Case TX130-40 TX130-43 TX130-45 TX140-43 TX140-45 TX170-45 Turbo Operation & Maintenance Manual

TX130-40 / TX130-43 / TX130-45 Turbo TX140-43 / TX140-45 Turbo TX170-45 Turbo

P.I.N. HGCTX13MN7HK40001 and after (TX130-40 turbo) P.I.N. HGCTX13MN7HK39001 and after (TX130-43 turbo) P.I.N. HGCTX13MN7HK38017 and after (TX130-45 turbo) P.I.N. HGCTX14MN7HK42003 and after (TX140-43 turbo) P.I.N. HGCTX14MN7HK41027 and after (TX140-45 turbo) P.I.N. HGCTX17MN7HK43027 and after (TX170-45 turbo)

Printed in Italy

87681534 GB

OPERATION AND MAINTENANCE INSTRUCTION MANUAL TX130--40 turbo TX130--43 turbo TX130--45 turbo TX140--43 turbo TX140--45 turbo TX170--45 turbo

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.

Model Stabilisers

TX130--40

TX130--43

TX130--45

TX140--43

TX140--45

TX170--45

no

small

large

small

large

large

Engine Max. lifting height (m)

88 kW (120 CV -- 118 HP) Turbo Aftercooler 12.300

12.450

12.450

13.550

13.550

16.600

Max. capacity (kg) at 500 mm from fork stop

4000

4300

4500

4300

4500

4500

Capacity at max. height (kg)

2600

3600

4000

3000

3600

2500

Extension at max. height (m)

1.200

0.500

0.000

0.500

0.300

1.000

Max. longitudinal extension (m) Capacity at max. extension (kg)

8.650 700

1700

9.330 1800

1400

12.540 1500

450

Weight (kg)

10480

10780

11760

Length (m)

5.850

6.070

6.135

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 Summary of safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--15 Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--16 Airborne Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--25 Load Status Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--26 Safety features and options vehicle secutiry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--38 Road travel requirements – in cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--39 Road travel requirements – external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--40 “CE” Regulations – Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--43 Universal Symbology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--45 Machine functions that are monitored by instruments, warning lights, and buzzers . . . . . . . . . . . . . . . . . . . 1--46

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.

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.

1--2

TH001097

1

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 *HGCTX17MN7HKXXXXX*

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

Example: *HGCTX17MN7HKXXXXX* 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.

TH001175

2

Vehicle Identification Plate The vehicle identification plate is located on the front side of the seat location. Record the data of your machine below.

TECHNICAL TYPE/MODEL UNIT SERIAL No. YEAR TH001172

3

1--3

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY Engine Identification The engine identification information is located on the right--hand side of the engine block. Record the information below for quick reference in case of necessity.

MODEL No. SERIAL No. DATE CODE

TH001192

4

Front and rear axle identification The serial number and axle type is 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. DATE CODE

1--4

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY 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. DATE CODE 1 TH001030

5

Identification plates in the cab The cab identification plate with serial number and details are printed on the plate to the front side of the seat. Record the serial number below for quick reference in the case of necessity.

SERIAL No. DATE CODE

TH001161

6

1--5

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: x Attachment type x Cubic capacity x Date of manufacture x Unladen weight x Serial No.

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

TH001004

7

1--6

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

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.

x

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.

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.

1--7

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--8

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--9

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY DRIVING CONSIDERATIONS

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”.

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

Under all circumstances, remain in control of your speed – DO NOT OVERSPEED.

Do not forget to fasten your safety belt.

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.

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.

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.

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

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: x

That is correctly placed and secured.

x

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

x

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

x

That this platform allows for the width of the machine.

TH001011

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

1--10

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY 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.

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.

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

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.

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

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.

TH001100

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

TH001101

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.

TH001015

Do not manoeuvre the load when the machine is in motion

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.

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.

1--11

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY 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.

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

TH001102

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

The employment of the Telehandler as lifting equipment is subject to the compliance of the laws in force in the country of use.

Apply the parking brake when lifting or depositing a difficult load or when on an incline.

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: x Lower the forks or attachment to rest on the ground; x Stop the engine; x 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.

TH001103

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.

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

TH001104

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.

TH001017

1--12

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

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.

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

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.

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--13

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.

TH001080

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.

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

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

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

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.

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

9. Keep equipment clean and properly maintained.

10. Do not drive equipment near open fires.

11. Never use the fuel for cleaning purposes.

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--14

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 SUMMARY OF SAFETY RULES

x

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.

x

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: x

Ensure that there is nobody within the machine operating range.

x

Do not stand or walk under the arm of the vehicle

x

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 x

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.

x

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

x

Install the fork guard.

x

Cab controls must be locked.

x

x

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

USE OF THE ATTACHMENTS

x

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

x

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

x

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.

x

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

USE OF THE LOADING BUCKET x

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

x

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

x

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 x

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.

x

Do not start or stop the machine with a jerk.

x

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.

x

Avoid oblique pulls and towing.

x

x

x

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

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

1--15

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY SAFETY DECALS

TH001171

8 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--16

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

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

b

b

b

b

b

b

b

b

b

b

b

b

b

b

b

b

b

b

b

b

b

b

b

b

TH001147

10 DANGER: Make sure that near electric power lines and poles, the attachment used is at a minimum distance of 8 meters (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

11

1--17

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

TH001149

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

TH001150

13 SAFETY HAT: Wear a safety hat for your own protection.

TH001151

14 OPERATOR’S MANUAL: Read the operator’s manual before attempting to operate the machine.

TH001152

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

TH001153

16

1--18

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY

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

TH001145

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

Safety key plate.

TH001154

18 1--19

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

1--20

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY Reversing running direction is admissible only in first gear.

TH001159

23 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.

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

TH001160

24 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

25

TH001144

26

1--21

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY

TH001162

27 MACHINE SAFETY DECALS 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--22

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

28

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

TH001164

29

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

TH001165

30

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

31

1--23

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

32

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

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

TH001169

34

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

35

1--24

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY AIRBORNE NOISE EMISSION NOISE LEVELS 2000/14/CE Guaranteed noise level LWA = 106 dB (A) Guaranteed noise level, set in compliance with the European directive 2000/14/CE Noise at the driving seat Assessed on identical machines, in compliance with EEC norms 95/27 and 86/662 LPA = 74 dB (A)

TH001106

36 *Noise level at rated speed in Cab

74 dB(A)

**External noise level

106 dB(A)

* Test results are in accordance with directive EEC 86/662 concerning maximum noise heard at operator’s ear level (under load). ** As a requirement to the European directive (EEC 2000/14/EC), listed below are the noise levels measured in dB(A), according to ISO 5131 Standard. The noise is measured with all the mechanisms engaged and running at normal operating speed for the specified use of the product.

1--25

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 C The green LED signal situations of a decreasing stability, but still normal. During normal operations, LED status is continually updated, conveying the current situation.

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 37

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.

Illumination of this alarm causes blocking of all the hydraulic functions relating to load manipulation.

The only enabled function will be the retraction of the telescopic arm.

TH001107

38 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--26

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY IMPORTANT: When lifting or craning, ensure the machine is on a level ground, apply service brakes.

LIFTING OR CRANING – S.W.L, SAFE WORKING LOADS Shown are the maximum loads for the model ranges for lifting or craning:

TX130--40 turbo -- TX130--43 turbo - TX130-- 45 turbo (without stabilisers or with stabilisers raised and with rear axle lock)

q

q

q

q

q

TX130--40 TX130--43 TX130--45 q

q

q

TH001074

39

1--27

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX130--40 turbo -- TX130--43 turbo - TX130-- 45 turbo (without stabilisers or with stabilisers raised and without rear axle lock)

q

q

q

q

q

TX130--40 TX130--43 TX130--45 q

q

q

TH001075

40

1--28

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX130--43 turbo (with stabilisers lowered)

TX130--43

TH00R031

41

1--29

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX130--45 turbo (with stabilisers lowered)

TX130--45

TH00R032

42

1--30

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX140--43 turbo - TX140-- 45 turbo (with stabilisers raised and with rear axle lock)

q

q

q

q

q

TX140--43 TX140--45

q

q

q TH001076

43

1--31

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX140--43 turbo - TX140-- 45 turbo (with stabilisers raised and without rear axle lock)

TX140--43 TX140--45

TH00R033

44

1--32

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX140--43 turbo (with stabilisers lowered)

TX140--43

TH00R034

45

1--33

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX140--45 turbo (with stabilisers lowered)

TX140--45

TH00R035

46

1--34

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX170--45 turbo (with stabilisers raised)

TX170--45

TH001025

47

1--35

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX170--45 turbo (with stabilisers raised and without rear axle lock)

TX170--45

TH001079

48 NOTE: This diagram must be considered when the rear axle lock manual control is selected.

1--36

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX170--45 turbo (with stabilisers lowered)

TX170--45

TH00R036

49

1--37

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

2

1

3

4

5

6

TH001109

50 1.

