Case TX130-30 TX130-33 Telehandlers Operator’s Manual 84266616 - PDF DOWNLOAD

TX130-30 / TX130-33

TX130-30 TX130-33 Telehandlers Telehandlers

Operator’s Manual Print No. 84266616

1st edition English 12/09

OPERATOR’S MANUAL TX130--30 TX130--33

IMPORTANT NOTICE This machine has been designed and manufactured for digging and moving earth and loose materials only.

Any other application will be considered contrary to the use designated by the Manufacturer that, as a consequence, cannot result responsible for damages to third parties and to the machine itself or personal injuries that eventually could derive from them. It is necessary to consider that, in taking the risk of an improper use, you assume the consequential responsibilities.

The compliance with operations for the use, maintenance and repairs described in this Manual, are essential elements qualifying the use designated by the Manufacturer.

This machine must be operated, serviced and repaired only by personnel previously trained about the equipment and the relevant safety rules, besides being authorised to operate the machine itself.

The User is always compelled to observe all general safety and injury prevention rules, as well as road regulations in case of operation on roads open to public traffic.

Any arbitrary modification implemented on this machine absolves the Manufacturer from any responsibility deriving from consequential damages or injuries.

The Manufacturer and all the organisations in its distribution network, including, but not limited to, national, regional or local distributors/dealers, decline any responsibility for damages that could derive from the abnormal performance of parts and/or components not approved by the Manufacturer, used for the maintenance and/or repair of the products manufactured or sold by the Manufacturer.

In any case, no warranty of any type is issued or imposed, regarding the products manufactured or sold by the Manufacturer for damages deriving from abnormal performance of parts and/or components not approved by the Manufacturer.

The information provided by this Manual is valid at the time of publication. Since the Manufacturer is constantly improving its products, some information could result not up--to date. In the event discrepancies are experienced, consult the Sales and Service Organization.

Model Engine Max. lifting height (m) Max. capacity (kg) a 500 mm from fork stop Capacity at max. height (kg) Extension at max. height (m) Max. longitudinal extension (m) Capacity at max. extension (kg) Weight (kg) Length (m)

TX130--30 no stab.

Turbocharged 74 kW 12.750 3300 2500 1.800

TX130--33 Small stab.

Turbocharged 74 kW 13.060 3300 2500 1.800 8.750

650

1350 9600 5.950

QUICK REFERENCE SECTION GUIDE 1 -- Safety Features and Vehicle Optional Safety 2 -- Controls, Instruments and Operation 3 -- Field Operation 4 -- Lubrication and Maintenance 5 -- Troubleshooting 6 -- Vehicle Storage 7 -- Accessories 8 -- Specifications and Data 9 -- Index

SECTION 1 SAFETY PRECAUTIONS AND INTRODUCTION This Manual has been prepared to provide you with in the correct procedure for running--in, driving, operating and maintenance of your new Telehandler.

Read this Manual carefully and keep it in a convenient place for future reference. If at any time you require advice concerning your machine, do not hesitate to contact your authorised dealer. They have company--trained personnel, genuine manufacturer’s parts and the necessary equipment to carry out all your service requirements.

CONTENTS OF THE SECTION Description Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2 Summary of safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--22 Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--23 Information concerning airborne noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--32 Information concerning hand--arm and whole--body vibration emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--32 Load Status Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--33 Safety features and vehicle secutiry options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--37 Road travel requirements – in cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--38 Road travel requirements – external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--39 “CE” Norms – Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--42 Universal Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--44 Machine functions monitored by instruments, luminous pilot lamps and buzzers . . . . . . . . . . . . . . . . . . . . . 1--45

1--1

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY GENERAL Your machine was designed to power and propel itself and it is intended for use in normal and customary applications. It is also designed to give maximum performance, economy and ease of operation under a wide variety of operating conditions.

The machine has been designed and manufactured according to the strictest quality standards and complies with the standard 2006/42/EC. However, the risk of accidents can never be completely excluded. That is why it is essential to observe elementary safety rules and precautions.

Prior to delivery, the machine was carefully inspected, both at the factory and by your dealer, to ensure that it reaches you in optimum condition. To maintain this condition and ensure trouble--free operation, it is important that the routine service operations, as specified in Section 4, of this Manual, are carried out at the recommended intervals.

MAIN COMPONENTS 15

12

9

16

17

14 13

8

10 11

7

18 19

2

3

4

5

6

1 TH001534

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Stabilizers Fuel tank Cab access step Cab door Hydraulic fluid reservoir Rear axle Cylinder compensation Ballast weight Extension cylinder Lift cylinder Engine compartment First section arm

1--2

13.

14.

15.

16.

17.

18.

19.

Second section arm Third section arm Chains boom extension/Back arm Tilt cylinder Equipment Leveling Cylinder Front axle

1

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY The machine has been designed and manufactured according to the strictest quality standards and complies with the standard 2006/42/EC. However, the risk of accidents can never be completely excluded.

That is why it is essential to observe elementary safety rules and precautions.

This machine with authorised equipment and accessories, has been designed exclusively for moving, lifting and transferring loads using a telescopic arm.

Do not use this machine for any application or purpose other than those described in this manual. If the machine is to be used for work involving the use of special attachments, accessories or equipment, consult your Dealer in order to be certain that any adaptations or modifications made are in keeping with the machine’s technical specifications and with prevailing safety requirements.

Any modification or adaptation which is not approved by the manufacturer may invalidate the machine’s initial conformity with safety requirements, and any person making such unapproved modifications is responsible for the consequences.

DO NOT operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely.

1--3

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY PRODUCT IDENTIFICATION Your machine and its major components are identified by various numbers and letters for recognition in After Sales Service. The following information provides the location of identification plates and stamped numbers on the machine and provide examples of what can be found on your machine.

Vehicle serial number The serial number is stamped at the front on the top of the right--hand main frame.

NOTE: Your dealer may require the serial number and identification numbers of components when requesting parts or service. These numbers will also be required as aid to identifying the machine if it is ever stolen, so keep them in a safe place.

TH001361

2

Vehicle Identification Plate The machine identification plate is located on the left hand of the seat pod. Record the data of your machine below.

TECHNICAL TYPE/MODEL UNIT SERIAL No. YEAR TH001529

1. Indicates the type or the model of the machine.

2. Indicates the homologation number of the market that the machine is destined for.

3. Indicates the serial number and registration number of the machine.

4. Indicates the total maximum weight that the machine can support.

5. Indicates the maximum weight for the front axle.

6. Indicates the maximum weight for the rear axle.

7. Indicates the maximum weight that the machine can tow.

8. Indicates the power of the engine expressed in Kw in compliance with standard ISO 14396.

9. Indicates the year of construction or manufacture of the machine.

1--4

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY Identification of turbocharged engine 74 kW The identification data of the engine are located on the right side of the cylinder block. Record the information below for quick reference in case of necessity.

ENGINE TYPE SERIAL NO.

TH001255

3

1--5

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY Front axle identification The serial number and axle type are printed on the plate located on the front of the axle housing. Record the information below for quick reference in the case of necessity.

AXLE TYPE SERIAL NO. DATA CODE TH001182

4

Rear axle identification The serial number and axle type are printed on the plate located on the front of the axle housing. Record the information below for quick reference in the case of necessity.

AXLE TYPE SERIAL NO. DATA CODE TH001183

5

T12000 PowerShift Transmission The serial number and type is printed on the plate (1), on the lower side of the transmission. Record the information below for quick reference in the case of necessity.

MODEL NO. SERIAL NO. DATA CODE

TH001184

6

1--6

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY Identification plate in the cab The cab identification plate includes the serial number and other data and is located in the front side of the seat. Record the serial number below for quick reference in the case of necessity.

SERIAL NO. DATA CODE TH001264

7

1--7

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY Identification of attachments A wide range of attachments is available for your Telehandler.

On each of the company approved attachments an identification plate is fitted, listing the type and characteristics of that attachment.

WARNING

Only the attachments approved by the manufacturer can be used on this machine. The manufacturer will be relieved of his responsibility in the event of modification or attachment adaptation carried out without the Manufacturers knowledge.

The details you will see printed on the plates mounted on the attachments are the following: • Attachment type • Cubic capacity • Date of manufacture • Unladen weight • Serial No.

An additional decal will be observed on equipment used for craning: • SWL (Safe Working Load) • Rated Load • Test No. CE

TH001114

8

1--8

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY

WARNING On machines having hydraulically, mechanically, and/or cable controlled equipment (such as shovels, loaders, dozers, excavators etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or repairing. If it is necessary to have the hydraulically, mechanically, and/or cable controlled equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical devices used for controlling the equipment.

MACHINE OUT OF SERVICE To decommission the machine it is necessary to provide particular equipment (hoists, hydraulic presses, containers for liquids etc.) and special tools listed in the Workshop Repair Manuals, available from Dealers.

This is in order to avoid that during decommissioning operations, dangerous situation occur both for the personnel and the environment.

The machine contains: • Fluids under pressure (hydraulic system, cooling system etc.); • Gas (air conditioner and accumulator, if installed); • Mechanical devices assembled under tension (arm, chain, lift cylinder); • Acid (batteries); • Heavy components (booms, buckets etc.).

WARNING •

•

•

The decommissioning of the machine must be performed exclusively by trained and qualified personnel authorised to do the job.

Start the disassembly of hydraulic components only after that the hydraulic oil and lubricants are completely cooled--off and after releasing residual pressures, as prescribed by the Repair Manuals.

Prior to proceeding with the disassembly operations, comply with the GENERAL SAFETY RULES and drain each component of the machine filled with fluids, both in tanks and the relevant systems.

DISPOSE OF WASTE IN AN APPROPRIATE MANNER •

The improper disposal of wastes is a menace for the environment. Potentially dangerous waste used on machines include lubricants, fuel, coolant, filters and batteries.

-- Use leak--proof containers when draining fluids.

Do not use containers for food or drinks that could encourage people to drink from them.

-- Do not disperse waste on the ground, in drainages or water tables.

-- Get informed about the appropriate manners to recycle or dispose of waste from local authorities or collection centres, or from your dealer.

1--9

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY ECOLOGICAL CONSIDERATIONS The following are recommendations which may be of assistance: •

Become acquainted with and ensure that you understand the relative legislation applicable to your Country.

4. Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids of fuels with lubricants. Do not mix used brake fluids or fuels with lubricants.

Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources.

5. Modern coolant mixtures, like antifreeze and other additives, should be replaced every two years. They should not be allowed to get into the soil but should be collected and disposed of safely.

•

Where no legislation exists, obtain information from suppliers of oils, antifreeze, cleaning agents, with regard to their effect on man and the environment and how to store, use and dispose of these substancesx safely.

6. Do not open the air--conditioning system yourself. Your Dealer or air--conditioning specialist has special equipment for discharging and charging the system.

Helpful hints 1. Avoid filling tanks using Jerry cans or inappropriate pressurised fuel delivery systems, which may cause considerable spillage.

2. In general avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances which can be harmful to your health.

3. Modern oils contain additives. Do not burn contaminated fuels and/or waste oils in ordinary heating systems.

1--10

7. Repair any leaks or defects in the engine cooling or hydraulic system immediately.

8. Do not increase the pressure in a pressurised circuit as this may lead to serious damage of the system components.

9. Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, causing the loss of oils and coolants.

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY GENUINE SPARE PARTS

GENERAL CONSIDERATIONS

All maintenance on these machines must be carried out using original parts.

Only qualified and trained staff can use the Telehandler. Its use is subjected to a driving permit granted by the person in charge in the operator’s company and subject to local legislation.

By allowing use of non--original parts, you run a risk: -- Legally, of being liable in the event of an accident.

-- Technically, of causing breakdowns to occur or of reducing your machine service life.

The operator should always keep an updated driving permit during service.

Remember:

The driver is not competent to authorise driving of the Telehandler by another person.

Any user who procures parts from another quarter does so at his own risk.

Moreover, the use must be in conformity with accepted practice in the profession.

Any user who modifies his machine or has it modified by a service company, must accept the liability for such modification.

The operator who finds that the Telehandler is not in good working condition or does not comply with the safety instructions, must inform immediately the person in charge.

The certificate of compliance only binds the maker for parts chosen or produced under maker’s control.

The maker sets out the practicalities of maintenance terms. The maker is in no way liable to the event of the user not complying with such terms.

Using counterfeit parts or components not approved by the manufacturer will affect warranty terms and could lead the maker to withdraw the machine certificate of compliance.

The driver is forbidden to carry out any repair or adjustment by himself. He shall keep his Telehandler perfectly clean, if he is in charge of this.

A copy of the Operator’s Manual must always be in the machine, in the place provided and in the language understood by the driver.

IMPORTANT: Allowing your local approved dealer to maintain your machine, you are legally covering yourself and receive the benefits of: -----

Guaranteed quality of work.

Original replacement parts.

Help with preventive maintenance.

Effective help with diagnosing faults.

Only the manufacturer knows the details of the Telehandler design and therefore has the best technological capability to carry out maintenance.

The machine must only be started or operated from the driver’s cab.

Respect safety instructions and the instructions described on the machine.

Make sure to replace every plate or decal, which becomes unreadable or damaged.

1--11

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY DAILY MAINTENANCE Carry out maintenance as required by the manufacturer – Refer to Section 4: “Lubrication and maintenance”.

In order to maintain the machine, we advise you to have your machine regularly checked by your dealer.

Before starting the machine, check daily the fluid levels of: -- Engine oil.

-- Hydraulic reservoir oil.

-- Transmission oil.

-- Fuel.

-- Cooling liquid.

-- Brake oil.

VEHICLE CHARACTERISTICS For your safety and safety of bystanders, do not alter either the structure or the different components of the machine by yourself.

PREPARING TO DRIVE Wear clothes suited for driving the machine, avoid loose or hanging clothes (neckties, etc.) and jewellery.

TYRES Familiarise yourself with the machine and the ground on which the machine is to be operated.

Ensure tyres are adapted to the nature of the ground.

Consult your dealer.

Mounting tyres inflated with foam should be avoided at all times. These are not accepted by the manufacturer without his specific authorisation.

OPERATING CONDITIONS We advise to fit the machine with a fire extinguisher.

Consult your dealer in case of doubt.

Take into account climatic and atmospheric conditions of any site you are working on.

Do not operate the machine in hazardous atmospheres, for which the machine is not designed.

For use in protected areas, example: oil refinery, explosive atmosphere, mining special equipment must be available (consult your dealer).

Protection against frost – Refer to Section 4: “Lubrication and Maintenance”.

Optional exterior lighting is available, consult your dealer.

Do not drive with wet hands or shoes, or soiled with greasy substances.

The operators must be fully acquainted with the location and operation of all controls, instruments and capabilities of the vehicle.

IMPORTANT: Prior to driving the Telehandler, with the engine running, turn the steering wheel, lock to lock. This ensures all hydraulic circuits are fully charged prior to operation.

Before driving the machine, check daily the functions of: -- Steering.

-- Brakes.

-- Hydraulic services.

-- Electric system.

NOTE: It is recommended that all instruments be checked for correct function, immediately after starting the engine, when the engine has warmed up and at frequent intervals when the machine is in use.

Should a fault occur, the engine should be stopped.

And any malfunction investigated and rectified within the shortest possible delay.

For better comfort, adjust the driver’s seat to your own convenience and adopt the correct position in the driver’s cab.

1--12

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY DRIVING CONSIDERATIONS The car with standard preparation can be used with a normal temperature range between 0 and +45 °C (113 °F). If the use range goes down to --20 °C (--4 °F), it must be equipped with ”cold start” optional with 10W30 oil viscosity and fuel with low cetane rating. For temperatures below --20 °C (--4 °F), artic oils and fuel suitable for this type of climate is to be used.

Beware of falling walls, landslides, materials or objects falling from the equipment that could hit the operator smashing through the cab window.

WARNING

Do not attempt to descend a gradient with the transmission in neutral. Always choose and engage the most suitable gear to maintain adequate speed while using engine braking and the brake pedal to avoid any risk of loss of control of vehicle.

WARNING

Whenever driving the machine on public roads or highway, always ensure that normal two--wheel steering is selected; refer to Section 2 “Controls, instruments and operation”.

Do not forget to fasten your safety belt.

WARNING

Do not use the machine with the engine running at more than 2400 rpm (corresponding to travel speed of 35 km/h). If this should occur, reduce speed immediately by releasing the accelerator pedal and pressing the brake pedal.

Using the vehicle at speeds of 2400 rpm or higher can lead to serious damage and will result in invalidation of repair under the terms of the warranty due to improper use of the vehicle.

If driving on roads open to public traffic, respect the rules of the highway code.

IMPORTANT: In the event of an engine failure, do not try to start the machine by pushing or towing.

Such operation may cause personal injury or severe damage to the transmission – Refer to section 2.

In the vent of abnormal or unexpected response of the machine, cut--off the engine at once.

Check the efficiency of service brakes and of the sound alarm.

Drive smoothly and progressively at all times and at a speed appropriate to ground conditions.

Look in the direction of progression and always keep good visibility of the road.

Whenever driving the Telehandler, keep a look out for overhead power cables.

TH001011

Keep a look out also for low overhanging objects, scaffolding, trenches, back--filled land.

TH001115

On wet, slippery or uneven ground, drive slowly.

Brake progressively and not sharply.

Use the control levers only for driving.

If towing a trailer ensure the trailer brake coupling is connected and turned “ON”.

Do not place any part of the body, outside the driver’s cabin, on in the way of lifting elements.

Do not allow passengers to ride on any part of the machine, or in the driver’s cabin.

TH001116

Do not drive with the foot on the brake pedal or with the parking brake applied.

1--13

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY Use the reverse gear of the machine with caution only from a stationary position.

Drive around obstacles when safe to do so.

Do not enter a loading platform without having checked: That is correctly placed and secured.

That the equipment to which it is linked (wagon, truck, etc.) cannot change position.

• That this platform allows for total weight of the machine, possibly laden.

• That this platform allows for the width of the machine.

Do not enter onto a footbridge, a floor or a freight elevator, without being sure that they can take the weight and overall dimensions of the machine, possibly laden, and without having checked that they are in good state.

• •

LOADER CONSIDERATIONS When picking up a load, check that the ground is as flat as possible.

Engage the forks fully under the load and transport it low down on the forks and with the front part of the arm retracted as far as possible and inclined backwards.

TH001117

Do not attempt to overfill and transport loads that could spill out of or fall off the attachment.

Do not use an unbraked trailer, if the single weight in charge exceeds the one imposed by the highway code.

Do not use a braked trailer without equipment for trailer braking on the Telehandler.

Do not leave the Telehandler unattended with engine running.

Do not let the engine idle for a too long a period of time.

TH001015

Do not manoeuvre the load when the machine is in motion.

The simultaneous use of two machines for handling heavy or bulky loads is a dangerous manoeuvre, requiring particular precautions. This can only be done exceptionally and in the presence of the person in charge of handling.

Take steep downward slopes in reverse motion and at low speed.

Avoid running too long distances in reverse.

WARNING

In the event of the machine overturning, do not try to leave the cab during the incident.

YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CABIN. Handle loads with care, at low speed and without sudden movements when transporting them at heights or when subject to important offsets.

1--14

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY Apply the parking brake when lifting or depositing a difficult load or when on an incline.

OPERATING ANGLE IMPORTANT: For safety reasons and for effective machine operation ensure that operating angles shown below are never exceeded.

Check ground stability and solidity before depositing the load.

Check the cleanness and protection of the quick release couplings of the attachment circuit.

IMPORTANT: When attachments are being changed, in order to avoid damage to the quick release couplings: • Lower the forks or attachment to rest on the ground.

• Stop the engine.

• Release the pressure in the attachment hydraulic circuit by operating the levers of the control valve (in case of an electric control on the control valve, switch on the electrical contact without starting the engine).

Lower the forks to the ground and apply the parking brake when the machine is not in use.

Ensure that the handling attachment is correctly fitted and locked on it bracket.

TH001118

Bring the forks up to the load to be lifted and keep them at right angles to the load itself; at the same time take into account the position of the load centre.

It is forbidden to carry people with the machine, unless it is equipped to do so, Optional attachments are available; consult your dealer.

For safety reasons, ensure that all loads are transported with the assumed centre of gravity in the Telehandler axis and that they are properly tied to avoid overturning risks.

TH001017

Do not leave a laden machine even with parking brake applied, on an incline. In case of failure in the mentioned case, cut off the engine and use special chocks to block the wheels.

Do not lift a load with one fork only.

Do not lift a sling load with only one fork or with the carriage. Optional attachments are available, consult your dealer.

Do not accelerate or brake sharply with a load on the forks.

TH001119

Do not stop the machine or turn with the load in an elevated position.

Ensure that any scaffold or loading platform is capable of bearing the load of the machine.

1--15

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY The employment of the Telehandler as lifting equipment is subject to the compliance of the laws in force in the country of use.

TH001120

Keep an eye on the load, above all on bends and particularly if the load is very bulky and not very steady.

TH001019

Check the good working condition of the handling devices of your machine.

Do not lift a load in excess of the rating of the machine or add counterweights, by whatever device.

TH001121

Do not attempt to carry out operations in excess of the capacity of the machine.

Ensure that pallets, boxes, etc… are in good state and appropriate to the load to be lifted.

Before lifting a load, ensure that the work site is unobstructed and operate the machine properly.

Do not allow anybody to come near the working area of the machine or pass beneath an elevated load.

1--16

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY ROPS / FOPS CAB PROTECTION STRUCTURE

WARNING

Your machine has the following cab protection structures: ROPS (Turnover protection structure) in compliance with directives ISO 3471, SAE 1040C or FOPS (Protection structure against falling objects) in compliance with directives ISO 3449, SAE J231. A ROPS structure comprises: a cab protection frame, with two or four pillars, designed to reduce the risk of the operator suffering serious injury in the case of an accident to a minimum. The protective structure, the fitting supports and the fastening elements on the machine are an integral part of the ROPS.

