SWITCH The windshield washer will operate when this switch is pressed and held down. When the switch is released, the windshield washer ceases to operate.

9. WARNING HORN BUTTON (Powershift) This hold-down switch operates the warning horn.

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES INSTRUMENT PANEL

11 1. BRAKE LIQUID LEVEL WARNING LAMP This lamp comes on and the audible warning device sounds when the brake liquid is at minimum level. See “Brake liquid reservoir”.

7. “ROAD” STEER INDICATOR LAMP (695 Super R) This lamp comes on when two wheel steer mode is selected and phased. See “Phasing procedure” in Section 5.

2. SIDE LIGHT AND DIPPED HEADLIGHT INDICATOR LAMP This indicator lamp lights up when the light switch is operated.

8. “CRAB” STEER INDICATOR LAMP (695 Super R) This lamp comes on when crab steer mode is selected and phased. See “Phasing procedure” in Section 5.

3. MAIN BEAM INDICATOR LAMP This indicator lamp comes on when the main beam headlights are turned on.

NOTE: If the three lamps come on at once this means there is a problem with the electrical circuit.

Consult your Dealer.

4. DIRECTION INDICATOR LAMP This lamp lights up when the direction indicators are working.

9. ENGINE OIL PRESSURE WARNING LAMP This warning lamp comes on and the audible warning device sounds when the engine oil pressure is too low. If the lamp comes on when the machine is working, move the machine to a place of safety, stop the engine, remove the starter switch key and find the cause of the problem.

5. AIR CONDITIONER INDICATOR LAMP (Optional) This lamp comes on when the air conditioner is working.

6. “4WS” STEER INDICATOR LAMP (695 Super R) This lamp comes on when four wheel steer mode is selected and phased. See “Phasing procedure” in Section 5.

10. COLD START INDICATOR LAMP (If fitted) This lamp lights up while the engine is being pre-heated.

4-9

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

12 11. ALTERNATOR CHARGE WARNING LAMP This warning lamp comes on when the alternator/fan belt is broken or when the alternator is not charging the battery. If the lamp comes on when the machine is working, move the machine to a place of safety, stop the engine, remove the starter switch key and find the cause of the problem.

12. PARKING BRAKE INDICATOR LAMP This indicator lamp comes on when the parking brake lever is in the raised position (wheels braked). See “Parking brake lever”.

13. AIR FILTER RESTRICTION WARNING LAMP This warning lamp comes on when the air filter primary element is to be cleaned or replaced.

See “Air filter” in Section 8.

14. TRANSMISSION OIL PRESSURE WARNING LAMP This lamp lights up and the audible alarm sounds when the transmission oil pressure is too low. If the lamp comes on when the machine is working, move the machine to a place of safety, stop the engine, remove the starter switch key and find the cause of the problem.

4-10

15. LOW FUEL LEVEL WARNING LAMP This warning lamp comes on when the fuel level is low. You have approximately an hour to fill the fuel tank.

NOTE: When the starter switch key is in the “ON” position, lamps (9), (11), (12), (13) and (14) come on for three seconds. After this time, only lamps (9), (11) and (14) remain alight. If one or more do not come on, the bulbs must be replaced. See “Replacing a bulb” in Section 10.

16. BATTERY CHARGE INDICATOR This indicator shows the state of charge of the battery. At normal charge the needle should be in the green area. If the needle is in the lower red area, this shows that the battery charge is insufficient or that the alternator is not charging the battery. If the needle is in the upper red area, this indicates excessive battery charge which may cause damage to the battery.

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 17. FUEL LEVEL GAUGE This gauge shows the quantity of fuel in the fuel tank.

18. HOURMETER The hourmeter shows the hours and tenths of hours for which the engine has been operated.

It also enables servicing operations to be scheduled.

See Section 7.

19. ENGINE TACHOMETER / REVOLUTIONS COUNTER The tachometer shows the engine speed in revolutions per minute.

The figures indicated must be multiplied by 1000.

Each intermediate mark shows a value of 100 rpm.

It is recommended not to exceed the green area on the gauge.

The revolutions counter shows travel speed in kilometres per hour (kmh) and miles per hour (mph). Road speed in 4th gear with 18.4-26 tyres (19A).

20. TRANSMISSION OIL TEMPERATURE INDICATOR This indicator shows the transmission oil temperature. When the temperature is normal, the needle is in the green area. If the needle is in the red area, change down to a lower gear. If the needle still remains in the red area, stop the machine travel, place the gear change lever and the direction of travel control lever in the neutral position and leave the engine running at 1000 rpm. If this operation does not enable the oil temperature to be reduced, check the gearbox oil level and make sure that the radiator and oil cooler are perfectly clean. See “Gearbox” in Section 8 and “Radiator and oil cooler” in Section 9.

21. ENGINE COOLANT SOLUTION TEMPERATURE INDICATOR This indicator shows the temperature of the engine coolant solution. When the temperature is normal the needle is in the green area. If the needle is in the red area the audible warning sounds. Move the machine to a place of safety, stop the engine, remove the starter switch key and check the coolant solution level. Make sure that the radiator and oil cooler are perfectly clean and that all the thermostats function correctly. See “Cooling system” in Section 8 and “Radiator and oil cooler” in Section 9.

4-11

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES OPERATOR’S COMPARTMENT CONTROLS

!

WARNING

!

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

STARTER SWITCH Located on the right of the operator’s seat (with seat in loader attachment position), this switch has five positions.

Key position: Position (1): Not used.

Position (2): Off. Position (3): On. Position (4): Start.

NOTE: In On position (1) the audible alarm sounds.

NOTE: See “Starting the engine” in Section 5.

13

NOTE: This key is also used for locking the cab doors, the engine guard and the fuel tank cap.

STEERING CONTROL A hydrostatic steering system is installed requiring minimum effort to turn the steering wheel. Familiarise yourself with the effort required to turn the wheel before driving the machine for the first time.

!

WARNING

!

Because your machine is equipped with hydrostatic power steering, never hold the steering wheel against either of the steering stops. Failure to observe this precaution may result in damage to the steering system components.

!

WARNING

!

In the event of a burst steering hose the machine will not be steerable, stop the machine immediately and contact your Dealer.

In the event of loss of power steering due to engine failure, the machine can still be driven to a place of safety. The force necessary to turn the steering wheel and steer the machine will, however, be much higher.

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14

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES DIRECTIONAL equipped)

INDICATOR

SWITCH

(ROPS

Located on the right of the steering wheel, this switch has three positions: Position (0): Neutral. No direction indicators will flash.

Position (1): The left-hand direction indicators will flash.

Position (2): The right-hand direction indicators will flash.

15 DIRECTION INDICATOR, HEADLIGHT MAIN BEAM AND FRONT WINDSHIELD WIPER AND WASHER REED SWITCH (Cab equipped) Located on the right of the steering wheel, this lever has five positions: Position (0): Neutral.

Position (1): The left-hand direction indicators and the direction indicator lamp under the steering wheel flash at the same speed.

Position (2): The right-hand direction indicators and the direction indicator lamp under the steering wheel flash at the same speed.

16 Position (3): (Lighting switch in low beam position).

Push the reed switch downwards for the headlight main beams and corresponding indicator lamp to light up.

17 Position (4): Turn the reed switch handle counterclockwise for the front windshield wiper to work.

0 = Stop I = Normal speed Position (5): (momentary action control) Press and hold down the button on the tip of the handle to operate the windshield washer.

18

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 4X4 POWERSHUTTLE TRANSMISSION CONTROLS

19 1. GEAR LEVER: Four gears are selectable for the required ground speeds in both forward or reverse travel.

2. TRANSMISSION DISCONNECT BUTTON: (On gear level) Prior to changing gear depress and hold down this switch which disengages transmission drive, select the required gear with the gear lever and release the switch to re-engage drive.

3. LOADER ATTACHMENT CONTROL LEVER 4. TRANSMISSION DISCONNECT BUTTON: (On loader attachment control lever) This button is used to disengage the transmission in order to increase loader attachment power.

4-14

5. MECHANICAL DIFFERENTIAL LOCK PEDAL: Depressing this pedal will lock both rear wheels together giving equal drive and will disengage when wheel torque equalises or foot brakes are applied.

6. TRANSMISSION POWERSHUTTLE DIRECTION LEVER: Movement of this lever from the neutral position will engage forward or rearward travel and will cause the audible warning device to sound.

NOTE: In reverse gear an audible alarm device sounds.

7. WARNING HORN BUTTON

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Transmission The transmission is fully synchronised providing four forward and four reverse speeds allowing gear ratio changes on the move. A torque converter is used to connect the engine to the transmission and the column mounted powershuttle lever (4) enables shifts between forward and reverse travel without disengaging gear ratios.

A “Transmission disconnect” feature is provided by finger operated buttons (2) on both the main gearshift lever (1) and loader control lever (3) of which disengages drive to the transmission to enable on the move gear changing.

!

WARNING

20

!

Always apply the parking brake whenever the machine is parked as the machine is free to roll even though the transmission gearshift lever and power reversing lever may be “In Gear” and the engine is turned “OFF”.

Gear Shift Lever The single gearshift lever (1) is used to select any one of the four gear ratios. The transmission disconnect button (2) is depressed and held as the lever is shifted from one gear to another and then released to re-connect transmission drive.

21

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Forward/Reverse Powershuttle Lever To select FORWARD travel, engage the required gear ratio with the gearshift lever, then with the engine idling lift the powershuttle lever from the neutral lock position (1) and move to the forward position (2). Use the foot throttle to control the engine and ground speed.

To reverse the direction of travel, reduce engine speed and move the power reversing from neutral lock position (1) and rearwards (3) for reverse travel an audible alarm device sounds.

IMPORTANT: The powershuttle lever is equipped with a neutral lock to prevent inadvertent engagement of the transmission. With this design the power reversing lever moves through a “T” slot for the forward and reverse positions.

IMPORTANT: When operating in low ambient temperatures with cold transmission oil, allow the oil to warm up before attempting to shift the powershuttle lever. The transmission can be shifted normally after the oil warms up.

NOTE: The horn will sound if the powershuttle lever is operated (forward or reverse) with the handbrake engaged.

NOTE: The powershuttle lever can be shifted at any engine speed, however, for safe, smooth operation the engine speed should be reduced to approximately 1200 rev/min.

This action is easily controlled by using the foot throttle to control engine and ground speed.

4-16

22

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Transmission Disconnect The 4x4 transmission provides for easy upward and downward gear ratio changes on the move. However, as a clutch is not used between the engine and transmission, the power flow from the engine to the transmission must be interrupted to shift from one gear ratio to another. This is accomplished by using a transmission disconnect (dump) button.

The finger operated button (2) on the main gearshift lever knob (1) is easy to operate.

!

WARNING

!

To avoid personal injury do not use the disconnect switch control to coast down hill. Excessive speed may cause loss of control, personal injury to a bystander or failure of the transmission.

23

To make upward gear ratio changes simply depress and hold the button (2) on the gearshift lever (1), while moving the lever from one gear ratio to another. When the desired gear ratio has been selected release the button and allow the unit to gain engine speed and ground speed. If another higher ratio is required repeat the procedure.

IMPORTANT: To avoid possible damage to the transmission hydraulic clutches never use the disconnect switch for inching the machine forward.

Inching the machine forward with the button will cause the clutches to slip excessively and overheat.

To make downward gear ratio changes or reduce ground speed, simply lower the engine speed, depress and hold the gearshift lever button and downshift the transmission. When the desired gear ratio has been selected release the button and adjust the engine speed to suit ground speed required.

Operating the machine in too high a gear or under too heavy a load will cause the torque converter to slip excessively and overheat. If the machine is overloaded, the engine speed will not exceed a range of 1800-2200 rev/min at maximum throttle and the torque converter will “stall” bringing the machine to a complete stop.

If “stall” does occur, there is still sufficient engine power to operate the loader however, to prevent the transmission from overheating, either reduce the load on the machine or select a lower gear ratio.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES IMPORTANT: Operating at a “stall” for more than 20 seconds can cause the transmission to overheat and can possibly damage the transmission. If the transmission overheats, the indicator needle rises into the red zone. Shift both the power reversing and gearshift levers to neutral. Idle the engine at 1000 rev/min. until the transmission oil is cooled sufficiently for the indicator needle to drop into the green zone. Once done, operations may resume.

24 DIFFERENTIAL LOCK PEDAL In conditions inducing wheel slip, hold down the differential lock pedal with your heel until the lock is felt to engage. The lock will automatically disengage when traction at the rear wheels equalises. If a rear wheel spins at speed, reduce the engine speed to idle before engaging the differential lock to minimise shock loads on the rear axle. See “Differential lock” in Section 5.

!

WARNING

!

Never use the differential lock at speeds above 8 km/h or when turning the machine. When engaged the lock will prevent the machine turning and personal injury could result.

4-18

25

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 4X2 POWERSHIFT TRANSMISSION CONTROL LEVER

26 1. TRANSMISSION POWERSHIFT DIRECTION LEVER: Four gears are selectable for the required ground speed in forward and two gears for reverse travel.

IMPORTANT: The gear changes and direction of travel are governed by the micro processor to maintain smooth and safe changes, irrespective of gear selected. Therefore Upshifting, downshifting or direction of travel through the gears will only occur when the monitored machine speed is safe to do so.

2. DIFFERENTIAL LOCK SELECTION SWITCH: Depressing the spring loaded switch will lock both rear wheels together giving equal drive and will disengage when wheel torque equalises or the foot brakes are applied.

3. LOADER ATTACHMENT CONTROL LEVER

4. TRANSMISSION DISCONNECT BUTTON 5. KICKDOWN SWITCH: If the machine is in 2nd gear and 1st is required for loader work engaging kickdown instantly drops the gear from 2nd to 1st. When reverse is selected the transmission reverts to 2nd gear.

4X2 POWERSHIFT TRANSMISSION The transmission fitted to this machine is designed to powershift gear changes supplying drive to the machine wheels depending upon the gear and direction selected. The transmission is controlled by a microprocessor in the Powershift lever unit (1).

The powershift lever (1) with electronic speed selection actuates the powershift transmission with four forward speeds, two reverse speeds.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 4X2 POWERSHIFT TRANSMISSION DISPLAY (EGS) - FORWARD SELECTION

27

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 4X2 POWERSHIFT TRANSMISSION DISPLAY (EGS) - REVERSE SELECTION

28

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Powershift Lever Display - (LEDs) LEDs - Numbered 1 through 4: Indicate the direction of travel by the colour of the LED Forward = Green Neutral = Red Reverse = Orange

and also indicate the selected shift lever gear.

3

29

STEADY ILLUMINATED LED: Indicates selected transmission gear.

FLASHING LED: Indicates the actual transmission gear engaged (if different from that selected).

LEDs - Numbered 1 through 8: Used during test modes

1

2

3

4

5

6

7

8

LED - Number 8: illuminates green when the machine is at a standstill (in normal mode).

1

2

3

4

5

6

7

8

LED - Letter T = Self-diagnostic Mode:

T

Used in self-diagnostic test mode and will illuminate during self test.

30

NOTE: In the event of a fault, (the light will flash), contact your Authorised Dealer for assistance.

LED - Letter N Indicates Neutral:

N

Illuminates when the transmission is shifted to neutral.

Powershift Lever and Microprocessor Functions The microprocessor controls the transmission and self checks its own memory continuously to ensure that gear selection and range changes are always performed in a safe manner.

Should a fault occur in the transmission or the microprocessor, the microprocessor will default to the reset mode.

31

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Reset Mode: When the microprocessor defaults to reset mode both the T and N LED’s are displayed simultaneously to indicate that a reset has taken place.

If no critical faults are active the microprocessor selects N2 and goes to the Neutral lock state. See “Driving with Powershift” chapter.

Limp home: If a fault is detected at power up the limp home facility is automatically selected.

IMPORTANT: If limp home is active, only 1st and 2nd gear will be selectable but without modulation.

Limp home active can be identified by the illumination of the following LEDs. - Consult your Dealer.

T - LED Flashing

N - LED

32

CONDITION

ON

Last fault currently shown on display

Flashing

Flashes Slower

Input error detected

Flashing

Flashes in Phase

Non critical output error detected

Flashing

Flashes Faster

Safety critical output error detected

4-23

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Selecting Neutral At power up, “Neutral and 2nd Gear” are automatically selected regardless of the powershift lever position (1). The LED-2 and the N-LED are illuminated RED, (neutral 2nd), the microprocessor is in a neutral lock state.

If after driving, neutral is selected and the shift lever stays in neutral for more than 3 seconds the microprocessor automatically defaults to the neutral lock state for safety. In neutral an automatic shift routine takes effect to prevent damage to the transmission due to overspeeding.

Leaving Neutral

33

A feature of the powershift lever is the neutral lock state, which does not allow forward or reverse direction drive to be selected. This feature prevents the machine accidentally moving should the lever be knocked into forward or reverse. To leave the neutral lock state, you select drive direction followed by an upshift by rotating the shift lever.

Selecting Forward To select forward travel push the lever away from you and the “F” LED will illuminate green.

NOTE: When forward is selected you will not be given any indication of gear selected, only the maximum selected gear the transmission will shift too.

The microprocessor is programmed to be an automatic speed based shift system.

In addition whether forward actually engages at that time, depends on the status of the machine, for example if on the move, road speed and direction will be considered before any shift changes take place.

34

Selecting Reverse To select reverse travel pull the lever towards you and the reverse “R” LED will illuminate orange.

NOTE: When reverse is selected you will not be given any indication of gear selected, only the maximum selected gear the transmission will shift too.

The microprocessor is programmed to be an automatic speed based shift system.

In addition whether reverse actually engages at that time, depends on the status of the machine, that is if on the move road speed and direction will be considered by the microprocessor.

35

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Up Shifting Up shifting to a desired gear from neutral is achieved by twisting the handgrip counter clockwise (+) in single movements. If held in this position the processor will advance the shift selection from 2 through to 4 in 1.8 sec intervals.

NOTE: An upshift request after a downshift is delayed for 2 seconds. Should an error occur with the speed sensor the microprocessor will not allow up shifts above 2nd gear and will be indicated by the “T” LED flashing and the “N” LED flashing slower.

NOTE: If climbing up a steep incline select 2nd and proceed, if speed and power allow upshift into 3rd and 4th.

36

Down Shifting

!

WARNING

!

If descending down a steep incline select 2nd and proceed, upshifting only when safe to do so. You can not downshift to reduce speed if the machine speed is above 15 km/h.

Downshifting to the desired gear is achieved by twisting the handgrip clockwise (-) in single movements. If held in this position the processor will decrease the shift from 4, if the shift lever was in this gear, through to 1 in 1.5 sec intervals.

37

NOTE: If the gear requested and the shift attainable are not the same because of torque convertor turbine RPM being too high, the gear position LED (e.g. LED 4) will flash and the shift lever position will illuminate, not flashing, (e.g. LED 2), until the requested gear is reached. When a gear position LED is flashing this indicates that the machine has to reduce speed to reach the requested gear.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Direction Changes Changing driving direction is achieved simply by shuttling the powershift lever between forward and reverse and vice versa which is allowed at any time.

The system response however depends on machine speed and currently engaged gear. When driving in 1st or 2nd gear direction changes are unrestricted and are granted immediately.

F1 - R1

F2 - R2

R1 - F1

R2 - F2

38 When driving forward in 3rd or 4th gear two responses are possible depending on machine speed.

RESPONSE 1: If the machine speed in forward is above 15 km/h and reverse is selected downshift engages but momentum forward remains, until the speed drops sufficiently to allow downshift to take place when reverse is achieved in 2nd gear.

RESPONSE 2: If the machine speed in forward is less than 15 km/h reverse takes place immediately into 2nd gear.

Should a speed sensor fault be detected while in F3 or F4 a downshift sequence to 2nd gear will take place and is indicated by the LED “T” flashing fast and the LED “N” flashing slowly.

39

NOTE: If the transmission is in forward 1st gear due to kick down the direction change will result in selection of reverse 2nd gear for efficient pull away. Refer to Kickdown for more information.

40

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Transmission Powershift In the previous paragraphs shift changes have been shown as precise movements and twist actions of the powershift lever. However the transmission can change gear automatically in forward or reverse as described in the following paragraph: Select forward and 4th gear on the powershift lever and with the handbrake released apply pressure to the foot accelerator. As the engine revs and machine speed increase the transmission will start from 2nd gear and change up through 3rd and 4th gears up to maximum road speed.

When you require to slow down or stop release the foot accelerator and apply the footbrake, the transmission will automatically downshift through 4th, 3rd and 2nd gear as the machine speed decreases.

Once stopped apply the handbrake and neutral will be selected by the microprocessor.

To select drive again, simply twist the handgrip to select 4th and with the handbrake released apply pressure to the foot accelerator.

Kick Down The kick down facility (2nd to 1st gear only) on this transmission increases torque instantly to the driving wheels and hence pushing power. For example when the loader is pushing into a pile and more torque is required at the wheels.

This is achieved by the instant gear change from 2nd to 1st by the use of the button (1) without the need to use the twist grip on the powershift lever.

NOTE: The kick down facility is only available when the transmission is in 2nd gear and the kickdown button (1) is depressed. If kick down can not be achieved (machine speed too high) the LED 1 will be illuminated and LED 2 will be flashing.

41

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Transmission Disconnect The disconnect feature is useful when loading, for example; when pushing the loader into a pile and you have sufficient dirt in the bucket press the disconnect switch which disengages the transmission and allows the full power of the engine to be directed to the hydraulic oil pump.

Disconnect is available in 1st and 2nd gear.

NOTE: Transmission disconnect is selectable, when the machine speed is less than 5 km/h and by depressing the button on the loader lever and remains active until the pedals or switch are released.

42

Speed Ranges The microprocessor controlling the powershift transmission is pre-programmed to control the speed at which the gear changes take place.

This effectively protects the transmission from excess forces, should gear changes be selected at higher speeds than is desirable.

(Except 695 Super R) shown in the chart opposite with an 18.4 X 26 R4 tyre fitted is the approximate (within 10%) maximum speed available and at which speed an automatic shift takes place in each gear. (...) = Automatic upshift speed [...] = Automatic downshift speed As can be seen when down shifting from 4th gear at maximum speed 39.5 km/h the microprocessor will not allow the down shift to take place until the speed has dropped to approximately 19.9 km/h.

Refer to the chart for complete upshift and downshift speed change details.

NOTE: In some countries the road speed of 40 km/h is not allowed. In these circumstances the transmission is governed to a maximum of 30 km/h and the shift speed range reduces accordingly.

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43

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Differential lock

!

WARNING

!

Never use the differential lock at speeds above 8 km/h or when turning the machine. When engaged the lock will prevent the machine turning and personal injury could result.

The differential lock fitted to this machine is operated by oil pressure and controlled by an electrically operated solenoid. The solenoid is energised when the switch (1) mounted on the loader attachment control lever. The differential lock effectively places both rear wheels into a direct drive when selected, this action stops one rear wheel spinning.

44

In conditions inducing wheel slip (differential lock not yet engaged), press down the differential lock switch and the lock will engage giving direct drive to both rear wheels.

The lock will remain engaged until either of the foot brakes are applied and the machine stops or by disengaging the switch. The warning light on the instrument panel will go out when the differential lock has disengaged. See “Differential lock” in Section 5.

ENGINE GUARD LOCKING AND UNLOCKING LEVER Located under the steering wheel, this lever has two positions: Pull the lever to unlock the engine guard.

Push the lever to lock the engine guard.

See “Engine guard”.

IMPORTANT: For any service work on the engine, raise the loader attachment and install the attachment support strut. See “Loader attachment support strut” and then place the “Do not start up” label on the instrument panel.

45

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES ADJUSTABLE STEERING COLUMN (Optional) The angle of the steering column can be varied through an approximate range of 10 - 20 degrees.

Adjustment is by release of the foot pedal at the base of the column. Apply a light pressure to this pedal and position the steering column to suit your needs.

With the column in the desired position release the foot pedal which will lock the column in position.

IMPORTANT: It is essential that the machine be brought to a complete halt before attempting to adjust the steering column tilt position. If this instruction is not observed an accident may occur.

OPERATOR’S COMPARTMENT READING LIGHT

AND

46

MAP

This light is mounted on the roof. Push the switch forward to turn on the compartment light. Push rearward to turn on the map reading light.

47 SUN VISOR Use the tab (1) to pull the sun visor down and place it in the position required. Push up the latch (2) to roll up the visor.

48

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES ENGINE ACCELERATOR PEDAL Located under the steering wheel, this pedal enables the engine speed to be increased or decreased.

Maximum speed: press the pedal fully down.

Idle speed: release the pedal.

This pedal is used for travel and for operating the loader attachment.

NOTE: This pedal is coupled with the engine throttle lever. Before using the pedal, make sure that the throttle lever is in the minimum speed position. See “Engine throttle lever”.

49

IMPORTANT: Never use this pedal when working with the backhoe attachment.

BRAKE PEDALS Located under the steering wheel, these two pedals (1) are equipped with a system (2) which enables them to be locked together or unlocked. This enables the machine either to be braked (pedals locked) by pressing either of the pedals or to be turned (pedals unlocked) to the right by pressing on the right-hand pedal or to the left by pressing on the left-hand pedal. Braking with one pedal only should only be carried out at low speed.

NOTE: When the pedals are locked and the brakes are applied the 2/4 wheel drive switch lights up on the front instrument panel.

!

WARNING

50

!

It is mandatory to make sure that the brake pedals are locked together before any road travel or travel in third or fourth gear. If this instruction is not observed an accident may occur.

To lock the two pedals together, tilt the latch so it engages on the left-hand pedal.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES ENGINE THROTTLE LEVER This lever enables the engine speed to be increased or decreased.

Slide forward: to increase speed.

Slide backward: to reduce speed.

IMPORTANT: Never use the lever during travel on public highways.

!

WARNING

!

If you use the backhoe attachment or if you are carrying out maintenance operations, use the engine throttle lever. The use of the lever for any other operation can cause accidents.

51

PARKING BRAKE LEVER Located on the right of the operator’s seat (with the seat in the loader attachment position), this lever enables the machine to be immobilized.

Raise the lever to immobilize the machine (wheels braked). In this position, the indicator light lights up on the instrument panel. Press and hold down the push button on the tip of the lever and then lower the lever to release the brakes (wheels are free to rotate). In this position, the lamp on the instrument panel is out.

IMPORTANT: (Powershuttle) When the lever is in the raised position, the audible warning device sounds if the direction of travel control lever is not in the neutral position. See “Direction of travel control lever”.

IMPORTANT: Never try to move the machine when the lever is in the raised position.

IMPORTANT: Before stopping the engine make sure the lever is in the raised position.

IMPORTANT: Before using the backhoe attachment controls, make sure that the lever is in the raised position.

!

WARNING

!

Any uncontrolled movement of the machine can cause an accident. Before turning the operator’s seat to the backhoe equipment working position, it is essential for the direction of travel lever and the gear change lever to be placed in the neutral position and the machine to be immobilized by means of the parking brake lever.

IMPORTANT: This lever can also be used as an emergency brake in the event of a main brake system failure.

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52

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FRONT AND REAR WINDSHIELD WASHER RESERVOIR This reservoir is located on the left-hand side of the cab and has two electric pumps controlled by a switch or the direction indicator, main beam headlight, front windshield washer and wiper switch. See “Operator’s compartment controls”.

NOTE: In cold weather, use windshield washer with low temperature capability.

IMPORTANT: Never operate the windshield washer switch when the reservoir is empty, since this may damage the electric pump.

53

RADIO COMPARTMENT Located on the left-hand side of the cab, this preequipped compartment is intended for installing a 12 volt radio.

54 AUXILIARY 12 VOLT SOCKET An auxiliary 12 volt power socket is located on the cab left-hand upright.

55

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES STORAGE AREAS Located at the front left and rear right, these areas can be used for cups, bottles etc.

56 BACKHOE ATTACHMENT BOOM UNLOCKING LEVER (580 Super R, 590 Super R) Located on the right-hand side of the cab (with the operator’s seat in backhoe attachment position), this lever is used to unlock the backhoe attachment lock plate after road travel.

See “Locking or unlocking the backhoe attachment” in Section 5.

57 BATTERY MASTER SWITCH The battery master switch is located under the console behind the brake pedals and is used to disconnect the electrical system completely from the battery.

When the master switch is in vertical position, the circuit is disconnected.

When the master switch is in horizontal position, the circuit is connected.

!

WARNING

!

The battery master switch must be switched off at the end of each working day, for machine service or for any operations on the electrical system.

It acts as an anti-theft device when the cab doors and windows are locked.

4-34

58

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FUSE AND RELAY LOCATION This cover is under the loader attachment controls and may be accessed via the right-hand cab door.

The fuses and relays are behind the cover. See “Fuses and relays” in Section 10.

59 CODED ANTI-THEFT SWITCH (Optional) Located on the right-hand console, this switch has a red flashing lamp and makes it possible to disengage the engine anti-start device, using the special electronic key. See “Coded anti-theft system”.

NOTE: It is recommended to keep the electronic key with the starter switch key. If the 5 keys (delivered with the machine) are lost they may not be replaced.

60 OPERATOR’S COMPARTMENT FAN (Optional) Turn the middle of the fan to stop or start it.

61 COAT HANGER HOOK This hook is on the left-hand cab upright.

62

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES OPERATOR’S SEAT To operate the machine correctly with maximum efficiency and comfort, the seat should be correctly adjusted to suit the weight and height of the operator.

!

WARNING

!

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

NOTE: The seat is in conformance with ISO 7096, 2000 Class EM5.

NOTE: The machine may be fitted with a pneumatic seat as an option.

ARMREST ANGLE ADJUSTMENT Raise the armrest, turn the knob (1) to obtain the desired armrest position and then lower the armrest.

63 CUSHION TILT ADJUSTMENT To adjust the cushion tilt angle, turn the knob (2) clockwise or counterclockwise, to increase or reduce the angle.

64

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SEAT BELT To attach the seat belt (3), insert the buckle in the socket (4).

65 To release the belt, press the button on the socket (4).

!

WARNING

!

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

66

!

WARNING

!

Do not use the seat belt without the ROPS/FOPS cab (or protective structure).

SEAT BACK ANGLE ADJUSTMENT To adjust the seat back angle, hold the lever (5) rearward, move the seat back to obtain the desired position and then release the lever.

67

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES PIVOTING Release the seat using lever (6) and swing it round.

Release the lever and make sure the seat is locked correctly in place.

68 COMBINED ADJUSTMENT

HEIGHT

AND

WEIGHT

(Mechanical version) Adjustment may be made to suit the operator’s size.

Turn the control (7) to obtain the desired height.

69 (Pneumatic version) Lower the handle (9) to decrease the rigidity of the suspension. Raise the handle to increase the rigidity of the suspension. The indicator (8) must be green when the operator is sitting on the seat.

70

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FORWARD AND REAR ADJUSTMENT Hold the lever (10) in raised position, slide the seat until the desired position is reached and then release the lever.

71 LUMBAR SUPPORT ADJUSTMENT Turn the knob (11) to obtain good back support from the seat back.

72

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LOADER ATTACHMENT CONTROLS

!

