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Copyright

325 and 330


Articulated Trucks
From serial number; 325: HHD0000108
330: HHD0000243

Operators Manual

Lep 6-38400 EN

Copyright

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS


MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.

The words Danger, Warning or Caution used on the safety decals have the following significance:

DANGER: Indicates an immediate hazardous situation that, if not avoided, could result in serious injury or even
death. The colour associated with Danger is RED.
WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in serious injury. The
colour associated with Warning is ORANGE.
CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in minor injury. It may also
be used to alert against unsafe practices. The colour associated with Caution is YELLOW.
Certain decals, in conformity with the ISO standard are in several parts. They must be interpreted as follows:

The upper panel indicates the nature of the danger.


The lower panel indicates appropriate avoidance of the danger.
Background colour is YELLOW.
Prohibition symbols such as
if used, are RED.

WARNING
IMPROPER OPERATION OF THIS MACHINE CAN CAUSE INJURY OR DEATH. BEFORE USING THIS
MACHINE, MAKE CERTAIN THAT EVERY OPERATOR:

Is instructed in safe and proper use of the machine.


Reads and understands the Manual(s) pertaining to the machine.
Reads and understands ALL Safety Decals on the machine.
Clears the area of other persons.
Learns and practises safe use of machine controls in a safe, clear area before operating this machine on a job
site.
It is your responsibility to observe pertinent laws and regulations and follow CASE instructions on machine
operation and maintenance.

Reproduction or translation, even partial, is prohibited without written authorization from CNH France S.A. Company
Copyright 2003 CNH France S.A.

Lep 6-38400 EN
Issued May 2003

Copyright

OPERATORS MANUAL
325
330

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QUICK REFERENCE SECTION GUIDE


The Sections in this book are shown below.

1 - To the owner/Safety
2 - Controls/Instruments/Accessories
3 - Operating instructions
4 - Servicing intervals/Lubrication/Fluids
5 - Maintenance/Adjustments
6 - Electrical system
7 - Storage
8 - Specifications
9 - Alphabetical index

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TABLE OF CONTENTS

SECTION 1 - TO THE OWNER/SAFETY ................................................................................................... 1-1


325 and 330 articulated trucks ................................................................................................................. 1-1
Legal documents ...................................................................................................................................... 1-2
Right, left, front and rear of the machine .................................................................................................. 1-3
Type, serial number and year of manufacture ......................................................................................... 1-4
Position of identification data on main component groups ....................................................................... 1-5
Identification of the main components of the machine ............................................................................. 1-8
Safety rules .............................................................................................................................................. 1-9
Prevention of fires .................................................................................................................................. 1-10
Overturning accidents ............................................................................................................................ 1-10
Instructions for use ................................................................................................................................. 1-11
Maintenance instructions ....................................................................................................................... 1-14
Decals .................................................................................................................................................... 1-17
Hand signals .......................................................................................................................................... 1-28
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES .................................................................... 2-1
Accessing the cab .................................................................................................................................... 2-1
Accessing the platforms ........................................................................................................................... 2-1
Door ......................................................................................................................................................... 2-2
Location of controls, instruments and accessories .................................................................................. 2-4
Drivers seat (Standard) ........................................................................................................................... 2-8
Drivers seat (Electro-pneumatic) ............................................................................................................. 2-9
Trainers seat ......................................................................................................................................... 2-10
Seat belts ............................................................................................................................................... 2-10
Accessory functions ............................................................................................................................... 2-11
SECTION 3 - OPERATING INSTRUCTIONS ............................................................................................. 3-1
Before operating the machine .................................................................................................................. 3-1
Operating the machine ............................................................................................................................. 3-1
Run-in period ............................................................................................................................................ 3-2
Filling the fuel tank ................................................................................................................................... 3-3
Starting and stopping the engine ............................................................................................................. 3-4
Starting the vehicle ................................................................................................................................... 3-8
Stopping and parking the vehicle ............................................................................................................. 3-9
Driving the vehicle .................................................................................................................................. 3-11
Using the automatic transmission .......................................................................................................... 3-13
Using the hydraulic retarder ................................................................................................................... 3-18
Use of the engine brake (jack brake) (330 model) ................................................................................. 3-18
Using the differential lock ....................................................................................................................... 3-19
Working with the vehicle ........................................................................................................................ 3-20
Towing the vehicle ................................................................................................................................. 3-23

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TABLE OF CONTENTS

Operating instructions (continued)


Emergency steering ................................................................................................................................3-24
Replacing a complete wheel ...................................................................................................................3-25
Climate control system operation ...........................................................................................................3-29
Overturning accidents .............................................................................................................................3-30
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS .............................................................. 4-1
Servicing instructions ................................................................................................................................4-1
Tools provided and their location ..............................................................................................................4-3
Preliminary operations ..............................................................................................................................4-3
Scheduled maintenance program in hours ...............................................................................................4-8
Lubrication and scheduled replacement chart (325 model) ....................................................................4-10
Lubrication and scheduled replacement chart (330 model) ....................................................................4-12
Operations to be carried out every day ..................................................................................................4-14
Engine ....................................................................................................................................................4-17
Fuel supply system (325 model) .............................................................................................................4-31
Fuel supply system (330 model) .............................................................................................................4-34
Air intake system ....................................................................................................................................4-35
Cooling system .......................................................................................................................................4-40
Automatic transmission ..........................................................................................................................4-45
Front axle/rear tandem axles ..................................................................................................................4-48
Hydraulic system ....................................................................................................................................4-51
Checking emergency pump control efficiency ........................................................................................4-56
Hood opening system .............................................................................................................................4-57
Greasing .................................................................................................................................................4-57
SECTION 5 - MAINTENANCE/ADJUSTMENTS ........................................................................................ 5-1
Suspension ...............................................................................................................................................5-1
Braking circuit ...........................................................................................................................................5-4
Tires and wheels ......................................................................................................................................5-6
Air conditioning system ...........................................................................................................................5-10
Bodywork ................................................................................................................................................5-12
Troubleshooting ......................................................................................................................................5-14
SECTION 6 - ELECTRICAL SYSTEM ........................................................................................................ 6-1
Precautions ...............................................................................................................................................6-1
Battery maintenance (not sealed) .............................................................................................................6-2
Control unit location ..................................................................................................................................6-5
Interconnection control unit ......................................................................................................................6-6
Fuse and relay box ...................................................................................................................................6-8
Lighting system .......................................................................................................................................6-11

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TABLE OF CONTENTS

SECTION 7 - STORAGE ............................................................................................................................. 7-1


Storing the vehicle .................................................................................................................................... 7-1
SECTION 8 - SPECIFICATIONS ................................................................................................................ 8-1
Main groups ............................................................................................................................................. 8-1
Dimensions .............................................................................................................................................. 8-2
Weights .................................................................................................................................................... 8-4
Horizontal center of gravity (during transport with unladen vehicle) ......................................................... 8-5
Securing points for transportation on trailer ............................................................................................. 8-5
Performance (325 model) ........................................................................................................................ 8-6
Performance (330 model) ........................................................................................................................ 8-7
Main group characteristics ....................................................................................................................... 8-8
Capacities .............................................................................................................................................. 8-12
SECTION 9 - ALPHABETICAL INDEX ...................................................................................................... 9-1

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TABLE OF CONTENTS

NOTES

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SECTION 1

30

TO THE OWNER/SAFETY
325 AND 330 ARTICULATED TRUCKS

174CU01

Dealer's Stamp

CNH France S.A.

1-1

Copyright
SECTION 1 - TO THE OWNER/SAFETY

Your machine has been designed and built to the


highest standards of quality. It conforms to all current
safety regulations. However, the risk of accidents can
never be completely excluded. That is why it is essential to observe elementary safety rules and precautions. Hazard control and accident prevention are
dependent upon the awareness, concern and prudence of the operator. Personnel involved in the operation, transport, maintenance and storage of
equipment must be suitably trained.
This manual contains important information concerning safety in operation, adjustment and maintenance
of your machine. Use the detailed alphabetical index
at the end of the manual to find what you are looking
for.
Use this manual as a guide; your machine is a working tool and you will always be able to count on it, as
long as it is correctly maintained.
Do not use the machine and prevent anyone else
using or servicing the machine before (you yourself or
other people) are fully aware of the instructions given
in this manual concerning safety, operation and maintenance. Only use operators who have proved their
ability to operate and maintain this machine in a correct, safe manner.
This machine was designed and made for the following use:
1. to haul excavated material in general;
2. to haul material coming from industrial or civil
engineering construction sites in general;
3. to haul material required to build infrastucturer and/or civil engineering constructions.
Do not use this machine for applications other than
those shown in this manual. Consult your Dealer for
any information concerning changes, additions or
modifications which have to be carried out on this
machine to ensure that these are in compliance with
the regulations and safety rules of various countries.
Any unauthorized modification could cause serious or
fatal injury. Any person carrying out such modifications
is entirely responsible for the consequences.
This operators manual must be kept in the "manual"
compartment provided for that purpose on this
machine. Make sure that the manual is in good condition. To obtain additional manuals or to obtain other
information concerning this machine, consult your
Dealer. Your Dealer can provide you with genuine
parts and has specially trained technicians who know
the best methods for repair and maintenance of your
machine.

1-2

LEGAL DOCUMENTS
A declaration defining the weight shown on the manufacturers identification plate
- Shows that the weight shown on the manufacturers
plate is a value covering the heaviest configuration
and which does not necessarily correspond with the
configuration that is being transported.
A "CE" certificate of conformity
- For a new construction equipment machine, series
produced as per the type approved model, designed
and manufactured in conformity with the requirements
of European Directive 98/37/CE, concerning machine
safety and mainly concerning:
1 - The following Directives:
- CE 89/336: Electromagnetic compatibility
- CE 2000/14: Noise emission
2 - The following European Standards:
- EN 474-1: Safety-General requirements
- EN 474-6: Specific requirements for dumper
IMPORTANT: An original of this "CE" conformity certificate is supplied with each machine and must be
kept carefully by the owner.
IMPORTANT: The official documents supplied with
the machine must be kept by the owner in order to
present them to any inspecting authority which may
request them.

Copyright
SECTION 1 - TO THE OWNER/SAFETY

RIGHT, LEFT, FRONT AND REAR OF THE MACHINE


As used in this manual, the terms "right", "left", "front"
and "rear" indicate the sides of the machine as seen
from the operators seat.
A.
B.
C.
D.

FRONT
REAR
RIGHT-HAND SIDE
LEFT-HAND SIDE

174MN10CA

B
2

1-3

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SECTION 1 - TO THE OWNER/SAFETY

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE


When ordering parts, requesting information or assistance, always give your Dealer the type, serial number
and year of manufacture of your machine.
In the spaces below, write the type, serial number and
year of manufacture of your machine.
MACHINE
Type................................................................................
Serial number.................................................................
Year of manufacturer .....................................................

CS01F537

CS01F537A

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SECTION 1 - TO THE OWNER/SAFETY

POSITION OF IDENTIFICATION DATA ON MAIN COMPONENT GROUPS


All the main vehicle component groups are identified
with a serial number to be found on the actual group,
in the positions shown below.

WARNING

The component group identification number is


always to be indicated when ordering parts.
CAB
The cab number is indicated on a plate in the cab on
the right.

CS01F538

5
CHASSIS
The chassis number is stamped on the right side of
the vehicle.

CS01F539

6
ENGINE
The type of engine and the serial number are indicated on a plate on the engine.

221DT01

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SECTION 1 - TO THE OWNER/SAFETY

TRANSMISSION
The type of transmission and the serial number are
indicated on a plate on the transmission.

CS01F541

8
DRIVE AXLES
The type of axle and the serial number are indicated
on a plate on the axle housing.
(1) Front
(2) Intermediate
(3) Rear

3
CS01F542

1-6

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SECTION 1 - TO THE OWNER/SAFETY

DUMP CYLINDER
The type and serial number are indicated on a plate
on the cylinder barrel.

CS01F543

10
FRONT SUSPENSION CYLINDER
The type and serial number are indicated on a plate
on the cylinder barrel.

CS01F544

11

1-7

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SECTION 1 - TO THE OWNER/SAFETY

IDENTIFICATION OF THE MAIN COMPONENTS OF THE MACHINE

174CU02

12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

1-8

Cab
Dump body
Central articulation joint
Engine
Transmission
Front axle
Intermediate axle
Rear axle
Suspension cylinder
Dump cylinder

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SECTION 1 - TO THE OWNER/SAFETY

SAFETY RULES

6.

The instructions and warnings given in this Operators


Manual illustrate the fundamental safety principles for
operating construction site articulated trucks.

The vehicle must only be driven by qualified personnel, who are authorized to do so by prevailing
legislation.

7.

Drivers must be in a suitable psychological and


physical state (no tiredness, effect of alcohol,
drugs, etc.)

8.

The procedures are not comprehensive. The Manufacturer cannot account for all the possible methods of
use and operation, nor evaluate all the possible consequences.

Furthermore, drivers must be familiar with the


position and operation of all controls, instruments,
gauges and warning lights in the vehicle. The
driver must also be able to evaluate possible failures which may occur and take the required precautions.

9.

Do not allow unqualified or unsuitable personnel


to use the vehicle.

Consequently, operators must be responsible and


careful at all times, to prevent hazardous situations for
themselves and others.

10. Maintenance and repair operations must be carried out by qualified personnel, who are familiar
with the arrangement and operation of assemblies and workshop tools.

These instructions are not comprehensive. They do


not illustrate all the potential hazards which may arise.
Operators must be aware of all the procedures
described in this Operators Manual. The procedures
advise against adopting work methods which could
cause injuries and/or affect safe use of the vehicle.

Use of the vehicle is subject to the respect of the specifications contained in this manual and safety regulations laid down by law in the country where the vehicle
is used. Knowledge of local legislation is mandatory
for all vehicle users.
Read this manual carefully. Contact an expert or call
the Manufacturer if in doubt.
SAFETY INFORMATION

11. Do not allow unqualified personnel to carry out


maintenance or repair operations on the vehicle.
12. Do not wear rings, wristwatches or loose and
hanging clothes when carrying out maintenance
and repair operations on the vehicle.
13. Do not use radio or personal stereo headphones
during operations to avoid distraction.

Always read the safety related decals.

14. Personnel must use the vehicle safety features


(seat belts) and personal protection devices during vehicle use and maintenance.

Replace the labels if they are damaged.

15. Safety equipment:

Always follow the recommended safety instructions.

GENERAL INSTRUCTIONS
1.

Make sure there is a first aid kit in the vehicle.


Check and replenish regularly.

2.

Make sure there is a list of emergency telephone


numbers. Keep it up-to-date.

3.

Vehicle personnel should be aware of basic first


aid procedures to be applied in the event of an
accident or casualty.

4.

Keep children away from the vehicle, the equipment and the materials used.

5.

Keep unauthorized personnel away from the


vehicle, the equipment and the materials used.

1.
2.
3.
4.
5.
6.

Hard hat
Safety glasses or face mask
Protective earphones
Thick gloves
Suitable clothes
Safety boots

1-9

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SECTION 1 - TO THE OWNER/SAFETY

PREVENTION OF FIRES
1.

Keep a suitably sized fire extinguisher in the vehicle. Check it regularly.

18. Stay away from the vehicle if a small fire occurs in


the brake or tire areas. The tires could explode.

2.

The portable fire extinguisher should only be


used by skilled personnel.

3.

Vehicle personnel must be familiar with the basic


techniques for dealing with fire.

19. Never stand in front of the tirewall. Keep a safety


distance of at least 15 meters (50 ft) from the
tread.

4.

Fuel and most lubricants and fluids are flammable.

5.

Do not smoke while refueling or adding fluids. Do


not refuel or add more fluid near open flames. Do
not handle fuel.

20. Stay away from the vehicle for a few hours after
putting out a fire to allow the tires time to cool
down.

OVERTURNING ACCIDENTS
Prevention
1.

Always check the limits for height and width during all stages of loading/unloading, and make
sure they are within the prescribed limits.

Check for leakage or residues of fuel, lubricants


and fluids which could cause minor fires before
starting the engine.

2.

Keep the wheels perpendicular to the slope when


driving up or down a gradient.

8.

Short circuits can cause fires.

3.

Do not make a U-turn on a gradient, to prevent


turning over.

9.

Regularly check the condition of battery terminals, wiring and electrical devices.

4.

Respect the transverse gradient permitted for the


vehicle when loaded and unloaded.

5.

Respect the values for maximum slope negotiation when unloaded and loaded.

6.

Check that the hammer for breaking the specially


treated glass is always kept in the cab.

6.

Stop the engine before refueling. Do not refuel in


enclosed places.

7.

10. Do not store flammable substances in places


which are not suitable for the purpose. Do not
pierce or burn pressurized containers or cylinders. Do not pile up materials soaked in flammable substances.
11. Be careful where you leave rags and/or replaced
materials which may contain flammable residues.
12. Put out all smouldering materials and open lights
before starting any maintenance operation.
13. Do not smoke during maintenance operations.

In the event of overturning


1.

Make sure that the personnel trained to use the


vehicle know where the emergency exits are and
the location of the special glass breaking tool.

2.

The following emergency exits can be used to


abandon the vehicle:

14. Do not use fuel, solvents or other flammable or


toxic fluids to clean mechanical parts. Use nonflammable, non-toxic, type-approved products on
the market.
15. Do not weld near tanks, pipes, reservoirs, electric
wires or flammable materials in general. Always
disconnect batteries prior to welding on vehicle.
16. Protect flammable parts with suitable guards
when welding.
17. Stay away from the vehicle and call a fire-fighting
expert team in the event of a large-scale fire.

1-10

1. door (open),
2. front right window (smash).
3.

Use the special tool, located at the bottom of the


window to break the specially treated glass.

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SECTION 1 - TO THE OWNER/SAFETY

INSTRUCTIONS FOR USE


CAB

STARTING AND STOPPING

1.

Use the steps and handles to get on and off.

1.

2.

Keep the steps and handles clean to avoid slipping.

Before starting, check the vehicle exterior for


problems, such as flat tires, fluid leakage or broken parts.

3.

Do not use flexible parts or controls such as handles. They could break or get damaged.

2.

Make sure no one is near the vehicle when starting the engine.

4.

Face the vehicle while you are getting on and off.


Have three points of contact (steps and handles)
at all times.

3.

Sound the horn before starting the engine.

4.

Start the engine while you are sitting in the


drivers seat.

5.

Do not start the engine by short-circuiting the


starter motor wires.

6.

Two people are required to start the engine with a


battery charger or auxiliary battery: one person
must sit in the drivers seat and the other person
must stand near the battery charger or auxiliary
battery.

7.

Do not carry out this operation if the battery is frozen. It could explode.

8.

Be aware of cable connection procedure and


polarity to prevent the risk of the batteries exploding or projecting electrolyte.

9.

Always wear gloves and eye protection when


approaching batteries.

5.

Do not jump on or off the vehicle.

6.

Do not get on or off while the vehicle is moving.

7.

Keep the floor clear of objects, tools or other


items which could interfere with the pedals.

8.

Keep the pedals clean (mud or grease).

9.

Eliminate anything which can reduce visibility or


distract the driver.

10. Keep windows and rear view mirrors clean.


11. With the vehicle stationary and the parking brake
applied, before starting up, check the position of
the seat, the steering wheel and the rear view
mirrors to ensure maximum driving comfort and
control accessibility.
12. Make these adjustments each time the driver is
changed.

10. Do not smoke or use open lights or flames near


batteries.

13. Drivers should be able to press the pedals down


fully and operate the controls correctly without
removing their backs from the backrest.

11. In the event of contact with electrolyte, wash the


affected area for at least 15 minutes and call a
doctor.

14. Do not adjust the seat, the steering wheel or the


rear view mirrors while driving or in any other way
than specified.

12. Do not run the engine in closed areas without a


suitable ventilation system for disposing of harmful exhaust in the air.

15. Always wear seat belts.

13. Never leave the vehicle with the engine running.

16. The belt must not be twisted. The belt should


wrapped around your hips, not your abdomen, to
prevent the risk of slipping forwards.

14. Do not park with the parking brake applied and a


gear engaged, even if you are sitting in the
drivers seat.

17. Replace a seat belt that was being worn during a


serious accident, even if it does not appear damaged.

15. Before leaving the vehicle parked in a suitable


area where it is not a hindrance, make sure that
the parking brake is applied and that the keys
have been removed from the control panel.

18. Do not make changes liable to decrease the


effectiveness of the seat belt.

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SECTION 1 - TO THE OWNER/SAFETY

16. Always apply the parking brake in the following


cases:
1. When the vehicle is parked for a long or short
time;

16. Do not use the vehicle if the parking brake is not


working properly.
WORKING THE VEHICLE
1.

Do not use the vehicle for purposes other than


those described by the Manufacturer.

2.

Always check height and width during the various


loading/unloading operations. Make sure they fall
within the specified limits.

3.

Beware of overhead obstacles, such as bridges,


cables and wires. Make sure that the load does
not hit them.

4.

Keep the wheels facing to the slope when driving


up or down a gradient.

5.

Do not make a U-turn on a gradient to prevent


rolling over.

6.

Respect the transverse gradient, permitted for a


laden and unladen vehicle.

7.

Respect the maximum possible gradient for a


laden and unladen vehicle.

8.

Look out for people when reversing and changing


direction.

9.

Ideally, a second person should be asked to signal when reversing. This person will be able to
observe the approach from a more favorable
position with respect to the driver.

2. When loading/unloading the vehicle.


DRIVING THE VEHICLE
1.

Make all the necessary adjustments (seat, steering wheel, rear view mirrors) before starting up.

2.

Check that the engine warning lights are giving


the correct indications.

3.

Sound the horn before driving off.

4.

Check that no one is driving near the vehicle


before driving off.

5.

Be very careful when steering: the front part of


the vehicle can move also when the vehicle is
stationary. This can be very dangerous for people
standing near the vehicle.

6.

7.

Check the ground surrounding the vehicle before


reversing to make sure there are no people or
obstacles.
Do not transport people in the cab or in other
parts of the vehicle, with the exception of the
trainers seat.

8.

Pay attention to signs, especially speed limits.


Never exceed the speed limit.

9.

Never drive at speeds which are forbidden and


dangerous for yourself or others.

10. Do not exceed the maximum speed allowed.


11. Switch the lights on at night and when visibility is
poor (dust, fog, rain). Slow down.
12. Never travel with the transmission in neutral.
13. Do not use the parking brake for slowing down or
stopping the vehicle.
14. Select the gearbox manual mode and use the low
gears (2nd and 3rd) to slow the vehicle down.
Use all the vehicles auxiliary brakes (retarder,
exhaust brake).
15. If the brakes overheat, select the gearbox manual
mode and use the low gears (2nd and 3rd) to
slow the vehicle down. Do not use the parking
brake to slow or stop the vehicle when it is moving. This should be done only in the event of an
emergency after sufficiently reducing the speed
with other methods.

1-12

10. Do not move the vehicle to loading position while


the loading machine bucket or excavator is moving overhead.
11. Stay inside the cab while loading the vehicle.
12. Make sure that the maximum capacity of the
vehicle is not exceeded during loading operations.
13. Make sure that the load is properly spread and
will not fall out of the dumper during transportation.
14. Check the area before unloading. Look out for
hazardous points: loose terrain, ditches, humps
and fencing.
15. Beware of icy ground; it may become treacherous
and slippery when the temperature rises.
16. Avoid loading and unloading on steep slopes; the
vehicle could roll over.
17. Be very careful of throwing the vehicle out of balance by the movement of material out of the
dumper during unloading operations.

Copyright
SECTION 1 - TO THE OWNER/SAFETY

18. Check that the dump body is in the correct position before driving off after unloading.
19. No one should ever stand in the loading and
unloading area of the vehicle.
20. When unloading using the external control, the
operator must never leave the control, which is
located in a safe position and must wear all the
required personal protection devices.
21. Never start off during loading or unloading operations.
22. Do not get on or off the vehicle during loading and
unloading operations.
23. When passing another vehicle, the unladen vehicle should give way to the loaded vehicle and a
vehicle driving downhill should give way to a vehicle driving uphill.
24. If other vehicles and/or other machines are used
in the working area, appoint a person in charge of
signaling and use signals which can be understood by all drivers. In this case, all personnel
must follow the instructions provided.

REPLACING A WHEEL
Wheel replacement operations require the utmost
care. They must be carried out by at least two experts,
using a hoist or a crane to handle the wheel. If possible, stop the unladen vehicle in a flat area, apply the
parking brake and remove the key from the control
panel. Make sure that the ground is firm enough for
the load to be supported. If in doubt, use plates and
platforms to prevent the vehicle from sinking.
1.

Only use the lifting points shown.

2.

Make sure that the lifting device is suitable to


carry out the operation and follow all safety
requirements.

3.

Do not use wheels or fasteners other than those


originally provided.

4.

Excessive tightening may be dangerous. Do not


use tubes or extensions other than those provided to tighten the wheel nuts.

5.

Check that the wheel nuts are tight after two or


three hours of vehicle operation.

6.

Check wheel nut tightness regularly.

TOWING THE VEHICLE


1.

Use the specific hitch points specifically provided


for towing the vehicle.

2.

Do not use cables, belts or chains for towing the


vehicle or to tow another vehicle; they could
break.

3.

Do not use cables, belts or chains for towing the


vehicle or to tow another vehicle if the braking
system of the vehicle being towed does not work.

4.

Always use a stiff, suitably dimensioned bar.

5.

An operator must always be aboard the vehicle


being towed.

6.

Do not stand near vehicles being towed.

7.

The parking brake will not work if the drive shaft is


removed from the rear transmission and/or the
planetary gears and/or the drive axles.

8.

In this case, install suitable chocks under the


wheels in both directions of travel to prevent
uncontrolled vehicle movement.

