CLAAS TARGO K SERIES Operator's Manual - PDF DOWNLOAD

CL A AS TTARGO ARGO K SERIES CLA

The machines covered in this handbook are designed essentially for agricultural use and associated applications. This is their intended use.

Any modifications made to the machine without prior written approval from CLAAS or if the machine is used in any way contrary to the intended use or if the machine is not properly driven or maintained then the Company will not accept any liability whatsoever for any damage or injury (whether direct or consequential).

The method of operation and maintenance specified in this handbook should be strictly adhered to.

For your parts requirements, it is essential that only genuine CLAAS parts are fitted. Any resultant damage from non genuine parts will invalidate your machine warranty.

Manufactured exclusively for CLAAS by Caterpillar (U.K.) Limited.

CONTENTS GENERAL DESCRIPTION INTRODUCTION Introduction to the handbook Running in Machine identification Safety section Safety messages General hazards SECTION 1 Before driving the machine - Safety warnings .......................................................................................... 1.1 Entering the cab .................................................................................................................................. 1.2 Emergency exit ................................................................................................................................... 1.3 Adjusting the seat ................................................................................................................................ 1.4 Adjusting the steering column and joystick mounting .............................................................................. 1.5 Cab layout and Controls ....................................................................................................................... 1.6 Instruments and warning lights .............................................................................................................. 1.9 Facia mounted switches ..................................................................................................................... 1.11 Steering column switches .................................................................................................................. 1.12 Side console switches ........................................................................................................................ 1.13 Boom and carriage controls ................................................................................................................ 1.14 Auxiliary controls ............................................................................................................................... 1.15 Steering modes ................................................................................................................................. 1.16 Starting and Stopping the engine ......................................................................................................... 1.17 Engaging gears - APC Powershift ........................................................................................................ 1.19 Engaging gears - powershift ................................................................................................................ 1.22 Driving the machine ............................................................................................................................ 1.23 Reversible cooling fan ......................................................................................................................... 1.25 Working the Telehandler ..................................................................................................................... 1.28 Longitudinal Stability Indicator ............................................................................................................. 1.28 Examples of instability situations ........................................................................................................ 1.30 Lifting envelope .................................................................................................................................. 1.31 Approaching a load - Working with pallet forks ...................................................................................... 1.33 Picking up a load - Working with pallet forks ......................................................................................... 1.34 Placing a load - Working with pallet forks ............................................................................................. 1.36 Lifting unpalletised loads .................................................................................................................... 1.37 Travelling .......................................................................................................................................... 1.38 Transporting the machine ................................................................................................................... 1.39 SECTION 2 Attachments - fitting and removal ..........................................................................................................

Hydraulically operated attachments ......................................................................................................

Working with front end attachments ......................................................................................................

Automatic trailer pick-up hitch (Auto-hitch) ............................................................................................

Manual trailer pick-up ..........................................................................................................................

Extension jibs and crane hooks ............................................................................................................

2.1 2.3 2.4 2.5 2.7 2.8

CONTENTS

SECTION 3 Safety Warnings ................................................................................................................................. 3.1 Access to service checkpoints ............................................................................................................. 3.2 Service schedule ................................................................................................................................. 3.3 Grease points ..................................................................................................................................... 3.6 Wheels and tyres ................................................................................................................................ 3.7 Engine oil level .................................................................................................................................... 3.8 Engine oil and filter .............................................................................................................................. 3.9 Cooling system ................................................................................................................................. 3.10 Fuel system ..................................................................................................................................... 3.14 Air cleaner ........................................................................................................................................ 3.18 Engine ............................................................................................................................................. 3.19 Fan drive system .............................................................................................................................. 3.20 Transmission and Transfer Box .......................................................................................................... 3.21 Axles ............................................................................................................................................... 3.24 Hydraulics ........................................................................................................................................ 3.25 Battery ............................................................................................................................................. 3.28 Auto-hitch ......................................................................................................................................... 3.29 Rockinger hitch ................................................................................................................................. 3.29 Windscreen washer bottle .................................................................................................................. 3.29 Cab and engine compartment ............................................................................................................. 3.30 SECTION 4 Machine specifications ........................................................................................................................ 4.1 Adjustments ....................................................................................................................................... 4.2 Lubricants and fluid specifications ......................................................................................................... 4.2 Capacities - fluid ................................................................................................................................. 4.3 Pressures .......................................................................................................................................... 4.3 Dimensions - machines fitted with standard tyres .................................................................................. 4.4 Fusebox ............................................................................................................................................ 4.5

CONTENTS SECTION 4 (continued) Sheet 4 - Head/side lights, fog lights, number plate lights, head flasher .................................................. 4.25 Sheet 4A - Head/side lights, fog lights, number plate lights, head flash .................................................. 4.26 Sheet 5 - Turn indicators, reverse lamps, steer sensors, top lights, radio ................................................ 4.27 Sheet 6 - Inst display, sensor switches, fan motor, aircon, interior light, beacon, fuel sender, fan reverse, hyd temp ....................................................................................................... 4.28 Sheet 7 - APC 50 with ign controlled APC bat feed, screened sensor cable, p/brake link .......................... 4.29 Sheet 7A - Non-APc, correct p/brake and trans dump, no p/brake controller, cicuit link ............................ 4.30

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GENERAL DESCRIPTION

The CLAAS range of telehandlers has a modern design that enables the machine to be operated over different terrain whilst utilizing a wide variety of CLAAS approved front mounted attachments.

The driver's cab is fully glazed, compliant with ROPS/FOPS legislation, and features excellent control layout and operator ergonomics. It can be complemented with the addition of air conditioning and other accessories including an air suspension seat.

The seat mounted electro-hydraulic joystick enables simultaneous operation of 3 hydraulic functions, proportionally, for simple and precise operation of the boom.

An ultra low boom design and curved front screen combine to provide unbeatable visibility all around the machine and to the attachment as it is raised to any height.

A limited slip differential in the front axle, together with four wheel drive and a choice of agricultural or industrial tyres enable the machine to operate on many typical surfaces.

INTRODUCTION Introduction to the Handbook The contents of the Operators Handbook are intended as a guide to the operation and servicing of the CLAAS telehandler range. The general method of operation of all these machines is the same. Any individual differences in the specification or operation are detailed separately.

Note: The procedures and illustrations contained in this manual refers to all models. Some illustrations may differ slightly from the actual machine This handbook is not a training manual. It is designed as a guide to the machine’s controls and working capacities and general maintenance only. It must not be removed from the machine and should be kept clean and in good condition. Additional copies of the handbook can be obtained from your CLAAS dealer.

Only trained operators should use this machine. CLAAS strongly recommends that anyone who is responsible for the operation and servicing of this machine be fully trained in its safe operation.

If you have any doubts about any aspects of the machine’s capability or servicing procedures, you must consult CLAAS through your local CLAAS dealer.

Throughout this handbook and on the machine there are safety notes. Each note starts with a single word. The meaning of these single words are explained below.

Identifies a hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured.

Identifies a reminder of safety practices. Failure to observe these safety practices could result in injury to the operator (or others) and possible damage to the machine.

In general these notes are used to indicate that the procedures being described in the Handbook must be followed to avoid serious injury or death to yourself or others. The notes are also used to protect the machine from unsafe servicing practises.

Pay particular attention to the safety notes given at the beginning of each section.

The operator must read all the Handbook and fully understand its contents before attempting to operate the machine.

Running In The “running in” period of your machine is extremely important, and the following instructions should be followed very closely until the first 50 hour service is due.

This service must be carried out by your Distributor.

1.

2.

Avoid overloading the engine.

Use the lower gears when pulling heavier loads, and avoid using your machine on full load or at high engine speeds, as this may result in premature wear.

3.

Check the instruments frequently, and keep the radiator, the oil and the hydraulic reservoirs filled to their recommended levels.

4.

Avoid prolonged ‘no-load' operation at either high or low engine speeds.

Operating in this way throughout the machines life will prove beneficial to its overall performance and efficiency.

INTRODUCTION

Machine Identification Please record the model and serial numbers of your machine in the spaces provided, and quote them when ordering parts.

Model - Year Machine serial number Key, door - L.H Key, start Engine Transmission unit Torque converter unit Front axle Rear axle

SAFETY SECTION SAFETY MESSAGES General Specific safety messages, in the form of signs or labels, are displayed at various locations on the machine and as close as possible to hazardous areas. The information displayed on each safety sign or label is intended to warn of possible hazards to the machine operator, personnel or equipment.

Any personnel involved in the operation or maintenace of this machine should be aware of the location and content of all safety signs and labels.

Safety signs and labels must be kept in a clean and legible condition. The following also applies: When cleaning a safety sign or label, do not use any solvent, fuel or other harsh chemicals. Use of these will loosen the adhesives that attach the signs or labels to the machine.

Replace any safety sign or label that is damaged or is not legible and cannot be cleaned.

Install a replacement safety sign or label for any that are missing.

NOTE Replacement safety sign or label can be obtained from any CLAAS dealership.

Parts or components, with a safety sign or label attached, may be replaced. In this case, a replacement safety sign or label must be attached to the part or component that has been installed.

SAFETY SECTION SAFETY MESSAGES CRUSH PREVENTION - GENERAL

Location This safety sign is located on the left side of the front of the chassis and on the front of the engine compartment cover.

Hazard It is hazardous for personnel to stand or work on, under or close to a suspended load or other unsupported components.

SAFETY SECTION SAFETY MESSAGES CRUSH PREVENTION WARNING - BOOM

Location This safety sign is located on the right side of the boom head end of the chassis.

Hazard It is hazardous for personnel to stand on, under or close to an unsupported boom.

DO NOT WELD ON THE ROPS/FOPS STRUCTURE

Location This safety sign is located on the inside of the cab ROPS/FOPS structure.

Hazard Drilling holes or welding in the ROPS/FOPS structure can weaken the structures.

SAFETY SECTION SAFETY MESSAGES DO NOT SPRAY ETHER INTO THE ENGINE AIR INTAKE

Location This safety sign is located on the cover for the engine air filter and on the engine valve cover.

Hazard Spraying ether into the engine in hazardous to personnel and can damage the engine.

SAFETY SECTION SAFETY MESSAGES HIGH TEMPERATURES IN THIS AREA

Location This safety sign is located on the rear of the engine compartment and on the inside, at the rear of the engine compartment.

Hazard A hazard exists to personnel, due to the high temperatures produced in these areas.

Note: This illustration is applicable to Machines with the 99hp engine only. Other Machines may have a different location for this safety lable.

SAFETY SECTION SAFETY MESSAGES ENGINE MAINTENANCE

Location This safety sign is located on the side of the engine compartment.

Hazard The engine must be switched OFF before any maintence is undertaken. Failure to do this can result in personal injury.

ROTATING PARTS - FAN Note: This illustration is applicable to Machines with the 99hp engine only. Other Machines may have a different location for this safety lable.

Location This safety sign is located on the top of the cowl for the radiator cooling fan.

Hazard Working in the vicinity of rotating fans is hazardous and can cause personal injury.

SAFETY SECTION SAFETY MESSAGES ENGINE MAINTENANCE

Location This safety sign is located on the side of the engine compartment.

Hazard The engine must be switched OFF before any maintence is undertaken. Failure to do this can result in personal injury.

ROTATING PARTS - FAN

Location This safety sign is located on the top of the cowl for the radiator cooling fan.

Hazard Working in the vicinity of rotating fans is hazardous and can cause personal injury.

Note: This illustration is applicable to Machines with the 99hp engine only. Other Machines may have a different location for this safety lable.

SAFETY SECTION SAFETY MESSAGES ROTATING PARTS - DRIVE BELTS

Location This safety sign is located at the inside, rear of the engine compartment.

Hazard Working in the vicinity of rotating drive belts is hazardous and can cause personal injury.

WHEEL CHOCKS

Location This safety sign is located on the wheel chock, if install.

Hazard The wheel chock must be used, when necessary, to prevent the machine moving. Failure to use the wheel chock can result in personal injury from crushing.

SAFETY SECTION SAFETY MESSAGES REAR SERVICES - HYDRAULIC PRESSURE

Location These two safety signs are located on the rear service panel.

Hazard High pressure hydraulic fluid is used in the services at the rear service panel. Machine operators must refer to the Operators Manual, before operating the rear services.

SAFETY SECTION GENERAL HAZARDS Introduction Warnings or Cautions for hazards that may be present when operating the machine, or during maintenance of the machine, are detailed at: Section 1 - Operation of the machine.

Section 2 - Maintenance of the machine.

The following Warnings and Cautions are of a general nature and are not task specific. All personnel operating or maintaining this machine must be fully aware of these warnings.

Do not smoke when you do maintenance on an air conditioner or when refrigerant gas may be present.

Inhalation of refrigerant fumes that have contacted a flame source, or through smoking, can cause personal injury or death.

Always wear the correct protective equipment, including a hard hat and protective glasses, as required.

General

Make sure the location of high voltage power lines and buried power cables are known. Serious injury or death, by electrocution, can occur if the machine contacts these hazards.

Do not wear loose loose clothing or jewelry, which can snag on the controls or machine structure, causing personal injury.

Make sure that all protective guards and covers are secured in place on the machine. If guards and covers are removed, a hazard to personnel will exist.

Make sure that all foreign objects and materials, such as oil, tools, debris and other items, are kept clear from equipment, walkways and steps on the machine. Failure to do this can cause personal injury.

Make sure that all loose items, such as tools, lunch boxes and other items, which are not part of the equipment, are secured correctly before operating the machine. Failure to do this can cause personal injury.

Machine operators must be aware of the correct hand signals and those personnel authorized to give them.

Operators must accept hand signals only from a single and authorized person.

Make sure that all fluids used during maintenance of the machine are stored in the correct containers. Never store these fluids in other types, such as glass containers.

Make sure that all fluids are disposed off correctly and in accordance with local Health and Safety Regulations.

Make sure that all cleaning fluids are used with care and that any necessary repairs are reported immediately.

Unauthorized personnel must not be permitted to operate or maintain this machine.

Make sure the the size of the machine, including any load, is known. This will ensure a correct and safe clearence is maintained, when operating the machine in confined spaces or near obstacles.

SAFETY SECTION GENERAL HAZARDS Pressurized air and water

Leaking fluid, even from a pin hole leak, can pentrate the skin, causing serious injury or death. Always use cardboard or a board to check fluid leaks. If fluid penetration of the skin occurs, you must seek medical help immediately, preferably from experienced medical staff.

If released, air or water in pressurized machine systems can cause debris or hot water to be ejected. This can cause personal injury. Care must be taken when working on pressurized machine systems.

Operators using pressurized air or water for cleaning purposes must wear the correct protective equipment. This includes protective clothing, shoes/ boots and goggles or face shield.

Operators using pressurized air or water for cleaning purposes must not exceed the following maximum operating pressures: Air - 205 kPa (30 psi) Water - 275 kPa (40 psi).

Fluid spillage

Residual hydraulic pressure Care must be taken to avoid fluid spillage during machine maintenance, testing, adjusting and repair. Before any possible fluid spillage can occur, a suitable container must be positioned to collect the fluid.

Refer to the Service Manual before releasing hydraulic pressure. Nonoperating hydraulic systems can retain residual hydraulic pressure. If released, this residual pressure can cause: Sudden movement of the machine or machine attachments.

Batteries

Disconnected hoses to whip.

Hydraulic fluid to be sprayed, causing a personal hazard through direct contact or ingestion.

Fluid penetration

Residual hydraulic pressure must be released before any hydraulic maintenance, disconnection or component removal is done. Refer to the Service Manual before releasing hydraulic pressure. Non-operating hydraulic systems can retain residual hydraulic pressure. If not released correctly, personal injury can occur.

The electrolyte in the battery is an acid, which if contacted, can cause personal injury. Do not permit eloctrolyte to come into contact with the skin or eyes.

Always wear protective glasses and, if possible gloves, when working with batteries. Wash the hands after contact with batteries and battery connectors.

