Case TX742 TX842 TX945 Telehandlers Operator’s Manual 84122853 - PDF DOWNLOAD

TX742 / TX842 / TX945

TX742 TX842 TX945 Telehandlers Telehandlers

Operator’s Manual Print No. 84122853

2nd edition English 10/08 replaces p/n 87684639 from serial no: HHATX742N7HK74001 (TX742) HHATX842N7HK75001 (TX842) HHATX945N8HK76001 (TX945)

OPERATION AND MAINTENANCE INSTRUCTION MANUAL TX742 TX842 TX945

COMPANY POLICY Company policy, which is one of continuous improvement, reserves the right to make changes in design and specification, without notice and without obligation to modify units previously built.

All data given in this book is 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.

PARTS AND ACCESSORIES Genuine parts and accessories have been specifically designed for these machines.

We would like to point out that “non--genuine” parts and accessories have not been examined and released by the manufacturer. The installation or use of such products could have negative effects upon the design characteristics of your machine, and thereby affect its safety. The manufacturer is not liable for any damage caused by the use of “non--genuine” parts and accessories.

MODEL CODES The complete range of telescopic handlers (Telehandler) described in this manual is identified in the text by reference to the maximum extension of the telescopic arm.

The vehicles listed below may not be available in all countries or markets, therefore for the latest information consult your authorized dealer.

Model Engine Max. lifting height ft (m) Max. capacity lb (kg) at 24 in (610 mm) in from fork heel Capacity at max. height lb (kg) Reach at max. height ft (m) Max. longitudinal extension ft (m) Capacity at max. extension lb (kg) Weight lb (kg) Length without forks in (m) Overall lenght in (m)

TX742 no Stab.

101 hp (74 kw) 41.8 (12.74) 6600 (2994)

TX842 with Stab. (opt.)

120 hp (88 kw) 41.8 (12.74) 8000 (3629)

TX945 with Stab. (opt.)

120 hp (88 kw) 44.6 (13.60) 9000 (4082)

3500 (1588) 5 (1.524) 29 (8.839) 1300 (590) 22700 (10300) 241.33 (6.130) 287.80 (7.310)

5000 (2268) 5 (1.524) 29 (8.839) 1600 (726) 24930 (11300) 241.53 (6.135) 288 (7.315)

5000 (2268) 3.45 (1.051) 30.84 (9.400) 1600 (726) 27778 (12600) 249.76 (6.344) 296.20 (7.524)

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 -- Forms and Declarations 10 -- Index

SECTION 1 SAFETY PRECAUTIONS AND INTRODUCTION This Manual has been prepared to provide you with 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--18 Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--19 Lateral stability (canopy version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--34 Lateral stability (cab with windows version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--34 Longitudinal stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--35 Safety features and vehicle secutiry options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--50 Road travel requirements – canopy version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--51 Road travel requirements – in cab with windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--52 Road travel requirements – external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--53 “EC” Norms – Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--54 Universal Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--56 Machine functions monitored by instruments, luminous pilot lamps and buzzers (canopy version) . . . . . 1--57 Machine functions monitored by instruments, luminous pilot lamps and buzzers (cab with windows version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--58

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.

TH001482

1

FIRST 50 HOUR SERVICE OPERATION After you have operated the machine for 50 hours, take your machine, together with this Manual, to your dealer. They can then perform the factory recommended 50--hour servicing and complete the service report sheets at the back of this book.

The first sheet is the dealer’s copy and should be removed by the dealer after service has been carried out. The second copy is your record of the service operaction performed.

Ensure that you and the dealer sign both copies.

WARRANTY Your machine is guaranteed according to the legal rights in your country and the contractual agreement with your retail dealer.

IMPORTANT: No warranty shall apply if the machine has not been used, adjusted or maintained according to instructions in this Operator’s Manual.

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2

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

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

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

TH001481

3

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

TECHNICAL TYPE/MODEL UNIT SERIAL No. YEAR TH001308

4

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SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY Identification of turbocharged engine 101 hp (74 kw) with aftercooler The identification data of the engine are located on the right side of the engine crankcase. Record the information below for quick reference in case of necessity.

MODEL No. SERIAL No. DATE CODE

TH001272

5

TH001273

6

Identification of turbocharged engine 120 hp (88 kw) with aftercooler The identification data of the engine are located on the right side of the engine crankcase. Record the information below for quick reference in case of necessity.

MODEL No. SERIAL No. DATE CODE

TH001309

7 1--4

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY Front 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 TH001205

8

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

TH001206

9

VD 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

TH001184

10

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SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY Identification plates in the cab (canopy version) The cab identification plate contains the serial number and further data and is collated on the front side of the seat compartment. Record the serial number below for quick reference in the case of necessity.

SERIAL No. DATE CODE The engine details are printed on the certification plate and mounted with the cab plate. Record the serial number below for quick reference in the case of necessity.

SERIAL No. DATE CODE

TH001207

11

Identification plates in the cab (with windows version)

TH00R101

12 1--6

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

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

WARNING

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

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

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

TH001218

13

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

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

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

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

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

•

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

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

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

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

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

GENERAL CONSIDERATIONS

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

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

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

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

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

Remember:

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

Any user who procures parts from another supplier 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.

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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.

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

TIRES Familiarize yourself with the machine and the ground on which the machine is to be operated.

Ensure tires are adapted to the nature of the ground.

Consult your dealer.

OPERATING CONDITIONS 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 time.

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

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SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY VISIBILITY The safety of personnel within the telehandler’s radius of operations as well as that of the telehandler and its operator, depends on the operator having good visibility of the environment immediately around the telehandler, under all circumstances at all times.

The telehandler was designed to provide the operator with good visibility (direct or indirect via rear view mirrors) of the immediate environment during movement with the telehandler empty and the boom in the transport position.

If the volume of the load limits visibility ahead, particular precautions must be taken: •

move in reverse;

•

adjust the site layout ;

•

be assisted by someone (outside the area of operations of the telehandler) who can directmovements, making sure that this person is always in view;

•

always avoid maneuvering too far in reverse.

With certain specific attachments, telehandler moving operations may need the boom to be in a high position. In this case, visibility on the right is limited and particular precautions must be taken: •

adjust the site layout;

•

be assisted by someone (outside the area of operations of the telehandler) who can direct movements.;

In any situation where visibility of the route is inadequate, obtain the help of someone (outside the area of operations of the telehandler) to direct movements, making sure that this person is always in view.

Maintain all componenets used for visibility clean, well adjusted, and in good working order: •

windows;

•

washers;

•

road and work lights;

•

rear view mirrors.

1--11

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

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

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

WARNING

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

Do not forget to fasten your safety belt.

TH001223

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.

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

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

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

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

In the event 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.

TH001224

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: • • • •

TH001011

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

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That is correctly placed and secured.

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

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

That this platform allows for the width of the machine.

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.

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

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

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

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

Avoid running too long distances in reverse.

Do not leave the Telehandler unattended with engine running.

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.

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

LOADER CONSIDERATIONS

WARNING

In the event of high winds, do not carry out handling work that jeopardizes the stability of the telehandler and its load, particularly if the load catches the wind badly.

Comply with site safety regulations.

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

WARNING

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.

TH001225

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

TH001226

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 center.

TH001015

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

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

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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.

TH001227

It is forbidden to carry people with the machine.

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.

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

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

Never stack loads on uneven ground, they may tip over.

WARNING

If the load or the attachment must remain above a structure for a long time, there is a risk that it will rest on the structure because of the jib descending caused by the oil in the cylinders cooling down.

To eliminate the risk: -- Regularly check the distance between the load or the attachment and the structure and re--adjust this if necessary.

-- If possible use the telehandler at an oil temperature as close as possible to the ambient.

TH001228

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

Always keep load as low as possible.

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: • Lower the forks or attachment to rest on the ground.

• Stop the engine.

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

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

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

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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.

TH001229

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

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

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

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

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY OPERATOR PROTECTIVE STRUCTURE

WARNING

Your machine is equipped with an operator Protective Structure, such as: a Rollover Protective Structure (ROPS) or Falling Object Protective Structure (FOPS) or Cab with ROPS. A ROPS may be a cab frame or a two--posted or four--posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS.

UNDERSTAND SIGNAL WORDS •

In this Manual you will find the following words referring to different hazard risks:

-- DANGER; -- WARNING; -- CAUTION. These words are always accompanied by the safety alert symbol.

The Protective Structure is a special safety component of your machine.

DANGER

DO NOT attach any device to the Protective Structure for pulling purposes. DO NOT drill holes to the Protective Structure.

WARNING

The Protective Structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the Protective Structure MUST be replaced so that it will provide the same protection as a new Protective Structure. Contact your dealer for Protective Structure inspection and replacement.

After an accident, fire, tip or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job site operation: •

The Protective Structure MUST be replaced.

•

The mounting or suspension for the Protective Structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

•

CAUTION IMPORTANT NOTE DANGER: indicates an imminent hazardous situation which, if not avoided, will result in death or serious injury.

WARNING: indicated a potential hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION: indicates a potential hazardous situation which, if not avoided, may result in minor or moderate injury.

All damaged parts MUST be replaced.

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT.

IMPORTANT: indicates a situation which, if not avoided, may cause damage to the machine.

NOTE: indicates an additional explanation for information purposes.

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

Ensure the workplace is sufficiently ventilated before starting the machine.

WARNING

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

This distance at minimum should be at least 5 metres.

WARNING

You must consult your local electricity agency. You could be electrocuted or seriously injured if you operate or park the machine too close to power cables.

Stop the engine when not in use.

ENGINE SHUTDOWN

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

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

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.

Use the recommended lubricants (Never use contaminated lubricants).

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.

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

WARNING

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

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

Change filter cartridges.

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

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

WARNING

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

Clean the machine or, at least, the area concerned before any maintenance intervention.

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.

1--16

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. Authorized 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.

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

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.

9. Keep equipment clean and properly maintained.

10. Do not drive equipment near open fires.

11. Never use fuel for cleaning purposes.

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

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.

FUEL CAPACITY = 35.66 USG (135 LT)

TH001208

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 damaged or lost, replace it with an approved cap. A non--approved, proprietary cap may not be safe.

1--17

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

•

For your safety always comply with the following rules: •

Ensure that there is nobody within the machine operating range.

•

Do not stand or walk under the arm of the vehicle

•

•

•

DRIVING ON ROADS OPEN TO PUBLIC TRAFFIC •

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

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

•

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

•

Install the fork guard.

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

•

Cab controls must be locked.

•

Optional roading lights and slow mowing vehicle sign.

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

USE OF THE ATTACHMENTS

•

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

•

In any case limit values on load charts must in no case be exceeded.

•

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

•

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

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.

•

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

•

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

USE OF THE LOADING BUCKET •

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

USING THE VEHICLE AS A CRANE •

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

•

Do not start or stop the machine with a jerk.

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

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

•

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

•

Avoid oblique pulls and towing.

•

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

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

•

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

•

•

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

1--18

WARNING

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY

SAFETY DECALS

TH001483

14 DECALS WITHIN THE CAB (CANOPY VERSION) 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--19

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY

TH001498

15 DECALS WITHIN THE CAB (CAB WITH WINDOWS VERSION)) 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--20

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.

TH001333

16 LOADER LIFT CAPACITY: ensure the loader is operated at all times safely and within its designed lift capacity; refer to safety booklet.

TH001324

17 LOADER LIFT CAPACITY: ensure the loader is operated at all times safely and within its designed lift capacity; refer to safety booklet and load charts.

For model cab with windows

TH001499

18

1--21

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY DANGER: Make sure that near electric power lines and poles, the attachment used is at a minimum distance of 25 ft (8 meters). The non compliance with this rule can cause personal injuries or death. For further information, please refer to the indications described in this section.

TH001338

19 MANIPULATOR FUNCTIONS: refer to this booklet to obtain detailed information about the manipulator functions.

For model TX742 standard (cab with canopy)

TH001219

20 MANIPULATOR FUNCTIONS: refer to this booklet to obtain detailed information about the manipulator functions.

For model TX842 -- TX945 standard (cab with canopy and cab with windows)

TH001332

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

TH001150

22

1--22

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY SAFETY HAT: wear a safety hat for your own protection.

TH001151

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

TH001152

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

TH001153

25

1--23

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY

TH001484

26 CONSOLE SAFETY DECALS (CANOPY VERSION) This page contains a list of the decals applied to the console.

1--24

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY

TH001500

CONSOLE SAFETY DECALS (CAB WITH WINDOWS VERSION)

27

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

Safety key plate. for model cab with windows

TH001154

28 1--25

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 fluid since it is highly corrosive and toxic.

TH001155

29

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

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

TH001401

31

When changing directions use only first gear.

TH001337

32

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

TH001335

26A The decal is related to the device of the rear lock switch. Refer to section 2 “Controls, Instruments and Operation” of this manual.

TH001236

33 1--26

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

TH001143

34

TH001144

35

1--27

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY

TH001485

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

Ensure they are maintained in a legible condition and replace if they become damaged or are unreadable at any time. * Only for model TX842 and TX945 with stabilizers.

1--28

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

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

TH001164

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

TH001165

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

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

TH001405

40 DANGER: to prevent crushing the lower limbs, when the stabilisers are actuated, make sure that there are no bystanders near the machine (only for models TX842--TX945).

TH001395

41 1--29

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

TH001167

42 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

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

TH001169

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

TH001403

45

1--30

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY WARNING: The plate indicates that the machine is equipped with a low polluting emission engine.

TH001418

46 WARNING: The decal indicates the machine parts that have reached high temperatures. Pay attention because contact could result in serious burns.

