New Holland FR9040 User manual

Part number 47500830
English
February 2013
Replaces part number 84339558
SERVICE MANUAL
FR9040 / FR9050 / FR9060 /
FR9080 / FR9090
Forage Harvester
PrintedinU.S.A.
Copyright © 2013 CNH America LLC. All Rights Reserved. NewHollandisaregisteredtrademarkofCNH America LLC.
Racine Wisconsin 53404 U.S.A.

Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.218]Fuelinjectionsystem...............................................................10.2
[10.400]Enginecoolingsystem.............................................................10.3
[10.414]Fananddrive......................................................................10.4
[10.418]Rotaryscreen......................................................................10.5
Maingearboxanddrive...............................................................14
[14.100]Maingearboxanddrive............................................................14.1
Transmission..............................................................................21
[21.114]Mechanicaltransmission...........................................................21.1
[21.130]Mechanicaltransmissionexternalcontrols.........................................21.2
[21.100]Mechanicaltransmissionlubricationsystem.......................................21.3
[21.145]Gearboxinternalcomponents......................................................21.4
[21.182]Differential..........................................................................21.5
Four-WheelDrive(4WD)system..................................................23
[23.101]Mechanicalcontrol.................................................................23.1
[23.304]Four-WheelDrive(4WD)gearbox.................................................23.2
Frontaxlesystem.......................................................................25
[25.100]Poweredfrontaxle.................................................................25.1
[25.102]Frontbevelgearsetanddifferential...............................................25.2
[25.310]Finaldrives.........................................................................25.3
Rearaxlesystem........................................................................27
[27.450]Rear-poweredsteerableaxle......................................................27.1
[27.550]Non-poweredrearaxle.............................................................27.2
Hydrostaticdrive.........................................................................29
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[29.100]Transmissionandsteeringhydrostaticcontrol.....................................29.1
[29.218]Pumpandmotorcomponents......................................................29.2
[29.202]Hydrostatictransmission...........................................................29.3
Brakesandcontrols....................................................................33
[33.202]Hydraulicservicebrakes...........................................................33.1
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.106]Variabledisplacementpump.......................................................35.2
[35.359]Maincontrolvalve..................................................................35.3
[35.350]Safetyandmainreliefvalves......................................................35.4
[35.600]Highowhydraulics................................................................35.5
[35.410]Headerorattachmentheightsystem..............................................35.6
[35.602]Headerorattachmentlevelingsystem.............................................35.7
[35.514]Upperfeedrollgearboxsystem....................................................35.8
[35.530]Spoutrotationcircuit...............................................................35.9
[35.532]Spoutraisingsystem.............................................................35.10
[35.534]Spoutdeectorsystem...........................................................35.11
Steering.....................................................................................41
[41.101]Steeringcontrol....................................................................41.1
[41.200]Hydrauliccontrolcomponents......................................................41.2
[41.206]Pump...............................................................................41.3
[41.216]Cylinders...........................................................................41.4
[41.432]Autoguidancesteering.............................................................41.5
Cabclimatecontrol.....................................................................50
[50.100]Heating.............................................................................50.1
[50.200]Airconditioning.....................................................................50.2
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
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[55.100]Harnessesandconnectors.........................................................55.2
[55.640]Electronicmodules.................................................................55.3
[55.610]Groundspeedcontrol..............................................................55.4
[55.019]Hydrostaticdrivecontrolsystem...................................................55.5
[55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls...................55.6
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.7
[55.421]Feedingcontrolsystem............................................................55.8
[55.830]Rotaryscreendriveandcleaning..................................................55.9