SAFETY SECTION GENERAL HAZARDS Disposal of waste material

The disposal of waste materials, including potentially harmful fluids, must be in accordance with local Health and Safety Regulations. Improper disposal procedures can be harmful to personnel and the environment.

Always use the correct and leakproof types of container for the storage of waste fluids. Do not dispose of these fluids by pouring onto the ground, into water sources or into drains. Improper disposal procedures can be harmful to personnel and the environment.

Avoid machining or brushing materials that may contain asbestos.

Before disposal, use a wet, damping down method to concentrate material dust and debris.

If possible, a vacuum cleaner fitted with a high particle air filter (HEPA), should be used to collect debris and dust.

Use exhaust ventilation on permanent machining work.

Wear an approved respirator if there is no other way to control any dust produced.

Always comply with the applicable environmental regulations for the disposal of asbestos.

Stay away from areas that may contain airborne asbestos particles.

Asbestos hazards Contact with asbestos must be avoided, particularly inhalation of airborne dust, which can cause serious injury or death.

Avoid creating dust if handling debris or components that may contain asbestos, such as brake pads and bands, liner material, clutch plates and some gaskets.

Never use compressed air for cleaning purposes.

Always comply with the applicable rules and regulations for the work place. In the United States, use the Occupational Safety and Health Administration (OSHA) requirements (refer to 29 CFR 1910.1001).

It is recommended that you only use genuine CLAAS equipment, components and parts, which are supplied asbestos free.

SAFETY SECTION GENERAL HAZARDS Crushing or cutting prevention

Support equipment correctly before you do any work or maintenance from beneath that equipment.

Support the cab correctly before you do any work or maintenance from beneath the cab.

Unless instructed otherwise, never attempt to do adjustments whilst the machine is moving or the engine is running.

Never attempt to start the engine by ‘jumping’ across the terminals of the starter solenoid. Doing this can result in unexpected machine movement.

Clearances in machine control linkages will change with control operation or machine movement. Always keep clear of controls or areas that may experience clearance changes.

Always keep clear of rotating or moving parts of the machine.

Always re-install any guard or cover that has temporarily removed.

Always keep objects clear of moving fan blades, which can throw or cut objects.

When handling cables, always wear protective gloves. Never use kinked or frayed cables.

Striking any object can cause debris chips to fly off, causing personal injury.

Always wear protective glasses/ goggles before striking an object and make sure that the area is clear of other personnel.

If a retaining pin is struck with force, it may be ejected and cause personal injury. Always wear protective glasses/ goggles before striking a retaininmg pin and make sure that the area is clear of other personnel.

Burn prevention

The engine and it’s associated components will get hot during operation, causing a potential burn hazard to personnel. Before you do any maintenance on the engine, you must: Avoid touching any part of an operating engine.

Always allow the engine to fully cool before you do any maintenance work.

Always release residual pressure in the air, hydraulic, lubrication and fuel systems and associated pipe lines/ hoses, before you do any maintenance work.

Hot fluids and surfaces can cause personal injury. Avoid direct contact with hot fluid or surfaces.

Always stop the engine and allow the filler cap for the hydraulic tank to cool fully, before you attempt to remove it (refer to this Manual for the correct procedure).

Fire extinguisher

Make sure the machine fire extinguisher is available and in a fully charged and serviceable condition.

Make sure you are fully aware of the operating instructions for the fire extinguisher.

Inspect and service the fire extinguisher at regular interrvals or in accordance with the manufacturers instructions.

SAFETY SECTION GENERAL HAZARDS Coolant hazards

The engine cooling system will become hot and pressurized during normal engine operation, causing a potential burn or scald hazard to personnel.

Remove all flammable materials such as fuel, oil and debris from the machine.

Do not allow the accumulation of flammable materials on or around the machine.

Always store fuels and lubricants in the correct and properly marked containers and away from unauthorized personnel.

Always allow the engine and cooling system to fully cool before you do any maintenance work, including draining the system.

Always store soiled oily rags and other flammable materials in protective containers.

Always stop the engine before you check the level of the coolant.

Do not smoke in ares that are used for the storage of flammable materials.

The cooling system conditioner contains alkali, which can cause personal injury. Do not allow alkali to contact the skin, eyes or mouth.

Do not operate the machine close to naked flames.

Always stop the engine and allow the coolant filler cap to cool fully, before you attempt to remove it. This must be done slowly, to release the residual pressure safely.

Fire and Explosion prevention

Make sure that heat shields, installed to prevent fluids or fluid spray from igniting, are fitted correctly.

Do not weld or flame cut any pipes or tanks that contain flammable fluids or gases. Always clean such pipes and tanks thoroughly with a non-flammable solvent first.

Examine all electrical wires daily and check and tighten all electrical connections. If necessary, repair loose or frayed wires before you operate the machine.

Dust produced from repairs to nonmetallic components, such as hoods or fenders, can be flammable. Always repair such components in a well ventilated area, away from naked flame and heat sources.

All fuels, most lubricants and some coolant mixtures are flammable and if leaking onto a hot surface or electrical components, can create a fire. Fire can cause severe personal injury or death.

Do not operate the machine close to a naked flame or heat source.

Leaking pipes and hoses can cause a fire. Examine all pipes, hoses and associated supports for wear, deteriation and damage and ensure that pipe and hose clamps are secure.

Make sure pipe and hose connections are correctly torqued.

SAFETY SECTION GENERAL HAZARDS Fire and Explosion prevention (continued)

Use caution when refuelling a machine.

When refuelling, never smoke, refuel close to naked flames or heat sources or refuel with the engine running.

Always refuel in outdoors.

Ether hazards

Ether is a flammable and toxic substance. Use in a well ventilated area and do not smoke when replacing an ether cylider or when using an ether spray.

When storing ether cylinders, you must make sure that they are not stored:

In living areas or in the operators cab of the machine.

In direct sunlight or in temperatures above 49 deg C (120 deg F).

Close to naked flame or heat sources.

Used ether cylinders must be disposed of correctly and kept away from unauthorized personnel. Never puncture an ether cylider.

Gases from the battery can explode.

Always keep the battery away from naked flames and heat sources and never smoke in a battery charging area.

Do not spray ether into an engine if the machine is fitted with a thermal starting aid for cold weather starting.

Pipes, tubes and hoses Leaks from loose or damaged pipes, tubes or hoses can cause a system failure or a fire. Examine pipes, tubes and hoses regularly, particularly for signs of damage, leaks or being loose.

Never check the charged state of a battery by placing a metal object across the battery terminals. Always use a voltmeter or hydrometer.

Never attempt to charge a frozen battery. Doing this may cause an explosion.

Never use bare hands to check for leaks from pipes, tubes or hoses.

Always use cardboard or a board and if necessary, torque connections to the recommended value.

Do not bend or strike high pressure pipes or install a bent or damaged high pressure pipe.

SAFETY SECTION GENERAL HAZARDS Pipes, tubes and hoses (continued) You must replace any pipe, tube or hose if:

Do not approach a warm or hot tyre.

Keep the minimum distances away from the tyre and stay outside the shaded areas (refer to illustration below).

End fittings are damaged or leaking.

Outer coverings are chafed or cut.

Wires are exposed.

Outer covering is blistered or ballooning.

Flexible portion of a hose is kinked.

Outer covers have embedded armoring.

End fittings are damaged displaced.

Clamps, guards and heat shields are installed to prevent vibration, contact between components and excessive heat. Make sure that all clamps, guards and heat shields are installed correctly.

Tyre hazards An air inflated tyre can expand and explode if excessive heat is applied through welding, heating rim components, external fire or excessive use of the brakes. An exploding tyre can eject axle and wheel debris 500 m (1500 ft) or more from the vehicle, causing damage and possibly personal injury or death. All personnel must be aware of the hazards of overheating tyres.

An over-inflated tyre can blow out or cause a rim failure. This can cause damage or personal injury. Inflation of tyres must only be done by trained personnel.

When you inflate a tyre, you must stand behind the tyre tread and use a selfattaching chuck.

Maintenance on tyres and rims can be hazardous. The use of incorrect procedures can result in a tyre exploding. An exploding tyre can eject axle and wheel debris 500 m (1500 ft) or more from the vehicle, causing damage and possibly personal injury or death. Maintenance on tyres and rims must be done only by trained personnel, using the correct tools and procedures. The tyre dealer or manufacturers instructions must be followed.

Electrical storm hazards If lightning is is the vicinity, personnel must keep away from the machine and not mount or dismount the machine.

Machine operators already in the cab must remain there until the lightning threat is gone.

Alternate exit.

Machines that have cabs may also be equiped with an alternative exit. For more information on alternative exits, refer to the Operation and Maintenance Manuals.

SAFETY SECTION GENERAL HAZARDS Mounting and dismounting the machine You must never attempt to mount, dismount or jump from a machine that is moving.

You must never use machine controls as hand holds when you enter or exit the operators cab.

Always mount or dismount the machine at the recognised locations, which have steps and/or hand holds. Make sure the steps and/or hand holds are clean and examined regularly. Make any necessary repairs.

The machine operator must be fully aware of the machines capabilities and limitations. The operator must also be familiar with the local working area or site and in particular:

Check the area for vertical and horizontal clearances.

Check for overhead obstructions.

Check for electrical power lines and make sure the machine keeps at least 8 m (25 ft) away.

Check for steam or compressed air lines.

Check the work area or site for changes in the stability of the ground surface, backfilled trenches and structural integrity of buildings, roofs and tunnels.

Check sewers and service ducts.

Make sure that the load charts and instructions plates in the cab are in a good condition and can be easily read.

Machine operators must be fully aware of how to use the load charts before operating the machine.

When you mount or dismount the machine, always keep a three-point contact with the steps and hand holds.

Three-point contact can be two feet/ one hand or two hands/one foot.

When you mount or dismount the machine, always face the machine and never attempt to carry tools or supplies.

Tools and supplies should be raised or lowered from the machine using a hand line.

Before starting the engine This machine must be operated only by correctly trained and authorised personnel. Certain local operating conditions may require the machine operator to obtain a operators licence or a certificate.

If the machine has a cab, make sure the door is secured shut and the windows are secured in the open or closed position. Make sure all windows are kept clean for maximum visibility.

SAFETY SECTION GENERAL HAZARDS Before starting the engine (continued) Always examine the seat belt and belt mounting before use. Replace any parts that are worn or damaged and always replace the seat belt after three years, regardless of condition. Never use a seat belt extension on a retractable seat belt.

Make sure that all protective guards and covers are correctly installed on the vehicle.

The seat belt must be adjusted such that full pedal travel can be achieved with the machine operators back against the back of the seat.

Make sure that the machine is equiped with a fully working lighting system that is adequate for the working conditions.

Always fasten the seat belt before operating the machine.

Make sure that the machine reverse alarm, horn and other warning devices are in full working order.

Make sure that all obstacles are cleared from the intended path or route of the machine.

Make sure that before the machine is started or moved, there are no personnel on, under or near the machine.

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OPERATION

1.1

BEFORE DRIVING THE MACHINE - SAFETY WARNINGS General Safety ALWAYS be aware of local and national regulations governing the use of this machine.

ALWAYS wear correctly fitting protective clothing. Loose or baggy clothing can be extremely dangerous when operating or servicing a machine.

Do not use the machine when there is lightning in your area.

NEVER bring the boom or load within 6 metres (20 feet) of overhead power cables.

Only skilled personnel are permitted to work with this machine.

Running-in procedure For the first 50 operating hours, always ensure appropriate gear selection and do not run your new machine on full load or at high speeds, as this may result in premature wear.

Pre-start safety checks The following checks must be carried out prior to commencing work. Particular attention must be given if the machine has been left idle for any period of time. All of these checks concern the continued operation of the machine and some concern your safety. Any defects should be inspected and corrected by your distributor or service engineer.

NEVER commence work with the machine until a "Daily or 10 hour service" has been carried out. (See Service Section).

NEVER walk or work under a raised boom without installing the BOOM SAFETY STOP!

Lower the boom before doing these checks or have an experienced operator do it for you.

Check that all noise reduction material (where fitted) within the engine compartments is secure.

Check areas around pivot points, rams and linkages are free from mud, ice or debris.

Check all windows, lights and mirrors are clean.

Check all grab handles, steps and platforms are clean and dry.

Check all decals can be clearly read.

Check fuel gauge on instrument panel, to ensure there is adequate fuel in the tank.

Check that the Brake/Dump switch (see Side console switches) is in the OFF position.

Check tyres for correct inflation and wear (see section 4) and ensure there are no cuts or penetration by sharp objects.

Using a machine with incorrectly inflated, damaged or excessively worn tyres could cause death or injury to you or others.

Check machine for any obvious damage.

Check all controls function correctly, are clean and not slippery.

Your machine may be fitted with a fire extinguisher. Do not remove it from the operators cab until it is required. Ensure it is checked regularly.

Machine fires must not be put out using water, always use foam, dry chemical or carbon dioxide extinguishers.

Entering the cab Always enter and leave the cab facing the machine. Shoes and hands should be dry and free of dirt.

Do not use the machine controls as handholds when entering or leaving the machine.

1.2

OPERATION

ENTERING THE CAB The door consists of independently hinged upper and lower sections, which allow the operator to drive with the lower section closed, whilst the upper section can either be fully opened and locked against the cab frame, or secured in ajar position.

To enter, unlock and press the lock barrel.

To open the door from inside the cab: Depress handle (A) Do not drive the machine with lower door open.

The upper door section can only be opened from the inside by depressing handle (B).

It may be swung fully open and secured against the cab exterior by catch (C) or secured in ajar position by swinging lever (E) and locating it in lower door section at (F).

To release when secured fully open, swing lever at (C) as shown, or from inside, move lever (D) sideways To release from ajar position depress lever (B).

Do not drive with the upper door section unsecured.

OPERATION EMERGENCY EXIT

Emergency exit hammer In the event of an emergency a pane of glass can be smashed using the emergency exit hammer (1) provided.

Fire extinguisher If your machine is fitted with a fire extinguisher, ensure it is regularly checked by a suitably qualified person. Do not remove it from the cab until it is needed.

Using the fire extinguisher 1 Remove extinguisher from stowage bracket (A).

2 Hold extinguisher upright, pull out safety pin (B).

3 Aim nozzle at base of fire.

4 Squeeze handles (C) to operate the extinguisher, release handles to stop flow.

After use, the extinguisher should be replaced or serviced.

1.3

1.4

CONTROLS

ADJUSTING THE SEAT Seat(s) Vehicles are provided with either 'Standard suspension' or 'Air suspension' extra comfort seats.

Ample adjustment is possible to give a comfortable ride whilst operating most controls.

Do not adjust the seat when the vehicle is in action.

1 Fore and aft position Pull lever (A) upwards to release and slide seat forward or backwards to required position. Release lever to lock seat in position.

2 Standard suspension and height adjustment Operator must be seated for adjustment.

Fold out handle (B), rotate left to raise the seat and right to lower the seat. Check ride indicator (G) shows green, if red readjust height. Within the band of the ride indicator there is 75mm of height adjustment for any driver.

3 Air suspension and height adjustment Operator must be seated for adjustment. Use lever (J) to adjust, pull to raise, press down to lower.

Check ride indicator (G ) shows green, if red readjust height. Within the band of the ride indicator there is 75mm of height adjustment for any driver.

4 Arm rest To adjust height of arm rest (C), rotate roller (D).

Arm can also be pivoted from horizontal to vertical position.

5 Back rest adjustment To adjust angle of back rest operator should be seated. Pull lever (E) upwards and lean forwards or backwards until desired position is obtained, release lever (E) to lock back rest in position.

6 Upstop control Both seat types are provided with a variable upstop control (F) to limit upward travel of the suspension.

Adjust as indicated on control.

Seat belt

7 Lumber support control Adjust to suit (H), from five selectable positions.

Ensure that the seat belt is always clean, and not frayed or damaged.

Your machine is fitted with a seat belt, the belt must be worn whenever the machine is being operated.

