Zetor Tractor ZX1.1 ZX2.1 ZX3.1 ZX4.1 ZX5.1 ZX1.1p ZX2.1p ZX3.1p ZX3.3p ZX3.4p ZX4.1p ZX5.1p ZX Seri

12166364 B1 2015-08 EN

Operator’s Manual

ZX Series

ZX1.1 | ZX2.1 | ZX3.1 | ZX4.1 | ZX5.1 | ZX1.1p | ZX2.1p | ZX3.1p | ZX3.3p | ZX3.4p | ZX4.1p | ZX5.1p

Original instructions Caution!

Read through the entire instruction manual before you start to use the product.

TABLE OF CONTENTS 1. PREFACE................................................. 3 1.1. General information.................................................... 3 1.2. Identification................................................................3 1.2.1. Model and serial number........................................3 1.3. Alignment reference.................................................... 4

2. DESCRIPTION AND DEFINITIONS.........5

2.1. Description...................................................................5 2.2. Definitions................................................................... 5 2.2.1. 3rd and 4th hydraulic function............................... 5 2.2.2. Clic-on.................................................................... 5 2.2.3. Hydraulic implement lock, Auto Plus.................... 6 2.2.4. Multi Doc 4 / Multi-connection MC 4................... 6 2.2.5. Loader Control System (LCS)................................6 2.2.6. ErgoDrive / ErgoDrive LCS................................... 6 2.2.7. ElectroDrive LCS / EasyDrive LCS.......................6 2.2.8. Plus Lock................................................................ 7 2.2.9. Position indicator.................................................... 7 2.2.10. Control valve........................................................ 7 2.2.11. Plus Compact Valve..............................................7 2.2.12. Hydraulic connection tool, Multi Doc 2............... 7 2.2.13. Hose kit.................................................................7 2.2.14. Boom suspension, PlusDrive................................8 2.2.15. Electrical shut-off of load damping function............................................................................. 8 2.2.16. Hose Burst Protection...........................................8 2.2.17. Counterweight (empty).........................................8 2.2.18. System DS, DM, DL, DXL.................................. 9 2.2.19. Parallel or non-parallel motion loader.................. 9 2.2.19.1. Loader with mechanical self-levelling............. 9 2.2.19.2. Loader without parallel movement.................. 9 2.3. Tool carrier................................................................ 10

3. SAFETY INSTRUCTIONS......................12

3.1. General information.................................................. 12 3.1.1. Guards................................................................... 12 3.1.2. Warning decals......................................................12 3.1.3. Explanation of warning levels.............................. 12 3.1.4. Explanation of symbols........................................ 13 3.1.5. Responsibility....................................................... 14 3.2. Installing the loader...................................................14 3.2.1. Tether stop............................................................ 15 3.3. Protection equipment.................................................15 3.4. Operation................................................................... 15 3.4.1. Before work.......................................................... 15 3.4.2. Operator's/Driver's position.................................. 16 3.4.3. Workplace............................................................. 16 3.4.4. Stability................................................................. 19 3.4.4.1. Load stability................................................... 19 3.4.4.2. The tractor's stability........................................20 3.5. Risk factors during work...........................................21 3.5.1. During transport....................................................21 3.5.2. During service.......................................................22 3.5.3. After work.............................................................23 3.5.3.1. Spare parts........................................................24 3.6. Location of warning and information decals.............25

4. DRIVING INSTRUCTIONS.....................26

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4.1. General information.................................................. 26 4.1.1. Counterweight.......................................................26 4.1.2. Track..................................................................... 27

4.1.3. Tether stop............................................................ 27 4.1.4. Hose Burst Protection (optional extra)................. 27 4.1.5. Front axle suspension........................................... 28 4.2. Tractor/loader hydraulic controls.............................. 29 4.3. EasyDrive LCS /ElectroDrive LCS Professional...................................................................... 29 4.3.1. Joystick/operating control.....................................29 4.3.1.1. Raise/lower the loader..................................... 30 4.3.1.2. Dump/Roll back the implement....................... 30 4.3.2. Button functions................................................... 30 4.3.2.1. Float position, lower........................................ 30 4.3.2.2. Float position emptying................................... 31 4.3.2.3. Third hydraulic function.................................. 31 4.3.2.4. Hydraulic lock, open........................................31 4.3.2.5. Hydraulic lock, close....................................... 31 4.3.2.6. Boom suspension............................................. 32 4.3.2.7. 4th service........................................................ 32 4.3.2.8. Transport mode................................................ 33 4.3.2.9. Pressure reduction............................................ 33 4.4. ErgoDrive/ErgoDrive LCS........................................ 33 4.4.1. Mechanically-controlled control valve and joystick............................................................................33 4.4.1.1. Raise/lower the loader..................................... 34 4.4.1.2. Dump/Roll back the implement....................... 34 4.4.1.3. Float position, lower........................................ 34 4.4.1.4. Float position emptying (ErgoDrive LCS).......35 4.4.1.5. Pressure reduction............................................ 35 4.4.2. Button functions................................................... 35 4.4.2.1. Third hydraulic function.................................. 35 4.4.2.2. Fourth hydraulic function................................ 36 4.4.2.3. Hydraulic implement lock................................36 4.4.2.4. Boom suspension............................................. 38 4.5. Tractor's own joystick/control valve......................... 38 4.5.1. Joystick................................................................. 38 4.5.1.1. Raise/lower the loader..................................... 39 4.5.1.2. Dump/Roll back the implement....................... 39 4.5.1.3. Pressure reduction............................................ 39 4.5.2. Button functions................................................... 39 4.5.2.1. Third and fourth hydraulic function.................39 4.5.2.2. Hydraulic implement lock................................39 4.6. Loader coupling and uncoupling...............................41 4.6.1. Coupling the loader - LCS................................... 41 4.6.2. Disconnecting the loader - LCS........................... 43 4.6.3. Locking of loader - US, UM and UL system. .......45 4.6.4. Unlocking the loader - US, UM and UL system............................................................................. 45 4.7. Coupling and uncoupling implements.......................45 4.7.1. Uncoupling implements, mechanical implement lock..................................................................................45 4.7.2. Coupling implements, mechanical implement lock..................................................................................46 4.7.3. Uncoupling implements, hydraulic implement lock..................................................................................48 4.7.4. Coupling implements, hydraulic implement lock..................................................................................48 4.8. Working with the loader............................................50 4.8.1. Load stability........................................................ 52 4.8.2. The tractor's stability............................................ 53 4.9. Boom suspension, PlusDrive.....................................54 4.9.1. Description............................................................54 4.9.2. Mechanical connection/disconnection.................. 55 1

4.9.3. Electronic connection/disconnection.................... 55

5. MAINTENANCE..................................... 56

5.1. Lubrication.................................................................56 5.2. Hydraulic system.......................................................56 5.2.1. Repairing/replacing hydraulic components.......... 57 5.2.1.1. Hydraulic cylinders.......................................... 57 5.2.1.2. Hydraulic hoses................................................58 5.2.1.3. Plus Compact Valve......................................... 58 5.3. Checking the loader and subframe screws................ 59 5.3.1. Tightening torques................................................ 59 5.3.1.1. Table - Tightening torque.................................60 5.4. Storage....................................................................... 60 5.5. Transporting the loader............................................. 60

6. TROUBLESHOOTING........................... 61 7. DATA...................................................... 64 7.1. Parallel movement.....................................................64 7.2. Non-parallel movement.............................................65 7.3. Other data.................................................................. 65

8. WIRING DIAGRAM................................ 66 9. WARRANTY CONDITIONS................... 67

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EC Declaration of Conformity........................................67

Preface

1. PREFACE 1.1. General information Warning!

Careless or incorrect use may result in serious injury or fatality for the driver or others.

Observe the safety instructions.

This user manual describes the operation and maintenance of an agricultural loader. The information in the user manual was correct when this manual went to press. Please visit your dealer if there is anything you do not understand in the manual.

One user manual is supplied with every machine in order to show the driver how it should be operated and maintained.

Read and use the information so that you can use the machine in a safe manner, in combination with short stoppages. This machine is designed with simple service in mind, and it can be maintained with normal hand tools.

Read and study the text in the user manual thoroughly before you start to use the machine. If you are not an experienced driver, study the user manual and ask an experienced driver to explain things to you. Your dealer can help you by teaching you about operation and suitable work methods. Keep this user manual readily available, preferably inside the tractor. Get a new user manual if the old one is damaged or lost.

Fig.1 Read through the entire user manual before you start to use the product.

Warning!

Read through the entire user manual before you start to use the product.

We reserve the right to introduce changes to design and specification, or improvements at any time, without prior notice or commitment.

Important! Combination loaders and loader subframes are designed for a specific tractor model. Contact the manufacturer for the correct combination for each tractor model. Do not fit incorrect combinations.

Installation and operation instructions for implements and accessories are not included in this user manual. Use the publications supplied with each implement.

1.2. Identification 1.2.1. Model and serial number Each loader has a machine sign (A) with an identification number. The sign is located on the inside of the left arm.

A

218272

Fig.2 Position of machine sign.

3

Preface

2014-XX-XX

The sign specifies: • Product: Machine name • Type: Type/model • Made by: Manufacturer's full address and country of manufacture • Ref. No.: Loader reference number • Serial No: Loader serial number • Date: Date of manufacture • Weight: Weight, max. load Always state: the type (A), serial number (B) and date of manufacture (C) during service questions or when spare parts are needed.

C #### EuroTest

Type

Made by

Certificate

Product

XXXXXXXXXXXXXXXXXXXX Ref.No.

Serial No.

Date

Weight

XXXXXXXXXX XXXX-XX-XX

XXXXXXXXXX/XXXXXXX

A B

C

XXXXXXX XXX kg

PART NO: XXXX XXXX

D

Fig.3 Machine sign.

Cylinders, valves, control cables and hoses are equipped with machine signs or punched/printed order numbers.

Fig.4 Marking of components, e.g., cylinders.

1.3. Alignment reference Throughout this user manual, references to the right (RH) and left (LH) are seen from the operator's seat in forward direction, with the operating control fitted to the right of the operator.

Note. Some illustrations in this user manual may show a different model of tractor or loader, compared with your loader. The same information applies to your equipment unless otherwise specified, however.

LH

RH

4

218272

Fig.5 Alignment reference

Description and definitions

2. DESCRIPTION AND DEFINITIONS Not all options fit all loaders. Please contact your dealer to ask about suitable options which are just right for your loader.

Not all accessories are available in all markets.

2.1. Description The front loader is designed to: • Be fitted to wheeled agricultural and forestry tractors.

• Manage various certified agricultural implements to lift, carry, cut, scrape, level, sweep and plough.

Warning!

Risk of crushing, jamming and tipping. If any of a loader's hoses break, the loader/implement/ load may fall uncontrolled. If a hose does break, remedy the issue immediately as per section 5.

