CLAAS SCORPION – AUSTRALIA 7045 7040 7030 Operator's Manual - PDF DOWNLOAD

SCORPION – AUSTRALIA 7045 7040 7030

(from serial no. 403 03 0146) (from serial no. 402 03 0177) (from serial no. 401 03 0196)

Operator's Manual

Original Operator's Manual

x

Translation of original Operator's Manual

–

The telehandlers described in this manual are to be used only for agricultural and related applications. This is the designated use they are to be put to.

If the machine is modified without the prior written consent of CLAAS, or if it used in a way which does not correspond to the designated use, or if the machine is not driven or serviced correctly, the firm shall not assume any responsibility whatsoever for injuries or damage (both direct damage and consequential damage).

Strictly observe the procedures regarding operation and maintenance described in this manual.

Moreover, use original CLAAS spare parts only. In the event that no original spare parts are used, the machine guarantee shall be void in case of damage resulting from failure to use original spare parts.

Exclusively built for CLAAS KGaA mbH by KRAMER-WERKE GmbH, Wacker-Neuson-Str. 1, D-88630 Pfullendorf/Germany.

Contents

Contents

Contents EC Declaration of Conformity EG EC declaration of conformity (model 401-03) .........................................................EG-1 EC declaration of conformity (model 402-03) .........................................................EG-2 EC declaration of conformity (model 403-03) .........................................................EG-3 Introduction 1 Operator's Manual ................................................................................................... 1-1 Important notice on this Operator's Manual ....................................................... 1-1 Important notice on machine safety ................................................................... 1-1 Notice on maintenance, repairs and spare parts ............................................... 1-1 Explanation of safety symbols ........................................................................... 1-2 Explanation of abbreviations and symbols ........................................................ 1-2 Machine outside view .............................................................................................. 1-3 Brief description of telehandler ................................................................................ 1-4 General information on the machine ................................................................. 1-4 Model designation – trade names ..................................................................... 1-4 Main components of machine ............................................................................ 1-4 Hydrostatic drive ................................................................................................ 1-5 Work hydraulics and 4 wheel steering ............................................................... 1-5 Cooling system .................................................................................................. 1-5 Telehandler warranty ............................................................................................... 1-5 Warranty claims ................................................................................................. 1-5 Fields of application and using a telehandler with an attachment ........................... 1-6 Authorised attachments ..................................................................................... 1-6 Legal regulations regarding telehandler operation .................................................. 1-7 Principal regulations for the operating staff ....................................................... 1-7 Driving licence ................................................................................................... 1-7 Licence/identification ......................................................................................... 1-7 Adjusting the headlights .................................................................................... 1-8 Machine inspections .......................................................................................... 1-8 Documents ........................................................................................................ 1-8 On-board equipment .......................................................................................... 1-9 Warning identification of telehandler on public roads (option) ........................... 1-9 Type labels and component numbers .................................................................... 1-10 Explanation of “Book” symbol .......................................................................... 1-10 Serial number .................................................................................................. 1-10 Cab number ..................................................................................................... 1-10 Engine number ................................................................................................ 1-11 Hydraulic pump number .................................................................................. 1-11 Variable displacement motor number .............................................................. 1-11 Variable displacement motor number (high speed option) .............................. 1-12 Front and rear axle numbers ........................................................................... 1-12 Description of labels .............................................................................................. 1-13 Important notice on signs and labels ............................................................... 1-13 Labels on the outside of the machine .............................................................. 1-13 Labels inside the cab ....................................................................................... 1-15 Labels in the engine compartment .................................................................. 1-20

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Contents Safety instructions 2 Identification of warnings and dangers .................................................................... 2-1 Designated use and exemption from liability ........................................................... 2-2 General conduct and safety instructions .................................................................. 2-3 Organisational measures ................................................................................... 2-3 Selection and qualification of staff, basic responsibilities .................................. 2-5 Safety instructions regarding operation ................................................................... 2-6 Normal operation ............................................................................................... 2-6 Applications with lifting gear .............................................................................. 2-8 Trailer operation ................................................................................................. 2-8 Attachment operation ......................................................................................... 2-9 Transport ........................................................................................................... 2-9 Safety instructions for maintenance ....................................................................... 2-10 Maintenance work on protective ROPS and FOPS structures .............................. 2-12 ROPS/FOPS description ................................................................................. 2-12 Cab, roll-over bar, protective screen ................................................................ 2-12 Warning of special hazards .................................................................................... 2-12 Electric energy ................................................................................................. 2-12 Gas, dust, steam, smoke ................................................................................. 2-13 Hydraulic equipment ........................................................................................ 2-13 Noise ................................................................................................................ 2-13 Oil, grease and other chemical substances ..................................................... 2-13 Battery ............................................................................................................. 2-14 Tyres ................................................................................................................ 2-14 Operation 3 Information regarding the description of the control elements ................................. 3-1 Inside of cab (overview) .......................................................................................... 3-2 Control elements on the control lever and switch consoles: overview ..................... 3-4 Indicator lights and warning lights: description ........................................................ 3-6 Indicator light check ........................................................................................... 3-6 Indicator light and warning light – indicating instrument .................................... 3-6 Indicator light and warning light – front instrument panel .................................. 3-8 Before putting the machine into operation ............................................................... 3-9 Important information for the operating staff ...................................................... 3-9 Running-in period .............................................................................................. 3-9 “Diesel engine start” checklist .......................................................................... 3-10 Checklist “Putting the machine into service” .................................................... 3-11 “Parking” checklist ........................................................................................... 3-11 Cab ........................................................................................................................ 3-12 Safety instructions regarding cab entrance and exit ........................................ 3-12 Safety instruction – side window (right) ........................................................... 3-12 Locking and unlocking the door ....................................................................... 3-13 Closing and opening the side window (to a gap) ............................................. 3-14 Completely opening and locking the side window ........................................... 3-14 Opening/closing the rear window ..................................................................... 3-15 Rear window emergency exit ........................................................................... 3-15 Seat ........................................................................................................................ 3-16 Important notice on seat adjustment ................................................................ 3-16 Seat adjustment: overview ............................................................................... 3-16 Weight adjustment ........................................................................................... 3-17 Backrest adjustment ........................................................................................ 3-17 Horizontal adjustment ...................................................................................... 3-17 Lumbar support adjustment (option) ................................................................ 3-18 Adjustment of horizontal suspension (option) .................................................. 3-18 Adjustable seat suspension damper (option) ................................................... 3-18 Heated seat (option) ........................................................................................ 3-18 I-2

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Contents Seat belt (lap belt) .................................................................................................. 3-19 Important notice on the seat belt ..................................................................... 3-19 Fastening the seat belt .................................................................................... 3-19 Unfastening the seat belt ................................................................................. 3-20 Longer/shorter lap belt adjustment: ................................................................. 3-20 Engine cover .......................................................................................................... 3-20 Opening/closing the engine cover ................................................................... 3-20 Air-suspension seat (option) .................................................................................. 3-21 Important notice on air-suspension seat operation .......................................... 3-21 Air-suspension seat operation ......................................................................... 3-21 Fire extinguisher (option) ....................................................................................... 3-21 Fire extinguisher operation .............................................................................. 3-21 Key-based drive interlock (option) ......................................................................... 3-22 Coding (“training”) new ignition keys ............................................................... 3-22 Enabling (locking) the drive interlock ............................................................... 3-23 Disabling (releasing) the drive interlock ........................................................... 3-23 Deleting coded keys ........................................................................................ 3-23 Safety functions ............................................................................................... 3-23 Drive interlock with code input (option) .................................................................. 3-24 Entering/changing the personal code .............................................................. 3-25 Enabling the drive interlock ............................................................................. 3-25 Disabling the drive interlock ............................................................................. 3-26 Putting the drive interlock out of operation ...................................................... 3-26 Putting the drive interlock back into operation again ....................................... 3-27 Interruption of drive interlock power ................................................................ 3-27 Drive interlock maintenance ............................................................................ 3-27 Battery master switch ............................................................................................ 3-27 Switching the battery master switch ON and OFF ........................................... 3-27 Oil and fuel preheater (option) ............................................................................... 3-28 Putting the coolant and oil preheater into operation ........................................ 3-28 Fuel preheater (option) .................................................................................... 3-28 Putting the diesel engine into operation ................................................................. 3-29 Preparing to start the engine ........................................................................... 3-29 Starting the diesel engine ................................................................................ 3-30 Avoiding running the engine under low-load conditions .................................. 3-31 Stopping the engine ......................................................................................... 3-31 Jump-starting the engine (external battery) ........................................................... 3-32 Safety instructions regarding external starting aids ......................................... 3-32 Providing external starting aid ......................................................................... 3-32 Error code displays (103 kW diesel engine) .......................................................... 3-33 Reading out the flash code .............................................................................. 3-33 Warning limit – coolant temperature ................................................................ 3-33 Warning limit – charge-air temperature ........................................................... 3-34 Warning limit – engine oil pressure ................................................................. 3-34 Overview – description of flashing codes ........................................................ 3-35 Preparing for driving on public roads ..................................................................... 3-38 Important notice regarding driving on public roads .......................................... 3-38 Safety equipment for driving on public roads .................................................. 3-39 Functional check of brakes, steering system and lights .................................. 3-39 Locking the control lever (joystick) and the 3rd control circuit (attachments) .. 3-39 Moving off the telehandler ..................................................................................... 3-40 Speed range selection ..................................................................................... 3-40 Driving direction selection (reversing operation forwards/reverse) .................. 3-41 Selecting a speed range (low-speed control option) ....................................... 3-42 Stopping/parking the machine ............................................................................... 3-43

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Contents Steering system ..................................................................................................... 3-44 Steering column height and angle adjustment ................................................. 3-44 Checking the steering system .......................................................................... 3-44 Synchronising the steering system .................................................................. 3-45 Changeover to front axle steering .................................................................... 3-46 Changing over to 4 wheel steering .................................................................. 3-46 Changing over to diagonal steering (crab steering option) .............................. 3-47 Accelerator pedal ................................................................................................... 3-48 Manual throttle (option) .......................................................................................... 3-48 Manual throttle operation ................................................................................. 3-48 Brake/inching pedal ............................................................................................... 3-49 Important notice on brake/inching pedal actuation .......................................... 3-49 Inching with the brake/inching pedal ................................................................ 3-49 Braking with the brake/inching pedal ............................................................... 3-49 Parking brake ......................................................................................................... 3-50 Notice on the parking brake ............................................................................. 3-50 Applying the parking brake .............................................................................. 3-50 Telescopic boom load stabiliser ............................................................................. 3-51 Information regarding the load stabiliser function ............................................ 3-51 Switching the load stabiliser ON or OFF .......................................................... 3-52 Differential lock ...................................................................................................... 3-53 Important information on the differential lock ................................................... 3-53 Switching the differential lock ON and OFF ..................................................... 3-53 Backup warning system (option) ............................................................................ 3-54 Information on the backup warning system ..................................................... 3-54 Electric mirror adjustment (option) ......................................................................... 3-54 Adjusting the rearview mirror ........................................................................... 3-54 Reversing fan (option) ............................................................................................ 3-54 Machine lights ........................................................................................................ 3-55 Notice on machine lights .................................................................................. 3-55 Machine lights operation .................................................................................. 3-55 Working lights operation .................................................................................. 3-56 Interior light operation (cab) ............................................................................. 3-56 Signalling system ................................................................................................... 3-57 Turn indicator operation ................................................................................... 3-57 Hazard warning system operation ................................................................... 3-57 Rotating beacon operation (option) ................................................................. 3-57 Cab heating and ventilation ................................................................................... 3-58 Description of the heating and ventilation system ........................................... 3-58 Ventilation and heating in fresh-air mode ........................................................ 3-58 Ventilation and heating in mixed mode ............................................................ 3-58 Air conditioning (option) ......................................................................................... 3-59 Information on putting the air conditioning into operation ................................ 3-59 Air conditioning operation ................................................................................ 3-59 Washer system ...................................................................................................... 3-60 Washer system operation ................................................................................ 3-60 Tank for washer system ................................................................................... 3-60 Telescopic boom control lever: overview ............................................................... 3-61 Operating the control lever for the lift, tilt and push-out rams .......................... 3-61 Safe load indicator for telescopic boom ................................................................. 3-62 Important notice on the safe load indicator ...................................................... 3-62 Important notice on the safe load indicator overload display ........................... 3-63 Overview of indicator lights on overload display .............................................. 3-63 Functional check of the safe load indicator ...................................................... 3-63 What to do when the indicator lights come on ................................................. 3-64 Overload cutoff with limit switch (from October 2010) ..................................... 3-64 Disabling the overload cutoff ........................................................................... 3-65 I-4

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Contents Operating the telescopic boom .............................................................................. 3-66 Raising/extending the telescopic boom ........................................................... 3-66 Retracting/lowering the telescopic boom ......................................................... 3-66 Emergency lowering of telescopic boom in case of diesel engine breakdown ...... 3-67 Lower or raise as follows: ................................................................................ 3-67 Operating and securing the 3rd control circuit ....................................................... 3-68 Locking and unlocking the quickhitch or an attachment .................................. 3-68 Equipping the machine with a standard bucket ..................................................... 3-69 Pressure relief on the quickhitch couplers ....................................................... 3-69 Fitting a standard bucket onto the quickhitch .................................................. 3-70 Field of application of bucket ........................................................................... 3-70 Mounting an attachment on a quickhitch with a hydraulic lock ........................ 3-70 Mounting an attachment on a quickhitch with a mechanical lock .................... 3-71 Removing a standard bucket from the quickhitch ............................................ 3-72 Working with the standard bucket .......................................................................... 3-73 Safety instructions regarding work with the bucket ......................................... 3-73 Driving on public roads with a standard bucket ............................................... 3-74 Moving with the bucket fully dumped out ......................................................... 3-74 Safety instructions for transporting material in a full bucket ............................ 3-75 Loading loose material .................................................................................... 3-76 Loading if the material is hard to penetrate ..................................................... 3-76 Removing material/digging in soft soil ............................................................. 3-77 Removing material/digging in hard soil ............................................................ 3-78 Grading ............................................................................................................ 3-78 Loading vehicles .............................................................................................. 3-78 Fitting pallet forks ................................................................................................... 3-79 Picking up pallet forks with the quickhitch ....................................................... 3-79 Removing the pallet forks from the quickhitch ................................................. 3-79 Driving on public roads with the pallet forks .................................................... 3-80 Pallet forks transport position without load ...................................................... 3-80 Working with the pallet forks .................................................................................. 3-81 Safety instructions regarding the use of the pallet forks .................................. 3-81 Brief instructions for fork arms ......................................................................... 3-83 Pallet forks payload ......................................................................................... 3-83 Adjusting the fork arms of the pallet forks ....................................................... 3-84 Description of load diagram for pallet forks and bucket ................................... 3-85 Picking up material with the pallet forks .......................................................... 3-86 Transporting loads with the pallet forks ........................................................... 3-87 “Hose burst valve” safety feature ........................................................................... 3-88 Emergency lowering of the telescopic boom with the hose burst valve .......... 3-88 Continuous operation of 3rd control circuit (option) ............................................... 3-89 Switching continuous operation of 3rd control circuit ON/OFF ........................ 3-89 Tilt ram lock (option) .............................................................................................. 3-89 Switching the tilt ram lock ON and OFF .......................................................... 3-89 Electric changeover valve for operation of 3rd control circuit as additional front control circuit (option) ..................................................... 3-90 Switching the additional control circuit ON or OFF .......................................... 3-90 Front/rear hydraulic additional control circuit (option) ............................................ 3-91 Important notice on the additional control circuit ............................................. 3-91 Quick couplers of additional control circuit (overview) ..................................... 3-91 Connecting an attachment onto the additional control circuit .......................... 3-92 Operation of additional control circuit .............................................................. 3-93 Automatic bucket repositioning (option) ................................................................. 3-94 Switching on the automatic bucket repositioning ............................................. 3-94 Tipping trailer connection (option) ......................................................................... 3-94 Tipping trailer connection (overview and operation) ........................................ 3-94

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Contents Operation of the Autohitch trailer coupling (option) ................................................ 3-95 Notice on the Autohitch trailer coupling ........................................................... 3-95 Unlocking and opening the Autohitch trailer coupling ...................................... 3-95 Locking the Autohitch trailer coupling .............................................................. 3-96 Automatic trailer coupling (option) ......................................................................... 3-97 Notice on using the trailer coupling .................................................................. 3-97 Attaching a trailer ............................................................................................. 3-97 Uncoupling the trailer ....................................................................................... 3-98 Compressed-air brake system (option) .................................................................. 3-99 Important safety instructions regarding the compressed-air braking system ... 3-99 Coupling and uncoupling compressed-air hoses ............................................. 3-99 Compressed-air gauge .................................................................................. 3-100 Hydraulic trailer brake (option) ............................................................................. 3-100 Notice on using the hydraulic trailer brake ..................................................... 3-100 Fitting attachments other than Kramer onto the quickhitch (option) .................... 3-101 Quickhitches for attachments from other manufacturers ............................... 3-101 Important notice on fitting attachments from other manufacturers ................ 3-101 Fitting attachments from other manufacturers ............................................... 3-102 Example: inspection plan for attachments other than Kramer ....................... 3-103 Mounting hydraulic attachments from other manufacturers ................................. 3-104 Important notice on mounting ........................................................................ 3-104 Mounting an attachment from another manucturer on the quickhitch ............ 3-104 Hydraulic connections: attachments from other manufacturers on the 3rd control circuit (example) ............................................................... 3-105 Removing attachments from other manufacturers from the quickhitch ......... 3-106 Towing the machine ............................................................................................. 3-107 Safety instructions for towing away ............................................................... 3-107 Getting ready for towing ................................................................................. 3-107 Towing the machine ....................................................................................... 3-108 Once towing is over ....................................................................................... 3-108 Loading and transporting the machine on a transport vehicle ............................. 3-109 Safety instructions regarding loading ............................................................. 3-109 Loading and tying down the machine ............................................................ 3-110 Tying down the machine ................................................................................ 3-110 Crane handling the machine ................................................................................ 3-111 Safety instructions regarding crane handling ................................................. 3-111 Crane handling .............................................................................................. 3-112 Decommissioning the machine for a longer time ................................................. 3-113 Preserving the piston rods of the hydraulic rams ........................................... 3-113 Preserving the diesel engine ......................................................................... 3-113 Final decommissioning of machine ...................................................................... 3-114 Information on decommissioning ................................................................... 3-114 Preparing disposal ......................................................................................... 3-114 Disposal ......................................................................................................... 3-114 Troubleshooting 4 Diesel engine malfunctions ...................................................................................... 4-1 Malfunctions in the air conditioning system (option) ................................................ 4-3

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Contents Maintenance 5 Important information on maintenance work ............................................................ 5-1 Maintenance staff .............................................................................................. 5-1 Important safety instructions on maintenance work .......................................... 5-1 Safety prop for telescopic boom .............................................................................. 5-2 Mounting the safety prop ................................................................................... 5-2 Fuel system ............................................................................................................. 5-3 General safety instructions for refuelling ........................................................... 5-3 Diesel fuel specification ..................................................................................... 5-3 Stationary fuel pumps ........................................................................................ 5-3 Refuelling ........................................................................................................... 5-4 Bleeding the fuel system ................................................................................... 5-4 Checking/replacing the fuel prefilter (water separator) ...................................... 5-5 Replacing the fuel filter ...................................................................................... 5-6 Cleaning the fuel cooler (option) ........................................................................ 5-6 Diesel engine lubrication system ............................................................................. 5-7 Important safety instructions for working on the lube oil system ....................... 5-7 Checking the engine oil level daily .................................................................... 5-7 Filling up engine oil ............................................................................................ 5-8 Replacing the engine oil (every 500 service hours) ........................................... 5-9 Replacing the engine oil filter (every 500 service hours) ................................. 5-10 Engine and hydraulics cooling system ................................................................... 5-11 Safety instructions regarding cooling system maintenance ............................. 5-11 Notice on inspection and cleaning work .......................................................... 5-11 Temperature gauge: diesel engine coolant ..................................................... 5-12 Checking the coolant level and quality ............................................................ 5-12 Filling up coolant .............................................................................................. 5-13 Draining coolant ............................................................................................... 5-14 Cleaning the radiator fins ................................................................................. 5-15 Cleaning the radiator with the reversing fan (option) ....................................... 5-16 Air filter ................................................................................................................... 5-17 Checking air filter contamination ..................................................................... 5-17 Checking the dust collector (option) once a day .............................................. 5-18 Replacing the filter cartridge at 500 s/h (service hours) .................................. 5-18 V-belts .................................................................................................................... 5-19 Checking the V-belts ....................................................................................... 5-19 Retightening the V-belts .................................................................................. 5-19 Hydraulic system ................................................................................................... 5-20 Specific safety instructions regarding the hydraulic system ............................ 5-20 Important notice on hydraulic oil ...................................................................... 5-20 Monitoring the hydraulic oil and the return filter ............................................... 5-21 Checking the hydraulic oil level once a day ..................................................... 5-22 Filling up hydraulic oil ...................................................................................... 5-22 Important notice regarding the use of biodegradable oil ................................. 5-23 Checking hydraulic pressure lines ......................................................................... 5-24 Safety instructions regarding pressure line checks ......................................... 5-24 Notice for the entrepreneur/owner ................................................................... 5-24 Lubrication work ..................................................................................................... 5-25 Preparing lubrication ........................................................................................ 5-25 Lubricating the rear axle oscillation-type bearing ............................................ 5-25 Lubricating the planetary drive bearing (front and rear axles) ......................... 5-25 Lubrication points on the telescopic boom: overview ...................................... 5-26 Description of lubrication points ....................................................................... 5-26 Lubricating the telescopic boom ...................................................................... 5-27 Checking and adjusting the slide plates .......................................................... 5-27

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Contents Lubricating with the central lubrication system (option) ......................................... 5-28 General functional description of the central lubrication system ...................... 5-28 Time control ..................................................................................................... 5-28 Repair work ...................................................................................................... 5-28 Setting the lubrication and break times ............................................................ 5-29 Filling the central lubrication system ................................................................ 5-29 Maintenance of the brake system .......................................................................... 5-30 Important safety instructions regarding the brake system ............................... 5-30 Checking/filling up the brake fluid level ............................................................ 5-30 Maintenance: compressed-air brake system (option) ............................................ 5-31 Checking the compressed-air tank and lines ................................................... 5-31 Checking compressor attachment and drive ................................................... 5-31 Tyres ...................................................................................................................... 5-32 Daily tyre checks .............................................................................................. 5-32 Changing wheels ............................................................................................. 5-33 Heating and ventilation system maintenance ........................................................ 5-34 General information on the heating system ..................................................... 5-34 Cleaning/replacing the fine-dust filter .............................................................. 5-34 Cleaning/replacing the recirculated-air filter .................................................... 5-34 Air conditioning (option): maintenance ................................................................... 5-35 Safety instructions regarding the air conditioning ............................................ 5-35 Filling up the air conditioning system ............................................................... 5-35 Checking the function, visual check and cleaning once a day ......................... 5-36 Maintenance of the electrical system ..................................................................... 5-37 Important notice ............................................................................................... 5-37 Safety instructions regarding the electrical system and the battery ................. 5-37 Checking/replacing the battery ........................................................................ 5-38 Checks at regular intervals .............................................................................. 5-39 Alternator ......................................................................................................... 5-39 Checking/replacing relays and fuses ............................................................... 5-39 Main fuse box with switching relays ................................................................. 5-40 Maintenance of the automatic trailer coupling (option) .......................................... 5-41 Cleaning and lubricating the trailer coupling .................................................... 5-41 Check the trailer coupling for wear .................................................................. 5-41 Cleaning and maintenance work ............................................................................ 5-42 Specific safety instructions regarding cleaning ................................................ 5-42 Cleaning inside the cab ................................................................................... 5-43 Cleaning the seat belt ...................................................................................... 5-43 Cleaning the exterior of the machine ............................................................... 5-43 Cleaning the engine and the engine compartment .......................................... 5-44 Checking screw connections ........................................................................... 5-44 Checking pivots and hinges ............................................................................. 5-44 Maintenance of attachments and of the work equipment ...................................... 5-44 Maintenance work “Aggressive Media” (option) ..................................................... 5-45 Important notice on anticorrosion protection .................................................... 5-45 Components coated with anticorrosive wax .................................................... 5-45 Measures for maintaining anticorrosive protection .......................................... 5-46 Applying the protective anticorrosion coating .................................................. 5-47 Treatment of oxidised surfaces ........................................................................ 5-47 Maintenance plan (overview) ................................................................................. 5-48 Fluids and lubricants ............................................................................................. 5-53 Maintenance label .................................................................................................. 5-54 Explanation of symbols on the maintenance label ........................................... 5-54 Maintenance label overview ............................................................................ 5-55

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Contents Specifications 6 Model and trade names: overview ........................................................................... 6-1 Frame ...................................................................................................................... 6-1 Engine ...................................................................................................................... 6-1 Oil/water fan ............................................................................................................. 6-2 Power train ............................................................................................................... 6-2 Variable displacement pump ............................................................................. 6-2 Variable displacement motor ............................................................................. 6-2 Axles ........................................................................................................................ 6-3 Front axle ........................................................................................................... 6-3 Rear axle ........................................................................................................... 6-3 Service and parking brake ....................................................................................... 6-4 Steering system ....................................................................................................... 6-4 Work hydraulics ....................................................................................................... 6-5 Hydraulic pump .................................................................................................. 6-5 Hydraulic ram protection .................................................................................... 6-5 Lift, tilt and push-out rams: velocity ................................................................... 6-5 Hydraulic pilot control ........................................................................................ 6-6 Usable consumer pressure at additional control circuit (option) ........................ 6-6 Electrical system ...................................................................................................... 6-7 Fuse assignment ............................................................................................... 6-7 Electric components .......................................................................................... 6-8 Main fuse box with relays (88 kW diesel engine) .............................................. 6-9 Main fuse box with relays (103 kW diesel engine) ............................................ 6-9 Switching relay assignment ............................................................................. 6-10 Tyres for models 401-03/402-03/403-03 ............................................................... 6-11 Machine weights, axle loads .................................................................................. 6-11 Noise levels ........................................................................................................... 6-12 Vibrations, oscillation and acceleration value ........................................................ 6-12 Coolant compound table ........................................................................................ 6-12 Tightening torques ................................................................................................. 6-13 General tightening torques .............................................................................. 6-13 Specific tightening torques .............................................................................. 6-13 Trailer couplings: trailer weight/drawbar load ........................................................ 6-13 Payload: load diagram model 401-03 (without counterweight) .............................. 6-14 Payload: load diagram model 401-03 (with counterweight 2 x 150 kg) ................. 6-15 Payload: load diagram model 402-03 (with counterweight 2 x 150 kg) ................. 6-16 Payload: load diagram model 402-03 (with counterweight 2 x 300 kg) ................. 6-17 Payload: model 403-03 load diagram .................................................................... 6-18 Dimensions with bucket ........................................................................................ 6-19 Dimensions with pallet forks ................................................................................. 6-20 Index S Index S-1

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Contents

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EC Declaration of Conformity

EC Declaration of Conformity EC Declaration of Conformity

EC declaration of conformity (model 401-03) Manufacturer Kramer-Werke GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf

Product Machine designation

400

Model/version

401-03 (7030)

Serial number

401 03 _ _ _ _ _

Output kW

88

Measured sound power level dB(A)

105.6

Guaranteed sound power level dB(A)

106

Conformity assessment procedure The following inspection body was involved in the procedure: Fachausschüsse Bau und Tiefbau (EU-Kennnummer: 0515) Prüf- und Zertifizierungsstelle im BG-PRÜFZERT Landsberger Str. 309 D-80687 München

Directives and standards We hereby declare that this product corresponds to the relevant regulations and requirements of the following EC Directives and standards: 2006/42/CE, 2000/14CE and EN ISO 3744, 2004/108/CE, DIN EN 1459, DIN EN ISO 12100-1 and 2, DIN EN 474-1 and 3, DIN EN 14121-1, DIN EN 3471, DIN EN 13510, EN ISO 3744, EN ISO 3746, DIN EN ISO 3449, DIN EN 13059

Responsible for documentation Dipl.-Ing. Manfred Mack KRAMER-WERKE GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf Pfullendorf, _ _. _ _. _ _ _ _ i. A.

Dipl.-Ing. Manfred Mack Head of Research & Development KRAMER-WERKE GmbH

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EG-1

EC Declaration of Conformity EC declaration of conformity (model 402-03) Manufacturer Kramer-Werke GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf

Product Machine designation

400

Model/version

402-03 (7040)

Serial number

402 03 _ _ _ _ _

Output kW

88

Measured sound power level dB(A)

105.6

Guaranteed sound power level dB(A)

106

Conformity assessment procedure The following inspection body was involved in the procedure: Fachausschüsse Bau und Tiefbau (EU-Kennnummer: 0515) Prüf- und Zertifizierungsstelle im BG-PRÜFZERT Landsberger Str. 309 D-80687 München

Directives and standards We hereby declare that this product corresponds to the relevant regulations and requirements of the following EC Directives and standards: 2006/42/CE, 2000/14CE and EN ISO 3744, 2004/108/CE, DIN EN 1459, DIN EN ISO 12100-1 and 2, DIN EN 474-1 and 3, DIN EN 14121-1, DIN EN 3471, DIN EN 13510, EN ISO 3744, EN ISO 3746, DIN EN ISO 3449, DIN EN 13059

Responsible for documentation Dipl.-Ing. Manfred Mack KRAMER-WERKE GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf Pfullendorf, _ _. _ _. _ _ _ _ i. A.