CAB DOOR: can be locked by with key.

2.

FUEL TANK PLUG: can be locked by with key.

3.

UNDER CAB COMPARTMENT: this tool carrier compartment can also be locked by key.

4.

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

5.

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.

1--38

6.

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.

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

TH001082

51 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”.

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.

2. HYDRAULIC FUNCTION LOCKOUT: the configuration key (1) must be set to “road” position (central position).

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

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--39

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

52

2 TH001201

53

2 TH001202

54 3

TH001195

55 1--40

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

56 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

TH001196

57 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

58

1--41

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

59 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

TH001199

60 10. LARGE STABILISER BLOCKING CABLE: when travelling on the road, make sure that steel cable (4) is secured in such a manner that the stabilisers are prevented from moving. This condition is valid for large stabilisers only.

4

TH001200

61

1--42

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY “CE” 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 the event additional equipment such as lifting platform is used, the safety regulations regarding such equipment is standard EN 280.

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

All the machines discussed in this manual have been developed and manufactured to comply with the requirements of the machinery safety directive and display a ‘CE’ mark in the following style.

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

NOISE

“CE” 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: ”CE” Directive CEE/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.

VIBRATION:

“CE” CEE/93/392

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

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

x

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;

x

make sure that the machine is maintained in efficient conditions;

x

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

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--43

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY x

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

x

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 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.

1--44

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

Thermostart starting aid

Alternator charge

Side lamps

Turn signals

N Front windscreen wipe

Transmission in neutral Slow or low setting

Fuel level Front windscreen wash Engine speed (rev/min x 100)

Heater temperature control Engine oil pressure

Roof beacon Accessory socket

Ground speed

Hydraulic and transmission filters

Transmission oil temperature

Hazard warning lights

Transmission oil pressure

Malfunction!

See operator’s manual

FWD engaged

Read operator’s manual

Rear windscreen wash/wipe Hours recorded

Horn

Heater fan Engine coolant temperature Air conditioner Coolant level Air filter blocked Machine lights

Brake reservoir oil level

Variable control Pressurised!

Open carefully

Warning!

Parking brake

Headlamp main beam

Headlamp dipped beam

Stop lamps

Hydraulic service Isolation switch

Axle unlock

Optional hydraulic function inhibition

Warning!

Corrosive substance Optional hydraulic function

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

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.

1--45

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

63 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

X

Reverse gear

X

Steering

X

For more detailed information about indicator meanings see Section 2.

1--46

Buzzer

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 driving or operating the machine, unless you are fully familiar with the controls.

IT IS TOO LATE TO LEARN ONCE THE MACHINE IS MOVING

CONTENTS SECTIONAL Description

Page

General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3 Hand and foot operating controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--6 Cab instruments and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--14 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--15 Instrumentat console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--16 Load status indicator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--20 Multi--function lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--22 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--23 Safety key and selecting operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--25 4x3 Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--26 Driving with the Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--26 Operating the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--29

2--1

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION Starting the engine with jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--32 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--33 Running--in procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--33 Driving the Telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--34 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--35 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--36 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--36 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--37 Machine storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--37

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 Cab internal width Turning radius

2450 mm 2445 mm 3120 mm 940 mm 3890 mm

Capacity Fuel tank Hydraulic system

135 l 180 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

TH002103

1

2--3

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION HAND AND FOOT OPERATING CONTROLS Shown in figure 2 is the cabin layout of a typical machine with Powershift transmission and hydraulically assisted controls for the telescopic arm.

NOTE: The layout controls in the diagram may vary between machines depending on options fitted to meet legislation in different Countries.

1. Hydraulic controls panel.

2. Instrument console.

3. Wheel alignment operating lever.

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

4. Safety key for selecting control modes: -- job size; -- road; -- people carrying platform.

5. Vehicle emergency lights switches, lights and various services switches.

6. Engine start key.

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.

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

12. Storage facility (on demand radio compartment).

13. 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.

7. Parking brake.

14. Pedal accelerator.

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

15. Foot brake pedal.

16. Anti overturning block forcing release button.

9. Road lights and direction indicator control lever.

17. Steering wheel height adjusting lever.

10. Ventilation duct.

18. Load control display.

19. Heating/conditioning control panel.

2--4

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION

1

2 3 4

9

8 13

10

12

11

17 16 14

15 5

6

5

7

19 18

TH002144

2

2--5

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

It is equipped with a rollover protection structure.

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.

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.

TH002081

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 TH002158

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.

FIRE PROTECTION 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.

TH002082

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

remove the fire extinguisher form its support;

x

remove the safety pin;

x

press the control lever full stroke and direct the jet toward the base of the fire.

6

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.

TH002081

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

2

TH002080

8 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 (1) the glass frame can be swung back and retained as shown below.

1

TH002083

9

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

10

3 TH002087

11 Rear window The rear window is locked by handle (1). Rotate it to open. The window has the function of emergency exit. In case of necessity, pull red coloured eye (2) to release the glass from the handle.

2

1

TH002145

12

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.

2.

3.

4.

5.

Horizontal sliding guide travel adjustment Seat height adjustment Fixing seat belt Backrest angle adjustment Weight adjustment (suspension)

3

1 2 5

TH002097

13

4

TH002089

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

--

Move handle 1 downward to release and ad just the steering wheel.

--

Move handle 1 upward to lock the steering wheel in the desired 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.

1

TH002011

15

2--10

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION CAB HEATING CONTROLS 1

2 Heater Blower Controls A three--speed blower is installed for heat circulation inside the cab, and is controlled by switch (1).

In position “ ” the fan is OFF. By rotating the knob clockwise, the fan is operated at low speed then the speed increases.With the windows and doors closed, the blower may be used to pressurise the cab to exclude dust.

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

TH002071

3 16

Heating temperature 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 warm--up the cab, the air conditioning system must be cut--off by actuating button (3) or by 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.

2--11

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION AIR CONDITIONING SYSTEM (WHERE FITTED) Circulating the air through the cooling unit (evaporator) causes heat reduction. This unit also serves to reduce the moisture and dirt content of the air, as the wet surface of the evaporator collects dust and pollen particles, which are drained off with the condensed moisture.

The system consists of two heat exchangers and a compressor inter--connected by tubing. The cooling unit, i.e. the evaporator, is located in the cab with the second heat exchanger (condenser) mounted in front of the engine radiator.

The pump (compressor) circulates the refrigerant liquid R134a, which is easily heated and cooled. The pump is mounted on the right--hand side of the engine and driven by a “V” belt from the crankshaft pulley.

NOTE: R--134a is the only refrigerant acceptable to your machine air conditioning system. Prior to seasonal operation of the air conditioner, it is essential that you close the heater knob fully OFF.

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

insert the fan at maximum speed through knob 1;

x

actuate knob 2 until maximum temperature is reached.

x

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

2--12

1

2 3 TH002146

17

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 pools of water will collect beneath the drain hose outlets under the cab when the machine is stationary.

REFRIGERANT R134a

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

Therefore it is important to following warning and directions are adhered to.

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

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

Should the refrigerant 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 qC), cover the area loosely with a bandage to protect the affected area against infection and consult a doctor immediately.

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

SUN VISOR Pull forward the visor 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.

TH002159

18

2--13

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION CAB INSTRUMENTS AND CONTROLS IMPORTANT: Switch and gauge positions may vary slightly from that shown: they are dependant upon options fitted and local market requirements.

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.

1

4 3 2

8

9

10 11

5

6

5

7

TH002148

19 1.

Hydraulic controls panel.

6.

Key start switch.

2.

Safety key for selecting control--operating modes.

7.

Load monitor display.

3.

Wheel--alignment operating lever.

8.

Powershift transmission control lever.

4.

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

9.

Multifunction switch for turn indicators and road lights.

5.

Vehicle emergency lights switches, lights and various services switches.

2--14

10. Storage facility/radio compartment.

11. Anti--overturn block forcing button.

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

A C

A -- TWO--WHEEL STEERING – Move the steering mode selection control valve 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

WARNING Before driving on the highway it is essential to check the alignment of the wheels and to drive with two wheels steering only.