DO NOT WELD, MAKE HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTION STRUCTURE. ANY TYPE OF MODIFICATION CAN REDUCE THE STRUCTURAL INTEGRITY OF THE SAFETY SYSTEM WITH FATAL CONSEQUENCES IN THE EVENT OF FIRE, OVERTURNING OR COLLISIONS. IMPORTANT: For total operating safety, the machine’s cab is designed to prevent flames from propagating in the event of a fire and to limit combustion as required by ISO 3795.

The cab protection structure is a special safety system of your machine.

DO NOT connect any towing device to the cab protection structure. DO NOT make holes in the cab protection structure.

The cab protection structure and the respective components for assembly and for fixing it to the machine, are a certified system. Damage due to fire, corrosion or tampering could weaken the structure, reducing its efficacy and threatening your safety. If damaged, the cab protection structure must be replaced so as to restore the original safety standards.

Contact your Dealer to check the functionality of the structure or if it has to be changed.

After a collision, fire or overturning, before resuming normal work operations, the following operations must be carried out by a qualified technician: •

Replacement of the cab protection structure.

•

Accurate inspection of the supports for fitting the protection structure, the driver’s seat and its support, the safety belts and their fixtures, the electric system inside the protection structure.

•

All damaged parts MUST be replaced.

1--17

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY UNDERSTANDING THE WARNING TERMS •

Safety warning terms are used in this manual to indicate the degree of danger, such as:

-- DANGER; -- CAUTION; -- WARNING. The above terms are always accompanied by the safety warning symbol.

DANGER CAUTION WARNING IMPORTANT NOTE DANGER: indicates an imminent situation of danger which, if not avoided, will cause death or serious injuries.

CAUTION: indicates a potential situation of danger which, if not avoided, could cause death or serious injuries.

WARNING: indicates a potential situation of danger which, if not avoided, could cause slight or minor injuries.

IMPORTANT: indicates a potential situation of danger which, if not avoided, could cause damage to the machine.

NOTE: indicates an additional explanation for an element of information.

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SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY ELECTRICAL POWER LINES

Ensure the workplace is sufficiently ventilated before starting the machine.

WARNING

When working near power lines, ensure that a safe distance is maintained between the working area of the Telehandler and the power line.

This distance at minimum should be at least 5 metres.

ENGINE SHUTDOWN Before stopping the machine after intensive work, let the engine idle a few moments to enable the cooling liquid and the oil to lower the engine and transmission temperature.

Do not forget this precaution (in the event of frequent stops of the engine), or else the temperature of certain parts will rise significantly due to stopping of the cooling system, with the risk of badly damaging such parts.

WARNING

Do not leave the key in the key start switch when the machine is unattended.

Stop the engine when not in use.

Do not run the engine without air filter, or with oil, water or fuel leaks.

Wait until the engine is cold before taking off the radiator cap.

Use the recommended lubricants (Never use contaminated lubricants).

Change filter cartridges.

Make sure that the evacuation of process materials and of spare parts is carried out in total safety and in an ecological way.

Clean the machine of any fuel, oil or grease trace.

MAINTENANCE CONSIDERATIONS Maintenance and keeping machine in proper condition are compulsory.

Clean the machine or, at least, the area concerned before any maintenance intervention, closing the cab door and windows.

If necessary, protect against penetration of water, steam or cleaning agents, components susceptible of being damaged, particularly electrical components and connections and the injection pump.

Wear clothes suitable for the maintenance of the machine. Avoid wearing jewellery and loose clothes.

Tie and protect your hair, if necessary.

Carry out repairs immediately, even if the repairs concerned are minor.

Repair all leaks immediately, even if the leak concerned is minor.

WARNING

Do not attempt to loosen unions, hoses or any hydraulic component with the circuit under pressure.

The handling and the dismounting of the balancing valves, which supply oil to the cylinders of your machine, can be dangerous. A balancing valve must only be dismounted when the cylinder concerned is at rest and the hydraulic circuit is not under residual pressure. Authorised technical staff only can carry out this operation.

Do not smoke or approach the machine with a flame, when the fuel tank is open or is being filled.

Do not fill the fuel tank when the engine is running.

Fill up the tank only in the spaces provided.

1--19

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY Isolate the battery before working on the electrical circuit or on the machine (e.g. welding).

FUEL CAPACITY = 135 LITRES

Do not deposit metal objects on the battery.

When carrying out electric welding work on the machine, isolate the battery. Connect the negative cable from the equipment directly to the part being welded; so as to avoid high tension current passing through the alternator.

SAFETY CAB Your machine is equipped with a safety cab and it must be maintained in serviceable condition.

NOTE: The following statements are for your own protection as well as other people.

1. Do not modify, drill or alter the safety cab in any way, as doing so could render you liable to legal prosecution.

2. Do not attempt to straighten or weld any part of the frame or retaining brackets, which have suffered damage. By doing so you may weaken the structure and endanger your safety.

TH001366

2. Never remove the fuel cap or refuel with the engine running or hot.

3. Do not smoke while refuelling or when standing near fuel.

4. Maintain control of the fuel filler pipe nozzle when filling the tank.

5. Do not fill the fuel tank to capacity. Allow room for expansion.

6. Wipe up spilled fuel immediately.

7. Always tighten the fuel tank cap securely.

3. Do not secure any parts on the safety cab with anything other than the special high tensile bolts and nuts specified.

8. If the original fuel tank cap is lost, replace it with an approved cap. A non--approved, proprietary cap may not be safe.

4. Do not attach chains or ropes to the cab for pulling purposes.

9. Keep equipment clean and properly maintained.

5. Do not take unnecessary risks even though your safety cab affords you the maximum protection possible.

DIESEL FUEL 1. Under no circumstances should rexiol, alcohol or blended fuels be added to diesel fuel. These combinations can create an increased fire or explosive hazard. In a closed container such a fuel tank, such blends are more explosive than pure gasoline. Do not use these blends.

1--20

10. Do not drive equipment near open fires.

11. Never use the fuel for cleaning purposes.

12. Arrange fuel purchase so that summer grade fuels are not held over and used in the winter.

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TOXIC AND DANGEROUS SUBSTANCES In the car are fluids, lubricants, paints, adhesives, coolants, etc. which can cause very serious injury to the operator. The following list describes some situations that may occur and any precautions to be taken.

• Battery acid causes severe burns. Batteries contain sulphuric acid. Avoid contact with skin, eyes or clothing.

•

Antidote external: flush with water.

•

Antidote internal: drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

•

Eyes: flush with water for 15 minutes and seek medical attention immediately.

•

Batteries produce explosive gases. Keep sparks, flame, cigars and cigarettes away. Ventilate when charging or using in enclosed area.

Always wear eye protection when working near batteries. Wash hands after handling. Keep out of reach of children. Failure to comply could result in serious injury or death.

•

Liquid refrigerant can cause severe and painful frostbite to your skin. Do not attempt to service the air conditioning system on this machine unless you are completely familiarized with air conditioning and the safety precautions which must be followed. Serious injury can result if you do not follow these instructions. Failure to comply could cause injury or death.

•

If the radiator is hot, remove the cap can cause the leakage of coolant boiling. Before removing the radiator cap, allow to cool the cooling system, turn the cap until the first mark and wait until you release pressure, then remove the cap.

•

Never use gasoline, naphtha or any other volatile material for any cleaning purposes. These materials may be toxic and/or flammable. Failure to comply could cause injury or death.

•

Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released.

This information is available from your dealer.

•

Before you service your machine, check the MSDS for each fluid, lubricant, etc., used in this machine. This information indicates what the risks are and how to service the machine safely.

Follow this information when servicing the machine.

•

Before you service this machine and before you dispose of the old fluids and lubricants, always remember the environment. Do not put oil or fluids into the ground or into containers that can leak.

•

Check with your local environmental or recycling center or your dealer for correct disposal information.

1--21

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY SUMMARY OF SAFETY RULES

•

When the machine is travelling, no manoeuvre of the load is allowed. The handling of materials must be performed with the boom lowered and all the slides retracted.

•

Maximum admissible speed with a suspended load is 5 km/h: it is therefore necessary to restrict hydraulic and mechanical operation speed.

For your safety always comply with the following rules: •

Ensure that there is nobody within the machine operating range.

•

Do not stand or walk under the arm of the vehicle

•

Before leaving your driving seat: -- set the gear selector in neutral; -- apply the parking brake; -- stop the engine.

DRIVING ON ROADS OPEN TO PUBLIC TRAFFIC •

On these roads steering is admissible only on the front axle.

Never lift loads greater than those shown on the carrying capacity diagram on the lifter. The operator must first assess the size of the load to be lifted.

•

The arm must be lowered to allow resting on the special ledge.

•

Install the fork guard.

•

The load diagram is meant for a machine on flat and stable ground. Avoid operating with loads on an unstable or sloping ground.

•

Cab controls must be locked.

•

Loads shown on load diagrams must be reduced by the weight of possible attachments.

•

Reduce the loads shown on the load diagram by the weight of the attachments used.

•

Indications provided by the anti--overturning system must be considered valid for machines in standard operating conditions on flat and stable ground, and with a functioning and correctly calibrated instrument. In any case limit values on load diagrams must in no case be exceeded.

•

The centre of gravity must be that of the load plus the attachments.

•

USE OF THE ATTACHMENTS

USE OF THE LOADING BUCKET •

When using the lifter with a loading bucket, the bucket filling operation must be performed with the loader arm extension fully retracted.

•

Set the forks in a symmetrical way with respect to the arm axis and uniformly distribute the load between the two forks.

•

When a load is handled, it is necessary to check its stability when driving uphill or downhill, operating, if necessary, on the fork tilt control to restore it to safe conditions.

USING THE VEHICLE AS A CRANE •

Do not lift loads that are not properly placed in slings.

Operations must all be performed with the minimum loader arm admissible under operating conditions.

•

Do not start or stop the machine with a jerk.

•

Avoid load oscillations and especially allowing the load to hang outside the pulling vertical line.

To lift a load it is recommended to raise the arm first and then operate the loader arm extension.

In a similar way, to lower a load, first pull in the extension, and then lower the arm.

•

Avoid oblique pulls and towing.

•

•

•

Avoid load lifting and transport operations over working or transit areas. Should this not be possible, give proper sound warnings.

1--22

WARNING

It is absolutely forbidden to tamper with or change the calibration values of the hydraulic system components.

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY

SAFETY DECALS

TH001362

9 DECALS WITHIN THE CAB Safety decals are placed on your machine as shown. They are intended as a guide for your personal safety and that of those working with you. Please take this manual, walk around your machine and note their content and location. Review these decals with your machine operators. Keep the decals legible. If they are not, obtain replacements from your dealer.

1--23

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY LOADER SAFETY: ensure that when operating the loader all safety precautions are observed for your safety and that of by standers.

WARNING: Ensure that when the machine is left unattended it cannot be a danger to safety.

TH001146

10 LOADER LIFT CAPACITY: Ensure the loader is operated at all times safely and within its designed lift capacity; refer to the indications described in this section.

TH001124

11 DANGER: Make sure that near electric power lines and poles, the attachment used is at a minimum distance of 8 metres (25 ft). The non compliance with this rule can cause personal injuries or death.

For further information, please refer to the indications described in this section.

TH001148

12

1--24

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY MANIPULATOR FUNCTIONS: refer to this booklet to obtain detailed information about the manipulator functions.

TH001368

13 SAFETY BELT: wear your safety belt at all times when the machine is in operation.

TH001150

14 SAFETY HAT: wear a safety hat for your own protection.

TH001151

15 OPERATOR’S MANUAL: read the operator’s manual before attempting to operate the machine.

TH001152

16 FIRE EXTINGUISHER: where fitted ensure the extinguisher complies with local regulations and is fully serviceable.

TH001153

17 1--25

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY

IMPORTANT: BUCKET USE The use of the bucket is allowed exclusively with the boom completely retracted.

TH001363

CONSOLE SAFETY DECALS This page contains a list of the decals applied to the console.

1--26

18

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY Location of brake fluid reservoir.

The tank containing the brake fluid is located in correspondence with this plate; beware in handling this fliuid since it is highly corrosive and toxic.

TH001155

19

Do not operate frame levelling controls when arm is raised. If frame position is changed when the arm is lifted, the machine can become unstable and overturn.

TH001156

20

SELECTOR OF STEERING GEOMETRY

TH001157

21

Before starting or operating the machine when working, follow the instructions and comply with safety rules.

TH001158

22

Reversing running direction is admissible only in first gear.

TH001159

In order to prevent injuries or fatalities due to the overturning of the machine when operating the bucket with an extended boom; the bucket bust be used exclusively with the boom fully retracted.

23 IMPORTANT: BUCKET USE The use of the bucket is allowed exclusively with the boom completely retracted.

TH001160

25A 1--27

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY To prevent the tipping over of the machine when operating on slopes, it is possible to rotate clockwise or counter clockwise the frame with respect to the axles. In this manner, the machine is levelled, preventing the creation of a dangerous situation for the operator.

TH001143

24

TH001144

25

1--28

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY

TH001535

26 MACHINE SAFETY DECALS (Externally Fitted) Shown above and listed on the following pages are the various safety decals that may be attached to your machine, dependant upon market requirements.

Ensure they are maintained in a legible condition and replace if they become damaged or are unreadable at any time.

1--29

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY DANGER: do not stand too close to a machine in operation, or operate the machine if people are close to the loader operating area.

Do not allow yourself or other persons to be trapped when the loader is in operation.

TH001163

27 WARNING: lift, tie down or tow the machine only from attaching points identified by this symbol.

TH001164

28 WARNING: the battery contains acid and should be treated with caution and disconnected whenever any maintenance is performed.

TH001165

29 WARNING: EXPLOSIVE GAS. Cigarettes, flames and sparks can cause battery explosion.

CORROSIVE POISON. Battery contains sulphuric acid. Avoid contact with eyes, skin and clothes.

TH001166

30

1--30

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY DANGER: do not remove the engine side panels with the engine running, because contained within the engine compartment there are components that can trap, cut and burn you. Before removing the engine side panels, switch off the key start, remove the key and consult the manual.

TH001167

31 CAUTION: ensure that only hydraulic oil is put into a tank with this symbol. Refer to Section 4, “Lubrication and Maintenance” of this manual.

TH001168

32 CAUTION: do not place any other substance than diesel fuel in contains which have this symbol.

TH001169

33 WARNING: do not unscrew or open the air conditioning system piping (if existing). The gas contained, in a liquid form, can cause serious damage and burns.

Consult his manual at Section 4 for further information.

TH001170

34

1--31

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY INFORMATION CONCERNING AIRBORNE NOISE EMISSION Sound power level LWA = 106 dB (A) Guaranteed sound power level (1), determined according to European Directive 2000/14/EC. Sound pressure level at operator’s station LpA = 74 dB (A) Equivalent continuous weighed sound pressure level ”A” in correspondence with the operator station with cab door and windows closed and fan of the heater/ conditioner operating, measured on identical machine, in compliance with standard ISO 6396:2008.

71477095 I--- D

1

TH001538

35 INFORMATION CONCERNING HAND--ARM AND WHOLE--BODY VIBRATION EMISSION The level of vibrations transmitted to the operator depends mainly upon the conditions of the ground on which operations take place, the mode of operation of the machine and its equipment. Thus, the exposure to vibrations can be considerably reduced when the following recommendations are complied with: -- use equipment compatible with the machine and the type of work do be done; -- adjust and lock the seat in the correct position; also inspect regularly the suspensions of the seat, performing the adjustments and repairs as required; -- perform regularly the current maintenance operations of the machine at the prescribed intervals; -- operate the equipment in a uniform manner, preventing, as far as possible, sharp movements or excessive loads; -- when travelling, avoid, as far as possible, particularly rough terrain or the impact against possible obstacles.

• the effective value of the acceleration issued by the machine to which the arms of the operator are subjected does not exceed 2,5 m/s2.

• the effective value of the acceleration issued by the machine to which the body is subjected does not exceed 0.5 m/s2.

1--32

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY LOAD STATUS INDICATOR PANEL The load status indicator warns the operator when the machine reaches the maximum authorised load condition.

WARNING

Any attempt to lift loads beyond the maximum allowed will result in an unsafe and unstable situation.

A -- GREEN SIGNAL LIGHT The green LED signal decreasing stability situations, nevertheless normal. During normal operations, LED status is continually updated, conveying the current situation.

C

B

B -- YELLOW SIGNAL LIGHT A Yellow LED warn of a critical stability situation, instability value approached 100% (overturning).

DANGER

Operator intervention is required to remedy to situation. You must lower the vehicle centre of gravity.

Continue lifting along the arc, which actually shifts the weight nearer the machine centre of gravity, or retract the telescopic arm if it is in an extended position, to move the weight nearer the machine centre of gravity.

TH001053

D 36

C -- RED SIGNAL LIGHT (VISUAL AND AUDIBLE ALARM) The signal light illuminates, when the machine reaches 100% of its maximum authorised load capacity. The audible alarm sounds simultaneously with the red signal light illuminated.

WARNING

Under these conditions the boom must be retracted or raised to return into safe conditions.

TH001129

37

D -- TEST SWITCH Operation of this switch tests the alarm and illuminates the warning lamp to ensure all is working correctly. Check each day before commencing work and if either are not functioning correctly, in your arm interest and in the interests of bystander safety do not attempt to use the machine as a loader until a repair has been performed.

1--33

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY LIFTING OR CRANING – S.W.L, SAFE WORKING LOADS Shown are the maximum loads for the model ranges for lifting or craning.

Load diagrams comply with EN 1459.

IMPORTANT: When lifting or craning, ensure the machine is on a level ground, apply service brakes.

TX130--30 (without stabilisers)

TX130--30

TH00R074

38

1--34

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX130--33 (with small stabilisers lowered)

TX130--33

TH00R076

39

1--35

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX130--33 (with small stabilisers raised)

TX130--33

TH00R075

40

1--36

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY SAFETY FEATURES AND OPTIONS VEHICLE SECURITY

1

3

2

TH001360

4

5 41

1.

CAB DOOR: can be locked by with key.

2.

FUEL TANK PLUG: can be locked by with key.

3.

HYDRAULIC OIL FILLER CAP: hydraulic system oil tank filler cap.

4.

ENGINE COMPARTMENT: can be locked by key.

When using the machine, this compartment must not be locked with a key or with a padlock, for quick emergency access to BATTERY ISOLATOR SWITCH.

5.

BATTERY ISOLATOR SWITCH: this is mounted on a bracket in a central position in an elevated position with respect to the two batteries, inside the engine compartment. When servicing the machine, use this switch to isolate the battery power. This switch also acts as security, and when switched off and the door is closed, it effectively isolates the vehicle.

1--37

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY ROAD TRAVEL REQUIREMENTS – IN CAB

TH001357

42 In Europe and countries outside the EEC it may be a requirement to use one, several or all the items shown hereafter for “ROAD TRAVEL REQUIREMENTS”.

2. HYDRAULIC FUNCTIONS CUT--OFF: configuration switch (1) must be moved into position “road”.

In this position manipulator operation, stabiliser and axle levelling cylinders are locked out.

1. LOADER ARM: when travelling on public roads ensure that loader arm is not in a position to cause hindrance or danger for on road travel.

Ensure that the telescopic arm is level with the line on the cab side window.

3. STEERING MODE SELECTION LEVER: be sure, when driving on roads, to select two steer wheel mode on the selector (2). This is the selector central position. Use the special safety stop (red) to lock the selector in this position.

1---30 1--38

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY ROAD TRAVEL REQUIREMENTS EXTERNAL In Europe and countries outside the EEC it may be a requirement to use one, several or all of the items shown for “ON ROAD TRAVEL” requirements.

Ensure that your machine complies with local legislation with regard to the fitting of this equipment, when travelling on road day and/or night.

1. WHEEL CHOCK: in some Countries it is compulsory to make available and to use a wheel wedge (1) when the vehicle is stationary. Ensure you comply where legislated.

2. LOADER ATTACHMENT GUARDS: if applicable, make sure that all the attachments are equipped with protection (2) or a signal, when required by law.

In case floating forks are used, install blocking device (3).

1 TH001194

43

2 TH001201

44

2 TH001202

45 3

TH001195

46 1--39

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY 3. ROTARY BEACON SIGNALLING A SLOW VEHICLE: when travelling on a road, this rotary beacon (1) must always be in operation, both during the day and at night.

To activate the rotary beacon, connect it to the auxiliary power socket present in the cab.

4. LICENCE PLATE: ensure that your machine complies with local legislation with regard to the fitting of this equipment. When travelling on the highway day and night.

1

TH001222

47 5. TRAVEL LIGHT: travel lights (2) are ON when the head lights and tail lights are activated. Make sure they are ON when travelling on the road.

The use of travel lights is regulated by the road code.

2

TH001364

48 6. STEERING GEOMETRY SELECTOR: when travelling on the road, it is essential to verify the alignment of the wheels, using steering geometry selector (3) in position ”A”.

In this case use exclusively the two steering wheels mode, otherwise, only the front wheels are steering.

A C

B

3

C

A

B

TH001197

49

1--40

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY 7. WORK LIGHTS: when travelling on the road, work lights (1) must be blanked by using the appropriate hoods.

1

TH001198

50 8. BOOM BLOCKING BRACKET: when travelling on the road, make sure that bracket (2) is secured between the frame and the boom, to prevent any accidental lifting.

9. BOOM EXTENSION BLOCKING BRACKET: when travelling on the road, make sure that bracket (3) is secured between the 1st and 2nd section of the boom to prevent any accidental extension.

3 2

TH001365

51

1--41

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY ‘EC’ REGULATIONS -- EUROPE GENERAL INFORMATION The conformity with the requisites and the standards on the subject of safety of Directive 98/37/EC allow the manufacturers of machines to apply the “EC” brand on their products starting from January 1, 1995.

In case of use of supplementary attachments, the rules relative to safety for the use of such attachments are regulated by standard EN 280.