WARNING

!

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

!

WARNING

!

Before using the controls make sure that the operator’s seat is correctly adjusted in the loader attachment position.

WITH STANDARD LOADER BUCKET Located on the right of the steering wheel, this nine position lever operates all the loader attachment controls. The speed of movement of each control depends on the tilting angle of the lever. In the intermediate position, two movements can be obtained simultaneously.

WITH 4 IN 1 LOADER BUCKET The function of the lever is identical to that of the machine fitted with the standard loader bucket, with the addition of the clam control. See “4 in 1 loader bucket clam control”.

LOADER CONTROLS, NEUTRAL AND HOLD

73

When in the neutral/hold position (0) the attachment movement can be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

RAISING THE LOADER ATTACHMENT With the lever in position (1), the attachment rises.

74

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LOWERING THE LOADER ATTACHMENT With the lever in position (2), the attachment lowers.

75 LOADER BUCKET FLOAT CONTROL With the lever in position (3), the bucket follows the contours of the ground without it being necessary to operate the lever.

NOTE: In this position the lever does not automatically return to neutral when it is released. It is necessary to move it manually.

76 FILLING THE LOADER BUCKET With the lever in position (4), the bucket rolls back (fills).

77 DUMPING THE LOADER BUCKET With the lever in position (5), the bucket rolls forward (dumps).

78

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LOADER ATTACHMENT AUTOMATIC RETURN TO DIG With the lever in position (6), the attachment lowers and simultaneously the loader bucket places itself in the digging position.

NOTE: It is possible to adjust the tilt angle for bucket dig. See “Adjustment of loader bucket automatic return to dig” in Section 9.

79 4 IN 1 LOADER BUCKET CLAM CONTROL (If fitted) This control operates the opening and closing of the 4 in 1 loader bucket clam. To use the control it is necessary to unlock the lever by means of the latch (A).

This control has three positions: Position (0): Neutral/hold. As soon as the lever is released, it automatically returns to the neutral position (0) and the clam remains in the position where it was when movement stopped.

Position (1): Open clam.

80

Press the latch (A) and tilt the lever to the right.

Position (2): Close clam.

Press the latch (A) and tilt the lever to the left.

IMPORTANT: The latch (A) must be in the locked position when the clam is not being used. It does not lock automatically, it has to be engaged manually.

TRANSMISSION DISCONNECT BUTTON Located on the lever, this push button, when pressed and held down, gives maximum power to the loader attachment cylinders. This will cause the transmission to revert to neutral. Release the clutch cut-out button to engage the transmission once more. See “Loader attachment operating instructions” in Section 6.

IMPORTANT: When the button is pressed, the machine free-wheels. If necessary, use the brakes to stop the machine.

81

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES DIFFERENTIAL LOCKING BUTTON (Powershift) Located on the control lever, this push button, when pressed and held down locks the differential. See “Differential Lock” in Section 5.

IMPORTANT: Never use the differential lock during travel on a public highway.

82 LOCKING THE LOADER ATTACHMENT CONTROLS (Specific to certain countries) This pin, located next to the control lever, is used for locking the attachment controls.

To lock the controls, remove the pin from its housing and install it in the specially provided hole in the console.

!

WARNING

!

Before leaving the operator’s compartment, undertaking any road travel or working with the backhoe attachment, place the pin in locking position.

83

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

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4-44

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES BACKHOE ATTACHMENT MECHANICAL CONTROLS VERSION IMPORTANT: Before using the backhoe attachment, make sure sideshift carriage locking switch (1) is in “ON” position and that the lock plate has been disengaged, either by means of the lever (3) or the switch (2).

84 IMPORTANT: Whenever the backhoe attachment is used the machine must be resting on its stabilizers.

!

WARNING

!

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

!

WARNING

!

Any uncontrolled movement of the machine can cause an accident. Before turning the operator’s seat to the backhoe attachment working position, it is essential to place the direction of travel control lever and the gear change lever (Powershuttle) in the neutral position and immobilize the machine by means of the parking brake lever. (Specific to certain countries, lock the loader attachment controls).

!

WARNING

85

!

Before using the backhoe controls, make sure that the operator’s seat is correctly adjusted in the backhoe attachment position.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES These control levers are used to operate the backhoe attachment. The speed of movement of each control depends on the angle to which the lever is tilted. In the intermediate position, two movements can be obtained simultaneously.

IMPORTANT: Whenever the backhoe attachment is used, it is mandatory for the machine to be resting on the stabilizers. See “Stabilizer controls” and “Setting the backhoe attachment in working position” in Section 5.

IMPORTANT: Three backhoe attachment control configurations exist, depending on the country concerned: - Standard configuration.

- ISO configuration.

- Cross-pattern configuration.

The operating pattern of the control levers is different. Check which configuration you have on your machine.

!

WARNING

!

Check control functions before operating the machine. Failure to check control pattern before operating can cause unexpected machine movement, death or serious injury.

STANDARD CONFIGURATION Backhoe boom and backhoe attachment swing left-hand control lever This lever has five positions: Position (0): Neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

Position (A): The backhoe boom lowers.

Position (B): The backhoe boom rises.

Position (C): The backhoe attachment swings to the left.

Position (D): The backhoe attachment swings to the right.

Backhoe dipper and backhoe bucket right-hand control lever This lever has five positions: Position (0): Neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

Position (E): The backhoe dipper extends.

Position (F): The backhoe dipper retracts.

Position (G): The backhoe bucket closes.

Position (H): The backhoe bucket opens.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES STANDARD CONFIGURATION

86

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES ISO CONFIGURATION Backhoe dipper and backhoe attachment swing left-hand control lever This lever has five positions: Position (0): Neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

Position (A): The backhoe dipper extends.

Position (B): The backhoe dipper retracts.

Position (C): The backhoe attachment swings to the left.

Position (D): The backhoe attachment swings to the right.

Backhoe boom and backhoe bucket right-hand control lever This lever has five positions: Position (0): Neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

Position (E): The backhoe boom lowers.

Position (F): The backhoe boom rises.

Position (G): The backhoe bucket closes.

Position (H): The backhoe bucket opens.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES ISO CONFIGURATION

87

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES CROSS-PATTERN CONFIGURATION Backhoe boom and backhoe attachment swing left-hand control lever This lever has five positions: Position (0): Neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

Position (A): The backhoe boom lowers.

Position (B): The backhoe boom rises.

Position (C): The backhoe attachment swings to the left.

Position (D): The backhoe attachment swings to the right.

Backhoe dipper and backhoe bucket right-hand control lever This lever has five positions: Position (0): Neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

Position (E): The backhoe dipper extends.

Position (F): The backhoe dipper retracts.

Position (G): The backhoe bucket closes.

Position (H): The backhoe bucket opens.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES CROSS-PATTERN CONFIGURATION

88

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LOCKING THE BACKHOE ATTACHMENT MECHANICAL CONTROLS (Specific to certain countries) This pin, located in front of the stabilizer control levers, is used for locking the attachment controls.

89 To lock the controls, remove the pin from its housing and install it in the specially provided hole in the console.

!

WARNING

!

Before leaving the operator’s compartment, undertaking any road travel or working with the backhoe attachment, place the pin in locking position.

90 STABILIZER MECHANICAL CONTROLS IMPORTANT: Whenever the backhoe attachment is used the machine must be resting on the stabilizers.

LEFT-HAND STABILIZER LEFT-HAND CONTROL LEVER This lever has three positions: Position (0): Neutral. This position stops the movement of the left-hand stabilizer.

As soon as the lever is released, it automatically returns to the neutral position (0) and the left-hand stabilizer stops raising or lowering.

Position (1): The left-hand stabilizer lowers.

Position (2): The left-hand stabilizer rises.

91

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES RIGHT-HAND STABILIZER RIGHT-HAND CONTROL LEVER This lever has three positions: Position (0): Neutral. This position stops the movement of the right-hand stabilizer.

As soon as the lever is released, it automatically returns to the neutral position (0) and the right-hand stabilizer stops raising or lowering.

Position (1): The right-hand stabilizer lowers.

Position (2): The right-hand stabilizer rises.

NOTE: To raise or lower the stabilizers at the same time, operate the two levers simultaneously.

IMPORTANT: Before machine travel or before using the loader attachment, make sure that the stabilizers are completely raised.

IMPORTANT: During road travel, the stabilizers must be completely raised and immobilized by means of the pins provided for that purpose.

See “Road travel” in Section 6.

NOTE: The machine is fitted with a safety valve on each stabilizer, to prevent the machine from falling to the ground in the event of a hydraulic tube or hose bursting accidentally.

Replace all defective tubes or hoses immediately.

LOCKING THE MECHANICAL STABILIZER CONTROLS (Specific to certain countries) This pin, located in front of the stabilizer control levers, is used for locking the stabilizer controls.

To lock the controls, remove the pin from its housing and install it in the specially provided hole in the console.

!

WARNING

!

Before leaving the operator’s compartment, undertaking any road travel or working with the backhoe attachment, place the pin in locking position.

92

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES TELESCOPIC DIPPER MECHANICAL CONTROL PEDAL (If fitted) This pedal has three positions: Position (0): Neutral.

This position enables the movement of the telescopic dipper to be stopped.

NOTE: The pedal automatically returns to this position as soon as it is released.

Position (1): The telescopic dipper extends.

Position (2): The telescopic dipper retracts.

Before using this pedal make sure that the telescopic dipper is mechanically unlocked.

See “Setting the backhoe attachment in the working position” in the “Operating Instructions” Section 5.

93

NOTE: Operating the backhoe attachment control levers and this pedal simultaneously will afford numerous possibilities of progressive functioning.

AUXILIARY TOOL CONTROL PEDAL (Optional) This pedal is located to the right of the backhoe attachment controls and is used for operating auxiliary tools, such as a hydraulic hammer.

See “Backhoe attachment auxiliary hydraulic tools” in Section 5.

94

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES BACKHOE ATTACHMENT HYDRAULIC CONTROLS VERSION

95 1. CONTROL CANCELLATION SWITCH: With the switch in “ON” (alight) position all the backhoe attachment controls are functional.

2. LEFT-HAND CONTROL LEVER: The left-hand lever controls attachment swing and the boom or the dipper (depending on the control pattern adopted).

3. RIGHT-HAND CONTROL LEVER: The righthand lever controls the bucket and the boom or the dipper (depending on the control pattern adopted).

NOTE: Speed of movement depends on the angle to which the control levers are tilted. In intermediate position two movements may be obtained simultaneously.

4. STABILIZER CONTROLS: The right-hand control is for the right-hand stabilizer and the lefthand control is for the left-hand stabilizer.

6. TELESCOPIC DIPPER CONTROLS: (proportional controls) (If fitted).

Press the right-hand button to extend the dipper.

Press the left-hand button to retract the dipper.

7. WRIST RESTS: The wrist rests may be adjusted to the required height.

8. HYDRAULIC CONTROL ARM TILT ADJUSTMENT: These controls are used to make control arm fore/aft and left-right adjustments.

9. WARNING HORN BUTTON: Press the tip of the left-hand control lever to sound the audible warning device (momentary action).

10. CONTROLS OF AUXILIARY BIDIRECTIONAL SECTION (If fitted): Proportional buttons for activation of additional equipment.

5. CONTROL PATTERN CHANGE SWITCH: This switch is used for changing the standard control pattern to the ISO pattern.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES IMPORTANT: Before using the backhoe attachment, make sure sideshift carriage locking switch (1) is in “ON” position and that the lock plate has been disengaged, either by means of the lever (3) or the switch (2).

96 IMPORTANT: Whenever the backhoe attachment is used the machine must be resting on the stabilizers.

!

WARNING

!

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

!

WARNING

!

Any uncontrolled movement of the machine can cause an accident. Before turning the operator’s seat to the backhoe attachment working position, it is essential to place the direction of travel control lever and the gear change lever (Powershuttle) in the neutral position and immobilize the machine by means of the parking brake lever. (Specific to certain countries, lock the loader attachment controls).

!

WARNING

!

Before using the backhoe controls, make sure that the operator’s seat is correctly adjusted in the backhoe attachment position.

IMPORTANT: Whenever the backhoe attachment is used, it is mandatory for the machine to be resting on the stabilizers. See “Stabilizer controls” and “Setting the backhoe attachment in working position” in Section 5.

4-56

97

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES IMPORTANT: Two backhoe attachment control configurations exist, depending on the country concerned: - Standard pattern or ISO pattern (to change, use the control pattern change switch).

The operating pattern of the control levers is different, see “Backhoe attachment mechanical controls”.

Check which configuration you have on your machine.

!

WARNING

!

Check control functions before operating the machine. Failure to check control pattern before operating can cause unexpected machine movement, death or serious injury.

CONTROL CANCELLATION SWITCH This control is located on the right-hand control arm.

In position (1) (lamp out) all functions are cancelled.

Push the switch upwards (2) (lamp on) to enable the stabilizer function.

Push the switch once more upwards (3) (lamp on) for all functions to be enabled.

!

WARNING

!

After using the attachment or before leaving the machine, always tilt the switch downwards (1) (lamp out). Never forget this basic safety requirement.

98

NOTE: On starting the engine the cancelled controls position (1) is selected automatically.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES STANDARD CONFIGURATION Backhoe boom and backhoe attachment swing left-hand control lever This lever has five positions: Position (0): Neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

Position (A): The backhoe boom lowers.

Position (B): The backhoe boom rises.

Position (C): The backhoe attachment swings to the left.

Position (D): The backhoe attachment swings to the right.

99

Backhoe dipper and backhoe bucket right-hand control lever This lever has five positions: Position (0): Neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

Position (E): The backhoe dipper extends.

Position (F): The backhoe dipper retracts.

Position (G): The backhoe bucket closes.

Position (H): The backhoe bucket opens.

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100

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES STABILIZER CONTROLS These controls are located on the left-hand control arm and may be used to operate the stabilizers independently or simultaneously. Controls are proportionally which can vary stabilizer speed.

IMPORTANT: Whenever the backhoe attachment is used the machine must be resting on the stabilizers.

LEFT-HAND STABILIZER LEFT-HAND CONTROL LEVER This lever has four positions: Position (0): Neutral. This position stops the movement of the left-hand stabilizer. As soon as the lever is released from positions (1) or (2), it automatically returns to the neutral position (0) and the left-hand stabilizer stops raising or lowering.

When held in position (1): The left-hand stabilizer lowers.

When held in position (2): The left-hand stabilizer rises.

101

Position (3): Not used.

RIGHT-HAND STABILIZER CONTROL LEVER

RIGHT-HAND

This lever has four positions: Position (0): Neutral. This position stops the movement of the right-hand stabilizer. As soon as the lever is released from positions (1) or (2), it automatically returns to the neutral position (0) and the righthand stabilizer stops raising or lowering.

When held in position (1): The right-hand stabilizer lowers.

When held in position (2): The right-hand stabilizer rises.

102

Position (3): Not used.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES CONTROL PATTERN CHANGE SWITCH (Boom/dipper) Located on the right-hand control arm, this switch is fitted with a locking device.

The switch is used to change from standard pattern to ISO version, or vice versa.

To unlock the switch, push the locking device (1) upwards and at the same time press the top of the switch. In this position the switch lights up and the controls are in ISO pattern.

The boom and dipper controls on the levers are now inverted.

Press the bottom of the switch to lock and return to standard pattern operation.

103 TELESCOPIC DIPPER CONTROLS (If fitted) Press and hold down the right-hand button (1) to extend the telescopic dipper. As soon as the button is released the dipper stops and remains in the position it occupied when the button was released.

Press and hold down the left-hand button (2) to retract the telescopic dipper. As soon as the button is released the dipper stops and remains in the position it occupied when the button was released.

Before using these controls, make sure the telescopic dipper is mechanically unlocked. See “Setting the backhoe attachment in the working position” in Section 5.

104

NOTE: Simultaneous operation of the backhoe controls and these controls will afford numerous possibilities of progressive functioning.

HYDRAULIC CONTROL ADJUSTMENTS

ARM

FORE/AFT

Hold and squeeze the two handles together and then tilt the control arms to the required position.

Release the handles.

105

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES CONTROL ARM RIGHT/LEFT ADJUSTMENTS Loosen the two knurled wheels located in front of each control arm and then tilt the control arms to the required position. Tighten the knurled wheels.

106 AUXILIARY BI-DIRECTIONAL CONTROLS (If fitted) Press the left-hand button (1) and hold down to get the oil flow down the left-hand side of the boom.

Press the left-hand button (2) and hold down to get the oil flow down the right-hand side of the boom.

107

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES HEATING (Optional) AND AIR CONDITIONING (Optional) CONTROLS The heating controls, ventilation and air conditioning are placed right of the cabin (operator’s seat in the loader attachment position). Each control is supplied on demand.

NOTE: In order to use the heating it is necessary to open the relevant feeding cock located at engine’s right side. See chapter “Heating feeding cock”.

108 FAN CONTROL This four position knob enables air flow to be adjusted in the operator’s compartment.

Position (0): Off. Position (1): Low. Position (2): Medium.

Position (3): High.

NOTE: The air will be hot or cold depending on the position of the heater control.

109 HEATING CONTROL This knob enables the air temperature to be adjusted in the operator’s compartment.

To increase the temperature, turn the control knob clockwise (warm).

To decrease the temperature, turn the control knob counterclockwise (cold).

110

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES AIR CONDITIONING CONTROL (Optional) HFC 134a refrigerant For technical details see decal placed on the left side of the motor cooler

!

WARNING

!

HFC 134a refrigerant can be dangerous if improperly handled. Therefore, it is important the following warnings and directions are adhered to.

HFC 134a has a boiling point of -12 °C. Never expose any part of the air conditioning system to flames or excessive heat because of the risk of fire or explosions and the production of phosgene gas.

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

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

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

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

111

The air conditioning control allows to obtain always the required temperature inside of the cabin.

To activate the air conditioning turn selector (2). At the activation the warning light (3) lights up. The selector (1) allows to choose the ideal temperature according to your requirement. Positioning selector (1) on “0” and turning selector (2) let you obtain less or more cold according to the selector (2) position.

By positioning selector (1) on any other position different from “0” you will obtain instead a mixture of warm and cold air and the desired clima inside of the cabin.

NOTE: The air conditioning can be set into operation, only if the ventilation selector (4) is not positioned on STOP.

112

Turn selector (4) on demand for air capacity.

IMPORTANT: When using the air conditioning, it is essential that all the windows of the operator’s compartment are completely closed.

NOTE: To ensure correct operation and full efficiency of the air conditioning system, it must be used at least once a week, even for a short time.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Air flow vents Air flow vents are connected to the heater housing and receive air from the blower motor, to direct warm or cold air onto the windshield and side windows or to the cab interior as required.

Each vent may be swivelled and adjusted to control the flow of air.

To open a vent, press one side of the disc and turn it, as required, to direct the air flow.

x1 000

The vents are located as follows: - two on the top of the main dashboard (A); - two to the rear of the operator seat (A); - two under the seat, one in front, the other on the rear (D); - two on the cab posts, right and left (B); - two on the ceiling, in front and back of operator’s head (C).

NOTE: The vents (B) and (C) are mounted only when air conditioned (optional) is fitted.

113

114 Air recirculation The air recirculation control is located under the seat, on the left side.

- When the knob (1) is positioned corresponding to the symbol (2) the air does not come in from the outside, and the air recirculation mode is activated.

- When the knob is positioned corresponding to the symbol (3) the air comes in from the outside.

115

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES CAB AIR FILTER This is located under the operator’s seat.

The filter element is made of special paper with an adhesive band around them acting as a seal.

Clean this element with compressed air, working from the clean side towards the outside. The air pressure must not exceed 2 bar and the nozzle must be held at least 300 mm from the element. See “Cab air filters” in Section 9.

IMPORTANT: Make sure you protect your face before using compressed air.

116

BRAKE FLUID RESERVOIR This is located under the steering console hatch.

The reservoir has a level warning lamp which lights up whenever the minimum level is reached. If the warning lamp lights up during operation, move the machine to a place of safety, shut down the engine, remove the ignition switch and find the cause of the problem.

To check the warning lamp is operative, remove the reservoir access hatch (1) and press the button on the filler cap. The warning lamp on the instrument panel should light up. If it does not, look for the cause of the problem.

To replace the brake fluid, see “Brake fluid” in Section 9.

117

FIRE EXTINGUISHER (Optional) The fire extinguisher is located to the right of the steering wheel.

On taking delivery of the machine, study the fire extinguisher operating instructions.

The instructions are printed on the extinguisher.

!

WARNING

!

Have the fire extinguisher inspected every year by a specialist.

118

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES OPERATOR’S COMPARTMENT WINDOWS CAB DOOR WINDOWS Partially opened Raise the handle and then push outwards and downwards to lock the window in partially opened position.

Fully opened With the window closed, raise the handle to horizontal position and then tilt it rearward to disengage it from the pin. Open the window until it engages in the rubber locking device.

Closed Make sure the window handle is engaged completely in the lock pin, close the window and then tilt the handle downwards.

119

CAB SIDE WINDOWS Use the window handle to open the window until it engages in the rubber locking device (1). Pull on item (2) to release the window.

IMPORTANT: Do not leave the windows free to swing but fix them in latched position.

IMPORTANT: When opening or closing windows, always hold them firmly until they are completely locked in position.

120 REAR WINDOWS Opening Release the locks (1) and swing the window inwards with the handles.

121

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Bring the window into horizontal position and lock it with the latches (2).

IMPORTANT: Make sure the window is completely locked.

Closing Release the latches (2) and tilt into lower position with the handles.

Lock the window with the locks (1).

122

LOADER ATTACHMENT SAFETY STRUT Located on the left-hand side of the loader attachment, this safety strut enables the loader attachment to be locked in the raised position in case of defects in the system.

LOCKED POSITION 1. Raise the loader attachment completely, stop the engine and remove the starter switch key.

2. Remove the pins and the safety strut from the loader arm. Put the pins back in place.

123 3. Place the strut on the cylinder rod and install the retaining strap.

!

WARNING

!

It is mandatory to install the safety strut when carrying out any operation requiring the loader attachment to be in the raised position.

124

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES UNLOCKED POSITION 1. Remove the strut from the cylinder rod.

125 2. Install the safety strut with the pins on the loader arm.

3. Start the engine and lower the loader attachment.

126

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES ENGINE GUARD The engine guard is opened and closed by means of the lever located in the operator’s compartment.

See “Engine guard locking and unlocking lever”.

Use the notches on the guard and then lift the guard.

To close the guard, lower it and then lock it by means of the lever located in the operator’s compartment.

!

WARNING

!

127

Before undertaking any road travel, make sure the engine guard is properly locked.

!

WARNING

!

It is essential to install the loader attachment support strut before any servicing work is done on the engine.

128

FUEL TANK Located on the left-hand side of the machine, the tank capacity is 145 litres (2WS), 124 litres (4WS).

NOTE: Clean around the filler cap before re-fuelling.

NOTE: In cold weather, use fuel corresponding to the ambient temperature, see “Fluids and lubricants” in Section 8.

IMPORTANT: In cold weather, fill the tank after each working day, to prevent the formation of condensation.

When installing the cap, make sure that it is correctly placed in the notches and then lock it, using the starter switch key.

!

WARNING

129

!

Never refill the tank when the engine is running.

Do not smoke during re-fuelling.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES HYDRAULIC RESERVOIR Located on the right-hand side of the machine, the capacity of the reservoir is 39 litres (2WS), 55 litres (4WS).

To refill the reservoir, see “Hydraulic system” in Section 8.

NOTE: Clean around the filler cap before refilling.

IMPORTANT: Use a suitable hydraulic fluid. See “Fluids and lubricants” in Section 8.

Use the special wrench delivered with the machine to remove the cap (1). See “Machine tooling”.

The sight glass (2) shows the level of fluid in the reservoir. See “Hydraulic system” in Section 8.

130

BATTERY AND TOOL BOX Located on the right-hand side of the machine, this box houses the battery and can be used for storing service tools.

IMPORTANT: Before carrying out any service work on the battery, see “Battery” in Section 10.

131

MACHINE TOOLING The machine is supplied with a hydraulic reservoir wrench and may also be supplied with tools (optional) for carrying out maintenance work. These are: -

A wheel nut wrench.

An adjustable wrench.

A tyre pressure gauge.

A grease pump.

A filter wrench.

A hammer.

An oil draining extension hose.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES REAR VIEW MIRRORS Make sure the right-hand and left-hand rear view mirrors are correctly adjusted before undertaking any travel.

132

HEATER CONTROL VALVE Located on the right-hand side of the engine, this valve enables the heater system to be turned on or off. See “Heater, ventilation and air conditioning (optional) controls”.

In cold weather, turn the valve to the left (open).

In hot weather, turn the valve to the right (closed).

NOTE: Make sure the engine is cold before using the valve.

133

REVERSIBLE STABILIZER PADS (Centre pivot backhoe version) (Optional) These stabilizer pads are intended for use in the street or on the job site. They may be turned around 180°, as required.

IMPORTANT: When these pads are used, there is danger of them fouling the cab windows.

Lower the stabilizers slightly before opening the windows to avoid any damage.

134

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LOADER BUCKET QUICK COUPLER (If fitted) It is possible to install a quick coupler (1) for the loader bucket on the loader arms, using the standard mounting pins (2). See the manufacturer’s instructions for further details.

QUICK REMOVAL AND INSTALLATION OF THE LOADER BUCKET 1. Make sure the bucket to be installed is in a safe area, on flat, level ground and with the upper pins in place.

2. Use the control lever (dumping position) to bring the quick coupler hooks over the bucket pins (3).

3. Use the control lever (digging position) to swing the bucket down onto the lower part of the quick coupler.

4. Shut down the engine and remove the starter switch key.

5. Install the pins (4) and retaining hardware.

IMPORTANT: Make sure the loader bucket is correctly installed with all its pins and locking rings before using the loader.

135

ROTATING BEACON (If fitted) The rotating beacon should be placed on the cab roof and the cable connected to one of the 12 volt sockets over the door on each side of the machine.

IMPORTANT: The rotating beacon must be installed and functioning when undertaking road travel.

See “Road travel” in Section 6.

136

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES ATTACHMENT SAFETY VALVES (If fitted) The purpose of the safety valves is to prevent the attachment falling out of control to the ground as a result of leakage from a valve spool in neutral position or a hydraulic hose or pipe bursting accidentally, as well as ensuring smooth and controlled descent of the attachment in the event of a hydraulic hose or pipe bursting accidentally.

Check the safety valves function correctly. A load holding check must be carried out every 6 months in conformance with the manufacturer’s instructions.

Consult your Dealer.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES BACKHOE BUCKET MECHANICAL QUICK COUPLER (If fitted)

!

WARNING

!

Never place your hand inside a quick coupler jaw when it is open.

It is possible to install a mechanical quick coupler (1) on the dipper using the standard pins.

1. Make sure the tool to be installed is in a safe area on hard, level ground with its pins in place.

2. Make sure the tool linkage pin is in maximum force (2) position.

IMPORTANT: It is imperative for the linkage pin to be in maximum force position, otherwise the quick coupler will not engage.

3. Make sure the quick coupler jaw is open.

4. Use the bucket and dipper controls to engage the quick coupler hook round the lower pin.

5. Use the bucket controls to engage and lock the pin (3) completely in the quick coupler jaw.

6. Shut down the engine and remove the starter switch key.

7. Install the quick coupler safety pin.

!

WARNING

!

Make sure the safety pin is correctly installed in the quick coupler as described in the manufacturer’s instructions after each tool change. In the event of any doubt concerning the safety pin or adjustments, do not hesitate to consult your Dealer.

To change the tool, release the jaw (with the safety pin removed) using the lever (4) supplied for opening it.

4-74

138

SECTION 5 OPERATING INSTRUCTIONS BEFORE OPERATING THE MACHINE

!

WARNING

!

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

Before operating the machine, observe the following instructions: 1. Check the levels (engine oil, hydraulic fluid and coolant fluid) and make sure that the various fluids correspond to the conditions of use. See “Operating the machine in cold weather” and “Fluids and lubricants” in Section 8.

2. Carry out the daily maintenance operations.

See Section 7.

3. Walk round the machine, look for any leaks and inspect the hoses. Tighten or replace any items as required. See Section 9.

4. Before undertaking any road travel, lock the attachments, raise the stabilizers completely and install the safety systems required by regulations. See “Road travel” in Section 6.

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

8. Clean or replace safety decals which are no longer legible. See “Decals” Section 3.

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

10. Make sure that the cab doors are closed correctly.

11. Remove anything which might hinder visibility.

Clean the windshield windows and rear view mirrors.

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

13. Make sure you know how to evacuate the machine (emergency exit via the right-hand door) in case access by the left-hand door is impossible.

14. Make sure that the right-hand door is not locked.

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

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

6. Check the condition and pressure of the tyres.

See Section 9 and Section 12.

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

5-1

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE

!

WARNING

!

11. Adapt your operating style to the type and conditions of work. See “Operating Instructions” Section 6.

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

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

When operating the machine the following instructions must be observed:

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

1. Start the engine taking into account weather conditions. See “Starting the engine”.

14. If the machine has to work in water, see “Operating the machine in water”.

2. Regularly consult the hourmeter to ensure Servicing Intervals are observed. See Section 7.

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

3. Respect the machine’s maximum slope angle.

Maximum angles: 25° in both the axial and lateral axes.

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

5. If this machine is new, see “Running-in period”.

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

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

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

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

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

5-2

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

17. Load lifting should be carried out in accordance with the instructions given in this manual and in accordance with prevailing regulations. See “Load lifting”.

18. Avoid running the engine in an enclosed space.

If necessary, ensure good ventilation under all circumstances.

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

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

21. When stopping the engine take account of weather conditions. See “Stopping the engine”.

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

SECTION 5 - OPERATING INSTRUCTIONS RUNNING-IN PERIOD Your machine will last longer and give better and more economical performance if you pay particular attention to the engine during the first twenty hours of operation.

During the running-in period, the following inspections and maintenance operations must be carried out in addition to the operations shown in the Maintenance Programme:

During this period:

Every ten hours or daily

Keep a close watch on the instrument panel.

Check the engine oil and coolant levels.

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

Check the transmission and rear axle oil levels.

To ensure adequate lubrication, idle the engine at 1000 rev/min. for one minute before placing a load on the engine.

Maintain the engine at the normal operating temperature.

Check the front axle oil level (4WD).

Check the backhoe and loader attachment lubrication.

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

See “Wheels and tyres” in Section 9.

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

5-3

SECTION 5 - OPERATING INSTRUCTIONS STARTING THE ENGINE NOTE: In cold weather, see “Starting the engine in cold weather”.

NOTE: After the machine has not been operated for an extended period, see “Starting up after storage” in Section 11.

NOTE: If you have to start the engine by means of a booster battery, see “Connecting a booster battery” in Section 10.

1. Check that the seat is properly locked in the loader attachment working position.

2. Adjust the seat and attach the seat belt.

3. Check that the parking brake lever is in raised position.

1 4. Check the engine throttle lever is in low idle position.