Dipl.-Ing. Manfred Mack Head of Research & Development KRAMER-WERKE GmbH

EG-2

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EC Declaration of Conformity EC declaration of conformity (model 403-03) Manufacturer Kramer-Werke GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf

Product Machine designation

400

Model/version

403-03 (7045)

Serial number

403 03 _ _ _ _ _

Output kW

88 (103)

Measured sound power level dB(A)

105.6 (103.8)

Guaranteed sound power level dB(A)

106 (104)

Conformity assessment procedure The following inspection body was involved in the procedure: Fachausschüsse Bau und Tiefbau (EU-Kennnummer: 0515) Prüf- und Zertifizierungsstelle im BG-PRÜFZERT Landsberger Str. 309 D-80687 München

Directives and standards We hereby declare that this product corresponds to the relevant regulations and requirements of the following EC Directives and standards: 2006/42/CE, 2000/14CE and EN ISO 3744, 2004/108/CE, DIN EN 1459, DIN EN ISO 12100-1 and 2, DIN EN 474-1 and 3, DIN EN 14121-1, DIN EN 3471, DIN EN 13510, EN ISO 3744, EN ISO 3746, DIN EN ISO 3449, DIN EN 13059

Responsible for documentation Dipl.-Ing. Manfred Mack KRAMER-WERKE GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf Pfullendorf, _ _. _ _. _ _ _ _ i. A.

Dipl.-Ing. Manfred Mack Head of Research & Development KRAMER-WERKE GmbH

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EG-3

EC Declaration of Conformity

EG-4

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Introduction

Introduction

1

Introduction

1.1 Operator's Manual Important notice on this Operator's Manual This Operator's Manual applies to the telehandler models 401-03, 402-03 and 403-03 It is primarily designated for the operator and provides instructions on the use, the adjustment, the operation and the maintenance of the machine.

Carefully read and understand the Operator's Manual before starting up, servicing or repairing the machine.

Pay particular attention to the “Safety Instructions” given in chapter 2.

The Operator's Manual must always be at hand at the place of use of the machine, and must therefore be kept in the storage compartment or net behind the seat.

Immediately replace an incomplete or illegible Operator's Manual with a new one.

In addition to the Operator's Manual, observe and instruct the operator in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.

CLAAS keep abreast of the latest technical developments and constantly improve their products. For this reason, we may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which have already been delivered and which will not be implemented on these machines.

Technical data, dimensions and weights are given as an indication only. Responsibility for errors or omissions not accepted.

Please contact your dealer if you require more information on the machine or the Operator's Manual.

Important notice on machine safety Your own safety, as well as the safety of others, depends to a great extent on how the machine is moved and operated.

Careful and prudent working is the best way to avoid accidents! – see chapter 2 “Selection and qualification of staff, basic responsibilities” on page 2-5.

Notice on maintenance, repairs and spare parts Operational safety and readiness of the machine do not only depend on your reliable control, but also on maintenance and servicing of the machine. This is why regular maintenance and service work is absolutely necessary.

Notice!

Repair work, maintenance or modifications may be carried out only by specifically trained technical staff or by a workshop!

Insist on using original spare parts when carrying out maintenance and repair work.

The machine's permits, certifications, registrations, etc., may be withdrawn if machine parts/components with a prescribed condition or quality, or machine parts/components that can put persons at risk during operation, are subsequently modified or exchanged.

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1-1

Introduction Explanation of safety symbols This symbol identifies safety warnings. It is used to warn against potential personal risk or danger.

Therefore, pay particular attention to the safety information following this symbol.

This symbol identifies danger for the machine. It is used to avoid potential danger on the machine.

Explanation of abbreviations and symbols The indication left or right in the descriptions always refers to the driving direction of the machine.

1-2

Symbols

Explanation

•

Identification of general enumerations or lists of an activity

☞ ➥

Identification of activities to carry out

Abbreviations

Explanation

max.

maximum

e.g.

for example

Fig.

Figures

S/h

Service hour

Order no.

Order or part number

(opt)

Option

Identification of results of an enumeration or lists of an activity

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Introduction 1.2 Machine outside view

5

6

7

8

10

9

4

11

12

3

13

14

4 3

15

2

16

1 17

18

Fig. 1:

Machine outside views

2

22 Pos.

Description

Pos.

21

20

12

19

Description

1

Front eye hook for towing/tying down the machine

14 Trailer coupling (option)

2

Headlights with turn indicators

15 Numberplate fixture (option)

3

Rear clearance light

16 Brake, rear and turn indicator lights

4

Working lights (front/rear right, option)

17 Door arrester

5

Left/right rearview mirrors

18 Rear eye hook for loading/tying down the machine

6

Boom working light (option)

19 Handle for access

7

Hydraulic connections (telescopic boom additional control circuit option)

20 Cab access

8

Air filter (preliminary separator option)

9

Engine cover

10 Eye hook1 only for installing/removing the cab 11

5

21 Battery (battery master switch option) 22 Front-edge protection 1.

Eye hooks are for removing the cab only, and may not be used for crane handling the machine

Rotating beacon (option)

12 Working light on left (standard) 13

Hydraulic connections (additional control circuit, option)

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1-3

Introduction 1.3 Brief description of telehandler General information on the machine According to German traffic regulations, the telehandler is a self-propelled work machine or tractor.

Get informed on and follow the legal regulations of your country.

Due to a wide range of possible attachments, the machine is a versatile and powerful helper in the construction industry, in agriculture and in recycling operations.

Other applications – see Fields of application and using a telehandler with an attachment on page 1-6.

Model designation – trade names The machine is identified by two designations: “Model designation” => stamped on the type label “Trade name” => affixed outside on the machine Model designation (version)

Trade name

401-03

7030

402-03

7040

403-03

7045

Main components of machine • Sturdy steel sheet frame; rubber-mounted engine • ROPS/FOPS tested cab (roll-over/falling object protection) ➥ ROPS is the abbreviation for “Roll Over Protective Structure” ➥ FOPS is the abbreviation for “Falling Object Protective Structure” • Water-cooled turbocharged Deutz four-cylinder in-line engine ➥ Exhaust emissions according to Directive 2004/26EC • Drive Automotive, progressive hydrostatic axial-piston gearbox ➥ Top speed 20 kph (30/40 kph option).

• Hydraulic power steering with emergency steering features (front wheel/four wheel/ diagonal steering) • Front and rear planetary steering axles, rear axle with oscillation • Service brake (multidisc brake) • Parking brake and auxiliary brake (spring-loaded brake effect on multidisc brake) • Telescopic boom

1-4

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Introduction Hydrostatic drive The diesel engine permanently drives a hydraulic pump (variable displacement pump), whose oil flow is sent to a hydraulic motor flanged on the gearbox. The hydraulic motor transmits its power to the front and rear axles (via the transfer gearbox and the cardan shaft) for permanent 4 wheel drive.

Work hydraulics and 4 wheel steering The diesel engine drives a gear or axial piston pump for the work hydraulics and the steering system, and a gear pump both for the fan (water/hydraulic oil radiator) and the boost pressure of the variable displacement pump (drive).

When the machine is in operation, the diesel engine output can be transmitted to the work hydraulics and the steering system to a large extent. This is made possible by a so-called inching valve which responds as soon as the service brake is used, reducing or cutting off power input of the drive. Therefore, engine output is fully available for the telescopic boom by pressing the accelerator pedal and the brake pedal at the same time.

Cooling system A combined water/hydraulic oil cooler (for the diesel engine and the hydraulic oil) is located in the engine compartment. The fan drive (water/hydraulic oil cooler) is hydraulically driven by a gear pump located at the diesel engine's power take-off (optional chargeair cooler).

The indicator lights on the instrument panel of the machine ensure constant monitoring of the engine and hydraulic oil temperature (indicator lights), as well as of the coolant temperature and level.

1.4 Telehandler warranty Warranty claims Warranty claims can be made only if the conditions of warranty have been observed.

They are included in the General Conditions of Sales and Delivery for new machines and spare parts sold by the dealers. Furthermore, the instructions in this Operator's Manual must be observed.

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1-5

Introduction 1.5 Fields of application and using a telehandler with an attachment The attachments will decide how the telehandler is used.

Caution!

In order to avoid damage to the machine, only the attachments in the table below have been certified for installation on the machine! ☞ See also the “Load Diagram” label affixed on the instrument panel Note that not all attachments specified in the table are allowed to be used on public roads Germany.

The attachments complying with German road traffic regulations and the applicable provisions are listed in the General Certification for Vehicles (Germany) or the data confirmation (Germany)!

Attachments that are not listed in the table require an EBE (separate certification for vehicles) made out by the competent authority!

Get informed on and follow the legal regulations of your country.

Notice!

Mounting attachments other than Kramer is only allowed if they correspond to the description in chapter “Operation” Fitting attachments other than Kramer onto the quickhitch (option) on page 3-101.

Authorised attachments Attachment

Attachment type no.

Dimensions

Struck/ heaped

Use

Standard bucket – normal material1

1000150361 1000150491

2400 mm (with teeth) 2400 mm (without teeth)

1.0/1.2 m 3

Loosening, picking up, transporting and loading loose or solid material (material density ≤ p = 1.8 t/m³)

Pallet forks1, 2, 3, 4 Pallet forks (fork arms with hydraulic side shift)1, 2, 3, 4 1.

2.

3.

4.

1-6

1000171857

Length 1200 mm

1000178248

Length 1500 mm

1000174576

Length 1200 mm

1000174581

Length 1600 mm

Telehandler model

401-03, 402-03, 403-03

Picking up and transporting pallets Load diagram Picking up, transporting and sideshifting pallets

402-03, 403-03

Pay attention to the safe load indicator during work Only with load diagram for telehandler Not certified for use on public roads in the Federal Republic of Germany (follow the national regulations) See the Operator's Manual of the attachment for putting the attachment into operation and using it

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Introduction 1.6 Legal regulations regarding telehandler operation Principal regulations for the operating staff • Read and understand the Operator's Manual before putting the machine into service! ➥ Pay particular attention to the chapter on safety on page 2-1 • Be sure to note the “Safety Instructions” labels on the telehandler!

• Transporting accompanying persons in the cab, on the telehandler or in/on the attachments is not allowed!

• Driving or operating the telehandler outside the operator's compartment is not allowed! ➥ Put the machine into operation only when seated • Before leaving the seat, apply the parking brake, stop the diesel engine and remove the ignition key!

• The telehandler may not be used for applications with lifting gear!

• The telehandler may not be used for transport jobs on public roads!

Driving licence Telehandlers may be driven on public roads only if the driver has a driving licence as defined by national traffic regulations.

German traffic regulations require the following driving licences for driving the telehandler: Driving licence category L (new, European Union) • Self-propelled work machines up to 25 kph • Tractors and agricultural or forestry machinery up to 32 kph (with trailer 25 kph) Driving licence category C (new, European Union) • Motor vehicles over 3500 kg (with trailers up to 750 kg) Driving licence category CE (new, European Union) • Motor vehicles over 3500 kg (with trailers over 750 kg) Driving licence category T (new, European Union) • Self-propelled work machines for agriculture and forestry up to 40 kph • Tractors and agricultural or forestry machinery up to 60 kph Get informed on and follow the legal regulations of your country.

Licence/identification § 3 FZV (German vehicle licensing ordinance) requires self-propelled work machines with maximum speeds over 20 kph to be fitted with their own numberplates in accordance with §8 FZV (German vehicle licensing ordinance). § 4b of FZV (German vehicle licensing ordinance) requires owners of self-propelled work machines with maximum speeds below 20 kph to affix their first name, surname and place of residence (company and registered office) in indelible print on the left-hand side of their machines.

Get informed on and follow the legal regulations of your country.

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1-7

Introduction Adjusting the headlights If a lightweight or superlightweight material bucket is fitted onto the machine, the headlights are covered by the buckets in transport position!

• When using a lightweight or superlightweight material bucket on public roads, mount the right and left-hand side headlights on the mirror brackets in a higher position and readjust them • Mounting the headlights in higher positions and readjusting them must be carried out by an authorised workshop • Please refer to the repair or service manual for mounting and adjusting the headlights

Machine inspections

A

Fig. 1:

Example: inspection label

In Germany, legislation requires all machine operators to have all machines and equipment inspected regularly (BGV A1/BetrSichV §10).

Inspections must be carried out as required, but at least once a year, by an expert and must be documented in written form. Subsequent inspections of detected defects must be carried out, too.

The competent inspection authority may require the inspection report to be available at the place where the machine is used. ☞ Affix inspection label A for evidence (example) Ensure that all work equipment/attachments, i.e. not only the machine, is checked.

This requirement is fulfilled, for instance, when the results are logged in a test booklet, file or report.

When operating the machines, the national safety regulations must be followed as well, for instance in Germany, the regulations for accident prevention “Deutsche Prüfstelle für Land- und Forsttechnik” (DPLF German inspection and certification body for agriculture and forestry) and the accident prevention regulation “Fahrzeuge (vehicles)” (BGV D29 § 57 clause 1).

Get informed on and follow the legal regulations of your country.

Documents German traffic regulations require to have the following documentation on board: • General Certification for Vehicles (Germany) or machine documentation • Driving licence • Test report according to legal regulations • Operator's Manual Get informed on and follow the legal regulations of your country.

1-8

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Introduction On-board equipment § 53 StVZO (German road traffic regulations) requires the following equipment to be supplied by the operator and to be fitted on the machine, for instance: • 1 warning triangle with design certification • 1 warning light with design certification • 1 first-aid kit in accordance with the legal regulations of your country Get informed on and follow the legal regulations of your country.

Warning identification of telehandler on public roads (option) § 52 clause 4.1 of StVZO German road traffic regulations requires machines that are used on public roads for the construction, maintenance and cleaning of roads or facilities to be fitted with the red and white warning identification as per DIN 30 710 in connection with a yellow rotating beacon (option).

Get informed on and follow the legal regulations of your country.

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1-9

Introduction 1.7 Type labels and component numbers Explanation of “Book” symbol The “Book” symbol on the signs and type labels indicates that the Operator's Manual contains more detailed information and explanations Fig. 2:

Explanation of “Book” symbol

Serial number The serial number is stamped on the machine frame A (next to the front axle attachment, on the front right in driving direction). It is also located on the type label.

Type label B is located on the front right on the machine frame in driving direction.

The CE mark C on the type label means that the machine meets the requirements of the Machine Directive (2006/42 EC) and that the conformity procedure has been carried out.

A

Type label indications (example)

C

B 1 2 3 4 5

Fig. 3:

11

Type label: location

6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

Machine model Version Serial no.

Year of construction Output (kW) Front gross axle weight rating (kg) Rear gross axle weight rating (kg) Gross weight rating (kg) Dead weight (kg) Maximum payload (kg)

11 Check number of EU approval

400 402 03 402 03 0463 210 88 6500 6500 10000 – – See General Certification for Vehicles (Germany) or the data confirmation (Germany)

Other data: – see Specifications on page 6-1

Cab number The type label (arrow) is located in the cab, at the top right in driving direction.

Fig. 4:

1-10

Cab type label

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Introduction Engine number The type label is located on the cylinder-head cover (engine).

Example: Deutz TCD 2012 L04 2V

Fig. 5:

Diesel engine number

Hydraulic pump number The type label (arrow) is located on the hydraulic pump housing (next to where the pump is installed on the diesel engine)

Fig. 6:

Hydraulic pump type label

Variable displacement motor number The type label (arrow) is located on the housing of the variable displacement motor.

Fig. 7:

Variable displacement motor type label

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1-11

Introduction Variable displacement motor number (high speed option) The type label (arrow) is located on the housing of the variable displacement motor.

Fig. 8:

Variable displacement motor type label (option)

Front and rear axle numbers The type label is located on the differential housing next to the steering ram (arrow).

Fig. 9:

1-12

Rear axle and gearbox type label

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Introduction 1.8 Description of labels Important notice on signs and labels Danger!

In order to avoid injury or danger of accidents, damaged or missing safety and warning signs and labels must be immediately replaced with new ones!

In particular this applies to signs and labels referring to danger of personal damage!

Labels on the outside of the machine Label: cab eye hooks The eye hooks on the cab are for removing the cab only and may not be used for cranelifting the machine.

Location Cab roof (4x).

Fig. 10: Eye hook label

A

B

Fig. 11: Label for points used for tying down the machine

Machine noise level label Noise levels produced by the machine LWA = sound power level – see chapter 6 “Noise levels” on page 6-12

XX

Location Rear window

Fig. 12: Noise level label

20

30

Fig. 13: Speed label

Fig. 14: Danger label

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Label: slinging points for loading and tying down the machine A slinging points for crane handling B slinging points for tying down the machine for transport – see Machine outside view on page 1-3 and “Loading and transporting the machine on a transport vehicle” on page 3-109 Location On left and right of the machine frame, above the front axle fixture and at the rear of the frame (next to the bearing of the telescopic boom)

40

Machine top speed label 20 kph (30/40 kph option).

Location At the rear and on the left/right side of the machine

Label: general indication of danger.

Caution! All persons must stay clear of the hazard zone of the telehandler.

Location Front left and right of telescopic boom, and at rear of machine.

1-13

Introduction

A

Label: filler opening for hydraulic oil A = hydraulic oil or B = biodegradable hydraulic oil Location Next to the filler opening (hydraulic oil tank) – see chapter 5 “Filling up hydraulic oil” on page 5-22.

B

Fig. 15: Label: filler opening for hydraulic oil

Label: fuel filler opening Use only the diesel fuels indicated.

• DIN EN 590 (EU)/ASTM D975-94 (USA)/EN 14214 (biodiesel) • Do not use diesel fuel with additives If other fuels are used, warranty rights shall not apply in case of diesel engine damage (guarantee)!

Location Near the filler inlet of the fuel tank (left-hand side of machine) – see chapter 5 “Refuelling” on page 5-4.

Fig. 16: Label: fuel filler opening

1 2 3

Battery master switch label In order to avoid malfunctions of the electronic fuel injection, do not immediately turn the battery master switch out of the notched position after stopping the engine! Follow the correct order (see label) Location Near the battery master switch (cab access) – see chapter 3 “Battery master switch” on page 3-27

Fig. 17: Battery master switch label

Label: safety strut (telescopic boom lift ram) Caution! Fit the safety strut onto the lift ram before carrying out maintenance work on the telescopic boom – see chapter 5 “Safety prop for telescopic boom” on page 5-2!

Location On the safety strut

Fig. 18: Label: lift ram strut

1-14

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Introduction Labels inside the cab Pallet forks load diagram label Load diagrams with maximum payload indications for pallet forks applications in telescopic operation!

Example: – see chapter 3 “Description of load diagram for pallet forks and bucket” on page 3-85 – see chapter 6 “Payload: load diagram model 401-03 (without counterweight)” on page 6-14 Location Load diagram label

Notice!

The load diagram is valid only for applications with pallet forks. Pay attention to the specific load diagrams of other attachments used!

Fig. 19: Pallet forks load diagram

Tyre pressure table label List of authorised types of tyres with prescribed tyre inflation pressures.– see chapter 6 “Tyres for models 401-03/402-03/403-03” on page 6-11 Location Load diagram label

Fig. 20: Tyre pressure table

A B

Brake fluid label A = Caution! Do not fill in any water!

B = Use only LHM brake fluids – see chapter 5 “Fluids and lubricants” on page 5-53.

Location On the brake-fluid tank

Fig. 21: Brake fluid label

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1-15

Introduction Label: locking the control lever (joystick) against unintentional operation Label: locking the control lever (joystick) during road travel!

• A = lock open • B= lock closed ➥ – see Locking the control lever (joystick) and the 3rd control circuit (attachments) on page 3-39 Location On the stop cock on the control lever console

A

B Fig. 22: Control lever lock label

B A

C

D

E

Fig. 23: Label: control lever operation overview

1-16

Label: control elements on control lever (joystick) • A = driving direction: (F) forwards/(R) reverse and (N) neutral position ➥ – see chapter 3 “Driving direction selection (reversing operation forwards/reverse)” on page 3-41 • B = differential lock ➥ – see chapter 3 “Differential lock” on page 3-53 • C = telescopic boom extension and retraction • D = telescopic boom: raise/lower and dump in/out ➥ – see chapter 3 “Retracting/lowering the telescopic boom” on page 3-66 ➥ – see chapter 3 “Raising/extending the telescopic boom” on page 3-66 • E = lock: attachment in quickhitch ➥ – see chapter 3 “Locking and unlocking the quickhitch or an attachment” on page 3-68 Location On the right on the side window

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Introduction

A

B

Label: additional control circuit operation (proportional controls) • A low flow capacity • B high flow capacity Location On the switch console on the right, at the rear

Fig. 24: Additional control circuit potentiometer

Label for operation of tipping trailer connection or Autohitch trailer coupling – see chapter 3 “Tipping trailer connection (option)” on page 3-94 – see chapter 3 “Operation of the Autohitch trailer coupling (option)” on page 3-95 Location On the right on the side window

Fig. 25: Label: tipping trailer/Autohitch trailer coupling

Label for differential lock operation 1 First stop the telehandler, then 2 switch on the differential lock ➥ – see chapter 3 “Differential lock” on page 3-53 Location On the right on the side window

1 Stop

2 1000157829

Fig. 26: Differential lock label

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1-17

Introduction Operator's Manual label Caution! Read the Operator's Manual before putting the machine into operation Location On the left-hand side member inside the cab.

Fig. 27: Operator's Manual label

Seat belt label • Operate the machine only from the seat • Fasten the seat belt before operating the machine • Read and understand the Operator's Manual Location On the left-hand side member inside the cab

Fig. 28: Label: seat, fastening the seat belt

Label: ensure machine stability • Ensure machine stability • Read and understand the Operator's Manual Location On the left-hand side member inside the cab

Fig. 29: Machine stability label

Label: remove the ignition key!

Caution! Remove ignition key before carrying out inspection and maintenance work on the machine.

• Before maintenance work: read the service manual • Only appropriately trained technical staff may carry out repair work Location On the left-hand side member inside the cab.

Fig. 30: Label: read and understand the service manual

Label: no transport of persons!

Warning! Lifting or transporting persons on the machine, in the bucket or on the pallet forks is not allowed.

Location Inside the cab, on upper left side of front window.

Fig. 31: Prohibitive label: no transport of persons

1-18

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Introduction Label: stopping the machine • 1 = at telehandler standstill • 2 = set driving direction to neutral with tip switch N on control lever (joystick) ➥ – see chapter 3 “Driving direction selection (reversing operation forwards/reverse)” on page 3-41 • 3 = service and/or parking brake operation ➥ – see chapter 3 “Brake/inching pedal” on page 3-49 ➥ – see chapter 3 “Parking brake” on page 3-50 Location On the right of the ignition lock Fig. 32: Label: stopping the telehandler

Label: danger in case of broken right-hand window In order to avoid danger of crushing or accidents, stop the machine immediately if the right-hand window is broken!

• Stop the engine and remove the ignition key • Apply the parking brake • Have the side window replaced by an authorised workshop Location Inside the cab

Fig. 33 : Label: danger in case of broken side window

Label for air conditioning system refill (option) Use only the refrigerants (see arrow) indicated on the label for refilling the air conditioning system.

Location In the engine compartment on the air guide plate of the radiator (coolant)

Fig. 34: Label for air conditioning refill

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1-19

Introduction Labels in the engine compartment

Fig. 35: Prohibitory label

Fig. 36: Label: hot fluid (coolant)

Label: danger of shearing Caution! Do not touch any moving or turning parts!

Carry out inspections and maintenance work only at diesel engine standstill!

Location In the area of the engine cooling (V-belt guard) Label: radiator under pressure, danger of scalding!

Caution! Do not open, radiator is hot and under pressure.

• Wear protective gloves and clothing • Open the radiator only after the coolant has cooled down • Open the cover carefully to the first stop notch to allow the pressure to escape Location In the engine compartment next to the radiator (coolant) Label: danger of burns!

Caution! Do not touch.

• Wear protective gloves and clothing during maintenance work Location Next to the exhaust silencer.

Fig. 37: Label: hot surface

1-20

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Safety instructions

Safety instructions

2

Safety instructions

2.1 Identification of warnings and dangers Important indications regarding the safety of the staff and the machine are identified in this Operator's Manual with the following terms and symbols:

Danger!

Failure to observe the instructions identified by this symbol can result in personal injury or death for the operator or other persons.

☞ Measures for avoiding danger

Caution!

Failure to observe the instructions identified by this symbol can result in damage to the machine. ☞ Measures for avoiding danger for the machine

Notice!

This symbol identifies instructions for a more efficient and economical use of the machine.

Environment!

Failure to observe the instructions identified by this symbol can result in damage to the environment.

The environment is in danger if environmentally hazardous material (e.g. waste oil) is not subject to proper use or disposal.

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2-1

Safety instructions 2.2 Designated use and exemption from liability • Carrying or transporting accompanying persons in the cab or on the telehandler is not allowed!

• Furthermore, transporting persons in and/or on attachment is not allowed!

• The machine may not be used for transport jobs on public roads!

• Fire hazard due to hot engine silencer – the machine may not be used in areas posing a fire hazard (hay or straw storage facilities, etc.) !

• The machine is intended for: • pallet forks operation, and moving earth, gravel, coarse gravel or ballast and rubble, and for applications with the attachments listed in chapter Introduction, Authorised attachments on page 1-6!

• tractor operation with the appropriate options and the national certifications (see also the General Certification for Vehicles (Germany) or the Data Confirmation of the machine) • Every other application is regarded as not designated for the use of the machine. The manufacturer will not be liable for damage resulting from use other than mentioned above. The user alone will bear the risk.

• Designated use also includes observing the instructions in the Operator's Manual and observing the conditions of maintenance and service!

• Observe the pertinent regulations relevant to accident prevention, other generally acknowledged regulations regarding safety and occupational medicine, as well as the regulations and standards relevant to motor vehicles and traffic which are valid in your country. The manufacturer shall not be liable for damage resulting from the failure to observe these regulations!

• The safety of the machine can be negatively affected by carrying out machine modifications without proper authority and by using spare parts, equipment, attachments and optional equipment which have not been checked and released by the manufacturer.

The manufacturer will not be liable for damage resulting from this!

• The manufacturer shall not be liable for personal injury and/or damage to property caused by failure to observe the safety instructions and the Operator's Manual, and by the negligence of the duty to exercise due care when: • handling • operating • servicing and carrying out maintenance work and • repairing the machine. This is also applicable in those cases in which special attention has not been drawn to the duty to exercise due care, in the safety instructions as well as in the operation and maintenance manuals (machine/diesel engine).

• Read and understand the Operator's Manual before starting up, servicing or repairing the machine. Observe the safety instructions!

• In applications with lifting gear, the machine is used according to its designated use only if the prescribed devices are installed and functional! Please refer to the General Certification for Vehicles (Germany) or the data confirmation (Germany) of the machine for information on the specific requirements!

2-2

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Safety instructions 2.3 General conduct and safety instructions Organisational measures • The machine has been designed and built in accordance with state-of-the-art standards and the recognised safety regulations. Nevertheless, its use can constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material property!

• The machine must only be used in technically perfect condition in accordance with its designated use and the instructions set forth in the Operator's Manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine! Any functional disorders, especially those affecting the safety of the machine, must therefore be rectified immediately.

Basic rule: Before starting up the machine, inspect the machine for safety in work and road operation!

• Careful and prudent working is the best way to avoid accidents!

• The Operator's Manual must always be at hand at the place of use of the machine, and must therefore be kept in the storage compartment provided for in the cab.

Immediately complete or replace an incomplete or illegible Operator's Manual!

• In addition to the Operator's Manual, observe and instruct the operator in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.

These compulsory regulations may also deal with handling hazardous substances, issuing and/or wearing personal protective equipment, or traffic regulations!

• With regard to specific operational features, e.g. those relevant to job organisation, work sequences or the persons entrusted with the work, supplement the Operator's Manual by corresponding instructions, including those relevant to supervising and reporting duties!

• Persons entrusted with work on the machine must have read and understood the Operator's Manual and in particular, chapter “Safety Instructions” before beginning work. This applies especially to persons working only occasionally on the machine, e.g. set-up or maintenance!

• The user/owner must check – at least from time to time – whether the persons entrusted with operation or maintenance of the machine are working in compliance with the Operator's Manual and are aware of risks and safety factors!

• The user/owner commits himself to operate and keep the machine in a perfect condition, and, if necessary or required by law, to require the operating or servicing persons to wear protective clothing etc.

• In the event of safety-relevant modifications or changes on the machine or of its behaviour, stop the machine immediately and report the malfunction to the competent authority/person.

Safety-relevant damage or malfunctions of the machine must be rectified immediately!

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Safety instructions • Never make any modifications, additions or conversions to the machine and its superstructures (e.g. cab, telescopic boom etc.), as well as to the attachments, which might affect safety without the approval of the manufacturer! This also applies to the installation and the adjustment of safety devices and valves, as well as to welding work on load-bearing elements!

• Spare parts must comply with the technical requirements specified by the manufacturer. Original spare parts can be relied to do so!

• Replace hydraulic hoses within stipulated and appropriate intervals even if no safetyrelevant defects have been detected!

• Before working on or with the machine, remove jewellery, such as rings, wristwatches, bracelets etc., and tie back long hair and do not wear loose-fitting garments, such as unbuttoned or unzipped jackets, ties or scarves.

Injury can result from being caught up in the machinery or from rings catching on moving parts!

• Keep the machine clean. This reduces • Fire hazard, e.g. due to oil-soaked rags lying around • Danger of injury, e.g. due to dirt or debris on the footholds, and • Danger of accidents e.g. due to dirt or debris on the brake or accelerator pedal!

• Observe all safety, warning and information signs and labels on the machine!

• Adhere to prescribed intervals or those specified in the Operator's Manual for routine checks/inspections and maintenance work!

• Tools and workshop equipment adapted to the task on hand are absolutely indispensable for carrying out service, inspection, maintenance or repair work!

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Safety instructions Selection and qualification of staff, basic responsibilities • Any work on or with the machine must be carried out by reliable staff only.

• Do not let unauthorised persons drive or work with the machine! Observe statutory minimum age limits!

• Employ only trained or instructed staff on the machine, and clearly and unequivocally define the individual responsibilities of the staff for operation, set-up, maintenance and repair!

• Define the machine operator's responsibilities – also with regard to observing traffic regulations. Give the operator the authority to refuse instructions by third parties that are contrary to safety!

• Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person!

• Work on the electrical system and equipment, on the chassis and the steering and brake systems must be carried out only by technical staff which has been specially trained for such work.

Work on the hydraulic system of the machine must be carried out only by staff with special knowledge and experience in hydraulic systems!

