New Holland B110 B115 TIER 3 Backhoe Loader Operator's Manual 87534321 - PDF DOWNLOAD

OPERATOR’S MANUAL BACKHOE LOADER

B110 B115 TIER 3

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Bur • Issued 03-2007 Printed in U.S.A. • Book/Form Number 87534321 NA Copyright © 2007. CNH America, LLC. All Rights Reserved.

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer.

REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

03-2007

B110, B115 TIER 3

87534321 NA

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY. Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: · DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury.

The color associated with Danger is RED. · WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

The color associated with Warning is ORANGE. · CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: · The first panel indicates the nature of the hazard. · The second panel indicates the appropriate avoidance of the hazard. · Background color is YELLOW · Prohibition symbols such as and STOP if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: · Is instructed in safe and proper use of the machine. · Reads and understands the Manual(s) pertaining to the machine. · Reads and understands ALL Safety Decals on the machine. · Clears the area of other persons. · Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow instructions on machine operation and maintenance.

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine.

Contact your Dealer for assistance in obtaining the manuals for your machine. Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and maintenance records.

Always give the Machine Name, Model, and P. I.N. (Product Identification Number) or S. N. (Serial Number) of your machine so your Dealer can provide the correct manuals for your machine.

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America LLC. Carol Stream, IL 60188 U.S.A.

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

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

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TABLE OF CONTENTS

SECTION 1 - TO THE OWNER .................................................................................................................. 1-1 B110 AND B115 LOADER BACKHOES ................................................................................................. 1-1 RIGHT, LEFT, FRONT AND REAR OF THE MACHINE ......................................................................... 1-4 SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS .................................................. 2-1 TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE .................................. 2-1 IDENTIFICATION OF MAIN COMPONENTS ......................................................................................... 2-4 SECTION 3 - SAFETY/DECALS/HANDS SIGNALS .................................................................................. 3-1 DECALS .................................................................................................................................................. 3-7 HAND SIGNALS ................................................................................................................................... 3-14 SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES .................................................................... 4-1 CAB DOORS ........................................................................................................................................... 4-1 STEPS AND ACCESS HANDLES .......................................................................................................... 4-1 FRONT INSTRUMENT PANEL ............................................................................................................... 4-2 SIDE MOUNTED INSTRUMENT PANEL ............................................................................................... 4-4 PERFORMANCE FUNCTIONALITY AND SWITCHES .......................................................................... 4-6 MAINTENANCE PROGRAM (SERVICE ................................................................................................. 4-7 SETUP MENU ......................................................................................................................................... 4-8 SIDE INSTRUMENT ............................................................................................................................... 4-9 OPERATOR’S COMPARTMENT CONTROLS ..................................................................................... 4-11 OPERATOR’S SEAT ............................................................................................................................ 4-36 LOADER ATTACHMENT CONTROLS ................................................................................................. 4-39 BACKHOE ATTACHMENT MECHANICAL CONTROLS VERSION .................................................... 4-42 BACKHOE ATTACHMENT HYDRAULIC CONTROLS ........................................................................ 4-52 HEATING (optional) AND AIR CONDITIONING (optional) CONTROLS .............................................. 4-59 CAB AIR FILTER .................................................................................................................................. 4-62 BRAKE FLUID RESERVOIR ................................................................................................................ 4-62 OPERATOR’S COMPARTMENT WINDOWS ....................................................................................... 4-63 LOADER ATTACHMENT SAFETY STRUT (B110) .............................................................................. 4-64 LOADER ATTACHMENT SAFETY STRUT (B115) .............................................................................. 4-66 FUEL TANK .......................................................................................................................................... 4-67 HYDRAULIC RESERVOIR ................................................................................................................... 4-67 BATTERY AND TOOL BOX .................................................................................................................. 4-68 REAR VIEW MIRRORS (if fitted) .......................................................................................................... 4-68 ENGINE SIDE GUARDS ....................................................................................................................... 4-68 HEATER CONTROL VALVE ................................................................................................................ 4-69 LOADER BUCKET MECHANICAL QUICK COUPLER (if fitted) ........................................................... 4-70 ROTATING BEACON (optional) ........................................................................................................... 4-70 ATTACHMENT SAFETY VALVES (optional) ........................................................................................ 4-71 REVERSIBLE STABILIZER PADS (optional) ....................................................................................... 4-71

TABLE OF CONTENTS

STABILIZERS SAFETY VALVES (If fitted) ........................................................................................... 4-71 BACKHOE BUCKET MECHANICAL QUICK COUPLER (optional) ...................................................... 4-72 SECTION 5 - OPERATING INSTRUCTIONS ............................................................................................. 5-1 BEFORE OPERATING THE MACHINE .................................................................................................. 5-1 OPERATING THE MACHINE .................................................................................................................. 5-2 RUNNING-IN PERIOD ............................................................................................................................ 5-3 STARTING THE ENGINE ....................................................................................................................... 5-4 STARTING THE ENGINE IN COLD WEATHER WITH AN AIR INTAKE HEATER (GRID HEATER) (optional) ................................................................................................................. 5-5 STOPPING THE ENGINE ....................................................................................................................... 5-6 OPERATING THE MACHINE IN COLD WEATHER ............................................................................... 5-7 OPERATING THE MACHINE IN HOT WEATHER ................................................................................. 5-7 SETTING THE BACKHOE ATTACHMENT IN WORKING POSITION ................................................... 5-8 LOCKING OR UNLOCKING THE BACKHOE ATTACHMENT ............................................................. 5-10 SETTING THE BACKHOE ATTACHMENT IN THE ROAD TRAVEL POSITION ................................. 5-12 ON ROAD TRAVEL REQUIREMENTS ................................................................................................. 5-13 REPLACING A BACKHOE BUCKET .................................................................................................... 5-14 REPLACING A LOADER BUCKET (B110) ........................................................................................... 5-15 REPLACING A LOADER BUCKET (B115) ........................................................................................... 5-16 DIFFERENTIAL LOCK .......................................................................................................................... 5-18 LOADER BUCKET WITH FORKS (optional) ......................................................................................... 5-20 BACKHOE ATTACHMENT AUXILIARY HYDRAULIC TOOLS (optional) ............................................. 5-25 HAND-HELD AUXILIARY HYDRAULIC TOOLS (optional) ................................................................... 5-26 2 OR 4 WHEEL DRIVE ......................................................................................................................... 5-27 LIFTING AND CRANING LOADS WITH THE LOADER ATTACHMENT .............................................. 5-28 MAXIMUM LIFTING LOADS USING BUCKET MOUNTED FORKS (if fitted) ....................................... 5-29 TRANSPORTING THE MACHINE ........................................................................................................ 5-30 LIFTING THE MACHINE ....................................................................................................................... 5-31 TOWING THE MACHINE ...................................................................................................................... 5-32 OPERATING THE MACHINE IN WATER ............................................................................................. 5-34 PARKING THE MACHINE ..................................................................................................................... 5-34 SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS .............................................................................. 6-1 INSTRUCTIONS FOR USE ..................................................................................................................... 6-1 ROAD TRAVEL ....................................................................................................................................... 6-2 JOB SITE TRAVEL .................................................................................................................................. 6-6 LOADER ATTACHMENT OPERATING INSTRUCTIONS ...................................................................... 6-8 BACKHOE ATTACHMENT OPERATING INSTRUCTIONS ................................................................. 6-13 BALLASTING AND TIRES .................................................................................................................... 6-19 SECTION 7 - SERVICING INTERVALS ...................................................................................................... 7-1 SERVICING INSTRUCTIONS ................................................................................................................. 7-1

TABLE OF CONTENTS

HOURMETER ......................................................................................................................................... 7-2 INTERVALS ............................................................................................................................................ 7-3 SECTION 8 - LUBRICATION/FILTERS/FLUIDS ........................................................................................ 8-1 FLUIDS AND LUBRICANTS ................................................................................................................... 8-1 FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS .......................................................... 8-2 GREASE POINTS ................................................................................................................................... 8-3 LEVELS ................................................................................................................................................... 8-9 ENGINE ................................................................................................................................................ 8-12 COOLING SYSTEM .............................................................................................................................. 8-15 FUEL SYSTEM ..................................................................................................................................... 8-17 RELEASING THE PRESSURE IN THE HYDRAULIC SYSTEM .......................................................... 8-22 HYDRAULIC SYSTEM .......................................................................................................................... 8-23 AIR FILTER ........................................................................................................................................... 8-28 TRANSMISSION (POWERSHUTTLE) .................................................................................................. 8-32 TRANSMISSION (POWERSHIFT) ........................................................................................................ 8-35 FRONT DRIVE AXLE AND REDUCTION GEARS ............................................................................... 8-38 REAR AXLE AND REDUCTION GEARS .............................................................................................. 8-41 SECTION 9 - MAINTENANCE/ADJUSTMENTS ........................................................................................ 9-1 WHEELS AND TIRES ............................................................................................................................. 9-1 LOADER BUCKET MECHANICAL/HYDRAULIC SELF LEVELLING/RETURN TO DIG ADJUSTMENT .................................................................................................................................... 9-3 RADIATOR AND AIR CONDITIONING CONDENSER (if fitted) ............................................................. 9-6 ENGINE ALTERNATOR AND FAN BELT ............................................................................................... 9-7 TURBOCHARGER .................................................................................................................................. 9-8 ENGINE ROCKER ARM CLEARANCE ADJUSTMENT ......................................................................... 9-9 MACHINE INSPECTION AND CLEANING ............................................................................................. 9-9 CYLINDER LEAK INSPECTION ........................................................................................................... 9-10 AIR CONDITIONING (optional) ............................................................................................................. 9-10 DRAINING THE TELESCOPIC DIPPER (HED) (if fitted) ..................................................................... 9-11 CAB FILTER ......................................................................................................................................... 9-12 HEATER UNIT AND AIR CONDITIONING COOLER (optional) ........................................................... 9-13 PARKING BRAKE ADJUSTMENT ........................................................................................................ 9-13 BRAKE FLUID ....................................................................................................................................... 9-14 BACKHOE BUCKET EXCAVATION ANGLE ........................................................................................ 9-15 TELESCOPIC DIPPER (HED) (optional) .............................................................................................. 9-15 FRONT WHEEL ADJUSTMENTS ......................................................................................................... 9-16 WHEEL ADJUSTMENTS (4WS) ........................................................................................................... 9-17 ROPS/FOPS CAB (or protective frame) ................................................................................................ 9-18 TROUBLESHOOTING .......................................................................................................................... 9-20

TABLE OF CONTENTS

SECTION 10 - ELECTRICAL SYSTEM .................................................................................................... 10-1 FUSES AND RELAYS ........................................................................................................................... 10-1 BATTERY .............................................................................................................................................. 10-7 CONNECTING A BOOSTER BATTERY ............................................................................................. 10-10 ALTERNATOR .................................................................................................................................... 10-11 STARTER MOTOR ............................................................................................................................. 10-11 BULBS ................................................................................................................................................. 10-12 REPLACING A BULB .......................................................................................................................... 10-12 SECTION 11 - STORAGE ......................................................................................................................... 11-1 SECTION 12 - SPECIFICATIONS ............................................................................................................. 12-1 ENGINE - 110 HP / 82 KW (B110 - B115 MODELS) ............................................................................ 12-1 COOLING SYSTEM .............................................................................................................................. 12-1 FUEL SYSTEM ...................................................................................................................................... 12-1 TRANSMISSION (B110 MODELS) ....................................................................................................... 12-1 TRANSMISSION (B115 MODELS) ....................................................................................................... 12-1 ELECTRICAL SYSTEM ......................................................................................................................... 12-2 BRAKES ................................................................................................................................................ 12-2 STEERING ............................................................................................................................................ 12-2 REAR AXLE .......................................................................................................................................... 12-2 HYDRAULIC SYSTEM .......................................................................................................................... 12-2 FRONT COUNTERWEIGHT ................................................................................................................. 12-2 RADIATOR COOLANTS ....................................................................................................................... 12-2 FRONT WHEEL TIRE PRESSURES AND PERMISSIBLE LOADS (B110) ......................................... 12-3 FOUR WHEEL DRIVE TIRE COMBINATIONS ..................................................................................... 12-3 REAR WHEEL TIRE PRESSURES AND PERMISSIBLE LOADS (B110) ............................................ 12-4 FRONT AND REAR WHEEL TIRE PRESSURES AND PERMISSIBLE LOADS (B115) ...................... 12-4 ROAD SPEEDS ..................................................................................................................................... 12-5 MODEL B110 LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE .................................. 12-6 MODEL B115 LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE .................................. 12-8 MODEL B110 BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE ............................. 12-10 MODEL B115 BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE ............................. 12-12 MODEL B110 LIFTING CAPACITIES ................................................................................................. 12-14 MODEL B115 LIFTING CAPACITIES ................................................................................................. 12-15 SECTION 13 - FORMS AND DECLARATIONS ....................................................................................... 13-1 INITIAL 50-HOUR SERVICE - CHECK AND ADJUST AS REQUIRED .............................................. 13-11

SECTION 1

4

TO THE OWNER B110 AND B115 LOADER BACKHOES

1 Dealer’s Stamp

1-1

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

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

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

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

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

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

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

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

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

1-2

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

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

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

FIRST 50 HOURS SERVICE After you have operated the machine for 50 hours, take your machine, together with this Manual, to your Dealer. He will then perform the factory recommended 50 hour service operations and complete the service report sheets at Section 13.

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

Ensure that you and the Dealer sign both copies.

NOTE: There may be a dealer charge for this service.

2

1-3

SECTION 1 - TO THE OWNER RIGHT, LEFT, FRONT AND REAR OF THE MACHINE The terms “right”, “left”, “front” and “rear”, when used in this manual, indicate the sides of the machine as seen from the operator’s seat.

OPERATOR AND SEAT ATTACHMENT POSITION 1.

2.

3.

4.

IN

LOADER

FRONT REAR RIGHT-HAND SIDE LEFT-HAND SIDE

3 OPERATOR AND SEAT ATTACHMENT POSITION 1.

2.

3.

4.

IN

BACKHOE

FRONT REAR RIGHT-HAND SIDE LEFT-HAND SIDE

4

1-4

SECTION 2

4

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

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

MACHINE Type.........................................................................

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

Year of manufacture ................................................

TM

Type/Model

Product Identification Number (PIN) Bar Code

1 ENGINE Type.........................................................................

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

2

2-1

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS FRONT AXLE Axle type ..................................................................

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

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

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

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

4 TRANSMISSION - 4x2 POWERSHIFT Model number ..........................................................

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

5 REAR AXLE - 2WS Axle type ..................................................................

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

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

6 2-2

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS REAR AXLE - 4WS Axle type..................................................................

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

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

7 CAB Serial number ..........................................................

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

8 PROTECTIVE FRAME (ROPS) Serial number.................................................................

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

9

2-3

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS IDENTIFICATION OF MAIN COMPONENTS

10

11 1.

2.

3.

4.

5.

6.

7.

2-4

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

8.

9.

10.

11.

12.

13.

14.

Backhoe boom Backhoe dipper or telescopic dipper (HED) Backhoe bucket Stabilizers Battery box Hydraulic reservoir Swing cylinder

SECTION 3

18

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

4.

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

5.

Make sure the doors and the engine side guards are correctly fastened before undertaking any travel.

6.

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

7.

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

8.

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

9.

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

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

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

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

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

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

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

BEFORE USING THE MACHINE ON ROAD AND JOB SITE 1.

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

2.

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

3.

Remove anything which might hinder visibility.

Clean the windshield, windows and rear view mirrors.

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

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

12. Make sure that you fully understand the significance of the safety decals on the machine.

Make sure that they are always clean and perfectly legible.

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

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

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

3-1

SECTION 3 - SAFETY/DECALS/HAND SIGNALS ROAD OPERATION

OPERATING THE MACHINE

1.

ON ROAD AND JOB SITE

(4WS) Before undertaking any road travel, select the 2 wheel steer position and install the flip over cover to lock the switch in that position.

1.

Do not allow anyone to climb onto the machine.

A passenger can fall or cause an accident.

2.

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

2.

3.

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

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

3.

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

4.

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

5.

Stop the engine and remove the ignition switch even for stops of short duration.

6.

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

7.

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

8.

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

9.

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

4.

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

ON THE JOB SITE 1.

2.

3.

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

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

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

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

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

4.

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

5.

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

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

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

Inspect and note all possible risks before driving the machine into a new working area.

Holes, obstacles, debris and other hazards in the working area can cause serious physical injury.

1.

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

2.

(4WS) Before undertaking any road travel, select the 2 wheel steer position and install the flip over cover to lock the switch in that position.

6.

3-2

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

ROAD OPERATION

SECTION 3 - SAFETY/DECALS/HAND SIGNALS ON THE JOB SITE 1.

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

2.

Avoid running the engine in an enclosed space.

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

3.

Do not work close to live overhead electric lines without first making sure that the minimum distances are observed: 5 meters (16 ft 5 in).

4.

5.

6.

7.

8.

9.

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

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

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

When moving the machine onto a trailer, place the gear change lever in first gear. Keep the loader bucket 20 cm (7.8 in) from the ground.

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

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

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

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

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

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

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

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

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

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

6. Raise the stabilizers completely and immobilize them mechanically.

7. Stop the engine and remove the ignition switch.

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

9. Make sure that the doors and the engine side guards are correctly fastened and lock the operator’s compartment doors.

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

3-3

SECTION 3 - SAFETY/DECALS/HAND SIGNALS MAINTENANCE AND ADJUSTMENTS 1.

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

2.

Wear suitable clothing when servicing the machine.

3.

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

4.

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

5.

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

6.

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

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

3. Stop the engine and remove the ignition switch.

4. Raise the parking brake lever.

5. Block the wheels to prevent any machine movement.

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

7.

3-4

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

8.

Do not carry out any welding operation on the machine without prior authorization from your Dealer.

9.

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

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

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

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

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

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

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

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

16. The machine’s structure is in conformity with the “FOPS” and “ROPS” protection standards.

Any modification (drilling, welding, etc.) may cause that conformity to be invalidated.

SECTION 3 - SAFETY/DECALS/HAND SIGNALS PREVENTION OF FIRE OR EXPLOSIONS 1.

Engine fuel can cause an explosion or a fire.

- Never re-fuel when the engine is running.

- Do not smoke during re-fuelling.

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

2.

Use a non-inflammable product for cleaning parts.

3.

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

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

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

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

4.

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

5.

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

6.

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

7.

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

8.

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

PREVENTION OF BURNS 1.

Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid any contact with the skin, eyes or clothing.

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

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

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

2.

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

3.

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

4.

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

Then remove the cap.

5.

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

3-5

SECTION 3 - SAFETY/DECALS/HAND SIGNALS ROPS/FOPS CAB (or protective frame)

GLIDE RIDE SYSTEM (optional)

1.

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

1.

2.

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

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

2.

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

3.

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

3.

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

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

4.

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

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

5.

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

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

3-6

SECTION 3 - SAFETY/DECALS/HAND SIGNALS DECALS

!

WARNING

!

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

!

WARNING

!

Make sure that all decals are perfectly legible.

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

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

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

READ OPERATOR’S MANUAL Decals which display the “Read Operators Manual” symbol are intended to direct the operator to the Operators Manual for further information regarding safety, maintenance, adjustments and/or procedures for specific areas of the machine. When a decal displays the following symbol refer to the Operator’s Manual.

1 READ SERVICE MANUAL When a decal displays the symbol shown below, refer to the appropriate page of the Service Manual.

2

3-7

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

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

3

3-8

SECTION 3 - SAFETY/DECALS/HAND SIGNALS

4

3-9

SECTION 3 - SAFETY/DECALS/HAND SIGNALS DECAL ILLUSTRATIONS Safety belt This decal reminds to wear your safety belt at all times to avoid all risk of being ejected in the event of the machine turning over.

5 Emergency stopping and parking brake This decal indicates the activation of parking brake.

6 Safety instructions This decal warns of possible misuse hazards during machine operation.

7 Brake oil This decal indicates the operator should check the brake oil level and that the operator should consult the Operator’s Manual for oil specification and fill volume.

8

3-10

SECTION 3 - SAFETY/DECALS/HAND SIGNALS Steering system (B115) This decal warns about the modes to perform that steering change.

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

10 Slinging points This decal shows the slinging points to be used when securing the machine for transport.

11 Danger of being burnt This decal warns that the radiator should never be touched nor should the coolant reservoir cap be removed while the cooling system is still hot. Wait for the system to cool down before starting any operation.

12 Battery This decal reminds you it is necessary to see “Battery” in Section 10.

13

3-11

SECTION 3 - SAFETY/DECALS/HAND SIGNALS Engine This decal warns that certain components in the engine compartment can trap your hand or cut you.

Before removing the engine side guards, shut down the engine, remove the starter switch key and consult the manual.

14 Hydraulic reservoir Make sure that you only fill a reservoir bearing this symbol with hydraulic fluid. See “Fluids and lubricants” in Section 8.

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

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

17 Starting the engine This decal warns that it is forbidden to start the engine by any other means than with the ignition switch.

18

3-12

SECTION 3 - SAFETY/DECALS/HAND SIGNALS Backhoe attachment precautions This decal warns of machine movement hazard during backhoe operation.

19 Backhoe attachment load lifting precautions This decal warns of the possibility of loss of machine control during lifting operations.

20 Stabilisers This decal warns not to stay near the stabilisators that while lowering could be dangerous.

21

3-13

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

MOVE AWAY FROM ME

START THE ENGINE

Wave hands forward and backward (palms out).

22 STOP THE ENGINE

25 GO THIS FAR

23 COME TO ME

26 ALL STOP AND HOLD

Wave hands forward and backward (palms in).

24

3-14

27

SECTION 3 - SAFETY/DECALS/HAND SIGNALS STOP

LOWER LOAD OR BUCKET

Wave one hand back and forth.

31 28

RAISE LOAD OR BUCKET SLOWLY

EMERGENCY STOP Wave both hands back and forth.

32 LOWER LOAD OR BUCKET SLOWLY 29 RAISE LOAD OR BUCKET

33 30

3-15

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

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

37 RAISE BACKHOE BOOM 34 TURN MACHINE RIGHT To stop movement, stop moving hand and clench fist.

38 LOWER BACKHOE BOOM

35 ROLL BACK LOADER BUCKET

39

36

3-16

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

BACKHOE BUCKET DUMP

40

43 RETRACT TELESCOPIC DIPPER (HED) (if fitted)

41

44 EXTEND TELESCOPIC DIPPER (HED) (if fitted)

42

45

BACKHOE DIPPER OUT

BACKHOE BUCKET DIG

3-17

SECTION 3 - SAFETY/DECALS/HAND SIGNALS

NOTES

3-18

SECTION 4

72

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

Lift the latch to open the right-hand and left-hand doors from the inside.

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

!

WARNING

!

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

1

NOTE: To lock the doors, use the ignition switch.

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

!

WARNING

!

Never use the steering wheel or the control levers to help yourself entering or leaving the operator’s compartment.

!

WARNING

!

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

!

WARNING

!

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

4-1

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FRONT INSTRUMENT PANEL

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

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

3. SIDE LIGHTS AND LOW BEAM LAMP This lamp comes on when the side lights or low beam are activated.

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

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

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

7. “CRAB” (4WS) STEER INDICATOR LAMP This lamp comes on when crab steer mode is selected and phased. See “Phasing procedure” in Section 5.

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

Consult your Dealer.

4-2

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 8. SPEEDOMETER (optional) The speedometer shows travel speed in kilometers per hour (kmh) and miles per hour (mph).

9. DIFFERENTIAL LOCK SWITCH (Powershift transmission) This switch is used to lock or unlock the differential. See “Locking the differential” in Section 5.

10. ROTATING BEACON SWITCH This switch is used to turn the rotating beacon on or off (if fitted).

11. LIGHT SWITCH The switch has three positions: - the first position is OFF; - the second position powers the gauge cluster, the parking lights, the low beams indicator lamp (3); - the third position enables the main beams, powers the low beams and main beams indicator lamp (4).

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

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

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

14. 2/4 WHEEL DRIVE SWITCH This switch is used to engage or disengage four wheel drive.

The switch has three positions: - First position (by pushing button on the right ): rear wheel drive with braking only on rear wheels (lamp off).

- Second position (by pushing button on the left ): four wheels drive with braking on four wheels (lamp on).

- Third position (by pushing a second time button on the left ): rear wheels drive and braking on four wheels.

See “2WD and 4WD” in Section 5.

NOTE: When the four wheel drive switch is in the “OFF” position and both brake pedals are operated together the four wheel drive, will automatically be engaged (above 3 Km/h - 1.864 mph) to give four wheel drive braking and disengage with brake pedals released.

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

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

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

4-3

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

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

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

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

2. HYDRAULIC SPEED CONTROL SWITCH (If fitted) See “Hydraulic speed control” in Section 5 for use during operation.

3. SWITCH FOR PILOT LOADER (Optional)

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

Do not use this system during the digging and loading operations with the front loader.

!

WARNING

!

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

4-4

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 5. LOADER ATTACHMENT LOCKING SWITCH (Optional) When operated, this switch is for preventing any movement of the loader attachment during travel.

6. SIDE INSTRUMENT (See side instrument) 7. UP/DOWN SWITCH By means of this control you can scroll the option of menu or data shown by the display of the diagnostics.

8. MENU ENTER SWITCH By means of this control you can visualize and confirm the options of menu show on the display.

9. REAR WINDSHIELD WIPER AND WASHER SWITCH The wiper is activated when the switch is depressed and will remain in function until the switch is returned to the “OFF” position.

The washer is operated by further depressing and holding switch. When the switch is released the wash will stop and return to the wipe position.

10. BACKHOE ATTACHMENT LOCKING SWITCH (Optional) The switch is used to lock or unlock the backhoe attachment locking plate in preparation for road travel. See “Locking or unlocking the backhoe attachment” in Section 5.

11. BACKHOE ATTACHMENT SIDESHIFT CARRIAGE LOCKING AND UNLOCKING SWITCH (sideshift backhoe version) This switch has 2 positions: The switch is used to lock or unlock the backhoe attachment sideshift carriage to allow lateral shifting. For sideshifting, see “Backhoe attachment sideshift” in Section 5.

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

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

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

NOTE: Never use the working lights during road travel.

4-5

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES PERFORMANCE FUNCTIONALITY AND SWITCHES Switches provided for Operator/ Service input: Z UP/DOWN SWITCH Use this UP/DOWN switch to scroll through the menus.

NOTE: Push the UP arrow at start up to display engine rpms on the digital display.

Z DISPLAY ENTER SWITCH Use this switch to select between display and service menus or enter selections.

The Diamond icon, or top portion of the switch, is used to select displays.

The 90 Degree Arrow icon, or bottom portion of the switch, is used to enter selected choices.

Using the display switches, you will be able to scroll through the following: - battery voltage; - backhoe loader hours; - setup.

Features adjustable in setup: 1. Backlighting dimming control 2. Maintenance/Service interval customization 3. Stored error codes 4. Grid heater presence - select/deselect whether the grid heater option is installed.

5. Low temperature idle speed setting - when the engine coolant temperature is below 10 °C (50 °F), the vehicle controller will change from a normal low idle to a low temperature idle which can be adjusted from 975 to 1500 rpm. The default setting is 1000 rpm.

6. High idle speed setting (2500 rpm maximun).

4-6

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES MAINTENANCE PROGRAM (SERVICE) Two different kinds of maintenance will be available: - light maintenance; - heavy maintenance.

LIGHT MAINTENANCE The hours shown will be the hours when light maintenance is required, not the standard hour counter.

HEAVY MAINTENANCE The hours shown will be the hours when heavy maintenance is required, not the standard hour counter.

HEAVY 1000

In Amber backlighting

LIGHT 500

In Amber backlighting The interval can be set between 50 and 500 hours in steps of 50 (0.0, 50, 100, 150, 200, 250, 300, 350, 400, 450, 500). The 0.0 setting turns the light maintenance feature off.

The interval can be set between 50 and 500 hours in steps of 100 (0.0, 500, 600, 700, 800, 900, 1000).

The 0.0 setting turns the heavy maintenance feature off.

DISPLAY FUNCTIONALITY When the hourmeter reaches the light service interval

MAIN SCREEN

3 seconds LIGHT

3 seconds

500

GREEN

AMBER

Audible alarm for 1 second when displaying either service interval the first time

When the hourmeter reaches the heavy service interval

MAIN SCREEN

3 seconds HEAVY

3 seconds

1000

GREEN

AMBER

4-7

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SETUP MENU

Enter to make the number flash then it can be adjusted

Dimmer

Increment Decrement Enter to make the number stop flashing Increment Decrement Service interval Increment Decrement Page#/total page CODE OCCURRENCE HOUR

Stored error code

3 second scroll unless up/down pressed Presence of grid heater

Select/Deselect

Enter to make the number flash then it can be adjusted

Idle and maximum engine speed

Increment Decrement Enter to make the number stop flashing

Hardware part number

Software part number

4-8

HARDWARE P/N ID VER

HARDWARE P/N ID VER

Enter to make the number flash then it can be adjusted Increment Decrement Enter to make the number stop flashing

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SIDE INSTRUMENT

4 1. CAUTION MASTER LAMP This lamp signals a not critical caution.

When this caution is “active”, it is necessary to change the operating mode, plan a down time to carry out maintenance or, if the fault continues, consult your dealer.

This lamp lights up at the same time of lamps (2), (4), (6), (7) and (10).

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

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

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

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

See “Air filter” in Section 8.