TH001473

47 WARNING: The plate indicates the periodical maintenance intervals to comply with. Please refer to the part relative to the maintenance described in this manual.

TH001487

48 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 Section 4 of this manual for further information. for model cab with windows

TH001170

49

1--31

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY LIFTING OPERATIONS Ensure that all local and national legislation governing lifting operations are fully satisfied before operating the machine. This should include the selection of the correct model of the machine for the operation, and the planning of the lifting operation itself.

Ensure that you comply fully with the approved codes of practice and guidelines of the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER 98) as prepared by the Health and Safety Executive (HSE) for machines operating within the United Kingdom.

Further information concerning the safe use of lifting and other equipment in the UK is available from the HSE information line.

USE OF MACHINES ON GRADIENTS OR SLOPES

It is essential that a risk assessment of the work to be done is completed and that the opertor complies with all safety precautions that the assessment identifies.

DRIVING UP AND DOWN GRADIENTS To ensure maximum traction do the following when driving on a gradient.

WARNING

Never raise the carriage more than 20 in (500mm) above the ground, or extend the boom when travelling up or down a gradient. The machine can become unstable and slide or tip over. You and others can be seriously injured or killed.

Drive and brake gently when travesing gradients.

Drive an “UNLADEN” machine forward down a gradient and in reverse up a gradient.

WARNING

Ensure that you have been trained and are familiar with the use of machines an gradients, and understand the adverse affects that gradients and site conditions can have on stability. Never use the machine on a gradient if you do not understand the recommended practices for the use of machines in such applications.

There are a number of factors which can adversely affect the stability of the machine and the safety of the machine and operator when used on a gradient.

These include, but are not limited to: (a) Site and ground conditions (b) Boom height and extension

TH001230

50 Drive a “LADEN” machine forward up a gradient and in reverse down a gradient.

(c) Nature and mass of load (d) Type of attachment (e) Tire pressure and condition Weather conditions (including wind velocity which could affect a suspended load). (f) Proximity of excavations and man--hole covers.

It is the responsibility of the competent people planning the job and those operating the machine to make judgement as to the safe use of the machine when used on a gradient, after having taken into account the specific application and conditions of use at the time.

1--32

TH001231

51

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY DRIVING ACROSS GRADIENTS Read and understand the following instructions before travelling across a gradient.

WARNING

Never raise the carriage more than 20 in (500mm) above the ground, or extend the boom when travelling across a gradient. The machine can become unstable and slide or tip over. You and others can be seriously injured or killed. Make sure the machine is level before the boom is extended or raised more than 20 in (500mm) above the ground.

TH001232

52

Maximum stability is achieved when the machine is operated on firm level ground. Stability will be reduced if the machine is operated on a cross gradient.

Never raise the carriage more than 20 in (500mm) above the ground when travelling across a gradient.

Fully retract the boom and travel slowly at walking pace.

Make sure you are aware of all factors that can affect the safe operation whilst driving across a gradient.

These factors may include: •

Site and ground conditions

•

Boom height and extension

•

Nature and mass of load

•

Type of attachment

•

Tire pressure and condition Weather conditions (including wind velocity which could affect a suspended load)

•

Proximity of excavations and man--hole covers.

It is the responsibility of the competent people planning the job and those operating machines to make judgement as to the safe use of the machine across a gradient, having taken into account the specific application and conditions of use at the time.

It is essential that a risk assessment of the work to be done is completed and that the operator complies with any safety precautions that the assessment identifies.

If you are unsure of the compatibility of the machine for a specific gradient, contact your dealer who will be pleased to advise you.

1--33

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY LIFTING OPERATIONS ON A SLOPE

WARNING

Performing lifting operations on gradients could be dangerous.

The machine could become unstable sideways and tip--over if the instructions provided in this section are not complied with and understood.

Failing to comply with these instructions can result n serious injuries or death.

Make sure that the guidelines provided by this manual are fully implemented and understood.

Lifting operations must not be performed on gradients unless the machine is leveled along its entire width (it must be leveled sideways).

WARNING

Stop the machine and engage the parking brake prior to performing any lifting operation.

LATERAL STABILITY (CANOPY VERSION) Always make sure that the machine stands on a firm and stable ground base and, by reading level gauge (1), make sure that the machine is leveled during the lifting operation.

If during the lifting cycle the level gauge indicates an unleveled condition (dark colored bead moving into 2), lower and retract the boom immediately and level the machine (see section 2 for description).

TH001221

2

1

2 53

LATERAL STABILITY (CAB WITH WINDOWS VERSION) Always make sure that the vehicle is on a bed of full and flat level. While watching the stability indicator bubble (3) show in the figure, make sure that the vehicle stays leveled during lifting operations.

If the level indicator shows an unlevel condition (bubble towards 10°) during lifting, lower and retract the boom immediately and level the vehicle.

The machine is perfectly levelled only when the air bubble is exactly in the centre of the stability indicator (3) as shown in the figure.

3

TH002395

54

1--34

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY LONGITUDINAL STABILITY The safety conditions for the lifting of the load are identified by the letters present on the left side of the second section of the boom (1) and by the scaled index (2) located on the left side of the first section of the boom. The combination of the two data given by the graphs listed following, provides the value of the load that can be lifted under safe conditions.

Ex.: -- the angle of the boom measured on the scaled index (2) is equivalent to 30 degrees; -- extension of the boom indicated by the letter D (1); -- maximum weight that can be lifted is equivalent to 2300 lb (1043 kg).

1

TH001497

2

TH001490

55

1--35

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

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

Put gear shift in neutral (see page 3- 5) and apply parking brake (see page 3- 4).

TX742 (without rear axle locking)

TH001320

56

1--36

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX742 (with rear axle locking)

TH001323

57

1--37

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX842 (without rear axle locking)

TH001314

58

1--38

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX842 (with rear axle locking)

TH001310

59

1--39

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX842 (with stabilizers)

TH001312

60

1--40

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX945 (without rear axle locking)

TH001317

61

1--41

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX945 (with rear axle locking)

TH001315

62

1--42

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX945 (with stabilizers)

TH001316

63

1--43

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY LOAD CHART DIAGRAM WITH FOAM FILLED WHEELS TX742 (without rear axle locking)

TH001322

64

1--44

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX742 (with rear axle locking)

TH001321

65

1--45

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX842 (without rear axle locking)

TH001313

66

1--46

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX842 (with rear axle locking)

TH001311

67

1--47

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX945 (without rear axle locking)

TH001318

68

1--48

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY TX945 (with rear axle locking)

TH001319

69

1--49

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

2

1

3 4 TH001491

70 1.

FUEL TANK CAP: can be locked by key.

2.

HYDRAULIC OIL FILLER CAP: can be locked by key.

3.

ENGINE COMPARTMENT: can be locked by key.

NOTE: 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--50

4.

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 -- CANOPY VERSION

1

TH001213

71 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. STEERING MODE SWITCH: when driving on the road, make sure that the two--steering wheels mode of switch (1) is selected. This position is the central one of the switch.

1--51

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

TH001082

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

2. HYDRAULIC 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.

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

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

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

1--52

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: it is a requirement in some countries that a wheel chock be available and used when the vehicle is stationary. Ensure you comply where legislated.

2. LOADER ATTACHMENT GUARDS: where applicable ensure all attachments carry a protective guard or warning where legislated.

3. WARNING BEACON SLOW MOVING MACHINE: when on the road this beacon should be illuminated day or night.

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.

5. RIDING LIGHTS: where fitted, are illuminated with the side lights. Make sure they are switched on when on the road.

6. STEERING CHOCKS: when travelling on the road ensure these chocks are placed over the exposed rear axle steering cylinders and locked in position with pins.

7. BOOM CYLINDER TRAVEL BRACKET: ensure when travelling on the highway that this bracket is placed over the lift cylinder rod to keep the attachment plate above road level.

1--53

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

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

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

VIBRATION:

‘EC’ EEC/93/392

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

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

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

•

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 “EC“ mark in the following style.

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

•

make sure that the machine is maintained in efficient conditions;

•

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

•

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

•

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

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

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

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.

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.

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:

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.

Hand and Arm (m/s2) = < 2,5

1--54

Whole body (m/s2) = < 0.5

NOTE: These machines not only meet the recommended safe levels of vibration but may operate at levels below that shown.

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY ENGINE IMPORTANT: According to directives no 2000/25/EC by the European Community and no. 40 CFR by U.S.A. it is prohibited to perform any form of tampering with the engine, including unloading non certifiable software. Any modification on an engine or the intake system found non complying with current specifications involves: legally that the engine is illegal for such market and shall not be protected by any insurance, the warranty on the engine and the fuel intake system becomes void, in accordance with what stated by the certificates, and the customer could incur in considerable costs in resetting the engine; technically incur in possible overloads of engine components, possible premature wear of the engine and excessive load of components and use of contaminated oil. Only personnel authorized by the Dealer can perform repairs on the fuel feeding system. The repairs must be perfomed only when implementing the specification provided by the Manufacturer.

1--55

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

Thermostart starting aid

Side lamps

Turn signals

Horn

Transmission in neutral

Roof beacon

Transmission oil temperature

Accessory socket

Alternator charge

Air filter blocked

Fuel level

Parking brake

Engine speed (rev/min x 100)

Stop lamps

Transmission oil pressure

Hazard warning lights

Hours recorded

Warning!

FWD engaged

Malfunction!

See operator’s manual

Optional hydraulic function inhibition

Variable control

Read operator’s manual

Pressurised!

Open carefully

Warning!

Corrosive substance

Engine oil pressure

Engine coolant temperature

Coolant level

Machine lights

N

Headlamp main beam

Optional hydraulic function Headlamp dipped beam

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

1--56

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

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY MACHINE FUNCTIONS THAT ARE MONITORED BY INSTRUMENTS, WARNING LIGHTS, AND BUZZERS (CANOPY VERSION) 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.

LP26

LP25

LP6

LP1

LP12

LP4

LP3

LP2

LP23

LP7 LP14 LP9 LP8

LP27

LP28

TH55R205

74 ID

Function

Warning light

LP1

Engine oil pressure warning light

X

LP2

Not used

LP3

Indicator light parking brake engaged

X

LP4

Generating indicator light

X

LP6

Crab steering indicator light

X

LP7

Not used

LP8

General indicator lights

X

LP9

Main beams indicator light

X

LP12

Thermostart heater light

X

LP14

Direction indicator lamps

X

LP23

Transmission oil pressure indicator light

X

LP25

Two wheel steering indicator light

X

LP26

Four wheel steering indicator light

X

LP27

Fuel reserve indicator light

X

LP28

Not used

Instrument

Buzzer X

For more detailed information about indicator meanings see Section 2.

1--57

SECTION 1 -- SAFETY FEATURES AND VEHICLE OPTIONAL SAFETY MACHINE FUNCTIONS THAT ARE MONITORED BY INSTRUMENTS, WARNING LIGHTS, AND BUZZERS (CAB WITH WINDOWS VERSION) 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

75 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--58

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 to drive or operate the machine unless you are fully accustomed to the controls.

IT IS TOO LATE TO LEARN ONCE THE MACHINE IS MOVING

CONTENTS SECTIONAL Description

Page

General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3 Hand and foot controls -- Canopy version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--6 Instruments and controls -- Canopy version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--9 Steering geometry button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--10 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--11 Lateral stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--17 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--18 Powershift transmission 4 x 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--21 Driving with the Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--21 Engine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--24

2--1

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION Hand and foot operating controls cab with windows version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--27 Instruments and control in cab with windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--39 Starting the machine with jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--51 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--52 Running--in procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--52 Electrical system main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--53 Driving the Telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--54 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--55 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--56 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--57 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--58 Machine storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--58

2--2

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

Dimensions * Height Track Wheel base Turning radius

100.4 in (2550 mm) 80.7 in (2050 mm) 122.8 in (3120 mm) 153.1 in (3890 mm)

Capacity * Fuel tank Hydraulic system Cooling quantity

35.66 USG (135 L) 47.55 USG (180 L) 3.17 USG (12 L)

Miscellaneous Transmission Powershift Forward gears 4 Reverse gears 3 * Road speed 21.5 mph (35 km/h) Hydraulic controls assisted Simultaneous hydraulic controls provided Hydraulic pump gear type Hydraulic system flow 30.38 gpm (115 l/min) * Except different specifications of foreign Countries.

TH002274

1

2--3

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION HAND AND FOOT OPERATING CONTROLS -- CANOPY VERSION 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. Left control panel.

2. Instrument console.

3. Right control panel.

4. Powershift gear selection lever, travel direction and horn.

5. Engine start key.

2--4

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

8. Foot brake pedal.

9. Pedal accelerator.

10. Machine stability monitoring instrument.

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION

2

4

5

1

3 7

6

9 8

10

TH002397

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. The cab provides the operator with maximum comfort under all ambient conditions.

WARNING

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

Standard features include the handrails and a compartment behind the seat where the Operation and Maintenance Manual is stored.

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

TH002398

3

2--6

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION SAFETY BELT 1

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.

2

TH002270

4

WARNING

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

NOTE: Torque the two seat belt monting bolts to 58 lb--ft (79 Nm).

2--7

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION HANDLES AND STEP Climb and leave the machine using the step and the appropriate handles illustrated in the figure.

TH002398

5 SEAT (WITH MACHANICAL SUSPENSION) 5

The seat is equipped with devices allowing adjusting seat pad inclination and height, backrest inclination and distance from controls.

6

4

1

WARNING

Before starting the machine adjust and lock 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.