• Seal off the danger area should it not be possible to keep a safe distance.

• Stop work if persons do not leave the danger area in spite of warning! Keep out of the danger area!

Observing the danger area • The danger area is the area in which persons are in danger due to the movements of the machine, work equipment, other equipment or load!

• This also includes the area affected by falling material, equipment or by parts which are thrown out.

• The danger area must be extended in the immediate vicinity of buildings, scaffolds or other elements of construction!

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Safety instructions 2.4 Safety instructions regarding operation Normal operation • Avoid any operational mode that might be prejudicial to safety!

• Before beginning work, familiarise yourself with the surroundings and circumstances of the work site. These are e.g. obstacles in the working and travelling area, the loadbearing capacity of the ground and any necessary barriers separating the work site from public roads!

• Take the necessary precautions to ensure that the machine is used only when in a safe and reliable state!

• Operate the machine only if all protective and safety-oriented devices, e.g. removable safety-devices, soundproofing elements and exhausters etc., are in place and fully functional!

• Check the machine at least once a day/per work shift for visible damage and defects.

Report any changes (incl. changes in the machine's working behaviour) to the competent organisation/person immediately! If necessary, stop the machine immediately and lock it!

• In the event of malfunctions, stop the machine immediately and lock it! Have any defects rectified immediately!

• Start and operate the machine from the seat only!

• Carry out start-up and shut-down procedures in accordance with the Operator's Manual, and observe the indicator lights!

• Before putting the machine/attachment into operation (start-up/moving), ensure that nobody is at risk by putting the machine/attachment into operation!

• Before driving with the machine, and also after interrupting work, check whether the brakes, the steering, signalling and light systems are functional!

• Before moving the machine always check whether the supplementary equipment and the attachments have been safely stowed away or attached!

• When driving on public roads, ways and places, observe the valid traffic regulations and, if necessary, ensure beforehand that the machine is in a condition perfectly compatible with these regulations!

• Always switch on the lights in conditions of poor visibility and after dark!

• No raising, lowering or carrying persons in the work equipment or attachments!

• Installing a work platform is prohibited! ➥ Installation is possible if the machine is fitted with the “Work platform” option at the factory. Always contact Kramer-Werke GmbH for installation!

• When crossing underpasses, bridges and tunnels, or when passing under overhead lines always ensure that there is enough clearance!

• When working close to overhead lines, there is always a risk of causing a dangerous or fatal sparkover oneself. Keep a safe distance from overhead lines under all circumstances when driving under them (ask the electricity supplier for the safe distance)!

• Always keep at a safe distance from the edges of building pits and slopes!

• Bear in mind the following when working in buildings or in enclosed areas: • Height of the ceiling/clearances • Width of entrances • Maximum load of ceilings and floors • Sufficient room ventilation – danger of poisoning!

• Avoid any operation that might be a risk to machine stability!

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Safety instructions • During operation on slopes, drive or work uphill or downhill. If driving across a slope cannot be avoided, bear in mind the tilting limit of the machine!

Always keep the attachments/work equipment close to the ground. This also applies to driving downhill!

When driving or working across a slope, the load must be on the uphill side of the machine!

• On sloping terrain always adapt your drive speed to the prevailing ground conditions!

Never change to lower gear on a slope but always before reaching it!

• After leaving the seat always secure the machine against unintentional movement and unauthorised use!

• Lower the work equipment/attachments to the ground • Apply (pull) the parking brake • Stop the diesel engine and remove the ignition key • Before starting work, check whether all safety devices are properly installed and functional • and an approved hazard warning light, warning triangle and first aid kit are at hand!

• Before moving the machine or before taking up work: • Ensure that visibility is sufficient (clean cab windows, adjust the rearview mirrors!)

• Adjust correct seat position (you must be able to press the brake/inching pedal as far as it will go). Never adjust the seat when driving or working!

• Fasten your seat belt • Inspect the immediate area (children!)

In the work area the operator is responsible for third parties!

• Caution when handling fuel – increased danger of fire!

Ensure that fuel does not come into contact with hot parts!

Do not smoke during refuelling, and avoid fire and sparks! Stop the engine during refuelling and do not smoke!

• Never get on or off a moving machine! Never jump off the machine!

• Should the lights of the machine not be sufficient for carrying out work safely, provide additional lighting of the work area!

• Installed work lights must not be switched on for travel on public roads. They can be switched on in work operation if users of public roads are not dazzled!

• Hydrostatic 4 wheel steering takes time getting used to it. Therefore, adjust the drive speed to your abilities and the circumstances. Selection and change of steering mode at machine standstill only!

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Safety instructions Applications with lifting gear Applications with lifting gear are understood as procedures involving raising, transporting and lowering loads with the help of slings and load-securing devices (e.g. ropes, chains).

In doing so, the help of persons is necessary for securing and detaching the load. This applies for example to raising and lowering pipes, shaft rings or containers!

• The machine may be used for applications with lifting gear only if the prescribed safety devices are in place and functional.

These are for instance a load diagram and safe possibilities of slinging and securing lifting gear (attachment, load hook)!

• The load must be secured so as to prevent it from falling or slipping!

• Persons guiding the load or securing it must stay in visual contact with the machine operator!

• The machine operator must guide the load the nearest possible to the ground and avoid any oscillating or swinging movements!

• The machine may be moved with a raised load only if the path of the machine is as level as possible!

• The persons attaching or securing loads may approach the boom from the side only, and only after the machine operator has given his permission. The machine operator may give his permission only after the machine is at a standstill and the work attachment no longer moves!

• Do not use any lifting gear (ropes, chains) which is damaged or not sufficiently dimensioned.

• Always wear protective gloves when working with lifting gear!

Trailer operation Trailer operation • For trailer operation, get informed on the legal regulations of your country which may require specific permits and equipment for using the machine as a tractor on public roads, such as trailer couplings, sockets etc.! ➥ Refer to the machine documentation ➥ Admissible trailer weights – see chapter 6 “Trailer couplings: trailer weight/drawbar load” on page 6-13 • Trailer operation with the towing device of the machine is not permitted!

• Operate the machine only if all protective facilities have been installed and are functional, and if all brake, light and hydraulic connections have been connected!

• If optional equipment is installed, all additionally required light installations, indicator lights etc., must be provided for and functional!

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Safety instructions Attachment operation Attachments • Prior to driving on public roads remove all attachments which cannot be secured in compliance with the legal regulations of your country! See also the footnote – see chapter 1 “Authorised attachments” on page 1-6!

• Attachments and counterweights affect handling, as well as the steering and brake capability of the machine!

• Fit the attachments with the specially required devices only!

• Before uncoupling or coupling hydraulic lines (hydraulic quick couplers), stop the diesel engine and release the pressure in the work hydraulics! ➥ – see chapter 3 “Locking and unlocking the quickhitch or an attachment” on page 3-68 • Coupling attachments requires special care!

• Secure attachments on the ground against unintentional movement!

• If the machine is equipped with a quickhitch, ensure that the attachment is safely locked in the quickhitch. The lock pin must be visible on either side of the bores on the attachment.

• Before starting work, secure attachments on the quickhitch against unintentional actuation of the lock!

• Be careful when mounting attachments onto the quickhitch: danger of personal injury due to crushing and shearing. Ensure that nobody is between the machine and the attachment before securing the machine and the attachment against movement!

Transport • The machine must be towed, loaded and transported only in accordance with the Operator's Manual!

• For towing the machine observe the prescribed transport position, admissible speed and itinerary!

• Use only suitable means of transport and lifting gear of adequate capacity/payload!

• Bear in mind the overall weight of the machine!

• Safely secure the machine on means of transport! Use suitable slinging points and load-securing devices!

• The recommissioning procedure must be strictly in accordance with the Operator's Manual!

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Safety instructions 2.5 Safety instructions for maintenance • Daily and weekly service and maintenance work must be carried out by a specifically trained driver. All other maintenance work must be carried out by trained and qualified staff only – see chapter 5 “Maintenance plan (overview)” on page 5-48.

• The brake and steering systems are crucial to safety.

• Maintenance work must be carried out by specifically trained staff and an authorised workshop only!

• Avoid any operational mode that might be prejudicial to safety!

• Observe the adjustment, maintenance and inspection activities and intervals set forth in the Operator's Manual, including information on the replacement of parts/partial equipment! These activities must be carried out by technical staff with specific training only!

• The machine may not be serviced, repaired or test-driven by unauthorised staff!

• The maintenance plan indicates when the maintenance work mentioned below must be carried out – see chapter 5 “Maintenance plan (overview)” on page 5-48 • Brief operating staff before beginning special operations and maintenance work!

Appoint a person to supervise the activities!

• In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices, or any work related to maintenance, inspection and repair, observe the start-up and shut-down procedures set forth in the Operator's Manual, and the information on maintenance work • Before taking up work on machine parts dangerous for life and limb (bruising, cutting), always ensure safe blocking/support of these areas!

• If required, secure the maintenance area appropriately!

• Prior to carrying out service, maintenance and repair work, attach a warning label, such as “Repair work – do not start machine!”, to the ignition lock/steering wheel or to the control elements. Remove the ignition key!

• Carry out maintenance and repair work only if the machine is parked on firm and level ground, • the forwards-reverse lever (tip switch on control lever) is in neutral position, • the parking brake is applied, • all hydraulically movable attachments and working equipment have been lowered to the ground, • the diesel engine is stopped and the ignition key is removed, • the machine is secured with the parking brake and wheel chocks to prevent it from rolling away.

• Should maintenance or repair be inevitable with the diesel engine running: • Only work in groups of two • Both persons must be authorised for the operation of the machine • One person must be seated on the seat and maintain visual contact with the other person • Observe the specific safety instructions in the work manual • Keep a safe distance from all rotating and moving parts, e.g. fan blades, V-belt drives, PTO shaft drives, fans etc.!

• Prior to carrying out maintenance work on the machine, ensure that no movable parts will roll away or start moving!

• To avoid the risk of accidents, parts and large assemblies being moved for replacement purposes must be carefully attached and secured to lifting gear.

• Use only suitable lifting gear and suspension systems in a technically perfect state with adequate load-bearing capacity!

Stay clear of suspended loads!

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Safety instructions • Have loads fastened and crane operators instructed by experienced persons only!

The person giving the instructions to the operator must be within sight or sound of him!

• Always use specially designed or otherwise safety-oriented ladders and working platforms to carry out overhead assembly work.

Never use machine parts or attachments/superstructures as a climbing aid!

Wear a safety harness when carrying out maintenance work at greater heights!

Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice!

• Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair work!

Do not use aggressive detergents!

Use lint-free cleaning rags!

• Before cleaning the machine with water, steam jet (high-pressure cleaner) or detergents, cover or tape up all openings which – for safety and functional reasons – must be protected against water, steam or detergent penetration. Special care must be taken with the electrical system!

• After cleaning, remove all covers and tapes applied for that purpose!

• After cleaning, examine all fuel, lubricant and hydraulic oil lines for leaks, chafe marks and damage!

Rectify all defects without delay!

• Always tighten any screwed connections that have been loosened during maintenance and repair!

• Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work!

• Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact!

• Do not use the work equipment as lifting platforms for persons!

• Carry out maintenance and repair work beneath a raised machine, work equipment/ attachments or additional equipment only if a safe and secure support has been provided for (the sole use of hydraulic rams, jacks etc. does not sufficiently secure raised machines or equipment/attachments)!

• Avoid contact with hot parts, such as the engine block or the exhaust system during the operation of the machine and for some time afterwards – danger of burns!

• Retainer pins can fly out or splinter when struck with force – danger of personal injury!

• Do not use starting fuel! This especially applies to those cases in which a heater plug (intake-air preheating) is used at the same time – danger of explosions!

• Apply special care when working on the fuel system – increased danger of fire!

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Safety instructions 2.6 Maintenance work on protective ROPS and FOPS structures ROPS/FOPS description • ROPS is the abbreviation for “Roll Over Protective Structure” • FOPS is the abbreviation for “Falling Object Protective Structure”

Cab, roll-over bar, protective screen • Straightening and welding work on cabs, roll-over bars and protective screens are prohibited. These structures must be replaced by original spare parts from the manufacturer!

• Drilling holes or modifying protective ROPS/FOPS structures is prohibited!

• Driving or working with the telehandler without installing the protective ROPS/FOPS structures correctly is prohibited!

2.7 Warning of special hazards Electric energy • Use only original fuses with the specified current rating!

Switch off the machine immediately and rectify the malfunction if trouble occurs in the electrical system!

• When working with the machine, maintain a safe distance from overhead electric lines!

If work must be carried out close to overhead lines, the equipment/attachments must be kept well away from them. Caution, danger! Get informed on the prescribed safety distances!

• If your machine comes into contact with a live wire • Do not leave the machine • Drive the machine out of the danger area • Warn others against approaching and touching the machine • Have the live wire de-energised • Do not leave the machine until the line that has been touched or damaged has been safely de-energised!

• Work on the electrical system may only be carried out by a technician with appropriate training, in accordance with the applicable electrical engineering rules!

• Inspect and check the electric equipment of the machine at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately!

• Observe the operating voltage of the machine/attachments!

• Always remove the earthing strap from the battery when working on the electrical system or when carrying out welding work!

• Starting with a battery jump cable can be dangerous if carried out improperly. Observe the safety instructions regarding the battery!

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Safety instructions Gas, dust, steam, smoke • Operate the machine only on adequately ventilated premises! Before starting internal combustion engines or operating fuel-operated heating systems on enclosed premises, ensure that there is sufficient ventilation!

Observe the regulations in force at the respective site!

• Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorised. There can be a risk of explosion and fire, for example!

• Before carrying out welding, flame-cutting and grinding work, clean the machine and its surroundings from dust and other inflammable substances, and ensure that the premises are adequately ventilated - danger of explosions!

Hydraulic equipment • Work on the hydraulic equipment of the machine must be carried out only by persons having special knowledge and experience in hydraulic systems!

• Check all lines, hoses and screwed connections regularly for leaks and obvious damage! Repair any damage and leaks immediately! Splashed oil can cause injury and fire!

• In accordance with the Operator's Manual/instructions for the respective assembly, release the pressure in all system sections and pressure lines (hydraulic system) to be opened before carrying out any implementing/repair work!

• Hydraulic and compressed-air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements!

Noise • During operation all sound baffles must be closed!

• Wear ear protectors if necessary!

Oil, grease and other chemical substances • When handling oil, grease and other chemical substances (e.g. battery electrolyte – sulphuric acid), observe the product-related safety regulations (safety data sheet)!

• Be careful when handling hot consumables – risk of burning or scalding!

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Safety instructions Battery • When handling the battery observe the specific safety instructions and regulations relevant to accident prevention. Batteries contain sulphuric acid – caustic!

• Especially when charging batteries, as well as during normal operation of batteries, an oxyhydrogen mixture is formed in the battery cells – danger of explosion!

• In the case of a frozen battery or of an insufficient electrolyte level, do not try start-up with a battery jump cable. The battery can burst or explode!

Tyres • Repair work on tyres and rims must be carried out by technical staff or by an authorised workshop only!

• Damaged tyres and/or wrong tyre pressure reduce the operational safety of the machine. Check the tyres regularly for correct inflation pressure and damage!

• Do not inflate tyres with inflammable gas – danger of explosion! Check the wheel nuts regularly for tightness. After changing wheels, retighten the wheel nuts after 10 service hours!

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Operation

Operation

3

Operation

Inside of cab (overview)

3.1 Information regarding the description of the control elements This chapter describes the controls, and contains information on the function and the handling of the indicator lights and controls in the cab.

The pages stated in the table refer to the description of the controls.

A combination of digits, or a combination of digits and letters (e.g. 40/18 or 40/A) used for identifying the control elements, means: fig. no.

40/control element no. 18 or position A in fig. no. 40 Figures carry no identification if they are placed to the left of the text.

You can unfold pages (3-2 and/or 3-4) for a better overview.

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3-1

Operation 1

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Inside of cab For more information see page 1 Front wiper................................................................................................................................................................................... 3-60 2 Storage compartment 3 Front window air vents................................................................................................................................................................. 3-58 4 Preheating start switch (ignition lock) ......................................................................................................................................... 3-30 5 Steering column adjustment ........................................................................................................................................................ 3-44 6 Side window air vents.................................................................................................................................................................. 3-58 7 Instrument panel 8 Safe load indicator....................................................................................................................................................................... 3-62 9 Fire extinguisher (option) ............................................................................................................................................................. 3-21 10 Heating switches.......................................................................................................................................................................... 3-58 11 Accelerator pedal 12 Control lever (joystick) .......................................................................................................................................................... 3-4, 3-61 13 Stop cock – control lever lock during road travel ......................................................................................................................... 3-39 14 Interior light 15 Switch panel – side console (right)................................................................................................................................................ 3-4 16 Drink holder 17 Storage net for Operator's Manual 18 Prepared installation for radio (option) 19 Loudspeakers (option) 20 Rear window air vents ................................................................................................................................................................. 3-58 21 Working light (standard on left/option on right)............................................................................................................................ 3-56 22 Steering electronics 23 Drive electronics (Susmic) 24 Central electrics (relays, fuse box etc.).......................................................................................................................................... 6-7 25 Rear wiper ................................................................................................................................................................................... 3-60 26 Rotating beacon........................................................................................................................................................................... 3-57 27 Aerial (option) 28 Proportional electronics 29 Rotary switch – fresh air/recirculated air...................................................................................................................................... 3-58 30 Socket (12 V) ............................................................................................................................................................................... 3-58 31 Fresh air filter............................................................................................................................................................................... 5-34 32 Seat belt....................................................................................................................................................................................... 3-19 33 Hook 34 Brake fluid tank............................................................................................................................................................................ 5-30 35 Bracket for first aid kit 36 Tank – washer system................................................................................................................................................................. 3-60 37 Seat ............................................................................................................................................................................................. 3-16 38 Roller sun-visor 39 Bracket for side window lock (upper door option)........................................................................................................................ 3-14 40 Steering wheel ............................................................................................................................................................................. 3-45 41 Brake/inching pedal ..................................................................................................................................................................... 3-49 42 Lock on cab ................................................................................................................................................................................. 3-14 43 Inside door lock............................................................................................................................................................................ 3-14 44 Multifunctional lever – turn indicators, headlights, wipers............................................................................................................ 3-57 45 Switch panel – side console (left) .................................................................................................................................................. 3-4 46 Front working light (option) .......................................................................................................................................................... 3-56

Fig. 38: Cab overview

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Operation Control elements on the control lever and switch consoles: overview

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3-3

Control elements on the control lever and switch consoles: overview

Operation 60 52

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3.3 Control elements on the control lever and switch consoles: overview

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Indicator lights on the indicating instrument For more information see page 47 Hour meter 48 Cold starter indicator light (yellow) ............................................................................................................................................... 3-30 49 High beam indicator light (blue)....................................................................................................................................................3-55 50 Coolant level indicator light (red)..................................................................................................................................................5-12 51 Hydraulic oil filter indicator light (red) ...........................................................................................................................................5-22 52 Air filter indicator light (yellow)...................................................................................................................................................... 5-17 53 Alternator charge function indicator light (red) .............................................................................................................................3-30 54 Indicator light (red) – parking brake and boost pressure monitoring (drive).................................................................................3-50 55 Engine oil pressure indicator light (red)........................................................................................................................................ 3-30 56 Indicator light (red) – 3rd control circuit, continuous operation..................................................................................................... 3-89 57 Right/left turn indicator light (green) for rear attachments ............................................................................................................3-57 58 Indicator light (green) – fuel/water separator..................................................................................................................................5-5 59 Fuel level indicator Indicator lights on the instrument panel For more information see page 60 Indicator light (red) – hydraulic system overheating..................................................................................................................... 5-21 61 Indicator light (red) – hydraulic oil level ........................................................................................................................................ 5-22 62 Differential lock indicator light (green) ..........................................................................................................................................3-53 63 Right/left turn indicator light (green) ............................................................................................................................................. 3-57 64 Indicator light (yellow) – hose burst valve (comes on if the load stabiliser is switched on).......................................................... 3-88 65 Indicator light (green) – front axle steering...................................................................................................................................3-46 66 4 wheel steering indicator light (green) ........................................................................................................................................ 3-46 67 Indicator light (green) – diagonal steering (crab steering option) .................................................................................................3-47 68 Steering synchronisation indicator light (red) ...............................................................................................................................3-45 69 Level indicator (option) 70 Forwards driving direction indicator light (green) ......................................................................................................................... 3-40 71 Reverse driving direction indicator light (green)...........................................................................................................................3-41 72 Speedometer (high speed option) 73 Temperature indicator with acoustic warning – diesel engine (115 °C ON/110 °C OFF) ............................................................ 5-11 74 Indicating instrument 75 Manual throttle potentiometer (option) .........................................................................................................................................3-42 76 Tip switch with error code displays (103 kW diesel engine).........................................................................................................3-33 77 Crawler gear potentiometer (option)............................................................................................................................................. 3-42 78 Tachometer (engine) 79 Indicator light (red) – disabling/enabling the overload cutoff ........................................................................................................3-65 Heating switch console For more information see page 80 Rotary switch – heating temperature............................................................................................................................................3-58 81 Rotary switch – heater fan............................................................................................................................................................3-58 82 Switch – tilt ram lock (option) .......................................................................................................................................................3-89 83 Mirror adjustment switch (option) ................................................................................................................................................. 3-54

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Fig. 43: Control lever (joystick)

113 Fig. 44: Switch panel – side console (right)

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Operation

Operation Side console switch panel on the left For more information see page 84 Hazard warning system switch (red) ............................................................................................................................................3-57 85 Switch (grey) – machine lights (low beam and rear lights)...........................................................................................................3-55 86 Switch (grey) – rotating beacon (option) ......................................................................................................................................3-57 87 Switch (grey) – front working light ................................................................................................................................................3-56 88 Switch (grey) – rear working light.................................................................................................................................................3-56 89 Switch (grey) – boom working light (option) .................................................................................................................................3-56 90 Switch with lock (green) – continuous operation of 3rd control circuit (option) ............................................................................3-89 91 Switch (green) – front/rear additional control circuit (option)........................................................................................................3-91 92 Switch (grey) – heated rear window + mirror heating (option) 93 Switch (grey) – fuel preheater (option).........................................................................................................................................3-28 94 Switch (grey) – front socket for electric attachments (option) ......................................................................................................3-90 95 Switch with lock (green) – 3rd control circuit lock ........................................................................................................................3-68 96 Air compressor pressure gauge (option).............................................................................................................................3-99, 5-31 97 Switch (green) – Autohitch trailer coupling (option) .....................................................................................................................3-95 98 Switch (green) – quickhitch release and emergency lowering.....................................................................................................3-68 99 Switch (green) – load stabiliser (option).......................................................................................................................................3-51 Side console switch panel on the right For more information see page 100Switch with lock (red) – parking brake .........................................................................................................................................3-50 101Switch with lock (blue) – 4 wheel/front axle steering....................................................................................................................3-46 102Switch (blue) with lock – diagonal (crab) steering........................................................................................................................3-47 103Tip switch (blue) – steering synchronisation ................................................................................................................................3-45 104Switch (blue) – work/drive range..................................................................................................................................................3-40 105Switch (grey) – rear wiper ............................................................................................................................................................3-60 106Switch (grey) – engine fan reversing operation (option) .....................................................................................................3-54, 5-16 107Switch (grey) – air conditioning system (option) .................................................................................................................3-59, 5-35 108Switch (green) – hydraulic tipping trailer connection (opton) .......................................................................................................3-94 109Tip switch (green) – hydraulically adjustable trailer coupling (Autohitch) or hydraulic connection for tipping trailer (option) ...................................................................................................................................3-94, 3-95 110Switch (green) – additional control circuit (option) .......................................................................................................................3-91 111 Not assigned 112 Not assigned 113Switch with lock (green) – disabling/enabling the overload cutoff................................................................................................3-65 114Potentiometer – rotary switch for additional control circuit (option)..............................................................................................3-91 Control lever (joystick) and multifunctional lever For more information see page 115Tip switch – driving direction in neutral ........................................................................................................................................3-41 116Scroll wheel – extend/retract telescopic boom.............................................................................................................................3-66 117Tip switch – front socket or bucket repositioning (option) ............................................................................................................3-94 118Scroll wheel – unlock/lock 3rd control circuit................................................................................................................................3-68 119Tip switch – differential lock .........................................................................................................................................................3-53 120Switch – forwards/reverse driving direction..................................................................................................................................3-41 121Rotary switch and tip switch – front wiper, washer pump ............................................................................................................3-60 122Horn tip switch..............................................................................................................................................................................3-57

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3-5

Operation 3.4 Indicator lights and warning lights: description Indicator light check When ignition is switched on, all indicator lights on the indicating instrument come on briefly for a check and then go out after a few seconds.

53

Notice!

54

55

P

Indicator lights 53/54/55 remain lit.

Caution!

For your own safety and in order to avoid consequential damage to the machine, have defective indicator lights immediately checked or replaced by an authorised workshop!

Indicator light and warning light – indicating instrument 48

49

High beam indicator light (blue) Comes on if high beam is switched on, or during headlight flashing.

50

Coolant level indicator light (red) Indicates that the coolant level in the radiator is too low: ☞ Check the coolant system for leaks, have possible damage repaired by an authorised workshop. Fill up coolant

51

Hydraulic oil filter indicator light (red) Indicates inadmissibly high pressure in the hydraulic return line to the tank – see chapter 5 “Monitoring the hydraulic oil and the return filter” on page 5-21.

52

53

3-6

Cold starter indicator light (yellow) Comes on when the key in preheating start switch is in position 1.

The air in the combustion chamber of the engine is preheated by means of a glow plug and a temperature-dependent time lag relay.

Air filter indicator light (yellow) Indicates air filter contamination.

Alternator charge function indicator light (red) The indicator light comes on when the ignition is turned on and goes out as soon as the engine runs.

The alternator and/or the V-belts are defective if the indicator light comes on with the engine running.

The battery is no longer charged.

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Operation 54

P

55

Parking brake indicator light (red) Comes on if the switch (see Fig. 44/100) is pressed.

Engine oil pressure indicator light (red) The indicator light comes on when the ignition is turned on and goes out as soon as the engine runs.

The indicator light also comes on if the engine oil pressure is too low. In this case: 1 Stop the machine immediately and stop the engine 2 Check the oil level

56

Indicator light (red) – continuous operation of 3rd control circuit (hydraulics) Comes on during operation of an attachment with its own hydraulic circuit (e.g. rotary broom with hydraulic motor).

57

Right/left turn indicator light (green) for rear attachment (option) Flashes intermittently when the turn indicators are used and a front or rear attachment is connected electrically.

58

Indicator light (red) – water separator (fuel system) Indicates that the water separator of the fuel prefilter contains water: 1 Drain water

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3-7

Operation Indicator light and warning light – front instrument panel 60

Hydraulic oil temperature indicator light (red) Indicates that the temperature in the hydraulic system is too high. ➥ – see chapter 5 “Monitoring the hydraulic oil and the return filter” on page 5-21

61

Indicator light (red) – hydraulic oil level Indicates that the hydraulic oil level in the tank is too low: ➥ – see chapter 5 “Checking the hydraulic oil level once a day” on page 5-22

62

Differential lock indicator light (green) Indicates that the differential lock is switched on

63

Right/left turn indicator light (green) Flashes intermittently when the turn indicators are used

64

Load stabiliser/hose burst valve indicator light (yellow) Indicates that the load stabiliser is switched on, and that the hose burst valve is switched off.– see chapter 3 “Telescopic boom load stabiliser” on page 3-51

65

Front axle steering indicator light (green) Indicates that front axle steering is switched on

66

4 wheel steering indicator light (green) Indicates that 4 wheel steering is switched on

67

Diagonal (crab) steering indicator light (green) Indicates that diagonal steering is switched on

68

Indicator light (red) – steering synchronisation Indicates that the wheels on both axles are aligned

71

70

79

73

3-8

Indicator light (green) – driving direction Indicates forwards/reverse driving direction Overload cutoff indicator light (red) Indicates that the hydraulic functions “Raising, Lowering, Dumping In/Out and Extending” locked by the safe load indicator are enabled again – see chapter 3 “Disabling the overload cutoff” on page 3-65.

Temperature indicator with acoustic warning – engine (coolant) The diesel engine's operating temperature is 80 – 105 °C. • Max. admissible temperature is 110 °C. • The acoustic warning sounds from 115 °C – see chapter 5 “Engine and hydraulics cooling system” on page 5-11

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Operation 3.5 Before putting the machine into operation Important information for the operating staff • The machine may be put into operation by instructed and authorised staff only – see Driving licence on page 1-7 and “Selection and qualification of staff, basic responsibilities” on page 2-5 of this Operator's Manual.

• The operating staff must have read and understood this Operator's Manual before putting the machine into operation • Only use the steps and handles when entering and leaving the cab • Face the machine as you enter and leave it • Never use the controls or movable lines and cables as handles • Keep the footholds and the handles clean to ensure a safe hold at all times; immediately remove dirt, such as oil, grease, earth, snow or ice • The machine may be put into operation only when the driver is seated • Fasten the seat belt (lap belt) • Never get on or off a moving machine! Never jump off the machine • Before leaving the machine, lower the telescopic boom, stop the diesel engine, remove the ignition key and apply the parking brake • Transporting accompanying persons in the cab and/or on the telehandler and the attachments is not allowed!

• The machine may only be used in technically perfect condition in accordance with its designated use and the instructions set forth in the Operator's Manual, and only by persons who are fully aware of the risks involved in operating the machine • Always observe the warning and information labels, and the load diagrams (e.g. pallet forks) of the telescopic boom • Immediately replace (or have replaced) damaged or illegible warning and information labels with new ones • Bear in mind the checklists on the following pages • – see chapter 3 ““Diesel engine start” checklist” on page 3-10 • – see chapter 3 “Checklist “Putting the machine into service”” on page 3-11 • – see chapter 3 ““Parking” checklist” on page 3-11

Running-in period Handle the machine carefully during its first 100 operating hours.