OPERATION ADJUSTING THE STEERING COLUMN AND JOYSTICK MOUNTING Steering column adjustment A To adjust the angle of the steering column: Pull lever upwards and position steering column to the required angle, release lever.

B To adjust the height of steering column: Push lever downwards and pull/push steering wheel into required position, release lever.

Joystick mounting adjustment Mounting is adjustable both for height and lateral movement. Locate the two 8mm Nyloc nuts mounted on far side of the joystick pod and using a 13mm spanner, slacken nuts, adjust position and re-tighten.

1.5

1.6 CAB LAYOUT AND CONTROLS

CONTROLS

CONTROLS

1.7

CAB LAYOUT AND CONTROLS 1

Steering wheel

Turn the steering wheel in the direction that you wish to travel.

2

Selected gear display panel

(See Engaging gear) Powershift transmissions with A.P.C. control only Displays selected gear.

3

Instrument Panel

(See Instruments and Warning Lights)

4

Instrument Panel Switches

(See Facia Mounted Switches)

5

11

Parking brake switch

The vehicle is equipped with SAHR parking and emergency braking system on the front axle, i.e.

Spring apply - Hydraulic Release. The parking brake is applied by means of a rocker switch with integral 'lock-on feature'.

To apply the parking brake, ensure the vehicle is stopped, then rock the switch to the ON position.

The machine is then held in neutral and the parking brake engaged indicator illuminates (see instruments).

In the event of engine and or electrical/hydraulic power failure the front axle brakes are automatically applied.

(See Facia Mounted switches) The parking brake must not be used to slow a moving machine, except in an emergency.

Overload Indicator

(See Working the Telehandler)

6

Forward/reverse control, gear selection and kickdown

12

Solo control joystick

(See Auxiliary controls)

(See Engaging gear)

7

Start Key

13 Standard Auxiliary Service (See Auxiliary controls)

(See Starting the engine)

8

Multi-switch

14 Front mounted Auxiliary Service (See Auxiliary controls)

(See Steering Column)

9

Accelerator pedal

The accelerator pedal controls the engine speed, push the pedal down to increase the engine speed.

10

Brake pedal

The brake pedal operates the power assisted brakes, push the pedal down to slow or stop the machine. Applying the brakes will automatically switch on the 'Stop Lights'.

Using a machine without both stop lights functioning correctly is often an offence and is dangerous.

15 Joystick isolator rotary switch (See Auxiliary controls)

16

Steering mode switch

(See Steering mode switch)

17

Wheel Alignment lights

(See Steering mode switch)

18

Side console switches

(See Side console controls)

19

Heat and Air condition controls

(See Side console controls) When the Brake/Dump switch (see Side console switches) is turned on, drive to the transmission is disengaged when the brake pedal is operated.

The brake dump switch must only be used when power boom operations are performed.` Not to be used for accurate loading or when manoeuvring.

NEVER drive the machine on or off highways with this function engaged.

20

Fuse and Relays board

Located below the Facia mounted switches on the left hand side.

For fuse and relay positions see Technical specifications section.

21

Radio position (Customer supply)

22

Fan Reverser switch

(Where fitted)

1.8

CONTROLS

CAB LAYOUT AND CONTROLS (continued) Interior light The interior light is fitted with an ON/OFF switch (A).

To replace the bulb (B) remove lens (C), by easing the lens lugs (D) from the holder (E). Replace the bulb then refit the lens.

Windscreen Heater vents The air flow is fed through vents at the base of the front and rear glass screens. Position vents as required.

Coat Hook Ensure that any item suspended from this hook, does not obscure the operators vision or impede operation of the machine.

Tool Location Suitable tools for wheel nut maintenance are located to the left of the operators seat.

Tools consist of a:Tommy Bar Extension Socket

CONTROLS

1.9

INSTRUMENTS AND WARNING LIGHTS

Warning lights

Instruments The machine instruments and indicator lights are located to the right of the steering column on the instrument panel.

1

Hour meter

Hour meter records the total number of hours the engine has been run.

These hours give an indication to servicing periods.

3

Warning light flashes when left indicator is operated.

6

Engine oil pressure

Lights when engine oil pressure drops below normal working pressure.

Light may illuminate briefly when engine is started, but should cancel once engine is running.

The machine should NOT be operated with this light illuminated.

Gauge: fuel

Indicates the amount of diesel fuel in the tank.

NEVER allow fuel gauge to read "Zero" before refilling, otherwise fuel system will require bleeding. (See Service-Fuel)

4

Direction indicator

Gauge: tachometer

The tachometer indicates the engine speed in revolutions per minute.

2

5

7

Not used

8

Air cleaner filter blockage

Indicates restriction of air passing to the engine.

The machine must NOT be operated with this light illuminated.

Gauge: engine coolant temperature

This indicates the temperature of the engine coolant. The reading may vary slightly according to the weather.

This machine must NOT be operated if, after a suitable running period the gauge reading is abnormally high.

9

Parking brake

Warning light illuminates when parking brake is ON. Do not attempt to drive machine with Parking Brake ON.

1.10

CONTROLS

INSTRUMENTS AND WARNING LIGHTS (continued)

Warning lights (continued) 10

Transmission oil pressure

Indicates transmission oil pressure has fallen below normal working pressure.

Light may illuminate briefly when engine is started and should cancel once engine is running.

The machine should NOT be operated with this light illuminated.

11

The machine must NOT be operated with this light illuminated.

Transmission oil temperature

14

Brake system pressure

Indicates low oil pressure within power brake system.

The machine must NOT be operated with this light illuminated.

15

Headlight main beam

Warning light illuminates when the headlight main beams are switched on.

Indicates excessive heat in transmission.

The machine should NOT be operated with this light illuminated.

12

Battery charge indicator

Light should go out a few seconds after engine has started. If not, a fault is present in the alternator charging system.

The machine must NOT be operated with this light illuminated.

16

Warning light flashes when right indicator is operated.

17

Trailer turn indicator

18

Road light indicator

Illuminates when road lights are switched on.

19

Hydraulic filter blockage

Illuminates to indicate hydraulic pressure filler element blockage due to contamination.

NOTE When starting under cold conditions i.e. below 0°C light may illuminate, allow machine to warm-up for a few minutes under 'light-load' conditions

Front work lights (Where fitted)

Illuminates when front work lights are switched on.

20 13

Direction indicator

Rear work lights (Where fitted)

Illuminates when rear work lights are switched on.

21

Hydraulic oil temperature (Where fitted)

Indicates excessive heat in hydraulic oil.

The machine must NOT be operated with this light illuminated.

CONTROLS

1.11

FACIA MOUNTED SWITCHES

1

Switch: Head and side lights

Rocker switch. Main and dip beam are controlled by the steering column multi-switch.

NOTE Head lights only illuminate when ignition is switched on.

7

Rocker switch. Press to switch on boom mounted working lights.

8 2

Switch: Rotating beacon

Rocker switch. Press to switch on rotating beacon.

3

Switch: Rear foglight

Rocker switch. Press to switch on the rear foglight.

The foglight will only work once the headlights have been switched on.

4

Switch: Front working lights (where fitted)

Rocker switch. Press to switch on the front working lights. The working lights will only work once the sidelights have been switched on.

6

Warning light: Steering system (where fitted)

Indicates low power assisted steering system pressure.

Stop and rectify fault.

NOTE Light will illuminate during engine start procedures.

9

Parking brake switch

Rocker switch (lockable) (See Cab layout and controls.)

Switch: Hazard warning lights

Rocker switch. When turned ON operates the Hazard warning lights (including instrument panel light).

5

Switch: Boom/Side working lights (where fitted)

Switch: Rear working lights (where fitted)

Rocker switch. Press to switch on the rear working lights. The working lights will only work once the sidelights have been switched on.

10

Warning light: Brake function

Indicates low brake system pressure. Stop and rectify fault.

11

Switch: Ignition

(See page 1.17)

1.12

CONTROLS

STEERING COLUMN SWITCHES The steering column is fitted with two 'stalk' switches. The left hand stalk controls transmission functions (see Engaging Gear), whilst the right hand stalk controls lights, wipers etc. as followsA Headlight flash Pull stalk upwards (towards steering wheel) to flash headlights.

B Headlight main beam ON Ensure head and sidelights switch is ON, push stalk down for main beam ON. Centre detent is dipped beam.

C and D Direction indicators.

Ensure start key switch is ON, pull stalk towards you to indicate RIGHT turn, push away from you to indicate turn LEFT. E Windscreen wiper/washer Ensure start key switch is set to ( I ).

Twist the right hand stalk grip to select the required wiper/washer function.

II I 0

Not used Windscreen wiper ON Windscreen wiper OFF Wash/Wipe

F

Horn

Ensure start key switch is set to ( I ), push button to sound horn.

Powershift transmission - multi-switch

OPERATION

1.13

SIDE CONSOLE CONTROLS 1 Joystick boom controls isolation switch (See Auxiliary controls) 2 Steering mode switch (See Steering modes) 3 Steering mode alignment indicator lights (See Steering modes) 4 Brake/dump selector switch Rocker switch. When pressed to switch on (light illuminates) selects neutral in the transmission when the service brakes are applied.

The brake dump function must be selected in all heavy-duty applications, such as digging, re-handling, and muck shifting.

Do not use for accurate loading or when manoeuvring the machine.

Do not use on the highway or when trailer towing.

5 Rear hydraulic service switch (See Auxiliary controls) 6 Rear wash/wiper switch Rocker switch. Press to switch on.

Cab Heater The machine is fitted with a three speed fan/heater unit providing unheated or heated air. Air conditioning is fitted as an option.

7

Air conditioning on/off switch

8 Ventilation fan switch - 3 speed Switch controls the three speed fan.

Works once the start key is turned to the (1) position.

(See Starting and Stopping the Engine).

NOTE Fan must be running when either heater control or air conditioning switches are ‘On’.

9 Heater temperature control Turn knob clockwise to turn heater ON. Turn knob anticlockwise to turn heater OFF. NOTE Turn heater OFF before switching air conditioner to ON position.

10 Fan reverser switch (Where fitted) (See Page1.25)

1.14

OPERATION

BOOM AND CARRIAGE CONTROLS Boom control NEVER operate controls while outside the cab.

NEVER bring the boom or load within 6 metres (20 feet) of overhead power cables.

Always consult the lifting envelope and/or boom indicators before and during boom manipulations.

The machine uses a dual axis joystick to control lift/ lower, crowd/dump and extend/retract functions.

Boom lift/lower A Forward to lower boom B Backwards to raise boom Carriage crowd/dump C Left to crowd back D Right to crowd forward By moving the control diagonally, any combination of the above boom and carriage operations can be achieved simultaneously.

Boom extend/retract Using the roller switch mounted in the joystick.

E1 Upwards to extend boom F1 Downwards to retract boom Gradual action of the roller switch gives variable control of the extend/retract speed, the further the roller is moved the faster the speed.

OPERATION AUXILIARY CONTROLS Auxiliary controls The machine is fitted with one auxiliary service as standard connected to the carriage. A further two auxiliary services can be fitted as options.

Joystick buttons (A1, A2) Standard auxiliary service control buttons coloured yellow.

(A3, A4) Front mounted optional auxiliary service control buttons - coloured black.

Rear mounted optional auxiliary service Selected by rocker switch (5).

(See Hydraulically operated attachments)

To operate or fit an attachment, see 'Attachments and Optional equipment'.

Joystick/Boom controls isolator rotary switch (1) By turning switch from 'off', position 'A', to:-

Carriage pins lockout This facility is provided to lockout the carriage hydraulic actuated locking pins, therefore preventing accidental release of an attachment.

To lock carriage pins turn rotary switch to position 'B'.

PUBLIC ROAD USE It is a legal requirement in certain countries to lockout all boom and auxiliary hydraulic functions when travelling on public roads.

To disable joystick/boom auxiliary controls, first centralise front and rear wheels, then turn rotary switch to position 'C'. This operation selects front wheel steer, and disables joystick, boom, carriage and button functions.

Carriage crowd lockout This facility is provided to lockout the carriage tilt function, therefore preventing accidental operation.

To lockout Carriage crowd function, turn rotary switch to position 'D'.

1.15

1.16

OPERATION

STEERING MODES The machine can be driven in any of three different steering modes. The modes are selected using the steering mode switch (2).

The machine must always be stationary before changing steering modes.

The three modes give the following steering characteristics: A Two wheel steer The front wheels steer with the rear wheels locked in the 'straight' position.

This mode MUST be used on public roads.

B Four wheel steer Both pairs of wheels steer so that the front and rear wheels run on the same turning circle radius.

This mode MUST NOT be used on public roads.

C 'Crab' steer Both pairs of wheels steer in the same direction so that the machine 'crabs' either to the left or right.

This mode MUST NOT be used on public roads.

Changing steering modes The machine must always be stationary before changing steering modes.

Before using any of the steering modes, always check alignment of the wheels as follows.

To align wheels Select steering mode B or C and turn the steering wheel until the REAR wheels indicator is illuminated.

The rear wheels are now in the straight ahead position.

Select steering mode A and turn the steering wheel until the FRONT and REAR wheels indicators are illuminated.

All four wheels are now in correct alignment, allowing any of the three steering modes to be selected using selector switch (2).

Operation with wheels out of align Under certain circumstances the operator may choose to use the machine with the rear wheels out of alignment.

Such a circumstance could be when operating the machine on a Silage Clamp with the rear wheels locked at an angle and using TWO WHEEL STEER mode (A), retaining the ability to turn the machine (D).

Never operate the machine on the highway with the rear wheels out of alignment.

OPERATION STARTING AND STOPPING THE ENGINE NEVER operate controls while outside the cab.

Ensure parking brake switch (11) is in the on position, see cab controls Forward/neutral/reverse lever (6) must be in neutral before engine will start.

To start a warm engine Depress accelerator (9) approximately quarterway of its travel.

Turn start key to (I). Warning lights on instrument console will light: Engine oil pressure Transmissions pressure Battery charging Brake function.

Turn start key to (III). Release key immediately when engine starts. Check warning lights have gone out.

To start a cold engine Turn start key to (I).

Fully depress accelerator (9).

Turn start key to thermostart (II) position and hold for 15 seconds.

Turn start key to (III) position to engage starter, hold for a maximum of 15 seconds. Release key immediately when engine starts. Check warning lights have gone out.

If the engine fails to start, turn the key to the (II) position and hold it there for 10 seconds. Then engage the starter motor again.

Release accelerator to a fast idle position for at least 30 seconds to ensure adequate lubrication of turbocharger.

If any warning light fails to cancel, stop engine and detect fault before continuing.

NOTE When starting under cold conditions i.e. below 0°C the hydraulic pressure filter element blockage warning light (13) may illuminate. Allow the machine to warm-up for a few minutes under light-load conditions.

1.17

1.18

OPERATION

STARTING AND STOPPING THE ENGINE (continued) DO NOT PROCEED IF A FAULT IS EVIDENT. If engine fails to start, allow a few minutes for the battery to recover, then repeat start key switch procedure.

Always remain in driving seat whenever engine is running.

Check engine coolant temperature: engine coolant temperature gauge should show a low reading when engine is first started.

Abnormally high readings, or failure to obtain a reading after a suitable period of engine running, denotes a fault and requires immediate attention.

Check fuel gauge: Always ensure an adequate amount of fuel is present in fuel tank.

Always check all hydraulic rams before commencing work. With the engine running, operate each hydraulic control, in turn, to fully extend and retract the rams.

Stopping the engine Allow the engine to run at approximately 1,000 rpm for 2 to 3 minutes before turning the start key to the (O) position.

OPERATION ENGAGING GEAR. APC POWERSHIFT Powershift transmission with Automatic Powershift Controller (APC) The FNR (Forward/Neutral/Reverse) gear lever controls the direction of travel and gear selection.

The transmission has 6 forward gears and 3 reverse gears. The actual gear engaged is shown by the LED display in front of the steering column, this does not naturally agree with the gear selected on the FNR lever (see table).