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SECTION 1 - TO THE OWNER/SAFETY

MAINTENANCE INSTRUCTIONS
INTRODUCTION

PREVENTING INJURIES

Personnel in charge of repairs must be aware of all


the procedures described in this Operators Manual.
The procedures advise against adopting work methods which could cause injuries and/or affect the safety
of the vehicle.

1.

Use the steps and handles provided for getting on


and off the front platforms.

2.

Use the steps and handles provided for getting on


and off the side platform.

3.

Keep the steps and handles clean to avoid slipping. Do not use flexible parts or controls such as
handles. They could break or get damaged.

4.

Face the vehicle while your are getting on and off.


Have three points of contact (steps and handles)
at all times.

5.

Do not jump on or off the vehicle.

6.

Do not get on or off while the vehicle is moving.

7.

Checking, bleeding, topping-off, maintenance


and replacement operations must be carried out
with the vehicle stationary, on level ground, in a
well lit and ventilated area. Apply the parking
brake, install chocks under the wheels and
remove the keys from the starter switch, unless
otherwise specified in the Operators Manual.

8.

Make sure that no one is sitting in the drivers


seat unless otherwise specified in this manual.

9.

Use portable lamps when the lighting is not adequate to illuminate working areas which cannot
easily be accessed otherwise.

The procedures are not comprehensive. The manufacturer cannot account for and evaluate all the possible methods of operation or the possible
consequences.
1.

Keep the place of work clean and dry. Do not


smoke during maintenance operations. Wear all
the required personal protection devices before
starting maintenance operations.

2.

Carry out maintenance operations as scheduled.

3.

Carry out all operations which are required for the


correct and safe use of the vehicle.

4.

Always install signs warning that operations are


being carried out on the vehicle.

5.

Do not allow unqualified personnel to carry out


maintenance or repair operations on the vehicle.

6.

Carry out maintenance and repair operations with


the utmost care.

7.

Only use the specific tools or wrenches expressly


specified for replacement, checking and maintenance operations.

8.

Never tamper with valves, regulators or other


devices, unless specified in the Operators Manual, to prevent damage to vehicle components
and consequent hazards for personnel.

9.

Always lock the articulation joint, unless otherwise specified. See "Preliminary operations" in
Section 4.

10. Always lock the dump body when operating in


such conditions. See "Preliminary operations" in
Section 4.
11. Make absolutely sure that the electrical power is
disconnected before working directly or indirectly
on electrical system parts by throwing the battery
disconnect switch.

1-14

10. Use a ladder or platform with steps complying


with safety regulations to carry out repairs and
maintenance operations in areas which cannot
be reached from the ground.
11. Keep hands and clothes away from moving parts
when carrying out operations with the engine running.
12. Never put your head or other parts of your body
(feet, hands) near belts or fans in motion, when
the engine is running.
13. Do not put your head or other parts of your body
(feet, hands) near shafts or parts in motion when
the engine is running.

Copyright
SECTION 1 - TO THE OWNER/SAFETY

14. Warn people who are near the vehicle before


starting the engine (e.g; for a test).

4.

Be very careful: drained oil and fluids, as well as


filters and surrounding parts, can be very hot.

15. Wait for at least four hours after stopping the vehicle before conducting maintenance operations to
avoid contact with hot parts. Be very careful of the
cooling fan which could start up suddenly.

5.

Ensure adequate ventilation to prevent the accumulation of toxic vapors while cleaning and
replacing filters.

6.

Do not weld in closed areas or areas which are


not suitably ventilated.

7.

Do not weld on or near painted surfaces to prevent developing toxic vapors.

8.

Remove the paint with suitable products, wash


the surfaces and leave to dry.

9.

Do not breathe in dust and toxic residues while


grinding and sand-blasting. Protect your face with
a mask and safety glasses.

16. Do not work over or under a vehicle propped up


on jacks or other lifting devices which are not suitable to ensure safety.
17. Unload the vehicle before jacking it up. Only use
the lifting points shown.
18. Make sure that the lifting device is suitable to
carry out the operations and meet safety requirements.
19. After jacking up the vehicle, prop it up before carrying out any operations underneath.
20. Fully deflate the tire before carrying out any type
of operation on tires or rims.
21. Never stand in front of the tirewall while your are
inflating a tire.
22. Never weld rims with tires fitted, to prevent explosions and fire.
23. Only use the expressly specified tools for inflating
accumulators with nitrogen.
24. Pressurized hydraulic system. Before you replace
the hydraulic filter or service the hydraulic system,
wear face protection and slowly loosen the
hydraulic reservoir fill cap to relieve the air pressure. If you do not follow these instructions, you
can be injured.

10. Use a suitable vacuum cleaner to remove dusty


residues from the vehicle or place of work.
11. Do not play with compressed air. Keep compressed air gun nozzles away from people.
12. Wear protective glasses with side guards and a
mask when using compressed air to clean filters,
to prevent injury caused by particles of dust. You
are advised to carry out the cleaning operations
in a ventilated area.
13. Be very careful before removing caps or covers
from reservoirs, radiators or cylinders: turn the
part slowly to discharge any residual pressure.
14. Stand to one side during bleeding operations and
always wear protective glasses. Loosen the
bleeder slowly a few turns to let out condensation
and fluid.

PREVENTING INTOXICATION AND CONTAMINATION

15. Discharge pressure from the circuits before carrying out operations.

1.

Do not run the engine in closed areas without a


suitable ventilation system for evacuating harmful
gas in the air.

16. Never use your hands to detect leakage of pressurized fluid.

2.

Avoid prolonged, repeated contacts of fuel, lubricant and fluids with the skin to prevent skin problems and other syndromes.

3.

Do not swallow fuel, lubricant or fluids. In the


event of accidental contact with the eyes, wash
the area thoroughly with water and contact a doctor.

17. Pressurized fluid leakage can penetrate the skin


and the eyes, causing very severe injuries.
18. Never use open lights or flames to detect leakage
from the air conditioning system. It could generate phosgene, a very dangerous gas.

1-15

Copyright
SECTION 1 - TO THE OWNER/SAFETY

PREVENTING BURNS AND ELECTROCUTION


1.

Be very careful of all parts of the vehicle which


can reach high operating temperatures: engine,
radiators, heat exchangers, exhaust pipe, transmission, axles, brake discs, hubs).

2.

Do not loosen the radiator cap when the engine is


hot. Let the coolant cool down before removing
the cap. In any event, remove the cap very carefully. Loosen the cap slowly to release the pressure and then remove it.

3.

Do not place sources of heat near pressurized


fluid tubes, to prevent sudden failures.

4.

Protect hoses and electrical wires with suitable


guards when welding.

5.

Batteries contain sulphuric acid: always wear


gloves and eye protection when approaching the
batteries.

6.

In the event of contact with electrolyte, wash the


affected area for at least 15 minutes and call a
doctor.

7.

Do not charge a frozen battery. It could explode.

8.

Be aware of battery cable connection procedure


and polarity to prevent the risk of the batteries
exploding or projecting electrolyte.

9.

Do not smoke or use open lights or flames near


the batteries.

10. Ensure adequate ventilation to prevent the accumulation of explosive gas while recharging the
battery.
11. Do not charge batteries near the workshop air
compressor intake.
12. Install the air compressor away from the area
where paint, fuel and batteries are stored to prevent taking in vapors.
13. Do not open the camera box or the monitor. Live
electrical parts inside.
14. All operations must be carried out by skilled, suitably equipped personnel.

1-16

Copyright
SECTION 1 - TO THE OWNER/SAFETY

DECALS

WARNING

An illegible or missing decal can have serious consequences. Check them every day. Make sure
that the decals are perfectly legible, clean them
regularly and replace all decals that are destroyed,
lost, painted over or no longer legible with new
ones. When parts bearing decals are replaced,
make sure to put a new decal on each new part.
When cleaning decals, use a cloth, water and soap.
Never use solvents, fuel, etc.
POSITION OF DECALS
When replacing a decal, make sure it is located as
shown in the illustration below.

174DT12

13
This chapter only covers decals relating to safety,
machine operation and servicing. Part numbers are
given in the Parts catalog.

You can obtain new decals from your Dealer.

1-17

Copyright
SECTION 1 - TO THE OWNER/SAFETY

TOWING EYE

CS01K513A

14
BATTERY MASTER SWITCH

CS01K514

15
FUEL TANK FILLER

CS01K515A

16

1-18

Copyright
SECTION 1 - TO THE OWNER/SAFETY

HOT SURFACES

CS01K516

17
KEEP CLEAR OF DRIVE SHAFT

CS01K517

18
CRUSH HAZARD

CS01K518

19

1-19

Copyright
SECTION 1 - TO THE OWNER/SAFETY

CRUSH HAZARD

CS01K519

20
VEHICLE TIE-DOWN

CS01K513B

21
SLIP HAZARD

CS01K520

22

1-20

Copyright
SECTION 1 - TO THE OWNER/SAFETY

HYDRAULIC OIL FILLER

10

CS01K521

23
MAINTENANCE CHART

11

500404634

24
CRUSH HAZARD

12

CS01K526

25

1-21

Copyright
SECTION 1 - TO THE OWNER/SAFETY

HAZARDOUS AREA

13

CS01K527

26
CENTRALIZED LUBRICATING POINT

14

CS01K528

27
TEST POINT

15

CS01K529A

28

1-22

Copyright
SECTION 1 - TO THE OWNER/SAFETY

CRUSH HAZARD

16

CS01K530A

29
ENTANGLEMENT HAZARD
Inside engine hood.

CS01K531

30
STARTING HAZARD
Inside engine hood.

CS01K532

31

1-23

Copyright
SECTION 1 - TO THE OWNER/SAFETY

DANGER OF BURNS
Inside engine hood.

CS01K533

32
HOIST CONTROL
Inside cab.

CS01K534A

33
SEAT BELT
Inside cab.

CS01K535

34

1-24

Copyright
SECTION 1 - TO THE OWNER/SAFETY

EMERGENCY EXIT
Inside cab.

CS01K536

35
DIFFERENTIAL LOCK
Inside cab.

CS01K537

36
PARKING BRAKE CONTROL
Inside cab.

CS01K539

37

1-25

Copyright
SECTION 1 - TO THE OWNER/SAFETY

READ THE OPERATORS MANUAL


Inside cab.

CS01K538

38
FLUID AND LUBRICANTS

CS03B001

39
Inside cab.
TIRE INFLATION PRESSURE
Inside cab.

CS01G502B

40

1-26

Copyright
SECTION 1 - TO THE OWNER/SAFETY

GEAR SELECTION
Inside cab.

500401346

41
VOLTAGE RATING
Inside cab.

500400259

42
EXTERNAL NOISE LEVEL
This decal shows the value in decibels of the noise
level outside the machine.

CS02G515

43

1-27

Copyright
SECTION 1 - TO THE OWNER/SAFETY

HAND SIGNALS
When operating the machine, never attempt to carry
out tasks calling for fine control or working in areas
where visibility is poor or impaired without seeking the
assistance of a signal man. Make perfectly sure that
you and the signal man understand the signals to be
used.
START THE ENGINE

COME TO ME
Wave hands back and forth (palms inwards).

PDE0002A

SHUT DOWN THE ENGINE

44

PDE0003A

46
MOVE AWAY FROM ME
Wave hands back and forth (palms outwards).

PDE0002

45
PDE0003

47

1-28

Copyright
SECTION 1 - TO THE OWNER/SAFETY

GO THIS FAR

EMERGENCY STOP
Wave hands back and forth.

PDE0004A

48
ALL STOP AND HOLD

PDE0005

51
TURN THE MACHINE TO THE LEFT
To stop movement, stop moving hand and clench fist.

PDE0004

49
STOP
Wave hand back and forth.

PDE0008A

52
TURN MACHINE RIGHT
To stop movement, stop moving hand and clench fist.

PDE0005A

50
PDE0008

53

1-29

Copyright
SECTION 1 - TO THE OWNER/SAFETY

NOTES

1-30

Copyright

SECTION 2

26

CONTROLS/INSTRUMENTS/ACCESSORIES
ACCESSING THE CAB
Always use the grips and steps which have been specifically designed to ensure good accessibility when
getting on and off the vehicle.

174NU01A

ACCESSING THE PLATFORMS


1.

Use the specific steps and handles for getting on


and off the front platforms.

174NS04

2
2.

Use the specific steps and handles for getting on


and off the side platform.

3.

Keep the steps and handles clean to avoid slipping. Do not use flexible parts or controls as handles. They could break or get damaged.

4.

Face the vehicle while you are getting on and off.


Maintain three points of contact (steps and handles) at all times.

5.

Do not jump on or off the vehicle.

6.

Do not get on or off while the vehicle is moving.


174NS05

2-1

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
DOOR
The door handle has a lock. To lock the door; turn the
key clockwise (a). To unlock the door; turn the key
counterclockwise (b). To open the door from the outside press the button on the handle.
NOTE: A courtesy light inside the cab will come on
automatically when the door is opened.

174NU02A

4
To open the door from the inside; lower the lever on
the lock. The following controls are arranged on the
inner side of the door:
a. Door opening lever;
b. Door closing handle;
c. Sliding window release levers.

174NU03

2-2

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

This page is intentionally left blank

2-3

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
LOCATION OF CONTROLS, INSTRUMENTS AND ACCESSORIES

WARNING

Before starting the engine, make sure that you are fully aware of the location and function of each control.
Incorrect operation of the controls could cause serious bodily injury.

208NU02B

2-4

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
1. Hourmeter

INSET A

2. Steering column tilt adjustment lever

1. Rotating beacon control

3. Climate control system controls

2. Rear foglight control

4. Air delivery vent

3. Lamp test control (TEST)

5. Turn indicators and horn control

4. Front working light control

6. Headlight and daytime flashing control

5. Rear view mirror heating control

7. Steering wheel

6. Road light control

8. Instrument panel and warning lamps


9. Automatic transmission display

INSET B
1. Retarder control (325 model)

10. Windshield wiper and washer control (325 model)

1. Engine stop/retarder control (330 model)

10. Windshield wiper, washer control and engine


idle regulator (330 model)

2. Longitudinal differential lock control

11. Air delivery vent


12. Starter key switch
13. Brake pedal
14. Accelerator pedal
15. Ashtray
16. Cigar lighter

3. Motorized mirror adjustment control


4. Hazard light control
5. Side window washer control
6. Low temperature starting control (325 model)
6. Not used (330 model)
7. Side window wiper control
8. Gear selector
9. Dump body control
10. Parking brake control

2-5

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
INSTRUMENT PANEL AND WARNING LAMPS

CS03B002

2-6

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
WARNING LAMP PANEL (INSET A)

INSTRUMENT PANEL

1. Not used

1. Speedometer

2. Cold startup device on (325 model)

2. Instrument light dimmer

2. Not used (330 model)

3. Tachometer

3. Clogged air cleaner


4. Not used

4. Engine oil pressure gauge and low pressure


warning lamp

5. Low battery charge

5. Fuel level gauge and reserve warning lamp

6. Hi-beam headlights on

6. Transmission oil temperature gauge

7. Position lights on

7. Engine coolant temperature gauge and overheating engine coolant warning lamp

8. Not used
9. Direction indicators on

8. Automatic transmission display

10. Hazard lights on


11. Parking brake applied
12. Not used
13. Not used
14. Not used
15. Not used
16. Emergency steering system failure
17. Not used (325 model)
17. Maintenance schedule (330 model)
18. Not used (325 model)
18. Engine malfunctioning level - CHECK (330 model)
19. Not used (325 model)
19. Serious engine malfunctioning (330 model)
20. Not used (325 model)
20. Cold start device timer (330 model)
21. Central splitter lock enabled
22. Differential lock between axles enabled
23. Raised dumper
24. Not used
25. Braking system fluid filter clogged
26. Hydraulic system filter clogged
27. Engine brake on
28. Brake circuit failure
29. Battery isolator on (325 model)
29. Not used (330 model)
30. Climate control on

2-7

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
DRIVERS SEAT (STANDARD)
Check and adjust the position of the seat if required
before starting the engine and adjust it, if required, to
ensure maximum driving comfort and accessibility to
controls.

WARNING

The vehicle must be stationary to carry out this


operation and the engine turned off.
WEIGHT ADJUSTMENT
This adjustment is obtained manually by turning the
specific control (1) either clockwise or counterclockwise to allow for increased or decreased weight on the
seat and the seat height.
CUSHION ANGLE ADJUSTMENT
The front and rear parts of the cushion can be
adjusted separately; adjust the cushion angle by
means of the levers (2) and (3), respectively.
BACKREST ANGLE ADJUSTMENT
Rest your back firmly against the backrest and adjust
the angle by means of the lever (4).
FORE/AFT POSITION ADJUSTMENT
Lift the lever (5) and slide the seat to the required position. Make sure that the mechanism is locked after
adjusting the seat position.
ARMREST POSITION ADJUSTMENT
Turn control (6) clockwise or anticlockwise to increase
or decrease armrest height.
HEAD REST ADJUSTMENT
The head rest height and angle can be adjusted.

174NU04

2-8

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
DRIVERS SEAT (ELECTRO-PNEUMATIC)
Check and adjust the position of the seat if required
before starting the engine and adjust it, if required, to
ensure maximum driving comfort and accessibility to
controls.

WARNING

The vehicle must be stationary to carry out this


operation and the engine turned off.
(A) SEAT HEATING
Use the switch to turn the heating on/off.
NOTE: The warning light built into the switch will light
up when the device is on.
(B) WEIGHT ADJUSTMENT
To adjust the reaction to the drivers weight use the
button:
+ for heavier weight
- for lighter weight.
(C) LUMBAR ADJUSTMENT
To adjust the seats lumbar support use the button.
(D) BACK SUPPORT ADJUSTMENT
To adjust the seats back support use the button.
CUSHION ANGLE ADJUSTMENT
The front and rear parts of the cushion can be
adjusted separately; adjust the cushion slant by
means of the levers (2) and (3), respectively.
BACKREST ANGLE ADJUSTMENT
Rest your back firmly against the backrest and adjust
the slant by means of the lever (4).
FORE/AFT POSITION ADJUSTMENT
Lift the lever (5) and slide the seat to the required position. Make sure that the mechanism is locked after
adjusting the seat position.

174NU82

ARMREST POSITION ADJUSTMENT


Turn control (6) clockwise or anticlockwise to increase
or decrease armrest height.
HEAD REST ADJUSTMENT
The head rest height and angle can be adjusted.

2-9

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
TRAINERS SEAT
A trainers seat is provided.
Proceed as follows to use the seat:
1.

Operate the lever and slide the drivers seat laterally;

2.

Lower the trainers seat;

3.

Reposition the drivers seat.

WARNING

The vehicle must be stationary to carry out this


operation and the engine off.

174NU05

10

SEAT BELTS
The vehicle is equipped with two-point seat belts complete with automatic reel.
The seat belt does not require manual adjustment: the
belt will automatically adjust to the most suitable
length for the driver allowing freedom of movement as
long as movements are not sudden.
The mechanism is sensitive to changes in vehicle
movement.
Consequently, the belt may lock in the following
cases:
- braking or sudden acceleration;
- vehicle on grade;
- vehicle cornering.

174NU06

11

To fasten the seat belt, take the tab and insert it in the
buckle until it clicks.

174NU07

12

2-10

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
To release the seat belt, press the button provided on
the upper side of the buckle.

WARNING

The vehicle must be stationary to carry out this


operation and the engine off.

174NU08

13

ACCESSORY FUNCTIONS
ADJUSTING THE STEERING WHEEL POSITION
Proceed as follows:
1.

Release the lever by pulling it upwards;

2.

Adjust the height and tilt of the steering wheel;

3.

Lock the lever by pushing it downwards.

WARNING

The vehicle must be stationary to carry out this


operation and the engine off.

174NU12

14
REAR VIEW MIRRORS
The right and left rear view mirrors can be adjusted
manually or by means of the rear view mirror power
control. Adjust the mirrors so that in his normal driving/
operating position the operator has complete visibility
along and throughout both sides of the truck.
Adjust to ensure the best lateral and rear view.

WARNING

The vehicle must be stationary to carry out this


operation.

174NU13A

15

2-11

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
SIDE WINDOWS
Press the knob with your hands and push the window
in the required direction to open/close the window.

174NU14

16
SUNSHADES
Pull tab (a) to lower the sunshade.
Pull cord (b) to lift the sunshade: the sunshade will
automatically roll itself up.

CS03B003

17
POSITION LIGHT AND HEADLIGHT CONTROL
The control has three positions:
Position A: OFF
Position B: position lights ON
Position C: headlights ON

174NU15

18

2-12

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
HEADLIGHT CONTROL
The control has two positions:
Position A: low-beam headlights
Position B: high-beam headlights
Press the button on the control lever (arrow) to flash
the headlights during daytime.

174NU16

19
TURN INDICATOR AND HORN CONTROL
The control has three positions:
Position A: OFF
Position B (up): right turn indicators
Position C (down): left turn indicators
Press the button on the control lever (arrow) to operate the horn.

174NU17

20
WINDSHIELD WIPER/WASHER CONTROL
The control has four positions:
Position A: OFF
Position B: intermittent wipe
Position C: slow wipe
Position D: fast wipe
Press the button (arrow) on the control lever to operate the windshield washer.

174NU18

21

2-13

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
REAR VIEW MIRROR POWER CONTROL
The rear view mirror switch has two positions:
Position A: right mirror
Position B: left mirror
Press button in the required direction to adjust the mirror:
- Arrow upwards: mirror upwards
- Arrow downwards: mirror downwards
- Arrow rightwards: mirror rightwards
- Arrow leftwards: mirror leftwards
174NU19

22
HEATED REAR VIEW MIRROR CONTROL
The control has two positions:
Position A: OFF
Position B: ON

174NU20

23
SIDE WINDOW WIPER CONTROL
The control has two positions:
Position A: OFF
Position B: ON

174NU21

24

2-14

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
SIDE WINDOW WASHER CONTROL
The control has two positions:
Position A: OFF
Position B: ON

174NU22

25
ROTATING BEACON CONTROL
The control has two positions:
Position A: OFF
Position B: ON

174NU70

26
REAR FOGLIGHT CONTROL
The control has two positions:
Position A: OFF
Position B: ON

174NU71

27

2-15

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
LAMP TEST CONTROL
The control has two positions:
Position A: OFF
Position B: ON
NOTE: It is good practice to check that the warning
lamps are working properly every day.

174NU72

28
FRONT WORK LIGHT CONTROL
The control has two positions:
Position A: OFF
Position B: ON

174NU73

29
HAZARD LIGHT CONTROL
The control has two positions:
Position A: OFF
Position B: ON

174NU24A

30

2-16

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
PARKING BRAKE
The control has two positions:
Position A: OFF
Position B: ON
IMPORTANT: The switch is fitted with a safety lever.
Use the lever (arrow) to release the switch.
To engage the parking brake, use the lever and at the
same time move the switch to position B (vehicle with
brake on).
To release the parking brake, use the lever and at the
same time move the switch to position A (vehicle withbrake off).

174NU28B

31

IMPORTANT: The specific warning lamp on the


instrument panel lights up when the parking brake is
engaged.
RETARDER CONTROL
The control has two positions:
Position A: OFF
Position B: ON
Press the switch to position B to switch the retarder
on.
Press the switch to position A to switch the retarder
off.

208NU05

32
LOW TEMPERATURE STARTING CONTROL
(325 MODEL)
The control has two positions:
Position A: OFF
Position B: ON
To facilitate low temperature starting, press the
device control.
For more information see "Starting and stopping the
engine" in Section 3.

208NU15

33

2-17

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
EXHAUST BRAKE CONTROL (330 MODEL)
The control has three positions:
Position A: OFF
Position B: partial operation
Position C: complete operation
Press the switch to position B or C to enable the
exhaust brake.
Press the switch to position A to disable the
exhaust brake.

208NU15

34
RETARDER AND EXHAUST BRAKE CONTROL
(330 MODEL)
The control has three positions:
Position A: OFF
Position B: retarder in operation
Press the switch to position B to enable the
retarder.
Move the switch to position A to disable the
retarder.
Position C: exhaust brake in operation (complete).
Press the switch to position C to enable the exhaust
brake.
Move the switch to position A to disable the exhaust
brake.

221NU175

35

ENGINE SPEED REGULATOR CONTROL


(330 MODEL)
The control has two positions:
Position (+): increase
Position (-): decrease
Press the switch (+) to increase the engine speed
value.
Press the switch (-) to decrease the engine speed
value.

178NU40

36

2-18

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
DOME LIGHT/MAP READING LIGHT CONTROL
Dome light (a) can be switched on by pressing the
switch as indicated:
Position A: OFF
Position B: ON
Map reading light (b) can be switched on by pressing
the switch as indicated:
Position A: OFF
Position C: ON
174NU79A

37
ENGINE STARTER SWITCH
The starter switch has three positions:
Position 0: all off, key can be removed
Position 1: run/prepare starting, electrical power on,
key cannot be removed
Position 2: engine starting

174NU80

38
SOUND SYSTEM INSTALLATION
The sound system is installed in the upper right-hand
side of the cab.
NOTE: See the Use and Maintenance manual supplied with the sound system for further information on
how to use it.

174NM87

39

2-19

Copyright
SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
CB TRANSCEIVER SET
The CB transceiver set can be installed in a special
compartment located in the upper left-hand side of the
cab.
NOTE: The CB set should be installed by the Customer.
Remove the lining corresponding to the shape of the
set to access the compartment.
The compartment houses the sets power supply
cables.
174NM88

40
CLOSED CIRCUIT CAMERA
The vehicle is equipped with a closed circuit camera
for monitoring the area behind the vehicle.
Press button (a) to switch the camera power supply
on (camera in stand-by).
IMPORTANT: Keep the camera normally in stand-by
unless the vehicle is to remain stationary for some
time.
Press button (b) to switch the camera on (camera in
operation, image displayed).
IMPORTANT: The camera is automatically set in
operation when the Reverse gear is selected. The
camera is automatically put into stand-by when the
Neutral or Forward gear is selected.