Unless otherwise indicated the wheels steering are only the ones in front.

C

A

B

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 for steering selection enabling to move in bias (crab steer).

TH002017

20

TH002112

1 21

2--15

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

TH002113

22

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

Tachometer and Hour Meter

2

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

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 23

2--16

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

1

This gauge (1) indicates the level of fuel in the tank on a continuous basis but is only operative with the key--start/stop switch in the “ON” position.

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

TH002115

24

WARNING LIGHTS -- 1st segment 1. Alternator charge warning light: the alternator (2) 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.

2. Engine (3) 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.

3. Brake reservoir oil low level indicator lamp (4).

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.

4 2

3

5

TH002116

25

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.

4. Thermostart (5) 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--17

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION WARNING LIGHTS 2nd segment 1. Transmission oil temperature warning light The indicator light comes ON when the transmission oil temperatures exceeds 120 qC.

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.

2 1

3

4

TH002117

26 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--18

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

TH002118

1 2

1. Main beams 2. Direction indicator lamps

27

WARNING LIGHTS -- 4th segment

TH002119

3

4

5

They indicate which is the steering scheme currently selected: 1. Two steering wheels (front ones) (3) 2. Bias translation (crab steer) (4) 3. Four steering wheels (5)

28

2--19

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 C The green LED signal situations of a decreasing stability, but still normal. During normal operations LED condition is continuously updated and shows the current situation.

B

A B -- YELLOW SIGNAL LIGHT (VISUAL ALARM) 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 raising along the arc that really moves the weight nearest the machine or retract the telescopic boom if it is in an extended position, to move the weight nearest the centre line of the machine.

TH001053

D 29

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.

When this alarms is on, all the hydraulic functions relating to load manipulation, to stabiliser lifting and to axle tilting are blocked.

The only allowed function will be the retraction of the telescopic arm unless the button described further imposes the locking of all functions.

2--20

TH001107

30

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION D -- TEST SWITCH C 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.

B

A

TH001053

D 31

BUTTON FORCING THE ANTI OVERTURNING BLOCK When this button is kept depressed during hazard conditions for unbalancing, normal hydraulic control functions are temporarily restored.

IMPORTANT: all operations must be performed while the button is kept depressed.

Corrective actions can be those of approaching load weight to the centre of gravity of the vehicle (lifting the load or retracting the arm), or actions intended to increase stability, such as lowering the stabilisers or correcting the axle inclination.

1

TH002026

32

WARNING Operate this button only if is possible to correct vehicle stability without being having to retract the telescopic arm.

DANGER OF OVERTURNING!!

2--21

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

TH002074

33

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

TH002075

34 Front windscreen washer Depress button (1) located at the outside end of the multi--function lever to operate the front windscreen washing function.

1

TH002076

35

2--22

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION SWITCHES SWITCHES (right hand 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.

6 1. Slow moving warning beacon – Depressing this switch operates the roof beacon.

7

8

9

1

2

3

4

5

TH002157

36

2. Road lights – three--position switch -- Off -- Side lights -- Low beams/high beams Selection between low beams and high beams is possible by operating the multi--function lever described in the previous chapter.

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

4. Front work lights (two--position switch) – When operated it illuminates the front work lights.

5. Rear work light (2--way switch) -- The rear light comes ON when actuated.

6. Additional (optional) lights mounted on the telescopic arm.

7. Attachment electric control.

8. Rear wiper/washer (optional). -- The function is activated when the button is pressed.

9. Hydraulic function inhibition (optional)

2--23

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. This switch provides two operational modes for the stabilisation system. a) Switching in neutral position. When the boom exceeds 30 degrees the lifting of both stabilisers in inhibited. In this position, the operator must refer to section 8 ”with stabilisers and axle locking”. b) Switch pressed. This provides the actuation of the stabilisers and the levelling of the frame with boom exceeding 30 degrees. In this position the operator must refer to the load capacity diagrams ”without stabilisers and without axle locking”.

WARNING With the arm lifted over 30q the lifting function of the right and left axle levelling stabilisers is inhibited.

Under these conditions, it is impossible to lift one or both stabilisers or make a levelling of the frame.

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.

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--24

1

2

3

4

TH002084

37

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION SAFETY KEY AND SELECTING OPERATION This is located on the right hand side of the steering column base. They key (1) enables selection of the hydraulic controls operating modes. It has three positions and operates as shown here below.

1

TH002078

38 A. “People carrying platform” position. It locks out the stabiliser lifting, vehicle levelling operations and steering mode selection. Telescopic arm control operation is transferred to the controls on the platform. In the cab all the functions relating to the arm and attachments are therefore locked out, while on the platform only the telescopic arm functions can operate, i.e. lifting / lowering, extension and retracting. Should this position be selected when the stabilisers are lifted, the load status panel will give a warning of the anomaly by illuminating the red LED together with the first and the second green LED.

A

B

TH002033

39

WARNING Make sure that the platform is hooked to the quick coupling and locked by the pin and safety pin, or, fo the hydraulic quick coupling, that both pins are fully extracted and inserted in the platform coupling.

(Read carefully the specific Manual for PERSONNEL CARRIER PLATFORM)

B. “Road” position. This locks out all the operations of the arm, stabilisers, levelling and steering mode selection. 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, it is advisable to remove the key before starting travel.

C

WARNING The “road” position forces the alignment of the wheels to the two wheel--steering configuration. If the special selector is positioned in a different way, there will be a misalignment between the selector position and the warning light on the dashboard. The rear wheels will be blocked to position as soon as they are in alignment with the travelling direction.

C. “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--25

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.

TH002079

40 HORN The horn is operated by pushing on the button at the end of the transmission lever.

DRIVING WITH THE POWERSHIFT TRANSMISSION

A

Neutral position (N) N

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

R

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

NOTE: the effective selection of forward at this time, depends upon the vehicle condition; if, for example, this is moving, the microprocessor will consider the speed on the road and the travelling direction before any gear shift takes place.

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

NOTE: the effective selection of reverse at this time, depends upon the vehicle condition; if, for example, this is moving, the microprocessor will consider the speed on the road and the travelling direction.

2--26

TH002091

41

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION Automatic up shifting Automatic up shifting from 1st gear position to the required gear is achieved by twisting the handgrip counter clockwise in single movements. The processor will advance the shift from 2nd to 4th in 1.8 sec.

Intervals.

NOTE: An automatic up--shift request, after a downshift is delayed for 1.5 seconds. Should an error occur with the speed sensor, the microprocessor will not allow upword shifts above the 2 nd gear.

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

TH002079

42

Automatic down shifting

WARNING If descending a steep incline, select 2nd gear and proceed upshifting only when safe to do so.

As a matter of fact, YOU CANNOT DOWNSHIFT TO REDUCE SPEED IF THE VEHICLE SPEED IS ABOVE 15 km/h.

Automatic 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 from forward to reverse and the other way round, which is allowed at any time.

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

2--27

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION TRANSMISSION DISCONNECTION Transmission disconnection can be performed in two different ways: 1. Powershift gear lever through the NEUTRAL position

1

2

2. Button on the manipulator transmission remains disconnected so long as the button is kept depressed.

2 TH002092

43

Shown speed ranges are calculated with wheels 13.00 – 24 corresponding to a wheel diameter of 1,200 mm. * Except Countries.

different

specifications

for

foreign

TH121229

44 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

45

2--28

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: x

Transmission oil pressure

x

Engine oil pressure

x

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

TH002093

46

2--29

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: x

Sit in the driver’s seat;

x

Ensure the parking brake is applied;

x

Ensure the Powershift lever is in neutral;

x

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--30

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

Move the starting key into position 2 (activation)

x

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

x

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: x

x

1

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.

2 3

TH002094

47

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--31

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:

x

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.

x

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.

x

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--32

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: x

Release the foot throttle.

x

Apply the parking brake.

x

Place the Powershift lever into NEUTRAL.

x

Lower the loader.

x

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.

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: x

Radiator coolant level

x

Engine oil level

x

Hydraulic system oil level

x

Transmission oil level

x

Axle oil level

x

Axle hub oil level

x

Transfer box

x

Loader lubrication fittings

x

All wheel nuts for tightness

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--33

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

x

Never allow the machine to over run when going downhill. Do not coast or free wheel down hills.

WARNING Observe the following precautions when driving the machine.

x

x

x

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

TH002098

x

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

x

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.

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

Always wear your seat belt.