• Do not load a cold diesel engine ➥ Let the diesel engine warm up at low engine speed (1/4 throttle) for about 30 seconds • Avoid loading the diesel engine at idling speed • Do not run the diesel engine at high speed for extended periods • Increase the load gradually while varying the diesel engine speed ➥ Full drive speed (machine dynamics) is reached as soon as the temperature of the drive reaches 20 – 30 °C • Strictly observe maintenance schedules and carry out (or have carried out) the specified maintenance work – see chapter 5 “Maintenance plan (overview)” on page 5-48

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3-9

Operation “Diesel engine start” checklist These checklists cannot claim to be exhaustive; they are merely intended as an aid for you in fulfilling your duties as a conscientious operator.

If the answer to one of the following questions is NO, first rectify the cause of the fault (or have it rectified) before starting or continuing work.

Questions are explained on the pages indicated below. ➥ Example: Enough fuel in the tank? See page (➠ 5-3) ✔

Diesel engine start checklist 1

Enough fuel in the tank? (➠ 5-3)

2

Engine oil level OK? (➠ 5-7)

3

Oil level in hydraulic tank OK? (➠ 5-22)

4

Water level in washer tank OK? (➠ 3-60)

5

V-belt condition and tension checked? (➠ 5-19)

6

Telescopic boom lubricated? (➠ 5-27)

7

Brake system (including parking brake) OK? (➠ 3-49)

8

Tyre condition and inflation pressure OK? (➠ 5-32, 6-11) Wheel nuts safely tightened (especially after a wheel change)?

9 (➠ 5-33, 6-13) Lights, signals, indicators, warning lights and indicator lights OK? 10 (➠ 3-55, 3-57, 3-6) 11 Windows, mirrors, lights and steps clean?

12 Attachment on the telescopic boom safely locked? (➠ 3-69) 13 Engine cover safely locked? (➠ 3-20) Especially after cleaning, maintenance or repair work: 14 Rags, tools and other loose objects removed?

Approved warning triangle, hazard warning light and first aid kit in the 15 machine? (➠ 1-6) 16 Seat position and rearview mirrors correctly adjusted? (➠ 3-16) 17 Seat belt fastened? (➠ 3-19)

3-10

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Operation Checklist “Putting the machine into service” After starting the engine and during operation, check and observe the following points: Checklist for putting the machine into service Indicator lights for engine oil pressure and alternator gone out?

1 (➠ 3-6) 2 Braking effect sufficient? (➠ 3-49) 3

Temperature gauge for engine coolant in normal range? (➠ 3-6)

4

Steering system working properly? (➠ 3-44)

5

Anyone dangerously close to the machine? (➠ 2-6, 3-38)

6

Safe load indicator checked and OK?

7

3rd control circuit locked? (➠ 3-68, 3-70)

✔

When driving on public roads, particular attention should be paid to the following points: 8

Telescopic boom completely retracted? (➠ 3-66)

9

Bucket and attachments in transport position? (➠ 3-39)

10 Transport locks installed? (➠ 3-39) Control lever for lift and tilt hydraulics of the telescopic boom locked with the 11 stop cock? (➠ 3-39) 12 Front-edge protection fitted to bucket? (➠ 3-39)

“Parking” checklist Check and observe the following points when parking the machine: Parking checklist Attachments on the telescopic boom lowered to the ground?

1 (➠ 3-43, 3-69) 2 Parking brake applied? (➠ 3-50) 3

Diesel engine stopped? (➠ 3-31)

4

Cab locked, especially if the machine cannot be supervised? (➠ 3-14)

✔

When parking on public roads: 5

Machine adequately secured? (➠ 3-43)

When parking on slopes: Machine additionally secured with chocks under the wheels to prevent it from 6 rolling away? (➠ 3-43)

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3-11

Operation

Operation 3.6 Cab Safety instructions regarding cab entrance and exit • Remove dirt (oil, grease, earth, snow and ice) from handles, footholds and shoes before entering the cab • Use only the machine footholds, platforms and handles for entering the cab • Face the machine as you enter and leave it

Safety instruction – side window (right) The right-hand side window (cab) is a safety element and must be immediately replaced by a new one even if it is only slightly damaged.

Danger!

In order to avoid danger of crushing or accidents, do not put the machine into operation if the right-hand window is broken, or stop the machine immediately if the right-hand window is damaged during operation!

☞ Keep a safe distance to the telescopic boom as you lower it to the ground

Fig. 45: Danger in case of broken side window

3-12

carefully ➥ – see chapter 3 “Operating the control lever for the lift, tilt and push-out rams” on page 3-61 ☞ Stop the diesel engine and remove the ignition key ☞ Apply the parking brake ☞ Have the side window replaced by an authorised workshop

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Operation Locking and unlocking the door Danger!

A

In order to avoid crushing and injury, lock the upper and lower cab doors when driving the machine!

☞ Close the door before moving the machine ☞ Secure the upper cab door with door arrester 42 ☞ Outside: press button A ☞ Inside: pull handle B upwards ☞ The upper door can be opened to ensure cab ventilation (option).

B

D

• Press lever C down • Open the upper door and secure it in door arrester 42 ☞ Close the upper cab door • From outside: press lever B of the door arrester forwards • From the inside: press button B ➥ The door is released from the lock by spring action • Safely lock the cab door in lock D of the lower door

Notice!

C

37

Lubricate the catch bolt of lock 37 at regular intervals.

42

B

Fig. 46:

Opening and locking the door

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3-13

Operation Closing and opening the side window (to a gap) Danger!

A

In order to avoid crushing and injury, close the door and the windows when driving the machine!

☞ Safely lock the side window with the lock lever ☞ Ensure that the open side window is engaged in the arrester ☞ Opening the side window • Turn lock lever A upwards ☞ Closing the side window • Turn lever A down The side window can be opened to a gap improve cab ventilation with the door closed. ☞ Opening the side window • Set lock lever A to the horizontal position and slide the side window outwards • Press the end of lever a downwards in the guide b

A a

b Fig. 47: Locking, unlocking and opening the side window to a gap

Completely opening and locking the side window The side window can fully opened to the rear and locked with the door closed. ☞ Opening the side window completely • Remove the end of lever a from the guide (arrow) • Open the side window completely and press it against arrester 42 ➥ The side window locks into place and is locked

a

Notice!

Lubricate the catch bolt of lock 37 at regular intervals.

37

42

☞ Closing an open side window • From outside: press lever B forwards • From the inside: press button B ➥ The side window is released from the lock by spring action • Close and safely lock the side window ➥ – see Closing the side window on page 3-14

B

Fig. 48: Fully opening the side window

3-14

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Operation Opening/closing the rear window Danger!

In order to avoid danger of injury, lock the open rear window with the lock lever!

The lock lever may be pulled out of the guide only in an emergency!

A

☞ Lock the rear window with the lock lever ☞ Remove the lock lever from the guide only in case of an emergency ☞ Do not use the side window as an exit unless in case of emergency! ☞ Opening the rear window • Unlock lock lever A in the direction of the arrow • Open the rear window • Engage lock A in the end of lever B with an audible click (arrow) ☞ Closing the open rear window • Lock the rear window in the reverse order B

Fig. 49: Rear window lock

Rear window emergency exit In case of an emergency, the rear window can be used to exit from the cab if the door can no longer be used. ☞ Exit the cab in an emergency as follows: • Stop the diesel engine • Switch off all current consumers and remove the ignition key • If possible, ask for help • Unlock lock lever A in the direction of the arrow • Remove the end of lever B completely from the guide (arrow) • Open the rear window • Before resuming normal service, engage the end of the lever in the guide and lock the rear window

A

B

Fig. 50: Emergency exit

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3-15

Operation 3.7 Seat Important notice on seat adjustment Correct seat operation and adjustment is a prerequisite for avoiding or minimising physical disorders related to bad posture, and for ensuring a high level of ride comfort.

• In order to avoid or minimise physical disorders related to bad posture, adjust the seat to the driver's weight before putting the machine into operation or when changing drivers.

• In order to avoid injuries, do not store any objects in the suspension travel range of the seat.

• Modifying the seat (e.g. by using spare parts other than original) can cause the approval given for the seat to be void and affect functions that are important for safety.

• If the seat functions do not work as usual (e.g. seat suspension), contact a workshop immediately for repair. ➥ Failure to do this can result in health hazards and increased danger of accidents!

Seat adjustment: overview Always adjust the seat to your individual needs. This will help avoid or minimise physical disorders related to bad posture

Danger!

In order to avoid danger of accidents, never adjust the seat when driving!

☞ Adjust the seat before moving the machine ☞ Ensure that the levers for seat adjustment are safely engaged

a

b

c

d

e

The seat can be set to the following positions: a = horizontal adjustment without control lever base b = weight adjustment (height adjustment with air suspension option) c = weight indication d = longitudinal adjustment with control lever base (option) e = backrest adjustment

Fig. 51: Seat adjustment

3-16

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Operation Weight adjustment ☞ Adjust as follows:

b

To adjust to a higher weight: • Sit down on the seat • Turn lever b clockwise ➥ Read the weight off indication c To adjust to a lower weight: • Turn lever b counterclockwise ➥ Read the weight off indication c

c

Fig. 52: Weight adjustment

Backrest adjustment ☞ Adjust as follows: • • • •

Sit down on the seat Pull lever d up and at the same time Lean back to push the backrest into the required position Let lever d lock into place

e

Fig. 53: Backrest adjustment

Horizontal adjustment ☞ Carry out longitudinal adjustment with the control lever base as follows: • Pull lever d up and at the same time • Move the seat forwards or backwards ➥ The control lever base is adjusted as well • Allow lever d to engage in required position ☞ Carry out longitudinal adjustment without the control lever base as follows: • Sit down on the seat • Pull lever a up and at the same time • Move the seat forwards or backwards • Allow lever a to engage in required position

d

a Fig. 54: Horizontal seat adjustment

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3-17

Operation Lumbar support adjustment (option) Turn handwheel 1 to the left or right to adjust the height and the intensity of the arch in the backrest padding.

1

Fig. 55: Lumbar support adjustment

Adjustment of horizontal suspension (option) Switching on the horizontal suspension with lever 2 may be recommendable under certain conditions (for instance driving with a trailer).

This enables the seat to dampen shocks in transport direction.

• Position a = horizontal suspension ON • Position b = horizontal suspension OFF

2

a

b

Fig. 56: Adjustment of horizontal suspension

Adjustable seat suspension damper (option) The driver can adjust the seat suspension to his own requirements and to different work conditions.

Four levels ranging from soft to hard are possible.

• Lever 3 in position a = soft • Lever 3 in position b = hard

3

a

b

Fig. 57: Adjustment of horizontal suspension

Heated seat (option) The heated seat is switched on with switch 4.

4

Fig. 58: Heated seat

3-18

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Operation 3.8 Seat belt (lap belt) Important notice on the seat belt The seat belt is for the driver's safety during work on construction sites and during road travel.

• The seat belt must not be twisted as you fasten it!

• Seat belt must run over the hips – not over the stomach – and must always be applied tightly!

• Do not place the seat belt over hard, edged or fragile items (tools, meter rule, glasses, pen) carried inside your clothes!

• Never buckle up 2 persons (children!) with one seat belt!

• Check the condition of the seat belt regularly.

• Have damaged seat belts immediately replaced by an authorised workshop!

• Always keep the seat belt clean, as coarse dirt can impair proper functioning!

• Seat belt buckle must not be obstructed by foreign bodies (paper or similar); otherwise the buckle latch cannot lock into place!

• Replace the seat belt after an accident!

• Have fastening points and seat fixture checked for bearing capacity!

Danger!

Never drive the machine without having fastened the seat belt – danger of injury!

☞ Fasten the seat belt before moving off!

Fastening the seat belt ☞ Fasten the seat belt as follows before moving off:

A

• Hold the belt at buckle latch A and run it slowly and steadily over the hips to buckle B • Insert buckle latch A into buckle B until it engages audibly (pull test) • Tighten the seat belt by pulling at its end ➥ The seat belt must always be tightly in place over the hips!

B

0763b0007.eps Fig. 59: Fastening the seat belt

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3-19

Operation Unfastening the seat belt ☞ Unfasten the seat belt as follows: • Hold the seat belt • Press red button C on buckle B ➥ Latch A is released from buckle B by spring action • Slowly return the seat belt to the retractor (option)

A C B 30763b0006.eps Fig. 60: Unfastening the seat belt

Longer/shorter lap belt adjustment: ☞ Lengthen/shorten the lap belt as follows:

A

• To lengthen, hold buckle latch A at a right angle to the seat belt and pull the seat belt to the required length • To shorten the lap belt, just pull the free end D of the belt

Notice!

When pulled slowly, the automatic seat belt offers full freedom of movement. It locks however during abrupt braking.

The automatic seat belt may also lock when passing through potholes or uneven terrain.

D

30763b0005.eps Fig. 61: Longer/shorter seat belt adjustment

3.9 Engine cover Opening/closing the engine cover ☞ Open the engine cover A

• Stop the engine and remove the ignition key • Pull handle A up • Pull the engine cover upwards ➥ The engine cover opens with the help of gas struts

☞ Close the engine cover • Firmly press down the engine cover until the lock engages with an audible click • Press handle A down ☞ Lock the engine cover • Close the engine cover with the ignition key (a padlock can be used in addition) Fig. 62:

3-20

Engine cover lock

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Operation 3.10 Air-suspension seat (option) Important notice on air-suspension seat operation Before putting the machine into operation, check the switches on the seat for correct function.

Danger!

In order to avoid danger of accidents, do not put a machine into operation with a defective air-suspension seat!

☞ Have the seat repaired by an authorised workshop

Air-suspension seat operation The air-suspension seat height can be adjusted continuously.

There are two settings for the automatic weight adjustment. The second setting allows for an individual height adjustment. ☞ Pull or press lever 4

➥ Seat height changes ➥ Upon reaching the upper or lower limit, the height is automatically adjusted to

4

ensure a minimum spring travel

Caution!

Do not run the air compressor for more than 1 minute to avoid damage to it!

Fig. 63: Air-suspension seat

3.11 Fire extinguisher (option) Fire extinguisher operation The fire extinguisher is not included in the machine's standard equipment (option).

If a fire extinguisher is retrofitted according to DIN-EN 3, then this must be carried out by an authorised workshop ☞ Operate the fire extinguisher according to the instructions printed on the fire extinguisher.

Caution!

In order to ensure the full serviceability of the fire extinguisher, ☞ Have the fire extinguisher checked at regular intervals and refilled • See the inspection tag ☞ Remove the fire extinguisher from the cab in an emergency only ☞ After the fire extinguisher has been used: have it filled by an authorised workshop, or replace it with a new one

Fig. 64: Fire extinguisher (option)

l

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3-21

Operation 3.12 Key-based drive interlock (option) The drive interlock is integrated in the ignition lock and can be enabled only with the blue ignition keys!

Scope of delivery: • Drive interlock installed in the machine • 2 x blue keys (coded) • 1 x red master key (for training the blue keys)

Coding (“training”) new ignition keys New personal keys are coded with the master key (red). This is why it must be carefully stored outside the machine.

Notice!

The drive interlock has only one master key!

• The drive interlock must be replaced by an authorised workshop if the master key is lost • The master key is only used for coding new keys, and cannot be used for disabling the drive interlock • Coding is carried out by inserting the master key in the ignition lock and by turning it to position '1' for a maximum 5 seconds. After the master key has been returned to position '0' and removed, you have 15 seconds for inserting a key that requires coding.

It must be inserted in the ignition lock and turned to position '1' in order to be registered as a valid key.

• Coding is automatically stopped if no key requiring coding is detected within 15 seconds.

• Several keys requiring coding can be inserted one after another in the ignition lock • Each key must remain at least 1 second in position '1'.

• Coding can be carried out for a maximum 10 keys

3-22

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Operation Enabling (locking) the drive interlock ☞ Apply the parking brake ➥ – see Parking brake on page 3-50 ☞ Stop the engine ☞ Remove the ignition key (blue) ➥ The drive interlock is enabled in 30 seconds

Notice!

The drive interlock remains disabled if the ignition key (blue) is not removed from the ignition lock!

Disabling (releasing) the drive interlock Start and stop the engine exactly as described on page 3-30 “Starting the diesel engine”. ☞ The system is enabled 5 seconds after the ignition key is inserted in the ignition lock ☞ Start the engine – see Starting the diesel engine on page 3-30

➥ The drive interlock is disabled as long as the engine runs

Deleting coded keys Deleting coded keys is necessary whenever a coded key is lost • All coded keys are deleted during deletion • After deletion has been carried out, all existing keys can be recoded • Deletion is carried out by inserting the master key in the ignition lock and by turning it to position '1' for a minimum 20 seconds.

• All coded keys are then deleted, and all existing keys can be recoded • The master key code is not deleted during deletion

Safety functions • The drive interlock remains enabled for 15 minutes and does not accept any valid keys if more than 5 keys with different invalid codes are inserted and turned in the ignition lock within 1 minute.

• This function avoids 'finding' the correct key by chance by trying different keys.

• Valid keys are accepted only after 15 minutes and after the position '0' of the ignition lock has been detected. This avoids testing keys without actuating the mechanical ignition lock, e.g. by moving the ignition lock to position '1' by force.

• Interruptions of the supply line or other control lines do not disable the drive interlock or delete data (e.g. data codes).

• All important data is saved in a non-volatile memory.

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3-23

Operation 3.13 Drive interlock with code input (option) The drive interlock is enabled or disabled with “personal” codes entered via the keypad.

Two codes are available: • The existing unchangeable six-digit main code for disabling the drive interlock, for entering a personal code or for changing the personal code • The four, five or six-digit personal code is used for disabling the drive interlock and is entered by the driver

Notice!

LED Fig. 65: Drive interlock (code input option)

3-24

We recommend using the personal code for disabling the system!

• Keep the main code in a safe place.

The keypad consists of: • 10 numeric keys for entering the codes • A (*) key for confirming the code that has been entered • An LED (red indicator light) • An internal acoustic signal for signalling specific procedures ➥ Example: a signal sounds to confirm a key has been pressed The keypad comes on: • When pressing any key • The keypad flashes to indicate specific system statuses

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Operation Entering/changing the personal code Notice!

The personal code must be entered correctly twice consecutively otherwise an error is indicated by means of a single flashing of the LED: • Codes consisting of 3 and less, or of more than 6 digits are ignored by the system • Simple codes (with identical or consecutive digits, e.g. 1, 2, 3, 4) are rejected by the system with four short acoustic signals • Entering a new personal codes replaces the previous code. A code can be changed any time if the main code is known In order to enter or modify the personal code, disable the drive interlock by entering the main code (6 digits) and pressing the (*) key: ☞ Proceed as follows: • Turn the ignition key to 1 ➥ The LED comes on for 2 seconds • Enter the new personal code within 20 seconds and confirm it with the (*) key after the LED has gone out • Enter the new personal code again and confirm it with the (*) key after a short flashing of the LED ➥ Confirmation: LED flashes twice briefly, then comes on for 2 seconds • Turn the ignition key to the zero position and remove it ➥ The new personal code is now set and can be used for disabling the drive interlock.

Enabling the drive interlock ☞ Stop the engine and remove the ignition key ➥ The drive interlock is automatically enabled ➥ Flashing LED (on the keypad)

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3-25

Operation Disabling the drive interlock ☞ Proceed as follows: • Enter the personal code or main code (6 digits).

• Press the (*) key. ➥ Confirmation: 2 long acoustic signals, long LED flashing, LED OFF = drive interlock is disabled ➥ Diesel engine can be started The diesel engine will not start if a wrong code has been entered ➥ Confirmation: 4 short acoustic signals, flashing LED = wrong code • Re-enter the code • Turn the ignition key and start the engine before the LED flashes again

Notice!

The keypad is blocked for 5 minutes and no codes can be entered if the wrong code is entered four times consecutively.

• Enter the code after 5 minutes • The keypad does not come on as long as it is blocked. It comes on briefly every 4 seconds and an acoustic signal sounds • Press the (*) key after every code • The LED comes on briefly when turning the ignition key to the engine start position

Putting the drive interlock out of operation We recommend putting the drive interlock out of operation if the machine has to stay in a workshop, for instance, or if the machine does not require any protection. This avoids having to communicate the code. ☞ Proceed as follows: • Disable the system by entering the personal or main code and by confirming with the (*) key • Turn the ignition key to position “ON” as soon as the LED goes out ➥ The LED comes on for 2 seconds • As soon as the LED goes out, press the (*) key for about 2 seconds until a short acoustic signal, followed by two further signals, sounds (within 20 seconds after the LED has gone out) • The LED now flashes very slowly, and the keypad is disabled • Turn the ignition key to the OFF position and remove it • The system is out of operation • The diesel engine can be started without entering the code.

Notice!

If the system is out of operation, the LED flashes slowly even if the ignition key is in the ON position.

• Procedure to follow for putting the system back into operation again – see Putting the drive interlock back into operation again on page 3-27

3-26

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Operation Putting the drive interlock back into operation again ☞ Press the (*) key for 2 seconds (ignition key in position OFF) until two short acoustic signals are given for confirmation

➥ The system is enabled again. The code must be entered to start the engine.

Interruption of drive interlock power If the drive interlock was enabled before electric power was interrupted, short acoustic signals are given upon switching on the keypad (similar to those that are given when entering the wrong code four times). In this case, wait until the acoustic signals are no longer given.

Then disable the drive interlock with the personal or main code.

The LED still does not come on if the drive interlock was disabled. The engine can be started before the LED starts flashing again.

If the drive interlock was out of operation, this status remains unchanged and the LED flashes slowly.

Drive interlock maintenance • The MED 310.1T drive interlock does not require any maintenance.

• Protect the keypad and the control unit from heat and humidity.

3.14 Battery master switch Switching the battery master switch ON and OFF The battery master switch separates the entire electrical system from the battery and ensures protection against unauthorised engine start.

The battery master switch is located outside the battery container underneath the access to the cab on the left.

Interrupting power supply

1 2 A

Caution!

3

In order to avoid malfunctions of the electronic fuel injection of the diesel engine, do not immediately turn the battery master switch out of the notched position after stopping the engine! ☞ Follow the correct order (see label)

Fig. 66: Battery master switch

☞ Switch off the battery master switch 1 2 3

First stop the diesel engine with the ignition key Wait at least 30 seconds Turn key A out of the notched position and remove it ☞ Switch on the battery master switch 1 Insert the key in the battery master switch 2 Turn the key to the notched position 3 Start the diesel engine

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3-27

Operation 3.15 Oil and fuel preheater (option) This equipment serves as a starting aid at temperatures below -5 °C and is located in the engine compartment, on the left in driving direction.

Putting the coolant and oil preheater into operation Heating elements warm up the diesel engine coolant circuit and the oil in the hydraulic oil tank.

The oil or coolant circuit can only be thoroughly warmed up if the preheating is connected over a longer period of time – preferably over night.

The connection (heating elements socket) is located on the hydraulic oil tank under the engine cover. ☞ Preheat the oil as follows: • Park the machine near a 220 V socket • First connect the special cable (green, supplied with the machine) with the machine socket, then insert the plug into the 220 V socket Before putting the diesel engine into operation • Remove the special cable from the 220 V socket and from the machine socket ☞ Start the diesel engine

Notice!

The oil preheater (option) reduces pollutant emissions during the warm-up phase by up to 60 %, saving fuel at the same time.

Fuel preheater (option)

AU TO

93

OF F

A B Fig. 67: Switch for fuel preheater (option)

The fuel preheater prevents paraffin crystals forming, which otherwise clog the fuel filter at low temperatures.

We recommend switching on the fuel preheater (option) at temperatures below 10 °C. The switch is located on the switch console on the left ☞ Press switch 93 to position B

➥ The fuel preheater is switched on ☞ Press switch 93 to position A ➥ The fuel preheater is switched off

Notice!

A heating element in the fuel line between the tank and the fuel prefilter is automatically switched on by a temperature sensor at temperatures below 45 °C, and switched off at temperatures over 50 °C. The indicator light in the switch comes on when the fuel is being preheated

3-28

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Operation 3.16 Putting the diesel engine into operation Preparing to start the engine Danger!

In order to avoid injury or danger of accidents, put the telehandler into operation only when the operator is seated on the seat!

• Run through the ““Diesel engine start” checklist” on page 3-10 • Switch on the battery master switch – see Battery master switch on page 3-27 • Adjust steering wheel position – see Steering column height and angle adjustment on page 3-44 • Adjust the mirrors • Adjust the seating position and sit down on the seat – see Seat on page 3-16

Notice!

All controls must be within easy reach. You must be able to move the brake and accelerator pedals to their limit positions!

• • • •

Fasten your seat belt Ensure that the “Parking brake” on page 3-50 is applied Ensure that the control lever (joystick) for the telescopic boom is in neutral position The motor will not start unless the parking brake is applied – see Parking brake on page 3-50 • the “Key-based drive interlock (option)” on page 3-22 or “Drive interlock with code input (option)” on page 3-24 is enabled

Notice!

The starter cannot be actuated if the engine is already running (start repeat interlock) • If the diesel engine does not start, interrupt the start attempt after a max. 10 seconds so that the battery can recover • Repeat the start attempt only after about 1 minute The engine cannot be started by tow starting the machine, as there is no driving connection between the engine and the gearbox (e.g. cardan shaft)!

(Hydrostatic drive).

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3-29

Operation Starting the diesel engine ☞ Start the diesel engine as follows:

0

1

• Apply the parking brake • Turn the ignition key (preheating start switch 4) to position “1” • The following indicator lights must come on ➥ Indicator light 55 for the engine oil pressure (88 kW diesel engine only)

2 3

4

Notice!

Fig. 68: Preheating start switch

53

54

55

➥ Indicator light 54 if the parking brake is applied ➥ Indicator light 53 for alternator charge function ➥ Cold starter indicator light 48

48 Fig. 69: Indicator lights on indicating instrument

00000

00 h

55

Nr_7_2.iso

Due to the electronic fuel injection, indicator light 55 (engine oil pressure, 103 KW diesel engine) does not come on when starting the engine!

Diesel engine errors are indicated in tip switch 76 by means of a flashing code!

• – see Error code displays (103 kW diesel engine) on page 3-33

76

Fig. 70: Error code display tip switch (103 kW diesel engine)

– Comes on for about 5 – 10 seconds at normal temperatures (up to 0°) – Comes on for about 15 – 60 second at low temperatures (below 0°) ➥ The intake air is preheated via a temperature-dependent time lag relay, and indicator light 48 goes out once the temperature is reached ☞ After indicator light 48 (cold starter) has gone out: • Press the accelerator pedal through about 1/4 of its travel • Turn the ignition key to position “3” and hold it until the engine runs • Release the ignition key • Check that the following indicator lights have gone out: ➥ Indicator light 55 (88 kW diesel engine only) ➥ Indicator light 53

Caution!

If the indicator lights indicated above do not go out, stop the engine immediately and have the reason checked by an authorised workshop!

• Replace defective indicator lights immediately

Caution!

Danger of damage to the engine and the exhaust gas turbocharger!

• Do not run the cold diesel engine at full throttle when starting • Let the diesel engine warm up at low engine speed (1/4 throttle) for about 30 seconds • Do not use additional starting aids (e.g. injection with start pilot) • At outside temperatures below -10 °C, we recommend retrofitting the machine with a fuel and/or engine preheater (option)

3-30

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Operation Avoiding running the engine under low-load conditions Caution!

The running performance of the engine can be negatively affected if it runs at high speed and at less than 20 % of the load, or permanently at idling speed.

• Effects: – Operating temperature is not reached – Increased lube oil consumption – Lube oil in exhaust system – Engine contamination and blue smoke in exhaust ☞ Always run the engine at loads of over 20 %

Stopping the engine

0

1

Caution!

2

In order to avoid heat accumulation and damage to the exhaust gas turbocharger, do not stop the engine from full throttle! ☞ Let the engine run at idling speed for about 2 minutes and then switch it off

3

4 Fig. 71: Stopping the engine

☞ Apply the parking brake to the last notch ☞ Turn the ignition key (preheating start switch 4) to position “0” and remove the ignition key

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3-31

Operation 3.17 Jump-starting the engine (external battery) Safety instructions regarding external starting aids Danger!

Danger of short circuits and of burns! The jump lead connected to the positive (+) terminal of the starting battery must never be brought into connection with electrically conductive vehicle parts • The external power source must deliver 12 V; higher supply voltages will damage the electrical system of the vehicles • Use only authorised jump leads which conform to the safety requirements and which are in perfect condition • Route the jump leads so they are not caught by rotating components in the engine compartment

Providing external starting aid ☞ Proceed as follows:

Flat battery

12 V

12 V Starting battery

• Drive the jump-starting vehicle close enough to the machine so that the jump leads can reach to connect the two batteries • Let the engine of the jump-starting vehicle run • First connect one end of the red jump lead (+) to the + terminal of the flat battery, then connect the other end to the + terminal of the starting battery • Connect one end of the black jump lead (-) to the – terminal of the starting battery • Connect the other end of the black jump lead (-) onto a solid metal component fimly mounted on the engine block or onto the engine block itself. Do not connect it to the negative terminal of the flat battery, as otherwise explosive gas emerging from the battery can ignite if sparks are formed!

• Start the engine of the machine with the flat battery Once the engine has started: • With the engine running, remove the jump leads in the reverse order • In order to avoid sparking, first disconnect the cable on the – terminal, then the one on the + terminal

Fig. 72: Starting aid with jump leads 34001b710_05.eps

3-32

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Operation 3.18 Error code displays (103 kW diesel engine) Reading out the flash code

00000

The tip switch with the error code displays 76 (integrated indicator light) is located on the instrument panel.

Engine errors are indicated by means of the flashing or continuously lit integrated indicator light.

Detailed information on pending errors can be read out only at engine standstill by means of these flashing codes.

Error display: the integrated indicator light comes on continuously, or the indicator light flashes ☞ Read out the error display with tip switch 76. To do this: press tip switch about 1 second

00 h

76

➥ The indicator light displays the error by means of the different lengths of the flashing

Nr_7_2.iso

Fig. 73: Reading out the error code display

signals (– see Overview – description of flashing codes on page 3-35) ☞ Error codes are read out as follows 2

3

1

Example: flashing code 2-3-1 ➥ 2 short (0.4 sec) – 3 long (0.8 sec) – 1 short (0.4 sec)

➥ Engine oil pressure = not enough or too much oil in the engine Please contact your dealer if you require more information

Warning limit – coolant temperature Error display

Tip switch 76 comes on continuously

Caution!