These directives are there to protect the consumers, and manufacturers to help guard against potential hazards from machinery.

All the machines dealt with in this manual have been designed and manufactured in compliance with standard 2006/42/EC and the requirements of the directive on the safety of machinery and, as a result, they bear the ”EC” trademark illustrated below.

In general it should be considered that any supplementary installed electrical equipment must comply with the EMC Directive 89/336/EEC and ‘EC’ marked.

NOISE

‘EC’ 2000/14/EC

These machines have been tested in accordance with the above safety directive and bear decals accordingly depicting the vehicle noise measured in decibels: 106 Lwa = Noise measured outside the vehicle in an open environmental situation.

74 Lpa = Noise in cab measured at operator ear level with the windows closed.

IMPORTANT: When working in confined spaces such as between buildings, external noise may be reflected back, and therefore noise in cab may increase, if cab windows are in the open position. For your own protection wear ear protection.

NOTE: These machines not only meet recommended safe noise levels but also may operate at noise levels better than that shown.

EMC – ELECTRICAL MECHANICAL INTERFERENCE: ”EC” Directive EEC/89/336 Some of these machines may be equipped with electronic components the functions of which may be influenced by the electromagnetic influence of other applications that are not part of the vehicle.

Such influences can generate hazards for persons if the following safety precautions are not taken into account.

In the case of supplementary installed equipment or appliances the user must verify whether the installation causes interference or disturbance to the vehicle components. If this is the case, the user must take action to correct it.

Particular attention should be paid to mobile equipment such as radio communication (telephones) which should be professionally fitted and should use an externally fixed antenna.

1--42

VIBRATION:

‘EC’ EEC/93/392

The exposure by the operator to vibrations can be reduced when the following recommendations are considered: •

always use equipment appropriate for the type of work to be performed;

•

the machine must be equipped with a seat complying with the comfort criteria established by EN ISO 7096: 2000; the same must be adjusted according to its own requirements;

•

make sure that the machine is maintained in efficient conditions;

•

steer, brake, accelerate, shift gear, move the equipment in a smooth manner;

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY •

during travel, adjust the speed of the machine so as to minimise vibrations;

•

keep the work site in good shape (remove stones and obstacles, fill depressions and ditches etc.).

With regards to this Directive, these machines have been tested and meet the recommended requirements.

During testing each machine is operated in predetermined work cycles, which cover all actions taken during a typical 8--hour working day. That is at idling, on road, loading and excavating.

The measurements taken are vibrations that can be felt through the body when seated in the vehicle, and at hand and arm level when operating the controls.

These machines meet the safe operating levels, (whole body to be 0.5 m/s2 or less) (hand and arm to be 2.5 m/s2 or less), results being indicated as below: Whole body (m/s2) = < 0.5

ENGINE IMPORTANT: According to directives no 2000/25/EC by the European Community and no. 40 CFR by U.S.A. it is prohibited to perform any form of tempering with the engine, including unloading non certifiable software. Any modification on an engine or the intake system found non complying with current specifications involves: legally that the engine is illegal for such market and shall not be protected by any insurance, the warranty on the engine and the fuel intake system becomes void, in accordance with what stated by the certificates, and the customer could incur in considerable costs in resetting the engine; technically incur in possible overloads of engine components, possible premature wear of the engine and excessive load of components and use of contaminated oil. Only personnel authorised by the Dealer can perform repairs on the fuel feeding system. The repairs must be perfomed only when implementing the specification provided by the Manufacturer.

Hand and Arm (m/s2) = < 2,5 NOTE: These machines not only meet the recommended safe levels of vibration but may operate at levels below that shown.

WARNING

The fuel system and engine on your machine are designed and built to government emission standards. Tampering by dealers, customers, operators and users is strictly prohibited by law.

Failure to comply could result in government fines, rework charges, invalid warranty, legal action and possible confiscation of the machine until rework to original condition is completed.

Engine service and/or repairs must be done by a certified technician only.

1--43

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY UNIVERSAL SYMBOLOGY

Thermostart starting aid Alternator charge Fuel level

Engine speed (rev/min x 100)

Front windscreen wipe

Front windscreen wash

Rear windscreen wash/wipe

Hours recorded

Engine oil pressure

Side lamps

Turn signals

Heater temperature control

N

Transmission in neutral

Transmission oil temperature

Horn

Roof beacon

Accessory socket

Hazard warning lights Transmission oil pressure

FWD engaged

Malfunction!

See operator’s manual

Heater fan Engine coolant temperature

Coolant level

Read operator’s manual Air conditioner

Air filter blocked

Brake reservoir oil level

Warning!

Machine lights

Headlamp main beam

Parking brake

Headlamp dipped beam

Stop lamps

Hydraulic service Isolation switch

Optional hydraulic function inhibition

Variable control Pressurised!

Open carefully

Warning!

Corrosive substance Optional hydraulic function 52

As a guide to the operation of the machines, various universal symbols have been utilised on the instruments, controls, switches and fuse box.

1--44

The symbols are shown with the indication of their meaning, however not all decals may be on your machine as some depend on options and accessories fitted.

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY MACHINE FUNCTIONS THAT ARE MONITORED BY INSTRUMENTS, WARNING LIGHTS, AND BUZZERS To protect the machine and identify operational items, warning lights and buzzers will respectively illuminate or sound should these components require operator’s attention. Listed below for ease of identifying these items are the components along with the respective light and buzzer.

TH001134

53 ID

Function

Warning light

Instrument

L1

Generator

X

L2

Engine oil pressure

X

L3

Brake oil level

X

L4

Engine glow plug pre--heating

X

L5

Transmission oil temperature

X

L6

Transmission oil pressure

X

L7

Parking brake

X

L8

Rear wheels alignment

X

L9

Main beams

X

L10

Turn indicators

X

L11

Two steering wheels

X

L12

Crab steering

X

L13

Four steering wheels

X

S1

Fuel level

X

S2

Engine rpm counter

X

S3

Tachometer / hour meter

X

S4

Engine coolant temperature

X

Buzzer

X

Reverse gear

X

Steering

X

For more detailed information about indicator meanings see Section 2.

1--45

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY

NOTES

1--46

SECTION 2 CONTROLS, INSTRUMENTS AND OPERATION

BEFORE OPERATING Read this section thoroughly. It details the location and operation of various instruments, switches and controls on your Telehandler. Do not start the engine or attempt to drive or operate the machine unless you are fully accustomed to the controls.

IT IS TOO LATE TO LEARN ONCE THE MACHINE IS MOVING

CONTENTS SECTIONAL Description

Page

General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3 Hand and foot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--6 Cab instruments and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--15 Wheel alignment operating leve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--16 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--17 Load status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--21 Multifunction lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--23 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--24 Operativeness selection switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--26 Powershift transmission 4 x 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--27 Driving with the Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--27 Engine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--30

2--1

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION Starting the machine with jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--33 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--34 Running--in procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--34 Driving the Telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--35 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--36 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--37 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--38 Machine storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--38

2--2

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION GENERAL DESCRIPTION The following tables contain the Telehandler specific values and dimensions. The following data are therefore the same for all the models sold.

Dimensions * Height Track Wheel base Turning radius

2450 mm 2445 mm 3120 mm 3890 mm

Capacity * Fuel tank Hydraulic system

135 L 185 L

Miscellaneous Transmission Forward gears Reverse gears * Road speed Hydraulic controls Simultaneous hydraulic controls Hydraulic pump Hydraulic system flow

Powershift 4 3 35 km/h assisted provided gear type 115 l/min

* Except different specifications of foreign Countries.

TH002107

1

2--3

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION HAND AND FOOT OPERATING CONTROLS IMPORTANT: At engine start up always fully retract all loader arm sections until the pressure valve is activated and remains activated for 10 seconds.

This ensures all arm sections and hoses become fully synchronised. If not synchronised, hose failure may result.

1. Left side control panel.

9. Multifunction front loader lever: -- telescopic arm extend/retract lever; -- loader boom lift and drop; -- attachment tip and return; -- aux. 1 function button; -- aux. 2 function button.

2. Instrument console.

3. Wheel alignment operating lever.

Select fully all steering modes at least once a day to ensure correct operation.

4. Right side control panel.

5. Engine start key.

6. Powershift gear selection lever, trevel direction and horn.

7. Road lights and direction indicator control lever.

8. Aeration outlets.

10. Steering wheel.

IMPORTANT: When starting up the engine and prior to driving away, turn the steering wheel completely from one side to the other to help hydraulic oil circulation.

11. Pedal accelerator.

12. Foot brake pedal.

13. Load control display.

14. Air conditioning control panel.

2--4

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION

10 2

1

3

9

6

11

7

8

12

4 5 13 14

TH55R235

2

2--5

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION CAB The cab has been designed for your comfort.

Has a protective structure against overturning and against falling objects. Also, the cab is equipped with large glassed areas providing maximum comfort to the operator, under all conditions.

WARNING

The protection provided by the rollover protection can be voided in the event any structural modification or damage occurs.

IMPORTANT: For total operating safety, the machine’s cab is designed to prevent flames from propagating in the event of a fire and to limit combustion as required by ISO 3795.

Standard features include a fresh air heater/defroster, optional air conditioning, sun visor, interior light, grab handles and an operator’s manual storage facility, behind the seat.

Entry and exit from the cab is aided by a wide door and footstep with anti--slip treads.

WARNING

Always lock the door in open position prior to using the handles connected to it.

Climb and leave the machine using the ladder and the appropriate handles illustrated in the figure.

TH002309

3 INTERIOR LIGHT The interior light (1) is mounted on the right hand side of the roof and it is lit by pushing on one side of the lamp transparent surface.

1

TH004103

4

2--6

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION SAFETY BELT Pull the seat belt (2) slowly from the left and place the buckle into the anchor point (1) at the right hand side of the seat (if the belt LOCKS during this operation, slowly return the belt to the rest position and repeat the procedure). In the event of hard braking, the belt will LOCK and restrain you from excessive forward movement.

The belts may be sponged down with clean soapy water. Do not use solvents, bleach or dye on the belts, as these chemicals will weaken the webbing.

1

2

TH002090

5

WARNING

Replace the seat belt when it shows signs of fraying, damage or general wear.

EXTINGUISHER The location arrangement for the fire extinguisher is on the cab left central beam as indicated by the arrow.

The fire extinguisher equipping the machine must comply with local regulations.

Make sure that it is constantly kept in perfect working conditions and that the operating instructions provided by the manufacturer on the fire extinguisher itself have been properly understood.

INSPECTION AND CARE EVERY MONTH -- It is recommended that you inspect the fire extinguisher once each month for damage and to insure that the gauge is working correctly.

EVERY 6 MONTHS -- Have the dry chemical removed and refilled by a fire equipment technician.

ONCE EACH YEAR -- Have the fire equipment technician inspect the fire extinguisher.

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6

To use the fire extinguisher in the event of fire: • • •

remove the fire extinguisher form its support; remove the safety pin; press the control lever full stroke and direct the jet toward the base of the fire.

WARNING

Ventilate the area after use in enclosed spaces.

NOTE: Recharge after use, even if partial.

2--7

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION HANDLES AND WINDOWS

WARNING

Always lock the door in open position prior to using the handles connected to it.

Climb and leave the machine using the ladder and the appropriate handles illustrated in the figure.

TH002309

7 Cab door handles The cab is equipped with a lockable external door handle (1) and supplied with two keys. To operate, insert the door key into the lock and turn clockwise or anti--clockwise to lock or unlock.

1

TH002310

8 The internal door handles (2) are opened from inside of the cab by pulling the lever.

2

TH002296

9 Cab door opening window For normal operation, the lower half of the door and the upper half with window can be blocked together to make a single unit. By release of the window catch (3) the glass frame can be swung back and retained as shown below.

3 TH002297

10 2--8

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION The glass frame catch (2), when pushed fully rearward into the retainer (1) will remain locked open until the button (3) on the inside of the cab is pushed to release it.

1

2

TH002086

11

3 TH002087

12 Rear window 4 The rear window is locked by the handle (4). Rotate it to open.

TH002205

13 The rear window also acts as an emergency exit.

Should a situation occur that requires you to leave the inside of the cab urgently, pull the red loop (5) which releases the glass from the handle support.

5

TH002206

14 2--9

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION SEAT The seat is equipped with devices allowing adjusting seat pad inclination and height, backrest inclination and distance from controls.

WARNING

Before starting the machine adjust and block seats to the more convenient and comfortable position.

Regularly check safety belts. There must be no traces of fraying, wear or other weakening which could lead to breakage.

Remember always to fasten the safety belts before moving the machine.

1. The seat can be moved forward or back by shifting the lever to the right.

2. Turn the knob to the right to lift the seat, turn it to the left to lower it.

3. By turning the lever to the right you can adjust the seat suspension.

4. Safety belt with holder.

5. Fixing the seat belt.

6. By turning the knob to right or left you can tilt the backrest into the desired position.

5

1 4

2 3

TH002299

15

6

TH002089

16 STEERING WHEEL ADJUSTMENT HANDLE This handle makes it possible to adjust the steering wheel, and it is below the steering column.

--

Shift handle (7) upward to release and adjust the steering wheel.

--

Shift handle (7) downward to lock the steering wheel in the required position.

The fan and heating system control panel is located on the right--hand side cab wall, to the side of the operator’s seat.

7

TH002135

17

2--10

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION CAB CLIMATE CONTROLS 1 Ventilation control There is a three--speed blower for heat circulation inside the cab, controlled by the switch (1).

In position “ ” the fan is OFF. By turning the knob clockwise, the fan is operated at low speed, then the speed increases up to the 3rd speed.

NOTE: With the windows and doors closed, the blower may be used to pressurise the cab and to exclude dust.

2

TH002137

3 18

Heating control The temperature of the air from the heating system is adjusted using control knob (2). Turn the knob clockwise to increase air temperature and counter clockwise to reduce it. To heat the cab, the engine must be at an adequate operating temperature. To heat the cab, the air conditioning system must be switched off by pressing button (3) or moving the fan knob into position “ ”.

WARNING

The cab air filters are designed to remove dust from the air but may not be effective for chemical vapours.

When working in an enclosed area, ensure there is adequate ventilation as exhaust fumes can suffocate you.

Demisting and defrosting To obtain a fast demisting/defrosting of the front, side and rear windows, proceed as follows: • switch on the fan at maximum speed with knob (1); •

turn knob (2) until maximum temperature is reached;

•

open the cab vents directing the hot air flow toward the windows.

NOTE: To obtain fast demisting/defrosting of the windows, let the engine run for at least 5 minutes.

2--11

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION CAB CONDITIONING CONTROLS (IF FITTED) Cooling To decrease the temperature inside the cab, proceed as indicated below: • close the cab door; •

press the button to switch on the conditioning system (3);

•

turn the knob (2) counter clockwise to decrease the air temperature;

•

turn the knob (1) clockwise to vary the fan speed.

Maximum cooling condition is obtained with the knob (2) turned completely counter clockwise and with the knob (1) turned completely clockwise (3rd speed).

NOTE: R--134a is the only coolant acceptable to your machine air conditioning system.

Demisting and defrosting To obtain a fast demisting/defrosting of the front, side and rear windows, proceed as follows: • reach the air conditioning system through knob 3; •

insert the fan at maximum speed through knob 1;

•

actuate knob 2 until maximum temperature is reached;

•

open the cab vents directing the hot air flow toward the glasses.

2--12

2

3

1

TH002139

19

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION AIRFLOW VENTS Airflow vents are conveniently positioned in the cab and may be independently adjusted, as required, to direct warm or cold air into the cab interior as required.

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

Air re--circulation Air re--circulation is recommended in conditions of high ambient temperature or humidity to reduce the load on the air conditioning system by passing already cooled and dehumidified air over the evaporator.

NOTE: The air conditioning can be operated with the cab heater on to eliminate moisture on a damp morning, but this action will not cool the cab.

To cool the cab on a hot day, ensure the cab heater is turned off.

If the Telehandler has been parked in the sun, quicken the cooling by operating the air--conditioning for 2--3 minutes at its coldest setting. Set maximum blower speed with a window left partially open to force most of the warm air from the cab.

With the air cooled sufficiently, close the window and adjust controls to the desired temperature. To ensure a correct operation of the system, make sure that the filter is regularly cleaned. Refer to maintenance Section 4.

It is the normal function of the air--conditioner to extract water from the air. As such it is possible that pools of water will collect beneath the drain hose outlets under the cab when the machine is stationary.

TH002166

20

TH002301

21

TH002300

22

TH002168

23 2--13

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION SUN VISOR Pull the visor forward and hook it to the catches on the roof crossmember. To retract the visor, unhook it and accompany it back to its seat. The spring device will rewind it back.

COOLANT R134a

WARNING

R--134a can be dangerous if improperly handled.

Therefore it is important to comply with the following warning and directions.

R--134a has a boiling point of –12 ° C. Never expose any part of the air--conditioner system to flame or excessive heat because of the risk of fire or explosion, and the production of phosgene gas.

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

Should the coolant come in contact with the skin use the same treatment used in the case of frostbite.

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

If coolant should contact the eyes wash immediately with cold clean water for at least 5 minutes and consult a doctor immediately.

2--14

TH002169

24

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION CAB INSTRUMENTS AND CONTROLS This section details the location and function of the instruments and related switches on your machine.

Before attempting to drive or operate the machine study this section carefully.

IMPORTANT: Switch and gauge positions may vary slightly from that shown: they are dependant upon options fitted and local market requirements.

3

1

2

6

7

4

5

8

TH002302

25 1.

Left side control panel.

4.

Right side control panel.

2.

Wheel--alignment operating lever.

5.

Key start switch.

3.

Instrumentation comprising: S Tachometer; S Hour gauge; S Engine temperature gauge; S Fuel gauge; S Warning lights panel.

6.

Powershift transmission control lever.

7.

Multifunction switch for turn indicators and road lights.

8.

Load monitor display.

2--15

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION STEERING GEOMETRY SELECTOR IMPORTANT: Before selecting one of the three possible steering positions, bring the four wheels into alignment, i.e. in the straight--ahead position.

A B

The rear wheels are aligned with the machine’s axle when the green lamp (1) is on.

C

On Telehandlers, the wheel alignment sensor is installed only on the rear axle. The front wheels must be aligned by eye.

A -- TWO--WHEEL STEERING -- Move the steering mode selection lever into position “A” for road travel (2--steering wheels), turn the steering wheel to verify that it is operating and check that the relevant indicator light (1) is ON on the instrument panel (rear wheels aligned).

B

C

A

B -- 2+2--WHEEL STEER. Shift the control valve lever to position B for wheel steering selection in pairs (or double steering).

C -- CRAB STEER -- Shift the control valve lever to position C to select the steering mode that allows diagonal movement (crab steer).

TH55R301

26 Wheel alignment procedure --

---

---

Procedure must be carried out with machine at a standstill, transmission in neutral and engine running.

Move the steering mode knob to position ’C’ or ’B’ (depending on how wheels were set previously).

Turn the steering wheel to check activation and ensure that the associated instrument panel indicator lamp (1) goes on (rear wheels aligned).

Once wheels are aligned, select position ’A’ for on--road operation.

Complete the procedure by aligning the front wheels by eye.

A

B

C

NOTE: carry out the wheel alignment procedure at least once a day and whenever the steering system does not respond to the selected steering mode.

1 TH002112

27

2--16

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION INSTRUMENT CONSOLE IMPORTANT: Gauges and switches mounted in the instrument panel may vary in position from that shown in this manual. This is dependent upon model and options fitted. Ensure you are familiar with all the functions before operation.

Engine coolant temperature gauge with warning buzzer The engine coolant temperature indicator (1) responds to a sensor fitted in the engine. During normal operation the indicator will tend to rise from the low point of the green segment to the centre of the gauge. When operating under heavy load conditions, the indicator may continue to rise just below the red segment and return to a lower position when normal machine operation is resumed.

Should the indicator rise into the red segment, a warning buzzer will sound. Stop the engine immediately and investigate the cause. Normal operations can be resumed once the engine has cooled sufficiently or the cause corrected.

1

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28

NOTE: When the key--start/stop switch is turned off, the gauge needle assumes a random position.

Tachometer and Hour Meter The tachometer (2), graduated to 3,000 rev/min is driven from the alternator and reflects true engine speed.

2

The hour meter (3) situated in the lower half of the tachometer reflects hours of engine operation and is driven from the alternator when running.

TH002114

3 29

2--17

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION Fuel level gauge

1

This instrument (1) indicates the fuel level in the tank in a continuous manner, but it operates only when the key starter switch is ON. NOTE: When the key--start/stop switch is turned off the gauge needle may assume a random position.

TH002115

30 WARNING LIGHTS -- 1st segment 2. Alternator charge warning light: the alternator charge warning light illuminates when the key start is turned on and will remain on until the engine is started. Once started the alternator is charging the battery and the lamp will be extinguished.

3. Engine oil pressure warning light: this indicates low oil pressure and should extinguish immediately after the engine starts. Should the oil pressure drop below the predetermined level, the warning light will illuminate.

4. Brake reservoir oil low level indicator lamp The warning light illuminates when the oil level in the reservoir is at a LOW LEVEL. If the lamp illuminates at any time, stop the machine immediately and investigate the cause, correct or top up with new oil to the level specified. To test the warning light, refer to the maintenance section of the manual.

WARNING

Corrective action must be taken immediately when this lamp illuminates. If not, failure of the brake system could occur, resulting in serious injury to yourself and others.

IMPORTANT: If the machine is left to run with the warning light ‘ON’ engine performance and fuel consumption will suffer.

5. Thermostart heater light: with the key start ‘ON’ this light is illuminated during the warm up period of the thermostart heater element. The light is extinguished once the temperature is achieved when the engine can be started.

2--18

2

3

4

5

TH002116

31

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION WARNING LIGHTS 2nd segment 1. Transmission oil temperature warning light Should the transmission oil temperature exceed a predetermined level the warning light will illuminate.

