CL

CLAA AS TTARGO
ARGO K SERIES
The machines covered in this handbook are designed essentially for agricultural use and associated
applications. This is their intended use.

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

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

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

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

 CONTENTS

GENERAL DESCRIPTION
INTRODUCTION
Introduction to the handbook
Running in
Machine identification
Safety section
Safety messages
General hazards

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

SECTION 2
Attachments - fitting and removal .......................................................................................................... 2.1
Hydraulically operated attachments ...................................................................................................... 2.3
Working with front end attachments ...................................................................................................... 2.4
Automatic trailer pick-up hitch (Auto-hitch) ............................................................................................ 2.5
Manual trailer pick-up .......................................................................................................................... 2.7
Extension jibs and crane hooks ............................................................................................................ 2.8
 CONTENTS

SECTION 3
Safety Warnings ................................................................................................................................. 3.1
Access to service checkpoints ............................................................................................................. 3.2
Service schedule ................................................................................................................................. 3.3
Grease points ..................................................................................................................................... 3.6
Wheels and tyres ................................................................................................................................ 3.7
Engine oil level .................................................................................................................................... 3.8
Engine oil and filter .............................................................................................................................. 3.9
Cooling system ................................................................................................................................. 3.10
Fuel system ..................................................................................................................................... 3.14
Air cleaner ........................................................................................................................................ 3.18
Engine ............................................................................................................................................. 3.19
Fan drive system .............................................................................................................................. 3.20
Transmission and Transfer Box .......................................................................................................... 3.21
Axles ............................................................................................................................................... 3.24
Hydraulics ........................................................................................................................................ 3.25
Battery ............................................................................................................................................. 3.28
Auto-hitch ......................................................................................................................................... 3.29
Rockinger hitch ................................................................................................................................. 3.29
Windscreen washer bottle .................................................................................................................. 3.29
Cab and engine compartment ............................................................................................................. 3.30

SECTION 4
Machine specifications ........................................................................................................................ 4.1
Adjustments ....................................................................................................................................... 4.2
Lubricants and fluid specifications ......................................................................................................... 4.2
Capacities - fluid ................................................................................................................................. 4.3
Pressures .......................................................................................................................................... 4.3
Dimensions - machines fitted with standard tyres .................................................................................. 4.4
Fusebox ............................................................................................................................................ 4.5
CONTENTS

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

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

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

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

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

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

Introduction to the Handbook

The contents of the Operators Handbook are intended as a guide to the operation and servicing of the CLAAS
telehandler range. The general method of operation of all these machines is the same. Any individual
differences in the specification or operation are detailed separately.
Note:
The procedures and illustrations contained in this manual refers to all models. Some illustrations may differ
slightly from the actual machine
This handbook is not a training manual. It is designed as a guide to the machine’s controls and working
capacities and general maintenance only. It must not be removed from the machine and should be kept clean
and in good condition. Additional copies of the handbook can be obtained from your CLAAS dealer.

Only trained operators should use this machine. CLAAS strongly recommends that anyone who is
responsible for the operation and servicing of this machine be fully trained in its safe operation.
If you have any doubts about any aspects of the machine’s capability or servicing procedures, you must
consult CLAAS through your local CLAAS dealer.

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

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

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

In general these notes are used to indicate that the procedures being described in the Handbook must be
followed to avoid serious injury or death to yourself or others. The notes are also used to protect the machine
from unsafe servicing practises.
Pay particular attention to the safety notes given at the beginning of each section.

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

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

1. Avoid overloading the engine.

2. Use the lower gears when pulling heavier loads, and avoid using your machine on full load or at high
engine speeds, as this may result in premature wear.
3. Check the instruments frequently, and keep the radiator, the oil and the hydraulic reservoirs filled to their
recommended levels.
4. Avoid prolonged ‘no-load' operation at either high or low engine speeds.
Operating in this way throughout the machines life will prove beneficial to its overall performance and efficiency.
 INTRODUCTION

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

Model - Year

Machine serial number

Key, door - L.H

Key, start

Engine

Transmission unit

Torque converter unit

Front axle

Rear axle
 SAFETY SECTION
SAFETY MESSAGES

General
Specific safety messages, in the form of signs or
labels, are displayed at various locations on the
machine and as close as possible to hazardous
areas. The information displayed on each safety
sign or label is intended to warn of possible hazards
to the machine operator, personnel or equipment.
Any personnel involved in the operation or
maintenace of this machine should be aware of the
location and content of all safety signs and labels.

Safety signs and labels must be kept in a clean and

legible condition. The following also applies:

When cleaning a safety sign or label,

do not use any solvent, fuel or other
harsh chemicals. Use of these will
loosen the adhesives that attach the
signs or labels to the machine.

Replace any safety sign or label that is

damaged or is not legible and cannot be
cleaned.

Install a replacement safety sign or label for

any that are missing.

NOTE Replacement safety sign or label can

be obtained from any CLAAS dealership.

Parts or components, with a safety sign or

label attached, may be replaced. In this case,
a replacement safety sign or label must be
attached to the part or component that has
been installed.
 SAFETY SECTION
SAFETY MESSAGES
CRUSH PREVENTION - GENERAL

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

Hazard
It is hazardous for personnel to stand or work on,
under or close to a suspended load or other
unsupported components.
 SAFETY SECTION
SAFETY MESSAGES
CRUSH PREVENTION WARNING - BOOM

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

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

DO NOT WELD ON THE ROPS/FOPS

STRUCTURE

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

Hazard
Drilling holes or welding in the ROPS/FOPS
structure can weaken the structures.
 SAFETY SECTION
SAFETY MESSAGES
DO NOT SPRAY ETHER INTO THE ENGINE AIR
INTAKE

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

Hazard
Spraying ether into the engine in hazardous to
personnel and can damage the engine.
 SAFETY SECTION
SAFETY MESSAGES
HIGH TEMPERATURES IN THIS AREA

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

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

Note: This illustration is applicable to Machines with

the 99hp engine only. Other Machines may have a
different location for this safety lable.
 SAFETY SECTION
SAFETY MESSAGES
ENGINE MAINTENANCE

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

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

ROTATING PARTS - FAN

Note: This illustration is applicable to Machines with

the 99hp engine only. Other Machines may have a
different location for this safety lable.

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

Hazard
Working in the vicinity of rotating fans is hazardous
and can cause personal injury.
 SAFETY SECTION
SAFETY MESSAGES
ENGINE MAINTENANCE

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

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

ROTATING PARTS - FAN

Location
This safety sign is located on the top of the cowl for
Note: This illustration is applicable to Machines with
the radiator cooling fan.
the 99hp engine only. Other Machines may have a
Hazard different location for this safety lable.

Working in the vicinity of rotating fans is hazardous

and can cause personal injury.
 SAFETY SECTION
SAFETY MESSAGES
ROTATING PARTS - DRIVE BELTS

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

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

WHEEL CHOCKS

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

Hazard
The wheel chock must be used, when necessary, to
prevent the machine moving. Failure to use the
wheel chock can result in personal injury from
crushing.
 SAFETY SECTION
SAFETY MESSAGES
REAR SERVICES - HYDRAULIC PRESSURE

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

Hazard
High pressure hydraulic fluid is used in the services
at the rear service panel. Machine operators must
refer to the Operators Manual, before operating the
rear services.

GENERAL HAZARDS
Introduction
Warnings or Cautions for hazards that may be
present when operating the machine, or during
maintenance of the machine, are detailed at:
Section 1 - Operation of the machine.
Section 2 - Maintenance of the machine.
The following Warnings and Cautions are of a
general nature and are not task specific. All
personnel operating or maintaining this machine
must be fully aware of these warnings.
General
Make sure the location of high voltage
power lines and buried power cables
are known. Serious injury or death, by
electrocution, can occur if the machine
contacts these hazards.
Do not wear loose loose clothing or
jewelry, which can snag on the
controls or machine structure,
causing personal injury.
Make sure that all protective guards
and covers are secured in place on the
machine. If guards and covers are
removed, a hazard to personnel will
exist.
Make sure that all foreign objects and
materials, such as oil, tools, debris and
other items, are kept clear from
equipment, walkways and steps on the
machine. Failure to do this can cause
personal injury.
Make sure that all loose items, such as
tools, lunch boxes and other items,
which are not part of the equipment,
are secured correctly before operating
the machine. Failure to do this can
cause personal injury.
SAFETY SECTION
Do not smoke when you do
maintenance on an air conditioner or
when refrigerant gas may be present.
Inhalation of refrigerant fumes that have
contacted a flame source, or through
smoking, can cause personal injury or
death.
Always wear the correct protective
equipment, including a hard hat and
protective glasses, as required.
Machine operators must be aware of
the correct hand signals and those
personnel authorized to give them.
Operators must accept hand signals
only from a single and authorized
person.
Make sure that all fluids used during
maintenance of the machine are stored
in the correct containers. Never store
these fluids in other types, such as
glass containers.
Make sure that all fluids are disposed
off correctly and in accordance with
local Health and Safety Regulations.
Make sure that all cleaning fluids are
used with care and that any necessary
repairs are reported immediately.
Unauthorized personnel must not be
permitted to operate or maintain this
machine.
Make sure the the size of the machine,
including any load, is known. This will
ensure a correct and safe clearence is
maintained, when operating the
machine in confined spaces or near
obstacles.
 SAFETY SECTION
GENERAL HAZARDS

Pressurized air and water
If released, air or water in pressurized
machine systems can cause debris or
hot water to be ejected. This can cause
personal injury. Care must be taken
when working on pressurized machine
systems.
Leaking fluid, even from a pin hole
leak, can pentrate the skin, causing
serious injury or death. Always use
cardboard or a board to check fluid
leaks. If fluid penetration of the skin
occurs, you must seek medical help
immediately, preferably from
experienced medical staff.

Operators using pressurized air or

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

Operators using pressurized air or

water for cleaning purposes must not
exceed the following maximum
operating pressures:
Air - 205 kPa (30 psi)
Water - 275 kPa (40 psi).
Fluid spillage

Residual hydraulic pressure

Care must be taken to avoid fluid
spillage during machine maintenance,
Refer to the Service Manual before testing, adjusting and repair. Before
releasing hydraulic pressure. Non- any possible fluid spillage can occur, a
operating hydraulic systems can retain suitable container must be positioned
residual hydraulic pressure. If released, to collect the fluid.
this residual pressure can cause:
Sudden movement of the machine or
machine attachments. Batteries
Disconnected hoses to whip.
Hydraulic fluid to be sprayed, causing The electrolyte in the battery is an acid,
a personal hazard through direct which if contacted, can cause personal
contact or ingestion. injury. Do not permit eloctrolyte to
come into contact with the skin or eyes.
Always wear protective glasses and, if
Fluid penetration possible gloves, when working with
batteries. Wash the hands after contact
with batteries and battery connectors.
Residual hydraulic pressure must be
released before any hydraulic
maintenance, disconnection or
component removal is done. Refer to
the Service Manual before releasing
hydraulic pressure. Non-operating
hydraulic systems can retain residual
hydraulic pressure. If not released
correctly, personal injury can occur.

GENERAL HAZARDS
Disposal of waste material
The disposal of waste materials,
including potentially harmful fluids, must
be in accordance with local Health and
Safety Regulations. Improper disposal
procedures can be harmful to personnel
and the environment.
Always use the correct and leakproof
types of container for the storage of
waste fluids. Do not dispose of these
fluids by pouring onto the ground, into
water sources or into drains. Improper
disposal procedures can be harmful to
personnel and the environment.
Asbestos hazards
Contact with asbestos must be avoided,
particularly inhalation of airborne dust,
which can cause serious injury or death.
Avoid creating dust if handling debris
or components that may contain
asbestos, such as brake pads and
bands, liner material, clutch plates
and some gaskets.
Never use compressed air for cleaning
purposes.
SAFETY SECTION
Avoid machining or brushing materials
that may contain asbestos.
Before disposal, use a wet, damping
down method to concentrate material
dust and debris.
If possible, a vacuum cleaner fitted
with a high particle air filter (HEPA),
should be used to collect debris and
dust.
Use exhaust ventilation on permanent
machining work.
Wear an approved respirator if there
is no other way to control any dust
produced.
Always comply with the applicable
environmental regulations for the
disposal of asbestos.
Stay away from areas that may contain
airborne asbestos particles.
Always comply with the applicable
rules and regulations for the work
place. In the United States, use the
Occupational Safety and Health
Administration (OSHA) requirements
(refer to 29 CFR 1910.1001).
It is recommended that you only use
genuine CLAAS equipment,
components and parts, which are
supplied asbestos free.
 SAFETY SECTION
GENERAL HAZARDS

Crushing or cutting prevention Burn prevention

Support equipment correctly before you
do any work or maintenance from
beneath that equipment.
Support the cab correctly before you
do any work or maintenance from
beneath the cab.
Unless instructed otherwise, never
attempt to do adjustments whilst the
machine is moving or the engine is
running.
The engine and it’s associated
components will get hot during
operation, causing a potential burn
hazard to personnel. Before you do
any maintenance on the engine, you
must:
Avoid touching any part of an
operating engine.
Always allow the engine to fully cool
before you do any maintenance work.

Never attempt to start the engine by

‘jumping’ across the terminals of the
starter solenoid. Doing this can result
in unexpected machine movement.
Clearances in machine control linkages
will change with control operation or
machine movement. Always keep clear
of controls or areas that may experience
clearance changes.
Always release residual pressure in
the air, hydraulic, lubrication and fuel
systems and associated pipe lines/
hoses, before you do any
maintenance work.
Hot fluids and surfaces can cause
personal injury. Avoid direct contact
with hot fluid or surfaces.

Always keep clear of rotating or moving

parts of the machine.
Always re-install any guard or cover
that has temporarily removed.
Always stop the engine and allow the
filler cap for the hydraulic tank to cool
fully, before you attempt to remove it
(refer to this Manual for the correct
procedure).

Always keep objects clear of moving Fire extinguisher

fan blades, which can throw or cut
objects.

Make sure the machine fire extinguisher

When handling cables, always wear
is available and in a fully charged and
protective gloves. Never use kinked or
serviceable condition.
frayed cables.

Striking any object can cause debris Make sure you are fully aware of the
chips to fly off, causing personal injury. operating instructions for the fire
Always wear protective glasses/ extinguisher.
goggles before striking an object and
make sure that the area is clear of other
Inspect and service the fire extinguisher
personnel.
at regular interrvals or in accordance
with the manufacturers instructions.
If a retaining pin is struck with force, it
may be ejected and cause personal
injury. Always wear protective glasses/
goggles before striking a retaininmg
pin and make sure that the area is clear
of other personnel.