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41

SATELLITE NAVIGATOR (ELECTRICALLY POWERED)


The vehicle is wired to power a satellite navigator.
The wiring is fitted for the system to be installed
under the drivers seat.

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SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
STEERING
Steering is controlled by means of the steering wheel.
Turn the steering wheel in the required direction
according to the required steering radius. Turn the
steering wheel in the opposite direction to straighten
the vehicle or steer in the opposite direction.
IMPORTANT: When cornering, the steering wheel
has no return action.
The vehicle will continue to following the set cornering
line when the steering wheel is released on a turn.
IMPORTANT:
174NU25

WARNING

43

If the electric emergency pump is triggered by an


abnormal reduction in the steering system pressure, this will set off an acoustic warning (continuous buzzer).

WARNING

If the buzzer sounds intermittently it means that


the electric emergency pump relay fuse (150 A)
has blown, and will not work if the need arises.
ACCELERATOR
The accelerator is controlled by means of a pedal on
the floor to be operated by the drivers right foot. Press
the pedal to increase the torque output by the engine
proportionally to the position of the pedal.

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SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
SERVICE BRAKE
The service brake is controlled by means of a pedal
on the floor to be operated by the drivers right foot.
Press the pedal to obtain a braking effect in proportion
to the exerted pressure.

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45
AUTOMATIC TRANSMISSION
The vehicle is equipped with an automatic transmission with six forward gears and three reverse gears,
plus a torque converter.
The transmission can also be operated manually.
The transmission is switched to automatic mode when
the engine is started.
Select the mode as follows:
- the transmission will always be in automatic mode
after engine startup;
- select the direction of travel, then either press the
button on the top of the lever or move the lever to the
side (either to the right or to the left) to change to manual mode;
- press the button to switch from one mode (automatic/manual) to the opposite one (manual/automatic).
NOTE: When "reverse" is selected, the transmission
automatically switches to manual mode.

2-22

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SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
The gearshift lever has three positions:
Position N (Neutral):
- engine ignition
- vehicle stationary and engine running
Position F(Forward):
- forward movement of the vehicle
Position R (Reverse):
- reverse movement of the vehicle
NOTE: An external buzzer will sound when the R
position is selected.
To shift from position (N) to position (F) or (R), keep
the button on the top of the lever pressed.
It is not possible to shift from position (N) to position
(F) or (R) if the parking brake is applied.
The gearshift lever has two possible selection modes
in manual mode:

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47

(a) Lever pushed leftwards (towards the driver): to


select a lower gear (shift down)
(b) Lever pushed rightwards (towards the side): to
select a higher gear (shift up).
For more information see "Using the automatic transmission" in Section 3.
LONGITUDINAL DIFFERENTIAL LOCK CONTROL
IMPORTANT: The vehicle is equipped with
transversal self-locking differentials on all axles.
These differentials are locked automatically to ensure
correct adherence grip of each wheel.

WARNING

Only use the differential lock when needed and


disengage it as soon as working conditions make
it no longer necessary.
Control switch positions:
Position A: OFF
Position B: longitudinal lock between
engaged
Position C: central differential lock engaged

axles

To lock:
- stop the vehicle with the wheels straight.
- press the switch to the required position before
driving away again.
IMPORTANT: In the event of problematic
engagement, repeat the operation moving at very
slow speed. A specific warning light and buzzer will
come on when the central differential lock is engaged.

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SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
To disengage the lock:
- stop the vehicle with the wheels straight.
- turn the switch to position (A) and drive off again.
For more information see "Using the differential lock"
in Section 3.
BODY HOIST CAB CONTROL
The control has three positions:
Position 0: OFF
Position 1: dumper raise
Position 2: dumper lower
For more information see "Working with the vehicle" in
Section 3.

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49
BODY HOIST GROUND CONTROL
The control has three positions:
Position 0: OFF
Position 1: dumper raise
Position 2: dumper lower
For more information see "Working with the vehicle" in
Section 3.

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SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
CLIMATE CONTROL SYSTEM CONTROLS
The vehicle is equipped with independent heating and
air conditioning systems.
Lever A: heater temperature adjustment
- forwards: ambient air
- backwards: heated air
Lever B: internal/external air circulation
- forwards: flap closed, internal air recirculation
- backwards: flap open, external air circulation
Knob C: three position fan speed adjustment
- clockwise: increase speed
- counterclockwise: decrease speed (position 0:
OFF)
Knob D: air conditioner intensity adjustment thermostat

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51

- clockwise: increase cooling


- counterclockwise: decrease cooling
Warning lamp (arrow): this will light up when the air
conditioner is enabled.
For operation see "Climate control system operation"
in Section 3.
FRIDGE
The fridge is installed in the lower right-hand side of
the cab.
The fridge is simply inserted into its compartment; it
can therefore be easily removed.
- Plug in the fridge to switch it on.
- Unplug the fridge to switch it off.

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52

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SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES
BATTERY MASTER SWITCH
Make absolutely sure that the electrical power is disconnected before working directly or indirectly on
electrical system parts by operating the battery disconnect switch (1).
(a): To connect power: turn switch to horizontal
position.
(b): To disconnect power: turn switch to vertical
position.

221NS01

53
IMPORTANT: With battery cut-out switch on the
respective warning light comes on.

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54

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SECTION 3

30

OPERATING INSTRUCTIONS
BEFORE OPERATING THE MACHINE

WARNING

Do not operate this machine until you read and


understand the instructions and warnings shown
in this manual.
Observe the operating instructions shown in this
chapter, since any other use without the prior
agreement of the manufacturer is considered to be
forbidden.
Before operating the machine, observe the following
instructions:
1.

Check the levels (engine oil, hydraulic fluid and


cooling system) and make sure that the various
fluids correspond to the conditions of use. See
"Fluids and lubricants" in Section 4.

2.

Carry out the daily maintenance operations. See


Section 4.

3.

Check around the machine, identify any leaks


and inspect the hoses. Tighten or replace where
necessary. See Section 5.

4.

Before carrying out any work in the hours of darkness, check that the lighting and signalling systems are operating correctly.

14. Make yourself aware of work site safety measures and hand signals.
15. Holes, obstacles, debris and other dangers on
the work site can cause serious bodily injury.
Inspect and identify all possible risks before driving the machine into a new working area.
16. Before starting the engine, give warning of your
presence by sounding the horn.
17. Never start the engine in any other manner than
that shown in this manual.
18. Avoid loose fitting clothing, loose or uncovered
long hair, and jewelry.
19. Different jobs will require different protective
equipment. Items such as hard hats, protective
shoes, heavy gloves, reflector type vests, respirators, ear protection, and eye protection can be
required. Before you start the job, determine what
protective equipment is required. Use this equipment at all times.

OPERATING THE MACHINE

WARNING

5.

Check the correct operation of the windshield


wipers.

Check the correct operation of all the controls and


all the safety devices in a safe, unobstructed area
before starting work.

6.

Check the condition and pressure of the tires.


See "Tires and wheels" in Section 5.

When operating the machine observe the following


instructions:

7.

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

1.

Start the engine, taking into account the weather


conditions. See "Starting the engine".

2.

If the machine is used under particularly severe


conditions (dusty or corrosive environment, etc.)
reduce the length of the servicing intervals.

3.

If this machine is new or if the engine has been


reconditioned, see "Run-in period".

4.

When operating on a work site on a public highway, use the regulation traffic signs, taking into
account the operating range of the machine.
Local regulations define the number, type and
location of reflective strips.

8.

Clean or change safety decals which are no


longer legible. See "Decals" in Section 1.

9.

Make sure that the engine hood is closed and


locked correctly.

10. Make sure that the cab door is closed correctly.


11. Remove anything which can obstruct visibility.
Clean the windows and rear view mirrors.
12. Make sure that no objects or tools are on the
machine or in the operators compartment.
13. Make sure that no one is under or on the
machine. The operator must be alone on the
machine.

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Copyright
SECTION 3 - OPERATING INSTRUCTIONS
5.

Be vigilant, make yourself aware of places where


other people are working close to your working
area. Keep all other people away from the
machine. Non-observance of these instructions
can cause serious bodily injury.

6.

Make sure that the operators seat is correctly


adjusted.

7.

Never operate a control or driving component


without being correctly seated in the operators
seat with the seat belt fastened.

8.

9.

Always make allowance for working conditions


(sloping or rough ground), the conditions of the
ground and weather conditions.
Never allow any other person within the working
range of the machine. Stop all movement until the
person has moved away.

10. Use all the controls gradually so that the machine


operates smoothly.
11. Before moving in reverse, make sure that there is
no one behind the machine.
12. Never work with the engine hood open.
13. When towing the machine, see "Towing the
machine".
14. Avoid running the engine in a confined space. If
this cannot be avoided, provide good ventilation
in all circumstances.
15. Dust, smoke or mist can reduce visibility and
cause an accident. Stop or slow down the
machine until normal visibility is regained.
16. In the event of an operating problem or damage,
move the machine to a safe place, shut down the
engine and remove the key. Identify or report the
defect and, if necessary, take measures to prevent the machine being operated.

3-2

RUN-IN PERIOD
Longer engine life, improved characteristics and
more economic operation can be obtained by taking
great care with the engine during the first thirty
operating hours.
During this period:
Warm the engine up before using it under load.
Do not run the engine for long periods at idle speed.
Check the warning and indicator lamps and indicators
and gauges frequently.
Check the oil levels and coolant solution levels frequently.
IMPORTANT: During the run-in period a certain
number of operations have to be carried out after the
first 100 and then 250 hours. See "Scheduled maintenance program" in Section 4.

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
FILLING THE FUEL TANK
IMPORTANT: Put out naked flames while refuelling.
Do not smoke.
The tank is fitted with sight glass to show the maximun
fuel level.
IMPORTANT: Keep the fuel tank as full as possible.
Use fuels of the specified types supplied by petroleum
companies. Do not use other than specified fuels. Use
of other than specified fuels can cause severe engine
damage.

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1
FILL UP USING THE FUEL FILLER
1.

Clean the filler area, open the filler cap and refuel
with fuel of the specified type.

2.

Close the cap carefully.

208NU11

2
FILL UP USING FILLER PUMP
1.

Clean the area around the fast-fit union, remove


the protective cap and insert the fuel pump hose
until it hooks up.

IMPORTANT: Make sure that the hose is correctly


hooked up to the fast-fit union.

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SECTION 3 - OPERATING INSTRUCTIONS
1.

Work the cock/switch present on the filling system.

2.

Press button to start the filler pump.

3.

Press button again to switch the filler pump off


when the maximum level is reached.

4.

Release the fuel pump hose and replace the protective cap.

208NU13A

STARTING AND STOPPING THE ENGINE


CHECKS BEFORE STARTING THE ENGINE
Turn the battery master switch to the horizontal position.
IMPORTANT: With battery cut-out switch on the
respective warning light comes on.
Turn the ignition switch to position (1), then check:
- fuel level
- engine oil level
- coolant level
- hydraulic oil level
- condition of tires
- absence of leaks
- absence of apparent damage to the vehicle
- operation of lights, warning lights, horns and windshield wipers
IMPORTANT: The vehicle must be on level ground to
check the levels. Top off the levels and fix any defect,
if required.

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SECTION 3 - OPERATING INSTRUCTIONS
STARTING THE ENGINE

WARNING

Before starting the engine in an enclosed space,


make sure there is adequate ventilation because
exhaust fumes are poisonous. Sound the horn
before starting the engine.
IMPORTANT: The gearshift lever must be in Neutral
to start the engine.
1.

Apply the parking brake.

2.

Check that the body hoist control is in OFF position.

3.

Place the gearshift lever in Neutral.

At normal temperature:
Turn the starter switch key to position (2) and release
it as soon as the engine starts.

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7
At low temperature (325 model):
If the vehicle is equipped with a device to facilitate low
temperature starting, press the device button and
release it immediately.

WARNING

Do not hold the button down to prevent damage to


the device.

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SECTION 3 - OPERATING INSTRUCTIONS
Wait for the warning light to go off, then turn the ignition switch to position 2 and release it as soon as the
engine starts.

WARNING

If the engine does not start, wait for at least ten


seconds before attempting again in order to let the
starter motor cool down. Do not run the starter
motor for longer than 30 seconds if the engine
does not start immediately.
208NU18

WARNING

If the engine fails to start, wait at least 60 seconds


before attempting to start the low temperature
startup device again.
At low temperature (330 model):
If the vehicle is equipped with a device to facilitate low
temperature starting, turn the ignition switch to position 1, wait for the warning light to go off, turn the ignition switch to position 2 and release it as soon as the
engine starts.

WARNING

If the engine does not start, wait for at least ten


seconds before attempting again in order to let the
starter motor cool down. Do not run the starter
motor for longer than 30 seconds if the engine
does not start immediately.

221NU02

10

WARNING

If the engine fails to start, wait at least 60 seconds


before attempting to start the low temperature
startup device again.

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Copyright
SECTION 3 - OPERATING INSTRUCTIONS
WARMING THE ENGINE
After starting the engine, check the engine oil pressure. The warning light should go out after a few seconds and the pressure should reach the correct level.
If this is not so, stop the engine and correct the cause
of the problem.

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11
After starting the engine, check that the brake warning
lights go out after a few seconds. If they do not go out
after a few seconds, stop the engine and correct the
cause of the problem.
After starting a cold engine, drive off slowly for a certain distance to warm the engine. Run the engine at
medium to low rpm.
After starting a hot engine, let it idle for at least 30 seconds before increasing the rpm to allow correct lubrication of the turbocharger.

WARNING

174NU45A

12

Do not idle the engine for a long time, either when


cold or hot.
STOPPING THE ENGINE
1.

Idle the engine for a few minutes to stabilize the


temperature and lubricate the turbocharger.

2.

Turn the starter switch key to 0 position.

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Copyright
SECTION 3 - OPERATING INSTRUCTIONS
STARTING THE VEHICLE

WARNING

Make sure that the area around the vehicle is clear


of personnel and obstructions before driving off.
Sound the horn before starting the vehicle.
IMPORTANT: The camera is automatically set in
operation when the reverse gear is selected.
1.

Check that all warning lights are off.

2.

Check that the dump body is in the down position.

3.

Release the parking brake and press the brake


pedal.

174NU27

14
4.

Press the button on the gearshift lever, push the


lever to Forward or Reverse and select automatic
or manual operation, as required, see "Using the
automatic transmission".

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Copyright
SECTION 3 - OPERATING INSTRUCTIONS
5.

Release the brake pedal and press the accelerator pedal: the vehicle will move off.

WARNING

With transmission oil at a temperature of < -12C


(10.4F) the electronic control unit will not allow
the gears to be engaged, forcing them into Neutral. The transmission warning lamp will light up.
To bring the transmission back into operation,
warm up the oil by running the engine at about
1500 rpm until the warning light goes out.
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16

STOPPING AND PARKING THE VEHICLE


STOPPING
1.

Release the accelerator pedal and press the


brake pedal.

STANDING STILL
1.

Press the brake pedal to stop the vehicle.

NOTE: The torque converter will allow you to keep


the vehicle stationary with the gearshift lever in Forward or Reverse, by pressing the brake pedal. You
are advised not to stay in this position for a long time,
however, because the transmission oil temperature
will rise rapidly.
174NU27

17
2.

Place the transmission in Neutral and apply the


parking brake. Release the brake pedal.

WARNING

The warning light in the switch will only indicate


that the switch position has been changed. The
instrument panel warning light will indicate
whether the parking brake is on. Wait for a few
seconds before releasing the brake pedal after
applying the parking brake.
174NU47A

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Copyright
SECTION 3 - OPERATING INSTRUCTIONS
3.

Stop the engine for prolonged stops and remove


the key from the starter switch.

WARNING

Do not leave the vehicle with the engine running.


PARKING
Take the following precautions when parking the vehicle for a long time:
1.

Fill the fuel tank to prevent the formation of condensation.

2.

Park the vehicle as far as possible on flat ground,


in a suitable area where it is not a hindrance.

3.

Place the transmission in Neutral, apply the parking brake, stop the engine and remove the key
from the starter switch.

4.

Inspect the vehicle to check for any damage or


leaks.

3-10

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SECTION 3 - OPERATING INSTRUCTIONS
DRIVING THE VEHICLE

174NU49A

20
PRECAUTIONS DURING THE INITIAL PERIOD OF
USE

Check the following parameters by means of the


instruments while traveling:

New vehicles require a short run-in period of at least


150/200 hours. Take the following precautions during
this time:

1.

The battery warning lamp (1) must be off at all


times.

2.

The engine coolant temperature (2) must be in


the specified range:
90 to 100C (194 to 212F)

3.

The oil pressure warning lamp (3) must be off


when the engine is running in normal working
conditions.

- Do not demand maximum engine power.


- After starting the engine, warm it up slowly, without
demanding an excessively high engine speed too
soon.
- Frequently check the engine oil level and the
transmission oil level.
- Check the auxiliary drive belt tension.
- Check the tightness of all wheel nuts.
NORMAL RUNNING
Do not exceed maximum engine speed, especially
downhill.
Use the transmission in manual mode to prevent driving for long stretches with the torque converter working. If this happens, select a lower gear. Extended use
of the torque converter will increase fuel consumption
and oil temperature.
Never travel with the transmission in Neutral.
Do not drain the fuel tank as this will cause the formation of air bubbles in the hoses and deposits of impurities which can reach the injection system from the
bottom of the tank.

WARNING

If the pressure is lower than the minimum level


(the alarm warning lamp is on), stop the vehicle,
stop the engine and investigate the causes.
4.

The automatic transmission oil temperature (4) in


normal working conditions must be in the specified range:
70 to 95C (160 to 200F)

WARNING

If the temperature is excessively high, select manual mode and engage a lower gear to prevent
torque converter slipping. If this is not sufficient,
stop the vehicle and investigate the causes.

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Copyright
SECTION 3 - OPERATING INSTRUCTIONS
USE OF THE ENGINE IDLE REGULATOR
(330 MODEL)
The system checks and maintains the engine idle.
The engine control unit ( ECU) is programmed to
maintain an engine idle speed of 600 rpm.
This value can be changed by the engine idle regulator.
This value is maintained whenever the engine
returns to idle until the engine is switched off.
When the engine is started again it will run at the
idle speed programmed in the ECU.
Conditions:
1.

Vehicle stationary and gear selector in Neutral.

2.

Engine running at steady operating temperature


(temperature above 30C/86F).

3.

Accelerator pedal not pressed.

Operation:
1.

Press the (+) key to increase the speed.

2.

Press the (-) key to decrease the speed

IMPORTANT: Each time the key is pressed it


increases or decreases the speed by about 25 rpm.
The maximum possible idle is 1200 rpm.
Deactivation:
1.

Switch the engine off. When the engine is started


again it will run at the programmed idle speed.

3-12

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SECTION 3 - OPERATING INSTRUCTIONS
USING THE AUTOMATIC TRANSMISSION

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22
DISPLAY
Information on the transmission running situation is
shown on the display.
Sector A: not used
Sector B: indicating the engaged gear, 1, 2 ..., 6
Sector C: indicating the engaged selection, F, N or R
Additional information (sectors B and C):
**: cold start, keep transmission in Neutral.
EE: interface error between display and electronic
control unit.
Two digt number: error in system corresponding to
the code shown.
IMPORTANT: If several errors are present, the
respective codes will appear in succession. This display will only appear when the gearshift lever is in
Neutral.
IMPORTANT: Contact your Dealer for additional
information on error codes.

a. arrow, indicating Automatic operation (with f);


b. bar, indicating pre-selection limited to first gear;
c. bar, indicating pre-selection limited to second
gear;
d. bar, indicating pre-selection limited to third gear;
e. bar, indicating pre-selection limited to fourth, fifth
or sixth gear;
f. arrow, indicating Automatic operation (with a);
NOTE: The arrows and bar will stay on in the event of
automatic operation without pre-selection. Arrows (a)
and (f) will flash in the event of operative kick-down.
All bars will flash in the event of a disengaged lock-up
clutch (torque converter running).
g. wrench: indicating a system error. This symbol will
flash to indicate that use is restricted. Call for service
as soon as possible;
h. stop: not used.

3-13

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
AUTOMATIC/MANUAL OPERATION
The transmission is switched to automatic mode when
the engine is started.
When the gearshift lever is pushed sideways in Neutral, the starting gear is pre-selected in automatic
mode.
NOTE: The highest possible starting gear is second
gear.
Select the mode as follows:
- select the direction of travel, then either press the
button on the top of the lever or move the lever to the
side (either to the right or to the left) to change to manual mode;
- press the button to switch from one mode (automatic/manual) to the opposite one (manual/automatic).
SELECT MANUAL MODE
- To pick up and drive uphill;
- To pick up and drive downhill;
- In particularly difficult conditions, such as on steep
grades, or on slippery or very rough surfaces.
Select automatic mode in normal conditions of vehicle
use.
The automatic transmission control system ensures
automatic torque converter lock-up clutch engagement that matches operational engine speed and
load.

174NU51A

23

The torque converter condition is displayed by means


of a warning lamp:
- Flashing warning lamp: torque converter slipping;
- Warning lamp on: clutch engaged.
IMPORTANT: the warning lamp does not indicate
transmission system errors.

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24

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Copyright
SECTION 3 - OPERATING INSTRUCTIONS
FORWARD/REVERSE SELECTION
The gearshift lever has three positions.
Position N (Neutral) is used for:
- engine starting;
- vehicle stationary and engine running.
Position F (Forward) is used for:
- forward movement of the vehicle.
Position R (Reverse) is used for:
- reverse movement of the vehicle.
Shifting from N to F or R is only possible by pressing
the button at the same time.

174NU53A

25

This maneuver keeps the transmission in automatic


mode when in position F; in position R, the transmission is in manual mode.
It is not possible to shift from position N to position F or
R if the parking brake is applied.

WARNING

Stop the vehicle completely before selecting


reverse from a forward gear or vice versa.
NOTE: An external audible warning device will sound
when Reverse is selected.
NOTE: When Reverse is selected, the transmission
automatically switches to manual mode.
MANUAL GEAR SELECTION
To change gear when gearshift lever is in position F or
R, move the lever to the side:
a. Lever pushed leftwards (towards the driver):
selects a lower gear (shift down);
b. Lever pushed rightwards (towards the side):
selects a higher gear (shift up).
Each movement to the side will correspond to one
gear shift.
Specifically, push the lever laterally:
- In Forward position to select forward gears.
- In Reverse position to select reverse gears.
NOTE: The highest possible starting gear is second
gear. However, if the vehicle is stopped in a higher
gear, the next start will be made in the last selected
gear.

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SECTION 3 - OPERATING INSTRUCTIONS

WARNING

First gear must be selected when setting off uphill


with full load.
You are advised to shift gears when the lock-up clutch
flashes to avoid overloading the torque converter.
IMPORTANT: The control system will prevent
gearshifts which are not compatible with vehicle and
engine speeds.
The transmission oil temperature will increase in the
event of prolonged torque converter operation (clutch
disengaged).
If the gauge indicates excessive temperature, shift to
a lower gear to engage the clutch and travel in such
conditions until the oil temperature returns to normal.

174NU54

27

3-16

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
AUTOMATIC MODE GEAR SELECTION
The automatic transmission control system selects the
most suitable gear in relation to engine speed and
load.
Starting from a standstill will take place automatically
in second gear.

WARNING

Change to manual mode and select first gear


when setting off uphill with full load.

174NU55M

28

174NU56M

29
KICK-DOWN
The driver can override the automatic transmission
shifting down a gear by means of the kick-down
device.
This possibility can be used to increase vehicle pickup after slowing down slightly, i.e. without the transmission automatically shifting to a lower gear.
Do not use this device continuously because it causes
strain on the transmission, puts stress on the assembly and leads to higher fuel consumption.
Press the accelerator pedal to the floor, to the stop, to
shift to the next lower gear.

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SECTION 3 - OPERATING INSTRUCTIONS
USING THE HYDRAULIC RETARDER
The hydraulic retarder is selected by a button located
on the control panel.
Use the retarder to reduce the vehicles speed when
cornering or going downhill, to prevent the brakes
over-heating.
The relative warning lamp on the instrument panel
lights up when the retarder is enabled.

208NU05

30

WARNING

The accelerator pedal is disabled when the


retarder is employed.

WARNING

The oil will heat up if the retarder is used continuously, and this will be indicated by instrument.
To prevent the oil overheating, disengage the
hydraulic retarder for short periods of time, and if
necessary select a lower gear.

174NU54

31

USE OF THE ENGINE BRAKE (JACK


BRAKE) (330 MODEL)
The jack brake is controlled by button on the control
panel.
Use the jack brake to reduce the vehicles speed
when cornering or going downhill to prevent the
brakes overheating.
The jack brake can be enabled partially or completely
depending on how much the vehicle needs to slow
down.
To prevent recoiling before the brake is completely
engaged, enable the jack brake partially for a few seconds.
The relative warning lamp will light up on the instrument panel when the retarder is enabled.

WARNING

The accelerator pedal is disabled when the


exhaust brake is employed.

3-18

208NU06

32

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
USING THE DIFFERENTIAL LOCK
The vehicle is equipped with transversal self-locking
differentials on all axles.
These differentials are locked automatically according to the adherence of each wheel.
The vehicle is equipped with a rear differential and
central differential which can be locked.
See "Longitudinal differential lock control" in Section 2.
Lock the rear differential and, if required, the central
differential before driving on surfaces giving poor
adherence.
NOTE: A special warning lamp and audible warning
device will come on when the central differential lock
is engaged.

174NU76

33

Do not lock the differential if one wheel is slipping, to


prevent damaging the mechanism: stop the vehicle
before engaging the lock.
Only use the differential lock when needed and disengage it as soon as conditions improve.