WARNING

If the light stays ‘on’, stop the engine as soon as possible and investigate the cause. Do not continue to drive the machine as failure of the transmission could occur and result in serious injury to you or bystanders.

1

2

3

4

TH002117

32 2. Transmission oil pressure indicator light The indicator light comes ON when the transmission oil pressure drops below the pre--determined value.

If the warning light illuminates, place the transmission in neutral and stop the engine immediately.

Check that oil level is correct and adjust as required.

If oil is lost or oil level is extremely low DO NOT ATTEMPT TO DRIVE THE MACHINE. Contact your dealer to investigate and consult the manual should it be necessary to tow the machine.

3. Park brake warning light.

The warning brake is illuminated when the parking brake is applied and the ignition is switched ON.

WARNING

Do not attempt to disconnect the warning apparatus in any way. Do not attempt to drive the machine with the parking brake applied, as serious damage to the machine brakes with possible failure will occur. This could result in serious injury to you and other people.

4. Rear wheel alignment indicator light.

The indicator light goes ON when the rear wheels are aligned.

2--19

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION WARNING LIGHTS -- 3rd segment

TH002118

1 2

1. Main beams 2. Direction indicator lamps

33

WARNING LIGHTS -- 4th segment They indicate which is the steering scheme currently selected:

TH002119

3

4

5

3. Two steering wheels (front ones) 4. Bias translation (crab steer) 5. Four steering wheels

34

2--20

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION LOAD STATUS INDICATOR PANEL The load status indicator panel warns the operator when the machine reaches the maximum authorised load condition.

WARNING

Any attempt to lift loads beyond this will result in an unsafe and unstable condition.

A -- GREEN SIGNAL LIGHT The two green LED’s warn that stability is decreasing, but nevertheless regular. During normal operations LED condition is continuously updated and shows the current situation.

C

B

B -- YELLOW SIGNAL LIGHT (VISUAL ALARM) A The yellow LED’s warn of a critical condition of the stability, instability level is approaching 100% (overturning).

DANGER

Operator’s intervention is required to remedy situation. It is necessary to attempt lowering the centre of gravity of the vehicle.

Continue lifting along the arc, which effectively shifts the load nearer the centre of gravity of the machine, or retract the telescopic arm if it is in an extended position, to move the load nearer the machine centre of gravity.

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D 35

C -- RED SIGNAL LIGHT (VISUAL AND SOUND ALARM) The signal light illuminates when the machine reaches 100% of its maximum authorised load capacity.

The audible alarm sound simultaneously with the red light signal illuminated.

This alarm coming on locks all the hydraulic functions relating to the handling of the load and the raising of the stabilizers.

WARNING

Under these conditions the boom must be retracted or raised to return into safe conditions.

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36

2--21

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION D -- TEST SWITCH Operation of this, switch tests the alarm and illuminates the warning lamp to ensure all is working correctly. Check each day before commencing work.

Should any of the devices malfunction, in the interest of yours and bystanders safety, do not attempt to use the machine as a loader until a repair has been performed.

C

B

A

TH001053

D 37

2--22

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION MULTI--FUNCTION LEVER Direction indicator stalk The direction (turn) indicators are operated (with the key start on) by the stalk switch (1) mounted to the right of the steering wheel.

--

When pulled UPWARD: THE LEFT HAND INDICATOR WILL FLASH.

--

When pushed DOWNWARD: from the neutral position the RIGHT HAND INDICATOR WILL FLASH.

1

TH002120

38

The warning light will flash when the direction indicators are flashing.

High beam/Low beam selector When the low beam headlights are on, push the stalk (1) forward from the central position to turn on the high beams and the related warning light on the console will illuminate.

Pulling the lever toward you obtain the high beam flashing function.

Front windscreen wiper Turn the lever to operate the windscreen wiping function (position 1), turn the lever the other way round (position 0) to deactivate the function and the wiper will be brought back to its rest position.

1

TH002121

39 Front windscreen washer Depress button (2) located at the outside end of the multi--function lever to operate the front windscreen washing function.

2

TH002122

40 2--23

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION SWITCHES SWITCHES (right side control panel) IMPORTANT: Switch positions may vary slightly from those shown, or it is possible that not all the shown switches are actually present since they depend upon the model and options installed on the machine.

All switches are internally illuminated with ignition ON and will become brighter when each individual function switch is selected.

1. Control mode selection switch: -- site; -- road.

2. Attachment electric control.

3. Optional rear wiper/washer. The function is activated by pressing the button.

4. Hydraulic function cut--off (optional) 5. Slow moving warning beacon – Depressing this switch operates the function of the roof beacon.

6. Road lights – three--position switch -- Off -- Sidelights -- Main/dipped beam headlights Main and dipped beam headlight selection is possible with the multifunction lever previously described.

7. Hazard flasher switch – Selected when required to warn of a hazard.

8. Front work light (2--way switch) – The front light comes ON when actuated 9. Rear work light (2--way switch) – The rear light comes ON when actuated 10. Trailer brake indicator light (optional).

The indicator light comes on, when the service brake is applied.

2--24

1

TH55R236

2

3

4

5

6

7

8

9

10 41

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION SWITCHES (left panel) IMPORTANT: The rocker switch position may vary slightly or may not be all available from that shown.

They are dependant upon the model and options fitted to your machines.

1. Supplementary lights (optional) assembled on telescopic arm.

2. Left stabiliser (3--position rocker switch). When the switch is in idle position (central) no function is activated. When the button upper side is pressed, the left stabiliser is lifted; when the button lower side is pressed, the stabiliser is lowered.

3. (3--position rocker switch). This switch controls the axle front levelling cylinder and makes it possible to change the vehicle tilting along the longitudinal axis. When the button upper side is pressed, the vehicle will tilt on the right--hand side; when the button lower side is pressed, the vehicle will tilt on the left--hand side.

1

2

3

4

TH55R237

42

4. Right stabiliser (3--position rocker switch). When the switch is in idle position (central) no function is activated. When the button upper side is pressed, the right stabiliser is lifted; when the button lower side is pressed, the stabiliser is lowered.

2--25

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION OPERATIVENESS SELECTION SWITCH This switch on the right hand panel of the machine allows to select operative hydraulic control modes, it has two positions and works ad described below.

A. “Road” position. This locks out all the operations of the arm, stabilisers and levelling. These settings correspond to the safety requirements for travelling on the road. When travelling on the road the other requirements must be complied with (arm, stabiliser guards position, etc.), before selecting this position. After selecting this position and checking the correct operation of the steering, wheel alignment and other settings for road travelling. The driver can therefore move the car.

B. “Jobsize” position. This is the position enabling all the normal cab controls; all the hydraulic control equipment is active. This is the position used in normal work conditions.

2--26

B

A TH002303

43

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION 4 X 3 POWERSHIFT TRANSMISSION Transmission control The transmission assembled on this machine is called Powershift.

The Powershift transmission lever is mounted on the left--hand side of the steering column and enables the electronic selection of four forward speeds and three reverse speeds.

TH002304

44 HORN The horn is operated by pushing on the button (1) at the end of the transmission lever.

1 TH002305

45

DRIVING WITH THE POWERSHIFT TRANSMISSION

A

Neutral position Select the neutral position by shifting the transmission lever to the centre.

N

Forward selection To select forward pull the lever toward the steering wheel and push it upward.

Selecting the reverse gear

R

TH002091

46

To select the reverse gear, pull the lever toward the steering wheel and push it downward.

2--27

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION Up shifting Up shifting from1st gear position to the required gear is achieved by twisting the handgrip (1) counter clockwise in single movements.

1

NOTE: if ascending a steep incline, select 2 nd gear and proceed; if speed and power allow, you can upshift into 3 rd and 4 th.

TH002173

47 Down shifting Downshifting to the desired gear is achieved by twisting the handgrip clockwise in single movements.

Direction changes Changing driving direction is achieved simply by shuttling the Powershift lever fromforward to reverse and the other way round, which is allowed at any time only in first gear.

WARNING

INVERSION OF DIRECTION IS ALLOWED ONLY IN FIRST GEAR.

2--28

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION TRANSMISSION DISCONNECTION The cutting--off of the transmission occurs through the NEUTRAL position of Powershift lever (1) as described at page 2--26.

1

TH002150

48 The speed ranges illustrated are calculated with wheels 400/80--24 T37. * Except Countries.

different

specifications

for

foreign

TH002141

49 PARKING BRAKE

WARNING

To prevent potential damages to mechanical components, do not engage the parking brake with the machine in motion.

Every time a stop occurs, move the gearshift lever into neutral and engage the parking brake.

TH002085

50

2--29

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION OPERATING THE ENGINE IMPORTANT: Certain machine functions have been classed as critical. In the case of malfunction, an audible alarm will sound and a warning light will illuminate until the malfunction is corrected or the key--start/stop switch is turned off. These functions are: •

Transmission oil pressure

•

Engine oil pressure

•

Brake reservoir oil level.

In the event of a fault occurring in one of the above functions while engine is running, stop the machine and correct the fault.

KEY--START AND STOP SWITCH NOTE: When the key--start/stop switch is turned to the “ON” position (2), an audible alarm will be activated until the engine is started or the key returned to the OFF position (1).

The machine has a three--position key--start/stop switch: 1 = OFF 2 = ON 3 = Engine start (Cranking) The key--start/stop switch on your machine also activates an electro--magnetic engine stop on the injection pump. Turning the key--start/stop switch to position (2) energises and lifts the valve allowing fuel to enter the pumping head of the fuel pump. Returning the key--start/stop switch to position (1), de--energises the valve, closing the fuel gallery of the pumping elements. Fuel is no longer injected into the engine and the engine stops.

1 2 3 TH002128

51

2--30

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION STARTING THE ENGINE IMPORTANT: Never push or tow the machine to start the engine. Doing so may overstress the drive train.

Prior to starting the engine, carry out the following: •

Sit in the driver’s seat;

•

Ensure the parking brake is applied;

•

Ensure the Powershift lever is in neutral;

•

Ensure the front loader is positioned on the ground.

WARNING

Check the area beneath the equipment to ensure that not injury or damage will be caused when the equipment is lowered.

NOTE: During engine start up the Powershift transmission will be forced to the NEUTRAL position. If the transmission lever is in a different position, it will be necessary to take to the NEUTRAL position and successively to the desired gear.

Should the engine fail to start, wait for 30 seconds before a new attempt. This is to prevent the batteries and the starter motor from overheating.

2--31

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION Under cold climates or when the engine is not warmed--up: •

Move the starting key into position 2 (activation).

•

Wait for the cold starting indicator completing the engine pre--heating phase.

•

Once the cold starting indicator light goes off, move the pedal throttle to half stroke and turn the starting/cut off switch fully clockwise into position 3. Operate the starter motor until the engine starts, then release the key and let it return into position 2.

In warm weather or when the engine is hot: •

•

1 2

Open the foot throttle halfway and turn the key-start/stop switch fully clockwise to position (3), operate the starting motor for a maximum of 60 seconds or until the engine starts, then allow the key to return to position (2).

Return the throttle to the idle position and check that all the warning lights go out and gauge readings are normal.

NOTE: When the key--start/stop switch is turned off, the gauge needle assumes a random position.

IMPORTANT: If the machine has been laid up for a period of four weeks or longer, without use, of if for any reason the Turbocharged oil supply tube has been disconnected, refer to the procedure outlined in “Preparing the machine after storage” in General Maintenance.

2--32

3

TH002129

52

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION STARTING THE ENGINE WITH JUMP LEADS WARNING

Operate the starting motor only from the operator’s seat. If consent to start is by--passed the engine may be started inadvertently with the transmission in gear.

Wear eye protection when charging the battery or starting the machine engine with a slave battery.

If it necessary to use jump leads with an external battery to start the machine, proceed as follows:

•

Connect one end of the jump lead to the machine 12 volt battery positive (+) terminal and the other to the auxiliary 12 volt battery positive (+) terminal.

•

Connect one end of the second jump lead to the auxiliary 12 volt battery negative (--) terminal and the other end to the machine engine block: following this procedure will prevent sparks occurring near the batteries. Follow the starting procedure previously described.

NOTE: When using a slave battery to start the engine ensure that the polarity is correct otherwise the alternator may be damaged.

•

When the engine starts allow it to run at idle speed, turn or all electrical equipment (lights, etc.) then disconnect the jump leads in the reverse order to the connecting procedure. This will help protect the alternator from damage due to extreme load charges.

NOTE: Your machine has an electromagnetic engine stop, it is therefor not possible to operate the machine without a battery installed. The machine will shut down when the power supply to the electromagnetic stop is disconnected (battery removed).

2--33

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION STOPPING THE ENGINE NOTE: Turbocharged engines only – Before stopping, idle the engine at 1,000 rev/min for approx. two minutes. This will allow the turbocharger and manifold to cool and prevent possible distortion of components.

To stop the engine, carry out the following procedure: •

Release the foot throttle.

•

Apply the parking brake.

•

Place the Powershift lever into NEUTRAL.

•

Lower the loader.

•

Turn the key--start/stop switch to the OFF position.

WARNING

Check the area beneath the equipment to ensure no injury or damage will be caused when the equipment is lowered.

RUNNING--IN PROCEDURE Your new machine will provide long and dependable service if given proper care during the first 50--hour running--in period and services at the recommended intervals.

To ensure adequate lubrication, idle the engine at 1,000 rev/min, for one minute before placing a load on the engine. Do not race the engine during the one--minute warm--up period.

After the engine has warmed sufficiently, cycle the loader cylinders several times to warm up the hydraulic system oil.

Avoid prolonged operation at either high or low engine speeds without a load on the engine.

2--34

Avoid overloading the engine. Operating in too high a gear under heavy load may cause excessive engine overloading. Overloading occurs when the engine will not respond to a throttle increase.

Use the lower gear rations when moving heavy loads and avoid continuous operation at constant engine speeds. Operating the machine in too low a gear with a light load and high engine speed will waste fuel. You will save fuel and minimise engine wear by selecting the correct gear ratio for each particular operation.

Check the instruments frequently and keep the radiator and oil reservoirs filled to the recommended levels. See details on section 4 of this manual.

Daily checks during running in include: •

Radiator coolant level

•

Engine oil level

•

Hydraulic system oil level

•

Transmission oil level

•

Axle oil level

•

Axle hub oil level

•

Transfer box

•

Loader lubrication fittings

•

Engine cleaner restriction indicator lights

•

All wheel nuts for tightness

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION DRIVING THE TELEHANDLER WARNING

Observe the following precautions when driving the machine.

WARNING

Do not attempt to descend a gradient with the transmission in neutral. Always choose and engage the most suitable gear to maintain adequate speed while using engine braking and the brake pedal to avoid any risk of loss of control of vehicle.

WARNING

•

Always drive with care and at speed compatible with safety, especially when operating over rough ground, crossing trenches or slopes, or when turning.

•

Always sit in the driver’s seat while starting or driving the machine.

•

Always wear your seat belt.

Do not use the machine with the engine running at more than 2400 rpm (corresponding to travel speed of 35 km/h). If this should occur, reduce speed immediately by releasing the accelerator pedal and pressing the brake pedal.

Using the vehicle at speeds of 2400 rpm or higher can lead to serious damage and will result in invalidation of repair under the terms of the warranty due to improper use of the vehicle.

TH002130

•

Always use transport chains when transporting the machine.

•

Dip the lights when meeting a machine at night.

Ensure the light are adjusted to avoid blinding an oncoming driver.

•

Avoid accidental contact with the gearshift lever while the engine is running. Unexpected machine movement can result.

•

In countries where legislation applies, use a rotating beacon and bucket tooth guards when travelling on public roads both day and night.

Refer to on Road requirements.

TH002131

•

Never allow the machine to over run when going downhill.

•

Any towed machine the total weight of which exceeds that of the towing machine must be equipped with brakes for safe operation. Ensure compliance with local regulations.

2--35

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION TRANSPORT WARNING

Do not stand in the action area of the loading zone of the telehandler on the transporting vehicle.

2

Use vehicles adequate for the task Load and unload the machine in a flat and firm area ensuring a safe standing for the wheels. Use ramps of an adequate strength, angle and height. The loading surface must always be kept clean and free from any trace of clay, oil or any other slippery materials.

Before loading or unloading the machine, make sure that the parking brake of the transporting vehicle is engaged and that the wheels of the vehicle are blocked. Have a flagman standing in a safe place, who can keep the ramps under control, the loading surface, the machine and the operator.

It is suggested that the loading and unloading from the trailer be done by a specialised person. The operator could not be skilled enough.

Lift the equipment from the ground just enough to prevent obstructing the manoeuvre.

Keep the engine at a low speed so that the machine climbs slowly the ramps and the loading surface.

Limit the use of the accelerator and steering controls to the minimum required.

Once the machine is loaded on the loading surface, lower the equipment, engage the parking brake and implement the entire procedure recommended for cutting--off and leaving the machine.

Block the wheels of the Telehandler with wedges (1) and secure it with safety chains (2).

2--36

1 TH002132

53

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION LIFTING Use a crane with a capacity sufficient to lift the machine (including the accessories if installed).

It is recommended that the lifting be done using the four lifting points provided for this purpose.

Before lifting check that all doors, cab and other mobile parts are secured.

Stay at a safe distance during lifting.

TH002307

54

Beware of crushed or folded chains or cables: do not use them for lifting or towing. Always wear heavy gloves when handling them.

The chains must be firmly secured: ensure that the connection is strong enough to hold the expected load. There must be no one in the vicinity of the connection, the chains or the tow cables. DO NOT PULL OR TOW WHEN THE OPERATOR CABS OF THE MACHINES INVOLVED ARE NOT EQUIPPED WITH THE NECESSARY PROTECTIONS AGAINST “WHIPLASH” OF THE CHAINS OR CABLES IF THEY WERE TO BECOME DISCONNECTED OR BREAK.

TH002308

55

2--37

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION CLEANING WARNING

Do not use cold water on a hot engine. Allow engine to cool to ambient temperature before cleaning, as damage to components such as fuel pump and other equipment may occur.

When the soft trim material inside the cab becomes dirty, it should be wiped clean. Dip a cloth in a warm water/detergent solution and wring out as much of the water as possible.

The floor matting should be cleaned with a vacuum cleaner and/or a stiff brush. If necessary a damp cloth may be used to remove obstinate stains. Allow the matting to dry naturally and avoid getting water under the mat.

External plastic parts, such as fenders and the roof, should be cleaned using warm water and a little detergent and rinsed with clear water.

MACHINE STORAGE When storing overnight, relieve oil pressure. Fully retract the extendible arm and let the boom down until the bucket comes to rest on the ground.

With engine stopped, activate the control levers to relieve any residual oil pressure in the extension cylinder.

WARNING

Always lower the loader bucket/attachment to the ground, shut off the engine and apply the parking brake before getting off the unit. Never get off the unit while it is in motion.

2--38

TH002133

56 NOTE: If using a high pressure washer to clean the machine, avoid aiming the jet directly at oil fill points, breathers, seals, instruments, decals and electrical connectors.

SECTION 3 FIELD OPERATION BEFORE OPERATING Read this section thoroughly. It details the operation and handling of loads with your Telehandler. Do not start the engine or attempt to drive or operate the machine unless you are fully accustomed to the controls.

IT IS TOO LATE TO LEARN ONCE THE MACHINE IS MOVING

CONTENTS OF THE SECTION Description

Page

Front loader controls/operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2 Load status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3 Load handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5 Installing attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--8 Ballasting and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--11 Weighting of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--12

3--1

SECTION 3 -- FIELD OPERATION FRONT LOADER CONTROLS / OPERATION MANIPULATOR ON--OFF CONTROL

WARNING

Study the safety precautions before operating the loader. Ensure that you are thoroughly familiar with the loader operating techniques before attempting to operate.

1

TH003098

1

To lift/ lower the arm and recall/turn over the attachment, move the lever (1) as indicated below: -- Forward to lower the arm; -- Backward to raise the arm; -- Leftward to call back the attachment; -- Rightward to overturn the attachment.

2 L

R

WARNING

3

To prevent the oil from overheating and/or uncontrolled movements of the tool, do not raise the arm at the same time as the tilt control when the tilt cylinder is in the end of travel position.

Two buttons are located near the upper part of the lever (1) which extend and retract the telescopic arm.

The telescopic arm is retracted when button (2) on the R (right) side is pressed; whereas the telescopic arm is extended when button (2) on the L (left) side is pressed.

Buttons (3 and 4), situated respectively on the front and rear of the manipulator lever (1) allow any auxiliary function to be used.

1

TH003099

2

4

TH03065

3

3--2

SECTION 3 -- FIELD OPERATION LOAD STATUS INDICATOR PANEL The load status indicator warns the operator when the machine reaches the maximum authorised load condition.

C

B

WARNING

Any attempt to lift loads beyond this will result in an unsafe and instable situation.

A

A -- GREEN SIGNAL LIGHT The three green LED signal situations of a decreasing stability, but still normal. During normal operations, the state of the LEDs is continuously updated and reports the current situation of the load on the rear axle.

TH001053

D 4

B -- YELLOW SIGNAL LIGHT (VISUAL ALARM) The two yellow LEDs signal a critical stability situation. The rear axle sensor monitors a minimum load, near zero, thus the instability is approaching 100% (tipping over).

DANGER

Operator’s intervention is required to remedy the situation. It must be attempted to lower the vehicle centre point.

Continue lifting along the arc through which the weight is effectively moved, the nearest possible to the machine centre of gravity or retract the telescopic arm if it is in extended position, in order to move the weight the nearest possible to the machine centre of gravity.

TH001129

5

3--3

SECTION 3 -- FIELD OPERATION C -- RED SIGNAL LIGHT (VISUAL AND SOUND ALARM) This signal light illuminates, when the machine reaches 100% of its maximum authorised load capacity. The sound alarm sounds simultaneously with the red signal light.