GENERAL HAZARDS
Coolant hazards
The engine cooling system will become
hot and pressurized during normal
engine operation, causing a potential
burn or scald hazard to personnel.
Always allow the engine and cooling
system to fully cool before you do any
maintenance work, including draining
the system.
Always stop the engine before you
check the level of the coolant.
The cooling system conditioner
contains alkali, which can cause
personal injury. Do not allow alkali to
contact the skin, eyes or mouth.
Always stop the engine and allow the
coolant filler cap to cool fully, before
you attempt to remove it. This must be
done slowly, to release the residual
pressure safely.
Fire and Explosion prevention
All fuels, most lubricants and some
coolant mixtures are flammable and if
leaking onto a hot surface or electrical
components, can create a fire. Fire can
cause severe personal injury or death.
Do not operate the machine close to
a naked flame or heat source.
SAFETY SECTION
Remove all flammable materials such
as fuel, oil and debris from the machine.
Do not allow the accumulation of
flammable materials on or around the
machine.
Always store fuels and lubricants in the
correct and properly marked containers
and away from unauthorized personnel.
Always store soiled oily rags and other
flammable materials in protective
containers.
Do not smoke in ares that are used for
the storage of flammable materials.
Do not operate the machine close to
naked flames.
Make sure that heat shields, installed
to prevent fluids or fluid spray from
igniting, are fitted correctly.
Do not weld or flame cut any pipes or
tanks that contain flammable fluids or
gases. Always clean such pipes and
tanks thoroughly with a non-flammable
solvent first.
Examine all electrical wires daily and
check and tighten all electrical
connections. If necessary, repair loose
or frayed wires before you operate the
machine.
Dust produced from repairs to non-
metallic components, such as hoods or
fenders, can be flammable. Always
repair such components in a well
ventilated area, away from naked flame
and heat sources.
Leaking pipes and hoses can cause a
fire. Examine all pipes, hoses and
associated supports for wear,
deteriation and damage and ensure
that pipe and hose clamps are secure.
Make sure pipe and hose connections
are correctly torqued.
 SAFETY SECTION
GENERAL HAZARDS
Fire and Explosion prevention (continued)
Use caution when refuelling a machine.
When refuelling, never smoke, refuel
close to naked flames or heat sources
or refuel with the engine running.
Always refuel in outdoors.
Gases from the battery can explode.
Always keep the battery away from
naked flames and heat sources and
never smoke in a battery charging area.
Never check the charged state of a
battery by placing a metal object across
the battery terminals. Always use a
voltmeter or hydrometer.
Never attempt to charge a frozen
battery. Doing this may cause an
explosion.
Ether hazards
Ether is a flammable and toxic
substance. Use in a well ventilated
area and do not smoke when replacing
an ether cylider or when using an ether
spray.
When storing ether cylinders, you must
make sure that they are not stored:
In living areas or in the operators cab
of the machine.
In direct sunlight or in temperatures
above 49 deg C (120 deg F).
Close to naked flame or heat sources.
Used ether cylinders must be disposed
of correctly and kept away from
unauthorized personnel. Never
puncture an ether cylider.
Do not spray ether into an engine if the
machine is fitted with a thermal starting
aid for cold weather starting.
Pipes, tubes and hoses
Leaks from loose or damaged pipes,
tubes or hoses can cause a system
failure or a fire. Examine pipes, tubes
and hoses regularly, particularly for
signs of damage, leaks or being loose.
Never use bare hands to check for
leaks from pipes, tubes or hoses.
Always use cardboard or a board and if
necessary, torque connections to the
recommended value.
Do not bend or strike high pressure
pipes or install a bent or damaged high
pressure pipe.

GENERAL HAZARDS
Pipes, tubes and hoses (continued)
You must replace any pipe, tube or
hose if:
End fittings are damaged or leaking.
Outer coverings are chafed or cut.
Wires are exposed.
Outer covering is blistered or
ballooning.
Flexible portion of a hose is kinked.
Outer covers have embedded
armoring.
End fittings are damaged displaced.
Clamps, guards and heat shields are
installed to prevent vibration, contact
between components and excessive
heat. Make sure that all clamps, guards
and heat shields are installed correctly.
Tyre hazards
An air inflated tyre can expand and
explode if excessive heat is applied
through welding, heating rim
components, external fire or excessive
use of the brakes. An exploding tyre
can eject axle and wheel debris 500 m
(1500 ft) or more from the vehicle,
causing damage and possibly personal
injury or death. All personnel must be
aware of the hazards of overheating
tyres.
An over-inflated tyre can blow out or
cause a rim failure. This can cause
damage or personal injury. Inflation of
tyres must only be done by trained
personnel.
When you inflate a tyre, you must stand
behind the tyre tread and use a self-
attaching chuck.
SAFETY SECTION
Do not approach a warm or hot tyre.
Keep the minimum distances away from
the tyre and stay outside the shaded
areas (refer to illustration below).
Maintenance on tyres and rims can be
hazardous. The use of incorrect
procedures can result in a tyre
exploding. An exploding tyre can eject
axle and wheel debris 500 m (1500 ft)
or more from the vehicle, causing
damage and possibly personal injury
or death. Maintenance on tyres and
rims must be done only by trained
personnel, using the correct tools and
procedures. The tyre dealer or
manufacturers instructions must be
followed.
Electrical storm hazards
If lightning is is the vicinity, personnel
must keep away from the machine and
not mount or dismount the machine.
Machine operators already in the cab
must remain there until the lightning
threat is gone.
Alternate exit.
Machines that have cabs may also be
equiped with an alternative exit. For
more information on alternative exits,
refer to the Operation and Maintenance
Manuals.
 SAFETY SECTION
GENERAL HAZARDS

Mounting and dismounting the machine
You must never attempt to mount,
dismount or jump from a machine that
is moving.
The machine operator must be fully
aware of the machines capabilities and
limitations. The operator must also be
familiar with the local working area or
site and in particular:

Check the area for vertical and

You must never use machine controls
as hand holds when you enter or exit
the operators cab.
Always mount or dismount the machine
at the recognised locations, which have
steps and/or hand holds. Make sure
the steps and/or hand holds are clean
and examined regularly. Make any
necessary repairs.
horizontal clearances.
Check for overhead obstructions.
Check for electrical power lines and
make sure the machine keeps at least
8 m (25 ft) away.
Check for steam or compressed air
lines.
Check the work area or site for
changes in the stability of the ground
surface, backfilled trenches and
structural integrity of buildings, roofs
and tunnels.
Check sewers and service ducts.

Make sure that the load charts and

instructions plates in the cab are in a
good condition and can be easily read.
Machine operators must be fully aware
of how to use the load charts before
operating the machine.

When you mount or dismount the

machine, always keep a three-point
contact with the steps and hand holds.
Three-point contact can be two feet/
one hand or two hands/one foot.

When you mount or dismount the

machine, always face the machine and
never attempt to carry tools or supplies.
Tools and supplies should be raised or
lowered from the machine using a hand
line.

Before starting the engine

If the machine has a cab, make sure
the door is secured shut and the
windows are secured in the open or
This machine must be operated only
closed position. Make sure all windows
by correctly trained and authorised
are kept clean for maximum visibility.
personnel. Certain local operating
conditions may require the machine
operator to obtain a operators licence
or a certificate.
 SAFETY SECTION
GENERAL HAZARDS

Before starting the engine (continued)

Always examine the seat belt and belt

mounting before use. Replace any
parts that are worn or damaged and
always replace the seat belt after three
years, regardless of condition. Never
use a seat belt extension on a
retractable seat belt.

Make sure that all protective guards

and covers are correctly installed on
the vehicle.

The seat belt must be adjusted such

that full pedal travel can be achieved
with the machine operators back
against the back of the seat.

Make sure that the machine is equiped

with a fully working lighting system that
is adequate for the working conditions.

Always fasten the seat belt before

operating the machine.

Make sure that the machine reverse

alarm, horn and other warning devices
are in full working order.

Make sure that all obstacles are cleared

from the intended path or route of the
machine.

Make sure that before the machine is

started or moved, there are no
personnel on, under or near the
machine.
THIS PAGE INTENTIONALLY BLANK
 OPERATION
BEFORE DRIVING THE MACHINE - SAFETY WARNINGS
General Safety
ALWAYS be aware of local and
national regulations governing the
use of this machine.
ALWAYS wear correctly fitting
protective clothing. Loose or baggy
clothing can be extremely dangerous
when operating or servicing a
machine.
Do not use the machine when there
is lightning in your area.
NEVER bring the boom or load within
6 metres (20 feet) of overhead power
cables.
Only skilled personnel are permitted
to work with this machine.
Running-in procedure
For the first 50 operating hours,
always ensure appropriate gear
selection and do not run your new
machine on full load or at high
speeds, as this may result in
premature wear.
Pre-start safety checks
The following checks must be carried out prior to
commencing work. Particular attention must be
given if the machine has been left idle for any period
of time. All of these checks concern the continued
operation of the machine and some concern your
safety. Any defects should be inspected and
corrected by your distributor or service engineer.
NEVER commence work with the
machine until a "Daily or 10 hour
service" has been carried out. (See
Service Section).
NEVER walk or work under a raised
boom without installing the BOOM
SAFETY STOP!
1.1
Lower the boom before doing these
checks or have an experienced
operator do it for you.
Check that all noise reduction material (where fitted)
within the engine compartments is secure.
Check areas around pivot points, rams and linkages
are free from mud, ice or debris.
Check all windows, lights and mirrors are clean.
Check all grab handles, steps and platforms are
clean and dry.
Check all decals can be clearly read.
Check fuel gauge on instrument panel, to ensure
there is adequate fuel in the tank.
Check that the Brake/Dump switch (see Side
console switches) is in the OFF position.
Check tyres for correct inflation and wear (see
section 4) and ensure there are no cuts or
penetration by sharp objects.
Using a machine with incorrectly
inflated, damaged or excessively
worn tyres could cause death or
injury to you or others.
Check machine for any obvious damage.
Check all controls function correctly, are clean and
not slippery.
Your machine may be fitted with a
fire extinguisher. Do not remove it
from the operators cab until it is
required. Ensure it is checked
regularly.
Machine fires must not be put out
using water, always use foam, dry
chemical or carbon dioxide
extinguishers.
Entering the cab
Always enter and leave the cab
facing the machine. Shoes and
hands should be dry and free of dirt.
Do not use the machine controls as
handholds when entering or leaving
the machine.
 1.2 OPERATION
ENTERING THE CAB
The door consists of independently hinged upper
and lower sections, which allow the operator to
drive with the lower section closed, whilst the upper
section can either be fully opened and locked
against the cab frame, or secured in ajar position.

To enter, unlock and press the lock barrel.

To open the door from inside the cab: Depress

handle (A)

Do not drive the machine with lower

door open.

The upper door section can only be opened from

the inside by depressing handle (B).

It may be swung fully open and secured against the

cab exterior by catch (C) or secured in ajar position
by swinging lever (E) and locating it in lower door
section at (F).

To release when secured fully open, swing lever at

(C) as shown, or from inside, move lever (D)
sideways

To release from ajar position depress lever (B).

Do not drive with the upper door

section unsecured.
 OPERATION 1.3
EMERGENCY EXIT

Emergency exit hammer

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

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

Using the fire extinguisher

1 Remove extinguisher from stowage bracket
(A).
2 Hold extinguisher upright, pull out safety pin
(B).
3 Aim nozzle at base of fire.
4 Squeeze handles (C) to operate the
extinguisher, release handles to stop flow.
After use, the extinguisher should be
replaced or serviced.
1.4 CONTROLS
ADJUSTING THE SEAT

Seat(s)
Vehicles are provided with either 'Standard
suspension' or 'Air suspension' extra comfort seats.
Ample adjustment is possible to give a comfortable
ride whilst operating most controls.
Do not adjust the seat when the
vehicle is in action.

1 Fore and aft position

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

2 Standard suspension and height adjustment

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

3 Air suspension and height adjustment

Operator must be seated for adjustment. Use lever
(J) to adjust, pull to raise, press down to lower.
Check ride indicator (G ) shows green, if red
readjust height. Within the band of the ride indicator
there is 75mm of height adjustment for any driver.

4 Arm rest
To adjust height of arm rest (C), rotate roller (D).
Arm can also be pivoted from horizontal to vertical
position.

5 Back rest adjustment

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

6 Upstop control Seat belt

Both seat types are provided with a variable upstop
Your machine is fitted with a seat
control (F) to limit upward travel of the suspension.
belt, the belt must be worn whenever
Adjust as indicated on control.
the machine is being operated.

7 Lumber support control Ensure that the seat belt is always clean, and not
Adjust to suit (H), from five selectable positions. frayed or damaged.
 OPERATION 1.5
ADJUSTING THE STEERING COLUMN AND JOYSTICK MOUNTING
Steering column adjustment
A To adjust the angle of the steering column:
Pull lever upwards and position steering column to
the required angle, release lever.
B To adjust the height of steering column:
Push lever downwards and pull/push steering wheel
into required position, release lever.

Joystick mounting adjustment

Mounting is adjustable both for height and lateral
movement. Locate the two 8mm Nyloc nuts
mounted on far side of the joystick pod and using a
13mm spanner, slacken nuts, adjust position and
re-tighten.
1.6 CONTROLS
CAB LAYOUT AND CONTROLS
 CONTROLS 1.7
CAB LAYOUT AND CONTROLS

1 Steering wheel 11 Parking brake switch

The vehicle is equipped with SAHR parking and
Turn the steering wheel in the direction that you
emergency braking system on the front axle, i.e.
wish to travel.
Spring apply - Hydraulic Release. The parking
2 Selected gear display panel brake is applied by means of a rocker switch with
integral 'lock-on feature'.
(See Engaging gear)
To apply the parking brake, ensure the vehicle is
Powershift transmissions with A.P.C. control only - stopped, then rock the switch to the ON position.
Displays selected gear. The machine is then held in neutral and the parking
brake engaged indicator illuminates (see
3 Instrument Panel instruments).
(See Instruments and Warning Lights) In the event of engine and or electrical/hydraulic
power failure the front axle brakes are automatically
4 Instrument Panel Switches applied.
(See Facia Mounted Switches) (See Facia Mounted switches)
5 Overload Indicator The parking brake must not be used
to slow a moving machine, except in
(See Working the Telehandler)
an emergency.
6 Forward/reverse control, gear 12 Solo control joystick
selection and kickdown
(See Auxiliary controls)
(See Engaging gear)
13 Standard Auxiliary Service
7 Start Key
(See Auxiliary controls)
(See Starting the engine)
14 Front mounted Auxiliary Service
8 Multi-switch
(See Auxiliary controls)
(See Steering Column)
15 Joystick isolator rotary switch
9 Accelerator pedal
(See Auxiliary controls)
The accelerator pedal controls the engine speed,
push the pedal down to increase the engine speed. 16 Steering mode switch
(See Steering mode switch)
10 Brake pedal
The brake pedal operates the power assisted 17 Wheel Alignment lights
brakes, push the pedal down to slow or stop the
(See Steering mode switch)
machine. Applying the brakes will automatically
switch on the 'Stop Lights'. 18 Side console switches
Using a machine without both stop (See Side console controls)
lights functioning correctly is often an
offence and is dangerous. 19 Heat and Air condition controls
(See Side console controls)
When the Brake/Dump switch (see Side
console switches) is turned on, drive to 20 Fuse and Relays board
the transmission is disengaged when Located below the Facia mounted switches on the
the brake pedal is operated. left hand side.
For fuse and relay positions see Technical
The brake dump switch must only be specifications section.
used when power boom operations
are performed.` 21 Radio position (Customer supply)
Not to be used for accurate loading
or when manoeuvring. 22 Fan Reverser switch
NEVER drive the machine on or off (Where fitted)
highways with this function engaged.
 1.8 CONTROLS
CAB LAYOUT AND CONTROLS (continued)

Interior light
The interior light is fitted with an ON/OFF switch (A).
To replace the bulb (B) remove lens (C), by easing
the lens lugs (D) from the holder (E). Replace the
bulb then refit the lens.