Maintenance. When changing parts, only use original spare parts to restore the machine to its original quality standard. Decontaminate the land in accordance with applicable requirements/ legislation in the country or region you are in.

Important! Power supply failure to the loader functions/ control circuits means that the ability to enable/disable features/valves/control circuits or perform movements will not work.

2.2. Definitions 2.2.1. 3rd and 4th hydraulic function.

The loader may be equipped with a third (1) and a fourth hydraulic function (2) for tools. Two solenoid valves are then installed on the cross tube.

2

1 0134-a

Fig.6 3rd and 4th hydraulic function.

2.2.2. Clic-on

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Automatic connection of implements.

5

Description and definitions

2.2.3. Hydraulic implement lock, Auto Plus This equipment allows the implement to be coupled both ON and OFF by using the loader's control valve/operating control.

Important! If the hoses are connected the wrong way, locking will not function.

The hoses from the implement lock cylinder are connected to the 3rd function.

Fig.7 Hydraulic implement locking.

2.2.4. Multi Doc 4 / Multi-connection MC 4 Function for connecting and disconnecting hydraulics for the loader. Eliminates the risk of incorrect connection and oil spill.

Fig.8 Multicoupler 4 (MC4)

2.2.5. Loader Control System (LCS) LCS consists of a control valve and a Joystick.

2.2.6. ErgoDrive / ErgoDrive LCS The ErgoDrive system is composed of a control valve and mechanical joystick as well as hydraulic connections and control cables for specified tractor models.

2.2.7. ElectroDrive LCS / EasyDrive LCS Installation kit as above but with an electrically operated valve and electronic joystick.

0418

6

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Fig.9 ElectroDrive valve unit (valve and master unit)

Description and definitions The joystick (LCS) is operated using only the thumb or thumb and index finger. On the unit there are buttons for extra functions and for making changes to the menus, as well as a display.

Fig.10 ElectroDrive joystick

2.2.8. Plus Lock Automatic coupling between loader and subframe.

2.2.9. Position indicator Device to indicate the angular position of the implement.

2.2.10. Control valve Valve intended for lifting and implement operation on the loader.

2.2.11. Plus Compact Valve Loader diverting valve. The valve diverts oil to lifting/ lowering, opening/emptying, 3rd and 4th function, plus controls implement movements and the hydraulic tool lock.

Oil is also distributed to the 3rd and 4th hydraulic function.

To control the hydraulic implement lock, 3rd function is required.

Fig.11 Plus Compact Valve

2.2.12. Hydraulic connection tool, Multi Doc 2 Function for connecting and disconnecting hydraulics for hydraulic implements. Eliminates the risk of incorrect connection and oil spill.

Fig.12 Hydraulic connection to tool.

2.2.13. Hose kit

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Hoses and hydraulic components for connecting the loader to the tractor's original valve.

7

Description and definitions

2.2.14. Boom suspension, PlusDrive Boom suspension, improves driver comfort and reduces stress on the tractor and loader when driving on rough surfaces.

Fig.13 Boom suspension.

2.2.15. Electrical shut-off of load damping function.

Closes and opens load damping function. Position I (closed) and position III (open).

Fig.14 Electrical shut-off of load dampening function.

2.2.16. Hose Burst Protection If the loader has the Hose Burst Protection optional extra fitted, individuals are permitted to be close to a raised load if required for work purposes. Hose Burst Protection protects against energy loss in the system. In the event of a hose burst, the loader will be locked in order to protect, as much as possible, any individual near the raised load.

For more information, contact the dealer.

Fig.15 Hose Burst Protection

2.2.17. Counterweight (empty) To increase tractor stability, a counterweight can be fitted, which is filled to the required weight for correct axle loading. Available in two sizes

8

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Fig.16 Counterweight (empty)

Description and definitions

2.2.18. System DS, DM, DL, DXL Distance between booms of the loader models: DS subframe - centre to centre distance = 900 mm.

DM subframe - centre to centre distance = 1040 mm.

DL subframe - centre to centre distance = 1200 mm.

DXL subframe - centre to centre distance= 1420 mm.

2.2.19. Parallel or non-parallel motion loader 2.2.19.1. Loader with mechanical selflevelling The loaders are equipped with mechanical self-leveling.

Parallel links keep the implement in the same angular position during the entire lifting/lowering movement.

Fig.17 Loader with mechanical self-levelling

2.2.19.2. Loader without parallel movement The implement changes its angle in relation to the ground during the entire lift/lowering movement.

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Fig.18 Loader without parallel movement

9

Description and definitions

2.3. Tool carrier

10

X Fig.19 The loader can be equipped with different tool carriers.

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The EURO (8) is the standard tool carrier for the loader in accordance with ISO 23206.

The loader can be equipped with other types of tool carrier systems (X), to fit your existing implement attachments.

The implement can be locked automatically (Clic on) or manually when attaching.

Optional equipment for hydraulic coupling and uncoupling is available.

Depending on loader model, there are alternative COMBIattachments that fit tools with tool hooks in another design, e.g., SMS (5) and Volvo BM (large), etc.

Use only implements adapted to the loader and suited for the work at hand.

1 = Skidsteer 8 = EURO 8+2 = EURO/MX 8+3 = EURO-ÅLÖ (Combi) 8+4 = EURO/FX 8+5 = EURO-SMS (Combi) 8+7 = EURO-ÅLÖ HD

Description and definitions

856

856

(3) Ålö

(3) Ålö M 11209710

M 11209715

690

690

(5) SMS

(5) SMS M 11209711

M 11209716

1080 690

(5) SMS

(9) BM Big M 11209713

M 11262817

1080

1080

790 790

(8) EURO

(8) EURO 20°

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M 11209714

M 11209717

11

Safety instructions

3. SAFETY INSTRUCTIONS 3.1. General information Driver safety is one of the most important matters when a new loader is designed. The design incorporates as many safety functions as possible. Several accidents occur every year which could have been avoided by taking a few seconds to think more carefully about the task in hand and through more careful operation of the loader/tractor.

Avoid personal injury. Read the following personal safety instructions and insist that everybody who works with you, or for you, also complies with the instructions.

Incorrectly designed implements can damage the loader.

For this reason, do not install third party implements without making sure that it has been approved by the loader manufacturer.

3.1.1. Guards This user manual contains a number of illustrations which show the guards removed, to give a better picture. Never use the machine with the guards removed. If a guard has been removed for service/repairs, re-install the guard before the machine is taken back into service.

3.1.2. Warning decals Warning decals are installed at various places on the loader and the implements. Localise, read and find out what the decals mean before the loader and the implements are used. See section 3.6. Location of warning and information decals..

Do not cover or remove any of the warning decals. If a warning decal is missing or illegible, replace it with a new decal. New warning decals are available from your dealer.

Fig.20 Locate, read and find out what the decals mean before the loader and implement are used.

3.1.3. Explanation of warning levels When you see the safety symbol and the signal word on decals or in the user manual, the instructions MUST be followed since they are related to your own personal safety.

Warning!

Means that an accident could occur if the instruction is not followed. The accident might lead to serious personal injury or fatality.

12

Fig.21 Safety symbol.

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Caution!

Means that an accident could occur if the instruction is not followed. An accident could lead to personal injury.

Safety instructions The following texts and instructions do not refer to personal safety, but are used consistently in the user manual, to provide tips about operation or service of the machine.

Important! Means that an accident could occur if the instruction is not followed. The accident might lead to damage to the property or to the process, or personal injury.

Note. Refers to extra information which could facilitate the understanding or implementation of a certain task.

3.1.4. Explanation of symbols A Instruction manual. Read the instruction manual — it contains important information for your safety.

B Safety symbol. Information adjacent to this symbol refers to your personal safety and must be observed.

C Implement lock. Check that coupled implements are locked in place.

D Risk of crushing. Never stand between the front of the loader and the cross-tube on the loader.

E Risk of falling. Do not use the loader to lift or transport people.

F Fall risk. Do not use the loader or the implement/bucket as a working platform.

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G Attention. Information adjacent to this symbol refers to your personal safety and refers to the section in the instruction manual.

13

Safety instructions

3.1.5. Responsibility Caution!

Always store this user manual as well as the tractor's own instruction manual in the tractor.

•

• •

If there is no user manual included with the tractor then obtain one from the dealer before fitting and using the loader.

Read through all material carefully and learn how to use the equipment in a safe and correct manner.

Only qualified individuals may use the tractor/loader/ implement.

Warning!

Only use the loader in the intended area of application.

Fig.22 Always store this user manual as well as the tractor's own instruction manual in the tractor.

Any accompanying passenger in the tractor must sit in the passenger seat as indicated by the manufacturer.

Warning!

Do not grip objects that extend the centre of gravity to a significant extent. This can lead to instability.

3.2. Installing the loader Warning!

The loader must not be connected in series with any of the tractor's functions. Working with the loader requires the operator's full attention.

Fig.23 The loader must not be connected in series with any of the tractor's functions.

Caution!

The tractor and loader use fluids under high pressure when working. Check all components and keep them in good condition.

Ensure that no hydraulic components are damaged, particularly hoses.

If the loader is operated in difficult/tough terrain, the hydraulic components/hoses must be checked every 30 days.

14

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Fig.24 NEVER use fingers or hands for leakage detection.

Safety instructions

3.2.1. Tether stop Warning!

The loader must not be operated with a programmable joystick or other equipment that enables automatic loader movements. If the deadman's grip does not work, switch off the tractor immediately. Resolve the fault before using the tractor again.

The deadman's grip means that an activated loader function returns to neutral if the operating control is released.

Important! Activated float position does not automatically return to neutral, but must be deactivated.

Fig.25 The loader must not be operated with a programmable joystick or other equipment that enables automatic loader movements.

If the loader is connected to a tractor valve with a programmable joystick, see the tractor's user manual for information on how the programmable function can be deactivated.

3.3. Protection equipment Warning!

If the tractor is equipped with a seatbelt, it must be used and be correctly adjusted during work.

Change damaged seat belts before the machine is used.

Fig.26 Wear the seatbelt when working.

3.4. Operation 3.4.1. Before work

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Familiarise yourself with the working area and terrain.

ALWAYS inspect the site before starting work. Look out for holes in the ground, stones and other hidden dangers.

• Do NOT drive a machine which is damaged or lacks any component. Make sure that the recommended maintenance work has been done before the machine is used.

• Check all controls regularly and adjust as necessary.

Ensure that the tractor's brakes are adjusted to pull evenly.

• Check all screws and nuts regularly for tightening, especially those that fix the tractor wheels. See section 5. Maintenance for information about tightening torques.

• Ensure that the loader is correctly installed on the tractor, and that all pins are locked.

• Change worn components before the machine is used.

Fig.27 Familiarize yourself with the working area before starting. Maintain a safe distance from electrical cables.