2

5-4

SECTION 5 - OPERATING INSTRUCTIONS 5. Check that the direction of travel lever (3) is in the neutral position.

NOTE: (Powershuttle) If this is not done the audible warning device will sound and it will be impossible to start the engine.

3 6. Check that the gear change lever is in the neutral position (Powershuttle).

7. If the machine is equipped with the coded antistart system, see “Coded anti-start system”.

4 8. Turn the starter switch key to the “ON” position.

Warning lights (1), (2), (3) and (4) should light up. If necessary, replace the defective bulbs.

See “Replacing a bulb” in Section 10.

9. Press the accelerator pedal down about a quarter of the way.

5 10. Turn the key to the starting position. Release the key as soon as the engine starts. If the engine stops, wait about one minute before starting the operation again.

IMPORTANT: Do not operate the starter for more than 20 seconds at a time. Do not operate the starter when the engine is running.

6

5-5

SECTION 5 - OPERATING INSTRUCTIONS 11. When the engine is running check the indicators and indicator lamps to make sure that all systems are operating correctly.

12. Using the accelerator pedal, run the engine at half speed until it has reached normal operating temperature.

NOTE: Do not run the engine at idle for too long, since this may cause the formation of deposits in the oil. Whenever conditions of use and safety allow it, run the engine at maximum speed.

7

STARTING THE ENGINE IN COLD WEATHER WITH AN AIR INTAKE HEATER (GRID HEATER) (Optional) This starting system activates when the ambient temperature is lower than 5 °C. 1. Carry out steps 1 to 8 of the normal engine starting procedure.

2. Wait for the indicator lamp (1) to go out.

NOTE: You have approximately 30 seconds to start the engine, after which it will be necessary to recommence the procedure.

3. Carry out steps 11 to 12 of the normal engine starting procedure.

8

5-6

SECTION 5 - OPERATING INSTRUCTIONS STARTING THE ENGINE AT TEMPERATURES BELOW -18 °C USING IMMERSION HEATER ASSISTANCE (If fitted) This starting system is to be used when the ambient temperature is between -18 °C and -29 °C. The immersion heater heats the engine coolant and is for use at temperatures below -18 °C. When used in conjunction with engine air heating, the immersion heater will be effective down to -29 °C. Consult your Dealer.

The system works on 115 volt or 230 volt Alternating Current.

!

WARNING

!

To avoid shocks or other injuries, never use an ungrounded or inadequate extension lead. Always use a grounded 3 core extension lead with a 3 wire plug which is rated for at least a 15 ampere load.

To operate the heater connect the heater plug to a suitable extension lead and switch on for two hours before carrying out the cold weather starting procedure.

NOTE: The heater may be left switched on for more than two hours without harm. However, no noticeable increase in the heater’s effectiveness will be achieved after this period of time.

STOPPING THE ENGINE 1. Place the direction of travel control lever in the neutral position.

9

5-7

SECTION 5 - OPERATING INSTRUCTIONS 2. Place the gear change lever in the neutral position (Powershuttle).

10 3. Raise the parking brake lever.

NOTE: (Powershuttle) The audible warning device will sound if the parking brake lever is raised while the direction of travel lever is not in the neutral position.

4. Allow the engine to run at idle speed for about one minute in order for the turbocharger to be lubricated correctly.

IMPORTANT: In cold weather, run the engine at low idle speed for three to five minutes.

11 5. Turn the starter switch key to the “OFF” position and remove the starter switch key.

IMPORTANT: If the engine is to be stopped for a long period, see “Parking the machine”.

12

5-8

SECTION 5 - OPERATING INSTRUCTIONS CODED ANTI-THEFT SYSTEM (Optional) To prevent risks of theft or unauthorised use of your machine, it can be equipped with an (optional) coded anti-start system.

It is impossible to start the engine if the personalised electronic key is not used.

CODED ANTI-START SWITCH This switch has a red flashing lamp and is located under a cover, to the left of the instrument panel.

To deactivate the anti-start system, insert the electronic key in the switch. The indicator lamp will go out.

Remove the electronic key from the switch. You then have 20 seconds to start the engine.

When stopping the engine, with the starter switch key in the “OFF” position, the indicator lamp stays off for 20 seconds, during which it is possible to restart the engine without using the electronic key.

After 20 seconds the indicator lamp flashes and the coded anti-start system is activated.

13

NOTE: Before leaving the operator’s compartment after stopping the engine, wait till the indicator lamp flashes to ensure that the anti-start system is working.

5-9

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN COLD WEATHER Observe the following recommendations: BATTERY It must be fully charged.

FUEL a) Refill the fuel tank after each working day to prevent the formation of condensation and the entry of water into the fuel system. b) To prevent the formation of crystals (-2 °C) use a low temperature fuel or mix a protective fluid with your fuel. See “Fluids and lubricants” in Section 8.

ENGINE OIL The engine oil must have a viscosity corresponding to the ambient temperature. See “Fluids and lubricants” in Section 8.

COOLANT SOLUTION It must have a specification corresponding to the ambient temperature. See “Fluids and lubricants” in Section 8.

OPERATING THE MACHINE IN HOT WEATHER Observe the following recommendations: 1. Maintain the correct level of coolant solution in the coolant reservoir.

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

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

4. Check the condition of the alternator and fan belt.

5. Use lubricants with the recommended degree of viscosity. See “Fluids and lubricants” in Section 8.

6. Use an appropriate coolant solution. See “Fluids and lubricants” in Section 8.

5-10

SECTION 5 - OPERATING INSTRUCTIONS SETTING THE BACKHOE ATTACHMENT IN WORKING POSITION

!

WARNING

!

Any uncontrolled movement of the machine can cause an accident. Before turning the operator’s seat to the backhoe attachment working position, it is essential to place the direction of travel control lever and the gear change lever in the neutral position and immobilize the machine by means of the parking brake lever. (Specific to certain countries, lock the loader attachment controls).

!

WARNING

!

Before using the backhoe attachment, place the seat in the backhoe attachment position. Always sit in the seat and attach the seat belt. Serious injury can result if these instructions are not observed.

1. Remove the backhoe attachment locking systems.

2. (Sideshift backhoe version) remove the strap from each stabilizer. The stabilizer pads may be turned around for better lateral stability.

IMPORTANT: Before undertaking any road travel, be sure to return the stabilizer pads to their original position.

3. Check that the direction of travel control lever is in the neutral position.

4. Make sure that the gear change lever is in the neutral position (Powershuttle).

5. Make sure that the parking brake lever is in the raised position.

14

6. Make sure the glide ride system (if fitted) is turned off and that the switch lamp is not alight.

7. Start the engine. Lower the loader bucket until it is resting horizontally on the ground. Press down on the ground with the bucket until the front wheels are no longer supporting the weight of the machine.

8. (Specific to certain countries) use the pin to lock the loader attachment controls.

15

5-11

SECTION 5 - OPERATING INSTRUCTIONS 9. Turn the seat round to the backhoe attachment position and adjust it correctly.

10. Accelerate and run the engine at the required speed.

11. Lower the stabilizers slightly, leaving the rear wheels in contact with the ground.

IMPORTANT: Whenever the backhoe attachment is used the machine must be resting on the stabilizers.

12. Place the backhoe attachment in line with the machine.

!

WARNING

!

Before operating the backhoe offset swing, ensure that no person is within its working range.

13. Raise the boom to release the lock plate.

A. Locked position B. Unlocked position

16

14. For any digging operation, also when using the telescopic dipper (if fitted), the pin and the retaining pin must be in unlocked position (B).

!

WARNING

!

Before starting work, make sure that no person is within the working range of the machine.

!

WARNING

!

Before starting work, check that all the backhoe controls operate correctly.

5-12

17

SECTION 5 - OPERATING INSTRUCTIONS LOCKING OR UNLOCKING THE BACKHOE ATTACHMENT Before undertaking any road travel with the machine, the backhoe attachment must be “locked” in transport position. In order to do this, retract the dipper completely up to the boom and then fully raise the boom so that the lock plate engages on the backhoe boom pins.

MECHANICALLY OPERATED CONTROL To lock the attachment, pull lever (1) backwards and raise the boom until the locking system (2) engages.

Release the lever.

18 To unlock the attachment, push lever (1) forwards to release the locking system (2) and then lower the boom.

19 ELECTRICALLY OPERATED CONTROL To unlock the attachment, place switch (1) in “OFF” position. The switch lights up and the locking plate is released. Lower the boom.

To unlock the attachment, place switch (1) in “ON” position. The switch goes out. Raise the boom until it engages.

!

WARNING

!

Do not attempt to use the backhoe attachment with the boom in locked position as this can cause serious damage.

20

5-13

SECTION 5 - OPERATING INSTRUCTIONS BACKHOE ATTACHMENT SIDESHIFT (Sideshift backhoe version) To dig alongside a building or fence, etc., it is possible to shift the backhoe attachment sideways to the right or the left.

1. The machine must be in the backhoe attachment position, see “Setting the machine in the backhoe attachment working position”.

2. Place the backhoe attachment on the left if you want to shift the attachment to the right or place it on the right if you want to shift it to the left, then place the attachment on the ground in the position shown.

3. Press the sideshift unlocking switch (1). The switch lamp lights up (“ON” position).

21 4. Operate the backhoe attachment controls alternately so as to slide the sideshift carriage sideways.

5. Once the attachment is in the side position required, swing it round into alignment with the machine.

6. Work on the opposite side of the sideshift carriage as much as possible. Otherwise, reduce the load in the bucket for better stability.

7. Press the sideshift locking switch (1). The switch lamp goes out (“OFF” position).

IMPORTANT: Except when the sideshift carriage is being moved, switch (1) should always be in “OFF” position. Never use the backhoe attachment with the sideshift carriage unlocked.

5-14

22

SECTION 5 - OPERATING INSTRUCTIONS SETTING THE BACKHOE ATTACHMENT IN THE ROAD TRAVEL POSITION IMPORTANT: This procedure must be used for road travel, for operating the loader attachment, when transporting the machine on a trailer and when parking the machine.

1. Check that the direction of travel control lever (1) is in the neutral position.

2. Make sure that the gear change lever (2) is in the neutral position (Powershuttle).

3. Make sure that the parking brake lever (3) is in the raised position.

4. Make sure that the operator’s seat (4) is correctly positioned.

5. Make sure that the machine is resting on the stabilizers and the loader bucket.

23 6. Retract the telescopic dipper completely and place the pin and split pin in the telescopic dipper locking hole (if fitted).

7. (Sideshift backhoe version), position the backhoe attachment sideshift carriage completely to the right.

8. Place the backhoe attachment in line with the machine.

9. Run the engine at about 900 rpm.

10. Retract completely the backhoe bucket and the backhoe dipper.

11. Lock the backhoe attachment. See “Locking or unlocking the backhoe attachment”.

24

12. (Sideshift backhoe version) swing the backhoe attachment completely to the left.

13. Raise the stabilizers completely.

14. Run the engine at low idle speed.

15. Turn the seat round to the loader attachment position. Raise the loader bucket.

16. Stop the engine and remove the starter switch key.

17. (Specific to certain countries) install all the mechanical locking systems in compliance with legal requirements. See “On road travel requirements”.

25

5-15

SECTION 5 - OPERATING INSTRUCTIONS ON ROAD TRAVEL REQUIREMENTS

26

5-16

SECTION 5 - OPERATING INSTRUCTIONS (Specific to certain countries) install all the mechanical locking systems in compliance with legal requirements.

Make sure your machine is in conformance with local legislation.

6. ROTATING BEACON: The rotating beacon should be placed on the cab roof, with the cable connected to one of the sockets mounted above the cab doors.

1. LICENCE PLATES: Make sure these are clean before undertaking any road travel.

7. TELESCOPIC DIPPER LOCKED PIN (If fitted): Place the pin and the retaining pin in the locked position.

2. LOADER BUCKET TOOTH GUARD: (attachment by a spring and hook to the loader bucket).

8. BACKHOE BUCKET RETAINING: Consisting of a retaining belt locking the backhoe bucket to the hook located in the rear side of the frame.

3. LOADER TIE DOWN STRAP: Ensure when travelling/transporting on the road the loader is secured to front tow point.

9. BACKHOE ATTACHMENT LOCKING Install the pin in the locking plate.

4. LOADER BUCKET RETAINING: Consisting of a yoke tie rod linking the loader bucket to the bucket link.

PIN:

10. STABILIZER STRAP: (sideshift backhoe version): Secure for on road use.

11. WARNING PANEL: This is clipped onto the bucket.

5. LOADER ATTACHMENT CYLINDER LOCKING: Raise the attachment sufficiently to be able to install the sleeve on the cylinder rod and retain it in place with a clip.

Lower the attachment slowly to enable the cylinder to come into contact with the sleeve and lock it.

5-17

SECTION 5 - OPERATING INSTRUCTIONS REPLACING A BACKHOE BUCKET REMOVAL 1. Park the machine on level ground.

2. Lower the stabilizers until they are resting on the ground.

3. Place the bucket flat on the ground.

4. Stop the engine and remove the starter switch key.

5. Remove the safety split pin (1).

6. Slide out the pin (2).

7. Start the engine.

8. Move the arm so that the hook (3) can get released from the bucket pin (4).

27 INSTALLATION 1. Start the engine.

2. Slowly approach the arm to the backhoe bucket paying attention that hook (3) engages in the bucket pin (4).

3. Move the arm so that the pin hole (2) aligns with the holes of the bucket lugs.

4. Stop the engine.

5. Insert the pin (2) and install the safety split pin (1).

5-18

SECTION 5 - OPERATING INSTRUCTIONS REPLACING A LOADER BUCKET REMOVAL 1. Park the machine on level ground.

2. Lower the bucket to the ground in dump position (tilted completely forward).

3. Stop the engine and remove the starter switch key.

4. If the machine is fitted with a 4x1 bucket, release the pressure in the bucket circuit.

See “Releasing pressure in the hydraulic system” in Section 8.

28 5. Remove the linkage pin retaining bolts and then remove the linkage pins (1).

!

WARNING

!

Always wear eye protection when using a tool that might project metal particles.

Use a hammer with a soft face, such as copper, for installing pins.

6. (4x1 bucket) disconnect and plug the hydraulic supply lines.

7. Start the engine.

8. Operate the attachment controls so as to release the bucket.

29

9. Reverse the machine away from the bucket.

5-19

SECTION 5 - OPERATING INSTRUCTIONS INSTALLATION 1. Make sure all bushings are completely clean.

Remove any dirt or foreign matter, if necessary.

2. Start the engine.

3. Use the attachment controls to engage the attachment between the bucket lugs.

4. Install the arm/bucket linkage pins (1) and then install the linkage pin retaining bolts.

5. Use the bucket controls to align the connecting rod orifices with the bucket lugs.

6. Shut down the engine and remove the starter switch key.

7. (4x1 bucket) release the pressure in the bucket circuit.

See “Releasing pressure in the hydraulic system” in Section 8.

8. Install the connecting rod/bucket linkage pins (1) and then install the linkage pin retaining bolts.

9. (4x1 bucket) remove the plugs and reconnect the hydraulic supply lines.

5-20

30

SECTION 5 - OPERATING INSTRUCTIONS DIFFERENTIAL LOCK The differential lock gives equal power to both rear wheels.

It is particularly useful when the wheels have insufficient adhesion, as in the following cases: IMPORTANT: Never use the differential lock during travel on a public highway.

WHEN THE MACHINE IS STUCK 1. Make sure that the rear wheels are not turning.

2. Press down the differential lock pedal (Powershuttle) and hold it in this position.

31 3. Press down the differential lock switch (Powershift) and hold it in this position.

4. Use the accelerator pedal to increase the engine speed and then release the differential lock button.

NOTE: The differential is released automatically when the locking system is disengaged, when rear wheel adhesion returns to normal, with no wheel slip, or when one of the brake pedals is operated.

32

5-21

SECTION 5 - OPERATING INSTRUCTIONS BEFORE CROSSING A SOFT OR MUDDY AREA

!

WARNING

!

Never use the differential lock at speeds above 8 km/h or when turning the machine. When engaged the lock will prevent the machine turning and personal injury could result.

NOTE: You can engage the differential lock when the machine is moving in a straight line.

1. Make sure that the machine is moving in a straight line and that both rear wheels are turning at the same speed.

2. Press down the differential lock pedal (Powershuttle) and hold it in this position until the area has been crossed.

33 3. Press down the differential lock switch (Powershift) and hold it in this position.

4. After you have moved through the area, release the differential lock button.

NOTE: You can cause damage to the transmission if you try to engage the differential lock when the machine is turning or if one rear wheel is rotating faster than the other rear wheel.

34

5-22

SECTION 5 - OPERATING INSTRUCTIONS LOADER BUCKET MOUNTED FORKS (Optional)

!

WARNING

!

The forks are heavy, so use great care when swinging them into their working and stowage position.

INSTALL FORKS IN WORKING POSITION 1. Place the loader bucket onto the flat level ground stop the engine, engage parking brake and remove the starter switch key.

2. Remove the retained pin and the pin (1).

3. Lower the fork (2) manually and carefully until it is laying in position against the bucket cutting edge.

IMPORTANT: The forks must be laying against the cutting edge, not against the bucket teeth.

35 4. Install the pin and the retained pin (1).

5. Repeat steps 2 to 4 for the other fork.

6. Slide the forks until they are suitably spaced for the intended job.

IMPORTANT: Both forks must be spaced equally each side of the centre of the bucket.

IMPORTANT: Never use the forks to lift the machine.

!

WARNING

!

When using the forks with a 4x1 bucket, never attempt to use the bucket jaw opening function.

36

5-23

SECTION 5 - OPERATING INSTRUCTIONS INSTALL THE FORKS IN REST POSITION 1. Place the bucket onto the flat level ground, stop the engine, engage parking brake and remove the starter switch key.

2. Remove the retained pin and the pin (1).

3. Tilt the fork (2) manually and carefully until it is rearwards into transport position.

37 4. Install the pin and retaining pin (1) in its housing.

NOTE: If necessary slide the fork to bring it into its housing.

5. Repeat steps 2 to 4 for the other fork.

IMPORTANT: The forks must be securely retained in their proper stowage positions using the correct pins and link pins. Improperly stowed forks may be cause sections injury.

38

5-24

SECTION 5 - OPERATING INSTRUCTIONS HYDRAULIC SPEED CONTROL Using the control during loader operation: When the hydraulic speed control switch is in the “OFF” position, oil is supplied to loader functions by two pump bodies (2 flows).

When the hydraulic speed control switch is in the “OFF” position, oil for loader functions is supplied by two pump bodies up to a pressure of 170 bar, beyond which it is supplied by only one. The flow from the second pump body returns directly to the reservoir, thereby reducing the total flow and increasing the loader bucket break out force.

Using the hydraulic speed control while the backhoe attachment is functioning: For occasional use of the backhoe attachment and in the interests of fuel consumption, place the switch in “ON” position. In this mode the attachment speed is reduced for pressures above 170 bar. For maximum backhoe loader performance the switch should be placed in the “OFF” position.

39

STEER PHASING (4WS) To select the type of steering required, turn the switch to the corresponding position. The corresponding position lamp will begin to flash on the instrument panel. Turn the steering wheel to the right and then to the left and the lamp will remain on permanently.

IMPORTANT: The steering mode has been successfully changed when the lamp stays on permanently.

Position 1 = “Road” Position 2 = “4WS” Position 3 = “Crab steer” IMPORTANT: When changing from one position to another the speed of the machine must be below 10 km/h and the steering wheel turned to full lock left and right. This allows the hydraulic cylinders to refill with oil and engage the steering selected.

40

The machine is fitted with an audible alarm device, which warns the operator when the machine is travelling at a speed higher than 12 km/h, in crab steering position.

5-25

SECTION 5 - OPERATING INSTRUCTIONS Road position (2 wheel steer) - Switch in position (1) Place the switch in vertical position. The front wheels now steer the machine, as conventionally.

IMPORTANT: The flip over cover (1) only needs to be installed on the switch when 2 wheel steer position is selected.

IMPORTANT: Before undertaking any road travel, select the 2 wheel steer position and install the flip over cover to lock the switch in that position.

41 4WS position - Switch in position (2) Turn the switch to the left and in this position both the front and rear wheels steer the machine, facing in opposite directions, thereby giving a shorter turning radius in comparison to conventional steering.

42 Crab steer position (the four wheels all steer in the same direction) - Switch in position (3) Turn the switch to the right. The machine will travel to the right or the left, in a straight line and at an angle of up to 15 degrees to the right or left of the straight ahead direction.

43

5-26

SECTION 5 - OPERATING INSTRUCTIONS PHASING PROCEDURE These machines need to be phased at least once a day, as follows.

To select the type of steering, turn the switch to the position corresponding to the type of steering required: Position 1 = “Road” Position 2 = “4WS” Position 3 = “Crab steer”

!

WARNING

!

Failure to phase the four wheel steering at least once per day may mean a reduction in steering effectiveness.

The steering must be phased: - At the start of each working day - At least once per day - If having difficulty in steering - After travelling for 24 km or more on the road in two wheel drive.

IMPORTANT: The following procedure must be carried out at least once a day.

Raise the machine supporting it on the bucket and stabilizers.

Select “Road” (1) position and turn the steering wheel completely to one side and then to the other.

Two wheel steering is a requirement for road use.

44 Select “4WS” (2) position and turn the steering wheel completely to one side and then to the other.

Select “Road” (1) position again and turn the steering wheel completely to one side and then to the other.

Lower the machine to the ground.

45

5-27

SECTION 5 - OPERATING INSTRUCTIONS BACKHOE ATTACHMENT AUXILIARY HYDRAULIC TOOLS (Optional) Before using auxiliary tools (3), it is mandatory to proceed as follows: - Place the direction of travel control lever in neutral position.

- Place the gear change lever in the neutral position (Powershuttle).

- Lower the loader bucket until it is pressing on the ground.

Shut down the engine, release all pressure in the auxiliary circuit, remove the plugs and connect the tool hoses to the couplings (1) at the end of the boom.

IMPORTANT: Inverting the connections can cause involuntary or untimely functioning of the tool or even damage it considerably. To avoid all risk of accidents, follow the manufacturer’s instructions carefully.

FLOW SELECTION It is up to the operator to decide which flow should be used by consulting the manufacturer’s operating instructions. Be sure to select the flow recommended. Excess flow can damage some equipment.

46

Place the accelerator lever in full speed position.

Press down the control pedal (2) to operate the tool.

Release the control pedal (2) to stop the tool.

Depending on the flow requirement recommendations, adjust the flow regulator on the chassis, at the rear of the machine. Consult your Dealer.

47

5-28

SECTION 5 - OPERATING INSTRUCTIONS HAND-HELD AUXILIARY HYDRAULIC TOOLS (Optional) Before using hand-held auxiliary tools, it is mandatory to proceed as follows: - Place the direction of travel control lever in neutral position.

- Apply the parking brake to prevent the machine from moving.

- Place the gear change lever in neutral (Powershuttle).

- Lower the loader bucket until it is pressing on the ground.

- Place the hand-held auxiliary hydraulic tool switch (1) in “OFF” position.

Shut down the engine, remove the plugs and connect the tool hoses to the couplings in front of the fuel tank. Coupling (3) is for the hydraulic fluid supply line and coupling (2) is for the return line.

IMPORTANT: Inverting the connections can cause involuntary or untimely functioning of the tool or even damage it considerably. To avoid all risk of accidents, follow the manufacturer’s instructions carefully.

48

FLOW SELECTION The operator must determine the flow to be used by consulting the tool manufacturer’s operating instructions. Be sure to select the flow specified. Excessive flow can damage some tools, making it necessary to adjust the flow regulator located on the chassis behind the machine, in front of the rear axle. Consult your Dealer.

Start the engine, place the accelerator lever in full speed position and then place the hand-held auxiliary hydraulic tool switch (1) in “ON” position. In this position the switch lamp lights up and the auxiliary tool may be operated.

49

When the auxiliary tool is no longer required, place the hand-held auxiliary hydraulic tool switch (1) in “OFF” position. The switch lamp goes out.

5-29

SECTION 5 - OPERATING INSTRUCTIONS TWO OR FOUR WHEEL DRIVE

!

WARNING

!

Machines with or without four wheel drive should not be allowed to exceed 40 km/h.

Over speeding by towing or coasting downhill may cause loss of control, personal injury, or failure of the drive line. Keep the machine in the same gear going downhill as would be used when going uphill.

Four Wheel Drive Switch (1) OFF= Rear Wheel Drive with four wheel drive braking.

50

NOTE: When the switch (1) is in “OFF” position and both brake pedals are pressed down at once, 4 wheel drive is engaged automatically (at speeds above 3 km/h) to ensure 4 wheel braking. As soon as the brake pedals are released, the machine returns to 2 wheel drive.

ON, 1st position = Rear Wheel Drive + Rear Wheel braking only.

ON, 2nd position = Permanent four Wheel Drive + Four Wheel Braking.

[See decal (2)] NOTE: To avoid undue tyre wear when travelling on the public highway or any hard surface, it is recommended that four wheel drive be disengaged, particularly in 3rd or 4th gear ratios.

2WD and 4WD conditions: IMPORTANT: 4WD braking is only active with both brake pedals latched together.

51

5-30

SECTION 5 - OPERATING INSTRUCTIONS LIFTING AND CRANING LOADS WITH THE LOADER ATTACHMENT

!

WARNING

!

Always operate on flat, hard ground where there are no obstacles.

IMPORTANT: No other system than that equipped with safety valves can be used to lift a load. Consult your Dealer.

LOADER BUCKET - With lifting ring The lifting ring is the only point to which loads may be attached on the loader bucket. The bucket must also be in dumping position.

52

LOADER BUCKET - Without lifting ring If the loader bucket is not supplied ex-works with a lifting ring, consult your Dealer.

NOTE: The installation of a lifting ring must be inspected and approved, by the competent authorities.

- It is mandatory to observe the values laid down in the load chart. See “Loader attachment maximum lifting loads”.

- Do not exceed the maximum lifting load.

- The maximum authorised load is 1000 kg.

53

- Steady the load a few centimetres above the ground so it is perfectly balanced before carrying out the lifting operation.

- Movements should be smooth and positive. Moving fast does not mean moving in a rough manner.

- Do not allow any person within the machine’s working range.

When moving with a load, be sure to: - Keep the load as close as possible to the ground.

- Travel mandatorily at low speed.

- Operate the controls smoothly to obtain precision movement and travel.

5-31

SECTION 5 - OPERATING INSTRUCTIONS LOADER ATTACHMENT MAXIMUM LIFTING LOADS 580 Super R and 590 Super R

54 695 Super R

55

5-32

SECTION 5 - OPERATING INSTRUCTIONS MAXIMUM LIFTING LOADS USING BUCKET MOUNTED PALLET FORKS (If fitted)

!

WARNING

!

Do not exceed the maximum safe working load for the loader. Ensure you comply with local “lifting” regulations, if in any doubt consult your Dealer.

IMPORTANT: When using the forks with the Multi Purpose Bucket option, ensure that the bucket jaws are in the closed position when attempting to lift a load. Do not attempt to open the bucket jaws with loaded pallet forks.

The machine must be on flat, hard, level ground.

56

The loader bucket must be fitted with pallet forks.

The pallet forks must be in horizontal position.

The maximum authorised load at a 515 mm load centre is 1000 kg.

FORK SPECIFICATIONS Fork Spacing - Minimum centres ............................................................................................................ 275 mm Fork Spacing - Maximum centres ......................................................................................................... 1773 mm Fork Length .......................................................................................................................................... 1026 mm Fork Width ................................................................................................................................................ 80 mm Maximum reach (Models 580 Super R and 590 Super R) (A) Reach Full Height ........................................................................................................................... 2319 mm (B) Reach Ground Level....................................................................................................................... 3186 mm (C) Lift Height ....................................................................................................................................... 2998 mm (D) Lift Height ....................................................................................................................................... 3458 mm Maximum reach (Model 695 Super R) (A) Reach Full Height ........................................................................................................................... 2194 mm (B) Reach Ground Level....................................................................................................................... 3186 mm (C) Lift Height ....................................................................................................................................... 3059 mm (D) Lift Height ....................................................................................................................................... 3518 mm

5-33

SECTION 5 - OPERATING INSTRUCTIONS LIFTING LOADS WITH THE BACKHOE ATTACHMENT

!

WARNING

!

Load lifting must be carried out in accordance with the instructions shown in this manual and in accordance with current regulations.

For load lifting, it is mandatory that the machine is equipped with safety valves, with a load fixing point and with a load lifting chart corresponding to the type of machine and its attachment. See “Maximum working loads”.

IMPORTANT: No other system than that equipped with safety valves can be used to lift a load. Consult your Dealer.

Make sure the distance between the attachment pivot pin and the lifting ring does not exceed a radius of 3.40 m for loads no greater than 1000 kg.

To lift a load, the following instructions must be followed: - Place the machine on flat, hard, level ground.

- Retract the loader bucket completely and place it so it is pressing on the ground. Lower the loader attachment until the front wheels just touch the ground without supporting the weight of the machine.

- Lower the stabilizers until the rear wheels just touch the ground without supporting the weight of the machine.

57

- The sideshift carriage must be locked hydraulically (sideshift backhoe version).

- If the machine is equipped with a telescopic dipper, it is mandatory for it to be completely retracted and mechanically locked.

- It is essential for the backhoe bucket cylinder rod to be completely extended.

- Use the load fixing point (the ring on the backhoe bucket connecting rod) (never use other load fixing points). See “Maximum working loads”. It is forbidden to weld hooks or lugs to the bottom of buckets.

58

5-34

SECTION 5 - OPERATING INSTRUCTIONS If the machine is not supplied ex-works with a lifting ring on the backhoe bucket connecting rod, consult your Dealer.

NOTE: The installation of a lifting ring must be inspected and approved, where necessary, by the competent authorities.

- Use slings and chains in perfect condition, able to support the load to be lifted and with an effective device preventing the slings or chains becoming unhooked.

- Check that the safety valves operate correctly. A pressure setting check must be carried out every six months in accordance with the manufacturer’s instructions. Consult your Dealer.

- Check that the load lifting chart you are using corresponds with the type of machine and its attachment. See “Maximum working loads with backhoe attachment”.

59

- It is essential that the values defined in the load lifting chart are observed.

- Do not allow any person within the machine’s working range.

- Use the controls gradually so as to move the attachment accurately.

5-35

SECTION 5 - OPERATING INSTRUCTIONS MAXIMUM WORKING LOADS WITH BACKHOE ATTACHMENT The load lifting chart shows the various authorized liftable loads at various reaches depending on the attachment installed on the machine.

The machine must be on flat, hard and level ground.

The loader bucket and the stabilizers must be pressing on the ground and the machine must be level.

It is mandatory for the backhoe attachment to be in the central axis of the machine.

The telescopic dipper (if fitted) must be in the completely retracted position and must be mechanically locked.

Loads are given in kg, for a machine without backhoe bucket, with the bucket cylinder rod completely extended and with the following safety margins: - 33% for stability, - 15% for hydraulic limit considerations, with the backhoe bucket connecting rod eye as the load fixing point.