[55.680]Autopilot/Autoguidance..........................................................55.10
[55.408]Warningindicators,alarms,andinstruments....................................55.11
[55.DTC]FAULTCODES..................................................................55.12
Attachments/Headers..................................................................58
[58.900]Beltfeeding........................................................................58.1
Productfeeding..........................................................................60
[60.103]Lowerfeedrolls....................................................................60.1
[60.107]Upperfeedrolls....................................................................60.2
[60.155]Metaldetector......................................................................60.3
Chopping...................................................................................64
[64.100]Cutterhead.........................................................................64.1
[64.106]Drum...............................................................................64.2
[64.130]Drumgearbox......................................................................64.3
[64.140]Sharpeningsystem.................................................................64.4
[64.150]Shearbar...........................................................................64.5
[64.160]Cropprocessor.....................................................................64.6
Ejection.....................................................................................70
[70.120]Blower..............................................................................70.1
[70.140]Spout...............................................................................70.2
Platform,cab,bodywork,anddecals.............................................90
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[90.150]Cab.................................................................................90.1
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INTRODUCTION
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Contents
INTRODUCTION
Basicinstructions-HowtouseandnavigatethroughthisManual.............................3
Advice.........................................................................................10
Foreword......................................................................................11
NotetotheOwner............................................................................12
Safetyrules...................................................................................13
Safetyrules...................................................................................17
Personalsafety...............................................................................19
Basicinstructions.............................................................................20
Torque........................................................................................23
Basicinstructions-ChainWearT ables-RollerChains......................................25
Conversionfactors............................................................................27
GeneralspecicationSystemprotectiondata................................................28
Productidentication..........................................................................31
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INTRODUCTION
Basicinstructions-HowtouseandnavigatethroughthisManual
Technicalinformation
Thismanualhasbeenproducedbyanewtechnicalinformationsystem.Thisnewsystemisdesignedtodeliver
technicalinformationelectronicallythroughWebdelivery(eTim),DVDandinpapermanuals.Acodingsystemcalled
SAPhasbeendevelopedtolinkthetechnicalinformationtootherProductSupportfunctions,e.g.,Warranty.
Technicalinformationiswrittentosupportthemaintenanceandserviceofthefunctionsorsystemsonacustomer's
machine.Whenacustomerhasaconcernonhismachineitisusuallybecauseafunctionorsystemonhismachine
isnotworkingatall,isnotworkingefciently,orisnotrespondingcorrectlytohiscommands.Whenyoureferto
thetechnicalinformationinthismanualtoresolvethatcustomer'sconcern,youwillndalltheinformationclassied
usingtheSAPcoding,accordingtothefunctionsorsystemsonthatmachine.Onceyouhavelocatedthetechnical
informationforthatfunctionorsystemthenyouwillndallthemechanical,electricalorhydraulicdevices,compo-
nents,assembliesandsubassembliesforthatfunctionorsystem.Youwillalsondallthetypesofinformationthat
havebeenwrittenforthatfunctionorsystem,thetechnicaldata(specications),thefunctionaldata(howitworks),
thediagnosticdata(faultcodesandtroubleshooting)andtheservicedata(remove,installadjust,etc.).
ByintegratingSAPcodingintotechnicalinformation,youwillbeabletosearchandretrievejusttherightpieceof
technicalinformationyouneedtoresolvethatcustomer'sconcernonhismachine.Thisismadepossiblebyattaching
3categoriestoeachpieceoftechnicalinformationduringtheauthoringprocess.
TherstcategoryistheLocation,thesecondcategoryistheInformationTypeandthethirdcategoryistheProduct:
•LOCATION-isthecomponentorfunctiononthemachine,thatthepieceoftechnicalinformationisgoingtodescribe
e.g.Fueltank.
•INFORMATIONTYPE-isthepieceoftechnicalinformationthathasbeenwrittenforaparticularcomponentor
functiononthemachinee.g.CapacitywouldbeatypeofT echnicalDatathatwoulddescribetheamountoffuel
heldbytheFueltank.
•PRODUCT-isthemodelforwhichthepieceoftechnicalinformationiswritten.
Everypieceoftechnicalinformationwillhavethose3categoriesattachedtoit.Youwillbeabletouseanycombination
ofthosecategoriestondtherightpieceoftechnicalinformationyouneedtoresolvethatcustomer'sconcernonhis
machine.