15

Safety instructions

3.4.2. Operator's/Driver's position Caution!

Only operate the machine when sitting in the driver's seat.

Fig.28 Only operate the machine when sitting in the driver's seat.

• •

•

Drive carefully and think about safety.

Always leave the brake pedals locked to each other.

NEVER use parted brakes with a loader mounted to avoid the risk of losing control of the tractor and/or the tractor overturning.

Always adjust the speed to the current conditions.

Never drive so fast that you cannot stop quickly in an emergency situation.

Fig.29 Always leave the brake pedals locked to each other.

3.4.3. Workplace Always check the machine's surroundings and ensure that all individuals, especially children, and animals have moved away before starting or driving the machine.

Caution!

Risk of crushing and jamming People can be inside the working area.

Make sure that nobody is close to the tractor when work starts. Only operate the tractor when sitting in the intended place in the driver's seat.

Warning!

If work requires any individual to be near a raised load, the loader must be fitted with Hose Burst Protection and function checked as per section 4.1.4. Hose Burst Protection (optional extra).

Fig.30 Before starting, make sure that no individuals are in the vicinity of the machine.

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You may not hear any shouting to attract your attention from individuals on the outside when you are sitting in the cab with the door closed.

Safety instructions

Warning!

Incorrectly locked implements can come loose.

The locking lever must have returned to its locked position. Ensure AT ALL TIMES that the connected implement is locked in place by pressing the front section of the implement towards the ground.

Fig.31 Check that the implement is secured by pressing its front end against the ground.

Warning!

Risk of crushing and jamming Incorrectly locked implements can come loose.

The lock indicator should return to locked position. Ensure AT ALL TIMES that the connected implement is locked in place by pressing the front section of the implement towards the ground.

Fig.32 Lock indication Learn the working area and terrain before beginning work.

Pay attention to vertical clearance and limitations that arise due to the increased reach.

Warning!

Risk of electric shock, crushing and jamming.

When driving with the loader lifted, make sure that there is enough room between the loader and power lines, barn roofs, etc.

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Warning!

Electric shock. Before digging, check that there are no hidden live electrical cables. To prevent personal injury or death, do NOT leave the driver's seat if any part of the loader comes into contact with an electrical cable. Reverse the tractor away from the electrical cable before leaving the tractor.

Fig.33 Familiarise yourself with the working area before starting. Maintain a safe distance from power lines and other obstacles.

17

Safety instructions

Warning!

Do NOT use the loader or the attachment as a working platform.

Fig.34 Do NOT use the loader or the attachment as a working platform.

Warning!

Do NOT use the loader or implement to lift or transport people.

Fig.35 Do NOT use the loader or implement to lift or transport people.

With standard fittings, the loader is NOT intended for lifting where any individual is required to be near the raised load.

For this type of lifting, the loader must be fitted with Hose Burst Protection which prevents the load falling if the hydraulics should fail.

For more information, see section 2.2.16. Hose Burst Protection.

Warning!

Do NOT stand, walk or work under a lifted loader. Make sure that you keep individuals, especially children and animals, away from the working area.

•

18

Always keep an eye on your workplace.

Never carry out work with an implement that requires another person to be in the vicinity of the loader, e.g. handling large sacks or pallets.

If any individual is required to be near the lifted load, then Hose Burst Protection must be fitted (accessory), see section 2.2.16. Hose Burst Protection.

Fig.36 Do NOT stand, walk or work under a lifted loader.

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• •

Safety instructions

3.4.4. Stability 3.4.4.1. Load stability Warning!

Always look at the implement. Objects can fall or roll backwards onto the driver when the loader is raised.

Only lift loads that fit and are designed for that specific implement.

Some implements should be equipped with a collapse protector.

Warning!

If the tractor is only equipped with Roll Over Protective Structure (ROPS), and does not have a Falling Objects Protective Structure (FOPS), there is only limited protection against falling loads. The driver risks injury if the load falls when the loader is operated at height.

FOPS is not designed to protect against all falling loads. It is therefore critical to use an implement that prevents the load from falling.

Exercise caution when working with raised loads.

The tractor may not be operated on public roads with a load in the implement.

• •

Fig.37 Pay attention to the implement, objects may fall off.

Only use implements that are approved for the relevant application.

Check that the load is positioned stably in the implement. In terms of loose material, the implement must not be overfilled, and for solid material, the load must not stick up above the rear of the implement.

Fig.38 Only lift loads that fit and are designed for that specific implement.

•

Adjust the tilt angle of the implement when the load is raised so that the load is not aimed at the driver.

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Fig.39 Exercise caution when working with raised loads.

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Safety instructions

3.4.4.2. The tractor's stability Warning!

Only use the attachment for the intended application area. Do not grip objects that extend the centre of gravity by a significant extent.

Warning!

Reduce speed when cornering to avoid overturning the machine.

Avoid sudden turns when driving down steep slopes.

•

Fig.40 Overturning risk

Always leave the engine in gear to obtain engine braking when driving downhill. Do not allow the tractor to roll freely. Use the same gear when driving downhill as when driving up.

Fig.41 Keep at a distance when working near slopes.

Warning!

Do NOT work on or close to steep slopes.

The distance from a slope must be as far or further than the height of the slope.

•

Drive straight up or down slopes (not horizontally).

Avoid braking sharply or driving away at speed. Lower the loader as far as possible.

Caution!

Lower the loader as much as possible when travelling/working. Reduce speed to be appropriate to the circumstances. When handling raised loads, there is increased risk of the tractor tipping. Be alert - if the tractor feels unstable, lower the load to increase stability.

•

Drive the tractor forwards up slopes with an empty bucket. Fill the bucket and then reverse slowly down the slope.

Fig.42 Lower the load and reduce the speed when cornering.

Caution!

Check that the machine has sufficient counterweight at the rear to stabilise the machine's load-carrying ability. The counterweight is essential for maintaining control of the machine.

20

Refer to section in the operator's manual for information on the counterweight and tread width.

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•

Safety instructions Also refer to the tractor operator's manual for further information.

3.5. Risk factors during work 3.5.1. During transport Caution!

When the machine is transporting goods on public roads or is carrying out work, ensure that the tractor's lamps, indicators and reflectors are visible.

Check that signs and lighting aren't obscured. Use additional warnings if needed.

Fig.43 During transport When driving either with or without a load, always lower the loader as far as possible to give maximum visibility and allow others to see you at all times.

Caution!

Drive at low speeds - max 10 km/h - with a load in the implement. Speed should be adapted to the terrain and the weight and centre of gravity of the load.

• • •

Disconnect or tilt up the implement to minimise the risk of damage in the event of collision.

Leave a margin for the vehicle's extra length and weight when cornering, braking etc.

Make sure that lamps and reflectors are visible during road transport and are not obscured by the implement.

0114c

Fig.44 Lower the loader to obtain maximal visibility.

Warning!

The loader must not be operated during transport. When transporting on public roads, the operating control must be mechanically locked in neutral, turned off or Transport mode activated. See section 4. Driving instructions.

Warning!

Only use the attachment for the intended application area. Do not grip objects that extend the centre of gravity by a significant extent.

Warning!

Always look at the implement. Objects can fall or roll backwards onto the driver when the loader is raised. Only lift loads that fit and are designed for that specific implement.

Warning!

Always look at the implement. Objects can fall out during transport. Only transport loads that are designed for each specific implement.

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Fig.45 Always look at the implement. Objects can fall or roll backwards onto the driver when the loader is raised.

21

Safety instructions

Caution!

Thermal shock. If the loader continues moving after the operating control is released: - turn off the tractor ignition - wait until the oil temperature has dropped - start the tractor and perform a function check before use, to ensure the tractor behaves normally.

During low outside temperatures, the hydraulic oil from the loader can come into contact with warm hydraulic oil from the tractor. In rare cases, thermal shock may occur in the loader's control valve. The loader may continue moving after the operating control is released.

Fig.46 Only lift loads which fit inside the implements.

3.5.2. During service Do NOT carry out any service on the loader when the tractor engine is running or hot, or when the machine is moving.

Fig.47 Before service, read the instructions and remove the ignition key.

The loader is equipped with a shut-off mechanism. The design can vary depending on the type of control valve.

Caution!

The loader's stop mechanism should be turned to the closed position during servicing.

The shut-off valve should be activated during service work, or when the loader is left in raised position for extended periods of time for any reason.

•

•

22

When working on the loader's hydraulic system, unload the hydraulic pressure by moving all hydraulic controls to all positions a number of times once the engine has been shut off.

Do NOT use the loader to lift the tractor during servicing of the tractor or the loader.

Fig.48 Turn the shut-off valve handle to the closed position during service work.

0361

Fig.49 Open the multi-connection to the open position during service work.

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Warning!

This shut-off valve may NOT be used when working in the loader's lift cylinders or associated lines. In such cases, the loader must be lowered to the ground. Turn off the tractor's engine and depressurise the oil pressure using the operating control before disconnecting any couplings or doing any other work on the hydraulics — oil subjected to high pressure can cause severe injuries.

Safety instructions

Caution!

Watch out for pressurised hydraulic fluid.

NEVER use fingers or hands for leakage detection. The fluid which flows out from small holes can be almost invisible. Use a piece of wood or cardboard instead.

• •

Undo hydraulic couplings slowly. Keep your hands and fingers away from loosened couplings.

Get medical attention at once if fluid penetrates your skin. Serious reactions and/or infections can rapidly occur if the oil is not removed at once by surgical operation.

Fig.50 NEVER use fingers or hands for leakage detection.

3.5.3. After work Warning!

Before you leave the operator's seat: 1.

2.

3.

4.

5.

6.

Lower the loader and implement to the ground.

Apply the park brake securely.

Move the gear lever to the neutral or park position.

Shut the engine off.

Remove the ignition key.

Move the control handle through all positions, then return the control handle to the centre position to unload the hydraulic pressure.

Fig.51 Lower the loader and remove the ignition key.

Warning!

To prevent accidental operation of the loader: Lock the joystick in neutral, turn off the operating control or activate Transport mode, see section 4. Driving instructions.

Fig.52 Leave the joystick in the neutral position.

Warning!

Never stand between the front of the tractor and the loader's cross tubes.

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Fig.53 Never stand between the front of the loader and the cross-tube on the loader.

23

Safety instructions

3.5.3.1. Spare parts

24

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When a spare part is needed for periodic maintenance or service, use only genuine, original equipment spare parts to restore your equipment to original specifications Particularly applies to hydraulic hoses, hydraulic pipes, adapters and boom suspension components. See the published spare parts sheets.

The manufacturer is not responsible for damages that may occur due to installation of non-approved parts and/or accessories.

Safety instructions

112 367 6

3.6. Location of warning and information decals.

D

C

A

B

A. Warning decal cross pipe, 1 pc.

(Part no. 11133876) B. Warning decal on implement attachment, 2 pcs.