If the backhoe bucket is installed on the machine the weight of the bucket must be deducted from the values given.

The reaches given as from the backhoe attachment swing pivot pin and the height is that of the load fixing point.

NOTE: Loads given are valid throughout the entire height range at the reach concerned.

5-36

SECTION 5 - OPERATING INSTRUCTIONS BACKHOE ATTACHMENT MAXIMUM LIFTING LOADS 580 Super R and 590 Super R

60 695 Super R

61

5-37

SECTION 5 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE ON THE TRAILER OF AN ARTICULATED VEHICLE

!

WARNING

!

This machine can slip and fall from a trailer or ramp and cause serious physical injury. Make sure that the trailer and the ramp are both clean. The machine must be in line with the trailer before being loaded.

Make sure you know the safety rules and regulations before transporting this machine. Make sure that the articulated vehicle and the machine are fitted with the correct safety equipment.

IMPORTANT: Loading and unloading the machine braking pedals need to be “locked” together.

LOADING 1. Place a chock behind the wheels of the trailer.

Install the trailer side extensions (if fitted).

2. Place the backhoe attachment in the road travel position. See “Setting the backhoe attachment in the road travel position”.

3. (695 Super R) Make sure the steering mode switch is in “Road” position.

4. Raise the loader bucket about 20 cm above the ramps.

11. Use chocks and chains to immobilize the machine and the backhoe attachment on the trailer.

12. Measure the distance between the ground and the highest point. You must know the total height.

NOTE: After a few kilometres, check that the machine has not moved and that the chains are still under tension.

5. Place the gear change lever in first gear and load the machine carefully onto the trailer.

UNLOADING

6. Lower the loader attachment so that the bucket is resting on the bed of the trailer. (Specific to certain countries), lock the loader attachment controls by means of the pin.

2. (Specific to certain countries) remove the loader attachment locking pin.

1. Remove the chocks and the retaining chains.

3. Raise the loader attachment to bring the bucket a few centimetres above the bed of the trailer.

7. Raise the parking brake lever and place the direction of travel control lever and gear change lever in neutral position. (Powershuttle).

4. Lower the parking brake lever and place the gear change lever in first gear.

8. Stop the engine and remove the starter switch key.

5. Slowly reverse the machine, at the same time raising the loader attachment so as to keep it a few centimetres above the bed of the trailer.

9. Make sure the windows, doors and engine guard is properly closed and locked.

10. Turn the rear view mirrors inwards.

5-38

6. Return the rear view mirrors to their correct position.

SECTION 5 - OPERATING INSTRUCTIONS LIFTING THE MACHINE IMPORTANT: Before lifting the machine, it is essential to place the backhoe attachment in the road travel position. See “Setting the backhoe attachment in the road travel position”.

The slinging points for the machine are shown by decals. See “Decals” in Section 3.

IMPORTANT: Never use any other slinging points than those shown by the decals.

Use suitable slings to lift the machine.

Make sure that the slings are in perfect condition and that they can take the weight of the machine.

!

WARNING

62

!

Do not allow anybody within the machine’s working range. Never swing the machine over people who are in proximity.

5-39

SECTION 5 - OPERATING INSTRUCTIONS TOWING THE MACHINE The machine should only be towed when it is undriveable.

First of all make sure that it can be towed without causing further damage.

Whenever possible carry out the repair at the site or consult your Dealer.

If the machine is on the public highway, make sure that no component of the machine projects onto the highway. If this cannot be avoided, install signs in accordance with regulations.

If the machine has to be towed with the engine shut down, it is necessary to uncouple the front and rear 4WD transmission shafts.

Before towing, be sure to do the following: 1. Check that steering can be used.

2. Place the gear lever (1) and powershuttle direction lever (2) in neutral (Powershuttle).

3. Place the gear lever (2) in neutral (Powershift).

4. If the engine is running, make sure the 4WD is disengaged.

!

WARNING

!

If the engine is not running, the force necessary to turn the steering wheel will be higher.

63 5. To tow the machine, attach a towing bar to one of the lifting points shown by the decals.

64

5-40

SECTION 5 - OPERATING INSTRUCTIONS 6. Make sure the attachments are raised sufficiently to avoid any interference with the ground or the trailer.

7. If it is not possible to raise the attachments sufficiently to avoid interference, then they must be removed.

65 (695 Super R)

!

WARNING

!

For towing purposes, “Road” (1) type steering must be selected.

If the engine is not running, the force necessary to turn the steering wheel will be higher.

!

WARNING

!

Towing is a delicate operation which is always performed at the risk of the user. The manufacturer’s guarantee does not apply to incidents or accidents occurring during towing. Whenever possible, carry out the repair at the location, without towing the machine.

!

WARNING

66

!

The machine must be towed very slowly (8 km/h maximum), over a short distance and only if it is really necessary.

!

WARNING

!

A towing bar must be used for all towing operations.

!

WARNING

!

When towing the operator must be alone on the machine. Make sure that no other person is on the machine or within the machine’s working range.

5-41

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN WATER 1. Make sure that the bed of the stream or stretch of water can support the weight of the machine.

2. The level of the water must not exceed the height of the centre of the front wheels.

IMPORTANT: Never work in water if the water level is higher than the centre of the front wheels.

3. Before taking the machine into the water, pump plenty of new grease into the machine’s attachment linkages.

IMPORTANT: Never work in fast-flowing water.

PARKING THE MACHINE 1. Park the machine on a flat, level surface away from any soft ground, excavations or poorly shored cavity.

2. Lower the loader bucket to the ground. (Specific to certain countries) use the locking pin to lock the loader. See “Locking the loader attachment controls” in Section 4.

3. Raise the parking brake lever and place the direction of travel control lever and gear change lever in neutral position (Powershuttle).

4. Place the backhoe attachment in the road travel position. See “Setting the backhoe attachment in the road travel position”.

5. Stop the engine and remove the switch key.

6. Release all pressure in the hydraulic circuits.

7. Lock the operator’s compartment doors and the engine guard.

8. If the machine is parked outdoors, cover the exhaust pipe so as to protect the engine against damp.

!

WARNING

!

Check that no part of the machine is protruding onto the public highway. If this cannot be avoided, install signs in accordance with regulations.

5-42

SECTION 6 JOB SITE AND ROAD INSTRUCTIONS INSTRUCTIONS FOR USE JOB SITE OPERATION

!

WARNING

!

Observe the instructions for use shown in this chapter. Any other practice without the prior approval of the manufacturer is considered as being forbidden.

ROAD OPERATION IMPORTANT: Road speed is subject to restrictions in certain countries. It is the operator’s responsibility to limit his speed accordingly.

1. Before carrying out any road travel, lock the attachments and install the safety systems required by regulations. The machine must be within the maximum dimensions permitted on the road in accordance with local road traffic regulations.

1. Be vigilant, be aware of places where other persons are working close to your working area.

Keep other persons away from the machine.

Serious physical injury can result if these instructions are not observed.

2. Make sure you know the location of underground pipes or cables before beginning work.

Electrical cables, gas pipes, water pipes or other underground installations can cause serious physical injury.

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

4. When travelling at right angles to the slope keep the loader bucket at ground level.

2. (695 Super R) Before undertaking any road travel, select the 2 wheel steer position and install the flip over cover to lock the switch in that position.

5. When travelling in the same direction as the slope, move onto the slope in low gear (first gear). Never travel down slopes with the gear change lever in the neutral position.

3. Raise the stabilizers completely and lock them mechanically.

6. When working on a slope, engage the front drive axle (4WD).

4. Check that the lighting and signalling systems operate correctly.

7. Holes, obstacles, debris and other hazards in the working area can cause serious physical injury. Always walk around and identify all possible hazards before operating the machine in a new working area.

5. Check that the brakes and steering operate correctly.

6. Check the condition and pressure of the tyres.

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

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

8. Never use the differential lock.

6-1

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS ROAD TRAVEL

!

WARNING

!

Before travelling on the road, make sure that the load on each axle, depending on the machine configuration, conforms to the road traffic regulations of the country concerned.

!

WARNING

!

Always fasten your seat belt before travelling on the road.

!

WARNING

!

It is essential to lock the attachments and install the safety systems required by regulations before travelling on the road.

!

WARNING

!

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

!

WARNING

!

Before undertaking any road travel, make sure that the backhoe attachment (if fitted) is in the road travel position and mechanically immobilized.

1. Place the backhoe attachment in the road travel position. See “Setting the backhoe attachment in the road travel position” in Section 5.

2. Make sure that the engine throttle lever is in the low idle position.

1

6-2

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS 3. Place the seat in the loader attachment position.

4. Place the loader attachment in the road travel position. See “On road travel requirements” in Section 5.

2 5. (Specific to certain countries) install the loader bucket tooth shield and locking devices. See “On road travel requirements” in Section 5.

3 6. Install the warning panels on the loader bucket (optional or specific to certain countries).

4

6-3

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS 7. Adjust the rear view mirrors correctly. Clean the licence plates if necessary.

5 8. Place the rotating beacon (specific to certain countries) on the cab roof, connect the cable and press the control switch, see “Rotating beacon switch” in Section 4.

9. Make sure the doors are properly closed and that the engine guard is locked.

6 10. Make sure that the two brake pedals are locked together.

7 11. Adjust the operator’s seat correctly. Fasten and adjust the seat belt.

8

6-4

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS 12. Make sure that the direction of travel control lever is in the neutral position and start the engine.

9 13. (Specific to certain countries) lock the loader attachment controls with the locking pin.

10 14. Make sure switch (1) is in “OFF” position (front wheel drive transmission disengaged).

11 15. Press the transmission disconnect button and then place the gear change lever in third or fourth gear. Release the button (Powershuttle).

12

6-5

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS 16. Place the gear change lever in third or fourth (Powershift).

13 17. Press the brake pedals down and lower the parking brake lever.

14 18. Tilt the direction of travel control lever forwards.

15 19. Release the brake pedals and control the travel speed by means of the accelerator pedal.

IMPORTANT: In the event of a brake system failure, immediately raise the parking brake lever.

!

WARNING

!

Check all gauges and indicator/warning lamps frequently.

16

6-6

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS JOB SITE TRAVEL NOTE: After road travel, remove all the road safety devices before carrying out any job site travel.

1. Make sure that the engine throttle lever is in the low idle position.

2. Make sure the stabilizers are completely raised.

3. Make sure the doors are properly closed and that the engine guard is locked.

17 4. Adjust the operator’s seat correctly. Attach the seat belt correctly and then adjust it.

18 5. Make sure that the direction of travel control lever is in the neutral position and start the engine.

6. Raise the attachment about 20 cm off the ground.

7. Choose the type of steering and traction necessary to suit the terrain.

19

6-7

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS 8. Press down the transmission disconnect button and then place the gear change lever in first or second gear (Powershuttle).

20 9. Place the gear change lever in first or second (Powershift).

10. Press the brake pedals down and lower the parking brake lever.

21 11. Place the direction of travel control lever in the desired position, forward or reverse.

12. Release the brake pedals and control the travel speed by means of the accelerator pedal.

!

WARNING

!

While travelling, check all gauges and indicator/ warning lamps frequently.

22

6-8

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS LOADER ATTACHMENT OPERATING INSTRUCTIONS The instructions contained in this chapter do not cover all possible conditions of use of the loader attachment. They only constitute basic information to enable the machine to be operated correctly.

IMPORTANT: Before operating in temperatures below -1 °C operate the engine for approximately 15 minutes at speeds below 1200 rev/min. to warm the oil to the normal operating temperature.

Where possible, always use the loader attachment at full engine speed.

NOTE: The first time it is operated, manoeuvre the machine in a clear area, at low speed.

NOTE: To operate the controls, see “Loader attachment controls” in Section 4.

!

WARNING

!

Automatic loader bucket levelling only operates when raising the attachment; it does not operate when lowering the attachment. You must take care to keep the bucket level during attachment lowering to avoid the load being dumped.

SAFETY INSTRUCTIONS - Be careful.

- Make sure that the operator’s seat is correctly adjusted in the loader attachment position.

- Attach the seat belt.

- Make sure that no other person is in the working range of the machine.

HYDRAULIC SPEED CONTROL Select the hydraulic speed control function on the front instrument panel.

23

6-9

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS TRANSMISSION DISCONNECT BUTTON To give maximum power to the loader bucket cylinders, press the push button and hold it down. This will cause the transmission to revert to neutral.

Release the clutch cut-out button to engage the transmission once more.

IMPORTANT: The machine will free wheel when the button is pressed. If necessary, use the brakes to stop the machine.

24 4 IN 1 LOADER BUCKET CLAM OPENING INDICATOR (If fitted) This indicator, located on the top right-hand side of the clam, allows the operator to see the degree of clam opening and the bucket digging depth.

When the pin (1) is positioned corresponding to the “0” the bucket is closed; when its position corresponds to the “1/2” the bucket is half-way opened and, when it faces the “4/4” the bucket is fully opened.

25 LOADING OPERATIONS To fill the bucket from a stock pile, set the bucket in the level position and lower the attachment with the control lever to “float” position.

26

6-10

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS When the loader has entered the pile, press down the transmission disconnect button, allow the control lever to move backwards and then simultaneously operate the controls to lift and roll back the bucket.

Lift and roll-back of the bucket will increase efficiency as a level bucket throughout the lifting cycle resists bucket lift and increases break away effort.

NOTE: Do not be concerned if the bucket is not completely filled during each pass. Maximum productivity is determined by the amount of material loaded in a given period of time. Time is lost if two or more attempts are made to fill the bucket on each pass.

!

WARNING

27

!

To avoid personal injury exercise care when undercutting high banks. Soil slides can be dangerous.

Load from the bank as low as possible for maximum efficiency. Remember that loader lift and breakaway capacities diminish rapidly as loading height is increased.

Dump the bucket completely, raise the attachment and then release the transmission disconnect button.

Keep the bucket position as low as possible, especially when working on sloping or rough ground.

!

WARNING

!

When working on a slope, keep the bucket as low as possible to ensure maximum stability.

When travelling with a full bucket on rough ground, keep the bucket as low as possible to avoid spillage.

28

Raise the loader high enough to clear any obstruction prior to dumping the load.

After the bucket is dumped, back away whilst lowering and levelling the bucket using the return to dig facility if required.

29

6-11

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS During hard surface operation, place the loader lever in “float” and keep the bucket level. This will permit the bucket to “float” on the contour of the working surface. If hydraulic down pressure is exerted, the bucket will wear faster than normal.

The “float” position will prevent the mixing of surface material with stockpile material. It will also reduce the chance of surface gouging when removing snow or other material.

When loading from a bank select the highest forward gear which will provide the most efficient loading operation without going into a “stall”. Keep the working area free of ruts and holes occasionally back grading with the bucket using the heel or low rear edge of the bucket.

For site stripping peeling or scraping, use down pressure with the loader lever in the lowered position, and a slight bucket angle to start the cut. Begin the cut at the notch approximately 50 mm deep and hold the depth by feathering the bucket to adjust the cutting lip up or down as required. When the machine front tyres enter the cut, adjust the lift arms to maintain the correct depth. Make additional cuts until the desired depth is reached.

Back grade the working area occasionally with the bucket flat and slight down pressure to keep the working area smooth and free from ruts or holes.

If the loader lever is moved for lift cylinder action without controlling the bucket angle, the bucket may gouge and leave a series of ruts in the surface.

To backfill a trench efficiently it is necessary to move the maximum amount of soil without losing speed of “stalling”. If a “stall” occurs downshift or reduce the depth of cut. If the machine is not working at capacity in the gear selected, increase the depth of cut.

Operate at right angles to the trench with the loader bucket level. Leave the soil in the bucket as emptying the bucket on each pass is time-consuming, and leave soil that drifts over the side of the bucket for the final clean up. One lengthwise clean up is usually sufficient to gain an acceptable grade after backfilling.

6-12

30

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS When backfilling from a large pile, shovel off the top of the pile, pushing toward the excavation. Drag some soil rearward to form a work ramp of convenient grade.

If during the backfill operation the machine front wheels get stuck in a trench dump the bucket and apply down pressure to lift the front wheels from the trench. Actuate the bucket as engine power is applied to move the machine rearwards.

NOTE: Maximum bucket down pressure may be obtained by “feathering” the loader lever to the right.

IMPORTANT: The Safe Working Load of the loader is calculated using a standard bucket, therefore, when using any other bucket or attachment for “lifting” or “craning” the weight of the bucket or attachment must be taken into account when calculating the rated load of the loader.

Safe Working Load = 1000 kg.

31 ORGANISING THE JOB SITE Use the shortest possible work cycle. The location provided for the trucks is an all important element. Spend a little time levelling the work area.

A smooth working surface facilitates the work of the machine and moving and parking the trucks. It gives a shorter work cycle.

!

WARNING

!

Operating the loader attachment with a full bucket on sloping ground can cause the machine to turn over. If possible avoid turning the steering wheel and always travel forwards when climbing a slope and in reverse when travelling down a slope. Keep the bucket as close as possible to the ground.

There is a risk of accident if these instructions are not observed.

32

6-13

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS

!

WARNING

!

On the job site, always keep the bucket as close as possible to the ground so as to increase the machine’s stability to the maximum and to ensure perfect visibility.

!

WARNING

!

On rough or slippery ground, when the bucket is full, drive the machine as slowly as possible. If these instructions are not observed there is a risk of accident.

BACKHOE ATTACHMENT OPERATING INSTRUCTIONS The instructions contained in this chapter do not cover all possible conditions of operation for the backhoe attachment. They only constitute basic information to enable the machine to be operated correctly.

IMPORTANT: To achieve an optimum balance between machine performance operate the machine at full engine speed.

NOTE: The first time it is operated, manoeuvre the machine in a clear area, at low speed.

NOTE: For the operation of the controls, see “Backhoe attachment controls” in Section 4.

SAFETY INSTRUCTIONS - Be careful.

- Make sure that the operator’s seat is correctly adjusted in the backhoe attachment position.

- Attach the seat belt.

- Make sure that no other person is in the working range of the machine.

- Place the attachment in the working position. See “Setting the machine in the backhoe attachment working position” in Section 5.

- Never dig near or under the stabilizers, since the machine could fall into the excavation.

- When working in an area of reduced visibility, for example next to a building, place a safety barrier and sign panels to prevent anyone coming near the machine.

6-14

GENERAL The backhoe attachment will dig more quickly if the work cycle is short and uninterrupted. Organize your work site so as to obtain a smooth work cycle.

If you try to use the backhoe bucket for digging too wide a trench, you may cause a stall situation (where the dipper control lever is tilted towards the rear but nothing happens). The hydraulic system main relief valve makes a noise when a hydraulic stall occurs. This overload causes the work cycle to be prolonged and it increases the hydraulic fluid temperature.

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS EXCAVATING METHOD

33

34 CORRECT

WRONG

WRONG

The backhoe bucket will dig in and cause a stall

The bucket is pushed upwards.

This will also increase the cycle time

OPERATING TECHNIQUES

!

WARNING

!

Never operate any of the backhoe control levers with the transport boom lock engaged.

Filling the backhoe bucket Fill the backhoe bucket by manoeuvring the dipper.

Keep the bottom of the backhoe bucket parallel to the cut. The backhoe bucket teeth and blade must cut the ground like the blade of a knife. The depth of dig varies depending on the type of material.

Dump the bucket contents onto the spoil pile, rolling out the bucket as the pile is approached. Avoid constant jarring or hammering-type contact between the spoil pile and bucket as this will cause wear to the bucket pins and bushings.

35

6-15

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS Moving the machine forwards when working on flat ground It is possible to use the backhoe attachment to move the machine forward at the same time as the excavation.

1. Make sure that the front wheels are straight.

2. Set the engine speed to 1000 rpm.

3. Release the machine’s brakes by means of the parking brake.

4. Raise the boom and retract the dipper, then move the boom so as to place the backhoe bucket teeth on stable ground.

5. Raise the stabilizers and the loader bucket about 20 cm from the ground.

36

6. Use the boom and dipper to move the machine.

7. After moving the machine, lower the stabilizers and place the loader bucket on the ground, then level the machine.

8. Use the parking brake to brake the machine.

IMPORTANT: This procedure can only be used on flat ground. Never use it on sloping ground. On sloping ground it is mandatory to turn the operator’s seat to the loader attachment position to move the machine by the normal procedure.

The machine can be moved sideways in the same fashion, except that the bucket must be flat to support the weight of the machine. Use the swing control to move the machine sideways to the required position.

Telescopic dipper To avoid the risk of damage and to extend the overall life of machines fitted with a telescopic dipper the following precautions must be observed.

- When the attachment is used for compacting operations, the telescopic dipper must be fully retracted and locked.

37

6-16

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS - Before returning to normal use, remove the pin and the retaining pin and place them in working position (A).

A. Locked position B. Unlocked position - When using the hand tool the telescopic dipper must be in unlocked position.

- When using a toothed bucket to break hard ground, avoid extending the dipper beyond 0.60 m.

- When digging in wet soil or mud and the bucket needs to be cleaned, do not knock the bucket against the ground with the dipper extended.

38

- Avoid overloading the attachment by using a bucket which is too big in harsh working conditions, as this will reduce the useful life of the machine.

- Do not bottom-out the swing cylinder with the dipper extended.

- For safety reasons, when working on sloping ground, do not swing the boom to dump the bucket contents on the side sloping down.

!

WARNING

!

Always wear your seat belt for protection in the event of the machine overturning. Never try to jump clear, always remain in the cab.

39

- When operating with the dipper fully extended, ensure that the bucket does not receive a sharp impact which will cause distortion of the cylinder rod.

6-17

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS Trenching Trenching is the most basic backhoe excavating operation. Other digging operations are merely variations of this basic function (i.e. filling the bucket, dumping the bucket, and moving the unit forward).

While trenching, it is generally important to maintain a level trench bottom. This is accomplished by setting the bucket at the correct angle of approach. Pull on the dipper lever to maintain the correct cutting angle as the bucket is crowding in (1) applying light pressure to the right. At the same time, pull on the lift lever (2) to relieve down pressure and keep the bucket in the same plane.

Continue the trench by moving forward. Moving too far will require excessive down pressure for digging, plus hand clean-up of the trench bottom. It is better to move a lesser amount than to move too far.

40

When using the backhoe for digging on slopes position the backhoe uphill wherever possible. If however, this is not practicable use the loader or backhoe to cut a level surface into the slope for the uphill wheel and stabilizer, and deposit the spoil from the slot onto the downhill side for the opposite wheel and stabilizer. When digging always deposit the spoil from the trench on the uphill side.

!

WARNING

!

When excavating across a slope it is not possible to make use of the loader bucket for added stability.

Do not overload the bucket and avoid swinging a loaded bucket to the downhill side of the slope.

41

To finish the far wall on a straight-walled excavation crowd out the bucket while forcing the bucket down the excavation from the boom. To finish the rear wall crowd in the bucket, while lifting with the boom, keeping the edges of the bucket horizontal.

42

6-18

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS When finishing straight walls in sandy soil, position a platform under the rear tyres and stabilizers to distribute the load over a larger area and reduce the possibility of a cave-in.

The platform will also reduce the possibility of the machine creeping rearwards if hard digging is encountered.

IMPORTANT: Do not backfill using the swing circuit and dragging the bucket sideways. Doing so can damage the dipstick, boom, swing cylinders or mainframe.

43 To backfill a trench, lift the bucket over the spoil pile and then crowd in the dipper and lift the boom. Pull both the crowd and boom levers simultaneously for smooth even backfilling.

44

6-19

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS BALLASTING AND TYRES Water

Tyre size

Total weight of solution per tyre

Litres

kg

kg

12.5/80-18

89

53

130

16.9-28

227

136

318

18.4-26

236

142

344

440/80 R28

220

129

347

NOTE: The tyres shown in the table above are for general fitment. Therefore tyres fitted to your machine may vary from those shown.

LIQUID BALLAST Filling the front and rear tyres with liquid ballast is a convenient method of adding weight. A solution of calcium chloride and water is recommended. This gives a low freezing point and provides a higher density than plain water.

!

WARNING

!

When mixing the ballast solution it is imperative the calcium chloride flakes are added to the water and the solution stirred until the calcium chloride is dissolved. Never add water to calcium chloride. If the flakes should contact the eyes, wash the eyes immediately with clean, cold water for at least 5 minutes. See a doctor as soon as possible.

NOTE: When filling a tyre with calcium chloride/ water solution the valve should be at the highest point on the wheel. The valve should be at the lowest point when checking or adjusting air pressure if the tyre is liquid ballasted.

The table above shows the quantity of calcium chloride and water required for each tyre size option and is based on 0.6 kg of calcium chloride per litre of water to give a 75% fill of the tyre. This calcium chloride/water solution will give protection from freezing down to an ambient temperature of -46 °C.

6-20

Calcium chloride

WEIGHTING LIMITATIONS Where additional stability during operation of the backhoe is required liquid ballast can be added to the tyres, as above table. Because special equipment is required to fill the tyres it is recommended that this be carried out by your Dealer.

IMPORTANT: Only add the quantity of ballast necessary to ensure stability. Excess ballast overloads the machine unnecessarily and increases fuel consumption. When adding ballast, do not exceed the maximum load ratings for the tyres. See “Tyre pressures and permissible loads” in Section 12.

For further information, consult your Dealer.

When adding ballast the total weight of the machine including liquid should not exceed the maximum specification.

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS MACHINE WEIGHTING When adding ballast to the machine, do not exceed the gross weight shown on the identification plates.

See “Type, serial number and year of manufacture of the machine” in Section 2.

NOTE: Total rear axle weight is measured with only the rear wheels on the scales, front axle weight with the front wheels on the scales.

45 (Except 695 Super R) Two wheel drive (2WD) front axle maximum permissible loading inclusive of ballast and loader in the transport position with no load in the bucket: Static load rating = 22730 kg Dynamic load rating = 5670 kg NOTE: The load capacity of the tyres may be lower than the load capacity of the front axle, the lower figure of the two must be used.

Four wheel drive (4WD) front axle maximum permissible loading inclusive of ballast and loader in the raised position with no load in the bucket:

46

Static load rating = 12230 kg Dynamic load rating = 6115 kg for a track measurement of 1830 mm.

Rear axle maximum permissible loading with ballast and backhoe in the raised position with no load in the bucket: Static load rating = 27750 kg Dynamic load rating = 8900 kg for a track measurement of 1727 mm.

6-21

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS (695 Super R) NOTE: Total rear axle weight is measured with only the rear wheels on the scales, front axle weight with the front wheels on the scales.

NOTE: The load capacity of the tyres may be lower than the load capacity of the front axle, the lower figure of the two must be used.

47 Four wheel front axle maximum permissible loading inclusive of ballast and loader in the raised position with no load in the bucket: Static load rating = 15210 kg Dynamic load rating = 8000 kg for a track measurement of 1890 mm.

Rear axle maximum permissible loading with ballast and backhoe in the raised position with no load in the bucket: Static load rating = 25000 kg Dynamic load rating = 10000 kg for a track measurement of 1890 mm.

6-22

48

SECTION 7 SERVICING INTERVALS SERVICING INSTRUCTIONS Observe the servicing intervals by the checking the hourmeter every day. Before starting maintenance, park the machine on flat, firm ground, away from any obstacles, with the loader bucket and the backhoe bucket on the ground. All maintenance operations must be carried out with the engine stopped and the key removed from the starter switch. It is preferable to wait for all circuits to cool down before starting work.

Clean the grease fittings before lubrication. Clean around plugs and filler holes before adding oil. No dust or dirt must enter the components or the circuits.

!

WARNING

!

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

!

WARNING

When performing maintenance work on the machine, place a “Do not start up” label on the instrument panel.

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

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

IMPORTANT: Observe the Servicing Intervals for all the machine’s filters. The life of the engine depends on clean filters.

IMPORTANT: Do not drain used oil into the ground or down a drain. Stock the oil in sealed containers for collection by a company which recycles or disposes of it.

!

If the attachment is raised or the machine moves when there is no operator, serious injury can result.

Before carrying out any servicing operator on this machine, proceed as follows: 1. Park the machine on a flat, level ground.

2. Lower the loader and backhoe attachments until they are resting on the ground.

3. Stop the engine and remove the starter switch key.

4. Raise the parking brake lever.

5. Lock the loader attachment controls (specific to certain countries).

6. Block the wheels to prevent any machine movement.

For all service work on the engine, install the loader attachment support strut.

!

WARNING

!

Never leave the operator’s compartment when the engine is running.

7-1

SECTION 7 - SERVICING INTERVALS HOURMETER The hourmeter enables servicing operations to be scheduled. It works in the same way as a clock when the engine is running.

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

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

1

7-2

SECTION 7 - SERVICING INTERVALS INTERVALS Servicing and inspection intervals are variable. All operations are scheduled on the following basis:

5-25 Steer phasing (4WS) 8-3

Loader attachment

-

10

26

10

8-3

Backhoe attachment (sideshift backhoe version)

24

10

8-3

Backhoe attachment (centre pivot backhoe version)

30

10

8-10 Windshield washer reservoir

1

10

8-13 Engine oil level

1

10

8-16 Level in coolant reservoir

1

9-4

Radiator, coolant and air conditioning condenser

1

9-5

Engine alternator and fan belt

10 10

1

10

1

10

8-25 Hydraulic pipes and hoses

-

10

8-4

Telescopic dipper (if fitted)

2

50

8-4

Sideshift carriage rails

2

50

8-4

Stabilizer slippers

2

50

8-4

Door hinges

4

50

8-4

Front axle trunnion bearings (2WD and 4WD)

2

50

8-5

Front axle king pins (2WD)

4

50

8-22 Hydraulic reservoir level

8-18 Fuel filter sediment

1

9-1

Tyre pressure

4

50

8-6

Differential lock linkage (Powershuttle)

1

250

8-6

Drive shafts

2

250

8-6

Drive shaft couplings front and rear

8-6

Steering knuckle (2WS and 4WS)

8-7

Seat rails

50

2

250

4/8

250

-

250

1

250

8-16 Cooling system hose and clamp check

-

250

8-20 Fuel tank sediment removal

1

250

8-11 Rear axle (NOTE C)

8-22 Fuel tank breather/Filler cap

1

8-31 Transmission oil level (Powershuttle)

1

8-34 Transmission oil level (Powershift) (NOTE B)

1

8-38 Rear drive axle breather

1

DRAIN

GREASE

CHECK

REPLACE

INTERVALS IN HOURS CLEAN

SERVICE POINTS

No. OF POINTS

Every 10 hours, or once a day, whichever comes first Every 50 hours, or once a week, whichever comes first Every 250 hours, or once every 3 months, whichever comes first Every 500 hours, or once every 6 months, whichever comes first Every 1000 hours, or once every year, whichever comes first Every 2000 hours, or once every 2 years, whichever comes first

PAGE

-

250 250 250 250

8-37 Front drive axle oil level (NOTE C)

1

8-37 Front drive axle breather

1

250

9-4

Radiator, coolant and air conditioning condenser

1

250

9-8

Air conditioning

1

250

250

7-3

9-10 Cab filter

-

250

9-11 Heater unit and air conditioning cooler

1

250

9-14 Telescopic dipper

1

250

10-6 Battery terminal tightness check

2

250

9-17 ROPS/FOPS Cab (NOTE C)

1

300

8-9

Engine oil (NOTE A)

1

DRAIN 500

8-14 Engine oil filter

1

500

8-18 Fuel filter (NOTE B)

1

500

8-26 Backhoe attachment safety valves

2

8-8

1

Brake pedal linkage

GREASE

CHECK

REPLACE

INTERVALS IN HOURS CLEAN

SERVICE POINTS

No. OF POINTS

PAGE

SECTION 7 - SERVICING INTERVALS

500 1000

8-23 Hydraulic oil filter

1

1000

8-22 Hydraulic system

1

1000

8-32 Transmission (Powershuttle)

1

1000

8-32 Transmission filter (Powershuttle)

1

8-33 Transmission screen filter (Powershuttle)

1

1000

8-31 Transmission breather (Powershuttle)

1

1000

8-34 Transmission (Powershift) (NOTE B)

1

8-35 Transmission filter (Powershift)

1

8-10 Front drive axle and reduction gears (4WD and 4WS)

1

1000

8-42 Rear axle

1

1000

8-43 Rear axle reduction gears

1

9-7

Engine rocker arm clearance adjustment

-

9-7

Machine inspection and cleaning

-

1000

1000 1000

1000 1000 1000

1000

10-6 Battery

-

1000

10-9 Alternator

-

1000 (8)

10-9 Starter motor

-

1000 (8)

8-16 Cooling system

1

9-12 Brake fluid

1

4-65 Fire extinguisher

1

8-27 Air filter elements

1

(2)

8-28 Primary cartridge

1

(4)

8-28 Secondary element

1

9-1

Wheel nut torque settings

-

(5)

9-8

Cylinder leak inspection

-

(6)

2000 (2) (1) (2) (4) (3)

9-14 Telescopic dipper (if fitted)

1

Checking and adjusting stabilizer play (sideshift backhoe 9-13 version)

2

(2)

9-15 Front wheel adjustments (2WS)

2

(7)

9-16 Front wheel adjustments (4WS)

2

(7)

7-4

(2)

(2)

2000

SECTION 7 - SERVICING INTERVALS (1) Have checked every year by a specialist.