3. STOP MASTER LAMP The stop master lamp signals a critical caution.

When this lamp lights up, stop the machine immediately and shut off the engine.

If this is not the case, the machine can get damaged or accidents may occur.

4-9

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 7. TRANSMISSION OIL PRESSURE WARNING LAMP This lamp lights up and the audible alarm sounds when the transmission oil pressure is too low. If the lamp comes on when the machine is working, move the machine to a place of safety, stop the engine, remove the starter switch key and find the cause of the problem.

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

9. GRID HEATER INDICATOR LAMP (If fitted) This lamp lights up while the engine is being pre-heated.

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

NOTE: When the starter switch key is in the “ON” all lamps light up and the instrument buzzer sounds for 5 seconds. Afterward the lamps light off and only lamp (2) remain alight. The gauges (11) and (12) set to position.

11. FUEL LEVEL GAUGE This gauge shows the quantity of fuel in the fuel tank.

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

4-10

13. DIAGNOSTICS DISPLAY By means of this display it is possible to visualize the various data of diagnostics. The service hours performed are indicated steadily.

14. ENGINE REVOLUTIONS COUNTER The revolutions counter shows the engine speed in revolutions per minute.

The figures indicated must be multiplied by 100.

Each intermediate mark shows a value of 100 rpm.

We recommend not to reach the red field.

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

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

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

!

WARNING

!

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

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

Key position: Position (1): Not used.

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

NOTE: In On position (3) the audible alarm sounds.

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

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

5

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

!

WARNING

!

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

!

WARNING

6

!

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

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

4-11

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES DIRECTION INDICATOR, HEADLIGHT MAIN BEAM AND FRONT WINDSHIELD WIPER AND WASHER SWITCH Located on the right of the steering wheel, this lever has five positions: Position (0): Neutral.

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

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

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

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

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

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

9

4-12

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

10 1.

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

2.

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

3.

LOADER ATTACHMENT CONTROL LEVER

4.

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

5.

TRANSMISSION SHUTTLE DIRECTION LEVER: Movement of this lever from the neutral position will engage forward or rearward travel.

NOTE: In reverse gear an audible alarm device sounds.

6.

WARNING HORN BUTTON

7.

TRANSMISSION DISCONNECT BUTTON (on the loader attachment control lever)

8.

ROLLER FOR THE PROPORTIONAL CONTROL OF LOADER BUCKET 4X1

4-13

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

A device for “transmission disconnect” is activated by pushing button (2), placed on the gear shift lever (1) or by pushing button (5), placed on the loader control lever (3).

11

!

WARNING

!

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

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

12

4-14

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

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

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

13

IMPORTANT: When operating in low ambient temperatures with cold transmission oil, allow the oil to warm up before attempting to shift the shuttle lever.

The transmission can be shifted normally after the oil warms up.

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

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

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

Transmission Disconnect The 4 x 4 transmission provides for easy upward and downward gear ratio changes on the move.

However, as a clutch is not used between the engine and transmission, the power flow from the engine to the transmission must be interrupted to shift from one gear ratio to another. This is accomplished by using a transmission disconnect (dump) button.

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

!

WARNING

!

14

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

4-15

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES To make upward gear ratio changes simply depress and hold the button (2) on the gearshift lever (1), while moving the lever from one gear ratio to another. When the desired gear ratio has been selected release the button and allow the unit to gain engine speed and ground speed. If another higher ratio is required repeat the procedure.

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

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

To make downward gear ratio changes or reduce ground speed, simply lower the engine speed, depress and hold the gearshift lever button and downshift the transmission.

15

When the desired gear ratio has been selected release the button and adjust the engine speed to suit ground speed required.

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

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

IMPORTANT: Operating at a “stall” for more than 20 seconds can cause the transmission to overheat and can possibly damage the transmission. If the transmission overheats, the needle (1) reaches the red field. Shift both the power reversing and gearshift levers to neutral. Let the engine run idle (1000 rpm) until transmission oil cools down enough to have the needle (1) return to correct position. Once the needle is returned to its position, all operations can be resumed.

16

4-16

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES DIFFERENTIAL LOCK PEDAL In conditions inducing wheel slip, hold down the differential lock pedal with your heel until the lock is felt to engage. The lock will automatically disengage when traction at the rear wheels equalises. If a rear wheel spins at speed, reduce the engine speed to idle before engaging the differential lock to minimise shock loads on the rear axle. See “Differential lock” in Section 5.

!

WARNING

!

Never use the differential lock at speeds above 8 km/h (5 mph) or when turning the machine. When engaged the lock will prevent the machine turning and personal injury could result.

17

4-17

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

18 1.

TRANSMISSION POWERSHIFT GEAR CHANGE AND DIRECTION LEVER: Four gears are selectable for the required ground speed in forward and 2 two gears for reverse travel.

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

2.

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

3.

WARNING HORN BUTTON

4.

LOADER ATTACHMENT CONTROL LEVER

4-18

5.

TRANSMISSION DISCONNECT BUTTON

6.

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

7.

ROLLER FOR THE PROPORTIONAL CONTROL OF LOADER BUCKET 4X1

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

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

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

19 4-19

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

20 4-20

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

and also indicate the selected shift lever gear.

3

21

STEADY ILLUMINATED LED: Indicates selected transmission gear.

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

LEDs - Numbered 1 through 8: Used during test modes

1

2

3

4

5

6

7

8

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

1

2

3

4

5

6

7

8

LED - Letter T = Self-diagnostic Mode:

T

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

22

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

LED - Letter N Indicates Neutral:

N

Illuminates when the transmission is shifted to neutral.

4-21

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Powershift Lever and Microprocessor Functions The microprocessor controls the transmission and self checks its own memory continuously to ensure that gear selection and range changes are always performed in a safe manner.

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

23 Reset Mode: When the microprocessor defaults to reset mode both the T and N LED’s are displayed simultaneously to indicate that a reset has taken place.

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

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

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

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

T - LED Flashing

N - LED ON

24

CONDITION Last fault currently shown on display

Flashing

Flashes Slower

Input error detected

Flashing

Flashes in Phase

Non critical output error detected

Flashing

Flashes Faster

Safety critical output error detected

4-22

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

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

Leaving Neutral

25

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

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

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

The microprocessor is programmed to be an automatic speed based shift system In addition whether forward actually engages at that time, depends on the status of the machine, for example if on the move, road speed and direction will be considered before any shift changes take place.

26

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

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

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

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

27

4-23

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Up Shifting Up shifting to a desired gear from neutral is achieved by twisting the handgrip counter clockwise (+) in single movements.

If held in this position the processor will advance the shift selection from 2 through to 4 in 1.8 sec intervals.

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

28

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

Down Shifting

!

WARNING

!

If descending down a steep incline select 2nd and proceed, upshifting only when safe to do so. You can not downshift to reduce speed if the machine speed is above 15 km/h (9.321 mph).

Downshifting to the desired gear is achieved by twisting the handgrip clockwise (-) in single movements.

If held in this position the processor will decrease the shift from 4, if the shift lever was in this gear, through to 1 in 1.5 sec intervals.

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

4-24

29

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

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

F1 - R1

F2 - R2

R1 - F1

R2 - F2

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

RESPONSE 1: If the machine speed in forward is above 15 km/h (9.321 mph) and reverse is selected downshift engages but momentum forward remains, until the speed drops sufficiently to allow downshift to take place when reverse is achieved in 2nd gear.

RESPONSE 2: If the machine speed in forward is less than 15 km/h (9.321 mph) reverse takes place immediately into 2nd gear.

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

31

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

4-25

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

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

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

32

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

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

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

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

4-26

33

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

Disconnect is available in 1st and 2nd gear.

NOTE: Transmission disconnect is selectable, when the machine speed is less than 5 km/h (3.107 mph) and by depressing the button on the loader lever and remains active until the pedals or switch are released.

34

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

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

Shown in the chart opposite with an 18.4 X 26 R4 tire fitted is the approximate (within 10%) maximum speed available and at which speed an automatic shift takes place in each gear. (...) = Automatic upshift speed [...] = Automatic downshift speed

35

As can be seen when down shifting from 4th gear at maximum speed 39.5 km/h (24.544 mph) the microprocessor will not allow the down shift to take place until the speed has dropped to approximately 19.9 km/h (12.365 mph). Refer to the chart for complete upshift and downshift speed change details.

NOTE: In some countries the road speed of 40 km/h (24.855 mph) is not allowed. In these circumstances the transmission is governed to a maximum of 30 km/h (18.641 mph) and the shift speed range reduces accordingly.

4-27

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES DIFFERENTIAL LOCK (electric)

!

WARNING

!

Never use the differential lock at speeds above 8 km/h (5 mph) or when turning the machine. When engaged the lock will prevent the machine turning and personal injury could result.

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

36

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

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

ADJUSTABLE STEERING COLUMN (optional) The angle of the steering column can be varied through an approximate range of 10 - 20 degrees.

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

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

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

4-28

37

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES STEER MODE SWITCH (4WS) Located on the console under the steering wheel, this switch has a locking cover and is used to select “Road”, “4 wheel steer” or “Crab steer”. See “4 wheel steer phasing” in Section 5.

This switch has 3 positions: 1st position = “Road” 2cnd position = “4 wheel steer” 3rd position = “Crab steer” IMPORTANT: Before undertaking any road travel, select “Road” mode and fold back the cover to lock the switch in this position.

38

OPERATOR’S COMPARTMENT AND MAP READING LIGHT This light is mounted on the roof. Opening the door, the ceiling light turns on. To switch off the light when the door is opened press “OFF”; to turn on the light with the door closed press “ON”.

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

40

4-29

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES WARNING HORN BUTTON To sound the warning horn button press the button: - (1) on the transmission control lever (only for Powershuttle models); - (2) on the loader control lever (only for Powershift models); - (3) on the backhoe attachment mechanical control lever (only for mechanical models); - (4) on the left hand backhoe attachment hydraulic control lever (only for pilot models).

41

42 ENGINE ACCELERATOR PEDAL Located under the steering wheel, this pedal enables the engine speed to be increased or decreased.

Maximum speed: press the pedal fully down.

Idle speed: release the pedal.

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

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

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

4-30

43

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES BRAKE PEDALS Located under the steering wheel, these two pedals are equipped with a system which enables them to be locked together or unlocked. This enables the machine either to be braked (pedals locked) by pressing either of the pedals or to be turned (pedals unlocked) to the right by pressing on the right-hand pedal or to the left by pressing on the left-hand pedal. Braking with one pedal only should only be carried out at low speed.

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

!

WARNING

44

!

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

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

ENGINE ACCELERATOR HANDLE This handle enables the engine speed to be increased or decreased.

Turn to U to increase the speed.

Turn to T to decrease the speed.

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

45

4-31

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES PARKING BRAKE LEVER Located on the right of the operator’s seat (with the seat in the loader attachment position), this lever enables the machine to be immobilized.

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

IMPORTANT: If the gear is being engaged when the parking brake is activated, will actuate the warning buzzer and the symbol “parking brake alarm” will appear on the display.

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

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

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

!

WARNING

!

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

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

4-32

46

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

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

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

47

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

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

49

4-33

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

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

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

51 FUSES AND RELAYS CONTROL UNIT This fuses and relays control unit is under side instrument panel and may be accessed via the righthand cab door. See “Fuses and relays” in Section 10.

Diagnostic socket On the left side of fuses and relays controller is installed the diagnostic socket. By means of this socket it is possible, getting connected with a computer, to have access to the engine data and to detect possible faults.

52

4-34

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES BATTERY MASTER SWITCH The battery master switch is located into battery compartment and is used to disconnect the electrical system completely from the battery.

When the master switch has un inclination of 45°, the circuit is disconnected.

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

!

WARNING

!

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

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

53

4-35

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

!

WARNING

!

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

SEATS (VINYL AND DE LUXE MODEL) Armrest angle adjustment Raise the armrest, turn the knob (1) to obtain the desired armrest position and then lower the armrest.

Cushion tilt adjustment To adjust the cushion tilt angle, turn the knob (2) clockwise or counterclockwise, to increase or reduce the angle.

Seat belt To attach the seat belt (3), insert the buckle in the socket (8).

To release the belt, press the button on the socket.

!

WARNING

!

Always fasten your seat belt before starting the engine. The machine is equipped with a roll over protection system (ROPS) which ensures your safety. The seat belt will protect you efficiently if you attach it correctly and if you always wear it.

The seat belt must not be too loose. It must not be twisted or caught in the seat.

!

WARNING

!

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

4-36

54

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Seat back angle adjustment To adjust the seat back angle, hold the lever (4) rearward, move the seat back to obtain the desired position and then release the lever.

Pivoting Release the seat using lever (5) and swing it round.

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

Combined height and weight adjustment Adjustment may be made to suit the operator’s size.

Turn the control (6) to obtain the desired height.

Forward and rear adjustment Hold the lever (7) in raised position, slide the seat until the desired position is reached and then release the lever.

Seat height adjustment The seat height can be adjusted to three detent positions. To raise the seat, pull lever (7) upwards and lift the seat to the required position. To lower the seat, pull the seat upwards to allow the detent to disengage and the seat to return to the lowest position.

4-37

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SEAT (DE LUXE MODEL, air version) Armrest angle adjustment Raise the armrest, turn the knob (1) to obtain the desired armrest position and then lower the armrest.

Cushion tilt adjustment To adjust the cushion tilt angle, turn the knob (2) clockwise or counterclockwise, to increase or reduce the angle.

Lumbar support adjustment Turn the knob (9) to obtain good back support from the seat back.

Seat belt To attach the seat belt (3), insert the buckle in the socket (8).

To release the belt, press the button on the socket.

!

WARNING

!

Always fasten your seat belt before starting the engine. The machine is equipped with a roll over protection system (ROPS) which ensures your safety. The seat belt will protect you efficiently if you attach it correctly and if you always wear it.

The seat belt must not be too loose. It must not be twisted or caught in the seat.

!

WARNING

!

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

Seat back angle adjustment To adjust the seat back angle, hold the lever (4) rearward, move the seat back to obtain the desired position and then release the lever.

Pivoting Release the seat using lever (5) and swing it round.

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

Combined height and weight adjustment Lower the lever (11) to reduce the rigidity of the suspension. Raise the lever to increase the rigidity of the suspension. The indicator (10) shows the result.

Forward and rear adjustment Hold the lever (7) in raised position, slide the seat until the desired position is reached and then release the lever.

4-38

55

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LOADER ATTACHMENT CONTROLS

!

WARNING

!

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

!

WARNING

!

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

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

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

LOADER CONTROLS, NEUTRAL AND HOLD

56

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

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

57

4-39

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

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

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

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

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

61 4-40

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

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

62 4 IN 1 LOADER BUCKET CLAM CONTROL (if fitted) This control operates the opening and closing of the 4 in 1 loader bucket clam.

This control is proportional: When releasing the roller (7), this returns automatically in the initial position (neutral) and the loader bucket remains positioned in the place where the motion has ceased.

It is possible to lock the roller into detent by moving the roller to the full forward (raised) position. To release the detent, press on the lower portion of the roller as your return it to the neutral position.

63

When shifting the roller (7) forward: the loader bucket clam closes (A).

When shifting the control (7) backward: the loader bucket clam opens (B).

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

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

64

4-41

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES BACKHOE ATTACHMENT MECHANICAL CONTROLS VERSION IMPORTANT: Before using the backhoe attachment, make sure that the lock hook has been disengaged, either by means of the lever (1) or the switch (2).

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

!

WARNING

!

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

!

WARNING

65

!

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

!

WARNING

!

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

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66

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES STABILIZER MECHANICAL CONTROLS IMPORTANT: Whenever the backhoe attachment is used the machine must be resting on the stabilizers.

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

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

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

RIGHT-HAND STABILIZER RIGHT-HAND CONTROL LEVER

67

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

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

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

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

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

IMPORTANT: During road travel, the stabilizers must be completely raised and immobilized by means of the pins provided for that purpose. See “Road travel” in Section 6.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES STANDARD CONFIGURATION

68 4-44

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

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

IMPORTANT: Four backhoe attachment control configurations exist: - Standard configuration.

- ISO configuration.

- Four levers pattern configuration.

- Cross-pattern configuration.

The operating pattern of the control levers is different.

Check which configuration you have on your machine.

!

WARNING

!

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

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

Position (A): The backhoe boom lowers.

Position (B): The backhoe boom rises.

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

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

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

Position (E): The backhoe dipper extends.

Position (F): The backhoe dipper retracts.

Position (G): The backhoe bucket closes.

Position (H): The backhoe bucket opens.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES ISO CONFIGURATION

69 4-46

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

Position (A): The backhoe dipper extends.

Position (B): The backhoe dipper retracts.

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

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

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

Position (E): The backhoe boom lowers.

Position (F): The backhoe boom rises.

Position (G): The backhoe bucket closes.

Position (H): The backhoe bucket opens.

4-47

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES BACKHOE CONTROL LEVER SHIFT PATTERN, FOUR LEVER PATTERN

70 Lever 1: Position (A): push the lever forward - dipstick crowds in.

Position (B): push the lever back - dipstick crowds out.

Lever 2: Position (C): push the lever forward - boom lifts.

Position (D): push the lever back - boom lowers.

4-48

Lever 3: Position (E): push the lever forward - bucket curls in.

Position (F): push the lever back - bucket curls out.

Lever 4: Position (G): push the lever forward - boom swings right.

Position (H): push the lever back - boom swings left.

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

71 4-49

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

Position (A): The backhoe boom lowers.

Position (B): The backhoe boom rises.

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

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

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

Position (E): The backhoe dipper extends.

Position (F): The backhoe dipper retracts.

Position (G): The backhoe bucket closes.

Position (H): The backhoe bucket opens.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES TELESCOPIC DIPPER (HED) MECHANICAL CONTROL PEDAL (if fitted) This pedal has three positions: Position (0): Neutral. This position enables the movement of the telescopic dipper (HED) to be stopped.

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

Position (1): The telescopic dipper (HED) extends.

Position (2): The telescopic dipper (HED) retracts.

Before using this pedal make sure that the telescopic dipper (HED) is mechanically unlocked. See “Setting the backhoe attachment in the working position” in the “Operating Instructions” Section 5.

72

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

AUXILIARY TOOL CONTROL PEDAL (optional) This pedal is located to the right of the backhoe attachment controls and is used for operating auxiliary tools, such as a hydraulic hammer. See “Backhoe attachment auxiliary hydraulic tools” in Section 5.

73

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

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

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

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

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

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

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

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6. TELESCOPIC DIPPER (HED) CONTROLS: (proportional controls) (if fitted).

Press the right-hand button to extend the dipper.

Press the left-hand button to retract the dipper.

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

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

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

10. AUXILIARY BI-DIRECTIONAL CONTROL (if fitted).

11. ONE TOUCH DECEL: By pressing this button the engine rpm sets to idle run. During this phase the accelerator handle and pedal are disabled.

By pressing again the button the engine rpm are restored and the accelerator handle and accelerator pedal as well.

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES IMPORTANT: Before using the backhoe attachment, make sure that the lock hook has been disengaged, either by means of the lever (1) or the switch (2).

!

WARNING

!

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

!

WARNING

!

75

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

!

WARNING

!

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

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

IMPORTANT: Two backhoe attachment control configurations exist: - Standard pattern or ISO pattern (to change, use the control pattern change switch).

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

Check which configuration you have on your machine.

!

WARNING

76

!

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

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES CONTROL CANCELLATION SWITCH This control is located on the right-hand control arm.

The switch has three positions: - position 1: by pressing the lower side (lamp off) all controls will disactivate; - position 2: by pressing the upper side (lamp on) stabilizators will activate; - position 3: by pressing again the upper side (lamp off) all controls will activate.

!

WARNING

!

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

77

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

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

Position (A): The backhoe boom lowers.

Position (B): The backhoe boom rises.

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

78

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

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

Position (E): The backhoe dipper extends.

Position (F): The backhoe dipper retracts.

Position (G): The backhoe bucket closes.

Position (H): The backhoe bucket opens.

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79

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

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

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

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

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

80

Position (3): See “Auto-Up feature”.

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

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

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

81

Position (3): See “Auto-Up feature”.

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES AUTO-UP FEATURE (optional) Position (3): When the levers are pulled back momentarily to this position and then released, they return to neutral position and the stabilizers automatically rise to road travel position, thereby leaving your hand free for other duties. To cancel the AutoUp action, push the levers up or down.

NOTE: If the Auto-Up feature is not installed on the machines the detents position is still present but it will not affect the stabilizer function.

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

82

IMPORTANT: During road travel, the stabilizers must be completely raised and immobilized by means of the pins provided for that purpose. See “Road travel” in Section 6.

CONTROL PATTERN CHANGE SWITCH (BOOM/DIPPER) Located on the right-hand control arm, this switch is fitted with a locking device.

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

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

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

Press the bottom of the switch (1) to lock and return to standard pattern operation.

83

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES TELESCOPIC DIPPER (HED) CONTROLS (if fitted) Press and hold down the right-hand button (1) to extend the telescopic dipper (HED). As soon as the button is released the dipper stops and remains in the position it occupied when the button was released.

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

By pressing button (3), it is possible to set the engine rpm to idle run disabling accelerator handle and accelerator pedal. By pressing again button (3) the engine rpm are restored and the accelerator handle and accelerator pedal as well.

84

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

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

CONTROL ARM FORE/AFT ADJUSTMENTS Hold and squeeze the two handles together and then tilt the control arms to the required position.

Release the handles.

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

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

86

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

87

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

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

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

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

Position (3): High.

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

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

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

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

90

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

!

WARNING

!

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

HFC 134a has a boiling point of -12 °C (10.4 °F).

Never expose any part of the air conditioning system to flames or excessive heat because of the risk of fire or explosions and the production of phosgene gas.

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

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

Warm the exposed area of skin with your hand or lukewarm water 32 °C (89.6 °F), cover loosely with a bandage to protect against infection and consult a doctor immediately.

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

91

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

To activate the air conditioning turn selector (2). At the activation the warning light (4) lights up on side instrument. The selector (1) allows to choose the ideal temperature according to your requirement.

Positioning selector (1) on “0” and turning selector (2) let you obtain less or more cold according to the selector (2) position. By positioning selector (1) on any other position different from “0” you will obtain instead a mixture of warm and cold air and the desired climate inside of the cabin.

92 NOTE: The air conditioning can be set into operation, only if the ventilation selector (3) is not positioned on STOP. Turn selector (3) on demand for air capacity.

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

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

93 4-60

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

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

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

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

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

94

Air recirculation

95

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

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

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

96

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

Clean this element with compressed air, working from the clean side towards the outside. The air pressure must not exceed 2 bar (29 psi) and the nozzle must be held at least 300 mm (12 in) from the element. See “Cab air filter” in Section 9.

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

97

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

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

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

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

4-62

98

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

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

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

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

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

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

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

101

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

IMPORTANT: Make sure the window is completely locked.

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

Lock the window with the locks (1).

102

LOADER ATTACHMENT SAFETY STRUT (B110) Located on the left-hand side of the loader attachment, this safety strut enables the loader attachment to be locked in the raised position in case of defects in the system.

LOCKED POSITION 1.

Raise the loader attachment completely, stop the engine and remove the ignition switch.

2.

Remove the retaining pin and split pin.

3.

Place the strut on the cylinder rod and install the pin and split pin in the holes in the strut.

103

!

WARNING

!

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

104

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES UNLOCKED POSITION 1.

Remove the retaining pin and split pin.

2.

Remove the strut from the lift arm and install the pin and split pin in the holes in the strut and the retaining lug.

3.

Start the engine and lower the loader attachment.

105

106

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LOADER ATTACHMENT SAFETY STRUT (B115) Located on the left-hand side of the loader attachment, this safety strut enables the loader attachment to be locked in the raised position in case of defects in the system.

LOCKED POSITION 1.

Raise the loader attachment completely, stop the engine and remove the ignition switch.

2.

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

3.

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

107

!

WARNING

!

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

108 UNLOCKED POSITION 1.

Remove the tang and the strut from the cylinder rod.

109

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 2.

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

3.

Start the engine and lower the loader attachment.

110

FUEL TANK Located on the left-hand side of the machine, the tank capacity is 135 liters (35.6 Us gal).

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

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

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

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

!

WARNING

111

!

Never refill the tank when the engine is running.

Do not smoke during re-fuelling.

HYDRAULIC RESERVOIR Located on the right-hand side of the machine, the capacity of the reservoir is 75 liters (19.8 Us gal).

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

NOTE: Clean around the filler cap before refilling.

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

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

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

112

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES BATTERY AND TOOL BOX Located on the right-hand side of the machine, this box houses the battery and can be used for storing service tools.

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

113

REAR VIEW MIRRORS (if fitted) Make sure the right-hand and left-hand rear view mirrors are correctly adjusted before undertaking any travel.

ENGINE SIDE GUARDS

114

These guards give access to the engine components. To open, turn the hand grip and swing the guard out and away.

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

!

WARNING

!

Before undertaking any road travel, make sure the guards are properly locked.

115

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SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES HEATER CONTROL VALVE Located on the right-hand side of the engine, this valve enables the heater system to be turned on or off. See “Heater, ventilation and air conditioning (optional) controls”.

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

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

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

116

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

QUICK REMOVAL AND INSTALLATION OF THE LOADER BUCKET 1.

Make sure the bucket to be installed is in a safe area, on flat, level ground and with the upper pins in place.

2.

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

3.

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

4.

Shut down the engine and remove the ignition switch.

5.

Install the pins (4) and retaining hardware.

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

117

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

IMPORTANT: The rotating beacon must be installed and functioning when undertaking road travel. See “Road travel” in Section 6.

118

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

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

Consult your Dealer.

120

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

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

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

121

STABILIZERS SAFETY VALVES (If fitted) They are installed on each stabilizer cylinder and have the aim to prevent the stabilizers lowering in case of hose or piping break.

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

!

WARNING

!

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

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

1.

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

2.

Make sure the tool linkage pin is in maximum force (3) position.

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

3.

Make sure the quick coupler jaw is open.

4.

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

5.

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

6.

Shut down the engine and remove the ignition switch.

7.

Install the quick coupler safety pin.

!

WARNING

!

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

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

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122

SECTION 5

34

OPERATING INSTRUCTIONS BEFORE OPERATING THE MACHINE

!

WARNING

!

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

Before operating the machine, observe the following instructions: 1.

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

2.

Carry out the daily maintenance operations.

See Section 7.

3.

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

4.

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

5.

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

6.

Check the condition and pressure of the tires.

See “Wheels and tires” in Section 9.

7.

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

8.

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

9.

Make sure that the engine side guards are closed and latched correctly.

11. Remove anything which might hinder visibility.

Clean the windshield windows and rear view mirrors.

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

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

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

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

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

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

5-1

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE

!

WARNING

!

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

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

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

When operating the machine the following instructions must be observed:

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

1.

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

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

2.

Regularly consult the hourmeter on the display of side instrument to ensure Servicing Intervals are observed. See Section 7.

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

3.

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

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

4.

If this machine is new. See “Running-in period”.

5.

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

6.

Do not work near overhead high-voltage electrical cables without checking beforehand that all necessary measures have been taken to respect the minimum distances: 5 meters (16 ft 5 in).

7.

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

8.

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

9.

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

5-2

16. Avoid running the engine in an enclosed space.

If necessary, ensure good ventilation under all circumstances.

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

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

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

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

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

During this period: Keep a close watch on the instrument panel.

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

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

Maintain the engine at the normal operating temperature.

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

During the running-in period, the following inspections and maintenance operations must be carried out in addition to the operations shown in the Maintenance Program: Every ten hours or daily Check the engine oil and coolant levels.

Check the transmission and rear axle oil levels.

Check the front axle oil level (4WD).

Check the backhoe and loader attachment lubrication.

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

See “Wheels and tires” in Section 9.

After the first 50 operating hours After the first 50 operating hours, consult your Dealer for the 50 hour servicing operations recommended by the manufacturer. The service report forms must be completed. See Section 13.

5-3

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

NOTE: In very cold starting conditions, the engine controller will limit the engine speed to a maximum of 1200 rpm to prevent damage to the engine.

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

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

1.

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

2.

Adjust the seat and attach the seat belt.

3.

Check that the parking brake lever (2) is in raised position.

4.

Check the engine accelerator handle is in low idle position.

5.

Check that the direction of travel lever (3) is in the neutral position.

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

6.

Check that the gear change lever (4) is in the neutral position (Powershuttle).

7.

Turn the ignition switch to the “ON” position. All lamps light up and the instrument buzzer sound for 5 seconds. Afterward the lamps light off and only lamp (5) remain alight. The gauges (6) and (7) set to the position.

8.

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

9.

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

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

5-4

1

2

SECTION 5 - OPERATING INSTRUCTIONS 10. When the engine is running check the indicators and indicator lamps to make sure that all systems are operating correctly.

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

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

STARTING THE ENGINE IN COLD WEATHER WITH AN AIR INTAKE HEATER (GRID HEATER) (optional) This starting system activates when the ambient temperature is lower than 5 °C (41 °F).

NOTE: In very cold starting conditions, the engine controller will limit the engine speed to a maximum of 1200 rpm to prevent damage to the engine.

1.

Carry out steps 1 to 8 of the normal engine starting procedure.

2.

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

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

3.

Carry out steps 10 to 11 of the normal engine starting procedure.

3 STARTING THE ENGINE AT TEMPERATURES BELOW -18 °C (0° F) USING IMMERSION HEATER ASSISTANCE (if fitted) This starting system is to be used when the ambient temperature is between -18 °C (-0.4 °F) and -29 °C (-20.2 °F).