WARNING

Do not steer the vehicle with the central differential


locked engaged to prevent causing severe damage to the transmission. Do not drive on terrain
where traction is good with the rear differential
lock engaged, to prevent causing severe damage
to the transmission and to the tires.

174NU77

34

174NU78

35

3-19

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
WORKING WITH THE VEHICLE
The typical working cycle of the vehicle, regardless of
the type of job, can be divided into four phases:
Loading, hauling, dumping and empty return.
LOADING
The most common methods of loading are with
hydraulic excavators and front end loaders.
The vehicle can be loaded equally well from the rear
or the side. The truck driver must facilitate loading
operations for maximum material movement. The
shorter the distance the loading unit has to travel, the
more loading cycles it can make in a given period and
the quicker the truck will be ready to move off.
Waiting vehicles should stay about two vehicle lengths
behind the vehicle being loaded to avoid any spillage
from the loading vehicle or truck.
For some jobs, the loading vehicle may work more
efficiently when trucks are positioned on both sides.
Thus, while one vehicle is being loaded, the other
vehicle can move into position on the opposite side.
Since the vehicle is usually backed into the loading
position with this method, the operator must be alert
and careful while backing, especially when not
assisted from the ground. Where possible, the vehicle
should be positioned downwind of the loader especially when dusty material is being loaded and/or on a
windy day.
A cleanup dozer or small loader is often worked in
conjunction with the main loader to keep the area
clear of bucket spillage. The truck driver must always
be alert to the position of these machines to prevent
accidents and congestion.
The following precautions should be observed when
approaching the loading area:
- Avoid rocks and other spillage which can damage
the vehicle and particularly the tires.
- Allow the cleanup machine sufficient time to clear up
such debris.
- Do not approach the loading vehicle when the
bucket is swinging overhead, to avoid being hit by falling material.

HAULING AND EMPTY RETURN


When traveling on the haul road, keep to a safe speed
for the haul road conditions and grades.
When approaching or encountering soft or slippery
terrain, stop the machine and engage the differential
locks in time to prevent getting stuck.
Release the locks as soon as the conditions return to
normal.
Avoid rocks or other spillage which can damage the
vehicle and particularly the tires.
Keep a safe distance from the vehicle ahead, particularly on slippery ground or in bad weather conditions.
Observe the rules relating to braking distances and
speed on the site.
DUMPING
The dumping operation usually depends on the type
of material being hauled.
Prior to dumping, be aware of overhead wires. If electrical wires are contacted, remain in cab to prevent
electrocution.
Spoil and waste material is either dumped or piled up
in reverse.
In this case, the operation should be supervised and
directed by personnel on the ground.
While backing to dump, the vehicle driver must watch
the person on the ground and obey his instructions
while remaining seated.
When dumping into a hopper, avoid hitting into the
protective rail with the tires or scraping them against
the guides.
When dumping material over a spoil bank, the driver
must know how close the vehicle can approach the
edge under all weather conditions.
Before dumping, make sure that the wheels are supported by compact, flat ground.
Never dump on unstable ground.
Never raise dump body on uneven ground. Doing so
may cause the body to rollover.
Always lower dump body prior to return travel.

3-20

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
TIPPING BODY WITH CAB CONTROL
Carry out the dumping operation in the following conditions:
- Vehicle stationary, on level ground;
- Gearshift lever in Neutral position;
- Parking brake applied.
1.

Place the dumper control in position (1);

2.

Accelerate to 1200 - 1500 rpm to extend the cylinders fully;

3.

Idle the engine when maximum extension is


reached and release the control.

IMPORTANT: Release the control to stop the


operation in progress. The control will automatically
switch to 0 position. During the lifting operation, the
respective warning lamp will come on and a siren will
sound.
After dumping proceed as follows:
1.

Place the control in position (2);

2.

Wait for the operation to end and release the control;

3.

Disengage the parking brake, select Forward


position and drive off.

208NU07A

36

IMPORTANT: Slow speed movements only are


allowed during dumping. Only first and second
forward gear and first reverse gear can be selected.

WARNING

Travel only with the dumper down, fully resting on


the chassis.

3-21

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
TIPPING BODY WITH GROUND CONTROL

WARNING

Use of the auxiliary dumper control is only allowed


for specific maintenance operations. Proceed
carefully and take all the required safety measures.
1.

Lock the articulation as shown in "Preliminary


operations" in Section 4.

2.

Start the engine and apply the parking brake.

3.

Move the dumper control to position (1) to fully


extend the cylinders.

4.

Release the control and stop the engine.

WARNING

Release the control to stop the operation in


progress. The control will automatically switch to
(0) position (dead-man control).
Lock the raised dumper as shown in "Preliminary
operations" in Section 4.
Proceed as follows to restore driving conditions:
1.

Remove the raised dumper safety lock;

2.

Start the engine and take the control to position (2);

3.

Wait for the operation to end and release the control;

4.

Stop the engine;

5.

Remove the articulation safety lock as shown in


"Preliminary operations" in Section 4.

3-22

208NU08

37

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
TOWING THE VEHICLE
Use the specific hitches provided for this purpose to
tow the vehicle:
- Front jacking/hitching points.

174NU57A

38
- Rear jacking/hitching points.

174NU58A

39
Always use a suitably fastened rigid towing bar.
Never use straps or chains.
1.

Disconnect the drive shafts on the differential side


and temporarily fasten them to the chassis in the
event of an engine or transmission failure (contact your Dealer for more information).

2.

Remain in Neutral position at all times.

WARNING

The vehicle can be towed only for very short distances at slow speed without removing the drive
shaft, e.g. to remove it from the working area. Do
not tow the vehicle without removing the drive
shafts, to prevent causing very severe damage to
the transmission.

156NS24

40

3-23

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
EMERGENCY STEERING
The hydraulic system will not work in the event of an
engine or transmission failure. The vehicle is
equipped with an electrically operated emergency
pump to assist steering.
1.

Turn the starter switch key to position (1).

174NU80

41
2.

Bring the gear selector to the Forward or the


Reverse position.

NOTE: When the emergency pump is enabled a


buzzer starts to sound continuously.
NOTE: If the buzzer sounds intermittently it means
that the emergency pump relay fuse has blown and
will therefore not work when it is necessary.
In this case, the braking system will also not work.
If the hydraulic steering system is faulty or if there is
no electrical power, lift the vehicle from the front as it is
not possible to turn the steering.
To tow the vehicle in the event of failures that result in
a loss of pressure in the hydraulic braking system it is
necessary to:
- type I: remove the parking brake calipers (contact your Dealer for further information);
- type II: release the parking brake calipers as indicated in "Braking system" in Section 4.
In the event of failures involving a differential or planetary gear, remove the planetary gear cover, remove
the drive axles and reinstall the planetary gear cover
(contact your Dealer for more information).

WARNING

The parking brake will not work if the planetary


gears and/or rear drive axles are removed. In this
case, arrange suitable chocks under the wheels in
both directions of travel to prevent uncontrolled
vehicle movements during disassembly and storage.

3-24

174NU53A

42

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
REPLACING A COMPLETE WHEEL

WARNING

The wheel replacement operation requires the


utmost care. The operation must be carried out by
at least two experts using a hoist or a crane to
handle the wheel.

WARNING

Exploding tires and/or rim parts can cause injury


or death. Keep yourself and others out of the
DANGER AREA. Stand on the tread side of the
tire. Always use the correct air pressure and follow
the instructions in this manual for adding air or
servicing the tires.

WARNING

Explosive separation of the tire and/or rim parts


can cause injury or death. When tire service is
necessary, have a qualified tire mechanic service
the tire.

WARNING

DO NOT weld to wheel or rim when a tire is


installed. Welding will cause an explosive air/gas
mixture that will be ignited with high temperatures.
This can happen to tires inflated or deflated.
Removing air or breaking bead is not adequate.
Tire MUST be completely removed from the rim
prior to welding.

3-25

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
REMOVAL
1.

If possible, stop the unloaded vehicle in a flat


area, stop the engine and apply the parking
brake.

2.

Remove the cap and the valve stem to make sure


that the wheel to be replaced is completely
deflated.

174NU60

43
3.

Loosen the fastening nuts on the wheel to be


removed without removing the nuts.

4.

Raise the vehicle to lift the wheel from the


ground. Then place suitable safety blocks under
the axle.

174NU61

44
5.

The vehicle can be lifted by a crane, gantry or


other suitable means, using suitable steel cables
fastened to the eye bolts provided for this purpose.
Front jacking/hitching points.

174NU57A

45

3-26

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
Rear jacking/hitching points.

174NU58A

46
6.

Fasten the wheel to a crane or other lifting device


and place a workshop jack under the wheel.

7.

Fully remove the fastening nuts.

8.

Then remove the wheel being careful not to damage the wheel studs. Position it safely on the
workshop jack and remove it.

174NU62

47
FITTING
Clean the wheel stud and nut threads. Clean the rim
and hub resting surfaces.
Fit the new wheel, bringing it up to the wheel studs
with a workshop jack and lifting it with a crane. Be
careful not to damage the stud threads.
Tighten the nuts slightly until the wheel is correctly
positioned on the hub.
Inflate the tire to a pressure of approximately 1.5 bar
(22 psi). See "Tires and wheels" in Section 5.

174NU63A

48

3-27

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
Lower the vehicle and tighten the nuts to the specified
torque using the sequence shown:
Wheel nuts: 590 Nm (435 lb.ft)
Inflate to the specified pressure. See "Tires and
wheels" in Section 5.

174NU64A

49
IN THE EVENT OF OVERTURNING
Make sure that the personnel trained to use the vehicle know where the emergency exits are and the location of the special glass breaking tool.
The following emergency exits can be used to abandon the vehicle:
- door (open);
- front right window (smash).

174NS07

50
Use the special tool, located at the bottom of the window to break the specially treated glass.
IMPORTANT: Check that the hammer for breaking
the specially treated glass is always kept in the cab.

174NS08

51

3-28

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
CLIMATE CONTROL SYSTEM OPERATION
HEATER ONLY
1.

Start the engine.

2.

Adjust the fan speed by means of knob (C).

3.

Select the required temperature using lever (A).

AIR CONDITIONER ONLY


1.

Start the engine.

2.

Adjust the fan speed by means of knob (C).

NOTE: The air conditioner will not work if the knob (C)
is in (0) position.
3.

Select the required temperature, using knob (D).

174NU34A

52

HEATER AND AIR CONDITIONER


1.

Start the engine.

2.

Adjust the fan speed by means of knob (C).

NOTE: The air conditioner will not work if the knob (C)
is in (0) position.
3.

Select the required temperature using lever (A)


(hot air) and knob (D) (cool air).

ADVICE FOR USE


Do not keep knob (D) (conditioner) in maximum position and knob (C) (fan) in minimum position to prevent
the formation of ice on the evaporator.
If the cab is overheated (vehicle parked for a long time
in the sun), turn knob (C) and (D) to maximum position
and air the cab by keeping the windows open for a few
minutes.

174NU34A

53

The condensation generated by drying the internal air


is drained by special tubes arranged under the vehicle.
Run the system for a few minutes to ensure full efficiency at least once a week, regardless of outside
temperature.

3-29

Copyright
SECTION 3 - OPERATING INSTRUCTIONS
OVERTURNING ACCIDENTS
PREVENTION
Always check the limits for height and width during all
stages of loading/unloading, and make sure they are
within the prescribed limits.
Keep the wheels perpendicular to the slope when
driving up or down a gradient.
Do not make a U-turn on a gradient, to prevent turning over.
Respect the transverse gradient permitted for the
loaded and unloaded vehicle.

156NS19

54
Respect the values for maximum slopes when
unloaded and loaded.

156NS20

55

3-30

Copyright

SECTION 4

60

SERVICING INTERVALS/LUBRICATION/FLUIDS
SERVICING INSTRUCTIONS
1.

2.

Operators are authorized to carry out the following operations while respecting general precautions:
- Checking levels and adding fluids, if required;
- Checking tire pressure and correcting, if
required.
- Air cleaner replacement.
- Grease application.
Read this chapter carefully before carrying out
maintenance operation, repair operations, refueling or carrying out any other operation on the
vehicle.

3.

Never allow unauthorized personnel to repair the


vehicle, replace vehicle parts or carry out maintenance operations.

4.

Keep the work area clean and dry.

5.

Do not smoke during the maintenance operations.

6.

Wear all the required personal protection devices


before starting maintenance operations.

7.

Carry out all maintenance operation with care.

8.

Use portable lamps when the lighting is not adequate and to illuminate working areas which cannot easily be accessed otherwise.

9.

Use a ladder or platform with steps that comply


with safety regulations to carry out repairs and
maintenance operations in areas which cannot
be reached from the ground.

10. All checking, bleeding, adding of fluids, maintenance and replacement operations must be carried out with the vehicle stationary, on level
ground, in a well lit and ventilated area. Apply the
parking brake, install chocks under the wheels
and remove the key from the starter switch.
11. Keep hands and clothes away from moving parts
when carrying out operations with the engine running.

15. Do not run the engine in enclosed areas without a


suitable ventilation system for evacuating the
harmful gas in the air.
16. Avoid prolonged, repeated contact between fuel,
lubricant and fluids and the skin, to prevent problems and other syndromes.
17. Be very careful before removing caps or covers
from reservoirs, radiators or cylinders: turn the
part slowly to discharge any residual pressure.
18. Do not loosen the radiator cap when the engine is
hot.
19. Let the coolant cool down before removing the
cap. In any event, remove the cap very carefully.
Loosen the cap slowly to release the pressure
and remove it.
20. Discharge pressure from circuits before carrying
out any operations.
21. Never use your hands or other body parts to
detect leakage of pressurized fluid.
22. Pressurized fluid leakage can penetrate the skin
and the eyes, causing very severe injuries.
23. If hydraulic fluid penetrates the skin, call a doctor
immediately. Hydraulic fluid escaping under pressure can have sufficient force to enter a persons
body by penetrating the skin and can cause serious injury and possibly death if proper medical
treatment by a physician familiar with this type of
injury is not received immediately. Keep body and
hands away from pin holes or nozzles which eject
hydraulic fluid under high pressure and use paper
or cardboard and NOT HANDS to search for
leaks.
24. Do not work over or under a vehicle propped up
on jacks or other lifting devices which are not suitable to ensure safety.
25. Unload the vehicle before jacking it up. Only use
the lifting points shown.

12. Do not put your head or other parts of your body


(feet, hands) near shafts or turning parts when
the engine is running.

26. Make sure that the lifting device is suitable to


carry out the operations and meet safety requirements.

13. Fully deflate the tire before carrying out any type
of operation on tires or rims.

27. After jacking up the vehicle, block it up firmly


before carrying out any operations underneath.

14. Warn people who are near the vehicle before


starting the engine (e.g. for a test).

4-1

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
28. Never tamper with valves, regulators or other
devices, unless specified in the Operators Manual, to prevent damage to vehicle components
and consequent hazards for personnel.
29. Wear safety glasses with side guards and a mask
when using compressed air to clean filters, to prevent injury caused by particles of dust. You are
advised to carry out the cleaning operations in a
ventilated area.
30. Batteries contain sulphuric acid: always wear
gloves and safety glasses when approaching batteries.
31. Check all levels with the vehicle on level ground,
the wheels straight and the parking brake applied.
32. Wait a few minutes for the level to stabilize before
checking.
33. Observe scrupulous cleanness of oil and fluid
containers when refilling.
34. Use oil and fluid of the same type used before in
the various assemblies when adding more.
35. Never tamper with valves, regulators or other
devices, unless specified in the Operators Manual, to prevent damage to vehicle components
and consequent hazards for personnel.
36. Never change the injection pump calibration, to
prevent damaging the engine and the transmission.

WARNING

Properly dispose of replaced material (brake pads,


filters, etc;) and materials resulting from maintenance operations and repairs (material soaked in
fuel, oil, powder, etc.) according to the laws in
force, as opposed to normal waste.
Collect and dispose of used lubricants and fluids,
according to the local regulation.
Collect and dispose of used batteries according to
the local regulation.
Drain and recharge the air-conditioning system
using the specified devices, according to the local
regulation.
IMPORTANT: Scheduled service intervals are based
on normal working conditions. The intervals may
change in relation to use, road conditions and environmental conditions. Contact your Dealer if in doubt or in
the event of failures which cannot be solved by applying normal maintenance procedures.

4-2

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
TOOLS PROVIDED AND THEIR LOCATION
The vehicle is equipped with the following tools, kept
in the tool box.
Mudguard compartment flap key.
Bonnet lift pump bar.

208NM01

PRELIMINARY OPERATIONS
ARTICULATION SAFETY LOCK
IMPORTANT: Always lock the articulation in safety
position unless otherwise specified.
1.

Align the vehicle and remove the pin (a).

2.

Turn the tie-rod forwards (b).

3.

Insert the pin in the slot on the front chassis (c)


and install the retaining pin.

156NS25

4-3

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
RAISED DUMPER SAFETY LOCK
IMPORTANT: Always lock the raised body for
servicing operations. Ensure that the dumper body is
empty prior to raising the dumper body and installing
the safety lock.
1.

Place the transmission in park position, apply the


parking brake and turn off the engine.

2.

Fully raise the dumper and remove the pin (a).

3.

Turn the tie-rod forwards (b).

4.

Insert the pin in the slot on the rear chassis (c)


and install the retaining pin.

174NS02

3
OPERATING THE BATTERY MASTER SWITCH
Make absolutely sure that the electrical power is disconnected before working directly or indirectly on
electrical system parts by operating the battery disconnect switch.
1.

To connect power; turn switch to horizontal position (a).

2.

To disconnect power; turn switch to vertical position (b).

221NS01

4-4

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
OPENING THE FRONT FENDERS
NOTE: Close the cab door before opening the front
fenders.
1.

Remove the lock bolt under fender towards front


of machine.

2.

Remove the stop pin from its seat.

174NM50

5
3.

Turn the fenders towards the rear of the vehicle.

174NM85

6
4.

Reinsert the stop pin into its seat and into the slot
in the fenders to keep the fenders open.

WARNING

Be careful once the fenders are open.


The operation should be carried out by two people.
5.

Reverse the operation to close the fenders.


174NM51

4-5

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
OPENING THE FENDER COMPARTMENT FLAP
Proceed as follows to open the compartment::
1.

Open the engine bonnet according to the version.

2.

Insert the key provided and turn the closing latch.

3.

Lift the flap.

Reverse the procedure to close the flap.

208NM03

8
OPENING THE HOOD MANUALLY
Proceed as follows to open the hood:
1.

Insert the lever in the specific housing.

2.

Turn the wheel clockwise and operate the lever


back and forth until the hood is fully opened.

Proceed as follows to close the hood:


1.

Insert the lever in the specific housing.

2.

Turn the wheel counterclockwise and operate the


lever back and forth until the hood is fully closed.
174NM52

9
OPENING THE HOOD ELECTRICALLY
Proceed as follows to open the hood:
1.

Turn the knob (a) clockwise and press the switch


(b) to fully tip the hood.

Proceed as follows to close the hood:


1.

Turn the knob (a) counterclockwise and press the


switch (b) to close the hood.

208NM12

10

4-6

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
OPENING COMPARTMENT UNDER ENGINE
Proceed as follows to open the compartment:
1.

Prop the cover.

2.

Remove both fastening bolts and gently lower the


cover until fully open.

To close the cover proceed as above in reverse order.


IMPORTANT: Do not move the vehicle with the cover
open to prevent serious damage.

208NM10

11
OPENING COMPARTMENT UNDER GEARBOX
Proceed as follows to open the compartment:
1.

Prop the cover.

2.

Remove both fastening bolts and gently lower the


cover until fully open.

To close the cover proceed as above in reverse order.


IMPORTANT: Do not move the vehicle with the cover
open to prevent serious damage.

208NM11

12

4-7

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS

Engine oil level

10 (5)

Engine coolant level

10 (5)

Hydraulic fluid level

10 (5)

Fan condition

10 (5)

Tire pressure/condition

10/100
(5)

Service brake

10 (5)

Accessory belts

10/100
(5)

Air conditioner compressor belts

10/250
(5)

Lights and warning lights

10 (5)

Windshield wiper

10 (5)

Windshield washer level

10 (5)

Fuel pre-filter/bleed sediment

100

Transmission oil level

100

Front suspension element height

100

Visually inspect hydraulic system for leakage

100

Fuel hose lines

100

Engine water sleeves

100

Air conditioner condenser

100

Air conditioner filter

100

Accessory belts

250

Planetary gear oil level

250

Axle oil level

250

Brake linings/disks

250

Engine oil breather


Battery maintenance (not sealed)

ADJUST

250
250

Fuel tank sediment

500

Hood tipping system oil level

500

Intake system air tightness

1000

Tappet clearance (325 model)

1000

Tappet clearance (330 model)

1500

Radiator surface

1000

Efficiency of emergency steering pump control

250

Efficiency of parking brake

250

Centralized lubricator (front and rear) (where applicable)

50

Automatic greasing (where applicable)

50

4-8

DRAIN WATER

CLEAN

LUBRICATE

REPLACE

CHANGE

SERVICE POINTS

CHECK

SCHEDULED MAINTENANCE PROGRAM IN HOURS

Copyright

ADJUST

DRAIN WATER

CLEAN

1000
(3)

Drive shaft greasing


Engine oil

250

Engine oil filter

250

Engine coolant filter (325 model)

500

Engine coolant filter (330 model)

250

Fuel filter (325 model)

500

Fuel filter (330 model)

250

Fuel pre-filter

500
1000
(1)

Transmission oil

1000
(1)

Transmission oil filter


1000
(2)

Axle/planetary gear case oil


Air cleaner main element

(6)

Air conditioner filter

(6)

1000

Engine coolant and cleaning circuit

2000

Hydraulic system oil

2000

Front suspension oil/gas

2000

2000

Hydraulic system filters


(intake, outlet, pump, brake)

2000
(1)

Secondary air cleaner filtering element

2000
(4)

Air conditioner system charge

LUBRICATE

REPLACE

CHANGE

SERVICE POINTS

CHECK

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS

1000
(3)

(1) First change/replacement when unit is new or serviced after 100 hours.
(2) First change/replacement when unit is new or serviced after 250 hours.
(3) Every 1000 hours of operation or once each year, whichever comes first.
(4) Or every three main filter replacements.
(5) Every 10 hours of operation or once each day, whichever comes first.
(6) Clean when the warning lamp on the instrument panel comes on, or replace once a year or after cleaning six
times.

4-9

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
LUBRICATION AND SCHEDULED REPLACEMENT CHART (325 MODEL)

174NM10FA

13

4-10

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
LUBRICATION AND SCHEDULED REPLACEMENT CHART KEY (325 MODEL)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Engine oil
Engine oil filter
Fuel filter
Fuel filter/separator
Main air cleaner (3)
Secondary air cleaner (4)
Engine coolant
Engine coolant filter
Automatic transmission oil (1)
Automatic transmission oil filter (1)
Axle/planetary gear case oil (2)
Suspension oil/gas
Hydraulic system oil
Hydraulic system oil filter (intake) (1)
Hydraulic system oil filter (pump outlet) (1)
Hydraulic system oil filter (brake) (1)
Front centralized lubricator
Rear centralized lubricator
Drive shaft lubricator
Air conditioner system fluid
Air conditioner filter

NOTE: Service frequency is expressed in hours.


(1)
(2)
(3)
(4)

First change/replacement when unit is new or serviced after 100 hours


First change/replacement when unit is new or serviced after 250 hours
Alternatively
Or every three main filter replacements

Engine oil

Transmission oil

Hydraulic fluid

Lubricating grease

Engine coolant

Air conditioner

4-11

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
LUBRICATION AND SCHEDULED REPLACEMENT CHART (330 MODEL)

500404634A

14

4-12

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
LUBRICATION AND SCHEDULED REPLACEMENT CHART KEY (330 MODEL)
1.
2.
3.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Engine oil
Engine oil filter
Fuel filter
Main air cleaner (3)
Secondary air cleaner (4)
Engine coolant
Engine coolant filter
Automatic transmission oil (1)
Automatic transmission oil filter (1)
Axle/planetary gear case oil (2)
Suspension oil/gas
Hydraulic system oil
Hydraulic system oil filter (intake) (1)
Hydraulic system oil filter (pump outlet) (1)
Hydraulic system oil filter (brake) (1)
Front centralized lubricator
Rear centralized lubricator
Drive shaft lubricator
Air conditioner system fluid
Air conditioner filter

NOTE: Service frequency is expressed in hours.


(1)
(2)
(3)
(4)

First change/replacement when unit is new or serviced after 100 hours


First change/replacement when unit is new or serviced after 250 hours
Alternatively
Or every three main filter replacements

4-13

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
OPERATIONS TO BE CARRIED OUT EVERY DAY
IMPORTANT: Check the levels with the vehicle on
level ground.
CHECKING ENGINE OIL LEVEL
1.

Open the engine hood.

2.

With the engine cold, remove the oil dipstick and


check that the level is between the references H
(high) and L (low) on the dipstick. Install the dipstick.

325 MODEL

IMPORTANT: If the engine is warm, stop the engine


and wait for ten minutes for the oil to drain into the
sump.

WARNING

Do not use the vehicle if the oil level is either


under or over the limits.
Lack of lubricant or excessive lubricant can damage the engine.

208NM13

15
330 MODEL

208NM14

16
3.

If required, add extra oil using oil of the same type


contained in the oil sump.

156NM11

17

4-14

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
CHECKING ENGINE COOLANT LEVEL
1.

Open the engine hood.

2.

With the engine cold, check that the fluid level is at


the specified distance from cap: 5 - 6 cm (1.97 2.36 in).

3.

Add extra coolant if required using a 50 - 50 mixture of water and antifreeze.

174NM01B

18
BLEEDING FUEL FILTER SEDIMENT
1.

Open the engine hood (only for filter on engine).

2.