(2) Regularly.

(3) Replace once a year or after 3 primary element cleanings.

(4) Wash every 250 hours or after 5 dry cleanings.

Replace when the warning light on the instrument panel comes on, or once a year, or after six cleanings.

(5) After the first 10 hours during the run in period and each time the wheels are changed.

(6) Check there are no leaks.

(7) Check and adjust occasionally.

(8) Have this checked by your Dealer.

NOTE A: Change every 150 hours for machines operating at temperatures below -12 °C. NOTE B: Change after the first 100 hours during the run in period.

NOTE C: After the first 50 hours during the run in period.

7-5

SECTION 7 - SERVICING INTERVALS

NOTES

7-6

SECTION 8 LUBRICATION/FILTERS/FLUIDS FLUIDS AND LUBRICANTS Fluids and lubricants must have the correct properties for each application.

OIL VISCOSITY/OIL USAGE RANGE Choose the correct oil viscosity grade from the chart on the right to suit the conditions.

NOTE: In areas where prolonged periods of extreme temperatures are encountered, local engine lubricant practices are acceptable; such as the use of SAE 5W in extreme low temperatures or SAE 50 in extreme high temperatures.

1

FUEL

ENVIRONMENT

Use fuel type no. 2.

The use of other fuels may cause loss of engine power and excessive fuel consumption.

Before carrying out any maintenance operation on the machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never put them in leaky receptacles.

In cold weather, a mixture of fuel no. 1 and no. 2 is temporarily permitted. Consult your fuel supplier.

If the temperature falls below the fuel cloud point (point at which wax appears), wax crystals in the fuel will cause a loss of engine power or make it impossible to start the engine.

NOTE: In cold weather, fill the fuel tank after each day’s work, to prevent the formation of condensation.

FUEL STORAGE Prolonged fuel storage causes foreign bodies or condensation water to accumulate in the storage tank. Many engine failures are caused by the presence of water in fuel.

Consult a local recycling or environmental centre, or a Dealer to obtain information on the correct method of disposing of these materials.

PLASTIC AND RESIN PARTS When cleaning plastic windows, the console, the instrument panel, the gauges, etc., avoid the use of petrol, paraffin, paint solvents, etc.

Use only water, soap and a soft cloth.

The use of petrol, paraffin, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

The storage tank should be placed outdoors and the fuel should be kept at as low a temperature as possible. Condensation water should be drained off at regular intervals.

8-1

SECTION 8 - LUBRICATION/FILTERS/FLUIDS FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS RECOMMENDED FLUIDS AND APPLICATION ENGINE - OIL Akcela No 1 Engine oil (15W40)

CASE Specifications

INTERNATIONAL Specifications

MS 1121

API CH-4, ACEA E5

MS 1710

HYDRAULIC SYSTEM Akcela Nexplore

MODELS

QUANTITY Litres

2WS - with filter 4WS - with filter

14 12.8

CUNA NC 956-16

ALL

24

MAT 3525

API GL4 ISO VG 32/46

2WS 4WS

140 118

Akcela Hydraulic Excavator Fluid Bio

MS 1230

ISO VG 46 DIN 51524 - part II

2WS 4WS

140 118

POWERSHUTTLE TRANSMISSION Akcela Nexplore

MAT 3525

API GL4 ISO VG 32/46

ALL

18

ATF DEXRON III

ALL

14

2WD (each)

0.2

COOLING SYSTEM Akcela Premium Anti-freeze antifreeze 50% water 50%

POWERSHIFT TRANSMISSION Akcela Trans XHD FRONT AXLE (2WS) Akcela Hy-Tran Ultra

MAT 3525 4WD

FRONT AXLE (4WS) Akcela Nexplore REAR AXLE (2WS) Akcela Hy-Tran Ultra + AOA Axle oil additive REAR AXLE (4WS) Akcela Nexplore

MAT 3525

API GL4 ISO VG 32/46

Differential

6.5

Wheel hub (each)

0.7

Differential

10.5

Wheel hub (each)

1.3

MAT 3525

21.2 0.8

MAT 3525

BRAKE MASTER CYLINDER Akcela LHM Fluid Mineral Oil

API GL4 ISO VG 32/46

ISO 7308

FUEL Decanted and filtered Diesel Fuel

Differential

11

Wheel hub (each)

1.3

ALL

1

2WS 4WS

145 124

GENERAL LUBRICATION JOINTS Akcela Multi-purpose grease

251H EP

NLGI 2

ALL

As required

TELESCOPIC DIPPER LUBRICATION Akcela Moly Grease

251 H EP-M

NLGI 2

ALL

As required

ALL

240 cc

AIR CONDITIONING COMPRESSOR PAG Oil SP 20

8-2

SECTION 8 - LUBRICATION/FILTERS/FLUIDS GREASE POINTS Type of grease, see “Fluids and lubricants” NOTE: The figures shown in brackets indicate the number of grease points.

Every 10 hours Loader attachment............................................. (26)

2 Backhoe attachment (Sideshift backhoe version) ............................... (24)

3 Backhoe attachment (Centre pivot backhoe version).......................... (30) NOTE: The number of grease points may vary depending on the types of accessory installed.

4

8-3

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Every 50 hours Telescopic dipper (if fitted) .................................(2) NOTE: Extend the telescopic dipper and apply grease on the four sliders.

5 Sideshift carriage rails..........................................(2) Stabilizer slippers .................................................(2) IMPORTANT: Before greasing the sliding surfaces, remove all accumulations of foreign matter.

6 Door hinges..........................................................(4)

7 Front axle trunnion bearings (2WD).....................(2)

8 8-4

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Front axle trunnion bearings (4WD) .................... (2)

9 Front wheel king pins (2WD) ............................... (4)

10

8-5

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Every 250 hours Differential lock linkage (Powershuttle) ................(1)

11 Drive shafts ..........................................................(2)

12 Drive shaft couplings front and rear .....................(2)

13 Steering knuckle (2WS) .......................................(4)

14 8-6

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Steering knuckle (4WS) ....................................... (8)

15 Seat rails.............................................................. (1) Wipe all moving parts with a clean cloth and apply a light coat of spray dry lubricant.

16

8-7

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Every 1000 hours or every years Brake pedal linkage Drive out the old grease with new until new grease appears at the end of each bearing and then wipe off the old grease with a rag.

17

8-8

SECTION 8 - LUBRICATION/FILTERS/FLUIDS LEVELS NOTE: The figures shown in brackets indicate the number of level points.

Every 10 hours Engine oil ............................................................ (1)

18 Coolant solution reservoir .................................. (1)

19 Hydraulic reservoir ............................................. (1)

20

8-9

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Windshield washer reservoir................................(1) NOTE: The windshield washer works on the gravity feed system. Do not remove the rubber tube as damage can be caused if liquid gets into the motor.

21 Every 250 hours Front drive axle reduction gears (4WD and 4WS)...................................................(2)

22 Differential............................................................(1)

23 Transmission .......................................................(1)

24 8-10

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Rear axle............................................................. (1)

25 Every 500 hours Backhoe attachment safety valves (if fitted) ........ (2)

26

8-11

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Every 1000 hours Battery............................................................ (1)/(2)

27

8-12

SECTION 8 - LUBRICATION/FILTERS/FLUIDS ENGINE SERVICE SPECIFICATIONS Oil level check ........................................................................................................ Every 10 hours or every day Oil change .................................................................................................................................Every 500 hours Or every 150 hours for machines working at temperatures below -12 °C Oil filter replacement..................................................................................................................Every 500 hours Type of oil ................................................................................................................. See “Fluids and lubricants” Oil capacity (including filter replacement) ....................................................... (2WS) 14 litres, (4WS) 12.8 litres LEVEL 1. Park the machine on flat, level ground.

2. Raise the loader attachment, stop the engine, remove the starter switch key and install the support strut.

3. Lift the engine guard.

4. After the engine has been stopped for 15 minutes, remove the dipstick, clean it with a clean cloth, replace it in the guide tube as far as it will go and then remove it again.

28 5. If the oil level is below the add mark, remove the filler cap and add oil up to the full mark on the dipstick.

29

8-13

SECTION 8 - LUBRICATION/FILTERS/FLUIDS 6. Replace the filler cap.

30 7. Lower the engine guard.

8. Remove the support strut and lower the loader attachment.

OIL CHANGE AND OIL FILTER REPLACEMENT NOTE: Drain the engine when it is still hot. The oil will flow more easily.

Use the extension drain hose from the tool box.

1. Park the machine on flat, level ground.

2. Raise the loader attachment, stop the engine, remove the starter switch key and install the support strut.

3. Lift the engine guard.

4. Remove the filler cap.

5. Remove the protection cap from the engine crankcase drain valve.

6. Screw the end of the extension drain hose onto the crankcase drain valve. Place the other end in a suitable container and allow the oil to flow out.

NOTE: Use a container of an adequate capacity.

7. Remove the extension drain hose and install the protection cap on the crankcase drain valve.

Place the extension drain hose in the tool box.

8-14

31

SECTION 8 - LUBRICATION/FILTERS/FLUIDS 8. Clean around the filter and remove it, using the filter wrench.

9. Apply clean oil to the new filter seal.

10. Install the new filter. Turn the filter until the seal is in contact with the filter head and then tighten it half a turn more by hand.

IMPORTANT: Do not use the filter wrench to install the filter. Excess tightening can damage the seal and the filter.

32 11. Fill the engine with new oil.

33 12. Run the engine for a few minutes and check for leaks. Then check the level again.

NOTE: Always wait 15 minutes to allow the oil to return to the engine sump before checking the oil level.

13. Lower the engine guard.

14. Remove the support strut and lower the loader attachment.

8-15

SECTION 8 - LUBRICATION/FILTERS/FLUIDS COOLING SYSTEM SERVICE SPECIFICATIONS Coolant reservoir level check...................................................................................................... Every 10 hours or every day Cooling system hose and clamp check..................................................................................... Every 250 hours Draining.........................................................................................................Every 2000 hours or every 2 years Cooling system capacity ......................................................................................................................... 24 litres Thermostat range......................................................................................................................... 81 °C to 96 °C Type of coolant:.........................................................................................................See “Fluids and lubricants”

!

WARNING

!

Scalding coolant solution can escape if the coolant reservoir cap is removed while the system is still hot. Allow the system to cool down completely before removing the cap.

!

WARNING

!

Check and service the cooling system according to the instructions given in this manual.

LEVEL IN COOLANT RESERVOIR The level of coolant solution should be checked when the engine is cold.

1. Park the machine on flat, level ground.

2. Raise the loader attachment, stop the engine, remove the starter switch key and install the support strut.

3. Lift the engine guard.

4. The level in the coolant reservoir must come up to between the marks. If necessary remove the cap and add more coolant solution.

34

8-16

SECTION 8 - LUBRICATION/FILTERS/FLUIDS DRAINING THE COOLING SYSTEM 1. Park the machine on flat, level ground.

!

WARNING

!

Do not remove the cap when the engine is hot. The circuit is still under pressure and you could be scalded.

2. Remove the lower panel to the right of the radiator.

35 3. Open the radiator drain valve and allow the coolant solution to flow out.

NOTE: Use a container of an adequate capacity.

4. After the system is completely drained, close the drain valve.

5. Rinse the system through with fresh water, drain again and fill the system as shown below.

NOTE: If you use a detergent solution for rinsing, follow the instructions for preparing the solution.

After draining the detergent solution, rinse again with fresh water.

36

6. Check the condition of the hoses, connections and the water pump. Make sure that the external surfaces of the engine and the radiator are clean.

FILLING 1. Fill the coolant reservoir with coolant solution.

NOTE: Fill the cooling circuit slowly to avoid the formation of air pockets.

2. Install the coolant reservoir cap.

IMPORTANT: Use the correct coolant solution.

3. Run the engine for a few minutes and then check the level in the coolant reservoir again.

Top up if necessary then install the cap.

4. Lower the engine guard.

5. Remove the support strut and lower the loader attachment.

37

8-17

SECTION 8 - LUBRICATION/FILTERS/FLUIDS FUEL SYSTEM SERVICE SPECIFICATIONS Fuel filter sediment removal........................................................................................................ Every 50 hours Fuel tank sediment removal...................................................................................................... Every 250 hours Fuel filter replacement .............................................................................................................. Every 500 hours (After the first 100 hours during the running-in period) Fuel tank capacity ........................................................................................... (2WS) 145 litres (4WS) 124 litres Type of fuel ...............................................................................................................See “Fluids and lubricants” REPLACING FILTER 1. Raise the loader attachment, stop the engine, remove the starter switch key and install the support strut.

2. Lift the engine guard 3. Clean around the filter head.

4. Place a receptacle of a suitable capacity under the filter and remove the filter, using the filter wrench.

38 5. Apply a fine layer of oil or grease on the new filter seal.

NOTE: Do not fill the new filter with fuel before installing it.

39

8-18

SECTION 8 - LUBRICATION/FILTERS/FLUIDS 6. Install the new filter. Turn the filter until the seal comes in contact with the filter head and then tighten an extra half turn by hand.

IMPORTANT: Do not use the filter wrench to tighten. Overtightening can damage the seal and the filter.

NOTE: It is imperative to use a genuine filter, as supplied by the manufacturer, when making the replacement, as unapproved filters can cause serious damage to the injection pump.

Prime the system.

40 PRIMING THE FUEL SYSTEM Make sure there is enough fuel in the fuel tank.

1. Loosen the bleed fitting two or three turns.

41 2. Operate the priming pump until fuel flows out with no air bubbles in it. Then retighten the bleed fitting.

3. Continue priming using the pump until there is a resistance, showing that the system is under pressure.

4. Start the engine, see “Starting the engine” in Section 5.

NOTE: The injection pump is self-ventilating, it does not need to be bled.

NOTE: Never operate the starter motor for more than thirty seconds at a time. Wait for two minutes before starting again.

42

8-19

SECTION 8 - LUBRICATION/FILTERS/FLUIDS The engine should run smoothly. If not, repeat the procedure.

If the problem persists, it is because air is still getting into the system. Check all the fittings for leaks.

5. Lower the engine guard.

6. Remove the support strut and lower the loader attachment.

FUEL TANK SEDIMENT REMOVAL Place a receptacle of a suitable capacity under the fuel tank, unscrew the bleed plug located under the fuel tank one or two turns and allow the soiled fuel to flow out. Then retighten the plug.

43

8-20

SECTION 8 - LUBRICATION/FILTERS/FLUIDS RELEASING THE PRESSURE IN THE HYDRAULIC SYSTEM Before carrying out any service operation on the hydraulic system, it is first necessary to release the pressure in all the circuits.

1. Lower the loader attachment and the backhoe attachment until they are resting on the ground.

2. Stop the engine.

3. Operate the loader attachment controls in all directions.

44 4. Operate the backhoe attachment controls in all directions.

45

8-21

SECTION 8 - LUBRICATION/FILTERS/FLUIDS HYDRAULIC SYSTEM SERVICE SPECIFICATIONS Hydraulic reservoir level check ................................................................................................... Every 10 hours or every day Hose and pipe check .......................................................................................................................... Every day Hydraulic fluid filter replacement....................................................................... Every 1000 hours or every year (after the first 50 hours during the running-in period) Cleaning the breather/filler cap ................................................................................................. Every 250 hours Draining the backhoe attachment safety valves (if fitted) ................................. Every 500 hours or twice a year Draining the circuit ............................................................................................ Every 1000 hours or every year Reservoir capacity .............................................................................................. (2WS) 39 litres (4WS) 55 litres Total system capacity ...................................................................................... (2WS) 140 litres (4WS) 118 litres Type of fluid...............................................................................................................See “Fluids and lubricants” RESERVOIR LEVEL 1. Park the machine on flat, level ground.

2. Make sure the attachments are in road travel position.

3. Stop the engine, remove the starter switch key and wait until the fluid reaches ambient temperature.

4. The fluid level should be in the middle of the sight gauge. Top up if necessary. See “Filling”.

IMPORTANT: Even when the fluid level is insufficient, a small quantity of hydraulic fluid remains in the lower part of the gauge. This does not mean that the fluid level is sufficient.

46 CLEANING THE BREATHER/FILLER CAP 1. Remove the cap, using the wrench supplied with the machine.

2. Use a suitable grease solvent to wash the cap.

3. Dry the cap with compressed air and install it.

IMPORTANT: When using compressed air, take the necessary precautions to protect your face.

47

8-22

SECTION 8 - LUBRICATION/FILTERS/FLUIDS REPLACING THE HYDRAULIC FLUID FILTER 1. Make sure the attachments are in road travel position, raise the parking brake lever, shut down the engine and remove the starter switch key.

2. Clean around the filter head which is located on the left-hand side of the machine.

3. Place a receptacle of a suitable capacity under the filter, loosen the filter by means of the filter wrench and then unscrew it by hand.

4. Apply a thin layer of oil on the new filter seal.

5. Install the new filter. Turn the filter until the seal is in contact with the filter head and tighten the filter a further half turn by hand.

IMPORTANT: Do not use the filter wrench to tighten. Overtightening can damage the seal and the filter.

48

6. Check that the fluid level comes up to the middle of the gauge. Add more fluid if necessary.

IMPORTANT: Even when the fluid level is insufficient, a small quantity of hydraulic fluid remains in the lower part of the gauge. This does not mean that the fluid level is sufficient.

NOTE: After the machine has been operating for some time, check for any leaks.

49

8-23

SECTION 8 - LUBRICATION/FILTERS/FLUIDS REPLACING THE HYDRAULIC FLUID Replacing the hydraulic fluid requires the fluid to be systematically drained from the main components (reservoir, pumps, cylinders, control valves, hydraulic motors and oil cooler).

We recommend you to consult your Dealer.

Draining NOTE: When carrying out draining, the hydraulic fluid must be at operating temperature.

1. Park the machine on flat, level ground.

2. Lower the loader bucket flat on the ground.

3. Make sure that the backhoe attachment is in the road travel position.

4. Place a container of a suitable capacity under the reservoir, remove the filler cap and drain plug and allow the oil to flow out.

5. Drain the other components by removing the supply and return unions. Consult your Dealer.

6. Install the reservoir drain plug.

Filling 1. Clean around the filler cap and fill the reservoir with the correct hydraulic fluid.

2. The fluid level should be in the middle of the sight glass.

3. Install the filler cap.

4. Start the engine and operate the loader attachment and backhoe attachment functions for 3 to 4 minutes.

5. Once again place the loader bucket flat on the ground and the backhoe attachment in the road travel position. Stop the engine and remove the starter switch key.

6. Check the level. The fluid level should come up to the middle of the gauge. Top up if necessary.

IMPORTANT: Even when the fluid level is insufficient, a small quantity of hydraulic fluid remains in the lower part of the gauge. This does not mean that the fluid level is sufficient.

8-24

50

SECTION 8 - LUBRICATION/FILTERS/FLUIDS HYDRAULIC PIPES AND HOSES Repair all hydraulic oil leaks promptly to avoid loss of oil and possible damage and dirt entry into the system. When checking for hydraulic leaks, start and operate the engine at 1200-1500 rev./min.

Remove and install new hoses immediately, if they are severely damaged by a cut or scrape, swollen at the fittings, or leaking.

!

WARNING

!

Check all hydraulic connections for leakage. If leakage is observed, shut off the engine, relieve all hydraulic pressure. Do not tighten any hydraulic connection while the system is under pressure.

51

If a hydraulic hose or tube is renewed the following procedure should be observed.

Release the fittings (1) and remove the hose or tube assembly, then remove and discard the O-ring seal (2) from the fitting.

Dip a new O-ring seal into clean hydraulic oil prior to installation. Install the new O-ring (2) into the fitting (1) and if necessary, retain in position using petroleum jelly.

Assemble the new hose or tube assembly and tighten the fitting finger tight, whilst holding the tube or hose assembly to prevent it from turning.

NOTE: Ensure that when tightening the hose or tube fitting, the hose or tube assembly does not turn. If the hose turns while tightening the fitting the O-ring seal may be damaged.

52

8-25

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Using two suitable wrenches, as shown, tighten the fitting to specification.

IMPORTANT: Ensure that when an hydraulic hose or pipe is renewed/installed, all components are absolutely clean and free from dirt. Failure to ensure absolute cleanliness will result in the hose/pipe leaking after installation or possible damage to other hydraulic system components.

To ensure a leak free joint is obtained, it is important that the fittings are not overtorqued or undertorqued.

Bleed the air from the system any time a hydraulic hose is removed, a pipe disconnected, or the system is opened to atmosphere. This is accomplished by running the engine at 1200-1500 rev/min., and actuating the loader or backhoe control levers (no load in the bucket) for approximately 15 minutes or until all air is expelled from the system.

53

After bleeding the system, position the loader bucket flat on the ground, put the backhoe into the transport position, and shut off the engine. Then check the hydraulic system oil level and add oil if necessary.

BACKHOE ATTACHMENT SAFETY VALVES (If fitted) 1. Lower the backhoe bucket until it is resting on the ground, stop the engine and remove the starter switch key.

2. Release all pressure in the backhoe attachment circuit.

3. Place a container of a suitable capacity under the hose, remove the plug and allow the fluid to flow out.

4. Wipe up any spilt fluid and install the hose plug.

54

8-26

SECTION 8 - LUBRICATION/FILTERS/FLUIDS AIR FILTER INSPECTION Be sure to carry out regular checks on the air filter, intake manifold, gaskets and seals. At the same time, check the intake manifold screws and hose clamps for tightness.

The hoses should be replaced before they are worn.

Check frequently that the air filter restriction warning lamp on the instrument panel is in good working order.

AIR FILTER RESTRICTION WARNING LAMP If the air filter restriction warning lamp comes on when the engine is running, the air filter elements must be checked.

55 AIR FILTER ELEMENTS Your machine is fitted with a two-stage air filtering system, consisting of a high capacity primary element, designed to provide optimal protection of the engine, plus a secondary element which provides extra engine protection.

The primary element can be cleaned. The secondary element can not be cleaned and should be replaced.

8-27

SECTION 8 - LUBRICATION/FILTERS/FLUIDS SERVICE SPECIFICATIONS Pre-filter maintenance................................................................................. Regularly check and clean the bowl Primary element maintenance ........................................Wash every 250 hours or after dry cleaning five times replace when the warning lamp lights up on the instrument panel Primary element replacement ............................................................................................................ Every year or after six cleanings Secondary element replacement ..................................................................................................... Once a year or after cleaning the primary element three times IMPORTANT: Carefully observe the air filter service intervals. The life of the engine depends on the cleanliness of the air filter.

CLEANING THE PRE-FILTER 1. Loosen the wing nut and remove the cover.

2. Remove and clean the bowl with a clean cloth.

3. Install the bowl and the cover and tighten the nut.

56 REMOVING THE ELEMENTS 1. Raise the loader attachment, stop the engine, remove the starter switch key and install the support strut.

2. Lift the engine guard.

3. Remove the filter cover.

4. Carefully remove the primary element.

57

8-28

SECTION 8 - LUBRICATION/FILTERS/FLUIDS 5. If the secondary element has to be replaced, carefully remove the secondary element.

IMPORTANT: The secondary element must not be cleaned. It must be replaced every year or after three cleanings of the primary element.

58 CLEANING THE PRIMARY ELEMENT If the primary element is dry: Blow compressed air from the inside towards the outside at very low pressure. The compressed air nozzle should be held at least three centimetres from the inside wall of the primary element. Cleaning is completed once no more dust comes out of the primary element.

IMPORTANT: Make sure you protect your face before using compressed air.

IMPORTANT: Compressed air pressure should not exceed 7 bar.

NOTE: Do not use compressed air if there is oil or soot in the element.

59

INSPECTING THE PRIMARY ELEMENT Check the primary element for damage by placing an inspection lamp inside.

IMPORTANT: Replace the element if light can be seen through a hole, however small.

8-29

SECTION 8 - LUBRICATION/FILTERS/FLUIDS INSTALLING THE ELEMENTS 1. Clean the inside of the filter body by means of a clean cloth.

2. Carefully install a secondary element if the old element had to be replaced.

60 3. Carefully install the primary element.

4. Install the filter cover.

61 5. Start the engine, run it at low idle speed and make sure that the filter restriction warning light on the instrument panel is not on.

6. Lower and lock the engine guard.

7. Remove the support strut and lower the loader attachment.

62

8-30

SECTION 8 - LUBRICATION/FILTERS/FLUIDS TRANSMISSION (POWERSHUTTLE) SERVICE SPECIFICATIONS Oil level check ...........................................................................................................................Every 250 hours (After the first 50 hours during the running-in period) Filter replacement..............................................................................................Every 1000 hours or every year Cleaning the breather ........................................................................................Every 1000 hours or every year Cleaning the screen filter...................................................................................Every 1000 hours or every year Oil change .........................................................................................................Every 1000 hours or every year Transmission capacity ............................................................................................................................ 18 litres Type of oil ................................................................................................................. See “Fluids and lubricants” LEVEL The oil level check should be carried out with the engine running at low speed and at normal operating temperature.

1. Park the machine on level ground.

2. Raise the loader attachment, stop the engine, remove the starter switch key and install the support strut.

3. Lift the engine guard.

4. Remove the dipstick, clean it with a clean cloth and replace it in the guide tube up to the stop.

Then remove it again.

5. If the oil level is below the mini mark, top up.

See “Filling”.

6. Lower and lock the engine guard.

7. Remove the support strut and lower the loader attachment.

63

8-31

SECTION 8 - LUBRICATION/FILTERS/FLUIDS DRAINING 1. Raise the loader attachment, stop the engine, remove the starter switch key and install the support strut.

2. Lift the engine guard.

NOTE: Change the oil while the transmission is still warm, the oil will flow more easily.

3. Place a container of a suitable capacity under the drain plug (1) and then remove the plug.

4. Remove the dipstick and allow the oil to flow out.

5. Install the drain plug and the dipstick.

64 REPLACING THE FILTER 1. Clean around the filter head.

2. Place a receptacle of a suitable capacity under the filter (1), loosen the filter by means of a filter wrench and then unscrew it by hand.

3. Apply a thin layer of oil on the new filter seal.

4. Install the new filter. Turn the filter until the seal is in contact with the filter head and tighten the filter a further half turn by hand.

IMPORTANT: Do not use the filter wrench to tighten. Overtightening can damage the seal and the filter.

65

8-32

SECTION 8 - LUBRICATION/FILTERS/FLUIDS CLEANING THE SCREEN FILTER 1. Clean around the cover plate (2) and remove it.

Check the condition of the O-ring and replace it if necessary. Remove the screen filter and clean it in a detergent solution.

IMPORTANT: Follow the instructions for the detergent solution.

2. Dry the screen filter carefully with compressed air and install it.

IMPORTANT: Make sure you protect your face before using compressed air.

3. Install and tighten the cover plate to 11 Nm. FILLING 1. Remove the dipstick and fill with the correct oil via the dipstick fill hole. Then replace the dipstick.

2. Check the oil level by means of the dipstick. Top up if necessary.

3. Drive the machine for a few minutes in first and second gear then stop the engine.

4. Check the oil level by means of the dipstick. Top up if necessary.

5. Lower and lock the engine guard.

6. Remove the support strut and lower the loader attachment.

66

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SECTION 8 - LUBRICATION/FILTERS/FLUIDS TRANSMISSION (POWERSHIFT) SERVICE SPECIFICATIONS Oil level check........................................................................................................................... Every 250 hours (After the first 50 hours during the running-in period) Filter replacement ............................................................................................. Every 1000 hours or every year Oil change......................................................................................................... Every 1000 hours or every year Transmission capacity............................................................................................................................. 14 litres Type of oil..................................................................................................................See “Fluids and lubricants” IMPORTANT: It is recommended to change the oil filter after 100 hours if the transmission is new or has been repaired.

LEVEL The oil level check should be carried out with the engine running at low speed and at normal operating temperature.

1. Park the machine on level ground.

2. Raise the loader attachment, stop the engine, remove the starter switch key and install the support strut.

3. Lift the engine guard.

4. Remove the dipstick, clean it with a clean cloth and replace it in the guide tube up to the stop.

Then remove it again.

5. If the oil level is below the mini mark, top up.

See “Filling”.

6. Lower and lock the engine guard.

7. Remove the support strut and lower the loader attachment.

67

8-34

SECTION 8 - LUBRICATION/FILTERS/FLUIDS DRAINING 1. Raise the loader attachment, stop the engine, remove the starter switch key and install the support strut.

2. Lift the engine guard.

NOTE: Change the oil while the transmission is still warm, the oil will flow more easily.

3. Place a container of a suitable capacity under the drain plug (1) and then remove the plug.

4. Remove the dipstick and allow the oil to flow out.

5. Install the drain plug and the dipstick.

68 REPLACING THE FILTER 1. Clean around the filter head.

2. Place a receptacle of a suitable capacity under the filter (1), loosen the filter by means of a filter wrench and then unscrew it by hand.