The immersion heater heats the engine coolant and is for use at temperatures below -18 °C (0.4 °F).

When used in conjunction with engine air heating, the immersion heater will be effective down to 29 °C (-20.2 °F).

Consult your Dealer.

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

5-5

SECTION 5 - OPERATING INSTRUCTIONS

!

WARNING

!

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

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

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

STOPPING THE ENGINE 1.

Place the direction of travel control lever (1) in the neutral position.

2.

Place the gear change lever (2) in the neutral position (Powershuttle).

3.

Raise the parking brake lever (3).

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

4.

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

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

5.

Turn the ignition switch (4) to the “OFF” position and remove the ignition switch.

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

4

5-6

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN COLD WEATHER Observe the following recommendations: BATTERY It must be fully charged.

FUEL a) Refill the fuel tank after each working day to prevent the formation of condensation and the entry of water into the fuel system. b) To prevent the formation of crystals (-2 °C) (28.4 °F) use a low temperature fuel or mix a protective fluid with your fuel. See “Fluids and lubricants” in Section 8.

ENGINE OIL The engine oil must have a viscosity corresponding to the ambient temperature. See “Fluids and lubricants” in Section 8.

COOLANT SOLUTION It must have a specification corresponding to the ambient temperature. See “Fluids and lubricants” in Section 8.

OPERATING THE MACHINE IN HOT WEATHER Observe the following recommendations: 1.

Maintain the correct level of coolant solution in the coolant reservoir.

2.

Check the condition of the radiator cap before starting. Replace the cap if necessary.

3.

Clean the radiator, the oil cooler and the engine carefully.

4.

Check the condition of the alternator and fan belt.

5.

Use lubricants with the recommended degree of viscosity. See “Fluids and lubricants” in Section 8.

6.

Use an appropriate coolant solution. See “Fluids and lubricants” in Section 8.

5-7

SECTION 5 - OPERATING INSTRUCTIONS SETTING THE BACKHOE ATTACHMENT IN WORKING POSITION

!

WARNING

!

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

!

WARNING

!

Before using the backhoe attachment, place the seat in the backhoe attachment position. Always sit in the seat and attach the seat belt. Serious injury can result if these instructions are not observed.

1.

Remove the backhoe attachment locking systems.

2.

Check that the direction of travel control lever is in the neutral position.

3.

Make sure that the gear change lever is in the neutral position (Powershuttle).

4.

Make sure that the parking brake lever is in the raised position.

5.

Make sure the glide ride system (1) (if fitted) is turned off and that the switch lamp is not alight.

6.

Start the engine. Lower the loader bucket until it is resting horizontally on the ground. Press down on the ground with the bucket until the front wheels are no longer supporting the weight of the machine.

7.

Turn the seat round to the backhoe attachment position and adjust it correctly.

8.

Accelerate and run the engine at the required speed.

5

5-8

SECTION 5 - OPERATING INSTRUCTIONS 9.

Lower the stabilizers slightly, leaving the rear wheels in contact with the ground.

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

10. Place the backhoe attachment in line with the machine.

!

WARNING

!

Before operating the backhoe offset swing, ensure that no person is within its working range.

11. Raise the boom to release the lock plate.

6

12. When using the telescopic dipper (HED) (if fitted) make sure that the pin is placed in telescopic dipper unlocking position.

A. Unlocked position B. Locked position

!

WARNING

!

Before starting work, make sure that no person is within the working range of the machine.

!

WARNING

!

Before starting work, check that all the backhoe controls operate correctly.

7

5-9

SECTION 5 - OPERATING INSTRUCTIONS LOCKING OR UNLOCKING THE BACKHOE ATTACHMENT Before undertaking any road travel with the machine, the backhoe attachment must be “locked” in transport position. In order to do this, retract the dipper completely up to the boom and then fully raise the boom so that the lock plate engages on the backhoe boom pins.

Mechanically operated control (if fitted) To lock the attachment, pull lever (1) backwards and raise the boom until the locking system (2) engages.

Release the lever.

8 To unlock the attachment, push lever (1) forwards to release the locking system (2) and then lower the boom.

9

5-10

SECTION 5 - OPERATING INSTRUCTIONS Electrically operated control (if fitted) To unlock the attachment, place switch (1) in “ON” position. The indicator lamp (2) lights off and the locking plate is released. Lower the boom.

10 To unlock the attachment, place switch (1) in “OFF” position. The indicator lamp (2) (mechanical backhoe models) or the indicator lamp (3) (pilot backhoe models) lights on. Raise the boom until it engages.

!

WARNING

!

Do not attempt to use the backhoe attachment with the boom in locked position as this can cause serious damage.

11

5-11

SECTION 5 - OPERATING INSTRUCTIONS SETTING THE BACKHOE ATTACHMENT IN THE ROAD TRAVEL POSITION IMPORTANT: This procedure must be used for road travel, for operating the loader attachment, when transporting the machine on a trailer and when parking the machine.

1.

Check that the direction of travel control lever (1) is in the neutral position.

2.

Make sure that the gear change lever (2) is in the neutral position (Powershuttle).

3.

Make sure that the parking brake lever (3) is in the raised position.

4.

Make sure that the operator’s seat (4) is correctly positioned.

5.

Make sure that the machine is resting on the stabilizers and the loader bucket.

12 6.

Retract the telescopic dipper (HED) completely (if fitted) and place the pin in the telescopic dipper (HED) locking position.

7.

Place the backhoe attachment in line with the machine.

8.

Run the engine at about 900 rpm.

9.

Retract completely the backhoe bucket and the backhoe dipper.

13

10. Retract completely the backhoe dipper.

11. Lock the backhoe attachment.

12. Raise the stabilizers completely.

13. Run the engine at low idle speed.

14. Turn the seat round to the loader attachment position. Raise the loader bucket.

15. Stop the engine and remove the ignition switch.

16. Install the safety systems in compliance with legal requirements. See “On road travel requirements”.

5-12

14

SECTION 5 - OPERATING INSTRUCTIONS ON ROAD TRAVEL REQUIREMENTS

15 Install the safety systems in compliance with legal requirements. Make sure your machine is in conformance with local legislation.

1.

BACKHOE ATTACHMENT LOCKING PIN (if fitted): Install the pin in the locking plate.

2.

SLOW MOVING VEHICLE EMBLEM (if fitted): This is clipped onto the bucket.

5-13

SECTION 5 - OPERATING INSTRUCTIONS REPLACING A BACKHOE BUCKET REMOVAL 1.

Park the machine on flat, level ground.

2.

Lower the stabilizers until they are resting on the ground.

3.

Place the bucket flat on the ground.

4.

Stop the engine and remove the ignition switch.

5.

Remove the retaining pins, the rings and the connecting rod/bucket linkage pin (1).

!

WARNING

!

Always wear eye protection when using a tool that might project metal particles. Use a hammer with a soft face, such as copper, for pins assembly/disassembly.

6.

Start the engine.

7.

Retract the bucket cylinder rod.

8.

Operate the attachment controls so that the dipper/bucket linkage pin is not under load from the dipper.

9.

Stop the engine and remove the ignition switch.

16

10. Remove the retaining pins, the rings and the dipper/bucket linkage pin (2).

11. Start the engine.

12. Operate the attachment controls so as to disconnect the dipper from the bucket.

INSTALLATION 1.

Start the engine.

2.

Extend the bucket cylinder rod to bring the connecting rods into their housing.

3.

Install the connecting rod/bucket linkage pin (1), along with the retaining rings and pins.

NOTE: The connecting rod/bucket linkage may be adjusted to suit the type of work to be performed.

Maximum bucket force position (3), maximum bucket opening range position, (4).

4.

Slightly raise the attachment and then operate the bucket and dipper control to bring the dipper lugs in line with the bucket lugs.

5.

Install the dipper/bucket linkage pin (2), along with the retaining rings and pins.

17 5-14

SECTION 5 - OPERATING INSTRUCTIONS REPLACING A LOADER BUCKET (B110) REMOVAL 1.

Park the machine on flat, level ground.

2.

Lower the bucket to the ground in dump position (tilted completely forward).

3.

Stop the engine and remove the ignition switch.

4.

If the machine is fitted with a 4x1 bucket, release the pressure in the bucket circuit. See “Releasing pressure in the hydraulic system” in Section 8.

5.

Remove the linkage pin retaining bolts and then remove the linkage pins (1).

!

WARNING

!

18

Always wear eye protection when using a tool that might project metal particles. Use a hammer with a soft face, such as copper, for pins assembly/disassembly.

6.

(4x1 bucket) disconnect and plug the hydraulic supply lines.

7.

Start the engine.

8.

Operate the attachment controls so as to release the bucket.

9.

Reverse the machine away from the bucket.

INSTALLATION 1.

Make sure all bushings are completely clean.

Remove any dirt or foreign matter, if necessary.

2.

Start the engine.

3.

Use the attachment controls to engage the attachment between the bucket lugs.

4.

Install the arm/bucket linkage pins (1) and then install the linkage pin retaining bolts.

5.

Use the bucket controls to align the connecting rod holes with the bucket lugs.

6.

Shut down the engine and remove the ignition switch.

7.

(4x1 bucket) release the pressure in the bucket circuit. See “Releasing pressure in the hydraulic system” in Section 8.

8.

Install the connecting rod/bucket linkage pins (1) and then install the linkage pin retaining bolts.

9.

(4x1 bucket) remove the plugs and reconnect the hydraulic supply lines.

19

5-15

SECTION 5 - OPERATING INSTRUCTIONS REPLACING A LOADER BUCKET (B115) REMOVAL 1.

Park the machine on flat, level ground.

2.

Lower the bucket to the ground in dump position (tilted completely forward).

3.

Stop the engine and remove the ignition switch.

4.

If the machine is fitted with a 4x1 bucket, release the pressure in the bucket circuit. See “Releasing pressure in the hydraulic system” in Section 8.

5.

Remove the snap rings and retaining pins and then drive out the linkage pins (1).

20

!

WARNING

!

Always wear eye protection when using a tool that might project metal particles. Use a hammer with a soft face, such as copper, for pins assembly/disassembly.

6.

(4x1 bucket) disconnect and plug the hydraulic supply lines.

7.

Start the engine.

8.

Operate the attachment controls so as to release the bucket.

9.

Reverse the machine away from the bucket.

5-16

21

SECTION 5 - OPERATING INSTRUCTIONS INSTALLATION 1.

Make sure all bushings are completely clean.

Remove any dirt or foreign matter, if necessary.

2.

Start the engine.

3.

Use the attachment controls to engage the attachment between the bucket lugs.

4.

Install the arm/bucket linkage pins (1) and then install the retaining pins and snap rings.

5.

Use the bucket controls to align the connecting rod holes with the bucket lugs.

6.

Shut down the engine and remove the ignition switch.

7.

(4x1 bucket) release the pressure in the bucket circuit. See “Releasing pressure in the hydraulic system” in Section 8.

8.

Install the connecting rod/bucket linkage pins (1) and then install the retaining pins and snap rings.

9.

(4x1 bucket) remove the plugs and reconnect the hydraulic supply lines.

22

5-17

SECTION 5 - OPERATING INSTRUCTIONS DIFFERENTIAL LOCK The differential lock gives equal power to both rear wheels.

It is particularly useful when the wheels have insufficient adhesion, as in the following cases: IMPORTANT: Never use the differential lock during travel on a public highway.

WHEN THE MACHINE IS STUCK 1.

Make sure that the rear wheels are not turning.

2.

Press down the differential lock pedal (Powershuttle) and hold it in this position.

3.

Press the differential lock switch (Powershift).

4.

Use the accelerator pedal to increase the engine speed and then release the differential lock button.

23

NOTE: The differential is released automatically when the locking system is disengaged, when rear wheel adhesion returns to normal, with no wheel slip, or when one of the brake pedals is operated.

24

5-18

SECTION 5 - OPERATING INSTRUCTIONS BEFORE CROSSING A SOFT OR MUDDY AREA

!

WARNING

!

Never use the differential lock at speeds above 8 km/h (5 mph) or when turning the machine. When engaged the lock will prevent the machine turning and personal injury could result.

NOTE: You can engage the differential lock when the machine is moving in a straight line.

1.

Make sure that the machine is moving in a straight line and that both rear wheels are turning at the same speed.

2.

Press down the differential lock pedal (Powershuttle) and hold it in this position until the area has been crossed.

25 3.

Press the differential lock switch (Powershift).

4.

After you have moved through the area, release the differential lock button.

NOTE: You can cause damage to the transmission if you try to engage the differential lock when the machine is turning or if one rear wheel is rotating faster than the other rear wheel.

26

5-19

SECTION 5 - OPERATING INSTRUCTIONS LOADER BUCKET WITH FORKS (optional)

!

WARNING

!

The forks are heavy, so use great care when swinging them into their working and stowage position.

INSTALL FORKS IN WORKING POSITION 1.

Place the loader bucket onto the flat level ground stop the engine, engage parking brake and remove the ignition switch.

2.

Remove the retained pin and the pin (1).

3.

Lower the fork (2) manually and carefully until it is laying in position against the bucket cutting edge.

IMPORTANT: The forks must be laying against the cutting edge, not against the bucket teeth.

27 4.

Install the pin and the retained pin (1).

5.

Repeat steps 2 to 4 for the other fork.

6.

Slide the forks until they are suitably spaced for the intended job.

IMPORTANT: Both forks must be spaced equally each side of the center of the bucket.

IMPORTANT: Never use the forks to lift the machine.

!

WARNING

!

When using the forks with a 4x1 bucket, never attempt to use the bucket jaw opening function.

5-20

28

SECTION 5 - OPERATING INSTRUCTIONS INSTALL THE FORKS IN REST POSITION 1.

Place the bucket onto the flat level ground, stop the engine, engage parking brake and remove the ignition switch.

2.

Remove the retained pin and the pin (1).

3.

Tilt the fork (2) manually and carefully until it is rearwards into transport position.

4.

Install the pin and retaining pin (1) in its housing.

29

NOTE: If necessary slide the fork to bring it into its housing.

5.

Repeat steps 2 to 4 for the other fork.

IMPORTANT: The forks must be securely retained in their proper stowage positions using the correct pins and link pins. Improperly stowed forks may be cause sections injury.

30

5-21

SECTION 5 - OPERATING INSTRUCTIONS FOUR WHEEL STEER PHASING (B115) To select the type of steering required, turn the switch to the corresponding position. The corresponding position lamp will begin to flash on the instrument panel. Turn the steering wheel to the right and then to the left and the lamp will remain on permanently.

IMPORTANT: The steering mode has been successfully changed when the lamp stays on permanently.

Position 1 = “Road” Position 2 = “Four wheel steer” Position 3 = “Crab steer” IMPORTANT: When changing from one position to another the speed of the machine must be below 10 km/h (6.214 mph) and the steering wheel turned to full lock left and right. This allows the hydraulic cylinders to refill with oil and engage the steering selected.

31

The machine is fitted with an audible alarm device, which warns the operator when the machine is travelling at a speed higher than 12 km/h (7.456 mph), in crab steering position.

Road position (2 wheel steer) - Switch in position (1) Place the switch in vertical position. The front wheels now steer the machine, as conventionally.

IMPORTANT: The lock tang (1) only needs to be installed on the switch when 2 wheel steer position is selected.

IMPORTANT: Before undertaking any road travel, select the 2 wheel steer position and install the lock tang to lock the switch in that position.

32 Four wheel steer position - Switch in position (2) Turn the switch to the left and in this position both the front and rear wheels steer the machine, facing in opposite directions, thereby giving a shorter turning radius in comparison to conventional steering.

33

5-22

SECTION 5 - OPERATING INSTRUCTIONS Crab steer position (the four wheels all steer in the same direction) - Switch in position (3) Turn the switch to the right. The machine will travel to the right or the left, in a straight line and at an angle of up to 15 degrees to the right or left of the straight ahead direction.

34 PHASING PROCEDURE These machines need to be phased at least once a day, as follows.

To select the type of steering, turn the switch to the position corresponding to the type of steering required: Position 1 = “Road” Position 2 = “Four wheel steer” Position 3 = “Crab steer”

!

WARNING

!

Failure to phase the four wheel steering at least once per day may mean a reduction in steering effectiveness.

The steering must be phased: - At the start of each working day - At least once per day - If having difficulty in steering - After travelling for 24 km (14.913 miles) or more on the road in two wheel drive IMPORTANT: the following procedure must be carried out at least once a day.

Raise the machine supporting it on the bucket and stabilizers.

Select “Road” (1) position and turn the steering wheel completely to one side and then to the other.

Two wheel steering is a requirement for road use.

35

5-23

SECTION 5 - OPERATING INSTRUCTIONS Select “4 wheel steer” (2) position and turn the steering wheel completely to one side and then to the other.

Select “Road” (1) position again and turn the steering wheel completely to one side and then to the other.

Lower the machine to the ground.

36

5-24

SECTION 5 - OPERATING INSTRUCTIONS BACKHOE ATTACHMENT AUXILIARY HYDRAULIC TOOLS (optional) Before using auxiliary tools (3), it is mandatory to proceed as follows: − Place the direction of travel control lever in neutral position. − Place the gear change lever in the neutral position (Powershuttle). − Lower the loader bucket until it is pressing on the ground.

Shut down the engine, release all pressure in the auxiliary circuit, remove the plugs and connect the tool hoses to the couplings (1) at the end of the boom.

IMPORTANT: Inverting the connections can cause involuntary or untimely functioning of the tool or even damage it considerably. To avoid all risk of accidents, follow the manufacturer’s instructions carefully.

37 FLOW SELECTION It is up to the operator to decide which flow should be used by consulting the manufacturer’s operating instructions. Be sure to select the flow recommended. Excess flow can damage some equipment.

Place the accelerator lever in full speed position.

Press down the control pedal (2) to operate the tool.

Release the control pedal (2) to stop the tool.

Depending on the flow requirement recommendations, adjust the flow regulator on the chassis, at the rear of the machine. Consult your Dealer.

38

5-25

SECTION 5 - OPERATING INSTRUCTIONS HAND-HELD AUXILIARY HYDRAULIC TOOLS (optional) Before using hand-held auxiliary tools, it is mandatory to proceed as follows: − Place the direction of travel control lever in neutral position. − Apply the parking brake to prevent the machine from moving. − Place the gear change lever in neutral (Powershuttle). − Lower the loader bucket until it is pressing on the ground. − Place the hand-held auxiliary hydraulic tool switch (1) in “OFF” position.

Shut down the engine, remove the plugs and connect the tool hoses to the couplings in front of the fuel tank. Coupling (3) is for the hydraulic fluid supply line and coupling (2) is for the return line.

IMPORTANT: Inverting the connections can cause involuntary or untimely functioning of the tool or even damage it considerably. To avoid all risk of accidents, follow the manufacturer’s instructions carefully.

39

FLOW SELECTION The operator must determine the flow to be used by consulting the tool manufacturer’s operating instructions. Be sure to select the flow specified. Excessive flow can damage some tools, making it necessary to adjust the flow regulator located on the chassis behind the machine, in front of the rear axle. Consult your Dealer.

Start the engine, place the accelerator lever in full speed position and then place the hand-held auxiliary hydraulic tool switch (1) in “ON” position. In this position the switch lamp lights up and the auxiliary tool may be operated.

When the auxiliary tool is no longer required, place the hand-held auxiliary hydraulic tool switch (1) in “OFF” position. The switch lamp goes out.

5-26

40

SECTION 5 - OPERATING INSTRUCTIONS 2 OR 4 WHEEL DRIVE

!

WARNING

!

Machines with or without four wheel drive should not be allowed to exceed 40 km/h (24.855 mph).

Over speeding by towing or coasting downhill may cause loss of control, personal injury, or failure of the drive line. Keep the machine in the same gear going downhill as would be used when going uphill.

Four Wheel Drive Switch (1) The switch has three positions: - First position (by pushing button on the right ): rear wheel drive with braking only on rear wheels (lamp off).

41

- Second position (by pushing button on the left ): four wheels drive with braking on four wheels (lamp on).

- Third position (by pushing a second time button on the left ): rear wheels drive and braking on four wheels.

See decal (2).

NOTE: When the switch (1) is in “OFF” position and both brake pedals are pressed down at once, 4 wheel drive is engaged automatically (at speeds above 3 km/h (1.864 mph) to ensure 4 wheel braking. As soon as the brake pedals are released, the machine returns to 2 wheel drive.

NOTE: To avoid undue tire wear when travelling on the public highway or any hard surface, it is recommended that four wheel drive be disengaged, particularly in 3rd or 4th gear ratios.

2WD AND 4WD CONDITIONS IMPORTANT: 4WD braking is only active with both brake pedals latched together.

5-27

SECTION 5 - OPERATING INSTRUCTIONS LIFTING AND CRANING LOADS WITH THE LOADER ATTACHMENT

!

WARNING

!

Always operate on flat, hard ground where there are no obstacles.

IMPORTANT: No other system than that equipped with safety valves can be used to lift a load. Consult your Dealer.

LOADER BUCKET - With lifting ring The lifting ring is the only point to which loads may be attached on the loader bucket. The bucket must also be in dumping position.

42

LOADER BUCKET - Without lifting ring If the loader bucket is not supplied ex-works with a lifting ring, consult your Dealer.

NOTE: The installation of a lifting ring must be inspected and approved, by the competent authorities.

43

5-28

SECTION 5 - OPERATING INSTRUCTIONS MAXIMUM LIFTING LOADS USING BUCKET MOUNTED FORKS (if fitted)

!

WARNING

!

Do not exceed the maximum safe working load for the loader. Ensure you comply with local “lifting” regulations, if in any doubt consult your Dealer.

IMPORTANT: When using the forks with the 4x1 Bucket option, ensure that the bucket jaws are in the closed position when attempting to lift a load. Do not attempt to open the bucket jaws with loaded forks.

The machine must be on flat, hard, level ground.

The loader bucket must be fitted with forks.

The forks must be in horizontal position.

FORK SPECIFICATIONS (B110) (A) Reach Full Height ................. 2200 mm (7 ft 3 in) (B) Reach Ground Level........... 2700 mm (8 ft 11 in) (C) Lift Height ........................... 3456 mm (11 ft 5 in) (D) Lift Height ............................ 3010 mm (9 ft 11in) Fork Spacing - Minimum centers ...... 275 mm (11 in) Fork Spacing - Maximum centers ...1773 mm (5 ft 10 in) Fork Length ................................ 1026 mm (3 ft 4 in) Fork Width ......................................... 80 mm (3.1 in)

44 FORK SPECIFICATIONS (B115) (A) Reach Full Height ................. 2350 mm (7 ft 9 in) (B) Reach Ground Level........... 2700 mm (8 ft 11 in) (C) Lift Height ........................... 3458 mm (11 ft 5 in) (D) Lift Height ........................... 3040 mm (9 ft 12 in) Fork Spacing - Minimum centers ...... 275 mm (11 in) Fork Spacing - Maximum centers ...1773 mm (5 ft 10 in) Fork Length ................................ 1026 mm (3 ft 4 in) Fork Width ......................................... 80 mm (3.1 in)

45

5-29

SECTION 5 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE

!

WARNING

!

This machine can slip and fall from a trailer or ramp and cause serious physical injury. Make sure that the trailer and the ramp are both clean. The machine must be in line with the trailer before being loaded.

Make sure you know the safety rules and regulations before transporting this machine. Make sure that the articulated vehicle and the machine are fitted with the correct safety equipment.

IMPORTANT: Loading and unloading the machine brake pedals need to be “locked” together.

LOADING 1.

Place a chock behind the wheels of the trailer.

Install the trailer side extensions (if fitted).

2.

Place the backhoe attachment in the road travel position. See “Setting the backhoe attachment in the road travel position”.

3.

(4WS) Make sure the steering mode switch is in “Road” position.

4.

Raise the loader bucket about 20 cm (7.8 in) above the ramps.

5.

Place the gear change lever in first gear and load the machine carefully onto the trailer.

6.

Lower the loader attachment so that the bucket is resting on the bed of the trailer. (Specific to certain countries), lock the loader attachment controls by means of the pin.

7.

Raise the parking brake lever and place the direction of travel control lever and gear change lever in neutral position. (Powershuttle).

8.

Stop the engine and remove the ignition switch.

9.

Make sure the windows, doors and engine side guards are properly closed and locked.

10. Turn the rear view mirrors inwards.

11. Use chocks and chains to immobilize the machine and the loader attachment on the trailer.

12. Measure the distance between the ground and the highest point. You must know the total height.

IMPORTANT: After a few kilometers/miles, check that the machine has not moved and that the chains are still under tension.

5-30

SECTION 5 - OPERATING INSTRUCTIONS UNLOADING 1.

Remove the chocks and the retaining chains.

2.

(Specific to certain countries) remove the loader attachment locking pin.

3.

Raise the loader attachment to bring the bucket a few centimeters above the bed of the trailer.

4.

Lower the parking brake lever and place the gear change lever in first gear.

5.

Slowly reverse the machine, at the same time raising the loader attachment so as to keep it a few centimeters above the bed of the trailer.

6.

Return the rear view mirrors to their correct position.

LIFTING THE MACHINE IMPORTANT: Before lifting the machine, it is essential to place the backhoe attachment in the road travel position. See “Setting the backhoe attachment in the road travel position”.

The hooking points for the machine are shown by decals. See “Decals” in Section 3.

IMPORTANT: Never use any other hooking points than those shown by the decals.

Use suitable slings to lift the machine.

Make sure that the slings are in perfect condition and that they can take the weight of the machine.

!

WARNING

46

!

Do not allow anybody within the machine’s working range. Never swing the machine over people who are in proximity.

5-31

SECTION 5 - OPERATING INSTRUCTIONS TOWING THE MACHINE The machine should only be towed when it is undriveable.

First of all make sure that it can be towed without causing further damage.

Whenever possible carry out the repair at the site or consult your Dealer.

If the machine is on the public highway, make sure that no component of the machine projects onto the highway. If this cannot be avoided, install signs in accordance with regulations.

If the machine has to be towed with the engine shut down, it is necessary to uncouple the front and rear (4WD) transmission shafts.

Before towing, be sure to do the following: 1.

Check that steering can be used.

2.

Place the gear lever (1) and powershuttle direction lever (2) in neutral (Powershuttle).

3.

Place the gear lever (2) in neutral (Powershift).

4.

If the engine is running, make sure the 4WD is disengaged.

!

WARNING

!

If the engine is not running, the force necessary to turn the steering wheel will be higher.

47 5.

To tow the machine, attach a towing bar to one of the hooking points shown by the decals.

48

5-32

SECTION 5 - OPERATING INSTRUCTIONS 6.

Make sure the attachments are raised sufficiently to avoid any interference with the ground or the trailer.

7.

If it is not possible to raise the attachments sufficiently to avoid interference, then they must be removed.

49 (4WS)

!

WARNING

!

For towing purposes, “Road” (1) type steering must be selected.

If the engine is not running, the force necessary to turn the steering wheel will be higher.

!

WARNING

!

Towing is a delicate operation which is always performed at the risk of the user. The manufacturer’s guarantee does not apply to incidents or accidents occurring during towing. Whenever possible, carry out the repair at the location, without towing the machine.

!

WARNING

50

!

The machine must be towed very slowly (8 kph (5 mph) maximum), over a short distance and only if it is really necessary.

!

WARNING

!

A towing bar must be used for all towing operations.

!

WARNING

!

When towing the operator must be alone on the machine. Make sure that no other person is on the machine or within the machine’s working range.

5-33

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN WATER 1.

Make sure that the bed of the stream or stretch of water can support the weight of the machine.

2.

The level of the water must not exceed the height of the center of the front wheels.

IMPORTANT: Never work in water if the water level is higher than the center of the front wheels.

3.

Before taking the machine into the water, pump plenty of new grease into the machine’s attachment linkages.

IMPORTANT: Never work in fast-flowing water.

PARKING THE MACHINE 1.

Park the machine on a flat, level surface away from any soft ground, excavations or poorly shored cavity.

2.

Lower the loader bucket to the ground.

3.

Raise the parking brake lever and place the direction of travel control lever and gear change lever in neutral position (Powershuttle).

4.

Place the backhoe attachment in the road travel position. See “Setting the backhoe attachment in the road travel position”.

5.

Stop the engine and remove the switch key.

6.

Release all pressure in the hydraulic circuits.

7.

Lock the operator’s compartment doors and the engine side guards.

8.

If the machine is parked outdoors, cover the exhaust pipe so as to protect the engine against damp.

!

WARNING

!

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

5-34

SECTION 6

22

JOB SITE AND ROAD INSTRUCTIONS INSTRUCTIONS FOR USE JOB SITE OPERATION

!

WARNING

!

Observe the instructions for use shown in this chapter. Any other practice without the prior approval of the manufacturer is considered as being forbidden.

1.

Be vigilant, be aware of places where other persons are working close to your working area.

Keep other persons away from the machine.

Serious physical injury can result if these instructions are not observed.

2.

Make sure you know the location of underground pipes or cables before beginning work.

Electrical cables, gas pipes, water pipes or other underground installations can cause serious physical injury.

3.

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

4.

When travelling at right angles to the slope keep the loader bucket at ground level.

5.

When travelling in the same direction as the slope, move onto the slope in low gear (first gear). Never travel down slopes with the gear change lever in the neutral position.

ROAD OPERATION IMPORTANT: Road speed is subject to restrictions in certain countries. It is the operator’s responsibility to limit his speed accordingly.