TH002099

x

Always use transport chains when transporting the machine.

x

Dip the lights when meeting a machine at night.

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

2--34

x

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.

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.

1 TH002100

48

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--35

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION TOWING Release the parking brake using the appropriate lever in the cab.

Use equipment or vehicles adequate for the purpose when operating.

Using cables when pulling or recovering, make sure that all parts are in good conditions and are free from defects or troubles.

The cables must be secured at the points provided for this purpose. Pass the cables through the frame holes and in correspondence with the front lifting points, as indicated in the figure to follow.

TH002147

49

LIFTING Use a crane of 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 the lifting.

TH002149

50

2--36

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.

TH002102

51 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.

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.

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--37

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION

NOTES

2--38

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 panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 WARNING

1

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

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

HANDGRIP BUTTONS It is made up of a proportional rolling switch (2) and of two buttons (3) and (4).

Rolling switch (2) makes it possible to extend the telescopic arm when moved forward or to retract it when moved rearward.

Buttons (3) and (4) are available for auxiliary functions.

To deactivate the functions of buttons 3 and 4, actuate the locking button of the hydraulic function (ref.

9 page 2--23)

TH003033

1

2 3 4

TH003018

2 LOWER BUTTON There is one instable buttons below, having the following functions: 1. Disconnecting the transmission 5

Since it is instable, button (5) keeps the transmission disconnected until it is released.

TH003019

3

3--2

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

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.

TH001107

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, of stabiliser lifting, and of axle tilting.

The only function allowed will be the telescopic arm retraction unless the function locking is not devicted by using the button described below.

D -- TEST SWITCH

C

B

A

TH001053

D 6

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.

ANTI--OVERTURNING BLOCK PRIORITY BUTTON So long as this button (1) is held down, normal hydraulic control functions are restored during instability conditions.

IMPORTANT: all the operations must be performed while the button (1) is held down.

Corrective action can be approaching load weight to the machine centre of gravity (lifting the load or retracting the arm), or actions intended to increase the stability such as lowering the stabilisers or the correction of the axle tilt.

WARNING Operate on this button only if it possible to correct vehicle stability when you are unable to retract the telescopic arm.

DANGER OF OVERTURNING!!

3--4

1

TH002026

7

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.

TH003037

8

3--5

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

7

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

8

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

9

TH003038

9

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.

TH003039

10

3--7

SECTION 3 -- FIELD OPERATION INSTALLING ATTACHMENTS PICKING UP AN ATTACHMENT (WITHOUT HYDRAULIC LOCKING) The attachment locking pin (1) and the clip (2) must be retained in the positions shown until required.

TH003058

11 Attachment hooking: 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

12 Lift the attachment from the ground to enable the locking of the carrier to the attachment.

TH003029

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

REMOVAL OF THE ATTACHMENT Proceed in the reverse order of picking up an attachment, while making sure to store the latter in the closed position and flat on the ground.

TH003059

14 3--8

SECTION 3 -- FIELD OPERATION PICKING UP AN ATTACHMENT (WITH HYDRAULIC LOCKING) Make sure that the attachment is in a position such to provide the locking of the quick coupling.

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

1 TH003056

15 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.

Lift the attachment from the ground so as to facilitate the locking.

TH003031

16 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.

TH003057

17 Actuate red button (2) to extend the locking rods with the subsequent locking of the attachment. To unlock the attachment, press green button (3).

2

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

3

TH003026

18 3--9

SECTION 3 -- FIELD OPERATION HYDRAULIC RELEASING Ensure attachment--locking hoses are connected to the quick release couplings.

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

TH003057

19 Actuate red button (1) to extend the locking rods with the subsequent locking of the attachment. To unlock the attachment and retract the rods, press green button (2).

1

2

TH003026

20 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 Tyre size

Water Litres

405/70--24 14 ply 400/80--24 12 ply 15 R 22.5

117

49

108

166

366

117

* 91

201

208

458

124

55

121

179

395

108

46

101

154

339

153

67

148

220

485

13.00--24 14 ply 15.5--R 25

Calcium Chloride kg lb.

Total weight of solution per tyre kg lb.

* It refers to kgs of magnesium chloride LIQUID BALLAST

WARNING

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.

21 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 qC. IMPORTANT: When filling a tyre with calcium chloride/water solution the valve should be at the highest point of the wheel, figure 21.

IMPORTANT: When checking or adjusting air pressure, if the tyre is liquid ballasted, the valve should be at the lowest point, figure 22.

22

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 TX130--40, TX130--43, TX130--45), 4.300 kg (maximum capacity TX140--43, TX140--45), 4.500 kg (maximum capacity TX170--45) in the bucket: TX130--40 TURBO TX130--43 TURBO TX130--45 TURBO

TX140--43 TURBO TX140--45 TURBO

Static load rating

15840

15840

16260

@ 10 km/h

12604

12604

13204

@ 35 km/h

6693

6693

7119

Front axle

TX170--45 TURBO TH003042

23

Rear axle maximum permissible loading:

Rear axle

TX130--40 TURBO TX130--43 TURBO TX130--45 TURBO

TX140--43 TURBO TX140--45 TURBO

TX170--45 TURBO

Static load rating

0

0

0

@ 10 km/h

2676

2676

3056

@ 35 km/h

5187

5187

5641

TH003043

24 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. On the inside of the back cover are recommended lubricants and coolants that should be used.

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--12 Every 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--13 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 At the first 50 hour service (when new) ensure the following service operations are carried out:

GENERAL FILLING AND SERVICE POINTS

1. Front axle differential oil check

DIESEL FUEL TANK CAPACITY 135 Litres

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

HYDRAULIC RESERVOIR 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. See inside back cover for lubricant quantities and types. 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 1

3

4

5

6 7

8

10

9

TH004001

1

4--2

SECTION 4 -- LUBRICATION AND MAINTENANCE ANALOGUE INSTRUMENT PANEL SERVICE WARNING LAMPS

1

2

3

6

4

5

TH004114

2 1.

Battery charge low warning lamp

2.

Engine oil pressure low warning lamp

3.

Brake oil minimum level warning lamp

4.

Transmission oil temperature (High) warning lamp

5.

Transmission oil pressure low warning lamp

6.

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

4--3

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

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

x

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

x

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

x

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

x

Keep equipment properly maintained.

Use fuel with a minimum cetane rating of 40 (diesel fuel No. 2 at ambient temperatures above --7 qC (20 qF) 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 TH004069

3

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

x

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 12 V.

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.

x

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

x

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.

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: x x x x x x

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: IIt is recommended to replace the outer element at the 500 hour maintenance 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.

1

Extract the outer element after loosening cover (1).

If dust is present inside the outer element (3), the element must be renewed. If satisfactory, clean the element by tapping both ends on the palm of the hand. Do not tap the element against a hard surface as it will be damaged or distorted.

TH004202

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 inner element (2). When, after cleaning, the outer elements (3) continues to appear blackish or oily, it could be necessary to replace the outer element (3) if damaged and/or replace the inner element.

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.

2

3 TH004203

5

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.

TH004204

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

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.

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

2

TH004205

7

SECTION 4 -- LUBRICATION AND MAINTENANCE TRANSMISSION OIL LEVEL Re--fill the transmission with the recommended type of oil approximately 13 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.

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

TH004061

8

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

WINDSCREEN WASHER RESERVOIR The windscreen washer reservoir (2) is located inside the cab on the left side near 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 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 qC (14 qF). Below this temperature, use pure detergent.

TH004062

9

HYDRAULIC OIL LEVEL The hydraulic tank cap (3) is located on the left rear side of the cab.

The hydraulic system oil level is checked though window (4) located under the cap.

3

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

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.

4 TH004063

10

4--9

SECTION 4 -- LUBRICATION AND MAINTENANCE TIMING OF THE EXTENSION OF THE BOOM In order to have a uniform extraction of all sections of the boom, perform generally the following manoeuvre prior to work operations. Extract boom 1 for about 500 -- 600 mm, retract it to full stroke and keep it in this position for 5 -- 6 seconds, continuing pressing the retraction control. Repeat the sequence 4 -- 5 times.

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.

TH004019

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.

TH004020

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

4--10

SECTION 4 -- LUBRICATION AND MAINTENANCE

TH004070

13

4--11

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

Page P No No.

