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OPERATOR'S MANUAL
MC60C/MC70C/MC85C/MC95C/MC105C
MCT70C/MCT85C/MCT95C
VOL
VO
MC 105C
Original Instructions
2012.02 TEC
Volvo, Shippensburg
OPERATORS MANUAL
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE
20026779A
Contents
Introduction
About This Manual ......................................................................................... 3
Machine Model and Serial Number .......................................................... 3
Using this Manual ..................................................................................... 3
Left Side, Right Side ................................................................................. 3
Cross References ..................................................................................... 3
Location of Manual ................................................................................... 3
Machine Description ...................................................................................... 5
The Skid Steer Loader .............................................................................. 5
Intended Use ............................................................................................ 5
Component Locations .............................................................................. 5
Safety Check List ........................................................................................... 7
Safety - Yours and Others ........................................................................ 7
General Safety ......................................................................................... 7
Operating Safety ...................................................................................... 9
Maintenance Safety ................................................................................ 12
Safety Labels ............................................................................................... 16
Introduction ............................................................................................. 16
Safety Label Identification ...................................................................... 17
USA Federal Clean Air Act .......................................................................... 20
Customer Assistance ............................................................................. 20
Normal Non-Road Engine Use ............................................................... 20
Non-Road Engine Use ........................................................................... 20
Service Performed By Your Local Dealer ............................................... 20
Preventative Maintenance Program ....................................................... 20
Fuel System ........................................................................................... 20
Identifying Your Machine ............................................................................. 22
Machine Identification Plate ................................................................... 22
Component Identification ........................................................................ 22
ROPS and FOPS ................................................................................... 23
European Community Standards ................................................................. 24
EC Declaration of Conformity ................................................................. 24
Declaration of Conformity ............................................................................ 25
Operation
Introduction .................................................................................................. 26
Before Entering the Cab .............................................................................. 27
Entering and Leaving the Cab ..................................................................... 28
Emergency Exits .................................................................................... 29
Doors and Windows .................................................................................... 31
Opening and Closing the Door ............................................................... 31
Opening and Closing the Side Window .................................................. 31
Glass ...................................................................................................... 32
Seat Controls ............................................................................................... 33
Introduction ............................................................................................. 33
Operators Seat - Mechanical Suspension .............................................. 33
Operators Seat - Heated Air Suspension ............................................... 33
Seat Belt ...................................................................................................... 35
Inertia Reel Seat Belt ............................................................................. 35
i i
Contents Contents
ii ii
Contents Contents
Routine Maintenance
Service Requirements ................................................................................. 90
Introduction ............................................................................................. 90
Owner/Operator Support ........................................................................ 90
Service/Maintenance Agreements ......................................................... 90
Fit for Purpose Tests for Lifting Equipment ............................................. 90
Obtaining Replacement Parts ................................................................. 90
Health and Safety ........................................................................................ 91
Lubricants ............................................................................................... 91
Battery .................................................................................................... 92
Service Schedules ....................................................................................... 94
Introduction ............................................................................................. 94
How to Use the Service Schedules ........................................................ 94
Calendar Equivalents ............................................................................. 94
Service Label .......................................................................................... 95
Pre-start Cold Checks, Service Points and Fluid Levels ........................ 98
Fluids, Lubricants and Capacities .............................................................. 102
Coolant Mixtures .................................................................................. 103
Fuels ..................................................................................................... 104
Tools .......................................................................................................... 110
Carrying Tools onto the Machine .......................................................... 110
Tool Locations (optional) ...................................................................... 110
Prepare the Machine for Maintenance ...................................................... 111
Introduction ........................................................................................... 111
How to Prepare the Machine for Maintenance (Loader Arm Lowered) 112
How to Prepare the Machine for Maintenance (Loader Arm Lifted) ..... 112
How to Prepare the Machine for Maintenance (Loader Arm and Cab Lifted)
114
Cleaning the Machine ................................................................................ 115
Checking for Damage ................................................................................ 116
Check the Machine Body and Structure ............................................... 116
Check the Tyres ................................................................................... 116
Check the Seat and Seat Belt .............................................................. 116
Check the Hydraulic Hoses and Fittings .............................................. 116
Checking the ROPS/FOPS Structure ................................................... 117
Greasing .................................................................................................... 118
Introduction ........................................................................................... 118
Access Panels ........................................................................................... 120
Introduction ........................................................................................... 120
Rear Door ............................................................................................. 120
Engine Top Cover ................................................................................. 120
Cab ....................................................................................................... 122
iii iii
Contents Contents
Optional Attachments
Introduction ................................................................................................ 146
Attachments For Your Machine ................................................................. 147
Impact Protection ....................................................................................... 151
Connecting/Disconnecting Hydraulic Hoses .............................................. 152
Introduction ........................................................................................... 152
Connecting the Hydraulic Hoses .......................................................... 152
Disconnecting the Hydraulic Hoses ...................................................... 153
Quick Release Couplings ..................................................................... 154
Auxiliary Operation .................................................................................... 156
Normal Operation ................................................................................. 156
High Flow Operation ............................................................................. 156
Hydraulic Attachment Bracket Control ....................................................... 157
To Release the Attachment .................................................................. 157
To Engage the Attachment ................................................................... 157
Manual Attachment Bracket Control .......................................................... 158
Engaging the Bucket/Attachments ....................................................... 158
Disengaging the Bucket/Attachments ................................................... 159
iv iv
Contents Contents
Specifications
Static Dimensions ...................................................................................... 168
Wheeled Machines - Vertical Lift .......................................................... 168
Wheeled Machines - Radial Lift ............................................................ 170
Tracked Machines - Vertical Lift ........................................................... 171
Tracked Machines - Radial Lift ............................................................. 172
Performance Dimensions .......................................................................... 173
Wheeled Machines ............................................................................... 173
Tracked Machines ................................................................................ 173
Machine Weights ....................................................................................... 174
Tyre Sizes And Pressures ......................................................................... 175
Noise Data ................................................................................................. 176
Introduction ........................................................................................... 176
All Machines ......................................................................................... 176
Vibration Data ............................................................................................ 177
Introduction ........................................................................................... 177
MC60C, MC70C, MC85C, MC95C, MC105C ...................................... 178
MCT70C, MCT85C, MCT95C .............................................................. 179
Travel Speeds ............................................................................................ 180
Auxiliary Pressures .................................................................................... 181
v v
Contents Contents
vi vi
Safety Notices
Important Information
T1-042
! WARNING
Denotes a hazard exists. If proper precautions are not
taken, the operator (or others) could be killed or
seriously injured.
INT-1-2-2
! CAUTION
Denotes a reminder of safety practices. Failure to
follow these safety practices could result in injury to
the operator (or others) and possible damage to the
machine.
INT-1-2-3
1 20026779A 1
Safety Notices
Important Information
2 20026779A 2
Introduction
About This Manual
3 20026779A 3
Introduction
About This Manual
4 20026779A 4
Introduction
Machine Description
Machine Description
The Skid Steer Loader is a self propelled skid steer 1 ROPS/FOPS Cab
machine fitted with either wheels or tracks. The main
structural support is designed to carry a front mounted 2 Fuel Tank
carriage onto which a bucket or an approved attachment
can be fitted. 3 Loader Arm
5 20026779A 5
Introduction
Machine Description
11
5
10
8,9 7 4
6
T054330
Fig 3.
6 20026779A 6
Introduction
Safety Check List
BE CAREFUL
BE ALERT
! WARNING
Care and Alertness
BE SAFE All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always be
alert for hazards.
INT-1-3-5
! WARNING
Clothing
You can be injured if you do not wear the proper
clothing. Loose clothing can get caught in the
machinery. Wear protective clothing to suit the job.
Examples of protective clothing are: a hard hat, safety
shoes, safety glasses, a well fitting overall, ear-
protectors and industrial gloves. Keep cuffs fastened.
Do not wear a necktie or scarf. Keep long hair
restrained. Remove rings, watches and personal
jewellery.
INT-1-3-6_2
! WARNING
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be aware
of medicines which can cause drowsiness.
INT-1-3-9_2
7 20026779A 7
Introduction
Safety Check List
! WARNING ! WARNING
Feeling Unwell Machine Modifications
Do not attempt to operate the machine if you are This machine is manufactured in compliance with
feeling unwell. By doing so you could be a danger to legislative and other requirements. It should not be
yourself and those you work with. altered in any way which could affect or invalidate any
8-1-2-4 of these requirements. For advice consult your
authorized distributor.
INT-1-3-10_2
! WARNING
Mobile Phones
Switch off your mobile phone before entering an area
with a potentially explosive atmosphere. Sparks in
such an area could cause an explosion or fire
resulting in death or serious injury.
! WARNING
Lifting Equipment
You can be injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all
local regulations.
INT-1-3-7_2
! WARNING
Raised Equipment
Never walk or work under raised equipment unless it
is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if
the control is operated (even with the engine stopped).
! WARNING
Raised Machine
NEVER position yourself or any part of your body
under a raised machine which is not properly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
INT-3-3-7_1
! DANGER
Lightning
Lightning can kill you. Do not use the machine if there
is lightning in your area.
5-1-1-2
8 20026779A 8
Introduction
Safety Check List
9 20026779A 9
Introduction
Safety Check List
! WARNING ! DANGER
Danger of Fire Working Platform
Airborne particles of light combustible material such Using the machine as a working platform is
as straw, grass, wood shavings, etc. must not be hazardous; you can fall off and be killed or injured.
allowed to accumulate within the engine compartment Never use the machine as a working platform.
or in the propshaft guards (when fitted). Inspect these 5-1-5-9
areas frequently and clean at the beginning of each
work shift or more often if required. Before opening
the engine cover, ensure that the top is clear of debris. ! WARNING
Machine Safety
5-3-1-12_3
Stop work at once if a fault develops. Abnormal
sounds and smells can be signs of trouble. Inspect
! WARNING and repair before resuming work.
8-1-2-3
Keep the machine controls clean and dry. Your hands
and feet could slide off slippery controls. If that
happens you could lose control of the machine. ! WARNING
2-2-3-6
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
! WARNING been running. Allow the engine and components to
Electrical Power Cables cool before servicing the unit.
You could be electrocuted or badly burned if you get 10-1-1-40
the machine or its attachments too close to electrical
power cables.
! WARNING
Travelling at High Speeds
You are strongly advised to make sure that the safety
Travelling at high speeds can cause accidents. Do not
arrangements on site comply with the local laws and
reverse in a high gear with full throttle. Always travel
regulations concerning work near electric power lines.
at a safe speed to suit working conditions.
Before you start using the machine, check with your INT-5-3-3
! CAUTION ! WARNING
If you have an attachment which is not covered in the You could be killed or seriously injured if you operate
Operator Manual do not install it, use it or remove it a machine with a damaged or missing ROPS/FOPS. If
until you have obtained, read and understood the the Roll Over Protection Structure (ROPS)/Falling
pertinent information. Install attachments only on the Objects Protection Structure (FOPS) has been in an
machines for which they were designed. accident, do not use the machine until the structure
5-5-1-1_2 has been renewed. Modifications and repairs that are
not approved by the manufacturer may be dangerous
and will invalidate the ROPS/FOPS certification.
! WARNING
INT-2-1-9_6
10 20026779A 10
Introduction
Safety Check List
! CAUTION ! WARNING
One-Fork Lifting High Loads
A load lifted on one fork can slip off. Never lift a load A high load can block your view and reduce the
with one fork. machine's stability. Travel with the load low to the
5-1-4-3 ground. Travel slowly and with caution over rough,
muddy or loose surfaces.
5-1-3-2
! CAUTION
Unloading
Never unload the forks by stopping the machine ! WARNING
suddenly. Follow the procedures in the Operator Slopes
Manual for unloading. Always drive a LOADED machine FORWARD UPHILL
5-1-4-4_2 and in REVERSE DOWNHILL.
! WARNING
! WARNING Controls
Forks/Turning You or others can be killed or seriously injured if you
The forks project in front of the machine. Make sure operate the control levers from outside the machine.
there is enough clearance for the forks when making Operate the control levers only when you are correctly
turns. seated.
5-1-5-4_2 0179_2
! CAUTION
Passengers
Passengers in or on the machine can cause accidents.
Do not carry passengers.
INT-2-2-2_1
11 20026779A 11
Introduction
Safety Check List
! WARNING
Maintenance Safety
Fires
If your machine is equipped with a fire extinguisher,
! WARNING
make sure it is checked regularly. Keep it in the correct Communications
machine location until you need to use it. Bad communications can cause accidents. If two or
more people are working on the machine, make sure
Do not use water to put out a machine fire, you could each is aware of what the others are doing. Before
spread an oil fire or get a shock from an electrical fire. starting the engine make sure the others are clear of
Use carbon dioxide, dry chemical or foam the danger areas; examples of danger areas are: the
extinguishers. Contact your nearest fire department as rotating blades and belt on the engine, the
quickly as possible. Firefighters should use self- attachments and linkages, and anywhere beneath or
contained breathing apparatus. behind the machine. People can be killed or injured if
INT-3-2-7_2 these precautions are not taken.
INT-3-1-5
! WARNING
! WARNING
Should the machine start to roll over, you can be Repairs
crushed if you try to leave the cab. If the machine If your machine does not function correctly in any way,
starts to roll over, do not try and jump from the cab. get it repaired straight away. Neglect of necessary
Stay in the cab, with your seat belt fastened. repairs could result in an accident or affect your
INT-2-1-12 health. Do not try to do repairs or any other type of
maintenance work you do not understand. To avoid
injury and/or damage get the work done by a specialist
! WARNING
Safe Working Loads engineer.
Overloading the machine can damage it and make it GEN-1-5_2
unstable. Study the specifications in the Operator
Manual before using the machine.
! WARNING
7-1-1-8_2 Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
! WARNING
Seat Belt or copper pin to remove and fit metal pins. Always
Operating the machine without a seat belt can be wear safety glasses.
dangerous. Before starting the engine, make sure your INT-3-1-3_2
seat belt is fastened. Check the tightness and
condition of the seat belt securing bolts regularly (see
! WARNING
maintenance schedules). Electrical Circuits
INT-2-1-8_1 Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
INT-3-1-4
! WARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If
fluid penetrates your skin, get medical help
immediately.
INT-3-1-10_3
12 20026779A 12
Introduction
Safety Check List
! WARNING ! CAUTION
Hydraulic Pressure Cylinders
Hydraulic fluid at system pressure can injure you. The efficiency of the cylinders will be affected if they
Before connecting or removing any hydraulic hose, are not kept free of solidified dirt. Clean dirt from
residual hydraulic pressure trapped in the service around the cylinders regularly. When leaving or
hose line must be vented. Make sure the hose service parking the machine, close all cylinders if possible to
line has been vented before connecting or removing reduce the risk of weather corrosion.
hoses. Make sure the engine cannot be started while INT-3-2-10
the hoses are open.