1.

Before carrying out any road travel, lock the attachments and install the safety systems required by regulations. The machine must be within the maximum dimensions permitted on the road in accordance with local road traffic regulations.

2.

(4WS) Before undertaking any road travel, select the 2 wheel steer position and install the flip over cover to lock the switch in that position.

3.

Raise the stabilizers completely.

6.

4.

Check that the lighting and signalling systems operate correctly.

When working on a slope, engage the front drive axle (4 wheel drive).

7.

Holes, obstacles, debris and other hazards in the working area can cause serious physical injury. Always walk around and identify all possible hazards before operating the machine in a new working area.

8.

Do not work close to live overhead electric lines without first making sure that the minimum distances are observed: 5 meters (16 ft 5 in).

5.

Check that the brakes and steering operate correctly.

6.

Check the condition and pressure of the tires.

7.

Never alight from the operator’s compartment leaving the engine running.

8.

Never use the differential lock.

6-1

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS ROAD TRAVEL

!

WARNING

!

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

!

WARNING

!

Always fasten your seat belt before travelling on the road.

!

WARNING

!

It is essential to lock the attachments and install the safety systems required by regulations before travelling on the road.

!

WARNING

!

Check that the lighting and signalling systems are operating correctly before travelling on the road.

!

WARNING

!

Before undertaking any road travel, make sure that the backhoe attachment (if fitted) is in the road travel position and mechanically immobilized.

1.

Place the backhoe attachment in the road travel position. See “Setting the backhoe attachment in the road travel position” in Section 5.

2.

Make sure that the engine accelerator handle is in the low idle position.

1

6-2

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS 3.

Place the seat in the loader attachment position.

4.

Raise the attachment about 20 cm (7.8 in) above the ground and roll back the loader bucket completely. Stop the engine and remove the ignition switch.

5.

Install the warning panels on the loader bucket.

6.

Adjust the rear view mirrors correctly.

7.

(If fitted) place the rotating beacon on the cab roof, connect the cable and press the control switch, see “Rotating beacon switch” in Section 4.

8.

Make sure the doors are properly closed and that the engine side guards are locked.

2

3

4

5 6-3

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS 9.

Make sure that the two brake pedals are locked together.

6 10. Adjust the operator’s seat correctly. Fasten and adjust the seat belt.

7 11. Make sure that the direction of travel control lever is in the neutral position and start the engine.

8 12. Make sure switch (1) is in “OFF” position (front wheel drive transmission disengaged) and turn on the rotating beacon (if fitted).

9 6-4

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS 13. Press the transmission disconnect button and then place the gear change lever in third or fourth gear. Release the button (Powershuttle).

10 14. Place the gear change lever in third or fourth (Powershift).

11 15. Press the brake pedals down and lower the parking brake lever.

12 16. Place the direction of travel control lever forwards.

13 6-5

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS 17. Release the brake pedals and control the travel speed by means of the accelerator pedal.

IMPORTANT: In the event of a brake system failure, immediately raise the parking brake lever.

!

WARNING

!

Check all gauges and indicator/warning lamps frequently.

JOB SITE TRAVEL

14

NOTE: After road travel, remove all the road safety devices before carrying out any job site travel.

1.

Make sure that the engine accelerator handle is in the low idle position.

2.

Make sure the stabilizers are completely raised.

3.

Make sure the doors are properly closed and that the engine side guards are locked.

4.

Adjust the operator’s seat correctly. Attach the seat belt correctly and then adjust it.

15

16

6-6

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS 5.

Make sure that the direction of travel control lever is in the neutral position and start the engine.

6.

Raise the attachment about 20 cm (7.8 in) off the ground.

7.

Choose the type of steering and traction necessary to suit the terrain.

8.

Press down the transmission disconnect button and then place the gear change lever in first or second gear (Powershuttle).

9.

Place the gear change lever in first or second (Powershift).

17

18

10. Press the brake pedals down and lower the parking brake lever.

19 11. Place the direction of travel control lever in the desired position, forward or reverse.

12. Release the brake pedals and control the travel speed by means of the accelerator pedal.

!

WARNING

!

While travelling, check all gauges and indicator/ warning lamps frequently.

20 6-7

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS LOADER ATTACHMENT OPERATING INSTRUCTIONS The instructions contained in this chapter do not cover all possible conditions of use of the loader attachment. They only constitute basic information to enable the machine to be operated correctly.

IMPORTANT: Before operating in temperatures below -1 °C (30 °F) operate the engine for approximately 15 minutes at speeds below 1200 rev/min. to warm the oil to the normal operating temperature.

Where possible, always use the loader attachment at full engine speed.

NOTE: The first time it is operated, maneuver the machine in a clear area, at low speed.

NOTE: To operate the controls, see “Loader attachment controls” in Section 4.

!

WARNING

!

Automatic loader bucket levelling only operates when raising the attachment; it does not operate when lowering the attachment. You must take care to keep the bucket level during attachment lowering to avoid the load being dumped.

SAFETY INSTRUCTIONS − Be careful. − Make sure that the operator’s seat is correctly adjusted in the loader attachment position. − Attach the seat belt. − Make sure that no other person is in the working range of the machine.

6-8

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS TRANSMISSION DISCONNECT BUTTON To give maximum power, press the push button and hold it down. This will cause the transmission to revert to neutral.

Release the clutch cut-out button to engage the transmission once more.

IMPORTANT: The machine will free wheel when the button is pressed. If necessary, use the brakes to stop the machine.

21 4 IN 1 LOADER BUCKET CLAM OPENING INDICATOR (if fitted) This indicator, located on the top right-hand side of the clam, allows the operator to see the degree of clam opening and the bucket digging depth.

When the pin (1) is positioned corresponding to the “0” the bucket is closed; when its position corresponds to the “1/2” the bucket is half-way opened and, when it faces the “4/4” the bucket is fully opened.

LOADING OPERATIONS

22

To fill the bucket from a stock pile, set the bucket in the level position and lower the attachment with the control lever to “float” position.

23

6-9

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS When the loader has entered the pile, press down the clutch cut-out button, allow the control lever to move backwards and then simultaneously operate the controls to lift and roll back the bucket.

Lift and roll-back of the bucket will increase efficiency as a level bucket throughout the lifting cycle resists bucket lift and increases break away effort.

NOTE: Do not be concerned if the bucket is not completely filled during each pass. Maximum productivity is determined by the amount of material loaded in a given period of time. Time is lost if two or more attempts are made to fill the bucket on each pass.

!

WARNING

24

!

To avoid personal injury exercise care when undercutting high banks. Soil slides can be dangerous.

Load from the bank as low as possible for maximum efficiency. Remember that loader lift and breakaway capacities diminish rapidly as loading height is increased.

Dump the bucket completely, raise the attachment and then release the transmission disconnect button.

Keep the bucket position as low as possible, especially when working on sloping or rough ground.

!

WARNING

!

When working on a slope, keep the bucket as low as possible to ensure maximum stability.

When travelling with a full bucket on rough ground, keep the bucket as low as possible to avoid spillage.

25 Raise the loader high enough to clear any obstruction prior to dumping the load.

After the bucket is dumped, back away whilst lowering and levelling the bucket using the return to dig facility if required.

26

6-10

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS During hard surface operation, place the loader lever in “float” and keep the bucket level. This will permit the bucket to “float” on the contour of the working surface. If hydraulic down pressure is exerted, the bucket will wear faster than normal.

The “float” position will prevent the mixing of surface material with stockpile material. It will also reduce the chance of surface gouging when removing snow or other material.

When loading from a bank select the highest forward gear which will provide the most efficient loading operation without going into a “stall”. Keep the working area free of ruts and holes occasionally back grading with the bucket using the low rear edge of the bucket.

For site stripping peeling or scraping, use down pressure with the loader lever in the lowered position, and a slight bucket angle to start the cut. Begin the cut at the notch approximately 50 mm (2 in) deep and hold the depth by feathering the bucket to adjust the cutting lip up or down as required. When the machine front tires enter the cut, adjust the lift arms to maintain the correct depth. Make additional cuts until the desired depth is reached.

Back grade the working area occasionally with the bucket flat and slight down pressure to keep the working area smooth and free from ruts or holes.

If the loader lever is moved for lift cylinder action without controlling the bucket angle, the bucket may gouge and leave a series of ruts in the surface.

27

To backfill a trench efficiently it is necessary to move the maximum amount of soil without losing speed. If a “stall” occurs downshift or reduce the depth of cut.

If the machine is not working at capacity in the gear selected, increase the depth of cut.

Operate at right angles to the trench with the loader bucket level. Leave the soil in the bucket as emptying the bucket on each pass is time-consuming, and leave soil that drifts over the side of the bucket for the final clean up. One lengthwise clean up is usually sufficient to gain an acceptable grade after backfilling.

6-11

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS When backfilling from a large pile, shovel off the top of the pile, pushing toward the excavation. Drag some soil rearward to form a work ramp of convenient grade.

If during the backfill operation the machine front wheels get stuck in a trench dump the bucket and apply down pressure to lift the front wheels from the trench. Actuate the bucket as engine power is applied to move the machine rearwards.

NOTE: Maximum bucket down pressure may be obtained by “feathering” the loader lever to the right.

IMPORTANT: The Safe Working Load of the loader is calculated using a standard bucket, therefore, when using any other bucket or attachment for “lifting” or “craning” the weight of the bucket or attachment must be taken into account when calculating the rated load of the loader.

28

Safe Working Load = 1000 kg (2204 lbs).

ORGANIZING THE JOB SITE Use the shortest possible work cycle. The location provided for the trucks is an all important element.

Spend a little time levelling the work area.

A smooth working surface facilitates the work of the machine and moving and parking the trucks. It gives a shorter work cycle.

!

WARNING

!

Operating the loader attachment with a full bucket on sloping ground can cause the machine to turn over. If possible avoid turning the steering wheel and always travel forwards when climbing a slope and in reverse when travelling down a slope. Keep the bucket as close as possible to the ground.

There is a risk of accident if these instructions are not observed.

!

WARNING

!

On the job site, always keep the bucket as close as possible to the ground so as to increase the machine’s stability to the maximum and to ensure perfect visibility.

!

WARNING

!

On rough or slippery ground, when the bucket is full, drive the machine as slowly as possible. If these instructions are not observed there is a risk of accident.

6-12

29

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS BACKHOE ATTACHMENT OPERATING INSTRUCTIONS The instructions contained in this chapter do not cover all possible conditions of operation for the backhoe attachment. They only constitute basic information to enable the machine to be operated correctly.

IMPORTANT: To achieve an optimum balance between machine performance and optimum fuel economy operate the machine at 1600 - 1700 rev/min.

NOTE: The first time it is operated, manoeuvre the machine in a clear area, at low speed.

NOTE: For the operation of the controls, see “Backhoe attachment controls” in Section 4.

SAFETY INSTRUCTIONS − Be careful. − Make sure that the operator’s seat is correctly adjusted in the backhoe attachment position. − Attach the seat belt. − Make sure that no other person is in the working range of the machine. − Place the attachment in the working position. See “Setting the machine in the backhoe attachment working position” in Section 5. − Never dig near or under the stabilizers, since the machine could fall into the excavation. − When working in an area of reduced visibility, for example next to a building, place a safety barrier and sign panels to prevent anyone coming near the machine.

GENERAL The backhoe attachment will dig more quickly if the work cycle is short and uninterrupted. Organize your work site so as to obtain a smooth work cycle.

If you try to use the backhoe bucket for digging too wide a trench, you may cause a stall situation (where the dipper control lever is tilted towards the rear but nothing happens). The hydraulic system main relief valve makes a noise when a hydraulic stall occurs. This overload causes the work cycle to be prolonged and it increases the hydraulic fluid temperature.

6-13

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS EXCAVATING METHOD

30

31 CORRECT

WRONG

WRONG

The backhoe bucket will dig in and The bucket is pushed upwards. This cause a stall will also increase the cycle time OPERATING TECHNIQUES

!

WARNING

!

Never operate any of the backhoe control levers with the transport boom lock engaged.

Filling the backhoe bucket Fill the backhoe bucket by maneuvering the dipper.

Keep the bottom of the backhoe bucket parallel to the cut. The backhoe bucket teeth and blade must cut the ground like the blade of a knife. The depth of dig varies depending on the type of material.

Dump the bucket contents onto the spoil pile, rolling out the bucket as the pile is approached. Avoid constant jarring or hammering-type contact between the spoil pile and bucket as this will cause wear to the bucket pins and bushings.

32

6-14

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS Moving the machine forwards when working on flat ground It is possible to use the backhoe attachment to move the machine forward at the same time as the excavation.

1.

Make sure that the front wheels are straight.

2.

Set the engine speed to 1000 rpm.

3.

Release the machine’s brakes by means of the parking brake.

4.

Raise the boom and retract the dipper, then move the boom so as to place the backhoe bucket teeth on stable ground.

5.

Raise the stabilizers and the loader bucket about 20 cm (7.8 in) from the ground.

6.

Use the boom and dipper to move the machine.

7.

After moving the machine, lower the stabilizers and place the loader bucket on the ground, then level the machine.

8.

Use the parking brake to brake the machine.

33

IMPORTANT: This procedure can only be used on flat ground. Never use it on sloping ground. On sloping ground it is mandatory to turn the operator’s seat to the loader attachment position to move the machine by the normal procedure.

The machine can be moved sideways in the same fashion, except that the bucket must be flat to support the weight of the machine. Use the swing control to move the machine sideways to the required position.

Telescopic dipper (HED) To avoid the risk of damage and to extend the overall life of machines fitted with a telescopic dipper (HED) the following precautions must be observed.

- When the attachment is used for compacting operations, the telescopic dipper (HED) must be fully retracted and locked.

34

6-15

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS - Before returning to normal use, install the pin in working position (2).

- When you use the hydraulic breaker, make sure that the telescopic dipper is retracted and the pin is in working position (2).

- When using a toothed bucket to break hard ground, avoid extending the dipper beyond 0.60 m (2 ft).

- When digging in wet soil or mud and the bucket needs to be cleaned, do not knock the bucket against the ground with the dipper extended.

35 - Avoid overloading the attachment by using a bucket which is too big in harsh working conditions, as this will reduce the useful life of the machine.

- Do not bottom-out the swing cylinder with the dipper extended.

- For safety reasons, when working on sloping ground, do not swing the boom to dump the bucket contents on the side sloping down.

!

WARNING

!

Always wear your seat belt for protection in the event of the machine overturning. Never try to jump clear, always remain in the cab.

36

- When operating with the dipper fully extended, ensure that the bucket does not receive a sharp impact which will cause distortion of the cylinder rod.

Trenching Trenching is the most basic backhoe excavating operation. Other digging operations are merely variations of this basic function (i.e. filling the bucket, dumping the bucket, and moving the unit forward).

While trenching, it is generally important to maintain a level trench bottom. This is accomplished by setting the bucket at the correct angle of approach.

- ISO configuration: Pull on the dipper lever to maintain the correct cutting angle as the bucket is crowding in (1) applying light pressure to the right.

At the same time, pull on the lift lever (2) to relieve down pressure and keep the bucket in the same plane.

6-16

37

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS - Four lever configuration: push lever (2) and pull lever (3) of rocker arm to hold the proper cutting angle while the bucket is getting filled. Pull at the same time the lifting lever (1) to release the pressure and to hold the bucket position.

38 Continue the trench by moving forward. Moving too far will require excessive down pressure for digging, plus hand clean-up of the trench bottom. It is better to move a lesser amount than to move too far.

When using the backhoe for digging on slopes position the backhoe uphill wherever possible. If however, this is not practicable use the loader or backhoe to cut a level surface into the slope for the uphill wheel and stabilizer, and deposit the spoil from the slot onto the downhill side for the opposite wheel and stabilizer. When digging always deposit the spoil from the trench on the uphill side.

!

WARNING

!

When excavating across a slope it is not possible to make use of the loader bucket for added stability.

Do not overload the bucket and avoid swinging a loaded bucket to the downhill side of the slope.

39

To finish the far wall on a straight-walled excavation crowd out the bucket while forcing the bucket down the excavation from the boom. To finish the rear wall crowd in the bucket, while lifting with the boom, keeping the edges of the bucket horizontal.

40

6-17

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS When finishing straight walls in sandy soil, position a platform under the rear tires and stabilizers to distribute the load over a larger area and reduce the possibility of a cave-in.

The platform will also reduce the possibility of the machine creeping rearwards if hard digging is encountered.

IMPORTANT: Do not backfill using the swing device and dragging the bucket sideways. Doing so can damage the dipstick, boom, swing cylinders or mainframe.

41 To backfill a trench, lift the bucket over the spoil pile and then crowd in the dipper and lift the boom. Pull both the crowd and boom levers simultaneously for smooth even backfilling.

42

43

6-18

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS BALLASTING AND TIRES Water

Tire size

Calcium chloride

Total weight tire

Liters

Gallons

US Gal.

kg

lbs

kg

lbs

46

10

12

27

60

73

160

11L-16 14-17,5

89

20

24

53

118

142

312

16.9-28

212

47

56

127

280

339

747

19.5L-24

212

47

56

127

280

339

747

NOTE: The tires shown in the table above are for general fitment. Therefore tires fitted to your machine may vary from those shown.

LIQUID BALLAST Filling the front and rear tires with liquid ballast is a convenient method of adding weight. A solution of calcium chloride and water is recommended. This gives a low freezing point and provides a higher density than plain water.

!

WARNING

!

WEIGHTING LIMITATIONS If your machine is fitted with a loader only, four 453.6 kg (998 lbs) weights, must be mounted at the rear of the unit to provide counter-balance during loader operation. This provides a total of 1814.4 kg (3992 lbs) counter-balance to the rear of the unit.

To obtain sufficient counter-balance for backhoe operation weight can be added to the unit in the form of cast counterweights and liquid ballast.

!

WARNING

!

When mixing the ballast solution it is imperative the calcium chloride flakes are added to the water and the solution stirred until the calcium chloride is dissolved. Never add water to calcium chloride. If the flakes should contact the eyes, wash the eyes immediately with clean, cold water for at least 5 minutes. See a doctor as soon as possible.

Do not operate the loader with the backhoe removed or with less than four 453.6 kg (998 lbs) or 1814.4 kg (3992 lbs) total, rear counterweights installed. Operating the unit with less than the recommended rear counterweight may cause the unit to become unstable and upset, causing possible personal injury.

NOTE: When filling a tire with calcium chloride/ water solution the valve should be at the highest point on the wheel. The valve should be at the lowest point when checking or adjusting air pressure if the tire is liquid ballasted.

Where additional stability during operation of the backhoe is required liquid ballast can be added to the tires, as above table. Because special equipment is required to fill the tires it is recommended that this be carried out by your Dealer.

The table above shows the quantity of calcium chloride and water required for each tire size option and is based on 0.6 kg (1 lbs) of calcium chloride per liter of water to give a 75% fill of the tire. This calcium chloride/water solution will give protection from freezing down to an ambient temperature of -46°C (51°F).

IMPORTANT: Only add the quantity of ballast necessary to ensure stability. Excess ballast overloads the machine unnecessarily and increases fuel consumption. When adding ballast, do not exceed the maximum load ratings for the tires. See “Tire pressures and permissible loads” in Section 12.

For further information, consult your Dealer.

When adding ballast the total weight of the machine including liquid, cast iron weights and equipment (if fitted) should not exceed the maximum specification.

6-19

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS MACHINE WEIGHTING When adding ballast to the machine, do not exceed the gross weight shown on the identification plates.

See “Type, serial number and year of manufacture of the machine” in Section 2.

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

44 (2WS) Two wheel drive (2WD) front axle maximum permissible loading inclusive of ballast and loader in the transport position with no load in the bucket: Static load rating= 22730 kg (50006 lbs) Dynamic load rating= 5670 kg (12474 lbs).

NOTE: The load capacity of the tires may be lower than the load capacity of the front axle, the lower figure of the two must be used.

Four wheel drive (4WD) front axle maximum permissible loading inclusive of ballast and loader in the raised position with no load in the bucket: Static load rating= 12230 kg (26906 lbs) Dynamic load rating= 6115 kg (13453 lbs) for a track measurement of 1830 mm (6 ft).

Rear axle maximum permissible loading with ballast and backhoe in the raised position with no load in the bucket: Static load rating= 27750 kg (61050 lbs) Dynamic load rating= 8900 kg (19580 lbs) for a track measurement of 1727 mm (5 ft 8 in).

6-20

45

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS (4WS) NOTE: Total weight on the rear axle is measured with only the rear wheels on the scales, weight on front axle with the front wheels on the scales.

NOTE: The load capacity of the tires may be lower than the load capacity of the front axle, the lower figure of the two must be used.

46 Front axle maximum permissible loading inclusive of ballast and loader in the raised position with no load in the bucket: Static load rating= 15210 kg (33462 lbs) Dynamic load rating= 8000 kg (17600 lbs) for a track measurement of 1890 mm (6 ft 3 in).

Rear axle maximum permissible loading with ballast and backhoe in the raised position with no load in the bucket: Static load rating= 25000 kg (55000 lbs) Dynamic load rating= 10000 kg (22000 lbs) for a track measurement of 1890 mm (6 ft 3 in).

47

6-21

SECTION 6 - JOB SITE AND ROAD INSTRUCTIONS

NOTES

6-22

SECTION 7

6

SERVICING INTERVALS SERVICING INSTRUCTIONS Observe the servicing intervals by the checking daily the hourmeter located on the display of the side instrument. Before starting maintenance, park the machine on flat, firm ground, away from any obstacles, with the loader bucket and the backhoe bucket on the ground. All maintenance operations must be carried out with the engine stopped and the key removed from the ignition switch. It is preferable to wait for all circuits to cool down before starting work.

Clean the grease fittings before lubrication. Clean around plugs and filler holes before adding oil. No dust or dirt must enter the components or the circuits.

!

WARNING

!

!

WARNING

!

!

WARNING

!

There is a risk of serious injury if maintenance or repairs are not performed correctly. If you do not understand the maintenance procedures, consult your Dealer.

When performing maintenance work on the machine, place a “Do not start up” label on the instrument panel.

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization. Consult your Dealer.

IMPORTANT: If you use your machine under particularly severe conditions (dusty or corrosive atmosphere, etc.) reduce the interval between servicing operations.

IMPORTANT: Observe the Servicing Intervals for all the machine’s filters. The life of the engine depends on clean filters.

IMPORTANT: Do not drain used oil into the ground or down a drain. Stock the oil in sealed containers for collection by a company which recycles or disposes of it.

If the attachment is raised or the machine moves when there is no operator, serious injury can result.

Before carrying out any servicing operator on this machine, proceed as follows: 1. Park the machine on a flat, level ground.

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

3. Stop the engine and remove the ignition switch.

4. Raise the parking brake lever.

5. Block the wheels to prevent any machine movement.

For all service work on the engine, install the loader attachment support strut.

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

7-1

SECTION 7 - SERVICING INTERVALS HOURMETER The hourmeter enables servicing operations to be scheduled. It works in the same way as a clock when the engine is running.

Servicing Intervals are properly calculated to guarantee safe and efficient machine operation.

Be sure to carry out all the servicing operations properly, as defined in this manual.

1

7-2

SECTION 7 - SERVICING INTERVALS INTERVALS

Steer phasing (4WS)

8-3

Loader attachment

24

10

8-3

Backhoe attachment

30

10

8-9

Windshield washer reservoir level

1

10

8-9/8-12

Engine oil level

1

10

8-9/8-15

Coolant reservoir level

1

10

9-6

Radiator

1

10

9-7

Alternator belt

1

10

Hydraulic oil tank level

1

10

8-26

Hydraulic pipes and hoses

-

10

8-4

Telescopic dipper (HED) (if fitted)

2

50

8-4

Door hinges

4

50

8-4

Front axle trunnion bearings (2WD)

2

50

8-5

Front axle trunnion bearings (4WD)

2

50

8-5

Front axle king pins (2WD)

4

50

8-5

Front axle trunnion housing

1

50

9-1

Tire pressure

4

8-6

Differential lock linkage

1

250

8-6

Drive shafts

2

250

8-6

Drive shaft couplings front and rear

2

250

8-7

Steering universal joint

4/8

250

8-7

Seat suspension

-

250

8-15

Cooling system hose and clamp tightness

-

250

8-21

Fuel tank sediment removal

1

250

8-23

Breather plug

1

DRAIN

GREASE

CHECK

5-22

8-9/8-23

-

REPLACE

INTERVALS IN HOURS CLEAN

SERVICE POINTS

NO. OF POINTS

PAGE

Servicing and inspection intervals are variable. All operations are scheduled on the following basis: - Every 10 hours, or once a day, whichever comes first - Every 50 hours, or once a week, whichever comes first - Every 250 hours, or once every 3 months, whichever comes first - Every 500 hours, or once every 6 months, whichever comes first - Every 1000 hours, or once every year, whichever comes first - Every 2000 hours, or once every 2 years, whichever comes first

10

50

250

7-3

7-4

DRAIN

GREASE

CHECK

REPLACE

INTERVALS IN HOURS CLEAN

SERVICE POINTS

NO. OF POINTS

PAGE

SECTION 7 - SERVICING INTERVALS

8-32

Transmission oil level (Powershuttle)

1

250

8-35

Transmission oil level (Powershift) (NOTE B)

1

250

8-38

Front drive axle breather (4WD and 4WS)

1

8-38

Front drive axle and reduction gear level (4WD and 4WS) (NOTE C)

1

8-41

Rear axle breather valve

1

250

8-41

Rear axle oil level

1

250

250

8-42

Rear axle reduction gear level

2

250

250

9-6

Radiator

1

250

9-10

Air conditioning

1

9-12

Cab filters

-

250

9-13

Heater unit and air conditioning cooler

1

250

9-15

Telescopic dipper (HED)

1

250

10-7

Battery terminal tightness

2

250

9-18

Cab ROPS/FOPS (NOTE C)

1

300

8-13

Engine oil (NOTE A)

1

8-13

Engine oil filter

1

500

8-17

Fuel pre-filter (NOTE B)

1

500

8-18

Fuel filter (NOTE B)

1

500

8-8

Brake pedal linkage

1

8-23

Hydraulic system

1

8-24

Hydraulic fluid filter

1

8-32

Transmission breather (Powershuttle)

1

8-33

Transmission (Powershuttle)

1

8-33

Transmission filter (Powershuttle)

1

8-33

Transmission screen filter (Powershuttle)

1

8-36

Transmission (Powershift)

1

8-36

Transmission filter (Powershift) (NOTE B)

1

8-39

Front drive axle and reduction gears (4WD and 4WS)

1

1000

8-43

Rear axle and reduction gears

1

1000

9-9

Engine rocker arm clearance adjustment

-

250 250

250

500

1000 1000 1000 1000 1000 1000 1000 1000 1000

1000

1000

9-9

Machine inspection

-

10-7

Battery electrolyte

-

1000

10-11

Alternator

-

1000 (3)

10-11

Starter motor

-

1000 (3)

8-16

Cooling system

1

9-14

Brake fluid

1

8-29

Secondary element

1

8-29

Primary element

1

9-1

Wheel nut torque settings

-

(5)

9-10

Cylinder leak inspection

-

(6)

9-11

Draining the telescopic dipper (HED) (if fitted)

1

9-16

Front wheel adjustment

2

DRAIN

GREASE

CHECK

REPLACE

INTERVALS IN HOURS CLEAN

SERVICE POINTS

NO. OF POINTS

PAGE

SECTION 7 - SERVICING INTERVALS

1000

2000 (2)

(4)

(2)

1000

(2)

1000

(2)

2000

(2) (7)

(1) Have checked every year by a specialist.

(2) Regularly.

(3) Have this checked by your Dealer.

(4) Clean when necessary according to environment conditions or when the lamp on the side instrument turns on.

(5) After the first 10 hours during the run in period and each time the wheels are changed.

(6) Check there are no leaks.

(7) Check and adjust occasionally.

NOTE A: Change every 150 hours for machines operating at temperatures below -12 °C (10 °F).

NOTE B: Change after the first 100 hours during the run in period.

NOTE C: After the first 50 hours during the run in period.

7-5

SECTION 7 - SERVICING INTERVALS

NOTES

7-6

SECTION 8

44

LUBRICATION/FILTERS/FLUIDS FLUIDS AND LUBRICANTS Fluids and lubricants must have the correct properties for each application.

OIL VISCOSITY/OIL USAGE RANGE Choose the correct oil viscosity grade from the chart on the right to suit the conditions.

NOTE: In areas where prolonged periods of extreme temperatures are encountered, local engine lubricant practices are acceptable; such as the use of SAE 5W in extreme low temperatures or SAE 50 in extreme high temperatures.

1

FUEL

ENVIRONMENT

Use fuel type No. 2.

The use of other fuels may cause loss of engine power and excessive fuel consumption.

Before carrying out any maintenance operation on the machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never put them in leaky receptacles.

In cold weather, a mixture of fuel no. 1 and no. 2 is temporarily permitted. Consult your fuel supplier.

If the temperature falls below the fuel cloud point (point at which wax appears), wax crystals in the fuel will cause a loss of engine power or make it impossible to start the engine.

IMPORTANT: In cold weather, fill the fuel tank after each day’s work, to prevent the formation of condensation.

FUEL STORAGE Prolonged fuel storage causes foreign bodies or condensation water to accumulate in the storage tank. Many engine failures are caused by the presence of water in fuel.

Consult a local recycling or environmental center, or a Dealer to obtain information on the correct method of disposing of these materials.