3 2 TH002271

6

1. The seat can be shifted forward or back by moving the lever to the right.

2. The seat rises when the knob is turned to the right, and is lowered when turned to the left.

3. Seat suspension is adjusted by turning the lever to the right.

4. Seatbelt with holder.

5. Fixing seatbelt.

Also, the machine is a ROPS version, the center of the seat has hole (6) draining the water that could accumulate.

SEAT STANDARD The seat is equipped with lever (1) providing the adjustment of the distance of the seat from the controls. Also, the machine is a ROPS version, the center of the seat has hole (6) draining the water that could accumulate.

NOTE: Torque the eight seat mounting bolts to 23 lb--ft (31 Nm).

5 6 1

4

TH002279

7 2--8

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

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

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

5

2 4 1

3

6

TH002399

8 1.

Left control panel.

3.

Right control panel.

2.

Instrumentation comprising: S Tachometer; S Hour gauge; S Engine temperature gauge; S Fuel gauge; S Warning lights panel; S Transmission temperature guage; S Battery charge indicator.

4.

Key start switch.

5.

Powershift transmission control lever.

6.

Machine stability monitoring instrument.

2--9

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

B

The indicator light present on the switch comes ON when the wheels of the rear axle are perfectly aligned.

A -- TWO--WHEEL STEERING – Shift the control valve switch for steering selection to position “A” for highway use (two--wheel steer), turn the steering wheel to ensure engagement and monitor the illumination of the lamp on the dashboard (rear wheels aligned).

A

C C

A

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.

B -- 2+2 STEEERING WHEELS -- Press the steering mode button into position B to select the twin steering wheels mode (or double steering).

TH55R220

9

C -- DIAGONAL TRAVEL -- Press the steering mode button into position C to select the mode providing lateral travel.

B

A

C

TH55R206

10

2--10

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 to the center 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

TH55R207

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

11

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

2

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

TH55R208

12

2--11

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION Fuel level gauge This instrument (1) indicates the fuel level in the tank in a continuous manner, but it operates only when the key starter switch is ON.

1

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

TH55R209

13 Transmission oil temperature gauge The transmission oil temperature gauge (2) is connected to a sensor installed on the transmission.

During normal operations, the gauge pointer tends to move upward toward the center of the instrument. In case the pointer enters the red segment, a buzzer comes ON. Stop the engine immediately and find the trouble that could have been caused by:

2

-- clogged oil filter; -- operating the machine under abnormal conditions; -- malfunction of the hydraulic system.

Overheating of the oil must be prevented since the characteristics of the oil could be altered jeopardizing the operation of the internal components.

Return to normal operations only after the oil is cooled off sufficiently or after the cause of the trouble has been corrected.

2--12

TH55R210

14

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION Battery charge indicator Instrument (1) indicates when the charge of the battery is too low or too high. During normal operations, the pointer of the instruments tends to stabilize over between the red segments of the gauge. Should the pointer move over the red segment on the left side of the gauge, there is the indication that the voltage of the batteries is too low. Should the pointer move over the red segment on the right side of the gauge, there is the indication that the voltage of the batteries is too high. Under both circumstances the instrument indicates a faulty operation of the batteries, thus it becomes necessary to contact the service organization to recharge the batteries or replace them, if required.

1

TH55R211

15

2--13

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION WARNING LIGHTS 1. Alternator charge warning light: the alternator charge warning light illuminates when the key start is turned on and will remain on until the engine is started. Once started the alternator is charging the battery and the lamp will be extinguished.

2

3

1

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

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

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

2--14

TH55R214

16

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION 1. Transmission oil pressure indicator light.

The indicator light glows and the buzzer comes ON when the transmission oil pressure drops below the pre--determined value.

2 3

1

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.

2. Park brake warning light.

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

4 TH55R215

17

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.

3. Indicator light, general lights, low beam lights, high beam lights, flasher.

The indicator light comes ON when the rotary switch is actuated.

4. Fuel reserve indicator light.

When the indicator light comes ON, it is necessary to refuel.

2--15

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION 1. Main beams 1

2. Direction indicator lamps

2

TH55R212

18

They indicate which is the steering scheme currently selected:

5

3

4

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

TH55R213

19

2--16

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION LIFTING OPERATIONS ON A SLOPE

WARNING

Performing lifting operations on gradients could be dangerous.

The machine could become unstable sideways and tip--over if the instructions provided in this section are not complied with and understood.

Failing to comply with these instructions can result n serious injuries or death.

Make sure that the guidelines provided by this manual are fully implemented and understood.

Lifting operations must not be performed on gradients unless the machine is leveled along its entire width (it must be leveled sideways).

WARNING

Stop the machine and engage the parking brake prior to performing any lifting operation.

LATERAL STABILITY Always make sure that the machine stands on a firm and stable ground base and, by reading machine stability monitoring instrument (1), make sure that the machine is leveled during the lifting operation.

If during the lifting cycle the level gauge indicates an unleveled condition (air bubble moving into 2), retract and lower the boom immediately and level the machine.

TH001221

2

1

2 20

2--17

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION SWITCHES SWITCHES (left 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.

1

2

3

5

4

1. Work light (optional) mounted on the telescopic boom.

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

1 2 3

3. Attachment hydraulic lock (optional).

4

4. Left stabilizer (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 stabilizer is lifted; when the button lower side is pressed, the stabilizer is lowered.

5. Frame leveling. (3--position rocker switch). This switch controls the front axle 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.

6. Right stabilizer (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 stabilizer is lifted; when the button lower side is pressed, the stabilizer is lowered.

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

2--18

6

5

6

7

7

TH002187

21

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.

5 4

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

1. Boom attachments (optional).

2. Rear axle release.

This switch provides two where required, 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 stabilizers and without axle locking”.

1

1

2

2

3

3

4

5

TH002186

22

WARNING

With the arm lifted over 30 degrees the lifting function of the right and left axle levelling stabilisers where required, is inhibited. Under these conditions, it is impossible to lift one or both stabilisers or make a levelling of the frame.

3. Rear work light (two--position switch) -- The rear light comes ON when actuated.

4. Turning lights. When pressing the top side of the button, the left lights flash. When pressing the bottom side, the right lights flash.

5. Steering geometry button. When pressing the top side of the button, the mode providing four steering wheels is selected. When pressing the lower side of the button, the diagonal travel or crab steer mode is selected. When pressing the central part of the button, the two steering wheels mode is elected.

The rear wheel indicator light in the switch will illuminate when rear wheels are straight inline.

2--19

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION 1. Hazard switch -- select to signal a dangerous situation.

2. Road lights -- Three--way rotary switch: -- when turning the switch into position “1” the general lights come ON; -- when turning the switch into position “2” the low beam lights come ON; -- when turning the switch into position “3” the high beam lights come ON; -- when pressing the switch, the high beam lights flash.

1

2

WARNING

Use machines on highway only if equipped with the optional road lights available through service organization company.

2

1

TH002185

23

2--20

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION 4 X 3 POWERSHIFT TRANSMISSION

1

Transmission control The transmission assembled on this machine is called Powershift.

The Powershift transmission lever (1) is mounted on the left--hand side of the steering column and enables the electronic selection of four forward speeds and three reverse speeds.

TH002400

24 HORN The horn is operated by pushing on the button (2) at the end of the transmission lever.

2

TH002189

25

DRIVING WITH THE POWERSHIFT TRANSMISSION Neutral position Select the neutral position by shifting the transmission lever to the centre.

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

Selecting the reverse gear

TH21R008

26

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

2--21

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION Up shifting

1

Up shifting from 1st gear position to the required gear is achieved by twisting the handgrip (1) counter clockwise in single movements.

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.

TH002400

Down shifting

27

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 only in first gear.

WARNING

INVERSION OF DIRECTION IS ALLOWED ONLY IN FIRST GEAR. TRANSMISSION DISCONNECTION

1

The cutting--off of the transmission occurs through the NEUTRAL position of Powershift lever (1) as described at page 2--21.

TH002400

28 The speed ranges illustrated are calculated with wheels 13.00--24TG 14PR. * Except Countries.

different

specifications

for

foreign

TH002272

29 2--22

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION PARKING BRAKE (with mechanical lock)

WARNING

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

The parking brake blocks the machine when stopped.

Every time the machine is parked, move the gearshift lever into neutral and engage the parking brake.

Brake engaged = ON Brake disengaged = OFF To engage the parking brake, mechanical block (1) must be removed (lowered) pressing button (2) on the lower side.

To disengage it, press it on the upper side.

TH002273

30

1

NOTE: When the engine is cut--off the parking brake is automatically engaged.

If during a stoppage the engine has been cut--off and the switch was left in position “OFF”, it is necessary to move the switch into position “ON” first and then into “OFF” to re--start the machine.

2 TH133091

31

IMPORTANT: A failure in the operating procedure or a failure in the electrical or hydraulic function can result in abrupt engagement of the Parking Brake.

Always wear your seat belt.

(without mechanical lock)

3

To engage the parking brake press button (3) on the lower side; to disengage it press it on the upper side.

TH133092

32

2--23

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

Transmission oil pressure

•

Engine oil pressure

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) energizes 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--energizes 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

TH002193

33

2--24

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

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

Sit in the driver’s seat;

•

Ensure the parking brake is applied;

•

Ensure the Powershift lever is in neutral;

WARNING

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

NOTE: The powershift transmission must be in the neutral position for the engine to start.

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--25

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

Move the starting key into position 2 (activation).

•

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

•

Once the cold starting indicator light goes off, move the foot throttle to half stroke and turn the starting/cut off switch fully clockwise into position 3. Operate the starter motor maximum 30 seconds until the engine starts, then release the key and let it return into position 2.

1

WARNING

2

Do not use ether if your machine is equipped with a grid heater.

3 In warm weather or when the engine is hot: •

•

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 30 seconds or until the engine starts, then allow the key to return to position (2).

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

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

IMPORTANT: If the machine has not ran for a period of four weeks or longer, 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--26

TH002401

34

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION HAND AND FOOT OPERATING CONTROLS CAB WITH WINDOWS VERION 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. Left 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.

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.

10. 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.

11. Storage facility (on demand radio compartment).

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

13. Pedal accelerator.

8. Road lights and direction indicator control lever.

14. Foot brake pedal.

9. Ventilation duct.

15. Anti overturning block forcing release button.

16. Steering wheel height adjusting lever.

17. Center panel.

18. Heating/conditioning control panel.

2--27

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION

TH55R271

35

2--28

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

It is equipped with a rollover protection structure.

Also, the cab is equipped with large windows, 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, 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 vehicle using the steps and the appropriate handles illustrated in the figure.

TH002402

36 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’s transparent surface.

TH002387

1 37

2--29

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.

WARNING

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

NOTE: Torque the two seat belt monting bolts to 58 lb--ft (79 Nm).

2--30

1 2

TH002388

38

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 in and out of the machine using the ladder and the appropriate handles illustrated in the figure.

TH002402

39 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

TH002403

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

2

TH002404

41 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 releasing the window catch (3) the glass frame can be swung back and retained as shown below.

3 TH002405

42 2--31

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.

2

1

TH002406

43

3 TH002087

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

TH002205

45 The rear window also acts as an emergency exit.

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

5

TH002206

46 2--32

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

WARNING

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

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

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

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

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

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

4. Safety belt with holder.

5. Fixing the seat belt.

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

5

4 1

2

3

TH002391

47

6

TH002089

48

2--33

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

7

WARNING

Before starting the machine adjust and block seats to the most 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. Lift lever (1) and move the backrest into the desired position. Release the lever to lock the position.

2. Turn knob (2) to set the seat in accordance to your weight.

3. Lift adjusting lever (3) upward and adjust the seat forward or backward, as desired. Release the lever to lock the position.

4. Lift lever (4) to tilt the seat forward or backward.

5. Securing the seat belt.

6. Safety belt with retractor.

7. Turn knob (7) to raise or lower the armrest in the desired position.

5

6 1

2 4 3 TH002392

49

Steering wheel adjustment handle This handle makes it possible to adjust the steering wheel, and it is below the steering column.

---

Move handle (8) upwards to release and adjust the steering wheel.

Move handle (8) downwards to lock the steering wheel in the chosen position.

8

TH002393

50

2--34

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION CAB HEATING--VENTILATION CONTROLS Ventilation control The fan and heating system control panel is located on the right--hand side cab wall, next to the operator’s seat.

There is a three--speed blower for heat circulation inside the cab, controlled by the switch (1).

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

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

2 1 TH002415

51

Heating control The temperature of the air from the heating system is adjusted using control knob (2). Turn the knob clockwise to increase air temperature and counter clockwise to reduce it. To heat the cab, the engine must be at an adequate operating temperature.

WARNING

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

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

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

turn knob (2) until maximum temperature is reached;

•

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

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

2--35

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

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

•

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

•

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

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

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

Demisting and defrosting To obtain fast demisting/defrosting of the front, side and rear windows, proceed as follows: • press the button to switch on the conditioning system (3); •

switch on the fan at maximum speed with knob (1);

•

turn knob (2) until maximum temperature is reached;

•

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

2--36

2 3

1

TH002227

52

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

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

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

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

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

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

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

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

TH002166

53

TH002337

54

TH002338

55

TH002354

56 2--37

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

COOLANT Freon R134a

WARNING

R134a can be dangerous if improperly handled.

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

Freon R134a has a boiling point of --12°C. Never expose any part of the air--conditioner system to flame or excessive heat because of the risk of fire or explosion, and the production of phosgene gas.

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

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

Warm the area with your hand or lukewarm water (32°C), cover the area loosely with a bandage to protect the affected area against infection and consult a doctor immediately If coolant should contact the eyes wash immediately with cold clean water for at least 5 minutes and consult a doctor immediately.