Thatinformationcouldbe:
•thedescriptionofhowtoremovethecylinderhead
•atableofspecicationsforahydraulicpump
•afaultcode
•atroubleshootingtable
•aspecialtool
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INTRODUCTION
Howtousethismanual
ThismanualisdividedintoSections.EachSectionisthendividedintoChapters.Contentspagesareincludedatthe
beginningofthemanual,theninsideeverySectionandinsideeveryChapter.AnalphabeticalIndexisincludedatthe
endofaChapter.PagenumberreferencesareincludedforeverypieceoftechnicalinformationlistedintheChapter
ContentsorChapterIndex.
EachChapterisdividedintofourInformationtypes:
•T echnicalData(specications)forallthemechanical,electricalorhydraulicdevices,componentsand,assemblies.
•FunctionalData(howitworks)forallthemechanical,electricalorhydraulicdevices,componentsandassemblies.
•DiagnosticData(faultcodes,electricalandhydraulictroubleshooting)forallthemechanical,electricalorhydraulic
devices,componentsandassemblies.
•ServiceData(removedisassembly,assemble,install)forallthemechanical,electricalorhydraulicdevices,com-
ponentsandassemblies.
Sections
Sectionsaregroupedaccordingtothemainfunctionsorasystemsonthemachine.EachSectionisidentiedbya
number00,35,55,etc.TheamountofSectionsincludedinthemanualwilldependonthetypeandfunctionofthe
machinethatthemanualiswrittenfor.EachSectionhasaContentspagelistedinalphabetic/numericorder.This
tableillustrateswhichSectionscouldbeincludedinamanualforaparticularproduct.
PRODUCT
Tractors
Vehicleswithworkingarms:backhoes,
excavators,skidsteers,….
Combines,forageharvesters,balers,….
Seeding,planting,oating,spraying
equipment,….
SECTIONMountedequipmentandtools,….
00-Maintenance
05-Machinecompletionandequipment
10-Engine
14-Maingearboxanddrive
18-Clutch
21-Transmission
23-Fourwheeldrivesystem
25-Frontaxlesystem
27-Rearaxlesystem
29-Hydrostaticdrive
31-Implementpowertake-off
33-Brakesandcontrols
35-Hydraulicsystems
36-Pneumaticsystem
37-Hitches,drawbarsandimplementcouplings
39-Framesandballasting
41-Steering
44-Wheels
46-Steeringclutches
48-Tracksandtracksuspension
50-Cabclimatecontrol
55-Electricalsystems
56-Grapeharvestershaking
58-Attachments/headers
60-Productfeeding
61-Meteringsystem
62-Pressing-Baleformation
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INTRODUCTION
63-Chemicalapplicators
64-Chopping
66-Threshing
68-Tying/Wrapping/Twisting
69-Balewagons
70-Ejection
71-Lubricationsystem
72-Separation
73-Residuehandling
74-Cleaning
75-Soilpreparation/Finishing
76-Secondarycleaning/Destemmer
77-Seeding
78-Spraying
79-Planting
80-Cropstorage/Unloading
82-Frontloaderandbucket
83-T elescopicsinglearm
84-Booms,dippersandbuckets
86-Dozerbladeandarm
88-Accessories
89-T ools
90-Platform,cab,bodyworkanddecals
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INTRODUCTION
Sectioncontents
SectionNumberDescription
Maintenance00
Machinecompletionandequipment05
Engine10
Maingearboxanddrive14
Clutch18
Transmission21
Fourwheeldrivesystem23
Frontaxlesystem25
Rearaxlesystem27
Hydrostaticdrive29
Implementpowertake-off31
Brakesandcontrols33
Hydraulicsystems35
ThisSectioncoversthecentralpartsofthehydraulic
system.Thecomponentsthatarededicatedtoa
specicfunctionarelistedintheChapterwhereallthe
technicalinformationforthatfunctionisincluded.
Pneumaticsystem36
ThisSectioncoversthepneumaticsystem.The
componentsthatarededicatedtoaspecicfunctionare
listedintheChapterwhereallthetechnicalinformation
forthatfunctionisincluded.
Hitches,drawbarsandimplementcouplings37
Framesandballasting39
Steering41
Wheels44
Steeringclutches46
Tracksandtracksuspension48
Cabclimatecontrol50
Electricalsystems55
TheSectioncoversthecentralpartsoftheelectrical,
electronic,andlightingsystems.Thecomponentsthat
arededicatedtoaspecicfunctionarelistedinthe
Chapterwhereallthetechnicalinformationforthat
functionisincluded.