PLASTIC AND RESIN PARTS When cleaning plastic windows, the console, the instrument panel, the gauges, etc., avoid the use of petrol, paraffin, paint solvents, etc.

Use only water, soap and a soft cloth.

The use of petrol, paraffin, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

The storage tank should be placed outdoors and the fuel should be kept at as low a temperature as possible. Condensation water should be drained off at regular intervals.

8-1

SECTION 8 - LUBRICATION/FILTERS/FLUIDS FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS RECOMMENDED FLUIDS AND APPLICATION ENGINE - OIL Ambra Master Gold HSP (15W40) COOLING SYSTEM Ambra Agriflu antifreeze 50% water 50%

NEW HOLLAND Specifications

INTERNATIONAL Specifications

NH 330 H

API CH-4/, ACEA E5

NH 900 A

CUNA NC 956-16

HYDRAULIC SYSTEM Ambra Mastertran

NH 410 C

Ambra Multi BIO-S Biodegradeable

NH410 HBS

MODELS

QUANTITY Liters Us gal

2WS - with filter 4WS - with filter

14 12.8

3.70 3.40

ALL

24

6.30

ALL

118

31.10

ALL

118

31.10

ALL

18

4.70

ALL

14

3.70

2WD (ea)

0.2

0.10

Differential

6.5

1.70

Wheel reduction gear (each)

0.7

0.20

Differential

10.5

2.80

Wheel reduction gear (each)

1.3

0.34

21.2

5.60

ISO 32/46, 10W-30, GL4

For Cold Weather Operation, See your Dealer POWERSHUTTLE TRANSMISSION Ambra Mastertran NH 410 C POWERSHIFT TRANSMISSION Ambra Hydrodex 3

NH 530 B

FRONT AXLE (2WS) Ambra Mastertran

NH 410 C

ATF DEXRON III

4WD

FRONT AXLE (4WS) Ambra Mastertran

REAR AXLE (2WS) Ambra Mastertran

NH 410 C

NH 410 C

AOA Axle oil additive, P/N 87304782 REAR AXLE (4WS) Ambra Mastertran

NH 610 A

ISO 7308

FUEL Decanted and filtered Diesel Fuel VARIOUS JOINTS Ambra Grease MG2

0.20

11

2.90

Wheel reduction gear (each)

1.3

0.34

ALL

1

0.26

ALL

135

35.50

NH 410 C

AOA Axle oil additive, P/N 87304782 BRAKES SYSTEM Ambra LHM Mineral Oil

0.8 Differential

QFK585/GR

NLGI 2

ALL

As required

QFK585/GR

NLGI 2

ALL

As required

ALL

As required

TELESCOPIC DIPPER Ambra Grease GR EXP AIR CONDITIONING COMPRESSOR PAG Oil SP 20

8-2

SECTION 8 - LUBRICATION/FILTERS/FLUIDS GREASE POINTS Type of grease, see “Fluids and lubricants” NOTE: The figures shown in brackets indicate the number of grease points.

Every 10 hours Loader attachment (B110) ................................. (24)

2 Loader attachment (B115) ................................. (24)

3 Backhoe attachment.......................................... (30) NOTE: The number of grease points may vary depending on the types of accessory installed.

4

8-3

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Every 50 hours Telescopic dipper (HED) (if fitted) ........................(2)

5 Door hinges..........................................................(4)

6 Front axle trunnion bearings (2WD) ..............................................................(2)

7

8-4

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Front axle trunnion bearings (4WD) .............................................................. (2)

8 Front wheel king pins (2WD) ............................... (4)

9 Front axle trunnion housing ................................. (1)

10

8-5

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Every 250 hours Differential lock linkage ........................................(1)

11 Drive shafts ..........................................................(2)

12 Drive shaft couplings front and rear .....................(2)

13

8-6

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Steering universal joint (2WS) ............................. (4)

14 Steering universal joint (4WS) ............................. (8)

15 Seat suspension .................................................. (1) Wipe all moving parts with a clean cloth and apply a light coat of spray dry lubrificant.

16

8-7

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Seat rails ..............................................................(2) Wipe all moving parts with a clean cloth and apply a light coat of spray dry lubrificant.

17 Every 1000 hours or every year Brake pedal linkage Drive out the old grease with new until new grease appears at the end of each bearing and then wipe off the old grease with a rag.

18

8-8

SECTION 8 - LUBRICATION/FILTERS/FLUIDS LEVELS Every 10 hours Engine oil............................................................. (1)

19 Coolant reservoir level......................................... (1)

20 Hydraulic oil tank ................................................. (1)

21 Windshield washer reservoir ............................... (1) NOTE: The windshield washer works on the gravity feed system. Do not remove the rubber tube as damage can be caused if liquid gets into the motor.

22 8-9

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Every 250 hours Front drive axle reduction gears (4WD and 4WS) ..............................................(2)

23 Differential............................................................(1)

24 Transmission........................................................(1)

25 Rear axle..............................................................(1)

26 8-10

SECTION 8 - LUBRICATION/FILTERS/FLUIDS Every 1000 hours Battery ................................................................. (1)

27

8-11

SECTION 8 - LUBRICATION/FILTERS/FLUIDS ENGINE SERVICE SPECIFICATIONS Oil level check.........................................................................................................Every 10 hours or every day Oil replacement......................................................................................................................... Every 500 hours Or every 150 hours for machines working at temperatures below -12 °C (10 °F) Oil filter replacement ................................................................................................................. Every 500 hours Type of oil.................................................................................................................. See “Fluids and lubricants” Oil capacity (including filter replacement) ........... .(2WS) 14 liters (3.70 Us gal), (4WS) 12.8 liters (3.40 Us gal) LEVEL 1.

Park the machine on flat, level ground.

2.

Raise the loader attachment, stop the engine, remove the ignition switch and install the support strut.

3.

Lift the left-hand engine side guard.

4.

After the engine has been stopped for 15 minutes, remove the dipstick, clean it with a clean cloth, replace it in the guide tube as far as it will go and then remove it again.

5.

If the oil level is below the add mark, remove the filler cap and add oil up to the full mark on the dipstick.

28

29

8-12

SECTION 8 - LUBRICATION/FILTERS/FLUIDS 6.

Retighten the filler cap.

30 7.

Lower and lock the engine side guard.

8.

Remove the support strut and lower the loader attachment.

OIL CHANGE AND OIL FILTER REPLACEMENT NOTE: Drain the engine when it is still hot. The oil will flow more easily.

Use the extension drain hose from the tool box.

1.

Park the machine on flat, level ground.

2.

Raise the loader attachment, stop the engine, remove the ignition switch and install the support strut.

3.

Remove the left-hand engine side guard.

4.

Remove the filler cap.

5.

Remove the protection cap from the engine crankcase drain valve.

6.

Screw the end of the extension drain hose onto the crankcase drain valve. Place the other end in a suitable container and allow the oil to flow out.

NOTE: Use a container of an adequate capacity.

7.

Remove the extension drain hose and install the protection cap on the crankcase drain valve.

Place the extension drain hose in the tool box.

8.

Lift the right-hand engine side guard.

31

8-13

SECTION 8 - LUBRICATION/FILTERS/FLUIDS 9.

Clean around the filter and remove it, using the filter wrench.

10. Apply clean oil to the new filter seal.

11. Install the new filter. Turn the filter until the seal is in contact with the filter head and then tighten it half a turn more by hand.

IMPORTANT: Do not use the filter wrench to install the filter. Excess tightening can damage the seal and the filter.

32 12. Fill the engine with new oil.

33 13. Run the engine for a few minutes and check for leaks. Then check the level again.

NOTE: Always wait 15 minutes to allow the oil to return to the engine sump before checking the oil level.

14. Lower and lock the engine side guards.

15. Lift the support strut and lower the loader attachment.

8-14

SECTION 8 - LUBRICATION/FILTERS/FLUIDS COOLING SYSTEM SERVICE SPECIFICATIONS Coolant reservoir level check ...................................................................................................... Every 10 hours or every day Cooling system hose and clamp tightness check......................................................................Every 250 hours Draining ........................................................................................................ Every 2000 hours or every 2 years Cooling system capacity .................................................................................................... 24 liters (6.30 Us gal) Thermostat range ..................................................................................... 81 °C to 96 °C (177.8 °F to 204.8 °F) Type of coolant ......................................................................................................... See “Fluids and lubricants”

!

WARNING

!

Scalding coolant solution can escape if the coolant reservoir cap is removed while the system is still hot. Allow the system to cool down completely before removing the cap.

!

WARNING

!

Check and service the cooling system according to the instructions given in this manual.

COOLANT SOLUTION LEVEL IN COOLANT RESERVOIR The level of coolant solution should be checked when the engine is cold.

1.

Park the machine on flat, level ground.

2.

Raise the loader attachment, stop the engine, remove the ignition switch and install the support strut.

3.

Lift the left-hand engine side guard.

4.

The level in the coolant reservoir must come up to between the marks. If necessary remove the cap and add more coolant solution.

34

8-15

SECTION 8 - LUBRICATION/FILTERS/FLUIDS DRAINING THE COOLING SYSTEM 1.

Park the machine on flat, level ground.

!

WARNING

!

Do not remove the cap when the engine is hot.

The circuit is still under pressure and you could be scalded.

2.

Remove the lower panel to the right of the radiator.

3.

Open the radiator drain valve and allow the coolant solution to flow out.

35

NOTE: Use a container of an adequate capacity.

4.

After the system is completely drained, close the drain valve.

5.

Rinse the system through with fresh water, drain again and fill the system as shown below.

NOTE: If you use a detergent solution for rinsing, follow the instructions for preparing the solution.

After draining the detergent solution, rinse again with fresh water.

6.

36

Check the condition of the hoses, connections and the water pump. Make sure that the external surfaces of the engine and the radiator are clean.

FILLING 1.

Fill the coolant reservoir with coolant solution.

NOTE: Fill the cooling circuit slowly to avoid the formation of air pockets.

2.

Install the coolant reservoir cap.

IMPORTANT: Use the correct coolant solution.

3.

Run the engine for a few minutes and then check the level in the coolant reservoir again.

Top up if necessary then install the cap.

4.

Lower and lock the engine side guard.

5.

Remove the support strut and lower the loader attachment.

37

8-16

SECTION 8 - LUBRICATION/FILTERS/FLUIDS FUEL SYSTEM SERVICE SPECIFICATIONS Fuel filter sediment removal ........................................................................................................Every 50 hours Fuel tank sediment removal ......................................................................................................Every 250 hours Fuel filter replacement ............................................................................................................... Every 500 hours (After the first 100 hours during the running-in period) Fuel pre-filter replacement......................................................................................................... Every 500 hours (After the first 100 hours during the running-in period) Fuel tank capacity............................................................................................................ 135 liters (35.6 Us gal) Type of fuel ............................................................................................................... See “Fluids and lubricants” REPLACING THE PRE-FILTER 1. Raise the loader attachment, stop the engine, remove the starter switch key and install the support strut.

2. Remove the left-hand engine side guard.

3. Clean around the pre-filter head.

4. Place a receptacle of a suitable capacity under the pre-filter.

5. Disconnect electric connector.

6. Unscrew and remove the pre-filter and the cartridge.

38 7. Apply a fine layer of oil or grease on the new filter seal.

NOTE: Do not fill the new pre-filter with fuel before installing it.

IMPORTANT: On the pre-filter is installed a sensor detecting the presence of water in the fuel. In this case a message appears on the display of side panel.

NOTE: Do not fill the new filter with fuel before installing it.

8. Install the new filter. Turn the filter until the seal comes in contact with the filter head and then tighten an extra half turn by hand.

39

IMPORTANT: Do not use the filter wrench to tighten. Overtightening can damage the seal and the filter.

NOTE: It is imperative to use a genuine filter, as supplied by the manufacturer, when making the replacement, as unapproved filters can cause serious damage to the injection pump.

Prime the system.

8-17

SECTION 8 - LUBRICATION/FILTERS/FLUIDS PROCEDURE AFTER FUEL PRE-FILTER CHANGE NOTE: Pre-filling of the filters is not recommended.

Unfiltered fuel may cause starting issues. Do not loosen any fuel lines or injector lines to bleed air from the system. They are very high pressure, loosening lines is dangerous and may require replacement of lines.

1.

Unscrew bleed screw (1) on pre-filter and activate hand primer (2) until fuel flows freely from the bleed screw. This generally takes 35-45 pumps to fill the fuel lines and the pre-filter. This can be done in about 30 seconds. Tighten bleed screw.

2.

Crank engine. Engine should start within 5 seconds.

40

REPLACING FILTER 1.

Raise the loader attachment, stop the engine, remove the ignition switch and install the support strut.

2.

Remove the left-hand engine side guard.

3.

Clean around the filter head.

4.

Place a receptacle of a suitable capacity under the filter and remove the filter, using the steel band wrench for filters.

5.

Remove the filter from the lower part of the engine.

6.

Apply a fine layer of oil or grease on the new filter seal.

41

NOTE: Do not fill the new filter with fuel before installing it.

7.

Install the new filter. Turn the filter until the seal comes in contact with the filter head and then tighten an extra half turn by hand.

IMPORTANT: Do not use the filter wrench to tighten. Overtightening can damage the seal and the filter.

NOTE: It is imperative to use a genuine filter, as supplied by the manufacturer, when making the replacement, as unapproved filters can cause serious damage to the injection pump.

Prime the system.

8-18

42

SECTION 8 - LUBRICATION/FILTERS/FLUIDS PROCEDURE AFTER FUEL FILTER REPLACE NOTE: Pre-filling of the filters is not recommended.

Unfiltered fuel may cause starting issues. Do not loosen any fuel lines or injector lines to bleed air from the system. They are very high pressure, loosening lines is dangerous and may require replacement of lines.

1.

Loosen bleed screw (1) on fuel filter head.

2.

Activate pre-filter hand primer (2) until fuel flows freely from the fitting on filter (No foam). This takes about 25-40 pumps of the hand primer.

This step can be completed in about 30 seconds. The amount of air in this filter has the greatest impact on how long the engine has to be cranked before it will start, so it is crucial that all the air be removed from the system at this point. Retighten bleed screw.

3.

43

The engine can now be cranked. Crank engine for no more than 30 seconds. If engine does not start, bleed air from the fuel filter again. Crank engine again until it starts.

The engine should be run for several minutes before turning off. The engine will start hard the next 4 or 5 times that it is started. Generally, the engine will crank for 10 seconds the second time it is started, about 5 seconds the third, and so on.

44

8-19

SECTION 8 - LUBRICATION/FILTERS/FLUIDS PRIMING THE FUEL SYSTEM NOTE: Pre-filling of the filters is not recommended.

Unfiltered fuel may cause starting issues. Do not loosen any fuel lines or injector lines to bleed air from the system. They are very high pressure, loosening lines is dangerous and may require replacement of lines.

1.

Open bleed screw (1) on pre-filter only and activate hand primer (2) until fuel flows freely from the bleed screw. This generally takes 35-45 pumps to fill the fuel lines and the pre-filter. This step can be done in about 30 seconds. Tighten bleed screw.

2.

Loosen bleed screw (3) on fuel filter head. This will require a 13 mm (0,5 in) wrench.

3.

Activate hand primer on fuel pre-filter until fuel flows freely from the fitting on filter (No foam).

This takes about 100-125 pumps if the fuel filter is empty. This step can be done in about 1 1/2 minutes. The amount of air in this filter has the greatest impact on how long the engine has to be cranked before it will start, so it is crucial that all the air be removed from the system at this point. Re-tighten bleed screw.

45

NOTE: Do not loosen any fuel lines or injector lines to bleed air from the system. They are very high pressure, loosening lines is dangerous and may require replacement of lines.

4.

The engine can now be cranked. Crank engine for no more than 30 seconds. If engine does not start, bleed air from the fuel filter again. Crank engine again until it starts.

5.

The engine should be run for several minutes before turning off. The engine will require longer than normal cranks times the next 4 or 5 times that it is started. Generally, the engine will crank for 10 seconds the second time it is started, about 5 seconds the third, and so on.

8-20

46

SECTION 8 - LUBRICATION/FILTERS/FLUIDS FUEL TANK SEDIMENT REMOVAL Place a receptacle of a suitable capacity under the fuel tank, unscrew the bleed plug located under the fuel tank one or two turns and allow the soiled fuel to flow out. Then retighten the plug.

47

8-21

SECTION 8 - LUBRICATION/FILTERS/FLUIDS RELEASING THE PRESSURE IN THE HYDRAULIC SYSTEM Before carrying out any service operation on the hydraulic system, it is first necessary to release the pressure in all the circuits.

1.

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

2.

Stop the engine.

3.

Operate the loader attachment controls in all directions.

48 4.

Operate the backhoe attachment controls in all directions.

49

50

8-22

SECTION 8 - LUBRICATION/FILTERS/FLUIDS HYDRAULIC SYSTEM SERVICE SPECIFICATIONS Hydraulic oil tank level check ...................................................................................................... Every 10 hours or every day Hose and pipe check ........................................................................................................................... Every day Hydraulic fluid filter replacement ....................................................................... Every 1000 hours or every year (after the first 50 hours during the running-in period) Cleaning the breather /filler cap ................................................................................................ Every 250 hours Draining the circuit and oil replacement ............................................................ Every 1000 hours or every year Reservoir capacity .............................................................................................................75 liters (19.8 Us gal) Total system capacity....................................................................................................... 118 liters (31.2 Us gal) Type of fluid .............................................................................................................. See “Fluids and lubricants” HYDRAULIC OIL TANK 1.

Park the machine on flat, level ground.

2.

Make sure the attachments are in road travel position.

3.

Stop the engine, remove the ignition switch and wait until the fluid reaches ambient temperature.

4.

The fluid level should be in the middle of the sight gauge. Top up if necessary. See “Filling”.

IMPORTANT: Even when the fluid level is insufficient, a small quantity of hydraulic fluid remains in the lower part of the gauge. This does not mean that the fluid level is sufficient.

51 CLEANING THE BREATHER/FILLER CAP 1.

Remove the cap, using the wrench supplied with the machine.

2.

Use a suitable grease solvent to wash the cap.

3.

Dry the cap with compressed air and install it.

IMPORTANT: When using compressed air, take the necessary precautions to protect your face.

52

8-23

SECTION 8 - LUBRICATION/FILTERS/FLUIDS REPLACING THE HYDRAULIC FLUID FILTER 1.

Make sure the attachments are in road travel position, raise the parking brake lever, shut down the engine and remove the ignition switch.

2.

Clean around the filter head which is located on the left-hand side of the machine.

3.

Place a receptacle of a suitable capacity under the filter, loosen the filter by means of the filter wrench and then unscrew it by hand.

4.

Apply a thin layer of oil on the new filter seal.

5.

Install the new filter. Turn the filter until the seal is in contact with the filter head and tighten the filter a further half turn by hand.

IMPORTANT: Do not use the filter wrench to tighten. Overtightening can damage the seal and the filter.

6.

53

Check that the fluid level comes up to the middle of the gauge. Add more fluid if necessary.

IMPORTANT: Even when the fluid level is insufficient, a small quantity of hydraulic fluid remains in the lower part of the gauge. This does not mean that the fluid level is sufficient.

NOTE: After the machine has been operating for some time, check for any leaks.

54

8-24

SECTION 8 - LUBRICATION/FILTERS/FLUIDS REPLACING THE HYDRAULIC FLUID Replacing the hydraulic fluid requires the fluid to be drained from the main components (reservoir, pumps, cylinders, control valves, hydraulic motors and oil cooler).

We recommend you to consult your Dealer.

Draining NOTE: When carrying out draining, the hydraulic fluid must be at operating temperature.

1.

Park the machine on flat, level ground.

2.

Lower the loader bucket flat on the ground.

3.

Make sure that the backhoe attachment is in the road travel position.

4.

Place a container of a suitable capacity under the reservoir, remove the filler cap and drain plug and allow the oil to flow out.

5.

Drain the other components by removing the supply and return unions. Consult your Dealer.

6.

Install the reservoir drain plug.

Filling 1.

Clean around the filler cap and fill the reservoir with the correct hydraulic fluid.

2.

The fluid level should be in the middle of the sight glass.

3.

Install the filler cap.

4.

Start the engine and operate the loader attachment and backhoe attachment functions for 3 to 4 minutes.

5.

Once again place the loader bucket flat on the ground and the backhoe attachment in the road travel position. Stop the engine and remove the ignition switch.

6.

Check the level. The fluid level should come up to the middle of the gauge. Top up if necessary.

55

IMPORTANT: Even when the fluid level is insufficient, a small quantity of hydraulic fluid remains in the lower part of the gauge. This does not mean that the fluid level is sufficient.

8-25

SECTION 8 - LUBRICATION/FILTERS/FLUIDS HYDRAULIC PIPES AND HOSES Repair all hydraulic oil leaks promptly to avoid loss of oil and possible damage and dirt entry into the system. When checking for hydraulic leaks, start and operate the engine at 1200-1500 rev./min.

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

!

WARNING

!

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

56

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

Release the fittings (1) and remove the hose or tube assembly, then remove and discard the O-ring seal (2).

Dip a new “O” ring seal into clean hydraulic oil prior to installation. Install the new “O” ring (2) into the fitting (1) and if necessary, retain in position using petroleum jelly.

Assemble the new hose or tube assembly and tighten the fitting finger tight, whilst holding the tube or hose assembly to prevent it from turning.

NOTE : Ensure that when tightening the hose or tube fitting, the hose or tube assembly does not turn.

If the hose turns while tightening the fitting the “O” ring seal may be damaged.

57

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SECTION 8 - LUBRICATION/FILTERS/FLUIDS Using two suitable wrenches, tighten the fitting to specification.

IMPORTANT: Ensure that when an hose or pipe is renewed/installed, all components are absolutely clean and free from dirt. Failure to ensure absolute cleanliness will result in the hose/pipe leaking after installation or possible damage to other hydraulic system components.

To ensure a leak free joint is obtained, it is important that the fittings are not overtorqued or undertorqued.

Bleed the air from the system any time a hydraulic hose is removed, a pipe disconnected, or the system is opened to atmosphere. This is accomplished by running the engine at 1200-1500 rev/min., and actuating the loader or backhoe control levers (no load in the bucket) for approximately 15 minutes or until all air is expelled from the system.

58

After bleeding the system, position the loader bucket flat on the ground, put the backhoe into the transport position, and shut off the engine. Then check the hydraulic system oil level and add oil if necessary.

8-27

SECTION 8 - LUBRICATION/FILTERS/FLUIDS AIR FILTER INSPECTION Be sure to carry out regular checks on the air filter, intake manifold, gaskets and seals. At the same time, check the intake manifold screws and hose clamps for tightness.

The hoses should be replaced before they are worn.

Check frequently that the air filter restriction warning lamp on the instrument panel is in good working order.

AIR FILTER RESTRICTION WARNING LAMP If the air filter restriction warning lamp comes on when the engine is running, the air filter elements must be checked.

59 AIR FILTER ELEMENTS Your machine is fitted with a two-stage air filtering system, consisting of a high capacity primary element, designed to provide optimal protection of the engine, plus a secondary element which provides extra engine protection.

The primary element can be cleaned. The secondary element can not be cleaned and should be replaced.

8-28

SECTION 8 - LUBRICATION/FILTERS/FLUIDS SERVICE SPECIFICATIONS Pre-filter maintenance ................................................................................ Regularly check and clean the bowl Cleaning primary element..............................................When necessary according to environment conditions.

Or when the lamp on side instrument turns on.

Primary element replacement.................................................................................................. Every 1000 hours Secondary element replacement............................................................................................. Every 1000 hours IMPORTANT: The life of the engine depends on the cleanliness of the air filter.

CLEANING THE PRE-FILTER (depending on model) 1.

Loosen the wing nut and remove the cover.

2.

Remove and clean the bowl with a clean cloth.

3.

Install the bowl and the cover and tighten the nut.

60 REMOVING THE ELEMENTS 1.

Raise the loader attachment, stop the engine, remove the ignition switch and install the support strut.

2.

Remove the left-hand engine side guard.

3.

Remove the filter cover.

4.

Carefully remove the primary element.

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8-29

SECTION 8 - LUBRICATION/FILTERS/FLUIDS 5.

If the secondary element has to be replaced, carefully remove the secondary element.

IMPORTANT: The secondary element must not be cleaned. It must be replaced every year or after three cleanings of the primary element.

62 CLEANING THE PRIMARY ELEMENT Blow compressed air from the inside towards the outside at very low pressure. The compressed air nozzle should be held at least three centimeters from the inside wall of the primary element. Cleaning is completed once no more dust comes out of the primary element.

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

IMPORTANT: Compressed air pressure should not exceed 7 bar (102 psi).

NOTE: Do not use compressed air if there is oil or soot in the element.

INSPECTING THE PRIMARY ELEMENT Check the primary element for damage by placing an inspection lamp inside.

IMPORTANT: Replace the element if light can be seen through a hole, however small.

8-30

63

SECTION 8 - LUBRICATION/FILTERS/FLUIDS INSTALLING THE ELEMENTS 1.

Clean the inside of the filter body by means of a clean cloth.

2.

Carefully install a secondary element if the old element had to be replaced.

3.

Carefully install the primary element.

4.

Install the filter cover.

5.

Start the engine, run it at low idle speed and make sure that the filter restriction warning light on the instrument panel is not on.

6.

Lower and lock the engine side guard.

7.

Remove the support strut and lower the loader attachment.

64

65

66

8-31

SECTION 8 - LUBRICATION/FILTERS/FLUIDS TRANSMISSION (POWERSHUTTLE) SERVICE SPECIFICATIONS Oil level check........................................................................................................................... Every 250 hours (After the first 50 hours during the running-in period) Filter replacement ............................................................................................. Every 1000 hours or every year Cleaning the breather ....................................................................................... Every 1000 hours or every year Cleaning the filter .............................................................................................. Every 1000 hours or every year Oil replacement................................................................................................. Every 1000 hours or every year Transmission capacity....................................................................................................... 18 liters (4.70 Us gal) Type of oil.................................................................................................................. See “Fluids and lubricants” LEVEL The oil level check should be carried out with the engine running at low speed and at normal operating temperature.

1.

Park the machine on flat, level ground.

2.

Raise the loader attachment, stop the engine, remove the ignition switch and install the support strut.

3.

Remove the left-hand engine side guard.

4.

Insert the starter switch key and restart the engine by keeping it at low idle.

5.

Remove the dipstick, clean it with a clean cloth and replace it in the guide tube up to the stop.

Then remove it again.

6.

If the oil level is below the mini mark, top up.

See “Filling”.

7.

Switch off engine.

8.

Lower and lock the engine side guard.

9.

Remove the support strut and lower the loader attachment.

67

8-32

SECTION 8 - LUBRICATION/FILTERS/FLUIDS OIL DRAINING 1.

Raise the loader attachment, stop the engine, remove the ignition switch and install the support strut.

2.

Remove the left-hand engine side guard.

NOTE: Change the oil while the transmission is still warm, the oil will flow more easily.

3.

Place a container of a suitable capacity under the drain plug (1) and then remove the plug.

4.

Remove the dipstick and allow the oil to flow out.

5.

Install the drain plug and the dipstick.

68 REPLACING THE FILTER 1.

Clean around the filter head.

2.

Place a receptacle of a suitable capacity under the filter (1), loosen the filter by means of a filter wrench and then unscrew it by hand.

3.

Apply a thin layer of oil on the new filter seal.

4.

Install the new filter. Turn the filter until the seal is in contact with the filter head and tighten the filter a further half turn by hand.

IMPORTANT: Do not use the filter wrench to tighten. Overtightening can damage the seal and the filter.

CLEANING THE FILTER 1.

Clean around the cover plate (2) and remove it.

Check the condition of the O-ring and replace it if necessary. Remove the screen filter and clean it in a detergent solution.

IMPORTANT: Follow the instructions for the detergent solution.

2.

69

Dry the screen filter carefully with compressed air and install it.

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

3.

Install and tighten the cover plate to 11 Nm (8.11 lbf ft).

8-33

SECTION 8 - LUBRICATION/FILTERS/FLUIDS FILLING 1.

Remove the dipstick and fill with the correct oil via the dipstick fill hole. Then replace the dipstick.

2.

Check the oil level by means of the dipstick. Top up if necessary.

3.

Drive the machine for a few minutes in first and second gear then stop the engine.

4.

Check the oil level by means of the dipstick. Top up if necessary.

5.

Lower and lock the engine side guard.

6.

Remove the support strut and lower the loader attachment.

8-34

70

SECTION 8 - LUBRICATION/FILTERS/FLUIDS TRANSMISSION (POWERSHIFT) SERVICE SPECIFICATIONS Oil level check ........................................................................................................................... Every 250 hours (After the first 50 hours during the running-in period) Filter replacement.............................................................................................. Every 1000 hours or every year Oil replacement ................................................................................................. Every 1000 hours or every year Transmission capacity ....................................................................................................... 14 liters (3.70 Us gal) Type of oil ................................................................................................................. See “Fluids and lubricants” IMPORTANT: It is recommended to change the oil filter after 100 hours if the transmission is new or has been repaired.

LEVEL The oil level check should be carried out with the engine running at low speed and at normal operating temperature.

1.

Park the machine on flat, level ground.

2.

Raise the loader attachment, stop the engine, remove the ignition switch and install the support strut.

3.

Remove the left-hand engine side guard.

4.

Insert the starter switch key and restart the engine by keeping it at low idle.

5.

Remove the dipstick, clean it with a clean cloth and replace it in the guide tube up to the stop.

Then remove it again.