To select forward travel: a The engine must be at idling speed. b Select required gear by twisting lever (A) and lift and push into forward position. c Release the parking brake by moving the parking brake rocker switch (11) to its 'locked-off' position. d Accelerate engine.

To change from one gear to another: Twist lever (A) to the gear required. The APC (Automatic Powershift Controller) will then manage the transmission to ensure that the gear selected is reached without risk of damage to the transmission.

The transmission will select gears 1 - 4 on command from the FNR lever providing the correct speed parameters are being met.

5th and 6th gears: When in 5th gear the transmission will automatically change between 5th and 4th gear as determined by the APC. When in 6th gear the transmission will automatically change between 6th, 5th and 4th gear as determined by the APC. Reverse Gears (Refer to table) For a 6/3 transmission the reverse gears shown in the display will be R1, R3 and R5, these correspond to the relevant forward gears. It is not possible to select R2 or R4.

To change direction of travel: a Reduce engine speed. b Brake to a stop. c Lift and move lever backwards from forward to reverse. d Release foot brake. e Accelerate engine.

1.19

1.20

OPERATION

ENGAGING GEAR. APC POWERSHIFT (continued)

KICKDOWN AND GEAR SELECTION TABLE FNR SHIFT LEVER POSITION

GEAR SELECTED

F1 F2 F3 F4

F1 F2 F3 F4

GEAR SELECTED AFTER KICKDOWN F1 F2 F3

*F5

F4

F3

F5

F4

F4

F3

*F5 *F6

F4

*F5

*R5 *R5 *R5 *R5 *R5

R1 R2 R3 R4

R1 R3 R3 R3

R1 R1 R1

F2 F3 F3 F3

*R5

*R5 *R5

R3

F3

R3

F3

*F6(A)

*R6 (A) Note 1.

Followed by time delayed downshift to F2.

Note 2.

Followed by time delayed upshift to F4.

*

GEAR SELECTED AFTER DIRECTION CHANGE R1 R3 R3 R3

(Note 1) (Note 2) (Note 2) (Note 2)

Positions & gear selection dependant on transmission specification/country of use.

OPERATION

1.21

ENGAGING GEAR. APC POWERSHIFT (continued) Mode Button The mode button (A) adjacent to the LED display (B) allows various screens to be selected by the operator.

On power-up the screen will briefly display a test pattern allowing a quick verification that the display functions correctly (C) this will then revert to the normal display indicating the gear position (D).

If the mode button is pressed once the display will show vehicle speed, expressed as turbine or input RPM. If no dot is shown in the display the figure shown is to be multiplied by 10 to give the correct value. If a dot is shown the figure shown is to be multiplied by 100. In this mode the ' T ' led is switched ON. Pressing the mode button again will show the nominal vehicle speed, expressed in Km/hr. In this mode the 'T'-led is switched off, unless the vehicle is stopped. If the ' T ' - led on the APC is illuminated whilst driving, then this indicates there is no speed sensor output. In this condition 5th and 6th gears cannot be achieved and no overspeed protection is present.

Pressing the mode button again will give diagnostic information which can be interpreted by the dealer technician.

Pressing the mode button again returns the screen to the normal display.

NOTE When the Joystick/Boom controls isolation switch (see page 1.15) is turned to position C, then the display will show vehicle speed in Km/hr regardless of mode button setting/operation.

Using kickdown: This works in all gears, excepting 1st and in both directions of travel. By pressing the button (E) on the end of the FNR lever the transmission will change down to the next lowest gear, as long as no over speeding will occur. If the transmission does not reach the conditions for changing a red led will blink in the display adjacent to the function being denied (i.e. gear number or direction indicator), after 5 seconds of noncompliance the request will be disregarded.

Once the lower gear is selected then the transmission can be made to return to the higher gear in three different ways, being: 1 Press button (E) once again 2 Select a new gear via the FNR twist grip 3 Moving the FNR lever to neutral or the opposite direction of travel.

WARNING: transmission overheating NEVER operate in too high a gear as this will cause the torque converter to slip and overheat, as indicated by the warning light.

ALWAYS stop if the warning light comes on and run the engine at a fast idle of 1000 to 1200 rev/ min. With both the forward/reverse lever and gear lever in neutral until the transmission cools and the warning light goes out.

1.22 ENGAGING GEAR. POWERSHIFT Powershift transmission with manual selection The FNR gear lever (1) operates Forward 1st, 2nd, 3rd and 4th gear functions and Reverse 1st, 2nd and 3rd gear functions.

To select forward travel: a The engine must be at idling speed. b Select required gear by twisting lever (A) and push into forward position. c Release the parking brake by moving the parking brake rocker switch (11) to its 'locked-off' position. d Accelerate engine.

To change from one gear to another: Twist lever (A) to the gear ratio required on upshifts. For down-shifts, slow vehicle to the appropriate speed before selecting gear.

To change direction of travel: a Reduce engine speed. b Brake to a stop. c Move lever (1) backwards from forward to reverse. d Release foot brake. e Accelerate engine.

WARNING: transmission overheating NEVER operate in too high a gear as this will cause the torque converter to slip and overheat, as indicated by the warning light.

ALWAYS stop if the warning light comes on and run the engine at a fast idle of 1000 to 1200 rev/ min. With both the forward/reverse lever and gear lever in neutral until the transmission cools and the warning light goes out.

NEVER restart after cooling the transmission unless the load has been reduced or a lower gear has been selected.

ALWAYS report to the workshop if the warning light indicates further overheating.

OPERATION

OPERATION DRIVING THE MACHINE Steering NEVER hold the steering on full lock for more than a few seconds because the excessive use of the relief valve will cause overheating of the components.

AVOID turning near trenches, especially when carrying a load.

ALWAYS drive slowly when changing direction, having due regard for the surface and type of load.

Gradients NOTE: Turbocharged machines Because of the characteristics of a turbocharger, it is necessary to maintain a high engine speed when you climb a gradient. To ensure the engine is not overloaded at low speeds, engage a lower gear When travelling up or down a gradient always obey the following: Never run down a gradient with the transmission in neutral When travelling down steep gradients control machine speed by selecting a lower gear or using the footbrake.

Do not exceed the maximum machine rated speed, particularly when travelling down steep gradients.

Slippery or loose surface conditions can adversely affect safe machine operation, particularly on gradients.

Choose routes that avoid steep, slippery or loose gradients.

Never park the machine on a gradient.

Never attempt to run on, or drive across a gradient.

Always travel up a gradient with the load facing uphill.

Always reverse down a gradient when loaded.

1.23

1.24

OPERATION

DRIVING THE MACHINE (continued)

Braking the machine The brake pedal operates the brakes in the conventional manner.

With the Brake/Dump switch (4) selected, the brake pedal when applied, disconnects the transmission drive. This removes any engine braking effect.

NEVER drive the machine, on highways with this function engaged,or when trailer towing.

NEVER make unnecessary 'crash' stops when travelling at speed, especially in forward direction.

Stopping the machine Release accelerator, and brake to a halt progressively.

Select neutral with both the gear lever and the forward/reverse control.

Apply parking brake when stationary (11).

ALWAYS turn the front and rear wheels from lock to lock when parking, to clear mud and water from the swivels and rams, thereby reducing the risk of wear and damage from dirt and ice.

Lower attachment or carriage to the ground. The engine should always be allowed to slow to idle for approximately two minutes before stopping , especially after extended periods of full load and full speed operation and for turbocharged engines (failure to do this could lead to premature engine/turbocharger wear).

Turn start key switch to the OFF position.

Leaving the machine Dump hydraulic pressure using the method described in: "Service - hydraulics".

Remove start key from switch and lock cab.

If parked on a slope, chock wheels.

If the machine is to be unattended for some time, remove the key from the electric isolation switch.

OPERATION DRIVING THE MACHINE (continued) Hydraulic oil temperature Machines from serial number 51200472 are fitted with a hydraulic oil temperature warning light.

The warning light (21) will illuminate when the hydraulic oil temperature exceeds a preset figure.

If, the warning light (21) illuminates, the operator must stop work to investigate the cause.

The cause could be due to grille or oil cooler/radiator core blockages and/or mechanical failure.

Material blockages must be cleared by manual cleaning as described on page 3.11.

Two methods are provided as options to reduce material blocking the cooling air intake grille and oil cooler/radiator cores.

These methods depend on machine serial numbers and are described as follows:

Automatic fan drive control (where fitted) For machines up to serial number 51200471 The automatic fan drive control stops the fan for a short period every few minutes to allow material to drop away from the intake grille.

To adjust the ON/OFF cycle – refer to Service Manual.

Reversible cooling fan drive For machines from serial number 51200472.

The reversible cooling fan allows cooling fan rotation to be reversed via switch (10). Reversing the fan rotation, causes material to be blown away from the intake grille and oil cooler/radiator core faces.

To reverse the fan drive, depress the rocker switch (10) and hold on for as long as required. But no longer than 30 seconds at a time.

The fan may be reversed at any time during machine operation and at any engine rpm setting.

Dependant on operational conditions frequent reversals for approximately 15 seconds every 10 to 20 minutes, should be beneficial in reducing oil cooler/radiator core blockages and thereby assist in maintaining engine coolant and hydraulic oil temperatures at their optimum.

1.25

1.26

OPERATION

DRIVING THE MACHINE (continued) Towing the machine The vehicle is equipped with SAHR braking system on the front axle, i.e.: Spring Applied, Hydraulically Released.

In the event of engine and or electrical/hydraulic power failure the front axle parking brakes are automatically applied.

To enable the vehicle to be towed, the parking brakes may be manually disengaged by evenly unscrewing screws (six) (A, B and C) as follows: DANGER! Block all four wheels to prevent vehicle movement. Failure to do so could result in death or injury if vehicle rolls away.

Once the wheels are blocked, locate the two groups of screws on the front axle, remove any dirt, and using an 8 mm Allen key, and working on one group of screws at a time, turn each screw clockwise (inwards) (D) one turn at a time, (care must be taken to tighten each screw alternatively to avoid internal damage) for about 5 to 5 1/2 turns until resistance is felt.

Repeat procedure with the other group of screws.

DANGER! Do not attempt to drive the vehicle with parking brakes manually disengaged.

ALWAYS remove both propeller shafts before towing the machine.

Remove prop shafts and connect tug vehicle with towbar and carefully remove blocking.

Vehicle may now be towed.

NEVER tow the machine above 5mph (8kph) as the lack of power assistance makes manual steering and braking very slow and strenuous.

ALWAYS tow the machine with a towbar, never with a chain or rope.

OPERATION DRIVING THE MACHINE (continued) Towing the machine (continued) Following repair, the brakes must be re-engaged as follows: DANGER! Block all four wheels to prevent vehicle movement. Failure to do so could result in death or injury if vehicle rolls away.

Once the wheels are blocked, again working on one group of screws at a time, using the 8 mm Allen key, turn each screw anticlockwise (outwards) (A) one turn at a time (care must be taken to loosen each screw alternatively to avoid internal damage) for about 5 to 5 1/2 turns until firm resistance is felt, then turn each screw clockwise (inwards) one quarter turn.

Repeat procedure with the other group of screws.

The parking brakes should now be re-engaged and the wheels locked.

Check that the brakes function correctly before putting the vehicle back into work.

1.27

1.28

OPERATION

WORKING THE TELEHANDLER The Telehandler should not be used by untrained operators.

The following pages explain some of the recommended techniques and procedures to enable the Telehandler to be used effectively and safely. The information given on the Load charts, Instability Situations examples, and the Longitudinal Stability Indicator (LSI) should be carefully read and understood.

It is important that you understand the parameters of the lifting envelopes located in the cab and the examples of instability situations that are included in this Handbook.

Longitudinal Stability Indicator (LSI) The LSI (A) is a progressive warning device measuring load on the rear axle, warning the operator when the machine is nearing its maximum safe working stability through the progressive illumination of a series of seven green, two amber and two red indicators.

The illumination of the two amber indicators will activate an intermittent audible alarm, whilst the illumination of the red indicators will continuously activate the audible alarm.

Turning the engine start switch to the on position initiates the LSI ‘internal-test’ function.

All indicators will illuminate and the alarm will sound, for a few seconds.

If functioning correctly, all indicators except for the bottom indicator (1) will extinguish and the alarm will cease.

Do not use the machine if the LSI ‘internal-test’ function fails.

Dependant on boom extension and angle a load of 50% machine rated capacity will cause the illumination of two or more indicators.

Increasing the load and/or boom extension or angle will cause the indicators to progressively illuminate.

With all green indicators illuminated the machine is within its longitudinal stability, but caution is necessary.

Further increases in load and/or boom extension or lowering the boom without retraction will cause the illumination of the two amber indicators and the intermittent sounding of the audible alarm. The machine is now at its limit of longitudinal stability.

Do not increase load, boom extension or change boom angle without retracting boom first, when the two amber indicators are illuminated.

If the two red indicators illuminate and the alarm sounds continuously, the machine longitudinal stability has been exceeded. Do not continue with work operations. Proceed with extreme caution to return to stable conditions by retracting boom, prior to lowering boom and removing or reducing load.

OPERATION WORKING THE TELEHANDLER (continued) Although the LSI is useful in giving an indication of machine stability, it does not replace the skills of a well trained and experienced operator.

The examples of instability situations show a series of instances that would cause the coloured indicators to change from 'green' through to 'Unstable red' as the longitudinal stability of the machine is endangered by incorrect operation.

ALWAYS observe and obey the LSI. Do not wait until the alarm sounds.

ALWAYS TEST THE LSI BEFORE WORK COMMENCES.

Checking the indicator The indicator is fitted with an external 'self-testing' facility. If the 'self-test' fails, the machine must NOT be used.

'Self-test' Before attempting to pick-up a load retract and level boom, press the test button (B), this should illuminate all of the indicators and cause the alarm to sound for a few seconds.

This test shows whether the electrical warning devices are functioning.

If functioning correctly all indicators except the bottom indicator (1) will extinguish and the alarm will cease.

NOTE If this test is carried out whilst the machine is carrying a load more than one indicator will remain illuminated.

Longitudinal stability indicator service The LSI must be tested every three months by your Distributor. All adjustments must be carried out with the correct test equipment.

NEVER use the machine with an inoperative stability indicator.

1.29

1.30

OPERATION

EXAMPLES OF INSTABILITY SITUATIONS 1

Overloading with the boom at constant reach creates instability.

ALWAYS REDUCE REACH AS THE LOAD IS INCREASED.

2

Extending the boom with a constant load creates instability.

NEVER EXTEND REACH WHEN YOU CAN MOVE NEARER, OR REDUCE LOAD BEFORE EXTENDING.

3

Lowering an extended and loaded boom creates instability.

ALWAYS RETRACT BOOM BEFORE LOWERING IT.

4

Attempting to lift a load that is too heavy for reach creates instability.

ALWAYS LIFT FROM CLOSE IN, WITH AS SHORT A REACH AS POSSIBLE.

OPERATION LIFTING ENVELOPE

1.31 European Specification pr EN1459 annexe B

The capacities and limits on the following Load Charts are for stationary machines fitted with standard forks only.

Do not operate raise or extend boom functions whilst the machine is moving.

Always retract and lower the boom as far as possible when travelling with a load.

Refer to the appropriate load chart for the attachments correct capacity and suitability. These charts must be understood and observed.

The weight of the load should always be known before picking or placing it.

The centre of gravity should not be more than 500mm (20") in front of the fork uprights.

Lifting envelope

Lifting envelope

Standard forks

Standard forks

1.32

OPERATION

LIFTING ENVELOPE (continued) European Specification pr EN1459 annexe B Lifting envelope Standard forks

OPERATION APPROACHING A LOAD - WORKING WITH PALLET FORKS When approaching a load, always ensure: The ground surface is firm and level and the load is approached 'squareon'.

A Stop the machine at the face of the load. The parking brake has been applied and neutral gear selected.

B Tilt the forks by gently moving the joystick lever to the right until the forks are horizontal.