Adjustment / Topping--up Lubrication / Greasing Clean Check

Every y 50 hours

Every y 250 hours

Every y 500 hours

Every 1000 hours or annually

Every 2000 hours or 2 years

Generall G maintenance

13

Radiator

13

Front loader arm fittings

14

Cab air filter

X X

14

Wheels and tyres

X

15

Front and rear wheel nuts

X

15

Front and rear axle joint bearings

X

15

Propeller shaft joints

X

16

Front and rear axle supports

X

16

Fuel filter

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

20

X X X

X X X X

X

Front and rear axle differential oil

X

X

20

Front and rear axle hub oil

X

X

20

Fuel filter

X

22*

Engine air cleaner (outer and inner element)

X

22

Hydraulic system oil filter

23

Battery electrolyte level

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

32

Brake oil

X X

33

Alternator charging system

X

34

Hydraulic hoses and tubing

X

35

All wheel toe--in

X

X

35

Steering stop

X

X

36

Bulbs

X

38

Fuses and relays

X

41

Wheels and tyres

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--12

X

X X

X X

X

X X

X X X

SECTION 4 -- LUBRICATION AND MAINTENANCE EVERY 50 HOURS 1

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.

TH004206

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

14

FRONT LOADER ARM SLIDING BLOCKS The loader arm must be regularly lubricated to maintain its operation efficiency. Always use recommended grease (see inside page of the back cover) 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.

TH004066

15 On the telescopic arm fixed section there are two lubricators taking grease to inner sliding blocks.

Pump in enough grease to guarantee the arm proper sliding. Check the new grease has replaced the old.

IMPORTANT: (only for 17 m) it is necessary to greave withdraw the arm completely with the control lever in “retract” position for a couple of seconds to make the arm outer cylinder work properly. Then extend it for 40--50 cm and withdraw it again by operating the lever for a few more seconds. Repeat this operation 7--8 times.

TH004017

16

4--13

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. Check that the radiator core and the fins are free from damage and are not dirty.

1

1

1

TH004065

17 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.

TH004071

18

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

19

4--14

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

1

Use a proprietcly grease as shown on the inside page of the back cover.

TH004015

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

4--15

SECTION 4 -- LUBRICATION AND MAINTENANCE 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 FUEL FILTER Open the engine compartment door, drain the water and sediments from the fuel filter through the draining valve indicated.

With engine inoperative, loosen the valve located below the filter about 4 full turns and move it downward about 2 cm (3/4 in).

Drain water and sediments until clean fuel only, floowsout.

Move the valve upward and tighten it, without over tightenin.

NOTE: The draining interval can be increased or decreased, as a function of the presence of water and the quantity of fuel.

4--16

TH004207

23

SECTION 4 -- LUBRICATION AND MAINTENANCE EVERY 250 HOURS ENGINE AIR CLEANER (outer element) Remove the element and clean as described.

Wash the element (1) 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.

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.

1 TH004208

24 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 24, 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.

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.

25

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.

4--17

SECTION 4 -- LUBRICATION AND MAINTENANCE FRONT LOADER ARM SLIDING BLOCKS Clean the sliding blocks and remove old grease, accumulations of dust and possible deposits.

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

TH004066

26 AIR CONDITIONING COMPRESSOR DRIVE BELT (where fitted)

1

Drive belt (1) of the compressor can be tensioned by tightening securing nut (2). Loosen the screws and ad just the arm to obtain a movement of the belt of 16 mm.

2

TH004115

27

4--18

SECTION 4 -- LUBRICATION AND MAINTENANCE EVERY 500 HOURS ENGINE OIL AND FILTER Warm the engine to operating temperature. Stop the engine, remove the drain plug cap and drain the used oil into a suitable container for disposal.

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 (1). 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 --12qC (10qF) 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.

1

TH004209

28 Refill the engine with clean oil through the filler tube (2) and check level on the dipstick. Run the engine for a few minutes to circulate the oil. Allow the oil to drain back to the sump for a short period before checking the level with the dipstick (3).

2

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

3

TH004210

29

4--19

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

30

FRONT AND REAR AXLE HUB OIL LEVEL Position the wheel hub with the level/filler plug (4) 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.

4

TH004027

31 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.

4--20

TH004211

32

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 TH004212

33 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--21

SECTION 4 -- LUBRICATION AND MAINTENANCE ENGINE AIR CLEANER (outer and inner element) Remove the inner element (1) and the outer element (2) and then dispose of them.

Clean the air cleaner cartridge inside with a damp, lint--free cloth placed on a push rod tip. Install new inner and outer elements.

2

TH004213

1 34

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.

To remove the filter, open the telescopic arm case rear compartment, then slacken and remove the cartridge. Dispose of the old filter and install a new one.

TH004011

35 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--22

SECTION 4 -- LUBRICATION AND MAINTENANCE BATTERY ELECTROLYTE LEVEL To reach the battery, open engine compartment door (1) turning knob (2).

1

2

TH004214

36 Check battery fluid level (3). When the machine is used with particularly high temperatures, check the fluid level more frequently. If the level is low, top--up each element with clean or distilled water, until the fluid level reaches the maximum level mark.

3

IMPORTANT: If the temperature is equal or below a 0° C (32° F) and water has been added into the battery, connect it to a battery charger or let the engine run for about two hours. This procedure is indispensable to ensure a correct mixing of the water with the electrolyte.

TH004215

Check that the battery and the engine compartment are clean, free from corrosion and undamaged. The mixing of dirt with the electrolyte or the presence of moisture on the upper side of the battery can cause its discharge.

37

After completing the maintenance of the battery, close engine compartment door (1) and secure it by turning knob (2).

4--23

SECTION 4 -- LUBRICATION AND MAINTENANCE WARNING Before you service a battery, always wear face protection, protective gloves and protective clothing.

Battery acid or battery explosion can cause serious injuries.

WARNING Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote -- EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

WARNING When the battery electrolyte is frozen, the battery can explode if: 1. you try to charge the battery; 2. ou try to jump start and run the engine.

To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

WARNING Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. when you disconnect the battery cables, always disconnect the negative (--) battery cable first; 2. when you connect the battery cables, always connect the negative (--) cable last; 3. do not short circuit the battery posts with metal items; 4. do not weld, grind, or smoke near a battery.

4--24

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 15 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.

3

TH004031

38 Unscrew the transmission oil filter (1) 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 ¾ of a turn.

1

TH004059

39

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

40 Fill the gear with the recommended oil type, around 14 litres, through the filler hole with dipstick (2) installed to the right of the base. Observe the following procedure.

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.

2

Operate the gearshift and check there are no leaks.

Re--check the gearshift oil level and top up, if needed.

TH004034

41

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 TH004026

42

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

43 ALTERNATOR DRIVE BELT 3 Check condition of the fan belt, ensure the belt is not frayed and is free of nicks and tears. A correctly tensioned belt can be deflected 13--19 mm when hand pressure is applied midway between the alternator and crankshaft pulley. If belt (1) needs to beadjusted, loosen nut (2) and actuate adjusting screw (3) to modify the tension of the belt. Re--torque the mounting bolts to 27.0 Nm after adjustment.

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.

2

1 TH004199

44

4--27

SECTION 4 -- LUBRICATION AND MAINTENANCE VALVE CLEARANCE 4

3

2

1

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

4

3

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.

45

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

46

4--28

SECTION 4 -- LUBRICATION AND MAINTENANCE EVERY 2000 HOURS OR EVERY TWO YEARS

ENGINE COOLANT 1

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: x

Increase rust prevention

x

Reduce scale formation

TH004206

47 x

Minimise cylinder wall erosion (pitting)

x

Reduce foaming of the coolant

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 Premium 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 Remove the coolant tank cap (1) and loosen the hose clamps for the fluid flow to the cabin heating system.

1

Disconnect the rubber hoses and make them pass through the engine underbody in order to drain the fluid into an external container.

After draining, flush the cooling system with clean water, via the cooling tank pressure cap (1).

When the flushing process is complete, install the hose. Refill the cooling system via the radiator recovery bottle pressure cap (1) until it is full.

NOTE: To avoid trapping air in the system, fill the radiator as slowly as practicable thereby allowing any air pockets to disperse.

The coolant to be used is dependent upon local availability.

Using Premium 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.

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. x

Avoid contact with eyes or prolonged and repeated skin contact.

x

Wear protective eyewear when using.

x

In case of contact with eyes, flush with water for 15 minutes and obtain medical attention.

x

Wash skin with soap and water after use.

x

Keep out of reach of children.

4--30

TH004216

48

SECTION 4 -- LUBRICATION AND MAINTENANCE Using plain water If you reside in a country where antifreeze is not available, use clean water premixed with 5% chemical inhibitor.