6.

If the oil level is below the mini mark, top up.

See “Filling”.

7.

Switch off engine.

8.

Lower and lock the engine side guard.

9.

Remove the support strut and lower the loader attachment.

71

8-35

SECTION 8 - LUBRICATION/FILTERS/FLUIDS OIL DRAINING 1.

Raise the loader attachment, stop the engine, remove the ignition switch and install the support strut.

2.

Remove the left-hand engine side guard.

NOTE: Change the oil while the transmission is still warm, the oil will flow more easily.

3.

Place a container of a suitable capacity under the drain plug (1) and then remove the plug.

4.

Remove the dipstick and allow the oil to flow out.

5.

Install the drain plug and the dipstick.

72 REPLACING THE FILTER 1.

Clean around the filter head.

2.

Place a receptacle of a suitable capacity under the filter (1), loosen the filter by means of a filter wrench and then unscrew it by hand.

3.

Apply a thin layer of oil on the new filter seal.

4.

Install the new filter. Turn the filter until the seal is in contact with the filter head and tighten the filter a further half turn by hand.

IMPORTANT: Do not use the filter wrench to tighten. Overtightening can damage the seal and the filter.

73

8-36

SECTION 8 - LUBRICATION/FILTERS/FLUIDS FILLING 1.

Remove the dipstick and fill with the correct oil via the dipstick fill hole. Then replace the dipstick.

2.

Check the oil level by means of the dipstick. Top up if necessary.

3.

Drive the machine for a few minutes in first and second gear then stop the engine.

4.

Check the oil level by means of the dipstick. Top up if necessary.

5.

Lower and lock the engine side guard.

6.

Remove the support strut and lower the loader attachment.

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SECTION 8 - LUBRICATION/FILTERS/FLUIDS FRONT DRIVE AXLE AND REDUCTION GEARS SERVICE SPECIFICATIONS Oil level check........................................................................................................................... Every 250 hours (After the first 50 hours during the running-in period) Cleaning the breather ............................................................................................................... Every 250 hours Oil replacement....................................................................................................................... Every 1000 hours Front drive axle oil capacity (2WD) .................................................................................. 0.4 liters (0.10 Us gal) Front drive axle oil capacity (4WD) ...............................................................7.9 ÷ 8.4 liters (2.10 ÷ 2.20 Us gal) Front drive axle oil capacity (4WS) ................................................................................ 13.1 liters (3.40 Us gal) Type of oil.................................................................................................................. See “Fluids and lubricants” FRONT DRIVE AXLE OIL LEVEL 1.

Park the machine on level ground, stop the engine and remove the starter switch key.

2.

Remove the plug and check that the oil is level with the level hole. If necessary, top up via this level hole.

3.

Install the plug.

75 FRONT AXLES REDUCTION GEAR OIL LEVEL 1.

Park the machine on level ground.

2.

Make sure that the direction of travel control lever and gear change lever are in neutral position.

3.

Use the loader attachment to raise the front of the machine slightly so that the front wheels are no longer in contact with the ground and place blocks under the front drive axle.

4.

Stop the engine and remove the ignition switch.

8-38

SECTION 8 - LUBRICATION/FILTERS/FLUIDS 5.

Manually turn the wheel until the level plug hole is in the horizontal position and remove the plug.

6.

The oil should be level with the level plug hole.

If necessary, top up via this leve plug hole.

7.

Install the plug.

8.

Repeat Steps 5 to 7 for the other reduction gear.

9.

Lower the machine to the ground.

76 CLEANING THE BREATHER VALVE (4WD) 1.

Clean around the breather valve and remove it.

2.

Clean the breather valve with a detergent solution.

IMPORTANT: Follow the instructions for the detergent solution.

3.

Carefully dry the breather valve with compressed air and install it.

77 DRAINING AND FILLING THE FRONT DRIVE AXLE 1.

Park the machine on level ground, stop the engine and remove the starter switch key.

2.

Place a container of a suitable capacity under the drain plug (1), remove the plugs (1) and (2) and allow the oil to flow out.

3.

Install the drain plug (1).

4.

Fill with oil via the filler plug (2) until the oil is level with the drain plug hole. Then install the plug.

78

8-39

SECTION 8 - LUBRICATION/FILTERS/FLUIDS DRAINING AND REFILLING THE FRONT AXLES REDUCTION GEARS 1.

Park the machine on level ground.

2.

Make sure that the direction of travel control lever and gear change lever are in neutral position.

3.

Use the loader attachment to raise the front of the machine slightly so that the front wheels are no longer in contact with the ground and place blocks under the front drive axle.

4.

Stop the engine and remove the ignition switch.

5.

Turn the wheel by hand until the drain plug hole is in the lowest position.

6.

Place a container of a suitable capacity under the reduction gear, remove the plug and allow the oil to flow out.

7.

Turn the wheel by hand until the drain plug hole is in the horizontal position and then fill via that drain plug hole until the oil is level with the drain plug hole.

8.

Install the plug.

9.

Repeat Steps 5 to 8 for the other reduction gear.

10. Lower the machine to the ground.

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8-40

SECTION 8 - LUBRICATION/FILTERS/FLUIDS REAR AXLE AND REDUCTION GEARS SERVICE SPECIFICATIONS Oil level check ........................................................................................................................... Every 250 hours (After the first 50 hours during the running-in period) Cleaning the breather ................................................................................................................ Every 250 hours Oil replacement ....................................................................................................................... Every 1000 hours Rear axle oil capacity (2WS) .......................................................................................... 21.2 liters (5.60 Us gal) Rear axle oil capacity (4WS) .......................................................................................... 13.6 liters (3.60 Us gal) Type of oil ................................................................................................................. See “Fluids and lubricants” REAR AXLE OIL LEVEL 1.

Park the machine on level ground and stop the engine.

2.

(Standard type and 2WS) Remove the fill plug (1) and check that the oil is level with the fill plug hole.

2.

(4WS) Remove the fill plug (2) and check that the oil is level with the fill plug hole.

3.

Install the plug.

80

81

8-41

SECTION 8 - LUBRICATION/FILTERS/FLUIDS REAR AXLES REDUCTION GEAR OIL LEVEL 1.

Park the machine on level ground.

2.

Make sure that the direction of travel control lever and gear change lever are in neutral position.

3.

Use the stabilizers to lift the rear of the machine slightly so that the rear wheels are no longer in contact with the ground. Place blocks under the rear axle.

4.

Stop the engine and remove the ignition switch.

5.

Manually turn the wheel until the drain plug hole is in the horizontal position and remove the plug.

6.

The oil should be level with the drain plug hole.

If necessary, top up via this drain plug hole.

7.

Install the plug.

8.

Repeat Steps 5 to 7 for the other reduction gear.

9.

Lower the machine to the ground.

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SECTION 8 - LUBRICATION/FILTERS/FLUIDS DRAINING AND FILLING THE REAR AXLE (2WS) 1.

Park the machine on level ground, stop the engine and remove the starter switch key.

2.

Place a container of a suitable capacity under the drain plug (1), remove the plugs (1) and (2) and allow the oil to flow out.

3.

Install the drain plug (1).

4.

Fill with oil via the hole (2) until the oil is level with the plug hole (2) and then install the plug (2).

83 (4WS) 1.

Park the machine on level ground, stop the engine and remove the starter switch key.

2.

Place a container of a suitable capacity under the drain plug (1), remove the plug (2) and allow the oil to flow out.

3.

Install the drain plug (1).

4.

Fill with oil via the plug hole (2) until the oil is level with the hole and then install the plug (2).

84

8-43

SECTION 8 - LUBRICATION/FILTERS/FLUIDS DRAINING AND FILLING THE REAR AXLES REDUCTION GEARS 1.

Park the machine on level ground.

2.

Make sure that the direction of travel control lever and gear change lever are in neutral position.

3.

Use the stabilizers to lift the rear of the machine slightly so that the rear wheels are no longer in contact with the ground. Place blocks under the rear axle.

4.

Stop the engine and remove the ignition switch.

5.

Turn the wheel by hand until the plug hole is in the lowest position.

6.

Place a container of a suitable capacity under the reduction gear, remove the plug and allow the oil to flow out.

7.

Turn the wheel by hand until the plug hole is in the horizontal position and then fill via that drain plug hole until the oil is level with the drain plug hole.

8.

Install the plug.

9.

Repeat Steps 5 to 8 for the other reduction gear.

10. Lower the machine to the ground.

85

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SECTION 9

22

MAINTENANCE/ADJUSTMENTS WHEELS AND TIRES

!

WARNING

!

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

!

WARNING

!

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

!

WARNING

!

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

TIRE PRESSURES See “Tire pressures and permissible loads” in Section 12.

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

Service specifications Pressure check.................................................................................................... Every 50 hours or every week WHEEL NUT TORQUE SETTINGS Service specifications Torque tightening check....................................................................................................After the first 10 hours during the running-in period and at every wheel change Front wheel nuts (2WS) .................................................................................................... 330 Nm (243.39 lbf ft) Rear wheel nuts (2WS) .................................................................................................... 540 Nm (398.28 lbf ft) Front and rear wheel nuts (4WS) ..................................................................................... 700 Nm (516.29 lbf ft)

9-1

SECTION 9 - MAINTENANCE/ADJUSTMENTS REPLACING A WHEEL 1.

Park the machine, hard, level ground, with no obstacles in the area. Set parking brake and chock wheels.

2.

Loosen the retaining nuts or screws from the wheel which is to be removed.

3.

Start the engine and use the loader attachment and the stabilizers to lift the machine until the wheels are no longer in contact with the ground.

4.

Stop the engine and remove the ignition switch.

5.

Place blocks under the axle for the wheel which is to be removed.

6.

Remove the nuts and remove the wheel.

7.

Install a new wheel, observing the orientation of the tread pattern.

8.

Install the nuts and tighten them to correct torque, see “Wheel nut torque settings”.

9.

Remove the blocks from under the axle.

10. Lower the machine to the ground.

NOTE: Make sure that the new wheel has a sufficient inflation pressure. Re-inflate it if necessary.

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

TIRE OR WHEEL SERVICE The servicing of tires and wheels for this machine should only be entrusted to a qualified mechanic, who will know how to inflate the tires while observing safety instructions. To avoid any accident, use a protective device (an inflation cage for tires), suitable tools and respect the procedure. Serious or fatal injury can result from a tire suddenly flying off a rim (one piece rim) or from the tire and/or the wheel components (a wheel consisting of several parts).

9-2

1

SECTION 9 - MAINTENANCE/ADJUSTMENTS LOADER BUCKET MECHANICAL/HYDRAULIC SELF LEVELLING/RETURN TO DIG ADJUSTMENT The self levelling linkage mounted on the right hand loader arm and frame automatically controls the angle of the loader bucket during the raising cycle of the lift arms to maintain a constant bucket level.

There is no self levelling during lowering.

Self levelling begins at the point where the tube (2) on the loader arm contacts the bell crank (1) and lifts the vertical linkage rod (3).

The tie rod then moves the bucket spool into the roll out position to level the bucket.

AUTOMATIC SELF LEVELLING CONTROL ADJUSTMENT 1.

Lower the loader to the ground.

2.

Disconnect the vertical tie rod (3) at the lower bell crank.

2

Raise loader arms so that the bottom pin is 800 mm (31.5 in) above the ground and fully roll back the bucket.

3 3.

Rotate the bell crank (1) till it touches the tube (2) on the loader arm. Make sure the lower bell crank arm is directing upwards.

4.

Adjust the length of the vertical rod (3) so that when re-connected, the end of the loader arm tube remains in contact with the bell crank.

5.

Securely tighten locknuts on vertical rod.

4

9-3

SECTION 9 - MAINTENANCE/ADJUSTMENTS Return to dig is an electrically activated feature which enables the operator to automatically return the bucket to a level digging position for a further work cycle with one simple movement of the loader control lever (3).

Whenever the bucket is rolled forward to dump the return to dig electrical circuit is completed and the solenoid on the bucket spool is energised.

When the loader bucket control lever (3) is moved diagonally left to the return to dig position (2) the electromagnet will hold the bucket spool in the roll back position until the bucket is in the level digging position at which time the indicator on the rod of the bucket self levelling linkage will pass in front of the sensor which de-energises the electromagnet on the bucket spool enabling the spool to return to the neutral position.

RETURN TO DIG SENSOR ADJUSTMENT The return to dig system consists of an electromagnet mounted on the bucket spool, a sensor (1) mounted on top of the loader arm and a pointer attached to the tube of the bucket self levelling linkage.

1.

Place the bucket on the ground in the preferred digging position.

2.

Adjust the position of the sensor such that when the bucket is in digging position and loader arms are lowered, half (50%) of the sensor face is obscured by the self levelling linkage pointer.

3.

Ensure the face of the sensor (1) is 3-6 mm (0.12-0.24 in) from the pointer (2) on the self levelling linkage.

5

As a visual aid for the operator, while seated in the cab, the pointer mounted on the loader arm can be seen to align with the pointer on the self levelling linkage, when the loader arms are lowered and the bucket is in the level digging position.

6

9-4

SECTION 9 - MAINTENANCE/ADJUSTMENTS (4WS) Return to dig is an electrically activated feature which enables the operator to automatically return the bucket to a level digging position for a further work cycle with one simple movement of the loader control lever (3).

Whenever the bucket is rolled forward to dump the return to dig electrical circuit is completed and the solenoid on the bucket spool is energised.

When the loader bucket control lever (3) is moved diagonally left to the return to dig position (2) the electromagnet will hold the bucket spool in the roll back position until the bucket is in the level digging position at which time the indicator on the rod of the bucket linkage will pass in front of the sensor which de-energises the electromagnet on the bucket spool enabling the spool to return to the neutral position.

7 RETURN TO DIG SENSOR ADJUSTMENT The return to dig system consists of an electromagnet mounted on the loader bucket control valve spool, a sensor (1) mounted on top of the loader arm and a pointer attached to the tube of the bucket self levelling linkage.

1.

Place the bucket on the ground in the preferred digging position.

2.

Check the dimensions of 88.5 mm and 7.5 mm (3.48 in and 0.3 in) are maintained as shown.

3.

Ensure the face of the sensor (1) is 6 mm (0.24 in) from the rod (2).

8

As a visual aid for the operator, while seated in the cab, the pointer mounted on the loader arm can be seen to align with the pointer on the return to dig linkage, when the loader arms are lowered and the bucket is in the level digging position.

9-5

SECTION 9 - MAINTENANCE/ADJUSTMENTS RADIATOR AND AIR CONDITIONING CONDENSER (if fitted) SERVICE SPECIFICATIONS Checking for leaks ..................................................................................................Every 10 hours or every day Cleaning.................................................................................................................................... Every 250 hours CLEANING 1.

Raise the loader attachment, stop the engine, remove the ignition switch and install the support strut.

2.

Remove the front grille.

3.

Unscrew and remove the upper fixing nuts.

4.

Remove the filter sideways.

5.

Removal of the attaching bolts allows the condenser to be raised for cleaning.

6.

Clean: Dry dust: use compressed air at a pressure not exceeding 7 bar (102 psi).

Mud: use a water jet.

Oily dust: use a detergent based solution and preferably a low pressure cleaning apparatus.

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

Ensure all dirt and debris is removed from between the condenser and engine coolant radiator. This action maintains efficient heat transfer for the condenser.

7.

Install the condenser.

8.

Install the grille.

9.

Remove the support strut and lower the loader attachment.

9-6

9

SECTION 9 - MAINTENANCE/ADJUSTMENTS ENGINE ALTERNATOR AND FAN BELT SERVICE SPECIFICATIONS Visual check ........................................................................................................... Every 10 hours or every day CHECK 1.

Raise the loader attachment, stop the engine, remove the ignition switch and install the support strut.

2.

Remove the right-hand engine panel.

3.

Visually check the condition of the fan belt.

Replace it if it is worn or damaged.

10 REPLACEMENT 1.

Insert the 1/2” square drive wrench in the hole in the tensioner roller.

2.

Exert just sufficient pressure on the wrench to slacken the fan belt.

3.

Slide the fan belt over the water pump pulley and then over the other pulleys.

4.

Install a new fan belt on the water pump pulley and on the crankshaft pulley.

5.

Insert the wrench in the hole in the tensioner roller.

6.

Exert pressure on the wrench so as to be able to pass the fan belt onto the alternator pulley.

7.

Lower and lock the engine side guard.

8.

Remove the support strut and lower the loader attachment.

11

9-7

SECTION 9 - MAINTENANCE/ADJUSTMENTS TURBOCHARGER Serious damage to the turbocharger bearing can result from inadequate lubrication if the following recommendations are not observed.

To prevent turbocharger bearing damage prior to the first start after a turbocharger has been newly installed or if for any reason, the oil supply to the turbocharger has been disconnected, or in cases where the engine is being started for the first time after a period of 4 weeks or more without use, the following procedure should be used: 1.

Disconnect the inlet and outlet oil pipes from the turbocharger and pour some clean engine oil into the oil inlet port, taking care that no contaminants enter the turbocharger.

2.

Remove the air inlet tube from the turbocharger and spin the compressor wheel by hand to prelubricate the bearings.

3.

Re-connect the oil inlet and air inlet tubes but not the oil outlet.

4.

Disconnect the electrical wire to the fuel injection pump fuel shut-off solenoid. Place a suitable receptacle below the oil outlet port and crank the engine until oil flows from the outlet port.

5.

Re-connect the oil outlet tube using a new gasket and tighten the retaining bolts to the torque.

Re-connect the fuel injection pump fuel shut-off solenoid wire.

6.

Check the engine oil level and add oil if necessary. Start the engine and check for oil and air leaks.

7.

Observe the oil pressure warning light. If the oil pressure warning light is not extinguished in the first few seconds of idling, stop the engine immediately and consult your Dealer.

On every start-up the engine should be allowed to idle (1000 rev/min maximum) for 60 seconds before operating under load, to ensure an adequate oil supply to the turbocharger bearing. The engine should also be allowed to idle without load for two minutes before shut-down to enable the oil to dissipate the heat from the turbocharger bearing.

9-8

SECTION 9 - MAINTENANCE/ADJUSTMENTS ENGINE ROCKER ARM CLEARANCE ADJUSTMENT SERVICE SPECIFICATIONS Inspection .......................................................................................................... Every 1000 hours or every year NOTE: Consult your Dealer.

With Tier 3 engines, because of the additional inner E.G.R. seat, the adjustment procedure of the valves clearance, that provides the adjustment of all valves by means of only two position of the drive shaft, cannot be used.

!

WARNING

!

Each cylinder must be checked by moving it to T.D.C. (Top Dead Centre) at compression end and by adjusting the clearance of both valves only on the cylinder concerned.

Adjust the clearance between rocker arms and valves by means of socket screw (1), wrench (2) and thickness gauge (3).

The clearance is: - inlet valves 0.25 ÷ 0.05 mm (0.01 ÷ 0.002 in) - outlet valves 0.50 ÷ 0.05 mm (0.02 ÷ 0.002 in)

12

MACHINE INSPECTION AND CLEANING SERVICE SPECIFICATIONS Inspection and cleaning........................................................................................................... Every 1000 hours Or whenever oil or grease has been spilt on the machine; clean such deposits off with steam or high pressure water with detergent.

Take advantage of this operation to make a visual check of all the welded components (possible appearance of cracks), and the attachment linkage.

Mark any leaks, check the condition of pipes and hoses.

9-9

SECTION 9 - MAINTENANCE/ADJUSTMENTS CYLINDER LEAK INSPECTION A cylinder rod should be slightly oily. Check for leaks after a working period, when the entire hydraulic system is at normal operating temperature.

1.

Clean the rod and the gland of the cylinder which is to be inspected.

2.

Work normally for 5 to 10 minutes.

3.

Extend the cylinder rod.

4.

Check for leaks.

ROD APPEARANCE

TEST

CONCLUSION

Dry

Slight traces of oil when a sheet of paper is rubbed over 20 cm (7.8 in) of the rod.

Normal

Slightly oily

The paper remains stuck when run over the rod.

Normal

Oily

A sheet of paper placed on the rod stays stuck to it.

Normal

Very oily or weeping

A ring of oil is visible on the rod after each rod extension.

Leak

Oil drips from the gland every time the cylinder rod is retracted.

Consult your Dealer

AIR CONDITIONING (optional) SERVICE SPECIFICATIONS Compressor drive belt inspection.............................................................................................. Every 250 hours The air conditioning system components require maintenance at regular intervals. Observe these intervals to ensure correct operation and full efficiency of the air conditioning. The air conditioning system contains HFC 134a refrigerant which is subject to strict regulations. Any problem with the system must be resolved quickly.

!

WARNING

!

Never perform any service operation on the air conditioning circuit. For any operation, consult an approved specialist.

NOTE: Run the air conditioning at least once a week, even for a short time. See “Heating, ventilation and air conditioning” in Section 4.

9-10

SECTION 9 - MAINTENANCE/ADJUSTMENTS COMPRESSOR DRIVE BELT INSPECTION 1.

Raise the loader attachment, stop the engine, remove the ignition switch and install the support strut.

2.

Remove the left-hand engine panel.

3.

Check the condition of the compressor drive belt. Replace it if it is worn or damaged and adjust the tension.

IMPORTANT: After replacing the drive belt, make an adjustment after the first 10 operating hours.

Check the belt tension and adjust if necessary.

To adjust the belt, loosen the mounting hardware, retighten the belt so as to obtain 16 mm (0.6 in) deflection on top side and then tighten the hardware to 33.9 Nm (25 lbf·ft).

IMPORTANT: The drive belt should not be overtightened (premature bearing wear) or too slack (premature belt wear).

4.

Lower and lock the engine side guard.

5.

Remove the support strut and lower the loader attachment.

13

DRAINING THE TELESCOPIC DIPPER (HED) (if fitted) Ensure the drain port (1) in the end of the dipper is kept clear to prevent accumulation of water inside the unit.

Inspect the port for evidence of hydraulic oil which would indicate a leak from the extension cylinder.

14

9-11

SECTION 9 - MAINTENANCE/ADJUSTMENTS CAB FILTER SERVICE SPECIFICATIONS Cleaning.................................................................................................................................... Every 250 hours or in case of reduced air circulation Before servicing the filter, switch off the blower and close all the windows and one door. Forcibly close the other door. The resulting back pressure will dislodge loose dirt from the underside of the filter.

Replace if the filter is ever damaged.

To remove the filter (1), release the clips (2), remove the grid (3) and take out the filter. Make sure the filter and sealing surfaces are not damaged during removal.

NOTE: In humid conditions do not switch on the blower prior to servicing the filter.

Clean the filter element (1) in water with a suitable detergent (consult your Dealer). Instructions for using the detergent are printed on the detergent packaging.

Shake off the excess water and allow to dry naturally.

The filter element (1) must be thoroughly dry before installation.

Clean the inside of each filter chamber with a damp lint-free cloth and re-install the filter.

9-12

15

SECTION 9 - MAINTENANCE/ADJUSTMENTS HEATER UNIT AND AIR CONDITIONING COOLER (optional) SERVICE SPECIFICATIONS Clean ......................................................................................................................................... Every 250 hours These are located in a pod under the cab seat support. To gain access it is necessary to remove the seat.

Clean the heater and cooler using compressed air not exceeding 7 bar (102 psi) taking care not to damage the radiator fins.

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

Clean the chamber with a damp, cloth and reassemble the pod filter element.

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

16

PARKING BRAKE ADJUSTMENT The parking brake is adjusted by tightening the inner adjuster nut (1) until the brake pad just contacts the disc at which point the 2nd outer nut should be tightened to lock the assembly.

The parking brake cable free movement can be adjusted by rotation of the cable knuckle (2) situated at the base of the parking brake cable where it attaches to the transmission by the quick release pin (3).

The parking brake should be adjusted to be fully “On” at the 4th ratchet position on the parking brake.

17

9-13

SECTION 9 - MAINTENANCE/ADJUSTMENTS BRAKE FLUID SERVICE SPECIFICATIONS Level check ....................................................................................................................................... Periodically Draining the circuit ..................................................................................................................... Every two years The foot brakes do not require adjustment other than a fluid change every 2 years, or before if the fluid is low or a leak has occurred.

18 Check the brake pumps for signs of leakage. Ensure the fluid level in the brake reservoir is checked periodically.

!

WARNING

!

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

NOTE: Before adding fluid to the brake fluid reservoir, make sure it is of the right type. Use of a wrong type of fluid can cause serious damage. See “Fuel and lubricant capacities and specifications” in Section 8.

9-14

19

SECTION 9 - MAINTENANCE/ADJUSTMENTS BACKHOE BUCKET EXCAVATION ANGLE It is possible to change the backhoe bucket opening angle, depending on the work which is to be carried out.

Position (1): Bucket maximum power.

Position (2): Enables the bucket to open 10° more and therefore to be able to dig vertical side trenches closer to the machine.

NOTE: To change the bucket fixing point, see “Replacing a backhoe bucket” in Section 5.

20

TELESCOPIC DIPPER (HED) (optional) SERVICE SPECIFICATIONS Checking and adjustment .......................................................................................................... Every 250 hours The telescopic dipper (HED) (if fitted) is equipped with adjustable wear pads (4) and adjusted by removing shims (1) from under the screws (2) located on the outside of the dipper on either side.

Retract the dipper and place it on a support so the bucket is not touching the ground. Remove a shim from each screw (2) on one side of the dipper.

IMPORTANT: Each time a new adjustment is made, carry it out on the other side of the dipper. If you are in any doubt concerning adjustments, consult your Dealer.

Install and tighten the screws to a torque between 350 and 400 Nm (258 - 295 lbf ft). Check the play again.

The play at point (3) should not exceed 1.5 mm (0.06 in).

When all adjusting shims have been removed the wear pads (4) will require changing. Consult your Dealer.

21

9-15

SECTION 9 - MAINTENANCE/ADJUSTMENTS FRONT WHEEL ADJUSTMENTS SERVICE SPECIFICATIONS Checking and adjustment ................................................................................................................. Periodically TOE-IN CHECK The front wheel toe-in is pre set and adjustment is not normally necessary. Occasional checks should be made to ensure the correct toe-in is maintained.

TOE-IN ADJUSTMENT 1.

Measure the toe-in by checking the track width between the front of the wheel rim (1) and the rear of the wheel rim (2) at hub height. The correct toe-in measurement is 0 - 6 mm (0 - 0.24 in).

2.

Loosen the lock nut (3) on each track rod and turn the hexagon (4) with a spanner until the correct toe-in setting is obtained. Tighten the lock nut and re-check the toe-in.

22

23

9-16

SECTION 9 - MAINTENANCE/ADJUSTMENTS WHEEL ADJUSTMENTS (4WS) SERVICE SPECIFICATIONS Checking and adjustment ..................................................................................................................Periodically TOE-IN CHECK The front wheel toe-in is pre set and adjustment is not normally necessary. Occasional checks should be made to ensure the correct toe-in is maintained.

TOE-IN ADJUSTMENT IMPORTANT: The machine wheels must be set to the normal 2 wheel steer position with the wheels set in a straight line.

1.

Measure the toe-in by checking the track width between the front of the wheel rim (1) and the rear of the wheel rim (2) at hub height. The correct toe-in measurement is 0 - 2 mm (0 - 0.07 in).

2.

Loosen the lock nut (3) on each track rod and turn the hexagon (4) with a spanner until the correct toe-in setting is obtained. Tighten the lock nut and re-check the toe-in.

24

25 STEERING STOPS Four steering stops (1) are incorporated in the axle, two each end. The two rear stops are adjustable and control the minimum turning circle. The two front stops are adjustable and should be set to prevent the tires touching the machine on full left and right lock with the axle fully oscillated.

To adjust, slacken the locknut (2) and turn the stop bolt (1) anti-clockwise to reduce the steering angle of the wheels or clockwise to increase the steering angle. Tighten the locknut.

26

9-17

SECTION 9 - MAINTENANCE/ADJUSTMENTS ROPS/FOPS CAB (or protective frame) SERVICE SPECIFICATIONS Inspection.................................................................................................................................. Every 300 hours (after the first 50 hours of operation) Your machine has a ROPS/FOPS cab (or frame).

ROPS: Roll over protective structure.

FOPS: Falling object protective structure.

An identification plate is attached to the ROPS/ FOPS cab (or frame). See “type, Serial Number And Year Of Manufacture Of The Machine” in Section 2 for: − The manufacturer’s address. − The ROPS/FOPS serial number. − The reference to the performance requirements met: ISO 3471-1 for the ROPS. ISO 3449 for the FOPS. MAINTENANCE AND INSPECTION

DAMAGE

Check the torque of the mounting screws and, if necessary, tighten the screws to the correct torque.

See “Mounting screw torque”.

If the machine has rolled over or if the ROPS/FOPS cab has been in some other type of accident, you must replace the damaged ROPS/FOPS components in order to conserve the same degree of protection you had previously.

Check the operator’s seat and the seat belt mounting hardware. Tighten the screws to the correct torque. Replace parts showing signs of wear or damage.

Check that there are no cracks, rust or holes in the ROPS/FOPS cab (or frame) and components. Age, weather and accidents can cause damage. If you have any doubt about the state of the ROPS/FOPS cab (or frame), consult your Dealer.

9-18

After an accident, check the following for damage: The ROPS/FOPS cab (or frame).

The lower ROPS/FOPS cab (or frame) chassis.

The operator’s seat.

The seat belt mounting hardware.

IMPORTANT : Before putting the machine back into service, make sure all the damaged components of the ROPS/FOPS cab (or frame) have been replaced. See the Parts Catalogue for your machine or consult your Dealer.