Windscreen Heater vents

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

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

Tool Location
Suitable tools for wheel nut maintenance are located
to the left of the operators seat.
Tools consist of a:-
Tommy Bar
Extension
Socket
 CONTROLS 1.9
INSTRUMENTS AND WARNING LIGHTS

Instruments Warning lights

The machine instruments and indicator lights are
located to the right of the steering column on the
instrument panel.
1 Gauge: tachometer
The tachometer indicates the engine speed in
revolutions per minute.
2 Hour meter
Hour meter records the total number of hours the
engine has been run.
These hours give an indication to servicing periods.
5 Direction indicator
Warning light flashes when left indicator is
operated.
6 Engine oil pressure
Lights when engine oil pressure drops below normal
working pressure.
Light may illuminate briefly when engine is started,
but should cancel once engine is running.
The machine should NOT be
operated with this light illuminated.

3 Gauge: fuel
Indicates the amount of diesel fuel in the tank.
NEVER allow fuel gauge to read
"Zero" before refilling, otherwise fuel
system will require bleeding. (See
Service-Fuel)
7 Not used
8 Air cleaner filter blockage
Indicates restriction of air passing to the engine.
The machine must NOT be operated
with this light illuminated.

4 Gauge: engine coolant temperature

This indicates the temperature of the engine 9 Parking brake
coolant. The reading may vary slightly according to Warning light illuminates when parking brake is ON.
the weather.
Do not attempt to drive machine with
This machine must NOT be operated Parking Brake ON.
if, after a suitable running period the
gauge reading is abnormally high.
 1.10 CONTROLS
INSTRUMENTS AND WARNING LIGHTS (continued)

Warning lights (continued) The machine must NOT be operated

with this light illuminated.
10 Transmission oil pressure
Indicates transmission oil pressure has fallen below 14 Brake system pressure
normal working pressure. Indicates low oil pressure within power brake system.
Light may illuminate briefly when engine is started and
The machine must NOT be operated
should cancel once engine is running.
with this light illuminated.
The machine should NOT be operated
with this light illuminated.
15 Headlight main beam
Warning light illuminates when the headlight main
11 Transmission oil temperature beams are switched on.
Indicates excessive heat in transmission.
16 Direction indicator
The machine should NOT be operated
with this light illuminated. Warning light flashes when right indicator is operated.

17 Trailer turn indicator

12 Battery charge indicator
18 Road light indicator
Light should go out a few seconds after engine has
started. If not, a fault is present in the alternator Illuminates when road lights are switched on.
charging system.
19 Front work lights (Where fitted)
The machine must NOT be operated
Illuminates when front work lights are switched on.
with this light illuminated.
20 Rear work lights (Where fitted)
13 Hydraulic filter blockage Illuminates when rear work lights are switched on.
Illuminates to indicate hydraulic pressure filler element
21 Hydraulic oil temperature (Where fitted)
blockage due to contamination.
NOTE When starting under cold conditions i.e. below Indicates excessive heat in hydraulic oil.
0°C light may illuminate, allow machine to warm-up for The machine must NOT be operated
a few minutes under 'light-load' conditions with this light illuminated.
 CONTROLS 1.11
FACIA MOUNTED SWITCHES

1 Switch: Head and side lights 7 Switch: Boom/Side working lights

(where fitted)
Rocker switch. Main and dip beam are controlled by
the steering column multi-switch. Rocker switch. Press to switch on boom mounted
working lights.
NOTE Head lights only illuminate when ignition is
switched on.
8 Warning light: Steering system (where
fitted)
2 Switch: Rotating beacon
Indicates low power assisted steering system pressure.
Rocker switch. Press to switch on rotating beacon. Stop and rectify fault.
NOTE Light will illuminate during engine start
3 Switch: Rear foglight procedures.
Rocker switch. Press to switch on the rear foglight.
The foglight will only work once the headlights have 9 Parking brake switch
been switched on. Rocker switch (lockable)
(See Cab layout and controls.)
4 Switch: Hazard warning lights
Rocker switch. When turned ON operates the Hazard 10 Warning light: Brake function
warning lights (including instrument panel light).
Indicates low brake system pressure. Stop and rectify
fault.
5 Switch: Front working lights (where
fitted) 11 Switch: Ignition
Rocker switch. Press to switch on the front working (See page 1.17)
lights. The working lights will only work once the
sidelights have been switched on.

6 Switch: Rear working lights (where

fitted)
Rocker switch. Press to switch on the rear working
lights. The working lights will only work once the
sidelights have been switched on.
 1.12 CONTROLS
STEERING COLUMN SWITCHES

The steering column is fitted with two 'stalk'

switches. The left hand stalk controls transmission
functions (see Engaging Gear), whilst the right hand
stalk controls lights, wipers etc. as follows-

A Headlight flash
Pull stalk upwards (towards steering wheel) to flash
headlights.

B Headlight main beam ON

Ensure head and sidelights switch is ON, push stalk Powershift transmission - multi-switch
down for main beam ON. Centre detent is dipped
beam.

C and D Direction indicators.

Ensure start key switch is ON, pull stalk towards you
to indicate RIGHT turn, push away from you to
indicate turn LEFT.

E Windscreen wiper/washer
Ensure start key switch is set to ( I ).

Twist the right hand stalk grip to select the required

wiper/washer function.
II Not used
I Windscreen wiper ON
0 Windscreen wiper OFF
Wash/Wipe

F Horn
Ensure start key switch is set to ( I ), push button to
sound horn.
 OPERATION 1.13
SIDE CONSOLE CONTROLS

1 Joystick boom controls isolation switch

(See Auxiliary controls)

2 Steering mode switch

(See Steering modes)

3 Steering mode alignment indicator lights

(See Steering modes)

4 Brake/dump selector switch

Rocker switch. When pressed to switch on (light
illuminates) selects neutral in the transmission when
the service brakes are applied.
The brake dump function must be
selected in all heavy-duty applications,
such as digging, re-handling, and muck
shifting.
Do not use for accurate loading or
when manoeuvring the machine.
Do not use on the highway or when
trailer towing.

5 Rear hydraulic service switch

(See Auxiliary controls)

6 Rear wash/wiper switch

Rocker switch. Press to switch on.

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

7 Air conditioning on/off switch

8 Ventilation fan switch - 3 speed

Switch controls the three speed fan.
Works once the start key is turned to the (1) position.
(See Starting and Stopping the Engine).
10 Fan reverser switch (Where fitted)
NOTE Fan must be running when either heater control
(See Page1.25)
or air conditioning switches are ‘On’.

9 Heater temperature control

Turn knob clockwise to turn heater ON.
Turn knob anticlockwise to turn heater OFF.
NOTE Turn heater OFF before switching air
conditioner to ON position.
 1.14 OPERATION
BOOM AND CARRIAGE CONTROLS
Boom control
NEVER operate controls while
outside the cab.

NEVER bring the boom or load within

6 metres (20 feet) of overhead power
cables.

Always consult the lifting envelope

and/or boom indicators before and
during boom manipulations.

The machine uses a dual axis joystick to control lift/

lower, crowd/dump and extend/retract functions.

Boom lift/lower
A Forward to lower boom
B Backwards to raise boom

Carriage crowd/dump
C Left to crowd back
D Right to crowd forward
By moving the control diagonally, any combination
of the above boom and carriage operations can be
achieved simultaneously.

Boom extend/retract
Using the roller switch mounted in the joystick.
E1 Upwards to extend boom
F1 Downwards to retract boom
Gradual action of the roller switch gives variable
control of the extend/retract speed, the further the
roller is moved the faster the speed.
 OPERATION 1.15
AUXILIARY CONTROLS

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

Joystick buttons
(A1, A2) Standard auxiliary service control
buttons coloured yellow.
(A3, A4) Front mounted optional auxiliary
service control buttons - coloured black.

Rear mounted optional auxiliary

service
Selected by rocker switch (5).
(See Hydraulically operated attachments)

To operate or fit an attachment, see

'Attachments and Optional equipment'.

Joystick/Boom controls isolator

rotary switch (1)
By turning switch from 'off', position 'A', to:-

Carriage pins lockout

This facility is provided to lockout the carriage
hydraulic actuated locking pins, therefore
preventing accidental release of an
attachment.
To lock carriage pins turn rotary switch to
position 'B'.

PUBLIC ROAD USE

It is a legal requirement in certain countries to
lockout all boom and auxiliary hydraulic
functions when travelling on public roads.
To disable joystick/boom auxiliary controls,
first centralise front and rear wheels, then turn
rotary switch to position 'C'. This operation
selects front wheel steer, and disables
joystick, boom, carriage and button functions.

Carriage crowd lockout

This facility is provided to lockout the carriage
tilt function, therefore preventing accidental
operation.
To lockout Carriage crowd function, turn rotary
switch to position 'D'.
 1.16 OPERATION
STEERING MODES
The machine can be driven in any of three different
steering modes. The modes are selected using the
steering mode switch (2).
The machine must always be
stationary before changing steering
modes.

The three modes give the following steering

characteristics:
A Two wheel steer
The front wheels steer with the rear wheels locked in
the 'straight' position.
This mode MUST be used on public roads.
B Four wheel steer
Both pairs of wheels steer so that the front and rear
wheels run on the same turning circle radius.
This mode MUST NOT be used on public roads.
C 'Crab' steer
Both pairs of wheels steer in the same direction so
that the machine 'crabs' either to the left or right.
This mode MUST NOT be used on public roads.

Changing steering modes

The machine must always be
stationary before changing steering
modes.

Before using any of the steering modes, always

check alignment of the wheels as follows.
To align wheels
Select steering mode B or C and turn the steering
wheel until the REAR wheels indicator is illuminated.
The rear wheels are now in the straight ahead
position.
Select steering mode A and turn the steering wheel
until the FRONT and REAR wheels indicators are
illuminated.
All four wheels are now in correct alignment, allowing
any of the three steering modes to be selected using
selector switch (2).
Operation with wheels out of align
Under certain circumstances the operator may
choose to use the machine with the rear wheels out
of alignment.
Such a circumstance could be when operating the
machine on a Silage Clamp with the rear wheels
locked at an angle and using TWO WHEEL STEER
mode (A), retaining the ability to turn the machine
(D).
Never operate the machine on the
highway with the rear wheels out of
alignment.
 OPERATION 1.17
STARTING AND STOPPING THE ENGINE
NEVER operate controls while
outside the cab.

Ensure parking brake switch (11) is in the on

position, see cab controls
Forward/neutral/reverse lever (6) must be in
neutral before engine will start.

To start a warm engine

Depress accelerator (9) approximately quarter-
way of its travel.
Turn start key to (I). Warning lights on instrument
console will light:
Engine oil pressure
Transmissions pressure
Battery charging
Brake function.
Turn start key to (III). Release key immediately
when engine starts. Check warning lights have
gone out.

To start a cold engine

Turn start key to (I).
Fully depress accelerator (9).
Turn start key to thermostart (II) position and hold
for 15 seconds.
Turn start key to (III) position to engage starter,
hold for a maximum of 15 seconds. Release key
immediately when engine starts. Check warning
lights have gone out.
If the engine fails to start, turn the key to the (II)
position and hold it there for 10 seconds. Then
engage the starter motor again.
Release accelerator to a fast idle position for at
least 30 seconds to ensure adequate lubrication
of turbocharger.
If any warning light fails to cancel,
stop engine and detect fault before
continuing.

NOTE When starting under cold conditions i.e.

below 0°C the hydraulic pressure filter element
blockage warning light (13) may illuminate. Allow
the machine to warm-up for a few minutes under
light-load conditions.
 1.18 OPERATION
STARTING AND STOPPING THE ENGINE (continued)
DO NOT PROCEED IF A FAULT IS EVIDENT.
If engine fails to start, allow a few minutes for
the battery to recover, then repeat start key
switch procedure.
Always remain in driving seat
whenever engine is running.

Check engine coolant temperature: engine

coolant temperature gauge should show a low
reading when engine is first started.
Abnormally high readings, or failure
to obtain a reading after a suitable
period of engine running, denotes a
fault and requires immediate
attention.

Check fuel gauge: Always ensure an adequate

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

Stopping the engine

Allow the engine to run at approximately 1,000
rpm for 2 to 3 minutes before turning the start key
to the (O) position.
 OPERATION 1.19
ENGAGING GEAR. APC POWERSHIFT

Powershift transmission with Automatic

Powershift Controller (APC)
The FNR (Forward/Neutral/Reverse) gear lever
controls the direction of travel and gear selection.
The transmission has 6 forward gears and 3
reverse gears. The actual gear engaged is
shown by the LED display in front of the steering
column, this does not naturally agree with the
gear selected on the FNR lever (see table).

To select forward travel:

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

To change from one gear to another:

Twist lever (A) to the gear required. The APC
(Automatic Powershift Controller) will then
manage the transmission to ensure that the gear
selected is reached without risk of damage to the
transmission.
The transmission will select gears 1 - 4 on
command from the FNR lever providing the
correct speed parameters are being met.

5th and 6th gears:

When in 5th gear the transmission will
automatically change between 5th and 4th gear
as determined by the APC.
When in 6th gear the transmission will
automatically change between 6th, 5th and 4th
gear as determined by the APC.

Reverse Gears (Refer to table)

For a 6/3 transmission the reverse gears shown
in the display will be R1, R3 and R5, these
correspond to the relevant forward gears. It is
not possible to select R2 or R4.

To change direction of travel:

a Reduce engine speed.
b Brake to a stop.
c Lift and move lever backwards from forward
to reverse.
d Release foot brake.
e Accelerate engine.
1.20 OPERATION
ENGAGING GEAR. APC POWERSHIFT (continued)

KICKDOWN AND GEAR SELECTION TABLE

FNR SHIFT GEAR GEAR GEAR SELECTED

LEVER SELECTED SELECTED AFTER DIRECTION
POSITION AFTER CHANGE
KICKDOWN
F1 F1 - R1
F2 F2 F1 R3
F3 F3 F2 R3
F4 F4 F3 R3
*F5 F4 F3 *R5
F5 F4 *R5
*F6(A) F4 F3 *R5
*F5 F4 *R5
*F6 *F5 *R5
R1 R1 - F2 (Note 1)
R2 R3 R1 F3
R3 R3 R1 F3 (Note 2)
R4 R3 R1 F3 (Note 2)
*R5 *R5 (Note 2)
R3 F3

*R6 (A) *R5 R3 F3

Note 1. Followed by time delayed downshift to F2.

Note 2. Followed by time delayed upshift to F4.

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

 OPERATION 1.21
ENGAGING GEAR. APC POWERSHIFT (continued)
Mode Button
The mode button (A) adjacent to the LED display
(B) allows various screens to be selected by the
operator.

On power-up the screen will briefly display a test

pattern allowing a quick verification that the
display functions correctly (C) this will then revert
to the normal display indicating the gear position
(D).

If the mode button is pressed once the display

will show vehicle speed, expressed as turbine or
input RPM. If no dot is shown in the display the
figure shown is to be multiplied by 10 to give the
correct value. If a dot is shown the figure shown
is to be multiplied by 100. In this mode the ' T ' -
led is switched ON.

Pressing the mode button again will show the

nominal vehicle speed, expressed in Km/hr. In
this mode the 'T'-led is switched off, unless the
vehicle is stopped. If the ' T ' - led on the APC is
illuminated whilst driving, then this indicates there
is no speed sensor output. In this condition 5th
and 6th gears cannot be achieved and no
overspeed protection is present.

Pressing the mode button again will give

diagnostic information which can be interpreted
by the dealer technician.