With the engine stopped, loosen the plug and


drain the soiled fuel.

3.

Tighten the plug without forcing it when sediment


free fuel flows out.

325 MODEL

208NM20

19
330 MODEL

174NM82

20

4-15

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
CHECKING ACCESSORY BELT CONDITION
1.

Open the engine hood and remove the protective


grid.

2.

When the engine is cold, check that the belt is not


frayed or cracked (small crosswise cracks are
allowed).

3.

Replace the belt, if required.

4.

Also check the condition of the air conditioner


compressor drive belt.
156NM15

21
CHECKING HYDRAULIC FLUID LEVEL

WARNING

Check the level with the dump body in the down


position.
1.

With the engine stopped, check that the level is


between the maximum (arrow) and minimum
marks on the hydraulic system reservoir.

2.

Add extra fluid if required, using fluid of the same


type contained in the reservoir.

3.

Visually check the main hydraulic system components for any signs of leakage.

174NM02A

22

CHECKING WINDSHIELD WASHER FLUID LEVEL


1.

Check whether the fluid level in the reservoir is


adequate.

2.

Add extra fluid, if required.

PERFORM THE FOLLOWING CHECKS BEFORE


USING THE VEHICLE:
1.

Fuel level in tank.

2.

Tire conditions.

3.

Operation of lights and warning lamps on instrument panel.

4.

Service and parking brake operation.

5.

Windshield wipers.

WARNING

Visually inspect the vehicle, checking working conditions and for damage/problems which may
cause damage to the vehicle or injury to operators.

4-16

174NM03

23

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
ENGINE
ENGINE OIL CHANGE

WARNING

Collect and dispose of used lubricants and fluids,


according to local regulations.
1.

Stop the warm engine and wait for the coolant


temperature to drop to 60C (140F).

2.

Open the engine hood.

3.

Have ready a container of a suitable capacity and


remove the dipstick.

4.

Clean the plug area, loosen the drain plug and


drain all the oil for the time required.

325 MODEL

IMPORTANT: Do not loosen the side plug which will


not allow drainage of all the sump.
5.

Clean the heading, install the drain plug and tighten to the specified torque.
Drain plug: 80 Nm (59 lb ft).

156NM20

24
330 MODEL

156NM22

25

4-17

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
6.

Remove engine oil filter and replace with new filter. See "Engine oil filter replacement".

7.

Clean the filler neck area and pour in in the specific amount of lubricant through the filler neck.

8.

Close the filler and install the dipstick in the housing.

9.

Start the engine and warm it up. Stop the engine


and wait for a few minutes.

325 MODEL

156NM21

26
330 MODEL

156NM23

27
10. Remove the oil dipstick and check that the level is
between the H (high) and L (low) marks on the
dipstick. Add extra oil, if required.

WARNING

Do not use the vehicle if the oil level is either


under or over the limits.
Lack of lubricant or excessive lubricant can damage the engine.

156NM11

28

4-18

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
ENGINE OIL FILTER REPLACEMENT

WARNING

Collect and dispose of used lubricants and fluids,


according to local regulations.

WARNING

Replace the oil filter at the frequency shown. If the


filter is obstructed, the bypass valve will permit
lubrication of the engine, but the circulating lubricant will not be filtered.
1.

Stop the warm engine and wait for the coolant


temperature to drop to 60C (140F).

2.

Open the engine hood.

3.

Loosen and remove the filtering cartridge using


an oil filter wrench. Carefully clean the housing.

325 MODEL

156NM24

29
330 MODEL

156NM28

30

4-19

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
4.

Fill the new cartridge with the specified lubricant


and apply the same lubricant to the seal.

156NM25

31
5.

Install the new cartridge and tighten by hand until


the seal comes into contact with the housing,
then turn another 3/4 of a turn.

WARNING

325 MODEL

Do not tighten the cartridge excessively. This


could damage the seal. Observe the specifications
provided by the supplier.
6.

Start the engine for a few minutes and check for


any signs of lubricant leakage.

7.

Check engine oil level and add extra oil, if required.

156NM26

32
330 MODEL

156NM28B

33

4-20

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
CLEANING THE ENGINE BREATHER
1.

Check the engine breather tube.

2.

Clean it if required.

WARNING

325 MODEL

Ice may form and temporarily obstruct the


breather in very cold weather. In this case, check
the breather every week or every day.

174NM04A

34
330 MODEL

174NM05

35

4-21

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
ACCESSORY DRIVE BELT (325 MODEL)
The engine is equipped with one alternator drive belt
and one fan drive belt, tensioned by means of an
adjustable device.
Check
1.

Open the engine hood and remove the protective


grid.

2.

When the engine is cold, check that the belt is not


frayed or cracked (small crosswise cracks are
allowed).

156NM15

36
3.

Manually press the longest stretch and check that


deflection is within the specified range.
Deflection: 9.5 - 12.5 mm (0.37 - 0.49 in)

174NM06

37
4.

If in doubt on belt tension, use a belt tensioner


gauge and refer to the respective tension charts.

174NM07

38

4-22

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
Replacement
1.

Open the engine hood and remove the protective


grid.

2.

When the engine is cold, use a square wrench to


turn the tensioner clockwise and loosen the belt.

WARNING

Do not turn the take-up device counterclockwise to


prevent damaging the internal load spring.

174NM08

39
3.

Remove the belt.

4.

Fit the new belt and release the tensioner.

WARNING

Do not turn the belt on the pulley to fit in the


groove. Do not use a tool (e.g. a screwdriver) as a
lever to prevent damaging and early breaking.
The belts must not touch the bottom on the
grooves or rub against surrounding parts.
174NM09

40
5.

Run the engine for ten minutes, stop it and wait


for it to cool down. Then check belt tension.

IMPORTANT: All new belts stretch after the initial


period of use. For this reason, you will need to check
tension frequently after replacement.

174NM06

41

4-23

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
AIR CONDITIONER COMPRESSOR DRIVE BELT (325 MODEL)
Check
1.

Open the engine hood.

2.

With the engine switched off and cold, check that


the belt is not frayed or cracked (small crosswise
cracks are allowed).

3.

Manually press the longest stretch and check that


deflection is within the specified range.
Deflection: 9.5 - 12.5 mm (0.37 - 0.49 in)

174NM72

42
Adjusting the tension
1.

Open the engine hood.

2.

With the engine switched off and cold, release the


lock nut and mounting nut, then adjust the compressor to regulate the tension

3.

Tighten both the nuts to the specified tightening


torque.

174NM73

43
Replacement
1.

Open the engine hood.

2.

With the engine switched off and cold, release the


lock nut and the mounting nut, then remove the
belt.

3.

Fit the new belt and adjust the tension.

NOTE: Take the same precautions specified for the


accessory drive belts.
4.

Run the engine for ten minutes, switch it off and


wait for it to cool down, then check the belt tension.

4-24

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
ACCESSORY DRIVE BELTS (330 MODEL)
The engine is equipped with one alternator drive belt
and one fan drive belt, tensioned by means of an
adjustable device.
Check
1.

Open the engine hood and remove the protective


grid.

2.

When the engine is cold, check that the belt is not


frayed or cracked (small crosswise cracks are
allowed).

156NM15

44
3.

Manually press the longest stretch and check that


deflection is within the specified range.
Deflection: 9.5 - 12.5 mm (0.37 - 0.49 in)

174NM012

45
4.

If in doubt on belt tension, use a belt tensioner


gauge and refer to the respective tension charts.

174NM13

46

4-25

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
Adjusting alternator drive belt tension
1.

Open the engine hood and remove the protective


grid.

2.

With the engine stopped and cold, loosen the


upper and lower fastening nuts.

174NM14

47
3.

Loosen the lock nut, then adjust the tensioner


device as follows:
- To reduce tension, loosen the tensioner device.
- To increase tension, tighten the tensioner
device.

4.

Loosen the lock nut, then tighten the nuts to the


specified torque:
- Alternator belt tightener lock nut: 80 Nm (60 lb ft).
- Alternator lock nut: 47 Nm (35 lb ft).

174NM15

48
Replacing the alternator drive belt
1.

Open the engine hood and remove the protective


grid.

2.

With the engine switched off and cold, loosen the


upper and lower fastening nuts.

174NM14

49

4-26

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
3.

Loosen the tensioner device.

174NM15

50
4.

Remove the belt.

5.

Fit the new belt and adjust the tension.

WARNING

Do not turn the belt on the pulley to make it fit in


the groove. Do not use a tool (e.g. a screwdriver)
as a lever, to prevent damaging and early breaking.
The belts must not touch the bottom of the
grooves or rub against surrounding parts.
6.

Run the engine for ten minutes, stop it and wait


for it to cool down. Then check belt tension.

WARNING

174NM16

51

All new belts stretch after the initial period of use.


For this reason, you will need to check tension
again.
Adjusting fan belt tension
1.

Open the engine hood and remove the protective


grid.

2.

With the engine switched off and cold, loosen the


fastening nut, then adjust the tensioner device as
follows.

- To reduce tension, loosen the tensioner device.


- To increase tension, tighten the tensioner device.
3.

Tighten the nut to the specified torque.

174NM17

52

4-27

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
Replacing the fan belt
1.

Open the engine hood and remove the protective


grid.

2.

With the engine switched off and cold, loosen the


fastening nut and the tensioner device.

174NM17

53
3.

Remove the belt.

4.

Fit the new belt and adjust the tension.

WARNING

Do not turn the belt on the pulley to make it fit in


the groove. Do not use a tool (e.g. a screwdriver)
as a lever, to prevent damaging and early breaking.
The belts must not touch the bottom of the
grooves or rub against surrounding parts.
5.

Run the engine for ten minutes, stop it and wait


for it to cool down. Then check the belt tension.

WARNING

All new belts stretch after the initial period of use.


For this reason, you will need to check tension
again.
.

4-28

174NM18

54

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
AIR CONDITIONER COMPRESSOR DRIVE BELT (330 MODEL)
1.

Open the engine hood.

2.

With the engine switched off and cold, check that


the belt is not frayed or cracked (small crosswise
cracks are allowed).

3.

Manually press the longest stretch and check that


deflection is within the specified range.
Deflection: 9.5 - 12.5 mm (0.37 - 0.49 in)

174NM70

55
Adjusting the tension
1.

Open the engine hood.

2.

With the engine switched off and cold, release the


securing nut, then adjust the take-up device as
follows:
- to reduce tension, move the take-up device nearer.
- to increase tension, move the take-up device
further away.

3.

Tighten the securing nut to the specified tightening torque.

174NM71

56
Replacement
1.

Open the engine hood.

2.

With the engine switched off and cold, release the


securing nut, then remove the belt.

3.

Fit the new belt and adjust the tension.

NOTE: Take the same precautions specified for the


accessory drive belts.
4.

Run the engine for ten minutes, switch it off and


wait for it to cool down, then check the belt tension.

4-29

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
ADJUSTING TAPPET CLEARANCE
IMPORTANT: Adjust on a cold engine (temperature
not exceeding 60C (140F).
Adjust the clearance by means of the screws and lock
nuts on the head of each rocker arm (contact your
Dealer for more information).

325 MODEL

174NM11

57
330 MODEL

174NM19

58
ADJUSTING INJECTOR PUMP CLEARANCE (330 MODEL)
IMPORTANT: Adjust on a cold engine (temperature
not exceeding 60C (140F).
Adjust the clearance by means of the screws and lock
nuts on the head of each injector and the specific
device (contact your Dealer for more information).

174NM20

59

4-30

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
FUEL SUPPLY SYSTEM (325 MODEL)
FUEL FILTER REPLACEMENT
The vehicle is equipped with:
- Separator pre-filter cartridge mounted on the
chassis at the side of the engine.

208NM18

60
- Double filter cartridge unit mounted on the engine.
1.

Open the engine hood (only for filter on engine).

2.

With the engine switched off, loosen and remove


the filter cartridge by means of an oil filter wrench
and carefully clean the support and engine.

174NM40A

61
3.

Fill the new cartridge with the specified fuel and


apply the engine oil lubricant to the seal.

156NM41

62

4-31

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
4.

Install the new cartridge and tighten by hand until


the seal comes into contact with the housing,
then turn another 3/4 of a turn.

WARNING

Do not tighten the cartridge excessively. This


could damage the seal. Observe the specifications
provided by the supplier.
IMPORTANT: You will need to bleed air from the fuel
supply circuit if either the cartridge was not completely
filled, with fuel, or if problems in starting the engine are
encountered.
5.

156NM42

63

Run the engine for a few minutes and check for


any signs of fuel leakage.

BLEEDING FUEL FEED CIRCUIT AIR


Bleed air from the fuel feed circuit in the following
cases:
-

after replacing the filter (if the filter is not filled);


after replacing the injection pump;
after pump-injector pipe leakage or replacement;
for starting the engine after storage;
after draining the fuel tank.

1.

Open the engine bonnet.

2.

Loosen the bleed valve.

156NM44

64

4-32

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
3.

Operate the pre-filter manually.

208NM19

65
4.

Operate the fuel pump manual control until the


fuel runs out without air bubbles.

5.

Close the bleed screw.

156NM45

66
FUEL TANK
1.

Loosen the drain plug and let a little fuel out to


drain the residues and condensate which normally form in the tank.

2.

Clean the drain plug. Check that the threading is


in good condition. Tighten to the specified torque:
Drain plug: 100 Nm (73 lb.ft)

WARNING

Keep the fuel tank as full as possible.


Use fuels of the specified types supplied by oil
companies.
Do not use other than specified fuels. Use of other
than specified fuels can cause severe engine
damage.

174NM22

67

4-33

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
FUEL SUPPLY SYSTEM (330 MODEL)
FUEL FILTER REPLACEMENT
The vehicle is equipped with a double cartridge filter
unit, installed on the engine.
1.

Open the engine hood (only for filter on engine).

2.

With the engine switched off, loosen and remove


the filter cartridge by means of an oil filter wrench
and carefully clean the support and engine.

208NM05A

68
3.

Fill the new cartridge with the specified fuel and


apply the engine oil lubricant to the seal.

156NM41

69
4.

Install the new cartridge and tighten by hand until


the seal comes into contact with the housing,
then turn another 3/4 of a turn.

WARNING

Do not tighten the cartridge excessively. This


could damage the seal. Observe the specifications
provided by the supplier.
5.

Run the engine for a few minutes and check for


any signs of fuel leakage.
156NM42

70

4-34

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
FUEL TANK
1.

Loosen the drain plug and let a little fuel out to


drain the residues and condensate which normally form in the tank.

2.

Clean the drain plug. Check that the threading is


in good condition. Tighten to the specified torque:
Drain plug: 100 Nm (73 lb.ft)

WARNING

Keep the fuel tank as full as possible.


Use fuels of the specified types supplied by oil
companies.
Do not use other than specified fuels. Use of other
than specified fuels can cause severe engine
damage.

174NM22

71

AIR INTAKE SYSTEM


Check intake system tightness
1.

Open the engine hood.

2.

Check tightness of intake system seals and fittings.

3.

Eliminate any leakage in the section between the


intake manifold and the turbocharger, to prevent
the risk of taking foreign bodies into the turbocharger and the engine.

4.

Eliminate any leakage in the section between the


turbocharger and the engine, to prevent loss of
engine efficiency.

325 MODEL

208NM20A

72
330 MODEL

208NM06

73

4-35

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
CHECKING TURBOCHARGER LUBRICATION
1.

Open the engine hood.

2.

Inspect the oil supply and return pipes to check


for any signs of leaks or failures which could
decrease the flow of lubricant.

WARNING

325 MODEL

Any reduction in oil supply, considering the high


operating speed of the turbocharger, would cause
failures.

174NM25

74
330 MODEL

174NM31

75

4-36

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
MAIN AIR FILTERING ELEMENT CLEANING/REPLACEMENT

WARNING

Clean the filtering element when the respective


warning lamp comes on.
Do not clean the filtering element every day.
Follow the specific frequencies.
The main filtering element can be cleaned up to
six times after which it must be replaced.
1.

Release the clips and remove the cover; empty


and clean it carefully.

174NM26A

76
2.

Remove the primary cartridge and clean using


the most appropriate of the following methods.

174NM27

77
Dust removal
Clean by blowing compressed air at a maximum pressure of 3 bar (45 psi), blowing air from the inside of the
filtering element outwards.

WARNING

Keep the jet of air a few inches away from the filtering pack to prevent damaging it.
Never clean the filtering element by knocking it on a
hard surface. If the filtering element is deformed in any
way, replace it.
156NM52

78
4-37

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
Cleaning with detergent and water
If the filtering element is dirty with soot or oil, use a
solution of water and detergent for cleaning it. Soak
the filtering element for 15 minutes in the solution.
Rinse carefully and dry in the air.

WARNING

Do not exceed the specified soaking time.


Do not use compressed air to dry the filtering element. Do not use heat.
Carry out the following checks before refitting the filtering element:
Check conditions of O-rings and plastic tabs. Replace
the filtering element, if required.
Check the condition of the filtering element by placing
a source of light inside; light will filter from the smallest
cracks, indicating that the filter must be replaced.

WARNING

Make sure the temperature does not exceed 60C


(140F) if a light source generating heat (e.g. a
lamp bulb) is used.

156NM53

79
Clean the rubber dust ejector, check its condition and
replace it if required. It must be flexible and free of
cracks.

174NM28

80

4-38

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
SECONDARY AIR FILTER ELEMENT REPLACEMENT

WARNING

The secondary element must not be cleaned. It


can only be replaced.
325 MODEL
Remove the element.

174NM29A

81
330 MODEL
Remove the wing nut and remove the element.

174NM29

82

4-39

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
COOLING SYSTEM
Change the engine coolant and clean the circuit.

WARNING

Collect and dispose of used lubricants and fluids,


according to the laws in force.
DRAINING
1.

With the engine stopped and cold, turn the heater


control valve to maximum, open the filler cap on
the reservoir.

174NM01B

83
2.

Have a container of a suitable capacity ready and


remove the line from the heat exchanger to the
pump intake. Drain the coolant.

3.

Wait for all the coolant to drain out and reconnect


the line.

156NM60

84

4-40

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
CLEANING
1.

Prepare a mixture of water and coolant system


detergent. Pour the mixture slowly through the
filler cap to reach the level and close the cap.

WARNING

Respect the proportions specified by the supplier.


Excessive concentration could damage the
engine.

WARNING

Detergents do not contain antifreeze. Do not leave


the vehicle standing in cold temperatures if the
coolant circuit contains a mixture of these products.
2.

Start the engine and let it run for one hour.

3.

Stop the engine and let it cool down. Drain the


mixture as shown above.

4.

Fill the circuit again with clean water. Run the


engine until the thermostat fully opens.

5.

Stop the engine and let it cool down. Drain the circuit as explained above. If the drained water is
still very dirty, repeat the cleaning operation with
detergent.

174NM01B

85

FILLING
1.

Arrange a block of resistant material of the specified thickness, corresponding to a 10% grade
(5 slope), under the front wheels of the vehicle.
Thickness: About 45 cm (17.5 in)

2.

Prepare a 50-50 mixture of water and specific


antifreeze. Pour the mixture slowly through the
filler cap. Do not close the cap;

3.

Start the engine and idle it. At the same time, add
mixture until all the air has been eliminated from
the circuit. Continue for at least 15 minutes;

4.

Close the filler cap.

WARNING

Check that the pressure check valve built into the


cap is working. Replace the cap if this is not the
case.

174NM01B

86

4-41

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
ANTIFREEZE CONCENTRATION CHECK
A 50-50 mixture of water and specific antifreeze is
required to protect the system from corrosion.
The minimum concentration of antifreeze depends on
the ambient temperature where the vehicle is in use.
water
antifreeze
Check the concentration of antifreeze in engine coolant by means of a specific refractometer.
NOTE: You are advised not to use a densimeter
because this device is not adequately accurate.
Always respect the suppliers mixing specifications if
particular additives are used.
156NM61

RADIATOR SURFACE CLEANING

87

Clean the outside of the radiator with compressed air


to remove accumulated debris (leaves, insects).
In the presence of stubborn dirt, brush the radiator
surface with a solution of detergent and water, then
use a jet of steam to remove the residual dirt.
COOLANT-TRANSMISSION OIL HEAT EXCHANGER TIGHTNESS
Visually check tightness of heat exchanger and
respective pipes..
ENGINE COOLANT FILTER REPLACEMENT (325 MODEL)
1.

Open the engine hood.

2.

With the engine stopped and cold, loosen the fastening screw and shut the valve.

208NM21

88

4-42

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SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
3.

Loosen and remove the filter cartridge using an


oil filter wrench and accurately clean the housing.

208NM22

89
4.

Apply engine lubricant to the seal, install the new


cartridge by hand until the seal comes into contact with the housing, then turn by another 3/4th
of a turn.

WARNING

Do not fasten the cartridge excessively. This could


damage the seal. Observe the instructions provided by the supplier.
NOTE: Replace the filter whenever top-up exceeding
50% is required or when the engine coolant is
replaced.
5.

208NM23

90

Open the valve and fasten the screw. Run the


engine for a few minutes and check for leakage.

WARNING

Do not forget to open the valve to prevent damaging the engine.

4-43

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
ENGINE COOLANT FILTER REPLACEMENT (330 MODEL)
1.

Open the engine hood.

2.

With the engine stopped and cold, close both valves.

174NM76

91
3.

Loosen and remove the filter cartridge using an


oil filter wrench and accurately clean the housing.

174NM77

92
4.

Apply engine lubricant to the seal, install the new


cartridge and tighten by hand until the seal comes
into contact with the housing, then turn by another 3/4th of a turn.

WARNING

Do not fasten the cartridge excessively. This could


damage the seal. Observe the instructions provided by the supplier.
NOTE: Replace the filter whenever top-up exceeding
50% is required or when the engine coolant is
replaced.
5.

Open both valves. Run the engine for a few minutes and check for leakage.

WARNING

Do not forget to open the valve to prevent damaging the engine.

4-44

174NM78

93

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
AUTOMATIC TRANSMISSION
OIL LEVEL CHECK
Correct oil level is essential for smooth operation of
the transmission. Insufficient oil can cause irregular
operation and damage the converter. Excessive oil
can cause the formation of emulsion and overheat the
transmission.
Cold check (15 - 45C) (59 - 113F)
1.

Start the engine and let it idle with the gearshift in


Neutral position for approximately one minute.
Apply parking brake.

2.

Clean the filler area, loosen the handle two or


three turns and remove the dipstick (located at
rear of front chassis) built into the filler. Check that
the oil level in the transmission is not below the
COLD mark (minimum level).

3.

Add extra oil, if required. Do not drain any oil in


excess, reposition the dipstick by refastening the
handle.

4.

208NM15B

94

Carry out a hot check as soon as possible.

Hot check (80 - 100C) (176 - 212F)


1.

Run the machine a certain distance to warm up


the transmission.

2.

Let the engine idle with the gearshift in Neutral


position. Apply parking brake.

3.

Clean the filler area, loosen the handle two or


three turns and remove the dipstick (located at
rear of front chassis) built into the filler. Check that
the oil level in the transmission is not within the
HOT range.

4.

Either add extra oil or drain the oil to reach the


specified level and reposition the dipstick by
refastening the handle.

5.

208NM15A

95

Check that breather is perfectly clean and working.

174NM32

96

4-45

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
TRANSMISSION OIL CHANGE

WARNING

Collect and dispose of used lubricants and fluids,


according to local regulations.
1.

Have a container of a suitable capacity ready,


clean the filler area, loosen the handle two or
three turns and remove the dipstick.

2.

Remove both drain plugs and fully drain the oil.

3.

Clean the drain plugs. Check that the threading is


in good condition. Apply sealant to both plugs and
tighten them to the specified torque:
Drain plug: 140 Nm (103 lb ft)

4.

Remove transmission oil filter and replace with


new filter. See "Transmission oil filter replacement".

5.

Pour in the specified amount of lubricant through


the filler and reposition the dipstick by refastening
the handle.

6.

Check the level again after a test drive.

156NM77

97

TRANSMISSION OIL FILTER REPLACEMENT

WARNING

Replace the filter when changing the oil.


1.

With the engine cold, loosen and remove the filter


cartridge using the specific tool and carefully
clean the housing and engine.

156NM78

98

4-46

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
2.

Fill the new cartridge with the specified lubricant


and apply the same lubricant to the seal.

156NM25

99
3.

Install the new cartridge and fasten the cartridge


by hand until the seal comes into contact with the
housing, then turn another 3/4 of a turn.

WARNING

Do not fasten the cartridge excessively. This could


damage the seal. Follow the suppliers recommendations.
4.

Run the engine for a few minutes and check for


any signs of leakage.

5.

Check transmission oil level and add extra oil, if


required.

156NM42

100

4-47

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
FRONT AXLE/REAR TANDEM AXLES
NOTE: The procedures described below refer to all
axles.
AXLE OIL/PLANETARY GEAR OIL LEVEL CHECK
1.

Move the reference mark of a hub to the horizontal position.

2.

Clean the cap area and open the cap. Lubricant


should drip out of the hole.

3.

If necessary, add oil as indicated in the next paragraph (Changing axle/reduction gear case oil).

4.

Close the filler cap and tighten it to at the specified torque.


filler cap: 150 Nm (111 lb ft)

NOTE: Simply check one of the reduction gear cases


on each axle.

156NM80B

101

NOTE: Do not use the center cap on the differential


for the check.

156NM80A

102
5.

Check that breather is clean and working perfectly.

156NM81

103

4-48

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
AXLE/PLANETARY GEAR OIL CHANGE

WARNING

Collect and dispose of used lubricants and fluids,


according to local regulations.
NOTE: It makes operations easier to remove both
wheels from the axial involved.
Draining
1.

Planetary gears: move the drain plug on one hub


to the lowest position.

2.

Have a container of a suitable capacity ready,


clean the plug areas and remove the level plug
(b) and the drain plug (a); drain all the lubricant.