SECTION 9 - MAINTENANCE/ADJUSTMENTS MOUNTING SCREW TORQUE The torque specifications for the screws used to mount the ROPS/FOPS cab (or frame) on the lower chassis is 380 Nm (280 lbf ft).

!

WARNING

!

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

!

WARNING

!

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

!

WARNING

!

If you operate this machine without a ROPS/FOPS cab (or frame) and the machine rolls over, you can be seriously injured or killed. Remove the ROPS/ FOPS cab only for service or replacement. Do not operate the machine with the ROPS/FOPS cab (or frame) removed.

!

WARNING

!

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

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

!

WARNING

!

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

9-19

SECTION 9 - MAINTENANCE/ADJUSTMENTS TROUBLESHOOTING IMPORTANT: The following troubleshooting table is designed for your guidance only. If any repairs are required beyond routine maintenance, your machine must be returned to your Dealer who has the correct tools, facilities and knowledge to perform repairs to the correct specification and safety standards.

ENGINE PROBLEMS

The engine does not start.

The engine stalls.

SOLUTIONS

No electric current in circuit

Reconnect the battery masterswitch (if fitted)

Batteries discharged or defective

Clean connectors, recharge or replace the batteries

Contaminated fuel

Drain and clean the fuel system

Fuel tank empty

Fill the fuel tank

Contaminated fuel

Drain and clean the fuel system

Fuel filters clogged

Replace fuel filters

Water pump drive belt slack

Check belt tensioner

Coolant level too low

Top up, look for leaks

Clogged air filter

Clean/replace air filter

Clogged air filter

Clean/replace air filter

Injector nozzle blocked or partially blocked

Consult your Dealer

Clogged air filter

Clean, replace the filter elements

The engine overheats.

Engine runs irregularly and insufficient power.

Large emissions of black or dark grey smoke.

POSSIBLE CAUSES

TRANSMISSION (POWERSHUTTLE) PROBLEMS

POSSIBLE CAUSES

SOLUTIONS

Transmission will not operate.

Low oil supply

Fill system with oil and check pump pressure

Transmission operation poor or jerky.

Electrical connections loose

Check electrical continuity

Low oil supply

Fill system with oil

Oil cooler air flow blocked

Clean all debris away from radiator

Handbrake dragging on

Adjust brake disc clearance

Transmission overheating torque convertor slipping.

TRANSMISSION (POWERSHIFT) PROBLEMS Transmission will not operate.

Transmission overheating torque convertor slipping.

9-20

POSSIBLE CAUSES

SOLUTIONS

Low oil supply

Fill system with oil and check pump pressure

Low oil supply

Fill system with oil

Oil cooler air flow blocked

Clean all debris away from radiator

Handbrake dragging on

Adjust brake disc clearance

SECTION 9 - MAINTENANCE/ADJUSTMENTS ELECTRICAL SYSTEM PROBLEMS

POSSIBLE CAUSES

SOLUTIONS

Loose or corroded battery connections

Clean and tighten connections

Sulphated batteries

Check battery open circuit voltage for 12.6 volts minimum.

Check electrolyte level and specific gravity

Battery master switch turned “OFF”

Reset battery master switch “ON”

Main machine fuse link blown

Establish reason of failure and replace fuse link

Loose or corroded connections

Clean and tighten loose connections

Low batteries output

Check battery open circuit voltage for 12.6 volts minimum.

Check electrolyte level and specific gravity

Incorrect viscosity engine oil

Use correct viscosity oil for temperature conditions

Transmission shift lever in gear

Place shift lever in neutral

Loose or corroded connections

Clean and tighten loose connections

Dead batteries

Charge or replace batteries

Low engine idle speed

Increase idle speed

Loose belt

Check belt tension

Malfunctioning batteries

Check battery open circuit voltage for 12.6 volts minimum.

Check electrolyte level and specific gravity

Malfunctioning alternator

Have authorized Dealer check alternator

Loose or corroded batteries connections

Clean and tighten connections

Sulphated batteries

Check battery open circuit voltage for 12.6 volts minimum.

Check electrolyte level and specific gravity

Loose or worn belt

Check belt tension. Replace belt if required

Charge indicator flashing indicating excessive charging voltage.

Malfunctioning alternator

Have authorised Dealer check alternator

Grid header indicator light blinks (optional).

Starting device inoperative

Consult your Dealer

Electrical system is inoperative.

Starter speed low and engine cranks slowly.

Starter inoperative.

Charge indicator lamp stays on with engine running.

Batteries will not charge.

9-21

SECTION 9 - MAINTENANCE/ADJUSTMENTS CAB PROBLEMS

Dust enters the cab.

Blower motor air flow low.

Air conditioner does not cool.

9-22

POSSIBLE CAUSES

SOLUTIONS

Improper seal around filter

Check seal condition

Blocked filter

Clean or replace filter

Defective filter

Replace filter

Excessive air leak(s)

Seal air leak(s)

Blocked filter or recirculation filter

Clean or replace filter(s)

Condenser plugged

Clean radiator, oil cooler and condenser

Low refrigerant

Check sight glass for bubbles.

Consult your Dealer

Belt slipping or damaged

Check automatic belt tensioner and belt condition

Heater control turned “ON”

Turn temperature control knob fully counterclockwise for maximum cooling

SECTION 10

14

ELECTRICAL SYSTEM FUSES AND RELAYS IMPORTANT: Never replace a fuse with a fuse of a different rating.

The fuses and relays box is located under the side instrument panel.

Near to the fuse and relay box is located also another fuse: 5 A fuse: Diagnostics, menu scroll switch, menu enter switch and (+30) antitheft.

1 The main circuit fuses of ECU control unit, of air conditioning and the starter relay and air conditioning relay are located on the front right hand side, behind the engine.

The fuses and relays used are as follows: 70 A fuse: Main circuit protection between the battery and the machine electrical system.

30 A fuse: Air conditioning 3rd speed (if fitted).

30 A fuse: ECU control unit.

10 A fuse: Air conditioning (if fitted).

5 A fuse: Fuel pre-filter.

2

No. 3 relays: Start.

Relay: Air conditioning (if fitted).

Located under the seat base: 25 A fuse: blower motor (if fitted) third speed.

NOTA: Remove the seat to gain access to this fuse.

3

10-1

SECTION 10 - ELECTRICAL SYSTEM The fuse of Grid heater is located on the front right hand side of engine.

7.5 A fuse: Grid Heater.

4

10-2

SECTION 10 - ELECTRICAL SYSTEM FUSES - POWERSHUTTLE WITH ROPS Fuse No.

Rating

Color

Circuit

F1/B

7.5 A

Brown

Fuel shut off solenoid, grid heater, supply (+15) ECU

F1/C

10 A

Red

Brake lights

F2/A

15 A

Blue

Instruments switch backlights, brake oil level sensor, air seat, parking brake

F2/C

15 A

Yellow

Pilot control

F3/A

3A

Violet

Rear right/front left side lights, instruments backlight

F3/B

3A

Violet

Rear left/front right side lights

F3/C

10 A

Red

Front work lights, 4x1 bucket, Glide Ride control

F4/A

5A

Red

Transmission shuttle lever, backup alarm

F4/B

10 A

Red

Rear auxiliary button, loader RTD, transmission disconnect switches

F4/C

10 A

Red

Rear work lights, backhoe transport lock

F5/A

15 A

Blue

Front inner work lights

F6/A

7.5 A

Brown

Rotary Beacon

F6/B

7.5 A

Brown

(+15) Turn signals

F6/C

7,5 A

Brown

Hand tool, 4WD

F7/A

10 A

Red

(+30) Hazard lights and horn

F1/A

F2/B

F5/B F5/C

F7/B

15 A

Optional

F7/C

6A

Optional

F8/A

15 A

Blue

Outer rear work lights

F8/B

15 A

Blue

Outer front work lights

F8/C

15 A

Blue

Inner rear work lights

RELAYS K1

Transmission shuttle lever relay

K3

Neutral safety start relay

K4

Loader return to dig relay

5

K5 K6

Inner front work lights relay

K7

Inner rear work lights relay

K8

Outer front work lights relay

K9

Outer rear work lights relay

K10

Reverse shuttle relay

K11

Forward shuttle relay

K12

Turn signal and hazard lights flasher

10-3

SECTION 10 - ELECTRICAL SYSTEM FUSES - POWERSHUTTLE WITH CAB Fuse No.

Rating

Color

Circuit

F1/A

15 A

Blue

Rear windshield wiper and rear windshield washer

F1/B

7.5 A

Brown

Fuel shut off solenoid, grid heater, supply (+15) ECU

F1/C

10 A

Red

Brake lights, 4-wheel braking

F2/A

15 A

Blue

Instruments switch backlights, brake oil level sensor, air seat, parking brake, buzzer

F2/B

15 A

Blue

Blower motor

F2/C

15 A

Yellow

Pilot control, pilot loader (optional)

F3/A

3A

Violet

Rear right/front left side lights, instruments backlight, air conditioner switch light

F3/B

3A

Violet

Rear left/front right side lights

F3/C

10 A

Red

Front work lights, 4x1 bucket, Glide Ride control

F4/A

5A

Orange

Transmission shuttle lever, back-up alarm

F4/B

10 A

Red

Rear auxiliary button, loader RTD, transmission disconnect switches

F4/C

10 A

Red

Rear work lights, backhoe transport lock

F5/A

15 A

Blue

Front inner work lights

F5/B F5/C F6/A

15 A

Brown

Rotary Beacon

F6/B

7.5 A

Brown

(+15) Turn signals Hand tool, 4WD

F6/C

7.5 A

Brown

F7/A

10 A

Red

(+30) Hazard lights and horn

Red

Aux 12 volt socket, radio, cab interior light

F7/B

10 A

F7/C

6A

Black *

Front windshield wiper

F8/A

15 A

Blue

Outer rear work lights

F8/B

15 A

Blue

Outer front work lights

F8/C

15 A

Blue

Inner rear work lights

* Special Bi Metal, re-setting Fuse RELAYS K1

Transmission shuttle lever relay

K3

Neutral safety start relay

K4

Loader return to dig relay

K5 K6

Inner front work lights relay

K7

Inner rear work lights relay

K8

Outer front work lights relay

K9

Outer rear work lights relay

K10

Reverse shuttle relay

K11

Forward shuttle relay

K12

Turn signal and hazard lights flasher

10-4

6

SECTION 10 - ELECTRICAL SYSTEM FUSES - POWERSHIFT WITH CAB Fuse No.

Rating

Color

Circuit

F1/A

15 A

Blue

Rear windshield wiper and rear windshield washer

F1/B

7.5 A

Brown

Fuel shut off solenoid, grid heater, supply (+15) ECU

F1/C

10 A

Red

Brake lights, 4-wheel braking

F2/A

15 A

Blue

Instruments switch backlights, brake oil level sensor, air seat, parking brake, buzzer Blower motor

F2/B

15 A

Blue

F2/C

15 A

Yellow Pilot control, pilot loader (optional)

F3/A

3A

Violet

Rear right/front left side lights, instruments backlight, air conditioner switch light

F3/B

3A

Violet

Rear left/front right side lights

F3/C

10 A

Red

Front work lights, 4x1 bucket, Glide Ride control

F4/A

7.5 A

Brown

Powershift operating lever, back-up alarm, 4WD switch

F4/B

10 A

Red

Rear auxiliary button, loader RTD, transmission disconnect switches

F4/C

10 A

Red

Rear work lights, backhoe transport lock

F5/A

15 A

Blue

Front inner work lights

F5/B F5/C F6/A

15 A

Brown Rotary Beacon

F6/B

7,5 A

Brown (+15) Turn signals

F6/C

7.5 A

Brown Hand tool, differential lock

F7/A

10 A

Red

(+30) Hazard lights and horn

F7/B

10 A

Red

Aux 12 volt socket, radio, cab interior light

F7/C

6A

Black *

Front windshield wiper

F8/A

15 A

Blue

Outer rear work lights

F8/B

15 A

Blue

Outer front work lights

F8/C

15 A

Blue

Inner rear work lights

7

* Special Bi Metal, re-setting Fuse RELAYS K3

Neutral safety start relay

K4

Loader return to dig relay

K5 K6

Inner front work lights relay

K7

Inner rear work lights relay

K8

Outer front work lights relay

K9

Outer rear work lights relay

K10

Differential lock relay

K12

Turn signal and hazard lights flasher

10-5

SECTION 10 - ELECTRICAL SYSTEM FUSES - POWERSHIFT WITH CAB - (4WS) Fuse No.

Rating Color

Circuit

F1/A

15 A

Blue

Rear windshield wiper and rear windshield washer

F1/B

7.5 A

Brown

Fuel shut off solenoid, grid heater, supply (+15) ECU

F1/C

10 A

Red

Brake lights, 4-wheel braking

F2/A

15 A

Blue

Instruments switch backlights, brake oil level sensor, air seat, parking brake, buzzer

F2/B

15 A

Blue

Blower motor

F2/C

15 A

Yellow Pilot control, pilot loader (optional)

F3/A

3A

Violet

Rear right/front left side lights, instruments backlight, air conditioner switch light

F3/B

3A

Violet

Rear left/front right side lights

F3/C

10 A

Red

Front work lights, 4x1 bucket, Glide Ride control

F4/A

7.5 A

Brown

Powershift operating, lever, back-up alarm

F4/B

10 A

Red

Rear auxiliary button, loader RTD, transmission disconnect switches

F4/C

10 A

Red

4WS control unit, 4WS switch, rear work lights and backhoe transport lock

F5/A

15 A

Blue

Front inner work lights

F5/B

10 A

Red

Grab handle driving lights low beam (optional)

F5/C

15 A

Blue

Grab handle driving lights high beam (optional)

F6/A

15 A

Brown

Rotary Beacon

F6/B

7.5 A

Brown

(+15) Turn signals

F6/C

7.5 A

Brown

Hand tool, 4WD

F7/A

10 A

Red

(+30) Hazard lights and horn

F7/B

10 A

Red

Aux 12 volt socket, radio, cab interior light

F7/C

6A

Black * Front windshield wiper

F8/A

15 A

Blue

Outer rear work lights

F8/B

15 A

Blue

Outer front work lights

F8/C

15 A

Blue

Inner rear work lights

* Special Bi Metal, re-setting Fuse RELAYS K3

Neutral safety start relay

K4

Loader return to dig relay

K5 K6

Inner front work lights relay

K7

Inner rear work lights relay

K8

Outer front work lights relay

K9

Outer rear work lights relay

K10

Optional

K12

Turn signal and hazard lights flasher

10-6

BUZZER BZ1

Warning buzzer (steering mode)

8

SECTION 10 - ELECTRICAL SYSTEM BATTERY NOTE: The machine can be installed with one or two batteries.

SERVICE SPECIFICATIONS Battery terminal tightness check................................................................................................ Every 250 hours Electrolyte level inspection ......................................................................................................Every 1000 hours ACCESS TO THE BATTERY Use the ignition switch to open the battery box in the oil tank.

Make sure the battery terminals are clean and coated with grease and make sure the cables are correctly tightened.

9 CHECKING THE ELECTROLYTE LEVEL Remove the vent plugs and check the level in each battery cell. The level should come up to 6 mm (0.24 in) above the separator plates. Add distilled water if necessary.

!

WARNING

!

Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid any contact with the skin, eyes or clothing.

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

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

EYES: rinse abundantly with water for15 minutes and consult a doctor.

10

10-7

SECTION 10 - ELECTRICAL SYSTEM

!

WARNING

!

A spark or flame can cause the hydrogen in a battery to explode. To prevent any risk of explosion, observe the following instructions: - Place the battery master switch key in the OFF position (disconnected) (if fitted).

- When disconnecting the battery cables, always disconnect the negative cable (-) first.

- When reconnecting the battery cables, always connect the negative (-) cable last.

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

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

!

WARNING

!

Batteries produce explosive gases. Keep away any flame, spark or cigarettes. Always provide good ventilation when charging a battery or using a battery in an enclosed space. Always protect your eyes when working near a battery.

!

WARNING

!

Before carrying out any welding on the machine or repair work on the electrical circuit, disconnect the battery and disconnect the B+ and D+ wires on the alternator. When reconnecting, check the wire markings.

!

WARNING

!

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

!

WARNING

!

Never touch the battery terminals with your hands.

This can induce a state of electrolysis and impair the main organs of the body.

10-8

SECTION 10 - ELECTRICAL SYSTEM REPLACING A BATTERY 1.

Remove the battery master switch support (6) without disconnect the battery cables.

2.

Remove the terminal covers and disconnect the cables, first from the negative terminal (1) then the positive terminal (2).

3.

Remove the nuts and washers (3), the clamping bar (4) and the brackets (5) and remove the old battery.

4.

Install the new battery.

5.

Install the brackets (5), the clamping bar (4) and the washers and nuts (3).

6.

Clean the cables and the connecting terminals and coat them with grease.

7.

Connect the cables, first to the positive terminal (2), then the negative terminal (1) and install the terminal covers.

8.

Remove the battery master switch support (6).

11

!

WARNING

!

Never reverse the battery terminals. Connect the positive cable to the positive terminal (+) and the negative cable to the negative terminal (-).

12

10-9

SECTION 10 - ELECTRICAL SYSTEM CONNECTING A BOOSTER BATTERY

!

WARNING

!

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

Always keep the battery charged to prevent the electrolyte freezing.

!

WARNING

!

Connecting jumper cables wrongly or short-circuiting battery terminals can cause an accident. Connect the jumper cables following the instructions in this manual.

IMPORTANT: Make sure that the voltage of the booster batteries is the same as that of the machine circuit (12 V).

1.

Open the battery box and then remove the tool box.

2.

Remove the terminal covers.

3.

Connect the positive (+) jumper cable to the positive (+) terminal of the machine’s battery.

4.

Connect the negative (-) jumper cable to one of the fastening screw (1) of hydraulic oil tank.

5.

Start the engine.

6.

First disconnect the negative (-) jumper cable, then disconnect the positive (+) jumper cable from the booster battery.

7.

Install the terminal covers.

8.

Install the tool box and close the battery box.

13

10-10

SECTION 10 - ELECTRICAL SYSTEM ALTERNATOR SERVICE SPECIFICATIONS Inspection ................................................................................................................................ Every 1000 hours

!

WARNING

!

Before carrying out any welding on the machine or repair work on the electrical circuit, disconnect the battery and disconnect the B+ and D+ wires on the alternator. When reconnecting, check the wire markings.

IMPORTANT: Do not use steam cleaning apparatus or cleaning solvent to clean the alternator.

Have the alternator checked by your Dealer.

14

STARTER MOTOR SERVICE SPECIFICATIONS Inspection ................................................................................................................................ Every 1000 hours Have the starter motor checked by your Dealer.

NOTE: Make sure the terminal protectors are correctly installed.

15

10-11

SECTION 10 - ELECTRICAL SYSTEM BULBS Operator’s compartment light...................................................................................................................... 10 W Instrument panel gauge ............................................................................................................................. 1.2 W Headlights .............................................................................................................................................. 60/55 W Front side lights (on headlight)...................................................................................................................... 4 W Front direction indicators............................................................................................................................. 21 W Rear direction indicators ............................................................................................................................. 21 W Rear stop/side lights ................................................................................................................................ 5/21 W Front work lights (on cab) ........................................................................................................................... 55 W Rear work lights (on cab) ............................................................................................................................ 55 W Rotating beacon (if fitted)............................................................................................................................ 55 W

REPLACING A BULB IMPORTANT: Never touch a halogen bulb with your fingers. Always use a clean cloth when handling halogen bulbs.

DRIVER’S SEAT LIGHT 1.

Remove the lens (1) unscrewing it by turning 90° through its central slot.

2.

Remove the bulb (2) and install a bulb of the same wattage (10 W).

3.

Reinstall the lens (1).

16 SWITCH LIGHTING 1.

Remove and disconnect the switch concerned.

2.

Remove the bulb holder. Remove the bulb and install a bulb of the same wattage (1.2W).

3.

Install the bulb holder and the switch.

17

10-12

SECTION 10 - ELECTRICAL SYSTEM HEADLIGHTS AND DIRECTION INDICATORS 1.

Remove the four screws and remove the light assembly.

2.

Disconnect the socket from the bulb holder connector. Fold back the clips, remove the defective bulb and replace it with a bulb of the same wattage.

3.

Remove out the bulb holder on the outside of the reflector to replace the direction indicator bulb.

NOTA: Access to the direction indicator bulb is gained by removing the reflector cover mounting screw.

NOTE: The headlight may be adjusted vertically and sideways by means of the recessed slotted screws.

18

FRONT AND REAR WORK LIGHTS 1.

Remove the screws and take off the light assembly.

2.

Remove the bulb and install a bulb of the same wattage (55 W).

3.

Install the light assembly and the screws.

19

10-13

SECTION 10 - ELECTRICAL SYSTEM

NOTES

10-14

SECTION 11

2

STORAGE PREPARATION FOR STORAGE

STARTING UP AFTER STORAGE

If the machine is to remain unused for a period exceeding 30 days, store it under cover or cover it with a waterproof tarpaulin.

Do not start the engine before carrying out the following operations:

1.

2.

3.

Clean the machine completely. Paint all surfaces of the machine where the paintwork is damaged, to avoid rust.

Check the machine for worn or damaged parts and replace as necessary.

Lubricate the machine and drain the transmission, hydraulic reservoir, rear axle and engine and refill with the correct grades of oil.

4.

Check the radiator coolant level. If the machine is within 100 hours of the 2000 hour scheduled service or within 2 months of the two year schedule service perform the service as in maintenance.

5.

Operate the loader so all loader cylinders are in the fully retracted position and all the bucket is resting on a block or piece of wood.

6.

Place the backhoe attachment in transport position.

7.

Stop the engine and operate all the hydraulic controls to release all residual pressure in the hydraulic circuits.

8.

Coat the exposed portions of the cylinder rods and control valve spools with grease.

9.

Charge the battery. Remove it from the machine and place it on a wooden pallet in a cool, dry place. If possible, store it in a building where the temperature is above 0 °C (32 °F).

Make sure the battery is clean. Check the electrolyte level regularly and make sure it is correct.

1.

Check the condition of the tires and the tire pressure.

2.

Fill the fuel tank.

3.

Check the level of the coolant solution.

4.

Check all oil and fluid levels.

5.

Install a fully charged battery.

6.

Remove the cover from the exhaust pipe opening.

7.

Remove the coat of protective grease from the areas concerned, for example the steering cylinders, valve spools, etc.

!

WARNING

!

Check the machine for leaks and for broken, defective or missing parts.

!

WARNING

!

Before starting the engine, make sure all the controls are in the neutral position. This will prevent any unexpected movement of the machine and of any electrical equipment.

!

WARNING

!

Avoid running the engine in an enclosed space.

Ensure adequate ventilation at all times.

10. Place blocks under the axles to remove the weight from the tires.

11. Cover the exhaust pipe opening.

11-1

SECTION 11 - STORAGE

NOTES

11-2

SECTION 12

16

SPECIFICATIONS ENGINE - 110 HP / 82 KW (B110 - B115 MODELS) Data (CEE 88/195) ............................................................... 110 hp/ 82 kW, turbocharged - Charge Air Cooled Type........................................................................................................................................................... Diesel No. of cylinders.................................................................................................................................................. 4 Bore ............................................................................................................................................... 104 mm (4 in) Stroke .........................................................................................................................................132 mm (5.2 in) Displacement...................................................................................................................... 4485 cm3 (273.6 in3) Compression Ratio .................................................................................................................................... 17.5:1 Firing Order .............................................................................................................................................. 1.3.4.2 Idle Speed.................................................................................................................................. 750-950 rev/min Maximum “No-Load” Speed................................................................................................... 2380-2480 rev/min Maximum “Full Load” Speed........................................................................................................... 2200 rev/min Maximum Torque (CEE) ..................................................................................................... 516 Nm (380.5 lbf ft)

COOLING SYSTEM Type...................................................................................................................................Pressurized Full Flow Fan Belt Type ..................................................................................................................... 8 Groove Serpentine Fan Belt Tension................................................................................................................. Automatic Tensioner Air Conditioning Compressor Belt ..........................................................................................................Single V Air Conditioning Belt Tension................................................................................................................... Manual Thermostat: Starts to Open at........................................................................................................................... 81 °C (178 °F) Fully Open at ................................................................................................................................ 96 °C (205 °F) Radiator Cap ............................................................................................................................. 0.90 bar (13 psi)

FUEL SYSTEM Injection Pump, Type ................................................................................................................Bosch Rotary VE Cold Start Device................................................................................................................ Optional Grid Heater Double Delivery Device ....................................................................................................................... Automatic Fuel Shut Off ......................................................................................................................................... Solenoid Lift Pump ........................................................................................................................................... Mechanical Timing ......................................................................................................................... 1 mm (0.04 in) lift @ TDC

TRANSMISSION (B110 MODELS) POWERSHUTTLE 4x4 = 4 Forward and 4 Reverse Gears Torque Convertor Ratio ............................................................................................................................. 2.63:1 POWERSHIFT 4x2 = 4 Forward and 2 Reverse Gears Torque Convertor Ratio ............................................................................................................................. 2.54:1

TRANSMISSION (B115 MODELS) POWERSHIFT 4x2 = 4 Forward and 2 Reverse Gears Torque Convertor Ratio ............................................................................................................................. 2.54:1

12-1

SECTION 12 - SPECIFICATIONS ELECTRICAL SYSTEM Alternator .................................................................................................................................................90 amp Battery Type..........................................................................................95 amp hr (12V/900 CCA) SAE - Single 60 amp hr (12V/600 CCA) SAE - Double Battery Disconnect via the Isolator Switch................................................................. on Negative/chassis cable Regulator ...................................................................................................................................... Transistorised Ground (Earth) ...................................................................................................................................... Negative Starting Motor...................................................................... Positive Engagement, Solenoid Operated (2.7 kW)

BRAKES Type .............................................................................................Wet Multi-Discs x8 per Axle (x4 per half Axle) Disc Diameter ............................................................................................................................ 203.2 mm (8 in) Parking Type ..................................................................................................................Single Disc on Driveline

STEERING Power Steering Type..........................................................................................................................Hydrostatic Power Steering Displacement 2WS .................................................................................125 cc/rev (7.6 in3/rev) Power Steering Displacement 4WS .................................................................................160 cc/rev (9.7 in3/rev) Turns Lock to Lock 2WD + 4WD......................................................................................... Left 3.25; Right 3.25 System Pressure.......................................................................................................177 ± 3 bar (2566 ± 44 psi)

REAR AXLE Type ..........................................................................................................Double Reduction, Inboard Planetary Differential Lock (Powershuttle Transmission).................................................................................. Mechanical Differential Lock (Powershift Transmission)....................................................................... Electrically Operated

HYDRAULIC SYSTEM Twin Gear Pump ....................................................................... Hydraulic System and Priority Steering System Hydraulic System Pressures: Main Relief Valve Pressure................................................................................ 206 - 210 bar (2987 - 3045 psi) Stabilizer Relief Valve Pressure ......................................................................... 196 - 202 bar (2842 - 2929 psi) Pump Flow: - 110 HP Turbo CAC ............................................................... 38 + 34 cc (2.3 + 2.1 in3), 160 l/min (42.10 gpm)

FRONT COUNTERWEIGHT Weight..................................................................................................................................... 223.4 kg (492 lbs) Weight (extra counterweight) ......................................................................... 26.2 kg (58 lbs) + 31.5 kg (69 lbs) Weight (B115 Models)................................................................................................................ 170 kg (374 lbs)

RADIATOR COOLANTS Engine cooler radiator and oil cooler.

In order to reduce deposits and corrosion, water in the cooling system should not exceed the following limits: Total hardness .................................................................................................................... 300 parts per million Chloride............................................................................................................................... 100 parts per million Sulphates ............................................................................................................................ 100 parts per million

12-2

SECTION 12 - SPECIFICATIONS FRONT WHEEL TIRE PRESSURES AND PERMISSIBLE LOADS (B110) The following charts give the approximate carrying capacity of the axle at the tire pressures indicated up to 30 km/h (18.641 mph).

Inflation Pressures in bar Tire size

Ply rating

1.5

1.7

1.9

2.1

2.2

2.4

2.6

2.8

3.0

11L - 16

10

1400

1480

1620

1720

1790

1880

2000

2080

2210

14-17.5

8

2780

3000

3205

3335

3465

3650

3830

3925

3.3

3.6

3.9

2340

2460

-

-

-

-

-

44

48

52

57

Permissible Load Capacity at the Axle (kg)

Inflation Pressures in psi Tire size

Ply rating

22

25

28

30

32

35

38

41

Permissible Load Capacity at the Axle (lbs) 11L - 16

10

3086

3262

3571

3791

3946

4144

4409

4585

4872

5158

5423

-

14-17.5

8

6130

6615

7065

7360

7640

8045

8445

8700

-

-

-

-

The above tables are for guidance only. For exact information regarding inflation pressures and loads for your particular tires consult your Dealer.

FOUR WHEEL DRIVE TIRE COMBINATIONS The tires fitted to machines with optional four wheel drive have been carefully selected to match the gearing of the transmission and axles. When renewing worn or damaged tires, always install tires of the same make, model and size as those removed. The installation of other tire combinations may result in excessive tire wear, loss of usable power or severe damage to drive line components. If in doubt, consult your Dealer.

12-3

SECTION 12 - SPECIFICATIONS REAR WHEEL TIRE PRESSURES AND PERMISSIBLE LOADS (B110) The following charts give the approximate carrying capacity of the axle at the tire pressures indicated up to 30 km/h (18.641 mph).