Grapeharvestershaking56
Attachments/headers58
Productfeeding60
Meteringsystem61
Pressing-Baleformation62
Chemicalapplicators63
Chopping64
Threshing66
Tying/Wrapping/Twisting68
Balewagons69
Ejection70
Lubricationsystem71
Separation72
Residuehandling73
Cleaning74
Soilpreparation/Finishing75
Secondarycleaning/Destemmer76
Seeding77
Spraying78
Planting79
Cropstorage/Unloading80
Frontloaderandbucket82
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INTRODUCTION
SectionNumberDescription
Telescopicsinglearm83
Booms,dippersandbuckets84
Dozerbladeandarm86
Accessories88
Tools89
Platform,cab,bodyworkanddecals90
ThisSectioncoversallthemainfunctionsandsystems
relatedtothebodyofthemachine,includingthe
operatorscabandtheplatform.
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INTRODUCTION
Chapters
EachChapterisidentiedbyanumbere.g.HydraulicSystems-Maincheckvalve-35.359.Therstnumberis
identicaltotheSectionnumberi.e.Chapter35.359isinsideSection35,HydraulicSystems.Thesecondnumberis
representativeoftheChaptercontainedwithintheSection.
CONTENTS
TheChapterContentslistsallthetechnicaldata(specications),functionaldata(howitworks),servicedata(remove,
installadjust,etc..)anddiagnosticdata(faultcodesandtroubleshooting)thathavebeenwritteninthatChapterfor
thatfunctionorsystemonthemachine.
Contents
HYDRAULICSYSTEMS-35
Maincontrolvalve-359
FUNCTIONALDATA
Maincontrolvalve-Sectionalview(35.359-C.10.A.30)
TECHNICALDATA
Maincontrolvalve-Generalspecications(35.359-D.40.A.10)
SERVICE
Maincontrolvalve-Remove(35.359-F .10.A.10)
INDEX
TheChapterIndexlistsinalphabeticalorderallthetypesofinformation(calledInformationUnits)thathavebeen
writteninthatChapterforthatfunctionorsystemonthemachine.
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INTRODUCTION
Informationunitsandinformationsearch
Eachchapteriscomposedofinformationunits.EachinformationunithasapagereferencewithinthatChapter.The
informationunitsprovideaquickandeasywaytondjusttherightpieceoftechnicalinformationyouarelookingfor.
ExampleinformationunitMaincontrolvalve-SectionalView(35.359)
InformationUnitSAPcode35Hydraulicsystems
SAPcodeclassication359Maincontrolvalve
Pageheaderandfooter
Thepageheaderwillcontainthefollowingreferences:
•SectionandChapterdescription
Thepagefooterwillcontainthefollowingreferences:
•PublicationnumberforthatManual,SectionorChapter.
•Versionreferenceforthatpublication.
•Publicationdate
•Section,chapterandpagereferencee.g.35.359/9
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INTRODUCTION
Advice
Allrepairandmaintenanceworkslistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven;andusing,wheneverappropriate,thespecialtools.
Anyonewhocarriesouttheaboveoperationswithoutcomplyingwiththeinstructionsshallberesponsibleforthe
subsequentdamages.
Themanufacturerandalltheorganizationsofit'sdistributionchain,including-withoutlimitation-national,regional,
orlocaldealers,rejectanyresponsibilityfordamagesduetotheanomalousbehaviorofpartsand/orcomponentsnot
approvedbythemanufacturerhimself,includingthoseusedfortheservicingorrepairoftheproductmanufactured
ormarketedbythemanufacturer.Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedor
marketedbythemanufacturerincaseofdamagesduetoananomalousbehaviorofpartsand/orcomponentsnot
approvedbythemanufacturer.
Theinformationinthismanualisup-to-dateatthedateofthepublication.Itisthepolicyofthemanufacturerfor
continuousimprovement.Someinformationmaynotbeupdatedduetomodicationsofatechnicalorcommercial
type,aswellastosuitthelawsandregulationsofdifferentcountries.