C Ensure that the forks are as widely spaced as possible to suit the load. Secure forks if they were adjusted.

D Raise the boom until the forks are level with the pallet. Slowly drive the machine forwards until the carriage touches the load.

If it is not possible to drive forward because of obstructions or the ground is not level: Then extend the boom and if necessary raise or lower the boom height until the carriage touches the load.

1.33

1.34

OPERATION

PICKING UP A LOAD - WORKING WITH PALLET FORKS NEVER use the machine for purposes other than those for which it was designed.

Maximum load capacities, load centres, reach and lift heights must be observed. These are illustrated in this Handbook.

NEVER walk or work under a raised load unless the boom safety stop has been installed.

ALWAYS place attachment level on the ground when the machine is not in use (unless a boom safety stop has been installed).

NEVER bring the boom or load within 6 metres (20 feet) of overhead power cables.

OPERATION PICKING UP A LOAD - WORKING WITH PALLET FORKS (continued) A Ensure forks will pass cleanly under load.

Drive slowly, engage forks centrally until the carriage touches the load. Apply the parking brake.

Select neutral gear NEVER operate the boom or attachments with the machine at speed.

B Raise the boom slowly to lift the load while watching that the lift envelope and boom indicators are within the safety limits. Replace load if in danger or doubt.

NEVER leave the machine unattended with the load or boom raised.

C Tilt the carriage back.

Retract and lower the boom to the travelling position, which is the lowest position that will give adequate ground clearance over the work site area.

D When the area behind the machine is clear, select a reverse gear, release the parking brake and slowly reverse away from the stack.

1.35

1.36

OPERATION

PLACING A LOAD - WORKING WITH PALLET FORKS ALWAYS ensure any scaffolding or loading platform can support the load before unloading onto it.

NEVER attempt to place a load on ground that is not firm, is unstable or incapable of supporting a fully laden machine.

A Approach the stack 'square-on', and have room to manoeuvre, then apply the parking brake and select neutral gear.

B Raise and extend the boom until the load is directly over the stack or position. Ensure that the lift envelope and boom indicators are within the safety limits.

Move nearer if necessary. Tilt the carriage until the forks are horizontal. Lower the load into position.

C When in a confined space, it may be necessary to raise and retract the boom to withdraw from the pallet. When the forks are clear, fully retract the boom, turn away from the stack, then lower the boom into a travelling position.

NEVER leave the machine unattended with the load or boom raised.

OPERATION LIFTING UNPALLETISED LOADS Tilt the carriage forward and then extend and slightly raise the boom to slide the forks under the load. If necessary, wedge the load to stop it moving away from the forks.

When loaded, chain securely onto the carriage and.

Tilt the carriage back and raise the boom to the travelling position.

Always find the centre of gravity or point of balance of loads of irregular shape and weight distribution.

Ensure that this centre of gravity is placed midway between the forks.

Perform a 'test' lift before completely lifting clear of the ground.

NEVER raise a load using only one fork.

NEVER sling a rope or chain from any part of the boom, forks or carriage.

ALWAYS use an approved lifting attachment.

1.37

1.38

OPERATION

TRAVELLING ALWAYS drive on surfaces that are known to be stable.

Travelling position When travelling, the boom must be set in the "travelling position". This consists of: The boom being fully retracted and at the lowest position (A) that will give adequate ground clearance (B); the carriage (and forks) (C) tilted as far back as possible.

Lock boom controls See boom function lockouts.

ALWAYS seek advice before using unfamiliar attachments or moving unfamiliar loads.

NEVER exceed 5mph (8kph) when carrying a load, or being towed.

It is recommended that ALL attachments are removed from the machine before travelling on public roads.

Before road travel It is a legal requirement in certain countries to lock out all boom and auxiliary hydraulic functions when travelling on public roads.

To disable all boom functions refer to auxiliary controls, select position (C) on isolation switch after ensuring rear wheels are aligned in the straight ahead position.

Travelling on gradients When travelling up or down a gradient always obey the following: Never run down a gradient with the transmission in neutral When travelling down steep gradients control machine speed by selecting a lower gear or using the footbrake.

Do not exceed the maximum machine rated speed, particularly when travelling down steep gradients.

Slippery or loose surface conditions can adversely affect safe machine operation, particularly on gradients.

Choose routes that avoid steep, slippery or loose gradients.

Never park the machine on a gradient.

Never attempt to run on, or drive across a gradient.

Always travel up a gradient with the load facing uphill.

Always reverse down a gradient when loaded.

OPERATION TRANSPORTING THE MACHINE Ensure the transporter is suitable in size and loading capacity to carry the machine in a safe and stable manner.

Loading the transporter Chock (1) the wheels of the transporter.

Fix ramps to the transporter which will give the smallest possible angle for the machine to climb.

Ensure the machine boom is in the "travelling" position.

Drive the machine on to the transporter. If necessary raise the boom slightly to avoid fouling the ramps.

Apply the brakes and select neutral with the gear lever and forward/reverse lever.

Lower carriage.

Stop the engine. Dump hydraulic pressure. Remove the starter key, and lock cab.

Remove the ramps from the transporter.

Anchoring the machine.

Chock the wheels of the machine (A).

Lash the wheels (B) to the transporter.

Some machines are manufactured with anchorage points at the front (C) and rear (D). If these are fitted, use them to anchor the frame.

Ensure that the driver of the transporter is aware of the overall dimensions and weight of his load (see "specifications").

1.39

THIS PAGE INTENTIONALLY BLANK

ATTACHMENTS AND OPTIONAL EQUIPMENT ATTACHMENTS - FITTING AND REMOVAL To remove pallet forks (where fitted) Lift the spring-loaded catches (A) on top of each fork. Slide a fork (D) across to the central gap (B) in the carriage bottom rail (C). Pivot the fork which is in gap (B) away from the bottom rail and move fork to one side of the gap. Repeat with other fork.

Tilt the carriage and lower it to the ground.

Withdraw from the forks (D).

To refit the forks, reverse the procedure.

ALWAYS slide forks away from yourself. Never pull forks into the demount position.

It is recommended that pallet forks are either parked and secured away from a thoroughfare or laid flat on the ground for safe storage.

To fit an attachment to the carriage When attachments are added to the carriage, their own weight becomes part of the load.

Only attachments designed or approved by CLAAS can be used with this machine.

Refer to the appropriate load chart for the attachments correct capacity and suitability. These charts must be understood and observed.

Mechanical locking pins To retract the quick release locking pins (E): Lift the latch (F) slightly to allow the release lever to be swung downwards.

Hydraulic Actuated locking pins When fitted, the hydraulic locking pin system is operated by two joystick mounted switches.

To retract the locking pins ensure the joystick/boom rotary isolation switch (1) is turned to position A, before operating buttons ( A1, A2).

Ensure attachment locking pins are fully retracted into the carriage.

2.1

2.2

ATTACHMENTS AND OPTIONAL EQUIPMENT

ATTACHMENTS - FITTING AND REMOVAL (continued) Check that the attachment is in good working order and that mounting lugs and locking tubes are clean.

Ensure attachment locking pins are fully retracted into the carriage.

Lower and tilt the carriage slightly forward (J) and drive the machine up to the attachment with the carriage (C) centrally aligned to the attachment mounting lugs (H).

Lift and roll back the carriage until the bottom rail (K) fits snugly to the attachment. Ensure the attachment is clear of the ground.

Manual locking pins Swing lever (F) upwards to engage locking pins (E).

Ensure lever is swung fully over and safety latch (G) is fully engaged, to prevent accidental retraction.

Hydraulic Actuated locking pins Only engage the pins when attachment is clear of the ground and holes/pins are correctly aligned otherwise damage may occur.

Lock the attachment to the carriage by operating the joystick mounted switches (A1, A2), to engage locking pins (E).

Carriage pins lockout switch The joystick/boom isolation rotary switch (1) isolates the carriage locking pin control, therefore stopping accidental operation and release of attachments.

Turn switch to position (B) to lock pins (See Auxiliary controls).

For attachments without hydraulic couplings: Raise and roll back the carriage to the travelling position. The machine is now ready for work.

ALWAYS check locking pins are engaged before tilting or operating any attachments.

ATTACHMENTS AND OPTIONAL EQUIPMENT HYDRAULICALLY OPERATED ATTACHMENTS Operating Principles All hydraulic powered attachments operate on similar principles i.e. push/pull and/or open/close.

The service hoses should be connected to give the following movements: Button (A1) to ‘Push’’ or ‘Open’ (O) Button (A2) to ‘Pull’ or ‘Close’ (C) Or if the second hydraulic service connections are used: Button (A3) to ‘Push’’ or ‘Open’ (O) Button (A4) to ‘Pull’ or ‘Close’ (C)

Quick Release Coupling Connection Before connecting the quick release couplings, ensure that the attachment is locked to the carriage and that the attachment is resting on the ground.

Dump hydraulic pressure from the service lines.

With the ignition turned to (I), operate the appropriate auxiliary control a few times (see Auxiliary controls).

ALWAYS clean hydraulic couplings before connection. Dirty couplings will damage hydraulic system.

Connect the attachment hoses to the hydraulic quick-release terminals (A) on the carriage.

Raise the carriage off the ground.

Check that the control buttons/switch operate the attachment correctly. If not, lower the carriage, stop the engine, dump hydraulic pressure and transpose the hoses on the quick-release terminals.

NEVER leave the machine unattended with pressure in the system.

2.3

2.4

ATTACHMENTS AND OPTIONAL EQUIPMENT

HYDRAULICALLY OPERATED ATTACHMENTS (continued) Quick Release Coupling Disconnection Before disconnecting the quick release couplings, ensure that the attachment is unladen and is resting on the ground.

Dump hydraulic pressure from the service lines.

With the ignition turned to (I), operate the appropriate auxiliary control a few times.

Couplings may now be disconnected.

NOTE: Wipe the coupling area clean before disconnection.

Locking pins may now be withdrawn and the carriage disengaged from the attachment by reversing the fitting procedure stated above.

Working with Front End Attachments Generally observe the safety and operational procedures given under “Working with pallet forks” and “Travelling” sections, noting that particular care must be taken when working with fork tines and grab attachments.

Avoid fully retracting and lowering the boom during operations requiring maximum “crowding use, otherwise damage can occur to tyre equipment.

It is recommended that ALL attachments are removed from the machine before travelling on public roads.

ATTACHMENTS AND OPTIONAL EQUIPMENT HYDRAULICALLY OPERATED ATTACHMENTS (continued) Rear mounted Auxiliary service Rocker switch (5) is a two position On/Off switch.

With the switch in the On position (depress to the left) the front service will be isolated, but the joystick buttons (A1) and (A2) will control the 'Push' or 'Open' or 'Pull' or 'Close' rear service function.

NOTE: On early models a three position rocker switch, sprung loaded to centre (neutral) position was used.

Rocking the switch to either the left or right will isolate the front services. The rear services will then either 'Push or Open', or, 'Pull or Close', depending on which direction the switch is rocked.

Auto-hitch The Auto-Hitch is operated via the Rear Auxiliary Service controls to Open (Lower) or Close (Raise) as described above. The Hitch is provided with a safety pin and latch mechanism (C), this mechanism MUST be engaged BEFORE towing or tipping a trailer.

The latch arm (D) is sprung loaded to the vertical position and will be pushed aside by the pins (E) when the hitch is being raised from the Open position. But once the pins (E) are engaged and resting on the latch arm, they can only be released by raising the hitch slightly and pulling the latch arm release handle (B) which in turn will pivot the latch arm clear allowing the hitch to be lowered.

2.5

2.6

ATTACHMENTS AND OPTIONAL EQUIPMENT

HYDRAULICALLY OPERATED ATTACHMENTS (continued) Automatic trailer pick-up hitch (Auto-Hitch) To operate Auto-Hitch and pick up a trailer Check that the auto-hitch mirror is adjusted so that the auto-hitch is clearly visible from the driving position.

Ensure hand valve (F) is in the vertical position.

Assuming that the hitch is in the closed position:Raise the hitch (see page 2.5) and pull the autohitch release handle (B), once the pins (E) are clear of the latch arm, (D) fully lower the hitch and release the release handle (B).

To tip a trailer body Connect the trailer hose to the machine quick release coupling (G). Turn hand valve (F) to horizontal position.

The joysticks buttons (A2) and (A3) can now be used to raise and lower the trailer body.

NOTE: On early models fitted with a three position rocker switch, rock the switch left or right to raise or lower the trailer body.

To uncouple trailer Fully lower the trailer body.

Dump hydraulic pressure from the service lines.

With the ignition turned to (I), operate the appropriate auxiliary control a few times (see Auxiliary controls).

Turn the hand valve (F) to vertical position.

Disconnect the trailer hose from the Q/R coupling (G).

Raise hitch so that the pins (E) clear locking latch arm (D).

Pull the auto-hitch release (B).

Lower the hitch Fully.

Draw forward and fully raise the hitch, ensure that the latch arm returns to the vertical position. Lower hitch slightly until the pins (E) are resting on the latch arm.

NOTE: In the event of a long period of disuse, it is advisable to purge the auto-hitch ram cylinder. With the engine running, pull out and hold the auto-hitch release knob, while operating the auto-hitch control lever several times in each direction to disperse any air from the system.

ATTACHMENTS AND OPTIONAL EQUIPMENT MANUAL TRAILER PICK-UP ROCKINGER HITCH Hitch mechanism is spring loaded.

Keep hands clear of hitch jaws when vertical pin (1) is in the raised position.

To connect trailer Rotate lever (2) until the pin (1) moving vertically, latches in the fully up position, allowing the release trigger (3) to swing rearwards.

Align hitch jaws and trailer eye, and reverse vehicle to trailer. As trailer eye contacts hitch jaws and trigger (3), latch mechanism releases spring loaded pin (1) and lever (2).

Check that pin is fully engaged with lower jaw before moving off.

Never leave vehicle with pin (1) in raised position. Firmly rotating lever (2) downwards will release pin.

Do not attempt to touch trigger.

DRAWBAR To connect trailer Remove pin (1) align vehicle and trailer eye and reverse vehicle with assistance to ensure easy connection.

Secure pin with attached lynch pin.

Manoeuvre with extreme care when assistance is being given by other person.

2.7

2.8

ATTACHMENTS AND OPTIONAL EQUIPMENT

EXTENSION JIBS AND CRANE HOOKS Regulations The use of Extension Jibs and Crane Hook attachments are subject to National Government regulations.

ALWAYS refer to, and conform with, these regulations.

Maximum rated loads The absolute rated loads for lifting hook attachments are (U.K. only): A Extension jib: 325Kg (716 lbs) B Fork mounted crane hook 1000Kg (2205 lbs) ALWAYS remember that the rated safe working loads apply to static loads only, and that swinging loads reduce stability, so: ALWAYS control swinging load with a guide rope in the charge of a banksman.

ALWAYS travel slowly, in low gear, with the load as near to the ground as possible.

ALWAYS ensure that the load to be lifted is within the rated safe working load of the machine and attachment before attempting to lift it.

NEVER exceed the rated safe working load for the machine with attachment. Contact the Manufacturers to establish the rated safe working load.

Warning indicators The lifting envelope and boom warning indicators are not specialist ‘crane’ indicators and do not give an accurate indication with lifting hook attachments.

Installing crane hook on forks Remove pins (A) from the crane hook.

Insert the forks fully through the sleeves (B).

NEVER support a crane hook using only one fork.

Secure the crane hook by re-inserting pins (A) behind the heel of the forks, and locking them in position with their latch pins.

SERVICE

3.1

SAFETY WARNINGS HEALTH AND SAFETY Always wear correct fitting protective clothing. Loose or baggy clothing can be extremely dangerous when operating or servicing a machine.

Where possible, work on or close to engines or machinery only when they are stopped. If this is not practical, remember to keep tools, test equipment and all parts of your body well away from moving parts Avoid contact with exhaust pipes, exhaust manifolds and silencers when a engine is running; these can be very hot Once stopped allow engine and engine systems to cool, before attempting maintenance.