Illumination of this alarm causes the locking of all the hydraulic functions relating to load manipulation and stabiliser lifting.

Under these conditions the boom must be retracted or raised to return into safe conditions.

C

B

A

D -- TEST SWITCH Operation of this switch tests the alarm and illuminates the warning lamp to ensure all is working correctly. Check each day before commencing work, and if either are not functioning correctly, in the interest of your safety and that of bystanders, do not attempt to use the machine as a loader until it has been repaired.

3--4

TH001053

D 6

SECTION 3 -- FIELD OPERATION LOAD HANDLING 1 LOAD HANDLING at ground level 1. Approach the load to be lifted with the jib retracted and the forks in a horizontal position.

2 2. With the brake ON and gearshift in neutral, adjust the fork spread to the maximum possible, to lift the load.

3 3. Extend the arm and raise the forks stopping in front of the load. If necessary lift slightly the arm when lifting the load.

4

4. Lift the load slightly from the ground, tilt the forks rearword and fully retract the telescopic arm.

5

LOAD HANDLING at a high level 5. Ensure that the forks will easily pass under the load.

IMPORTANT: Always think about the distance between the stack and the front of the Telehandler necessary to fit the forks under the load. Use the shortest possible length of the arm.

6

6. Drive slowly forward with the forks, stopping in front of the load; apply the parking brake and place the gear lever in neutral.

TH003045

7

3--5

SECTION 3 -- FIELD OPERATION 7. Lift the load slightly and tilt back the load to stabilise it.

8. Reverse the Telehandler and bring the load into the transport position by retracting the arm and then by lowering the arm.

7

8

9. Slowly approach the area, in transport position, where load is to be set down.

9

TH003046

8

3--6

SECTION 3 -- FIELD OPERATION LOAD HANDLING High level 10. Lift and extend the arm until the load is above the stack, if necessary move the Telehandler closer to the stack, apply the parking brake and place the reversing lever in neutral.

10

11. Place the load in a horizontal position and lay the latter down on the stack by lowering and retracting the arm, in order to position the load correctly.

Free the forks by retracting and lifting alternately the arm or, if possible, by reversing the Telehandler.

11

Return the arm and forks to transport position.

LOAD HANDLING Round loads 12. Tilt the forks forward and extend the arm during this operation, tilt the forks backwords to slip under the load. As necessary wedge the load.

12

LOAD HANDLING Load status indictor 13. Always watch the load status indicator when handling a load.

13

Should the indicator signal a warning, as safely as possible, retract the arm and lower the arm to the ground.

NOTE: If not fitted, an automatic cut out option is available. Consult your dealer.

BUCKET USE 14. The use of the bucket is allowed exclusively with the boom completely retracted.

TH003047

9

3--7

SECTION 3 -- FIELD OPERATION FITTING THE ATTACHMENTS FITTING AN ATTACHMENT (WITH HYDRAULIC LOCK) The attachment locking pin (1) and the clip (2) must be retained in the positions shown until required.

2

1

TH003144

10 Fitting the attachment: position the machine with the boom lowered in front and parallel with the attachment and tilt the quick coupling forward.

Move the quick coupling under the attachment lock plate, lift the boom slightly, tilt the trolley backward to position the attachment.

TH003028

11 Lift the attachment from the ground in order to lock it.

TH003029

12 HAND LOCKING OF ATTACHMENT Insert the locking pin (1) in the quick coupling and secure it with the stopper (2).

REMOVING THE ATTACHMENT

2

Proceed in inverse order to fitting an attachment, making sure to store the latter in closed position and flat on the ground.

1 TH003145

13 3--8

SECTION 3 -- FIELD OPERATION FITTING AN ATTACHMENT (WITH HYDRAULIC LOCK) Make sure that the attachment is in a position such to allow the locking of the quick coupling.

Check that the rods of the locking cylinder (1) are retracted.

1

TH003141

14 Position the machine with the boom lowered in front and parallel with the attachment and tilt the quick coupling forward.

Move the quick coupling under the attachment lock plate, lift the boom slightly, tilt the quick coupling backward to position the attachment.

Lift the attachment from the ground in order to lock it.

TH003031

15 HYDRAULIC LOCKING (OPTION) Connect attachment--locking hoses to the quick release couplings.

IMPORTANT: Before connecting or disconnecting hoses to the quick release couplings always stop the engine.

TH003140

16 Press the button (1) on the loader control lever to let out the blocking rods.

WARNING

Check the correct extraction of the locking rods and the subsequent positive hooking of the attachment prior to operating the machine.

1

TH003100

17 3--9

SECTION 3 -- FIELD OPERATION HYDRAULIC RELEASE OF THE ATTACHMENT Ensure the attachment locking hoses are connected to the quick release couplings.

IMPORTANT: Before connecting or disconnecting hoses to the quick release couplings always stop the engine.

DANGER

Do not retract the blocking rods with the arm raised, but lower the attachment to the ground first so that it cannot fall, causing serious and even mortal injuries.

TH003140

18

Press the button (1) on the loader control lever to retract the blocking rods.

REMOVING THE ATTACHMENT

1

Proceed in inverse order to fitting an attachment, making sure to store the latter in closed position and flat on the ground.

TH03075

19 AUXILIARY HYDRAULIC SERVICE The auxiliary hydraulic couplings, when not in use by the hydraulic locking plate can be used on other applications.

With the engine off, disconnect the hoses from the quick release couplings and connect them to the attachment you wish to run using this hydraulic service.

Restart the engine and, using the operating lever as above, run the attachment you have connected.

3--10

SECTION 3 -- FIELD OPERATION BALLASTING AND TYRES Water

Tyre size

Litres

Calcium Chloride kg

lb.

Total weight of solution per tyre kg

lb.

400/80--24 T37 405/70--24 14PR TL MPT--01 15R22.5 XF TL (H) 405/70--24 14PR TL MPT 4L I3 405/70--24 14PR TL MPT R--1 405/70--20 14PR TL MPT R--1 405/70--20 14PR TL MPT 4L I3 405/70--20 14PR TL MPT--01 * It refers to kgs of magnesium chloride

WARNING

LIQUID BALLAST Filling the front and rear tyres with liquid ballast is a convenient method of adding weight to the machine where greater traction or stability is required.

While it is an acceptable practice to add weight to the tyres using this method, IT IS NOT ACCEPTABLE TO FILL THE TYRES WITH FOAM UNDER ANY CIRCUMSTANCES.

To achieve this a solution of calcium chloride and water (which is recommended) can be added in the tyre. This mix replaces 75% of the volume of air in the tyre with the water / calcium mixture.

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.

20 The table above shows the quantity of calcium chloride and water required for each tyre size option and is based on 2.3 kg. of calcium chloride / water 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 –35 °C. IMPORTANT: When filling a tyre with calcium chloride/water solution the valve should be at the highest point of the wheel, figure 18.

IMPORTANT: When checking or adjusting air pressure, if the tyre is liquid ballasted, the valve should be at the lowest point, figure 19.

21 3--11

SECTION 3 -- FIELD OPERATION WEIGHTING OF MACHINE Weighting of wheels entails greater vehicle stability and a greater grip on the ground.

Depending on the weight and on the greater grip on the wheels, also the torque the whole transmission must withstand is increase. To avoid serious damage to motion transmission elements, loads on axles must be checked.

NOTE: When ballasting the machine do not exceed the gross machine weight as identified on the data plates; refer to Section 1 for plate position.

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.

Front axle maximum permissible loading for front axle, inclusive of ballast and loader in the raised position with a load of 4,000--kg (maximum capacity) in the bucket: Front axle

TX130--30 TX130--33

Static load rating

12900

@ 10 km/h

10500

@ 35 km/h

9600 TH003048

22

Rear axle maximum permissible loading: Rear axle Static load rating

TX130--30 TX130--33 /

@ 10 km/h

2400

@ 35 km/h

6550

TH003049

23 NOTE: Total rear axle weight is measured with only the rear wheels on the scales, while front axle weight is measured with front wheels on the scales.

3--12

SECTION 4 LUBRICATION AND MAINTENANCE This section covers all the service procedures necessary to maintain your vehicle. The lubricants and refrigerants that should be used are listed at the end of the manual.

On the following page are the items protected by warning lights that must be investigated should they illuminate between service intervals.

WARNING

Before any maintenance or service is performed on the vehicle ensure the parking brake is on and the wheels are chocked/blocked to prevent vehicle movement.

Whenever the vehicle is to be disassembled for maintenance ensure the key start or battery are immobilised to prevent engine start up.

WARNING

Do not mix different types of manufactured fluids or lubricants. Use only what is recommended for your vehicle as shown at the back of this Manual.

CONTENTS Description Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2 Daily checks required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--8 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--13 Every 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--14 Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--17 Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--19 Every 1000 hours or annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--25 Every 2000 hours or every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--29 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--33

4--1

SECTION 4 -- LUBRICATION AND MAINTENANCE GENERAL

At the first 50 hour service (when new) ensure the following service operations are carried out:

FILLING AND SERVICE POINTS

1. Front axle differential oil check

DIESEL FUEL TANK (11) CAPACITY 135 Litres

2. Tightness check for all wheel nuts 3. Transmission oil level check

HYDRAULIC RESERVOIR (12) OIL CAPACITY 185 Litres

4. Transmission oil filter change

NOTE: Ensure that the vehicle is on level ground and that the cylinders are in the transport position, before checking oil levels. The quantities and types of lubricant are listed at the end of the manual. To prevent dirt ingress when changing oils or filters, always clean the area around the filter, filters, level plugs and dipsticks before checking or charging.

5. Engine oil and filter change, refill to oil level 6. Fan belt tension check and adjustment 7. Rear axle differential oil level check 8. Hydraulic reservoir oil filter 9. Axle hubs x4 oil level check 10. Brake oil level check Inspect and grease all fittings

2

3

1

4

5

6

7

8

11

10

12

9

TH004294

1

4--2

SECTION 4 -- LUBRICATION AND MAINTENANCE ANALOGUE INSTRUMENT PANEL SERVICE WARNING LAMPS When the warning light comes on you must stop the machine and check the cause.

1

2

3

4

5

6

TH004121

2 1.

Battery charge low warning lamp

2.

Engine oil pressure low warning lamp

3.

Brake oil minimum level warning lamp

4.

Engine pre--heating indicator light (optional for cold climates)

5.

Transmission oil temperature (High) warning lamp

6.

Transmission oil pressure low warning lamp

4--3

SECTION 4 -- LUBRICATION AND MAINTENANCE DIESEL FUEL Before handling fuel, or filling tanks, observe the following: • Clean the filler cap area (1). Fill the tank at the end of each day to reduce overnight condensation.

•

Do not fill the tank to capacity. Allow room for expansion and wipe up spilt fuel immediately.

•

Never take the cap off or refuel with the engine running or hot.

•

When filling the tank, keep control of the nozzle and do not smoke.

•

If the original fuel tank cap is lost, replace it with an approved cap and tighten securely. A proprietary cap may not be safe.

•

Keep equipment properly maintained.

Use fuel with a minimum cetane rating of 40 (diesel fuel No. 2 at ambient temperatures above --7°C (20°F) or No. 1 below this temperature). At very low ambient temperatures and/or at high altitudes, a fuel with a higher cetane rating is required.

Precautions should be taken to ensure stored fuel is free of dirt, water, etc. Fuel should be stored in black iron tanks, not galvanised tanks, as the zinc coating will react with the fuel and form compounds that will contaminate the injection pump and injectors.

Bulk storage tanks should be installed away from direct sunlight and angled slightly so sediment in the tank will settle away from the outlet pipe. To facilitate moisture and sediment removal, a drain plug should be provided at the lowest point at the opposite end from the outlet pipe.

Fuel purchases should be arranged so that summer grade fuels are not held over and used in winter.

WARNING

Under no circumstances should gasoline, alcohol or dieselhol (a mixture of diesel fuel and alcohol) be added to diesel fuel because of the increased fire or explosion risks. In a closed container such as a fuel tank they are more explosive than pure gasoline. Do not use these blends. Additionally, dieselhol is not approved due to possible inadequate lubrication of the fuel injection system.

4--4

1 TH001366

3

SECTION 4 -- LUBRICATION AND MAINTENANCE ELECTRIC SYSTEM PROTECTION DURING CHARGING AND WELDING OPERATIONS

•

The welding machine wires must not be over, next or cross any electric wire or electronic component while welding is being performed.

Observe the following precautions to prevent damaging the electronic and electric systems: 6. Always disconnect the battery negative terminal when charging the car batteries with a charger.

1. NEVER do or cut off any charge circuit connection, battery connections included, when the engine is running.

2. NEVER earth any charging component.

3. DO NOT use an auxiliary battery with tension over 12V.

4. ALWAYS respect the correct polarity when batteries are installed or when an auxiliary battery is used to start the engine. Observe the instructions in the Operator’s Manual during jump starting. Connect positive to positive and negative to negative.

5. ALWAYS disconnect the battery negative terminal before making arc welding on the vehicle or any other instrument connected to it.

•

Place the welding machine earth terminal as closest as possible to the welding area.

•

If welding has to be done next to an electronic module, remove the latter from the vehicle.

You are recommended to have this operation performed by an authorised dealer.

WARNING

Batteries contain sulphuric acid. If it comes into contact with the skin, rinse abundantly with water for five minutes and call a doctor. Avoid contact with the skin, the eyes and clothes. Wear eye goggles when working next to batteries.

IMPORTANT: If the two battery earth wire connections are not disconnected before performing charging or welding operations on the vehicle or instruments connected to it, the electric and electronic systems will be seriously damaged.

4--5

SECTION 4 -- LUBRICATION AND MAINTENANCE NOTE: During the first 50- hour operation it is necessary to clean and lubricate the front loader arm sliding blocks every 10 hours.

NOTE: After the first 50- hour operation it is necessary to check and clean the air cleaner outer element, if needed.

IMPORTANT: anyway, the air cleaner outer element shall be cleaned in the event the “air cleaner obstruction” dashboard warning light should illuminate.

The following paragraphs describe daily maintenance operations to be performed in order to keep the vehicle efficiency.

The following elements should be checked and topped up every day: • • • • • •

Engine oil Radiator coolant Transmission oil Washer reservoir Hydraulic system oil Cylinder and bush lubrication.

Always maintain the battery terminals well tightened and protected against corrosion. Remove the battery and clean the terminals and the battery outer side with a weak mixture of ammonia or sodium bicarbonate diluted into water, if needed. Make sure such mixture does not get into the battery. Lubricate the battery terminals with vaseline to prevent rust formation (verdigris).

WARNING

Whenever the vehicle has to be disassembled to perform maintenance operations, make sure the engine has been immobilised to prevent start up.

IMPORTANT: Make sure that exhausted oil and exhausted oil filters are disposed of respecting human beings and the environment. Observe the local law in force.

As far as maintenance operation deadlines and details, make reference to the “Maintenance chart”.

4--6

NOTE: After the first 100 hours of operation, it is necessary to replace the gearbox oil filter.

SECTION 4 -- LUBRICATION AND MAINTENANCE SERVICING THE ENGINE AIR CLEANER A poorly maintained air cleaner will mean loss of power, excessive fuel consumption and reduction in engine life.

IMPORTANT: It is recommended to clean the outer element ONLY when the restriction indicator light illuminates or change it at the 500 hr Service interval.

Unnecessary and too frequent cleaning exposes the element to handling damage which could allow dust and dirt to by--pass the filter process and cause engine wear.

Extract the outer element (3) after having unscrewed the lid (1). If there is dust inside the outer element, the element must be renewed. If satisfactory, clean the element by tapping both ends on the palm of your hand. Do not tap the element against a hard surface as it may be damaged or distorted.

1

TH004161

4

Alternatively, compressed air, as a pressure not exceeding 2 bar may be used. Insert the air line nozzle inside the element and blow the dust from the inside to the outside. Blow loose particles from the outside of the element by holding the nozzle at least 150mm from the element. Protect the eyes when carrying out this operation.

NOTE: Do not remove the inner element (2). If, after cleaning the outer element (3), it has a sooty or oily appearance or if the air cleaner restriction warning light dose not extinguish or illuminates shortly after servicing, then the outer element (3) may require changing if damaged and/or the inner element needs replacing.

2

3

TH004162

5

Clean the inside of the air cleaner casing using a damp, lint--free cloth on a probe, taking care not to damage the inner element. Re--install the outer element ensuring that the rubber seal on the end is not loose or damaged.

4--7

SECTION 4 -- LUBRICATION AND MAINTENANCE DAILY CHECKS REQUIRED ENGINE OIL LEVEL Before checking the engine oil level, stop the engine and wait for a short period to allow the oil to drain back into the sump. Check the oil level with the dipstick (1).

1

IMPORTANT: Do not overfill beyond maximum oil level (keep oil in the safe zone on the dipstick).

If necessary, remove the filler cap (left--hand side of engine) and add oil through the filler tube. See Specifications for the recommended oil grade.

TH004277

6 RADIATOR COOLANT RECOVERY NOTE: Unless affected by leakage in the cooling system, topping up of the coolant is not necessary.

2

Your vehicle is equipped with a coolant recovery system and as long as coolant is visible (2) between the sight marks, topping up will not be required. During operation of the vehicle the heating and cooling process (expanding and contracting) of the coolant is expelled or retrieved by the radiator from the recovery tank.

WARNING

The cooling system runs under pressure and is hot.

Care must be taken when removing the radiator, expansion bottle cap or hoses if the engine is hot.

Coolant should be kept off the skin. Adhere to the precautions outlined on the antifreeze and inhibitor containers.

WARNING

The machine components and piping can reach high temperatures during operation. Therefore the machine should be switched off and left to cool down before carrying out checks and maintenance operations: risk of burns.

RADIATOR COOLANT During manufacture, an antifreeze solution containing a measure of chemical inhibitor is charged into the cooling system of your vehicle to provide protection from corrosion and freezing.

In the event of leakage, such as may occur with a failed heater or radiator hose, the chemically charged coolant will be lost. In this event, it is extremely important that any lost coolant is replaced by the correct coolant for your vehicle. Refer to lubricants and coolants at the back of the book or consult your local authorised dealer.

4--8

TH004081

7

SECTION 4 -- LUBRICATION AND MAINTENANCE TRANSMISSION OIL LEVEL Re--fill the transmission with the recommended type of oil approximately 17 Litres through the dipstick tube situated to the right of the engine block using the following procedure.

1

Check the level of the oil in the transmission at normal operating temperature, with engine at idle, with the gear lever and shuttle lever in neutral using dipstick (1). As necessary add oil and ensure it registers between the minimum and maximum marks on the dipstick.

WARNING

TH004279

8

The machine components and piping can reach high temperatures during operation. Therefore the machine should be switched off and left to cool down before carrying out checks and maintenance operations: risk of burns.

Operate the transmission and check for leaks, recheck the transmission oil level and if necessary add more oil.

NOTE: The oil level should be gauged when the dipstick is fully seated into the tube.

WINDSCREEN WASHER RESERVOIR Tank (2) of the windshield washer is located in the appropriate compartment, inside the cab, on the side of the operator’s seat.

2

Remove the filler cap and add a windscreen washer solution as required and install the filler cap.

NOTE: Do not remove the rubber hose from the washer motor as the motor is gravity fed and the solution will pass through the motor assembly.

NOTE: Use detergent fluid Tutela Professional SC35 diluted with water in relation to the temperature of use. With a 50 -- 50 solution of detergent and water the liquid does not freeze until -- 10 °C (14 °F). Below this temperature, use pure detergent.

TH004082

9

4--9

SECTION 4 -- LUBRICATION AND MAINTENANCE HYDRAULIC SYSTEM OIL LEVEL The hydraulic tank cap (3) is located on the left side of the machine.

3

The level of the hydraulic system oil is checked through sight gauge (4) indicated in the figure.

NOTE: The hydraulic oil should be visible in the sight glass when all cylinders in the loader are in the transport position.

WARNING

The hydraulic fluid reservoir is pressurised. Make sure that the pressure is entirely discharged before removing the cap.

Should the oil not be visible in the sight glass (4), unscrew the oil reservoir filter (3) and top up with the recommended oil, see specifications.

WARNING

Hydraulic fluid is highly corrosive. Always wear gloves and protective goggles to prevent skin irritation.

In case of contact with hydraulic fluid, rinse immediately with plenty of water and seek medical advice.

4--10

4 TH004297

10

SECTION 4 -- LUBRICATION AND MAINTENANCE CYLINDER AND BUSH LUBRICATION Check the two arm lifting cylinder bushes are lubricated. If not, pump in the type of grease recommended by the manufacturer until filling.

TH004196

11 The chassis hinged side lubrication can be performed only by lifting the arm up to its maximum inclination in order to access the bush lubricators.

TH004197

12 As to the other areas requiring lubrication and the respective lubricator position, refer to the figure on the following page.

4--11

SECTION 4 -- LUBRICATION AND MAINTENANCE

TH004296

13

4--12

SECTION 4 -- LUBRICATION AND MAINTENANCE MAINTENANCE CHART Wash Draining / Bleeding Change Service interval

Page P No.

Adjustment / Topping--up Lubrication / Greasing Clean Check

Every 50 hours

Every y 250 hours

Every 500 hours

Every 1000 hours or annually

Every 2000 hours or 2 years

Generall G maintenance

14

Radiator

X

14

Front loader arm fittings

15

Cab air filter

X X

15

Wheels and tyres

X

16

Front and rear wheel nuts

X

16

Front and rear axle joint bearings

X

16

Propeller shaft joints

X

16

Front and rear axle supports

X

17

Engine air cleaner (outer element)

18

Front loader arm fittings

18

Climate control system compressor drive belt (if fitted)

19

Engine oil and filter

21

Front and rear axle differential oil

X

X

21

Front and rear axle hub oil

X

X

21

Fuel filter

X

23*

Engine air cleaner (outer and inner element)

X

24

Hydraulic system oil filter

X

25

Transmission/drogbox oil and filter

X X

26**

Front and rear axle differential oil

X X

27

Front and rear axle hub oil

X X

27

Alternator drive belt

X

X

28

Valve clearance

X

X

28

Cab air cleaner

X

29***

Engine coolant

X X

32

Hydraulic reservoir output strainer

32

Hydraulic system oil

X X

33

Brake oil

X X

34

Alternator charging system

X

35

Hydraulic hoses and tubing

X

37

All wheel toe--in

X

X

38

Steering stop

X

X

38

Bulbs

X

X

40

Fuses and relays

X

X

43

Wheels and tyres

X

X X X

X X X

X X X

X X

X

* In clean environments the changing of filters could be extended to 1000 hours. ** If axle noise increases during braking, advance oil change. *** Frequency depends upon engine coolant in use.