Incaseofquestions,refertoyourSalesandServiceNetworks.
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INTRODUCTION
Foreword
Soil,air,andwaterarevitalfactorsofagricultureandlifeingeneral.Whenlegislationdoesnotyetrulethetreatment
ofsomeofthesubstancesrequiredbyadvancedtechnology,soundjudgmentshouldgoverntheuseanddisposalof
productsofachemicalandpetrochemicalnature.
NOTE:Thefollowingarerecommendationsthatmaybeofassistance:
•Becomeacquaintedwithandensurethatyouunderstandtherelativelegislationapplicabletoyourcountry.
•Wherenolegislationexists,obtaininformationfromsuppliersofoils,lters,batteries,fuels,antifreeze,cleaning
agents,etc.,withregardtotheireffectonmanandnatureandhowtosafelystore,use,anddisposeofthese
substances.
•Agriculturalconsultantswill,inmanycases,beabletohelpyouaswell.
Helpfulhints
•Avoidllingtanksusingcansorinappropriatepressurizedfueldeliverysystemsthatmaycauseconsiderable
spillage.
•Ingeneral,avoidskincontactwithallfuels,oils,acids,solvents,etc.Mostofthemcontainsubstancesthatmaybe
harmfultoyourhealth.
•Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems.
•Avoidspillagewhendrainingoffusedenginecoolantmixtures,engine,gearboxandhydraulicoils,brakeuids,etc.
Donotmixdrainedbrakeuidsorfuelswithlubricants.Storethemsafelyuntiltheycanbedisposedofinaproper
waytocomplywithlocallegislationandavailableresources.
•Moderncoolantmixtures,i.e.antifreezeandotheradditives,shouldbereplacedeverytwoyears.Theyshouldnot
beallowedtogetintothesoil,butshouldbecollectedanddisposedofproperly.
•Donotopentheair-conditioningsystemyourself.Itcontainsgasesthatshouldnotbereleasedintotheatmosphere.
YourNEWHOLLANDAGRICULTUREdealerorairconditioningspecialisthasaspecialextractorforthispurpose
andwillhavetorechargethesystemproperly.
•Repairanyleaksordefectsintheenginecoolingorhydraulicsystemimmediately.
•Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure.
•Protecthosesduringweldingaspenetratingweldsplattermayburnaholeorweakenthem,allowingthelossof
oils,coolant,etc.
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INTRODUCTION
NotetotheOwner
Enginerepairinformation:
Theenginerepairinformationisnotcontainedwithinthismanual.
Forenginerepairinformation,pleaserefertotherespectiveServiceManualfortheenginetypeusedinyourvehicle.
FaultCodeResolution(FCR)information:
TheFCRinformationisnotcontainedwithinthepaperversionofthemanual.
ForFCRinformation,pleaserefertotheElectronicServiceTool(EST)ortheelectronicversionofthismanual.
ElectronicServiceTool(EST)information:
TheESTinformationandhowtohandleControlModules(CM)(e.g.:resettingoftheCM,etc.)isnotcontainedwithin
thismanual.
ForESTinformation,pleaserefertotheElectronicServiceToolUser'sGuide.
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INTRODUCTION
Safetyrules
PRECAUTIONARYSTATEMENTS
PersonalSafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibleinjuryordeath.
Throughoutthismanualandonmachinedecals,youwillndprecautionarystatements("DANGER","WARNING",
and"CAUTION")followedbyspecicinstructions.Theseprecautionsareintendedforthepersonalsafetyofyouand
thoseworkingwithyou.Pleasetakethetimetoreadthem.
DANGER
DANGERindicatesahazardoussituationwhich,ifnotavoided,willresultindeathorseriousinjury.Thecolor
associatedwithDangerisRED.
M1169A
WARNING
WARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresultindeathorseriousinjury.The
colorassociatedwithWarningisORANGE.
M1170A
CAUTION
CAUTION,usedwiththesafetyalertsymbol,indicatesahazardoussituationwhich,ifnotavoided,could
resultinminorormoderateinjury.ThecolorassociatedwithCautionisYELLOW.