Pressing the mode button again returns the

screen to the normal display.

NOTE When the Joystick/Boom controls isolation

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

Using kickdown:
This works in all gears, excepting 1st and in both
directions of travel. By pressing the button (E) on
the end of the FNR lever the transmission will
change down to the next lowest gear, as long as
no over speeding will occur. If the transmission WARNING: transmission overheating
does not reach the conditions for changing a red NEVER operate in too high a gear as this will
led will blink in the display adjacent to the cause the torque converter to slip and
function being denied (i.e. gear number or overheat, as indicated by the warning light.
direction indicator), after 5 seconds of ALWAYS stop if the warning light comes on and
noncompliance the request will be disregarded. run the engine at a fast idle of 1000 to 1200 rev/
Once the lower gear is selected then the min. With both the forward/reverse lever and
transmission can be made to return to the higher gear lever in neutral until the transmission cools
gear in three different ways, being: and the warning light goes out.
1 Press button (E) once again
2 Select a new gear via the FNR twist grip
3 Moving the FNR lever to neutral or the
opposite direction of travel.
 1.22 OPERATION
ENGAGING GEAR. POWERSHIFT

Powershift transmission with manual

selection
The FNR gear lever (1) operates Forward 1st,
2nd, 3rd and 4th gear functions and Reverse
1st, 2nd and 3rd gear functions.

To select forward travel:

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

To change from one gear to another:

Twist lever (A) to the gear ratio required on up-
shifts. For down-shifts, slow vehicle to the
appropriate speed before selecting gear.

To change direction of travel:

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

WARNING: transmission overheating

NEVER operate in too high a gear as this will
cause the torque converter to slip and overheat,
as indicated by the warning light.
ALWAYS stop if the warning light comes on and
run the engine at a fast idle of 1000 to 1200 rev/
min. With both the forward/reverse lever and
gear lever in neutral until the transmission cools
and the warning light goes out.
NEVER restart after cooling the transmission
unless the load has been reduced or a lower gear
has been selected.
ALWAYS report to the workshop if the warning
light indicates further overheating.
 OPERATION 1.23
DRIVING THE MACHINE

Steering
NEVER hold the steering on full lock for more
than a few seconds because the excessive use
of the relief valve will cause overheating of the
components.
AVOID turning near trenches,
especially when carrying a load.

ALWAYS drive slowly when

changing direction, having due
regard for the surface and type of
load.

Gradients
NOTE: Turbocharged machines
Because of the characteristics of a turbocharger,
it is necessary to maintain a high engine speed
when you climb a gradient. To ensure the engine
is not overloaded at low speeds, engage a lower
gear
When travelling up or down a
gradient always obey the following:
Never run down a gradient with the
transmission in neutral
When travelling down steep gradients
control machine speed by selecting a
lower gear or using the footbrake.
Do not exceed the maximum machine
rated speed, particularly when travelling
down steep gradients.
Slippery or loose surface
conditions can adversely affect
safe machine operation, particularly
on gradients.
Choose routes that avoid steep,
slippery or loose gradients.
Never park the machine on a
gradient.
Never attempt to run on, or drive
across a gradient.
Always travel up a gradient with
the load facing uphill.
Always reverse down a gradient
when loaded.
 1.24 OPERATION
DRIVING THE MACHINE (continued)

Braking the machine

The brake pedal operates the brakes in the
conventional manner.
With the Brake/Dump switch (4)
selected, the brake pedal when
applied, disconnects the
transmission drive. This removes
any engine braking effect.
NEVER drive the machine, on
highways with this function
engaged,or when trailer towing.
NEVER make unnecessary 'crash'
stops when travelling at speed,
especially in forward direction.

Stopping the machine

Release accelerator, and brake to a halt
progressively.
Select neutral with both the gear lever and the
forward/reverse control.
Apply parking brake when stationary (11).
ALWAYS turn the front and rear
wheels from lock to lock when
parking, to clear mud and water
from the swivels and rams, thereby
reducing the risk of wear and
damage from dirt and ice.

Lower attachment or carriage to the ground. The

engine should always be allowed to slow to idle
for approximately two minutes before stopping ,
especially after extended periods of full load and
full speed operation and for turbocharged
engines (failure to do this could lead to
premature engine/turbocharger wear).
Turn start key switch to the OFF position.

Leaving the machine

Dump hydraulic pressure using the method
described in: "Service - hydraulics".
Remove start key from switch and lock cab.
If parked on a slope, chock wheels.
If the machine is to be unattended for some time,
remove the key from the electric isolation switch.
 OPERATION 1.25
DRIVING THE MACHINE (continued)

Hydraulic oil temperature

Machines from serial number 51200472 are fitted
with a hydraulic oil temperature warning light.
The warning light (21) will illuminate when the
hydraulic oil temperature exceeds a preset figure.
If, the warning light (21) illuminates, the operator
must stop work to investigate the cause.
The cause could be due to grille or oil cooler/radiator
core blockages and/or mechanical failure.
Material blockages must be cleared by manual
cleaning as described on page 3.11.
Two methods are provided as options to reduce
material blocking the cooling air intake grille and oil
cooler/radiator cores.
These methods depend on machine serial numbers
and are described as follows:

Automatic fan drive control (where fitted)

For machines up to serial number 51200471
The automatic fan drive control stops the fan for a
short period every few minutes to allow material to
drop away from the intake grille.
To adjust the ON/OFF cycle – refer to Service
Manual.

Reversible cooling fan drive

For machines from serial number 51200472.
The reversible cooling fan allows cooling fan rotation
to be reversed via switch (10). Reversing the fan
rotation, causes material to be blown away from the
intake grille and oil cooler/radiator core faces.
To reverse the fan drive, depress the rocker switch
(10) and hold on for as long as required. But no
longer than 30 seconds at a time.
The fan may be reversed at any time during
machine operation and at any engine rpm setting.
Dependant on operational conditions frequent
reversals for approximately 15 seconds every 10 to
20 minutes, should be beneficial in reducing oil
cooler/radiator core blockages and thereby assist in
maintaining engine coolant and hydraulic oil
temperatures at their optimum.
 1.26 OPERATION
DRIVING THE MACHINE (continued)

Towing the machine

The vehicle is equipped with SAHR
braking system on the front axle, i.e.:
Spring Applied, Hydraulically
Released.

In the event of engine and or electrical/hydraulic

power failure the front axle parking brakes are
automatically applied.

To enable the vehicle to be towed, the parking

brakes may be manually disengaged by evenly
unscrewing screws (six) (A, B and C) as follows:

DANGER! Block all four wheels to

prevent vehicle movement. Failure to
do so could result in death or injury if
vehicle rolls away.

Once the wheels are blocked, locate the two groups

of screws on the front axle, remove any dirt, and
using an 8 mm Allen key, and working on one group
of screws at a time, turn each screw clockwise
(inwards) (D) one turn at a time, (care must be taken
to tighten each screw alternatively to avoid internal
damage) for about 5 to 5 1/2 turns until resistance is
felt.
Repeat procedure with the other group of screws.
DANGER! Do not attempt to drive the
vehicle with parking brakes manually
disengaged.

ALWAYS remove both propeller

shafts before towing the machine.

Remove prop shafts and connect tug vehicle with

towbar and carefully remove blocking.
Vehicle may now be towed.
NEVER tow the machine above
5mph (8kph) as the lack of power
assistance makes manual steering
and braking very slow and strenuous.

ALWAYS tow the machine with a

towbar, never with a chain or rope.
 OPERATION 1.27
DRIVING THE MACHINE (continued)
Towing the machine (continued)
Following repair, the brakes must be re-engaged as
follows:
DANGER! Block all four wheels to
prevent vehicle movement. Failure to
do so could result in death or injury if
vehicle rolls away.

Once the wheels are blocked, again working on one

group of screws at a time, using the 8 mm Allen key,
turn each screw anticlockwise (outwards) (A) one
turn at a time (care must be taken to loosen each
screw alternatively to avoid internal damage) for
about 5 to 5 1/2 turns until firm resistance is felt,
then turn each screw clockwise (inwards) one
quarter turn.
Repeat procedure with the other group of screws.
The parking brakes should now be re-engaged and
the wheels locked.
Check that the brakes function correctly before
putting the vehicle back into work.
 1.28 OPERATION
WORKING THE TELEHANDLER
The Telehandler should not be used by untrained
operators.
The following pages explain some of the
recommended techniques and procedures to
enable the Telehandler to be used effectively and
safely. The information given on the Load charts,
Instability Situations examples, and the Longitudinal
Stability Indicator (LSI) should be carefully read and
understood.
It is important that you understand
the parameters of the lifting
envelopes located in the cab and the
examples of instability situations that
are included in this Handbook.

Longitudinal Stability Indicator (LSI)

The LSI (A) is a progressive warning device
measuring load on the rear axle, warning the
operator when the machine is nearing its maximum
safe working stability through the progressive
illumination of a series of seven green, two amber
and two red indicators.
The illumination of the two amber indicators will
activate an intermittent audible alarm, whilst the
illumination of the red indicators will continuously
activate the audible alarm.
Turning the engine start switch to the on position Further increases in load and/or boom extension or
initiates the LSI ‘internal-test’ function. lowering the boom without retraction will cause the
All indicators will illuminate and the alarm will illumination of the two amber indicators and the
sound, for a few seconds. intermittent sounding of the audible alarm. The
machine is now at its limit of longitudinal stability.
If functioning correctly, all indicators except for the
bottom indicator (1) will extinguish and the alarm Do not increase load, boom
will cease. extension or change boom angle
without retracting boom first, when
Do not use the machine if the LSI
the two amber indicators are
‘internal-test’ function fails.
illuminated.

Dependant on boom extension and angle a load of If the two red indicators illuminate
50% machine rated capacity will cause the and the alarm sounds continuously,
illumination of two or more indicators. the machine longitudinal stability has
been exceeded. Do not continue
Increasing the load and/or boom extension or angle
with work operations. Proceed with
will cause the indicators to progressively illuminate.
extreme caution to return to stable
With all green indicators illuminated the machine is conditions by retracting boom, prior
within its longitudinal stability, but caution is to lowering boom and removing or
necessary. reducing load.
 OPERATION 1.29
WORKING THE TELEHANDLER (continued)
Although the LSI is useful in giving an indication of
machine stability, it does not replace the skills of a
well trained and experienced operator.
The examples of instability situations show a series
of instances that would cause the coloured
indicators to change from 'green' through to
'Unstable red' as the longitudinal stability of the
machine is endangered by incorrect operation.
ALWAYS observe and obey the LSI.
Do not wait until the alarm sounds.

ALWAYS TEST THE LSI BEFORE WORK

COMMENCES.

Checking the indicator

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

'Self-test'
Before attempting to pick-up a load retract and level
boom, press the test button (B), this should
illuminate all of the indicators and cause the alarm
to sound for a few seconds.
This test shows whether the electrical warning
devices are functioning.
If functioning correctly all indicators except the
bottom indicator (1) will extinguish and the alarm will
cease.
NOTE If this test is carried out whilst the machine
is carrying a load more than one indicator will
remain illuminated.

Longitudinal stability indicator service

The LSI must be tested every three months by your
Distributor. All adjustments must be carried out with
the correct test equipment.
NEVER use the machine with an
inoperative stability indicator.
1.30 OPERATION
EXAMPLES OF INSTABILITY SITUATIONS
1 Overloading with the boom at constant reach creates instability.
ALWAYS REDUCE REACH AS THE LOAD IS INCREASED.

2 Extending the boom with a constant load creates instability.

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

3 Lowering an extended and loaded boom creates instability.

ALWAYS RETRACT BOOM BEFORE LOWERING IT.

4 Attempting to lift a load that is too heavy for reach creates instability.
ALWAYS LIFT FROM CLOSE IN, WITH AS SHORT A REACH AS POSSIBLE.
 OPERATION 1.31
LIFTING ENVELOPE European Specification pr EN1459 annexe B
The capacities and limits on the
following Load Charts are for
stationary machines fitted with
standard forks only.
Do not operate raise or extend boom
functions whilst the machine is
moving.
Always retract and lower the boom
as far as possible when travelling
with a load.

Refer to the appropriate load chart

for the attachments correct capacity
and suitability. These charts must be
understood and observed.

The weight of the load should always be known

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

Lifting envelope Lifting envelope

Standard forks Standard forks
 1.32 OPERATION
LIFTING ENVELOPE (continued) European Specification pr EN1459 annexe B

Lifting envelope
Standard forks
 OPERATION 1.33
APPROACHING A LOAD - WORKING WITH PALLET FORKS
When approaching a load, always
ensure:
The ground surface is firm and level
and the load is approached 'square-
on'.

A Stop the machine at the face of the load. The

parking brake has been applied and neutral gear
selected.

B Tilt the forks by gently moving the joystick

lever to the right until the forks are horizontal.

C Ensure that the forks are as widely spaced as

possible to suit the load. Secure forks if they were
adjusted.

D Raise the boom until the forks are level with

the pallet. Slowly drive the machine forwards until
the carriage touches the load.
If it is not possible to drive forward because of
obstructions or the ground is not level: Then extend
the boom and if necessary raise or lower the boom
height until the carriage touches the load.
1.34 OPERATION
PICKING UP A LOAD - WORKING WITH PALLET FORKS
NEVER use the machine for
purposes other than those for which
it was designed.

Maximum load capacities, load

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

NEVER walk or work under a raised

load unless the boom safety stop has
been installed.

ALWAYS place attachment level on

the ground when the machine is not
in use (unless a boom safety stop
has been installed).
NEVER bring the boom or load within
6 metres (20 feet) of overhead power
cables.
 OPERATION 1.35
PICKING UP A LOAD - WORKING WITH PALLET FORKS (continued)
A Ensure forks will pass cleanly under load.
Drive slowly, engage forks centrally until the
carriage touches the load. Apply the parking brake.
Select neutral gear
NEVER operate the boom or
attachments with the machine at
speed.

B Raise the boom slowly to lift the load while

watching that the lift envelope and boom indicators
are within the safety limits. Replace load if in danger
or doubt.
NEVER leave the machine
unattended with the load or boom
raised.

C Tilt the carriage back.

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

D When the area behind the machine is clear,

select a reverse gear, release the parking brake and
slowly reverse away from the stack.
1.36 OPERATION
PLACING A LOAD - WORKING WITH PALLET FORKS
ALWAYS ensure any scaffolding or
loading platform can support the load
before unloading onto it.

NEVER attempt to place a load on

ground that is not firm, is unstable or
incapable of supporting a fully laden
machine.

A Approach the stack 'square-on', and have

room to manoeuvre, then apply the parking brake
and select neutral gear.

B Raise and extend the boom until the load is

directly over the stack or position. Ensure that the lift
envelope and boom indicators are within the safety
limits.
Move nearer if necessary. Tilt the carriage until the
forks are horizontal. Lower the load into position.

C When in a confined space, it may be

necessary to raise and retract the boom to withdraw
from the pallet. When the forks are clear, fully
retract the boom, turn away from the stack, then
lower the boom into a travelling position.
NEVER leave the machine
unattended with the load or boom
raised.
 OPERATION 1.37
LIFTING UNPALLETISED LOADS
Tilt the carriage forward and then extend and
slightly raise the boom to slide the forks under the
load. If necessary, wedge the load to stop it moving
away from the forks.
When loaded, chain securely onto the carriage and.
Tilt the carriage back and raise the boom to the
travelling position.