INT-3-1-11_2
! CAUTION
Cleaning
! WARNING Cleaning metal parts with incorrect solvents can cause
Fuel corrosion. Use only recommended cleaning agents
Fuel is flammable; keep naked flames away from the and solvents.
fuel system. Stop the engine immediately if a fuel leak INT-3-2-11
is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel ! WARNING
which could cause a fire. There could be a fire and
When using cleaning agents, solvents or other
injury if you do not follow these precautions.
chemicals, you must adhere to the manufacturer's
INT-3-2-2_3
instructions and safety precautions.
GEN-1-9
! WARNING
Oil
Oil is toxic. If you swallow any oil, do not induce ! CAUTION
'O' rings, Seals and Gaskets
vomiting, seek medical advice. Used engine oil
Badly fitted, damaged or rotted 'O' rings, seals and
contains harmful contaminants which can cause skin
gaskets can cause leakages and possible accidents.
cancer. Do not handle used engine oil more than
Renew whenever disturbed unless otherwise
necessary. Always use barrier cream or wear gloves to
instructed. Do not use Triochloroethane or paint
prevent skin contact. Wash skin contaminated with oil
thinners near 'O' rings and seals.
thoroughly in warm soapy water. Do not use petrol
(gasoline), diesel fuel or paraffin (kerosene) to clean INT-3-2-12
your skin.
INT-3-2-3 ! WARNING
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the
! CAUTION hoses regularly. Do not use the machine if a hose or
hose fitting is damaged.
It is illegal to pollute drains, sewers or the ground.
Clean up all spilt fluids and/or lubricants. INT-3-3-2_4
13 20026779A 13
Introduction
Safety Check List
! WARNING ! WARNING
Arc Welding
Certain seals and gaskets (e.g. crankshaft oil seal) on To prevent the possibility of damage to electronic
these machines contain fluoroelastomeric materials components, disconnect the battery and the alternator
such as Viton, FluorelTM and Technoflon. before arc-welding on the machine or attached
Fluoroelastomeric materials subjected to high implements.
temperatures can produce highly corrosive
hydrofluoric acid. THIS ACID CAN SEVERELY BURN. If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control
New fluoroelastomeric components at ambient units (E.C.U.s), monitor displays, etc., then disconnect
temperature require no special safety precautions. them before welding. Failure to disconnect the
sensitive electrical equipment could result in
Used fluoroelastomeric components whose irreparable damage to these components.
temperatures have not exceeded 300C (572F) require
no special safety precautions. If evidence of Parts of the machine are made from cast iron; welds
decomposition (e.g. charring) is found, refer to the on cast iron can weaken the structure and break. Do
next paragraph for safety instructions DO NOT TOUCH not weld cast iron. Do not connect the welder cable or
COMPONENT OR SURROUNDING AREA. apply any weld to any part of the engine.
Used fluoroelastomeric components subjected to Always connect the welder earth (ground) cable to the
temperatures greater than 300C (572F) (e.g. engine same component that is being welded, i.e. boom or
fire) must be treated using the following safety dipper, to avoid damage to pivot pins, bearings and
procedure. Make sure that heavy duty gloves and bushes. Attach the welder earth (ground) cable no
special safety glasses are worn: more than 0.6 metres (2 feet) from the part being
welded.
1 Thoroughly wash contaminated area with 10% INT-3-1-15_2
calcium hydroxide or other suitable alkali
solution, if necessary use wire wool to remove
burnt remains. ! WARNING
Counterweights
Your machine may be fitted with counterweights. They
2 Thoroughly wash contaminated area with
are extremely heavy. Do not attempt to remove them.
detergent and water.
INT-3-2-5
! WARNING ! WARNING
Protect your eyes when grinding metal. Wear safety Compressed air is dangerous. Wear suitable eye
glasses or goggles. Remove or protect any protection and gloves. Never point a compressed air
combustible materials from the area which could be jet at yourself or others.
ignited by sparks. 0147_1
GEN-1-12
! WARNING
! WARNING Accumulators
The accumulators contain hydraulic fluid and gas at
To avoid burning, wear protective gloves when high pressure. Prior to any work being carried out on
handling hot components. To protect your eyes, wear systems incorporating accumulators, the system
goggles when using a brush to clean components. pressure must be exhausted by an authorized
HYD-1-3_2 distributor, as the sudden release of the hydraulic fluid
or gas may cause injury.
INT-3-1-17
14 20026779A 14
Introduction
Safety Check List
! WARNING ! WARNING
Petrol (Gasoline)
Do not use petrol (gasoline) in this machine. Do not An exploding tyre can kill. Inflated tyres can explode if
mix petrol (gasoline) with the diesel fuel; in storage over-heated or over-inflated. Follow the instructions
tanks the petrol (gasoline) will rise to the top and form given when inflating the tyres. Do not cut or weld the
flammable vapours. rims. Use a tyre/wheel specialist for all repair work.
INT-3-1-6 2-3-2-7_2
! CAUTION ! WARNING
Jacking
Do not disconnect the battery while the engine is A machine can roll off jacks and crush you unless the
running, otherwise the electrical circuits may be wheels have been blocked. Always block the wheels at
damaged. the opposite end of the machine that is to be jacked.
INT-3-1-14 Do not work underneath a machine supported only by
jacks. Always support a jacked-up machine on axle
stands before working underneath it.
! WARNING INT-3-2-8
! DANGER ! WARNING
Electrolyte Asbestos
Battery electrolyte is toxic and corrosive. Do not Asbestos dust can damage your lungs. Some engine
breathe the gases given off by the battery. Keep the gaskets contain asbestos. Do not dismantle the
electrolyte away from your clothes, skin, mouth and engine or exhaust system; get these jobs done by a
eyes. Wear safety glasses. qualified person who has a copy of the engine service
INT-3-2-1_3 manual.
5-1-6-1
! WARNING
Battery Terminals
The machine is negatively earthed (grounded). Always
connect the negative pole of the battery to ground.
15 20026779A 15
Introduction
Safety Labels
Safety Labels
Introduction
T1-014_2
! WARNING
Safety Labels
Safety labels on the machine warn you of particular
hazards. You can be injured if you do not obey the
safety instructions shown.
INT-1-3-11
NOTE
The illustration(s) show a typical machine model.
Your machine may look different from the model
shown.
16 20026779A 16
Introduction
Safety Labels
Fig 4. Safety Label Locations - Wheeled Machine Shown, Tracked Machine Similar
17 20026779A 17
Introduction
Safety Labels
Labels and Descriptions
Description: Burns to fingers and
hands. Stay a safe distance away.
Description: Emergency exit.
817-70004-4
817/19457
817-19457-1
332-P7131-1
817-70014-3
Description: Crush hazard. Do not
operate the controls from outside of
the machine.
Description: Crushing of whole body.
Install the maintenance strut before
you start maintenance work below a
raised attachment. >>How to
Prepare the Machine for
817-70018-2
Maintenance (Loader Arm
Lowered) (112)
817-70104-4
Description: Crush hazard. Do not
lean out of open window.
332-P4634-1
332-P7181-1
Description: Crush hazard. Falling
material. Bucket is not self levelling.
Consult operators manual.
Description: Do not use as step.
332/L4754-1
332-X4855-1
18 20026779A 18
Introduction
Safety Labels
332-P7132-1
332-X4276-2
332-P4712-1
332-V3761-1
19 20026779A 19
Introduction
USA Federal Clean Air Act
The Federal Clean Air Act Section 203 (a) (3) prohibits the In order to document that the proper regular maintenance
removal of air pollution control devices or the modification has been performed on the non-road engine, Volvo
of an EPA-certified non-road engine to a non-certified recommends that the owner keep all records and receipts
configuration. of such maintenance. These records and receipts should
be transferred to each subsequent purchaser of the non-
The Federal regulations implementing the Clean Air Act for road engine.
nonroad engines, 40 C.F.R.Section 89.1003(a)(3)(i), reads
as follows: Service Performed By Your Local Dealer
The following act and the causing thereof are prohibited: Your local dealer is best qualified to give you good,
For a person to remove or render inoperative a device or dependable service since he has trained service
element of design installed on or in a non-road engine technicians and is equipped with genuine original
vehicle or equipment in compliance with regulations under manufacturers parts and special tools, as well as the
this part prior to its sale and delivery to the ultimate latest technical publications. Discuss your servicing and
purchaser or for a person knowingly to remove or render maintenance requirements with your local dealer. He can
inoperative such a device or element of design after the tailor a maintenance program for your needs.
sale and delivery to the ultimate purchaser.
For regular scheduled service or maintenance, it is
The law provides a penalty of up to $2,750 for each advisable to contact your local dealer in advance to
violation. arrange for an appointment to ensure availability of the
correct equipment and service technician to work on your
An example of a prohibited modification is the recalibration machine. This will aid your local dealer in efforts to
of the fuel system so that the engine will exceed the decrease service time on your machine.
certified horsepower or torque.
Preventative Maintenance Program
You should not make a change to an EPA-certified non-
road engine that would result in an engine that does not
To retain the dependability, noise level and exhaust
match the engine configuration certified to meet the
emission control performance originally built into your
Federal Standards.
conventional non-road engine, it is essential that the non-
road engine receive periodic service, inspections,
Customer Assistance adjustments and maintenance.
20 20026779A 20
Introduction
USA Federal Clean Air Act
Check for fuel leaks
NOTE
A second person must either check the hoses or
stay in the cab, since leaving the cab causes the
engine to shut down.
21 20026779A 21
Introduction
Identifying Your Machine
Component Identification
NOTE
The machine model and build specification is Typical Engine Identification Number
indicated by the PIN. Refer to >>Typical Product
T1-050
Identification Number (22).
The engine data label is located on the cylinder block at
position A. >>Fig 6. (22) The data label includes the
The serial number of each major unit is also stamped on
engine identification number.
the unit itself. If a major unit is replaced by a new one, the
serial number on the identification plate will be wrong.
A typical engine identification number is explained as
Either stamp the new number of the unit on the
follows:
identification plate, or simply stamp out the old number.
This will prevent the wrong unit number being quoted when
replacement parts are ordered. GP 50261 U 500405 M
1 2 3 4 5
The machine and engine serial numbers can help identify
exactly the type of equipment you have.
1 Engine Type
DESIGNATION
TYPE
TYPE
Product Identification
Product
TYPE
TYPE
Product Identification
Product
VOLVO ENGINE
ENGINE POWER
POWER kW @ RPM, kW @ RPM, ISO 14396
ISO 14396
332/L8245
332/L8245 VOLVO ENGINE
ENGINE POWER
POWER kW @ RPM, kW @ RPM, ISO 14396
ISO 14396
332/L8245
332/L8245
2 Build Number
3 Country of manufacture
U = United Kingdom
5 Year of Manufacture
Fig 5.
G E O 1 4 5 T V C 0 0 0 1 2 3 4 5
Fig 6.
A B C D
V1098040
22 20026779A 22
Introduction
Identifying Your Machine
ROPS and FOPS The falling objects protection structure (FOPS) is fitted with
a dataplate. The dataplate indicates what level protection
the structure provides.
! WARNING
There are two levels of FOPS:
You could be killed or seriously injured if you operate
a machine with a damaged or missing ROPS/FOPS. If Level I Impact Protection - impact strength for
the Roll Over Protection Structure (ROPS)/Falling protection from small falling objects (e.g. bricks, small
Objects Protection Structure (FOPS) has been in an concrete blocks, hand tools) encountered in
accident, do not use the machine until the structure operations such as highway maintenance,
has been renewed. Modifications and repairs that are landscaping and other construction site services.
not approved by the manufacturer may be dangerous
Level II Impact Protection - impact strength for
and will invalidate the ROPS/FOPS certification.
protection from heavy falling objects (e.g. trees,
INT-2-1-9_6 rocks) for machines involved in site clearing,
overhead demolition or forestry.
! WARNING
Seat Belts
The ROPS/FOPS is designed to give you protection in
an accident. If you do not wear your seat belt, you
could be thrown out of the machine and crushed. You
must wear a seat belt when using the machine. Fasten
the seat belt before starting the engine.
0153
A bolt on falling object guard is available which also carries Fig 9. Level 2 Label
a certified label fitted to the guard. >>FOPS Data Plate
(23).
! WARNING
Do not use the machine if the falling objects protection
level provided by the structure is not sufficient for the
application. Falling objects can cause serious injury.
8-2-8-17
23 20026779A 23
Introduction
European Community Standards
EC Declaration of Conformity
A completed copy of the EC Declaration of Conformity is
supplied with all machines manufactured according to EC
type examination and/or self-certification requirements.
24 20026779A 24
Introduction
Declaration of Conformity
Declaration of Conformity
COMPLIES WITH THE PROVISIONS OF THE MACHINERY DIRECTIVE (DIRECTIVE 2006/42/EC AS AMENDED).
THE FOLLOWING STANDARDS HAVE BEEN USED: EN 500-1:2006 +A1:2009
EN 500-4:2006 +A1:2009
NAME AND ADDRESS OF THE PERSON WHO ENGINEERING MANAGER
COMPILES THE TECHNICAL DOCUMENTATION: J.C. BAMFORD EXCAVATORS LIMITED
LAKESIDE WORKS
ROCESTER, STAFFORDSHIRE
UNITED KINGDOM
ST14 5JP
COMPLIES WITH THE PROVISIONS OF THE NOISE EMISSIONS IN THE ENVIRONMENT BY EQUIPMENT FOR
USE OUTDOORS DIRECTIVE (DIRECTIVE 2000/14/EC AS AMENDED)
NAME AND ADDRESS OF THE PERSON WHO KEEPS PRINCIPLE ENGINEER, NVH
THE TECHNICAL DOCUMENTATION: J.C. BAMFORD EXCAVATORS LIMITED
LAKESIDE WORKS
ROCESTER, STAFFORDSHIRE
UNITED KINGDOM
ST14 5JP
CONFORMTIY ASSESSMENT PROCEDURE: ANNEX VI - PROCEDURE 1
NAME AND ADDRESS OF NOTIFIED BODY: A.V. TECHNOLOGY
A.V. HOUSE
BIRDHALL LANE
STOCKPORT, CHESHIRE
UNITED KINGDOM
SK3 0XU
MEASURED SOUND POWER LEVEL ON EQUIPMENT SEE >>Noise Data (176)
REPRESENTATIVE FOR THIS TYPE:
GUARANTEED SOUND POWER LEVEL FOR THIS SEE >>Noise Data (176)
EQUIPMENT:
NET INSTALLED POWER / MASS OF APPLIANCE: SEE >>Performance Dimensions (173)
25 20026779A 25
Operation
Introduction
T2-006_2
Before you start the machine, you must know how the
machine operates. Use your manual to identify each
control lever, switch, gauge, button and pedal. Do not
guess. If there is anything you do not understand, ask your
authorized distributor.