M1171A
FAILURETOFOLLOW"DANGER","WARNING",AND"CAUTION"INSTRUCTIONSMAYRESULTINSERIOUS
BODILYINJURY ,DAMAGETOHEALTHORDEATH.
NOTICE:Installnewdecalsiftheolddecalsaredestroyed,lostpaintedoverorcannotberead.Whenpartsare
replacedthathavedecalsmakesureyouinstallanewdecalwitheachnewpart.
MACHINESAFETY
NOTICE:Theword"notice"isusedtoinformthereaderofsomethingtheyneedtoknowtopreventminormachine
damageifacertainprocedureisnotfollowed.
Theprecautionarystatements("Important")isfollowedbyspecicinstructions.Thisstatementisintendedformachine
safety.
INFORMATION
NOTE:Instructionsusedtoidentifyandpresentsupplementaryinformation.
LEGALOBLIGATIONS
Thismachinemaybeequippedwithspecialguardingorotherdevicesincompliancewithlocallegislation.Someto
theserequireactiveusebytheoperator.Therefor,checklocallegislationsontheusageofthismachine.
ACCIDENTPREVENTION
Mostaccidentsorinjuriesthatoccurinworkshopsaretheresultofnoncompliancetosimpleandfundamentalsafety
principles.Forthisreason,INMOSTCASESTHESEACCIDENTSCANBEAVOIDEDbyapplyingthefundamental
safetyprinciples,actingwiththenecessarycautionandcare.
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INTRODUCTION
Accidentsmayoccurwithalltypesofmachine,regardlessofhowwellthemachineinquestionwasdesignedand
built.
DANGER
Shutdownthemachine,removekey,besureallmovingpartshavestoppedandallpressureinthesystems
isrelievedbeforecleaning,adjustingorlubricatingtheequipment.Failuretocomplywillresultindeathor
seriousinjury.
M871
SAFETYREQUIREMENTSFORFLUIDPOWERSYSTEMSANDCOMPONENTS-HY-
DRAULICS(EUROPEANSTANDARDEN982)
•Flexiblehoseassembliesmustnotbeconstructedfromhoseswhichhavebeenpreviouslyusedaspartofahose
assembly.
•Donotweldhydraulicpipes:whenexiblehosesorpipingaredamaged,replacethemimmediately.
•Itisforbiddentomodifyahydraulicaccumulatorbymachining,weldingoranyotherway.
•Beforeremovinghydraulicaccumulatorsforservicing,theliquidpressureintheaccumulatorsmustbereducedto
zero.
•Pressurecheckonhydraulicaccumulatorsmustbecarriedoutbyamethodrecommendedbytheaccumulator
manufacturer.
•T akecarenottoexceedthemaximumallowedpressureoftheaccumulator.Afteranycheckoradjustment,check
forleakagesorgasinthehosesorpipes.
SAFETYRULES
Generalguidelines
•Carefullyfollowspeciedrepairandmaintenanceprocedures.
•Whenappropriate,useP .P .E(PersonalProtectiveEquipment)
•Donotwearrings,wristwatches,jewellery,unbuttonedorloosearticlesofclothingsuchas:ties,tornclothing,
scarves,openjacketsorshirtswithopenzipsthatmayremainentangledinmovingparts.Itisadvisedtowear
approvedsafetyclothing,e.g.:non-slipfootwear,gloves,safetygoggles,helmets,etc.
•Donotcarryoutrepairoperationswithsomeonesittinginthedriver'sseat,unlessthepersonisatrainedtechnician
whoisassistingwiththeoperationinquestion.
•Donotoperatethemachineoruseanyoftheimplementsfromdifferentpositions,otherthanthedriver'sseat.
•Donotcarryoutoperationsonthemachinewiththeenginerunning,unlessspecicallyindicated.
•Bringallhydrauliccylinderstothehomepositions(down,retracted,etc.)beforeengineshutdown.
•Stoptheengineandcheckthatthehydrauliccircuitsarepressure-freebeforeremovingcaps,covers,valves,etc.