Mix two complete bottles of inhibitor with 23 Litres of clean water. This will provide more coolant mixture than is actually required. The excess coolant should be kept in a specially marked container and used for top up purposes.

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

22,0 Litres Premium

4--31

SECTION 4 -- LUBRICATION AND MAINTENANCE HYDRAULIC RESERVOIR OUTPUT GRILLED FILTER

1

The hydraulic circuit is protected by a grilled filter which must be maintained to prevent dirt from penetrating the hydraulic circuit.

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.

TH004055

49 HYDRAULIC OIL Check the hydraulic oil level at the eye glass (3) with the loader in transport position and, if necessary, top up the reservoir through the filler cap (2) 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 180 Litres in position and remove the drain plug.

2

3 TH004063

50 FOOT BRAKE The brake oil reservoir (4) is mounted above the steering console behind the access cover.

The reservoir oil level is monitored by a low level warning light that will illuminate should the oil level reduce to an unsafe quantity. If the light illuminates stop the machine immediately and investigate the cause.

To test the warning lamp press the small rubber button situated in the filler cap. The lamp on the instrument console should illuminate, if not investigate the cause and correct the fault.

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.

4--32

4 TH004038

51

WARNING Owners should be aware of any local regulations concerning testing of braking systems. Regularly maintain the brakes to ensure compliance with the law and ensure your safety. If in doubt, contact your dealer.

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. x

NEVER make or break any of the charging circuit connections, including the battery, when the engine is running.

x

NEVER short any of the charging components to ground.

TH004200

x

ALWAYS disconnect the battery ground cable before carrying out arc welding on the machine or on any instrument attached to the machine.

x

ALWAYS disconnect the battery ground cable when charging the battery in the machine using a battery charger.

52

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

x

DO NOT use a slave battery of higher than 12 volt nominal voltage.

x

ALWAYS observe correct polarity when installing the battery or using a slave battery to start the engine. Follow the instructions on page 2--32 when jump starting the vehicle.

CONNECT POSITIVE TO POSITIVE AND NEGATIVE TO NEGATIVE.

4--33

SECTION 4 -- LUBRICATION AND MAINTENANCE HYDRAULIC HOSES AND TUBING Repair all hydraulic oil leaks promptly to avoid loss of oil and possible damage and dirt entry into the system. When checking for hydraulic leaks, start and operate the engine at 1200--1500 rev./min.

Remove and install new hoses immediately, if they are severely damaged by a cut or a scrape, swollen at the fittings, or leaking.

If a hydraulic hose or tube is renewed the following procedure should be observed.

TH004039

53 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 petroleum jelly.

WARNING Check all hydraulic connections for leakage. If leakage is observed, shut off the engine, relieve all hydraulic pressure. Do not tighten any hydraulic connection while the system is under pressure.

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 specification, Figure 50.

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.

4--34

IMPORTANT: Ensure that when an 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.

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.

2 1 TH004040

54 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 TH004041

55

4--35

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.

TH004042

56

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.

The indicator bulb can be accessed by removal of the lens cover retaining screw.

TH004043

57 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--36

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

1

TH004118

58 Rear work lamp All bulbs are accessible after the moulded plastic lens assembly screws have been removed.

TH004074

59 Rear, stop and direction indicator All bulbs are accessible after the moulded plastic lens assembly screws (2) have been removed.

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 20q anti--clockwise.

2 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.

TH004119

60

4--37

SECTION 4 -- LUBRICATION AND MAINTENANCE Rocker switch bulb replacement The rocker switches are internally illuminated by a bulb which can be remove from the rear of the switch assembly (1).

1 To gain access to the switch remove the console attaching screws and rotate the console.

The bulb is of the capless type, rated at 1.2 W and is press--fitted in the retainer. After changing the bulb, push the retainer into the back of switch.

61

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.

TH004047

IMPORTANT: Do no replace a blown fuse with another of a different rating.

4--38

62

SECTION 4 -- LUBRICATION AND MAINTENANCE FUSES NAME

DESCRIPTION

VALUE

F1

Fuse Cold starter kit -- boom sensor -- LH stabil. sensor

5A

F2

Fuse Conditioner

3A

F3

Fuse radio

3A

F4

Fuse optional

3A

F5

Fuse LH stabiliser lowering

7.5A

F6

Fuse rear axle sensor

7.5A

F7

Fuse upper wiper

10A

F8

Fuse heating

15A

F9

Fuse front work lights

15A

F10

Fuse work selector

10A

F11

Fuse micro stop

7.5A

F12

Fuse extension/retraction

15A

F13

Fuse optional

5A

F14

Fuse warning

10A

F15

Fuse rotary beacon

10A

F16

Fuse working mode -- proportional ev.

10A

F17

Fuse low boom sensor

10A

F18

Fuse horn

15A

F19

Fuse rear wiper

10A

F20

Fuse engine cut--off

10A

F21

Fuse option IN/OUT

10A

F22

Fuse boom work lights

15A

F23

Fuse front wiper

10A

F24

Fuse tail lights -- plate light

F25

Fuse optional

F26

Fuse ceiling light

5A

F27

Fuse compressor

10A

F28

Engine cut--off

10A

F29

Fuse basket ON

15A

F30

Fuse momentum instrument

5A

F31

Fuse attachments

5A

F32

Fuse instrument lights

3A

F33

Fuse gearshift safety + parking brake

10A

F34

Fuse back--up buzzer

5A

F35

Fuse rear work lights

15A

F36

Fuse tail lights -- cigarette lighter-- radio

5A

F37

Fuse high beams

15A

F38

Fuse low beams

15A

F39

Fuse cigarette lighter

20A

5A 7.5A

4--39

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 stabilizer Relay stabilisers Relay option (OUT) Relay gearshift safety Relay back--up buzzer Relay extraction Relay low beam lights Relay low boom sensor Relay levelling Relay steering selector Relay parking brake Relay 2nd speed Relay reverse Relay retraction Relay high beam Controller Flasher Relay engine cut--off Relay horn Relay option “IN“ Relay 1st speed Forward Relay 4st speed

TH004117

63 4--40

SECTION 4 -- LUBRICATION AND MAINTENANCE x

Ensure the rim is clean and free of rust or damage. Do not weld, braze, otherwise repair or use a damaged rim.

x

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.

x

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.

x

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.

x

Machine wheels are very heavy. Handle with care and ensure, when stored, that they cannot topple and cause injury.

x

Never attempt tyre repairs on a public road or highway.

x

Ensure the jack is placed on a firm, level surface.

x

Ensure the jack has adequate capacity to lift your vehicle.

x

Use jack stands or other suitable blocking to support the vehicle while repairing tyres.

x

Do not put any part of your body under the vehicle or start the engine while the vehicle is on the jack.

x

Never hit a tyre or rim with a hammer.

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.

x

After seating the beads, adjust inflation pressure to the recommended operating pressure.

x

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.

x

Torque wheel to axle nuts to specification after re--installing the wheel. Check nut tightness daily until torque stabilises.

4--41

SECTION 4 -- LUBRICATION AND MAINTENANCE

NOTES

4--42

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7 Cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7

5--1

SECTION 5 -- TROUBLESHOOTING ENGINE PROBLEM Engine g does not start. start

Engine g runs unevenlyy and/or stalls. ll

POSSIBLE CAUSE No fuel or insufficient. insufficient Air in fuel system.

Wrong fuel type for operating temperature.

Supply system contaminated.

Fuel filter clogged.

Fuel injector/s faulty.

Fuel solenoid valve or solenoid valve relay faulty.

Flat battery.

Fuel filter clogged.

Supply system contaminated.

Fuel solenoid valve maladjusted.

Fuel injector/s faulty.

Condensate in the fuel filter.

Air filter clogged.

Engine lacks power.

Impurities in the fuel tank, impure fuel.

Overloaded engine.

Air filter clogged.

Fuel filter clogged.

Wrong fuel type.

Overheated engine.

Low engine operating temperature.

Wrong valve distance.

Fuel injector/s faulty.

High idle too low.

Aftercooler radiator clogged.

5--2

REMEDY Check fuel level. level Bleed the supply system.

Use the right type of fuel for temperature conditions.

Clean the system.

Replace the filter element.

Contact an authorised dealership.

Contact an authorised dealership.

Replace the battery or start the engine with the recharging cables.

Replace the fuel filter.

Clean the system.

Contact an authorised dealership.

Contact an authorised dealership.

Operate the fuel filter cock to drain condensate water.