4--13

SECTION 4 -- LUBRICATION AND MAINTENANCE EVERY 50 HOURS RADIATOR The engine radiator (1) is situated inside the engine compartment. It must always be clean to make sure the air flows inside it and cools the engine down.

Fins clogged with oily substances shall be clean with a deterging solution, preferably applied with a low pressure water washing machine.

Remove dirt on a regular basis, especially between the radiator fins, with low pressure water or air.

1 TH004281

14

WARNING

The machine components and piping can reach high temperatures during operation. Therefore the machine should be switched off and left to cool down before carrying out checks and maintenance operations: risk of burns.

The oil radiator is mounted in front of the water radiator. Make sure air flows between the two elements.

FRONT LOADER ARM SLIDING BLOCKS The loader arm must be regularly lubricated to maintain its operation efficiency. Always use recommended grease and apply it in the sliding points, after the loader arm has been extended. Distribute the grease so that it flows inside, towards the sliding blocks which cannot be accessed.

TH004221

15

4--14

SECTION 4 -- LUBRICATION AND MAINTENANCE CAB AIR FILTER Remove screws (1) securing the filter retaining grill and remove the filter to clean it.

Clean the housing with a damp cloth and re--assemble the pod filter element with the seal facing the inside of the cover.

The heater matrix for cab heating and air conditioning evaporator for cab cooling are fitted in the compartment under the seat. Clean the heater and cooler using compressed air not exceeding 7 bar taking care not to damage the radiator fins.

1

1

1

TH004065

16

NOTE: The filter should be cleaned more frequently when operating in extremely dusty conditions. Reassemble as previously described.

WHEELS AND TYRES

WARNING

Industrial tyres because of their size contain large volumes of air and as such extreme caution must be taken when inflating these tyres. Suitable protection against explosion of the tyre should be used between you and the tyre during inflation.

The maximum pressure to which you can inflate your tyre is moulded into the tyre wall for your guidance.

Consult your local dealer for assistance.

TH004086

17

Check and adjust the front and rear tyre pressures and inspect the tread and sidewalls for damage.

Adjust the tyre pressures to suit the load being carried. See Tyre Pressure and Load tables.

When fitting new tyres to your vehicle it is imperative that you have fitted the correct tyres as recommended by the vehicle manufacturer.

Incorrect tyre fitting could result with the tyre profile not fitting the rim profile. This will result in an inadequate seal allowing a high pressure leak or premature bead failure.

Inspect the rims for cracks or damage on a regular basis, and if either have penetrated the bead area change the wheel rim.

TH004029

18

4--15

SECTION 4 -- LUBRICATION AND MAINTENANCE FRONT AND REAR WHEEL NUTS Check the front and rear wheel nut tightness.

The nut tightening torque between the wheel rim and the hub must be 542 Nm.

TH004132

19 FRONT AND AXLE JOINT BEARINGS Lubricators (1) are on the front and rear axle four edges, on the wheel inner hub.

Use commercially available grease indicated in the lubricants table at the end of the manual.

1

TH004137

20 DRIVE SHAFT JOINTS The front and rear drive shafts are fitted with one lubricator each, one for each edge, i.e. four lubricators.

TH004016

21 FRONT AND REAR AXLE SUPPORTS Each axle is supported by two supports anchored to the chassis. The support bushes, two for each axle, must be lubricated with the appropriate lubricators, as shown in the figure.

TH004018

22 4--16

SECTION 4 -- LUBRICATION AND MAINTENANCE EVERY 250 HOURS ENGINE AIR CLEANER (outer element) Release the clips (1) to unscrew the lid (2) of the engine air cleaner housing.

2

Remove the outer element (3) and clean it as described.

1

Wash the element (3) at 250 hours or after five dry cleanings, whichever occurs first.

Seal the small opening at the outer end of the element, then immerse completely in warm water containing a little non--sudsing detergent.

TH004180

23

Allow to soak for at least 15 minutes with the open end above the water line. After soaking, shake the element in the water, taking care not to allow dirty water outside the element to splash over to the inside.

3

IMPORTANT: Never use fuel oil, petrol, solvent or water hotter than the hand can stand, otherwise the element may be damaged.

Use only a mild non--sudsing detergent and warm water to clean.

Rinse the element in clean running water, Figure 25, allow the water to run from the inside through the element. If a hose is used do not use high pressure. A gentle trickle of water is sufficient and will not damage the paper pleats. Allow to dry naturally.

TH004170

24

IMPORTANT: Do not attempt to ‘dry’ the element with heat or compressed air or install before thoroughly dry as it may rupture. It is recommended that a new element is installed at this service and the washed element allowed to dry and then be retained for installation at the next service.

After drying thoroughly, use a light inside the element to check for damage to the paper. The element should be discarded if pin pricks of light can be seen or if there are areas of the paper that appear thin. If the paper is bunched, the metal casing of the element is distorted or the seal is loose or damaged, then the element should likewise be discarded and a new one installed.

25

4--17

SECTION 4 -- LUBRICATION AND MAINTENANCE FRONT LOADER ARM SLIDING BLOCKS Proceed with the cleaning of pads removing old grease, dirt accumulations and any scaling.

Lubricate again according to the procedure described for 50--hour maintenance.

TH004221

26 AIR CONDITIONING COMPRESSOR DRIVE BELT (where fitted) The drive belt (1) of the compressor can be tensioned by tightening the securing nut (2). Loosen the screws and adjust the arm to obtain a movement of the belt of 16 mm.

For these operations refer also to the repair manual.

2 1

WARNING

The machine components and piping can reach high temperatures during operation. Therefore the machine should be switched off and left to cool down before carrying out checks and maintenance operations: risk of burns.

4--18

TH004134

27

SECTION 4 -- LUBRICATION AND MAINTENANCE EVERY 500 HOURS ENGINE OIL AND FILTER

WARNING

The machine components and piping can reach high temperatures during operation. Therefore the machine should be switched off and left to cool down before carrying out checks and maintenance operations: risk of burns.

Drain the oil when the engine is warm, proceeding as follows: -- Take a container with a suitable capacity; -- Remove the drainage cap (1) of the engine sump and let the oil flow out. To facilitate drainage, remove the oil filler cap (3); -- Screw the drainage cap (1) back on.

1

TH004282

28

WARNING

Used engine oil is a contaminated substance and should be disposed of safely and correctly in accordance with local law and legislation.

Unscrew and discard the oil filter (2). Clean the face of the filter head, apply a small amount of new engine oil to the seal on the new filter and install handtight.

IMPORTANT: Do not over--tighten the filter, refer to the instructions printed on the filter, or tighten handtight to the filter head – plus ¾ of a turn.

NOTE: Engines operating at temperatures below --12°C (10°F) should have the oil changed every 250 hours of operation. Under these conditions the engine oil filter needs only to be changed at the 500 hour service as described above.

2 TH004315

29

3

Fill the engine with clean oil through filler neck (3) and check the level with dipstick (4). Run the engine for a few minutes to circulate the oil. Wait a little so that the oil can drain into the sump prior to checking the oil again with dipstick (4).

IMPORTANT: Do not overfill beyond the maximum oil level as shown (keep oil in safe area on the dipstick).

4 TH004284

30

4--19

SECTION 4 -- LUBRICATION AND MAINTENANCE WARNING

Do not run the engine of this machine in enclosed spaces without ventilation that can remove harmful exhaust gases.

AVOID POLLUTING THE ENVIRONMENT. Dispose of hydraulic fluids, lubricants and coolants and the filtering elements impregnated with these fluids according to the local and national regulations in force which classify these materials as polluting, harmful or dangerous waste.

WARNING

Avoid contact of hot oil with the skin.

The oil temperature could cause serious burns. The lubricant used is also toxic if swallowed, if its vapours are inhaled, or in the case of prolonged contact.

4--20

SECTION 4 -- LUBRICATION AND MAINTENANCE FRONT AND REAR AXLE DIFFERENTIAL OIL LEVEL

1

Remove the filler plug (1) mounted in front of the differential. Ensure that the oil reaches the level plugs (2). If necessary, top up through the opening (1) and re--install the level filler plugs.

2

Ensure axle breather is free of obstruction or blockage where fitted.

2 3

If required, draining of old oil is through plugs (3).

TH004026

31

FRONT AND REAR AXLE HUB OIL LEVEL Position the wheel hub with the level/filler plug (1) in the horizontal position. Remove the level/filler plug and, if necessary, top up until oil flows from the filler plug opening. Re--install the plug.

1

TH004027

32 FUEL FILTER Unscrew the filter retainer and discard it. Fit a new filter as instructed on the filter casing.

NOTE: Do not use a rag to clean the filter base and head as absolute cleanliness is essential for this operation. It is essential that an approved filter is used for this operation as use of non--approved parts may result in serious damage to the fuel injection equipment.

If, after replacing the filter, it is necessary to prime the fuel system, observe the following procedure.

TH004090

33

WARNING

The machine components and piping can reach high temperatures during operation. Therefore the machine should be switched off and left to cool down before carrying out checks and maintenance operations: risk of burns.

4--21

SECTION 4 -- LUBRICATION AND MAINTENANCE PRIMING THE FUEL SYSTEM Ensure there is sufficient fuel in the tank.

Operate the hand primer (1) on the fuel lift pump to ensure fuel has entered the filter assembly. Continue to pump the hand primer until resistance is felt, indicating that the system is pressurised (primed).

With the throttle in the maximum no--load speed position operate the starting motor to crank the engine. The fuel injection pump is self--servicing and does not require bleeding.

1

TH004091

34 IMPORTANT: Do not crank the starting motor continuously for more than 60 seconds as doing so may cause starting motor failure.

If the engine fails to start after 60 seconds, repeat the priming procedure outlined above.

4--22

SECTION 4 -- LUBRICATION AND MAINTENANCE ENGINE AIR CLEANER (outer and inner element) Release the clips (1) to unscrew the lid (2) of the engine air cleaner housing.

2

Remove the outer element (3) and the inner element (4) and eliminate them.

1

Clean the air cleaner cartridge inside with a damp, lint--free cloth placed on a push rod tip. Install new inner and outer elements.

TH004180

35

4

3

TH004162

36

4--23

SECTION 4 -- LUBRICATION AND MAINTENANCE HYDRAULIC RESERVOIR OIL FILTER IMPORTANT: To maintain a clean hydraulic system, always perform recommended maintenance and replace the filter. Do not use a substitute filter that may allow damaging abrasive particles to enter the system.

1

WARNING

Fluid under pressure. Always rest the hydraulic bucket/attachment on the ground. Shut the engine off and move the hydraulic control levers through all movements several times to relieve residual pressure in the system. Failure to comply could result in serious injury or death.

TH004413

37

Open the rear compartment of the telescopic arm box by removing the fours fixing screws (1). Remove the hyraulic oil filter (2), unscrew and extract the cartridge. Remove the old filter and assemble a new one.

WARNING

Never drain oil or remove the oil filter while the engine is running Failure to comply could result in serious injury or death.

2 TH004412

Operate the loader to purge air from the system and re--check the oil level.

IMPORTANT: A plugged screen will cause pump cavitation. To maintain a clean hydraulic system, always use the recommended replacement filter. Do not use a substitute filter that may allow damaging abrasive particles to enter the system.

4--24

38

SECTION 4 -- LUBRICATION AND MAINTENANCE EVERY 1000 HOURS OR ANNUALLY TRANSMISSION/DROP BOX OIL AND FILTER With the oil hot and the vehicle on level ground remove the drain plug (1) and allow the oil to drain into a suitable container at least 17 Litres. Re--install the drain plug after the oil is drained.

1

Unscrew the gearcase plug (2) and collect the oil in the container. Wait until oil draining is finished and re--install the plug.

2

Drain the drop box oil through the plug hole (3).

Re--install the drain plug after the oil is drained.

WARNING

The machine components and piping can reach high temperatures during operation. Therefore the machine should be switched off and left to cool down before carrying out checks and maintenance operations: risk of burns.

3

TH004031

39 Unscrew the transmission oil filter (4) mounted to the top and left of the transmission and discard. Lubricate the new filter oil seal with clean transmission oil and install. The new filter should be hand tight, plus 3/4 of a turn.

4

TH004093

40

4--25

SECTION 4 -- LUBRICATION AND MAINTENANCE Fill the drop box case with the recommended oil type through the drain plug (1). The case capacity is 1 litre. Check the oil level through the lens above the drain plug. Re--install the drain plug (1).

1 TH004033

41 Fill the gear with the recommended oil type, around 17 litres, through the filler hole with dipstick (2) installed to the right of the base. Observe the following procedure.

2

Use the dipstick (2) and check the gear oil level at usual operating temperature, with engine running idle and gear lever in neutral position. Add the required oil quantity and make sure the level is between minimum and maximum.

Operate the gearshift and check there are no leaks.

Re--check the gearshift oil level and top up, if needed.

TH004279

42

NOTE: The oil level shall be measured with the dipstick completely inside the filler plug.

FRONT AND REAR AXLE DIFFERENTIAL OIL

3

To drain the differential, remove the plug (3) and drain from plug holes (5) the oil into a suitable container.

Re--install the plugs (5) and fill the differential through the plug hole (3). Make sure the oil reaches the level/ filler plug hole (4). Install plugs (3) and (4).

4

4

5 TH004105

43

4--26

SECTION 4 -- LUBRICATION AND MAINTENANCE FRONT AND REAR AXLE HUB DRAINING Position the oil plug (1) at the lowest point and drain the oil into a suitable container.

To refill rotate the hubs so that the plug (1) reaches a horizontal position compared to the hub centre.

Replace the oil to the filler level and re--install the plug (1).

1

TH004027

44 ALTERNATOR DRIVE BELT

5

If the belt (2) needs to be adjusted, loosen nut (3) and nut (4) along with the washer and act on the adjusting screw (5).

After adjusting tighten nut (4). Tighten nut (3) to a 27 Nm torque.

IMPORTANT: When prying the alternator away from the engine, apply pressure at the front housing only.

Do not pry on the rear housing as damage may result. Also, adhere to the alternator precautions in this Section.

WARNING

3 4 2 TH004289

45

The machine components and piping can reach high temperatures during operation. Therefore the machine should be switched off and left to cool down before carrying out checks and maintenance operations: risk of burns.

4--27

SECTION 4 -- LUBRICATION AND MAINTENANCE VALVE CLEARANCE 4

Correct valve clearance is one of the essential factors for the engine high performance. Excessive clearance may cause engine noise and increase wear, while insufficient clearance may reduce the engine performance and burn the valves.

To check clearance, rotate the crankshaft clockwise so that the valves are completely open. Check and adjust the valves.

Open valves 1 suction/3 drain 3 suction/4 drain 2 drain/4 suction 1 drain/2 suction

3

4

2

3

1

2

1

Valves to be adjusted 2 drain/4 suction 1 drain/2 suction 1 suction/3 drain 3 suction/4 drain

Suction valve clearance – cold 0.25 ±0.05 mm Drain valve clearance – cold 0.50 ±0.05 mm Insert the thickness gauge between each valve stem and the rocker arms. Turn the screw and adjust its clearance.

46

CAB AIR FILTER Remove the cover and discard the filter.

Clean the inside of the filter chamber with a damp lint--free cloth and install the new filter element.

1

1

1

TH004065

47

4--28

SECTION 4 -- LUBRICATION AND MAINTENANCE EVERY 2000 HOURS OR EVERY TWO YEARS ENGINE COOLANT The engine cooling system (1) is factory filled with a high quality water and antifreeze mixture. The antifreeze contains a chemical corrosion preventative enhancing and extending the protection provided by conventional additives.

The inhibitor will: •

Increase rust prevention;

•

Reduce scale formation;

•

Minimise cylinder wall erosion (pitting);

•

Reduce foaming of the coolant.

1 TH004281

48

The chemical inhibitor must be replenished, at intervals, to maintain the optimum protection level. This protection is provided by draining and flushing the system and refilling with a 50% solution of Ambra Agriflu antifreeze or, where this antifreeze is not available, with a measured dosage of chemical inhibitor.

Draining and refilling the cooling system

WARNING

The cooling system operates under pressure which is controlled by the radiator pressure cap. It is dangerous to remove the pressure cap while the system is hot.

When cool, use a thick cloth and turn the cap slowly to the first stop and allow the pressure to escape before fully removing the cap. Coolant should be kept away from the skin. Adhere to the precautions outlined on the antifreeze and inhibitor containers, where used.

IMPORTANT: It is essential that an approved pressure cap is used. If the cap is mislaid or damaged, obtain a replacement from your dealer.

4--29

SECTION 4 -- LUBRICATION AND MAINTENANCE IMPORTANT: During cooling system emptying and filling stage it is advisable to enable the cabin heating controls as described in section 2 of this manual. This operation allows to empty and refill the cabin heater and relevant pipes.

Put a container under the radiator outlet. When the engine is cold empty the fluid from the radiator removing the plug (1) indicated in the figure at the bottom of the radiator. After emptying the coolant, put back the plug. After emptying, refill the cooling system form the pressurized plug (2), removing the screw (3) to bleed the air from the system.

1

TH10R074

NOTE: To avoid trapping air in the system, fill the radiator as slowly as practicable thereby allowing any air pockets to disperse.

49

The coolant to be used is dependent upon local availability.

2

Using Ambra Agriflu Antifreeze Use a solution of 50% clean water and 50% antifreeze. The inhibitor already in this antifreeze is sufficient to protect your engine for a further 1200 hours or two years, whichever occurs first.

3

Using a proprietary antifreeze Where antifreeze meeting the above--mentioned specification is not available, use a proprietary, heavy duty antifreeze premixed with 5% chemical inhibitor.

WARNING

Inhibitor solution is irritating to eyes and skin. It contains buffered potassium hydroxide.

•

Avoid contact with eyes or prolonged and repeated skin contact.

•

Wear protective eyewear when using.

•

In case of contact with eyes, flush with water for 15 minutes and obtain medical attention.

•

Wash skin with soap and water after use.

•

Keep out of reach of children.

4--30

TH004267

50

SECTION 4 -- LUBRICATION AND MAINTENANCE After refilling the system – All coolant solutions Check that the coolant level is within the area of the sight glass in the radiator header tank.

Start and run the engine to circulate the coolant. Stop the engine and top up the radiator, via the filler cap, with the same coolant solution, as previously described.

NOTE: The coolant level may drop as it is pumped around the cooling system.

The foot brakes do not require adjustment other than an oil change every 2 years, or before if the oil is low or a leak has occurred. Check the brake cylinders for signs of leakage. Ensure the oil level in the brake reservoir is checked periodically.

System capacity maximum Coolant capacity Antifreeze specification

12.0 Litres Ambra Agriflu

Clean water specification Total hardness 300 parts per million Chlorides 100 parts per million Sulphates 1.100 parts per million

4--31

SECTION 4 -- LUBRICATION AND MAINTENANCE HYDRAULIC RESERVOIR OUTPUT GRILLED FILTER The hydraulic circuit is protected by a grilled filter which must be maintained to prevent dirt from penetrating the hydraulic circuit.

1

When the oil is drained out of the reservoir, the output grilled filter can be removed for service. To dot this, remove the plate (1) which makes it possible to access the oil tank. The plate can be reached from the compartment under the cabin.

This grilled filter should be cleaned in a suitable solution to remove all dirt and impurities.

TH004301

51

WARNING

Hydraulic fluid is highly corrosive. Always wear gloves and protective goggles to prevent skin irritation.

In case of contact with hydraulic fluid, rinse immediately with plenty of water and seek medical advice.

WARNING

The hydraulic fluid reservoir is pressurised. Make sure that the pressure is entirely discharged before removing the cap.

HYDRAULIC OIL Check the hydraulic oil level at the eye glass (2) with the loader in transport position and, if necessary, top up the reservoir through the filler cap (3) with the recommended oil, see Specifications. Operate the loader to purge air from the system and re--check the reservoir oil level.

NOTE: Should it be necessary to drain the hydraulic reservoir oil at any time, place a suitable container capable of holding at least 185 Litres in position and remove the drain plug (4).

3

2 TH004297

52

WARNING

Hydraulic fluid is highly corrosive. Always wear gloves and protective goggles to prevent skin irritation.

In case of contact with hydraulic fluid, rinse immediately with plenty of water and seek medical advice.

WARNING

4

The hydraulic fluid reservoir is pressurised. Make sure that the pressure is entirely discharged before removing the cap.

TH004302

53

4--32

SECTION 4 -- LUBRICATION AND MAINTENANCE FOOT BRAKE Remove the access cover (1) by means of the fixing knob (2) to access the brake oil reservoir (3).

2

The foot brakes do not require adjustment other than an oil change every 2 years, or before that if the oil is low or a leak has occurred. Check the brake cylinders for signs of leakage. Ensure the oil level in the brake reservoir is checked periodically.

1

WARNING

Brake fluid is highly corrosive. Always wear gloves and protective goggles to prevent skin irritation. In case of contact with hydraulic fluid, rinse immediately with plenty of water and seek medical advice.

TH004303

54

WARNING

Owners should be aware of any local regulations concerning testing of braking systems. Regularly service the brakes to ensure compliance with the law and ensure your safety. If in doubt, contact your dealer.