Coolant temperature 111 °C (see also temperature indicator 73 on the instrument panel)

Tip switch 76 flashes

Danger!

Coolant temperature 119 °C (see also temperature indicator 73 on the instrument panel)

Tip switch 76 goes out

Coolant temperature below 109 °C (see also temperature indicator 73 on the instrument panel)

00 0291 628 0 - BA SCORPION – AUSTRALIA

Troubleshooting 1 2 3 4 5 6 1 2

Stop the machine as quickly as possible Read out the error with the ignition switched on – see Overview – description of flashing codes on page 3-35 Let the diesel engine run briefly at idling speed so it can cool down, then stop the engine Check the coolant level or fill up the coolant Check the cooling circuit for leaks Have repair work carried out by an authorised workshop if necessary

3 4 5

Stop the machine and the diesel engine immediately Read out the error with the ignition switched on – see Overview – description of flashing codes on page 3-35 Check the coolant level or fill up the coolant Check the cooling circuit for leaks Have repair work carried out by an authorised workshop if necessary

1 2

Start the diesel engine Check the cooling system for leaks and correct function

3-33

Operation Warning limit – charge-air temperature Error display

Tip switch 76 comes on continuously

Troubleshooting

Caution!

Charge-air temperature 95 °C Dirty radiator

1 2 3 4

Tip switch 76 flashes

Tip switch 76 goes out

Danger!

Charge-air temperature 110 °C Very dirty radiator Charge-air temperature below 90 °C

1 2

Stop the machine and the diesel engine immediately Read out the error with the ignition switched on – see Overview – description of flashing codes on page 3-35 Clean the radiator from the engine side with compressed air or with the reversing fan (option) Have repair work carried out by an authorised workshop if necessary

4

Stop the machine and the diesel engine immediately Read out the error with the ignition switched on – see Overview – description of flashing codes on page 3-35 Clean the radiator from the engine side with compressed air or with the reversing fan (option) Have repair work carried out by an authorised workshop if necessary

1 2

Start the diesel engine Check the cooling system for leaks and correct function

3

Warning limit – engine oil pressure Error display Tip switch 76 comes on continuously

Troubleshooting

Caution!

Engine oil pressure too low

1 2 3 4 1 2

Tip switch 76 flashes

Tip switch 76 goes out

3-34

Danger!

No engine oil pressure

–

Stop the machine and the diesel engine as quickly as possible Read out the error with the ignition switched on – see Overview – description of flashing codes on page 3-35 Fill up engine oil or replace it according to the maintenance plan Have repair work carried out by an authorised workshop if necessary

3 4 5

Stop the machine and the diesel engine immediately Read out the error with the ignition switched on – see Overview – description of flashing codes on page 3-35 Fill up engine oil or replace it according to the maintenance plan Check the diesel engine for oil loss Have repair work carried out by an authorised workshop if necessary

1

Start the diesel engine and check for correct function

00 0291 628 0 - BA SCORPION – AUSTRALIA

Operation Overview – description of flashing codes Flash code

Component

Description

1-2-3

Coolant temperature indicator light

Open wiring or short circuit

1-2-6

Manual throttle

Open wiring or short circuit, signal not plausible

1-2-8

Charge-air temperature sensor

Open wiring or short circuit

1-3-3

Customer-specific sensor

Open wiring or short circuit (sensor 1)

1-3-3

Customer-specific temperature

Not within specified system reaction range (temperature 1)

1-3-4

Rail pressure

Positive regulator divergence (speed-sensitive) not within specified range

1-3-5

Fuel metering unit

Flow rate not within specified range

1-3-5

Oil pressure indicator light

Open wiring or short circuit

1-3-6

Air filter

Pressure beyond specified system reaction range

1-3-7

Main relay

Short circuit (relay 1)

1-4-2

Engine operation indicator light

Open wiring or internal error of control unit

1-4-3

Multiple position switch

Open wiring or short circuit, input voltage not within specificed range (switch 1)

1-4-4

Oil temperature sensor

Open wiring or short circuit

1-4-4

Oil temperature

Below specified system reaction range

1-4-5

Jumper switch

Jammed switch

1-4-6

Rail pressure relief valve

Opening error

1-4-7

Rail pressure sensor

Open wiring or short circuit

1-4-7

Rail pressure sensor

Signal divergence when starting or after run, beyond specified range

1-5-1

Several injectors

Short circuit (row of cylinders 1)

1-5-4

Separate injector

Short circuit (injector 1)

1-5-4

Separate injector

Open wiring (injector 1)

1-5-5

Separate injector

Short circuit (injector 2)

1-5-5

Separate injector

Open wiring (injector 2)

1-5-6

Separate injector

Short circuit (injector 3)

1-5-6

Separate injector

Open wiring (injector 3)

1-6-1

Separate injector

Short circuit (injector 4)

1-6-1

Separate injector

Open wiring (injector 4)

2-1-2

Revs sensor

Motor runs only with camshaft speed signal

2-1-2

Revs sensor

Bad or missing camshaft speed signal

2-1-2

Revs sensor

Bad or missing crankshaft speed signal

2-1-3

Revs sensor

Phase displacement of crankshaft and camshaft speed signals

2-1-4

Overspeed

Overspeed due to error with system reaction

2-1-4

Overspeed

Overspeed in overrun (trailing throttle) with system reaction

2-1-6

Fuel low-pressure sensor

Open wiring or short circuit

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3-35

Operation 2-1-6

Low fuel pressure

Below specified range with system reaction

2-1-9

Engine brake flap (actuator)

Engine brake flap (actuator): open wiring or short circuit

2-2-3

Charge-air pressure sensor

Open wiring or short circuit

2-2-3

Charge-air pressure

Not within specified range with system reaction

2-2-4

Oil pressure sensor

Open wiring or short circuit

2-2-5

Coolant temperature sensor

Open wiring or short circuit

2-2-6

Drive pedal/analog potentiometer

Open wiring or short circuit, signal not plausible (analog pedal)

2-2-7

Fuel temperature sensor

Fuel temperature sensor: open wiring or short circuit

2-2-8

Fuel filter water level

Open wiring or short circuit

2-2-8

Water level in fuel filter

Beyond specified range

2-3-1

Oil pressure

Beyond specified range

2-3-1

Oil pressure

Below specified range

2-3-2

Coolant temperature

Not within specified range with system reaction

2-3-3

Charge-air temperature

Beyond specified system reaction range

2-3-5

Coolant level

Not within specified range with system reaction

2-3-7

Fuel temperature

Beyond specified system reaction range

2-3-8

Fan actuator

Fan actuator: open wiring or short circuit

2-3-8

Fan speed

Beyond specified system reaction range

2-4-1

Separate cylinder

Misfiring (cylinder 1)

2-4-1

Separate cylinder

Misfiring (cylinder 2)

2-4-1

Separate cylinder

Misfiring (cylinder 3)

2-4-1

Separate cylinder

Misfiring (cylinder 4)

2-4-1

Several cylinders

Misfiring

2-4-1

Misfiring

Misfiring with system reaction

2-6-1

Misfiring

Short circuit against earth or emergency stop (relay 2)

2-6-3

Preheating relay

Open wiring or short circuit

2-6-3

Preheating solenoid valve

Open wiring or short circuit

2-7-1

CAN bus switched off

Open wiring or short circuit, switched off (CAN bus A)

2-9-2

Control unit, internal error

Defective environmental pressure sensor

3-1-8

Battery

Voltage below specified range

3-1-8

Battery voltage

Beyond specified system reaction range

3-2-8

Preheating indicator light

Open wiring or short circuit

3-4-1

Engine stop demand

Engine stop demand ignored by operator

4-1-4

EGR positioner (external)

Short circuit

5-1-2

Starting relay

Starting relay (+ side): short circuit

5-1-3

Diagnostics indicator light

Open wiring or short circuit, prevented by control unit

5-1-4

Terminal 15

Ignition ON not detected

3-36

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Operation 5-1-5

Terminal 50

Engine start, jammed switch

5-2-1

Machine speed signal

Speed over specified range, missing signal or not plausible

5-2-6

CAN message

Missing or value over specified range (message “DecV1” = pseudopedal)

5-2-8

Engine brake (internal)

Internal engine brake: open wiring or short circuit

5-3-1

Solenoid valve dwell period

Not within specified range or missing (cylinder 1)

5-3-2

Solenoid valve dwell period

Not within specified range or missing (cylinder 2)

5-3-3

Solenoid valve dwell period

Not within specified range or missing (cylinder 3)

5-3-4

Solenoid valve dwell period

Not within specified range or missing (cylinder 4)

5-5-5

Engine performance indication output

Engine performance indication output: open wiring or short circuit

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3-37

Operation 3.19 Preparing for driving on public roads Important notice regarding driving on public roads • The machine is subject to the applicable national legal regulations (e.g. StVZO German road traffic regulations) and to the provisions laid down in the General Certification for Vehicles (Germany), the data confirmation (Germany) or the machine certification papers • Carrying or transporting accompanying persons in the cab or on the telehandler is not allowed!

• Only the attachments are certified for use on public roads that are described in the General Certification for Vehicles (Germany), the data confirmation (Germany), licence certificate or in this Operator's Manual on page 1-6 “Authorised attachments” (the footnotes must be taken into account).

• Remove inadmissible attachments • German road traffic regulations prohibit driving on public roads if the distance between the front edge of the bucket and the centre of the steering wheel is over 3500 mm in transport position. Remove attachments • Driving on public roads with a loaded attachment is prohibited!

• Pay attention to the trailer weights/drawbar loads on the trailer coupling – see chapter 6 “Trailer couplings: trailer weight/drawbar load” on page 6-13 • Readjust the lights when fitting lightweight material buckets • Switch off the working lights when driving on public roads – see Working lights operation on page 3-56

Caution!

When driving downhill, the brake pedal must be used to support the braking effect of the drive. This avoids damage to the drive and the engine due to excessive speed. ☞ Shift to 1st speed on extremely steep slopes – see Speed range selection on page 3-40! ☞ Reduce engine speed: remove your foot from the accelerator pedal ☞ Reduce your drive speed with the service brake

3-38

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Operation Safety equipment for driving on public roads • Dump in the quickhitch and the bucket as far as it will go and raise the telescopic boom to transport position ➥ B = the red marks on the telescopic boom and the machine frame must coincide.

• Mount front-edge protection C on the leading edge of the bucket • In trailer operation: Check the trailer coupling for proper locking and the hydraulic or compressed-air brake (option) for secure connection with the tractor • Securely tie down the load on the trailer • Remove the protective screen (option) from the front window • High speed version (25 – 40 kph): switch the steering system to front axle steering – see Changeover to front axle steering on page 3-46 • Secure the control lever (joystick) and the 3rd control circuit of the telescopic boom – see Locking the control lever (joystick) and the 3rd control circuit (attachments) on page 3-39 • Switch on the load stabiliser – see Telescopic boom load stabiliser on page 3-51 • Adjust the steering column height and inclination (option) • Fasten your seat belt – see Seat belt (lap belt) on page 3-19

B C

200 mm A Fig. 74: Transport position

Functional check of brakes, steering system and lights • • • •

– see Steering system on page 3-44 – see Brake/inching pedal on page 3-49 – see Machine lights on page 3-55 – see Signalling system on page 3-57

Locking the control lever (joystick) and the 3rd control circuit (attachments)

13

B

A

C 95 A B Fig. 75: Control lever lock

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Danger!

In order to avoid danger of accidents, lock the control lever (joystick) and the 3rd control circuit against unintentional actuation when driving on public roads!

The lock (stop cock) for the control lever (joystick) is located on the console of the control lever base to the right of the seat. ☞ Locking the control lever (joystick): • Push stop cock 13 lever to the left A ➥ The control valve is cut off from the hydraulic oil circuit

☞ Unlocking the control lever (joystick): • Push stop cock 13 lever backwards B ➥ The control lever (joystick) is connected with the hydraulic oil circuit As soon as an attachment is picked up with the quickhitch, the 3rd control circuit is automatically secured to avoid unlocking the attachment. However, it must be fully locked when driving on public roads.

• Slide lock C on switch 95 in the direction of the arrow and press the switch to position A at the same time • Release lock C ➥ 3rd control circuit is fully locked – see Operating and securing the 3rd control circuit on page 3-68

3-39

Operation 3.20 Moving off the telehandler Speed range selection The telehandler has two speed ranges. l

Symbol Drive speed

120 65 115 Joyst ic. iso

Speed range = 0 – 7 kph

Used for work involving short loading cycles, i.e. a rapid succession of loading and unloading operations, e.g. onto a truck, and for work requiring precise speed adjustment.

Speed range = 0 – 20 kph (standard) 30/40 kph (option)

For long-haul travel

Selecting the speed range 0 – 7 kph ☞ After starting the engine, proceed as follows: • Set the driving direction to neutral with tip switch 115 on the control lever • Press switch 104 to position A • Select the required driving direction with switch 120 on the control lever (joystick) ➥ – see Driving direction selection (reversing operation forwards/reverse) on page 3-41 Selecting the

101

S

104

A

B Fig. 76: Switch for speed range selection

Recommended

speed range 0 – 20 kph (30 kph option)

☞ After starting the engine, proceed as follows: • Set the driving direction to neutral with tip switch 115 on the control lever • Press switch 104 to position B • Select the required driving direction with switch 120 (on the joystick) ➥ – see Driving direction selection (reversing operation forwards/reverse) on page 3-41 Selecting the

speed range (0 – 40 kph option)

Notice!

The 40 kph speed range is active only if front axle steering is switched on – see Changeover to front axle steering on page 3-46.

☞ After starting the engine, proceed as follows: • Set the driving direction to neutral with tip switch 115 on the control lever • Press switch 104 to position B • Press lock S in switch 101 in the direction of the arrow and at the same time, press the switch to position B • Release lock S ➥ Front axle steering is enabled • Select the required driving direction with switch 120 on the control lever ➥ – see Driving direction selection (reversing operation forwards/reverse) on page 3-41

3-40

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Operation Driving direction selection (reversing operation forwards/reverse) Danger!

In order to avoid danger of accidents, selecting the driving direction (reversing operation forwards/reverse) is not allowed when driving on public roads!

☞ Select the driving direction on public roads only at standstill ☞ After selecting the speed range, select the driving direction as follows: • Release the parking brake • Select the driving direction by pressing switch 120 on the control lever forwards or backwards ➥ Indicator lights 70 or 71 come on • Press the drive pedal slowly ➥ Machine moves off • Test the brakes at low speed

F 120 R 115

Notice!

Joystic.iso

70

71

Fig. 77: Changing direction

When driving the machine forwards or reverse, the driving direction can only be changed if the machine is braked to less than 12 kph.

• The indicator light flashes at speeds over 12 kph

☞ Reversing operation (changing driving direction) • Reduce the drive speed (0 – 12 kph) • Select the driving direction by pressing switch 120 on the control lever forwards or backwards ➥ F = forwards, indicator light 70 comes on ➥ R = reverse, indicator light 71 comes on ☞ Neutral position (stopping the machine) • Reduce the drive speed (0 – 12 kph) • Press tip switch 115 on the control lever ➥ Indicator lights 70 and 71 come on • Brake the machine to a standstill with the service brake • Apply the parking brake

Notice!

If the driving direction selection is rejected (no function): • The driving direction was selected at a speed of more than 12 kph, or tip switch 115 (drive – neutral position) was unintentionally actuated!

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3-41

Operation Selecting a speed range (low-speed control option) The drive speed can be set continuously with the low-speed control This function is especially useful for operation of hydraulically driven attachments (e.g. rotary broom, rotary hoe) in order to ensure continuous drive speed.

Drive speed is set via crawler gear potentiometer 77 at constant engine speed.

Notice!

The crawler gear potentiometer 77 is active only if the speed range selected!

is

☞ Operate low-speed control as follows: 77 A

B Fig. 78: Crawler gear potentiometer

104

• Press switch 104 to position A ➥ Crawler gear potentiometer 77 is enabled • Set the drive speed with crawler gear potentiometer 77 (see table) Symbol Drive speed

Recommended

Speed range = 0 – 7 kph

Used for work involving short loading cycles, i.e. a rapid succession of loading and unloading operations, e.g. onto a truck, and for work requiring precise speed adjustment.

Speed range = 0 – 20 kph (standard) Speed range = 0 – 30/40 kph (option)

For long-haul travel

Notice!

Important! Once the low-speed travel is over, set crawler gear potentiometer 77 to “Hare” so maximum speed can be reached again in normal operation!

3-42

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Operation 3.21 Stopping/parking the machine Danger!

In order to avoid danger of accidents, prevent the machine from rolling away if it is parked on a slope!

☞ Use the parking brake to park the machine safely and to prevent it rolling away – see Parking brake on page 3-50 ☞ In addition to the parking brake, secure the machine by placing chocks under the downhill sides of the wheels

☞ Stopping/parking the machine • Reduce engine speed: remove your foot from the accelerator pedal • Stop the machine with the service brake • Set the driving direction to neutral with the tip switch on the joystick – see Driving direction selection (reversing operation forwards/reverse) on page 3-41 • Press the parking brake switch – see Parking brake on page 3-50 • Lower the telescopic boom completely and set the bucket horizontally with the ground – see Operating the telescopic boom on page 3-66 • Stop the engine. To do this: turn the ignition key to “0” and remove it ➥ The drive interlock (option) is enabled

Caution!

In order to avoid engine damage, allow the engine to run for a while after operation under full load so that the temperature can stabilise, and then stop the engine • Close and lock the windows and the door as you leave the cab • Lock the engine cover securely • Remove the key from the battery master switch – see Battery master switch on page 3-27 On slopes: • Additionally secure the machine by placing chocks under the downhill sides of the wheels

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3-43

Operation 3.22 Steering system Steering column height and angle adjustment The steering column height and angle can be set to the driver's individual size.

5

Danger!

A

In order to avoid danger of accidents, do not adjust the steering column when driving or working!

B

☞ Stop the machine ☞ Apply the parking brake ☞ Adjust the steering column to your requirements

Fig. 79: Steering column adjustment

Function Height adjustment

Angle adjustment

Operation • Pull lever 5 upwards A and pull or push the steering column to the correct position • Release lever 5, the steering column is locked • Press lever 5 downwards B and tilt the steering column to the correct position • Release lever 5, the steering column is locked

Checking the steering system ☞ Functional check: with the engine running, turn the steering wheel to the left and right as far as it will go

Notice!

The steering system is only operational when the engine is running!

The machine can still be steered if the diesel engine or the pump drive breaks down – emergency steering feature.

Turning the steering wheel requires greater effort! Take this into account especially when towing the machine!

• Adapt towing speed to the altered steering behaviour! (Walking pace)

3-44

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Operation Synchronising the steering system Due to leakage and overpressure control in the steering hydraulics, the front and rear axle wheels of the machine, after extended operation, no longer follow the same track when driving straight-ahead. The steering system must be synchronised from time to time.

Danger!

In order to avoid danger of accidents, do not synchronise the steering system when driving the machine on public roads!

☞ Synchronise the steering system before driving on public roads

68

101

103

A

B

Fig. 80: Steering synchronisation

104

When starting the machine, the steering synchronisation automatically sets the wheels of the front and rear axle parallel to each other by turning the steering wheel to either side.

Synchronisation is over as soon as both steering rams of the front and rear axles have passed through the straight-ahead position from both directions. Indicator light 68 on the instrument panel goes out

Notice!

Synchronisation is only possible in 1st speed The 2nd speed range (switch 104) can be selected but is not active until synchronisation is over.

Carry out synchronisation on level ground!

☞ Proceed as follows: • Select the 1st speed range: press switch 104 to position A • Switch from front axle steering to 4 wheel steering with switch 101 in position A • Select forwards driving direction – see Driving direction selection (reversing operation forwards/reverse) on page 3-41 • Press and hold tip switch 103 in position B • Move off at walking pace while steering to the left and right until indicator light 68 goes out ➥ Steering synchronisation is over.

• Carry out a functional check of the steering system and select the steering mode ➥ – see Changeover to front axle steering on page 3-46 ➥ – see Changing over to 4 wheel steering on page 3-46 ➥ – see Changing over to diagonal steering (crab steering option) on page 3-47

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3-45

Operation Changeover to front axle steering

66

65

Danger!

67

In order to avoid danger of accidents, do not change steering mode when driving!

101

S

☞ See the General Certification for Vehicles (Germany) or the data confirmation (Germany)

A

☞ Proceed as follows:

B Fig. 81:

• Slide lock S in switch 101 in the direction of the arrow and press the switch to position A at the same time • Release lock S • Turn the steering wheel to the left and/or right until the wheels of the front and rear axles have passed through the straight-ahead position from both directions ➥ Indicator light 65 for front axle steering comes on ➥ Indicator lights 66 (4 wheel steering) and 67 (diagonal steering, option) go out ➥ Front axle steering is in operation

Steering mode selection (front axle steering)

Changing over to 4 wheel steering Danger!

66

65

67 S

101

A

3-46

☞ Slow down the machine to less than 20 kph under all circumstances ☞ If the machine is equipped with high speed (option), the speed range is automatically reduced to 20 or 30 kph by changing over

☞ Proceed as follows:

B Fig. 82:

Changing over from front axle to 4 wheel steering at high speed (high speed option) causes danger of accidents!

Steering mode selection (4 wheel steering)

• Slide lock S in switch 101 in the direction of the arrow and press the switch to position B at the same time • Release lock S • Turn the steering wheel to the left and/or right until the wheels of the front axle have passed through the straight-ahead position from both directions ➥ Indicator light 66 for 4 wheel steering comes on ➥ Indicator lights 65 (front axle steering) and 67 (diagonal steering, option) go out ➥ 4 wheel steering is in operation

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Operation Changing over to diagonal steering (crab steering option) Danger!

In order to avoid danger of accidents, driving on public roads with diagonal steering (crab steering) is not allowed!

☞ Change over to 4 wheel steering mode, or to front axle steering in the case of the optional high speed mode, before driving on public roads! ☞ – see Changing over to 4 wheel steering on page 3-46or“Changeover to front axle steering” on page 3-46

Notice!

66 101

65 S

67 102

Select 4 WHEEL STEERING mode first before changing over to diagonal steering mode!

☞ Select the 4 wheel steering mode A

B Fig. 83:

Steering mode selection (diagonal steering)

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• Slide lock S in switch 101 in the direction of the arrow and press the switch to position A at the same time • Release lock S ☞ Switch on diagonal steering • Slide lock S in switch 102 in the direction of the arrow and press the switch to position B at the same time • Release lock S • Turn the steering wheel to the left and/or right until the wheels of the front and rear axles have passed through the straight-ahead position from both directions ➥ Indicator light 67 for diagonal steering comes on ➥ Indicator lights 65 (front axle steering) and 66 (4 wheel steering) go out ➥ Diagonal steering (crab steering) is in operation

3-47

Operation 3.23 Accelerator pedal The drive speed is set continuously with the accelerator pedal

Notice!

Maximum speed depends on the speed range selected.

– see Speed range selection on page 3-40!

3.24 Manual throttle (option) Manual throttle operation

A B

The manual throttle function is especially useful for operating hydraulic attachments which need a continuous supply of hydraulic oil.

Manual throttle operation with lever • The manual throttle is located on the right of the side console Manual throttle operation with potentiometer (electronically, 103 kW diesel engine only) • Manual throttle 75 (potentiometer) is installed on the instrument panel

Danger!

Fig. 84: Mechanical manual throttle (option)

In order to avoid danger of accidents, setting engine speed with the manual throttle is not allowed when driving on public roads!

Use the manual throttle for work operation only!

☞ Before driving on public roads: • Set the manual throttle to idling position A • Set the engine speed with the accelerator pedal only

A B

Position A B

Engine speed Idling speed = minimum engine speed Full throttle = maximum engine speed

75 Fig. 85: Electronic manual throttle (option)

3-48

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Operation 3.25 Brake/inching pedal Important notice on brake/inching pedal actuation Caution! The brake/inching pedal is located on the left in the machine.

• Dirt accumulation and objects in the area of the brake/inching pedal result in brake malfunctions • Keep the brake/inching pedal clean and remove all objects in the area of the pedal Careful when stopping on slopes!

• Press the brake/inching pedal down with force until the braking effect is felt

Inching with the brake/inching pedal ☞ Press the brake/inching pedal down slightly ➥ In the inching range (pedal pressed lightly), the pedal can be used like a car's clutch. ➥ The drive's output is reduced and the engine power is now available for the work hydraulics. This makes it possible to raise the telescopic boom more quickly

Notice!

Caution! The brake lights do not come on when inching!

• For the brake lights to come on, press the brake/inching pedal down with force

Braking with the brake/inching pedal ☞ Carry out the brake test as follows: • Before moving off, check whether a firm resistance is felt after half the pedal travel and whether the brake lights come on • Check by looking back in the rearview mirror that no-one is hindered by the brake manoeuvre.

• Press the brake/inching pedal down at slow speed and check the brake effect

Caution!

When driving downhill, the brake pedal must be used to support the braking effect of the drive. This avoids damage to the drive and/or the diesel engine due to excessive speed.

In addition, shift to 1st speed first before driving on extremely steep slopes! ☞ Reduce engine speed: remove your foot from the accelerator pedal ☞ Select the 1st speed range ☞ Reduce your drive speed with the brake/inching pedal

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3-49

Operation 3.26 Parking brake Notice on the parking brake Notice!

A starting interlock prevents the machine from starting with the parking brake applied.

Applying the parking brake automatically cancels the selection of the forwards/ reverse driving direction (drive) and switches the drive to neutral.

Applying the parking brake S

Danger!

A

Applying the parking brake when driving can brake the machine abruptly (spring brake actuator)!

Only apply the parking brake in an emergency if the service brake breaks down!

B

☞ In normal operation use only the brake/inching pedal as a service brake 100

54

The switch for parking brake operation is located on the switch console on the right ☞ Apply the parking brake • Press lock S in switch 100 in the direction of the arrow and at the same time, press the switch to position B ➥ Indicator light 54 on the indicating instrument comes on ➥ Selection of forwards/reverse driving direction (drive) is automatically cancelled and neutral activated ➥ The engine can be started

☞ Release the parking brake Fig. 86: Parking brake

• Press lock S in switch 101 in the direction of the arrow and at the same time, press the switch to position A ➥ Indicator light 54 on the indicating instrument goes out ➥ The machine is ready to move off

Caution!

If the parking brake indicator light 54 does not go out with the engine running and the brake released, or if it comes on when driving the machine – Possible boost pressure loss in the drive! ☞ Stop the machine immediately to avoid damage • Stop the engine • Apply the parking brake • Have the error repaired by an authorised workshop

3-50

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Operation 3.27 Telescopic boom load stabiliser Information regarding the load stabiliser function The load stabiliser cushions and dampens the movements of the telescopic boom. It avoids unstable oscillating movements of the telehandler when driving the machine and increases drive comfort and safety!

Notice!

Always switch on the load stabiliser when driving on public roads!

In order to ensure the full functionality of the load stabiliser, pay attention to the following: • Lower the telescopic boom to transport position • Do not retract the tilt ram fully to the limit • Briefly release the hydraulic pressure on the tilt ram after dumping in

Caution!

Switching on the load stabiliser automatically switches off the hose burst valve, so that there is no protection in the event of line damage in the hydraulic system!

• Indicator light 64 on the instrument panel comes on – see “Hose burst valve” safety feature on page 3-88 ☞ Switch off the load stabiliser during pallet forks operation – see Switching the load stabiliser ON or OFF on page 3-52

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3-51

Operation Switching the load stabiliser ON or OFF Switch 99 for load stabiliser operation is located on the switch console on the left.

99 64 A B

AUTO

Notice!

The telescopic boom yields easily with the load stabiliser switched on, making it difficult to carry out any precise lifting movements.

• Switch off the load stabiliser during pallet forks operation

OFF

C Fig. 87: Load stabiliser switch

☞ Switch on the load stabiliser for automatic operation For driving on public roads, for lighter work with the telescopic boom and for light offroad transport • Press switch 99 to position A ➥ The load stabiliser is automatically switched on if the machine moves faster than 7 kph ➥ Indicator light 64 on the instrument panel comes on

☞ Switch on the load stabiliser for continuous operation • Press switch 99 to position C ➥ The load stabiliser is immediately in continuous operation (no drive speed control) ➥ Indicator light 64 on the instrument panel goes out

☞ Switch off the load stabiliser For heavy-duty work, e.g. picking up excavated material • Press switch 99 to centre position B ➥ The load stabiliser is switched off ➥ Indicator light 64 on the instrument panel goes out (the hose burst valve is switched on)

3-52

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Operation 3.28 Differential lock Important information on the differential lock The 100 % front axle differential lock neutralises the compensating effect of the differential, i.e. traction is distributed evenly to both front wheels.

Caution!

In order to avoid damage to the differential, ☞ Switch on the differential lock only if you expect a wheel to spin, e.g. when working on slopes or on slippery ground! ☞ Switch on the differential lock only at machine standstill ☞ Switch off the differential lock when cornering

Switching the differential lock ON and OFF

119

62

Joystic.iso

Fig. 88: Tip switch for differential lock

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In order to avoid damage to the differential lock when switching it on, it can only be enabled by pressing tip switch 119 on the control lever and the brake/inching pedal! ☞ Switching on the differential lock • Stop the machine • Press and hold tip switch 119 on the control lever • Press the brake/inching pedal briefly (3 – 5 sec) until indicator light 62 on the instrument panel comes on ➥ The differential lock is enabled • Carefully move off the machine with tip switch 119 pressed ☞ Switching off the differential lock • First reduce drive speed and engine speed • Release tip switch 119 on the control lever ➥ Indicator light 62 on the instrument panel goes out, the differential lock is disabled

3-53

Operation 3.29 Backup warning system (option) Information on the backup warning system The backup warning system consists of a signal transmitter fitted on the rear of the telehandler.