Clean the filter as shown in the “Lubrication and Maintenance” chapter.

Empty the tank, wash it with fuel free of impurities and refill it.

Engage a lower gear o reduce the load.

Make the air filter maintenance.

Replace the fuel filter.

Use the right type of fuel.

See: “Engine overheats”.

Check thermostats.

Check and adjust.

Have the injectors checked at an authorised dealership.

Contact an authorised dealership.

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 tension of the belt.

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.

Gearshift does not work properly or works unevenly.

Gearshift overheats.

5--4

The microprocessor deactivated drive transmission due to a gearshift failure.

Contact an authorised dealership.

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 the tension of the belt.

Replace the belt in case of necessity.

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

CABIN PROBLEM Dust in the cabin.

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 the tension of the belt and its 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 Vehicle prolonged inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2 Tyres and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2 Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3 Vehicle preparation after a 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. x

Clean the vehicle accurately and retouch the paint where needed to prevent rust formation.

x

Check whether there are any worn or damaged elements and replace them if needed.

x

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.

x

Bleed the fuel tank and fill it with 9 litres of stabilised fuel.

x

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.

x

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.

x

x

Operate the front loader so that all cylinders reach retsected position and place the bucket on a block or a piece of wood.

Start the vehicle and reach the loading position and then fasten the loading chain or engage the loading clamp.

x

Turn the engine off and release hydraulic pressure in all circuits.

x

Apply a light grease layer on the exposed cylinder rod area of the vehicle and front loader hydraulic cylinders.

x

Remove and charge the battery. Keep it in a dry and warm place and charge it by and then during storage.

x

Place some supports under the axles to relieve weight from the wheels.

6--2

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. x

The vehicle wheels are very heavy. Handle them with care and once stored, make sure they cannot fall down and hurt someone.

x

Never try to repair tyres on a public road.

x

Make sure that the hydraulic jack is positioned on a solid and flat surface.

x

Make sure that the hydraulic jack has a capacity adequate to lift the machine.

x

Use stands or other securing devices adequate to hold the machine during the repair of tyres.

x

Do not place any part of the body under the machine, nor start the engine while the machine is standing on an hydraulic jack.

x

Never hit the tyres or rims with a hammer.

x

Make sure the rim is clean and without rust or any other damages. Do not weld, braze, repair or use a damaged rim.

x

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.

x

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.

SECTION 6 -- VEHICLE STORAGE x

Always activate the parking brake and place block under the wheels to prevent the machine from moving.

x

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: x

Connect the first wire end to the vehicle 12 V battery positive terminal (+) and the other wire end to the 12 V auxiliary battery positive terminal (+).

x

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. x

After making the beads reaching the right position, adjust inflating pressure at the prescribed working pressure.

x

Do not inflate a very or completely flat tyre until it has been checked by an skilled person.

x

After refitting the wheel, tighten the wheel and axle nuts as prescribed. Check the nut tightening every day until the torque stabilizes.

x

Make reference to the section on the vehicle weighing before adding load on the wheels.

NOTE: When an auxiliary battery is used, make sure polarity is correct in order not to damage the alternator. x

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

JUMP STARTING

WARNING

x

Inflate tyres according to prescribed pressure.

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.

x

Fill the tank.

x

Check the radiator coolant level.

x

Check all oil levels.

x

Install a charged battery.

x

Uncover the exhaust pipe.

x

Remove grease from concerned areas, such as steering cylinders, drive pins, etc.

Use eye goggles when discharging a battery or jump starting the vehicle.

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 13 metres = 10480 kg 14 metres = 10780 kg 17 metres = 11760 kg TH001097

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

Quick compler attachment without bar

Width mm

890

Weight Capacity kg kg

194

TH007015

7--2

SECTION 7 -- ACCESSORIES

Description

Width mm

Quick compler attachment with bar

890

Weight Capacity kg kg

194

TH007016

Hydraulic quick coupler attachment

890

210

TH007017

Pallet fork carriage

1200

118

TH007018

7--3

SECTION 7 -- ACCESSORIES

Description

Pallet fork carriage with side--shift

Width mm

1200

Weight Capacity kg kg

280

TH007019

Carriage forks pair 100 x 50

1200

114

2000

TH007020

1225

214

1470

212

Floating pallet fork carrier on sliding rod

TH007021

7--4

SECTION 7 -- ACCESSORIES

Description

Width mm

Weight Capacity kg kg

Floating forks pair 150 x 50

1200

--

4000

Floating forks pair 100 x 40

1200

--

2000

TH007022

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 y 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 TH007004

7--5

SECTION 7 -- ACCESSORIES

Description

Width mm

Weight Capacity kg kg

Tubular derrick L = 3000 with winch

378

1500

Tubular derrick L = 3000 with winch

392

900 TH007005

Concrete mixing bucket

1980

730

TH007006

Lifting hook on carriage forks

740

60

4000

TH007007

Hydraulic lifting winch on raft

950

290

TH007008

7--6

SECTION 7 -- ACCESSORIES

Description

Lifting hook on raft

Width mm

820

Weight Capacity kg kg

135

TH007009

Log fork

2000

498

TH007010

4 in 1 multipurpose bucket capacity 1 mc

2500

790

1600 kg/mc

TH007011

Fork extension Length = 2000 mm

100

Fork extension Length = 2500 mm

105 TH007023

7--7

SECTION 7 -- ACCESSORIES

Description

Width mm

Platform for materials

1200

Weight Capacity kg kg

292

TH007024

Swinging personnel carrier platform

2300

1050

300

TH007025

Fixed personnel carrier platform

2100

245

300

TH007026

7--8

SECTION 7 -- ACCESSORIES

Description

Concrete bucket

Width mm

1180

Weight Capacity kg kg

230

TH007027

7--9

SECTION 7 -- ACCESSORIES

NOTES

7--10

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--40 turbo -- TX130--43 turbo -- TX130--45 turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--3 TX140--43 turbo -- TX140--45 turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 TX170--45 turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--13 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--17 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--17 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--17 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Radiator coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Four wheel drive tyre combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Weight of machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--20

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 Stabilisers

TX130--40

TX130--43

TX130--45

TX140--43

TX140--45

TX170--45

no

small

large

small

large

large

Engine Max. lifting height (m)

88 kW (120 CV -- 118 HP) Turbo Aftercooler 12.300

12.450

12.450

13.550

13.550

16.600

Max. capacity (kg) at 500 mm from fork stop

4000

4300

4500

4300

4500

4500

Capacity at max. height (kg)

2600

3600

4000

3000

3600

2500

Extension at max. height (m)

1.200

0.500

0.000

0.500

0.300

1.000

Max. longitudinal extension (m) Capacity at max. extension (kg)

8.650 700

1700

9.330 1800

1400

12.540 1500

450

Weight (kg)

10480

10780

11760

Length (m)

5.850

6.070

6.135

8--2

SECTION 8 -- SPECIFICATIONS AND DATA

TH100012

1

TX130--40 turbo -- TX130--43 turbo -- TX130--45 turbo A

1200 mm

K

1260 mm

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

* Value measured with tyres 405/70x24

8--3

SECTION 8 -- SPECIFICATIONS AND DATA TX130--40 turbo -- TX130--43 turbo - TX130-- 45 turbo (without stabilisers or with stabilisers raised and with rear axle lock)

q

q

q

q

q

TX130--40 TX130--43 TX130--45 q

q

q

TH001074

2

8--4

SECTION 8 -- SPECIFICATIONS AND DATA TX130--40 turbo -- TX130--43 turbo - TX130-- 45 turbo (without stabilisers or with stabilisers raised and without rear axle lock)

q

q

q

q

q

TX130--40 TX130--43 TX130--45 q

q

q

TH001075

3

8--5

SECTION 8 -- SPECIFICATIONS AND DATA TX130--43 turbo (with stabilisers lowered)

TX130--43

TH00R031

4

8--6

SECTION 8 -- SPECIFICATIONS AND DATA TX130--45 turbo (with stabilisers lowered)

TX130--45

TH00R032

5

8--7

SECTION 8 -- SPECIFICATIONS AND DATA

TH100017

6

TX140--43 turbo -- TX140--45 turbo A

1200 mm

K

1260 mm

B

3120 mm

T

4552 mm

C

1837 mm

U

2730 mm

D

6070 mm

V

5390 mm

E

7270 mm

V1

980 mm

F

2050 mm

V2

3890 mm

G

402* mm

W

2445 mm

I

1100 mm

* Value measured with tyres 405/70x24 8--8

SECTION 8 -- SPECIFICATIONS AND DATA TX140--43 turbo - TX140-- 45 turbo (with stabilisers raised and with rear axle lock)

q

q

q

q

q

TX140--43 TX140--45

q

q

q TH001076

7

8--9

SECTION 8 -- SPECIFICATIONS AND DATA TX140--43 turbo - TX140-- 45 turbo (with stabilisers raised and without rear axle lock)