3.

Repeat the procedure on the other hub.

156NM82A

104
4.

All axles: have a container of a suitable capacity


ready. Clean the plug areas and remove the level
plug (b) and the drain plug (a), drain all the lubricant.

156NM83

105
5.

Intermediate axle: in addition to the procedure


explained above, clean the differential plug area
and remove the plug (b) and the drain plug (a);
drain all the lubricant.

6.

Clean the drain plugs. Check that the threading is


in good condition. Apply sealant to the plugs and
tighten them to the specified torque after refilling.
Axle drain plug: 150 Nm (111 lb.ft)
Differential lock drain plug: 70 Nm (52 lb.ft)

156NM120A

106

4-49

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
Filling

WARNING

The amount of lubricant envisaged for each axle is


approximately 20 litres (5.3 US Gal).
The operation should be performed in two stages:
partial filling from the axle and then the rest from
one of the reduction gear cases.
All axles: fill partially with the specified lubricant until it
overflows from the filler cap hole (b), then replace the
seal, apply sealant paste on the cap and tighten it to
the specified torque;
filler cap: 150 Nm (111 lb ft)

156NM123

107
Intermediate axle only: fill with approximately
1.5 liters (0.375 US Gal) of the specific lubricant
through the differential cap hole (b), then replace the
seal, apply sealant paste on the cap and tighten it to
the specified torque;
filler cap: 150 Nm (111 lb ft)

156NM120A

108
All axles: bring the reference mark on a hub to the
horizontal position, fill with the remaining amount of
lubricant until it overflows from the cap hole. Close the
cap, do a test run and recheck the level, adding more
lubricant if necessary until it overflows. Replace the
seal, apply sealant paste on the cap and tighten it to
the specified torque;
filler cap: 150 Nm (111 lb ft)

156NM80B

109

4-50

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
HYDRAULIC SYSTEM

WARNING

Pressurized hydraulic system. Before you replace


the hydraulic filter or service the hydraulic system,
wear face protection and slowly loosen the hydraulic
reservoir fill cap to relieve the air pressure. If you do
not follow these instructions, you can be injured.
RELEASING THE HYDRAULIC SYSTEM PRESSURE
NOTE: The pipes that may contain oil under pressure
when the engine is off are to be found between the
recharge valve of the accumulators and:
the accumulators;
the pedal valve;
the parking brake valve.
1.

Switch the engine off.

2.

Operate the service brake control until the brake


lights go out.

3.

Work the parking brake repeatedly until the parking brake warning lamp comes on.

4.

Then work the parking brake at least another ten


times.

5.

Since the pressure switch is calibrated at 3 bar


(43.51 psi), work the control at least five more
times.

The system does not have any other parts under pressure.
CHECKING STEERING EMERGENCY PUMP CONTROL EFFICIENCY
1.

Position the vehicle on a flat surface that is wide


enough for the front part of the vehicle to be turned completely both right and left.

2.

Switch the engine off, move the selector lever to


Neutral and engage the parking brake.

174NU53A

110

4-51

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
3.

With the engine off, move the start---up switch to


MAR;

4.

Bring the gear selector to the Forward postion.

At this point the buzzer should come on to indicate the


emergency steering pump control has cut in.

174NU80

111
HYDRAULIC OIL CHANGE
Collect and dispose of used lubricants and fluids,
according to the laws in force.
1.

Have a container of a suitable capacity ready,


clean the filler plug and drain plug areas and
remove the filler plug.

156NM88

112
2.

Remove the drain plug and fully drain the fluid.

3.

Clean the drain plug. Check that the threading is


in good conditions. Replace the drain plug. Tighten it to the specified torque.
Drain plug: 100 Nm (73 lb.ft)

4.

Pour in the specified amount of fluid through the


filler and close it.

5.

Bleed the system. See "Hydraulic system bleed".

156NM89

113

4-52

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
PRESSURIZED OIL FILTER (PUMP OUTLET) REPLACEMENT
1.

Drain the reservoir as explained in the preceding


paragraph.

2.

With the engine stopped, loosen and remove the


filter cartridge with a hexagonal wrench and carefully clean the housing.

156NM90

114
3.

Replace the filter element with seals fitted in the


cartridge.

4.

Fill the new cartridge with the specified fluid and


apply the same fluid to the seals.

5.

Install the filter and tighten by hand until the seal


comes into contact with the housing, then tighten
another 3/4 of a turn.

WARNING

Do not fasten the cartridge excessively. This could


damage the seal. Follow the suppliers instructions.
6.

Fill the reservoir as explained in the preceding


paragraph.

7.

Run the engine for a few minutes and check for


leakage.

8.

Bleed the system. See "Hydraulic system bleed".

156NM91

115

4-53

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
INNER HYDRAULIC OIL FILTER (INTAKE) REPLACEMENT
1.

Drain the reservoir as explained in the respective


paragraph.

2.

Remove the bolted cover.

156NM92

116
3.

Loosen the cartridge and remove it from the housing.

4.

Install the filter and tighten by hand until the seal


comes into contact with the housing, then tighten
another 3/4 of a turn.

WARNING

Do not tighten the cartridge excessively. This


could damage the seal. Follow the suppliers
instructions.
5.

Replace the bolted cover and gasket.

6.

Fill the reservoir as explained in the preceding


paragraph.

7.

Bleed the system.

174NM83A

117

CHANGING HYDRAULIC BRAKE OIL FILTER


1.

Drain the reservoir as explained in the preceding


paragraph.

2.

With the engine stopped, loosen and remove the


filter cartridge and carefully clean the housing.

3.

Fill the new cartridge with the specified fluid and


apply the same fluid to the seals.

4.

Install the cartridge and tighten by hand until the


seal comes into contact with the housing, then
tighten another 3/4 of a turn.

WARNING

Do not fasten the cartridge excessively. This could


damage the seal. Follow the suppliers instructions.

4-54

174NM33

118

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
5.

Fill the reservoir as explained in the preceding


paragraph.

6.

Run the engine for a few minutes and check for


any signs of leakage.

7.

Bleed the system. See "Hydraulic system bleed".

FITTING AND HOSE TIGHTNESS CHECK


Visually check the tightness of the system and respective hoses.

WARNING

In the event of defects or leakage concerning the


hydraulic system, repairs must be carried out
before using the vehicle again. Check by implementing all the specific safety precautions.
HYDRAULIC SYSTEM BLEED
NOTE: The vehicle is equipped with a single hydraulic
system split into three circuits: braking circuit, steering
circuit, dump circuit. Bleed each of the three circuits
separately.
Braking circuit
1.

Press the brake pedal down fully and hold it in


this position.

2.

Remove the dust cap, then fit a transparent tube


on the breather valve. Submerge one end of the
tube in a bowl containing enough oil to cover the
tube.

3.

Loosen the valve letting out the oil and the air
bubbles. Close it after a few seconds.

NOTE: Close the valve if the end of the clear tube is


not submerged.
4.

Fully release the brake pedal.

5.

Repeat the operation until oil without bubbles


comes out of the breather valve.

6.

Fit the dust cap and repeat the operation on the


other braking units of the vehicle.

7.

At the end of the operation, check the oil level in


the reservoir and add extra oil, if required.

1731302A

119

4-55

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
Steering circuit
1.

Start the engine, steer slowly and fully to the right


and then to the left.

2.

Repeat the operation a few times to eliminate the


air bubbles in the circuit.

3.

At the end of the operation, check the oil level in


the reservoir and add extra oil, if required.

Dumping circuit
1.

Start the engine and tip the body to fill the circuit.

2.

Bring the dumper back to the down position.

3.

Repeat the operation several times to eliminate


the bubbles in the circuit.

4.

At the end of the operation, check the oil level in


the reservoir and add extra oil, if required.

CHECKING EMERGENCY PUMP CONTROL EFFICIENCY


1.

Position the vehicle on a flat surface that is wide


enough for the front part of the vehicle to be turned completely both right and left.

2.

Switch the engine off, move the selector lever to


Neutral and engage the parking brake.

3.

With the engine off, move the start-up switch (1)


to MAR.

4.

Bring the gear selector to the Forward position. At


this point the buzzer and the warning lamp should
come on to indicate the emergency steering
pump has cut in.

5.

Turn the steering completely to left and right to


check that the steering is working properly.

IMPORTANT: The check should not take any longer


than 30 seconds so as not to drain the batteries.
174NU80

120

4-56

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
HOOD OPENING SYSTEM
Check that the oil level is as specified, when the hood
is lowered, through the cap.
Oil level (distance from cap): 1 cm (0.39 in)

174NM55

121

GREASING
CENTRALISED GREASE POINTS (where applicable)
The vehicle is equipped with two centralized lubricators for the front and rear sections, respectively. Use a
manual grease gun only. Never use a high pressure
grease gun.
NOTE: Pump two or three times only to ensure effective lubrication.
1.

Clean the fitting concerned.

2.

Inject grease of the specified type into the front


centralized lubricator.

174NM84A

122

4-57

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
3.

Inject grease of the specified type into the rear


centralized lubricator.

NOTE: Inspect all grease points to ensure that grease


is being received at all points. If no grease is visible,
add more grease until grease is visible.

174NM63

123
AUTOMATIC GREASING SYSTEM (where applicable)
The vehicle is equipped with automatic greasing system.
1.

Clean the grease point (arrow).

2.

Fully replenish with the specifeed grease.

NOTE: The device is calibrated by constructor. Dont


tamper witl it!
Contact assistance center for further information.
221NM30

124

4-58

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS
GREASING THE DRIVE SHAFTS
The cardan joints and the supports are fitted with
greasers.
Remove the pebble guard cover to get at the lower
part of the transmission output shaft and its supports (detail).
Only use a hand pump for greasing, never a high
pressure greaser.
NOTE: Two or three shots are sufficient to guarantee
proper lubrication.
1.

Clean the relevant joint.

2.

Inject the specified grease into the joints indicated.

221NM03

125

4-59

Copyright
SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS

NOTES

4-60

Copyright

SECTION 5

22

MAINTENANCE/ADJUSTMENTS
SUSPENSION

WARNING

The following operations must be carried out by


suitably equipped, expert personnel. Use exclusively the equipment specifically required to carry
out suspension inflating operations.
NOTE: Carry out the following operations on both
suspension elements in parallel.
FRONT SUSPENSION
DEVICE

ELEMENT

INFLATING

A. Checking device
B. Inflating device
C. Copper seal
D. Copper seal
E. Pressure gauge (0 100 bar) (0 1450 psi)
F. Hose
G. Transparent tube
H. Hose
I. Nitrogen cylinder fitting
L. Hose fitting
Contact your Dealer for more information.

174NM35

1
EQUIPMENT CONNECTION DIAGRAM
a. Suspension element
b. Nitrogen cylinder
A. Checking device
B. Inflating device
E. Pressure gauge (0 100 bar) (0 1450 psi)
IN. Nitrogen into suspension tap
OUT. Nitrogen suspension breather tap
Contact your Dealer for more information.
SUSPENSION OIL ELEMENT CHANGE
Remove the element from the vehicle to change the
oil (contact your Dealer for more information).

174NM36

5-1

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
SUSPENSION ELEMENT PRESSURE CHECK
NOTE: Carry out the check after parking the vehicle
for at least one hour.
1.

Raise the vehicle wheels off the ground with suitable lifting devices to fully extend the suspension.

2.

Remove the protective cap on the cylinder.

174NM37

3
3.

Fit the check tool (A) in the housing and connect


the inflation tool (B) to the checking device tool
(A).

4.

Check that the inlet tap IN and the breather tap


OUT on the inflation tool (B) are closed.

5.

Slowly tighten the handwheel on the checking


device (A) and check that the pressure on the
gauge (E) is within the specified range:
Suspension element pressure = 682 bar
(950 1015 psi)

6.

Loosen the handwheel on the checking device


(A), remove all the equipment and install the protective cap.

174NM36

5-2

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
SUSPENSION ELEMENT INFLATION
1.

Loosen the protective cap on the cylinder.

174NM37

5
2.

Fit the checking (A) in the housing and connect


the inflation tool (B) to the device (A).

3.

Check that the inlet tap IN and the breather tap


OUT on the inflation tool (B) are closed.

4.

Slowly tighten the handwheel on the device (A)


and read the pressure on the gauge (E).

5.

Open the nitrogen cylinder tap (b) and the inlet


tap IN to let nitrogen into the suspension element
(a).

6.

Inject nitrogen at a pressure of approximately


75-80 bar (1088-1161 psi), then close the inlet tap
IN and the cylinder tap.

7.

Adjust the suspension element pressure to the


specific value by means of the breather tap OUT.
Suspension element pressure = 682 bar
(950 1015 psi)

8.

Close the breather tap OUT, loosen the handwheel on the device (A), remove all the equipment and install the protective cap.
174NM36

5-3

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
BRAKING CIRCUIT
CHECKING BRAKE PAD WEAR
1.

Check that the thickness of each pad is within the


specified range.
Thickness (S) 3 mm (1/8 in)

2.

Check that the thickness of the brake disc is


within the specified range.
Thickness (d) 14 mm (1/2 in)

3.

Replace as required (contact your Dealer for


more information).

4.

Replace the wheel and repeat the operation on all


the vehicle braking circuit units.
174NM38

7
PARKING BRAKE CALIPER RELEASE
To tow the vehicle in the event of failures that result in
the loss of pressure in the hydraulic braking system,
release the parking brake calipers as follows:
1.

Position wedges under the wheels in both directions to prevent the vehicle moving during the
release operations.

2.

Clean both calipers on the outside and in the area


around the bulkhead.

3.

Remove cover to reach the adjustment screw.

4.

Loosen the adjustment screw (arrow) until the


pads stop braking.

NOTE: Readjust before using the vehicle normally.

221NM04

5-4

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
CHECKING PARKING BRAKE EFFICIENCY
1.

Position the vehicle on a flat surface that is wide


enough to allow small movements.

2.

Switch the engine off, move the selector lever to


Neutral and engage the parking brake, the parking brake warning lamp should light up.

3.

With the engine off and ignition switch in MAR


position, disengage the parking brake, the parking brake warning lamp should go out.

4.

Operate the service brake control until the brake


lights go out.

5.

Repeatedly engage and disengage the parking


brake until the warning lamp remains lit when the
control is disengaged.

6.

Start the engine and wait for the parking brake


warning lamp to go out.

7.

Select manual, insert the first speed, let the vehicle move forward VERY SLOWLY, then engage
the parking brake: the warning lamp should light
up and the vehicle should stop immediately (the
gearbox automatically goes into Neutral).

174NU53A

174NU28B

10

221NM01

11

5-5

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
TIRES AND WHEELS

WARNING

Exploding tires and/or rim parts can cause injury


or death. Keep yourself and others out of the
DANGER AREA. Stand on the tread side of the
tire. Always use the correct air pressure and follow
the instructions in this manual for adding air or
servicing the tires.

WARNING

Explosive separation of the tire and/or rim parts


can cause injury or death. When tire service is
necessary, have a qualified tire mechanic service
the tire.

WARNING

DO NOT weld to wheel or rim when a tire is


installed. Welding will cause an explosive air/gas
mixture that will be ignited with high temperatures.
This can happen to tires inflated or deflated.
Removing air or breaking bead is not adequate.
Tire MUST be completely removed from the rim
prior to welding.

5-6

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS

B910410J

12
The above illustration show danger areas caused by
exploding tires and/or rim parts. KEEP YOURSELF
AND OTHERS OUT OF THESE DANGER AREAS.

The next page shows the correct methods that you


MUST use when adding air or servicing a tire.

5-7

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
ADDING AIR TO THE TIRES
This procedure is only for adding air to the tire. If the
tire has lost most or all of the air, do the following:
1.

Before you add air, have the wheel correctly


installed on the machine or put the wheel in a
restraining device (tire inflation cage).

2.

Use an air hose with remote shutoff valve and a


self-locking air chuck.

3.

Stand BEHIND the tread of the tire and make


sure ALL persons are away from the side of the
tire before you start to add air.

4.

Inflate the tire to the recommended air pressure.


DO NOT inflate the tire more than the recommended pressure given on the following page.

B790490R

13
TIRE OR RIM SERVICE
Always have a qualified tire mechanic service the tires
and rims for this machine. It is recommended that you
have the mechanic inflate the tires. To prevent accidents, use a restraining device (tire inflation cage),
correct equipment and correct procedure. Explosive
separation of the tire (single piece rim) or the tire and/
or rim parts (multi-piece rim) can cause serious injury
or death.

5-8

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
TIRE AND WHEEL CHECK
1.

Check that the tire inflation pressure is within the


specified range.
325 MODEL
POSITION

PRESSURE

Front

2.75 bar

39.9 psi

Rear

3 bar

43.5 psi

330 MODEL
POSITION

PRESSURE

Front

3.75 bar

54.5 psi

Rear

3.75 bar

54.5 psi

2.

174NM39

14

Otherwise: correct the pressure, as required.

NOTE: Check pressure and inflate the tires when


cold.
3.

Check the condition of the rims.

4.

Check that all bolts are tightened to the specified


torque.

5.

Check tire wear.

6.

Check tires for visible cuts; check the tires do not


touch the vehicle.

TIRE INFLATION
1.

Remove the protective cap and connect the inflation device fitting to the valve.

2.

Take to specified pressure.

3.

Disconnect the fitting and install the protective


cap.

NOTE: Check the pressure and inflate the tires when


cold.

174NU60

15

5-9

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
AIR CONDITIONING SYSTEM
CONDENSER CLEANING
1.

Open the engine hood and loosen the two screws


fastening the condenser.

156NM110

16
2.

Tilt the condenser forwards.

3.

Inspect and clean the condenser with compressed air (maximum 5 bar (72 psi)). Install and
fasten the screws.

156NM111

17
CAB AIR FILTER CLEANING/REPLACEMENT
1.

Release the fastening clips and open the cover.

156NM112

18

5-10

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
2.

Remove the filter.

3.

Replace the filter or clean in with compressed air


(maximum 5 bar/72 psi). Install and fasten the
screws.

NOTE: The filter must be mounted with the arrows (a)


pointing towards the passenger compartment.
If there is no mark, marke one to facilitate reassembly.

156NM113A

19
SYSTEM CHARGE CHECK
Check the system charge once a year or when
reduced cooling is noticed (see your Dealer).

WARNING

The checking and recharging operations must be


carried out by suitably equipped expert personnel.
R134a (tetrafluoroethane) coolant is used. This
coolant is classified as an environmentally-friendly
product by law. Do not use this fluid in systems
working with the previous fluid, R12 (Freon 12).
For reasons of incompatibility between compressor oil and fluid, do not use R12 in systems
designed to use R134a.

WARNING

Do not discharge R134a into the atmosphere.


Although the product has a zero ozone depletion
potential it has a global warming potential.
Recovery and recycling procedures are governed
by law.
Always use type-approved coolant recovery and
recharging devices.
Do not mix different coolants in the same device.

5-11

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
BODYWORK
FRONT WINDSHIELD WIPER BLADE REPLACEMENT
1.

Lift the arm and blade.

2.

Loosen the screws fastening the blade and


remove it.

3.

Fit the new blade and fasten the screws.

NOTE: Follow the suppliers specifications.

174NM40

20
SIDE WINDSHIELD WIPER BLADE REPLACEMENT
1.

Lift the arm and blade.

2.

Push the blade backwards, disengage it from the


stop and remove it.

3.

Fit the correct adapter on the new blade and bring


the blade up to the clip to fasten it in the adapter.

4.

Pull the blade to fasten the adapter clip.

NOTE: Follow the suppliers specifications.


174NM41

21
WINDSHIELD WASHER FLUID RESERVOIR
You are advised to use a specific antifreeze product
mixed with water as shown in the table.
TEMPERATURE

PRODUCT

WATER

-35C (-31F)

-20C (-4F)

-10C (14F)

0C (32F)

summer

10

1.

Open the flap, remove the cap and fill completely.

2.

Refasten the cap and close the flap.

NOTE: Follow the detergent proportions recommended by the supplier.

5-12

174NM03

22

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
CLEANING
Wash the vehicle regularly with mild products and
water to eliminate any traces of corrosive agents (salt,
sand, etc.).
Dry carefully with compressed air to avoid any accumulations.
Do not use products containing aromatic solvents,
methanol or hydrocarbons for cleaning paintwork.
Do not use a jet of water or steam to clean the inside
of the cab.
Alternatively, use specific products, carefully observing the instructions provided by the product manufacturer.
When cleaning plastic parts do not use gasoline, kerosene, paint solvents, etc. Use soap and water and a
clean cloth only.
The use of gasoline, paraffin, paint solvents, etc. will
cause discoloration, cracks or deformation of these
parts.
Ensure good ventilation in the cab until the products
have dried. Never use chloride solvents (trichlorethylene, hyperchloride, etc).
Wash seat belts with warm water and mild soap.
Rinse and dry in the shade. Never use strong detergents, bleach or dies. Avoid any chemical substance
which could weaken the fibers.

5-13

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
TROUBLESHOOTING
ENGINE
PROBLEM

The engine does not start

POSSIBLE CAUSE

SOLUTION

Battery connections deteriorated and/or


disconnected. Dead battery

Clean, check and fasten terminal nuts


and/or replace them, if they are
damaged. Recharge the battery or
replace it, if required

Fuel filters obstructed

Replace the filters

Water and/or air in the fuel feed circuit

Check and bleed water and/or air in the


system

At low temperature, the starter motor


runs but the engine does not start;
damaged thermal starter (where fitted)
Injectors dirty and/or obstructed
See your Dealer
Shutdown device ineffective
Injection pump is out of timing and/or
automatic advance variator is faulty
(325 model)

Battery cables and/or connections loose,


broken or corroded (excessive
The engine either does not crank or
resistance)
cranks slowly
Lubricant characteristics are not suitable
for engine operating conditions

The engine stops running

Check battery cables and connections

Change oil and filters

Low fuel level in tank; presence of air in


the fuel supply system and/or poor
quality fuel or fuel unsuitable for the
application

Fill the tank with suitable fuel; check for


air in the supply circuit and bleed, if
required

Fuel filter or fuel intake manifold


obstructed

Replace the fuel filter

Fuel starts congealing due to the cold


temperature

Check the fuel heater, where fitted. A


fuel heater may be required in certain
climates

The air intake system is excessively


restricted

Clean or replace air cleaner and intake


pipe, as required

Fuel intake obstructed; fuel switch off


valve closed; exhaust system obstructed
See your Dealer
Engine brake incorrectly adjusted
(330 model)
The engine decelerates slowly
The engine does not stop

5-14

Accelerator pedal jammed

Released the accelerator pedal

Ignition key circuit failure

See your Dealer

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS

PROBLEM

Poor performance or irregular


engine operation

POSSIBLE CAUSE

SOLUTION

The altitude is high

Engine power decreases at higher


altitudes

Excessive load with reference to nominal


engine power

Reduce vehicle load or shift to a lower


gear

Poor quality fuel or fuel unsuitable for the


application

Drain the tank and fill with fuel of the


appropriate type

The air intake system is excessively


restricted

Clean or replace air cleaner and intake


pipe, as required

Fuel filter obstructed or air in the fuel


supply system

Replace the fuel filter and bleed the air

Excessive air temperature in intake


manifold
Intake or exhaust leakage; turbocharger
damaged; fuel exhaust pipe obstructed

See your Dealer

Incorrect head unit adjustment

Excessive engine noise

Degraded or diluted lubricant oil

Change oil and filters

Poor quality fuel or fuel unsuitable for the


application

Drain the tank and fill with fuel of the


appropriate type

Oil pressure low; engine mounts worn;


damaged or inappropriate; damper
damaged; engine worn with excessive
internal play

See your Dealer

Coolant level lower than specified and/or


excessive antifreeze concentration

Check engine and cooling system for


external leakage of coolant. Top off
coolant. check antifreeze concentration.
Otherwise, see your Dealer

Intercooler air cooling radiator fins,


radiator fins or air conditioner condenser
fins damaged or obstructed

Check intercooler, air conditioner


condenser and radiator fins. Clean, if
required

Cooling system hose broken, obstructed


or leaking; accessory belt loose, radiator
cap inappropriate, damaged or with low
pressure index

See your Dealer

Filling pipe or breather pipe either


partially or completely obstructed, or
arranged incorrectly

Check breather pipe and filling pipe for


correct arrangement and obstructions

Mechanical and environmental


conditions effect fuel consumption

Consider environmental temperature,


wind, tire size, axle alignment, type of
terrain and spoilers when evaluating fuel
consumption

Incorrect use

See operating instructions

Fuel leakage

See your Dealer

Engine overheating

Excessive fuel consumption

5-15

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS

PROBLEM

Excessive lubricant oil


consumption

POSSIBLE CAUSE

SOLUTION

Check actual oil consumption

Check amount of oil added in relation to


distance driven

Lubricant characteristics are not suitable


Change oil and filters. Use oil of the
for conditions of operation of the engine. specified type. Check correct oil change
Oil change frequency inadequate
frequency
Lubricant oil leakage

Check for leakage of oil from the engine.