Part no. 1123673 C. Warning decal on bearing box, 2 pcs.

(Part no. 1123674)

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D. Lifting decal on inside of loader arm, x 2.

(Art. no. 1123676)

25

Driving instructions

4. DRIVING INSTRUCTIONS 4.1. General information The front loader is designed to: • Be fitted to wheeled agricultural and forestry tractors.

• Manage various certified agricultural implements to lift, carry, cut, scrape, level, sweep and plough.

Warning!

Risk of crushing, jamming and tipping. If any of a loader's hoses break, the loader/implement/ load may fall uncontrolled. If a hose does break, remedy the issue immediately as per section 5.

Maintenance. When changing parts, only use original spare parts to restore the machine to its original quality standard. Decontaminate the land in accordance with applicable requirements/ legislation in the country or region you are in.

Important! Power supply failure to the loader functions/ control circuits means that the ability to enable/disable features/valves/control circuits or perform movements will not work.

4.1.1. Counterweight Caution!

Overturning and slipping risk. The tractor can overturn or start slipping and thus cause personal injury. Check that a counterweight is fitted which is suitable for the implement and working space.

Tractor

Front axle

Back axle

4WD

40%

60%

26

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The size of the counterweight varies with its placement and the tractor's equipment (model, rim and tyre combination, etc.). Check that the required counterweight is in place so that the tractor does not overturn and loses traction when the brakes are suddenly applied with a fully loaded implement. Please read the tractor's instruction manual or contact your dealer.

A 4-wheel drive tractor has the advantage of traction from the front axle. Use the counterweight at the rear to maintain the correct front/rear axle loading and avoid abnormally large stresses on the front axle when the loader is used.

Recommended allocation of gross weight (with empty implement) on the tractor's front and rear axles:

Driving instructions

4.1.2. Track Caution!

Overturning risk. To increase stability, the tractor's track width must be as wide as possible.

To increase stability, the tractor's track must be as wide as possible. Maximum width (A) across front wheels.

Install the rear tyres and adjust the rear wheels to the maximum recommended track (B).

Study the tractor's instruction manual for information about recommended tyres, track and adjustment.

For tractors/loaders with a high centre of gravity or an unusual configuration, a wider minimum track width may be needed to achieve the same stability.

A

B

Fig.54 Increase to maximum track for best stability.

4.1.3. Tether stop Warning!

The loader must not be operated with a programmable joystick or other equipment that enables automatic loader movements. If the deadman's grip does not work, switch off the tractor immediately. Resolve the fault before using the tractor again.

The deadman's grip means that an activated loader function returns to neutral if the operating control is released.

Important! Activated float position does not automatically return to neutral, but must be deactivated.

Fig.55 The loader must not be operated with a programmable joystick or other equipment that enables automatic loader movements.

If the loader is connected to a tractor valve with a programmable joystick, see the tractor's user manual for information on how the programmable function can be deactivated.

4.1.4. Hose Burst Protection (optional extra) Warning!

If work requires any individual to be near a raised load, the loader must be fitted with Hose Burst Protection and function checked as per section 4.1.4. Hose Burst Protection (optional extra).

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If the loader is fitted with Hose Burst Protection, Float position or boom suspension will not work.

• Float position: When Float position is activated, Hose Burst Protection is activated and the loader is locked.

• Boom suspension: Does not work as Hose Burst Protection blocks the lifting cylinders and therefore stops the boom suspension from working. On loaders manufactured before 31/12/2010, the boom suspension mode must be deactivated for the loader to be lowered.

27

Driving instructions

Caution!

If the Hose Burst Protection option is fitted, it MUST be assumed that there is still some trapped pressure following depressurisation. Remove hydraulic components/hoses with extreme care.

(If the operator lacks knowledge on hydraulics, take advice from an authorised workshop for disassembly).

Simplified function check A function check should be carried out after: • Hose Burst Protection has been fitted.

• The machine has undergone maintenance and begun work that requires personnel to be near a raised load.

• With continuous operation, a function check should be carried out at least once every 30 days, if work requires personnel to be near a raised load.

If the simplified function check shows a fault or if anyone suspects something is wrong, the system MUST be checked at an authorised workshop. The system must then be checked in accordance with the same verification for approving Hose Burst Protection.

1. Check - Lifting, fit a bucket, fill to half load.

- Raise the loader to around 1.5 m above the ground.

- Lower the loader to around 1 m above the ground.

- Activate the float position for lifting. Note the result, i.e. the fall height.

- The noted fall height may not exceed 300 mm in the first 10 seconds. Under 300 mm means the system is OK. (The fall height is always lower if the load is lowered. If the load is raised and float position is activated, the fall height reduces considerably.)

2. Check - Tilt, fit a bucket, fill to half load.

Note. This check can only be carried out if the loader's operating unit has the float position tilt function.

-

-

Raise the loader to around 1 m above the ground, tilt the implement - it should be slightly tilted backwards so the load does not fall out.

Activate the tilt float position, note the result.

The change in angle on the bucket should be minimal. (There is no guide value for how much the tilt may turn, but it should be a negligible movement).

4.1.5. Front axle suspension

28

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Important! Tractors with front axle suspension. The loader may cause increased wear on the components in the front suspension. Always lock out the front suspension if this option is available. Read the tractor's operator's manual.

Driving instructions

4.2. Tractor/loader hydraulic controls The loader's hydraulic system can be connected to the tractor hydraulic system in two ways.

Using alternative 1, the tractor hydraulic system is connected to the loader control valve. With this alternative, there are the following designs: • EasyDrive LCS • ElectroDrive LCS Professional • ErgoDrive LCS • ErgoDrive Alternative 2 is to use the tractor's original joystick to control the movements of the loader.

4.3. EasyDrive LCS /ElectroDrive LCS Professional Note. The electronic joystick is available in two variants: ElectroDrive LCS Professional and EasyDrive LCS. •

•

•

EasyDrive LCS and ElectroDrive LCS Professional are electrical hydraulically-controlled control valves with an operating control. The operating control is available as EasyDrive LCS or Electrodrive LCS. ElectroDrive LCS Professional can be configured and adapted as required, such as programmable quick select buttons, setting the 3rd function and adjustable shake function. EasyDrive LCS is a simpler option without the additional setting options.

The base functions for EasyDrive LCS and ElectroDrive LCS Professional are identical unless otherwise stated. For other functions, see the user manual for each control system.

Fig.56 EasyDrive LCS /ElectroDrive LCS Professional Display symbols Float position emptying

4.3.1. Joystick/operating control

Float position, lower

If the joystick is released, it returns to the neutral position and the functions are inactive, with the exception of Lowering, Emptying and 3rd functions.

Hydraulic lock, open

Note. It is only ElectroDrive LCS which has continuous 3rd function.

Hydraulic lock, open

Hydraulic lock, close

Pressure reduction

Transport mode, with deactivation memory

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Fig.57 Display symbols

29

Driving instructions

4.3.1.1. Raise/lower the loader • •

Move the control backwards (1) to lift the loader.

Move the control forwards (2) to lower the loader.

2

1 Fig.58 Raise (1)/Lower (2) the loader.

4.3.1.2. Dump/Roll back the implement • •

Move the lever to the left (3) to angle the implement upward.

Move the lever to the right (4) to angle the implement downward.

4

3

Fig.59 Open (3)/Empty (4).

4.3.2. Button functions 4.3.2.1. Float position, lower

F4

Caution!

The lowering or emptying position combined with bucket work or implement work should only be used at low speeds.

5

Activate: • Press and hold F4 and move the control forwards (5) to lower.

• Release F4 and the control.

• Float position, active, symbol illuminates.

Deactivate: • Move the control backwards (lift).

• Symbol switches off.

5

Note. If the Hose Burst Protection option is fitted, the float position will not work. Hose Burst Protection will lock the loader when the float position is activated for lowering or emptying.

30

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Fig.60 Float position lowering F4 + (5)

Driving instructions

4.3.2.2. Float position emptying

F4

Caution!

The lowering or emptying position combined with bucket work or implement work should only be used at low speeds.

6

Activate: • Press and hold F4 and move the control outwards (6) (emptying).

• Release F4 and the control.

• Float position, active, symbol illuminates.

Deactivate: • Move the control inwards (roll back).

• Symbol switches off.

6

Note. If the Hose Burst Protection option is fitted, the float position will not work. Hose Burst Protection will lock the loader when the float position is activated for lowering or emptying.

Fig.61 Button function, float position emptying F4 and (6).

4.3.2.3. Third hydraulic function •

F2

The third hydraulic function is controlled by pressing and holding F2 whilst moving the joystick left (3) (closes the implement) or right (4) (opens the implement).

Note. When the F2 button is released, the 3rd function stops immediately.

F2 + (3) Close F2 + (4) Open

3

4

Fig.62 Button function, third hydraulic function.

4.3.2.4. Hydraulic lock, open • •

•

F4

Simultaneously (within 1 second) press F4 and D8 until the symbol ”Hydraulic lock, open” is flashing.

Open by simultaneously pressing F2 and moving the joystick outwards (4). The symbol for ”Hydraulic lock, open” is shown on the display.

Confirm the opening is complete by pressing D8. The display stops flashing.

F2

D8

3

4

Fig.63 Button function, hydraulic lock

4.3.2.5. Hydraulic lock, close

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•

Lock by pressing F2 and simultaneously moving the control inwards (3).

31

Driving instructions • •

The symbol for ”Hydraulic lock, close” is shown on the display.

The system is locked within 30 seconds if no confirmation is given by pressing F4 or D8.

Warning!

Risk of crushing and jamming Incorrectly locked implements can come loose.

The lock indicator should return to locked position. Ensure AT ALL TIMES that the connected implement is locked in place by pressing the front section of the implement towards the ground.

Fig.64 Lock indication

4.3.2.6. Boom suspension Load damping [boom suspension] (on/off) is configured as standard with quick select button D8.

The symbol is visible in the information section when the boom suspension function is activated, and disappears when the function is deactivated.

Alternatively: Activate: • Select the boom suspension symbol in the menu and use D6 to confirm.

Deactivate: • Select the boom suspension symbol in the menu and use D6 to confirm.

D6

D8

Fig.65 Button function, boom suspension

Note. If the Hose Burst Protection option is fitted, the boom suspension will not work. Hose Burst Protection blocks the lifting cylinders and therefore stops the boom suspension from working.

4.3.2.7. 4th service

F3

Activate: • Select the symbol in the quick select menu then press and hold D6 for one second to confirm.

• Press and hold F3 whilst moving the joystick right (4) (opens the implement) or left (3) (closes the implement).

Note. When the F3 button is released, the 4th function stops immediately.

Deactivate: • Select the symbol in the quick select menu then press and hold D6 for one second to confirm.

4th service must be activated in order to function.

If the 4th function is activated without the 4th being installed, an error message appears in the display.