3. Apply a thin layer of oil on the new filter seal.

4. Install the new filter. Turn the filter until the seal is in contact with the filter head and tighten the filter a further half turn by hand.

IMPORTANT: Do not use the filter wrench to tighten. Overtightening can damage the seal and the filter.

69

8-35

SECTION 8 - LUBRICATION/FILTERS/FLUIDS FILLING 1. Remove the dipstick and fill with the correct oil via the dipstick fill hole. Then replace the dipstick.

2. Check the oil level by means of the dipstick. Top up if necessary.

3. Drive the machine for a few minutes in first and second gear then stop the engine.

4. Check the oil level by means of the dipstick. Top up if necessary.

5. Lower and lock the engine guard.

6. Remove the support strut and lower the loader attachment.

8-36

70

SECTION 8 - LUBRICATION/FILTERS/FLUIDS FRONT DRIVE AXLE SERVICE SPECIFICATIONS Oil level check ...........................................................................................................................Every 250 hours (After the first 50 hours during the running-in period) Cleaning the breather ................................................................................................................Every 250 hours Oil change ...............................................................................................................................Every 1000 hours Front drive axle oil capacity (2WD)........................................................................................................ 0.4 litres Front drive axle oil capacity (4WD)............................................................................................... 7.9 ÷ 8.4 litres Front drive axle oil capacity (4WS) ...................................................................................................... 13.1 litres Type of oil ................................................................................................................. See “Fluids and lubricants” FRONT DRIVE AXLE OIL LEVEL 1. Park the machine on level ground, stop the engine and remove the starter switch key.

2. Remove the plug and check that the oil is level with the plug hole.

3. Install the plug.

71 FRONT REDUCTION GEAR OIL LEVEL 1. Park the machine on level ground.

2. Make sure that the direction of travel control lever and gear change lever are in neutral position.

3. Use the loader attachment to raise the front of the machine slightly so that the front wheels are no longer in contact with the ground and place blocks under the front drive axle.

4. Stop the engine and remove the starter switch key.

8-37

SECTION 8 - LUBRICATION/FILTERS/FLUIDS 5. Manually turn the wheel until the plug hole is in the horizontal position and remove the plug.

6. The oil should be level with the plug hole.

7. Install the plug.

8. Repeat Steps 5 to 7 for the other reduction gear.

9. Lower the machine to the ground.

72 CLEANING THE BREATHER 1. Clean around the breather and remove it.

2. Clean the breather with a detergent solution.

IMPORTANT: Follow the instructions for the detergent solution.

3. Carefully dry the breather with compressed air and install it.

73 DRAINING AND FILLING THE FRONT DRIVE AXLE 1. Park the machine on level ground, stop the engine and remove the starter switch key.

2. Place a container of a suitable capacity under the drain plug (1), remove the plugs (1) and (2) and allow the oil to flow out.

3. Install the drain plug (1).

4. Fill with oil via the filler plug hole (2) until the oil is level with the drain plug hole. Then install the plug.

74

8-38

SECTION 8 - LUBRICATION/FILTERS/FLUIDS DRAINING AND REFILLING REDUCTION GEARS

THE

FRONT

1. Park the machine on level ground.

2. Make sure that the direction of travel control lever and gear change lever are in neutral position.

3. Use the loader attachment to raise the front of the machine slightly so that the front wheels are no longer in contact with the ground and place blocks under the front drive axle.

4. Stop the engine and remove the starter switch key.

5. Turn the wheel by hand until the plug hole is in the lowest position.

6. Place a container of a suitable capacity under the reduction gear, remove the plug and allow the oil to flow out.

7. Turn the wheel by hand until the plug hole is in the horizontal position and then fill via that plug hole until the oil is level with the plug hole.

8. Install the plug.

9. Repeat Steps 5 to 8 for the other reduction gear.

10. Lower the machine to the ground.

75

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SECTION 8 - LUBRICATION/FILTERS/FLUIDS REAR AXLE SERVICE SPECIFICATIONS Oil level check........................................................................................................................... Every 250 hours (After the first 50 hours during the running-in period) Cleaning the breather ............................................................................................................... Every 250 hours Oil change............................................................................................................................... Every 1000 hours Rear axle oil capacity (2WS)................................................................................................................ 21.2 litres Rear axle oil capacity (4WS)................................................................................................................ 13.6 litres Type of oil..................................................................................................................See “Fluids and lubricants” REAR AXLE OIL LEVEL 1. Park the machine on level ground and stop the engine.

2. (2WS) Remove the fill plug (1) and check that the oil is level with the fill plug hole.

76 3. (4WS) Remove the fill plug (2) and check that the oil is level with the plug hole.

4. Install the plug.

77

8-40

SECTION 8 - LUBRICATION/FILTERS/FLUIDS REAR REDUCTION GEAR OIL LEVEL 1. Park the machine on level ground.

2. Make sure that the direction of travel control lever and gear change lever are in neutral position.

3. Use the stabilizers to lift the rear of the machine slightly so that the rear wheels are no longer in contact with the ground. Place blocks under the rear axle.

4. Stop the engine and remove the starter switch key.

5. Manually turn the wheel until the plug hole is in the horizontal position and remove the plug.

6. The oil should be level with the plug hole.

7. Install the plug.

8. Repeat Steps 5 to 7 for the other reduction gear.

9. Lower the machine to the ground.

78

8-41

SECTION 8 - LUBRICATION/FILTERS/FLUIDS DRAINING AND FILLING THE REAR AXLE (2WS) 1. Park the machine on level ground, stop the engine and remove the starter switch key.

2. Place a container of a suitable capacity under the drain plug (1), remove the plugs (1) and (2) and allow the oil to flow out.

3. Install the drain plug (1).

4. Fill with oil via the hole (2) until the oil is level with the plug hole (2) and then install the plugs (1) and (2).

79 (4WS) 1. Park the machine on level ground, stop the engine and remove the starter switch key.

2. Place a container of a suitable capacity under the drain plug (1), remove the plug (2) and allow the oil to flow out.

3. Install the drain plug (1).

4. Fill with oil via the plug hole (2) until the oil is level with the hole and then install the plugs (2).

80

8-42

SECTION 8 - LUBRICATION/FILTERS/FLUIDS DRAINING AND FILLING REDUCTION GEARS

THE

REAR

1. Park the machine on level ground.

2. Make sure that the direction of travel control lever and gear change lever are in neutral position.

3. Use the stabilizers to lift the rear of the machine slightly so that the rear wheels are no longer in contact with the ground. Place blocks under the rear axle.

4. Stop the engine and remove the starter switch key.

5. Turn the wheel by hand until the plug hole is in the lowest position.

6. Place a container of a suitable capacity under the reduction gear, remove the plug and allow the oil to flow out.

7. Turn the wheel by hand until the plug hole is in the horizontal position and then fill via that plug hole until the oil is level with the plug hole.

8. Install the plug.

9. Repeat Steps 5 to 8 for the other reduction gear.

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SECTION 8 - LUBRICATION/FILTERS/FLUIDS

NOTES

8-44

SECTION 9 MAINTENANCE/ADJUSTMENTS WHEELS AND TYRES

!

WARNING

!

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

!

WARNING

!

WARNING

!

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

!

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

TYRE PRESSURES See “Tyre pressures and permissible loads” in Section 12.

IMPORTANT: Make sure you protect your face before using compressed air.

Service specifications Pressure check.................................................................................................... Every 50 hours or every week WHEEL NUT TORQUE SETTINGS Service specifications Torque tightening check....................................................................................................After the first 10 hours during the running-in period and at every wheel change Front wheel nuts ..................................................................................................................................... 330 Nm Rear wheel nuts (2 wheel drive) ............................................................................................................. 542 Nm Rear wheel nuts (4 wheel drive) ............................................................................................................. 700 Nm

9-1

SECTION 9 - MAINTENANCE/ADJUSTMENTS REPLACING A WHEEL 1. Park the machine on hard, level ground, with no obstacles in the area. Set parking brake and chock wheels.

2. Loosen the retaining nuts or screws from the wheel which is to be removed.

3. Start the engine and use the loader attachment and the stabilizers to lift the machine until the wheels are no longer in contact with the ground.

4. Stop the engine and remove the starter switch key.

5. Place blocks under the axle for the wheel which is to be removed.

6. Remove the nuts and remove the wheel.

7. Install a new wheel, observing the orientation of the tread pattern.

8. Install the nuts and tighten them to correct torque, see “Wheel nut torque settings”.

9. Remove the blocks from under the axle.

10. Lower the machine to the ground.

NOTE: Make sure that the new wheel has a sufficient inflation pressure. Re-inflate it if necessary.

IMPORTANT: Make sure you protect your face before using compressed air.

TYRE OR WHEEL SERVICE The servicing of tyres and wheels for this machine should only be entrusted to a qualified mechanic, who will know how to inflate the tyres while observing safety instructions. To avoid any accident, use a protective device (an inflation cage for tyres), suitable tools and respect the procedure. Serious or fatal injury can result from a tyre suddenly flying off a rim (one piece rim) or from the tyre and/or the wheel components (a wheel consisting of several parts).

9-2

1

SECTION 9 - MAINTENANCE/ADJUSTMENTS LOADER BUCKET MECHANICAL/HYDRAULIC SELF LEVELLING/RETURN TO DIG ADJUSTMENT Return to dig is an electrically activated feature which enables the operator to automatically return the bucket to a level digging position for a further work cycle with one simple movement of the loader control lever (3).

Whenever the bucket is rolled forward to dump the return to dig electrical circuit is completed and the solenoid on the bucket spool is energised.

When the loader bucket control lever (3) is moved diagonally left to the return to dig position (2) the electromagnet will hold the bucket spool in the roll back position until the bucket is in the level digging position at which time the indicator on the rod of the bucket self levelling linkage will pass in front of the sensor which de-energises the electromagnet on the bucket spool enabling the spool to return to the neutral position.

2 RETURN TO DIG SENSOR ADJUSTMENT The return to dig system consists of an electromagnet mounted on the loader bucket control valve spool, a sensor (1) mounted on top of the loader arm and a pointer attached to the tube of the bucket self levelling linkage.

1. Place the bucket on the ground in the preferred digging position.

2. Check the dimensions of 88.5 mm and 7.5 mm are maintained as shown.

3. Ensure the face of the sensor (1) is 6 mm from rod (2).

As a visual aid for the operator, while seated in the cab, the pointer mounted on the loader arm can be seen to align with the pointer on return to dig linkage, when the loader arms are lowered and the bucket is in the level digging position.

3

9-3

SECTION 9 - MAINTENANCE/ADJUSTMENTS RADIATOR, COOLANT AND AIR CONDITIONING CONDENSER (If fitted) SERVICE SPECIFICATIONS Checking for leaks ..................................................................................................Every 10 hours or every day Cleaning.................................................................................................................................... Every 250 hours CLEANING 1. Raise the loader attachment, stop the engine, remove the ignition switch and install the support strut.

2. Remove the front grille.

3. Unscrew and remove the upper fixing nuts.

4. Shift the filter sideways.

5. Removal of the attaching bolts allows the condenser to be raised for cleaning.

6. Clean: Dry dust: use compressed air at a pressure not exceeding 7 bar.

Mud: use a water jet.

Oily dust: use a detergent based solution and preferably a low pressure cleaning apparatus.

IMPORTANT: Make sure you protect your face before using compressed air.

Ensure all dirt and debris is removed from between the condenser and engine coolant radiator. This action maintains efficient heat transfer for the condenser.

7. Install the condenser.

8. Install the grille.

9. Remove the support strut and lower the loader attachment.

9-4

4

SECTION 9 - MAINTENANCE/ADJUSTMENTS ENGINE ALTERNATOR AND FAN BELT SERVICE SPECIFICATIONS Visual check ........................................................................................................... Every 10 hours or every day CHECK 1. Raise the loader attachment, stop the engine, remove the starter switch key and install the support strut.

2. Lift the engine guard.

3. Visually check the condition of the fan belt.

Replace it if it is worn or damaged.

5 REPLACEMENT 1. Insert the 1/2” square drive wrench in the hole in the tensioner roller.

2. Exert just sufficient pressure on the key to slacken the fan belt.

3. Slide the fan belt over the water pump pulley and then over the other pulleys.

4. Install a new fan belt on the water pump pulley and on the crankshaft pulley.

5. Insert the key in the hole in the tensioner roller.

6. Exert pressure on the key so as to be able to pass the fan belt onto the alternator pulley.

7. Lower and lock the engine guard.

6

8. Remove the support strut and lower the loader attachment.

9-5

SECTION 9 - MAINTENANCE/ADJUSTMENTS TURBOCHARGER Serious damage to the turbocharger bearing can result from inadequate lubrication if the following recommendations are not observed.

To prevent turbocharger bearing damage prior to the first start after a turbocharger has been newly installed or if for any reason, the oil supply to the turbocharger has been disconnected, or in cases where the engine is being started for the first time after a period of 4 weeks or more without use, the following procedure should be used: 1. Disconnect the inlet and outlet oil pipes from the turbocharger and pour some clean engine oil into the oil inlet port, taking care that no contaminants enter the turbocharger.

2. Remove the air inlet tube from the turbocharger and spin the compressor wheel by hand to prelubricate the bearings.

3. Re-connect the oil inlet and air inlet tubes but not the oil outlet.

4. Disconnect the electrical wire to the fuel injection pump fuel shut-off solenoid. Place a suitable receptacle below the oil outlet port and crank the engine until oil flows from the outlet port.

5. Re-connect the oil outlet tube using a new gasket and tighten the retaining bolts to the torque.

Re-connect the fuel injection pump fuel shut-off solenoid wire.

6. Check the engine oil level and add oil if necessary. Start the engine and check for oil and air leaks.

7. Observe the oil pressure warning light. If the oil pressure warning light is not extinguished in the first few seconds of idling, stop the engine immediately and consult your Dealer.

On every start-up the engine should be allowed to idle (1000 rev/min maximum) for 60 seconds before operating under load, to ensure an adequate oil supply to the turbocharger bearing. The engine should also be allowed to idle without load for two minutes before shut-down to enable the oil to dissipate the heat from the turbocharger bearing.

9-6

SECTION 9 - MAINTENANCE/ADJUSTMENTS ENGINE ROCKER ARM CLEARANCE ADJUSTMENT SERVICE SPECIFICATIONS Inspection ..........................................................................................................Every 1000 hours or every year NOTE: Consult your Dealer.

To check the clearance, turn the crankshaft “clockwise” so the valves are fully open, then check and adjust.

Valves Open .................................. Valves to adjust 1 Inlet 3 Exhaust............................2 Exhaust 4 Inlet 3 Inlet 4 Exhaust............................1 Exhaust 2 Inlet 2 Exhaust 4 Inlet............................1 Inlet 3 Exhaust 1 Exhaust 2 Inlet............................3 Inlet 4 Exhaust Inlet valve clearance - Cold 0.30 ± 0.05 mm.

Exhaust valve clearance - Cold 0.55 ± 0.05 mm.

The feeler gauge (A) must be inserted between each valve stem and rocker arm. Turn the screw to adjust the clearance.

7

MACHINE INSPECTION AND CLEANING SERVICE SPECIFICATIONS Inspection and cleaning...........................................................................................................Every 1000 hours Or whenever oil or grease has been spilt on the machine; clean such deposits off with steam or high pressure water with detergent.

Take advantage of this operation to make a visual check of all the welded components (possible appearance of cracks), and the attachment linkage.

Mark any leaks, check the condition of pipes and hoses.

9-7

SECTION 9 - MAINTENANCE/ADJUSTMENTS CYLINDER LEAK INSPECTION A cylinder rod should be slightly oily. Check for leaks after a working period, when the entire hydraulic system is at normal operating temperature.

1. Clean the rod and the gland of the cylinder which is to be inspected.

2. Work normally for 5 to 10 minutes.

3. Extend the cylinder rod.

4. Check for leaks.

ROD APPEARANCE

TEST

CONCLUSION

Dry

Slight traces of oil when a sheet of paper is rubbed over 20 cm of the rod.

Normal

Slightly oily

The paper remains stuck when run over the rod.

Normal

Oily

A sheet of paper placed on the rod stays stuck to it.

Normal

Very oily or weeping

A ring of oil is visible on the rod after each rod extension.

Leak

Oil drips from the gland every time the cylinder rod is retracted.

AIR CONDITIONING (Optional) The air conditioning system components require maintenance at regular intervals. Observe these intervals to ensure correct operation and full efficiency of the air conditioning. The air conditioning system contains HFC 134a refrigerant which is subject to strict regulations. Any problem with the system must be resolved quickly.

!

WARNING

!

Never perform any service operation on the air conditioning circuit. For any operation, consult an approved specialist.

NOTE: Run the air conditioning at least once a week, even for a short time. See “Heating, ventilation and air conditioning” in Section 4.

9-8

Consult your Dealer

SECTION 9 - MAINTENANCE/ADJUSTMENTS SERVICE SPECIFICATIONS Compressor drive belt inspection ..............................................................................................Every 250 hours COMPRESSOR DRIVE BELT INSPECTION 1. Raise the loader attachment, stop the engine, remove the starter switch key and install the support strut.

2. Lift the engine guard.

3. Check the condition of the compressor drive belt. Replace it if it is worn or damaged and adjust the tension.

IMPORTANT: After replacing the drive belt, make an adjustment after the first 10 operating hours.

Check the belt tension and adjust if necessary.

To adjust the belt, loosen the mounting hardware, retighten the belt so as to obtain 16 mm deflection on top side and then tighten the hardware to 33.9 Nm. IMPORTANT: The drive belt should not be overtightened (premature bearing wear) or too slack (premature belt wear).

8

4. Lower and lock the engine guard.

5. Remove the support strut and lower the loader attachment.

DRAINING THE TELESCOPIC DIPPER (If fitted) Ensure the drain port (1) in the end of the dipper is kept clear to prevent accumulation of water inside the unit.

Inspect the port for evidence of hydraulic oil which would indicate a leak from the extension cylinder.

9

9-9

SECTION 9 - MAINTENANCE/ADJUSTMENTS CAB FILTERS SERVICE SPECIFICATIONS Filter cleaning............................................................................................................................ Every 250 hours or in case of reduced air circulation Before servicing the filter, switch off the blower and close all the windows and one door. Forcibly close the other door. The resulting back pressure will dislodge loose dirt from the underside of the filter.

Replace if the filter is ever damaged.

To remove the filter element (1), release the clips (2), remove the grid (3) and take out the filter element. Make sure the element and sealing surfaces are not damaged during removal.

NOTE: In humid conditions do not switch on the blower prior to servicing the filters.

Clean the filter element (1) in water with a suitable detergent (consult your Dealer). Instructions for using the detergent are printed on the detergent packaging.

Shake off the excess water and allow to dry naturally.

The filter element (1) must be thoroughly dry before installation.

Clean the inside of each filter chamber with a damp lint-free cloth and re-install the filter.

9-10

10

SECTION 9 - MAINTENANCE/ADJUSTMENTS HEATER UNIT AND AIR CONDITIONING COOLER (Optional) SERVICE SPECIFICATIONS Clean .........................................................................................................................................Every 250 hours These are located in a pod under the cab seat support. To gain access it is necessary to remove the seat.

Clean the heater and cooler using compressed air not exceeding 7 bar taking care not to damage the radiator fins.

IMPORTANT: Make sure you protect your face before using compressed air.

Clean the chamber with a damp, cloth and reassemble the pod filter element.

NOTE: The filter should be cleaned more frequently when operating in extremely dusty conditions.

11

PARKING BRAKE ADJUSTMENT The parking brake is adjusted by tightening the inner adjuster nut (1) until the brake pad just contacts the disc at which point the 2nd outer nut should be tightened to lock the assembly.

The parking brake cable free movement can be adjusted by rotation of the cable knuckle (2) situated at the base of the parking brake cable where it attaches to the transmission by the quick release pin (3).

The parking brake should be adjusted to be fully “ON” at the 4th ratchet position on the parking brake.

12

9-11

SECTION 9 - MAINTENANCE/ADJUSTMENTS BRAKE FLUID SERVICE SPECIFICATIONS Level check ....................................................................................................................................... Periodically Draining the circuit ..................................................................................................................... Every two years The foot brakes do not require adjustment other than a fluid change every 2 years, or before if the fluid is low or a leak has occurred.

13 Check the brake cylinders for signs of leakage.

Ensure the fluid level in the brake reservoir is checked periodically.

!

WARNING

!

Owners should be aware of any local regulations concerning testing of braking systems. Regularly maintain the brakes to ensure compliance with the law and ensure your safety. If in doubt, consult your Dealer.

NOTE: Before adding fluid to the brake fluid reservoir, make sure it is of the right type. Use of a wrong type of fluid can cause serious damage. See “Fuel and lubricant capacities and specifications” in Section 8.

9-12

14

SECTION 9 - MAINTENANCE/ADJUSTMENTS CHECKING AND ADJUSTING STABILIZER PLAY (Sideshift backhoe version) SERVICE SPECIFICATIONS Inspect and adjust ............................................................................................................................ Periodically INSPECTION 1. Raise the stabilizers, stop the engine and remove the starter switch key.

2. Push each stabilizer forwards and backwards by hand. The stabilizers should not move. If there is any movement, carry out the adjustment.

ADJUSTMENT The stabilizer wear adjustment can be achieved by removal of one of the shims (1) held in position by the support plate.

As required, remove one shim and retighten the bolts to 27 Nm. If necessary, perform the same operation on the other stabilizer.

15

BACKHOE BUCKET EXCAVATION POSITION It is possible to change the backhoe bucket opening angle, depending on the work which is to be carried out.

Position (1): Bucket maximum power.

Position (2): Enables the bucket to open 10° more and therefore to be able to dig vertical side trenches closer to the machine.

NOTE: To change the bucket fixing point, see “Replacing a backhoe bucket” in Section 5.

16

9-13

SECTION 9 - MAINTENANCE/ADJUSTMENTS TELESCOPIC DIPPER (Optional) SERVICE SPECIFICATIONS Checking and adjustment ......................................................................................................... Every 250 hours The telescopic dipper (if fitted) is equipped with adjustable wear pads (4) and adjusted by removing shims (1) from under the screws (2) located on the outside of the dipper on either side.

Retract the dipper and place it on a support so the bucket is not touching the ground. Remove a shim from each screw on one side of the dipper.

IMPORTANT: Each time a new adjustment is made, carry it out on the other side of the dipper. If you are in any doubt concerning adjustments, consult your Dealer.

Install and tighten the screws to a torque between 350 and 400 Nm. Check the play again.

The play at point (3) should not exceed 1.5 mm.

When all adjusting shims have been removed the wear pads (4) will require changing. Consult your Dealer.

17

9-14

SECTION 9 - MAINTENANCE/ADJUSTMENTS FRONT WHEEL ADJUSTMENTS (2WS) SERVICE SPECIFICATIONS Checking and adjustment ............................................................................................................... Occasionally TOE-IN CHECK The front wheel toe-in is pre set and adjustment is not normally necessary. Occasional checks should be made to ensure the correct toe-in is maintained.

TOE-IN ADJUSTMENT 1. Measure the toe-in by checking the track width between the front of the wheel rim (1) and the rear of the wheel rim (2) at hub height. The correct toe-in measurement is 0-6 mm.

18 2. Loosen the lock nut (1) on each track rod and turn the hexagon (2) with a spanner until the correct toe-in setting is obtained. Tighten the lock nut and re-check the toe-in.

19 STEERING STOPS (4WD) Four steering stops (1) are incorporated in the axle, two each end. The two rear stops are adjustable and control the minimum turning circle. The two front stops are adjustable and should be set to prevent the tyres touching the machine on full left and right lock with the axle fully oscillated.

To adjust, slacken the locknut (2) and turn the stop bolt (1) anti-clockwise to reduce the steering angle of the wheels or clockwise to increase the steering angle. Tighten the locknut.

20

9-15

SECTION 9 - MAINTENANCE/ADJUSTMENTS FRONT WHEEL ADJUSTMENTS (4WS) SERVICE SPECIFICATIONS Checking and adjustment ............................................................................................................... Occasionally TOE-IN CHECK The front and rear wheel toe-in is pre set and adjustment is not normally necessary. Occasional checks should be made to ensure the correct toe-in is maintained.

TOE-IN ADJUSTMENT IMPORTANT: The machine wheels must be set to the normal 2 wheel steer position with the wheels set in a straight line.

1. Measure the toe-in by checking the track width between the front of the wheel rim (1) and the rear of the wheel rim (2) at hub height. The correct toe-in measurement is 0-2 mm.

21

2. Loosen the lock nut (1) on each track rod and turn the hexagon (2) with a spanner until the correct toe-in setting is obtained. Tighten the lock nut and re-check the toe-in.

22 STEERING STOPS Four steering stops (1) are incorporated in the axle, two each end. The two rear stops are adjustable and control the minimum turning circle. The two front stops are adjustable and should be set to prevent the tyres touching the machine on full left and right lock with the axle fully oscillated.

To adjust, slacken the locknut (2) and turn the stop bolt (1) anti-clockwise to reduce the steering angle of the wheels or clockwise to increase the steering angle. Tighten the locknut.

23

9-16

SECTION 9 - MAINTENANCE/ADJUSTMENTS ROPS/FOPS CAB (Or protective frame) Your machine has a ROPS/FOPS cab (or frame).

ROPS: Roll over protective structure.

FOPS: Falling object protective structure.

An identification plate is attached to the ROPS/ FOPS cab (or frame). See “Type, Serial Number And Year Of Manufacture Of The Machine” in Section 2 for: - The manufacturer’s address.

- The ROPS/FOPS serial number.

- The reference to the performance requirements met: ISO 3471-1 for the ROPS. ISO 3449 for the FOPS. SERVICE SPECIFICATIONS Inspection ..................................................................................................................................Every 300 hours (after the first 50 hours of operation) MAINTENANCE AND INSPECTION Check the torque of the mounting screws and, if necessary, tighten the screws to the correct torque.

See “Mounting screw torque”.

Check the operator’s seat and the seat belt mounting hardware. Tighten the screws to the correct torque. Replace parts showing signs of wear or damage.

Check that there are no cracks, rust or holes in the ROPS/FOPS cab (or frame) and components. Age, weather and accidents can cause damage. If you have any doubt about the state of the ROPS/FOPS cab (or frame), consult your Dealer.

DAMAGE If the machine has rolled over or if the ROPS/FOPS cab (or frame) has been in some other type of accident, you must replace the damaged ROPS/FOPS components in order to conserve the same degree of protection you had previously.

After an accident, check the following for damage: The ROPS/FOPS cab (or frame).

The lower ROPS/FOPS cab (or frame) chassis.

The operator’s seat.

The seat belt mounting hardware.

IMPORTANT: Before putting the machine back into service, make sure all the damaged components of the ROPS/FOPS cab (or frame) have been replaced. See the Parts Catalogue for your machine or consult your Dealer.

9-17

SECTION 9 - MAINTENANCE/ADJUSTMENTS MOUNTING SCREW TORQUE The torque specifications for the screws used to mount the ROPS/FOPS cab (or frame) on the lower chassis is 380 Nm.

!

WARNING

!

Do not try to weld or straighten the ROP/FOPS cab (or frame).

!

WARNING

!

Do not modify the ROPS/FOPS cab (or frame) in any manner. Unauthorized modification, such as welding, drilling, cutting and adding attachments, as well as any damage resulting from collisions or the machine rolling over, could weaken the structure and reduce your protection. Replace the ROPS/ FOPS cab (or frame) if subjected to roll over or damage. Do not attempt to repair it.

!

WARNING

!

If you operate this machine without a ROPS/FOPS cab (or frame) and the machine rolls over, you can be seriously injured or killed. Remove the ROPS/ FOPS cab only for service or replacement. Do not operate the machine with the ROPS/FOPS cab (or frame) removed.

!

WARNING

!

Do not install accessories (fixed or otherwise) which can increase the weight of the machine. This could cause serious accidents. Do not exceed the maximum weight shown on the ROPS/FOPS cab (or frame) identification plate.

!

WARNING

!

Improper ROPS/FOPS cab (or frame) inspection or maintenance can cause serious injury. Carry out the recommended ROPS/FOPS cab (or frame) inspection procedure shown in this manual. If it is necessary to replace ROPS/FOPS parts or the ROPS/ FOPS cab (or frame), use only the replacement parts shown in the Parts Catalogue for your machine.

9-18

SECTION 9 - MAINTENANCE/ADJUSTMENTS TROUBLESHOOTING IMPORTANT: The following troubleshooting table is designed for your guidance only. If any repairs are required beyond routine maintenance, your machine must be returned to your Dealer who has the correct tools, facilities and knowledge to perform repairs to the correct specification and safety standards.

ENGINE PROBLEMS

The engine does not start.

The engine does not start in cold weather.

POSSIBLE CAUSES

SOLUTIONS

No electric current in circuit

Reconnect the battery master switch

Batteries discharged or defective

Recharge or replace the batteries

Batteries discharged or defective

Clean connections or repair

Incorrect injection pump timing

Consult your Dealer

Contaminated fuel

Drain and clean the fuel system

Fuel tank empty

Fill the fuel tank

No fuel supply

Consult your Dealer

Air in fuel system

Bleed the fuel system

Defective starter motor

Consult your Dealer

Fuel system blocked by the formation of crystals caused by the use of poor quality fuel

Drain and fill with suitable fuel.

Replace fuel filters

Incorrect functioning of cold weather start device

Consult your Dealer

Idle speed too low Irregular flow from lift pump

The engine stalls.

Consult your Dealer

Contaminated fuel

Drain and clean the fuel system

Fuel filters clogged

Replace fuel filters

Air in fuel system

Bleed the fuel system

Defective injection pump controls Abnormal play between camshaft cams and tappets

Consult your Dealer

Valves attacked by carbon, corrosion or wear Defective water pump Malfunction of thermostat Cooling orifices obstructed in the cylinder head and the cylinder block The engine overheats.

Consult your Dealer

Water pump drive belt slack

Check and replace belt tensioner

Coolant level too low

Top up, look for leaks

Incorrect engine timing Incorrect injection pump calibration Clogged air filter

Consult your Dealer Clean/replace air filter

9-19

SECTION 9 - MAINTENANCE/ADJUSTMENTS

PROBLEMS

POSSIBLE CAUSES

SOLUTIONS

Incorrect injection pump timing Incorrect functioning of cold weather starting device Excessive wear on pistons

Consult your Dealer

Incorrect speed regulator calibration Engine runs irregularly and insufficient power.

Injectors partially obstructed or defective Contaminated fuel

Drain and clean the fuel system

Incorrect clearance between the camshaft cams and the tappets

Consult your Dealer

Defective turbocharger Clogged air filter

Clean/replace air filter

Defective injectors

Consult your Dealer

Fuel lines or filters clogged

Blow through lines with compressed air, replace fuel filters

Incorrectly adjusted injection pump Knocking crankshaft causing excess play at one or more crankshaft bearing journals or at the bearing shoulders Engine is knocking.

Unbalanced crankshaft Flyweel screws loose

Consult your Dealer

Connecting rods bent Noise from excess play between piston pin and connecting rod bushing.