TX140--43 TX140--45

TH00R033

8

8--10

SECTION 8 -- SPECIFICATIONS AND DATA TX140--43 turbo (with stabilisers lowered)

TX140--43

TH00R034

9

8--11

SECTION 8 -- SPECIFICATIONS AND DATA TX140--45 turbo (with stabilisers lowered)

TX140--45

TH00R035

10

8--12

SECTION 8 -- SPECIFICATIONS AND DATA

TH100022

11

TX170--45 turbo A

1200 mm

K

1260 mm

B

3120 mm

T

4598 mm

C

1902 mm

U

2730 mm

D

6135 mm

V

5445 mm

E

7335 mm

V1

980 mm

F

2050 mm

V2

3890 mm

G

402* mm

W

2445 mm

I

1100 mm

* Value measured with tyres 405/70x24 8--13

SECTION 8 -- SPECIFICATIONS AND DATA TX170--45 turbo (with stabilisers raised)

TX170--45

TH001025

12

8--14

SECTION 8 -- SPECIFICATIONS AND DATA TX170--45 turbo (with stabilisers raised and without rear axle lock)

TX170--45

TH001079

13 NOTE: This diagram must be considered when the rear axle lock manual control is selected.

8--15

SECTION 8 -- SPECIFICATIONS AND DATA TX170--45 turbo (with stabilisers lowered)

TX170--45

TH00R036

14

8--16

SECTION 8 -- SPECIFICATIONS AND DATA ENGINE DATA

88 kW (120 Cv) Turbo Aftercooler

Type No. of cylinders Bore Stroke Displacement Compression ratio Firing order

mm mm cm3

Diesel 4 in line 104 132 4485 17.5 : 1 1.3.4.2

Idle speed Maximum ‘No--load’ speed

rev/min rev/min

700--900 2380--2480

Rated speed Maximum torque (1400 rev/min)

rev/min

2200 515 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 9 blade 10 -- 16 mm 16 mm 81qC 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--17

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

65 A 12 V 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 203.2 mm Mechanical, disc on the transmission

STEERING Power steering type Pump type System pressure Wheel toe--in

Hydrostatic Gear 175 bar 0 -- 2 mm

FRONT AXLE Chassis mounted Differential lock

Floating with levelling cylinder No

REAR AXLE Chassis mounted

8--18

Floating with arm deflection 10q 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 13 metres = 10480 kg 14 metres = 10780 kg 17 metres = 11760 kg TH001097

15 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 determine the precise weight of your machine it will be necessary to place your machine on an official weigh--bridge.

8--19

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.

Models

TYRE SIZE

13 00 -- 24 14 ply 13.00 405/70 -- 24 14 ply TX130--40 turbo TX130 43 turbo TX130--43 TX130--45 turbo

15 5 R25 15.5 15 R22.5 R22 5 400/80 -- 24 14 ply 13 00 -- 24 14 ply 13.00 405/70 -- 24 14 ply

TX140 43 turbo TX140--43 TX140--45 turbo

15 5 R25 15.5 15 R22.5 R22 5 400/80 -- 24 14 ply 13 00 -- 24 14 ply 13.00 405/70 -- 24 14 ply

TX170 45 turbo TX170--45

15 5 R25 15.5 15 R22.5 R22 5 400/80 -- 24 14 ply

FRONT REAR

PRESSURE [bar]*

PRESSURE AXLE WEIGHT (unladen static)

AXLE WEIGHT (rated dynamic)

front

4,5

4650

6390

rear

4,5

6060

5321

front

4

4650

6390

rear

4

6060

5321

front

4,5

4650

6390

rear

4,5

6060

5321

front

4,5

4650

6390

rear

4,5

6060

5321

front

4,25

4650

6390

rear

4,25

6060

5321

front

4,5

5380

7300

rear

4,5

6000

5200

front

4

5380

7300

rear

4

6000

5200

front

4,5

5380

7300

rear

4,5

6000

5200

front

4,5

5380

7300

rear

4,5

6000

5200

front

4,25

5380

7300

rear

4,25

6000

5200

front

4,5

5730

7470

rear

4,5

6360

5620

front

4

5730

7470

rear

4

6360

5620

front

4,5

5730

7470

rear

4,5

6360

5620

front

4,5

5730

7470

rear

4,5

6360

5620

front

4,25

5730

7470

rear

4,25

6360

5620

* Listed pressures refer to inflation for use on size.

The above figures reflect the “approximate weights” of a standard machine without attachments.

8--20

SECTION 9 CONTENTS

CONTENTS OF SECTION 1 Description Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2 Summary of safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--15 Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--16 Airborne Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--25 Load Status Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--26 Safety features and options vehicle secutiry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--38 Road travel requirements – in cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--39 Road travel requirements – external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--40 “CE” Regulations – Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--43 Universal Symbology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--45 Machine functions that are monitored by instruments, warning lights, and buzzers . . . . . . . . . . . . . . . . . . . 1--46

CONTENTS OF SECTION 2 Description Page General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3 Hand and foot operating controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--6 Cab instruments and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--14 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--15 Instrumentat console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--16 Load status indicator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--20 Multi--function lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--22 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--23 Safety key and selecting operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--25 4x3 Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--26 Driving with the Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--26 Operating the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--29 Starting the engine with jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--32 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--33 Running--in procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--33 Driving the Telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--34 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--35 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--36 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--36 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--37 Machine storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--37 9--1

SECTION 9 -- INDEX

CONTENTS OF SECTION 3 Description Page Front loader controls/operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2 Load status indicator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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--12 Every 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--13 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7 Cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7

CONTENTS OF SECTION 6 Description Page Vehicle prolonged inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2 Tyres and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2 Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3 Vehicle preparation after a 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 TX130--40 turbo -- TX130--43 turbo -- TX130--45 turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--3 TX140--43 turbo -- TX140--45 turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8 TX170--45 turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--13 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--17 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--17 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--17 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Radiator coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Four wheel drive tyre combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Weight of machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--20

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 qC --25 qC

--15 qC

+20 qC

+40 qC

SAE 5W--30

SAE 10W--30

SAE 15W--40

--22 qF

--13 qF

+5 qF

+68 qF

+104 qF

NOTE: It is advised to use fuel with sulphur contents below 1.3% SUGGESTED FLUIDS AND THEIR APPLICATION

Oil – ENGINE CASE Nº 1 15W40 CASE Nº 1 10W30 Oil – POWERSHIFT TRANSMISSION TCH 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 Hydraulic Fluid 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 (qC)

ACEA E5 API CH--4, CG--4/SL

7,6 litres (including engine oil filter) 12,9 + 4 litres (lines and radiator)

From –10 to +50

7 litres

From --20 to +50

ATF Type A Suffix A ALLISON C4 API GL5 e API GL5 LS GO 90 LS ZF TE--ML 05 API GL5

0,75 litres

API GL5

0,65 litres

ISO VG 46 DIN 51524

180 litres

H2O

12 litres 12 litres

M6C 59--A

1 litre

NLGI 2

As required

NLGI 2

As required

From --40 to +50

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.

&23<5,*+7 %<

4ECHNICAL 0UBLICATIONS $EPT ,ECCE 2EPRODUCTION OF TEXT OR ILLUSTRATION IN WHOLE OR IN PART IS STRICTLY PROHIBITED

3ULQW QR 9 0RINTED BY 3ATIZ 4URIN )TALY &RRUGLQDPHQWR (GLWRULDOH 6DWL] 7RULQR

TX130-40 / TX130-43 / TX130-45 Turbo TX140-43 / TX140-45 Turbo TX170-45 Turbo

P.I.N. HGCTX13MN7HK40001 and after (TX130-40 turbo) P.I.N. HGCTX13MN7HK39001 and after (TX130-43 turbo) P.I.N. HGCTX13MN7HK38017 and after (TX130-45 turbo) P.I.N. HGCTX14MN7HK42003 and after (TX140-43 turbo) P.I.N. HGCTX14MN7HK41027 and after (TX140-45 turbo) P.I.N. HGCTX17MN7HK43027 and after (TX170-45 turbo)

Printed in Italy

87681534 GB