D6 3

4

Fig.66 Button function, 4th function

32

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Note. When ESV is installed and not used, the 4th service must be de-selected in the quick select menu.

Driving instructions

4.3.2.8. Transport mode Activate: • Select the transport function symbol and confirm with D6 for at least 2 seconds, the symbol is illuminated.

Deactivate: • Select the transport function symbol and confirm with D6 for at least 2 seconds.

• The symbol is turned off.

Transport mode means that the control functions are closed, except for the boom suspension, which is activated.

More functions are described in the separate manual. See the user manual for the respective system.

D6 Fig.67 Button function, transport mode

4.3.2.9. Pressure reduction Activate: • Select the pressure reduction symbol and confirm with D6.

• Press F4. If the button is released before 5 seconds, the function is deactivated; after 5 seconds, the function remains constantly activated and the symbol is shown in the display.

Deactivate: • Press and hold F4 or move the lever.

4.4. ErgoDrive/ErgoDrive LCS

F4

D6 (5 sek)

D6

Fig.68 Button function, depressurisation

Ergo Drive

Ergo Drive LCS

Fig.69 ErgoDrive/ErgoDrive LCS

4.4.1. Mechanically-controlled control valve and joystick

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If the joystick is released, it returns to the neutral position and the functions are inactive, with the exception of Lowering and Emptying functions.

The control valve is equipped with a control lever of joystick type, located by the operator's seat. The lever is connected to the hydraulic control valve via two control cables.

Fig.70 Control valve, mechanically operated.

33

Driving instructions The joystick can be locked in neutral to prevent inadvertent operation of the loader.

Fig.71 Control lever of joystick type, ErgoDrive.

4.4.1.1. Raise/lower the loader Ergo Drive LCS

Move the lever backwards (1) to lift the loader beam.

Move the lever forwards (2) to lower the loader beam with constant force.

Ergo Drive

2

2

1

1

Fig.72 Raise/lower the loader.

4.4.1.2. Dump/Roll back the implement Move the lever to the left (3) to open up the implement.

Move the lever to the right (4) to angle the implement downward.

Note. The movements are reversed for left-hand fitting.

Ergo Drive LCS

3

Ergo Drive

4

3

4

Fig.73 Empty/angle implement upwards.

4.4.1.3. Float position, lower Caution!

The lowering or emptying position combined with bucket work or implement work should only be used at low speeds.

Ergo Drive LCS 5

Ergo Drive 5

Move the lever forwards into the float position (5) and release the lever to lower the loader beam without any downward force.

To cancel the float function, move the lever backwards slightly (out of the float position) and release it.

34

Fig.74 Float position, lower.

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Note. If the Hose Burst Protection option is fitted, the float position will not work. Hose Burst Protection will lock the loader when the float position is activated for lowering or emptying.

Driving instructions

4.4.1.4. Float position emptying (ErgoDrive LCS)

6

Caution!

The lowering or emptying position combined with bucket work or implement work should only be used at low speeds.

To empty the tool without a downward force, move the joystick to the right to the float position (6) and release the joystick. To cancel the function, move the lever to the left (out of the float position) and release it.

Warning!

Do not use the implement float position function together with 3rd or 4th service. Risk of crushing injuries.

Fig.75 Float position emptying.

Note. If the Hose Burst Protection option is fitted, the float position will not work. Hose Burst Protection will lock the loader when the float position is activated for lowering or emptying.

4.4.1.5. Pressure reduction Turn off the engine.

Move the joystick to its furthest points.

4.4.2. Button functions 4.4.2.1. Third hydraulic function The third hydraulic function is controlled by pressing and holding button A whilst moving the joystick left (3) (closes the implement) or right (4) (opens the implement).

Note. When button A is released, the 3rd function stops immediately.

A

Also applicable to tractors with reversal valves.

3

4 A + 3 Close A + 4 Open

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Fig.76 Button function, third hydraulic function.

35

Driving instructions

4.4.2.2. Fourth hydraulic function The fourth hydraulic function is controlled by pressing and holding button B whilst moving the joystick left (3) (closes the implement) or right (4) (opens the implement).

Note. When button B is released, the 4th function stops immediately.

B

3

4 B + 3 Close B + 4 Open

Fig.77 Button function, fourth hydraulic function.

4.4.2.3. Hydraulic implement lock Coupling and uncoupling.

Warning!

Risk of crushing and jamming Incorrectly locked implements can come loose.

The lock indicator should return to locked position. Ensure AT ALL TIMES that the connected implement is locked in place by pressing the front section of the implement towards the ground.

36

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Fig.78 Lock indication

Driving instructions Operating the hydraulic implement lock.

1. Press rocker switch (D).

2. Depress switch (A).

3. Move the joystick to the left (3) to close the hydraulic lock.

4. Move the joystick to the right (4) to open the hydraulic lock.

When the rocker switch (D) is released, it returns to the off position.

D A

3

4 D + A + (3) Close D + A + (4) Open

Fig.79 Button function, hydraulic tool lock.

The rocker switch (D) is located at the joystick control, or on the tractor's instrument panel.

D

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Fig.80 Rocker switch for hydraulic tool lock.

37

Driving instructions

4.4.2.4. Boom suspension Note. When working with tools which require the lifting cylinders to be double-acting, select position (I) on switch (C).

C

The boom suspension function can be controlled electronically with switch (C). The boom suspension is deactivated in position (I) and activated in position (III).

See also section 4.9. Boom suspension, PlusDrive.

Note. If the Hose Burst Protection option is fitted, the boom suspension will not work. Hose Burst Protection blocks the lifting cylinders and therefore stops the boom suspension from working.

Fig.81 Rocker switch for ErgoDrive.

4.5. Tractor's own joystick/control valve On tractors with electronic control of the hydraulics, the control lever is located on the right of the operator’s seat.

The loader is then controlled by the tractor's control valve.

Fig.82 Control lever.

Four hoses are connected directly between the tractor's hydraulic system and the loader.

Fig.83 Connection, tractor to loader.

4.5.1. Joystick

38

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Expected movement pattern when connecting the tractor's own joystick and control valve.

Driving instructions

4.5.1.1. Raise/lower the loader 1. Move the lever backwards (1) to lift the loader beam.

2. Move the lever forwards (2) to lower the loader beam with constant force.

2

1

Fig.84 Raise/lower the loader.

4.5.1.2. Dump/Roll back the implement Move the lever to the left (3) to open up the implement.

Move the lever to the right (4) to angle the implement downward.

3

4

Fig.85 Open (3)/Empty (4) the implement

4.5.1.3. Pressure reduction See tractor's user manual.

4.5.2. Button functions 4.5.2.1. Third and fourth hydraulic function The third and fourth hydraulic functions are used to control the implement hydraulics and the hydraulic tool lock.

Requires customised hose kit and the tractor joystick to operate the functions. Refer to the tractor user manual for operation.

4.5.2.2. Hydraulic implement lock

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Coupling and uncoupling.

39

Driving instructions

Warning!

Risk of crushing and jamming Incorrectly locked implements can come loose.

The lock indicator should return to locked position. Ensure AT ALL TIMES that the connected implement is locked in place by pressing the front section of the implement towards the ground.

Fig.86 Lock indication Operating the hydraulic implement lock.

1. Press and hold rocker switch (D).

2. Activating the third function, please refer to the tractor manual.

Move the joystick to the left to close (3) the tool lock.

Move the joystick to the right (4) to open the tool lock.

The movements are reversed for left-hand fitting.

D

Note. (X) is the tractor manufacturer's button to activate the 3rd function.

3

4

D + X + (3) Close D + X + (4) Open

40

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Fig.87 Button function, hydraulic tool lock

Driving instructions

4.6. Loader coupling and uncoupling 4.6.1. Coupling the loader - LCS.

Caution!

Risk of crushing and jamming Air in hydraulic hoses and cylinders can cause jerky, unexpected movement.

Run the engine at low speed and make slow movements with the joystick to purge any air from the hydraulic system.

Caution!

Risk of crushing and jamming Keep hands and feet away from moving components. Do NOT use your fingers to check the alignment of holes or pins — use a mandrel or a steel rod.

Caution!

Risk of crushing and jamming If the loader valve is in a depressurised or float position then sudden and unforeseen movements may occur when the hydraulics are connected.

Caution!

The loader may fall. It is essential to ensure the hoses are placed in the hose clamps as shown in the manual so that they do not get caught in the tractor.

1. It is essential to ensure the hoses are placed in the hose clamps as shown in the manual so that they do not get caught in the tractor.

2. Make sure that the locking system is in the unlocked position.

3. Drive the tractor forwards carefully until the base mast slowly enters the bearing box.

Connect the hydraulics (steps 4-6) 4. Depressurise the system. If there is any difficulty in coupling the quick release couplings, this will be because the oil pressure has not been eliminated.

5. Open the handle on the female coupling of the multi coupling. Place the female coupling on the central post so that the couplings meet.

6. Connect by moving the handle to the end position. Never apply force to the quick couplings during this step. Only use hand strength when connecting. Do not reverse or pump the handle when in this position, as this may damage the seals.

7. Tilt the implement downward in order to securely settle the bearing box in the subframe upright.

8. Lift the loader. The locking system will then automatically lock the loader to the mast with the lock pin. (Check that the loader is securely locked to the subframe).

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9. Fold back the support legs towards the loader beam and lock it.

41

Driving instructions

1

2

2

1

3 psi bar

4

P=0

5 6 Single Multi

7

3 2

8 9

42

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1

Driving instructions

4.6.2. Disconnecting the loader - LCS.

Caution!

Risk of crushing and jamming The loader may fall downwards.

Always install a bucket or other suitable implement on the loader before the loader is disconnected from the tractor.

Caution!

Risk of crushing and jamming If the loader valve is in a depressurised or float position then sudden and unforeseen movements may occur when the hydraulics are connected.

Caution!

If the rear section of the implement is more that 15 cm above ground when uncoupling the loader there is risk of damaging the hoses.

1. Position the tractor on a flat and firm surface. Tip the implement forwards and lower the loader beam so that the rear part of the implement is 100 - 150 mm above the ground.

2. Loosen the support legs by pulling the upper part upwards. Fold down the support legs and fix the stay in each support leg.

Note that there are two alternative holes for attaching the stay.

3. Disengage the locking system by pulling out the handle and turning it to the open position (both sides).

4. Release the brakes and lower the loader beam until the cylinders are fully retracted. Turn the implement upwards carefully so that the rear part of the loader is raised and comes loose from the subframe. Allow the implement to rest against the surface below.

Disconnect the hydraulics (steps 5-8) 5. Stop the tractor engine. Depressurise the system. Help the process by moving the joystick to all its end positions.

6. Unlock the multi coupling by pressing the lock button and turning the handle to the left.

7. Disconnect the hoses. Place them in the hose guide.

8. Fit the dust guard to the multi coupling/quick coupling.

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9. Reverse the tractor carefully until it is completely free from the loader.