Always find the centre of gravity or point of balance

of loads of irregular shape and weight distribution.
Ensure that this centre of gravity is placed midway
between the forks.
Perform a 'test' lift before completely
lifting clear of the ground.

NEVER raise a load using only one

fork.

NEVER sling a rope or chain from

any part of the boom, forks or
carriage.
ALWAYS use an approved lifting
attachment.
 1.38 OPERATION
TRAVELLING
ALWAYS drive on surfaces that are
known to be stable.

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

Lock boom controls

Travelling on gradients
See boom function lockouts.
When travelling up or down a
ALWAYS seek advice before using
gradient always obey the following:
unfamiliar attachments or moving
unfamiliar loads. Never run down a gradient with the
transmission in neutral
When travelling down steep
NEVER exceed 5mph (8kph) when gradients control machine speed by
carrying a load, or being towed. selecting a lower gear or using the
footbrake.
Do not exceed the maximum
It is recommended that ALL machine rated speed, particularly
attachments are removed from the when travelling down steep
machine before travelling on public gradients.
roads. Slippery or loose surface
conditions can adversely affect
safe machine operation, particularly
on gradients.
Before road travel
It is a legal requirement in certain countries to lock Choose routes that avoid steep,
out all boom and auxiliary hydraulic functions when slippery or loose gradients.
travelling on public roads. Never park the machine on a
To disable all boom functions refer to auxiliary gradient.
controls, select position (C) on isolation switch after Never attempt to run on, or drive
ensuring rear wheels are aligned in the straight across a gradient.
ahead position.
Always travel up a gradient with
the load facing uphill.
Always reverse down a gradient
when loaded.
OPERATION 1.39
TRANSPORTING THE MACHINE
Ensure the transporter is suitable in
size and loading capacity to carry the
machine in a safe and stable manner.

Loading the transporter

Chock (1) the wheels of the transporter.
Fix ramps to the transporter which will give the
smallest possible angle for the machine to climb.
Ensure the machine boom is in the "travelling"
position.
Drive the machine on to the transporter. If
necessary raise the boom slightly to avoid fouling
the ramps.
Apply the brakes and select neutral with the gear
lever and forward/reverse lever.
Lower carriage.
Stop the engine. Dump hydraulic pressure. Remove
the starter key, and lock cab.
Remove the ramps from the transporter.

Anchoring the machine.

Chock the wheels of the machine (A).
Lash the wheels (B) to the transporter.
Some machines are manufactured with anchorage
points at the front (C) and rear (D). If these are
fitted, use them to anchor the frame.
Ensure that the driver of the
transporter is aware of the overall
dimensions and weight of his load
(see "specifications").
THIS PAGE INTENTIONALLY BLANK
 ATTACHMENTS AND OPTIONAL EQUIPMENT 2.1
ATTACHMENTS - FITTING AND REMOVAL

To remove pallet forks (where fitted)

Lift the spring-loaded catches (A) on top of each
fork. Slide a fork (D) across to the central gap (B) in
the carriage bottom rail (C). Pivot the fork which is in
gap (B) away from the bottom rail and move fork to
one side of the gap. Repeat with other fork.
Tilt the carriage and lower it to the ground.
Withdraw from the forks (D).
To refit the forks, reverse the procedure.
ALWAYS slide forks away from
yourself. Never pull forks into the de-
mount position.

It is recommended that pallet forks

are either parked and secured away
from a thoroughfare or laid flat on the
ground for safe storage.

To fit an attachment to the carriage

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

Only attachments designed or

approved by CLAAS can be used
with this machine.

Refer to the appropriate load chart

for the attachments correct capacity
and suitability. These charts must be
understood and observed.

Mechanical locking pins

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

Hydraulic Actuated locking pins

When fitted, the hydraulic locking pin system is
operated by two joystick mounted switches.
To retract the locking pins ensure the joystick/boom
rotary isolation switch (1) is turned to position A,
before operating buttons ( A1, A2).
Ensure attachment locking pins are fully retracted
into the carriage.
 2.2 ATTACHMENTS AND OPTIONAL EQUIPMENT
ATTACHMENTS - FITTING AND REMOVAL (continued)

Check that the attachment is in good working order

and that mounting lugs and locking tubes are clean.
Ensure attachment locking pins are fully retracted
into the carriage.
Lower and tilt the carriage slightly forward (J) and
drive the machine up to the attachment with the
carriage (C) centrally aligned to the attachment
mounting lugs (H).
Lift and roll back the carriage until the bottom rail
(K) fits snugly to the attachment. Ensure the
attachment is clear of the ground.

Manual locking pins

Swing lever (F) upwards to engage locking pins (E).
Ensure lever is swung fully over and safety latch (G)
is fully engaged, to prevent accidental retraction.

Hydraulic Actuated locking pins

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

Lock the attachment to the carriage by operating the

joystick mounted switches (A1, A2), to engage
locking pins (E).

Carriage pins lockout switch

The joystick/boom isolation rotary switch (1) isolates
the carriage locking pin control, therefore stopping
accidental operation and release of attachments.
Turn switch to position (B) to lock pins (See
Auxiliary controls).

For attachments without hydraulic

couplings:
Raise and roll back the carriage to the travelling
position. The machine is now ready for work.

ALWAYS check locking pins are

engaged before tilting or operating
any attachments.
 ATTACHMENTS AND OPTIONAL EQUIPMENT 2.3
HYDRAULICALLY OPERATED ATTACHMENTS

Operating Principles
All hydraulic powered attachments operate on
similar principles i.e. push/pull and/or open/close.

The service hoses should be connected to give the

following movements:

Button (A1) to ‘Push’’ or ‘Open’ (O)

Button (A2) to ‘Pull’ or ‘Close’ (C)

Or if the second hydraulic service connections are

used:

Button (A3) to ‘Push’’ or ‘Open’ (O)

Button (A4) to ‘Pull’ or ‘Close’ (C)

Quick Release Coupling Connection

Before connecting the quick release couplings,
ensure that the attachment is locked to the carriage
and that the attachment is resting on the ground.
Dump hydraulic pressure from the
service lines.

With the ignition turned to (I), operate the

appropriate auxiliary control a few times (see
Auxiliary controls).
ALWAYS clean hydraulic couplings
before connection. Dirty couplings
will damage hydraulic system.

Connect the attachment hoses to the hydraulic

quick-release terminals (A) on the carriage.
Raise the carriage off the ground.
Check that the control buttons/switch operate the
attachment correctly. If not, lower the carriage, stop
the engine, dump hydraulic pressure and transpose
the hoses on the quick-release terminals.
NEVER leave the machine
unattended with pressure in the
system.
 2.4 ATTACHMENTS AND OPTIONAL EQUIPMENT
HYDRAULICALLY OPERATED ATTACHMENTS (continued)

Quick Release Coupling Disconnection

Before disconnecting the quick release couplings,
ensure that the attachment is unladen and is resting
on the ground.
Dump hydraulic pressure from the
service lines.

With the ignition turned to (I), operate the

appropriate auxiliary control a few times.
Couplings may now be disconnected.
NOTE: Wipe the coupling area clean before
disconnection.
Locking pins may now be withdrawn and the
carriage disengaged from the attachment by
reversing the fitting procedure stated above.

Working with Front End Attachments

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

Avoid fully retracting and lowering the

boom during operations requiring
maximum “crowding use, otherwise
damage can occur to tyre equipment.

It is recommended that ALL

attachments are removed from the
machine before travelling on public
roads.
 ATTACHMENTS AND OPTIONAL EQUIPMENT 2.5
HYDRAULICALLY OPERATED ATTACHMENTS (continued)

Rear mounted Auxiliary service

Rocker switch (5) is a two position On/Off switch.
With the switch in the On position (depress to the
left) the front service will be isolated, but the joystick
buttons (A1) and (A2) will control the 'Push' or
'Open' or 'Pull' or 'Close' rear service function.
NOTE: On early models a three position rocker
switch, sprung loaded to centre (neutral) position
was used.
Rocking the switch to either the left or right will
isolate the front services. The rear services will
then either 'Push or Open', or, 'Pull or Close',
depending on which direction the switch is rocked.

Auto-hitch
The Auto-Hitch is operated via the Rear Auxiliary
Service controls to Open (Lower) or Close (Raise)
as described above. The Hitch is provided with a
safety pin and latch mechanism (C), this
mechanism MUST be engaged BEFORE towing or
tipping a trailer.
The latch arm (D) is sprung loaded to the vertical
position and will be pushed aside by the pins (E)
when the hitch is being raised from the Open
position. But once the pins (E) are engaged and
resting on the latch arm, they can only be released
by raising the hitch slightly and pulling the latch arm
release handle (B) which in turn will pivot the latch
arm clear allowing the hitch to be lowered.
 2.6 ATTACHMENTS AND OPTIONAL EQUIPMENT
HYDRAULICALLY OPERATED ATTACHMENTS (continued)
Automatic trailer pick-up hitch (Auto-Hitch)

To operate Auto-Hitch and pick up a trailer

Check that the auto-hitch mirror is adjusted so that
the auto-hitch is clearly visible from the driving
position.
Ensure hand valve (F) is in the vertical position.
Assuming that the hitch is in the closed position:-
Raise the hitch (see page 2.5) and pull the auto-
hitch release handle (B), once the pins (E) are clear
of the latch arm, (D) fully lower the hitch and release
the release handle (B).

To tip a trailer body

Connect the trailer hose to the machine quick
release coupling (G). Turn hand valve (F) to
horizontal position.
The joysticks buttons (A2) and (A3) can now be
used to raise and lower the trailer body.
NOTE: On early models fitted with a three position
rocker switch, rock the switch left or right to raise or
lower the trailer body.

To uncouple trailer
Fully lower the trailer body.
Dump hydraulic pressure from the
service lines.

With the ignition turned to (I), operate the

appropriate auxiliary control a few times (see
Auxiliary controls).
Turn the hand valve (F) to vertical position.
Disconnect the trailer hose from the Q/R coupling
(G).
Raise hitch so that the pins (E) clear locking latch
arm (D).
Pull the auto-hitch release (B).
Lower the hitch Fully.
Draw forward and fully raise the hitch, ensure that
the latch arm returns to the vertical position. Lower
hitch slightly until the pins (E) are resting on the
latch arm.

NOTE: In the event of a long period of disuse, it is

advisable to purge the auto-hitch ram cylinder. With
the engine running, pull out and hold the auto-hitch
release knob, while operating the auto-hitch control
lever several times in each direction to disperse any
air from the system.
 ATTACHMENTS AND OPTIONAL EQUIPMENT 2.7
MANUAL TRAILER PICK-UP

ROCKINGER HITCH
Hitch mechanism is spring loaded.
Keep hands clear of hitch jaws when
vertical pin (1) is in the raised
position.

To connect trailer
Rotate lever (2) until the pin (1) moving vertically,
latches in the fully up position, allowing the release
trigger (3) to swing rearwards.
Align hitch jaws and trailer eye, and reverse vehicle
to trailer. As trailer eye contacts hitch jaws and
trigger (3), latch mechanism releases spring loaded
pin (1) and lever (2).
Check that pin is fully engaged with lower jaw
before moving off.

Never leave vehicle with pin (1) in

raised position. Firmly rotating lever
(2) downwards will release pin.
Do not attempt to touch trigger.

DRAWBAR

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

Manoeuvre with extreme care when

assistance is being given by other
person.
 2.8 ATTACHMENTS AND OPTIONAL EQUIPMENT
EXTENSION JIBS AND CRANE HOOKS
Regulations
The use of Extension Jibs and Crane Hook
attachments are subject to National Government
regulations.
ALWAYS refer to, and conform with, these
regulations.

Maximum rated loads

The absolute rated loads for lifting hook
attachments are (U.K. only):
A Extension jib: 325Kg (716 lbs)
B Fork mounted crane hook 1000Kg
(2205 lbs)
ALWAYS remember that the rated
safe working loads apply to static
loads only, and that swinging loads
reduce stability, so:
ALWAYS control swinging load with
a guide rope in the charge of a
banksman.
ALWAYS travel slowly, in low gear,
with the load as near to the ground
as possible.
ALWAYS ensure that the load to be
lifted is within the rated safe working
load of the machine and attachment
before attempting to lift it.
NEVER exceed the rated safe
working load for the machine with
attachment. Contact the
Manufacturers to establish the rated
safe working load.

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

Installing crane hook on forks

Remove pins (A) from the crane hook.
Insert the forks fully through the sleeves (B).
NEVER support a crane hook using
only one fork.

Secure the crane hook by re-inserting pins (A)

behind the heel of the forks, and locking them in
position with their latch pins.
SERVICE
SAFETY WARNINGS
HEALTH AND SAFETY
Always wear correct fitting protective
clothing. Loose or baggy clothing
can be extremely dangerous when
operating or servicing a machine.
Where possible, work on or close to
engines or machinery only when
they are stopped. If this is not
practical, remember to keep tools,
test equipment and all parts of your
body well away from moving parts
Avoid contact with exhaust pipes,
exhaust manifolds and silencers
when a engine is running; these can
be very hot
Once stopped allow engine and
engine systems to cool, before
attempting maintenance.
Many liquids used in this machine
are harmful if taken internally or
splashed into the eyes. In the event
of accidentally swallowing oil, diesel
fuel, antifreeze, battery acid etc., DO
NOT induce vomiting, but SEEK
QUALIFIED MEDICAL
ASSISTANCE IMMEDIATELY
Always obtain advice before mixing
oils; some are incompatible
Never run an engine in an enclosed
space.
Always disconnect battery cables
before using an external charger, or
to prevent unauthorised usage when
unattended or during a repair
Always work out of doors or in a
3.1
well-ventilated area. Dust found on
the machine or produced during
work on the machine should be
removed by extraction, not by
blowing. Dust waste should be
dampened, placed in a sealed
container and marked, to ensure
safe disposal
Always dump pressure from the
hydraulic system before carrying out
any kind of maintenance or
adjustment. (see Service -
Hydraulics)
Never leave the machine unattended
with pressure in the system
Fine jets of hydraulic fluid at high
pressure can penetrate the skin. Do
not use your fingers to check for
hydraulic fluid leaks. Do not put your
face close to suspected leaks. If
hydraulic fluid penetrates your skin
SEEK QUALIFIED MEDICAL
ASSISTANCE IMMEDIATELY
Always conform to service
schedules except where:
(a) Warning light or warning indicator
calls for immediate attention.
(b) Adverse conditions necessitate
more frequent service.
Never allow unqualified personnel to
attempt to remove or replace any
part of the machine, or anyone to
remove large or heavy components
without adequate lifting tackle
Never attempt to lift or hold up the
machine using the lash-down points.
 3.2 SERVICE
ACCESS TO SERVICE CHECK POINTS
Apply the brakes and chock the wheels
before servicing the machine.

NEVER work under a raised boom

without installing the SAFETY STOP!