Worn crank bearing shells Noisy timing Excessive maximum pump flow Cold weather starting device incorrectly calibrated or defective Excess delay at injection pump

Consult your Dealer

The injection pump is too advanced Injector nozzle orifices blocked or partially blocked Large emissions of black or dark grey smoke.

Clogged air filter Loss of compression due to: piston rings seized or worn; worn liners; damaged or maladjusted valves Incorrect injectors, different type or incorrectly calibrated Incorrect injection pipe internal diameter; ends narrowed due to repeated blockages

9-20

Clean, replace the filter elements

Consult your Dealer

SECTION 9 - MAINTENANCE/ADJUSTMENTS

PROBLEMS

POSSIBLE CAUSES

SOLUTIONS

Excess delay at injection pump Malfunction of automatic cold weather starting device Defective injector Blue, grey/blue, grey smoke, turning to white.

Loss of oil at piston rings caused by seized or worn rings or worn liners

Consult your Dealer

Oil passing through the inlet valves or guides due to wear on the valve stems/guides Engine too cold (thermostat seized or ineffective)

TRANSMISSION (POWERSHUTTLE) PROBLEMS

POSSIBLE CAUSES

SOLUTIONS

Transmission will not operate.

Low oil supply

Fill system with oil and check pump pressure

Modulator valve sticking or requires resetting

Consult your Dealer

Electrical connections loose

Check electrical continuity

Torque convertor worn

Replace as necessary

Low oil supply

Fill system with oil

Oil cooler air flow blocked

Clean all debris away from radiator

Handbrake dragging on

Adjust brake disc clearance

POSSIBLE CAUSES

SOLUTIONS

Low oil supply

Fill system with oil and check pump pressure

Transmission operation poor or jerky.

Transmission overheating torque convertor slipping.

TRANSMISSION (POWERSHIFT) PROBLEMS

Transmission will not operate.

Modulator valve / solenoid failure Powershift microprocessor disabled drive detecting a fault in the transmission

Transmission operation poor or jerky.

Transmission overheating torque convertor slipping.

Consult your Dealer

Modulator valve sticking

Consult your Dealer

Electrical connections loose

Check electrical continuity

Low oil pressure

Consult your Dealer

Low oil supply

Fill system with oil

Oil cooler air flow blocked

Clean all debris away from radiator

Torque convertor worn

Consult your Dealer

Handbrake dragging on

Adjust brake disc clearance

9-21

SECTION 9 - MAINTENANCE/ADJUSTMENTS ELECTRICAL SYSTEM PROBLEMS

POSSIBLE CAUSES

SOLUTIONS

Loose or corroded battery connections

Clean and tighten connections

Sulphated batteries

Check battery open circuit voltage for 12.6 volts minimum. Check electrolyte level and specific gravity

Battery isolator switch turned “OFF”

Re-instate isolator switch “ON”

Main machine fuse link blown

Establish reason of failure and replace fuse link

Loose or corroded connections

Clean and tighten loose connections

Low battery output

Check battery open circuit voltage for 12.6 volts minimum. Check electrolyte level and specific gravity

Incorrect viscosity engine oil

Use correct viscosity oil for temperature conditions

Transmission shift lever in gear

Place shift lever in neutral

Loose or corroded connections

Clean and tighten loose connections

Dead batteries

Charge or replace batteries

Low engine idle speed

Increase idle speed

Electrical system is inoperative.

Starter speed low and engine cranks slowly.

Starter inoperative.

Charge indicator lamp stays on with engine running.

Batteries will not charge.

Charge indicator flashing indicating excessive charging voltage.

9-22

Loose belt

Check belt tension

Malfunctioning battery

Check battery open circuit voltage for 12.6 volts minimum. Check electrolyte level and specific gravity

Malfunctioning alternator

Have authorized Dealer check alternator

Loose or corroded terminal connections

Clean and tighten connections

Sulphated batteries

Check battery open circuit voltage for 12.6 volts minimum. Check electrolyte level and specific gravity

Loose or worn belt

Check belt tension. Replace belt if required

Malfunctioning alternator

Have authorised Dealer check alternator

SECTION 9 - MAINTENANCE/ADJUSTMENTS BRAKES PROBLEMS

POSSIBLE CAUSES

SOLUTIONS

Brake piston seal leaking Pedal bottoms with engine stopped.

Worn brake, discs Brake bleeder not sealing

Consult your Dealer

Leakage in brake valve(s) Leakage in brake valve Excessive pedal travel.

Air in system Brake piston seal leaking

Consult your Dealer

Brake bleeder not sealing

HYDRAULICS PROBLEMS

POSSIBLE CAUSES

SOLUTIONS

Pump drive inoperative Pump worn All circuits fail to operate.

Low oil level

Consult your Dealer

Faulty system relief valve Restricted pump suction line Pump worn Slow operation or loss of power in all circuits.

Restricted pump suction line

Consult your Dealer

Faulty system relief valve

CAB PROBLEMS

Dust enters the cab.

Blower motor air flow low.

Air conditioner does not cool.

POSSIBLE CAUSES

SOLUTIONS

Improper seal around filter element

Check seal condition

Blocked filter

Clean or replace filter

Defective filter

Replace filter

Excessive air leak(s)

Seal air leak(s)

Blocked filter or recirculation filter

Clean or replace filter(s)

Heater core or evaporator core blocked

Consult your Dealer

Condenser plugged

Clean radiator, oil cooler and condenser

Low refrigerant

Check sight glass for bubbles.

Consult your Dealer

Belt slipping or damaged

Check automatic belt tensioner and belt condition

Heater control turned “ON”

Turn temperature control knob fully counterclockwise for maximum cooling

9-23

SECTION 9 - MAINTENANCE/ADJUSTMENTS

NOTES

9-24

SECTION 10 ELECTRICAL SYSTEM FUSES AND RELAYS The fuse and relay box is located under the right side console.

1 The main circuit and air conditioning fuses and the starter and air conditioning relays are located on the front right hand side outer of the cab, behind the engine.

The fuses and relays used are as follows: 80 Amp fuse: Main circuit protection between the battery and the machine electrical system.

10 Amp fuse: Air conditioning (if fitted).

Relay: Starter motor circuit.

Relay: Air conditioning (if fitted).

IMPORTANT: Never replace a fuse with a fuse of a different rating.

2

Located under the seat base: 25 Amp fuse: blower motor (if fitted) third speed.

NOTE: Remove the seat to gain access to this fuse.

3

10-1

SECTION 10 - ELECTRICAL SYSTEM FUSES - POWERSHUTTLE WITH ROPS

BUZZER

Fuse No.

BZ1

Rating Colour Circuit

Warning buzzer

F1/A F1/B

7.5 A Brown

Fuel shut off, antitheft power supply, grid heater

CONNECTORS

F1/C

10 A

Red

Stop lights

CN

F2/A

15 A

Blue

Instruments power supply, brake oil level sensor, seat, buzzer

F2/C

15 A

Yellow Pilot control

F3/A

3A

Violet

Rear right/front left side lights, instruments illumination

F3/B

3A

Violet

Rear left/front right side lights, number plate light

F3/C

10 A

Red

Front work lights, tools rapid connection, ride control, double delivery

F4/A

5A

Red

Forward speed, reverse speed, reverse buzzer, speed

F4/B

10 A

Red

Rear hammer button, grab level valve and sensor, clutch shut off buttons

F4/C

10 A

Red

Rear excavator lock, rear translation lock, rear work lights

F5/A

15 A

Blue

Front inner work lights

F5/B

10 A

Red

Traffic lights

F5/C

15 A

Blue

Main beam

Main harness connections into fuse board

F2/B

F6/A

7.5 A Brown

Beacon lamp

F6/B

7.5 A Brown

(+15) Flasher

F6/C

7.5 A Brown

Hand hammer, 4WD

F7/A

10 A

Red

(+30) Flasher, (+30) antitheft, horn

F7/B

15 A

F7/C

6A

F8/A

15 A

Blue

Outer rear work lights

F8/B

15 A

Blue

Outer front work lights

F8/C

15 A

Blue

Inner rear work lights

RELAYS K1

Forward-reverse speed switch

K2

Speed alarm, hand brake

K3

Starting

K4

Grab level solenoid valve

K5

Traffic and main beam lights

K6

Inner front work lights

K7

Inner rear work lights

K8

Outer front work lights

K9

Outer rear work lights

K10

Reverse speed

K11

Forward speed

K12

Flasher

10-2

4

SECTION 10 - ELECTRICAL SYSTEM FUSES - POWERSHUTTLE WITH CAB

BUZZER

Fuse Rating Colour Circuit No.

BZ1

Blue

Rear windshield wiper and rear windshield washer

F1/A

15 A

F1/B

7.5 A Brown

Fuel shut off, antitheft power supply, grid heater

F1/C

10 A

Red

Stop lights

F2/A

15 A

Blue

Instruments power supply, brake oil level sensor, seat, buzzer

F2/B

15 A

Blue

Conditioner

F2/C

15 A

Yellow Pilot control

F3/A

3A

Violet

Rear right/front left side lights, instruments illumination, conditioner, illumination

F3/B

3A

Violet

Rear left/front right side lights, number plate light

F3/C

10 A

Red

Front work lights, tools rapid connection, ride control, double delivery switches

F4/A

5A

Orange

Forward speed, reverse speed, reverse buzzer, speed

F4/B

10 A

Red

Rear hammer button, grab level valve and sensor, clutch shut off buttons

F4/C

10 A

Red

Rear excavator lock, rear translation lock, rear work lights

F5/A

15 A

Blue

Front inner work lights

F5/B

10 A

Red

Traffic lights

F5/C

15 A

Blue

Main beam

F6/A

7.5 A Brown

Beacon lamp

F6/B

7.5 A Brown

(+15) Flasher

F6/C

7.5 A Brown

Hand hammer, 4WD

F7/A

10 A

Red

(+30) Flasher, (+30) antitheft, horn

F7/B

10 A

Red

Current intake, radio, roff lamp

F7/C

6A

Black

Front windshield wiper

F8/A

15 A

Blue

Outer rear work lights

F8/B

15 A

Blue

Outer front work lights

F8/C

15 A

Blue

Inner rear work lights

Warning buzzer

CONNECTORS CN

Main harness connections into fuse board

RELAYS K1

Forward-reverse speed switch

K2

Speed alarm, hand brake

K3

Starting

K4

Grab level solenoid valve

K5

Traffic and main beam lights

K6

Inner front work lights

K7

Inner rear work lights

K8

Outer front work lights

K9

Outer rear work lights

K10

Reverse speed

K11

Forward speed

K12

Flasher

5

10-3

SECTION 10 - ELECTRICAL SYSTEM FUSES - POWERSHIFT WITH CAB

BUZZER

Fuse Rating Colour Circuit No.

BZ1

Blue

Rear windshield wiper, rear windshield wiper switch and rear windshield washer

F1/A

15 A

F1/B

7.5 A Brown

Fuel shut off, antitheft power supply, grid heater

F1/C

10 A

Red

Stop lights

F2/A

15 A

Blue

Instruments power supply, lamps, brake oil level sensor, seat, buzzer Conditioner

F2/B

15 A

Blue

F2/C

15 A

Yellow Pilot control

F3/A

3A

Violet

Rear right/front left side lights, instruments illumination, conditioner, illumination

F3/B

3A

Violet

Rear left/front right side lights, number plate light

F3/C

10 A

Red

Front work lights, tools rapid connection, ride control, double delivery, cold start

F4/A

7.5 A Brown

Egs power supply, clutch shut off button, differential lock, 4WD

F4/B

10 A

Red

Rear hammer button, grab level valve and sensor

F4/C

10 A

Red

Excavator rear lock, rear translation lock, rear work lights

F5/A

15 A

Blue

Front inner work lights

F5/B

10 A

Red

Traffic lights

F5/C

15 A

Blue

Main beam

F6/A

7.5 A Brown

Beacon lamp

F6/B

7.5 A Brown

(+15) Warning

F6/C

7.5 A Brown

Hand hammer

F7/A

10 A

Red

(+30) Warning, (+30) antitheft, horn

F7/B

10 A

Red

Current intake, radio, roff lamp

F7/C

6A

Black

Front windshield wiper

F8/A

15 A

Blue

Outer rear work lights

F8/B

15 A

Blue

Outer front work lights

F8/C

15 A

Blue

Inner rear work lights

Warning buzzer

CONNECTORS CN

Main harness connections into fuse board

RELAYS K2

Speed alarm, hand brake

K3

Starting

K4

Grab level solenoid valve

K5

Traffic and main beam lights

K6

Inner front work lights

K7

Inner rear work lights

K8

Outer front work lights

K9

Outer rear work lights

K10

Optional

K11

Not connected

K12

Flasher

10-4

6

SECTION 10 - ELECTRICAL SYSTEM FUSES - 4WS

BUZZER

Fuse Rating Colour Circuit No.

BZ1

Blue

Warning buzzer

Rear windshield wiper, rear windshield wiper switch and rear windshield washer

F1/A

15 A

F1/B

7.5 A Brown

Fuel shut off, antitheft power supply, grid heater

CONNECTORS

F1/C

10 A

Red

Stop lights

CN

F2/A

15 A

Blue

Instruments power supply, lamps, brake oil level sensor, seat, buzzer

F2/B

15 A

Blue

Conditioner

F2/C

15 A

Yellow Pilot control

F3/A

3A

Violet

Rear right/front left side lights, instruments illumination, conditioner, illumination

F3/B

3A

Violet

Rear left/front right side lights, number plate light

F3/C

10 A

Red

Front work lights, tools rapid connection, ride control, double delivery, cold start

F4/A

7.5 A Brown

Egs power supply, clutch shut off button, 4WD

F4/B

10 A

Red

Rear hammer button, grab level valve and sensor

F4/C

10 A

Red

Power supply 4WS unit, 4WS, excavator rear lock, rear translation lock, rear work lights

F5/A

15 A

Blue

Front inner work lights

F5/B

10 A

Red

Traffic lights

F5/C

15 A

Blue

Main beam

F6/A

7.5 A Brown

Beacon lamp

F6/B

7.5 A Brown

(+15) Warning

F6/C

7.5 A Brown

Hand hammer, 4WD

F7/A

10 A

Red

(+30) Warning, (+30) antitheft, horn

F7/B

10 A

Red

Current intake, radio, roff lamp

F7/C

6A

Black

Front windshield wiper

F8/A

15 A

Blue

Outer rear work lights

F8/B

15 A

Blue

Outer front work lights

F8/C

15 A

Blue

Inner rear work lights

Main harness connections into fuse board

RELAYS K2

Speed alarm, hand brake

K3

Starting

K4

Grab level solenoid valve

K5

Traffic and main beam lights

K6

Inner front work lights

K7

Inner rear work lights

K8

Outer front work lights

K9

Outer rear work lights

K10

Optional

K11

Not connected

K12

Flasher

7

10-5

SECTION 10 - ELECTRICAL SYSTEM BATTERY NOTE: The machine can be installed with one or two batteries.

SERVICE SPECIFICATIONS Battery terminal tightness check ............................................................................................... Every 250 hours Electrolyte level inspection...................................................................................................... Every 1000 hours ACCESS TO THE BATTERY Use the ignition switch to open the battery box in the oil tank.

Make sure the battery terminals are clean and coated with grease and make sure the cables are correctly tightened.

8 CHECKING THE ELECTROLYTE LEVEL Remove the vent plugs and check the level in each battery cell. The level should come up to 6 mm above the separator plates. Add distilled water if necessary.

!

WARNING

!

Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid any contact with the skin, eyes or clothing.

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

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

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

10-6

9

SECTION 10 - ELECTRICAL SYSTEM

!

WARNING

!

A spark or flame can cause the hydrogen in a battery to explode. To prevent any risk of explosion, observe the following instructions: - Place the battery master switch key in the “OFF” position (disconnected).

- When disconnecting the battery cables, always disconnect the negative cable (-) first.

- When reconnecting the battery cables, always connect the negative (-) cable last.

- Never short-circuit the battery terminals with metal objects.

- Do not weld, grind or smoke near a battery.

!

WARNING

!

Batteries produce explosive gases. Keep away any flame, spark or cigarettes. Always provide good ventilation when charging a battery or using a battery in an enclosed space. Always protect your eyes when working near a battery.

!

WARNING

!

Before carrying out any welding on the machine or repair work on the electrical circuit, disconnect the battery and disconnect the B+ and D+ wires on the alternator. When reconnecting, check the wire markings.

!

WARNING

!

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

!

WARNING

!

Never touch the battery terminals with your hands.

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

REPLACING A BATTERY 1. Remove the terminal covers and disconnect the cables, first from the negative terminal (1) then the positive terminal (2).

2. Remove the nuts and washers (3), the clamping bar (4) and the brackets (5) and remove the old battery.

3. Install the new battery.

10 4. Install the brackets (5), the clamping bar (4) and the washers and nuts (3).

5. Clean the cables and the connecting terminals and coat them with grease.

6. Connect the cables, first to the positive terminal (2), then the negative terminal (1) and install the terminal covers.

!

WARNING

!

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

11

10-7

SECTION 10 - ELECTRICAL SYSTEM CONNECTING A BOOSTER BATTERY

!

WARNING

!

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

Always keep the battery charged to prevent the electrolyte freezing.

!

WARNING

!

Connecting jumper cables wrongly or shortcircuiting battery terminals can cause an accident.

Connect the jumper cables following the instructions in this manual.

IMPORTANT: Make sure that the voltage of the booster batteries is the same as that of the machine circuit (12 volts).

1. Open the battery box and then remove the tool box.

2. Remove the terminal covers.

3. Connect the positive (+) jumper cable to the positive (+) terminal of the machine’s battery.

4. Connect the negative (-) jumper cable to one of the fastening screw (1) of tank.

5. Start the engine.

6. First disconnect the negative (-) jumper cable, then disconnect the positive (+) jumper cable from the booster battery.

7. Install the terminal covers.

8. Install the tool box and close the battery box.

10-8

12

SECTION 10 - ELECTRICAL SYSTEM ALTERNATOR SERVICE SPECIFICATIONS Inspection ................................................................................................................................Every 1000 hours

!

WARNING

!

Before carrying out any welding on the machine or repair work on the electrical circuit, disconnect the battery and disconnect the B+ and D+ wires on the alternator. When reconnecting, check the wire markings.

IMPORTANT: Do not use steam cleaning apparatus or cleaning solvent to clean the alternator.

Have the alternator checked by your Dealer.

NOTE: Make sure the terminal protectors are correctly installed.

13

STARTER MOTOR SERVICE SPECIFICATIONS Inspection ................................................................................................................................Every 1000 hours Have the starter motor checked by your Dealer.

NOTE: Make sure the terminal protectors are correctly installed.

14

10-9

SECTION 10 - ELECTRICAL SYSTEM BULBS Operator’s compartment light...................................................................................................................... 10 W Instrument panel indicator lamp................................................................................................................. 1.2 W Instrument panel gauge ............................................................................................................................. 1.2 W Headlights .............................................................................................................................................. 60/55 W Front side lights (on headlight)...................................................................................................................... 4 W Front direction indicators............................................................................................................................. 21 W Rear direction indicators ............................................................................................................................. 21 W Rear stop/side lights ................................................................................................................................ 5/21 W Front work lights (on cab) ........................................................................................................................... 55 W Rear work lights (on cab) ............................................................................................................................ 55 W Registration plate light (specific to certain countries).................................................................................. 10 W Rotating beacon (specific to certain countries) ........................................................................................... 55 W

REPLACING A BULB IMPORTANT: Never touch a halogen bulb with your fingers. Always use a clean cloth when handling halogen bulbs.

OPERATOR’S COMPARTMENT LIGHT 1. Remove the lens (1) unscrewing it by turning 90° through its central slot.

2. Remove the bulb (2) and install a bulb of the same wattage (10 W).

3. Reinstall the lens (1).

15 INSTRUMENT PANEL LIGHT 1. Place the battery master switch in OFF position (electricity cut off in system).

2. Remove the two screws that fasten the instrument panel to the console. Disconnect the electrical connection behind the instrument panel.

3. Remove the instrument panel and turn it upside down. Remove the two screws from the cover.

4. Remove the cover.

16

10-10

SECTION 10 - ELECTRICAL SYSTEM 5. Turn the socket to the left, pull out the socket/ bulb assembly (1.2 W) and replace it.

6. Install the cover carefully, to avoid damaging the seal.

7. Install the two cover screws and make the electrical connection.

8. Install the instrument panel on the console.

Install the two mounting screws.

9. Place the battery master switch in ON position (electricity supplied to system).

17 MAIN BEAM LIGHTS

HEADLIGHTS

AND

POSITION

1. Remove the four screws, remove the retaining frame and remove the light assembly.

2. Remove the plug from the light base. Fold back the clips, remove the defective bulb and replace it with a bulb of the same wattage (60/55 W).

18 3. Install the light unit. Install the retaining frame and the four screws. To change a side light bulb, carry out Step 1 then remove the bulb and install a bulb of the same wattage (4 W). Install the retaining frame and the four screws.

19

10-11

SECTION 10 - ELECTRICAL SYSTEM FRONT DIRECTION INDICATOR 1. Remove the two screws and remove the lens.

2. Remove the bulb and install bulb of the same wattage (21 W).

3. Install the lens and the two screws.

20 REAR LIGHTS (Sideshift backhoe version) 1. Remove the two screws and remove the lens.

2. Remove the bulbs and install bulbs of the same wattage.

Direction indicator (21 W).

Stop/Side light (21/5 W).

3. Install the lens and the two screws.

21 FRONT AND REAR WORK LIGHTS 1. Remove the screws and take off the light assembly.

2. Remove the clip and the bulb holder. Remove the bulb and install a bulb of the same wattage (55 W).

3. Install the bulb holder and the clip.

4. Install the light assembly and the screws.

22

10-12

SECTION 10 - ELECTRICAL SYSTEM LICENCE PLATE LIGHT (Specific to certain countries) 1. Remove the two screws and remove the lens.

2. Remove the bulbs and install bulbs of the same wattage (10 W).

3. Install the lens and the two screws.

23 ROTARY LIGHT (Specific to certain countries) 1. Unscrew the lens, remove the bulb and install a bulb of the same wattage (55 W). Install the lens.

24

10-13

SECTION 10 - ELECTRICAL SYSTEM

NOTES

10-14

SECTION 11 STORAGE PREPARATION FOR STORAGE

STARTING UP AFTER STORAGE

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

Do not start the engine before carrying out the following operations:

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

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

3. Lubricate the machine and drain the transmission, hydraulic reservoir, rear axle and engine and refill with the correct grades of oil.

4. Check the radiator coolant level. If the machine is within 100 hours of the 2000 hours scheduled service or within 2 months of the two year schedule service perform the service as in maintenance.

5. Operate the loader so all loader cylinders are in the fully retracted position and all the bucket is resting on a block or piece of wood.

6. Place the backhoe attachment in transport position.

7. Stop the engine and operate all the hydraulic controls to release all residual pressure in the hydraulic circuits.

8. Coat the exposed portions of the cylinder rods and control valve spools with grease.

9. Charge the battery. Remove it from the machine and place it on a wooden pallet in a cool, dry place. If possible, store it in a building where the temperature is above 0 °C. Make sure the battery is clean. Check the electrolyte level regularly and make sure it is correct.

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

2. Fill the fuel tank.

3. Check the level of the coolant solution.

4. Check all oil and fluid levels.

5. Install a fully charged battery.

6. Remove the cover from the exhaust pipe opening.

7. Remove the coat of protective grease from the areas concerned, for example the steering cylinders, valve spools, etc.

!

WARNING

!

Check the machine for leaks and for broken, defective or missing parts.

!

WARNING

!

Before starting the engine, make sure all the controls are in the neutral position. This will prevent any unexpected movement of the machine and of any electrical equipment.

!

WARNING

!

Avoid running the engine in an enclosed space.

Ensure adequate ventilation at all times.

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

11. Cover the exhaust pipe opening.

11-1

SECTION 11 - STORAGE

NOTES

11-2

SECTION 12 SPECIFICATIONS ENGINE - 95 HP / 71 KW (580 Super R Models) Data (CEE 88/195) ..................................................................................................95 hp/ 71 kW, turbocharged Type........................................................................................................................................................... Diesel No. of cylinders.................................................................................................................................................. 4 Bore ........................................................................................................................................................ 104 mm Stroke ..................................................................................................................................................... 132 mm Displacement....................................................................................................................................... 4500 cm3 Compression Ratio ....................................................................................................................................17.5:1 Firing Order .............................................................................................................................................. 1.3.4.2 Idle Speed.................................................................................................................................. 850-950 rev/min Maximum “No-Load” Speed................................................................................................... 2380-2480 rev/min Maximum “Full Load” Speed..................................................................................................2225-2275 rev/min Maximum Torque (CEE) ......................................................................................................................... 398 Nm

ENGINE - 110 HP / 82 KW (590 Super R and 695 Super R Models) Data (CEE 88/195) ............................................................... 110 hp/ 82 kW, turbocharged - Charge Air Cooled Type........................................................................................................................................................... Diesel No. of cylinders.................................................................................................................................................. 4 Bore ........................................................................................................................................................ 104 mm Stroke ..................................................................................................................................................... 132 mm Displacement....................................................................................................................................... 4500 cm3 Compression Ratio ....................................................................................................................................17.5:1 Firing Order .............................................................................................................................................. 1.3.4.2 Idle Speed.................................................................................................................................. 850-950 rev/min Maximum “No-Load” Speed................................................................................................... 2380-2480 rev/min Maximum “Full Load” Speed..................................................................................................2225-2275 rev/min Maximum Torque (CEE) ......................................................................................................................... 480 Nm

COOLING SYSTEM Type.................................................................................................................................. Pressurized Full Flow Fan Belt Type .....................................................................................................................8 Groove Serpentine Fan Belt Tension................................................................................................................. Automatic Tensioner Air Conditioning Compressor Belt ......................................................................................................... Single V Air Conditioning Belt Tension................................................................................................................... Manual Thermostat: Starts to Open at.........................................................................................................................................81 °C Fully Open at ..............................................................................................................................................96 °C Radiator Cap ..........................................................................................................................................0.90 bar

12-1

SECTION 12 - SPECIFICATIONS FUEL SYSTEM Injection Pump Type ................................................................................................................ Bosch Rotary VE Cold Start Device ............................................................................................................... Optional Grid Heater Excess Fuel Device ............................................................................................................................ Automatic Fuel Shut Off......................................................................................................................................... Solenoid Lift Pump........................................................................................................................................... Mechanical Timing ....................................................................................................................................... 1 mm lift @ TDC

TRANSMISSION (580 Super R and 590 Super R Models) POWERSHUTTLE 4x4 = 4 Forward and 4 Reverse Gears Torque Convertor Ratio............................................................................................................................. 2.38:1 POWERSHIFT 4x2 = 4 Forward and 2 Reverse Gears Torque Convertor Ratio............................................................................................................................. 2.31:1

TRANSMISSION (695 Super R Models) POWERSHIFT 4x2 = 4 Forward and 2 Reverse Gears Torque Convertor Ratio............................................................................................................................. 2.31:1

ELECTRICAL SYSTEM Alternator ................................................................................................................................................ 90 amp Battery Type..........................................................................................95 amp hr (12V/900 CCA) SAE - Single 60 amp hr (12V/600 CCA) SAE - Double Battery Disconnect via the Isolator Switch.................................................................on Negative/chassis cable Regulator ...................................................................................................................................... Transistorised Ground (Earth) ...................................................................................................................................... Negative Starting Motor...................................................................... Positive Engagement, Solenoid Operated (2.7 kW)

BRAKES Type ............................................................................................ Wet Multi-Discs x8 per Axle (x4 per half Axle) Disc Diameter ..................................................................................................................................... 203.2 mm Parking Type ..................................................................................................................Single Disc on Driveline

STEERING Power Steering Type..........................................................................................................................Hydrostatic Power Steering Displacement (580 Super R + 590 Super R) .......................................................... 125 cm3/rev Power Steering Displacement (695 Super R) .................................................................................. 160 cm3/rev Turns Lock to Lock (2WD + 4WD) ...................................................................................... Left 3.25; Right 3.25 System Pressure............................................................................................................................... 177 ± 3 bar

12-2

SECTION 12 - SPECIFICATIONS REAR AXLE Type.......................................................................................................... Double Reduction, Inboard Planetary Differential Lock (Powershuttle Transmission) ..................................................................................Mechanical Differential Lock (Powershift Transmission) .......................................................................Electrically Operated

HYDRAULIC SYSTEM Twin Gear Pump....................................................................... Hydraulic System and Priority Steering System Hydraulic System Pressure: Main Relief Valve Pressure ........................................................................................................... 206 - 210 bar Stabilizer Relief Valve Pressure..................................................................................................... 196 - 202 bar Pump Flow: - 95 HP Turbo ..................................................................................................................34 + 34 cm3, 151 l/min - 110 HP Turbo CAC........................................................................................................38 + 34 cm3, 160 l/min

MAXIMUM SLOPE WHEN USING THE MACHINE Axial slope ..................................................................................................................................................... 25° Lateral slope .................................................................................................................................................. 25°

FRONT COUNTERWEIGHT Weight ...................................................................................................................................................... 160 kg

RADIATOR COOLANTS Anti-freeze should be changed every 2000 hours or 24 months.

In order to reduce deposits and corrosion, water in the cooling system should not exceed the following limits: Total hardness ....................................................................................................................300 parts per million Chloride ...............................................................................................................................100 parts per million Sulphates.............................................................................................................................100 parts per million

NOISE LEVEL Certified by the manufacturer.

In accordance with European directive 2000/14/EC - Stage II. Internal noise level (LpA)...................................................................................................................77 decibels External noise level (LwA) (580 Super R) .......................................................................................102 decibels External noise level (LwA) (590 Super R and 695 Super R) ...........................................................103 decibels

VIBRATION LEVEL INSIDE THE CAB Upper members............................................................................................................ level lower than 2.5 m/s² Abdomen ...................................................................................................................... level lower than 0.5 m/s²

12-3

SECTION 12 - SPECIFICATIONS TYRES 2 WHEEL DRIVE (580 Super R Models) Front..........................................................................................................................................................11L-16 Rear ....................................................................................................................................... 18.4-26 or 16.9-28 4 WHEEL DRIVE (580 Super R and 590 Super R Models) Front................................................................................................................................................... 12.5/80-18 Rear ....................................................................................................................................... 18.4-26 or 16.9-28 4 WHEEL STEER (695 Super R Models) Front/Rear............................................................................................................ 16.9x24 or 16.9x28 or 440/80

FOUR WHEEL DRIVE TYRE COMBINATIONS The tyres fitted to machines with optional four wheel drive have been carefully selected to match the gearing of the transmission and axles. When renewing worn or damaged tyres, always install tyres of the same make, model and size as those removed. The installation of other tyre combinations may result in excessive tyre wear, loss of usable power or severe damage to drive line components. If in doubt, consult your Dealer.

The following charts give the approximate carrying capacity of the axle at the tyre pressures indicated up to 30 km/h.