2--38

TH002169

57

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

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

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

TH002394

58 1.

Left panel.

6.

Key start switch.

2.

Safety key for selecting control--operating modes.

7.

Center panel.

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.

10. Storage facility/radio compartment.

11. Anti--overturn block forcing button.

Vehicle emergency lights switches, lights and various services switches.

2--39

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

A B

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

WARNING

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

Unless otherwise stated, two--wheel steer uses the front wheels only.

B

C

A

C

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

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

TH55R301

59

TH002112

1 60

2--40

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

61

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

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

2

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

TH002114

3 62

2--41

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

63

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.

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--42

2

3

4

5

TH002116

64

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 °C.

WARNING

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

1

2

3

4

TH002117

65 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--43

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

TH002118

1 2

1. Main beams 2. Direction indicator lamps

66

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

TH002119

3

4

5

1. Two steering wheels (front ones) (3) 2. Bias translation (crab steer) (4) 3. Four steering wheels (5)

67

2--44

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION LIFTING ON SLOPES WARNING

Lifting operations on slopes can be dangerous.

The vehicle may become laterally unstable and tip over if the instructions in this section are not followed and understood.

You and others can be seriously injured or killed. Be sure you follow and fully understand the guidelines provided in this manual.

Lifting operations should not be undertaken on slopes unless the vehicle is at the level along its width (it must stay leveled laterally).

WARNING

Stop the vehicle and engage the parking brake before carrying out any lifting operation.

LATERAL STABILITY

1

Always make sure that the vehicle is on a bed of full and flat level. While watching the stability indicator bubble (1) show in the figure, make sure that the vehicle stays leveled during lifting operations.

If the level indicator shows an unlevel condition (bubble towards 10°) during lifting, lower and retract the boom immediately and level the vehicle.

The machine is perfectly levelled only when the air bubble is exactly in the centre of the stability indicator (1) as shown in the figure.

TH002365

68 BUTTON FORCING THE ANTI OVERTURNING BLOCK When this button (1) is kept depressed during hazard conditions for unbalancing, normal hydraulic control functions are temporarily restored.

1

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

Corrective actions can be to move the weight of the load onto the vehicle’s centre of gravity (lifting the load or retracting the arm).

TH002332

WARNING

69

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

DANGER OF OVERTURNING!!

2--45

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

70

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

71 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

72 2--46

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”.

1

2

3

4

TH002427

73

WARNING

With the arm lifted over 30° 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--47

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.

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).

10. Roof wiper switch.

Pressing the switch activates the cab roof wiper.

2--48

7

8

9

1

2

3

4

5

TH002428

74

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION PARKING BRAKE (with mechanical lock)

WARNING

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

The parking brake blocks the machine when stopped.

Every time the machine is parked, move the gearshift lever into neutral and engage the parking brake.

Brake engaged = ON Brake disengaged = OFF

TH002396

75

To engage the parking brake, mechanical block (1) must be removed (lowered) pressing button (2) on the lower side.

To disengage it, press it on the upper side.

NOTE: When the engine is cut--off the parking brake is automatically engaged.

If during a stoppage the engine has been cut--off and the switch was left in position “OFF”, it is necessary to move the switch into position “ON” first and then into “OFF” to re--start the machine.

IMPORTANT: A failure in the operating procedure or a failure in the electrical or hydraulic function can result in abrupt engagement of the Parking Brake.

Always wear your seat belt.

1

2 TH133091

76

(without mechanical lock) To engage the parking brake press button (3) on the lower side; to disengage it press it on the upper side.

3

TH002416

77

2--49

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION SAFETY KEY AND SELECTING OPERATION 1

This is located on the right hand side of the steering column base. The key (1) enables selection of the hydraulic controls operating modes. It has two positions and operates as shown here below.

A. “Road” position. It inhibits all arm manoeuvres, levelling and selection of the steering mode.

These settings correspond to the safety requirements for driving on the road. If transferred onto a road, all requirements must be complied with (position of the arm, protections, etc.) before selecting this position. After selecting this position and checking the correct operation of the steering, wheel alignment and other settings for road travelling, the driver must remove the key before starting travel so as to prevent unwanted operation.

TH002343

78

A

B

B. “Site” position. It is the position that enables all normal cab controls. All hydraulically controlled equipment is activated. This is the position used in normal work conditions.

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 in position as soon as they are aligned along the running direction.

2--50

TH002355

79

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION STARTING THE ENGINE WITH JUMP CABLES 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 is necessary to use jump leads with an external battery to start the machine, proceed as follows:

•

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

•

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

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

•

When the engine starts allow it to run at idle speed, turn on 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--51

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

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

Release the foot throttle.

•

Apply the parking brake.

•

Place the Powershift lever into NEUTRAL.

•

Lower the attachment.

•

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

WARNING

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

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

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

After the engine has warmed sufficiently, cycle the hydraulic 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--52

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 minimize engine wear by selecting the correct gear ratio for each particular operation.

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

Daily checks during running in include: •

Radiator coolant level

•

Engine oil level

•

Hydraulic system oil level

•

Transmission oil level

•

Axle oil level

•

Axle hub oil level

•

Transfer box

•

Cylinder and bushings lubrication fittings

•

Engine cleaner restriction indicator lights

•

All wheel nuts for tightness

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION ELECTRICAL SYSTEM MAIN SWITCH WARNING

Do not cut--off the batteries while the engine is running. Always move the starter switch into position “OFF” before cutting them off.

IMPORTANT: Do not cut--off the engine using the battery cut--off switch.

The switch is accessible by opening the engine hood.

The key of the electrical system main switch must be in ON when the system must be energised.

Turn the switch key into OFF when the machine is going to be parked at the end of the work shift and axtract the key.

By doing this, eventual abuses on the machine by unauthorised persons are discouraged.

TH002426

80

2--53

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

•

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.

•

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

TH001223

•

•

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

•

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

Refer to on Road requirements.

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

•

Always wear your seat belt.

•

Always use transport chains when transporting the machine.

•

Dim the lights when meeting a machine at night.

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

2--54

TH002199

•

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 2

WARNING

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

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 TH002200

81

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 qualified operator. The operator can not be too skilled.

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

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--55

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION TOWING WARNING

Ensure that the wheels are blocked with wedges before releasing the parking brake.

When the engine will start and run release the parking brake pushing the appropriate button in the cab.

When the engine is switch OFF turn brake release screws (1) in on front axle.

1 TH002292

82 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.

The cables must be secured at the points provided for this purpose.

WARNING

Keep exposed personnel clear of anchor points and cables or chains.

TH002195

83

Do not pull unless operator’s compartment of machines involved are properly guarded against potential cable or chain backlash.

Prior to the towing, make sure that the cable or the towing bar are in good conditions and are strong enough for the towing. Use a cable or a towing bar having a capacity of at least 1.5 times the gross mass of the pulling machine, in the event a disabled machine stuck in mud must be recovered or must be towed on a slope.

When towing, connect the towing cable to the prescribed points on the fame only, if installed.

These towing instructions are intended to move a machine incapable of moving on its own a short distance at slow speed. Pull the machine at a speed of 20 km/h (12.4 mph) or lower toward a place suitable for the repair operation.

2--56

TH002324

84

SECTION 2 -- CONTROLS, INSTRUMENTS AND OPERATION LIFTING The same recommendations seen in the preceding point for the use of cables and chains apply.

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.

TH002196

85

Stay at a safe distance during the lifting.

TH002280

86

2--57

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.

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--58

TH001482

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

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

IT IS TOO LATE TO LEARN ONCE THE MACHINE IS MOVING

CONTENTS OF THE SECTION Description

Page

Front loader controls/operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2 Lateral stability (Canopy version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4 Lateral stability (Cab with windows version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5 Load handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--6 Installing attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--9 Ballasting and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--11 Weighting of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--12

3--1

SECTION 3 -- FIELD OPERATION FRONT LOADER CONTROLS / OPERATION PILOT VALVE CONTROL ON -- OFF FOR MODEL TX742 STANDARD (CAB WITH CANOPY)

WARNING

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

1

TH003063

1 To lift, lower, retract and extend the boom move the lever (1): -- Forward to lower the boom; -- Rearward to raise the boom; -- Leftward to retract the boom; -- Rightward to extend the boom.

2 L

R

3

When pressing tilt control button (2) into R (right) the attachment roll/tilt attachment down; when pressing on L (left) it roll/tilt attachment up. Buttons (3 and 4) located respectively on the front and rear side of the pilot valve are available for auxiliary functions.

1

TH003064

2 IMPORTANT: In order to avoid the excessive heating of the hydraulic oil and/or uncontrolled movements of the tool, not to carry out the raising command of boom at the same time to the tilt command when the tilt cylinder is to bottom position.

4

TH001389

3 3--2

SECTION 3 -- FIELD OPERATION FRONT LOADER CONTROLS / OPERATION PILOT VALVE CONTROL ELECTROPROPORTIONAL FOR MODELS TX842 -- TX945 STANDARD FOR MODEL TX742 OPTIONAL (CAB WITH CANOPY AND CAB WITH WINDOWS)

1

WARNING

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, retract and extend the boom move the lever (1): -- Forward to lower the boom; -- Rearward to raise the boom; -- Leftward to retract the boom; -- Rightward to extend the boom.

It is composed of a swinging proportional switch (2) and two buttons (3) and (4).

Swinging switch (2) provides the roll/tilt of the attachment up when it is moved forward and the roll/tilt down of the attachment when it is moved backward. Buttons (3) and (4) are available for auxiliary functions.

TH004318

4 2 3 4

TH004319

5

IMPORTANT: In order to avoid the excessive heating of the hydraulic oil and/or uncontrolled movements of the tool, not to carry out the raising command of boom at the same time to the tilt command when the tilt cylinder is to bottom position.

5

LOWER BUTTON There is one button below, having the following functions: 1. Disconnecting the transmission.

Button (5) keeps the transmission disconnected until it is released.

TH004320

6

3--3

SECTION 3 -- FIELD OPERATION LIFTING OPERATIONS ON A SLOPE

WARNING

Performing lifting operations on gradients could be dangerous.

The machine could become unstable sideways and tip--over if the instructions provided in this section are not complied with and understood.

Failing to comply with these instructions can result n serious injuries or death.

Make sure that the guidelines provided by this manual are fully implemented and understood.

Lifting operations must not be performed on gradients unless the machine is leveled along its entire width (it must be leveled sideways).

WARNING

Stop the machine and engage the parking brake prior to performing any lifting operation.

LATERAL STABILITY (CANOPY VERSION) Always make sure that the machine stands on a firm and stable ground base and, by reading machine stability monitoring instrument (1), make sure that the machine is leveled during the lifting operation.

If during the lifting cycle the level gauge indicates an unleveled condition (air bubble moving into 2), retract and lower the boom immediately and level the machine (see section 2 for description).

TH001221

2

1

2 7

3--4

SECTION 3 -- FIELD OPERATION LIFTING ON SLOPES WARNING

Lifting operations on slopes can be dangerous.

The vehicle may become laterally unstable and tip over if the instructions in this section are not followed and understood.

You and others can be seriously injured or killed. Be sure you follow and fully understand the guidelines provided in this manual.

Lifting operations should not be undertaken on slopes unless the vehicle is at the level along its width (it must stay leveled laterally).

WARNING

Stop the vehicle and engage the parking brake before carrying out any lifting operation.

LATERAL STABILITY (CAB WITH WINDOWS VERSION) Always make sure that the vehicle is on a bed of full and flat level. While watching the stability indicator bubble (1) show in the figure, make sure that the vehicle stays leveled during lifting operations.

If the level indicator shows an unlevel condition (bubble towards 10°) during lifting, lower and retract the boom immediately and level the vehicle.

The machine is perfectly levelled only when the air bubble is exactly in the centre of the stability indicator (1) as shown in the figure.

1

TH002365

8

3--5

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

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

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

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

TH003071

9

3--6

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

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

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

TH003072

10

3--7

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 forward and reverse lever in neutral.

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.

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 backwards to slip under the load. As necessary wedge the load.

BUCKET USE 13. When using an bucket attachment use only with the boom fully retracted.

TH003124

11

3--8

SECTION 3 -- FIELD OPERATION INSTALLING ATTACHMENTS PICKING UP AN ATTACHMENT (WITHOUT HYDRAULIC LOCKING) 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.

TH003076

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

TH003077

13 Turn blocking plate (1) in the direction indicated in the figure.

1

TH003078

14 Insert locking pin (2) in the quick release coupling and in the attachment and secure it making sure that blocking plate (1) pushed by the relevant spring, seats in the slot of pin (2).

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.

TH003079

15 3--9

SECTION 3 -- FIELD OPERATION 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 TIRES Rolling circle in (mm)

Capacity lb (kg)

21.5 (35)

Inflation pressure psi (bar)* 65.3 (4.5)

155 (3.937)

8272 (3752)

21.5 (35)

--

155 (3.937)

8272 (3752)

Tire

Speed mph (km/h)

13.00--24TG 14PR 13.00--24TG 14PR (foam filled)

* The pressures listed refer to inflation for site use.

The data listed here above correspond to the “approximative weight” of a standard machine, without equipment.

FOAM BALLAST The front and rear tires with foam ballast are tires type adapt to adding weight to the machine where greater traction or stability is required.

WARNING

IT IS NOT ACCEPTABLE TO FILL THE TIRES WITH LIQUID SOLUTION OR GAS USE ONLY AIR.

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 the increase. To avoid serious damage to 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 tires may be lower than the load capacity of the front axle. The lower figure of the two must be used.