Engine Bonnet:
The bonnet, on early models, is retained in the closed
position with one lockable catch, later models are
fitted with a lockable catch and a separate over-
centre latch.
To release, use the service tool provided, unlock the
catch and, where fitted release the over-centre latch.
The bonnet is counter-balanced by gas struts.
This will give access to:
Battery isolation switch
Start relays
Air filter switch
Engine oil dipstick and filler
Engine oil filter
Engine fuel filter and water trap
Engine fuel lift pump
Rear service plate:
Fuel injection pump and injectors
Located at chassis rear and secured with four screws
Alternator and fan belts gives access to:
Starter motor Change over valve
Radiator and Header tank Pilot valve accumulator
Hydraulic pump(s) Main control valve
Fan motor Trailer braking valve (when fitted).
Transmission filter and dipstick
Transmission oil cooler Cab pod front hatch, secured with six screws, gives
Hydraulic oil filler cap access to:
Hydraulic filter Brake valve
Hydraulic oil cooler (when fitted) Throttle cable
Steer valve.
Engine pod:
Later models are fitted with an ‘Undertray assembly’. Cab pod side hatches provided either side of cab door
step, gives access to:
The assembly is complete with two access doors
secured with catches, which require the use of the Windscreen washer bottle filler
service tool provided. Battery compartment.
Remove the doors to give access to:
Engine and transmission drain points. Cab gives access to:
Diesel tank - located under drivers seat
Fuse and relay box-located under LH dash
cover.
Heater bleed screw
SERVICE 3.3
SERVICE
Introduction
To obtain the best performance from your vehicle and the longest life, you must ensure that the maintenance
operations are done at the intervals indicated in the Service Schedule.
Each vehicle is supplied with the engine manufacturers User's Handbook, and whilst certain information relating
to general engine maintenance is repeated in this section to provide an overall vehicle Service Schedule; the
vehicle operator must follow the engine manufacturers User's Handbook maintenance recommendations and
service instructions.

SERVICE SCHEDULE

SERVICE OPERATION REFERENCE PAGE

Warning lights and indicators: REQUIRE IMMEDIATE ACTION

Warning light "illuminates": Check operation (Trained personnel only)

Brakes
Warning light "illuminates": Clean air cleaner Air cleaner
Warning light "illuminates": Change hydraulic filter Hydraulic system

As required
Change: Primary (inner) air cleaner element Air cleaner 3.18
Change/clean: Secondary (outer) air cleaner element Air cleaner 3.18
Clean: Air pre-cleaner Air cleaner 3.18

Every 10 operating hours, or daily

Check: Engine oil level Engine oil 3.8
Check: Coolant level Cooling system 3.11
Check: Radiator airways Cooling system 3.10
Check: Fuel tank level Fuel system 3.14
Check/Clean: Air pre-cleaner Air cleaner 3.18
Check: Transmission and Transfer Box oil levels Transmission 3.21
Check: Hydraulic oil level Hydraulic system 3.26
Check: Hydraulic in-line filter Hydraulic system 3.25
Change: Hydraulic filter element Hydraulic system 3.25
Check: Noise reduction panels Cab/Engine compartment 3.30
Check: Wheel nut tightness Wheels and tyres 3.7
Check/Clean: Secondary (outer) air cleaner element Air cleaner 3.18
Check: Function of the parking brake and adjust if necessary.
Check: Brake pedal travel
Check the action of the brake pedal; it should have a short travel and firm action. If travel is
excessive, or the action spongy, have the brakes serviced by your distributor.
3.4 SERVICE
SERVICE SCHEDULE

Every 20 operating hours

Grease: Front and rear axle centre pivot bearings Greasing points 3.6
Grease: All propeller shafts Greasing points 3.6
Grease: Bright metal and pivots Greasing points 3.6
Drain: Fuel pre-filter Fuel system 3.15
Grease: Auto-hitch locking catch and cable Attachments 3.29
Grease: Rockinger hitch Attachments 3.29

"Initial" 50 operating hours

Check: Engine idle speed (Trained personnel only, see engine manual)
Check: Prop-shaft fasteners Transmission 3.21
Check: Fan drive belt tension Fan drive system 3.20

"Initial" 100 operating hours

Change: Transfer box oil Transmission 3.22
Change: Transmission oil and oil filter Transmission 3.22

Every 50 operating hours, or weekly

Clean: Hydraulic tank breather Hydraulic system 3.26
Check: Tyre pressure Wheels and tyres 3.7
Check: Tyre condition Wheels and tyres 3.7
Check: Battery electrolyte level Battery 3.28
Check: Front and rear axle case/wheel hub oil levels Axles 3.24

Every 500 operating hours

Check: Frame assembly bolts
Check: All structural nuts and bolts for tightness.
Check: Prop-shaft fasteners Transmission 3.21
Change: Engine oil and filter Engine oil and filter 3.8
Check: Engine idle speed Engine 3.19
Change: Fuel filter canister Fuel system 3.15
Change: Fuel pre-filter element Fuel system 3.17
Change: Hydraulic filter element Hydraulic system 3.26
Check: Alternator belt tension Engine 3.19
 SERVICE 3.5
SERVICE SCHEDULE

Every 500 operating hours continued

Change: Air cleaner outer element Air cleaner 3.18
Change: Air cleaner inner element Air cleaner 3.18
Check: Fan drive belt tension Fan drive system 3.20
Change: Cab air filter element Cab 3.30

Every 1000 operating hours

Check: Fuel injectors (atomisers) Engine 3.19
Check: Valve clearances Engine 3.19
Clean: Alternator brushes Engine 3.19
Change: Transfer box oil Transmission 3.22
Change: Transmission oil and oil filter Transmission 3.22
Check: Coolant quality Cooling system 3.12
Change: Front and rear axle case/wheel hub oil Axles 3.24
Check: Cooling system hoses Cooling system 3.12
Clean: Rad/oil cooler cores Cooling system 3.12

Every 1500 hours, or yearly

Change: Air cleaner outer element Air cleaner 3.18
Change: Hydraulic oil Hydraulics 3.27

Every 2000 hours

Check: Cooler hoses Cooling system 3.12
Check: Brakes, have the braking system checked and overhauled by your distributor.

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

Laying-up protection
When a machine is to remain idle, remove the battery to the workshop. Seal all openings: air
intake, exhaust breathers. Grease bright parts and protect rubber components from direct
sunlight. Fill the fuel tank, check tyre pressures and exhaust any pressure from the hydraulic
system.
 3.6 SERVICE
GREASE POINTS
Every 20 operating hours
Always use lubricants of the grade Always clean grease nipples, filler
specified. caps etc. BEFORE and AFTER
Lubrication.

Always lubricate and service

BEFORE work commences, and
within the periods specified.

Bright metal parts * Oil all pivots and linkages not fitted with a
Clean the carriage top bar, and any other bright metal grease nipple.
parts which need protection from the elements, with
solvent; dry and coat with a film of grease.
 SERVICE 3.7
WHEELS AND TYRES

Every 10 operating hours, or daily

Wheel nuts
Tighten these whenever necessary, every ten
hours or daily.
After a wheel change, the nuts should be checked
several times a day until they maintain their correct
setting.
For wheel nut tightening torque (see “Machine
Specifications”)

Every 50 operating hours, or weekly

Check tyre pressures

When adding air to a tyre, ensure
the area is clear of personnel.

Never over-inflate a tyre beyond its

specified pressure.

Check the tyre pressure.

Check pressures only when the tyres are cold.
For correct pressures (see “Machine
Specifications”).

Tyre condition
Check the tyres for damage and deterioration.
 3.8 SERVICE
ENGINE OIL LEVEL

Every 10 operating hours, or daily

Check engine oil pressure

Check oil pressure warning light (1) is not
illuminated when engine is running.

Check engine oil level.

Ensure the machine is standing on level ground
and that the engine is stopped.
Allow a hot engine to cool for 15 minutes.
Pull out dipstick (3) and wipe with a clean rag.
Insert the dipstick fully and again remove it. At no
time should the level of the oil fall below the 'Min'
mark on the dipstick.
If necessary, remove oil filler cap (2) and top-up to
the 'Max' mark on the dipstick with clean oil of the
recommended grade.
For correct grade of engine oil, (see "Machine
Specifications").

Every 500 operating hours

Change engine oil and filter

Lubrication oil cleanliness is vital for
the successful operation of your
engine. The oil should be stored
under the cleanest possible
conditions.
When changing or topping-up oil,
use only clean receptacles.
Do not allow oil to come into contact
with the rubber hoses on the engine.
Before removing any drain plugs,
ensure a suitable container is placed
on the ground to catch spilt oil.
When removing drain plugs,
remember to stand on one side to
avoid oil which will spill from the
drain plug hole.

Warm the engine to normal operating temperature.

Ensure that the machine is standing on level ground
and that the engine is stopped.
Remove ‘Undertray doors’ (Where fitted) using the
service tool provided.
Clean area around the oil filter canister (6) and oil
drain plug (5).
Place a suitable container under the oil drain plug (5)
. Ensure that the container is large enough to hold all
the oil, (see "Machine Specifications")
 SERVICE 3.9
ENGINE OIL AND FILTER (continued)
Remove the oil drain plug (5) and its "O" ring and
drain the oil from the sump. Ensure the "O" ring is
not damaged and refit the drain plug and its "O" ring
and tighten the plug to 34 Nm (25 lb./ft).
Using a suitable strap wrench, unscrew and discard
the oil filter canister (6) and ensure that canister
adaptor (7) is secure in the filter head.
Thoroughly clean the housing contact surface for the
oil filter canister (6).
Pre-fill the new oil filter canister (6) with clean
engine oil of the correct grade, (see "Machine
Specifications").
Apply a thin film of clean engine oil to the seal of the
oil filter canister (6).
Fit the oil filter canister (6) and tighten it firmly by
hand only. Do not use a strap wrench.
Refill the engine with the correct grade of oil, (see
"Machine Specifications") up to the "Max : mark on
the dipstick (3).
On turbocharged engines, ensure the engine will
not start by disconnecting the electrical stop
solenoid (4) wiring of the fuel injection pump. Operate
the starter motor until oil pressure is obtained, when
the indicator light extinguishes. Reconnect the stop
solenoid wiring.
Operate the engine and check for any leakage from
the oil filter canister (6). When the engine has
cooled, check the oil level on the dipstick (3) and if
necessary, top-up.
Wipe Undertray doors and insulating material and
reassemble.
 3.10 SERVICE
COOLING SYSTEM
Every 10 operating hours, or daily

Antifreeze is toxic and must never

be taken internally. If swallowed
accidentally, medical advice should
be sought immediately.
Antifreeze is corrosive to the skin. If
accidentally spilled onto the skin, it
should be washed off immediately. It
is advisable to wear protective
clothing when handling antifreeze
and other similar corrosive
substances.
Wash hands with soap and water
after use.
Keep antifreeze out of the reach of
children.
Never start the engine without liquid
in the cooling system.

The cooling system efficiency depends on the

cleanliness of the air intake grille, radiator/oil cooler
faces and cores (on later models - the bonnet air
ducts).
Check the air intake grille and radiator etc. for
blockage or debris. Clean if necessary, using a
brush or low pressure air wand. Take care to
avoid damage to finning. Cleaning frequency will
depend on operating conditions.
Options available on later models are Automatic
fan control or Reversible fan drive systems,
frequent use of these features will assist in
reducing material blockages and therefore cleaning
frequency.
Refer to Page 1.25
 SERVICE 3.11
COOLING SYSTEM (continued)
Every 10 operating hours, or daily
Check and if necessary "top-up" the cooling system.
Never check the coolant level with the
engine running.
The cooling system is pressurised,
and care should be taken when
removing the header tank cap when
the engine is hot.
Remove the filler cap (1) SLOWLY. If
there is liquid in the header tank, the
system may be refilled with safety. If
not, allow the engine to cool
completely before topping-up.
If the machine is working continuously
in hot weather, check the level several
times a day.

Top-up with coolant to between 0.5 in - 1in (13 - 25

mm) below the filler neck (1), with the correct coolant
mixture. Refit the filler cap (1).
If the cooling system has leaked due to heater or
hose failure, it is extremely important that any lost
coolant is replaced by a pre-mixed solution of
antifreeze, and water. DO NOT use leak additives.

Every 10 operating hours, or daily

Check and if necessary "top-up" the cooling system.

Never check the coolant level with the

engine running.
The cooling system is pressurised,
and care should be taken when
removing the header tank cap when
the engine is hot.
Remove the filler cap (1) SLOWLY. If
there is liquid in the header tank, the
system may be refilled with safety. If
not, allow the engine to cool
completely before topping-up.
If the machine is working continuously
in hot weather, check the level several
times a day.

Top-up with the correct coolant mixture until the fluid

level can be seen half way up the sight glass (2).
Refit the filler cap (1).
If the cooling system has leaked due to heater or
hose failure, it is extremely important that any lost
coolant is replaced by a pre-mixed solution of
antifreeze, and water. DO NOT use leak additives.
 3.12 SERVICE
COOLING SYSTEM (continued)

Every 1000 operating hours

Check engine coolant quality

Never remove the radiator cap with
the engine running.
The cooling system is pressurised,
and care should be taken when
removing the radiator cap when the
engine is hot.
Check the coolant quality with an anti freeze tester,
if poor, drain system and renew.
Before removing any drain plugs
ensure a suitable container is placed
on the ground to catch spilt coolant.
When opening drain plugs,
remember to stand on one side to
avoid coolant which will spill from the
drain hole.

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

Open engine pod cover.
Locate radiator drain plug (2).
Place a suitable container on the ground to catch the
draining coolant.
Drain off the coolant by removing the filler cap (1),
radiator drain plug (2) and engine drain plugs (A) and
(B). Flush the system with clean water, and refit the
radiator and engine drain plugs.
Refill with coolant until the header tank is 2/3 full and
refit the filler cap (1).
It is preferable to use a coolant mixture of 50%
antifreeze and 50 % water, as this will give greater
protection against freezing and engine corrosion.
Always use antifreeze of the correct type and grade.

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

Clean system
Clean radiator, transmission oil cooler cores, and
where fitted the hydraulic oil cooler fins, taking care
to avoid damage to finning.
Run engine - for a few minutes, stop, check
level, top up if necessary - reset heater control.
 SERVICE 3.13
COOLING SYSTEM (continued)

Every 1000 operating hours

Check engine coolant quality

Never remove the radiator cap with
the engine running.
The cooling system is pressurised,
and care should be taken when
removing the radiator cap when the
engine is hot.
Check the coolant quality with an anti freeze tester,
if poor, drain system and renew.
Before removing any drain plugs
ensure a suitable container is placed
on the ground to catch spilt coolant.
When opening drain plugs,
remember to stand on one side to
avoid coolant which will spill from the
drain hole.

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

Open engine pod cover.
Locate radiator drain plug (3) at the position shown
on the illustration, but on the rear of the radiator. To
access the drain plug (3) remove the under pod
guards.
Place a suitable container on the ground to catch the
draining coolant.
Drain off the coolant by removing the filler cap (1),
radiator drain plug (3) and engine drain plugs (A) and
(B). Flush the system with clean water, and refit the
radiator and engine drain plugs.
Refill with coolant until the fluid level can be seen half
way up the sight glass (2). Refit the filler cap (1).
It is preferable to use a coolant mixture of 50%
antifreeze and 50 % water, as this will give greater
protection against freezing and engine corrosion.
Always use antifreeze of the correct type and grade.

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

Clean system
Clean radiator, transmission oil cooler cores, and
where fitted the hydraulic oil cooler fins, taking care
to avoid damage to finning.
Run engine - for a few minutes, stop, check
level, top up if necessary - reset heater control.
 3.14 SERVICE
FUEL SYSTEM

Every 10 operating hours, or daily

Check fuel tank level

The gauge (1) on the instrument console indicates
the amount of diesel fuel in the tank.
Fill the fuel tank at the end of each day to reduce
overnight condensation within the tank.
Never add gasoline or any other fuel
mixes to diesel fuel because of
increased risk of fire or explosion.