Many liquids used in this machine are harmful if taken internally or splashed into the eyes. In the event of accidentally swallowing oil, diesel fuel, antifreeze, battery acid etc., DO NOT induce vomiting, but SEEK QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY Always obtain advice before mixing oils; some are incompatible

Never run an engine in an enclosed space.

Always disconnect battery cables before using an external charger, or to prevent unauthorised usage when unattended or during a repair Always work out of doors or in a

well-ventilated area. Dust found on the machine or produced during work on the machine should be removed by extraction, not by blowing. Dust waste should be dampened, placed in a sealed container and marked, to ensure safe disposal Always dump pressure from the hydraulic system before carrying out any kind of maintenance or adjustment. (see Service Hydraulics) Never leave the machine unattended with pressure in the system Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. If hydraulic fluid penetrates your skin SEEK QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY Always conform to service schedules except where: (a) Warning light or warning indicator calls for immediate attention. (b) Adverse conditions necessitate more frequent service.

Never allow unqualified personnel to attempt to remove or replace any part of the machine, or anyone to remove large or heavy components without adequate lifting tackle Never attempt to lift or hold up the machine using the lash-down points.

3.2

SERVICE

ACCESS TO SERVICE CHECK POINTS Apply the brakes and chock the wheels before servicing the machine.

NEVER work under a raised boom without installing the SAFETY STOP!

Engine Bonnet: The bonnet, on early models, is retained in the closed position with one lockable catch, later models are fitted with a lockable catch and a separate overcentre latch.

To release, use the service tool provided, unlock the catch and, where fitted release the over-centre latch.

The bonnet is counter-balanced by gas struts.

This will give access to: Battery isolation switch Start relays Air filter switch Engine oil dipstick and filler Engine oil filter Engine fuel filter and water trap Engine fuel lift pump Fuel injection pump and injectors Alternator and fan belts Starter motor Radiator and Header tank Hydraulic pump(s) Fan motor Transmission filter and dipstick Transmission oil cooler Hydraulic oil filler cap Hydraulic filter Hydraulic oil cooler (when fitted) Engine pod: Later models are fitted with an ‘Undertray assembly’.

The assembly is complete with two access doors secured with catches, which require the use of the service tool provided.

Remove the doors to give access to: Engine and transmission drain points.

Rear service plate: Located at chassis rear and secured with four screws gives access to: Change over valve Pilot valve accumulator Main control valve Trailer braking valve (when fitted).

Cab pod front hatch, secured with six screws, gives access to: Brake valve Throttle cable Steer valve.

Cab pod side hatches provided either side of cab door step, gives access to: Windscreen washer bottle filler Battery compartment.

Cab gives access to: Diesel tank - located under drivers seat Fuse and relay box-located under LH dash cover.

Heater bleed screw

SERVICE

3.3

SERVICE Introduction To obtain the best performance from your vehicle and the longest life, you must ensure that the maintenance operations are done at the intervals indicated in the Service Schedule.

Each vehicle is supplied with the engine manufacturers User's Handbook, and whilst certain information relating to general engine maintenance is repeated in this section to provide an overall vehicle Service Schedule; the vehicle operator must follow the engine manufacturers User's Handbook maintenance recommendations and service instructions.

SERVICE SCHEDULE SERVICE OPERATION

REFERENCE

PAGE

Warning lights and indicators: REQUIRE IMMEDIATE ACTION

Warning light "illuminates": Check operation (Trained personnel only) Brakes Warning light "illuminates": Clean air cleaner

Air cleaner

Warning light "illuminates": Change hydraulic filter

Hydraulic system

As required Change: Primary (inner) air cleaner element

Air cleaner

3.18

Change/clean: Secondary (outer) air cleaner element

Air cleaner

3.18

Clean: Air pre-cleaner

Air cleaner

3.18

Check: Engine oil level

Engine oil

3.8

Check: Coolant level

Cooling system

3.11

Check: Radiator airways

Cooling system

3.10

Check: Fuel tank level

Fuel system

3.14

Check/Clean: Air pre-cleaner

Air cleaner

3.18

Check: Transmission and Transfer Box oil levels

Transmission

3.21

Check: Hydraulic oil level

Hydraulic system

3.26

Check: Hydraulic in-line filter

Hydraulic system

3.25

Change: Hydraulic filter element

Hydraulic system

3.25

Every 10 operating hours, or daily

Check: Noise reduction panels

Cab/Engine compartment 3.30

Check: Wheel nut tightness

Wheels and tyres

3.7

Check/Clean: Secondary (outer) air cleaner element

Air cleaner

3.18

Check: Function of the parking brake and adjust if necessary.

Check: Brake pedal travel Check the action of the brake pedal; it should have a short travel and firm action. If travel is excessive, or the action spongy, have the brakes serviced by your distributor.

3.4

SERVICE

SERVICE SCHEDULE Every 20 operating hours Grease: Front and rear axle centre pivot bearings

Greasing points

3.6

Grease: All propeller shafts

Greasing points

3.6

Grease: Bright metal and pivots

Greasing points

3.6

Drain: Fuel pre-filter

Fuel system

3.15

Grease: Auto-hitch locking catch and cable

Attachments

3.29

Grease: Rockinger hitch

Attachments

3.29

"Initial" 50 operating hours Check: Engine idle speed (Trained personnel only, see engine manual) Check: Prop-shaft fasteners

Transmission

3.21

Check: Fan drive belt tension

Fan drive system

3.20

Change: Transfer box oil

Transmission

3.22

Change: Transmission oil and oil filter

Transmission

3.22

Clean: Hydraulic tank breather

Hydraulic system

3.26

Check: Tyre pressure

Wheels and tyres

3.7

Check: Tyre condition

Wheels and tyres

3.7

Check: Battery electrolyte level

Battery

3.28

Check: Front and rear axle case/wheel hub oil levels

Axles

3.24

Check: Prop-shaft fasteners

Transmission

3.21

Change: Engine oil and filter

Engine oil and filter 3.8

Check: Engine idle speed

Engine

3.19

Change: Fuel filter canister

Fuel system

3.15

Change: Fuel pre-filter element

Fuel system

3.17

Change: Hydraulic filter element

Hydraulic system

3.26

Check: Alternator belt tension

Engine

3.19

"Initial" 100 operating hours

Every 50 operating hours, or weekly

Every 500 operating hours Check: Frame assembly bolts Check: All structural nuts and bolts for tightness.

SERVICE

3.5

SERVICE SCHEDULE

Every 500 operating hours continued Change: Air cleaner outer element

Air cleaner

3.18

Change: Air cleaner inner element

Air cleaner

3.18

Check: Fan drive belt tension

Fan drive system

3.20

Change: Cab air filter element

Cab

3.30

Check: Fuel injectors (atomisers)

Engine

3.19

Check: Valve clearances

Engine

3.19

Clean: Alternator brushes

Engine

3.19

Change: Transfer box oil

Transmission

3.22

Change: Transmission oil and oil filter

Transmission

3.22

Check: Coolant quality

Cooling system

3.12

Change: Front and rear axle case/wheel hub oil

Axles

3.24

Check: Cooling system hoses

Cooling system

3.12

Clean: Rad/oil cooler cores

Cooling system

3.12

Change: Air cleaner outer element

Air cleaner

3.18

Change: Hydraulic oil

Hydraulics

3.27

Cooling system

3.12

Every 1000 operating hours

Every 1500 hours, or yearly

Every 2000 hours Check: Cooler hoses

Check: Brakes, have the braking system checked and overhauled by your distributor.

Extra services For dirty work conditions increase the frequency of all services during extremes of dirt, vegetable waste, heat and cold, especially those relating to clean air, cooling efficiency, lubrication and machine cleanliness.

Laying-up protection When a machine is to remain idle, remove the battery to the workshop. Seal all openings: air intake, exhaust breathers. Grease bright parts and protect rubber components from direct sunlight. Fill the fuel tank, check tyre pressures and exhaust any pressure from the hydraulic system.

3.6

SERVICE

GREASE POINTS Every 20 operating hours Always use lubricants of the grade specified.

Always clean grease nipples, filler caps etc. BEFORE and AFTER Lubrication.

Always lubricate and service BEFORE work commences, and within the periods specified.

Bright metal parts Clean the carriage top bar, and any other bright metal parts which need protection from the elements, with solvent; dry and coat with a film of grease.

* Oil all pivots and linkages not fitted with a grease nipple.

SERVICE WHEELS AND TYRES Every 10 operating hours, or daily Wheel nuts Tighten these whenever necessary, every ten hours or daily.

After a wheel change, the nuts should be checked several times a day until they maintain their correct setting.

For wheel nut tightening torque (see “Machine Specifications”)

Every 50 operating hours, or weekly Check tyre pressures When adding air to a tyre, ensure the area is clear of personnel.

Never over-inflate a tyre beyond its specified pressure.

Check the tyre pressure.

Check pressures only when the tyres are cold.

For correct pressures (see “Machine Specifications”).

Tyre condition Check the tyres for damage and deterioration.

3.7

3.8

SERVICE

ENGINE OIL LEVEL Every 10 operating hours, or daily Check engine oil pressure Check oil pressure warning light (1) is not illuminated when engine is running.

Check engine oil level.

Ensure the machine is standing on level ground and that the engine is stopped.

Allow a hot engine to cool for 15 minutes.

Pull out dipstick (3) and wipe with a clean rag.

Insert the dipstick fully and again remove it. At no time should the level of the oil fall below the 'Min' mark on the dipstick.

If necessary, remove oil filler cap (2) and top-up to the 'Max' mark on the dipstick with clean oil of the recommended grade.

For correct grade of engine oil, (see "Machine Specifications").

Every 500 operating hours Change engine oil and filter Lubrication oil cleanliness is vital for the successful operation of your engine. The oil should be stored under the cleanest possible conditions.

When changing or topping-up oil, use only clean receptacles.

Do not allow oil to come into contact with the rubber hoses on the engine.

Before removing any drain plugs, ensure a suitable container is placed on the ground to catch spilt oil.

When removing drain plugs, remember to stand on one side to avoid oil which will spill from the drain plug hole.

Warm the engine to normal operating temperature.

Ensure that the machine is standing on level ground and that the engine is stopped.

Remove ‘Undertray doors’ (Where fitted) using the service tool provided.

Clean area around the oil filter canister (6) and oil drain plug (5).

Place a suitable container under the oil drain plug (5) . Ensure that the container is large enough to hold all the oil, (see "Machine Specifications")

SERVICE ENGINE OIL AND FILTER (continued) Remove the oil drain plug (5) and its "O" ring and drain the oil from the sump. Ensure the "O" ring is not damaged and refit the drain plug and its "O" ring and tighten the plug to 34 Nm (25 lb./ft).

Using a suitable strap wrench, unscrew and discard the oil filter canister (6) and ensure that canister adaptor (7) is secure in the filter head.

Thoroughly clean the housing contact surface for the oil filter canister (6).

Pre-fill the new oil filter canister (6) with clean engine oil of the correct grade, (see "Machine Specifications").

Apply a thin film of clean engine oil to the seal of the oil filter canister (6).

Fit the oil filter canister (6) and tighten it firmly by hand only. Do not use a strap wrench.

Refill the engine with the correct grade of oil, (see "Machine Specifications") up to the "Max : mark on the dipstick (3).

On turbocharged engines, ensure the engine will not start by disconnecting the electrical stop solenoid (4) wiring of the fuel injection pump. Operate the starter motor until oil pressure is obtained, when the indicator light extinguishes. Reconnect the stop solenoid wiring.

Operate the engine and check for any leakage from the oil filter canister (6). When the engine has cooled, check the oil level on the dipstick (3) and if necessary, top-up.

Wipe Undertray doors and insulating material and reassemble.

3.9

3.10

SERVICE

COOLING SYSTEM Every 10 operating hours, or daily Antifreeze is toxic and must never be taken internally. If swallowed accidentally, medical advice should be sought immediately.

Antifreeze is corrosive to the skin. If accidentally spilled onto the skin, it should be washed off immediately. It is advisable to wear protective clothing when handling antifreeze and other similar corrosive substances.

Wash hands with soap and water after use.

Keep antifreeze out of the reach of children.

Never start the engine without liquid in the cooling system.

The cooling system efficiency depends on the cleanliness of the air intake grille, radiator/oil cooler faces and cores (on later models - the bonnet air ducts).

Check the air intake grille and radiator etc. for blockage or debris. Clean if necessary, using a brush or low pressure air wand. Take care to avoid damage to finning. Cleaning frequency will depend on operating conditions.

Options available on later models are Automatic fan control or Reversible fan drive systems, frequent use of these features will assist in reducing material blockages and therefore cleaning frequency.

Refer to Page 1.25

SERVICE COOLING SYSTEM (continued) Every 10 operating hours, or daily Check and if necessary "top-up" the cooling system.

Never check the coolant level with the engine running.

The cooling system is pressurised, and care should be taken when removing the header tank cap when the engine is hot.

Remove the filler cap (1) SLOWLY. If there is liquid in the header tank, the system may be refilled with safety. If not, allow the engine to cool completely before topping-up.

If the machine is working continuously in hot weather, check the level several times a day.

Top-up with coolant to between 0.5 in - 1in (13 - 25 mm) below the filler neck (1), with the correct coolant mixture. Refit the filler cap (1).

If the cooling system has leaked due to heater or hose failure, it is extremely important that any lost coolant is replaced by a pre-mixed solution of antifreeze, and water. DO NOT use leak additives.

Every 10 operating hours, or daily Check and if necessary "top-up" the cooling system.

Never check the coolant level with the engine running.

The cooling system is pressurised, and care should be taken when removing the header tank cap when the engine is hot.

Remove the filler cap (1) SLOWLY. If there is liquid in the header tank, the system may be refilled with safety. If not, allow the engine to cool completely before topping-up.

If the machine is working continuously in hot weather, check the level several times a day.

Top-up with the correct coolant mixture until the fluid level can be seen half way up the sight glass (2).

Refit the filler cap (1).

If the cooling system has leaked due to heater or hose failure, it is extremely important that any lost coolant is replaced by a pre-mixed solution of antifreeze, and water. DO NOT use leak additives.

3.11

3.12

SERVICE

COOLING SYSTEM (continued) Every 1000 operating hours Check engine coolant quality Never remove the radiator cap with the engine running.

The cooling system is pressurised, and care should be taken when removing the radiator cap when the engine is hot.

Check the coolant quality with an anti freeze tester, if poor, drain system and renew.

Before removing any drain plugs ensure a suitable container is placed on the ground to catch spilt coolant.

When opening drain plugs, remember to stand on one side to avoid coolant which will spill from the drain hole.

Turn heater control switch (see page 1.13) fully on.

Open engine pod cover.

Locate radiator drain plug (2).

Place a suitable container on the ground to catch the draining coolant.

Drain off the coolant by removing the filler cap (1), radiator drain plug (2) and engine drain plugs (A) and (B). Flush the system with clean water, and refit the radiator and engine drain plugs.

Refill with coolant until the header tank is 2/3 full and refit the filler cap (1).

It is preferable to use a coolant mixture of 50% antifreeze and 50 % water, as this will give greater protection against freezing and engine corrosion.

Always use antifreeze of the correct type and grade.

Check hoses During the renewal of coolant, carefully examine all the radiator and heater hoses for cracks, cuts and damage.

Clean system Clean radiator, transmission oil cooler cores, and where fitted the hydraulic oil cooler fins, taking care to avoid damage to finning.

Run engine - for a few minutes, stop, check level, top up if necessary - reset heater control.

SERVICE COOLING SYSTEM (continued) Every 1000 operating hours Check engine coolant quality Never remove the radiator cap with the engine running.

The cooling system is pressurised, and care should be taken when removing the radiator cap when the engine is hot.

Check the coolant quality with an anti freeze tester, if poor, drain system and renew.

Before removing any drain plugs ensure a suitable container is placed on the ground to catch spilt coolant.