The maximum permissible loading for front and rear axle, inclusive of ballast and arm attachment in the raised position is shown below:

Static load rating

TX742

TX842

TX945

31500 lb

35134 lb

38982 lb

(69445 kg)

(77457 kg)

(85940 kg)

TH003150

16

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 immobilized 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--9 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--13 Every 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--14 Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--17 Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--19 Every 1000 hours or annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--24 Every 1000 hours or every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--28 Every 2000 hours or every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--31 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--33

4--1

SECTION 4 -- LUBRICATION AND MAINTENANCE GENERAL

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

FILLING AND SERVICE POINTS

1. Front axle differential oil check

DIESEL FUEL TANK (11) CAPACITY 35.66 USG (135 Litres)

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

HYDRAULIC RESERVOIR (12) OIL CAPACITY 47.55 USG (180 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 filler opening, filters, level plugs and dipsticks before adding or changing.

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 4x4 oil level check 10. Brake oil level check Inspect and grease all fittings

2

3

1

4

5

6

7

8

11

10

12

9

TH004290

1

4--2

SECTION 4 -- LUBRICATION AND MAINTENANCE ANALOGUE INSTRUMENT PANEL SERVICE WARNING LAMPS (CANOPY VERSION)

1

2

3

4

5

6

7

8

9

TH004288

2 1.

Indicator light, 2 + 2 steering wheels (round effect)

2.

Indicator light, two steering wheels (rear wheels aligned)

3.

Indicator light, diagonal travel (crab diagram)

4.

Indicator light, engine oil pressure

5.

Indicator light, cold starting device

6.

Indicator light, alternator charge

7.

Indicator light, parking brake engaged

8.

Indicator light, transmission oil pressure

9.

Indicator light, fuel reserve

4--3

SECTION 4 -- LUBRICATION AND MAINTENANCE ANALOGUE INSTRUMENT PANEL SERVICE WARNING LAMPS (CAB WITH WINDOWS VERSION)

1

2

3

6

4

5

TH004114

3 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--4

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

•

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

•

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

•

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

•

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

•

Keep equipment properly maintained.

1

TH004195

4

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

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

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

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

WARNING

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

4--5

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

•

The welding machine wires must not be over, next to 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 batteries with a charger.

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

2. NEVER ground any charging component.

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

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

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

•

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

•

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

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

4--6

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 ground 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.

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 100 hours of operation, it is necessary to replace the transmission oil filter.

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: • • • • •

Engine oil Radiator coolant Transmission oil Hydraulic system oil Cylinder and bushing 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 petrolem jelly to prevent corrosion.

WARNING

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

IMPORTANT: Make sure that used oil and used 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--7

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

IMPORTANT: It is recommended to clean the outer element or change it at the 500 hr Service interval.

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

Extract the outer element (2) after removing the cap (1). If dust is present inside the outer element, the element must be replace. 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.

1

TH004161

5 Alternatively, compressed air, as a pressure not exceeding 29 psi (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 5.9 in (150 mm) from the element. Protect the eyes when carrying out this operation.

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

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

4--8

3

2

TH004162

6

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).

Ensure the machine is parked on a level surface and the frame is level as indicated by the machine stability monitoring instrument.

TH004277

If necessary, remove the filler cap (on the rear valve cover on engine) and add oil through the filler tube.

See Specifications for the recommended oil grade.

7

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.

2

TH004278

8

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 authorized dealer.

4--9

SECTION 4 -- LUBRICATION AND MAINTENANCE TRANSMISSION OIL LEVEL Re--fill the transmission with the recommended type of oil approximately 4.5 USG (17 Litres) through the dipstick tube situated to the right of the engine block using the following procedure.

1

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

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

TH004279

9

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

Ensure the machine is parked on a level surface and the frame is level as indicated by the machine stability monitoring instrument.

HYDRAULIC SYSTEM OIL LEVEL The hydraulic tank cap (2) is located on the left side of the machine.

2

The level of the hydraulic system oil is checked through sight gauge (3) indicated in the figure.

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

Ensure the machine is parked on a level surface and the frame is level as indicated by the machine stability monitoring instrument.

Should the oil not be visible in the sight glass (3), unscrew the oil reservoir filter (2) and top up with the recommended oil, see specifications.

4--10

3 TH004373

10

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 maneuver prior to work operations. Extract boom 1 for about 19.7 -- 23.6 in (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 BUSHING LUBRICATION Check the two arm lifting cylinder bushings are lubricated. If not, pump in the type of grease recommended by the manufacturer until filling.

TH004196

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

TH004197

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

4--11

SECTION 4 -- LUBRICATION AND MAINTENANCE

TH004374

13

4--12

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

Page P No.

Adjustment / Topping--up Lubrication / Greasing Clean Check

Every 50 hours

Every 250 hours

Every 500 hours

Every 1000 hours or annually ll

Every 1000 hours or 2 years Every 2000 E hours or 2 years

Generall G maintenance

13

Radiator

X

13

Front loader arm fittings

13

Fuel filter condensation draining

14

Wheels and tires

X

15

Front and rear wheel nuts

X

15

Front and rear axle joint bearings

X

15

Propeller shaft joints

X

15

Front and rear axle supports

X

16

Engine air cleaner (outer element)

17

Front loader arm fittings

18

Engine oil and filter

19

Front and rear axle differential oil

X

X

19

Front and rear axle hub oil

X

X

19

Fuel filter

X

21*

Engine air cleaner (outer and inner element)

X

22

Hydraulic system oil filter

X

22

Transmission/dropbox oil and filter

X X

24**

Front and rear axle differential oil

X X

25

Front and rear axle hub oil

X X

25

Alternator drive belt

X

X

26

Valve clearance

X

X

27***

Engine coolant

30

Hydraulic reservoir output strainer

30

Hydraulic system oil

X X

31

Brake oil

X X

32

Alternator charging system

X

33

Hydraulic hoses and tubing

X

34

All wheel toe--in

X

X

34

Steering stop

X

X

35

Bulbs

X

X

37

Fuses and relays

X

X

42

Wheels and tires

X

X X X X

X X X X

X X X X

X

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

4--13

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

Fins clogged with oily substances shall be clean with a detergent 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.

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

1 TH004281

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.

TH004168

15 FUEL FILTER CONDENSATION DRAINING Open the engine cover and drain the water and sediments from the fuel filter using the draining valve indicated.

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

Drain water and sediments until clean fuel only, flows out.

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--14

TH004194

16

SECTION 4 -- LUBRICATION AND MAINTENANCE WHEELS AND TIRES

WARNING

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

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

Consult your local dealer for assistance.

TH001482

17

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

Adjust the tire pressures to suit the load being carried. See Tire Pressure and Load tables.

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

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

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

TH004029

18

4--15

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

The nut tightening torque between the wheel rim and the hub must be 400 lbf--ft (542 Nm).

FRONT AND AXLE JOINT BEARINGS Grease fitting (1) are on the front and rear axle four edges, on the wheel inner hub both top and bottom.

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

1

TH004169

19 DRIVE SHAFT JOINTS The front and rear drive shafts are fitted with one grease fitting each, one for each edge, i.e. four grease fittings.

TH004016

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

TH004018

21

4--16

SECTION 4 -- LUBRICATION AND MAINTENANCE EVERY 250 HOURS ENGINE AIR CLEANER (outer element) Free locks (1) to loosen of the engine air cleaner seat cover (2).

2

Remove the element (3) and clean as described.

1

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

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

TH004180

22

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

3

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

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

Rinse the element in clean running water, Figure 23, 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.

TH004170

23

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 be discarded and a new one installed.

24

4--17

SECTION 4 -- LUBRICATION AND MAINTENANCE FRONT ARM SLIDING BLOCKS Proceed with the cleaning of pads (1) removing old grease, dirt accumulations and any scaling.

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

1

TH004168

25

4--18

SECTION 4 -- LUBRICATION AND MAINTENANCE EVERY 500 HOURS ENGINE OIL AND FILTER

1

Drain the oil with the engine hot, as follows: -- Prepare a container that is the right size; -- Remove the plug (1) from the engine oil sump and let the oil pour out. To make drainage easier, remove the oil filling cap (3); -- Screw the drain plug back in (1).

WARNING

Used engine oil is a contaminated substance and should be disposed of safely and correctly in accordance with local law and legislation.

TH004282

26

Unscrew and discard the oil filter (2) safety and correctly in accordance with local law and lagislation.

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 10° F (--12° C) should have the oil changed every 250 hours of operation. Under these conditions the engine oil filter needs only to be changed at the 500 hour service as described above.

2 TH004283

27

Fill the engine with clean oil through filler neck (3) and check the level with dipstick (4). Run the engine for a few minutes to circulate the oil. Ensure the machine is parked on a level surface and the frame is level as indicated by the machine stability monitoring instrument. Wait a few minutes that the oil can drain into the sump prior to checking the oil again with dipstick (4).

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

WARNING

3

4 TH004284

28

Do not run the engine of this vehicle in enclosed, non--ventilated places. It must be possible to evacuate the harmful exhaust gases.

AVOID ENVIRONMENTAL POLLUTION. Eliminate the hydraulic fluids, lubricants and coolants and filtering elements soaked with these fluids according to local and national laws in force that classify these materials as polluting, harmful or hazardous waste.

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

29

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

TH004174

30 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 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

TH004175

31

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--priming and does not require bleeding.

1

TH004176

32 IMPORTANT: Do not crank the starting motor continuously for more than 30 seconds as doing so may cause starting motor failure.

If the engine fails to start after 30 seconds, repeat the priming procedure outlined above.

4--21

SECTION 4 -- LUBRICATION AND MAINTENANCE ENGINE AIR CLEANER (outer and inner element) Unhook holders (1) to remove cover (2) of the engine air cleaner seat.

2

Remove the outer element (3) and the inner element (4) and then dispose of them.

1

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

TH004180

33

4

3

TH004162

34

4--22

SECTION 4 -- LUBRICATION AND MAINTENANCE HYDRAULIC RESERVOIR OIL FILTER 1

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.

Open the rear box of the telescopic boom by removing four securing screws (1).

Remove hydraulic filter (2) loosen and extract the cartridge. Discard the old filter and install a new one, safety and correctly in accordance with local law and legislation.

1

TH004293

35

Operate the loader to purge air from the system and re--check the oil level.

IMPORTANT: 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.

TH004285

2 36

4--23

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 4.5 USG (17 Litres).

Re--install the drain plug after the oil is drained.

1

Unscrew the gearcase plug (2) and collect the oil in the container. Wait until oil draining is finished and re--install the plug.

2

Drain the drop box oil through the plug hole (3).

Re--install the drain plug after the oil is drained.

3

TH004031

37 Fill the drop box case with the recommended oil type through the fill plug (1). The case capacity is 0.75 liters (0.2 gal). Check the oil level through the lens above the drain plug.

1 TH004033

38

4--24

SECTION 4 -- LUBRICATION AND MAINTENANCE Unscrew the transmission oil filter (4) mounted to the top and left of the transmission and discard safety and correctly in accordance with local law and legislation. Lubricate the new filter oil seal with clean transmission oil and install. The new filter should be hand tight, plus ¾ of a turn.

4

TH004286

39 Fill the gear with the recommended oil type, around 4.5 USG (17 Litres), through the filler hole with dipstick (2) installed to the right of the base. Observe the following procedure.

2

Use the dipstick (2) and check the gear oil level at usual operating temperature, with engine running idle and gear lever in neutral position. Add the required oil quantity and make sure the level is between minimum and maximum.

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

TH004279

40

NOTE: The oil level shall be measured with the dipstick completely inside the filler plug.

FRONT AND REAR AXLE DIFFERENTIAL OIL

3

To drain the differential, remove the plug (3) and drain from plug holes (5) the oil into a suitable container.

Re--install the plugs (5) and fill the differential through the plug hole (3). Make sure the oil reaches the level/ filler plug hole (4). Install plugs (3) and (4).

4

4

5 TH004105

41

4--25

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

42 ALTERNATOR DRIVE BELT

5

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 (0.5--0.75 in) when hand pressure is applied midway between the alternator and crankshaft pulley. If the belt (2) needs to be adjusted, loosen nut (3) and nut (4) including the washer then act on the regulating screw (5). After regulating tighten the nut (4). Tighten nut (3) to 20 lbf--ft (27 Nm) torque.

3 4 2 TH004289

43

4--26

SECTION 4 -- LUBRICATION AND MAINTENANCE VALVE CLEARANCE 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 intake/3 exhaust 3 intake/4 exhaust 2 exhaust/4 intake 1 exhaust/2 intake

4

3

4

2

3

1

2

1

Valves to be adjusted 2 exhaust/4 intake 1 exhaust/2 intake 1 intake/3 exhaust 3 intake/4 exhaust

Intake valve clearance – cold 0.009±0.020 in (0.25±0.05 mm) Exhaust valve clearance – cold 0.019±0.020 in (0.50±0.05 mm) Insert the thickness gauge between each valve stem and the rocker arms. Turn the screw and adjust its clearance.

44

4--27

SECTION 4 -- LUBRICATION AND MAINTENANCE EVERY 1000 HOURS OR EVERY TWO YEARS ENGINE COOLANT The engine cooling system (1) is factory filled with a high quality water and antifreeze mixture. The antifreeze contains a chemical corrosion preventative enhancing and extending the protection provided by conventional additives.

The inhibitor will: •

Increase rust prevention;

•

Reduce scale formation;

•

Minimize cylinder wall erosion (pitting);

•

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 Ambra Agriflu antifreeze or, where this antifreeze is not available, with a measured amount 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--28

1 TH004281

45

SECTION 4 -- LUBRICATION AND MAINTENANCE IMPORTANT: During the loading and unloading stages of the cooling system it is advisable to enabled the cab heating controls as described in section 2 of this manual.