Finally, do not rush the job of learning, make sure you fully
understand everything in the Operation section. Take your
time and work efficiently and safely.
Remember
BE CAREFUL
BE ALERT
BE SAFE
26 20026779A 26
Operation
Before Entering the Cab
27 20026779A 27
Operation
Entering and Leaving the Cab
! WARNING
Entering/Leaving
Entering or leaving the cab or canopy must only be
made where steps and handrails are provided. Always
face the machine when entering and leaving. Make
sure the step(s), handrails and your boot soles are
clean and dry. Do not jump from the machine. Do not
use the machine controls as handholds, use the
handrails.
INT-2-1-7_1
T058530
Fig 2. Tracked Machine
NOTE
When entering or leaving the machine use the
door on the left side of the machine, the front
opening must only be used as an emergency exit.
>>Emergency Exits (29).
NOTICE
IMPORTANT
Before entering or leaving the machine make
sure that the left arm rest and Interlock bar are in
their raised positions. >>Safety Equipment (64).
T055610-1
Fig 1. Wheeled Machine
Fig 3. Canopy
28 20026779A 28
Operation
Entering and Leaving the Cab
When the machine comes to rest following an accident, d Store the front screen assembly safely to prevent
turn the ignition switch to the OFF position, if at all possible damage.
and remove the seat belt.
1 Cab Door D
817/19457
D
If the machine is still upright and the door is
unobstructed, this is the best way out since it provides
both a footrest and handrails. If the machine has
overturned, the door should be considered along with
the alternative route below, according to the
circumstances.
T057080-1
1 Cab Door
29 20026779A 29
Operation
Entering and Leaving the Cab
30 20026779A 30
Operation
Doors and Windows
Opening and Closing the Door Close the door from the inside by pulling the closing bar B
firmly; it will latch itself.
NOTE To open the door from the inside, pull lever C back to
Whenever the door latch is released, the door release the latch.
swings open automatically under pressure from a
gas strut. Strut life can be extended if the door is
prevented from swinging open violently. NOTE
Close the canopy door by pulling on the top of it.
To open the door from the outside, unlock it with the key
provided and pull handle A to release the latch. A
B
C
B
31 20026779A 31
Operation
Doors and Windows
position release the latch. Make sure the latch has properly
engaged in the frame at B.
Glass
Depending on machine specification, windows Cand D are
provided to function as guards. Damaged windows must
be replaced with those of equivalent specification before
the machine is used again. The machine must not be used
with window D, or optional steel mesh removed. The rear
glass E and the Left side glass F are tempered.
E
F
D
C
32 20026779A 32
Operation
Seat Controls
Seat Controls
The operator's seat can be adjusted for your comfort. A Fore/Aft (Seat Only)
correctly adjusted seat will reduce operator fatigue.
Position the seat so that you can comfortably reach the Lift lever 2 and slide the seat into the required position
machine controls. For driving the machine, adjust the seat relative to the Control Levers and interlock bar. Release
so that you can depress the pedals fully with your back the lever 2. Make sure the seat is locked in position and
against the seat back. that your arms are comfortable on the Control Levers. A
correctly adjusted seat will optimise visibility and comfort
on the foot pedals (if fitted)
Operators Seat - Mechanical Suspension
Fore/Aft (Seat and Consoles)
To move the seat and the left and right consoles, which are
all mounted on the seat base, lift lever 1 and slide the seat
base into the required position. Release lever 1. Make sure
the seat base is locked in position. A correctly adjusted
seat will optimise visibility and comfort on the foot pedals
(if fitted).
Weight
Backrest
2 1
A335162-7
Fig 7.
33 20026779A 33
Operation
Seat Controls
Air
Backrest
Heated Seat
2 4
1
Fig 8.
34 20026779A 34
Operation
Seat Belt
Seat Belt
Inertia Reel Seat Belt Check the Seat Belt is Operating Correctly
T2-001_2
1 Sit correctly in the seat and fasten the seat belt as
! WARNING described.
If you do not wear your seat belt you could be thrown 2 Hold the middle of the seat belt as shown at D and
about inside the machine, or thrown out of the tug. The seat belt should 'lock'.
machine and crushed. You must wear a seat belt when
using the machine. Fasten the seat belt before starting
the engine. ! WARNING
8-2-9-2_1
If the seat belt does not 'lock' when you check if the
seat belt is operating correctly, do not drive the
! WARNING machine. Get the seat belt repaired or replaced
immediately.
When a seat belt is fitted to your machine replace it 2-2-2-1
with a new one if it is damaged, if the fabric is worn, or
if the machine has been in an accident. Fit a new seat
belt every three years.
2-3-1-7_1
1 Sit correctly in the seat. Pull the belt from its reel
holder in one continuous movement.
C006850-1
Fig 10.
! WARNING
Release the seat belt only after switching off the
engine.
2-2-1-10
C006840-1 2 Let the seat belt retract into its reel holder.
Fig 9.
NOTE
If the belt 'locks' before the male fitting A has
been engaged, allow the belt to fully retract in its
reel holder and then try again. The inertia
mechanism may lock if you pull the belt too
sharply or if the machine is parked on an incline.
In such cases, ease the belt gently from its reel
holder.
35 20026779A 35
Operation
Seat Belt
36 20026779A 36
Operation
Visibility Aids
Visibility Aids
37 20026779A 37
Operation
Visibility Aids
Machine Maskings
160
38 20026779A 38
Operation
Cab Layout
Cab Layout
F Q
J
E
H K
L
P D
C N
A B
Fig 13.
39 20026779A 39
Operation
Cab Layout
Component Key
A >>Left Armrest (64) (Contains 12V Volt Accessory socket)
B >>Right Interlock Bar (65)
C Left Lever>>Drive Controls, Switches and Instruments (41)
D Right Lever >>Operating Levers and Pedals (61)
E >>Left Hand Switch Panel (45)
F >>Radio (56)
G >>Front Panel (46)
H >>Cab Heater and Air Conditioning (Optional) (46)
J >>Instruments (52)
K Hand Throttle >>Right Hand Switch Panel (49)
L >>Ignition Switch (51)
40 20026779A 40
Operation
Drive Controls, Switches and Instruments
Drive Controls
Single Lever A
The machine is driven by use of the drive control lever A.
This lever performs two functions: forward/reverse drive
and steering. It is spring loaded to its central (neutral)
position.
Forward/Reverse Drive
Steering
The machine can also be turned round (spin turn) within its
own length. To spin turn to the left as at H, move the lever F G
from the neutral position to the left. To spin turn to the right C
as at J, move the lever from the neutral position to the
right. B
D E
Avoid excessive or too rapid movements of the lever which
could cause the machine to become unstable. Return the
H J
lever to the central position when the manoeuvre is
complete.
G F
C
Fig 14.
41 20026779A 41
Operation
Drive Controls, Switches and Instruments
Foot Throttle Control (Optional)
Fig 15.
NOTE
For details of the hand throttle control knob refer
to Right Hand Switch Panel. >>Right Hand
Switch Panel (49).
42 20026779A 42
Operation
Drive Controls, Switches and Instruments
! CAUTION
Do not switch from high to low speed when the
machine is travelling quickly otherwise the machine
will slow suddenly.
0069
2 Horn
T055270-2
Fig 16.
43 20026779A 43
Operation
Drive Controls, Switches and Instruments
Seven Function Lever 4 Not used
2 6 Aux Hold
T055270-3
Fig 17.
1 Horn
3 Not used
44 20026779A 44
Operation
Drive Controls, Switches and Instruments
Left Hand Switch Panel D Not Used
E Not Used
A B C E J
F G H D
G Not Used
H Sidelights (Option)
Press to switch the side lights ON. When
T053720-2
the side lights are ON the LED is
Fig 18. illuminated.
NOTE
When a function is fitted and enabled its switch is
back lit (dark when not fitted or enabled). The
LED above each switch is illuminated when the J Hazard Lights (Option)
function is selected. Press to switch the hazard warning lights
ON. When the hazard warning lights are
A Hydraulic Attachment Bracket Unlock on the LED is illuminated.
(Option)
Press and hold to unlock the attachment
bracket.
! WARNING
Do not drive on the road with the work lights switched
on. You can interfere with other drivers visibility and
cause an accident.
B Boom Suspension System (BSS)
2-2-2-5_1
(Option)
When the loader arm is fully lowered
press to activate BSS. ! WARNING
It is illegal to travel on public highways without proper
road lights. Do not take the machine on public
highways unless it is equipped with the optional road
light kit.
3-2-1-1
C High Flow AUX (Option)
Press to enable high flow aux. This switch
has to be pressed before the standard
aux is selected (it cannot be selected
when aux is running). When high flow is
selected the LED illuminates
45 20026779A 45
Operation
Drive Controls, Switches and Instruments
Cab Heater and Air Conditioning (Optional) Front Panel
C A
T053370-1
Fig 20.
Six air vents D , two to the front screen, one to the floor of
the cab and three on the operator, direct the air flow. The
floor vent has a manually operated on/off control.
46 20026779A 46
Operation
Drive Controls, Switches and Instruments
Right Lever
NOTE
If button C is pressed without switch A selected
the previously set position will be re-engaged.
NOTE
If no previously set position is recognised
maximum flow will be engaged.
Fig 21.
47 20026779A 47
Operation
Drive Controls, Switches and Instruments
Seven Function Lever (optional)
Fig 22.
48 20026779A 48
Operation
Drive Controls, Switches and Instruments
Right Hand Switch Panel C Loader Isolate
Audible/Visual. Press to turn ON the loader
L isolation. When the loader is isolated the
LED illuminates.
A
F
D Level Lift (Option)
G
Press to turn ON the Level lift. When the
level lift is ON the LED illuminates.
H D B E C E Auxiliary Isolate
Press to turn ON the aux isolation. When
the aux is isolated the LED illuminates.
Fig 23. F UP
G DOWN
49 20026779A 49
Operation
Drive Controls, Switches and Instruments
K Ignition Switch
>>Ignition Switch (51)
L LCD
50 20026779A 50
Operation
Drive Controls, Switches and Instruments
Ignition Switch Table 1.
Switch Numerals
Key Start (Standard) Front Work Lights B 1,2,3
I - On. Turning the switch in this position connects the After the fourth numeral of the pin code has been set, the
battery to the electrical circuits The switch will spring back machine can be started.
to this position when released from ll.
If a valid PIN code has been entered or the machine has
The right hand cluster will perform a system check. been running in the previous 15 seconds, it will not be
required to be entered again.
! CAUTION
! CAUTION
If any of the audible/visual warnings operate while the
engine is running, stop the engine as soon as it is safe If any of the audible/visual warnings operate while the
to do so and rectify the fault. engine is running, stop the engine as soon as it is safe
to do so and rectify the fault.
4-2-1-2
4-2-1-2
II - Start. Operates the starter motor to turn the engine.
II - Start. Operates the starter motor to turn the engine.
Keyless Start with PIN Code (Option)
Cab Interior Light
The keyless start option enables the operator to start the T2-020
machine without a ignition key. Instead the right switch Press either end of the light unit A to switch on the cab
panel is used to enter a 4 digit pin code and the ignition interior light. Pressing the other end will switch the light off.
switch can be turned by a handle.
Make sure the light is turned off when you intend to leave
The ignition switch has three positions. the machine for a long period of time.
T055120F
Fig 24.
51 20026779A 51
Operation
Drive Controls, Switches and Instruments
K Creep
Visual. Indicates that creep speed mode is
selected.
C Hydraulic Oil Temperature
Audible/Visual. The icon will turn red when
the temperature rises too high. The light will
flash and the alarm will sound if the
hydraulic oil temperature becomes critical.
STOP will also be displayed on the LCD.
52 20026779A 52
Operation
Drive Controls, Switches and Instruments
L Direction Indicators
Audible/Visual. Illuminates when the turn
signal/hazards are selected.
M Malfunction
Audible/Visual. An amber light indicates
caution and red light indicates a critical
warning. Stop the machine immediately
and contact your dealer.
N High Speed
Visual. Illuminates when high speed is
activated.
O Bucket Float
Visual. Illuminates when float is activated.
53 20026779A 53
Operation
Drive Controls, Switches and Instruments
Right Hand Switch Panel Logic Control
T055120
Fig 27.
Use the up and down buttons and the i button on the right
hand switch panel to scroll through the information screens
to show information. >>Right Hand Switch Panel (49).
54 20026779A 54
Operation
Drive Controls, Switches and Instruments
C Tachometer
Displays the engine speed.
D Clock
Displays the time.
E Error
Error is active.
F Error Code
Error code menu.
55 20026779A 55
Operation
Drive Controls, Switches and Instruments
Radio
1 2 3 4 5a 6
7a
JENSEN
9
MUTE DISP AM/FM AUX WB TIMER
HEAVY DUTY
JENSEN
VOL+ 8b
TIMER
AM TUN AUDIO TUN
MENU +
VOL-
SEEK SEEK
7b
+
AM/FM/WB RECEIVER JHD910
1 2 3 4 5 6
IN
X
AU
5b
8a
C074830
Fig 28.
To briefly display the software version on the LCD, press This shows the time.
and hold the power button for more than five seconds.
Liquid Crystal Display
Mute
The Liquid Crystal Display (LCD) panel 4 displays the
Press MUTE button 2 to silence the audio output in tuner, frequency, time and activated functions.
weather band or auxiliary input mode.
Volume
When no adjustment is made for ten seconds, the time will be set and normal operation will resume.
56 20026779A 56
Operation
Drive Controls, Switches and Instruments
Timer Beep Confirm (On or Off)
To directly access timer mode momentarily press the Determines if a beep will be heard each time a button
TIMER button 6. >>Fig 28. (56) is pressed.
Briefly press the TIMER button to start the timer function Operation Region (USA or Euro)
and the TIMER icon will flash in the display.
Selects the appropriate operating region.
Press the TIMER button again to stop the timer and the
TIMER icon will remain in the display (without flashing). Clock Display (12 or 24)
Press the button again briefly to resume the timer, or press Selects a 12-hour or 24-hour clock display.
and hold it for three seconds to reset it to zero and to
remove the Timer icon from the display. Display Brightness (Low, Mid or High)
To connect a portable audio device (MP3 player, iPOD, Back light Colour (Amber or Green)
etc.) to the radio use the audio patch cord (included) to
connect the headphone or line level output of the device to Determines the back light colour of the unit.
the 1/8" auxiliary input jack 5b. >>Fig 28. (56).