TYRES PRESSURES The following charts give the approximate carrying capacity of the axle at the tyre pressures indicated up to 30 km/h.

580 Super R and 590 Super R Models Inflation Pressures in bar 1.5

Front

1.7

1.9

2.1

2.2

2.4

2.6

2.8

3.0

3.3

3.6

3.9

Permissible Load Capacity at the Axle (kg) 12.5/80-18

1550 1665 1790 1890 1940 2040 2140 2265 2330 2425 2575 2720 Inflation Pressures in bar

Rear

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

2.0

2.2

2.3

2.4

2.6

-

-

-

Permissible Load Capacity at the Axle (kg) 16.9-28

3800 4000 4200 4460 4780 4900 5090 5380 5660 5800 6190

The above tables are for guidance only. For exact information regarding inflation pressures and loads for your particular tyres consult your Dealer.

12-4

SECTION 12 - SPECIFICATIONS TRAVEL SPEED (580 Super R and 590 Super R Models) With 16.9-28 rear tyres and engine at full speed Powershuttle Transmission

1st gear

2nd gear

3rd gear

4th gear

Forward

5.99 km/h

9.64 km/h

20.53 km/h

36.49 km/h

Reverse

7.19 km/h

11.57 km/h

24.62 km/h

43.79 km/h

Powershift Transmission

1st gear

2nd gear

3rd gear

4th gear

Forward

5.90 km/h

11.20 km/h

22.20 km/h

39.20 km/h

Reverse

7.10 km/h

13.20 km/h

-

-

2nd gear

3rd gear

4th gear

With 16.9-28 rear tyres and engine at full speed Powershuttle Transmission

1st gear

Forward

6.12 km/h

9.84 km/h

20.95 km/h

37.25 km/h

Reverse

7.34 km/h

11.81 km/h

25.13 km/h

44.70 km/h

Powershift Transmission

1st gear

2nd gear

3rd gear

4th gear

Forward

6.00 km/h

11.20 km/h

21.80 km/h

39.20 km/h

Reverse

7.10 km/h

13.20 km/h

-

-

1st gear

2nd gear

3rd gear

4th gear

Forward

5.90 km/h

11.20 km/h

22.20 km/h

39.20 km/h

Reverse

7.10 km/h

13.30 km/h

-

-

TRAVEL SPEED (695 Super R Models) With 16.9-28 rear tyres and engine at full speed

12-5

SECTION 12 - SPECIFICATIONS MODELS 580 Super R and 590 Super R LOADER ATTACHMENT - DIMENSIONS AND PERFORMANCE

1 Dimensions A. B. C. D. E. F. G. H. I. J. K. L. M. N. P. Q.

Maximum height Bucket/loader linkage point height Dump height Maximum roll back at ground level Dump angle Reach fully raised Height to top of cab Digging depth Axle centre to front of bucket on ground Wheelbase Rear drive axle centre to swing post centre Rear drive axle centre to rear of backhoe bucket Overall length Height to top of boom Overall width Loader bucket width

12-6

SECTION 12 - SPECIFICATIONS

TYRES

FRONT

REAR

2 WHEEL DRIVE (580 Super R)

11L-16F

18.4-26

4 WHEEL DRIVE

12.5/80-18

18.4-26

Dimensions

2 WHEEL DRIVE (580 Super R) with standard bucket

4 WHEEL DRIVE with standard bucket

A

4130 mm

4250 mm

B

3345 mm

3460 mm

C

2550 mm

2685 mm

D

45°

45°

E

45°

45°

F

875 mm

830 mm

G

2950 mm

2950 mm

H

240 mm

120 mm

I

2060 mm

1973 mm

J

2175 mm

2175 mm

K

1325 mm

1325 mm

L

1630 mm

1630 mm

M

5865 mm

5778 mm

N

4000 mm

4000 mm

P

2430 mm

2430 mm

Q

2250 mm

2250 mm

Performance

2 WHEEL DRIVE (580 Super R)

4 WHEEL DRIVE

Lift capacity at maximum height

3325 kg

3450 kg

Breakout force

6556 daN

6537 daN

LOADER BUCKETS Type

Standard 3

4 in 1

6 in 1 (with forks) 3

Heaped capacity

1.00 m

1.00 m

1.00 m3

Width

2250 mm

2250 mm

2250 mm

Weight

410 kg

800 kg

960 kg

12-7

SECTION 12 - SPECIFICATIONS MODEL 695 Super R (Sideshift version) LOADER ATTACHMENT - DIMENSIONS AND PERFORMANCE

2 Dimensions A. B. C. D. E. F. G. H. I. J. K. L. M. N. P. Q.

Maximum height Bucket/loader linkage point height Dump height Maximum roll back at ground level Dump angle Reach fully raised Height to top of cab Digging depth Axle centre to front of bucket on ground Wheelbase Rear drive axle centre to swing post centre Rear drive axle centre to rear of backhoe bucket Overall length Height to top of boom Overall width Loader bucket width

12-8

SECTION 12 - SPECIFICATIONS

TYRES

FRONT

REAR

440/80R28

440/R28

Dimensions

Standard bucket

4 in 1 bucket

6 in 1 bucket (with forks)

A

4347 mm

4460 mm

4460 mm

B

3491 mm

3518 mm

3518 mm

C

2717 mm

2753 mm

2753 mm

D

45°

45°

45°

E

45°

45°

45°

F

744 mm

690mm

690mm

G

2900 mm

2900 mm

2900 mm

H

113 mm

90 mm

90 mm

I

1975 mm

1980 mm

1980 mm

J

2200 mm

2200 mm

2200 mm

K

1324 mm

1324 mm

1324 mm

L

1630 mm

1630 mm

1630 mm

M

5783 mm

5788 mm

5788 mm

N

3935 mm

3935 mm

3935 mm

P

2480 mm

2480 mm

2480 mm

Q

2400 mm

2400 mm

2400 mm

Performance

Standard bucket

4 in 1 bucket

6 in 1 bucket (with forks)

Lift capacity at maximum height

3386 kg

3075 kg

2950 kg

Breakout force

5413 daN

5600 daN

5600 daN

LOADER BUCKETS Type

Standard 3

4 in 1

6 in 1 (with forks) 3

Heaped capacity

1.15 m

1.15 m

1.15 m3

Width

2400 mm

2400 mm

2400 mm

Weight

426 kg

830 kg

990 kg

12-9

SECTION 12 - SPECIFICATIONS MODEL 695 Super R (Centre pivot version) LOADER ATTACHMENT - DIMENSIONS AND PERFORMANCE

3 Dimensions A. B. C. D. E. F. G. H. I. J. K. L. M. N. P. Q.

Maximum height Bucket/loader linkage point height Dump height Maximum roll back at ground level Dump angle Reach fully raised Height to top of cab Digging depth Axle centre to front of bucket on ground Wheelbase Rear drive axle centre to swing post centre Rear drive axle centre to rear of backhoe bucket Overall length Height to top of boom Overall width Loader bucket width

12-10

SECTION 12 - SPECIFICATIONS

TYRES

FRONT

REAR

16.9-28

16.9-28

Dimensions

Standard bucket

4 in 1 bucket

6 in 1 bucket (with forks)

A

4347 mm

4460 mm

4460 mm

B

3491 mm

3518 mm

3518 mm

C

2717 mm

2753 mm

2753 mm

D

45°

45°

45°

E

45°

45°

45°

F

744 mm

690 mm

690 mm

G

2900 mm

2900 mm

2900 mm

H

113 mm

90 mm

90 mm

I

1975 mm

1980 mm

1980 mm

J

2200 mm

2200 mm

2200 mm

K

1324 mm

1324 mm

1324 mm

L

3040 mm

3040 mm

3040 mm

M

7220 mm

7225 mm

7225 mm

N

3935 mm

3935 mm

3935 mm

P

2230 mm

2230 mm

2230 mm

Q

2400 mm

2400 mm

2400 mm

Performance

Standard bucket

4 in 1 bucket

6 in 1 bucket (with forks)

Lift capacity at maximum height

3386 kg

3075 kg

2950 kg

Breakout force

5413 daN

5600 daN

5600 daN

LOADER BUCKETS Type

Standard 3

4 in 1

6 in 1 (with forks) 3

Heaped capacity

1.15 m

1.15 m

1.15 m3

Width

2400 mm

2400 mm

2400 mm

Weight

426 kg

830 kg

990 kg

12-11

SECTION 12 - SPECIFICATIONS MODELS 580 Super R and 590 Super R BACKHOE ATTACHMENT - DIMENSIONS AND PERFORMANCE

4 Dimensions A. B. C. D. E. F. G. J. K. L. M.

Loading reach Bucket rotation Operating height, fully raised Loading height maximum Reach from swing post Reach from rear axle centre line Maximum length of surface excavation Maximum digging depth Stabilizer spread - transport Stabilizer spread - working Stabilizer pad levelling angle

12-12

SECTION 12 - SPECIFICATIONS

TYRES

FRONT

REAR

12.5/80-18

18.4-26

Dimensions

standard dipper

telescopic dipper (extended)

A

1828 mm

2757 mm

B

200°

204°

C

5837 mm

6537 mm

D

3917 mm

4645 mm

E

5906 mm

6992 mm

F

7231 mm

8317 mm

G

6454 mm

7540 mm

J

4612 mm

5799 mm

K

2280 mm

2280 mm

L

2790 mm

2790 mm

M

14°

14°

Performance

standard dipper

telescopic dipper (extended)

Swing arc

180°

180°

Maximum digging force dipper cylinder

3623 daN

2581 daN

Maximum digging force bucket cylinder

5234 daN

5234 daN

Lift capacity through dipper arc

1975 kg

1470 kg

Lift capacity, dipper 3.66 m above ground

2040 kg

1490 kg

Lift capacity at 4.26 m above ground

1590 kg

1040 kg

Telescopic dipper extension length

-

1200 mm

BACKHOE BUCKETS Struck capacity SAE J 296

Width

Weight

76 L

305 mm

108 kg

109 L

457 mm

130 kg

153 L

610 mm

160 kg

196 L

762 mm

180 kg

238 L

914 mm

208 kg

12-13

SECTION 12 - SPECIFICATIONS MODEL 695 Super R (Sideshift version) BACKHOE ATTACHMENT - DIMENSIONS AND PERFORMANCE

5 Dimensions A. B. C. D. E. F. G. J. K. L. M.

Loading reach Bucket rotation Operating height, fully raised Loading height maximum Reach from swing post Reach from rear axle centre line Maximum length of surface excavation Maximum digging depth Stabilizer spread - transport Stabilizer spread - working Stabilizer pad levelling angle

12-14

SECTION 12 - SPECIFICATIONS

TYRES

FRONT

REAR

440/80R28

440/80R28

Dimensions

standard dipper

telescopic dipper (extended)

A

1899 mm

2844 mm

B

200°

200°

C

5815 mm

6492 mm

D

3908 mm

4615 mm

E

5903 mm

6990 mm

F

7228 mm

8315 mm

G

6518 mm

7605 mm

J

4623 mm

5805 mm

K

2280 mm

2280 mm

L

2790 mm

2790 mm

M

14°

14°

Performance

standard dipper

telescopic dipper (extended)

Swing arc

180°

180°

Maximum digging force dipper cylinder

3623 daN

2591 daN

Maximum digging force bucket cylinder

5234 daN

5234 daN

Lift capacity through dipper arc

2260 kg

1610 kg

Lift capacity, dipper 3.66 m above ground

2325 kg

1610 kg

Lift capacity at 4.26 m above ground

1520 kg

1000 kg

Telescopic dipper extension length

-

1200 mm

BACKHOE BUCKETS Struck capacity SAE J 296

Width

Weight

76 L

305 mm

108 kg

109 L

457 mm

130 kg

153 L

610 mm

160 kg

196 L

762 mm

180 kg

238 L

914 mm

208 kg

12-15

SECTION 12 - SPECIFICATIONS MODEL 695 Super R (Centre pivot version) BACKHOE ATTACHMENT - DIMENSIONS AND PERFORMANCE

6 Dimensions A. B. C. D. E. F. G. J. K. L. M.

Loading reach Bucket rotation Operating height, fully raised Loading height maximum Reach from swing post Reach from rear axle centre line Maximum length of surface excavation Maximum digging depth Stabilizer spread - transport Stabilizer spread - working Stabilizer pad levelling angle

12-16

SECTION 12 - SPECIFICATIONS

TYRES

FRONT

REAR

440/80R28

440/80R28

Dimensions

standard dipper

telescopic dipper (extended)

A

1870 mm

2855 mm

B

200°

200°

C

5737 mm

6421 mm

D

4002 mm

4686 mm

E

5836 mm

6922 mm

F

7161 mm

8247 mm

G

6346 mm

7432 mm

J

4556 mm

5738 mm

K

2280 mm

2280 mm

L

2790 mm

2790 mm

M

14°

14°

Performance

standard dipper

telescopic dipper (extended)

Swing arc

180°

180°

Maximum digging force dipper cylinder

3744 daN

2643 daN

Maximum digging force bucket cylinder

5603 daN

5603 daN

Lift capacity through dipper arc

2350 kg

1560 kg

Lift capacity, dipper 3.66 m above ground

2475 kg

1560 kg

Lift capacity at 4.26 m above ground

1470 kg

950 kg

Telescopic dipper extension length

-

1200 mm

BACKHOE BUCKETS Struck capacity SAE J 296

Width

Weight

76 L

305 mm

108 kg

109 L

457 mm

130 kg

153 L

610 mm

160 kg

196 L

762 mm

180 kg

238 L

914 mm

208 kg

12-17

SECTION 12 - SPECIFICATIONS MODELS 580 Super R AND 590 Super R LIFTING CAPACITIES LIFTING CAPACITIES DURING OPERATION - SAE RATED

NORMAL

The following tables reflect the lifting capacities of the Backhoe Dipper (A) and Boom (B) on a typical 4WD machine.

NOTE: Capacities shown may vary slightly between machines dependant upon options fitted, pressure settings and market requirements.

Lifting capacities are given in kg for a standard dipper and a telescopic dipper.

7 Standard dipper Dipper - A

Boom - B

Telescopic dipper (retracted) Dipper - A

1200

Boom - B

Telescopic dipper (extended) Dipper - A

1120

1590

Height/Depth

Boom - B

m

610

+5.4

920

+4.9

1490

1515

1040

+4.3

2040

1690

1930

1580

1490

1100

+3.6

1975

1710

1870

1590

1470

1125

+3.0

2010

1650

1900

1540

1490

1135

+2.4

2165

1560

2050

1440

1555

1135

+1.8

2630

1510

2495

1390

1685

1105

+1.2

3860

1490

3690

1370

1950

1090

+0.6

1500

1375

2785

1090

0 (ground)

1540

1405

3850

1100

-0.6

1530

1380

1110

-1.2

1520

1370

1115

-1.8

1540

1380

1125

-2.4

1605

1435

1155

-3.0

1875

1675

1210

-3.6

1360

-4.2

1930

-4.8

12-18

SECTION 12 - SPECIFICATIONS MODEL 695 Super R (Sideshift version) LIFTING CAPACITIES LIFTING CAPACITIES DURING OPERATION - SAE RATED

NORMAL

The following tables reflect the lifting capacities of the Backhoe Dipper (A) and Boom (B).

NOTE: Capacities shown may vary slightly between machines dependant upon options fitted, pressure settings and market requirements.

Lifting capacities are given in kg for a standard dipper and a telescopic dipper.

8

Standard dipper Dipper - A

Boom - B

Telescopic dipper (retracted) Dipper - A

1120

Boom - B

Telescopic dipper (extended) Dipper - A

1040

1520

Height/Depth

Boom - B

m

570

+5.4

865

+4.9

1415

1510

1000

+4.3

2325

1650

2215

1535

1610

1070

+3.6

2260

1680

2150

1560

1645

1105

+3.0

2300

1675

2190

1550

1670

1120

+2.4

2480

1660

2360

1530

1760

1125

+1.8

3015

1630

2885

1500

1885

1130

+1.2

4400

1605

4230

1470

2135

1125

+0.6

1580

1440

3250

1125

0 (ground)

1560

1415

4420

1120

-0.6

1550

1400

1125

-1.2

1550

1400

1130

-1.8

1575

1415

1145

-2.4

1660

1490

1180

-3.0

2025

1815

1245

-3.6

1420

-4.2

2155

-4.8

12-19

SECTION 12 - SPECIFICATIONS MODEL 695 Super R (Centre pivot version) LIFTING CAPACITIES LIFTING CAPACITIES DURING OPERATION - SAE RATED

NORMAL

The following tables reflect the lifting capacities of the Backhoe Dipper (A) and Boom (B).

NOTE: Capacities shown may vary slightly between machines dependant upon options fitted, pressure settings and market requirements.

Lifting capacities are given in kg for a standard dipper and a telescopic dipper.

9

Standard dipper Dipper - A

Boom - B

Telescopic dipper (retracted) Dipper - A

1075

Boom - B

Telescopic dipper (extended) Dipper - A

990

1470

Height/Depth

Boom - B

m

605

+5.4

905

+4.9

1365

1460

950

+4.3

2270

1600

2165

1485

1560

1020

+3.6

2195

1630

2090

1510

1595

1055

+3.0

2240

1625

2135

1500

1620

1070

+2.4

2445

1610

2330

1480

1700

1075

+1.8

3090

1580

2960

1450

1835

1080

+1.2

4960

1555

4790

1420

2080

1075

+0.6

1390

3425

1075

0 (ground)

1510

1365

5065

1070

-0.6

1500

1350

1075

-1.2

1500

1345

1080

-1.8

1525

1365

1090

-2.4

1610

1440

1130

-3.0

1970

1760

1195

-3.6

1370

-4.2

2105

-4.8

1530

12-20

SECTION 13 ALPHABETICAL INDEX B

Symbols “4WS” Steer indicator lamp (695 Super R)......... 4-9

Battery master switch ...................................... 4-34

“CRAB” Steer indicator lamp (695 Super R) ..... 4-9

Before operating the machine ........................... 5-1

“ROAD” Steer indicator lamp (695 Super R) ..... 4-9

Before using the machine .................................. 3-1 Brake fluid ....................................................... 9-12

Numerics 2/4 Wheel drive switch ...............................4-3, 4-5 4X2 Powershift transmission control lever ...... 4-19 4X2 Powershift transmission display (EGS) - Forward selection ................................ 4-20 4X2 Powershift transmission display (EGS) - Reverse selection ....................................... 4-21 4X4 Powershuttle transmission controls

....... 4-14

Brake fluid reservoir ........................................ 4-65 Brake liquid level warning lamp ......................... 4-9 Brake pedals ................................................... 4-31 Brakes ............................................................. 12-2 Bulbs ............................................................. 10-10 C Cab air filter ............................................ 4-65

A

Cab doors .......................................................... 4-1

Adjustable steering column ............................. 4-30

Cab filters ........................................................ 9-10

Air conditioner indicator lamp ............................ 4-9

Checking and adjusting stabilizer play ............ 9-13

Air conditioning .................................................. 9-8

Coat hanger hook ............................................ 4-35

Air filter ............................................................ 8-27

Coded anti-theft switch .................................... 4-35

Air filter restriction warning lamp ..................... 4-10

Coded anti-theft system .................................... 5-9

Alternator ......................................................... 10-9

Cold start indicator lamp .................................... 4-9

Alternator charge warning lamp ...................... 4-10

Connecting a booster battery .......................... 10-8

Attachment safety valves ................................ 4-73

Control arm right/left adjustments ................... 4-61

Auxiliary 12 volt socket .................................... 4-33

Control cancellation switch .....................4-55, 4-57

Auxiliary bi-directional controls ........................ 4-61

Control pattern change switch ................4-55, 4-60

Auxiliary tool control pedal .............................. 4-54

Controls of auxiliary bidirectional section ........ 4-55

B Backhoe attachment auxiliary hydraulic tools . 5-28 Backhoe attachment boom unlocking lever (580 Super R, 590 Super R) ......................... 4-34

Controls/instruments/accessories ..................... 4-1 Cooling system .......................................8-16, 12-1 Cylinder leak inspection .................................... 9-8 D

Backhoe attachment hydraulic controls version . 4-55

Decals ............................................................... 3-7

Backhoe attachment locking switch .................. 4-7

Differential lock ................................................ 5-21

Backhoe attachment maximum lifting loads .... 5-37

Differential lock pedal ...................................... 4-18

Backhoe attachment mechanical controls version 4-45

Differential lock selection switch ...................... 4-19

Backhoe attachment operating instructions .... 6-14

Differential locking button (Powershift) ............ 4-43

Backhoe attachment sideshift ......................... 5-14

Direction indicator lamp ..................................... 4-9

Backhoe attachment sideshift carriage locking and unlocking switch .......................... 4-7

Direction indicator, headlight main beam and front windshield wiper and washer reed switch . 4-13

Backhoe bucket excavation position ............... 9-13

Directional indicator switch .............................. 4-13

Backhoe bucket mechanical quick coupler ..... 4-74

Draining the telescopic dipper ........................... 9-9

Ballasting and tyres ......................................... 6-20 Battery ............................................................. 10-6

E

Battery and tool box ........................................ 4-70

Electrical system ....................................10-1, 12-2

Battery charge indicator .................................. 4-10

Engine ............................................................. 8-13

13-1

SECTION 13 - ALPHABETICAL INDEX E

H

Engine(590 Super R and 695 Super R) ........... 12-1

Heater unit and air conditioning cooler ............. 9-11

Engine (580 Super R)................................. 2-1

Heating and air conditioning controls ............... 4-62

Engine accelerator pedal ................................. 4-31

Hourmeter ................................................ 4-11, 7-2

Engine alternator and fan belt ............................ 9-5

Hydraulic control arm fore/aft adjustments ...... 4-60

Engine coolant solution temperature indicator . 4-11

Hydraulic control arm tilt adjustment ................ 4-55

Engine guard ................................................... 4-69

Hydraulic reservoir ........................................... 4-70

Engine guard locking and unlocking lever ...... 4-29

Hydraulic speed control ................................... 5-25

Engine oil pressure warning lamp ...................... 4-9

Hydraulic speed control switch .................. 4-3, 4-6

Engine rocker arm clearance adjustment ........... 9-7

Hydraulic system ................................... 8-22, 12-3

Engine tachometer / revolutions counter........ 4-11 Engine throttle lever ......................................... 4-32 Environment ....................................................... 8-1

I Identification numbers/machine components .... 2-1 Identification of main components ..................... 2-5

F

Instructions for use ............................................ 6-1

Fire extinguisher .............................................. 4-65

Instrument panel ................................................ 4-9

Fluid and lubricant capacities and specifications .. 8-2

Intervals ............................................................. 7-3

Fluids and lubricants .......................................... 8-1 Four wheel drive tyre combinations ................. 12-4 Front and rear windshield washer reservoir ..... 4-33 Front counterweight ......................................... 12-3

J Job site and road instructions ............................ 6-1 Job site travel ..................................................... 6-7

Front drive axle ................................................ 8-37

K

Front instrument panel (580 Super R - 590 Super R) .......................... 4-3

Kickdown switch .............................................. 4-19

Front instrument panel (695 Super R) ............... 4-5

L

Front wheel adjustments (2WS) ...................... 9-15

Left-hand control lever ..................................... 4-55

Front wheel adjustments (4WS) ...................... 9-16

Levels ................................................................ 8-9

Front work lights switch ..................................... 4-7

Lifting and craning loads with the loade attachment .................................................... 5-31

Fuel level gauge....................................... 4-11 Fuel system ........................................... 8-18, 12-2 Fuel tank .......................................................... 4-69 Fuse and relay location .................................... 4-35 Fuses and relays ............................................. 10-1

Lifting loads with the backhoe attachment ....... 5-34 Lifting the machine ........................................... 5-39 Light switch ........................................................ 4-7 Loader attachment automatic return to dig ...... 4-42 Loader attachment control lever ............ 4-14, 4-19

G

Loader attachment controls ............................. 4-40

Gear lever ........................................................ 4-14

Loader attachment locking switch .............. 4-3, 4-5

Glide ride system ............................................... 3-6

Loader attachment maximum lifting loads ....... 5-32

Glide ride system control switch ................ 4-4, 4-6

Loader attachment operating instructions .......... 6-9

Grease points .................................................... 8-3

Loader attachment safety strut ........................ 4-67

H

Loader bucket mechanical/hydraulic self levelling/return to dig adjustment ............. 9-3

Hand signals .................................................... 3-14

Loader bucket mounted forks .......................... 5-23

Hand-held auxiliary hydraulic tool controls 4-3, 4-5 Hand-held auxiliary hydraulic tools .................. 5-29 Hazard light switch ..................................... 4-4, 4-6 Heater control valve ......................................... 4-71

13-2

Loader bucket quick coupler ............................ 4-72 Locking or unlocking the backhoe attachment . 5-13 Locking the backhoe attachment mechanical controls ...................................... 4-52

SECTION 13 - ALPHABETICAL INDEX L

O

Locking the loader attachment controls ........... 4-43

Operating instructions ....................................... 5-1

Locking the mechanical stabilizer controls ...... 4-53

Operating the machine ...............................3-3, 5-2

Low fuel level warning lamp ............................ 4-10

Operating the machine in cold weather ........... 5-10

Lubrication/filters/fluids ...................................... 8-1 M Machine inspection and cleaning ...................... 9-7 Machine tooling ............................................... 4-70 Main beam indicator lamp ............................ 4-9 Maintenance and adjustments .......................... 3-4 Maintenance/adjustments ................................. 9-1

Operating the machine in hot weather ............ 5-10 Operating the machine in water ...................... 5-42 Operator’s compartment and map reading light ... 4-30 Operator’s compartment controls .................... 4-12 Operator’s compartment fan ............................ 4-35 Operator’s compartment windows ................... 4-66 Operator’s seat ................................................ 4-36

Manual mode selection switch ...................4-4, 4-6

P

Maximum lifting loads using bucket mounted pallet forks ..................................... 5-33

Parking brake adjustment ................................ 9-11

Maximum slope when using the machine ....... 12-3

Parking brake lever ......................................... 4-32

Maximum working loads with backhoe attachment .................................................... 5-36

Parking the machine .................................3-4, 5-42

Mechanical differential lock pedal ................... 4-14 Model 695 Super R (centre pivot version) backhoe attachment - Dimensions and performance .................. 12-16

Parking brake indicator lamp ........................... 4-10

Plastic and resin parts ....................................... 8-1 Presentation ...................................................... 1-3 Prevention of burns ........................................... 3-6 Prevention of fire or explosions ......................... 3-5

Model 695 Super R (centre pivot version) lifting capacities .......................................... 12-20

Prevention of risks associated with vibrations ... 3-2

Model 695 Super R (Centre pivot version) loader attachment - Dimensions and performance .................. 12-10

R Radiator coolants ............................................ 12-3 Radiator, coolant and air conditioning condenser .. 9-4

Model 695 Super R (sideshift version) backhoe attachment - Dimensions and performance .................. 12-14

Radio compartment ......................................... 4-33

Model 695 Super R (sideshift version) lifting capacities ............. 12-19

Rear view mirrors ............................................ 4-71

Model 695 Super R (Sideshift version) loader attachment - Dimensions and performance .................... 12-8

Rear windshield wiper switch ............................ 4-8

Models 580 Super R and 590 Super R backhoe attachment - Dimensions and performance .................. 12-12

Rear axle ................................................8-40, 12-3 Rear windshield washer switch ......................... 4-8 Rear work lights switch ...................................... 4-8 Relays ............................................................. 10-5 Releasing the pressure in the hydraulic system . 8-21 Replacing a backhoe bucket ........................... 5-18

Models 580 Super R and 590 Super R lifting capacities .......................................... 12-18

Replacing a bulb ............................................ 10-10

Models 580 Super R and 590 Super R loader attachment - Dimensions and performance .................... 12-6

Reversible stabilizer pads (Centre pivot backhoe version) .................... 4-71

N

Right-hand control lever .................................. 4-55

Noise level ....................................................... 12-3

Road travel ........................................................ 6-2

O Official documents ............................................. 1-2 On road travel requirements ............................ 5-16

Replacing a loader bucket ............................... 5-19

Right, left, front and rear of the machine ........... 1-3

Rops/fops cab ..........................................3-6, 9-17 Rotating beacon .............................................. 4-72 Rotating beacon switch ..............................4-3, 4-5 Running-in period .............................................. 5-3 13-3

SECTION 13 - ALPHABETICAL INDEX S

T

Safety instructions ............................................. 3-1

Telescopic dipper ............................................. 9-14

Safety/decals/hands signals .............................. 3-1

Telescopic dipper controls ..................... 4-55, 4-60

Service specifications ...................................... 10-9

Telescopic dipper mechanical control pedal .... 4-54

Servicing instructions ......................................... 7-1

To the owner ...................................................... 1-1

Servicing Intervals ............................................. 7-1

Towing the machine ......................................... 5-40

Setting the backhoe attachment in the road travel position .............................. 5-15

Transmission (580 Super R and 590 Super R) 12-2

Setting the backhoe attachment in working position ........................................ 5-11 Side light and dipped headlight indicator lamp .. 4-9 Side mounted instrument panel ......................... 4-7 Specifications ................................................... 12-1 Stabilizer controls .................................. 4-55, 4-59 Stabilizer mechanical controls ......................... 4-52 Starter motor .................................................... 10-9 Starter switch ................................................... 4-12 Starting the engine ............................................. 5-4 Starting the engine in cold weather with an air intake heater (Grid heater) ............ 5-6

Transmission (695 Super R) ............................ 12-2 Transmission (Powershift) ............................... 8-34 Transmission (Powershuttle) ........................... 8-31 Transmission disconnect button ...4-14, 4-19, 4-42 Transmission oil pressure warning lamp ......... 4-10 Transmission oil temperature indicator ............ 4-11 Transmission powershift direction lever ........... 4-19 Transmission powershuttle direction lever ....... 4-14 Transporting the machine ................................ 5-38 Travel speed .................................................... 12-5 Troubleshooting ............................................... 9-19 Turbocharger ..................................................... 9-6

Steer mode switch ............................................. 4-5

Two or four wheel drive ................................... 5-30

Steer phasing (4WS) ....................................... 5-25

Type, serial number and year of manufacture of the machine ................................................ 2-1

Steering ........................................................... 12-2 Steering control ................................................ 4-12 Steps and access handles .................................. 4-1

Tyres ................................................................ 12-4 Tyres pressures ............................................... 12-4

Stopping the engine ........................................... 5-7

V

Storage ............................................................ 11-1

Vibration level inside the cab ........................... 12-3

Storage areas .................................................. 4-34 Sun visor .......................................................... 4-30 Switch for optional equipment ............................ 4-3

W Warning horn button ........4-4, 4-6, 4-8, 4-14, 4-55 Wheels and tyres ............................................... 9-1 Wrist rests ........................................................ 4-55

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.

13-4

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 Italy

OM US JAUNE gabarit MM.qxd

31/10/2007

12:07

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Loader Backhoes 580 Super R, 590 Super R and 695 Super R Series 2

Operator’s Manual Lep 6-86452 EN