3

TH004304

55

4--33

SECTION 4 -- LUBRICATION AND MAINTENANCE GENERAL MAINTENANCE ALTERNATOR CHARGING SYSTEM To avoid damage to the components of the alternator charging system, service precautions must be observed as follows: •

NEVER make or break any of the charging circuit connections, including the battery, when the engine is running.

•

NEVER short any of the charging components to ground.

TH004227

•

ALWAYS disconnect the battery ground cable before carrying out arc welding on the machine or on any instrument attached to the machine.

•

ALWAYS disconnect the battery ground cable when charging the battery in the machine using a battery charger.

WARNING

The machine components and piping can reach high temperatures during operation. Therefore the machine should be switched off and left to cool down before carrying out checks and maintenance operations: risk of burns.

WARNING

Wear eye protection when charging the battery or starting the vehicle engine with a slave battery.

•

DO NOT use a slave battery of higher than 12 volt nominal voltage.

•

ALWAYS observe correct polarity when installing the battery or using a slave battery to start the engine. Follow the instructions on page 2--33 when jump starting the vehicle.

CONNECT POSITIVE TO POSITIVE AND NEGATIVE TO NEGATIVE.

4--34

56

SECTION 4 -- LUBRICATION AND MAINTENANCE HYDRAULIC HOSES AND TUBING

WARNING

Inspect lines, fittings and hoses at regular intervals, checking for leaks and damage.

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 rpm.

Remove and install new hoses immediately, if they are severely damaged by a cut or a scrape, swollen at the fittings, or leaking.

TH004039

57

If a hydraulic hose or tube is renewed the following procedure should be observed.

WARNING

Turn off the engine and ensure that circuits are no longer under pressure before removing panels, housings, caps, plugs or covers.

CAUTION

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.

4--35

SECTION 4 -- LUBRICATION AND MAINTENANCE Release the fittings and remove the hose or tube assembly, then remove and discard the O--ring seal from the fitting.

Dip a new O--ring seal into clean hydraulic oil prior to installation. Install the new O--ring into the fitting and, if necessary, retain in position using Vaseline.

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.

Using two suitable wrenches, as shown, tighten the fitting to the prescribed torque, Figure 57.

To ensure a leak--free joint is obtained, it is important that the fittings ARE NOT OVER TORQUED OR UNDER TORQUED. Bleed the air from the system any time a hydraulic hose is removed, a tube disconnected, or the system is opened to atmosphere. This is accomplished by running the engine at 1200--1500 rev./min., and actuating the loader control levers (no load in the bucket) for approximately 15 minutes or until air is expelled from the system.

After bleeding the system, position the loader bucket flat on the ground and shut off the engine. Then check the hydraulic system oil level and add oil if necessary.

IMPORTANT: Ensure that when a hydraulic hose or tube is renewed/installed, all components are absolutely clean and free from dirt. Failure to ensure absolute cleanliness will result in the hose/tube leaking after installation or possible damage to other hydraulic system components.

WARNING

NEVER USE YOUR HANDS to identify pressure leakages. Pressure fluid leaks are strong enough to pierce the skin and cause injuries.

CAUTION

Always wear a face shield, gloves, goggles and protective clothing.

4--36

SECTION 4 -- LUBRICATION AND MAINTENANCE WHEEL TOE--IN IMPORTANT: Ensure the wheels are set to the two wheel steer road position aligned straight ahead prior to adjustment.

The 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.

Should it be necessary to adjust the toe--in setting proceed as follows.

Measure the toe--in by checking the track width between the front of the wheel rim and the rear of the wheel rim at hub height. The correct toe--in measurement is 0--2 mm.

Loosen the lock nut (2) on each track rod and turn the hexagon adjuster (1) with a spanner until the correct toe--in setting is obtained. Tighten the lock nut and re--check the toe--in.

1

2

TH004111

58 STEERING STOPS Four steering stops (3) 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 vehicle on full left and right lock with the axle fully oscillated.

To adjust, slacken the locknut (4) and turn the stop bolt (3) anti--clockwise to reduce the steering angle of the wheels or clockwise to increase the steering angle. Tighten the locknut.

4 3 TH004112

59

4--37

SECTION 4 -- LUBRICATION AND MAINTENANCE BULB REPLACEMENT Work lamp bulb replacement, front To gain access to the bulb, remove the securing screws, gently remove the lens cover and remove the bulb. Replacement of the bulb follows the removal procedure in reverse.

NOTE: Modern headlights and worklamps tend to have halogen bulbs fitted. Never touch a halogen bulb with the fingers. Natural moisture in the skin will cause the bulb to burn out when the lamp is switched on. Always use a clean cloth or tissue when handling halogen bulbs.

TH004098

60

Headlight and indicator bulb replacement

1

To gain access to the headlight bulbs, extract the four securing screws (1), gently remove the lens cover and remove the plug from the rear of the bulb, release the retaining spring and extract the bulb. The sidelight bulb is removed by pulling the bulb carrier out of the reflector assembly. Replacement of the bulbs follow the removal procedure in reverse.

1

The indicator bulb can be accessed by removal of the lens cover retaining screw.

TH004099

61 Loader mounted work lights (optional) To gain access to the bulb, extract the securing screws, gently remove the lens cover and remove the bulb.

Replacement of the bulb follows the removal procedure in reverse.

4--38

SECTION 4 -- LUBRICATION AND MAINTENANCE Interior lamp bulb replacement The interior lamp bulb is accessible after removal of the moulded plastic lens cover (1). The bulb may be removed by exerting outward pressure on one of the retaining tangs and sliding the opposite end of the bulb from its retaining tang. Installation of the bulb and lens cover follow the removal procedure in reverse.

1

TH004103

62 Rear work light The bulb is accessible after removing the retaining screws of the plastic lens.

TH004074

63 Rear, stop and direction indicator All bulbs are accessible after removing securing screws (2) of the plastic lenses.

The bulbs have a bayonet cap fitting with offset pins for the brake light bulb and parallel pins for the direction indicator bulb. Both bulbs may be removed by depressing slightly and rotating approximately 20° anti--clockwise.

Replacement of the bulbs follows the removal procedure in reverse, however ensure the brake light offset pins align with the socket correctly. The lens can be replaced after the electrics have been tested.

2

TH004101

64

4--39

SECTION 4 -- LUBRICATION AND MAINTENANCE License plate light 1

This bulb can be replaced after removing the protection cap and removing securing screws (1).

TH004107

65 Rocker switch bulb replacement The rocker switches are internally illuminated by a bulb which can be remove from the rear of the switch assembly (2).

2 To gain access to the switch remove the console attaching screws and rotate the console.

The bulb is of the capless type, rated at 1.2W and is press--fitted in the retainer. After changing the bulb, push the retainer into the back of switch.

TH004108

66 FUSE AND RELAY REPLACEMENT The vehicle fuse and relay board is located beneath the front console cover behind the steering wheel.

The fuses are numbered and reference to the used symbols will permit rapid identification of the circuits they protect.

NOTE: Certain optional items of equipment may not be installed on your vehicle. However, the fuses are still installed and may be used as spares.

IMPORTANT: Do no replace a blown fuse with another of a different rating.

4--40

TH004102

67

SECTION 4 -- LUBRICATION AND MAINTENANCE FUSES NAME F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30 F31 F32 F33 F34 F35 F36 F37 F38 F39

DESCRIPTION Fuse, relay KC power Fuse, conditioner Fuse, radio Fuse, optional Fuse, stabiliser lowering Fuse, rear axle sensor Fuse, upper windshield Fuse, heating Fuse, front work lights Fuse, rear axle release Fuse, micro stop Fuse, extraction/retraction Fuse, optional Fuse, warning Fuse, rotary beacon Fuse, optional Fuse, low boom sensor Fuse, horn Fuse, rear wiper Fuse, optional Fuse, motion in/out Fuse, boom work lights Fuse, front wiper Fuse, tail light + license plate light Fuse, optional Fuse, ceiling light Fuse, compressor Engine cut--off Fuse, basket ON Fuse, tip--over instrument Fuse, attachments Fuse, lighting Fuse, speed safety + parking brake Fuse, back--up alarm Fuse, rear work lights Fuse tail lights Fuse, high beams Fuse, low beams Fuse, cigarette lighter

VALUE 5A 3A 3A 3A 7.5A 7A 10A 15A 15A 10A 5A 15A 5A 10A 10A 10A 10A 15A 10A 10A 10A 15A 10A 5A 7.5A 5A 10A 10A 15A 5A 7.5A 3A 10A 5A 15A 5A 15A 15A 20A

4--41

SECTION 4 -- LUBRICATION AND MAINTENANCE RELAYS NAME K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24

DESCRIPTION Relay 100% motion cut Relay stabilisers safety Relay stabilisers Relay Optional (OUT) Relay gear--shift safety Relay backup alarm Relay extension Relay low beams Relay low boom sensor Relay levelling Relay steering selector Relay parking brake Relay 2 speed Relay reverse Relay retraction Relay hign beams Controller Flasher Relay engine cut--off Relay horn Relay option “IN” Relay 1 speed Relay forward Relay, 4 speed

TH004106

68

4--42

SECTION 4 -- LUBRICATION AND MAINTENANCE •

Ensure the rim is clean and free of rust or damage. Do not weld, braze, otherwise repair or use a damaged rim.

•

Do not inflate a tyre unless the rim is mounted on the vehicle or is secured so that it will not move if the tyre or rim should suddenly fail.

When checking the tyre pressures, inspect the tyres for damaged tread and side walls. Neglected damaged will lead to early tyre failure.

•

Inflation pressure affects the amount of weight that a tyre may carry. Locate the tyre size for your vehicle in the Tyre Pressure and Load tables in Section 8 of this Manual. Do not exceed the load for the pressure listed. Do not over or under inflate the tyres.

When fitting a new or repaired tyre, use a clip--on valve adaptor with a remote gauge that allows the operator to stand clear of the tyre while inflating it. Use a safety cage, if available.

•

Do not inflate a steering tyre above the manufacturer’s maximum pressure shown on the tyre or beyond the maximum shown in the Tyre Pressure and Load tables, if the tyre is not marked with the maximum pressure.

TYRES AND WHEELS General maintenance Upon receiving your vehicle, check the air pressure in the tyres and re--check every 50 hours or weekly.

WARNING

Inflating or servicing tyres can be dangerous. Whenever possible, trained personnel should be called in to service or install tyres. In any event, to avoid the possibility of serious or fatal injury, follow the safety precautions below.

WARNING

Never inflate a traction tyre, front tyre on a four wheel drive vehicle or any rear tyre over 2.4 bar. If the bead does not seat on the rim by the time this pressure is reached, deflate the tyre, re--lubricate the bead with a soap/water solution and re--inflate. Do not use oil or grease. INFLATION BEYOND 2.4 bar with unseated beads may break the bead or rim with explosive force sufficient to cause a serious injury.

•

Machine wheels are very heavy. Handle with care and ensure, when stored, that they cannot topple and cause injury.

•

Never attempt tyre repairs on a public road or highway.

•

Ensure the jack is placed on a firm, level surface.

•

Ensure the jack has adequate capacity to lift your vehicle.

•

After seating the beads, adjust inflation pressure to the recommended operating pressure.

•

Use jack stands or other suitable blocking to support the vehicle while repairing tyres.

•

Do not re--inflate a tyre that has been run flat or seriously under--inflated until it has been inspected for damage by a qualified person.

•

Do not put any part of your body under the vehicle or start the engine while the vehicle is on the jack.

•

Torque wheel to axle nuts to specification after re--installing the wheel. Check nut tightness daily until torque stabilises.

•

Never hit a tyre or rim with a hammer.

4--43

SECTION 4 -- LUBRICATION AND MAINTENANCE

NOTES

4--44

SECTION 5 TROUBLESHOOTING IMPORTANT: The following troubleshooting tables are only a guide. Should any repairs different from ordinary maintenance be required, the vehicle must be taken to the dealership having the tools, equipment and necessary knowledge to make repairs in conformity with specifications and safety rules.

CONTENTS Description Page Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2 Gearshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5 Hydraulic system troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--8

5--1

SECTION 5 -- TROUBLESHOOTING ENGINE PROBLEM Engine does not start. start

Engine runs unevenly and/or stalls stalls.

Engine lacks power.

5--2

POSSIBLE CAUSE

REMEDY

No fuel or insufficient. insufficient

Check fuel level. level

Air in fuel system.

Bleed the supply system.

Wrong fuel type for operating temperature.

Use the right type of fuel for temperature conditions.

Supply system contaminated.

Clean the system.

Fuel filter clogged.

Replace the filter element.

Fuel injector/s faulty.

Contact an authorised dealership.

Fuel solenoid valve or solenoid valve relay faulty.

Contact an authorised dealership.

Flat battery.

Replace the battery or start the engine with the recharging cables.

Fuel filter clogged.

Replace the fuel filter.

Supply system contaminated.

Clean the system.

Fuel solenoid valve maladjusted.

Contact an authorised dealership.

Fuel injector/s faulty.

Contact an authorised dealership.

Condensate in the fuel filter.

Operate the fuel filter cock to drain condensate water.

Air filter clogged.

Clean the filter as shown in the “Lubrication and Maintenance” chapter.

Impurities in the fuel tank, impure fuel.

Empty the tank, wash it with fuel free of impurities and refill it.

Overloaded engine.

Engage a lower gear o reduce the load.

Air filter clogged.

Make the air filter maintenance.

Fuel filter clogged.

Replace the fuel filter.

Wrong fuel type.

Use the right type of fuel.

Overheated engine.

See: “Engine overheats”.

Low engine operating temperature.

Check thermostats.

Wrong valve distance.

Check and adjust.

Fuel injector/s faulty.

Have the injectors checked at an authorised dealership.

High idle too low.

Contact an authorised dealership.

Aftercooler radiator clogged.

Clean the radiator.

SECTION 5 -- TROUBLESHOOTING ENGINE (Cont.)

PROBLEM Engine knocks.

POSSIBLE CAUSE

REMEDY

Insufficient oil level.

Top up with the right oil quantity.

Insufficient oil pressure.

Contact an authorised dealership.

Overheated engine.

See: “Engine overheats”.

High advance.

Contact an authorised dealership.

Engine low working temperature.

Thermostat/s faulty.

Replace the thermostat/s.

Insufficient oil pressure.

Insufficient oil level.

Top up as needed.

Wrong oil quantity or viscosity.

Empty and refill with oil of the right quality and viscosity.

Oil pump faulty.

Contact an authorised dealership.

Engine oil level too high.

Reduce the oil level.

Wrong oil viscosity.

Use oil with the right viscosity.

Outside oil blow--by.

Repair leaks.

Scraper rings worn.

Contact an authorised dealership.

Oil vapour collector clogged.

Contact an authorised dealership.

Radiator pipes dirty.

Clean.

Engine overloaded.

Engage a lower gear or reduce the load.

Insufficient engine oil level.

Top up as needed.

Insufficient coolant level.

Fill the coolant collecting tank.

Check if there is any blow--by from the cooling system.

Coolant collecting tank cap faulty or not tightened.

Replace the pressurised cap or tighten it in the correct way.

Loose or worn fan belt.

Check the automatic tensioner.

Replace the belt if worn.

Cooling system clogged.

Wash the cooling system.

Thermostat/s faulty.

Check thermostats.

Blow--by from hose pipes.

Tighten pipe hose unions.

Temperature indicator or transmitter faulty.

Contact an authorised dealership.

Replace engine oil.

Replace the engine oil.

Oil over--consumption.

Engine overheats.

5--3

SECTION 5 -- TROUBLESHOOTING ENGINE (Cont.)

PROBLEM Fuel over--consumption.

POSSIBLE CAUSE

REMEDY

Wrong fuel type.

Use the right fuel type.

Air filter clogged or dirty.

Engine overloaded.

Make the air filter maintenance.

Engage a lower gear or reduce the load.

Check thermostats.

Have the injectors checked at an authorised dealership.

Contact an authorised dealership.

Engine low temperature.

Injectors dirty.

Injection pump faulty or not correctly calibrated.

GEARSHIFT PROBLEM Gearshift does not work.

POSSIBLE CAUSE Insufficient oil delivery.

REMEDY Fill the system with oil and check the pump pressure.

One or more solenoid valve faulty. Contact an authorised dealership.

Contact an authorised dealership.

Gearshift does not work properly or works k unevenly. l

Gearshift overheats.

5--4

Overheated oil.

Put the gear in NEUTRAL position and let the engine run idle for the time needed to let the oil cool down.

Modulating valve blocked.

Contact an authorised dealership.

Loose electrical connections.

Check electric continuity.

Insufficient oil pressure.

Contact an authorised dealership.

Insufficient oil delivery.

Fill the system with oil and check the pump pressure.

Water radiator clogged.

Remove waste from the radiator.

Torque converter worn.

Contact an authorised dealership.

Prolonged operation in stall conditions.

See: “Engine overheats”.

SECTION 5 -- TROUBLESHOOTING ELECTRICAL SYSTEM PROBLEM 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.

POSSIBLE CAUSE

REMEDY

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.

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.

Fuse or relay faulty.

Replace.

Low engine idle speed.

Increase idle speed.

Loose belt.

Check belt tension.

Malfunctioning battery.

Check battery open circuit voltage for 12.6 volts minimum. Check electrolyte level and specific gravity.

Malfunctioning alternator.

Have the alternator checked at an authorised dealership.

Loose or corroded alternator contacts.

Clean and tighten loose connections.

Loose or corroded terminal connections.

Clean and tighten loose connections.

Sulphated batteries.

Check battery open circuit voltage for 12.6 volts minimum. Check electrolyte level and specific gravity.

Loose or worn belt.

Check automatic belt tensioner.

Replace belt if required.

5--5

SECTION 5 -- TROUBLESHOOTING ELECTRICAL SYSTEM (Cont.)

PROBLEM Load indicator panel signals errors in the system (fixed red LED with some green LEDS)

POSSIBLE CAUSE Load checking system faulty (no electrical connection with load cell, wrong calibration, etc.)

REMEDY Contact an authorised dealership.

HYDRAULIC SYSTEM PROBLEM All circuits fail to operate

POSSIBLE CAUSE

REMEDY

Pump drive inoperative.

Pump worn.

Low oil level.

Contact an authorised dealership.

System limiting pump faulty.

Restricted pump suction line.

Protection on because of safety key.

Slow operation or loss of power in all circuits.

Check the safety key is in “Size” position

Pump worn.

Restricted pump suction line.

Contact an authorised dealership.

System limiting pump faulty.

5--6

Oil leak from the circuit.

Check the hydraulic circuit tightness and repair possible leaks.

Malfunctioning power control pump.

Contact an authorised dealership.

SECTION 5 -- TROUBLESHOOTING BRAKES PROBLEM Excessive pedal stroke.

POSSIBLE CAUSE

REMEDY

Blow--by from the brake piston lining.

Brake, discs worn.

Brake bleeding valve not tight.

Contact an authorised dealership.

Blow--by from brake valve/s.

Air in the system.

Oil leak form the circuit

CAB PROBLEM Dust in the cab.

POSSIBLE CAUSE

REMEDY

Inadequate filter gasket.

Check gasket conditions.

Filter clogged.

Clean or replace filter.

Malfunctioning filter.

Replace filter.

Insufficient fan motor air flow.

Air or recirculation filters clogged.

Clean or replace filter/s.

Low heating.

Heater or cooler pipes clogged.

Contact an authorised dealership.

Air conditioner low cooling action.

External condenser clogged.

Clean radiator, intercooler and condenser.

Low coolant level.

Check bubble presence through the check window. Contact an authorised dealership.

Belt slipping or damaged belt.

Check automatic belt tensioner and belt conditions.

Heating on.

Turn the temperature adjusting knob anticlockwise to reach the maximum cooling effect.

5--7

SECTION 5 -- TROUBLESHOOTING

NOTES

5--8

SECTION 6 VEHICLE STORAGE This section is about the vehicle preparation for storage (long inactivity).

CONTENTS Description Page Long vehicle inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2 Tyres and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2 Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3 Vehicle preparation after prolonged inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4

6--1

SECTION 6 -- VEHICLE STORAGE VEHICLE PROLONGED INACTIVITY Before storing the vehicle for a long time it is necessary to adopt the following precautions.

•

Clean the vehicle accurately and retouch the paint where needed to prevent rust formation.

•

Check whether there are any worn or damaged elements and replace them if needed.

•

Lubricate the vehicle and drain the gearshift, the hydraulic reservoir, the drive system, the axles and the engine and fill them with the right oil quantity.

•

Bleed the fuel tank and fill it with 9 litres of stabilised fuel.

•

Let the engine run for 10 minutes in order to distribute the special fuel to the injection pump and the injectors. In this way the injector and pump sticking up is prevented when the vehicle has to be stored for a long time.

•

Check the coolant level in the radiator. If less than 100 hours to the following 1000--hour (or less) maintenance operation are left or less then 2 months before the every--two--year maintenance operation are left, observe the prescribed maintenance deadline.

•

Operate the front loader so that all cylinders reach retsected position and place the bucket on a block or a piece of wood.

TYRES AND WHEELS General maintenance When the vehicle is received, check the tyre air pressure and remember to check it every 50 hours or every week.

When the tyre pressure is checked, make sure the tread and the tyres sides are not damaged. Possible overlooked damages might make the tyre fail prematurely.

Inflating pressure affects the weight a tyre can bear.

Identify the tyre dimension for the involved vehicle in the Tyre Pressures and Weights table in Section 8 of this handbook. Do not overcome the load for the listed pressures. Do not inflate tyre more or less than the prescribed value.

WARNING

Inflating or making operations on the tyres can be very dangerous. Whenever possible, have maintenance operations and/or tyre installation performed by skilled people. Anyway, strictly observe the following safety precautions to avoid serious or even lethal injuries.

•

The vehicle wheels are very heavy. Handle them with care and once stored, make sure they cannot fall down and hurt someone.

•

Never try to repair tyres on a public road.

•

Make sure the jack is placed on a solid and flat surface.