Turn On Volume (0-40)
Press the AUX button 5a to select auxiliary input mode.
Selects desired volume level for the unit to assume
Audio and Menu Adjustment when turned on.
Press the AUDIO/MENU button 9 momentarily to step Determines if the weather band alert feature is
through the following audio adjustment options: activated.
Bass NOTE
Treble The weather band is available for certain
Balance (left to right) territories only.
When the desired option appears in the display, press the When the desired option appears in the display, press
VOL+ button 7a or VOL- button 7b to adjust that audio VOL+ or VOL- to adjust that menu option.
feature.
When no adjustments have been made for three seconds,
When no adjustments have been made for three seconds, the unit will resume normal operation.
the unit will resume normal operation.
Menu Adjustment
57 20026779A 57
Operation
Drive Controls, Switches and Instruments
Tuner Operation
10 14
JENSEN
11a
MUTE DISP AM/FM AUX WB TIMER
HEAVY DUTY
JENSEN
VOL+ 11b
AM TUN AUDIO TUN
MENU +
VOL-
CH2
SEEK SEEK
+
AM/FM/WB RECEIVER JHD910
1 2 3 4 5 6
IN
X
AU
13 12a 12b
C074840
Fig 29.
Select a Band To store a station, select a band (if needed), then select a
station. Hold a preset button for three seconds. The current
Press the AM/FM button 10 momentarily to directly access station will be stored and the corresponding preset number
tuner mode from any other function mode. will appear in the display.
When the unit is already in tuner mode, briefly press AM/ To recall a station, select a band (if needed). Press a
FM to change between two AM bands (AM1 and AM2) and preset button momentarily and the unit will tune to the
three FM bands (FM1, FM2 and FM3). corresponding stored station.
NOTE NOTE
If the unit is programmed for European operation, Preset buttons recall channels 1-6 on weather
the sequence will be MW1, MW2, FM1, FM2 and band and cannot be set by the user.
FM3.
Manual Tuning
Press and hold TUN+ or TUN- for more than one second
to tune continuously in the selected direction until the
button is released.
Seek Tuning
Preset Stations
58 20026779A 58
Operation
Drive Controls, Switches and Instruments
Weather Band Operation (USA only)
10 14
JENSEN
11a
MUTE DISP AM/FM AUX WB TIMER
HEAVY DUTY
JENSEN
VOL+ 11b
AM TUN AUDIO TUN
MENU +
VOL-
CH2
SEEK SEEK
+
AM/FM/WB RECEIVER JHD910
1 2 3 4 5 6
IN
X
AU
13 12a 12b
C074840
Fig 30.
Press the WB button 14 to directly access the weather Depending on location, it is possible you will receive a very
band mode from any other function mode. weak signal or none at all. Also, similar to AM and FM
signals, weather band signals are subject to surrounding
What is the NOAA Weather Radio? conditions, weather, obstructions of the signal by hills or
mountains, etc.
This is a nationwide system that broadcasts local weather
emergency information 24 hours a day. If no NOAA signals are found/received, the NO SIG icon
will flash in the display and the tuner will scan all seven
The U.S. network has more than 530 stations covering the NOAA frequencies every 30 seconds.
50 states as well as the adjacent costal waters, Puerto
Rico, the U.S. Virgin Islands and the U.S. Pacific How will I know I am tuned to the weather band?
Territories.
When you select the weather band, the WB icon will
Each local area has its own transmitting station and there appear on the display panel, along with the current channel
are a total of seven broadcasting frequencies used: indication. Press TUN+ or TUN- to tune to each of the
seven channels until you find the weather band station
162.400MHz (CH1) broadcasting in your area.
162.425MHz (CH2)
NOAA Weather Alert
162.450MHz (CH3)
162.475MHz (CH4) The Weather Alert function adds an additional level of user
162.500MHz (CH5) safety by automatically switching from the current function
162.525MHz (CH6) mode to weather band mode for a minimum of 60 seconds
if a NOAA warning tone (1050 Hz) is received/detected. If
162.550MHz (CH7) no additional warning tone is received for 60 seconds, the
unit will switch back to the last known function mode.
How many stations can I expect to receive?
The Weather Alert function can be turned on or off by
Since the broadcasts are local weather and information, the Audio/Menu key, as described. >>Menu Adjustment
the transmission power is usually very low (much less than (57)
AM or FM stations) so you will usually receive only one
station unless you are on the edge of two or more When ON (default), the Weather Alert icon appears in the
broadcast signals. The most you will receive will be two or display and the weather tuner remains active, even when
three, and that is rare. the radio is turned off (as long as the power is still applied
59 20026779A 59
Operation
Drive Controls, Switches and Instruments
to the radio). If a weather alert is issued, the radio will turn
on and play the announcement. for 60 seconds, then turn
back off and revert to weather alert monitor mode.
NOTE
If the unit is programmed for European operation,
the WB function will be disabled.
60 20026779A 60
Operation
Operating Levers and Pedals
Loader Controls
Single Lever
NOTE
When float is selected the bucket is free to ride up
and down over the ground as the machine
travels. Float will remain selected until switch 3 is
pressed again.
5 To roll the bucket back (tilt), push the lever to the left.
T055210
61 20026779A 61
Operation
Operating Levers and Pedals
Dual Lever (Optional)
1 2 5 4
Loader Arm Control
NOTE
When float is selected the bucket is free to ride up
and down over the ground as the machine 4
travels. Float will remain selected until switch 3 is
pressed again. 2
T055240-1
Bucket Control
Fig 32.
The bucket is rolled forward (dumped) or rolled back
(tilted) by lateral movement of the right hand control lever.
2 To roll the bucket back (tilt) push the lever to the left.
! CAUTION
Do not attempt to operate the machine immediately
after starting in cold conditions, i.e. below -5C (20F).
The machine may not respond properly to control
movements. Allow at least 10 minutes warm up time
with the engine at half throttle. Operate the arm and
bucket controls to warm the hydraulic oil.
3-1-1-5_1
62 20026779A 62
Operation
Operating Levers and Pedals
! WARNING
The load could spill and you or others could be hurt or
killed. Level lift does not function when lowering the
attachment. The attachment will tip forwards during
lowering, even if the Level lift function is selected. You
must roll back the attachment during lowering to
prevent the attachment tipping forwards otherwise.
T057940
Fig 33.
63 20026779A 63
Operation
Safety Equipment
Safety Equipment
T057280
Fig 35.
T058510
Fig 34.
64 20026779A 64
Operation
Safety Equipment
Right Interlock Bar
T055190-3
Fig 37.
Fig 36.
NOTE
After removing the plug, the cap will be closed by
the spring hinge.
NOTE
DO NOT leave the beacon on the cab roof when
not in use. Stow securely.
65 20026779A 65
Operation
Safety Equipment
Operation
T2-041_3
! WARNING
Do not use the fire extinguisher in a confined space.
Make sure that the area is well ventilated during and S170520-3
after using the fire extinguisher. Fig 38.
4-2-3-1
The fire extinguisher should be inspected daily. Refer to
Routine Maintenance, Fire Extinguisher (if fitted).
! WARNING
After any use, the extinguisher should be replaced or
serviced.
4-2-3-2
66 20026779A 66
Operation
Before Starting The Engine
NOTE ! WARNING
If you are using the machine in very cold or very
hot climates. >>Operating Environment (80) When a seat belt is fitted to your machine replace it
with a new one if it is damaged, if the fabric is worn, or
1 Do a Pre-Start Inspection. if the machine has been in an accident. Fit a new seat
belt every three years.
For your own safety (and others') and for a maximum 2-3-1-7_1
service life of your machine, do a pre-start inspection
before starting the engine. i Check that the following are in working order:
a If you haven't already done it, do a walk round Lights, Warning Lights, Horn, Indicator Lights, All
inspection of the outside of the machine. Switches, Direction Indicators, Hazard Warning
>>Before Entering the Cab (27). Lights, Front Screen Washer and Wipers (if fitted).
b Remove dirt and rubbish from the cab interior, 2 Enter the cab and seat yourself. >>Entering and
specially around the pedals and control levers. Leaving the Cab (28)
Loose articles can fall and strike you or roll on the 7 Ensure the drive control is in neutral.
floor. You could be knocked unconscious, or the
controls could get jammed. If that happens you could
lose control of the machine.
2-2-3-7_1
67 20026779A 67
Operation
Starting the Engine
! CAUTION
Do not attempt to operate the machine immediately
after starting in cold conditions, i.e. below 0C (32F).
The machine may not respond properly to control
movements. Allow at least 10 minutes warm up time
with the engine at half throttle. Operate the arm and
bucket controls to warm the hydraulic oil.
3-1-1-5_1 C
! WARNING
Do not use ether or other starting fluids to assist cold
starting. Using these fluids may result in an explosion
causing possible injury and/or damage to the engine. D
3-2-1-9
NOTE
>>Ambient Temperatures Below -20C (Below
-4F) (69)
NOTE
>>Ambient Temperatures -12C to -20C (10F
to -4F) (69). A B
NOTE
>>Ambient Temperatures 0C to -12C (32F
to 10F) (69).
NOTE
>>Ambient Temperatures 10C to 0C (50F to T055280
32F) (69) Fig 39.
68 20026779A 68
Operation
Starting the Engine
8 Check for normal machine operation prior to starting 5 Allow the engine to sit at idle for 5 minutes with no
work. operation of the hydraulic services (transmission or
loader).
NOTE
6 Operate the loader arm for 5 minutes.
New engines do not require a running-in period.
The engine/machine should be used in a normal
work cycle immediately; glazing of the piston Ambient Temperatures 0C to -12C
cylinder bores resulting in excessive oil (32F to 10F)
consumption could occur if the engine is gently
run-in. Under no circumstances should the 1 Turn the ignition switch to position I.
engine be allowed to idle for extended periods;
(e.g. warming up without load). 2 A 20 second glow plug countdown must be observed.
Ambient Temperatures Below -20C 3 Turn the ignition switch D fully clockwise against the
(Below -4F) spring to position II to start the engine.
The Block heaters are available in two versions, 110V and 4 As soon as the engine starts, release the ignition
240V. Check that the electricity supply is the correct switch which will return to position I.
voltage before connecting it to the machine.
5 Operate the loader arm and observe proper cycle
When block heaters are fitted, their connectors can be times.
found on the right hand side of the engine bay stowed
above the fuel water separator filter. >>Access Panels
(120)
69 20026779A 69
Operation
Preparing The Machine For Travel
1 Lower the loader arm to the lowest safe travel position In the U.K., before travelling on public roads, it is your
B. responsibility as a user to comply with The Road Vehicles
(Construction and Use) (Amendment) Regulations 1997
2 Roll back (tilt) the bucket or other attachment C. ("Bridge Bashing Regs."). By way of guidance only, the
following steps may be taken to comply:
3 Press the loader isolate switch to isolate the loader
controls if BSS is not engaged.>>Right Hand Switch
Panel (49). NOTICE
IMPORTANT
While this information is believed to be correct,
Volvo cannot be aware of all circumstances in
which Volvo machines may be operated on a
Public Highway and it is the responsibility of the
user to ensure compliance with the regulations.
! WARNING
It is illegal to travel on public highways without proper
road lights. Do not take the machine on public
highways unless it is equipped with the optional road
light kit.
3-2-1-1
! WARNING
Do not drive on the road with the work lights switched
on. You can interfere with other drivers visibility and
cause an accident.
2-2-2-5_1
Fig 41.
70 20026779A 70
Operation
Preparing The Machine For Travel
d Move lever A slowly in a clockwise direction to its sure there is adequate ground clearance below the boom
horizontal position to prevent the arm from being and attachment to allow for this movement.
raised.
To Engage the BSS
e Close the rear door. >>Access Panels (120).
1 The attachment must be resting on the ground.
To allow the arm to be raised again move lever A
to its vertical position. 2 Press the BSS button A in the left hand panel.
Transportation Link (If fitted) 3 If the BSS does not activate the BSS light will flash
then time out.
The optional transportation link A can be fitted to the
machine between the loader arm and the attachment 4 Ensure that the LED remains lit.
bracket to prevent the bucket from opening during transit.
The link is stowed in position B when not in use. 5 Once the light remains lit raise loader arm to a safe
travel position.
A A
B
T057090
Fig 42.
The switch for the side lights is on the left switch panel.
NOTICE
IMPORTANT >>Left Hand Switch Panel (45).
When using BSS do not allow the boom to collide
with the machine structure or the ground. The The front dipped beam and rear lights switch is on the right
boom may need to be periodically moved switch panel. >>Right Hand Switch Panel (49).
upwards to maintain the correct height.
71 20026779A 71
Operation
Testing the Park Brake
! WARNING
Before testing the park brake make sure the area
around the machine is clear of people.
2-2-4-5
A
! WARNING
Be careful, if the park brake is not functioning and the
drive controls are in neutral the machine will roll down
the slope. To stop the machine engage drive controls.
0149
! WARNING
Do not use a machine with a faulty park brake.
3-2-3-10_2
! WARNING B
Non approved modifications to drive ratios, machine
weight or wheel and tyre sizes may adversely affect
the performance of the park brake. Fig 44.
3-2-3-11
72 20026779A 72
Operation
Getting the Machine Moving
Getting Moving
1 Check your seat and seat belt
! WARNING
Do not dismount a moving machine.
3-2-3-12
73 20026779A 73
Operation
Stopping and Parking the Machine
! WARNING
You or others can be killed or injured if you suddenly
change from forward to reverse, or vice versa, when
travelling. The machine will immediately reverse
direction without warning to others. Always follow the
recommended procedure for changing between
forward and reverse drive.
3-2-1-5
! WARNING
Ensure that the foot pedals are isolated before exiting
the machine.
3-2-1-15
74 20026779A 74
Operation
Working With The Machine
Operating Practices and Site Safety implication and gives no warranty or representation of
T2-057_2
assurance in respect of the accuracy of the same.
This section explains some techniques and procedures for
efficient and safe use of the machine and its attachments. Remember that your machine is mobile. Whenever
Attention is also drawn to the various safety aspects of possible, manoeuvre it into a position which combines
operating on site. safety and efficiency. But if you have to choose, always
remember that: Safety must come first.