43

Driving instructions

3

2

1

3 2

1 10-20 cm

1 2

5

4

6

4

1

psi bar

3

2

P

P=0 8

7 9

Single Multi

44

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7

Driving instructions

4.6.3. Locking of loader - US, UM and UL system.

Lift the loader up onto the subframe. Holes for attaching the lifting hooks are found on the inside of the knee plates.

1. Fit the retaining forks.

2. Fit the pins.

3. Turn the pins towards the stop of the retaining forks.

4. Tighten the tension bolts (100Nm).

Fig.88 Install the tensioning forks and pins.

4.6.4. Unlocking the loader - US, UM and UL system.

1.

2.

3.

4.

Loosen the tension bolts.

Turn the pins away from the stop of the retaining fork.

Remove the pins.

Remove the retaining forks.

Fig.89 Loosen the tensioning forks.

4.7. Coupling and uncoupling implements 4.7.1. Uncoupling implements, mechanical implement lock Raise the loader about 1 meter off the ground and position the implement level to the ground.

Turn off the tractor engine and lock the loader control lever in the neutral position.

Apply the parking brake.

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Fig.90 Lift the load horizontal to the ground, turn off the engine, lock control lever in neutral position.

45

Driving instructions Move the locking lever to the open position, position 1.

Position 1

Fig.91 Move the locking lever to the open position, position 1.

Start the engine and lower the loader to the ground until the tool can be disconnected from the loader tool carrier. The lock lever is now released from position 1 and moves to position 2.

Reverse away from the implement.

Position 1

Position 2

Fig.92 Lower the loader until the implement is loose.

Caution!

Risk of jamming.

The lock lever is spring loaded in position 1 and 2.

Caution!

Risk of jamming.

Keep hands and feet away from moving components. Do NOT use your fingers to check the fit of holes/pins, use a mandrel or a steel rod.

Position 2

Fig.93 The lock lever is spring loaded in position 1 and 2.

4.7.2. Coupling implements, mechanical implement lock Angle the tool carrier towards "empty bucket" to its mechanical stop and position the tool carrier 5-10cm under the implement hooks.

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Fig.94 Tilt the tool carrier forward.

Driving instructions Drive the tractor forwards slowly to position the tool carrier under the hooks on the implement.

The position of the implement hooks in relation to the tool carrier during disconnection can be observed from the operator's seat.

When the tool carrier contacts the implement, raise the loader to “hook” the implement on the tool carrier.

Angle up the tool carrier.

The tool carrier must be visible from the driver's cab.

2 1

Fig.95 Position the tool carrier under the implement hooks, raise the loader and roll back the tool carrier.

When the locking hole in the implement comes into contact with the Clic-on system on the tool carrier, the implement will automatically be locked into place. The lock lever is released and moves to position 3.

3

Note. This coupling procedure must be tested in each case, depending on the combination of implement and option, to make sure that nothing catches.

Fig.96 Open the implement to activate the Clic-on locking system. The lock lever moves to position 3.

Read this before you start to work with the loader/ implement.

Warning!

Risk of crushing and jamming Incorrectly locked implements can come loose.

The locking lever must have returned to its locked position. Ensure AT ALL TIMES that the coupled implement is locked in place by pressing the front section of the implement towards the ground.

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Fig.97 Check that the implement is secured by pressing its front end against the ground.

47

Driving instructions

Caution!

When connecting hydraulic implements which use 3rd and/or 4th function, it must be ensured that the implement movements follow these patterns: - Closing the implement = Activate 3rd/4th function, move joystick sideways, towards operator.

- Opening the implement = Activate 3rd/4th function, move joystick sideways, away from operator.

Incorrect movement patterns may mean the load is lost. Remedy this problem immediately.

Fig.98 Check carefully that there is no risk of collision between loader and implement.

4.7.3. Uncoupling implements, hydraulic implement lock Important! If the hoses are connected the wrong way, locking will not function.

Raise the loader about 1 meter off the ground and position the implement level to the ground.

Opening the implement lock, see section 4.2. Tractor/ loader hydraulic controls.

Lower the loader to the ground until the implement can be disconnected from the loader tool carrier.

Important! Position the implement on a level and solid surface.

Fig.99 Raise the loader about 1 meter off the ground and position the implement level to the ground.

Reverse away from the implement.

4.7.4. Coupling implements, hydraulic implement lock Angle the tool carrier towards "empty bucket" to its mechanical stop and position the tool carrier 5-10cm under the implement hooks.

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Fig.100 Tilt the tool carrier forward.

Driving instructions Drive the tractor forwards slowly to position the tool carrier under the hooks on the implement.

The position of the implement hooks in relation to the tool carrier during disconnection can be observed from the operator's seat.

When the tool carrier contacts the implement, raise the loader to “hook” the implement on the tool carrier.

Angle up the tool carrier.

2

Closing the hydraulic implement lock, see section 4.2.

Tractor/loader hydraulic controls.

The tool carrier must be visible from the driver's cab.

Note. This coupling procedure must be tested in each case, depending on the combination of implement and option, to make sure that nothing catches.

1

Fig.101 Position the tool carrier under the implement hooks, raise the loader and roll back the tool carrier.

Read this before you start to work with the loader/ implement.

Warning!

Risk of crushing and jamming Incorrectly locked implements can come loose.

The lock indicator should return to locked position. Ensure AT ALL TIMES that the connected implement is locked in place by pressing the front section of the implement towards the ground.

Fig.102 Lock indication

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Fig.103 Check that the implement is secured by pressing its front end against the ground.

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Driving instructions Note. Check carefully that there is no risk of collision between loader and implement.

Fig.104 Check carefully that there is no risk of collision between loader and implement.

4.8. Working with the loader Warning!

Risk of electric shock, crushing and jamming.

When driving with the loader lifted, make sure that there is enough room between the loader and power lines, barn roofs, etc.

Warning!

Electric shock. Before digging, check that there are no hidden live electrical cables. To prevent personal injury or death, do NOT leave the driver's seat if any part of the loader comes into contact with an electrical cable. Reverse the tractor away from the electrical cable before leaving the tractor.

Caution!

Risk of crushing and jamming People can be inside the working area.

Make sure that nobody is close to the tractor when work starts. Only operate the tractor when sitting in the intended place in the driver's seat.

Fig.105 Ensure that there is enough room between the loader/ implement and power lines, barn roofs, etc.

Fig.106 Maintain a safe distance from power lines and other obstacles.

Warning!

If work requires any individual to be near a raised load, the loader must be fitted with Hose Burst Protection and function checked as per section 4.1.4. Hose Burst Protection (optional extra).

Caution!

Risk of crushing and jamming Before leaving the cab, lower the implement to the ground, lock the brakes and turn off the engine. Remove the ignition key if the machine is left without supervision.

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If you work with the loader on an uphill slope, drive straight upwards, fill the bucket and reverse downhill.

Driving along the side of a slope can cause overturning.

Driving instructions

Warning!

Do NOT use the loader or the attachment as a working platform.

Fig.107 Do NOT use the loader or the attachment as a working platform.

Warning!

Do NOT use the loader or implement to lift or transport people.

•

Only qualified individuals may use the tractor/loader/ implement.

•

Read section 3.4.4. Stability in the user manual for information about the counterweight and track width. Also read the tractor user manual for further information.

Fig.108 Do NOT use the loader or implement to lift or transport people.

Fig.109 Check that the implement is secured by pressing its front end against the ground.

Warning!

Do NOT stand, walk or work under a lifted loader. Make sure that you keep individuals, especially children and animals, away from the working area.

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Fig.110 Do NOT stand, walk or work under a lifted loader.

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Driving instructions

4.8.1. Load stability Warning!

Always look at the implement. Objects can fall or roll backwards onto the driver when the loader is raised.

Only lift loads that fit and are designed for that specific implement.

Some implements should be equipped with a collapse protector.

Fig.111 Pay attention to the implement, objects may fall off.

Warning!

If the tractor is only equipped with Roll Over Protective Structure (ROPS), and does not have a Falling Objects Protective Structure (FOPS), there is only limited protection against falling loads. The driver risks injury if the load falls when the loader is operated at height.

FOPS is not designed to protect against all falling loads. It is therefore critical to use an implement with a collapse protector which prevents the load from falling.

Exercise caution when working with raised loads.

The tractor may not be operated on public roads with a load in the implement.

Important! Incorrectly designed implements can damage the loader. For this reason, do not install third party implements without making sure that it has been approved by the loader manufacturer.

Check that the bucket or other implements are correctly installed on the tool carrier and that the pins are in the locked position. Press the tip of the implement against the ground (1) to check that the implement is firmly fixed (2).

• Only use implements that are approved for the relevant application.

• Check that the load is positioned stably in the implement. In terms of loose material, the implement must not be overfilled, and for solid material, the load must not stick up above the rear of the implement.

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Fig.112 Only lift loads that fit and are designed for that specific implement.

Driving instructions •

Adjust the tilt angle of the implement when the load is raised so that the load is not aimed at the driver.

4.8.2. The tractor's stability Caution!

Check that the machine has sufficient counterweight at the rear to stabilise the machine's load-carrying ability. The counterweight is essential for maintaining control of the machine.

•

Move the tyres to the widest recommended setting to increase stability.

•

Read section 3.4.4. Stability in the user manual for information about the counterweight and track width. Also read the tractor user manual for further information.

Refer to section in the operator's manual for information on the counterweight and tread width.

Also refer to the tractor operator's manual for further information.

•

Fig.113 Exercise caution when working with raised loads.

Warning!

Only use the attachment for the intended application area. Do not grip objects that extend the centre of gravity by a significant extent.

Warning!

Do NOT work on or close to steep slopes.

The distance from a slope must be as far or further than the height of the slope.

•

•

Drive straight up or down slopes (not horizontally).

Avoid braking sharply or driving away at speed. Lower the loader as far as possible.

Drive the tractor forwards up slopes with an empty bucket. Fill the bucket and then reverse slowly down the slope.

Fig.114 Keep at a distance when working near slopes.

Warning!

Reduce speed when cornering to avoid overturning the machine.

Avoid sudden turns when driving down steep slopes.

Caution!

Drive at low speeds - max 10 km/h - with a load in the implement. Speed should be adapted to the terrain and the weight and centre of gravity of the load.

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•

Always leave the engine in gear to obtain engine braking when driving downhill. Do not allow the tractor to roll freely. Use the same gear when driving downhill as when driving up.

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Driving instructions

Caution!

Lower the loader as much as possible when travelling/working. Reduce speed to be appropriate to the circumstances. When handling raised loads, there is increased risk of the tractor tipping. Be alert - if the tractor feels unstable, lower the load to increase stability.

Fig.115 Lower the load and reduce the speed when cornering.