This operation allows to empty and refill the cab heater and the relevant pipes.

Locate a container under the radiator outlet. While the engine is cold empty the liquid from the radiator removing the plug (1) that is located at the bottom of the radiator as indicated on the figure.

After emptying the coolant, put back the plug. Fill up the cooling system again by removing the pressurised cap (2), removing the plug (3) from the system air outlet.

1

TH10R074

46

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

2

The coolant to be used is dependent upon local availability.

Using Ambra Agriflu Antifreeze

3

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.

TH004267

47

WARNING

Inhibitor solution is irritating to eyes and skin. It contains buffered potassium hydroxide.

•

Avoid contact with eyes or prolonged and repeated skin contact.

•

Wear protective eyewear when using.

•

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

•

Wash skin with soap and water after use.

•

Keep out of reach of children.

4--29

SECTION 4 -- LUBRICATION AND MAINTENANCE After refilling the system – All coolant solutions Check that the coolant level is within the area of the sight glass in the radiator over flow bottle.

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.

System capacity maximum Coolant capacity Antifreeze specification Clean water specification Total hardness Chlorides Sulphates

4--30

3.2 USG (12 Litres) Ambra Agriflu 300 parts per million 100 parts per million 100 parts per million

SECTION 4 -- LUBRICATION AND MAINTENANCE EVERY 2000 HOURS OR EVERY TWO YEARS HYDRAULIC RESERVOIR OUTPUT SCREEN FILTER The hydraulic circuit is protected by a screen filter which must be maintained to prevent dirt from penetrating the hydraulic circuit.

After draining the oil from the tank by removing plug (1), the outlet mesh filter can be removed for maintenance.

To do this, remove the plate (2) which makes it possible to access the oil tank. The plate can be reached from the compartment under the cabin.

This screen filter should be cleaned in a suitable solution to remove all dirt and impurities.

1

TH004182

48

2

TH004183

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 (4) with the recommended oil, see Specifications. Operate the loader to purge air from the system and re--check the reservoir oil level. Ensure the machine is parked on a level as surface and the frame is level as indicated by the machine stability monitoring instrument.

NOTE: Should it be necessary to drain the hydraulic reservoir oil at any time, place a suitable container capable of holding at least 48.87 USG (185 Litres) in position and remove the drain plug.

4

3 TH004375

50

4--31

SECTION 4 -- LUBRICATION AND MAINTENANCE FOOT BRAKE The brake oil reservoir (1) is mounted above the steering console.

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.

1

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.

4--32

TH004185

51

SECTION 4 -- LUBRICATION AND MAINTENANCE GENERAL MAINTENANCE ALTERNATOR CHARGING SYSTEM To avoid damage to the components of the alternator charging system, service precautions must be observed as follows: •

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

•

NEVER short any of the charging components to ground.

TH004200

•

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

•

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

52

WARNING

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

•

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

•

ALWAYS observe correct polarity when installing the battery or using a slave battery to start the engine. Follow the instructions on page 2--27 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, while 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 51.

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.

Ensure the machine is parked on a level as surface and the frame is level as indicated by the machine stability monitoring instrument.

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 tie rod and turn the hexagon adjuster (1) with a spanner until the correct toe--in setting is obtained. Tighten the lock nut and re--check the toe--in.

1 2

TH004186

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 tires touching the vehicle on full left and right lock with the axle fully oscillated.

To adjust, loosen 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.

3

4

TH004187

55

4--35

SECTION 4 -- LUBRICATION AND MAINTENANCE LIGHTS (OPTIONAL) 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.

TH004188

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.

1

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

TH004099

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.

TH004376

58

4--36

SECTION 4 -- LUBRICATION AND MAINTENANCE Rear work light The bulb is accessible after removing the retaining screws of the plastic lens.

TH004377

59 Rear, stop and direction indicator All bulbs are accessible after removing securing screws (1) of the plastic lenses.

The bulbs have a bayonet cap fitting with offset pins for the brake light bulb and parallel pins for the direction indicator bulb. Both bulbs may be removed by depressing slightly and rotating approximately 20° counter--clockwise.

Replacement of the bulbs follows the removal procedure in reverse, however ensure the brake light offset pins align with the socket correctly. The lens can be replaced after the lights have been tested.

1

TH004101

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 1.2W and is press--fit in the retainer. After changing the bulb, push the retainer into the back of switch.

TH004190

61 FUSE AND RELAY To reach the panel containing the fuses and relays of the machine, remove six securing screws (2) of cover (3).

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.

2

TH004287

3 62

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

TH004192

63

4--38

SECTION 4 -- LUBRICATION AND MAINTENANCE FUSES Fuses ON--OFF version (TX742) NAME F1 F2 F3 F4 F6 F7 F9 F10 F11 F12 F17 F18 F19 F20 F21 F23 F24 F25 F26 F27 F28 F29 F30 F31 F32 FG1.1 FG1.2 FG3

DESCRIPTION Fuse, engine cut--off Panel instrument Fuse, transmission Fuse, attachments Fuse, rotary beacon Fuse, flasher Fuse, low beam lights Fuse, high beam lights Fuse, panel light and trafic light Fuse, trafic light Fuse, boom work lights Fuse, front work lights Fuse, rear work lights Fuse, solenoid valve Fuse, general lights Fuse, extension/retraction ON--OFF Fuse, IN/OUT option Fuse, descent/ascent stabilizer Fuse, low boom sensor Fuse, rear axle locking Fuse, horn Fuse, back--up alarm Fuse, flasher Fuse, rear axle sensor Fuse, arm sensor preheating kit Fuse, general Fuse, general Fuse, preheating filter

VALUE 7.5A 3A 10A 7.5A 10A 10A 15A 15A 5A 5A 15A 15A 15A 10A 7.5A 10A 10A 7.5A 10A 3A 15A 5A 7.5A 7A 5A 80A 80A 20A

4--39

SECTION 4 -- LUBRICATION AND MAINTENANCE RELAYS Relay ON--OFF version (TX742) DESCRIPTION NAME K1 Relay, 1° speed K2 Relay, 2° speed K3 Relay, reverse K4 Relay, 4° speed K5 Relay, forward motion K6 Relay, decluch trasmission K7 Relay, reverse speed buzzer K8 Relay, stabilizer K9 Relay, two steering wheels indicator light K10 Relay, diagonal steering travel light K11 Relay, round steering light K12 Relay, preheating light K13 Relay, horn K14 Relay, hand brake switch K15 Relay, low boom sensor K16 Relay, stabilizer K17 Relay, “IN” option K18 Relay, optional (Out) K19 Relay, retraction K20 Relay, telescopic motion K406 Relay, flasher K407 Relay, high beam lights K408 Relay, low beam lights KA Relay, starting switch KD Relay, key KT Relay, preheating

TH55R103

64

4--40

SECTION 4 -- LUBRICATION AND MAINTENANCE FUSES Fuses, electro--proportional version (TX842--TX945) NAME F1 F2 F3 F4 F6 F7 F9 F10 F11 F12 F17 F18 F19 F20 F21 F22 F24 F25 F26 F27 F28 F29 F30 F31 F32 FG1.1 FG1.2 FG3

DESCRIPTION Fuse, engine cut--off Fuse, panel instrument Fuse, transmission Fuse, attachments Fuse, rotary beacon Fuse, flasher Fuse, low beam lights Fuse, high beam lights Fuse, panel light and trafic light Fuse, trafic light Fuse, boom work lights Fuse, front work lights Fuse, rear work lights Fuse, overloading system+servocommand solenoid valve Fuse, general lights Fuse, electro--proportional Fuse, IN/OUT option Fuse, descent/ascent stabilizer Fuse, low boom sensor Fuse, rear axle locking Fuse, horn Fuse, back--up alarm Fuse, flasher Fuse, rear axle sensor Fuse, arm sensor preheating kit Fuse, general Fuse, general Fuse, preheating filter

VALUE 7.5A 3A 10A 7.5A 10A 10A 15A 15A 5A 5A 15A 15A 15A 10A 10A 10A 10A 7.5A 10A 3A 15A 5A 7.5A 7A 5A 80A 80A 20A

4--41

SECTION 4 -- LUBRICATION AND MAINTENANCE RELAYS Relay, electro--proportional version (TX842--TX945) NAME K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K406 K407 K408 KA KD KT

DESCRIPTION Relay, 1° speed Relay, 2° speed Relay, reverse Relay, 4° speed Relay, forward motion Relay, decluch transmission Relay, reverse speed buzzer Relay, stabilizer Relay, two steering wheels indicator light Relay, diagonal steering travel light Relay, round steering light Relay, preheating light Relay, horn Relay, hand brake switch Relay, low boom sensor Relay, stabilizer Relay, “IN” option Relay, optional (Out) Relay, retraction Relay, telescopic motion Relay, flasher Relay, high beam lights Relay, low beam lights Relay, starting switch Relay, key Relay, preheating

TH55R103

65 4--42

SECTION 4 -- LUBRICATION AND MAINTENANCE •

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

•

Do not inflate a tire unless the rim is mounted on the vehicle or is secured so that it will not move if the tire or rim should suddenly fail.

When checking the tire pressures, inspect the tires for damaged tread and side walls. Neglected damaged will lead to early tire failure.

•

Inflation pressure affects the amount of weight that a tire may carry. Locate the tire size for your vehicle in the Tire 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 tires.

When inflating a new or repaired tire, use a clip--on valve adaptor with a remote gauge that allows the operator to stand clear of the tire while inflating it. Use a safety cage, if available.

•

Do not inflate a steering tire above the manufacturer’s maximum pressure shown on the tire or beyond the maximum shown in the Tire Pressure and Load tables, if the tire is not marked with the maximum pressure.

TIRES AND WHEELS General maintenance Upon receiving your vehicle, check the air pressure in the tires and re--check every 50 hours or weekly.

WARNING

Inflating or servicing tires can be dangerous. Whenever possible, trained personnel should be called in to service or install tires. In any event, to avoid the possibility of serious or fatal injury, follow the safety precautions below.

•

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

•

Never attempt tire repairs on a public road or highway.

•

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

•

Ensure the jack has adequate capacity to lift your vehicle.

•

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

•

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

•

Never hit a tire or rim with a hammer.

WARNING

Never inflate a tire, on a vehicle over 34.8 psi (2.4 bar).

If the bead does not seat on the rim by the time this pressure is reached, deflate the tire, re--lubricate the bead with a soap/water solution and re--inflate. Do not use oil or grease. INFLATION BEYOND 34.8 psi (2.4 bar) with unseated beads may break the bead or rim with explosive force sufficient to cause a serious injury.

•

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

•

Do not re--inflate a tire that has been run flat or seriously under--inflated until it has been inspected for damage by a qualified person.

•

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

4--43

SECTION 4 -- LUBRICATION AND MAINTENANCE

NOTES

4--44

SECTION 5 TROUBLESHOOTING IMPORTANT: The following troubleshooting tables are only a guide. Should any repairs different from ordinary maintenance be required, the vehicle must be taken to the dealership having the tools, equipment and necessary knowledge to make repairs in conformity with specifications and safety rules.

CONTENTS Description Page Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2 Gearshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5 Hydraulic system troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6

5--1

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

Engine runs unevenly and/or stalls stalls.

Engine lacks power.

5--2

POSSIBLE CAUSE

REMEDY

No fuel or insufficient. insufficient

Check fuel level. level

Air in fuel system.

Bleed the supply system.

Wrong fuel type for operating temperature.

Use the right type of fuel for temperature conditions.

Supply system contaminated.

Clean the system.

Fuel filter clogged.

Replace the filter element.

Fuel injector/s faulty.

Contact an authorized dealership.

Fuel solenoid valve or solenoid valve relay faulty.

Contact an authorized dealership.

Battery hot charged.

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

Fuel filter clogged.

Replace the fuel filter.

Supply system contaminated.

Clean the system.

Fuel solenoid valve maladjusted.

Contact an authorized dealership.

Fuel injector/s faulty.

Contact an authorized dealership.

Water in the fuel filter.

Operate the fuel filter cock to drain condensate water.

Air filter clogged.

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

Impurities in the fuel tank, impure fuel.

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

Overloaded engine.

Engage a lower gear o reduce the load.

Air filter clogged.

Make the air filter maintenance.

Fuel filter clogged.

Replace the fuel filter.

Wrong fuel type.

Use the right type of fuel.

Overheated engine.

See: “Engine overheats”.

Low engine operating temperature.

Check thermostats.

Wrong valve clearance.

Check and adjust.

Fuel injector/s faulty.

Have the injectors checked at an authorized dealership.

High idle too low.

Contact an authorised dealership.

Aftercooler radiator clogged.

Clean the radiator.

SECTION 5 -- TROUBLESHOOTING ENGINE (Cont.)

PROBLEM Engine knocks.

POSSIBLE CAUSE

REMEDY

Insufficient oil level.

Top up with the right oil quantity.

Insufficient oil pressure.

Contact an authorized dealership.

Overheated engine.

See: “Engine overheats”.

High advance.

Contact an authorized dealership.

Wrong fuel.

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 authorized 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 authorized dealership.

Oil vapour collector clogged.

Contact an authorized 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 pressurized cap or tighten it in the correct way.

Loose or worn fan 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 sensor faulty.

Contact an authorized dealership.

Replace engine oil.

Replace the engine oil.

Oil high--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 authorized dealership.

Contact an authorized dealership.

Engine low temperature.

Injectors dirty.

Injection pump faulty or not correctly calibrated.