Read and understand this section before you start working
with the machine. Clothing and Safety Equipment
T2-069
Make sure that you have had adequate training and that Do not wear loose clothing or jewellery that can get caught
you are confident in your ability to operate the machine on controls or moving parts. Wear protective clothing and
safely before you use it. Practice using the machine and its personal safety equipment issued or called for by the job
attachments until you are completely familiar with the conditions, local regulations or as specified by your
controls and what they do. employer.
With a careful, well trained and experienced operator, your Danger Zone
machine is a safe and efficient machine. With an T2-046
inexperienced or careless operator, it can be dangerous. The danger zone is the circular area around the machine
Do not put your life, or the lives of others, at risk by using where the moving parts can reach. During operation of the
the machine irresponsibly. machine, keep all persons out of the danger zone. Persons
in the danger zone could be injured. Refer to
Before you start to work, tell your work mates what you will Specifications.
be doing and where you will be working. On a busy site,
use a signalman.
Lifting (Object Handling)
Appropriate job site organisation is required in order to
Do not use this machine for lifting or craning operations.
minimise hazards that are caused by restricted visibility.
Job site organisation is a collection of rules and
procedures that coordinates machines and people that Log Moving/Handling
work together in the same area. Examples of job site T2-047
organisation include: Do not use the machine to move or handle logs unless it
has been fitted with adequate log protection. You could
Restricted areas cause serious injury to yourself and damage the machine.
Contact your authoirzed dealer.
Controlled patterns of machine movement
A system of communication
Safety Practices
P2-2019_3
You and/or your company could be legally liable for any
Read Operating Safety (Introduction Section), plus the
damage you may cause to public utilities. It is your
following information.
responsibility to make sure that you know the locations of
any public utility cables or pipes on the site which could be
damaged by your machine. ! WARNING
Reworking Old Sites
Before doing any job not covered in this manual, find out There could be dangerous materials such as
the correct procedure. Your local distributor will be glad to asbestos, poisonous chemicals or other harmful
advise you. substances buried on the site. If you uncover any
containers or you see any signs of toxic waste, stop
There are a wide variety of situations in which your the machine and advise the site manager immediately.
machine may be used. Consequently, in all cases, the 2-2-5-5
applicability of these notes must be determined by the
person seeking to apply them, on the basis of his/her own
judgement, in the light of the conditions in which use is
intended and subject to all relevant statutory requirements.
75 20026779A 75
Operation
Working With The Machine
! WARNING
Operating Practices
Water Supplies and Drains
Before you start using the machine, check with your
! DANGER
local public water supplier if there are buried pipes Drive Safely
and drains on the site. If there are, obtain a map of their Drive the machine smoothly. Spin turn manoeuvres,
locations and follow the advice given by the water zig-zag driving or turning too fast can cause the
supplier. vehicle to overturn.
8-1-2-2_2
You are strongly advised to make sure that the safety
arrangements on site comply with the local laws and
regulations concerning work near buried pipes and ! WARNING
drains. Travelling
2-2-5-6 Always travel with the loader arm set to its lowest
position with the bucket (attachment bracket) rolled
back (tilted). A raised loader arm with a loaded bucket
! WARNING will make the machine unstable. A raised loader arm
Fibre Optic Cables will also drastically reduce your visibility.
If you cut through a fibre optic cable, Do not look into 3-1-1-2_1
the end of it, your eyes could be permanently
damaged. Avoid exaggerated movements of the lever(s) which could
8-2-9-20 cause the machine to go out of control through violent
changes of speed and/or direction.
! WARNING
Underground Gas Pipes When moving off from rest, gently move the Drive Control
Before you start using the machine, check with your Lever(s) from the neutral position. Gradually increase the
local gas company if there are any buried gas pipes on lever movement until the desired speed is reached.
the site.
! WARNING
If there are buried gas pipes we recommend that you
ask the gas company for any specific advice regarding You or others can be killed or injured if you suddenly
the way you should work on the site. change from forward to reverse, or vice versa, when
travelling. The machine will immediately reverse
Some modern gas pipes cannot be detected by metal direction without warning to others. Always follow the
detectors, so it is essential that an accurate map of recommended procedure for changing between
buried gas pipes is obtained before any excavation forward and reverse drive.
work commences. 3-2-1-5
Hand dig trial holes to obtain precise pipe locations. When changing between forward and reverse drive,
Any cast iron pipes found should be assumed to be always bring the machine to rest first by progressively
gas pipes until contrary evidence is obtained. moving the Drive Control Lever(s) into the neutral position.
Older gas pipes can be damaged by heavy vehicles Always negotiate a turn by gentle, progressive use of the
driving over the ground above them. lever(s) until the required rate of turn is achieved, and
straighten up in the same way afterwards. Never suddenly
Leaking gas is highly explosive. change from a turn in one direction to a turn in the opposite
direction.
If a gas leak is suspected, contact the local gas
company immediately and warn all personnel on the When moving the machine, stay alert for obstructions and
site. Ban smoking, ensure that all naked lights are possible hazards.
extinguished and switch off any engines which may be
running. When travelling downhill, adjust the forward/reverse
setting of the Drive Control Lever(s) to achieve a suitable,
You are strongly advised to make sure that the safety steady speed.
arrangements on site comply with the local laws and
regulations concerning work near buried gas pipes. Remember that the Drive Control Lever(s) are like a
2-2-6-1_1 progressive gear lever, not a throttle, i.e. full lever travel
represents high gear. If the engine gets overloaded and
seems likely to stall, ease off the Drive Control Lever(s) to
allow the engine speed to pick up again. To spin turn, use
small lever movements (a low gear) otherwise the engine
may stall.
76 20026779A 76
Operation
Working With The Machine
When overloading of the engine seems to be a recurring
problem, increase the setting of the Hand Throttle Lever if ! WARNING
the engine is not already running at its preset maximum
Do not operate the machine on an incline of 35 or
speed. If the engine is already running at its maximum
more as it can cause damage to the engine.
speed, reduce the load by easing off the Drive Control
Lever(s). 3-2-1-14
Fig 45.
! WARNING 35
T055340
When digging, keep the bucket horizontal. Digging Fig 47.
with the bucket tilted forward may cause damage to
the bucket or the machine. Lifting Operations on Slopes
3-2-1-13
! WARNING
Conducting lifting operations on gradients can be
dangerous. The machine can become laterally
unstable and tip over. You and others can be seriously
injured or killed.
3-1-1-7
! WARNING
Stop the machine and apply the park brake before
conducting any lifting operations.
0020
77 20026779A 77
Operation
Working With The Machine
! WARNING ! WARNING
Controls
You or others can be killed or seriously injured if you When loading with material from a high bank or pile,
operate the control levers from outside the machine. remove any overhang first. Watch out for sliding
Operate the control levers only when you are correctly material. If overhanging material falls, you and your
seated. machine could be buried.
0179_2 2-2-6-3
Remember that you will be driving the machine while you On hard surfaces, as the bucket enters the pile, start rolling
are using the loader. Keep alert for bystanders and back (tilting) the bucket while raising the loading arm at the
possible hazards. Stay in the correct driving position. Keep same time. This will sweep the bucket up the pile,
your seat belt fastened. gathering material as it goes.
Keep the loader arm fully down when travelling. This Easing back the Drive Control Lever(s) will give more
increases your visibility and makes the machine more power to operate the bucket. Try to fill the bucket in one
stable. pass. Half full buckets are less productive.
Never lower the seat bar to the working position unless you When moving the load, roll the bucket right back to prevent
or someone suitably qualified is seated correctly in the spillage.
machine and the door is properly closed and latched.
When you are loading from a pile of loose material, start at
the bottom and follow up the face as shown. Approach the
! WARNING pile with the bucket level and skimming the ground.
Slopes
When transporting a load on a slope, drive slowly and In tightly packed material, start at the top and work down.
keep the load uphill of the machine. This will increase
stability. When removing material from a stockpile, start at a
2-1-1-5 bucket's height from the base. Once the height of the
stockpile has been reduced, begin loading from the base.
! WARNING
If the machine should accidentally tip forward, stop
the engine as soon as possible after righting the
machine and check the engine oil level. Some oil loss
can occur if this happens.
A
3-2-1-10_1
! WARNING
Should the machine start to roll over, you can be
crushed if you try to leave the cab. If the machine
starts to roll over, do not try and jump from the cab. T054340
Fig 48.
Stay in the cab, with your seat belt fastened.
INT-2-1-12
78 20026779A 78
Operation
Working With The Machine
Loading a Truck Use of Machines on Gradients or Slopes
T2-004_2
Put the truck(s) at an angle of about 45 to the pile, as Do not use the machine on gradients of more that 35
shown. This cuts out unnecessary manoeuvring. Allow
enough distance for the bucket to reach its unloading
height while you are travelling, without slowing down. ! WARNING
Keep the wind on your back. This keeps dust away from Ensure that you have been trained and are familiar
you and your machine. with the use of machines on gradients, and
understand the adverse affects that gradients and site
Move your machine as close as possible to the truck conditions can have on stability. Never use the
before unloading. machine on a gradient if you do not understand the
recommended practices for the use of machines in
If the truck body is about as long as a bucket's width, tip the such applications.
load into the centre of the truck. If the truck is two bucket- 0017
widths long or more, load the front of the truck first.
145500-2
Fig 49.
79 20026779A 79
Operation
Operating Environment
Operating Environment
5 Fill the fuel tank at the end of each work period. This
will help to prevent condensation forming on the tank
walls.
NOTICE
IMPORTANT
Do not connect two batteries in series to give 24
volts for starting as this can cause damage to the
electrical circuits.
80 20026779A 80
Operation
Refuelling The Machine
If air enters the fuel system, the engine speed will vary
dramatically and low power will be experienced. The
symptoms may be made worse when the machine
operates on steep gradients.
NOTE
If you Increase the engine speed or load while
there is air in the fuel system, then subsequent
damage to the engine can occur.
If the fuel supply contains air, you must stop the engine, fill
the fuel tank then bleed the fuel system to remove the air.
Refer to Routine Maintenance, Fuel System.
NOTICE
IMPORTANT
You must bleed the fuel system after a fuel filter
change.
81 20026779A 81
Operation
Refuelling The Machine
Filling the Tank We recommend that you lock the fuel cap A to prevent
theft and tampering.
NOTICE
IMPORTANT
Before you add the fuel to the machine, refer to
Fluids, Lubricants and Capacities, Fuels. If
you use the incorrect type of fuel or fuel which is
contaminated, then damage to the fuel injection
system can occur.
! CAUTION
Consult your fuel supplier or authorized distributor
about the suitability of any fuel you are unsure of.
GEN-9-2
! WARNING
Fuel A
Fuel is flammable; keep naked flames away from the
fuel system. Stop the engine immediately if a fuel leak
is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel
which could cause a fire. There could be a fire and T055160
injury if you do not follow these precautions. Fig 50.
INT-3-2-2_3
! WARNING
Do not use petrol (gasoline) in this machine. Do not
mix with the diesel fuel; in storage tanks the petrol
(gasoline) will rise to the top and form flammable
vapours.
INT-3-1-6
! WARNING
Mobile Phones
Switch off your mobile phone before entering an area
with a potentially explosive atmosphere. Sparks in
such an area could cause an explosion or fire
resulting in death or serious injury.
! CAUTION
Spilt fuel may cause skidding and therefore accidents.
Clean any spilt fuel immediately.
At the end of every working day, fill the tank with the correct
type of fuel. This will prevent overnight condensation from
developing in the fuel.
82 20026779A 82
Operation
Moving A Disabled Machine
Fig 51.
Fig 52.
83 20026779A 83
Operation
Moving A Disabled Machine
! WARNING
Lifting Equipment
You can be injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the item to 817/01803
Before installation and every use, visually inspect the lifting FOPS Level 2 Lift Points
points, paying particular attention to any evidence of
corrosion, wear, weld cracks and deformations. Ensure the The machine must be fitted with the four approved lifting
bolt threads seat in the tapped holes correctly. Apply eyes A, two at the front and two at the rear of the cab,
Loctite thread locker and torque tighten the lifting points to secured by the correct bolts. These lifting eyes are
190 Nm (140 lbf-ft). The ring body must be left free to rotate obtainable only from the manufacturers local authorized
and must be adjusted before attaching the lifting dealer or distributor. Do not use nongenuine substitutes
equipment. The lifting points are not suited for turning which may not be strong enough for the job.
under load. When attaching the lifting equipment pinches
and impacts must be avoided. Damage of the lifting eyes Before installation and every use, visually inspect the lifting
caused by sharp edges must also be avoided. points, paying particular attention to any evidence of
corrosion, wear, weld cracks and deformations. Ensure the
Always check that the lifting eyes are securely fastened bolt threads seat in the tapped holes correctly. Apply
into the cab before attaching the lifting chains. Loctite thread locker and torque tighten the lifting points to
190 Nm. The ring body must be left free to rotate and must
Lower the loader arm to its lowest position. Check that the be adjusted before attaching the lifting equipment. The
cab is unable to tilt and securely closed. >>Operation lifting points are not suited for turning under load. When
Position (120) attaching the lifting equipment pinches and impacts must
be avoided. Damage of the lifting eyes caused by sharp
Ensure the boom lower valve is fully closed with its lever in edges must also be avoided.
the horizontal position. >>Fig 52. (83)
Always check that the eye bolts are securely fastened into
the cab before attaching the lifting chains.
84 20026779A 84
Operation
Moving A Disabled Machine
Lower the loader arm to its lowest position. Check that the
cab is unable to tilt and securely closed.>>Operation
Position (120)
Ensure the boom lower valve is fully closed with its lever in
the horizontal position. >>Fig 52. (83)
Before lifting the machine into the air, take the strain and
ensure that lifting equipment is secure.
817/01803
A
B
85 20026779A 85
Operation
Transporting The Machine
Using a Trailer
! WARNING
The safe transit of the load is the responsibility of the
transport contractor and driver. Any machine,
attachments or parts that may move during transit
must be adequately secured.
5-2-5-9
NOTE
Before transporting the machine make sure you T054370
will be obeying the rules and laws of all the areas Fig 55.
that the machine will be carried through.
b Carefully reverse the machine onto the trailer.
Make sure that the transporting vehicle is suitable. Refer to
Specification section for the static dimensions of your c When the machine is safely in position, lower the
machine. >>Static Dimensions (168). loader arm to its lowest position.
a >>Retrieval (83).
86 20026779A 86
Operation
Transporting The Machine
Using a Truck
Provided a crane of adequate capacity is available, it is
permissible to lift a machine directly onto the back of a
suitable truck. For a safe and correct lifting procedure.
>>Safe Lifting Procedure (84). >>Transportation
Safety (87) 332/S5833
! WARNING C
Lifting Equipment
You can be injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the item to
C
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all
local regulations.