4.9. Boom suspension, PlusDrive 4.9.1. Description The boom suspension dampens the vertical movements of the loader when driving on uneven ground. It consists of one or two dampers, depending on loader model.

The load damper can be activated and inactivated mechanically at the load damper (2) or electrically at the driver's seat.

PlusDrive can be engaged during most applications, but can be disengaged when careful operation with accurate control of the loader is required.

When working with tools that require double-acting function, for example. Silosplit, use position I or II for mechanical deactivation and position I for electrical deactivation.

1

2

Fig.116 Mechanical deactivation of boom suspension.

Caution!

The accumulators (1) are pressurised. Repair, maintenance and commissioning must only be done by authorised personnel.

Warning!

Do not open/disassemble the accumulator before the gas and oil side is depressurised. The cylinder contains nitrogen, which can cause a risk of suffocation.

No work may be done on the pressure vessel.

Welding, drilling or opening the tank by force is not allowed

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Note. The accumulators (1) used with the PlusDrive system are pre-charged and can not be re-charged. Contact your dealer for service.

Driving instructions

4.9.2. Mechanical connection/ disconnection Caution!

Risk of jamming. When activating/connecting the boom suspension, there may be an unexpected/ limited loader movement.

The implement should be lowered to the ground. Turn off the engine and depressurise the hydraulic system (see section 4. Driving instructions). The knob cannot be turned without first depressurising the system.

Mechanical deactivation position I. Mechanical activation: Two working positions, II and III. Position I = Closed Position II = Dampers open to lift cylinders' (+)side.

Position III = Dampers open to the lift cylinders' (+)side and a drain to the lift cylinders' (-)side.

In position III, a drain takes place from the (-)side to the (+)side on the lift cylinders. This means reduced force downwards, which ceases when the control lever is moved to the neutral position.

Selecting a position for mechanical connection/ disconnection can only be done when the system has been depressurised. Lower the loader to the ground and move the control lever to float position, lift before a new position is selected.

4.9.3. Electronic connection/ disconnection Caution!

Risk of jamming. When activating/connecting the boom suspension, there may be an unexpected/ limited loader movement.

The implement should be lowered to the ground.

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Electronic deactivation: Position I. Electronic activation: One working position, III. Position I = Closed Position III = Dampers open to the lift cylinders' (+)side and a drain to the lift cylinders' (-)side.

In position III, a drain takes place from the (-)side to the (+)side on the lift cylinders. This means reduced force downwards, which ceases when the control lever is moved to the neutral position.

Lower the loader to the ground and move the control lever to float position, lift before a new position is selected.

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Maintenance

5. MAINTENANCE During maintenance/service, use personal protective gear such as protective clothing, gloves and goggles.

When a spare part is needed for periodic maintenance or service, use only genuine, original equipment spare parts to restore your equipment to original specifications Particularly applies to hydraulic hoses, hydraulic pipes, adapters and boom suspension components. See the published spare parts sheets.

The manufacturer is not responsible for damages that may occur due to installation of non-approved parts and/or accessories.

Warning!

Never stand between the front of the tractor and the loader's cross tubes.

Fig.117 Never stand between the front of the tractor and the loader's cross tubes.

5.1. Lubrication Operating hours = loader's time in movement.

Lubricate the following grease nipples with universal grease every 10 operating hours.

Warning!

Risk of crushing and jamming The loader may fall downwards.

Lower the loader to the ground before you start greasing.

Grease nipples on every pivot pin on both sides of the loader.

The number of lubrication nipples varies depending on the loader model.

Fig.118 Grease nipples on every pivot pin on both sides of the loader.

5.2. Hydraulic system Check the oil level in the tractor hydraulic oil tank regularly, with the loader lowered to the ground. Use the oil specified in the tractor instruction manual.

Check the hydraulic components and hydraulic connections for leaks.

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Fig.119 NEVER use fingers or hands for leakage detection.

Maintenance

Warning!

Pressurised oil.

Hydraulic oil at high pressure can be injected into the body in the event of leakage and cause serious injury, blindness or fatality. Leakage may be invisible.

Use approved protective safety glasses and protect the skin using strong leather gloves for example. Use cardboard or wood for leakage detection. If fluid has entered the skin then it MUST be removed within a couple of hours by a doctor who can treat this type of injury.

The loader is equipped with a shut-off mechanism. The design can vary depending on the type of control valve.

Caution!

The loader's stop mechanism should be turned to the closed position during servicing.

Warning!

This shut-off valve may NOT be used when working in the loader's lift cylinders or associated lines. In such cases, the loader must be lowered to the ground. Turn off the tractor's engine and depressurise the oil pressure using the operating control before disconnecting any couplings or doing any other work on the hydraulics — oil subjected to high pressure can cause severe injuries.

Check hoses and connections for wear and leakage at regular intervals. Ensure that hoses have sufficient clearance and do not scrape against other components.

Replace damaged hoses and tighten all connections.

The cylinders are double-acting. They must always be maintained in good condition for optimal function. Leaks, internal or external, affect performance and may be dangerous.

This loader requires a hydraulic system that works at high pressure. Only use spare parts approved by the manufacturer.

Fig.120 Turn the shut-off valve handle to the closed position during service work.

0361

Fig.121 Open the multi-connection to the open position during service work.

5.2.1. Repairing/replacing hydraulic components 5.2.1.1. Hydraulic cylinders

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When disassembling hydraulic cylinders, the loader's hydraulic system must be depressurised for as long as possible. To depressurise each operating control, see section 4. Driving instructions and the separate user manuals.

The removal, repair and fitting of the hydraulic cylinders require special tools to prevent damage to internal components. We recommend that a cylinder that needs repairing be sent to an authorised dealer to be fixed.

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Maintenance

Caution!

If the Hose Burst Protection option is fitted, it MUST be assumed that there is still some trapped pressure following depressurisation. Remove hydraulic components/hoses with extreme care.

(If the operator lacks knowledge on hydraulics, take advice from an authorised workshop for disassembly).

5.2.1.2. Hydraulic hoses If a hose does break, remedy the issue immediately. When changing parts, only use original spare parts to restore the machine to its original quality standard.

Important! If a hose CANNOT be safely replaced, the loader must be lowered to the ground and depressurised.

Following hose replacement, a lifting and a lowering movement must be carried out. Operate all loader functions several times to remove air from the system. Air in the system can cause jerky movements.

Caution!

Hose Burst Protection. If a hose bursts and the loader is not in an ideal location, it can be driven down to ground level if the air cylinders' minus sides can be pressurised. Ensure that the loader can be lowered safely. Decontaminate the land in accordance with applicable requirements/ legislation in the country or region you are in.

5.2.1.3. Plus Compact Valve Plus Compact Valve is fitted with quick couplings to make replacement simpler and easier.

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Fig.122 Connection and disconnection of Plug In connection

Maintenance Disconnection 1. Remove the assembly stop using a screwdriver.

2. Push the male coupling all the way in.

3. The coupling is now ready to disconnect.

4. Pull the hose backwards to disconnect.

5. Refit the assembly stop to the hose.

1

3 2

4 Fig.123 Disconnection Connection 1. Make sure that the assembly stop is in place.

2. DO NOT install the male connector without the assembly stop in place.

3. Push the male coupling all the way in until the assembly stop touches the female coupling.

4. Make sure that there is no play between the assembly stop and the female coupling.

5. Make sure that the coupling is securely connected by trying to pull it apart.

1

2

3

4 Fig.124 Connection

5.3. Checking the loader and subframe screws.

Operating hours = loader's time in movement.

Check that all screws are tightened to the specified torque, first after 10 hours of operation and then every 50 hours of operation.

Caution!

Check the loader and subframe for cracks, loose screws or other damage that may negatively affect function and could lead to personal injury.

When changing parts, only use original spare parts to restore the machine to its original quality standard. In continuous operation, check every 50 operating hours.

5.3.1. Tightening torques

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Tighten all screws on the loader and all fasteners in accordance with 5.3.1.1. Table - Tightening torque.

If a different tightening torque is stated in the fitting instructions, it shall take precedence over the torque stated in the table.

Tighten all the screws on the loader and all fasteners, except in the cases where the tightening torque is specified in the assembly instructions.

The torques apply to clean, dry threads. Lubricated threads may mean that the fastener is tightened too hard. Damaged or dirty threads can cause torque values to be too low.

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Maintenance A torque amplifier may be needed when tightening screws to high torque values.

Tightening torques should be checked immediately after installation, and several times after a short period of use.

Incorrect tightening can damage the structure of the loader and/or tractor.

5.3.1.1. Table - Tightening torque Grade 5 (Class 8.8) Screw

Grade 8 (Class 10.9) Screw

Diameter

Torque

Diameter

Torque

1 /4”

13.6 Nm (10 lb-ft)

1 /4”

14.9 Nm (11 lb-ft)

5/16”

27.1 Nm (20 lb-ft)

5/16”

32.5 Nm (24 lb-ft)

3/8”

47.5 Nm (35 lb-ft)

3/8”

59.7 Nm (44 lb-ft)

7/16”

75 Nm (55 lb-ft)

7/16”

96.3 Nm (71 lb-ft)

1/2”

100 Nm (85 lb-ft)

1/2”

154.6 Nm (114 lb-ft)

5/8”

230 Nm (170 lb-ft )

5/8”

301 Nm (222 lb-ft)

3/4”

405 Nm (300 lb-ft)

3/4”

440.6 Nm (325 lb-ft)

M8

27.1 Nm (20 lb-ft)

M8

32.5 Nm (24 lb-ft)

M10

54.2 Nm (40 lb-ft)

M10

63.7 Nm (47 lb-ft)

M12

94.9 Nm (70 lb-ft)

M12

108.4 Nm (80 lb-ft)

M14

119.3 Nm (88 lb-ft)

M14

176.3 Nm (130 lb-ft)

M16

189.8 Nm (140 lb-ft)

M16

271.2 Nm (200 lb-ft)

M20

385 Nm (284 lb-ft)

M20

542.3 Nm (400 lb-ft)

5.4. Storage If the loader is not to be used for a long period of time, apply a thin layer of grease to visible piston rods in order to protect them.

5.5. Transporting the loader

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If the loader needs to be transported, such as for repair, the loader must either: 1. Be transported fitted on a tractor.

2. Be transported without any implements, tied on a pallet and with retracted support legs.

3. be transported without any implements, just the loader with retracted support legs. When lifting the loader on to the transport vehicle, use the designated loader lifting points.

Troubleshooting

6. TROUBLESHOOTING Faulty functioning of the loader is frequently caused by factors not related to the loader: • Check the oil level in the tractor's hydraulic tank. Top up to the correct level.

• Check that the correct oil is used. Only use the oil specified in the tractor's instruction manual. The wrong oil can cause foaming, heating and internal leakage.

• Make sure that hoses and couplings are correctly installed and connected to the tractor. Hydraulic couplings must be fully inserted.