TRANSMISSION PROBLEM Transmission 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 authorized dealership.

Contact an authorized dealership.

Put the gear in NEUTRAL position and let the engine run idle for the time needed to let the oil cool down.

Transmission does not work properly l or works k unevenly. l

Transmission overheats.

5--4

Modulating valve blocked.

Contact an authorized dealership.

Loose electrical connections.

Check electric continuity.

Insufficient oil pressure.

Contact an authorized 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 authorized 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.

Turn on 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 authorized 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 belt tensioner. Replace belt if required.

5--5

SECTION 5 -- TROUBLESHOOTING HYDRAULIC SYSTEM PROBLEM All circuits fail to operate

POSSIBLE CAUSE

REMEDY

Pump drive inoperative.

Pump worn.

Low oil level.

Contact an authorized dealership.

System limiting pump faulty.

Restricted pump suction line.

Main relay behind fuse panel.

Slow operation or loss of power in all circuits.

Pump worn.

Restricted pump suction line.

Contact an authorized dealership.

System limiting pump faulty.

Oil leak from the circuit.

Check the hydraulic circuit tightness and repair possible leaks.

Malfunctioning power control pump.

Contact an authorized dealership.

BRAKES PROBLEM Excessive pedal stroke.

POSSIBLE CAUSE

REMEDY

Blow--by from the brake piston seal.

Brake, discs worn.

Brake bleeding valve not tight.

Blow--by from brake valve/s.

Air in the system.

Oil leak form the circuit

5--6

Contact an authorized dealership.

SECTION 6 VEHICLE STORAGE This section is about the vehicle preparation for storage (long inactivity).

CONTENTS Description Page Long vehicle inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2 Tires and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2 Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3 Vehicle preparation after prolonged inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4

6--1

SECTION 6 -- VEHICLE STORAGE VEHICLE PROLONGED INACTIVITY Before storing the vehicle for a long time it is necessary to adopt the following precautions.

•

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

•

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

•

Lubricate the vehicle.

•

Drain the fuel tank and fill it with 9 litres of stabilized fuel.

•

Let the engine run for 10 minutes in order to distribute the special fuel to the injection pump and the injectors. In this way the injector and pump seizing up is prevented when the vehicle has to be stored for a long time.

•

Check the coolant level in the radiator. If less than 100 hours to the following 1000--hour (or less) maintenance operation are left or less then 2 months before the every--two--year maintenance operation are left, observe the prescribed maintenance deadline.

TIRES AND WHEELS General maintenance When the vehicle is received, check the tire air pressure and remember to check it every 50 hours or every week.

When the tire pressure is checked, make sure the tread and the tires sides are not damaged. Possible overlooked damages might make the tire fail prematurely.

Inflating pressure affects the weight a tire can bear.

Identify the tire dimension for the involved vehicle in the Tire Pressures and Weights table in Section 8 of this handbook. Do not overcome the load for the listed pressures. Do not inflate tire more or less than the prescribed value.

WARNING

Inflating or making operations on the tires can be very dangerous. Whenever possible, have maintenance operations and/or tire installation performed by skilled people. Anyway, strictly observe the following safety precautions to avoid serious or even lethal injuries.

•

Operate the front attachment so that all cylinders reach rested position and place the attachment on a block or a piece of wood.

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

•

Never try to repair tires on a public road.

•

•

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

Make sure the jack is placed on a solid and flat surface.

•

Make sure the jack capacity is adequate for the vehicle lifting.

•

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

•

Use jack stands or other appropriate blocking devices to support the vehicle during tire repairing.

•

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

•

Do not place any part of your body under the vehicle and do not start the engine while the vehicle is on the jack.

•

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

•

Never hit the tires or rims with a hammer.

•

•

Cover the exhanst pipe.

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

•

Do not inflate a tire if the rim is not installed on the vehicle or in a safety cage so that it cannot move in the event the tire or the rim should suddenly get broken.

•

When a new or repaired tire is installed, use an clip on adapter with remote controlled pressure gauge which makes it possible for the operator to keep at distance from the tire during inflation.

Use a safety cage, if needed.

•

6--2

SECTION 6 -- VEHICLE STORAGE •

Do not inflate steering tires (front tires on simple drive vehicles) beyond the maximum pressure prescribed by the manufacturer and indicated on the tire itself. Do not inflate the tire beyond the maximum value indicated in the Tire Pressures and Weights tables in Section 8, if the maximum pressure is not indicated on the tire.

If you need to connect the wires to an external battery to start the engine, proceed as follows: •

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

•

Connect the second cable end to the auxiliary battery negative terminal (--) and the other cable 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 tires (front tires on 4--tire drive, rear tires in general) beyond 34.8 psi (2.4 bar). If the bead does not find its position on the rim when such pressure is reached, deflate the tire, lubricate the bead with a mixture of water and soap and inflate again. Do not use oil or grease. INFLATION OVER 34.8 psi (2.4 bar) with the bead not in position can make the bead or rim blow out and seriously hurt someone.

•

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

•

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

•

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

•

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

JUMP STARTING

WARNING

Operate the starter only from the driver’s seat. If the starter switch is bypassed, the engine might be started accidentally with the gear engaged.

Use eye protection when charging a battery or jump starting the vehicle.

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

•

After starting the engine, let it run idle, turn on all electric devices (lights, etc.) and disconnect the charging wires by reversing the connecting procedure. In this way the alternator is protected against possible damages due to sudden load variations.

NOTE: The vehicle is fitted with an fuel shut off electrovalve and therefore it is not possible to make it run when the battery is not installed. The engine turns off when the electric power supply to the fuel shut off electrovalve is cut off (disconnected battery).

VEHICLE PREPARATION AFTER A PROLONGED INACTIVITY •

Inflate tires according to prescribed pressure.

•

Fill the tank.

•

Check the radiator coolant level.

•

Check all oil levels.

•

Install a charged battery.

•

Uncover the exhaust pipe.

•

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

6--3

SECTION 6 -- VEHICLE STORAGE TURBOCHARGER The turbocharger bearing can be seriously damaged if not lubricated appropriately and if the following precautions are not adopted.

In order to prevent damaging the turbocharger bearing during the first start--up after a new turbocharger has been installed, or in case the turbocharger oil supply should be disconnected for any reason, or should the engine be started for the first time after being stored for or more than 4 weeks, proceed as follows: •

Disconnect the wire going to the fuel shutoff.

Crank engine until you get oil pressure. Do not crank for more than 30 seconds without letting starter cool down for a couple minutes. When you see oil pressure, hook fuel shutoff back up and start engine and run at low idle for several minutes. Check for oil leaks.

•

Check the engine oil level and top up, if needed.

Start the engine and check that there are no oil or air leaks.

•

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 manufacturer 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 Operating weight TX742

= 22700 lb (10300 kg)

TX842

= 24930 lb (11300 kg)

TX945

= 27778 lb (12600 kg)

Operating weight (with foam filled wheels) TX742

= 24900 lb (11300 kg)

TX842

= 27134 lb (12300 kg)

TX945

= 29982 lb (13600 kg)

TH001482

1 IMPORTANT: The information shown above and below is for general guidance when estimating machine weight and will not necessarily take into account tires 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

Floating forks pair 100 x 50

Width Weight in (mm) lb (kg)

47.2 (1200)

251 (114)

Capacity lb (kg)

4409 (2000)

TH007033

7--2

SECTION 7 -- ACCESSORIES

Description

1.5 cu.yd bucket with bolted teeth

Width Weight in (mm) lb (kg)

98.4 (2500)

1411 (640)

Capacity yd3 (m3)

1.44 (1,1)

TH007028

1.5 cu.yd bucket without teeth

98.4 (2500)

1334 (605)

1.44 (1,1)

TH007032

Tilt carriage ± 7° for forks 2”

53.9 (1370)

401 (182)

--

TH007030

7--3

SECTION 7 -- ACCESSORIES

Description

Carriage for forks 2”

Width Weight in (mm) lb (kg)

53.9 (1370)

357 (162)

Capacity yd3 (m3)

--

TH007031

Mechanical style carrier

--

123 (56)

--

TH007029

7--4

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 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--20 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--20 Radiator coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--20 Four wheel drive tire combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--20 Weight of machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--20 Tire pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--21

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

TX742

TX842

TX945

Engine

no Stab.

101 hp (74 kw)

with Stab. (opt.)

120 hp (88 kw)

with Stab. (opt.)

120 hp (88 kw)

Max. lifting height ft (m)

41.8 (12.74)

41.8 (12.74)

44.6 (13.60)

Max. capacity lb (kg) at 24 in (610 mm) in from fork heel Capacity at max. height lb (kg)

6600 (2994)

8000 (3629)

9000 (4082)

3500 (1588)

5000 (2268)

5000 (2268)

Reach at max. height ft (m) Max. longitudinal extension ft (m)

5 (1.524) 29 (8.839)

5 (1.524) 29 (8.839)

3.45 (1.051) 30.84 (9.400)

Capacity at max. extension lb (kg)

1300 (590)

1600 (726)

1600 (726)

Weight lb (kg)

22700 (10300)

24930 (11300)

27778 (12600)

Length without forks in (m)

241.33 (6.130)

241.53 (6.135)

249.76 (6.344)

Overall lenght in (m)

287.80 (7.310)

288 (7.315)

296.20 (7.524)

8--2

SECTION 8 -- SPECIFICATIONS AND DATA

TH00R072

1 Model A B C D E F

TX742 48 in (1200 mm) 123 in (3120 mm) 73.85 in (1876 mm) 241.33 in (6130 mm) 287.8 in (7310 mm) 80.71 in (2050 mm)

TX842 48 in (1200 mm) 123 in (3120 mm) 73.85 in (1876 mm) 241.53 in (6135 mm) 280 in (7315 mm) 80.71 in (2050 mm)

TX945 48 in (1200 mm) 123 in (3120 mm) 81.70 in (2075 mm) 249.76 in (6344 mm) 296.2 in (7524 mm) 80.71 in (2050 mm)

G I U W

18.5 in (470 mm) 44.7 in (1135 mm) 100.4 in (2550 mm) 96.25 in (2445 mm)

18.5 in (470 mm) 44.84 in (1139 mm) 100.4 in (2550 mm) 96.25 in (2445 mm)

18.5 in (470 mm) 45.23 in (1149 mm) 100.4 in (2550 mm) 96.25 in (2445 mm)

Valve measured with tires 13.00 -- 24TG 14PR

8--3

SECTION 8 -- SPECIFICATIONS AND DATA

TH001320

2

TX742 (without rear axle locking)

8--4

SECTION 8 -- SPECIFICATIONS AND DATA

TH001323

3

TX742 (with rear axle locking)

8--5

SECTION 8 -- SPECIFICATIONS AND DATA

TH001314

4

TX842 (without rear axle locking)

8--6

SECTION 8 -- SPECIFICATIONS AND DATA

TH001310

5

TX842 (with rear axle locking)

8--7

SECTION 8 -- SPECIFICATIONS AND DATA

TH001312

6

TX842 (with stabilizers)

8--8

SECTION 8 -- SPECIFICATIONS AND DATA

TH001317

7

TX945 (without rear axle locking)

8--9

SECTION 8 -- SPECIFICATIONS AND DATA

TH001315

8

TX945 (with rear axle locking)

8--10

SECTION 8 -- SPECIFICATIONS AND DATA

TH001316

9

TX945 (with stabilizers)

8--11

SECTION 8 -- SPECIFICATIONS AND DATA LOAD CHART DIAGRAM WITH FOAM FILLED WHEELS

TH001322

10

TX742 (without rear axle locking)

8--12

SECTION 8 -- SPECIFICATIONS AND DATA

TH001321

11

TX742 (with rear axle locking)

8--13

SECTION 8 -- SPECIFICATIONS AND DATA

TH001313

12

TX842 (without rear axle locking)

8--14

SECTION 8 -- SPECIFICATIONS AND DATA

TH001311

13

TX842 (with rear axle locking)

8--15

SECTION 8 -- SPECIFICATIONS AND DATA

TH001318

14

TX945 (without rear axle locking)

8--16

SECTION 8 -- SPECIFICATIONS AND DATA

TH001319

15

TX945 (with rear axle locking)

8--17

SECTION 8 -- SPECIFICATIONS AND DATA ENGINE DATA TX742 101 HP (74 kW) Turbo - charged

Type No. of cylinders

TX842-- TX945 120 HP (88 kW) Turbo - charged

with aftercooler

with aftercooler

Diesel

Diesel

4 in--line

4 in--line

Bore

in (mm)

4.1 (104)

4.1 (104)

Stroke

in (mm)

5.2 (132)

5.2 (132)

4485

4485

Compression ratio

17.5 : 1

17.5 : 1

Firing order

1.3.4.2

1.3.4.2

Displacement

cm3

Idle speed

rev/min

1000--1050

850--950

Maximum ‘No--load’ speed

rev/min

2300--2400

2300--2400

Rated speed

rev/min

2200

2200

317 (430)

379.8 (515)

Maximum torque

lbf--ft (Nm)

COOLING SYSTEM Type Fan Fan belt deflection Thermostat: Starts to open at Radiator cap

Pressurized full flow by--pass with expansion chamber 7 blades (TX742) -- 9 blades (TX842--TX945) 0.4 -- 0.6 in (10 -- 16 mm) 177.8 °F (81 °C) 14.5 psi (1 bar)

FUEL SYSTEM Injection pump Type Cold start device Excess fuel device Fuel shut off Lift pump

8--18

Rotary Thermostart Automatic governor Solenoid Mechanical

SECTION 8 -- SPECIFICATIONS AND DATA TRANSMISSION POWERSHIFT – T12000 4x3 = 4 forward and 3 reverse gears Gear

Ratio

I

4.025

II

2.048

III

1.000

IV

0.662

ELECTRICAL SYSTEM Alternator Battery type Optional Battery cut--off by switch Ground Starting motor Light bulb (optional) Stop/tail light bulb (optional) Outer light bulb (optional) Flasher light bulb (optional) Work light bulb (optional) Instrument/warning light bulb (optional) Switch light bulb (standard)

65 amp.