INT-1-3-7_2
! WARNING
Raised Equipment X
Never walk or work under raised equipment unless it
is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if
the control is operated (even with the engine stopped).
C E D
Transportation Safety
332/S5833
87 20026779A 87
Operation
Storage of the Machine
If you will not use the machine for an extended period, you Put the Machine into Storage
must store the machine correctly. If you prepare the T2-077
machine carefully and apply on-going care you can 1 Park the machine on level, solid ground.
prevent deterioration and damage to the machine while it
is in storage. Park the machine in a position where the machine is
easy to get access (in case the machine does not
Storage Area start at the end of the storage period).
The machine can be stored in a temperature range of: Place suitable timbers under the machine to eliminate
direct contact with the ground.
-40C to 54C (-40F to 129F).
2 Retract all cylinders and lower the attachments to the
When possible, you must keep the machine in a dry ground.
building or shelter.
3 Vent the hydraulic system.
If only an outdoor storage area is available, look for a
storage area with good drainage. 4 Remove the starter key.
If the machine is to be out of use for an extended period, 5 Apply a thin layer of grease or petroleum jelly to all
careful preparation and on-going care will minimise the exposed cylinder piston rods.
possibility of deterioration and damage while in storage.
6 Rectify any damage to paint finish in a professional
way.
Prepare the Machine for Storage
7 Remove the battery. Charge the battery.
1 Clean the machine to remove all unwanted material
and corrosive products.
Keep the battery in warm, dry conditions. Charge the
battery periodically.
Dry the machine to remove solvents and moisture.
NOTE
A A For battery removal and charging, refer to the
service manual.
During Storage
T2-078
4 Fill the fuel tank to prevent a build up of condensation 4 Start the engine.
in the tank.
88 20026779A 88
Operation
Storage of the Machine
5 Operate the hydraulic controls.
89 20026779A 89
Routine Maintenance
Service Requirements
Your machine has been designed and built to give 3 Date of purchase and hours of work.
maximum performance, economy and ease of use under a
wide variety of operating conditions. Prior to delivery, your 4 Nature of the problem.
machine was inspected both at the Factory and by your
Distributor to ensure that it reaches you in optimum Remember, only your an authorized distributor has access
condition. To maintain this condition and ensure trouble to the vast resources available to help support you. In
free operation it is important that the routine services, as addition, your distributor is able to offer a variety of
specified in this Manual, are carried out by an approved programmes covering Warranty, Fixed Price Servicing,
distributor at the recommended intervals. Safety Inspections, including weight tests, covering both
legal and insurance requirements.
This section of the Manual gives full details of the service
requirements necessary to maintain your machine at peak Service/Maintenance Agreements
efficiency.
To help plan and spread the costs of maintaining your
A Service Manual for your machine is available from your machine, we strongly recommend you take advantage of
distributor. The Service Manual contains information on the many Service and Maintenance Agreements your
how to repair, dismantle and assemble your machine Distributor can offer. These can be tailor made to meet
correctly. your operating conditions, work schedule etc.
It can be seen from the Service Schedules on the following Please consult your distributor for details.
pages that many essential service checks should only be
carried out by a trained specialist. Only Authorized Fit for Purpose Tests for Lifting
Distributor Service Engineers have been trained to carry
Equipment
out such specialist tasks, and only Authorized Distributor
T3-097
Service Engineers are equipped with the necessary
All lifting equipment (for example forks, lifting hooks and
special tools and test equipment to perform such tasks,
shackles) need regular inspection and testing by a
thoroughly, safely, accurately and efficiently.
competent person to ensure they are fit for purpose.
Only an authorized distributor is fully able to maintain and
This may be needed every six months or at least annually
service your machine.
in some countries to meet and comply with legislation and
for insurance purposes.
A Service Record Sheet or Book is provided which will
enable you to plan your service requirements and keep a
Check with your local distributor for further advice.
service history record. It should be dated, signed and
stamped by your Distributor each time your machine is
serviced. Obtaining Replacement Parts
T3-096
Remember, if your machine has been correctly If you use non-genuine authorized parts or consumables,
maintained, not only will it give you improved reliability but then you can compromise the health and safety of the
its resale value will be greatly enhanced. operator and cause machine failure
Owner/Operator Support A Parts Book for your machine is available from your
distributor. The Parts Book will help you identify parts and
order them from your distributor.
If you encounter a problem, you should contact your
Distributor's Service Department who are there to help
Your dealer will need to know the exact model, build and
you!
serial number of your machine. See Identifying Your
Machine (Introduction section).
You will have been given the names of the relevant service
contacts at your Distributor when the machine was
The data plate also shows the serial numbers of the
installed.
engine, transmission and axle(s), where applicable. But
remember if any of these units have been changed, the
To get the most from your Distributor please help them to
serial number on the data plate may be wrong. Check on
satisfy you by:
the unit itself.
1 Giving your name, address and telephone number.
90 20026779A 90
Routine Maintenance
Health and Safety
Lubricants Handling
T3-060_2
Introduction
! WARNING
Oil
It is most important that you read and understand this Oil is toxic. If you swallow any oil, do not induce
information and the publications referred to. Make sure all vomiting, seek medical advice. Used engine oil
your colleagues who are concerned with lubricants read it contains harmful contaminants which can cause skin
too. cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves to
Hygiene prevent skin contact. Wash skin contaminated with oil
thoroughly in warm soapy water. Do not use, diesel
Lubricants are not a health risk when used properly for fuel or kerosene to clean your skin.
their intended purposes. INT-3-2-3
Whenever you are handling oil products you should Used engine crankcase lubricants contain harmful
maintain good standards of care and personal and plant contaminants.
hygiene. For details of these precautions we advise you to
read the relevant publications issued by your local health Here are precautions to protect your health when handling
authority, plus the following. used engine oil:
Eyes
91 20026779A 91
Routine Maintenance
Health and Safety
Swallowing
! CAUTION
If oil is swallowed do not induce vomiting. Get medical
Do not disconnect the battery while the engine is
advice.
running, otherwise the electrical circuits may be
damaged.
Skin
INT-3-1-14
Fires ! DANGER
Electrolyte
Battery electrolyte is toxic and corrosive. Do not
! WARNING breathe the gases given off by the battery. Keep the
electrolyte away from your clothes, skin, mouth and
Do not use water to put out an oil fire. This will only eyes. Wear safety glasses.
spread it because oil floats on water. INT-3-2-1_3
! WARNING
! WARNING
Batteries give off an explosive gas. Do not smoke Battery Gases
when handling or working on the battery. Keep the Batteries give off explosive gases. Keep flames and
battery away from sparks and flames. sparks away from the battery. Do not smoke close to
the battery. Make sure there is good ventilation in
Battery electrolyte contains sulphuric acid. It can burn closed areas where batteries are being used or
you if it touches your skin or eyes. Wear goggles. charged. Do not check the battery charge by shorting
Handle the battery carefully to prevent spillage. Keep the terminals with metal; use an approved battery
metallic items (watches, rings, zippers etc) away from tester.
the battery terminals. Such items could short the INT-3-1-8_2
terminals and burn you.
92 20026779A 92
Routine Maintenance
Health and Safety
Warning Symbols
Symbol Meaning
Keep away from children.
A289230-1
Shield eyes.
A289260-1
A289280
Explosive Gas.
A289250
Battery acid.
A289240
A289270
Recycle
Is swallowed
93 20026779A 93
Routine Maintenance
Service Schedules
Service Schedules
A badly maintained machine is a danger to the operator In the example shown, A shows all service requirements to
and the people working around him. Make sure that the be carried out every 10 hours and B shows the
regular maintenance and lubrication jobs listed in the requirements to be carried out every 500 hours.
service schedules are done to keep the machine in a safe
and efficient working condition.
NOTICE
IMPORTANT
Services should be carried out at either the hourly
! WARNING interval or calendar interval, whichever occurs
first. Refer to Calendar Equivalents.
Maintenance must be done only by suitably qualified
and competent persons. NOTICE
IMPORTANT
The intervals given in the schedules must not be
Before doing any maintenance make sure the machine exceeded. If the machine is operated under
is safe, it should be correctly parked on level ground. severe conditions (high temperature, dust, water,
etc.), shorten the intervals.
To prevent anyone starting the engine, remove the
starter key. Disconnect the battery when you are not
using electrical power. If you do not take these
precautions you could be killed or injured.
8-3-1-1
795390-1
Calendar Equivalents
Calendar equivalents:
Every 10 Hours = Daily
Every 50 Hours = Weekly
Every 500 Hours = Six Months
Every 1000 Hours = Yearly
Every 2000 Hours = 2 Years
94 20026779A 94
Routine Maintenance
Service Schedules
Service Label
The service label is located inside the rear door. It is a
visual representation of the daily, weekly and six monthly
service checks. The label serves as a reminder of these
service checks and their intervals. Use the label and the
service schedule in this manual to perform the service
checks on time.
A
T058500
Fig 1.
95 20026779A 95
Routine Maintenance
Service Schedules
MC60C, MC70C, MC85C, MC95C, MC105C
MC60C MC70C
MC85C MC95C MC105C
Fig 2.
96 20026779A 96
Routine Maintenance
Service Schedules
MCT70C, MCT85C, MCT95C
MCT70C
MCT85C MCT95C
Fig 3.
97 20026779A 97
Routine Maintenance
Service Schedules
Radiator 7 - Clean
98 20026779A 98
Routine Maintenance
Service Schedules
HYDRAULICS
Oil Change
Oil Level 12 - Check
99 20026779A 99
Routine Maintenance
Service Schedules
ATTACHMENTS - ALL
Replace any damaged parts and excessively - Check
worn parts.
Grease all joints - Grease
Check for hydraulic leaks - Check
All safety labels are in place, are clean, and - Check
are legible.
Clean - Clean
PALLET FORKS
Grease top rail slots - Grease
GRAPPLE BUCKET
Activate the attachment cylinder(s) with the - Check
machine at a slow idle. Check for hydraulic
leaks or other problems.
(1) If operating under arduous conditions, change the engine oil and filter every 250 hours.
(2) The oil service interval will be affected by the fuel quality. Refer to Fuel System in the Maintenance section for more
information.
(3) More frequently if operating in dusty working environments.
(4) This may be required every six months or at least annually in some countries to meet and comply with legislation and
for insurance purposes.
(1) For information about the different container sizes that are available (and their part numbers), contact your
dealer.
Coolant Mixtures
T3-009_3
! WARNING
Antifreeze can be harmful. Obey the manufacturer's
instructions when handling full strength or diluted
antifreeze.
7-3-4-4_1
NOTICE
IMPORTANT
Do not exceed a 60% concentration, as the
freezing protection provided reduces beyond this
point.
Fuels give the following results: long engine life and acceptable
exhaust emissions levels. The fuel must meet the
minimum requirements that is stated. >>Table 2. ( 104)
NOTE >>Table 3. ( 106)
These recommendations are subject to change
without notice. Contact your local distributor for
the most up to date recommendations. NOTE
The footnotes are a key part of the Specification
Diesel Fuel Requirements for Distillate Diesel Fuel Table. Read ALL of the
footnotes.
Satisfactory engine performance is dependent on the use
of a good quality fuel. The use of a good quality fuel will
Table 2.
Specification for Distillate Diesel Fuel(1)
Property Units Requirements ASTM Test ISO Test
Aromatics %Volume 35% maximum D1319 ISO 3837
Ash %Weight 0.02% maximum D482 ISO 6245
Carbon Residue on 10% %Weight 0.35% maximum D524 ISO 4262
Bottoms
Cetane Number(2) - 40 minimum D613/D6890 ISO 5165
Cloud Point C The cloud point must not exceed the D2500 ISO 3015
lowest expected ambient temperature
Copper Strip Corrosion - No. 3 maximum D130 ISO 2160
Density at 15C (59F)(3) Kg/M 801 minimum and 876 maximum No equivalent ISO 3675
test ISO 12185
Distillation C 10% at 282C (539.6F) maximum D86 ISO 3405
90% at 3600C (680F) maximum
Flash Point C legal limit D93 ISO 2719
Thermal Stability - Minimum of 80% reflectance after D6468 No equivalent test
aging for 180 minute at 150C (302F)
Pour Point C Pour Point6C (42.8F) minimum D97 ISO 3016
below ambient temperature
Sulfur(1)(4) %mass The level of sulfur that is in the fuel is D5453/D26222 ISO 20846
controlled by emissions regulations. ISO 20884
Refer to Table for more information.
>>Table 3. ( 106)
Kinematic Viscosity(5) MM/S (cSt) The viscosity of the fuel that is D445 ISO 3405
delivered to the fuel injection pump 1.4
minimum/4.5 maximum
Water and Sediment %Weight 0.1% maximum D1796 ISO 3734
Water %Weight 0.1% maximum D1744 No equivalent test
Sediment %Weight 0.05% maximum D473 ISO 3735
Gums and Resins (6) mg/100mL 10mg per 100mL maximum D381 ISO 6246
Lubricity corrected wear mm 0.46 maximum D6079 ISO 12156-1
scar diameter at 60C
(140F)(7)
(1) The specification includes the requirements for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have < or = 15 ppm
(0.0015%) sulfur. Refer to ASTM D5453, ASTM D2622, or ISO 20846, ISO20884 test methods. The specification
includes the requirements for Low Sulfur Diesel (LSD). LSD fuel will have < or = 500 ppm (0.05%) sulfur. Refer to
ASTM 5453, ASTM D2622, ISO 20846 and ISO 20884 test methods.
(2) A fuel with a higher cetane number is recommended in order to operate at a higher altitude or cold weather.
(3) Via standards tables, the equivalent API gravity for the minimum density of 801 Kg/m3 (kilogram per cubic meter) is
45 and for the maximum density is 876 Kg/m3 is 30.
NOTE
Operating with fuels that do not meet the
recommendations can cause the following
effects: Starting difficulty, poor combustion,
deposits in the fuel injectors, reduced service life
of the fuel system, deposits in the combustion
chamber, and reduced service life of the engine.
This is an indication of the mixture of different This group of fuel specifications is considered acceptable,
hydrocarbons in the fuel. A high ratio of light weight but these fuels MAY reduce the engine life and
hydrocarbons can affect the characteristics of combustion. performance.
Cold Weather Fuel There are many other diesel fuel specifications that are
published by governments and by technological societies.
The European standard "EN590" contains climate Usually, those specifications do not review all the
dependant requirements and a range of options. The requirements that are addressed the tables. >>Table 2.
options can be applied differently in each country. There ( 104) >>Table 3. ( 106) To ensure optimum engine
are 5 classes that are given to arctic climates and severe performance, a complete fuel analysis should be obtained
winter climates. 0, 1, 2, 3, and 4. before engine operation. The fuel analysis should include
all of the properties that are stated in the tables.