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

Never smoke when refilling the tank.

Always keep control of the filler
pump nozzle.

Stop the engine.

Clean around the filler cap (2).
Remove the cap.
Fill tank with diesel fuel .
Do not fill the tank to capacity. Allow
room for expansion and wipe up spilt
fuel immediately, otherwise
paintwork will be damaged.

Turn the start key switch to the warning lights

position. Check gauge (1).
If the level of fuel in tank is sufficient, replace the
filler cap and lower the cover and lock it.
SERVICE 3.15
FUEL SYSTEM (continued)
Diesel fuel is inflammable. Do not
smoke while carrying out
maintenance on the fuel system. Do
not carry out maintenance to the fuel
system near naked lights or sources
of sparks, such as welding
equipment.

Every 20 operating hours or daily

Drain fuel pre-filter

Drain water from pre-filter by removing the drain plug
(1). Replace the drain plug when uncontaminated fuel
flows from the bowl.
NOTE: This operation should be carried out more
frequently in high condensation conditions. It is
good practise to fill the fuel tank at the end of each
day to minimise condensation.

Every 500 operating hours

Change fuel filter Canister

It is important that only the genuine
Perkins fuel filter canister is used.
The use of a wrong canister can
cause damage to the fuel injection
pump.
1 Thoroughly clean the outside surfaces of the
fuel filter assembly.
2 Loosen the drain device (A1) at the bottom of
the filter and allow the water/fuel to drain into a
suitable container.
3 Use a strap wrench or similar tool to loosen
the filter canister and remove the canister.
4 Ensure that the threaded adaptor (B1) is
secure in the filter head and that the inside of the
head is clean.
Some of the fuel filter canisters fitted
in the factory has a special sealant
applied to the threads of the adaptor.
Filter canisters supplied in service
have an inner seal assembly (B2)
instead. The seal is held in position
by a plastic clip. Damage to the fuel
injection pump may occur if the
canister seals are not fitted correctly.
5 Lubricate lightly the two top seals (B2) and
(B3) of the new canister with clean fuel. Fit the new
canister to the filter head and tighten, by hand only.
 3.16 SERVICE
FUEL SYSTEM (continued)

Bleeding the fuel system

The fuel oil in the injection system is
under high pressure and injector
spray, in particular, can penetrate
the skin and cause serious injury.

The fuel system on this vehicle is of a self venting

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

If the system or a component in the system has

been drained - to avoid excessive battery drain:
1 Turn the start key to position ( I ),
(ignition on).
2 Loosen vent plug (C1) and operate the lever
of the fuel lift pump (5) slowly until fuel, free
from air, flows from the vent plug (C1).
Close vent plug (C1).
If the drive cam of the fuel lift pump is at the point of
maximum cam lift, it will not be possible to operate
the priming lever.
In this situation, the crankshaft must be turned half
a revolution.
3 Operate the starter motor until the engine
starts.
4 If the engine runs correctly for a short time
and then stops or runs roughly, check for air
in the fuel system. If there is air in the fuel
system, there is probably a leakage in the
low pressure system.
5 Refer to the Perkins User's Handbook or
Service manual to bleed the fuel injection
system.
 SERVICE 3.17
FUEL SYSTEM (continued)

Diesel fuel is inflammable. Do not 11 Close the drain tap (2) and remove the fuel
smoke while carrying out container.
maintenance on the fuel system. Do 12 Ensure there are no fuel leaks from the fuel
not carry out maintenance to the fuel filter assembly.
system near naked lights or sources
of sparks, such as welding
equipment.

Every 500 operating hours

Change fuel filter element

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

Do not allow dirt to enter the fuel system.

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

1 Place a suitable container below the filter

assembly to catch spilled fuel.
2 Thoroughly clean the outside surfaces of the
fuel filter assembly.
3 Open the drain tap (2) at the bottom of the filter
case to drain the fuel.
4 If necessary, use a strap wrench or similar tool
to loosen the fuel case (1) and remove the filter case
and element from the filter head (4).
5 Press down on the filter element (3) against
the spring pressure and rotate the element (3) to the
left. Remove and discard the filter element (3) and
seal (6).
6 Make sure the inside of the filter case (1) and
the inside of the filter head are clean (4).
7 Put a new filter element (3) into the filter case
(1) and press it down against the spring pressure.
Turn the filter element (3) to the right to lock it into
the filter case (1).
8 Lubricate lightly a new seal (6) and the seal
contact surfaces with clean fuel. Fit the new new
seal (6) on the filter case (1) .
9 Make sure the mounting thread (5) inside the
filter element (3) is clean and not damaged.
10 Engage the filter case (1) to the filter head (4)
and tighten, by hand only, until the filter assembly
contacts the filter head (4). Hand tighten the filter
case (1) a further 1/8th of a turn. Do not use a strap
wrench.
 3.18
AIR CLEANER
A restriction indicator and/or switch is mounted
adjacent to the cleaner to provide a visual warning,
on the cab instrument panel (page 1.9 item 8), of
element condition.
The engine must not be operated when the warning
light is illuminated, stop the engine immediately and
clean or replace the filter element(s).
Every 10 operating hours, or daily, or as
indicated via the warning light
Check and clean the pre-cleaner if fitted (6)
Where necessary, clean the pre-cleaner more than
once a day. Ensure the area around the air-cleaner
is clear of debris.
Unscrew wing nut, remove lid and glass bowl,
clean with a lint-free cloth and reassemble.
Check and clean the outer element
Remove end cover (2) by pulling yellow tag (1) and
twisting cover to left. Pull cover away from housing
(7) to replace elements.
Empty cover and vacuator valve (5) and clean with
a lint-free cloth.
Check vacuator valve for damage and replace as
necessary.
Remove the outer element (3) by pulling it towards
you, clean the inside of the air cleaner housing with
a lint-free cloth, take care not to disturb or damage
the inner element (4).
To reassemble, reverse the operation.
Outer element cleaning
A damaged element must never be
reinstalled. The element must be
replaced after it has been cleaned
six times, cleaning degrades the
filtration media. Engine damage can
result if the element is not replaced.
A dirty or damaged element can
cause loss of performance and
engine damage. The element must
be serviced as detailed in this
section in order not to invalidate the
warranty.
SERVICE
It is recommended that the outer element is
replaced once a year irrespective of how many
times it has been cleaned.
The inner element is not to be cleaned and must be
replaced if damaged or dirty.
Remove loose dirt from element using compressed
air, working from the clean to the dirty side. The air
pressure is not to exceed 6 bar, and the nozzle
should be 5 cm away from the element.
Mark element to record number of times cleaned.
Reassemble the air cleaner .
Every 500 operating hours
If the restriction indicator warning
light has not illuminated during this
period it must be suspected that
there is a leak in the system or the
indicator has malfunctioned.
Check that the air cleaner casing
and pipes are not damaged.
Check that all pipe connections are
tight.
Check that the restrictor switch and
warning light function correctly.
Remove and clean the pre-cleaner assembly.
Remove the outer element (3) and inner element
(4) and discard.
Thoroughly clean inside the housing (7), cover (2)
and vacuator (5). Check for damage and replace
parts as necessary.
Replace inner and outer filter elements.
Reassemble the air cleaner.
Check the induction hose (8) is free from damage
and that all connections are air tight.
 SERVICE 3.19
ENGINE

Every 500 operating hours

Check engine alternator belt tension

Renew a belt if it is worn or damaged.
Check belt tension using a 'Fenner' or similar
tension indicator. A force of 45N applied at the mid-
centre should result in a deflection of 10mm.
To adjust:- Loosen the pivot fasteners of the
alternator (1) and the adjustment bar (2). Adjust
alternator to give correct tension and tighten the
fasteners.
Re-check belt tension.
New belts should be re-checked after the first
20 hours of use.

Engine idle speed

Have your distributor check, and if necessary,
adjust the idle speed (see engine manual).
It should be possible to lift an unladen boom with
the engine at idle speed.

Every 1000 operating hours or yearly

Valve tip clearances

Have the valve tip clearances checked by your
distributor.

Fuel injectors (Atomisers)

Have the fuel injectors removed and tested by the
workshop and replace after servicing.

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

Initial 50 and every 500 operating hours

Check fan drive belt tension

Before attempting adjustments
ensure that engine is off and
isolation switch key is removed.

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

Renew the belt if worn or damaged.

Check belt tension using a 'Fenner' or similar tension
indicator.
A force of 26N applied at the mid-centre should
result in a deflection of 8mm.
Insufficient tension will result in loss of fan speed
and inconsequence poor cooling performance.
Loosen motor fasteners (1) and back nut (2) adjust
jacking screw (3). Tighten fasteners and back nut.
Re-check belt tension and readjust if necessary.
 SERVICE 3.21
TRANMISSION AND TRANSFER BOX

Every 10 operating hours, or daily

Check transmission oil level

Only check the oil level when the
engine is running.

Park the machine on level ground and apply

handbrake.
With the engine running at low idle speed, pull out
dipstick (1) and wipe clean with rag, insert the
dipstick fully and again remove it. The oil level
should be at the full mark, and at no time should be
allowed to drop below the minimum level mark.
The oil level should be topped up by inserting a
funnel into the dipstick tube. For the correct grade
of oil, (see "Machine Specifications").
Oil should be poured in small
amounts ensuring the transmission
is not over filled. Care should be
exercised so that no oil is spilt or
flows from the filler neck.
Powershift
Check transfer box oil
Check transfer box oil level with engine stopped.
Visually check oil level through the sight glass (2 ), the
oil level should be at the midway position.
Remove plug (3 ) to top up.
Do not overfill. For the correct grade of oil, (see
"Machine Specifications").

First initial 50 hours and Every 500

operating hours

Check Propeller Shaft Fastenings

Using a suitable torque wrench check the
security of the tab washers (where fitted) and the
tightness of the propshaft fastenings.

Propshaft 1
A 63 Nm
B 40 Nm

Propshaft 2
A 63 Nm
B 40 Nm
 3.22 SERVICE
TRANSMISSION AND TRANSFER BOX (continued)

Initial 100 and every 1000 operating hours

Change transfer box oil

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

Run the machine to warm the oil (65-93°) then

switch off the engine.
Remove ignition and isolator switch keys.
Clean area surrounding sight glass (2), filler plug
(3), and drain plug (4).
Position suitable container beneath drain plug.
Remove magnetic drain plug and filler plug, allow oil
to drain for several minutes, before replacing drain
plug.
Refill with clean oil of the correct quantity and grade.
For the correct quantity and grade of oil, (see
"Machine Specifications").
Oil level should be at the midway position within the
sight glass.
Do not over fill.
Powershift

Change transmission oil and filter

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

Run the machine to warm the oil (65-93°) then

switch off the engine.
Remove ignition and isolator switch keys.
Remove ‘Undertray doors’ (Where fitted) using the
service tool provided.
 SERVICE 3.23
TRANSMISSION AND TRANSFER BOX (continued)
“Water To Oil” Cooler
Note It is not necessary to drain this cooler type.
Proceed as above to drain and refill oil within the
transmission, but DO NOT ATTEMPT TO DRAIN
THE COOLER.

Check hoses
During the oil change, carefully examine all the
transmission hoses for cracks, cuts and damage.
Clean cores
Clean radiator and oil cooler cores before securing
oil cooler in working position.
Check level Oil Cooler on the 99 hp Machine shown - 122 hp
Machine similar.
Run engine at low idle speed to prime convertor
and lines.
Re-check level with engine running at low idle
speed and add oil to bring to FULL mark.
Make final check when oil is hot 82-93°C, fill as
necessary to FULL mark.
The oil level should be at the FULL mark, and at no
time should be allowed to drop below the minimum
level mark.
The oil level should be topped up by inserting a
funnel into the dipstick tube.
Oil should be poured in small
amounts ensuring the transmission
is not over filled. Care should be
exercised so that no oil is spilt or
flows from the filler neck.
For the correct grade of oil, (see "Machine
Specifications")
Wipe doors and insulating material and
reassemble.
 3.24 SERVICE
AXLES

Every 50 operating hours, or weekly

Check: Front and rear axle case, and wheel

hub oil levels
Park the machine on level ground and leave the
machine stationary for 2 minutes.
Clean the area surrounding the plugs
before removal.

Fig. 1
Differential case ( Fig. 1)
Note Two filler plugs are fitted to the axle. The
differential case oil level can be checked
using filler plug (1) on either side of the unit.
Remove plug (1) and check level.
The differential case oil levels is correct when it
reaches the level of the filler plug hole (1).
If the oil level is low, top-up with clean oil of the
correct type and grade (see "Machine
Specifications").
Refit plug (1).

Wheel hubs ( Fig. 2) Fig. 2

Check each hub individually.
Rotate the axle hub until the filler/level plug (3) is at
the 3 o' clock position. Remove plug (3) and check
level.
The wheel hub oil level is correct when it reaches
the level of the filler plug hole.
If the oil level is low, top-up with clean oil of the
correct type and grade (see "Machine
Specifications")
Refit plug (3).

Every 1000 operating hours Fig. 3

Change: Front and rear axle case, and

wheel hub oil
Change differential case and wheel hub lubrication
oil in the front and rear axles.
Clean area surrounding plugs before
removal.
Before removing drain plugs, place a
suitable container below the drain
plug.
When removing drain plugs, be sure
to stand on one side to avoid oil
which will spill from the hole.
Rotate axle hubs until drain plugs are at the bottom
(Fig 3).
Drain lubrication oils by removing the plugs (1 and
2) in the differential casing and filler/drain plugs (3)
in the hubs.
Allow oil to fully drain before refitting drain plugs and
refilling.
Refit drain plugs (2) and (3).
Refill using the same procedure as oil level check
(as above), and refit all plugs.
 SERVICE 3.25
HYDRAULICS
ALWAYS practise the greatest cleanliness
when servicing hydraulic components.

Dumping hydraulic pressure

Always dump all hydraulic pressure
from the system before servicing any
hydraulic component.
Ensure there is sufficient space and
headroom around the machine
before operating any hydraulic
control.

To dump pressure:
Stop the engine.
With the ignition switch turned to (I), operate each
hydraulic function in both directions several times.
An accumulator mounted at the rear of the
chassis stores pressure to operate the control valve
while dumping pressure.

Every 10 operating hours, or daily

Check hydraulic in-line filter.

Always have the engine running at maximum rev/
min. when checking the filter blockage warning light
(1). When the filter blockage warning light
illuminates change the filter element
IMMEDIATELY.
When the warning light is illuminated
NO filtration is taking place. Always
change the filter IMMEDIATELY.

NOTE When starting under cold conditions

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

To change filter element

Fine jets of hydraulic fluid at high
pressure can penetrate the skin. Do
not use your fingers to check for
hydraulic fluid leaks. Do not put your
face close to suspected leaks. If
hydraulic fluid penetrates your skin
seek medical help immediately.
Before changing filter element, stop
the engine close all rams and dump
hydraulic pressure. Remove ignition Wash out bowl in solvent, and dry with an air hose.
and isolation switch keys. Do not use a rag.
Clean the outside of the filter and remove bowl by Lubricate the contact surfaces with clean hydraulic
unscrewing it. oil, fit new seals and new element
Discard old element. Refit bowl and tighten securely.
3.26 SERVICE
HYDRAULICS (continued)

Every 10 operating hours

Check hydraulic oil level
Do not check oil level before all rams are fully
closed, and the engine has been stopped for 2
minutes.
Open engine pod cover and check level through sight
gauge (3). Oil level must be visible, and above the
red line.
Clean filler cap (1) and surrounding area before
removing cap, top up with clean hydraulic oil (see
machine specifications) if required.
Do not over fill.
Refit filler cap (1).