When opening drain plugs, remember to stand on one side to avoid coolant which will spill from the drain hole.

Turn heater control switch (see page 1.13) fully on.

Open engine pod cover.

Locate radiator drain plug (3) at the position shown on the illustration, but on the rear of the radiator. To access the drain plug (3) remove the under pod guards.

Place a suitable container on the ground to catch the draining coolant.

Drain off the coolant by removing the filler cap (1), radiator drain plug (3) and engine drain plugs (A) and (B). Flush the system with clean water, and refit the radiator and engine drain plugs.

Refill with coolant until the fluid level can be seen half way up the sight glass (2). Refit the filler cap (1).

It is preferable to use a coolant mixture of 50% antifreeze and 50 % water, as this will give greater protection against freezing and engine corrosion.

Always use antifreeze of the correct type and grade.

Check hoses During the renewal of coolant, carefully examine all the radiator and heater hoses for cracks, cuts and damage.

Clean system Clean radiator, transmission oil cooler cores, and where fitted the hydraulic oil cooler fins, taking care to avoid damage to finning.

Run engine - for a few minutes, stop, check level, top up if necessary - reset heater control.

3.13

3.14

SERVICE

FUEL SYSTEM Every 10 operating hours, or daily Check fuel tank level The gauge (1) on the instrument console indicates the amount of diesel fuel in the tank.

Fill the fuel tank at the end of each day to reduce overnight condensation within the tank.

Never add gasoline or any other fuel mixes to diesel fuel because of increased risk of fire or explosion.

To fill tank: Never remove the filler cap, or refuel, with the engine running.

Never smoke when refilling the tank.

Always keep control of the filler pump nozzle.

Stop the engine.

Clean around the filler cap (2).

Remove the cap.

Fill tank with diesel fuel .

Do not fill the tank to capacity. Allow room for expansion and wipe up spilt fuel immediately, otherwise paintwork will be damaged.

Turn the start key switch to the warning lights position. Check gauge (1).

If the level of fuel in tank is sufficient, replace the filler cap and lower the cover and lock it.

SERVICE FUEL SYSTEM (continued) Diesel fuel is inflammable. Do not smoke while carrying out maintenance on the fuel system. Do not carry out maintenance to the fuel system near naked lights or sources of sparks, such as welding equipment.

Every 20 operating hours or daily Drain fuel pre-filter Drain water from pre-filter by removing the drain plug (1). Replace the drain plug when uncontaminated fuel flows from the bowl.

NOTE: This operation should be carried out more frequently in high condensation conditions. It is good practise to fill the fuel tank at the end of each day to minimise condensation.

Every 500 operating hours Change fuel filter Canister It is important that only the genuine Perkins fuel filter canister is used.

The use of a wrong canister can cause damage to the fuel injection pump.

1 Thoroughly clean the outside surfaces of the fuel filter assembly.

2 Loosen the drain device (A1) at the bottom of the filter and allow the water/fuel to drain into a suitable container.

3 Use a strap wrench or similar tool to loosen the filter canister and remove the canister.

4 Ensure that the threaded adaptor (B1) is secure in the filter head and that the inside of the head is clean.

Some of the fuel filter canisters fitted in the factory has a special sealant applied to the threads of the adaptor.

Filter canisters supplied in service have an inner seal assembly (B2) instead. The seal is held in position by a plastic clip. Damage to the fuel injection pump may occur if the canister seals are not fitted correctly.

5 Lubricate lightly the two top seals (B2) and (B3) of the new canister with clean fuel. Fit the new canister to the filter head and tighten, by hand only.

3.15

3.16

SERVICE

FUEL SYSTEM (continued) Bleeding the fuel system The fuel oil in the injection system is under high pressure and injector spray, in particular, can penetrate the skin and cause serious injury.

The fuel system on this vehicle is of a self venting type.

If the fuel filter canister has been changed, or if the engine has been stopped by air in the fuel system: Ensure that fuel has been added to the tank or that the leakage has been corrected; 1 Turn the ignition on and start the engine.

If the system or a component in the system has been drained - to avoid excessive battery drain: 1 Turn the start key to position ( I ), (ignition on).

2 Loosen vent plug (C1) and operate the lever of the fuel lift pump (5) slowly until fuel, free from air, flows from the vent plug (C1).

Close vent plug (C1).

If the drive cam of the fuel lift pump is at the point of maximum cam lift, it will not be possible to operate the priming lever.

In this situation, the crankshaft must be turned half a revolution.

3 Operate the starter motor until the engine starts.

4 If the engine runs correctly for a short time and then stops or runs roughly, check for air in the fuel system. If there is air in the fuel system, there is probably a leakage in the low pressure system.

5 Refer to the Perkins User's Handbook or Service manual to bleed the fuel injection system.

SERVICE

3.17

FUEL SYSTEM (continued) Diesel fuel is inflammable. Do not smoke while carrying out maintenance on the fuel system. Do not carry out maintenance to the fuel system near naked lights or sources of sparks, such as welding equipment.

Every 500 operating hours Change fuel filter element It is important that only the genuine Perkins fuel pre-filter element is used. The use of a wrong element can cause damage to the fuel injection pump.

Do not allow dirt to enter the fuel system.

Always clean the area around a fuel connection before you disconnect it.

Always cover open fuel connections.

1 Place a suitable container below the filter assembly to catch spilled fuel.

2 Thoroughly clean the outside surfaces of the fuel filter assembly.

3 Open the drain tap (2) at the bottom of the filter case to drain the fuel.

4 If necessary, use a strap wrench or similar tool to loosen the fuel case (1) and remove the filter case and element from the filter head (4).

5 Press down on the filter element (3) against the spring pressure and rotate the element (3) to the left. Remove and discard the filter element (3) and seal (6).

6 Make sure the inside of the filter case (1) and the inside of the filter head are clean (4).

7 Put a new filter element (3) into the filter case (1) and press it down against the spring pressure.

Turn the filter element (3) to the right to lock it into the filter case (1).

8 Lubricate lightly a new seal (6) and the seal contact surfaces with clean fuel. Fit the new new seal (6) on the filter case (1) .

9 Make sure the mounting thread (5) inside the filter element (3) is clean and not damaged.

10 Engage the filter case (1) to the filter head (4) and tighten, by hand only, until the filter assembly contacts the filter head (4). Hand tighten the filter case (1) a further 1/8th of a turn. Do not use a strap wrench.

11 Close the drain tap (2) and remove the fuel container.

12 Ensure there are no fuel leaks from the fuel filter assembly.

3.18

SERVICE

AIR CLEANER A restriction indicator and/or switch is mounted adjacent to the cleaner to provide a visual warning, on the cab instrument panel (page 1.9 item 8), of element condition.

The engine must not be operated when the warning light is illuminated, stop the engine immediately and clean or replace the filter element(s).

Every 10 operating hours, or daily, or as indicated via the warning light Check and clean the pre-cleaner if fitted (6) Where necessary, clean the pre-cleaner more than once a day. Ensure the area around the air-cleaner is clear of debris.

Unscrew wing nut, remove lid and glass bowl, clean with a lint-free cloth and reassemble.

Check and clean the outer element Remove end cover (2) by pulling yellow tag (1) and twisting cover to left. Pull cover away from housing (7) to replace elements.

Empty cover and vacuator valve (5) and clean with a lint-free cloth.

Check vacuator valve for damage and replace as necessary.

Remove the outer element (3) by pulling it towards you, clean the inside of the air cleaner housing with a lint-free cloth, take care not to disturb or damage the inner element (4).

To reassemble, reverse the operation.

Outer element cleaning A damaged element must never be reinstalled. The element must be replaced after it has been cleaned six times, cleaning degrades the filtration media. Engine damage can result if the element is not replaced.

A dirty or damaged element can cause loss of performance and engine damage. The element must be serviced as detailed in this section in order not to invalidate the warranty.

It is recommended that the outer element is replaced once a year irrespective of how many times it has been cleaned.

The inner element is not to be cleaned and must be replaced if damaged or dirty.

Remove loose dirt from element using compressed air, working from the clean to the dirty side. The air pressure is not to exceed 6 bar, and the nozzle should be 5 cm away from the element.

Mark element to record number of times cleaned.

Reassemble the air cleaner .

Every 500 operating hours If the restriction indicator warning light has not illuminated during this period it must be suspected that there is a leak in the system or the indicator has malfunctioned.

Check that the air cleaner casing and pipes are not damaged.

Check that all pipe connections are tight.

Check that the restrictor switch and warning light function correctly.

Remove and clean the pre-cleaner assembly.

Remove the outer element (3) and inner element (4) and discard.

Thoroughly clean inside the housing (7), cover (2) and vacuator (5). Check for damage and replace parts as necessary.

Replace inner and outer filter elements.

Reassemble the air cleaner.

Check the induction hose (8) is free from damage and that all connections are air tight.

SERVICE ENGINE Every 500 operating hours Check engine alternator belt tension Renew a belt if it is worn or damaged.

Check belt tension using a 'Fenner' or similar tension indicator. A force of 45N applied at the midcentre should result in a deflection of 10mm.

To adjust:- Loosen the pivot fasteners of the alternator (1) and the adjustment bar (2). Adjust alternator to give correct tension and tighten the fasteners.

Re-check belt tension.

New belts should be re-checked after the first 20 hours of use.

Engine idle speed Have your distributor check, and if necessary, adjust the idle speed (see engine manual).

It should be possible to lift an unladen boom with the engine at idle speed.

Every 1000 operating hours or yearly Valve tip clearances Have the valve tip clearances checked by your distributor.

Fuel injectors (Atomisers) Have the fuel injectors removed and tested by the workshop and replace after servicing.

Alternator brushes Have the alternator brush box cleaned and brushes renewed by an auto electrician. Always disconnect the battery earth connection before removing or replacing the alternator.

3.19

3.20

SERVICE

FAN DRIVE SYSTEM Initial 50 and every 500 operating hours Check fan drive belt tension Before attempting adjustments ensure that engine is off and isolation switch key is removed.

Note: On some Machines, access to the fan belt and adjustment mechanism is through the access panel, located on the front panel of the engine pod.

Renew the belt if worn or damaged.

Check belt tension using a 'Fenner' or similar tension indicator.

A force of 26N applied at the mid-centre should result in a deflection of 8mm.

Insufficient tension will result in loss of fan speed and inconsequence poor cooling performance.

Loosen motor fasteners (1) and back nut (2) adjust jacking screw (3). Tighten fasteners and back nut.

Re-check belt tension and readjust if necessary.

SERVICE

3.21

TRANMISSION AND TRANSFER BOX Every 10 operating hours, or daily Check transmission oil level Only check the oil level when the engine is running.

Park the machine on level ground and apply handbrake.

With the engine running at low idle speed, pull out dipstick (1) and wipe clean with rag, insert the dipstick fully and again remove it. The oil level should be at the full mark, and at no time should be allowed to drop below the minimum level mark.

The oil level should be topped up by inserting a funnel into the dipstick tube. For the correct grade of oil, (see "Machine Specifications").

Oil should be poured in small amounts ensuring the transmission is not over filled. Care should be exercised so that no oil is spilt or flows from the filler neck.

Check transfer box oil Check transfer box oil level with engine stopped.

Visually check oil level through the sight glass (2 ), the oil level should be at the midway position.

Remove plug (3 ) to top up.

Do not overfill. For the correct grade of oil, (see "Machine Specifications").

First initial 50 hours and Every 500 operating hours Check Propeller Shaft Fastenings Using a suitable torque wrench check the security of the tab washers (where fitted) and the tightness of the propshaft fastenings.

Propshaft 1 A 63 Nm B 40 Nm Propshaft 2 A 63 Nm B 40 Nm

Powershift

3.22

SERVICE

TRANSMISSION AND TRANSFER BOX (continued) Initial 100 and every 1000 operating hours Change transfer box oil Only change the oil with the machine on level ground with wheels chocked and battery isolation key removed.

Run the machine to warm the oil (65-93°) then switch off the engine.

Remove ignition and isolator switch keys.

Clean area surrounding sight glass (2), filler plug (3), and drain plug (4).

Position suitable container beneath drain plug.

Remove magnetic drain plug and filler plug, allow oil to drain for several minutes, before replacing drain plug.

Refill with clean oil of the correct quantity and grade.

For the correct quantity and grade of oil, (see "Machine Specifications").

Oil level should be at the midway position within the sight glass.

Do not over fill.

Powershift

Change transmission oil and filter Only change the oil with the machine on level ground with wheels chocked and battery isolation key removed.

Run the machine to warm the oil (65-93°) then switch off the engine.

Remove ignition and isolator switch keys.

Remove ‘Undertray doors’ (Where fitted) using the service tool provided.

SERVICE

3.23

TRANSMISSION AND TRANSFER BOX (continued) “Water To Oil” Cooler Note It is not necessary to drain this cooler type.

Proceed as above to drain and refill oil within the transmission, but DO NOT ATTEMPT TO DRAIN THE COOLER.

Check hoses During the oil change, carefully examine all the transmission hoses for cracks, cuts and damage.

Clean cores Clean radiator and oil cooler cores before securing oil cooler in working position.

Check level Run engine at low idle speed to prime convertor and lines.

Re-check level with engine running at low idle speed and add oil to bring to FULL mark.

Make final check when oil is hot 82-93°C, fill as necessary to FULL mark.

The oil level should be at the FULL mark, and at no time should be allowed to drop below the minimum level mark.

The oil level should be topped up by inserting a funnel into the dipstick tube.

Oil should be poured in small amounts ensuring the transmission is not over filled. Care should be exercised so that no oil is spilt or flows from the filler neck.

For the correct grade of oil, (see "Machine Specifications") Wipe doors and insulating material and reassemble.

Oil Cooler on the 99 hp Machine shown - 122 hp Machine similar.

3.24

SERVICE

AXLES Every 50 operating hours, or weekly Check: Front and rear axle case, and wheel hub oil levels Park the machine on level ground and leave the machine stationary for 2 minutes.

Clean the area surrounding the plugs before removal.

Fig. 1 Differential case ( Fig. 1) Note Two filler plugs are fitted to the axle. The differential case oil level can be checked using filler plug (1) on either side of the unit.

Remove plug (1) and check level.

The differential case oil levels is correct when it reaches the level of the filler plug hole (1).

If the oil level is low, top-up with clean oil of the correct type and grade (see "Machine Specifications").

Refit plug (1).

Wheel hubs ( Fig. 2)

Fig. 2

Check each hub individually.

Rotate the axle hub until the filler/level plug (3) is at the 3 o' clock position. Remove plug (3) and check level.

The wheel hub oil level is correct when it reaches the level of the filler plug hole.

If the oil level is low, top-up with clean oil of the correct type and grade (see "Machine Specifications") Refit plug (3).

Every 1000 operating hours

Fig. 3

Change: Front and rear axle case, and wheel hub oil Change differential case and wheel hub lubrication oil in the front and rear axles.

Clean area surrounding plugs before removal.

Before removing drain plugs, place a suitable container below the drain plug.

When removing drain plugs, be sure to stand on one side to avoid oil which will spill from the hole.

Rotate axle hubs until drain plugs are at the bottom (Fig 3).

Drain lubrication oils by removing the plugs (1 and 2) in the differential casing and filler/drain plugs (3) in the hubs.

Allow oil to fully drain before refitting drain plugs and refilling.

Refit drain plugs (2) and (3).

Refill using the same procedure as oil level check (as above), and refit all plugs.

SERVICE

3.25

HYDRAULICS ALWAYS practise the greatest cleanliness when servicing hydraulic components.

Dumping hydraulic pressure Always dump all hydraulic pressure from the system before servicing any hydraulic component.

Ensure there is sufficient space and headroom around the machine before operating any hydraulic control.

To dump pressure: Stop the engine.

With the ignition switch turned to (I), operate each hydraulic function in both directions several times.

An accumulator mounted at the rear of the chassis stores pressure to operate the control valve while dumping pressure.

Every 10 operating hours, or daily Check hydraulic in-line filter.