Fuel that complies with "EN590" CLASS 4 can be used at
temperatures as low as -44C (-47.2F). Refer to "EN590 Fuel Additive
for a detailed discretion of the physical properties of the
fuel Supplemental diesel fuel additives are not generally
recommended. This is due to potential damage to the fuel
The diesel fuel "ASTM D975 Grade 1-D S15 or S500 that system or the engine. Your fuel supplier or the fuel
is used in the United States of America may be used in manufacturer will add the appropriate supplemental diesel
very cold temperatures that are below -18C (-0.4F). fuel additives.
In extreme cold ambient conditions, you may also use Additives may be required in some special circumstances.
fuels that are listed in the table. >>Table 5. ( 109) These Fuel additives need to be used with caution. The additive
fuels are intended to be used in temperatures that can be may not be compatible with the fuel. Some additives may
as low as -54C (-65.2F). precipitate. This action causes deposits in the fuel system.
The deposits may cause seizure. Some additives may be
Table 5. corrosive, and some additives may be harmful to the
Light Distillate Fuels(1) elastomers in the fuel system. Some additives may raise
fuel sulfur levels above the maximum that is allowed by the
Specification Grade
EPA or the other regulatory agencies. Contact your fuel
MIL-DTL-5624U JP-5 supplier for those circumstances when fuel additives are
MIL-DTL-83133E JP-8 required. Your fuel supplier can recommend the
appropriate fuel additive and the correct level of treatment.
ASTM D1655 Jet-A- I
NOTE
For the best results, your fuel supplier should
treat the fuel when additives are required. The
treated fuel must meet the requirements that are
stated the tables. >>Table 2. ( 104) >>Table 3.
( 106)
Tools
B
C
T057990
Fig 5.
T057850
Fig 4. Wheel Brace
Introduction
A
! WARNING
Maintenance must be done only by suitably qualified
and competent persons.
! WARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
T055350
Disconnect the battery, to prevent the engine being Fig 6.
started while you are beneath the machine.
GEN-4-1_1
3 Put the attachment flat on the ground. 4 Raise the arm just far enough to install the strut.
4 Stop the engine and remove the ignition key. 5 Stop the engine and remove the ignition key.
If the keyless ignition option is fitted stop the engine If the keyless ignition option is fitted stop the engine
and wait 15 seconds. and wait 15 seconds.
! WARNING
Raised Equipment
Never walk or work under raised equipment unless it
is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if
the control is operated (even with the engine stopped).
NOTE
If you lift the arm to get access for maintenance,
you must install the maintenance strut on the
arm.
T055550
Fig 7. Storage Vertical Lift
NOTE
Lower the arm carefully, to prevent possible
damage to the strut. Stop as soon as the weight
of the arm is on the strut.
T055550
Fig 10.
Check the Machine Body and Structure Check the Seat and Seat Belt
T3-063_3 T3-008_2
Inspect all pivot point welds. Inspect the seat belt for signs of fraying and stretching.
Inspect the conditioin of all pivot points. Check that the stitching is not loose or damaged. Check
Check pivot pins are correctly in place and secured by that the buckle assembly is undamaged and works
their locking devices. correctly.
Check pivot pins are correctly in place and secured by their Check that the belt mounting bolts are undamaged,
locking devices. correctly fitted and tightened.
Check steps and handrails are undamaged and secure. Check seats are undamaged and secure. Check seat
adjustments for correct operation.
Check for broken, cracked or crazed window glass and
mirrors. Replace damaged items. Check the Hydraulic Hoses and Fittings
T3-072
Install the valve caps firmly to prevent dirt from entering the
valve. Inspect for leaks when you check the tyre
pressures.
Inspect the tyre valve for leaks, when you check the tyre
pressures.
! WARNING
You could be killed or seriously injured if you operate
a machine with a damaged or missing ROPS/FOPS. If
the Roll Over Protection Structure (ROPS)/Falling
Objects Protection Structure (FOPS) has been in an
accident, do not use the machine until the structure
has been renewed. Modifications and repairs that are
not approved by the manufacturer may be dangerous
and will invalidate the ROPS/FOPS certification.
INT-2-1-9_6
Greasing
! CAUTION
Waxoyl contains turpentine substitute which is
flammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep
flames away during the drying period.
NOTE
The machine must always be greased after
pressure washing or steam cleaning.
NOTE
Where applicable, refer to the manufacturers
manual for instructions on the maintenance of
optional attachments.
! WARNING
Raised Equipment
Never walk or work under raised equipment unless it
is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if
the control is operated (even with the engine stopped).
2 3
1
1 3
Access Panels
Rear Door 2 Swing the door to the right and push it closed.
Maintenance Position
A B
T057360
Fig 13.
4 Swing the door open to the left. 4 Lift the cooling pack and fan assembly B.
NOTE
The engine top cover must be closed before the
rear door is closed
Fig 15.
Maintenance Position If the keyless ignition option is fitted stop the engine
and wait 15 seconds.
NOTICE
IMPORTANT
If you raise the cab to get access for maintenance
you must install the cab maintenance strut.
NOTE
The loader arm must be raised before tilting the
cab. >>How to Prepare the Machine for T055180-1
T054060
Fig 16.
T054110-1
Fig 19. Stowed Position
T054100
T054110-2
Fig 18.
Fig 20. Strut Supporting the Cab
! WARNING
Raised Machine
NEVER position yourself or any part of your body
under a raised machine which is not properly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
INT-3-3-7_1
1 Make sure the area between the cab and the chassis
is clear before you lower the cab.
NOTE
Do not push on the front glass if fitted. The glass
could break.
T058000
4 Install the two rear mounting nuts A and compression Fig 21.
plates B to secure the cab. Torque tighten to 205 Nm.
(151 lbf-ft).
B A
NOTE
The compression plate B is critical for ROPS
integrity. Only replace with the correct approved
part.
NOTE
Never operate the machine with the cab in the
raised position. Always secure the cab using the
rear mounting nuts and compression plates
tightened to the correct torque. If they are not T055180-1
T054130
Fig 23.
NOTICE
IMPORTANT
Do not use the machine without the intake filter
fitted.
Electrical System
Refer to the service manual for battery maintenance. Use only sound booster cables with securely attached
connectors. Connect one jump lead at a time.
Maintenance free batteries used in normal temperate
climate applications should not need topping up. However, The machine has a negative ground electrical system.
in certain conditions (such as prolonged operation at Check which battery terminal is positive (+) before
tropical temperatures or if the alternator overcharges) the making any connections.
electrolyte should be checked.
Keep metal watch straps and jewellery away from the
jump lead connectors and the battery terminals - an
accidental short could cause serious burns and
damage equipment.
NOTE
A good frame ground is part of the main frame,
free from paint and dirt. Do not use a pivot pin for
a ground.
Fig 24.
! WARNING
Table 6. Primary Fuses
When the engine is running, there are rotating parts in Fuse No. Circuits Protected Rating
the engine compartment. Before disconnecting the
cables, make sure that you have no loose clothing 1 ECU, Right hand console, Left 60 Amp
(cuffs, ties etc.) which could get caught in rotating hand console
parts. 2 Control Lever, Heated Seat, 60 Amp
2-2-4-3 Engine ECU, Beacon, Horn
3 Worklights, Radio, Interior light 60 Amp
5 Disconnect the negative booster cable from the
machine frame ground. Then disconnect it from the 4 Starter, Glow Plugs 100 Amp
booster supply. 5 (option) AC, Wash Wipe 60 Amp
Fig 25.
Fuses and Relays
Remember to check the Individual circuit fuses as well as
Primary Fuses the primary fuses. >>Individual Circuit Fuses (128).
To further protect the machine wiring harnesses and
electrical circuits, a primary fuse box A is fitted to the
battery positive terminal. >>Table 6. Primary Fuses ( 127)
A
Fig 27. Individual Circuit Fuses
T055190-2
Fig 26.
If the machine is fitted with the seven function Control The relays are located behind a cover A behind the
Lever then there are additional fuses situated underneath operators seat. >>Fig 26. ( 128). >>Table 9. Relays
the right hand arm rest. Remove the top cover to access ( 129).
the fuses.
Table 9. Relays
Table 8. Individual Circuit Fuses Relay Description
Fuse Circuits Protected Rating
A Ignition 1
No. (Amps)
B Ignition 2
1 12V Supply to Attachment 20
C Not Used
2 Attachment Primary Function 20
Solenoids D Horn
3 Attachment Secondary Function 20 E Front Worklights
Solenoids F Rear Worklights
4 Attachment Third Function Solenoids 20 G Not Used
5 Attachment Fourth Function Solenoids 10 H Not Used
J Not Used
K Ignition - Wash/Wipe (optional)
L Ignition - HVAC (optional)
M Not Used (optional)
5 4 3 2 1
A B C
T057420-2
Fig 28.
G H J
K L M
Fig 29.
Fig 30. Relays
Fig 31. A B C
D E F
G H
T057420-3
Fig 32. Seven Function Relays
! CAUTION
Before carrying out arc welding on the machine,
disconnect the battery and alternator to protect the
circuits and components. The battery cables must still
be disconnected even if a battery master switch is
fitted.
INT-3-1-13
Fig 33.
Engine
! CAUTION
It is illegal to pollute drains, sewers or the ground.
Clean up all spilt fluids and/or lubricants.
Fig 34.
! WARNING
Oil
Changing the Oil and Filter
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
Refer to the service manual for changing the engine oil and
contains harmful contaminants which can cause skin
filter.
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves to
prevent skin contact. Wash skin contaminated with oil
thoroughly in warm soapy water. Do not use, diesel
fuel or kerosene to clean your skin.
INT-3-2-3
! WARNING
Do not exceed the correct level of engine oil in the
sump. If there is too much engine oil, the excess must
be drained to the correct level. An excess of engine oil
could cause the engine speed to increase rapidly
without control.
GEN-1-18
5 Fit filler cap and dipstick, make sure that they are fully
inserted and tightened.
NOTE
! WARNING If the level in the expansion bottle or radiator is
low, then continue with steps 8 to 10.
The cooling system is pressurised when the coolant is
hot. When you remove the cap, hot coolant can spray
8 Carefully loosen cap B on the radiator. Let any
out and burn you. Make sure that the engine is cool
pressure escape before removing the cap. Fill with
before you work on the cooling system.
pre-mixed water/antifreeze until it reaches the correct
9-3-3-1_2
level and replace cap B.
1 Make the machine safe with the arm lowered.
9 Fill the coolant reservoir A with antifreeze mixture
>>Prepare the Machine for Maintenance (111)
until it reaches the COLD level.
2 Stop the engine and let it cool down.
10 Run the engine for a while to raise the coolant to
working temperature and pressure. Stop the engine,
3 Open the rear door. >>Access Panels (120).
checks for leaks and re-check the fluid level.
Fig 35.
Alternator Belt
If the belt requires adjustment:
Check and Adjust the Alternator Belt
a Loosen bolts B and C which secure the alternator.
! WARNING
! CAUTION
Make sure the engine cannot be started. Disconnect the
battery before doing this job. Any leverage required to position the alternator must
be applied at the drive end bracket only, using a
wooden lever.
1 Make the machine safe with the arm lowered. See
>>Prepare the Machine for Maintenance (111)
b Reposition the alternator until belt deflection at
2 Open the rear door. See >>Access Panels (120) point X is 7 mm (0.28 in).
3 Remove the bolts A securing the drive belt guard and c Tighten bolts B and C.
remove the drive belt guard.
6 Refit the drive belt guard.
NOTICE
IMPORTANT
You must refit the belt guard.
! WARNING
A
You or others could be seriously injured by rotating parts if
the alternator drive belt cover plate is not fitted. Always refit
the cover plate before starting the engine.
Fig 36.
Air-Conditioning Compressor Belt d Use a poly V-belt tension meter to check the belt
tension. When correctly set, the belt has a tension
Check and Adjust the Alternator Air- of 1070N.
Conditioning Compressor Belt
5 Refit the drive belt guard.
! WARNING NOTICE
IMPORTANT
You must refit the belt guard.
Make sure the engine cannot be started. Disconnect
the battery before doing this job.
! WARNING
1 Make the machine safe with the arm lowered. See You or others could be seriously injured by rotating
>>Prepare the Machine for Maintenance (111) parts if the alternator drive belt cover plate is not fitted.
Always refit the cover plate before starting the engine.
2 Open the rear door. See >>Access Panels (120)
Fig 37.
C
Fig 38.
! CAUTION
NOTICE
IMPORTANT
Do not run the engine with the dust valve K Do not run the engine when the element has been
removed. removed.
0173
3 Check the dust valve K is not blocked.
4 Inspect the rubber flaps for cuts and nicks and check NOTE
that the rubber is not perished. Renew if necessary. Do not attempt to wash or clean the elements -
they must only be renewed.
NOTE
Do not run the engine with the dust valve K
removed.
NOTE
In a dusty environment, the outer element may
have to be changed more frequently than the
service schedule recommendation. A new inner
element must be fitted at least every third time the
outer element is changed. As a reminder, mark
the inner element with a pen each time the outer
element is changed.
Fig 39.
Refer to the service manual for changing the engine air
cleaner elements.
Fuel System
! WARNING
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of pressurised
fluid and wear protective glasses. If fluid penetrates
your skin, get medical help immediately.
0177
! CAUTION
Do not allow dirt to enter the system. Before
disconnecting any part of the system, thoroughly
clean around the connection. When a component has
been disconnected, always fit protective caps and
plugs to prevent dirt ingress.
! CAUTION
Running the engine with air in the system could
damage the fuel injection pump. After maintenance,
the system must be bled to remove any air.
2-3-3-11
! WARNING
The fuel system incorporates an electric pump, which
is fed from the machine's ignition circuit. Ensure the
ignition is turned OFF whenever the fuel system is
being worked on. There could be a fire or personal
injury if you do not follow this precaution.
Fuel Filter
Changing the Engine Mounted Fuel Filter
Element
NOTE
Do not operate the electric priming pump for
prolonged periods without fuel.
Hydraulic System
! WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open. A
INT-3-1-11_2
Fig 40.
! CAUTION
Using incorrect fluid could damage the system. See
Fluids, Capacities and Lubricants for the correct fluid.
The fluid can harm your skin. Wear rubber gloves.
Cover cuts or grazes.
2-3-5-1_2
! CAUTION
Do not allow dirt to enter the system. Before
disconnecting any part of the system, thoroughly
clean around the connection. When a component has
been disconnected, always fit protective caps and
plugs to prevent dirt ingress.