See your Dealer

Lubricant characteristics are not suitable


for engine operating conditions

Change oil and filters. Use oil of the


specified type

Lubricant oil level over or under specified


level

Check oil level. Remove or add oil, if


required

Oil filter obstructed

Change oil and filters. Change oil more


frequently

Engine worn

See your Dealer

Poor quality fuel or fuel unsuitable for the


application

Drain the tank and fill with fuel of the


appropriate type

Turbocharger impeller not to


specifications; intake or exhaust leakage
and/or fuel exhaust pipe obstructed

See your Dealer

Cold engine

Warm the engine up to normal working


temperature

Poor quality fuel or fuel unsuitable for the


application

Drain the tank and fill with fuel of the


appropriate type

Coolant temperature too cold

See "coolant temperature too cold"


or see your Dealer

POSSIBLE CAUSE

SOLUTION

Automatic transmission shifts


either at wrong speed (too fast/too
slow) or problematically

Regulator box damaged; control valve


spring badly set and valves not working
freely

See your Dealer

The vehicle moves fast in first and


reverse gear

Engine idling speed too fast

See your Dealer

Oil level too low or too high

Check and restore level

No circulation of engine coolant in heat


exchanger

See your Dealer

Heat exchanger obstructed (oil side or


coolant side)

Eliminate obstructions

Irregular lubricant oil pressure

Excessive black smoke in exhaust

Excessive white smoke in exhaust

AUTOMATIC TRANSMISSION
PROBLEM

Transmission overheats in all gears

5-16

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS

PROBLEM
Engine pick-up speed high with
vehicle not moving

POSSIBLE CAUSE

SOLUTION

Insufficient oil

Add extra oil to correct oil level

Forward gear clutch slips


See your Dealer
Clutch pressure insufficient

Engine pick-up speed low with


vehicle not moving

Dirty oil

Clutch slips in all gears

Poor engine performance (not due to


altitude)
See your Dealer
Poor functioning of converter
components
Oil not changed at specified frequency

Change oil, fit new filtering element

Oil filter damaged

Replace the filter

Clutch faulty

See your Dealer

Insufficient oil

Top off oil level

Insufficient pressure
See your Dealer
Worn clutches slip
One specific clutch slips

One specific gear slips

Forward gear clutch does not disengage


(forward gear)

See your Dealer

Reverse gear clutch does not disengage


(reverse gear)

No transmission response when


gear lever is shifted

Gear lever electrical connection and/or


control unit damaged and/or
disconnected

Restore connections and contact the


Dealer, if required

Insufficient main pressure

See your Dealer

Oil level too high

Remove the required amount of oil to


restore the correct level

Converter pump hub seal worn. Worn


converter pump hub
Oil leakage

Oil intake tube leaking or missing


Output shaft flange seal worn or
damaged

See your Dealer

Seal bearing surface of flange worn


Breather valve obstructed
Transmission bent or incorrectly
balanced
Vibration or noise

Transmission loose at fork/flange

See your Dealer

Worn or dry mounts

5-17

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
TRANSMISSION
PROBLEM

POSSIBLE CAUSE

SOLUTION

Distorted drive shafts and/or worn


mounts
Vibration or noise

Incorrectly balanced drive train

See your Dealer

Insufficient part lubrication


Distorted drive shafts
Excessive mount wear

Flange fork badly aligned and/or fork


offset

See your Dealer

Transmission not balanced

AXLE AND DIFFERENTIAL


PROBLEM

Vibrations

Continuous noise

POSSIBLE CAUSE

SOLUTION

Wheels not fitted correctly

Remove wheels and replace them


correctly

Broken and/or damaged gear teeth


Satellite gear set or flange box
excessively offset

See your Dealer

Insufficient lubrication

Restore level

Differential/hub/wheel bearing worn


See your Dealer
Broken and/or damaged gear teeth
Pinion-crown clearance not correct

Noise when accelerating and


releasing

Bearings damaged

See your Dealer

Satellite gear set axial play excessive


Incorrect operation of self-locking
differential

Use suitable oil with anti-slipping


additives

Satellite gear set or planetary gear set


worn
Satellite gear set pins worn and/or
damaged
Noise when cornering

See your Dealer

Harsh knocks when accelerating or


decelerating
Structure anchoring the chassis loose

Fasten the screws at the specified


torque

Imperfect gear adjustment


Anchoring structure pin clearance
excessive
Nuts or bolts loose

Fasten the nuts or bolts to the specified


torque

Oil seals worn. Casing cracked

See your Dealer

Lubricant leakage

5-18

See your Dealer

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
FRONT SUSPENSION
PROBLEM

POSSIBLE CAUSE

SOLUTION

Nitrogen or oil pressure loss


Suspension often reaches end of
stroke

Nitrogen pressure low and/or minimum


oil level

See your Dealer

HYDRAULIC SYSTEM
(common for brake, dump and steering circuits)
PROBLEM

No hydraulic function (noisy


pumps)

Slow hydraulic functions

Hydraulic system oil overheats

POSSIBLE CAUSE

SOLUTION

No oil in system

Add oil to reach indicated level

Intake filter obstructed

Clean filter and replace, if required

Hydraulic pump worn and/or not


working; damaged intake hoses

See your Dealer

Oil level low

Fill the reservoir to the full level

Oil cold

Wait a few minutes with the engine


running before using the vehicle

Oil not correct

The oil used is not suitable. Drain the


reservoir and use oil of the correct type

Engine ratio too low

Increase engine rpm

Pump worn and/or pump intake hose


pinched

See your Dealer

Incorrect and/or contaminated oil

Drain the reservoir and use oil of the


correct type

Oil level low

Fill the reservoir to the indicated level

Filters obstructed

Replace with new filters

Hydraulic components either not


adjusted properly and/or not working
Pump worn

See your Dealer

Oil radiator obstructed


Air leakage into pump intake pipe
Air leakage into pump intake pipe and
twisted or damaged oil pipes

See your Dealer

Oil not correct

The oil used is not suitable. Drain the


reservoir and use oil of the correct type

Water in oil

Change the oil

Oil level either high or low

Restore correct oil level by adding or


removing oil

Emulsified oil

5-19

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
BRAKES
PROBLEM

Insufficient or unbalanced braking


effect

POSSIBLE CAUSE

SOLUTION

Brake linings and/or discs worn

Replace brake linings and/or discs

Lubricant on brake discs

Clean brake discs. Seek source of


lubricant and repair, as required

Brake caliper incorrectly adjusted

See your Dealer

Brake linings not genuine parts

Replace the lines

Hydraulic tubes damaged and/or loose


fittings
Pump intake pipe leakage

See your Dealer

Hydraulic pump not working and/or worn


Brake calliper incorrectly adjusted
Brakes are jammed

See your Dealer


Jammed control units

DUMPER
PROBLEM

POSSIBLE CAUSE

SOLUTION

Control in cab not connected correctly


Dumper does not work

Hydraulic tubes and cylinders damaged


and/or loose fititngs
Hydraulic pump not working and/or worn

Dumper works but cannot lift loads

Hydraulic pump and/or hydraulic pipes


damaged

See your Dealer

See Hydraulic system troubleshooting Slow hydraulic functions

See your Dealer

Pump intake pipe leakage


Cylinder movement is rough and
locks during lifting or retracting

Air in cylinders

Bleed the system

Cylinder seizure

See your Dealer

POSSIBLE CAUSE

SOLUTION

Presence of dirt in system

Bleed and wash the system. Fill with


clean oil

Differential locks engaged

Stop vehicle, disengage differentials

STEERING
PROBLEM
Apparent impossibility to steering
when the steering wheel is turned
slowly

Steering cylinder seized


Slow/hard steering

See your Dealer


System excessively worn

The steering wheel keeps turning

The steering wheel is not centered

5-20

Presence of dirt in system

Bleed and wash the system. Fill with


clean oil

Burring on tie-rod or stem. Sleeve and


stem locked together, centering springs
broken

See your Dealer

Steering column valve seizure.


Centering springs broken

See your Dealer

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS
TIRES AND WHEELS
PROBLEM

POSSIBLE CAUSE

SOLUTION

Perforation in bead area


Replace the tire
Cuts and grooves in tire
Air leakage from tire

Damaged valve and/or rim or broken


welding

See your Dealer

Components damaged

5-21

Copyright
SECTION 5 - MAINTENANCE/ADJUSTMENTS

NOTES

5-22

Copyright

SECTION 6

14

ELECTRICAL SYSTEM
PRECAUTIONS
Make absolutely sure that the electrical power is disconnected before working directly or indirectly on
electrical system parts by turning off the battery master switch.
Proceed as follows:
1.

To connect power: turn switch to horizontal position (a).

2.

To disconnect power: turn switch to vertical position (b).

WARNING

The vehicle electrical system should work even if


the battery is dead.
If this is not the case, switch on a load of at least
20 W (position lights) to prevent the voltage
exceeding the specified values.

221NS01

Observe the following rules of good practice to prevent damaging beyond repair the electronic control
unit fitted in the vehicle:
1.

Disconnect the battery disconnect switch before


carrying out arc welding operations on the chassis. Remove the control unit to weld near the control unit.

2.

After a service operation requiring battery disconneciton, make sure that the terminals are well
connected.

3.

Do not use a battery charger to start the engine.

4.

Disconnect the batteries to recharge them.

5.

Do not disconnect the control unit connectors


when the engine is running or the control units
are under power.

6.

Do not disconnect the batteries when the engine


is running.

7.

Remove the transmission control unit in the event


of operations at temperatures exceeding 80C
(176F) (oven painting, etc.).

6-1

Copyright
SECTION 6 - ELECTRICAL SYSTEM
BATTERY MAINTENANCE (NOT SEALED)
IMPORTANT: Sealed batteries (maintenance free) do
not require addition of water in normal working
conditions and mild climates. The electrolyte should
be checked approximately once a year in tropical
climates.
1.

Access the battery compartment in front of the


right-hand fender.

2.

Carefully clean the batteries, the cables and the


case, removing rust and dirt, which can cause
voltage drops.

174NM42

2
3.

Check through the caps that the distance


between the electrolyte and the upper edge of the
plate of each element is as specified:
Level-plate distance 10 - 12 mm (0.4 - 0.5 in)

4.

If required, top off with distilled water when the


batteries are cold and at rest, through the specific
filler holes.

5.

Check the battery charge with a densimeter.


Temperature
ambient air

Electrolyte density
(100% of charge)

g/dm3 (oz/in3)

40

104

1.265 (0.0073)

20

68

1.285 (0.0074)

32

1.300 (0.0075)

-20

-4

1.365 (0.0078)

6-2

174NM43

Copyright
SECTION 6 - ELECTRICAL SYSTEM
RECHARGING BATTERY WITH EXTERNAL DEVICES
Batteries should normally be removed from the vehicle to be recharged.
If this is not possible, the batteries can also be
recharged using an external source (battery charger)
connected directly to the battery terminals.
NOTE: The vehicle is equipped with a 24 volt electrical system with negative ground.
1.

Lay the cables on the ground ensuring that the


terminals do not touch metal parts or each other.
Connect the red cable (A) to the POSITIVE terminal of the dead battery.

2.

Connect the black cable (B) to the NEGATIVE


terminal of the dead battery.

3.

Set the recharge time and correct. Start recharging.

WARNING

Respect the instructions provided by the battery


charger supplier. Respect the sequence of operations. Do not reverse the polarity when making the
connection.

174NM44

4
JUMP STARTING
When the batteries are discharged, connect the vehicle to the external batteries to restart it.

WARNING

The vehicle is equipped with a 24 volt electrical


system with negative ground. Only use 24 volt batteries to jump start the engine.
a.

Lay the cables on the ground ensuring that the


terminals do not touch metal parts or each other.
Connect one end of the red cable (A) to the POSITIVE terminal of the dead battery.

b.

Connect the other end of the red cable (A) to the


POSITIVE terminal of the external battery.

c.

Connect one end of the black cable (B) to the


NEGATIVE terminal of the external battery. Connect the other end of the black terminal (B) to any
point of the chassis of the vehicle to be started
where there is good grounding.

174NU43

6-3

Copyright
SECTION 6 - ELECTRICAL SYSTEM

WARNING

Select a connection point as distant as possible


from the vehicle batteries. Make sure that the two
vehicles do not come into contact. Respect the
sequence of the operation. Do not reverse the
polarity when making the connection. Use cables
with a suitable cross-section area.
After starting the engine, disconnect the cables by
reversing the connection sequence.

WARNING

The vehicle electrical system should work even if


the batteries are dead. If this is not possible,
switch on a load of at least 20W (position lights) to
prevent the voltage exceeding the specified values.
In any case verify the causes of the battery discharge.

6-4

Copyright
SECTION 6 - ELECTRICAL SYSTEM
CONTROL UNIT LOCATION
GEARBOX CONTROL UNIT

108DT02

6
ENGINE CONTROL UNIT (330 MODEL)

108DT03

6-5

Copyright
SECTION 6 - ELECTRICAL SYSTEM
INTERCONNECTION CONTROL UNIT
1

4
CS03B004

8
1.

Side dashboard

2.

Driver seat

3.

Central compartment

4.

Interconnection unit

6-6

Copyright
SECTION 6 - ELECTRICAL SYSTEM

This page is intentionally left blank

6-7

Copyright
SECTION 6 - ELECTRICAL SYSTEM
FUSE AND RELAY BOX
The fuses protecting electrical system devices and the
relays are arranged in a specific compartment in the
lower part of the cab.
NOTE: Seek the cause of the failure in the electrical
system if a fuse blows repeatedly. Never install a fuse
that has a higher Amperage rating than the original.

174NM45

9
FUSE FUNCTIONS

CS03B005

10
1.

White

2.

Black

3.

Red

6-8

Copyright
SECTION 6 - ELECTRICAL SYSTEM
Fuse
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Amp
7.5
7.5
3
7.5
7.5
7.5
7.5
20
5

Location
A1
B2
C3
C3
D4
D4
E5
F6

Fuse
21
22
23
23
24
24
25
26

Amp
10
10

Location
A1
B2
C3
D4
E5
F6

Fuse
31
32
33
34
35
36

Amp
7.5
7.5
3/15
30
15
20

Location
A1
B2
C3
D4
E5
F6

Fuse
41
42
43
44
45
46

Amp
10
7.5
7.5
7.5

10
7.5
5
3
7.5
10
7.5
7.5
7.5
3
10
7.5
15
20

5
5

Function
Position lights - Instrument panel light - Switches
Position lights - Warning light
Main beam lights on - Dipped headlights off with main beams on
LH dipped-beam light
RH dipped-beam light
LH main beam - warning light
RH main beam light
Front work light (75W x 4)
Rear fog light
Not used
Horns
Coil relay E33 - Mirror motor - heating
Instruments
Warning lights
Windscreen wiper - washer
Hazard lights
Direction indicator lights
Brake lights - Reversing gear
Park brake - tipping control
Ceiling lamp - warning light battery disconnect switch ON
Climate control (compressor)
Beacon lights
Electro-pneumatic seat heated
Climate control (ventilation control)
Function (white color)
Power supply + 30 E.C.U. engine
Power supply + 30 E.C.U. engine
Not used (325 model)
Power supply + 15 warning lights engine working / E.C.U. engine (330 model)
Not used (325 model)
Engine brake control - relays E37 - E38 (330 model)
Not used
Not used
Function (SERVICES) (black color)
LH side wipers
RH side wipers - Side winder washer pump
Refuelling tank pump / lube device - hour counter - Coil PA
Power supply bonnet lifter pump OPT
Current connector 12V - Cigar ligter 12V
Potential divider 24/12V (camera - radio - CB - services 12V)

Function (GEARBOX) (red color)


Power supply E.C.U. EST 37 (+15) - retarder OPT - relays E17/E21
Power supply E.C.U. EST 37 (+30 memory)
Differential and splitter lock - safety emergency pump - relays E23/E22
Steering and buzzer emergency pump
Not used
Not used
6-9

Copyright
SECTION 6 - ELECTRICAL SYSTEM
RELAY FUNCTIONS

208DT05

11
Relay

Function

E1

Not used

E2

Headlamps circuit (dipped, main)

E3

Ignition key services 50 A (not during ignition)

E4

Flashing

E5

Park brake

E6

Stop lights

E7

Not used

E8

Not used

E9

Intermittent wiper

E10

Dipped beam light - Main beam light

E11

Front headlights (20 A)

E12
E13

Relay
E23
E24
E24
E25
E26
D1
D6
D6

Function
Safety emergency pump steering (buzzer)
Not used (325 model)
Kick Down (330 model)
LH side wiper
RH side wiper
Emergency pump diodes steering
Retarder warning lights (325 model)
Retarder and engine brake warning lights
(330 model)

E27

Side window washer/wiper pump

E28

Hour meter tank refuelling pump/Lube device

E29

Climate control

Horn

E30

Stand-By camera (12V)

Not used

E31

Battery warning light ON

E14A

Ejector

D2

Park brake/body up - warning light diodes

E14B

Not used

E37

Not used (325 model)

E15

Not used

E37

Engine brake (330 model)

E17

Body hoist (1st and 2nd gear limit during tipping)

E38

Not used (325 model)

E18

Reversing buzzer - reversing lamp - E30 relay

E38

Engine brake (330 model)

E19

Steering emergency pump

GB

Ignition key services

E20

K1 relay (gearbox in idle)

GD

Lifter bonnet (pump)

E21

Park brake

PA

Tank refuelling pump

E22

Splitter

TA

Cold start aid timer relay (325 model)

6-10

Copyright
SECTION 6 - ELECTRICAL SYSTEM
LIGHTING SYSTEM
HEADLIGHT BULB REPLACEMENT
Headlights: High-beam headlight, low-beam headlight, front position light.
1.

Access the compartment in front of the fender of


the concerned headlight. See "Opening the hood"
in Section 4.

2.

Remove the complete light cluster by loosening


the fastening screw and disconnecting the electrical connector.

3.

Remove the boot.

4.

Release the clip and remove the headlight bulb.

5.

Remove the position light bulb.

6.

Replace by following the above procedure in


reverse.

174NM47

12

IMPORTANT: Do not touch a halogen bulb with your


fingers. This could effect correct operation.
DIRECTING THE HEADLIGHTS
The headlights must be redirected after complete
removal of headlights. You are advised to use appropriate equipment to carry out this operation.
In any case, adequately correct setting can be
obtained as follows:
1.

Position the unladen vehicle, with tires inflated at


the specified pressure, on flat ground in front of a
light colored wall.

2.

Draw two crosses on the wall corresponding to


the center points of each headlight.

3.

Back the vehicle 10 m (10.94 yd) and switch on


the low-beams. The distance between the
crosses and the reference points P-P should be
10% of the height between the middle of the
crosses and the ground (tolerance 1%).

174NM48

13

6-11

Copyright
SECTION 6 - ELECTRICAL SYSTEM
4.

If required, turn the headlight by means of the fastening nut.

174NM56

14
FRONT TURN INDICATOR/FRONT
LIGHT BULB REPLACEMENT

POSITION

1.

Access the compartment in front of the fender of


the concerned headlight. See "Opening the hood"
in Section 4.

2.

Remove the complete light cluster by loosening


the fastening screw and disconnecting the electrical connector.

3.

Remove the lens and replace the turn indicator


bulb.

4.

Refit by following the above procedure in reverse.

174NM57A

15
SIDE TURN INDICATOR BULB REPLACEMENT
1.

Remove the light cluster by loosening the fastening nuts and disconnect the electrical connector.

2.

Replace the bulb.

3.

Refit by following the above procedure in reverse.

174NM58A

16

6-12

Copyright
SECTION 6 - ELECTRICAL SYSTEM
REAR WARNING LIGHT BULB REPLACEMENT
Rear headlight: position light, brake light, turn indicators.
1.

Remove the protective grid by loosening the fastening screws.

2.

Remove the lens and replace the position light


bulb (a), the direction indicator light bulb (b), the
brake light bulb (c).

3.

Replace by following the above procedure in


reverse.
174NM59

17
REAR LIGHT BULB REPLACEMENT
Rear lights: reverse (a), rear foglight (b).
1.

Remove the lens by loosening the fastening


screws and replace the bulb.

2.

Replace by following the above procedure in


reverse.

208NM17

18
WORK HEADLIGHT BULB REPLACEMENT
1.

Remove the complete light cluster by loosening


the fastening screws and disconnecting the electrical connector.

2.

Remove the boot.

3.

Release the clip and remove the bulb.

4.

Replace by following the above procedure in


reverse.

WARNING

!
174NM61

Do not touch a halogen bulb with your fingers.


This could effect correct operation.

19

6-13

Copyright
SECTION 6 - ELECTRICAL SYSTEM
REPLACING THE MAP
READING LIGHT/DOME LIGHT BULB
1.

Using a screwdriver, prise the transparent cover


(a) off and replace the bulb.

2.

Unscrew the map light (b) and replace the bulb.

3.

Refit by reversing the removal sequence.

183NM97

20
LIST OF BULBS
Use
Headlights:
High beam and low beam light
Position
Front turn indicators
Side turn indicator
Rear fixed lights:
Position
Stop
Turn
Work light
Reverse light
Fog light
(See Parts Catalog for part numbers)

6-14

Type

Watt

Double filament halogen


Round
Round
Round

75/70
4
21
5

Round
Round
Round
Halogen
Round
Round

5
21
21
75
21
21

Copyright

SECTION 7

STORAGE
STORING THE VEHICLE
The following service operations are required in the
event of long storage (parking for longer than three
months) to protect functionality of units and vehicle
operation.
Disregarding these operations may necessitate overhauling when the vehicle returns to use.
CLEANING
Wash the vehicle to remove mud and dirt. Remove
stones which may be jammed between the tires or the
suspension units and remove deposits from the containers and cab floor.
Wash the external parts with a jet of steam and detergent. Be careful not to direct the jet directly onto the
most exposed parts of the electrical system.
Do not use the jet of steam to clean inside the cab.

MAINTENANCE
Change the following:
1.
2.
3.
4.

Furthermore:
1.
2.
3.

Repair fluid leakage by replacing sleeves, caps or


seals which are not perfectly tight.
Apply paint where the paint is scuffed but not rusted.
Where required, remove all traces of corrosion and
rust by means of suitable mechanical devices. Clean
the concerned parts, apply rustproof protection and
paint.
Protect centralized lubricators from paint.

Fill the reservoirs (fuel, hydraulic oil) to prevent


the formation of condensation.
Lubricate the entire vehicle in the specified greasing points.
Apply rustproof protection to all mechanical parts
subject to corrosion.

Remove the battery from the vehicle and store in a


dry, ventilated place.

CHECKS AND REPAIRS


Inspect and test the vehicle. Carry out the repairs
required.

Engine oil.
Transmission oil.
Engine coolant.
Hydraulic fluid.

WARNING

Do not stack batteries, to avoid damaging the


ones underneath. Furthermore, do not overload
the floor.
Batteries will discharge when not in use: on an average, a battery will lose half its charge in 60 days. Proceed as follows for correct battery conservation:
1.
2.
3.

Clean the outside very carefully.


Regularly check the electrolyte level.
Charge the battery every 30 days at a charge
intensity of less than 1/10th of nominal capacity.

WARNING

Used batteries must be not be stored for longer


than six months: alternatively, fit the batteries in
other vehicles.

7-1

Copyright
SECTION 7 - STORAGE
STORAGE
Store the vehicle in a sheltered, clean, dry place.
Lift the vehicle using suitable lifting devices and
arrange it on stands to raise the tires off the ground.
Remove all traces of oil and grease from the tires.
Inflate the tires to a pressure of approximately 1 bar
(14 psi) and protect from direct light with a suitable
cover.
RETURN TO SERVICE
The following checks are required to make the vehicle
operational when resuming service.
Change the following:
1.

Engine oil (only for storage exceeding one year)

2.

Transmission oil (only for storage exceeding one


year).

3.

Engine coolant (only for storage exceeding two


years).

4.

Hydraulic fluid (only for storage exceeding two


years).

Lubricate the entire vehicle at the specified greasing


points.
Charge the batteries as described above. Check the
charge after one day: replace the battery if the charge
drops, even partially.
Fit the batteries on the vehicle and apply pure Vaseline to the terminals.
Inflate the tires to the specified pressure. Furthermore,
check that the tires are not damaged or cracked.
Inspect and test the vehicle. Carry out the repairs
required. Specifically, eliminate any traces of rust and
paint the concerned parts. Eliminate any leakage of
fluids.