Always have the engine running at maximum rev/ min. when checking the filter blockage warning light (1). When the filter blockage warning light illuminates change the filter element IMMEDIATELY. When the warning light is illuminated NO filtration is taking place. Always change the filter IMMEDIATELY. NOTE When starting under cold conditions i.e. below 0°C, light may illuminate, allow machine to warm-up for a few minutes under 'light-load' conditions.

To change filter element Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. If hydraulic fluid penetrates your skin seek medical help immediately.

Before changing filter element, stop the engine close all rams and dump hydraulic pressure. Remove ignition and isolation switch keys.

Clean the outside of the filter and remove bowl by unscrewing it.

Discard old element.

Wash out bowl in solvent, and dry with an air hose.

Do not use a rag.

Lubricate the contact surfaces with clean hydraulic oil, fit new seals and new element Refit bowl and tighten securely.

3.26 HYDRAULICS (continued) Every 10 operating hours Check hydraulic oil level Do not check oil level before all rams are fully closed, and the engine has been stopped for 2 minutes.

Open engine pod cover and check level through sight gauge (3). Oil level must be visible, and above the red line.

Clean filler cap (1) and surrounding area before removing cap, top up with clean hydraulic oil (see machine specifications) if required.

Do not over fill.

Refit filler cap (1).

Every 50 operating hours Clean hydraulic tank breather Clean breather (4) and surrounding area. Unscrew the breather. Immerse the breather (4) in solvent.

Agitate the breather in the solvent to remove dirt.

Dry the breather (4), check and replace the O ring on the underside of the breather (4) if necessary and reassemble.

Every 500 operating hours Change in-line filter element (see "Every 10 operating hours, or daily")

SERVICE

SERVICE HYDRAULICS (continued) Every 1500 operating hours, or yearly Change hydraulic oil Run the engine and operate the hydraulics to warm the oil.

Ensure all rams are fully closed.

Switch off engine and dump hydraulic pressure.

Remove ignition and isolation switch keys.

Disconnect battery earth strap.

Clean the areas surrounding the drain plug (2), filler cap (1) and breather (4) before removal.

Before removing drain plug, ensure a suitable container is placed on the ground to catch oil. When removing drain plug, be sure to stand on one side to avoid oil which will spill from the hole. Dispose of waste oil in a safe manner.

Drain the tank by removing filler cap (1) and drain plug (2), positioned under hydraulic tank closest to the machine chassis.

Flush out the tank with clean hydraulic oil taking extreme care to remove all dirt and foreign matter.

Refit drain plug (2).

Change the in-line filter element, (see "Every 10 operating hours, or daily").

Clean the filler cap (1) and breather (4) by immersing in solvent and agitating to remove the dirt.

Dry both, check and replace seals if necessary and reassemble.

Refill the hydraulic tank with clean hydraulic oil of the correct type and grade. The oil level must be visible, within the sight gauge (3) and above the red line.

Do not over fill.

For the correct type and grade of oil, (see "Machine Specifications") Reconnect the battery earth strap and run the engine to circulate the oil. Operate the hydraulic controls to purge any air.

Close all rams, switch off engine and allow to stand for two minutes, check oil level (3) and top up if necessary.

Do not over fill.

3.27

3.28

SERVICE

BATTERY The battery compartment is located within the cab pod. To open, use service tool to release catch (1) and slide battery tray outwards. (The tray cannot be fully removed).

The battery contains a sulphuric acid electrolyte which can cause severe burns and produce explosive gases.

Avoid contact with the skin, eyes and clothing. If spilled onto the skin, flush immediately with cold water. If splashed into the eyes, flush immediately with cold water for 15 minutes and get prompt medical attention. Do not take internally. If accidentally swallowed, drink large quantities of water or milk, followed by milk of magnesia, beaten eggs or vegetable oil. Call a doctor immediately.

Do not use a naked flame to check the electrolyte level. Keep sparks and flames away from the battery.

Do not produce sparks with cable clamps when charging the battery or starting the engine with a slave battery.

Always disconnect battery leads before carrying out any maintenance to the electrical system.

Battery removal If the battery is to be removed from the machine, ensure the following procedure is used.

Switch the engine OFF. Remove isolation switch key located within engine pod.

Remove the start key from the cab.

Ensure all electrical circuits are switched OFF. Disconnect the earth (-) lead from the battery before removing the positive (+) lead.

Lift the battery from the machine.

When installing the battery, the positive (+) lead must be connected first.

Every 50 operating hours, or weekly Check battery electrolyte level Wear protective goggles and impervious gloves for this operation.

Ensure that the electrical connections are clean and tight, and coat the terminals with petroleum jelly to protect them from corrosion.

Remove battery filler plugs (1) and check that the electrolyte level is between 6 - 9 mm (0.25 - 0.37 in) above the tops of the separators.

Some batteries have translucent cases; the electrolyte level in these should be between the 'Min' and 'Max' marks.

If necessary, top-up with distilled water.

Where batteries have 'trough' fillers, add distilled water to the filling trough until the trough just begins to fill with water.

In cold weather, distilled water should only be added immediately before starting the engine.

Replace battery filler plugs (1) and tighten securely.

SERVICE AUTOHITCH Auto-hitch maintenance is simple but essential, both for occasional or constant usage.

Never allow mud and debris to accumulate on or around the auto-hitch.

Every 20 operating hours Lubricate the locking catch pivot (1) on both sides of the hitch, and release cable and clevis (2).

Check that the return springs (3) are secure.

ROCKINGER HITCH Rockinger hitch maintenance is simple but essential, both for occasional or constant usage.

Never allow mud and debris to accumulate on or around the hitch.

Hitch mechanism is spring loaded.

Keep hands clear of hitch jaws when vertical pin (1) is in the raised position.

Every 20 operating hours Ensure operating lever (2) is horizontal and vertical pin (1) is fully down as shown before applying grease to nipple (3) and lightly oil adjacent spring mechanism.

WINDSCREEN WASHER BOTTLE The washer bottle compartment is located within the cab pod. To open use service tool provided to release catch (1) and remove plate.

Use good quality washer fluid, dilute according to suppliers instructions.

3.29

3.30

SERVICE

CAB AND ENGINE COMPARTMENT Cab KEEP CLEAN! Cleaning the cab both externally and internally will aid visibility and driver comfort.

Exterior - Conventional steam cleaners may be used, taking care to avoid water ingress to cab air intake.

Interior should be regularly brush cleaned. Wipe facia panels etc., with a damp cloth. Do not attempt to clean cab interior with steam or water.

Keep the ventilation/heater air intake louvre (A) free of material ingress.

Change cab air intake filter by removing plate (B) and pulling out element (C).

Frequency will depend on operating conditions but replace at least every 500 hours.

Heater The heater assembly is located behind the driver’s seat, underneath the rear trim panel.

In the event of failure refer to Service manual.

Air Conditioning. Optional The unit must be serviced by personnel, specifically trained in servicing air-conditioning units containing refrigerant gases.

In the event of failure refer to Service manual.

Engine compartment KEEP CLEAN! Do not attempt to clean engine and surrounding areas when engine is hot.

Keep engine and ancillary equipment free of oil and dirt contamination.

Do not attempt to clean by high pressure steam or water.

Every 10 operating hours or daily Check that all noise reduction panels are secure and free of damage

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TECHNICAL INFORMATION

4.1

MACHINE SPECIFICATIONS Engine(s) 99 hp

Type Firing order Cubic capacity

Direct injection 4 cylinder diesel 1-3-4-2 242 in3, 3990cc

Power output

75 Kw, @ 2200 rev/min.

Max. Peak Torque 403 Nm, (297 lbf/ft) @ 1400 rev/min.

122 hp

Cubic capacity

268 in3, 4400cc

Power output

90.5 Kw, @ 2200 rev/min.

Max. Peak Torque 500 Nm, (369 lbf/ft) @ 1400 rev/min.

Cooling

Type Thermostat

Liquid, by gear driven pump and pressurised radiator.

Opens at 70°C to 80°C Fully open at 90°C to 95°C

Electrics

System Battery Starter Alternator

12 volt negative earth 128 ampere hours Pre-engaged, heavy duty 75 Kw, 65 amp output 90.5 Kw, 85 amp output Integral with alternator

Regulator Fuel system

Injection pump Lift pump Air cleaner Fuel filter

Rotary Mechanical, diaphragm or Electronic fuel pump with pre-filter.

Dry dual element with electrical blockage warning light.

Renewable element Chassis mounted Pre-filter with water drain (where fitted)

Brakes

Service

Hydraulically activated Inboard oil immersed discs on front and rear axle, acting through four wheel drive.

Spring applied, fail safe.

Parking Front axle

Double reduction by bevel set and planetary hub reduction gears, and parking brake. Limited slip differential.

Rear axle

Double reduction by bevel set and planetary hub reduction gears.

Transmission Standard Hydraulic

Filtration

Powershift with integral torque converter, giving instant selection of forward and reverse gears.

Main circuit. Load sensing pump. 122 I/min @ 2300 rev/min.

Tank with suction vent Auxiliary circuit. Gear pump. 50 I/min @ 2300 rev/min.

Continuous operation through auxiliary circuit, low pressure filter with electric "Blockage indicator" and renewable element.

Speed

40 km/h (25mph) with 445R x 24 tyres

Tyres (Primary options)

15.5/80-24 400/74 R24 17.5 LR24 19.5 LR24

Boom

Firestone Goodyeat - Ind Michelin Michelin

2 stage telescopic, of rectangular hollow construction with nonmetallic wear strips, carriage vertical self levelling, and quick-release attachments.

4.2

TECHNICAL INFORMATION

MACHINE SPECIFICATIONS Machine weight TYPE

K 50 K 60

K 70

6963 KG 7605 KG 7800 KG

NOTE The average weights listed above are for standard specification machines. Weights for individual machine specification may differ.

ADJUSTMENTS Idling speed

940 - 970 rev/min

Maximum no load speed 75 KW Engine

2390 rev/min

90.5 KW Engine Valve tappet clearances, cold or hot

inlet exhaust

2320 rev/min 0.20mm (0.008 in)

Fan belt free play midway between pulleys

0.46mm (0.018 in) 10 mm (3/8 in)

Wheel nut tightening torque

300 Nm (220 lbf ft)

LUBRICANTS AND FLUID SPECIFICATIONS APPLICATION Diesel engine oil

EXAMPLE FLUIDS

INT. SPECIFICATION

-20°C to 50°C

CAT MultiGrade DEO SAE 10W40

API CG SAE 10W 40

-40°C to 10°C

CAT MultiGrade DEO SAE 0W20

API CG SAE 0W20

Transmission

CAT HYDO SAE 10W

SAE 10W

Transfer box

Geartex LS85W-90

CMC GL5

Axles

CAT TDTO SAE 10W

Antifreeze and summer coolant

CAT Extended Life Coolant

Hydraulic system

CAT HYDO SAE 10 W

SAE 10W

General grease

Multifak All Purpose Grease

MP/L2

Transmission and Transfer box

4.2

TECHNICAL INFORMATION

MACHINE SPECIFICATIONS Machine weight TYPE

K 50 K 60 K 70

6963 KG 7605 KG 7800 KG

NOTE The average weights listed above are for standard specification machines. Weights for individual machine specification may differ.

ADJUSTMENTS Idling speed

940 - 970 rev/min

Maximum no load speed 75 KW Engine

2390 rev/min

90.5 KW Engine Valve tappet clearances, cold or hot

inlet exhaust

2320 rev/min 0.20mm (0.008 in)

Fan belt free play midway between pulleys

0.46mm (0.018 in) 10 mm (3/8 in)

Wheel nut tightening torque

300 Nm (220 lbf ft)

LUBRICANTS AND FLUID SPECIFICATIONS APPLICATION Diesel engine oil

EXAMPLE FLUIDS

INT. SPECIFICATION

-20°C to 50°C

CAT MultiGrade DEO SAE 10W40

API CG SAE 10W 40

-40°C to 10°C

CAT MultiGrade DEO SAE 0W20

API CG SAE 0W20

Transmission

CAT HYDO SAE 10W

SAE 10W

Transfer box

Geartex LS85W-90

CMC GL5

Axles

CAT TDTO SAE 10W

Antifreeze and summer coolant

CAT Extended Life Coolant

Hydraulic system

CAT HYDO SAE 10 W

SAE 10W

General grease

Multifak All Purpose Grease

MP/L2

Transmission and Transfer box

TECHNICAL INFORMATION

4.3

MACHINE SPECIFICATIONS

CAPACITIES - FLUID US Gals

UK Gals

Litres

Engine

Oil

2.37

1.98

9.00

Transmission 4WD cooler

Oil

4.22

3.5

16

Transmission - Transfer box

Oil

0.12

0.1

0.4

Front

Oil

2.51

2.09

9.50

Rear

Oil

2.64

2.20

10.00

Final Drive (ea)

Oil

0.21

0.18

0.80

Hydraulic system

Tank capacity

17.40

14.30

65.00

Fuel oil

Tank capacity

53.00

44.00

200.00

Cooling system

Total capacity

8.22

6.85

31.00

1.72

1.43

6.50

Axles -

Screen washer

PRESSURES Radiator cap Hydraulic system

Main relief valve

Tyres: (primary options)

bar

lb/in2

0.68

10.0

250

3625

FRONT

REAR

2

bar

lb/in2

3.5

51

3.0

43.5

bar

lb/in

400/74 R24

(Goodyear - Ind)

15.5/80 X 24

(Firestone)

3.75

55

3.0

43.5

17.5 LR24

(Michelin)

3.5

51

3.0

43.5

19.5 LR24

(Michelin)

3.5

51

3.0

43.5

4.4

TECHNICAL INFORMATION

DIMENSIONS - machines fitted with standard tyres A

Overall width over bodywork

mm 2235

B

Track

1875

C

Width over tyres

D

Overall height

2395

E

Inside width of cab

900

F

Wheel base

2800

G

Overall length (to front of tyres)

4015

H

Overall length (to front of Kwiki carriage)

4730

I

Ground clearance

450

J

Outside turning radius

3475

(15.5 TYRES) (15.5 TYRES)

2300

TECHNICAL INFORMATION

4.5

FUSE BOX

Fuses

F17 7.5 Amp - Right hand dip beam

F1

7.5 Amp - Rear wiper

F18 7.5 Amp - Left hand dip beam

F2

7.5 Amp - Working lights

F19 10 Amp - Hazard warning light

F3

10 Amp - Road switch

F20 10 Amp - Transmission controls

F4

10 Amp - Direction indicators/Radio

F21 10 Amp - Interior light/Beacon/Din socket

F5

25 Amp - Heater

F6

5 Amp - Hydraulic controls

F22 15 Amp - Steering column multifunction switch

F7

3 Amp - Safe load indicator

F23 10 Amp - Headlight flash

F8

10 Amp - Rear fog lights

F24 7.5 Amp - Instrument panel

F9

15 Amp - Rear working lights

Relays

F10 10 Amp - Front working lights

R1

Boom working lights

F11 10 Amp - Engine run/Fuel sender/ Brake low pressure lights

R2

Ignition

R3

Direction indicators

F12 10 Amps - Stop lights/Steering sensor/ Transmission dump light

R4

Transmission dump

F13 5 Amp - Right hand side light

R5

Front working lights

F14 5 Amp - Left hand side light

R6

Rear working lights

F15 7.5 Amp - Right hand main beam

R7

Side working lights

F16 7.5 Amp - Left hand main beam

R8

Headlights

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Following the policy of CLAAS to improve its products with continual technical development, CLAAS reserves the right to make alterations which may not necessarily correspond to the text and illustrations contained in this publication, and without incurring obligation to alter any machines previously produced or delivered.

Technical data, dimensions and weights are given as an indication only. Responsibility for errors or omissions is not accepted.

Reproduction or translation of this publication, in whole or part, is not permitted without the written consent of Caterpillar.

All rights under the provision of the Copyright Act are reserved.

Claas No. 319560.6 Caterpillar No. 2133881 10/2003