NOTE
If no attachment is fitted, ensure the Attachment
Bracket front face is approximately vertical.
Allow the hydraulic fluid temperature to cool before Changing the Hydraulic Oil and Filters
removing the hydraulic tank filler cap. Open the cap
slowly to prevent oil being forced out of the filler neck. Refer to the service manual for changing the hydraulic oil
5-3-4-8 and filters.
Transmission
An exploding tyre can kill. Inflated tyres can explode if Refer to the service manual for tightening the wheel nuts.
over-heated or over-inflated. Follow the instructions
given when inflating the tyres. Do not cut or weld the
rims. Use a tyre/wheel specialist for all repair work.
2-3-2-7_2
! WARNING
Wheels and tyres are heavy. Take care when lifting or
moving them.
Procedure
T3-067_2
! WARNING
If, for whatever reason, a wheel stud is renewed, all the
studs for that wheel must be changed as a set, since
the remaining studs may have been damaged.
2-3-2-8
Tracks
Track Adjustment
Correct track tension is important for good performance
and to prevent the tracks from dismounting. The track
tension is controlled by the forward idler which is attached
to a grease filled hydraulic cylinder.
Fig 42.
NOTICE
IMPORTANT
Use front screen antifreeze only, Do not use
engine coolant antifreeze.
NOTE
If the needle is in or very near the RED segment
at either end of the gauge, the extinguisher must
be serviced or replaced.
Fig 43.
Before selecting an attachment for use, assess the Remember, do not operate attachments until you have
application and select the appropriate attachment. The read and fully understand the attachment operating
density of any materials being handled will affect the instructions.
selection of the appropriate attachment.
These attachments will help increase the productivity of
your machine, for more information contact your
! CAUTION distributor.
If you have an attachment which is not covered in the
Do not operate or work with attachments until the machine
Operator Manual do not install it, use it or remove it
hydraulic oil has reached its normal working temperature.
until you have obtained, read and understood the
pertinent information. Install attachments only on the
Hydraulic attachments are only compatible with auxiliary
machines for which they were designed.
couplers positioned on the right hand side of the loader
5-5-1-1_2 arm, and not with the left hand auxiliary coupler option.
NOTE
A Lexan front screen must be fitted to the machine when these attachments are used. Contact your dealer.
Impact Protection
! WARNING
When using an attachment for example a hydraulic
breaker, where the risk of flying debris is present, a
protective layer or screen guard must be attached to
the front of the cab to protect the operator from flying
debris which could cause injury.
8-5-1-5
The label A states that the machine is not fitted with glass
protection.
332/V3761
Fig 1.
T037400
Fig 2.
b Make sure that the hose does not touch hot parts.
High ambient temperatures can cause the hose to
fail.
T037420
Fig 3.
c Stop the engine then remove the starter key. b Operate the related control to increase the
pressure in the hydraulic system.
d Check for indications of leakage at the hose
connections. Correct, as necessary. c Stop the engine then remove the starter key.
! WARNING
The external surfaces of the couplings must be clean
before connecting or disconnecting. Ingress of dirt
will cause fluid leaks and difficulty in connecting or
disconnecting. You could be killed or seriously injured
by faulty Quick Release Couplings.
2-4-1-15
C007100-1
Fig 5.
Auxiliary Operation
The auxiliary hoses are located on top of the boom. 1 Ensure that the AUX enable switch B is off. The LED
is ON. >>Right Hand Switch Panel (49).
To Engage Auxiliary Flow
2 Press the high flow switch A on the left hand switch
1 Press the AUX enable switch on the right hand switch panel and ensure the LED is ON. >>Fig 6. (156).
panel. The LED illuminates. >>Right Hand Switch >>Left Hand Switch Panel (45)
Panel (49).
T057960
Fig 7.
T057980
Fig 9.
T057970 6 Move the loader control lever to roll back the bucket/
Fig 8. attachment slightly.
To Engage the Attachment 7 Once hitch plate C is engaged depress and hold the
lock switch B.
1 Align the machine square to the bucket/attachment.
8 Ensure the hydraulic cylinder is fully retracted and
visually inspect that locking pins are engaged into the
attachment.
T057980-1
Fig 10.
D D
A
Fig 11.
D D
A
Fig 12.
1 Stop and park the machine on level ground. 7 Return to the cab seat, lower the Safety Seat Bar and
start the engine.
2 Lower the bucket/attachment to the ground.
8 Operate the loader Control Lever as if to roll forward
3 Stop the engine and relieve hydraulic circuit pressure. the bucket/attachment >>Drive Controls, Switches
>>Releasing the Auxiliary Hydraulic Pressure and Instruments (41).When the hitch plate A has
(139). disengaged from the lips on the bucket/attachment,
reverse the machine clear.
! WARNING
Do not lean out of the cab to operate the Attachment
Bracket levers. If the controls are moved accidentally
you could be killed or injured.
3-4-1-8
Attachment Frame
Some attachments, e.g. hammers and earth drills, utilise 3 Drive the machine forward until the Attachment
an attachment frame for installing on a Skid Steer Loader. Bracket plate touches the attachment frame then
stop.
Installation and Removal
4 Slowly tilt the plate backwards until it engages the
Installation attachment frame lip. Raise the loader arm until the
frame is in contact with the Attachment Bracket plate,
1 Stand the attachment frame on level ground as shown top and bottom.
at A. Drive the Skid Steer Loader squarely up to the
frame and stop. 5 Push Attachment Bracket levers fully in, as at position
E, to engage locking pins F and secure the
attachment frame.
Removal
Fig 13.
! WARNING
Do not lean out of the cab to operate the Attachment
Bracket levers. If the controls are moved accidentally
you could be killed or injured.
3-4-1-8
F
Fig 14.
Buckets
T057380
Fig 15. Typical Bracket Attachment Framework
Bucket
Maintenance
>>Service Schedules (94)
Pallet Forks
! CAUTION
Fork Spacing
Loads can fall off incorrectly spaced forks. Always
space the forks correctly for the load. Make sure the
forks are completely under the load before lifting.
5-1-4-2
Operation
Control
Road Travel
! WARNING
The Quick-Hitch forks must not be fitted for road
travel. Failure to comply may render the operator
vulnerable to criminal prosecution. If the machine has
to travel on public roads the forks must be removed.
2-4-5-4
Maintenance
>>Service Schedules (94)
2 Lift the forks off of their rail and move them left or right
to the required positions.
Specifications
Static Dimensions
J
M
G
F
D
E
L
C
P
O H B
K
N A
TO55170
Fig 1.
Table 1.
MC85/95/105C
A Overall length m (ft-in) 3.49 (11-5)
B Wheel base m (ft-in) 1.07 (3-6)
C Angle of departure degrees 25
D Overall height m (ft-in) 1.98 (6-6)
E Dump height m (ft-in) 2.26 (7-5)
F Loadover height m (ft-in) 2.84 (9-4)
G Height to hinge pin, fully raised m (ft-in) 3.0 (9-10)
H Reach at ground level (toe plate horizontal) m (ft-in) 1.0 (3-3)
I Max reach at full height m (ft-in) 1.21 (4-0)
J Reach at full height - fully dumped m (ft-in) 0.86 (2-10)
K Dig depth (toe plate horizontal) clearance mm (in) -10 (-0.4)
L Rollback at ground degrees 30
M Dump angle degrees 42
N Bucket width (standard) m (ft-in) 1.68 (5-6)
O Width over tyres (standard) m (ft-in) 1.52 (5-0)
Turning radius - Bucket corner radius m (ft-in) 2.09 (6-10)
MC85/95/105C
Turning radius - Attachment Bracket radius m (ft-in) 1.14 (3.9)
Turning radius - Rear chassis radius m (ft-in) 1.65 (5-5)
P Ground Clearance mm (in) 210 (8.3)
NOTE
Dimensions specified with GP bucket
J
M
G
F
D
E
L
C
P
O H B
K
N A
NOTE
Dimensions specified with GP bucket
T055250
Fig 2.
Table 2.
MCT 85/95C
A Overall length m (ft-in) 3.49 (11-5)
B Wheel base m (ft-in) 1.78 (5-10)
C Angle of departure degrees 27
D Overall height m (ft-in) 2.0 (6-7)
E Dump height m (ft-in) 2.29 (7-6)
F Loadover height m (ft-in) 2.85 (9-4)
G Height to hinge pin, fully raised m (ft-in) 3.02 (9-10)
H Reach at ground level (toe plate horizontal) m (ft-in) 1.0 (3-3)
I Max reach at full height m (ft-in) 1.21 (4-0)
J Reach at full height - fully dumped m (ft-in) 0.85 (2-9)
K Dig depth (toe plate horizontal) clearance mm (in) -10 (-0.4)
L Rollback at ground degrees 30
M Dump angle degrees 42
N Bucket width (standard) m (ft-in) 1.68 (5-6)
O Width over tracks (standard) m (ft-in) 1.68 (5-6)
Turning radius - Bucket corner radius m (ft-in) 2.09 (6-10)
Turning radius - Attachment Bracket radius m (ft-in) 1.14 (3-9)
Turning radius - Rear chassis radius m (ft-in) 1.65 (5-5)
P Ground Clearance mm (in) 230 (9.1)
NOTE
Dimensions specified with GP bucket
NOTE
Dimensions specified with GP bucket
Performance Dimensions
Wheeled Machines
Table 3.
MC60C MC70C MC85C MC95C MC105C
Rated Operating Capacity (1) kg (lbs) 612 (1349) 703 (1550) 795 (1753) 862 (1900) 930 (2050)
Tipping Load (1) kg (lbs) 1224 (2699) 1406 (3100) 1590 (3505) 1724 (3801) 1860 (4101)
Loader Lift(2) kg (lbs) 1440 (3175) 1770 (3902) 1570 (3461) 1570 (3461) 1570 (3461)
Bucket Tilt(2) kg (lbs) 1820 (4012) 1820 (4012) 2140 (4718) 2140 (4718) 2140 (4718)
System pressure bar (psi) 230 (3335) 230 (3335) 230 (3335) 230 (3335) 230 (3335)
Engine horsepower Hp/(kW) 47.9 (35.7) 59.9 (44.7) 59.9 (44.7) 59.9 (44.7) 59.9 (44.7)
Hydraulic flow/ pump l/m (gpm) 70 (15) 70 (15) 70 (15) 70 (15) 70 (15)
capacity @ 2600 rpm @ 2800 rpm @ 2800 rpm @ 2800 rpm @ 2800 rpm
Table 4.
MCT 70C MCT 85C MCT 95C
Rated Operating Capacity (1) kg (lbs) 680 (1499) 862 (1900) 930 (2050)
Tipping Load (1) kg (lbs) 1943 (4284) 2463 (5430) 2657 (5858)
Loader Lift (2) kg (lbs) 1770 (3902) 1570 (3461) 1570 (3461)
Bucket Tilt(2) kg (lbs) 1820 (4012) 2140 (4718) 2140 (4718)
System pressure bar (psi) 230 (3335) 230 (3335) 230 (3335)
Engine horsepower Hp/(kW) 59.9 (44.7) 59.9 (44.7) 59.9 (44.7)
Hydraulic flow/ pump capacity l/m (gpm) 70 (15) 70 (15) 70 (15)
@ 2800 rpm @ 2800 rpm @ 2800 rpm
NOTE
Dimensions specified with GP bucket
Machine Weights
Table 5.
MC60C MC70C MC85C MC95C MC105C
Total weight
(1) kg (lbs) 2752 (6067) 2844 (6270) 2960 (6526) 3080 (6790) 3215 (7088)
Table 6.
MC 70C MCT85C MCT95C
Total weight(1) kg (lbs) 3870 (8532) 4060 (8951) 4220 (9303)
(1) Fully operational with Attachment Bracket, standard bucket, full fuel tank, cab - full specification
+ 75kg (165lb ) operator:
Table 7.
Size (in) width x diameter Ply Make Name Pressure bar (lbf/in2)
7 x 15 14 PLY Solideal SKS Extra 4.2 (61)
10 x 16.5 8 PLY Solideal SKS Extra 4.2 (61)
10 x 16.5 10 PLY Solideal Lifemaster 4.2 (61)
10 x 16.5 8 PLY Hauler SKS Hauler 4.2 (61)
33 x 6 10 PLY Brawler S Flex -
7 x 15 5.5 PLY Solids -
Noise Data
For information relating to this machine when used with (1) Engine Net Power = 35.7kW
other approved attachments, please refer to the literature (2) Engine Net Power = 44.7kW
accompanying the attachments.
Definition of terms:
LpA A-weighted sound pressure level measured at the
operator's station.(1)
LwA Equivalent A-weighted sound power level emitted
by the machine.(2)
Vibration Data
Fig 3.
X X X
1.52
1.29
1.01
0.87
0.04
Fig 4. Whole-Body Vibration Emission Under Representative Operating Conditions (According to the Intended
Use) (Dominant Axis (X, Y or Z), Machine Duties (D1-D5))
NOTE
Errors bars are due to variations in vibration
emissions due to measurement uncertainty (50%
in accordance with EN 12096:1997).
X X X
1.37
1.17
0.97
0.69
0.051
Fig 5. Whole-Body Vibration Emission Under Representative Operating Conditions (According to the Intended
Use) (Dominant Axis (X, Y or Z), Machine Duties (D1-D5))
NOTE
Errors bars are due to variations in vibration
emissions due to measurement uncertainty (50%
in accordance with EN 12096:1997).
Travel Speeds
Table 11.
MC60C MC70C MC85C MC95C MC105C
Single Speed mph 7.5 (12) 7.5 (12) 7.5 (12) 7.5 (12) 7.5 (12)
(kph)
Two Speed mph - 7.5 (12) / 11.5 (18.5) 7.5 (12) / 11.5 (18.5) 7.5 (12) / 11.5 (18.5) 7.5 (12) / 11.5 (18.5)
Low/High (kph)
Table 12.
MCT70C MCT85C MCT95C
Single Speed mph (kph) 6.2 (10) 6.2 (10) 6.2 (10)
Two Speed Low/High mph (kph) 5.6 (9) / 7.8 (12.5) 5.6 (9) / 7.8 (12.5) 5.6 (9) / 7.8 (12.5)
NOTE
Travel speeds will be dependant upon tyre size,
type and condition.
Auxiliary Pressures
Table 13.
Auxiliary Flow at 2400 RPM Auxiliary Pressure
Standard Flow 70 l/min (15 gpm) 230 bar (3336 psi)
High Flow 100 l/min (22 gpm) 230 bar (3336 psi)