The signal transmitter generates an acoustic signal when shifting into reverse.

The acoustic level is about 103 dB (A) at a distance of 1 m and at a frequency of 2800 Hz.

Danger!

In order to avoid danger of accidents, do not rely on the backup warning system under any circumnstances when reversing with the machine!

☞ Ensure that nobody is within the danger area of the machine when changing the driving direction

3.30 Electric mirror adjustment (option) Adjusting the rearview mirror 83

U F

R

L R D

The right-hand side and the rear mirrors can be adjusted electrically by pressing the switch laterally.

Switch 83 is located on the right-hand side console ☞ Operate as follows: • Turn the switch to position F (right-hand side mirror) • Turn the switch to position R (rear mirror) • Press the switch on the side ➥ U = mirror moves upwards ➥ D = mirror moves downwards ➥ R = mirror moves to the right ➥ L = mirror moves to the left

Fig. 89: Electric mirror adjustment (option)

3.31 Reversing fan (option) 106

A

Pressing switch 106 reverses the direction of rotation of the fan, cleans the radiator and maintains the temperature of the engine and hydraulic oil radiator at an optimal level.

Tip switch 106 for automatic cleaning is located on the instrument panel on the right • Cleaning the radiator – see chapter 5 “Cleaning the radiator with the reversing fan (option)” on page 5-16

B Fig. 90: Reversing fan

3-54

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Operation 3.32 Machine lights Notice on machine lights • The machine lights (main headlights) can be equipped with optional screens for protection against damage (falling rocks).

• The protective screens are not authorised for driving on public roads (StVZO German road traffic regulations) and must be removed!

• Get informed on and follow the legal regulations of your country!

Machine lights operation The switch panel for the machine lights is located on the left on the instrument panel.

Side marker light operation

49

ON

Press switch 85 to the 1st position B

Indicator light in switch comes on

OFF

Press switch 85 to position A

Indicator light in switch goes out

Low beam operation A

44

Function

ON

Press switch 85 to the 2nd position B

Indicator light in switch comes on

OFF

Press switch 85 to position A

Indicator light in switch goes out

B 85

Function

Notice!

Only the side marker lights stay lit if ignition is switched off while low beam is still switched on!

II I

High beam operation

0

I

II

Lenkst ockscha lt _li .i so

ON

Fig. 91: Machine lights

OFF

With low beam switched on, pull lever 44 to position II towards the steering wheel and release Pull lever 44 to position II towards the steering wheel and release

Headlight flasher operation ON

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Pull lever 44 briefly upwards to position I

Function High beam and indicator light 49 on the indicating instrument come on High beam and indicator light 49 on the indicating instrument go out Function High beam and indicator light 49 on the indicating instrument come on

3-55

Operation Working lights operation Danger!

Danger of accidents! The working light can dazzle motorists on public roads.

☞ Do not switch on the working light when driving on public roads. When

operating the machine, only switch the working light on when no-one can be dazzled by it!

The switches are located on the switch console on the left 87

88

89

A

Operation of front and/or rear working lights on the cab (option) ON

B

OFF

Fig. 92: Working light switches

Press switches 87 and/or 88 to position B Press switches 87 and/or 88 to position A

Function Indicator light in switch comes on Indicator light in switch goes out

Front boom working light operation (option)

Function

ON

Press switch 89 to position B

Indicator light in switch comes on

OFF

Press switch 89 to position A

Indicator light in switch goes out

Interior light operation (cab) ☞ Interior light without door contact switch 14

L

0 T

• Switch to the left L ➥ Interior light ON (continuous operation) • Move the switch to the centre position 0 ➥ Interior light OFF

☞ Interior light with door contact switch (option) • Switch to the right D ➥ The interior light is switched ON and OFF by opening and closing the door (door contact)

Fig. 93: Switch for interior light

3-56

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Operation 3.33 Signalling system Turn indicator operation l

Operating the turn indicators

44

63

R

RIGHT

Push lever 44 forwards R

LEFT

Pull lever 44 to the rear L

Function Indicator light 63 on the instrument panel flashes Indicator light 63 on the instrument panel flashes

0

I II

Notice!

Lenkstockschalt_li.iso

L

The turn indicator system is not in order if indicator light 63 flashes about twice as fast as normally!

• Have the turn indicator system repaired

Fig. 94: Turn indicators

Hazard warning system operation The hazard warning switch is located on the switch console on the left 84

63

Operating the hazard warning system Press hazard warning switch 84 to position B Press hazard warning switch 84 to position A

ON A

OFF

Function The indicator light in the switch and indicator light 63 both flash The indicator light in the switch and indicator light 63 both go out

B Fig. 95: Switch for hazard warning system

Rotating beacon operation (option) The switch is located on the switch console on the left Rotating beacon operation (option)

Function

ON

Press switch 86 to position B

Indicator light in switch comes on

OFF

Press switch 86 to position A

Indicator light in switch goes out

86 A B Fig. 96: Switch for rotating beacon

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Notice!

Legal regulations of your country may require you not to switch on the rotating beacon on public roads unless the road is within the machine's working range and the machine represents an obstruction to the normal flow of traffic when the machine is in work operation.

Get informed on and follow the legal regulations of your country.

3-57

Operation 3.34 Cab heating and ventilation Description of the heating and ventilation system The air flow is guided to the front window via the two defroster vents Fig. 38/3, to one leg room vent and to the rear window via the two defroster vents Fig. 38/20.

Each nozzle can be closed and directed separately.

Notice!

The machine heater can be set to 2 operating modes: • Ventilation • Heating

Ventilation and heating in fresh-air mode

80

81

Rotary switches 80/81 are located on the heating switch console on the right.

Rotary switch 29 is located on the side console on the left next to the seat. ☞ Ventilate the cab in fresh-air mode as follows: • Rotary switch 81 in positions 1 – 3 • Rotary switch 29 in position D ☞ Heat the cab in fresh-air mode as follows: • Rotary switch 81 in positions 1 – 3 • Set rotary switch 80 to the required temperature C = cold/W = warm • Turn rotary switch 29 fully to position D

Fig. 97: Heating switches

Ventilation and heating in mixed mode 29

D E

Notice!

Ventilation and heating in mixed mode, and ventilation and heating in recirculated-air mode only valid up to serial numbers: 7030 – 401 03 0487 / 7040 – 402 03 0508 / 7045 – 403 03 0345

☞ Ventilate and heat the cab in mixed mode as follows:

D

E

• Rotary switch 81 in positions 1 – 3 • Set rotary switch 80 to the required temperature C = cold/W = warm • Turn rotary switch 29 to between positions D and E ☞ Ventilate and heat the cab in recirculated-air mode as follows: • Rotary switch 81 in positions 1 – 3 • Set rotary switch 80 to the required temperature C = cold/W = warm • Turn rotary switch 29 fully to position E

Fig. 98: Mixed mode switch

3-58

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Operation 3.35 Air conditioning (option) Information on putting the air conditioning into operation For cooling and heating, the air conditioning system supplies dehumidified and purified air to the cab.

In order to achieve best air conditioning results: • Before putting into operation, ventilate thoroughly to remove trapped warm air from the cab • Close the windows and the door • Set the fan to maximum output first, and then adjust it to your needs • In order to prevent condensation water from forming on the condensor, switch off the air conditioning system in due time before the end of work

Caution!

In order to avoid functional errors and possible loss of the refrigerant: ☞ Run the air conditioning system once a month. This prevents the seals in the compressor from drying and becoming brittle ☞ Regularly check the V-belt for tension and cracks – see chapter 5 “Air conditioning (option): maintenance” on page 5-35 ☞ Clean a dirty condensor – see chapter 5 “Air conditioning (option): maintenance” on page 5-35 ☞ Have the air conditioning checked at least once a year by an authorised workshop ☞ The air conditioning system must be repaired, serviced and filled with a refrigerant by trained staff and an authorised workshop only

Air conditioning operation The air conditioning switch is located on the switch console on the right. ☞ Press switch 107 to position B

107

A

➥ Indicator light in switch comes on ➥ Air conditioning in operation

Notice!

B

The air conditioning system allows you to select the same operating modes as with the heating and ventilation system!

Fig. 99: Air conditioning switch

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3-59

Operation 3.36 Washer system Washer system operation Front wiper operation Turn rotary switch 121 on the lever to the first position Turn rotary switch 121 on the lever to the second position Turn rotary switch 121 on the lever completely back

ON ON OFF

121

Function Intermittent wipe Continuous wiping Wipers return to base position

Fig. 100: Switch for front and rear wipers

Washer pump operation (front window)

A

ON

Press and hold rotary switch 121 on the lever to the right A

OFF

Release rotary switch 121 on the lever

121 Fig. 101: Washer pump

105

A

Wiper operation (rear window)

Function

ON

Press switch 105 to position B

Rear wiper is on

OFF

Press switch 105 to position A

Rear wiper returns to base position

Washer pump operation (rear window) B

ON

Press and hold switch 105 beyond position B (tip switch function)

Fig. 102: Rear wiper switch

Tank for washer system Tank filler inlet 36 is located in the cab underneath the cover on the left next to the seat

Notice!

36

Fill with clean tap water only!

Add a suitable cleaning agent if required.

In winter: add antifreeze for washer systems to the water. Refer to the antifreeze instructions for further information on concentrations – see chapter 5 “Fluids and lubricants” on page 5-53.

Fig. 103: Tank for washer system

3-60

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Operation

Operation 3.37 Telescopic boom control lever: overview Operating the control lever for the lift, tilt and push-out rams Danger!

118

Danger of accidents and injury!

117

☞ Before leaving the seat, and when driving on public roads, lock the control

C

lever (telescopic boom) and the 3rd control circuit (quickhitch) against unintentional actuation!

• – see Locking the control lever (joystick) and the 3rd control circuit (attachments) on page 3-39 • – see Operating and securing the 3rd control circuit on page 3-68

B

A

116 D

Notice!

12

Safety feature! The telescopic boom cannot be lowered with the engine and the ignition switched off!

– see Emergency lowering of telescopic boom in case of diesel engine breakdown on page 3-67

Joystic.iso

Fig. 104: Control lever for telescopic boom

Position Operation

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Function

A

To the left

Tilts in the attachment

B

To the right

Dumps out the attachment

C

Forwards

Lowers the telescopic boom

D

Backwards

Raises the telescopic boom

116

Potentiometer wheel

Retracts and extends the telescopic boom

117

Tip switch

118

Potentiometer wheel

Front socket for attachment (option) or bucket repositioning (option) 3rd control circuit for locking and unlocking the quickhitch or for hydraulic attachment

3-61

Operation 3.38 Safe load indicator for telescopic boom Important notice on the safe load indicator • The safe load indicator has been installed for bucket and pallet forks operation with varying reaches.

• During work operation, the electronic safe load indicator continuously monitors the weight changes on the rear axle • Indicator 8 is installed inside the cab at the upper right.

• Visible and acoustic signals warn the operator of critical loads on the telescopic boom that might cause the machine to tip over to the front.

8

Fig. 105: Control lever for telescopic boom

Notice!

The safe load indicator has been set by the manufacturer, and may only be set and adjusted again by an authorised workshop in the case of repair work!

The safe load indicator does not give the following warnings: • Sudden overload of telescopic boom • Driving with raised load • Off-road driving or driving on surfaces with obstacles and holes • Driving or turning round on slopes • Driving too fast or cornering sharply in curves

Danger!

Danger of tipping over! Lateral loads are not monitored by the safe load indicator.

The maximum load is effective with the telescopic boom fully extended and raised, or fully extended and horizontal!

☞ Reduce the load immediately by retracting and lowering the telescopic boom!

☞ Work carefully! Adapt your drive speed and loads to the terrain. ☞ Refer to the load diagram for the maximum authorised loads! (See labels affixed on the instrument panel.)

• See also the description on page 3-85 and payload indications on page 6-15

3-62

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Operation Important notice on the safe load indicator overload display The LEDs a, b and c indicate the load effective on the telescopic boom – in percent of the safe work load.

Danger!

A defective safe load indicator will cause the machine to tip over!

In order to avoid danger, regularly check the safe load indicator for proper functioning!

➥ – see Functional check of the safe load indicator on page 3-63 • Have a defective safe load indicator immediately repaired by an authorised workshop

Overview of indicator lights on overload display c b a

a b c d e

4 green LEDs = loads are between 45 and 90 % 1 orange LED = indication of loads between 90 and 100 % 1 red LED = indication of loads over 100 % Green LED = readiness Tip switch (TEST) for checking the system

e d Fig. 106: Overview of safe load indicator display

Functional check of the safe load indicator c

Notice!

b

The check can be carried out at any time, even during operation.

a

☞ For a functional check, press the TEST push button e • If all LEDs (green, orange, red) flash and the alarm sounds: ➥ Safe load indicator is OK • When the first green, orange and red LEDs all flash and an alarm sounds in addition: ➥ System error of safe load indicator ➥ Have the safe load indicator immediately checked and repaired by a trained and authorised technician or a workshop!

e d Fig. 107: Functional check of the safe load indicator

Notice!

If repair work cannot be carried out immediately and the warning sound bothers, the system error can be switched off with tip switch e until the machine is started again! l

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3-63

Operation What to do when the indicator lights come on c b d

a

Fig. 108: Display of safe load indicator functions

C

• Green diode d (readiness) comes on ➥ The safe load indicator is in operation • Green LEDs a (1 – 4) come on ➥ OK! = the load is between 45 and 90 % • Green LEDs a (1 – 4) and the orange LED b flash ➥ Work with extreme caution! A load of 90 – 100 % is reached • Reduce the load. To do this: retract the telescopic boom and carefully lower the load within the safety range (see load diagram) • All LEDs (a, b, c) flash and an alarm sounds ➥ Caution, danger of tipping over! The load is too heavy ➥ The hydraulic functions “Raise, Lower, Dump In/Out and Extend” of the telescopic boom are automatically disabled by the overload cutoff • Retract the telescopic boom. To do this: scroll potentiometer wheel 116 on the control lever backwards until the load of the telescopic boom is between 45 and 90 % ➥ Green LEDs a (1 – 4) and the orange LED b flash • Carefully lower the load within the safe range (see load diagram affixed on the side window)

Notice!

B

A

116 D Joystic.i so

If the telescopic boom cannot be retracted for some reason, for instance due to an obstacle, the disabled hydraulic functions have to be enabled again with the overload cutoff to reduce the load!

The overload cutoff is temporarily disabled for this!

• – see Disabling the overload cutoff on page 3-65

Fig. 109: Retract the telescopic boom

Overload cutoff with limit switch (from October 2010) The automatic overload cutoff is disabled by means of a limit switch when the telescopic boom is fully retracted.

Standard equipment with limit switch from serial numbers: Model 401 03 0484 (7030) Model 402 03 0503 (7040) Model 402 03 0416 (7045)

Danger!

Danger of tipping over! The machine tips over if the telescopic boom is overloaded in this condition!

☞ Carry out work only within the safe load range (see load diagram affixed on the instrument panel)

3-64

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Operation Disabling the overload cutoff Tip switch 113 for disabling the overload cutoff is located on the left-hand instrument panel.

Indicator light 79 comes on when the overload cutoff is disabled.

79 A C

Danger!

B B

A

113

In order to avoid danger of tipping over with the machine, disable the overload cutoff only when the machine is at a standstill and only in situations of extreme emergency!

☞ Lower the load within the safe range only at diesel engine idling speed (see D

load diagram affixed on the side window)

Joystic.i so

Fig. 110: Overload cutoff

Notice!

For reasons of safety, the overload cutoff can be disabled only using both hands at the same time!

☞ Disable the overload cutoff as follows: • Stop the machine and apply the parking brake • Press and hold tip switch 113 in position B with your left hand ➥ Indicator light 79 comes on, the overload cutoff is disabled • At the same time, operate the control lever with your right hand hand and lower the load within the safe range (see load diagram affixed on the side window) ➥ If this reduces the overload, the green LEDs on the display come on – see Overview of indicator lights on overload display on page 3-63 • Release tip switch 113 ➥ Indicator light 79 goes out and the overload cutoff is enabled

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3-65

Operation 3.39 Operating the telescopic boom Raising/extending the telescopic boom Danger!

Danger of tipping over! The maximum load is effective with the telescopic boom fully extended and raised, or fully extended and horizontal!

☞ Carefully retract and then lower the telescopic boom ☞ Bear in mind the safe load indicator – see Safe load indicator for telescopic boom on page 3-62

D

12

☞ Operate the telescopic boom as follows: • • • •

Joysti c.iso

A

Raise the retracted telescopic boom to the required height. To do this: Pull control lever 12 backwards D Extend the telescopic boom. To do this: Scroll potentiometer wheel 116 on control lever 12 forwards (arrow A) until reaching the required length of the telescopic boom

116 12

Joystic. iso

Fig. 111: Raising/extending the telescopic boom

Retracting/lowering the telescopic boom Danger!

In order to avoid danger of tipping over to the front, lower the telescopic boom only after it has been retracted!

C

116

☞ Always retract the telescopic boom first before you lower it ☞ Bear in mind the safe load indicator • – see Safe load indicator for telescopic boom on page 3-62

12 Joystic. iso

Fig. 112: Retracting/lowering the telescopic boom

3-66

☞ Operate the telescopic boom as follows: • Retract the telescopic boom. To do this: scroll potentiometer wheel 116 on control lever 12 backwards until the telescopic boom is fully retracted • Lower the retracted telescopic boom. To do this: push control lever 12 forwards C

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Operation 3.40 Emergency lowering of telescopic boom in case of diesel engine breakdown Lower or raise as follows: Notice!

Safety feature! The telescopic boom cannot be lowered with the ignition switched off and/or in case of diesel engine breakdown!

• The telescopic boom can only be lowered as follows!

Danger!

In order to avoid danger of tipping over, do not lower an extended telescopic boom!

☞ Retract and lower the telescopic boom as described below ☞ Lowering the telescopic boom

C

116 98 12 D

AUTO

OFF

Joyst ic.iso

Fig. 113: Emergency lowering of telescopic boom

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• Ensure that no-one is dangerously close to the machine • Apply the parking brake • Switch on ignition ☞ If the telescopic boom is still extended: • Press switch 98 and at the same time, scroll and hold potentiometer wheel 116 on control lever 12 backwards • Fully retract the telescopic boom with auxiliary means (pulley block) • Release potentiometer wheel 116 on control lever 12 • Press switch 98 and at the same time, slowly push and hold control lever 12 forwards C until the telescopic boom is lowered to transport position • In case of diesel engine breakdown, have an authorised workshop carry out checks and repair work ☞ Raising the telescopic boom • Switch on ignition • Press switch 98, and slowly pull and hold control lever 12 backwards D • Raise the telescopic boom to transport position with lifting gear (crane) • Release switch 98 and control lever 12 • In case of diesel engine breakdown, have an authorised workshop carry out checks and repair work

3-67

Operation 3.41 Operating and securing the 3rd control circuit Locking and unlocking the quickhitch or an attachment Notice!

The attachment locked onto the quickhitch is secured against unintentional operation of scroll wheel 118 on the control lever. The attachment can only be unlocked by pressing switch 98 (on the instrument panel on the left) in addition.

118

98

Unlocking the 3rd control circuit

Function

1 AUTO

OFF

C A Joystic. iso

B 95 56 Fig. 114: Operation of 3rd control circuit

3-68

Slide lock C in switch 95 in the direction of the arrow and press it Indicator light 56 comes on to position B 3rd control circuit is unlocked 2 Release lock C

Locking the attachment

Function

Scroll wheel 118 (on the control lever) upwards

The attachment is locked in the quickhitch and automatically secured against unlocking

Unlocking the attachment

Function

Press switch 98 and scroll wheel 118 (on the control lever) downwards at the The attachment on the quickhitch is unlocked same time 3rd control circuit – hydraulic attachment The attachment is operated with the 3rd control circuit after having changed over the flexible lines (quick couplers of the quickhitch) to the attachment (e.g. multipurpose bucket)!

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Operation 3.42 Equipping the machine with a standard bucket Pressure relief on the quickhitch couplers Notice!

The hydraulic system of the machine is still pressurised even when the engine is not running! The hydraulic quick couplers can be released, however they cannot be re-attached because the pressure in the hydraulic lines has not been released.

• Release the pressure in the system before mounting or removing an attachment!

☞ Proceed as follows: A

118 B

98 AUTO

OFF

Joyst ic.iso

Fig. 115: Releasing the pressure in the hydraulic lines

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• Lower the telescopic boom and apply the parking brake ➥ – see Parking brake on page 3-50 • Unlock the 3rd control circuit ➥ – see Operating and securing the 3rd control circuit on page 3-68 • Stop the engine, but do not switch off ignition • Press and hold switch 98 , and at the same time, scroll and hold potentiometer wheel 118 on control lever 12 upwards and downwards about 8 seconds in either position ➥ Pressure in hydraulic lines is released • Switch off ignition and remove the ignition key

3-69

Operation Fitting a standard bucket onto the quickhitch Field of application of bucket • The standard bucket is mainly used for digging earth, and for loosening, picking up, transporting and loading loose or solid materials.

• Get informed on the legal regulations of your country which may prohibit driving on public roads with a full bucket! – see chapter 1 “Authorised attachments” on page 1-6!

• In addition, bear in mind the mandatory regulations relevant to accident prevention.

Mounting an attachment on a quickhitch with a hydraulic lock 118 C

Danger!

In order to avoid danger of accidents, ensure that before starting work that the attachment is safely locked onto the quickhitch by means of the lock ram!

E

B

☞ Lock pin E must be visible on either side in the bores on the attachment

A

12

D

☞ Mount and lock the bucket hydraulically

Joysti c.iso

3

1

2 2

E

• Release the hydraulic pressure on the 3rd control circuit, and unlock the circuit ➥ – see Pressure relief on the quickhitch couplers on page 3-69 • Approach the telehandler to the attachment • Lower the telescopic boom. To do this: push control lever 12 forwards C • Tilt the quickhitch forwards 1. To do this: push control lever 12 to the right B • Raise the telescopic boom 2 until the mount of the quickhitch engages in the mount of the attachment. To do this: pull the control lever backwards D • Tilt in the quickhitch fully 3. To do this: push control lever 12 to the left A • Scroll potentiometer wheel 118 on control lever 12 downwards ➥ Lock pin E engages in the mounting bores of the attachment and is automatically secured against unlocking ➥ Ensure that lock pin E can be seen on either side of the attachment

Fig. 116: Picking up and locking hydraulically

3-70

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Operation Mounting an attachment on a quickhitch with a mechanical lock ☞ Mount and lock the bucket mechanically

118 C

• Remove safety pin A from lock pin B, and remove the lock pin completely out of the quickhitch by hand

E

B

Notice!

A

Lock pin B is laterally fastened and safely locked on the telescopic boom for storage!

12

D Joystic.i so

• Approach the telehandler to the attachment and carefully pick up the attachment with the catch hooks • Dump in the attachment completely • Slide lock pins B through the mounting bores of the attachment and of the quickhitch, and secure them with safety pins A on the quickhitch • Ensure that lock pin B on the opposite side is visible in the mounting bore of the attachment

3

1

2 2

A

C

B

Fig. 117: Picking up and locking mechanically

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3-71

Operation Removing a standard bucket from the quickhitch 118

Notice!

C

Remove the attachment from the quickhitch so that after unlocking it will stand safely and not tip over!

98

B A

AUTO

12

D

☞ Lowering a hydraulically locked bucket

OFF

• Release the hydraulic pressure on the 3rd control circuit, and unlock the circuit ➥ – see Pressure relief on the quickhitch couplers on page 3-69 • Drive the telehandler to the drop-off position • Lower telescopic boom 5. To do this: push control lever 12 to position C until the attachment is about 5 – 10 cm horizontal above the ground • Press and hold switch 98 to position B and at the same time, scroll potentiometer wheel 118 on control lever 12 downwards ➥ Lock pin E moves out of the mounting bores of the attachment • Tilt the quickhitch forwards 4 a little. To do this: push the control lever 12 to position B • Lower the telescopic boom completely 5. To do this: press control lever 12 to position C • Reverse the telehandler away from the attachment ☞ Lowering a mechanically locked bucket • Remove safety pin A from lock pin B, remove the lock pin completely out of the quickhitch by hand and insert it in the bracket on the side of the boom • Tilt the quickhitch forwards 4 and at the same time, lower the telescopic boom 5 until the attachment is on the ground without applying any pressure • Tilt in the quickhitch completely 6 • Reverse the telehandler away from the attachment • Slide lock pin B into the quickhitch • Safely lock it with safety pin A

Joysti c.iso

4

5 E

A

C

B

Fig. 118: Removing a standard bucket

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Operation 3.43 Working with the standard bucket Safety instructions regarding work with the bucket • Bear in mind the safety instructions given in chapter 2 before working with the machine.

• – see Designated use and exemption from liability on page 2-2, • – see General conduct and safety instructions on page 2-3, • – see Safety instructions regarding operation on page 2-6 • Before starting work, check whether the attachment is safely locked onto the quickhitch by means of the lock ram! ➥ You must be able to see the lock pins on either side (left/right) in the mounting bores on the attachment • Never drive up to the edge of a pit from outside – danger of cave-in!

• Never undermine the foundations of walls – danger of collapse!

• Bear in mind the load diagram and the safe load indicator. Both are located in the cab – see What to do when the indicator lights come on on page 3-64!

• When working with the machine, look out for high-voltage cables, underground cables, gas and water pipes!

• Switch off the load stabiliser, as it will yield very easily, making it difficult to carry out any precise lifting movements! ➥ – see Telescopic boom load stabiliser on page 3-51

Caution!

In order to avoid damage to the telescopic boom, push and pull material only with the telescopic boom completely retracted!

If the bucket is very full, the material may fall over the rear of the bucket and the slide surfaces of the extended telescopic boom may become dirty. ☞ Do not completely tilt in a full bucket if the telescopic boom is extended

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3-73

Operation Driving on public roads with a standard bucket Notice!

When driving on public roads, equip the machine only with attachments that are certified for this machine! (See General Certification for Vehicles (Germany) or the data confirmation (Germany), and “Fields of application and using a telehandler with an attachment” on page 1-6 in this Operator's Manual!

☞ Proceed as follows: B C

200 mm A Fig. 119: Transport position with bucket

• Empty and dump in the standard bucket • Fully retract the telescopic boom • Raise the telescopic boom to transport position until the red marks B on the telescopic boom and the frame are aligned ➥ If both marks B coincide, ground clearance in connection with the standard bucket and standard tyres is about 200 mm.

• Cover the blade or teeth of the bucket across their entire width with the protection C provided

Notice!

Driving on public roads with a full bucket is not allowed in Germany!

Get informed on and follow the legal regulations of your country.

Moving with the bucket fully dumped out Caution!

In order to avoid damage to the tyres, do not move the machine with the bucket fully dumped out! ☞ Tilt in the bucket and lower it to transport position Fig. 120: Tyre damage in transport position

3-74

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Operation Safety instructions for transporting material in a full bucket Danger!

In order to avoid danger of falling material, do not transport loads with a raised and extended telescopic boom!

☞ Always dump in the attachment a little towards the machine, carry it as A

Wrong

close as possible to the ground and bear in mind the required ground clearance!

If it is dumped in, the bucket is moved parallel to its initial position as the telescopic boom is raised! If the bucket is unintentionally dumped in to the limit in the raised position, material can fall over the rear of the bucket (this also applies to all other attachments)!

☞ Do not dump in a raised bucket (B) ☞ In case of a bulky load:

B

Right

Fig. 121: Safety instructions for transporting material

• Secure the load • Fit the rear of the bucket with a protection • Install a protective screen (option) onto the cab • Use attachments with hydraulic grabs (option) ☞ Ensure good visibility of the material you want to pick up and of the work and travel range ☞ Bear in mind the safe load indicator – see What to do when the indicator lights come on on page 3-64

Danger!

In order to avoid danger of tipping over when driving or manoeuvring on slopes with a full bucket, dump in the bucket fully and and set the telescopic boom to transport position!

Whenever possible, drive in reverse when transporting a bucket loaded with material down a steep slope

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3-75

Operation Loading loose material C

Caution!

B

A D

B

B

In order to avoid damage to the telescopic boom, push and pull material only with the telescopic boom completely retracted!

☞ Load as follows: • Align the blade parallel with the ground A • Lower the telescopic boom to the ground B. To do this: push the control lever forwards C • Drive forwards into the material A When the diesel engine speed decreases due to too much material: • Slightly raise the telescopic boom B. To do this: pull the control lever backwards D

A Fig. 122: Driving into the material

Loading if the material is hard to penetrate ☞ Load as follows:

C

• As for loading loose material, but in addition: tilt the bucket in and out a little. To do this: move the control lever to the left and right A and B When the bucket is full: • Dump in the bucket C. To do this: push the control lever to the left A • Reverse out of the material A • Raise the bucket to transport position B

B

A D

A

C B Fig. 123: Loading if the material is hard to penetrate

3-76

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Operation Removing material/digging in soft soil ☞ Load as follows:

C

• Place the bucket horizontally on the ground B. To do this: push the control lever forwards C

B

A D

B

Fig. 124: Lowering the telescopic boom horizontally to the ground

• Adjust the digging angle 1. To do this: push the control lever to the right B C

B

A D

1 1 Fig. 125: Adjusting the digging angle

• Drive the machine forwards 1 Once the bucket has penetrated the soil: • Set the digging angle a little flatter 2. To do this: push the control lever to the left A, so that the layer being removed is as even as possible and so that the wheel spin is reduced • Proceed as for loading loose material

C

B

A D

1

2 Fig. 126: Removing an even layer

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3-77

Operation Removing material/digging in hard soil ☞ Remove and dig as follows: C

B

A D

3

1

• Lower the bucket horizontally to the ground 1. To do this: push the control lever forwards C • Adjust the digging angle flatter 2 than for digging in soft soil. To do this: push the control lever to the left A • Drive the machine forwards 3 and • Press the bucket downwards a little. To do this: push the control lever forwards C a little

2 Fig. 127: Removing hard soil

C

B

A D

3

Once the bucket has penetrated the soil: • Adjust the digging angle a little flatter 1. To do this: push the control lever to the left A, so that • Layer being removed is as even as possible and • Wheel spin is reduced • Move the control lever to the left and right A and B to loosen the material • Proceed as for loading material hard to penetrate

1 Fig. 128: Adjusting the digging angle flatter

Grading ☞ Grade as follows: • Lower the telescopic boom horizontally to the ground (1) • Reverse across the surface to be graded (2)

1 2

Fig. 129: Grading

Loading vehicles ☞ Load vehicles as follows:

Fig. 130: Loading vehicles

3-78

• If possible, the truck and the working direction of the telehandler should form an angle of 45° • Only raise the full bucket to the dump height when you are driving in a straight line towards the truck If possible dump with the wind behind you to keep the dust away from your eyes, air filters and fans

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Operation 3.44 Fitting pallet forks Picking up pallet forks with the quickhitch Notice!