Every 50 operating hours

Clean hydraulic tank breather

Clean breather (4) and surrounding area. Unscrew

the breather. Immerse the breather (4) in solvent.
Agitate the breather in the solvent to remove dirt.
Dry the breather (4), check and replace the O ring on
the underside of the breather (4) if necessary and
reassemble.

Every 500 operating hours

Change in-line filter element

(see "Every 10 operating hours, or daily")
 SERVICE 3.27
HYDRAULICS (continued)

Every 1500 operating hours, or yearly

Change hydraulic oil

Run the engine and operate the hydraulics to warm
the oil.
Ensure all rams are fully closed.
Switch off engine and dump hydraulic pressure.
Remove ignition and isolation switch keys.
Disconnect battery earth strap.

Clean the areas surrounding the

drain plug (2), filler cap (1) and
breather (4) before removal.

Before removing drain plug, ensure

a suitable container is placed on the
ground to catch oil. When removing
drain plug, be sure to stand on one
side to avoid oil which will spill from
the hole. Dispose of waste oil in a
safe manner.
Drain the tank by removing filler cap (1) and drain
plug (2), positioned under hydraulic tank closest to
the machine chassis.
Flush out the tank with clean hydraulic oil taking
extreme care to remove all dirt and foreign matter.
Refit drain plug (2).
Change the in-line filter element, (see "Every 10
operating hours, or daily").
Clean the filler cap (1) and breather (4) by
immersing in solvent and agitating to remove the
dirt.
Dry both, check and replace seals if necessary and
reassemble.
Refill the hydraulic tank with clean hydraulic oil of
the correct type and grade. The oil level must be
visible, within the sight gauge (3) and above the red
line.
Do not over fill.
For the correct type and grade of oil, (see "Machine
Specifications")

Reconnect the battery earth strap and run the

engine to circulate the oil. Operate the hydraulic
controls to purge any air.
Close all rams, switch off engine and allow to stand
for two minutes, check oil level (3) and top up if
necessary.
Do not over fill.
 3.28 SERVICE
BATTERY

The battery compartment is located within the cab

pod. To open, use service tool to release catch (1)
and slide battery tray outwards. (The tray cannot
be fully removed).
The battery contains a sulphuric acid
electrolyte which can cause severe
burns and produce explosive gases.
Avoid contact with the skin, eyes and
clothing. If spilled onto the skin, flush
immediately with cold water. If
splashed into the eyes, flush
immediately with cold water for 15
minutes and get prompt medical
attention. Do not take internally. If
accidentally swallowed, drink large
quantities of water or milk, followed
by milk of magnesia, beaten eggs or
vegetable oil. Call a doctor
immediately.

Do not use a naked flame to check

the electrolyte level. Keep sparks
and flames away from the battery.
Do not produce sparks with cable
clamps when charging the battery or
starting the engine with a slave
battery.

Always disconnect battery leads

before carrying out any maintenance
to the electrical system. Every 50 operating hours, or weekly

Check battery electrolyte level

Battery removal
If the battery is to be removed from
the machine, ensure the following
procedure is used.
Switch the engine OFF.
Remove isolation switch key located within engine
pod.
Remove the start key from the cab.
Ensure all electrical circuits are switched OFF.
Disconnect the earth (-) lead from the battery
before removing the positive (+) lead.
Lift the battery from the machine.
When installing the battery, the
positive (+) lead must be connected
first.
Wear protective goggles and
impervious gloves for this operation.
Ensure that the electrical connections are clean
and tight, and coat the terminals with petroleum
jelly to protect them from corrosion.
Remove battery filler plugs (1) and check that the
electrolyte level is between 6 - 9 mm (0.25 - 0.37
in) above the tops of the separators.
Some batteries have translucent cases; the
electrolyte level in these should be between the
'Min' and 'Max' marks.
If necessary, top-up with distilled water.
Where batteries have 'trough' fillers, add distilled
water to the filling trough until the trough just begins
to fill with water.
In cold weather, distilled water
should only be added immediately
before starting the engine.

Replace battery filler plugs (1) and tighten securely.

 SERVICE 3.29
AUTOHITCH
Auto-hitch maintenance is simple but essential,
both for occasional or constant usage.
Never allow mud and debris to accumulate on or
around the auto-hitch.

Every 20 operating hours

Lubricate the locking catch pivot (1) on both sides
of the hitch, and release cable and clevis (2).
Check that the return springs (3) are secure.

ROCKINGER HITCH
Rockinger hitch maintenance is simple but
essential, both for occasional or constant usage.
Never allow mud and debris to accumulate on or
around the hitch.
Hitch mechanism is spring loaded.
Keep hands clear of hitch jaws when
vertical pin (1) is in the raised
position.

Every 20 operating hours

Ensure operating lever (2) is horizontal and vertical
pin (1) is fully down as shown before applying
grease to nipple (3) and lightly oil adjacent spring
mechanism.

WINDSCREEN WASHER BOTTLE

The washer bottle compartment is located within the
cab pod. To open use service tool provided to release
catch (1) and remove plate.
Use good quality washer fluid, dilute according to
suppliers instructions.
 3.30 SERVICE
CAB AND ENGINE COMPARTMENT
Cab
KEEP CLEAN!

Cleaning the cab both externally and internally will

aid visibility and driver comfort.
Exterior - Conventional steam cleaners may be
used, taking care to avoid water ingress to cab air
intake.
Interior should be regularly brush cleaned. Wipe
facia panels etc., with a damp cloth. Do not
attempt to clean cab interior with steam or water.
Keep the ventilation/heater air intake louvre (A) free
of material ingress.
Change cab air intake filter by removing plate (B)
and pulling out element (C).
Frequency will depend on operating conditions but
replace at least every 500 hours.

Heater
The heater assembly is located behind the driver’s
seat, underneath the rear trim panel.
In the event of failure refer to Service manual.

Air Conditioning. Optional

The unit must be serviced by personnel, specifically
trained in servicing air-conditioning units containing
refrigerant gases.
In the event of failure refer to Service manual.

Engine compartment
KEEP CLEAN!
Do not attempt to clean engine and
surrounding areas when engine is
hot.

Keep engine and ancillary equipment free of oil and

dirt contamination.
Do not attempt to clean by high pressure steam or
water.

Every 10 operating hours or daily

Check that all noise reduction panels are secure

and free of damage
THIS PAGE INTENTIONALLY BLANK
 TECHNICAL INFORMATION 4.1
MACHINE SPECIFICATIONS
Engine(s) Type Direct injection 4 cylinder diesel
Firing order 1-3-4-2
99 hp Cubic capacity 242 in3, 3990cc
Power output 75 Kw, @ 2200 rev/min.
Max. Peak Torque 403 Nm, (297 lbf/ft) @ 1400 rev/min.
122 hp Cubic capacity 268 in3, 4400cc
Power output 90.5 Kw, @ 2200 rev/min.
Max. Peak Torque 500 Nm, (369 lbf/ft) @ 1400 rev/min.

Cooling Type Liquid, by gear driven pump and pressurised radiator.

Thermostat Opens at 70°C to 80°C
Fully open at 90°C to 95°C

Electrics System 12 volt negative earth

Battery 128 ampere hours
Starter Pre-engaged, heavy duty
Alternator 75 Kw, 65 amp output
90.5 Kw, 85 amp output
Regulator Integral with alternator

Fuel system Injection pump Rotary

Lift pump Mechanical, diaphragm or Electronic fuel pump with pre-filter.
Air cleaner Dry dual element with electrical blockage warning light.
Fuel filter Renewable element
Chassis mounted Pre-filter with water drain (where fitted)

Brakes Service Hydraulically activated Inboard oil immersed discs on front and rear axle,
acting through four wheel drive.
Parking Spring applied, fail safe.

Front axle Double reduction by bevel set and planetary hub reduction gears, and parking brake. Limited slip
differential.

Rear axle Double reduction by bevel set and planetary hub reduction gears.

Transmission Standard Powershift with integral torque converter, giving instant selection of forward
and reverse gears.

Hydraulic Main circuit. Load sensing pump. 122 I/min @ 2300 rev/min.
Tank with suction vent
Auxiliary circuit. Gear pump. 50 I/min @ 2300 rev/min.
Filtration Continuous operation through auxiliary circuit, low pressure filter with electric "Blockage indicator"
and renewable element.

Speed 40 km/h (25mph) with 445R x 24 tyres

Tyres 15.5/80-24 Firestone

(Primary options) 400/74 R24 Goodyeat - Ind
17.5 LR24 Michelin
19.5 LR24 Michelin

Boom 2 stage telescopic, of rectangular hollow construction with nonmetallic wear strips, carriage vertical
self levelling, and quick-release attachments.
 4.2 TECHNICAL INFORMATION
MACHINE SPECIFICATIONS
Machine weight
TYPE K 50 6963 KG
K 60 7605 KG
K 70 7800 KG

NOTE The average weights listed above are for standard specification machines. Weights for individual
machine specification may differ.

ADJUSTMENTS
Idling speed 940 - 970 rev/min
Maximum no load speed
75 KW Engine 2390 rev/min
90.5 KW Engine 2320 rev/min
Valve tappet clearances, cold or hot inlet 0.20mm (0.008 in)
exhaust 0.46mm (0.018 in)
Fan belt free play midway between pulleys 10 mm (3/8 in)
Wheel nut tightening torque 300 Nm (220 lbf ft)

LUBRICANTS AND FLUID SPECIFICATIONS

APPLICATION EXAMPLE FLUIDS INT. SPECIFICATION
Diesel engine oil -20°C to 50°C CAT MultiGrade DEO SAE 10W40 API CG SAE 10W 40
-40°C to 10°C CAT MultiGrade DEO SAE 0W20 API CG SAE 0W20
Transmission and Transfer box
Transmission CAT HYDO SAE 10W SAE 10W
Transfer box Geartex LS85W-90 CMC GL5
Axles CAT TDTO SAE 10W
Antifreeze and summer coolant CAT Extended Life Coolant
Hydraulic system CAT HYDO SAE 10 W SAE 10W
General grease Multifak All Purpose Grease MP/L2
 4.2 TECHNICAL INFORMATION
MACHINE SPECIFICATIONS
Machine weight
TYPE K 50 6963 KG
K 60 7605 KG
K 70 7800 KG

NOTE The average weights listed above are for standard specification machines. Weights for individual
machine specification may differ.

ADJUSTMENTS
Idling speed 940 - 970 rev/min
Maximum no load speed
75 KW Engine 2390 rev/min
90.5 KW Engine 2320 rev/min
Valve tappet clearances, cold or hot inlet 0.20mm (0.008 in)
exhaust 0.46mm (0.018 in)
Fan belt free play midway between pulleys 10 mm (3/8 in)
Wheel nut tightening torque 300 Nm (220 lbf ft)

LUBRICANTS AND FLUID SPECIFICATIONS

APPLICATION EXAMPLE FLUIDS INT. SPECIFICATION
Diesel engine oil -20°C to 50°C CAT MultiGrade DEO SAE 10W40 API CG SAE 10W 40
-40°C to 10°C CAT MultiGrade DEO SAE 0W20 API CG SAE 0W20
Transmission and Transfer box
Transmission CAT HYDO SAE 10W SAE 10W
Transfer box Geartex LS85W-90 CMC GL5
Axles CAT TDTO SAE 10W
Antifreeze and summer coolant CAT Extended Life Coolant
Hydraulic system CAT HYDO SAE 10 W SAE 10W
General grease Multifak All Purpose Grease MP/L2
 TECHNICAL INFORMATION 4.3
MACHINE SPECIFICATIONS

CAPACITIES - FLUID
US Gals UK Gals Litres
Engine Oil 2.37 1.98 9.00
Transmission 4WD cooler Oil 4.22 3.5 16
Transmission - Transfer box Oil 0.12 0.1 0.4
Axles -
Front Oil 2.51 2.09 9.50
Rear Oil 2.64 2.20 10.00
Final Drive (ea) Oil 0.21 0.18 0.80
Hydraulic system Tank capacity 17.40 14.30 65.00
Fuel oil Tank capacity 53.00 44.00 200.00
Cooling system Total capacity 8.22 6.85 31.00
Screen washer 1.72 1.43 6.50

PRESSURES
bar lb/in2
Radiator cap 0.68 10.0
Hydraulic system Main relief valve 250 3625

Tyres: (primary options) FRONT REAR

2
bar lb/in bar lb/in2
400/74 R24 (Goodyear - Ind) 3.5 51 3.0 43.5
15.5/80 X 24 (Firestone) 3.75 55 3.0 43.5
17.5 LR24 (Michelin) 3.5 51 3.0 43.5
19.5 LR24 (Michelin) 3.5 51 3.0 43.5
 4.4 TECHNICAL INFORMATION
DIMENSIONS - machines fitted with standard tyres
mm
A Overall width over bodywork 2235

B Track (15.5 TYRES) 1875

C Width over tyres (15.5 TYRES) 2300

D Overall height 2395

E Inside width of cab 900

F Wheel base 2800

G Overall length (to front of tyres) 4015

H Overall length (to front of Kwiki carriage) 4730

I Ground clearance 450

J Outside turning radius 3475

 TECHNICAL INFORMATION 4.5
FUSE BOX

Fuses F17 7.5 Amp - Right hand dip beam

F1 7.5 Amp - Rear wiper F18 7.5 Amp - Left hand dip beam

F2 7.5 Amp - Working lights F19 10 Amp - Hazard warning light

F3 10 Amp - Road switch F20 10 Amp - Transmission controls

F4 10 Amp - Direction indicators/Radio F21 10 Amp - Interior light/Beacon/Din

socket
F5 25 Amp - Heater
F22 15 Amp - Steering column
F6 5 Amp - Hydraulic controls multifunction switch

F7 3 Amp - Safe load indicator F23 10 Amp - Headlight flash

F8 10 Amp - Rear fog lights F24 7.5 Amp - Instrument panel

F9 15 Amp - Rear working lights Relays

F10 10 Amp - Front working lights R1 Boom working lights

F11 10 Amp - Engine run/Fuel sender/ R2 Ignition

Brake low pressure lights
R3 Direction indicators
F12 10 Amps - Stop lights/Steering sensor/
Transmission dump light R4 Transmission dump

F13 5 Amp - Right hand side light R5 Front working lights

F14 5 Amp - Left hand side light R6 Rear working lights

F15 7.5 Amp - Right hand main beam R7 Side working lights

F16 7.5 Amp - Left hand main beam R8 Headlights

THIS PAGE INTENTIONALLY BLANK
Following the policy of CLAAS to improve its products
with continual technical development, CLAAS reserves
the right to make alterations which may not necessarily
correspond to the text and illustrations contained in
this publication, and without incurring obligation to alter
any machines previously produced or delivered.

Technical data, dimensions and weights are given as

an indication only. Responsibility for errors or
omissions is not accepted.

Reproduction or translation of this publication, in whole

or part, is not permitted without the written consent of
Caterpillar.

All rights under the provision of the Copyright Act are

reserved.
 Claas No. 319560.6
Caterpillar No. 2133881
10/2003