• Check that the oil is clean and free from moisture.

Change the oil and filter as necessary.

• Check hoses and couplings for leakage, cuts and twists.

• Low temperatures can cause slow movements or cause the loader to function irregularly until the normal working temperature is reached. Check whether the oil is holding its normal working temperature before testing the loader.

• When using the tractor's own valve for operation of the loader, make sure that the tractor valve has been adjusted for double action. Check that the flow control has been set to the maximum value.

• Move the loader's cylinders to their end positions several times to remove air from the hoses and cylinders.

Most problems which occur with the loader are simple in nature and can be easily rectified. Use the "Troubleshooting table" on the following pages to help you localise and solve problems.

Please contact your dealer if you need more help.

Problem

Possible cause

Action

Lifting and implement cylinders do not function

Low hydraulic oil level.

Check and top up with hydraulic oil.

Hydraulic hoses connected incorrectly.

Check and connect the hoses correctly.

Hydraulic hoses to/from control valve are “blocked”.

Check hoses for damage (kinks, twists etc.)

Loader control valve or tractor's main Contact your dealer. reduction valve has got stuck in the open position.

Low system pressure from pump.

Contact your dealer.

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Lift or implement cylinders not working. Break in control cables for control valve. Inspect. Change if necessary.

Hydraulic quick-release couplings not fully inserted.

Check the connection. Change coupling(s) if necessary.

Blocked hydraulic hose/pipe.

Look for damage to hose/pipe which could block oil flow between cylinder and control valve.

Piston unit damaged (does not seal).

Contact your dealer.

Blocked control valve.

Contact your dealer.

Damaged quick-release coupling.

Change quick-release coupling.

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Troubleshooting

Problem

Possible cause

Action

Lift and/or implement cylinders working Hydraulic hoses connected incorrectly. in the wrong direction compared to lever deflection.

Control cables for single lever control

Connect hydraulic hoses to correct socket.

Air in hydraulic oil (generally shown by Low hydraulic oil level. foaming).

Check and top up with hydraulic oil to correct level.

connected incorrectly.

Air leakage in hydraulic pump suction side.

Contact your dealer.

Contact your dealer.

Foaming due to wrong type of hydraulic Read the tractor instruction manual and oil being used. top up using the recommended type of hydraulic oil.

Slow or jerky lifting movement.

Low hydraulic oil level. Cold hydraulic oil.

Check and top up with hydraulic oil. Let the hydraulic oil warm up to working temperature.

Engine speed too low (hydraulic pump speed is then too low).

Increase engine speed to improve loader performance.

Too heavy load in bucket. Material weight exceeds loader's specified capacity.

Reduce the load in the bucket.

Control valve cable system binds or is damaged.

Contact your dealer.

Air in the hydraulic oil.

See “Air in the hydraulic oil”.

Hydraulic quick-release couplings not fully inserted.

Check the couplings. Repair or change.

Restriction in hydraulic hose or pipe (hoses/pipes have become twisted or crushed).

Contact your dealer.

Lifting cylinder piston unit leaks.

Contact your dealer.

Pressure limiting valve working irregularly or set too low.

Contact your dealer.

Noise from the system's pressure limiting valve (squeaking)

Insufficient lifting capacity.

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Inadequate capacity in hydraulic pump.

See “Inadequate pump capacity”.

Cold hydraulic oil.

Let the hydraulic oil warm up to working temperature.

Too heavy load in bucket. Material weight exceeds loader's specified capacity.

Reduce the load in the bucket.

Pressure limiting valve set lower than specification.

Contact your dealer.

Restriction in hydraulic hose, pipe or quick-release coupling.

Contact your dealer.

Engine speed too low.

Increase engine speed.

Too heavy load in bucket. Material weight exceeds loader's specified capacity.

Reduce load.

Pressure limiting valve set lower than specification.

Contact your dealer.

Piston in lifting cylinders leaks.

Contact your dealer.

Internal leakage in control valve.

Contact your dealer.

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Internal leakage in control valve (bypass Contact your dealer. flow in valve).

Troubleshooting

Problem

Possible cause

Action

Damaged hydraulic pump.

Contact your dealer.

The load drops with the control valve's spool into neutral position. Note: Depending on the loader model, the value that the loader is allowed to sink by is between 0.5 and 1.5 mm/min, measured at the piston rod.

Piston in lifting cylinders leaks.

Contact your dealer.

Internal leakage in control valve.

Contact your dealer.

Solenoid valve spool(s) do not return to neutral position.

Control valve centring spring is damaged.

Contact your dealer.

Control valve spool binds in its bore.

Contact your dealer.

Control lever or cable system binds.

Find the reason for binding and repair it.

Loose hydraulic unions.

Tighten loose connections.

Damaged hydraulic hoses, pipes, couplings or O-rings in couplings.

Find the reason for the leakage and change the damaged component.

Damaged O-ring in control valve.

Contact your dealer.

External hydraulic oil leakage.

Control valve or cable system binds and Contact your dealer. prevents valve spool from returning to centre position.

Control valve spool or housing damaged Contact your dealer. and/or worn.

Piston rod seal in cylinder leaks.

Contact your dealer.

Cold hydraulic oil.

Let the hydraulic oil warm up to working temperature. Increase engine speed.

Engine speed too low.

Increase engine speed.

Low hydraulic oil flow.

Please refer to the tractor operator's manual for service recommendations.

Restriction in hydraulic hose.

Contact your dealer.

Fault in hydraulic pump.

Contact your dealer.

Lifting cylinder piston rods bent.

Abnormally high shock loading during lowering movement.

Contact your dealer.

Bucket cylinder piston rods are bent when bucket cylinders are extended.

Grading or excavation work with bucket Contact your dealer. cylinders fully extended.

Implement lock can not be locked.

If the hoses are connected the wrong way, locking will not function.

Contact your dealer.

Problem

Possible cause

Action

The loader will not lower

The Hose Burst Protection option is Deactivate boom suspension. fitted on a loader older than 31/12/2010.

Float position does not work

The Hose Burst Protection option is fitted.

Uninstall Hose Burst Protection to regain the function.

Boom suspension does not work.

The Hose Burst Protection option is fitted.

Uninstall Hose Burst Protection to regain the function.

Inadequate pump capacity.

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Hose Burst Protection

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Data

7. DATA J

7.1. Parallel movement ZX1.1P

ZX2.1P

ZX3.1P

ZX3.3P

ZX3.4P

ZX4.1P

ZX5.1P

A Lifting height to 3,20 pivot point (B+300)

3,50

3,75

3,75

3,90

4,00

4,25

B Lift height below flat implement

2,90

3,20

3,45

3,45

3,60

3,70

3,95

C Dimension to pivot 1,57 point

1,71

1,82

1,82

2,0

2,0

2.3

D Calculated height to 1,52 pivot point

1,57

1,65

1,65

1,65

1,70

1,73

E Dump angle on top 63

58

60

60

55

55

52

F Breaking up angle on top

45

55

56

56

58

58

59

G Breaking up angle at ground level

41

44

43

43

44

45

45

0,1-0,2

I

Max lifting force lb/kg (800 mm from arm centre at ground level).

3307 / 1500

3373 / 1530

4211 / 1910

4960 / 2250

3968 / 1800

4564 / 2070

5137 / 2330

J

Range with loader in highest position (m)

1,34

1,30

1,40

1,40

1,40

1,46

1,52

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H Calculated undermining

Data

7.2. Non-parallel movement ZX1.1

ZX2.1

ZX3.1

ZX4.1

ZX5.1

A Lifting height to 3,20 pivot point (B+250)

3,50

3,75

4,00

4,25

B Lift height below flat implement

2,90

3,20

3,45

3,70

3,95

C Dimension to pivot 1,57 point

1,71

1,88

2,1

2,38

D Calculated height to 1,52 pivot point

1,57

1,65

1,70

1,73

E Dump angle on top 64

58

60

56

52

F Breaking up angle on top

125

136

131

135

126

G Breaking up angle at ground level

41

44

43

46

45

H Calculated undermining

0,1–0,2

I

Max lifting force lb/kg (800 mm from arm centre at ground level).

2998 / 1360

3064 / 1390

3814 / 1730

4101 / 1860

4696 / 2130

J

Range with loader in highest position (m)

1,49

1,5

1,57

1,59

1,73

Technical data may vary, depending on tractor model and implement.

7.3. Other data

224407

Max hydraulic pressure 21 MPa/210 bar/3045 psi.

Electrical system 12 volts.

65

Wiring diagram

66

202256

8. WIRING DIAGRAM

Warranty Conditions

9. WARRANTY CONDITIONS ÅLÖ AB undertakes, for a period of 12 (twelve) months from the day that the loader/equipment was delivered to the purchaser, to replace or repair components which need to be rectified due to faults in the material or manufacturing. This is on condition that the fault is immediately notified to the supplier, and that the faulty loader/component is made freely available to the supplier.

For replaced components, the warranty is valid only for the remaining duration of the original warranty.

The warranty does not cover faults caused by accidents, inadequate maintenance, modification or incorrect installation by the purchaser. When heavily worn components are replaced under warranty, the purchaser shall be charged for the time that they have been used.

No compensation will be given for personal injury, stoppage, consequential damage or other losses.

Testing or fault diagnosis at the request of the purchaser will be carried out without charge to the purchaser if defects are established in that connection.

Otherwise the purchaser is charged for all costs.

Temporary repairs or extra costs incurred since work has been done outside ordinary working hours will not be compensated.

EC DECLARATION OF CONFORMITY (Directive 2006/42/EC, Annex 2A) ÅLÖ AB Brännland 300 SE-901 37 Umeå, Sweden Tel. +46 (0)90 17 05 00 Hereby certifies that: From January 2011, the front loader models described in this instruction manual (see front page) A. manufactured in conformity with the provisions in the COUNCIL DIRECTIVE dated 17 May 2006 on mutual approximation of the laws of the Member States relating to machinery, 2006/42/EC, with special reference to Annex 1 of the Directive on essential safety and health requirements in relation to the construction and manufacture of machines. dated 15 December 2004 on the approximation of the laws of the Member States on electromagnetic compatibility, 2004/108/EC. B. manufactured according to the following harmonised standards: EN ISO 12100:2010 EN ISO 4413:2010, EN ISO 14892, EN 12525:2000 A2:2010, EN 60204-1.

SMP Svensk Maskinprovning AB, Box 7035, SE-75007 Uppsala, Sweden, has carried out voluntary type control for ÅLÖ AB. The certificate has number: SEC/09/2050 – front loader.

The person authorised to compile technical documentation at ÅLÖ AB is Tomas Nygren, Product Development Director.

223764

Umeå 2015-08-06 Johan P Schlyter Managing Director

67

ÅLÖ AB, SE-901 37 UMEÅ, SWEDEN www.alo.se