The pallet forks are picked up and mounted on the quickhitch in the same way as the standard bucket • – see Fitting a standard bucket onto the quickhitch on page 3-70 E

Danger!

Fig. 131: Checking the lock pins

In order to avoid danger of accidents, ensure that before starting work that the attachment is safely locked onto the quickhitch by means of the lock ram!

☞ Lock pin must E be visible on either side in the bores on the attachment

Removing the pallet forks from the quickhitch Notice!

The pallet forks are removed from the quickhitch in the same way as the standard bucket • – see Removing a standard bucket from the quickhitch on page 3-72

Caution!

Fig. 132: Driving without an attachment

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In order to avoid damage to the tyres, do not move the machine with the quickhitch fully dumped out! ☞ Dump in the quickhitch and lower the telescopic boom to transport position

3-79

Operation Driving on public roads with the pallet forks Notice!

Driving on public roads with an attachment is prohibited if the distance between the front edge of the forks and the centre of the steering wheel is over 3500 mm in transport position.

• – see chapter 1 “Fields of application and using a telehandler with an attachment” on page 1-6

☞ Prepare the machine for road travel as follows: A

200 mm B Fig. 133: Transport position with pallet forks

• Remove the load off the pallet forks • Retract the telescopic boom fully and lower or raise it to transport position ➥ See red marks B on the telescopic boom and side window on the right (cab) ➥ The distance between the fork arms and the ground is about 200 mm • Cover the fork arms across their entire width with the protection A provided • If the machine is equipped with pallet forks with foldable fork arms (option), fold them backwards and secure them Get informed on and follow the legal regulations of your country.

Pallet forks transport position without load Caution!

In order to avoid damage to the tyres, do not move the machine with the pallet forks fully dumped out! ☞ Tilt in the pallet forks and lower them to transport position

Fig. 134: Moving the machine without load

3-80

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Operation 3.45 Working with the pallet forks Safety instructions regarding the use of the pallet forks

a

b

Picking up the load • Stay clear of suspended loads a!

• Do not transport persons in the attachment • The pallet forks may not be used for applications with lifting gear!

• Follow the safety instructions in the Operator's Manual of the attachment!

• Before starting work, ensure that the fork arms on the fork frame are safely locked!

Secure with locking lever against sliding sideways!

• Never use bent, cracked or otherwise damaged fork arms/pallet forks!

• Do not overload the attachment or the machine, observe the load diagram!

• Bear in mind the machine's stability and angle of inclination ➥ – see Safe load indicator for telescopic boom on page 3-62 ➥ – see Description of load diagram for pallet forks and bucket on page 3-85 • Never exceed the maximum load!

• Approach the material as closely as possible!

• Always approach the material with the machine wheels in straight-ahead position!

• Always load on firm and level ground with sufficient load-bearing capacity only!

• Never raise a load with only one fork arm!

• Move the fork arms all the way through under the pallets, as far as they will go, so that the load is picked up the nearest possible to the fork frame!

• Move under the load with the straight fork arms as far apart as possible and at an equal distance from the left and right side of the load b!

126801d0.ai

Fig. 135: Loading the pallet forks

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3-81

Operation Transporting load • Pay attention to the front and rear angle of inclination and to the lateral angle of inclination – see Description of load diagram for pallet forks and bucket on page 3-85!

• Always tilt in the attachment a little (towards the machine) for transport!

• Always transport the load close to the ground!

• Maintain a distance of a minimum 6 m between the telescopic boom/load and overhead lines!

• Never operate the telescopic boom and the attachments at higher machine speed!

• Never leave the machine with the load raised!

• Secure the 3rd control circuit on the machine – see Operating and securing the 3rd control circuit on page 3-68!

• Do not lower the extended telescopic boom from a high fork arm position – always retract the telescopic boom first!

• When driving or working across a slope, the load must be on the uphill side of the machine/attachment. Drive the machine backwards on sloping terrain to prevent the load from falling off and the machine from tilting forwards when braking • When transporting large bulk loads drive the machine backwards for improved visibility • Pay attention to the load-bearing capacity of bridges, basement ceilings, vaults etc., before moving the machine on them!

• Bear in mind the clearances of underpasses, tunnels, gates etc. before driving through or under them!

Setting down loads • Loads must only be set down on a suitable base with sufficient stability and loadbearing capacity • Do not stack or set down in higher places loads which are not properly packaged or which have shifted, or load units with damaged pallets/stacking containers • Set down loads only in places where they will stand safely without tilting, falling down or sliding! Affix appropriate marks to loads which have been set down, especially in the area of public and private traffic!

• Pay attention to the load-bearing capacity of the set-down area (e.g. truck platforms, storage area in high-bay warehouses etc.)

• Load the loading area of vehicles or trailers evenly and distribute the load evenly on the axles • Stack loads only up to the authorised maximum pallet height • Do not set down loads too near to slopes, construction pits etc.

• Do not set down loads in transit or escape routes, and not in front of safety facilities or works equipment which must be accessible at any time

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Operation Brief instructions for fork arms The following brief instructions are based on the “Guidelines for testing and repairing fork arms” (© by VETTER Umformtechnik GmbH): • Use fork arms only according to their designated use • Do not exceed the load centre and the load-bearing capacity • Always keep fork arms clean • Load both fork arms evenly • Do not use standard fork arms as reverse forks • Do not push, pull or shove the fork arms, or move them in at a slanting angle (danger of damaging them due to lateral forces) • Do not pull off loads, or allow them to fall onto the fork arms • Tie down loads, if necessary, to avoid loosing them • Do not raise with the tilt ram (tilt device) • Bear in mind the limits of application for the fork lift, and its Operator's Manuals • Carry out frequent visual checks • Have regular checks carried out according to the Operator's Manual and the legal regulations of your country • Do not modify the fork arms, or attach any additional device • Only the manufacturer is authorised to carry out repair work on the fork arms • No transport of persons on the fork arms • No transport of molten material • Working on overhead lines is not allowed • Observe the legal regulations of your country when driving on public roads • The operator/driver must check at regular intervals: • Lock: functional check • Hooks: visual check for cracks and deformations • Bend: visual check for indents, nicks and cracks • Bend and blade: do not use any longer if worn over 10 % • Blade and tip: check for deformations • In case of damage or if you are unsure: immediately stop using the fork arms!

Pallet forks payload The payload depends on how the telehandler is equipped!

Pallet forks payloads are described in chapter “Specifications” • – see chapter 6 “Payload: load diagram model 401-03 (without counterweight)” on page 6-14 • – see chapter 6 “Payload: load diagram model 401-03 (with counterweight 2 x 150 kg)” on page 6-15 • – see chapter 6 “Payload: load diagram model 402-03 (with counterweight 2 x 150 kg)” on page 6-16 • – see chapter 6 “Payload: load diagram model 402-03 (with counterweight 2 x 300 kg)” on page 6-17 • – see chapter 6 “Payload: model 403-03 load diagram” on page 6-18

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3-83

Operation Adjusting the fork arms of the pallet forks Danger!

In order to prevent the fork arms from slipping or sliding sideways, the safety pins of the fork arms must be safely locked in the notches on the fork frame.

☞ Check that the locking levers a on the fork arms are folded down and safely engaged in the fork frame!

126801f0.ai

Fig. 136: Fork arms position

☞ Adjust the fork arms as follows: • Set the locking lever to the vertical position a ➥ The fork arms can be moved on the fork frame • Slide the fork arms to the required distance until the safety pin engages in a slot on the fork frame • Fold down locking lever again, position b ➥ The upper edge of the locking lever must be flush with the edge c. ➥ Also refer to the Operator's Manual of the pallet forks

a

b c

126801e0.ai

Fig. 137: Locking the fork arms

3-84

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Operation Description of load diagram for pallet forks and bucket

1

2

The load diagrams shown on the label are authorised only for applications with the released buckets and pallet forks – see chapter 1 “Authorised attachments” on page 1-6!

Danger!

In order to avoid danger of tipping over with the telehandler, ensure the machine's stability when picking up loads!

The weight of the attachment (e.g. pallet forks) and the load must not exceed the specified payload range!

☞ Pay attention to telescopic boom extension and to the indications on

the load diagram (A, B, C, D) ☞ Pay attention to the (front and rear) angle of inclination 1 and to the lateral angle of inclination 2 ☞ Bear in mind the safe load indicator (see page 3-62)

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3-85

Operation Picking up material with the pallet forks Danger!

In order to avoid danger of tipping over and of accidents when working with the pallet forks, always observe the safe load indicator and the load diagram when working with the pallet forks!

☞ Adapt your drive speed and loads to the terrain. ☞ Read the maximum authorised loads off the load diagram ☞ Bear in mind the safe load indicator ☞ In case of an alarm: retract and lower the telescopic boom

Notice!

Switch off the load stabiliser during pallet forks operation!

• The telescopic boom yields easily with the load stabiliser switched on, making it difficult to carry out any precise lifting movements.

• Increase the tyre pressure by 0.5 bar

☞ Proceed as follows: • Stop the telehandler immediately in front of the material • Set the fork arms parallel to the ground • Check the distance of the fork arms to the centre line (dashed line) ➥ The fork arms must be at the same distance from the centre line and as far apart as possible

Fig. 138: Position of tines to material

• Adjust the height of the fork arms so that the pallet can be correctly loaded • Move carefully forwards until the fork frame is in contact with the material • Ensure that the pallet is safely loaded on the fork arms Fig. 139: Picking up the load

2.

4.

1.

3.

Fig. 140: Raising the telescopic boom

• Raise the telescopic boom slightly (3), making sure that the preset limits of the load diagram and the safe load indicator are not exceeded!

• In case of doubt or danger, lower the load immediately!

• Tilt the fork frame backwards a little (1) • Retract the telescopic boom completely (2) • Ensure that the area behind the telehandler is clear • Reverse carefully (4) until the telescopic boom can be lowered to transport position • Transport the material in transport position only

➥ (about 200 mm above the ground)

Fig. 141: Transport position – pallet forks

3-86

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Operation Transporting loads with the pallet forks Danger!

When transporting material with a raised and extended telescopic boom, with a raised fork frame tilted too much to the rear (this also applies to all other attachments) and in strong wind and in conditions of poor visibility, there is danger of tipping over!

☞ Transport material only with the telescopic boom lowered ☞ Align the fork frame with the material parallel to the surface where you want to set down the material ☞ Avoid high storage positions for material which should not be exposed to wind ☞ Ensure good visibility of the material you want to pick up and of the work and travel range

3.

2.

1.

☞ Proceed as follows:

4.

Fig. 142: Setting down the material

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5.

• Approach the storage position ensuring the material is in the middle of the stack • Raise the telescopic boom (1) • Extend the telescopic boom (2) carefully until the load is positioned precisely above the stack • Adjust the inclination of the fork arms (3) • Lower the telescopic boom slowly (4), making sure that the preset limits of the load diagram and the safe load indicator are not exceeded! In case of doubt or danger, stop stacking immediately! ☞ Ensure that the fork arms are no longer under load: • Ensure that the area behind the machine is clear • Carefully reverse from the stack (5) until the telescopic boom can be lowered to the transport position • Tilt the fork frame backwards

3-87

Operation 3.46 “Hose burst valve” safety feature Emergency lowering of the telescopic boom with the hose burst valve The hose burst valve prevents the telescopic boom from being lowered or dumped out without being braked, in the event of a bursting hose or pipe!

Notice!

Switching on the load stabiliser automatically switches off the hose burst valve!

• Switch off the load stabiliser to ensure that the the hose burst valve works correctly – see Telescopic boom load stabiliser on page 3-51.

☞ Preparing emergency lowering:

C

118 98

D AUTO

OFF

Fig. 143: Hose burst valve emergency lowering

• Ensure that no-one is dangerously close to the machine • Apply the parking brake • Switch on ignition If the telescopic boom is still extended: • Press switch 98 and at the same time, press potentiometer scroll wheel 118 on control lever backwards and hold • Fully retract the telescopic boom with auxiliary means (pulley block) ☞ Lowering the telescopic boom • Press and hold switch 98 and at the same time, slowly push the control lever forwards C until the telescopic boom is lowered to transport position ☞ Raising the telescopic boom • Press switch 98, and pull and hold control lever backwards D • Raise the telescopic boom to transport position with lifting gear (crane) • Release switch 98 and control lever ☞ Secure the machine after emergency lowering • Switch off ignition and remove the ignition key • Lock the cab • Secure the environment of the machine and attachment • Have a burst hose or pipe, and the hose burst valve immediately repaired by an authorised workshop and trained staff

Environment!

Use a suitable container to collect the hydraulic oil as it drains and dispose of it in an environmentally friendly manner. Always contact the relevant authorities or commercial establishments in charge of oil disposal before disposing of biodegradable oil.

3-88

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Operation 3.47 Continuous operation of 3rd control circuit (option) Switching continuous operation of 3rd control circuit ON/OFF D

S

S

56 A

Quick couplers D of the 3rd control circuit can also be used for continuous operation of attachments with hydraulic motors (e.g. rotary brooms) or of attachments with their own hydraulic circuits and control valves.

After an attachment has been fitted and safely locked onto the quickhitch, continuous operation is carried out by means of switches 95 and 90 (switch console on the left) as follows: ☞ Switching on continuous operation • Slide switch 95 (lock S) in the direction of the arrow and press it to position B ➥ 3rd control circuit switched ON ➥ Indicator light 56 on the indicating instrument comes on • Slide switch 90 (lock S) in the direction of the arrow and press it to position B ➥ 3rd control circuit is in continuous operation ☞ Switching off continuous operation • Slide switch 90 (lock S) in the direction of the arrow and press it to position A ➥ Continuous operation of the 3rd control circuit is switched OFF

B 95

90

Fig. 144: Continuous operation of 3rd control circuit

3.48 Tilt ram lock (option) Switching the tilt ram lock ON and OFF

82

Fig. 145: Operation of key-operated switch

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This option is used for securing the tilt ram if it must not be operated (e.g. when setting down material on high piles).

Key-operated switch 82 for operating this option is located on the switch console on the right. ☞ Switching on the tilt ram lock • With the telescopic boom in transport position, set the tilt ram and the material to the required position • Turn the key-operated switch 82 to the symbol ➥ The tilt ram is locked and can no longer be moved in the position to which it has been adjusted • Setting down the material ☞ Switching off the tilt ram lock • Turn the key-operated switch 82 to the symbol ➥ The tilt ram is unlocked and can be operated again

3-89

Operation 3.49 Electric changeover valve for operation of 3rd control circuit as additional front control circuit (option) Switching the additional control circuit ON or OFF Quick couplers V for operation of hydraulic front attachments with additional hydraulic functions.

Functions enabled with scroll wheel 118 on the control lever can be carried out without changing over hydraulic hoses.

The additional control circuit is switched on with switch 95 or, depending on machine options, with switch 94 (switch console on the left) or tip switch 117 (option) on the control lever.

V

Caution!

Clean the quick couplers carefully before connecting an attachment in order to ensure proper function and sealing features!

☞ Switching on the additional control circuit

56 118 A 117

B 94

Joyst ic.iso

Fig. 146: Hydraulic connections

S

95

• Slide switch 95 (lock S) in the direction of the arrow and press it to position B ➥ 3rd control circuit switched ON ➥ Indicator light 56 on the indicating instrument comes on • Depending on machine options: press switch 94 to position B or tip switch 117 (option) on the control lever • The attachment can be operated with scroll wheel 118 on the control lever ☞ Switching OFF the additional control circuit • Depending on machine options: press switch 94 to position B or tip switch 117 on the control lever ➥ Additional control circuit switched OFF ➥ Indicator light in switch goes out

Notice!

See the Operator's Manuals of the attachment manufacturers for installing and operating the attachments!

3-90

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Operation 3.50 Front/rear hydraulic additional control circuit (option) Important notice on the additional control circuit The additional control circuit is put into operation via switch 91 (switch console on left) and switch 110 (switch console on the right).

The quantity of oil (litres) is continuously set with potentiometer 114 (rotary switch on the switch console on the right).

Caution!

Clean the quick couplers carefully before connecting an attachment in order to ensure proper function and sealing features!

Notice!

The quick couplers can be released, however they cannot be re-attached because the pressure in the hydraulic lines has not been released.

• Release the pressure in the system and the pressure lines when mounting or removing an attachment

Quick couplers of additional control circuit (overview) Quick couplers are mounted at the rear of the machine and/or on the outside of the telescopic boom for operating hydraulic attachments with additional hydraulic functions Quick couplers on rear frame: overview • 2 quick couplers HZ (1 x pressure, switchable, 1 x return via hydraulic filter) • 1 quick coupler HR (leak oil line direct to the tank) Overview of quick couplers on upper side of telescopic boom • Quick couplers VS (pressure, switchable) • Quick couplers VZ (return via hydraulic filter) • Quick couplers VR (leak oil line direct to the tank)

HR

HZ

Notice!

VR

VS

The rear HR and front VR quick couplers are used for attachments with an unpressurised return (leak oil)!

VZ

Fig. 147: Additional control circuit: overview

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3-91

Operation Connecting an attachment onto the additional control circuit ☞ Connect an attachment as follows:

S A

AUTO

OFF

B 98

91 110

B

Caution!

114 A Fig. 148: Operation of additional control circuit

3-92

• Lower the telescopic boom and apply the parking brake • Stop the engine, but do not switch off ignition • Slide lock S on switch 91 in the direction of the arrow and press the switch to position B • Release lock S • Press and hold tip switch 98 and at the same time, press and hold switch 110 in either position about 8 seconds ➥ Pressure in hydraulic lines is released • Switch off ignition and remove the ignition key • Connect the attachment to the quick couplers as required, either at the rear of the frame or to those on the telescopic boom, see Fig. 147

No operation of attachments at the front and rear quick couplers at the same time! ☞ Uncouple the attachment if it is not used • See the Operator's Manuals of the attachment manufacturers for installing and operating the attachments!

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Operation Operation of additional control circuit ☞ Switching the additional control circuit ON/OFF after connecting an attachment A

S

B

91

A

110

B B

• Apply the parking brake • Start the diesel engine • Slide lock S on switch 91 in the direction of the arrow and press the switch to position B • Release lock S • Press switch 110 to position A or B (control circuit selection) • Adjust the oil quantity with potentiometer 114 (rotary switch in the switch console on the right) ➥ A => less oil ➥ B => more oil ➥ The HZ and VS quick couplers are pressurised

Notice!

114

If switches 91 and/or 110 are still switched on when starting the diesel engine, the additional control circuit is automatically locked for reasons of safety. Furthermore, the setting of the oil quantity is automatically reset to minimum when restarting.

Proceed as follows: • Switch off switches 91 and 110 and switch them on again (see above) • Turn back potentiometer 114 (rotary switch) to minimum A and then reset the required quantity of oil • Before stopping the engine, turn back potentiometer 114 (rotary switch) to minimum A and switch off switch 91 • If switch 91 is unintentionally switched off and on during operation, the quantity of oil previously adjusted remains unchanged.

A

HZ

VS

VZ

Fig. 149: Operation of additional control circuit

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3-93

Operation 3.51 Automatic bucket repositioning (option) Switching on the automatic bucket repositioning The bucket repositioning function can be used for carrying out cyclical work (e.g. loading trucks) efficiently and with minimum impact to the material: by pressing a button, the attachment is automatically positioned from the dump-out position to the preset work position (e.g. leading edge of bucket aligned parallel to the ground). ☞ Program the required base position as follows: • Set the bucket to the base position (see figure) • Press tip switch 117 (control lever) and switch 98 (switch console on the left) at the same time for about 10 seconds, and then release them ➥ The base position is programmed • After loading a truck, for instance, press tip switch 117 briefly on the control lever ➥ The bucket is automatically tilted in to the preset base position • Pick up the load

117 98 AUTO

OFF

Joystic. iso

Fig. 150: Operation of bucket repositioning

3.52 Tipping trailer connection (option) Tipping trailer connection (overview and operation)

A

S

B

91

S

108

109

A B

K

Notice!

Only tipping trailers with single-action tilt ram can be operated with this option.

Tipping trailer connection K is operated via switch 91 (on the switch console on the left) and via switch 108 (only with optional Autohitch trailer coupling) and tip switch 109 (both on the switch console on the right). ☞ Connect the flexible line and operate the tipping trailer feature as follows: • Clean the quick coupler • Connect the flexible line of the hydraulic tipping trailer feature to quick coupler K ☞ Switch off the additional control circuit. To do this: • Slide switch 91 (lock S) in the direction of the arrow and press it to position A ☞ If the machine is equipped with an Autohitch trailer coupling: • Slide switch 108 (lock S) in the direction of the arrow and press it to position B • Press tip switch 109 to position A or B ➥ A= raise tipping trailer feature ➥ B = lower tipping trailer feature

Fig. 151: Operation of tipping trailer feature (option)

3-94

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Operation 3.53 Operation of the Autohitch trailer coupling (option) Notice on the Autohitch trailer coupling The Autohitch trailer coupling H allows you to hitch a trailer onto the telehandler while remaining seated.

The Autohitch trailer coupling is operated via switch 88 (switch console on the left) and switch 109 (switch console on the right).

Notice!

Autohitch trailer couplings with EC acceptance are certified for use on public roads in Germany (StVZO German road traffic regulations).

Please refer to the General Certification for Vehicles or to the data confirmation (Germany) for information on the attachments and the specific requirements.

Get informed on and follow the legal regulations of your country. ☞ Gross trailer weight rating: – see chapter 6 “Trailer couplings: trailer weight/ drawbar load” on page 6-13

Unlocking and opening the Autohitch trailer coupling ☞ Unlocking the towing gear AU TO

97

OFF

B 108 109

A B

• Press tip switch 97 to position B and at the same time, press switch 109 in the direction of the arrow A ➥ Towing gear H moves upwards to the final position (arrow G) and automatically unlocks the safety lock ☞ Opening the towing gear • Slide the lock on tip switch 108 downwards and press the tip switch to position B • Release the lock • Press and hold tip switch 97 in position B and at the same time, press switch 109 in the direction of the arrow B ➥ Towing gear H moves downwards (arrow O)

Notice!

Open and close the trailer coupling when the diesel engine is running at low speed (up to about a max. 1500 rpm)!

Note: Too much oil flows at higher engine speed causing the pressure relief valve to respond, and the locking/unlocking functions to be carried out more slowly, and not faster. This in turn results in a higher energy consumption!

H G

O

Fig. 152: Opening the Autohitch trailer coupling

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3-95

Operation Locking the Autohitch trailer coupling AU TO

97

Danger!

OFF

If the trailer is not coupled correctly, there is an extreme danger of accidents!

B 108 109

A B

• • • • •

Check the proper function of the safety lock once a day Do not exceed the load values for the Autohitch coupling (see type label) Adjust the rearview mirror correctly to ensure visibility to the rear Remove dirt from the towing pin After you have coupled the trailer onto the telehandler, check whether the towing gear is safely locked

☞ Coupling the trailer onto the trailer coupling

H G

Fig. 153: Locking the Autohitch trailer coupling

3-96

O

• Use the mirror to carefully approach to the trailer until the towing pin appears below the eyelet of the trailer drawbar • Slide the lock on tip switch 108 downwards and press the tip switch to position B • Release the lock • Press and hold tip switch 97 in position B and at the same time, press and hold switch 109 in the direction of the arrow A until the towing gear audibly encounters resistance (arrow G) ➥ Check whether the trailer is safely locked ☞ Uncoupling the trailer from the trailer coupling • Prevent the trailer rolling away (parking brake, wheel chocks) • Press and hold tip switch 97 in position A and at the same time, press and hold switch 109 in the direction of the arrow A until the towing gear audibly encounters resistance (arrow G) • Check whether the trailer is safely locked ➥ – see Opening the towing gear on page 3-95

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Operation 3.54 Automatic trailer coupling (option) Notice on using the trailer coupling The automatic trailer coupling is used for tractor vehicles according to German road traffic regulations. Get informed on the legal regulations of your country for operating this coupling!

• Follow the regulations of the employer's liability insurance associations of your country when coupling or uncoupling a trailer.

• The attachments (trailer) and the trailer coupling use are listed in the General Certification for Vehicles (Germany) or the data confirmation (Germany) • Bear in mind the trailer and drawbar loads – see chapter 6 “Trailer couplings: trailer weight/drawbar load” on page 6-13 • Have a damaged or defective trailer coupling immediately repaired or replaced by an authorised workshop

Attaching a trailer Danger!

In order to avoid danger of accidents, always check that the lock pin is correctly and safely coupled ino the lower bore of the coupling jaw!

☞ Keep your hands clear of the coupling jaw when checking (danger of crushing!)

☞ Check the trailer coupling for damage ➥ Have a damaged or defective trailer coupling immediately repaired or

A

replaced by an authorised workshop

☞ Coupling the trailer onto the tractor

A

B

Fig. 154: Trailer coupling (option)

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• • • •

Press lever A upwards until it locks into place Check whether the coupling jaw is locked Set the height of the trailer drawbar to the middle of the coupling jaw Reverse the tractor vehicle slowly until the trailer drawbar engages in the coupling jaw with an audible click ➥ The trailer is locked in the coupling jaw as the drawbar touches release trigger B • Stop the engine • Apply the parking brake • Visually check the locking condition • Make the electric and hydraulic connections from the trailer to the tractor vehicle • Release the trailer brake ➥ Refer to the Operator's Manual of the trailer ☞ Closing the coupling by hand (e.g. for a tow cable) • Carefully pull the pommel of lever A downwards in closing direction by hand

3-97

Operation Uncoupling the trailer ☞ Uncoupling the trailer from the trailer coupling

A

Fig. 155 : Uncoupling the trailer coupling

• • • • • • •

Park the machine and the trailer on level ground Stop the engine Apply the parking brake Switch off ignition and remove the ignition key Secure the trailer with wheel chocks Apply the trailer parking brake Disconnect the electric and hydraulic connections from the tractor vehicle to the trailer • Close the quick couplers on the machine and the trailer with the protective caps provided • Uncouple the trailer. To do this: carefully pull the pommel of lever A of the trailer coupling upwards until the lever locks into place

Notice!

In order to avoid dirt accumulation in the trailer coupling eyelets, close them again after having uncoupled the trailer!

• Press the pommel of lever A of the trailer coupling downwards until the lever locks into place

3-98

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Operation 3.55 Compressed-air brake system (option) Important safety instructions regarding the compressed-air braking system • With a trailer coupled, only move off if the compressed-air pressure gauge in the cab shows a pressure of 5.0 bar • When driving without a trailer, the covers of the coupling heads on the tractor vehicle must be closed • The coupling heads on the trailer must be closed as well, or inserted in the dummy coupling heads • Before attaching the trailer, ensure that the sealing rings of the coupling heads are clean and that they are not damaged • Coupling head colours ➥ Single-circuit brake system C = black ➥ Dual-circuit brake system A = red (tank), B = yellow (brake) • Before moving off, set the lever of the trailer brake-power controller to the position corresponding to the load (empty, half empty, full) • Trailers allowed to drive over 25 kph must undergo specific inspections as required by German road traffic regulations.

Get informed on and follow the legal regulations of your country!

• Do not exceed the maximum gross weight rating of the trailer • The maximum drive speed of the tractor/trailer combination is always the maximum speed of the slowest trailer • Check the drive belt on the compressed-air compressor at regular intervals for correct tension and damage • Have repair and adjustment work on the brake system carried out by an authorised workshop only

Coupling and uncoupling compressed-air hoses B

A

Danger!

Follow the correct order for uncoupling the pressure hoses under all circumstances to prevent the trailer rolling away!

C Fig. 156: Compressed-air brake couplings (option)

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Dual-circuit brake system ☞ Coupling: • First couple the pressure hose onto the yellow coupling head B, then the pressure hose onto the red coupling head A ☞ Uncoupling: • First uncouple the pressure hose from the red coupling head A (tank), then the pressure hose from the yellow coupling head B (brake) Single-circuit brake system Couple the pressure hose to the black coupling head C

3-99

Operation Compressed-air gauge Danger!

Before moving off with a trailer, pressure gauge 96 must show a system pressure of at least 5 bar. Danger of accidents if the system pressure is below 5 bar!

96

☞ Let the diesel engine run at machine standstill until the compressed-air brake system is filled

Fig. 157: Compressed-air brake gauge (option)

➥ Specified value: 6 – 8 bar ➥ Carry out a brake test If the air pressure drops below 5 bar when driving ☞ Stop the machine immediately and have the pressure loss repaired

➥ – see chapter 5 “Maintenance: compressed-air brake system (option)” on page 5-31

3.56 Hydraulic trailer brake (option) Notice on using the hydraulic trailer brake • Quick coupler A for the hydraulic trailer brake is mounted at the rear of the machine (on the right in driving direction).

• The hydraulic trailer brake is operated with the machine's service brake!

• Caution! Only trailers with hydraulic brakes may be used that are certified for a braking pressure of a maximum 150 bar at full braking!

A Fig. 158: Hydraulic trailer brake connection

Notice!

The hydraulic trailer brake is certified for public roads in Germany (StVZO German road traffic regulations) provided it is adapted to the tractor!

• Refer to the General Certification for Vehicles (Germany), the data confirmation (Germany) or the licence certificate (Germany) for the applicable provisions!

Get informed on and follow the legal regulations of your country, or have country-specific final acceptance carried out!

Caution!