•Allrepairandmaintenanceoperationsmustbecarriedoutusingextremecareandattention.
•Servicestepsandplatformsusedintheworkshoporelsewhereshouldbebuiltaccordingtotheapplicablestan-
dardsandlegislation.
•Disconnectthepowertakeoff(p.t.o).andlabelthecontrolstoindicatethatthemachineisbeingserviced.Any
partsthataretoberaisesmustbelockedinposition.
•Brakesareinoperativewhenmanuallyreleasedforrepairormaintenancepurposes.Useblocksorsimilardevices
tosecurethemachineintheseconditions.
•Onlyusespeciedtowingpointsfortowingthemachine.Connectpartscarefully.Makesurethatallpinsand/or
locksaresecuredinpositionbeforeapplyingtraction.Neverremainnearthetowingbars,cablesorchainsthatare
operatingunderload.
•Whenloadingorunloadingthemachinefromthetrailer(orothermeansoftransport),selectaatareacapableof
sustainingthetrailerortruckwheels.Firmlysecurethemachinetothetruckortrailerandlockthewheelsinthe
positionusedbythecarrier.
•Electricheaters,battery-chargersandsimilarequipmentmustonlybepoweredbyauxiliarypowersupplieswith
efcientgroundinsulationtoavoidelectricalshockhazards.
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INTRODUCTION
•Alwaysusesuitablehoistingorliftingdeviceswhenraisingormovingheavyparts.
•Keepbystandersaway.
•Neverusegasoline,dieseloilorotherinammableliquidsascleaningagents.Usenon-inammable,nontoxic
commerciallyavailablesolvents.
•Wearsafetygoggleswithsideguardswhencleaningpartswithcompressedair.
•Donotruntheengineinenclosedspaceswithoutsuitableventilationorexhaustextraction.
•Neveruseopenamesforlightingwhenworkingonthemachineorcheckingforleaks.
•Allmovementsmustbecarriedoutcarefullywhenworkingunder,onornearthemachine.Wearpersonalprotective
equipment(P .P .E.):helmets,gogglesandspecialfootwear.
•Whencarryingoutcheckswiththeenginerunning,requesttheassistanceofanoperatorinthedriver'sseat.The
operatormustmaintainvisualcontactwiththeservicetechnicianatalltimes.
•Ifoperatingoutsidetheworkshop,positionthemachineonaatsurfaceandlockinposition.Ifworkingonaslope,
lockthemachineinposition.Movetoaatareaassoonasissafelypossible.
•Damagedorbentchainsorcablesareunreliable.Donotusethemforliftingortowing.Alwaysusesuitablepro-
tectivegloveswhenhandlingchainsorcables.
•Chainsshouldalwaysbesafelysecured.Makesurethatthehitch-uppointiscapableofsustainingtheloadin
question.Keeptheareanearthehitch-uppoint,chainsorcablesfreeofallbystanders.
•MaintenanceandrepairoperationsmustbecarriedoutinaCLEANandDRYarea.Cleanupanywateroroil
spillageimmediately.
•Donotcreatepilesofoilorgrease-soakedragsastheyrepresentaseriousrehazard.Alwaysstoreragsina
closedmetalcontainer.
•Beforeengagingthemachine,makesurethattherearenopersonswithinthemachineorimplementrangeofaction.
•Emptyyourpocketsofallobjectsthatmayfallaccidentallyunobservedintothemachineinnercompartments.
•Whenmetalpartsarestickingout,useprotectivegogglesorgoggleswithsideguards,helmets,specialfootwear
andgloves.
•Whenwelding,useprotectivesafetydevices:tintedsafetygoggles,helmets,specialoveralls,glovesandfootwear.
Allpersonspresentintheareawhereweldingistakingplacemustweartintedgoggles.NEVERLOOKDIRECTLY
ATTHEWELDINGARCWITHOUTSUITABLEEYEPROTECTION.
•Alwaysdisconnectbatterygroundterminalwhenwelding.
•Metalcablestendtofraywithrepeateduse.Alwaysusesuitableprotectivedevices(gloves,goggles,etc.)when
handlingcables.
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