•

Make sure the jack capacity is adequate for the vehicle lifting.

•

Start the vehicle and reach the loading position and then fasten the loading chain or engage the loading clamp.

•

Use jack stands or other appropriate clamping devices to support the vehicle during tyre repairing.

•

Turn the engine off and release hydraulic pressure in all circuits.

•

Do not place any part of your body under the vehicle and do not start the engine while the vehicle is on the jack.

•

Apply a light grease layer on the exposed cylinder rod area of the vehicle and front loader hydraulic cylinders.

•

Never hit the tyres or rims with a hammer.

•

Make sure the rim is clean and without rust or any other damages. Do not weld, braze, repair or use a damaged rim.

•

Do not inflate a tyre if the rim is not installed on the vehicle or clamped so that it cannot move in the event the tyre or the rim should suddenly get broken.

•

When a new or repaired tyre is installed, use an adapter for spring valves with remote controlled pressure gauge which makes it possible for the operator to keep at distance from the tyre during inflation. Use a safety cage, if needed.

•

• •

Remove and charge the battery. Keep it in a dry and warm place and charge it by and then during storage.

Place some supports under the axles to relieve weight from the wheels.

Cover the exhanst pipe.

6--2

SECTION 6 -- VEHICLE STORAGE •

Do not inflate steering wheels (front wheels on simple drive vehicles) beyond the maximum pressure prescribed by the manufacturer and indicated on the tyre itself. Do not inflate the tyre beyond the maximum value indicated in the Tyre Pressures and Weights tables in Section 8, if the maximum pressure is not indicated on the tyre.

If you need to connect the wires to an external battery to start the engine, proceed as follows: •

Connect the first wire end to the vehicle 12V battery positive terminal (+) and the other wire end to the 12V auxiliary battery positive terminal (+).

•

Connect the second wire end to the auxiliary battery negative terminal (--) and the other wire end to the engine base. This will avoid the generation of sparks between the two batteries. Follow the previously described start--up procedure.

WARNING

Never inflate drive wheels (front wheels on 4--wheel drive, rear wheels in general) beyond 2.4 bars. If the bead does not find its position on the rim when such pressure is reached, deflate the tyre, lubricate the bead with a mixture of water and soap and inflate again. Do not use oil or grease. INFLATION OVER 2.4 bars with the bead not in position can make the bead or rim blow out and seriously hurt someone.

•

After making the beads reaching the right position, adjust inflating pressure at the prescribed working pressure.

•

Do not inflate a very or completely flat tyre until it has been checked by an skilled person.

•

After refitting the wheel, tighten the wheel and axle nuts as prescribed. Check the nut tightening every day until the torque stabilizes.

•

Make reference to the section on the vehicle weighing before adding load on the wheels.

JUMP STARTING

WARNING

Operate the starter only from the driver’s seat. If the starter switch is bypassed, the engine might be started accidentally with the gear engaged.

Use eye goggles when discharging a battery or jump starting the vehicle.

NOTE: When an auxiliary battery is used, make sure polarity is correct in order not to damage the alternator.

•

After starting the engine, let it run idle, turn on all electric devices (lights, etc.) and disconnect the charging wires by reversing the connecting procedure. In this way the alternator is protected against possible damages due to sudden load variations.

NOTE: The vehicle is fitted with an fuel shut off electrovalve and therefore it is not possible to make it run when the battery is not installed. The engine turns off when the electric power supply to the fuel shut off electrovalve is cut off (disconnected battery).

VEHICLE PREPARATION AFTER A PROLONGED INACTIVITY •

Inflate tyres according to prescribed pressure.

•

Fill the tank.

•

Check the radiator coolant level.

•

Check all oil levels.

•

Install a charged battery.

•

Uncover the exhaust pipe.

•

Remove grease from concerned areas, such as steering cylinders, drive pins, etc.

6--3

SECTION 6 -- VEHICLE STORAGE TURBOCHARGER The turbocharger bearing can be seriously damaged if not lubricated appropriately and if the following precautions are not adopted.

In order to prevent damaging the turbocharger bearing during the first start--up after a new turbocharger has been installed, or in case the turbocharger oil supply should be disconnected for any reason, or should the engine be started for the first time after being stored for or more than 4 weeks, proceed as follows: 1. Disconnect the turbocharger oil input and output pipes and pour in clean engine oil through the filling hole. Make sure no impurities get into the turbocharger.

2. Remove the turbocharger air input pipe and turn the rotation unit by hand in order to pre--lubricate bearings.

3. Reconnect the oil input pipe and the air input pipe, but not the oil output pipe.

4. Disconnect the wire going to the fuel shut off electrovalve. Place an appropriate container under the oil output oil and let the engine run until oil comes out of the hole.

5. Reconnect the oil output pipe with a new gasket and tighten the fastening nuts to the prescribed torque. Refer to the Technical Data in Section 8.

Reconnect the arrest electric magnet wire.

6. Check the engine oil level and top up, if needed.

Start the engine and check that there are no oil or air leaks.

7. Look at the oil pressure warning light. If this warning light does not go off after the engine has been running idle a couple of seconds, stop the engine immediately and contact the dealership.

Whenever the engine is started, let it run idle (1000 rpm max) for 60 seconds before working under load, in order to assure the turbocharger bearing oil supply is correct. Even before turning the engine off, let it run idle for two minutes, in order to let the turbocharger bearing oil cool down.

6--4

SECTION 7 ACCESSORIES INTRODUCTION A wide range of attachments are available for your vehicle, as shown and described in the following text.

The operator’s manual with load charts should be kept in the place provided, and used for guidance when using and working with these attachments.

Some particular applications may require the adaptation of an attachment. Consult your dealer.

WARNING

Only the attachments approved by the manufacture can be used on the vehicle. The manufacturer cannot be held responsible in the event of modifications or attachment adaptation carried out without the manufacturer’s knowledge.

CONTENTS Description Page Weight of machine and attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--2 Attachment dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--2

7--1

SECTION 7 -- ACCESSORIES WEIGHT OF MACHINES AND ATTACHMENTS

Weight TX130--30 = 9.400 kg TX130--33 = 9.600 kg TH007014

1 IMPORTANT: The information shown above and below is for general guidance when estimating machine weight and will not necessarily take into account tyres that may be fitted, fluid levels or additional equipment. To determine the precise weight of your machine it will be necessary to place your machine onto an official weigh--bridge.

The above figures reflect the “approximate weights” of a standard machine without attachments.

To establish the weight of your individual machine add where identified the weight of the attachment.

Weights of the attachments can be taken from the following attachment descriptions, or attachment certification plate.

ATTACHMENT DIMENSIONS

Description

Width mm

Weight Capacity kg kg

Quick compler attachment without bar

890

194

Quick compler attachment with bar

890

194

Hydraulic quick coupler attachment

890

210

Pallet fork carriage

1200

118

Pallet fork carriage with side--shift

1200

280

Carriage forks pair 100 x 50

1200

114

1225

214

Floating Fl ti pallet ll t fork f k carrier i on sliding rod Floating forks pair 100 x 50

7--2

4000

1470 1560 1200

114

4000

TH007013

SECTION 7 -- ACCESSORIES

Description

Width mm

Weight Capacity kg kg

1.2 mc bucket with bolted teeth

2500

605

1600 kg/mc

1.2 mc bucket without teeth

2500

570

1600 kg/mc

0.8 mc bucket with bolted teeth

2500

483

1600 kg/mc

0.8 mc bucket without teeth

2500

448

1600 kg/mc

0.6 mc bucket with bolted teeth

2500

473

1600 kg/mc

0.6 mc bucket without teeth

2500

438

1600 kg/mc

L=2000 Manually extendable crane jib (removable derrick) Length g 2000 ÷ 3000

L=2500

TH007002

450

344

L=3000

350

250 TH007003

Tubular derrick L = 3000 without winch

268

1500

Tubular derrick L = 4000 without winch

282

900

Tubular derrick L = 3000 with winch

378

1500

Tubular derrick L = 3000 with winch

392

900

TH007004

TH007005

Concrete mixing bucket

1980

730

TH007006

7--3

SECTION 7 -- ACCESSORIES

Description

Lifting hook on carriage forks

Width mm

740

Weight Capacity kg kg

60

4000

TH007007

Hydraulic lifting winch on raft

950

290

TH007008

Lifting hook on raft

820

135

TH007009

Log fork

2000

498

TH007010

7--4

SECTION 7 -- ACCESSORIES

Description

4 in 1 multipurpose bucket capacity 1 mc

Width mm

2500

Weight Capacity kg kg

790

1600 kg/mc

TH007011

Fork extension Length = 2000 mm

100

Fork extension Length = 2500 mm

105

Platform for materials

1200

292

7--5

SECTION 7 -- ACCESSORIES

NOTES

7--6

SECTION 8 SPECIFICATIONS AND DATA The general specifications given on the following pages are provided for your information and reference. Should you require further information or more detailed information consult your Dealer.

CONTENTS Description Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--2 TX130--30/TX130--33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--3 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--7 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--7 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--7 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--9 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--9 Radiator coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--9 Four wheel drive tyre combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--9 Weight of machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--9 Tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--10

8--1

SECTION 8 -- SPECIFICATIONS AND DATA GENERAL NOTE: “The manufacturer” follows a policy of continuous improvement and reserves the right to make changes in design and specifications at any time without notice and without obligation to modify units previously built.

All data given in this book are subject to production variations. Dimensions and weights are approximate only and the illustrations do not necessarily show machines in standard condition. For exact information about any particular machine, please consult your Dealer.

Model

TX130--30

TX130--33

no stab.

Small stab.

Turbocharged 74 kW 12.750

Turbocharged 74 kW 13.060

Max. capacity (kg) a 500 mm from fork stop

3300

3300

Capacity at max. height (kg)

2500

2500

Extension at max. height (m)

1.800

Engine Max. lifting height (m)

Max. longitudinal extension (m) Capacity at max. extension (kg)

1.800 8.750

650

1350

Weight (kg)

9600

Length (m)

5.950

8--2

SECTION 8 -- SPECIFICATIONS AND DATA

TH008011

1

TX130--30 TX130--33 1200 mm

K

B

3120 mm

T

4396 mm

C

1617 mm

U

2730 mm

D

5850 mm

V

5204 mm

E

7050 mm

V1

980 mm

F

2050 mm

V2

3890 mm

G

402* mm

W

2445 mm

I

1100 mm

A

1260 mm

* Value measured with tyres 405/70x24 8--3

SECTION 8 -- SPECIFICATIONS AND DATA

TX130--30

TH00R074

2 TX130--30 (without stabilisers)

8--4

SECTION 8 -- SPECIFICATIONS AND DATA

TX130--33

TH00R076

3 TX130--33 (with small stabilisers lowered)

8--5

SECTION 8 -- SPECIFICATIONS AND DATA

TX130--33

TH00R075

4 TX130--33 (with small stabilisers raised)

8--6

SECTION 8 -- SPECIFICATIONS AND DATA ENGINE DATA 74 kW (101 HP) Turbocharged with Aftercooler Type

Diesel

No. of cylinders

4 in--line

Bore

mm

104

Stroke

mm

132

Displacement

cm3

4485

Compression ratio

17,5 : 1

Firing order

1.3.4.2

Idle speed

rev/min

1000--1050

Maximum ‘No--load’ speed

rev/min

2300--2400

Rated speed

rev/min

2200

Maximum torque

430 Nm

COOLING SYSTEM Type Fan Fan belt deflection Drive belt deflection Air conditioning compressor Thermostat: Starts to open at Radiator cap

Pressurized full flow by--pass with expansion chamber 7 blade 10 -- 16 mm 16 mm 81 °C 1 bar

FUEL SYSTEM Injection pump Type Cold start device Excess fuel device Fuel shut off Lift pump

Rotary Thermostart Automatic governor Solenoid Mechanical

8--7

SECTION 8 -- SPECIFICATIONS AND DATA TRANSMISSION POWERSHIFT – T12000 4x3 = 4 forward and 3 reverse gears Gear

Ratio

Stall speed (RPM)

I

4.025

2349

II

2.048

2309

III

1.000

2248

IV

0.662

2170

ELECTRICAL SYSTEM Alternator Battery type Optional Battery disconnect via the isolator switch Regulator Ground (Earth) Starting motor Headlight bulb Stop/tail light bulb Interior light bulb Flasher light bulb Work light bulbs Instrument/warning light bulbs Rocker switch bulbs

95 amp.

12 volt negative earth 160 Ah on negative / chassis cable Transistored negative Positive engagement, solenoid operated (3.1 kw) 40/45W 5/21W bayonet cap 5W festoon and 10W bayonet cap 21W bayonet cap 55W H3 halogen 1.2W capless 1.2W capless

BRAKES Type Disc diameter Parking type

Wet multi--disc 8 per axle 203.2mm Mechanical, disc on the transmission

STEERING Power steering type Pump type System pressure Wheel toe--in

Hydrostatic Gear 175 bar 0 -- 2mm

FRONT AXLE Chassis mounted Differential lock

Floating with levelling cylinder No

REAR AXLE Chassis mounted

8--8

Floating with arm deflection 10° oscillation and automatic lock

SECTION 8 -- SPECIFICATIONS AND DATA HYDRAULIC SYSTEM Gear pump Hydraulic system pressure: Main system pressure Steering system pressure

Hydraulic system and steering system 240 bar 175 bar

TORQUES

Nm

Wheel nuts Cab attaching bolts

540 380

RADIATOR COOLANTS Anti--freeze should be changed every 1000 hours or 24 months.

FOUR WHEEL DRIVE TYRE COMBINATIONS The tyres fitted to machines with 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.

WEIGHT OF MACHINES

Weight TX130--30 = 9.400 kg TX130--33 = 9.600 kg

TH007014

5 IMPORTANT: The information shown is for general guidance when estimating machine weight and will not necessarily take into account tyres that may be fitted, fluid levels or additional equipment. To deter-

mine the precise weight of your machine it will be necessary to place your machine on an official weigh--bridge.

8--9

SECTION 8 -- SPECIFICATIONS AND DATA TYRE PRESSURES The tables are for guidance only. For exact information regarding inflation pressures and loads for your particular tyres, consult your Dealer.

Model

Axle

FRONT

TX TX130--30 TX130--33

REAR

Tyre 400/80--24 T37 405/70--24 14PR TL MPT--01 15R22.5 XF TL (H) 405/70--24 14PR TL MPT 4L I3 405/70--24 14PR TL MPT R--1 405/70--20 14PR TL MPT R--1 405/70--20 14PR TL MPT 4L I3 405/70--20 14PR TL MPT--01 400/80--24 T37 405/70--24 14PR TL MPT--01 15R22.5 XF TL (H) 405/70--24 14PR TL MPT 4L I3 405/70--24 14PR TL MPT R--1 405/70--20 14PR TL MPT R--1 405/70--20 14PR TL MPT 4L I3 405/70--20 14PR TL MPT--01

Speed (km/h) 50 40 39 35 40 40 35 40 50 40 39 35 40 40 35 40

Inflation pressure (bar)* 4.25 4.0 6.5 4.5 4.5 5.5 5.5 3.5 4.25 4.0 6.5 4.5 4.5 5.5 5.5 3.5

Capacity (kg)

Rolling circle (m)

wheel

axle

3,825 3,465 3,390 3,544 3,593 3,220 3,183 3,165 3,825 3,465 3,390 3,544 3,593 3,220 3,183 3,165

3650 3885 3620 4005 4005 3790 3790 3575 3650 3885 3620 4005 4005 3790 3790 3575

7300 7770 7240 8010 8010 7580 7580 7150 7300 7770 7240 8010 8010 7580 7580 7150

* Listed pressures refer to inflation for use on size.

The above figures reflect the “approximate weights” of a standard machine without attachments.

8--10

SECTION 9 CONTENTS CONTENTS OF SECTION 1 Description Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2 Summary of safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--22 Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--23 Information concerning airborne noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--32 Information concerning hand--arm and whole--body vibration emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--32 Load Status Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--33 Safety features and vehicle secutiry options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--37 Road travel requirements – in cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--38 Road travel requirements – external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--39 “CE” Norms – Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--42 Universal Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--44 Machine functions monitored by instruments, luminous pilot lamps and buzzers . . . . . . . . . . . . . . . . . . . . . 1--45

CONTENTS OF SECTION 2 Description Page General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3 Hand and foot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--6 Cab instruments and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--15 Wheel alignment operating leve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--16 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--17 Load status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--21 Multifunction lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--23 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--24 Operativeness selection switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--26 Powershift transmission 4 x 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--27 Driving with the Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--27 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--30 Starting the machine with jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--33 Engine stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--34 Running--in procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--34 Driving the Telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--35 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--36 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--37 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--38 Machine storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--38 9--1

SECTION 9 -- INDEX

CONTENTS OF SECTION 3 Description Page Front loader controls/operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2 Load status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3 Load handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5 Installing attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--8 Ballasting and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--11 Weighting of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--12

CONTENTS OF SECTION 4 Description Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2 Daily checks required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--8 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--13 Every 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--14 Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--17 Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--19 Every 1000 hours or annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--25 Every 2000 hours or every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--29 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--33

CONTENTS OF SECTION 5 Description Page Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2 Gearshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic system troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5--4 5--5 5--6 5--7 5--7

CONTENTS OF SECTION 6 Description Page Long vehicle inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2 Tyres and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2 Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3 Vehicle preparation after prolonged inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4 9--2

SECTION 9 -- INDEX

CONTENTS OF SECTION 7 Description Page Weight of machines and attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--2 Attachment dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--2

CONTENTS OF SECTION 8 Description Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--7 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--7 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--7 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--9 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--9 Radiator coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--9 Four wheel drive tyre combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--9 Weight of machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--9 Tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--10

9--3

TELEHANDLER TELESCOPIC LIFTER LUBRICANTS AND COOLANTS Engine oil correct viscosity grade depends on ambient temperature. Refer to the table on the right for selecting engine oil for your machine.

NOTE: In areas with long periods of extreme temperature, local lubrication procedures are admissible, such as using SAE 5W30 where there are extremely low temperatures or SAE 50 where there are extremely high temperatures.

Sulphur contents in fuel.

Engine oil replacement interval is shown in Section 3. Local fuel can however have a high sulphur content: in this case engine oil replacement interval must be changed as follows: Sulphur contents in % Oil replacement interval Below 0.5 Normal 05.5 to 1.0 Half the normal Over 1.0 One fourth the normal

--30 °C --25 °C

--15 °C

+20 °C

+40 °C

SAE 5W--30

SAE 10W--30

SAE 15W--40

--22 °F

--13 °F

+5 °F

+68 °F

+104 °F

NOTE: It is advised to use fuel with sulphur contents below 1.3% SUGGESTED FLUIDS AND THEIR APPLICATION

Oil – ENGINE AKCELA Nº 1 15W40 AKCELA Nº 1 10W30 Oil – POWERSHIFT TRANSMISSION AKCELA TCH FLUID 10W Oil – FRONT AND REAR AXLE FUCHS TITAN GEAR LS 90 85W90 Oil – DROP BOX 135H EP 80W90 OIL – FRONT/REAR AXLE HUB 135H EP 80W90 OIL – FRONT LOADER HYDRAULIC SYSTEM AKCELA NEXPLORE 10W30 ENGINE RADIATOR Water Premium Antifreeze BRAKE CONTROL CIRCUIT – OIL LHM Fluid CRANE ARM SHOES – GREASE 251H EP GENERAL – GREASE 251H EP CONDITIONER COMPRESSOR Freon R134a FUEL Diesel Fuel

International Specification

Quantity

Ambient Temperature °F (°C)

ACEA E5 API CH--4, CG--4/SL

7,6 litres (including engine oil filter) 12,9 + 4 litres (lines and radiator)

From –14 to +122 From (–10 to +50)

ATF Type A Suffix A ALLISON C4 API GL5 e API GL5 LS GO 90 LS ZF TE--ML 05

7 litres

From –4 to +122 From (--20 to +50)

API GL5

0,75 litres

API GL5

0,65 litres

ISO VG 46 DIN 51524

185 litres

From –4 to +122 From (--20 to +50)

50% H2O 50% ANTIFREEZE

12 litres 12 litres

From –31 to +122 From (--35 to +50)

M6C 59--A

1 litre

NLGI 2

As required

From –40 to +122 From (--40 to +50)

NLGI 2

As required

From –40 to +122 From (--40 to +50)

1800 gr 135 litres

NOTE: Fluid and lubricant quantities are meant as overall. Drained fluid or lubricant quantities might not correspond to those stated because part of the oil or fluid could be trapped by some machine components.

DECLARATION OF CONFORMITY ”CE” The previous pages include a copy of the Declaration of Conformity ”CE” (DdC CE).

The EC DoC is the manufacturer’s declaration about equipment compliance to relevant EU provisions.

Please keep the original document in a safe place. Local authorities may require you to show this document in order to assure compliance of your equipment.

Translation of this declaration in your own country language is provided on the reverse page of the original document. For your better and easier understanding of the document hereafter you’ll find some explanatory notes.

1. Under section 1.2 are listed those options or variants which have safety related functions. Some of them are standard provided, like FOPS or ROPS (please refer to page 1--18 for other detail). Others are available upon customer request.

2. Under point 2 are listed all information required by EU ”Outdoor Noise” Directive 2000/14/EC. Please refer your own original EC DoC for specific equipment information. Other information about equipment guaranteed sound power level (LWA) can be found on page 1--32. On the same page are indicated information about operators station noise level (LpA) which is not matter of above mentioned EU Directive and therefore not indicated on it.

3. Generic serial number for this equipment type. Sequence of letters and numbers may vary depending on equipment configuration.

4. EC DoC serial number. Please make reference to this number when requiring information or support to New Holland about EC DoC. 5. Signature of a person authorised to sign the document on behalf of the company.

COPYRIGHT BY Technical Publications Dept. -- Lecce

F No part of the text or illustrations of this publication may be reproduced.

Print No. 84266616 -- English -- XII -- 2009