7-2

Copyright

SECTION 8

12

SPECIFICATIONS
MAIN GROUPS
325 MODEL
Engine .................................................................................... Cummins 6CTAA 8.3 - C260 (Turbo 6 cylinders)
Transmission .................................................................................................................................ZF 6 WG 210
Front axle................................................................................................................................................ ZF AP9
Intermediate axle .................................................................................................................................... ZF AP9
Rear axle ................................................................................................................................................ ZF AP9
330 MODEL
Engine ........................................................................................ Cummins QSM 11 - C290 (Turbo 6 cylinders)
Transmission .................................................................................................................................ZF 6 WG 210
Front axle................................................................................................................................................ ZF AP9
Intermediate axle .................................................................................................................................... ZF AP9
Rear axle ................................................................................................................................................ ZF AP9

8-1

Copyright
SECTION 8 - SPECIFICATIONS
DIMENSIONS

174DT01A

8-2

Copyright
SECTION 8 - SPECIFICATIONS
325 MODEL
(A) Wheel base.......................................................................................................................5.183 m (16.99 ft)
(B) Front tread ..........................................................................................................................2.795 m (9.16 ft)
(C) Rear tread...........................................................................................................................2.795 m (9.16 ft)
(D) Front overhang ...................................................................................................................2.519 m (8.27 ft)
(E) Rear overhang ....................................................................................................................1.258 m (4.12 ft)
(F) Overall length....................................................................................................................9.820 m (32.22 ft)
(G) Maximum width ..................................................................................................................2.605 m (8.54 ft)
(H) Maximum height of unladen vehicle ................................................................................. 3.638 m (11.94 ft)
(I) Minimum height from ground (ground clearance) ................................................................0.481 m (1.58 ft)
(L) Loading height.....................................................................................................................2.728 m (8.95 ft)
(M) Maximum height with raised dumper ...............................................................................6.453 m (21.17 ft)
(N) Maximum tipping angle............................................................................................................................67
Turning circle between kerbs..................................................................................................4.362 m (14.30 ft)
Turning circle between walls...................................................................................................8.182 m (26.83 ft)
330 MODEL
(A) Wheel base.......................................................................................................................5.142 m (16.87 ft)
(B) Front tread ..........................................................................................................................2.934 m (9.93 ft)
(C) Rear tread...........................................................................................................................2.513 m (8.24 ft)
(D) Front overhang ...................................................................................................................2.317 m (7.60 ft)
(E) Rear overhang ....................................................................................................................1.292 m (4.24 ft)
(F) Overall length....................................................................................................................9.797 m (32.14 ft)
(G) Maximum width ..................................................................................................................2.605 m (8.54 ft)
(H) Maximum height of unladen vehicle ................................................................................. 3.644 m (11.95 ft)
(I) Minimum height from ground (ground clearance) ................................................................0.480 m (1.57 ft)
(L) Loading height.....................................................................................................................2.840 m (9.32 ft)
(M) Maximum height with raised dumper ...............................................................................6.415 m (21.05 ft)
(N) Maximum tipping angle............................................................................................................................67
Turning circle between kerbs..................................................................................................4.295 m (14.09 ft)
Turning circle between walls...................................................................................................8.163 m (26.78 ft)

8-3

Copyright
SECTION 8 - SPECIFICATIONS
WEIGHTS
325 MODEL
Vehicle tare weight in full running order ....................................................18 650 kg (20.56 US ton) (41 116 lb)
Tare weight distribution
Front axle (49%) ..................................................................................... 9150 kg (10.08 US ton) (20 172 lb)
Rear axle (51%)...................................................................................... 9500 kg (10.47 US ton) (20 944 lb)
Total weight loaded .................................................................................. 41 650 kg (45.91 US ton) (91 822 lb)
Maximum allowed weight
Front axle (33.6%) ............................................................................... 14 000 kg (15.43 US ton) (30 865 lb)
Rear axle (66.4%)................................................................................ 27 650 kg (30.48 US ton) (60 958 lb)
Capacity ................................................................................................... 23 000 kg (25.35 US ton) (50 706 lb)
330 MODEL
Vehicle tare weight in full running order .................................................... 20 160kg (22.22 US ton) (44 445 lb)
Tare weight distribution
Front axle (50.9%) .................................................................................12 260kg (11.31 US ton) (22 619 lb)
Rear axle (49.1%)................................................................................... 9900 kg (10.91 US ton) (21 826 lb)
Total weight loaded ................................................................................ 47 160 kg (51.99 US ton) (103 970 lb)
Maximum allowed weight
Front axle (21.8%) ............................................................................... 14 160 kg (16.53 US ton) (33 069 lb)
Rear axle (78.2%)................................................................................ 33 000 kg (36.38 US ton) (72 753 lb)
Capacity ................................................................................................... 27 000 kg (29.76 US ton) (59 525 lb)

8-4

Copyright
SECTION 8 - SPECIFICATIONS
HORIZONTAL CENTER OF GRAVITY (During transport with unladen vehicle)

CS03B006

2
(A) 2.543 m (8.34 ft) (325 model)

(A) 2.587 m (8.4 ft) (330 model)

SECURING POINTS FOR TRANSPORTATION ON TRAILER

174DT15

3
(A) Front securing points
(B) Rear securing points
(C) Central securing points
8-5

Copyright
SECTION 8 - SPECIFICATIONS
PERFORMANCE (325 MODEL)
Type of tires

23.5 R 25

Axle reduction ratio


Gear

1 : 21.85

Lock-up

Gearbox ratio

Total ratio

Speed km/h (mph) (*)

Max. gradient (%)

First gear

1 : 5.562

121.530

5.3 (3.233)

33.1

Second gear

1 : 3.615

78.988

8.1 (5.033)

20.3

Third gear

1 : 2.255

49.272

13.0 (8.078)

12.0

Fourth gear

1 : 1.466

32.032

20.0 (12.427)

7.2

Fifth gear

1 : 0.943

20.605

31.1 (19.325)

4.0

Sixth gear

1 : 0.613

13.394

47.8 (29.702)

1.9

First Reverse gear

1 : 5.274

115.237

5.6 (3.480)

33.1

Second Reverse gear

1 : 2.138

46.715

13.7 (8.513)

11.2

Third Reverse gear

1 : 0.894

19.534

32.8 (20.381)

3.7

(*) Speed that can be reached with engine running at 2200 tr/mn (rpm) and tire rolling circumference of
4.85 m (190.94 in)
Minimum speed at maximum torque in first gear .............................................................. 3.4 km/h (2.113 mph)
Max. speed (theoretical) ...............................................................................................47.8 km/h (29.702 mph)
Maximum gradient in first gear (theoretical)..............................................................................................33.1%
Maximum gradient that can be climbed in first gear (with converter on, theoretical) ...................................60%
Weight/power ratio ....................................................................................................157.8 kg/CV (354.0 lb/HP)

8-6

Copyright
SECTION 8 - SPECIFICATIONS
PERFORMANCE (330 MODEL)
Type of tires

23.5 R 25

Axle reduction ratio


Gear

1 : 21.85

Lock-up

Gearbox ratio

Total ratio

Speed km/h (mph) (*) Max. gradient (%)

First gear

1 : 5.350

116.898

5.2 (3.2)

41.7

Second gear

1 : 3.446

75.295

8.1 (5.0)

25.0

Third gear

1 : 2.206

48.201

12.7 (7.9)

15.2

Fourth gear

1 : 1.421

31.049

19.7 (12.2)

9.2

Fifth gear

1 : 0.969

21.173

28.9 (18.0)

5.7

Sixth gear

1 : 0.624

13.634

44.8 (27.8)

3.1

First Reverse gear

1 : 5.350

116.898

5.2 (3.2)

41.7

Second Reverse gear

1 : 2.206

48.201

12.7 (7.9)

15.2

Third Reverse gear

1 : 0.969

21.173

28.9 (18.0)

5.7

(*) Speed that can be reached with engine running at 2100 tr/mn (rpm) and tire rolling circumference of
4.85 m (190.94 in)
Minimum speed at maximum torque in first gear.................................................................. 2.5 km/h (1.6 mph)
Max. speed (theoretical) ................................................................................................... 44.8 km/h (27.8 mph)
Maximum gradeability in first gear (theoretical)........................................................................................ 41.7%
Maximum gradeability in first gear (with converter on, theoretical) .......................................................... 52.7%
Weight/power ratio................................................................................................ 147.66 kg/CV (330.06 lb/HP)

8-7

Copyright
SECTION 8 - SPECIFICATIONS
MAIN GROUP CHARACTERISTICS
ENGINE (325 MODEL)
6CTAA 8.3 - C260
Main characteristics
Number of cylinders........................................................................................................................... 6 in-line
Bore .....................................................................................................................................114 mm (4.49 in)
Stroke ..................................................................................................................................135 mm (5.32 in)
Displacement................................................................................................................8 270 cm3 (504.5 in3)
Compression ratio ..............................................................................................................................16.5 : 1
Cycle....................................................................................................................................... Diesel 4 stroke
Turbocharger type ................................................................................................................. Fixed geometry
Type of intake ............................................................................................................................... Aftercooler
Power data
Maximum power output ....................................................................................................... 194 kW (264 hp)
SAE J1995........................................................................................................................194 kW (260 BHP)
Running at approx. .........................................................................................................................2 200 rpm
Maximum torque........................................................................................................... 1123 Nm (828.3 lb ft)
Running at approx. .............................................................................................................. 1400 tr/mn (rpm)
Injection system
Type of injection.................................................................................................................................... Direct
Injection system................................................................................................................... Distributor pump
Ignition order.......................................................................................................................1 - 5 - 3 - 6 - 2 - 4
Adjustments
Cold tappet clearance adjustment
Intake valves ........................................................................................................................ 0.30 mm (0.012 in)
Exhaust valves ..................................................................................................................... 0.61 mm (0.024 in)
ENGINE (330 MODEL)
QSM11 - C290
Main characteristics
Number of cylinders........................................................................................................................... 6 in-line
Bore .....................................................................................................................................125 mm (4.92 in)
Stroke ..................................................................................................................................147 mm (5.78 in)
Displacement.................................................................................................................10 800 cm3 (659 in3)
Compression ratio ..............................................................................................................................16.0 : 1
Cycle....................................................................................................................................... Diesel 4 stroke
Turbocharger type ................................................................................................................. Fixed geometry
Type of intake ............................................................................................................................... Aftercooler
Power data
Maximum power output
SAE J1995........................................................................................................................... 216 kW (294 hp)
Running at approx. ..........................................................................................................................2100 rpm
Maximum torque.............................................................................................................. 1291 Nm (952 lb ft)
Running at approx. .............................................................................................................. 1400 tr/mn (rpm)
Injection system
Type of injection.................................................................................................................................... Direct
Ignition order.......................................................................................................................1 - 5 - 3 - 6 - 2 - 4

8-8

Copyright
SECTION 8 - SPECIFICATIONS
Adjustments
Cold tappet clearance adjustment
Intake valves ........................................................................................................................ 0.35 mm (0.014 in)
Exhaust valves ..................................................................................................................... 0.68 mm (0.027 in)
Braking system
Type ........................................................................................................................................... "Jake" brake
System characteristics ............................................................................................. Exhaust braking system
AUTOMATIC TRANSMISSION
ZF 6WG210
Transmission with 6 forward gears and 3 reverse.
Single stage torque converter with lock-up in all gears.
Stall ratio (325 model)............................................................................................................................ 1.77 : 1
Stall ratio (330 model)............................................................................................................................ 1.54 : 1
Incorporated differential lockable by tooth engagement between front axle and intermediate axles.
Gear ratios:
Normal
First ....................................................................................................................................................... 5.562
Second .................................................................................................................................................. 3.615
Third ...................................................................................................................................................... 2.255
Fourth .................................................................................................................................................... 1.466
Fifth ....................................................................................................................................................... 0.943
Sixth ...................................................................................................................................................... 0.613
First RG ................................................................................................................................................. 5.274
Second RG............................................................................................................................................ 2.148
Third RG................................................................................................................................................ 0.894
RG = Reverse gear
FRONT DRIVE AXLE
ZF AP9
Rigid type axle with planetary reduction gears on hubs; limited-slip differential
Center bevel gear reduction ratio ................................................................................................................ 3.44
Planetary final reduction ratio in wheel hubs ............................................................................................... 6.35
Total reduction ratio ................................................................................................................................... 21.85
INTERMEDIATE AND REAR DRIVE AXLES
ZF AP9
Rigid type axle with planetary reduction gears on hubs; differential
The differential on the intermediate axle distributes the torque between the intermediate and rear axle. Can
be locked by a control in the cab.
Center bevel gear reduction ratio ................................................................................................................ 3.44
Planetary final reduction ratio in wheel hubs ............................................................................................... 6.35
Total reduction ratio ................................................................................................................................... 21.85

8-9

Copyright
SECTION 8 - SPECIFICATIONS
BRAKES
Completely hydraulic braking system with separate circuits for front and rear brakes: braking pump controlled by
engine and hydraulic pressure accumulators.
Service brake
Disc brake with two calipers per axle, each with four pistons.
Braking pressure....................................................................................................................150 bar (2176 psi)
Parking brake
Disc brake with double caliper and hydraulic spring release activation acting on rear transmission shaft.
WHEELS AND TIRES
Five-piece rims on six wheels
Steel rims
Rims......................................................................................................................................................19.5 - 25
Tires ...................................................................................................................................23.5 R 25 (standard)
SUSPENSION
Front
Two hydro-nitrogen cylinders (oil/gas) for more flexibility and damping.
Working pressure (static load) ...............................................................................................130 bar (1886 psi)
Rear
Double rigid rocker distributing the load on the intermediate and rear axles with torque rod oscillation and
improved ground traction.
STEERING
Orbitrol
Hydraulically controlled steering with flow amplifier by means of two double acting hydraulic cylinders on
articulated joint between frames.
System fitted with main gear pump controlled from transmission and electrically controlled emergency pump
(see hydraulic system).
Steering angle....................................................................................................................... 45 both directions
HYDRAULIC SYSTEM
The hydraulic system uses three hydraulic pumps
Main pump (steering and dumping) ........................................................................... 117 cm3/rev (7.09 in3/rev)
Steering emergency pump...........................................................................................32 cm3/rev (1.94 in3/rev)
Brake pump.............................................................................. 19.5 cm3/rev (1.18 in3/rev) - 175 bar (2539 psi)
All circuits (steering, dumping, braking) use the same hydraulic oil tank.
An oil filter, housed in the tank on the intake manifold and two high pressure filters, located on the pump delivery
line, are used to filter the oil. An air-oil heat exchanger is used to cool the hydraulic circuit and maintain optimal
temperature.
DUMPING
System with gear pump controlled from transmission (see Hydraulic system).
Two multi-stage, double acting hydraulic cyinders mounted on ball joints inside the chassis to allow dumper
raising and lowering.
Dumping angle.............................................................................................................................................. 67

8-10

Copyright
SECTION 8 - SPECIFICATIONS
DUMP BODY (325 MODEL)
Flat bedded steel structure with box type reinforcement and supporting flexible pads. Walls and bed in high abrasion resistance steel.
Capacity
Struck (SAE 1:1) ............................................................................................................... 11.0 m3 (14.4 yd3)
Heaped (SAE 2:1) ............................................................................................................. 13.5 m3 (17.7 yd3)
DUMP BODY (330 MODEL)
Flat bedded steel structure with box type reinforcement and supporting flexible pads. Walls and bed in high abrasion resistance steel.
Capacity
Struck (SAE 1:1) ............................................................................................................... 13.2 m3 (17.3 yd3)
Heaped (SAE 2:1) ............................................................................................................. 16.5 m3 (21.6 yd3)
ELECTRICAL SYSTEM
Voltage.........................................................................................................................................................24 V
Alternator ............................................................................................................................................. 24 V/70A
Starter motor............................................................................................................................................ 4.8 kW
Batteries (n.2) ............................................................................................... 12 V 140 Ah (connected in series)
Characteristics............................................................................................................ 1200A (SAE) 750A (IEC)
Dimensions....................................................................................(18.8 x 30.5 x 19.7) cm (7.37 x 12 x 7.75) in
CHASSIS
The chassis consists of two independent structures articulated in the middle.
The front and rear parts of the chassis are connected with a heavy-duty turntable bearing with heavy duty pin
joint and taper roller bearings that allow the parts to rotate and oscillate.
The chassis is built of boxed sections made of highly - resistant steel (Hardox 400) and plates that weld them
together.

8-11

Copyright
SECTION 8 - SPECIFICATIONS
CAPACITIES
Components

Capacity

Specifications

L (US Gal)

Kg (lb)

(325 model)

22 (5.81)

19.2 (42.33)

ACEA E3 - API GF 4

(330 model)

33 (8.71)

28.9 (63.8)

MIL L2104E lev.

12.9 (3.4)

12.9 (28.4)

2 (0.53)

1.7 (3.75)

ATF DEXRON II

325 (85.86)

ASTM D-975

CASE
Ref.

Engine
SAE 15W40 oil

CASE
No. 1

Engine cooling
Protective anti-freeze (325 model)
mixture/water
(330 model)

ASTM D336

Hood lifting circuit


Hydraulic fluid

Hy-Tran
Ultra

Fuel tank
Diesel
Transmission
ACEA E3
SAE 15W40 oil

26 (6.87)

22.8 (50.27)

MIL L2104E lev.

CASE
No. 1

API GF4
Axles + final reduction gears
Front
SAE 85W140 oil

Intermediate
Rear

20 (5.28)

17.5 (38.58)

21.5 (5.68)

18.8 (41.45)

20 (5.28)

17.5 (38.58)

1.6 (0.42)

1.4 (3.1)

250 (66.04)

218.8 (482.37)

N.L.G.I. 2

MIL L2105D
API GL5

CASE
135 H
EP

Suspension
Hydraulic fluid

ATF DEXRON II

Hy-Tran
Ultra

Hydraulic system
Hydraulic fluid

ISO VG 46
DIN 51524/51525

Air conditionning system


Refrigerant fluid R134a
Greasing
Lubricating grease

8-12

Hy-Tran
Ultra

Copyright

SECTION 9

ALPHABETICAL INDEX
A

Accelerator........................................................ 2-21
Accessing the cab ............................................... 2-1
Accessing the platforms ...................................... 2-1
Accessory drive belt .......................................... 4-22
Accessory drive belts ........................................ 4-25
Accessory functions .......................................... 2-11
Adding air to the tires .......................................... 5-8
Adjusting injector pump clearance..................... 4-30
Adjusting tappet clearance ................................ 4-30
Adjusting the steering wheel position................. 2-11
Air conditioner compressor drive belt........ 4-24, 4-29
Air conditioning system ..................................... 5-10
Air intake system............................................... 4-35
Antifreeze concentration check ......................... 4-42
Articulation safety lock......................................... 4-3
Automatic transmission ................... 2-22, 4-45, 4-48
Axle oil/planetary gear oil level check ................ 4-48
Axle/planetary gear oil change .......................... 4-49

Climate control system controls ......................... 2-25


Climate control system operation....................... 3-29
Closed circuit camera ........................................ 2-20
Condenser cleaning........................................... 5-10
Control unit location............................................. 6-5
Controls/Instruments/Accessories ....................... 2-1
Coolant-transmission oil heat
exchanger tightness ...................................... 4-42
Cooling system.................................................. 4-40
D
Decals ............................................................... 1-17
Dimensions ......................................................... 8-2
Directing the headlights ..................................... 6-11
Dome light/map reading light control.................. 2-19
Door .................................................................... 2-2
Drivers seat (electro-pneumatic) ......................... 2-9
Drivers seat (standard) ....................................... 2-8
Driving the vehicle ............................................. 3-11

B
Battery maintenance ........................................... 6-2
Battery master switch ........................................ 2-26
Before operating the machine ............................. 3-1
Bleeding fuel feed circuit air .............................. 4-32
Bleeding fuel filter sediment .............................. 4-15
Body hoist cab control ....................................... 2-24
Body hoist ground control.................................. 2-24
Bodywork .......................................................... 5-12
Braking circuit...................................................... 5-4
C
Cab air filter cleaning/replacement .................... 5-10
Capacities ......................................................... 8-12
CB transceiver set............................................. 2-20
Changing hydraulic brake oil filter...................... 4-54
Checking accessory belt condition .................... 4-16
Checking brake pad wear.................................... 5-4
Checking emergency pump control efficiency.... 4-56
Checking engine coolant level........................... 4-15
Checking engine oil level................................... 4-14
Checking hydraulic fluid level ............................ 4-16
Checking turbocharger lubrication ..................... 4-36
Checking windshield washer fluid level.............. 4-16
Checks before starting the engine ....................... 3-4
Cleaning bodywork............................................ 5-13
Cleaning the engine breather ............................ 4-21

E
Electrical system.................................................. 6-1
Emergency steering........................................... 3-24
Engine............................................................... 4-17
Engine control unit............................................... 6-5
Engine coolant filter replacement....................... 4-42
Engine oil change .............................................. 4-17
Engine oil filter replacement............................... 4-19
Engine speed regulator control .......................... 2-18
Engine starter switch ......................................... 2-19
Equipment connection diagram ........................... 5-1
Exhaust brake control........................................ 2-18
F
Filling the fuel tank............................................... 3-3
Fitting and hose tightness check........................ 4-55
Fridge ................................................................ 2-25
Front axle/rear tandem axles ............................. 4-48
Front suspension element inflating device ........... 5-1
Front turn indicator/front position light bulb
replacement .................................................. 6-12
Front windshield wiper blade replacement ......... 5-12
Front work light control ...................................... 2-16
Fuel filter replacement ..............................4-31, 4-34
Fuel supply system............................................ 4-31
Fuel tank ..................................................4-33, 4-35
13-1

Copyright
SECTION 9 - ALPHABETICAL INDEX
F

Fuse and relay box .............................................. 6-8


Fuse functions ..................................................... 6-8

Main groups ........................................................ 8-1


Maintenance instructions ................................... 1-14
Maintenance/Adjustments ................................... 5-1

G
Gearbox control unit ............................................ 6-5
Greasing............................................................ 4-57
Greasing the drive shafts................................... 4-59
H
Hand signals...................................................... 1-28
Hazard light control............................................ 2-16
Headlight bulb replacement ............................... 6-11
Headlight control................................................ 2-13
Heated rear view mirror control.......................... 2-14
Hood opening system........................................ 4-57
Horizontal center of gravity .................................. 8-5
Hydraulic oil change .......................................... 4-52
Hydraulic system ............................................... 4-51
Hydraulic system bleed...................................... 4-55
I
Identification of the main components
of the machine................................................. 1-8
Inner hydraulic oil filter (intake) replacement...... 4-54
Instructions for use ............................................ 1-11
Instrument panel and warning lamps ................... 2-6
Interconnection control unit.................................. 6-6
J

O
Opening compartment under engine ................... 4-7
Opening compartment under gearbox ................. 4-7
Opening the fender compartment flap ................. 4-6
Opening the front fenders .................................... 4-5
Opening the hood electrically .............................. 4-6
Opening the hood manually................................. 4-6
Operating instructions.......................................... 3-1
Operating the battery master switch .................... 4-4
Operating the machine ........................................ 3-1
Operations to be carried out every day .............. 4-14
Overturning accidents............................... 1-10, 3-30
P
Parking brake .................................................... 2-17
Parking brake caliper release .......................5-4, 5-5
Performance........................................................ 8-6
Position light and headlight control .................... 2-12
Position of identification data on main
component groups .......................................... 1-5
Precautions ......................................................... 6-1
Precautions during the initial period of use ........ 3-11
Preliminary operations......................................... 4-3
Pressurized oil filter (pump outlet) replacement . 4-53
Prevention of fires.............................................. 1-10

Jump starting....................................................... 6-3


R
L
Lamp test control ............................................... 2-16
Legal documents ................................................. 1-2
Lighting system.................................................. 6-11
List of bulbs ....................................................... 6-14
Location of controls, instruments
and accessories .............................................. 2-4
Longitudinal differential lock control ................... 2-23
Low temperature starting control........................ 2-17
Lubrication and scheduled replacement
chart.....................................................4-10, 4-12
Lubrication and scheduled replacement
chart key ....................................................... 4-11
M
Main air filtering element cleaning/replacement . 4-37
Main group characteristics ................................... 8-8
13-2

Radiator surface cleaning .................................. 4-42


Raised dumper safety lock .................................. 4-4
Rear foglight control .......................................... 2-15
Rear light bulb replacement............................... 6-13
Rear view mirror power control .......................... 2-14
Rear view mirrors .............................................. 2-11
Rear warning light bulb replacement.................. 6-13
Recharging battery with external devices ............ 6-3
Relay functions.................................................. 6-10
Replacing a complete wheel.............................. 3-25
Replacing the map reading light/dome light bulb 6-14
Retarder control................................................. 2-17
Right, left, front and rear of the machine .............. 1-3
Rotating beacon control..................................... 2-15
Run-in period....................................................... 3-2

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SECTION 9 - ALPHABETICAL INDEX
S

Safety rules ......................................................... 1-9


Scheduled maintenance program in hours .......... 4-8
Seat belts .......................................................... 2-10
Secondary air filter element replacement .......... 4-39
Securing points for transportation on trailer ......... 8-5
Service brake .................................................... 2-22
Servicing instructions .......................................... 4-1
Servicing intervals/Lubrication/Fluids................... 4-1
Side turn indicator bulb replacement ................. 6-12
Side window washer control .............................. 2-15
Side window wiper control ................................. 2-14
Side windows .................................................... 2-12
Side windshield wiper blade replacement.......... 5-12
Sound system installation.................................. 2-19
Specifications ...................................................... 8-1
Starting and stopping the engine ......................... 3-4
Starting the engine .............................................. 3-5
Starting the vehicle.............................................. 3-8
Steering ............................................................ 2-21
Stopping and parking the vehicle......................... 3-9
Stopping the engine ............................................ 3-7
Storage ............................................................... 7-1
Storing the vehicle............................................... 7-1
Sunshades ........................................................ 2-12
Suspension ......................................................... 5-1
Suspension element inflation............................... 5-3
Suspension element pressure check................... 5-2
Suspension oil element change........................... 5-1
System charge check ........................................ 5-11

Tipping body with cab control ............................ 3-21


Tipping body with ground control ....................... 3-22
Tire and wheel check........................................... 5-9
Tire inflation......................................................... 5-9
Tire or rim service................................................ 5-8
Tires and wheels ................................................. 5-6
To the owner/Safety ............................................ 1-1
Tools provided and their location ......................... 4-3
Towing the vehicle............................................. 3-23
Trainers seat..................................................... 2-10
Transmission oil change .................................... 4-46
Transmission oil filter replacement..................... 4-46
Troubleshooting................................................. 5-14
Turn indicator and horn control .......................... 2-13
Type, serial number and year of manufacture...... 1-4
U
Use of the engine brake..................................... 3-18
Use of the engine idle regulator ......................... 3-12
Using the automatic transmission ...................... 3-13
Using the differential lock................................... 3-19
Using the hydraulic retarder............................... 3-18
W
Warming the engine ............................................ 3-7
Weights ............................................................... 8-4
Windshield washer fluid reservoir ...................... 5-12
Windshield wiper/washer control ....................... 2-13
Work headlight bulb replacement ...................... 6-13
Working with the vehicle .................................... 3-20

13-3

Copyright
SECTION 9 - ALPHABETICAL INDEX

NOTE: CNH France S.A. Company reserves the right to make changes in the specification and design of the
machine without prior notice and without incurring any obligation to modify units previously sold.
The description of the models shown in this manual has been made in accordance with the technical specifications
known as of the date of design of this document.

13-4

Copyright

CASE TECHNICAL MANUALS


You can obtain manuals on the operation, maintenance and repair of your machine from your CASE Dealer.
To ensure quick and efficient service, consult your CASE Dealer for assistance in ordering the correct manuals for your machine.
Your CASE Dealer can deal with orders for operators manuals, parts catalogues and service manuals.
Always give the type and serial number of your machine so that your CASE Dealer can supply you with the
right manuals for your machine.

Copyright

Printed in France