Inflation Pressures in bar Tire size

Ply rating

1.1

1.2

1.3

1.4

16.9-24

10

3556

3675

4040

4260

4408

4625

4890

5100

5300

5470

16.9-28-R4

10

3800

4000

4200

4460

4780

4900

5090

5380

5660

17.5L-24

10

3430

3740

3995

4160

4275

4530

4675

4780

19.5-24-R4

10

3990

4245

4610

4220

5150

5300

5580

5805

Tire size

Ply rating

1.5

1.6

1.7

1.8

1.9

2.0

2.2

2.3

2.4

2.6

5810

-

-

-

5800

6190

-

-

-

4950

5200

5450

5610

5820

-

5990

6170

6710

6710

7120

-

29

32

33

35

38

Permissible Load Capacity at the Axle (kg)

Inflation Pressures in psi 16

17

19

20

22

23

25

26

28

Permissible Load Capacity at the Axle (lbs) 16.9-24

10

7823

8085

8888

9698 10175 10758 11220 11660 12034 12782

-

-

-

16.9-28-R4

10

8380

8820

9260 10275 10540 10805 11220 11860 12480 12785 13465

-

-

-

17.5L-24

10

7546

8228

8789

9966 10285 10516 10890 11440 11990 12342 12804

-

19.5-24-R4

10

8800

9360 10160 10400 11360 11680 12300 12800 13200 13600 14800 14800 15700

-

9372

9152

9405

The above tables are for guidance only. For exact information regarding inflation pressures and loads for your particular tires consult your Dealer.

FRONT AND REAR WHEEL TIRE PRESSURES AND PERMISSIBLE LOADS (B115) The following charts give the approximate carrying capacity of the axle at the tire pressures indicated.

Inflation Pressures in bar Tire size

1.0

1.1

1.3

1.4

1.5

1.7

1.8

1.9

2.0

2.1

2.2

2.3

2.4

2.5

2.6

Permissible Load Capacity at the Axle (kg) 16.9-24-R4 1650 1775 2020 2130 2240 2445 2550 2650 2735 2820 2905 2990 3080 3165 3250 16.9-28-R4 1760 1895 2155 2775 2390 2610 2720 2830 2920 3005 3095 3190 3280 3370 3465 Inflation Pressures in psi Tire size

14.5 16.0 18.9 20.3 21.8 24.7 26.1 27.6 29.0 30.5 31.9 33.4 34.8 36.3 37.7 Permissible Load Capacity at the Axle (lbs)

16.9-24-R4 3630 3905 4444 4686 4849 5379 5610 5830 6017 6204 6391 6578 6776 6963 7150 16.9-28-R4 3872 4169 4741 6105 5258 5742 5984 6226 6424 6611 6809 7018 7216 7414 7623 The above tables are for guidance only. For exact information regarding inflation pressures and loads for your particular tires consult your Dealer.

12-4

SECTION 12 - SPECIFICATIONS ROAD SPEEDS The following tables show the approximate ground speeds in km/h and miles/h at rated engine speed.

Powershuttle Transmission Gear Ratio

Powershift Transmission

Rear Tire 16.9 - 28 and 21.5 L-24 km/h

miles/h

km/h

miles/h

1st Forward

5.39

3.34

6.2

3.9

2nd Forward

8.68

5.39

11.8

7.3

3rd Forward

18.47

11.47

23.4

14.5

4th Forward

32.84

20.40

41.4

25.7

1st Reverse

6.47

3.97

7.5

4.6

2nd Reverse

10.41

6.48

14

8.7

3rd Reverse

22.16

13.70

-

-

4th Reverse

39.41

24.48

-

-

Powershuttle Transmission Gear Ratio 1st Forward

Rear Tire 16.9-24

Rear Tire 17.5 L- 24

km/h

miles/h

km/h

miles/h

4.99

3.10

4.82

2.99

2nd Forward

8.03

4.98

7.76

4.82

3rd Forward

17.09

10.60

16.53

10.20

4th Forward

30.38

18.87

29.38

18.26

1st Reverse

5.99

3.70

5.79

3.59

2nd Reverse

9.63

5.98

9.32

5.80

3rd Reverse

20.50

12.70

19.82

12.30

4th Reverse

36.46

22.60

35.26

21.90

Powershuttle Transmission Gear Ratio

Rear Tire 19.5 L- 24 km/h

miles/h

1st Forward

5.12

3.18

2nd Forward

8.24

5.12

3rd Forward

17.54

10.89

4th Forward

31.19

19.30

1st Reverse

6.14

3.80

2nd Reverse

9.89

5.79

3rd Reverse

21.04

13.07

4th Reverse

37.42

23.25

12-5

SECTION 12 - SPECIFICATIONS MODEL B110 LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE

1 Dimensions A. Maximum height B. Bucket/loader linkage point height C. Dump height D. Maximum roll back at ground level E. Dump angle F. Reach fully raised G. Height to top of cab H. Digging depth I. Axle center to front of bucket on ground J. Wheelbase K. Rear drive axle center to swing post center L. Rear drive axle center to rear of backhoe bucket M. Overall length N. Height to top of boom P. Loader bucket width Q. Overall width

12-6

SECTION 12 - SPECIFICATIONS

TIRES

FRONT

REAR

2WD

11L-16F

19.5L-24R4

4WD

12-16.5

19.5L-24R4

Dimensions

2WD

4WD

A

4270 mm (14 ft)

4284 mm (14 ft 1 in)

B

3442 mm (11 ft 4 in)

3456 mm (11 ft 4 in)

C

2694 mm (8 ft 10 in)

2710 mm (8 ft 11 in)

D

39°

39°

E

45°

45°

F

800 mm (2 ft 7 in)

795 mm (2 ft 7 in)

G

2885 mm (9 ft 6 in)

2885 mm (9 ft 6 in)

H

146 mm (6 in)

130 mm (5 in)

I

2007 mm (6 ft 7 in)

1997 mm (6 ft 7 in)

J

2175 mm (7 ft 2 in)

2175 mm (7 ft 2 in)

K

1120 mm (3 ft 8 in)

1120 mm (3 ft 8 in)

L

2993 mm (9 ft 10 in)

3003 mm (9 ft 10 in)

M

7175 mm (23 ft 6 in)

7175 mm (23 ft 6 in)

N

3965 mm (13 ft 0 in)

3965 mm (13 ft 0 in)

P

2250 mm (7 ft 5 in)

2250 mm (7 ft 5 in)

Q

2261 mm (7 ft 5 in)

2261 mm (7 ft 5 in)

Performance

2WD

4WD

Lift capacity at maximum height

3529 kg (7782 lbs)

3529 kg (7782 lbs)

Breakout force

6004 daN (13498 lbs)

6204 daN (13947 lbs)

LOADER BUCKETS Type

Standard

4 in 1

6 in 1 (with forks)

Heaped capacity

1.0 m3 (264 Us gal)

1.0 m3 (264 Us gal)

1.0 m3 (264 Us gal)

Width

2250 mm (7 ft 5 in)

2250 mm (7 ft 5 in)

2250 mm (7 ft 5 in)

Weight

400 kg (881.5 lbs)

800 kg (1763 lbs)

960 kg (2116 lbs)

12-7

SECTION 12 - SPECIFICATIONS MODEL B115 LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE

2 Dimensions A. Maximum height B. Bucket/loader linkage point height C. Dump height D. Maximum roll back at ground level E. Dump angle F. Reach fully raised G. Height to top of cab H. Digging depth I. Axle center to front of bucket on ground J. Wheelbase K. Rear drive axle center to swing post center L. Rear drive axle center to rear of backhoe bucket M. Overall length N. Height to top of boom P. Loader bucket / Overall width Q. Stabilizer transport width

12-8

SECTION 12 - SPECIFICATIONS

TIRES

FRONT

REAR

16.9-28

16.9-28

Dimensions

Standard bucket

4 in 1 bucket

6 in 1 bucket (with forks)

A

4296 mm (14 ft 1 in)

4409 mm (14 ft 6 in)

4409 mm (14 ft 6 in)

B

3440 mm (11 ft 3 in)

3440 mm (11 ft 3 in)

3440 mm (11 ft 3 in)

C

2666 mm (8 ft 9 in)

2675 mm (8 ft 9 in)

2675 mm (8 ft 9 in)

D

45°

45°

45°

E

45°

45°

45°

F

795 mm (2 ft 7 in)

744 mm (2 ft 5 in)

744 mm (2 ft 5 in)

G

2900 mm (9 ft 10 in)

2900 mm (9 ft 6 in)

2900 mm (9 ft 6 in)

H

154 mm (6 in)

154 mm (6 in)

154 mm (6 in)

I

2030 mm (6 ft 8 in)

2012 mm (6 ft 7 in)

2012 mm (6 ft 7 in)

J

2200 mm (7 ft 3 in)

2200 mm (7 ft 3 in)

2200 mm (7 ft 3 in)

K

1120 mm (3 ft 8 in)

1120 mm (3 ft 8 in)

1120 mm (3 ft 8 in)

L

3025 mm (9 ft 11 in)

3025 mm (9 ft 11 in)

3025 mm (9 ft 11 in)

M

7255 mm (23 ft 10 in)

7237 mm (23 ft 9 in)

7237 mm (23 ft 9 in)

N

3950 mm (12 ft 12 in)

3950 mm (12 ft 12 in)

3950 mm (12 ft 12 in)

P

2400 mm (7 ft 10 in)

2400 mm (7 ft 10 in)

2400 mm (7 ft 10 in)

Q

2261 mm (7 ft 5 in)

2261 mm (7 ft 5 in)

2261 mm (7 ft 5 in)

Performance

Standard bucket

4 in 1 bucket

6 in 1 bucket (with forks)

Lift capacity at maximum height

3386 kg (7464 lbs)

3075 kg (6779 lbs)

2935 kg (6470 lbs)

Breakout force

5413 daN (12169 lbs)

5500 daN (12365 lbs)

5500 daN (12365 lbs)

LOADER BUCKETS Type

Standard 3

4 in 1 3

6 in 1 (with forks)

Heaped capacity

1.15 m (303 Us gal)

1.15 m (303 Us gal)

1.15 m3 (303 Us gal)

Width

2400 mm (7 ft 10 in)

2400 mm (7 ft 10 in)

2400 mm (7 ft 10 in)

Weight

426 kg (939 lbs)

830 kg (1829.5 lbs)

990 kg (2182 lbs)

12-9

SECTION 12 - SPECIFICATIONS MODEL B110 BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE

3 Dimensions A. Loading reach B. Bucket rotation C. Operating height, fully raised D. Loading height maximum E. Reach from swing post F. Reach from rear axle center line G. Maximum length of surface excavation J. Maximum digging depth K. Stabilizer spread - transport L. Stabilizer spread - working M. Stabilizer pad levelling angle

12-10

SECTION 12 - SPECIFICATIONS

TIRES

FRONT

REAR

12-16.5

19.5L-28R4

Dimensions

standard dipper

telescopic dipper (HED) (extended)

A

1927 mm (6 ft 4 in)

2866 mm (9 ft 5 in)

B

204°

204°

C

5728 mm (18 ft 10 in)

6425 mm (21 ft 1 in)

D

3910 mm (12 ft 10 in)

4628 mm (15 ft 2 in)

E

5843 mm (19 ft 2 in)

6927 mm (22 ft 9 in)

F

6963 mm (22 ft 10 in)

8047 mm (26 ft 5 in)

G

5755 mm (18 ft 11 in)

8816 mm (28 ft 11 in)

J

4592 mm (15 ft 1 in)

5776 mm (18ft 11in)

K

2261 mm (7 ft 5 in)

2261 mm (7 ft 5 in)

L

3230 mm (10 ft 7 in)

3230 mm (10 ft 7 in)

M

14°

14°

Performance

standard dipper

telescopic dipper (HED) (extended)

Swing arc

180°

180°

Maximum digging force dipper cylinder

3600 daN (8093 lbs)

2568 daN (5773 lbs)

Maximum digging force bucket cylinder

5700 daN (12814 lbs)

5700 daN (12814 lbs)

Lift capacity through dipper arc

2615 kg (5770 lbs)

1510 kg (3330 lbs)

Lift capacity, dipper 3.66 m (12 ft) above ground

2640 kg (5820 lbs)

1605 kg (3540 lbs)

Lift capacity at 4.26 m (14 ft) above ground

1545 kg (3405 lbs)

1015 kg (2235 lbs)

Telescopic dipper (HED) extension length

-

1200 mm (3 ft 11 in)

BACKHOE BUCKETS Struck capacity SAE J 296

Width

Weight

76 L (20 Us gal)

305 mm (1 ft)

108 kg (238 lbs)

109 L (29 Us gal)

457 mm (1 ft 6 in)

130 kg (287 lbs)

153 L (40 Us gal)

610 mm (2 ft)

160 kg (353 lbs)

196 L (52 Us gal)

762 mm (2 ft 6 in)

180 kg (397 lbs)

238 L (63 Us gal)

914 mm (2 ft 12 in)

208 kg (459 lbs)

12-11

SECTION 12 - SPECIFICATIONS MODEL B115 BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE

4 Dimensions A. Loading reach B. Bucket rotation C. Operating height, fully raised D. Loading height maximum E. Reach from swing post F. Reach from rear axle center line G. Maximum length of surface excavation J. Maximum digging depth K. Stabilizer spread - transport L. Stabilizer spread - working M. Stabilizer pad levelling angle

12-12

SECTION 12 - SPECIFICATIONS

TIRES

FRONT

REAR

16.9-4

16.9-4

Dimensions

standard dipper

telescopic dipper (HED) (extended)

A

2002 mm (6 ft 7 in)

3001 mm (9 ft 10 in)

B

204°

204°

C

5660 mm (18 ft 7 in)

6320 mm (20 ft 9 in)

D

3857 mm (12 ft 8 in)

4541 mm (14 ft 11 in)

E

5841 mm (19 ft 2 in)

6927 mm (22 ft 9 in)

F

6963 mm (22 ft 10 in)

8050 mm (26 ft 5 in)

G

6216 mm (20 ft 5 in)

8873 mm (29 ft 1 in)

J

4636 mm (15 ft 3 in)

5810 mm (19 ft 1 in)

K

2261 mm (7 ft 5 in)

2261 mm (7 ft 5 in)

L

3230 mm (10 ft 7 in)

3230 mm (10 ft 7 in)

M

14°

14°

Performance

standard dipper

telescopic dipper (HED) (extended)

Swing arc

180°

180°

Maximum digging force dipper cylinder

3600 daN (8093 lbs)

2568 daN (5773 lbs)

Maximum digging force bucket cylinder

5700 daN (12814 lbs)

5700 daN (12814 lbs)

Lift capacity through dipper arc

2560 kg (5642 lbs)

1500 kg (3306 lbs)

Lift capacity, dipper 3.66 m (12 ft) above ground

2620 kg (5774 lbs)

1600 kg (3526 lbs)

Lift capacity at 4.26 m (14 ft) above ground

1485 kg (3273 lbs)

975 kg (2149 lbs)

Telescopic dipper (HED) extension length

-

1200 mm (3 ft 11 in)

BACKHOE BUCKETS Struck capacity SAE J 296

Width

Weight

76 L (20 Us gal)

305 mm (1 ft)

108 kg (238 lbs)

109 L (29 Us gal)

457 mm (1 ft 6 in)

130 kg (287 lbs)

153 L (40 Us gal)

610 mm (2 ft)

160 kg (353 lbs)

196 L (52 Us gal)

762 mm (2 ft 6 in)

180 kg (397 lbs)

238 L (63 Us gal)

914 mm (2 ft 12 in)

208 kg (459 lbs)

12-13

SECTION 12 - SPECIFICATIONS MODEL B110 LIFTING CAPACITIES LIFTING CAPACITIES DURING NORMAL OPERATION - SAE RATED The following tables reflect the lifting capacities of the Backhoe Dipper (A) and Boom (B) on a typical 4WD machine.

NOTE: Capacities shown may vary slightly between machines dependant upon options fitted, pressure settings and market requirements.

Lifting capacities are given in kg (lbs) for a standard dipper and a telescopic dipper (HED).

5 Standard dipper Dipper - A

Boom - B

Telescopic dipper (HED) (retracted)

Telescopic dipper (HED) (extended)

Dipper - A

Dipper - A

Boom - B

Height/Depth

Boom - B

m (ft)

590 (1300)

+5.4 (18)

1160 (2560)

1085 (2390)

880 (1945)

+4.9 (16)

1545 (3405)

1445 (3185)

1510 (3330)

1015 (2235)

+4.3 (14)

2640 (5820)

1665 (3675)

2585 (5705)

1555 (3430)

1605 (3540)

1080 (2380)

+3.6 (12)

2615 (5770)

1695 (3735)

2505 (5520)

1575 (3470)

1655 (3655)

1110 (2450)

+3.0 (10)

2665 (5880)

1680 (3710)

2550 (5625)

1560 (3440)

1680 (3705)

1125 (2475)

+2.4 (8)

2915 (6425)

1660 (3665)

2790 (6155)

1530 (3375)

1755 (3865)

1125 (2480)

+1.8 (6)

3700 (8155)

1630 (3590)

3555 (7840)

1495 (3300)

1850 (4080)

1125 (2480)

+1.2 (4)

6080 (13410)

1600 (3525)

5910 (13030)

1460 (3225)

2075 (4575)

1120 (2470)

+0.6 (2)

12-14

1570 (3460)

1430 (3155)

3235 (7135)

1115 (2455)

0 (ground)

1545 (3410)

1400 (3090)

5787 (12755)

1110 (2450)

-0.6 (2)

1530 (3370)

1380 (3045)

1110 (2450)

-1.2 (4)

1525 (3360)

1370 (3025)

1115 (2455)

-1.8 (6)

1540 (3400)

1380 (3045)

1125 (2480)

-2.4 (8)

1610 (3550)

1435 (3170)

1150 (2540)

-3.0 (10)

1920 (4230)

1710 (3770)

1210 (2670)

-3.6 (12)

1350 (2985)

-4.2 (14)

1990 (4390)

-4.8 (16)

SECTION 12 - SPECIFICATIONS MODEL B115 LIFTING CAPACITIES LIFTING CAPACITIES DURING NORMAL OPERATION - SAE RATED The following tables reflect the lifting capacities of the Backhoe Dipper (A) and Boom (B) on a typical 4WD machine.

NOTE: Capacities shown may vary slightly between machines dependant upon options fitted, pressure settings and market requirements.

Lifting capacities are given in kg (lbs) for a standard dipper and a telescopic dipper (HED).

6 Standard dipper Dipper - A

Boom - B

Telescopic dipper (HED) (retracted)

Telescopic dipper (HED) (extended)

Dipper - A

Dipper - A

Boom - B

Height/Depth

Boom - B

m (ft)

545 (1205)

+5.4 (18)

1085 (2390)

1005 (2215)

835 (1840)

+4.9 (16)

1485 (3275)

1385 (3050)

1500 (3305)

975 (2150)

+4.3 (14)

2620 (5775)

1625 (3580)

2425 (5610)

1510 (3330)

1600 (3525)

1050 (2315)

+3.6 (12)

2560 (5645)

1660 (3660)

2450 (5400)

1540 (3395)

1615 (3560)

1090 (2400)

+3,0 (10)

2620 (5775)

1660 (3660)

2505 (5525)

1535 (3385)

1640 (3615)

1105 (2435)

+2.4 (8)

2875 (6340)

1645 (3625)

2750 (6065)

1515 (3340)

1730 (3815)

1115 (2460)

+1.8 (6)

3700 (8155)

1620 (3570)

3550 (7825)

1490 (3285)

1870 (4120)

1120 (2470)

+1.2 (4)

6280 (13845)

1600 (3525)

6075 (13395)

1460 (3220)

2120 (4675)

1120 (2470)

+0.6 (2)

1575 (3475)

1435 (3165)

3660 (8070)

1115 (2460)

0 (ground)

1555 (3430)

1410 (3110)

5745 (12665)

1115 (2460)

-0.6 (2)

1545 (3405)

1400 (3085)

1120 (2470)

-1.2 (4)

1550 (3415)

1395 (3075)

1125 (2480)

-1.8 (6)

1580 (3485)

1415 (3120)

1145 (2525)

-2.4 (8)

1670 (3680)

1500 (3305)

1180 (2600)

-3.0 (10)

2070 (4565)

1855 (4090)

1250 (2755)

-3.6 (12)

1430 (3150)

-4.2 (14)

2230 (4915)

-4.8 (16)

12-15

SECTION 12 - SPECIFICATIONS

NOTES

12-16

SECTION 13

14

FORMS AND DECLARATIONS TABLE OF CONTENTS PRE DELIVERY REPORT, OWNER COPY, 13-3 PRE DELIVERY REPORT, DEALER COPY, 13-5 DELIVERY REPORT, OWNER COPY, 13-7 DELIVERY REPORT, DEALER COPY, 13-9 50 HOURS 1ST SERVICE SHEET, OWNER COPY, 13-11 50 HOURS 1ST SERVICE SHEET, DEALER COPY, 13-13

1

13-1

SECTION 13 - FORMS AND DECLARATIONS

NOTES

13-2

" SECTION 13 - FORMS AND DECLARATIONS OWNER COPY

PRE DELIVERY REPORT Machines are inspected and fully serviced prior to leaving the plant. However, it is recommended that the following items be checked, as they may have been altered for shipping purposes or relate to the performance and safe operation of the machine. ( ) Tire pressure. ( ) Fluid and oil leaks. ( ) SMV emblem installed (optional). ( ) Flashing lights/tail lights/brake lights operation. ( ) Seat belt operation. ( ) Safety start switch operation.

Machine model number .......................................................................................................................................

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

Service technician signature.............................. ............................................. Date...........................................

13-3

SECTION 13 - FORMS AND DECLARATIONS

13-4

" SECTION 13 - FORMS AND DECLARATIONS DEALER COPY

PRE DELIVERY REPORT Machines are inspected and fully serviced prior to leaving the plant. However, it is recommended that the following items be checked, as they may have been altered for shipping purposes or relate to the performance and safe operation of the machine. ( ) Tire pressure. ( ) Fluid and oil leaks. ( ) SMV emblem installed (optional). ( ) Flashing lights/tail lights/brake lights operation. ( ) Seat belt operation. ( ) Safety start switch operation.

Machine model number .......................................................................................................................................

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

Service technician signature.............................. ............................................. Date...........................................

13-5

SECTION 13 - FORMS AND DECLARATIONS

13-6

" SECTION 13 - FORMS AND DECLARATIONS OWNER COPY

DELIVERY REPORT Owner’s name .....................................................................................................................................................

Address ...............................................................................................................................................................

Delivery date........................................................................................................................................................

Dealer’s name .....................................................................................................................................................

Address ...............................................................................................................................................................

Machine serial number ........................................................................................................................................

Using the operator’s manual as a guide, instruction was given as indicated by the checkmarks. ( ) Instruct customer on the operation of the machine. Emphasize safety and discuss the safety information in the operator’s manual. ( ) Advise customer to use the seat belt at all times. ( ) Advise customer to return machine for initial 50 hour service check. ( ) Explain how to perform the recommended lubrication and periodic service. ( ) Explain maintenance and adjustment instructions. ( ) Make certain the customer has a copy of the operator’s manual. ( ) Record serial numbers at front of operator’s manual. ( ) Explain warranty policy.

Dealer representative signature ........................ ............................................. Date...........................................

I have been instructed in the operation, maintenance, and safety features of this machine as detailed in the operator’s manual.

Owner’s signature.............................................. ............................................. Date...........................................

13-7

SECTION 13 - FORMS AND DECLARATIONS

13-8

" SECTION 13 - FORMS AND DECLARATIONS DEALER COPY

DELIVERY REPORT Owner’s name .....................................................................................................................................................

Address ...............................................................................................................................................................

Delivery date........................................................................................................................................................

Dealer’s name .....................................................................................................................................................

Address ...............................................................................................................................................................

Machine serial number ........................................................................................................................................

Using the operator’s manual as a guide, instruction was given as indicated by the checkmarks. ( ) Instruct customer on the operation of the machine. Emphasize safety and discuss the safety information in the operator’s manual. ( ) Advise customer to use the seat belt at all times. ( ) Advise customer to return machine for initial 50 hour service check. ( ) Explain how to perform the recommended lubrication and periodic service. ( ) Explain maintenance and adjustment instructions. ( ) Make certain the customer has a copy of the operator’s manual. ( ) Record serial numbers at front of operator’s manual. ( ) Explain warranty policy.

Dealer representative signature ........................ ............................................. Date...........................................

I have been instructed in the operation, maintenance, and safety features of this machine as detailed in the operator’s manual.

Owner’s signature.............................................. ............................................. Date...........................................

13-9

SECTION 13 - FORMS AND DECLARATIONS

13-10

" SECTION 13 - FORMS AND DECLARATIONS INITIAL 50-HOUR SERVICE - CHECK AND ADJUST AS REQUIRED INOPERATIVE SERVICE CHECKS 1. Tire pressure 2. Air cleaner and hose connections 3. Drain fuel filter and water separator and bleed system 4. Radiator coolant level 5. All belt tensions 6. Battery cleanliness, vent opening electrolyte level, and specific gravity not less than 1.240 7. Check all electrical cables and wire routings are away from sharp edges, moving parts and exhaust heat 8. Replace hydraulic oil filter 9. Replace transmission oil filter 10. Brake liquid level, brake pedal locking and adjustment 11. Hydraulic system oil level 12. Transmission oil level 13. Rear and front axles oil level 14. Check wheel nuts for tightness 15. Adjust valve clearances 16. Lubrication fittings and pivots 17. Check the loader equipment pivot pin for tightness 18. Change front axle differential oil and front axle hub oil (4WD) 19. Clean, inspect and grease front wheel bearings (2WD) 20. Check the front counterweight mounting hardware for tightness 21. Cab door and lock operation and seal condition 22. Cab interior upholstery, trim and mouldings 23. Cab window operation, window props and latches, seal condition 24. Cab sun visor operation 25. Cab filter installation INSPECTION PERFORMED - WARRANTY EXPLAINED

OPERATIVE SERVICE CHECKS All operative checks are to be performed with the machine at normal operating temperature.

1. Lights and instruments for proper operation 2. Fluid and oil leaks 3. Engine maximum no-load speed and idle speed adjustments and fuel shut-off 4. Accelerator linkage adjustment 5. Loader for proper operation and performance 6. Backhoe proper operation and performance 7. Windshield wiper/washer operation 8. Heater temperature control 9. Air conditioner operation PERFORMANCE SERVICE CHECKS 1. Engine operation including accelerator and governor operation 2. Transmission, including control lever 3. Steering control 4. Differential lock engagement and disengagement 5. Brake action 6. All optional equipment and accessories SAFETY ITEMS CHECKS 1. ROPS/FOPS bolt torque 2. Seat belt condition and bolt torque 3. Safety start switch

MACHINE MODEL

NOTA: There may be a Dealer charge for this service MACHINE SERIAL NO.

Owner’s signature

Date

Dealer’s signature

Date

13-11

SECTION 13 - FORMS AND DECLARATIONS

13-12

" SECTION 13 - FORMS AND DECLARATIONS INITIAL 50-HOUR SERVICE - CHECK AND ADJUST AS REQUIRED INOPERATIVE SERVICE CHECKS 1. Tire pressure 2. Air cleaner and hose connections 3. Drain fuel filter and water separator and bleed system 4. Radiator coolant level 5. All belt tensions 6. Battery cleanliness, vent opening electrolyte level, and specific gravity not less than 1.240 7. Check all electrical cables and wire routings are away from sharp edges, moving parts and exhaust heat 8. Replace hydraulic oil filter 9. Replace transmission oil filter 10. Brake liquid level, brake pedal locking and adjustment 11. Hydraulic system oil level 12. Transmission oil level 13. Rear and front axles oil level 14. Check wheel nuts for tightness 15. Adjust valve clearances 16. Lubrication fittings and pivots 17. Check the loader equipment pivot pin for tightness 18. Change front axle differential oil and front axle hub oil (4WD) 19. Clean, inspect and grease front wheel bearings (2WD) 20. Check the front counterweight mounting hardware for tightness 21. Cab door and lock operation and seal condition 22. Cab interior upholstery, trim and mouldings 23. Cab window operation, window props and latches, seal condition 24. Cab sun visor operation 25. Cab filter installation INSPECTION PERFORMED - WARRANTY EXPLAINED

OPERATIVE SERVICE CHECKS All operative checks are to be performed with the machine at normal operating temperature.

1. Lights and instruments for proper operation 2. Fluid and oil leaks 3. Engine maximum no-load speed and idle speed adjustments and fuel shut-off 4. Accelerator linkage adjustment 5. Loader for proper operation and performance 6. Backhoe proper operation and performance 7. Windshield wiper/washer operation 8. Heater temperature control 9. Air conditioner operation PERFORMANCE SERVICE CHECKS 1. Engine operation including accelerator and governor operation 2. Transmission, including control lever 3. Steering control 4. Differential lock engagement and disengagement 5. Brake action 6. All optional equipment and accessories SAFETY ITEMS CHECKS 1. ROPS/FOPS bolt torque 2. Seat belt condition and bolt torque 3. Safety start switch

MACHINE MODEL

NOTA: There may be a Dealer charge for this service MACHINE SERIAL NO.

Owner’s signature

Date

Dealer’s signature

Date

13-13

SECTION 13 - FORMS AND DECLARATIONS

13-14