12 volt grounded negative earth 190 Ah on negative / frame cable negative Positive engagement, electrically controlled (3.1 kw) 40/45W 5/21W bayonet socket 5W (string) and 10W bayonet socket 21W with bayonet socket 55W H3 halogen 1.2W w/out socket 1.2W w/out socket

BRAKES Type Disc diameter Parking type

Oil--bath, multi--disc 8 per axle 8 in (203.2mm) Electro--hydraulic disc on front axle SAHR

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

Orbitrol Gear 2538.2 psi (175 bar) 0 -- 0.07 in (0 -- 2 mm)

FRONT AXLE Type Mounted on front frame Differential lock

Planetary steering axle Swinging with levelling cylinder No

REAR AXLE Type Mounted on rear frame

Planetary steering axle Floating with swing and automatic locking when boom angle exceeds 30°

8--19

SECTION 8 -- SPECIFICATIONS AND DATA HYDRAULIC SYSTEM Gear pump Hydraulic system pressure: Main system pressure Steering system pressure

Hydraulic system and steering system 3480 psi (240 bar) 2538 psi (175 bar)

TORQUES

Lbf -- ft (Nm)

Wheel nuts Cab attaching bolts

398.3 (540) 280.3 (380)

RADIATOR COOLANTS NOTE: To reduce deposits and limit corrosion, the water used in the cooling system must not exceed the following limits: Total hardness 300 ppm

Chloride 100 ppm

Sulphates 100 ppm

FOUR WHEEL DRIVE TIRE COMBINATIONS The tires 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 tires, always install tires of the same make, model and size as those removed. The installation of other tire combinations may result in excessive tire wear, loss of usable power or severe damage to drive line components. If in doubt, consult your Dealer.

WEIGHT OF MACHINES Operating weight TX742

= 22700 lb (10300 kg)

TX842

= 24930 lb (11300 kg)

TX945

= 27778 lb (12600 kg)

Operating weight (with foam filled wheels) TX742

= 24900 lb (11300 kg)

TX842

= 27134 lb (12300 kg)

TX945

= 29982 lb (13600 kg)

TH001482

1 IMPORTANT: The information shown is for general guidance when estimating machine weight and will not necessarily take into account tires 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.

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

8--20

SECTION 8 -- SPECIFICATIONS AND DATA TIRE PRESSURES The tables are for guidance only. For exact information regarding inflation pressures and loads for your particular tires, consult your Dealer.

Model TX742 TX842 TX945

Axle Front Rear

Tire 13.00--24TG 14PR 13.00--24TG 14PR (foam filled) 13.00--24TG 14PR 13.00--24TG 14PR (foam filled)

Rolling circle

Speed mph (km/h) 21.5 (35) 21.5 (35)

Inflation pressure psi (bar)* 65.3 (4.5) --

in (m) 155 (3.937) 155 (3.937)

8272 (3752) 8272 (3752)

21.5 (35) 21.5 (35)

65.3 (4.5) --

155 (3.937) 155 (3.937)

8272 (3752) 8272 (3752)

Capacity lb (kg)

* Listed pressures refer to inflation for use on size.

8--21

SECTION 8 -- SPECIFICATIONS AND DATA

NOTES

8--22

SECTION 9 FORMS AND DECLARATIONS This sections contains the 1st Service Sheet for Customer and Dealer and Company declaration.

CONTENTS Description Page 1st Service Sheet – Dealer’s copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--3 1st Service Sheet – Owner’s copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--5

9--1

9--2

✄

DEALER’S COPY FIRST SERVICE SHEET – CHECK AND ADJUST AS REQUIRED INOPERATIVE SERVICE CHECKS 1. Tire pressure 2. Air cleaner, pre cleaner/hose connection 3. Drain fuel filter and bleed system 4. Radiator coolant level 5. All belt tension 6. Battery cleanliness, vent openings 7. Check all electrical cables and wire routings are away from sharp edges, moving parts and exhaust heat 8. Renew engine oil and filter 9. Renew hydraulic oil filter 10. Renew transmission oil filter 11. Brake pedal reservoir oil level 12. Check hydraulic system oil level 13. Check transmission oil level 14. Check front/rear wheel nuts for tightness 15. Adjust valve clearances 16. Lubrication fittings and pivots 17. Check drop box oil 18. Check front and rear axle differential oil 19. Check front and rear axle hub oil 20. Cab door/lock operations and seal condition 21. Cab interior upholsters, trim and moldings 22. Cab window operation, window props and latches, seal condition 23. Cab sun visor operation 24. Cab filter installation

V V V V V V

V V V V V V V V V V V V V V V V V V

OPERATIVE SERVICE CHECKS All operative checks are to be performed wit the machine at normal operating temperature.

1. Lights and instrument for proper operation V 2. Fluid and oil leaks V 3. Engine maximum no--load speed and idle speed adjustments and fuel shut--off V 4. Throttle linkage adjustment V 5. Loader for proper operation/performance V 6. Windshield wiper and washer operation V 7. Roof wiper and washer operation V 8. Heater temperature control V 9. Pressuriser fan speed operation V 10. Air conditioner operation V PERFORMANCE SERVICE CHECKS 1. Engine operation including throttle and governor operation 2. Transmission, including control lever 3. Steering control 4. Park/brake action 5. All optional equipment and accessories

V V V V V

SAFETY ITEM CHECKS 1. Seat belt condition and bolt torque

V

INSPECTION PERFORMED – WARRANTY EXPLAINED MACHINE MODEL No. MACHINE SERIAL No. Owner’s signature

date

Dealer’s signature

date

9--3

9--4

✄ OWNER’S COPY FIRST SERVICE SHEET – CHECK AND ADJUST AS REQUIRED INOPERATIVE SERVICE CHECKS 1. Tire pressure 2. Air cleaner, pre cleaner/hose connection 3. Drain fuel filter and bleed system 4. Radiator coolant level 5. All belt tension 6. Battery cleanliness, vent openings 7. Check all electrical cables and wire routings are away from sharp edges, moving parts and exhaust heat 8. Renew engine oil and filter 9. Renew hydraulic oil filter 10. Renew transmission oil filter 11. Brake pedal reservoir oil level 12. Check hydraulic system oil level 13. Check transmission oil level 14. Check front/rear wheel nuts for tightness 15. Adjust valve clearances 16. Lubrication fittings and pivots 17. Check drop box oil 18. Check front and rear axle differential oil 19. Check front and rear axle hub oil 20. Cab door/lock operations and seal condition 21. Cab interior upholsters, trim and moldings 22. Cab window operation, window props and latches, seal condition 23. Cab sun visor operation 24. Cab filter installation

V V V V V V

V V V V V V V V V V V V V V V V V V

OPERATIVE SERVICE CHECKS All operative checks are to be performed wit the machine at normal operating temperature.

1. Lights and instrument for proper operation V 2. Fluid and oil leaks V 3. Engine maximum no--load speed and idle speed adjustments and fuel shut--off V 4. Throttle linkage adjustment V 5. Loader for proper operation/performance V 6. Windshield wiper and washer operation V 7. Roof wiper and washer operation V 8. Heater temperature control V 9. Pressuriser fan speed operation V 10. Air conditioner operation V PERFORMANCE SERVICE CHECKS 1. Engine operation including throttle and governor operation 2. Transmission, including control lever 3. Steering control 4. Park/brake action 5. All optional equipment and accessories

V V V V V

SAFETY ITEM CHECKS 1. Seat belt condition and bolt torque

V

INSPECTION PERFORMED – WARRANTY EXPLAINED MACHINE MODEL No. MACHINE SERIAL No. Owner’s signature

date

Dealer’s signature

date

9--5

9--6

SECTION 10 CONTENTS

CONTENTS OF SECTION 1 Description Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2 Summary of safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--18 Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--19 Lateral stability (canopy version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--34 Lateral stability (cab with windows version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--34 Longitudinal stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--35 Safety features and vehicle secutiry options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--50 Road travel requirements – canopy version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--51 Road travel requirements – in cab with windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--52 Road travel requirements – external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--53 “EC” Norms – Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--54 Universal Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--56 Machine functions monitored by instruments, luminous pilot lamps and buzzers (canopy version) . . . . . 1--57 Machine functions monitored by instruments, luminous pilot lamps and buzzers (cab with windows version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--58

CONTENTS OF SECTION 2 Description

Page

General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3 Hand and foot controls -- Canopy version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--6 Instruments and controls -- Canopy version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--9 Steering geometry button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--10 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--11 Lateral stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--17 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--18 Powershift transmission 4 x 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--21 Driving with the Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--21 Engine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--24 Hand and foot operating controls cab with windows version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--27 Instruments and control in cab with windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--39 Starting the machine with jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--51 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--52 Running--in procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--52 Electrical system main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--53 10--1

SECTION 10 -- INDEX Driving the Telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2--54 2--55 2--56 2--57 2--58 2--58

CONTENTS OF SECTION 3 Description Page Front loader controls/operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2 Lateral stability (Canopy version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4 Lateral stability (Cab with windows version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5 Load handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--6 Installing attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--9 Ballasting and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--11 Weighting of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--12

CONTENTS OF SECTION 4 Description Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2 Daily checks required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--9 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--13 Every 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--14 Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--17 Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--19 Every 1000 hours or annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--24 Every 1000 hours or every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--28 Every 2000 hours or every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--31 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--33

CONTENTS OF SECTION 5 Description Page Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2 Gearshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5 Hydraulic system troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6

10--2

SECTION 10 -- INDEX

CONTENTS OF SECTION 6 Description Page Long vehicle inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2 Tires and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2 Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3 Vehicle preparation after prolonged inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4

CONTENTS OF SECTION 7 Description Page Weight of machines and attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--2 Attachment dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--2

CONTENTS OF SECTION 8 Description Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--18 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--19 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--20 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--20 Radiator coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--20 Four wheel drive tire combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--20 Weight of machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--20 Tire pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--21

CONTENTS OF SECTION 9 Description Page st 1 Service Sheet – Dealer’s copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--3 1st Service Sheet – Owner’s copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--5

10--3

TELEHANDLER TELESCOPIC LIFTER LUBRICANTS AND COOLANTS Engine oil correct viscosity grade depends on ambient temperature. Refer to the table on the right for selecting engine oil for your machine.

NOTE: In areas with long periods of extreme temperature, local lubrication procedures are admissible, such as using SAE 5W30 where there are extremely low temperatures or SAE 50 where there are extremely high temperatures.

Sulphur contents in fuel.

Engine oil replacement interval is shown in Section 3. Local fuel can however have a high sulphur content: in this case engine oil replacement interval must be changed as follows: Sulphur contents in % Oil replacement interval Below 0.5 Normal 05.5 to 1.0 Half the normal Over 1.0 One fourth the normal

--30 °C --25 °C

--15 °C

+20 °C

+40 °C

SAE 5W--30

SAE 10W--30

SAE 15W--40

--22 °F

--13 °F

+5 °F

+68 °F

+104 °F

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

Oil – ENGINE AKCELA Nº 1 15W40 AKCELA Nº 1 10W30 Oil – POWERSHIFT TRANSMISSION AKCELA TCH FLUID 10W Oil – FRONT AND REAR AXLE FUCHS TITAN GEAR LS 90 85W90 Oil – DROP BOX 135H EP 80W90 Oil – FRONT/REAR AXLE HUB 135H EP 80W90 Oil – FRONT LOADER HYDRAULIC SYSTEM AKCELA NEXPLORE 10W30 ENGINE RADIATOR Water Premium Antifreeze Oil –BRAKE CONTROL CIRCUIT LHM Fluid ARM SHOES – Grease 251H EP GENERAL – GREASE 251H EP CONDITIONER COMPRESSOR Freon R134a FUEL Diesel Fuel

International Specification

ACEA -- E5 API CH--4, CG--4/SL ATF Type A Suffix A ALLISON C4 API GL5 and API GL5 LS GO 90 LS ZF TE--ML 05

Quantity USG

2.01 (7.6 litres) (including engine oil filter) 3.41+1.06 ( (12.9 + 4 litres)) (lines and radiator)

Ambient Temperature °F (°C) From +14 to +122 From (–10 to +50)

1.85 (7 litres) 0.20 (0.75 litres) 0.17 (0.65 litres)

From --4 to +122 From (--20 to +50)

From --4 to +122

50% H2O 50% ANTRIFREEZE

48.87 (185 litres) 3.17 (12 litres) (12 litres)

M6C 59--A

0.26 (1 litre)

NLGI 2

As required

From --40 to +122 From (--40 to +50)

NLGI 2

As required

From --40 to +122 From (--40 to +50)

API GL5 API GL5 ISO VG 46 DIN 51524

From (--20 to +50) From --31 to +122 From (--35 to +50)

4 lb (1800 gr) 35.66 (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.

CNH Italia S.p.A. --Viale delle Nazioni, 55 -- 41100 MODENA -- Italy Printed No. 84122853 -- English (10/08)

PRINTED IN ITALY  2008 CNH ITALIA S.p.A. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CNH ITALIA S.p.A. policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notice is reserved.

All data given in this manual is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show tractors in standard condition. For exact information about any particular machine, please consult your dealer.