Clean the quick coupler carefully before connecting the flexible line of the trailer in order to maintain proper function and sealing features!

• Inspection and maintenance work on the hydraulic brake may be carried out only by trained staff or an authorised workshop

3-100

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Operation 3.57 Fitting attachments other than Kramer onto the quickhitch (option) Quickhitches for attachments from other manufacturers The following quickhitches can be purchased from your dealer • Quickhitch for Volvo attachments • Quickhitch for TBV attachments • Quickhitch for MANITOU attachments • Quickhitch for MATBRO attachments • Quickhitch for Sanderson attachments • Quickhitch for JCB Q-fit attachments

Notice!

The attachments listed in chapter 1 ““Fields of application and using a telehandler with an attachment” on page 1-6”, cannot be fitted to the quickhitches listed above!

Important notice on fitting attachments from other manufacturers • An EC declaration of conformity and a stability test according to DIN EN 474 must be carried out and load diagram drawn for attachments used with the quickhitches indicated above. ➥ For more information – see Example: inspection plan for attachments other than Kramer on page 3-103 • Follow the safety regulations of your country regarding accident prevention during operation of machines and attachments.

• In Germany, all machine operators are required to have all machines and equipment inspected regularly by a qualified person.

• Inspections and necessary re-examinations of defects that have been detected must be documented in written form.

• The competent inspection authority may require the inspection report to be available at the place where the machine is used.

• Bear in mind that all work equipment is inspected, i.e. not only the machine but also all technical auxiliary means, tools and attachments. ➥ Work equipment is defined as all tools, attachments, machines or systems Get informed on and follow the legal regulations of your country.

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3-101

Operation Fitting attachments from other manufacturers The hydraulic hoses are fitted and connected on the quickhitch in the same way as the standard bucket or pallet forks! ➥ – see Equipping the machine with a standard bucket on page 3-69 ➥ – see Fitting pallet forks on page 3-79

Caution!

Important! In order to ensure machine stability, the dimensions (length/width), the material density and the loads of these attachments from other manufacturers must correspond to the attachments listed in Chapter 1 ““Fields of application and using a telehandler with an attachment” on page 1-6”!

Notice!

Stability must be calculated by authorised staff or an authorised workshop!

• Pallet forks = safety factor = S 1.25/S 1.67 Max. moment = (FL x XL) + 362.0 daN x (372.9 mm + X) FL, XL, X indicated in load diagram (See load diagram affixed on side window in cab) • Buckets = safety factor = S 2.0 • Depending on the legal regulations of your country, a separate certification for vehicles issued by the specific authorities may be necessary if the dimensions (length/width), material density and loads of the attachments are not in compliance with the requirements • Also refer to “Example: inspection plan for attachments other than Kramer” on page 3-103 to calculate stability

Fig. 159: Attachments from other manufacturers: data

3-102

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Operation Example: inspection plan for attachments other than Kramer Machine model: Serial no.: Job no.: Stability Wheelbase [mm] Front left wheel [N] Front right wheel [N] Rear left wheel [N] Rear right wheel [N]

Attachment type: Attachment no.:

Date:

Actual value

Remarks

Checked by:

[N] Front axle =

Stability (calculated)

S=

Rear axle = Required Existing With gamma =

Specifications

Specified

Actual value

Proof of stability as per DIN EN 474

Yes Yes Remarks

No No

Dump-in angle (lower position) Dump-out angle (upper position) Distance between payload centre and centre of front axle [mm] Capacity as per type label [l] Gamma as per type label Weight of attachment [kg] Attachment functions

Remarks

Hitching the attachment onto the telehandler Mechanically OK Yes Hydraulically OK Yes Electrically OK Yes Mechanical stops OK Yes Hose routing OK Yes Nominal width of pressure line [mm] Nominal width of return line [mm] Pressures At idling speed [bar] Under full load [bar] Admissible hydraulic pressures not exceeded at nominal load of boundary states [bar]

Specified

No No No Dump out/tilt in No No 10 10 Actual value

Remarks Oil 50 °C Oil 50 °C

Other remarks:

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3-103

Operation 3.58 Mounting hydraulic attachments from other manufacturers Important notice on mounting Caution!

When fitting attachments from other manufacturers onto the quickhitches, the dimensions (length/width), the material density and the loads of these attachments must be in compliance with the legal regulations of your country or “Authorised attachments” on page 1-6! ☞ Also refer to “Fitting attachments other than Kramer onto the quickhitch (option)” on page 3-101

Notice!

Refer to the attachment's Operator's Manual for information on how to use and operate attachments from other manufacturers!

Before connecting the hydraulics of the attachment to the 3rd control circuit, ensure that the pressure on the quickhitch couplers is released!

• – see Pressure relief on the quickhitch couplers on page 3-69

Mounting an attachment from another manucturer on the quickhitch An attachment from another manufacturer is picked up and mounted on the quickhitch in the same way as the standard bucket. ➥ – see Fitting a standard bucket onto the quickhitch on page 3-70

Danger!

Before starting work, ensure that the attachment is safely locked onto the quickhitch by means of the lock ram.

☞ The lock pin must be visible on either side in the bores on the attachment

Fig. 160: Checking the lock pins

3-104

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Operation Hydraulic connections: attachments from other manufacturers on the 3rd control circuit (example) Notice!

B

A

D

C

Refer to the attachment's Operator's Manual for an exact description of the hydraulic connections.

If the attachment is placed in direct sunlight over a longer period of time, the oil in the hydraulic rams will warm up. This creates pressure making it considerably difficult to attach the hydraulic lines to the hydraulic connections.

• – see Pressure relief on the quickhitch couplers on page 3-69

Caution!

D

C

Fig. 161: Connecting the hydraulic lines to the quickhitch

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In order to avoid damage to the hydraulic system, the hydraulic connections must be clean and properly connected! ☞ Thoroughly clean the hydraulic plug-and-socket connections ☞ In order to avoid squeezing hoses and operating the hydraulic functions incorrectly, do not connect hydraulic plug-and-socket connections crosswise

☞ Proceed as follows: • Stop the engine • Apply the parking brake • Release the pressure in the hydraulic lines – see Pressure relief on the quickhitch couplers on page 3-69 • Clean the hydraulic connections on the quickhitch • Connect flexible lines A and B of the attachment onto the quick couplers of the quickhitch ➥ Flexible line A onto quick coupler C ➥ Flexible line B onto quick coupler D • Check the function of the attachment before working

3-105

Operation Removing attachments from other manufacturers from the quickhitch ☞ Proceed as follows: B

A

D

C

• • • •

Lower the attachment to the ground Stop the engine, but do not switch off ignition Apply the parking brake Release the pressure in the hydraulic lines of the 3rd control circuit ➥ – see Pressure relief on the quickhitch couplers on page 3-69 • Remove flexible lines A and B of the attachment from the quick couplers of the quickhitch, and close them with the caps provided to this effect • Start the engine and lower the attachment to the ground

Notice!

D

C

Attachments from other manufacturers are lowered in the same way as a standard bucket – see Removing a standard bucket from the quickhitch on page 3-72

Danger!

Fig. 162: Connecting the hydraulic lines to the quickhitch

3-106

In order to avoid danger of tipping over, position the attachment so that it will stand safely on the ground once it is unlocked!

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Operation 3.59 Towing the machine Safety instructions for towing away • In order to avoid danger of accidents, the towing vehicle must have enough tractive power and be fitted with a safe brake system • The machine may only be towed using suitable towing equipment (towing bar) in connection with suitable towing facilities, such as a towing coupling, hooks and eyes!

• Ensure that no-one is between the vehicles!

• The machine can be towed with a cable if the service brakes and steering are fully operational!

Getting ready for towing Variable displacement pump (drive) B

Caution!

In order to avoid damage to the variable displacement pump or variable displacement motor, open the high-pressure valves A on the variable displacement pump before towing away the machine!

A

☞ Disabling the variable displacement pump (drive) (neutral position) • • • •

Apply the parking brake Stop the diesel engine Switch off ignition and remove the ignition key Switch over both HP relief valves B on variable displacement pump A to towing. To do this: • Unscrew the HP valves B 3 – 4 turns with an allen key

Fig. 163: Disabling hydraulic pump TMP 89

Caution!

Reset the variable displacement pump to drive operation once towing the machine is over! ☞ – see Once towing is over on page 3-108

A B

Fig. 164: Disable hydraulic pump H1 P 078

1

A

Disabling (releasing) the brake discs in the front axle If the diesel engine or the hydraulic pump breaks down, the brake discs in the axle are automatically enabled (spring-loaded brake system is blocked)!

The spring-loaded brake system must be opened mechanically in order to be able to tow away the machine. ☞ Disable (release) the brake discs as follows: • Slacken lock nut A on set screw 1 (2 on either side of the axle tube) with a hexagon socket spanner (13 mm) and unscrew by about 8 mm • Evenly screw in set screws 1 (2 on either side of the axle tube) alternately until you can feel a resistance • Evenly screw in set screws 1 (2 on either side of the axle tube) alternately by a max. 1 turn against the pressure of the spring-loaded brake ➥ The brake discs are released

Fig. 165: Release the parking brake

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3-107

Operation Towing the machine B

Danger!

In order to avoid danger of accidents, the towing vehicle must have enough tractive power and be fitted with a safe brake system

☞ If the diesel engine is broken down, tow the machine only with a towing bar ➥ See chapter “Specifications” on page 6-1 for the machine's dimensions

A

and weights! ☞ Eye hooks for towing the machine – see chapter 1 “Machine outside view” on page 1-3 ☞ If possible, run the diesel engine at idling speed when towing the machine

Fig. 166: Disabling hydraulic pump TMP 89

Notice!

Steering and braking requires greater effort if the diesel engine breaks down!

• Tow away the machine from the danger area only after you have opened the high-pressure valves and the brake discs • Do not tow more than 300 m • Do not tow faster than 8 kph

A B

Fig. 167: Disable hydraulic pump H1 P 078

Once towing is over

1

Danger!

In order to avoid danger of accidents, reactivate open brake discs in the axle and the disabled variable displacement pump once towing is over!

30 mm

☞ Reactivating the variable displacement pump (drive) A Fig. 168: Releasing the parking brake for towing

3-108

• Screw in high pressure valves B by 3 – 4 turns and tighten the locknut to 85 Nm (see Fig. 166 or Fig. 167) ☞ Enabling the brake discs in the front axle • Unscrew set screws 1 (2 on either side of the axle tube) evenly and alternately until reaching 30 mm between the end of the screw head and the contact area (lock nut – axle tube) • Secure the set screw with lock nut A (2 on either side of the axle tube) ➥ Important! Do not modify the dimension of 30 mm as you secure the set screw ➥ The service brake is enabled • Once activation is over: check the service and the parking brakes for correct function

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Operation 3.60 Loading and transporting the machine on a transport vehicle Safety instructions regarding loading • The transport vehicle must be of adequate size – for the dimensions and weights of the machine to be loaded and transported, see chapter Specifications on page 6-11!

• Remove mud, snow or ice from the loading area and from the tyres of the machine to be loaded • Secure the transport vehicle against unintentional movement • When placing the machine to be loaded on the platform, ensure that the load is at the lowest possible position and that the centre of gravity of the load is in the centre line of the transport vehicle if possible (load distribution plan).

• No not exceed the gross weight rating and the gross axle weight rating of the transport vehicle • Ensure that the load does not fall short of the minimum axle load of the steering axle of the transport vehicle, otherwise the steering behaviour of the vehicle is seriously affected • Place partial loads so as to ensure an even load on all axles of the transport vehicle • Store or secure the load (machine) with suitable auxiliary means so that it cannot slip, slide, roll, tip over or fall, or cause the vehicle to tip over under usual transport conditions ➥ Usual transport conditions are conditions in the which the brakes are slammed on, evasive manoeuvres are carried out with the vehicle or in which uneven roadways are driven on ➥ Auxiliary means are e.g. anti-slip bases and linings, load-securing straps and chains, clamping beams, protective paddings, nets, edge protectors and many others • Always use the existing lashing points when using belts and chains – see chapter 1 “Machine outside view” on page 1-3.

• Use only tested ropes, belts, hooks and shackles (lockable brackets with screws or socket pins) for tying down!

• Depending on the load, adapt your drive speed to the road and traffic conditions and to the handling of the transport vehicle

Caution!

When loading and driving on ramps, the diesel engine can be damaged if the engine oil level is too low. ☞ Check the oil level of the diesel engine • The oil level must be visible at the MAX mark of the oil dipstick

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3-109

Operation Loading and tying down the machine ☞ Load as follows:

20˚ 30864brampe.eps

Fig. 169: Access ramps

• Secure the transport vehicle with chocks to prevent it from rolling • Place the access ramps at the smallest possible angle ➥ Do not exceed an angle of 20° ➥ Use access ramps with an antiskid surface only • Ensure that the loading area is clear and access to it is not obstructed – e.g. by superstructures • Ensure that the access ramps and the wheels of the machine are free of oil, grease and ice • Check the oil level of the diesel engine ➥ The oil level must be visible at the MAX mark of the oil dipstick • Start the machine • Raise the telescopic boom enough so that it will not touch the access ramps • Carefully drive the machine onto the middle of the transport vehicle • Set the drive to neutral – see Driving direction selection (reversing operation forwards/reverse) on page 3-41 • Lower the telescopic boom to the loading area • Stop the engine • Apply the parking brake – see Applying the parking brake on page 3-50 • Remove the ignition key • Do not allow anyone to stay in the cab, lock the door and the engine cover • Ensure that the overall height of the machine is not exceeded

Tying down the machine A

Fig. 170: Tying down the machine

3-110

☞ Tie down as follows: • Secure all tyres of the machine with chocks in front of, behind and at the sides of each wheel • Do not place cables, belts etc. over sharp-edged objects • Use only tested ropes, belts, hooks and shackles (lockable brackets with screws or socket pins) for tying down • Firmly tie down the machine at the eye hooks – see symbol A on the front and rear machine frame – see chapter 1 “Machine outside view” on page 1-3 – with sufficiently dimensioned belts or chains onto the platform • Before transporting the machine through heavy rain: close the outlet of the exhaust silencer with a simple cap or suitable adhesive tape • Ensure that the driver of the transport vehicle knows the overall height, width and weight (including the loaded machine) before moving off, and the legal transport regulations of the country or countries in which transport will take place!

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Operation 3.61 Crane handling the machine Safety instructions regarding crane handling In order to avoid danger of injury or accidents, bear in mind the following notices when loading the machine!

• Ensure that no-one is in the machine to be loaded!

• Seal off the danger area!

• The crane and the lifting gear must have suitable dimensions!

• Take into account the machine's overall weight – see chapter 6 “Machine weights, axle loads” on page 6-11!

• Use only tested ropes, belts, hooks and shackles (lockable brackets with screws or socket pins) for fastening!

• The slinging points on the machine are marked with symbols – see Crane handling on page 3-112!

• Have loads fastened and crane operators instructed by experienced persons only!

• The person giving the instructions to the crane operator must be within sight or sound of him!

• The crane operator must observe all movements of the load and the lifting gear! Secure the machine against unintentional movement!

• The crane operator may move a load only after making sure that the load is safely fastened and nobody is within the danger area, or after receiving a signal from the persons attaching or securing loads!

• The load must not be fastened by winding the lifting rope or lifting chain around it!

• Bear in mind the load distribution (centre of gravity) when fastening the lifting gear!

• Load the machine only with the standard bucket empty and in transport position!

• Stay clear of suspended loads • Follow the safety instructions in this Operator's Manual on page 2-1 under all circumstances!

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3-111

Operation Crane handling ☞ Handle the machine with a crane as follows: • Mount and safely lock the standard bucket – see Equipping the machine with a standard bucket on page 3-69 • Empty and dump in the standard bucket, and lower it to transport position – see Driving on public roads with a standard bucket on page 3-74 • Set the drive to neutral – see Driving direction selection (reversing operation forwards/reverse) on page 3-41 • Stop the engine and remove the ignition key • Apply the parking brake – see Applying the parking brake on page 3-50 • Lock the cab and the engine cover • Fasten the machine at the 4 slinging points (symbol A on the frame) with sufficiently dimensioned lifting gear ➥ – see chapter 1 “Machine outside view” on page 1-3 • Carefully raise the machine with the crane A Fig. 171: Label for crane handling

3-112

B

Caution!

The slinging points B on the cab are for removing the cab only and may not be used for crane-lifting the machine – see chapter 1 “Machine outside view” on page 1-3.

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Operation 3.62 Decommissioning the machine for a longer time Danger!

Machines parked on slopes can roll away.

☞ Park the machine on level and firm ground only ☞ Additionally secure the machine by placing chocks under the downhill sides of the wheels!

☞ Proceed as follows: • Lower the telescopic boom completely and set the bucket horizontally with the ground – see Operating the telescopic boom on page 3-66 • Set the drive to neutral – see Driving direction selection (reversing operation forwards/reverse) on page 3-41 • Stop the engine and remove the ignition key ➥ The drive interlock (option) is enabled

Caution!

After operation at full power: ☞ Allow the engine to run for a while so that the temperature can stabilise, then stop the engine • • • •

Apply the parking brake – see Applying the parking brake on page 3-50 Close and lock the windows and the door as you leave the cab Lock the engine cover securely Remove the key from the battery master switch – see Switching the battery master switch ON and OFF on page 3-27

Preserving the piston rods of the hydraulic rams ☞ Proceed as follows: • If possible, retract the piston rods of the hydraulic rams to protect them against damage. If this is not possible, apply grease to the piston rods and to the bare parts of the hydraulic rams that are not paint-coated • Before putting the machine into operation, do not clean the piston rods with a grease solvent or a high-pressure cleaner ➥ The scraper is not water-tight ➥ Water in the guide bushing causes corrosion and damage to the piston rod

Preserving the diesel engine • Preserving inside • Preserving outside

Notice!

Preserving work may be carried out by an authorised workshop only!

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3-113

Operation 3.63 Final decommissioning of machine Information on decommissioning If the telehandler is no longer used according to its designated use, ensure that it is decommissioned or put out of operation and disposed of according to applicable regulations.

Preparing disposal • Follow all applicable safety regulations regarding machine decommissioning!

• Ensure that the machine cannot be operated between decommissioning and disposal!

• Ensure that there is no leakage of environmentally hazardous consumables, and that the machine presents no other hazards at its storage place!

• Ensure that the telescopic boom is fully lowered and that the bucket is placed horizontally on the ground! Mount all protective devices!

• Ensure that the parking brake is used to park the machine safely and to prevent it rolling away and that the machine is secured in addition by placing chocks under the downhill sides of the wheels!

• Secure the machine against unauthorised use! Safely lock all openings (doors, windows, engine cover) of the machine!

• Repair all leaks on the diesel engine, tanks, gearbox and hydraulic system!

• Remove the battery!

• Store the machine at a location that is secured against access by unauthorised persons!

Environment!

Avoid environmental damage!

Do not allow the oil and oily wastes to get into the ground or stretches of water!

Dispose of different materials and consumables separately and in an environmentally friendly manner!

Disposal Further recycling of the machine must be made in accordance with state-of-the-art standards applicable at the time of recycling, and in compliance with the safety regulations regarding accident prevention!

• All parts must be disposed of (depending on material) at appropriate sites!

• Separate the material as you recycle parts!

• Ensure environmentally compatible disposal of consumables as well!

3-114

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Troubleshooting

Troubleshooting

4

Troubleshooting The information given in this chapter is provided for the fast and reliable detection of malfunctions.

4.1 Diesel engine malfunctions Diesel engine repairs may be carried out only by authorised workshops and trained staff.

Diesel engine malfunctions

Possible causes

Remedy

See

Parking brake not applied

• Release the parking brake

3-50

Drive lever not in neutral

• Contact an authorised workshop

3-41

Wrong SAE grade of engine lubrication oil

• Observe fuel specification when filling up

5-53

Fuel grade does not comply with specifica• Contact an authorised workshop tions Engine does not start or is not easy to start

Insufficient fuel supply

• Replace the battery with a new one

Defective or flat battery Loose or oxidised cable connections in starter circuit Defective starter, or pinion does not engage

– • Contact an authorised workshop – – • Observe fuel specification when filling up

Fuel grade does not comply with specifications Engine starts, but does not run smoothly or faultless

Engine overheats. Temperature warning system responds

Wrong valve clearance

– 5-53

• Contact an authorised workshop

Injection line leaks

– –

Defective fuel injector

• Fill up engine oil • Observe engine oil specification

–

Oil level too low

• Contact an authorised workshop

5-8

Oil level too high

• Replace air filter

5-8

Dirty air filter

• Contact an authorised workshop

5-18

Defective air filter maintenance switch or gauge

• Clean the radiator

5-17

Dirty oil/water radiator fins Defective fan, torn or loose V-belt Defective fuel injector

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– 5-37

Wrong valve clearance Defective fuel injector

5-53

5-15 • Contact an authorised workshop

5-19 –

4-1

Troubleshooting Diesel engine malfunctions

Insufficient engine output

Possible causes

Remedy

See

Oil level too high

• Observe fuel specification when filling up

5-8

Fuel grade does not comply with specifica• Replace air filter tions

5-53

Dirty air filter

5-18

Defective air filter maintenance switch or gauge

5-17

Wrong valve clearance Injection line leaks

– • Contact an authorised workshop

Defective fuel injector

–

Injection line leaks

–

Engine does not run on all cylinders Insufficient fuel supply • Fill up engine oil • Observe engine oil specification

–

Oil level too low

• Move machine out of inclination

5-8

• Contact an authorised workshop • Observe engine oil specification

–

Wrong SAE grade of engine lubrication oil

Blue

White

Oil level too high

5-7 –

Oil level too high

• Avoid too long engine idle times

5-7

Engine inclination too high

• Contact an authorised workshop

–

Engine starting temperature too low

• Move machine out of inclination

–

Fuel grade does not comply with specifica• Contact an authorised workshop tions

Dirty air filter Defective air filter maintenance switch or gauge Wrong valve clearance Defective fuel injector

4-2

5-53

• Move machine out of inclination

Defective fuel injector

Black

• Contact an authorised workshop

Engine inclination too high

Wrong valve clearance

Engine smoke

–

Defective fuel injector

Insufficient or no engine oil pressure Engine inclination too high

Engine oil consumption too high

–

• Observe fuel specification when filling up • Contact an authorised workshop • Replace air filter • Contact an authorised workshop

5-53 – – 5-17 5-17 – –

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Troubleshooting 4.2 Malfunctions in the air conditioning system (option) Only authorised workshops and trained staff may carry out repairs, and fill up and empty the air conditioning system!

Malfunctions in the air conditioning system

Possible causes Defective or loose fuse

Fan does not run

Reduced fan output

Defective fan motor

–

Short circuit in cable or in fan switch

• Contact an authorised workshop

– –

Dirty contacts

–

Size of electric lines too small

–

Flow temperature too low Defective thermostat Dirty heat exchanger fins

Loss of refrigerant on equipment

6-7 –

Heat exchanger extremely dirty

No or insufficient heating output

• Replace fuses

See page

Interrupted line

Defective fan switch Fan cannot be switched off

Remedy

• Clean the heat exchanger • Contact an authorised workshop • Clean the heat exchanger

5-36 – – 5-36

Loose hose connection

–

Damaged hose

–

Damaged heat exchanger

–

Interruption in solenoid coil of compressor

–

Loose or torn V-belt Compressor does not run

Condensor overflow Iced-up condensor Clogged condensor Loss of refrigerant

V-grooved pulley does not turn even though magnetic clutch is attracted

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–

Compressor clutch slips

–

Defective controls

–

Expansion valve is stuck in open position

–

Thermostat sensor in wrong position

–

Defective expansion valve or thermostat

–

Dirty radiator fins

• Clean the condensor

5-36

Refrigerating-agent line interrupted

–

System leak

–

Clogged fan duct Insufficient refrigerating output

• Contact an authorised workshop

• Contact an authorised workshop

–

Level of refrigerant too low

–

Humidity in system

–

4-3

Troubleshooting Malfunctions in the air conditioning system

System cools with interruptions

Possible causes

Remedy

Line interruption, insufficient ground connections or loose contacts in solenoid coil of compressor

–

Defective fan motor

–

Loose or excessively worn V-belt

–

Loose condensor bracket or inside parts • of compressor Very loud system

4-4

See page

Contact an authorised workshop

–

Excessive wear of fan motor

–

System overfill

–

Not enough refrigerant in the system

–

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Maintenance

Maintenance

5

Maintenance

5.1 Important information on maintenance work Maintenance staff Operational readiness and the service life of the telehandler are heavily dependent on maintenance.

• Daily and weekly service and maintenance work must be carried out by a specifically trained driver – see Maintenance plan (overview) on page 5-48.

• All other maintenance work that is not described in this Operator's Manual must be carried out only by the trained and qualified staff of an authorised workshop.

• The manufacturer shall not be liable for damage or personal injuries caused by failure to observe the specific manuals!

• Please contact your dealer if you require more information on maintenance work.

Notice!

Refer to the maintenance plan for the maintenance work.

• – see Maintenance plan (overview) on page 5-48 Insist on using original spare parts when carrying out maintenance and repair work.

The machine's permits, certifications, registrations, etc., may be withdrawn if machine parts/components with a prescribed condition or quality, or machine parts/components that can put persons at risk during operation, are subsequently modified or exchanged.

Important safety instructions on maintenance work • Follow all safety instructions given in this Operator's Manual • In order to avoid danger of injury, do not carry out work on a hot and running diesel engine • Follow the danger indications and safety instructions when carrying out maintenance work • Park the machine on firm and level ground and secure it to prevent it from rolling away • Stop the diesel engine and remove the ignition key • Secure the raised telescopic boom against unintentional lowering • Remove the key if the machine is equipped with the “Battery master switch” option • Follow the maintenance and safety instructions given in the Operator's Manuals of the attachments • Use a suitable container to collect oil and fuel as it drains and dispose of it in an environmentally friendly manner

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5-1

Maintenance 5.2 Safety prop for telescopic boom Mounting the safety prop The safety prop is located at the front right of the machine frame over the axle mounting.

Danger!

A

Do not carry out assembly and maintenance work if the telescopic boom is raised and not secured, otherwise there is a danger of crushing and injury!

☞ Fit safety prop A on the extended lift ram and ☞ secure it with pin B (or a screw) (see figure)

B

☞ Mount the safety prop on the lift ram as follows: • • • • • •

Park the machine on firm and level ground Empty the attachment (bucket) Tilts in the attachment Retract the telescopic boom Raise the telescopic boom Take the safety prop from its storage place ➥ Remove the safety pin in order to be able to turn pin B out of the threaded bore • Mount the safety prop over the piston rod of the extended lift ram • Lock the safety prop with pin B and secure it with the safety pin

A

Caution!

A

Mount it as shown in Fig. 172 in order to avoid damage to the piston rod and the safety prop. ☞ Opening showing downwards

B

Notice!

Fig. 172: Safety prop for telescopic boom

5-2

Before putting the machine into operation, remove the safety prop from the lift ram and fasten it in its storage place again (front right machine frame)!

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Maintenance 5.3 Fuel system General safety instructions for refuelling • • • • •

Extreme caution is essential when handling fuel – high risk of fire!

Never carry out work on the fuel system in the vicinity of naked flames or sparks!

Do not smoke when working on the fuel system or when refuelling!

Before refuelling, stop the engine and remove the ignition key!

Do not refuel in closed rooms!

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner! Keep the machine clean to reduce the risk of fire and wipe away fuel spills immediately!

Diesel fuel specification Caution!

Use only the diesel fuels listed in the table below! ☞ If other fuels are used, warranty rights shall not apply in case of diesel engine damage (guarantee)! ☞ Do not use diesel fuel with additives

Specification

Cetane number

Use (°C)

DIN 51628/DIN EN 590 (EU) ASTM D975-94 (USA)

Min. 49

Up to -44 °C outside temperature

EN 14214 (biodiesel)

Min. 51

Up to -20 °C outside temperature

Stationary fuel pumps Wrong

Right

✗

✓

Fig. 173: Refuelling from a barrel

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Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually contaminated.

Even small dirt particles cause increased engine wear and fuel system malfunctions, and reduce fuel filter effectiveness Refuelling from barrels If refuelling from barrels cannot be avoided, note the following points: • Barrels must neither be rolled nor tilted before refuelling • Protect the suction pipe opening of the barrel pump with a fine-mesh strainer • Immerse it down to a max. 15 cm above the floor of the barrel • Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter • Keep all refuelling containers clean at all times

5-3

Maintenance Refuelling Filler inlet A of the fuel tank is located on the left in driving direction, behind the cab A

Danger!

Danger of fire and suffocation! Do not refuel in closed rooms!

☞ Proceed as follows before filling up the fuel tank:

Fig. 174: Fuel filler inlet

• • • •

Lower the telescopic boom to the ground Stop the diesel engine and remove the ignition key Clean the area around the filler opening before opening the filler cap Open the filler cap and fill the fuel tank through the filling screen

Notice!

Fuel may be drained and the fuel tank may be cleaned only by an authorised workshop!

Bleeding the fuel system

1

2

Fig. 175: Bleeding the fuel system

5-4

Bleed the fuel system in the following cases: • After removing and fitting the fuel filter, prefilter or the fuel lines back on again • After running the fuel tank empty • After running the engine again, after it has been out of operation for a longer period of time ☞ Bleed the fuel system as follows: • Stop the engine • Apply the parking brake with the switch • Switch off ignition and remove the ignition key • Fill the fuel tank • Place the container under the engine • Open the engine cover • Slacken bleed screw 1 on the injection pump by a few turns • Press button 2 on the fuel prefilter with your hand (pumping movement) until the fuel comes out free of air from the slackened bleed screw • Tighten bleed screw 1 • Start the engine If the engine runs smoothly for a while, and then stops; or if it does not run smoothly: • Stop the engine • Check once again if there is any air in the fuel system • Bleed the fuel system again as described above • Have this checked by authorised staff if necessary

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Maintenance Checking/replacing the fuel prefilter (water separator) ☞ Drain the condensation water in the fuel prefilter every 50 s/h (service hours) ☞ At the latest when indicator light (Fig. 39/58) on the instrument panel comes on

Danger!

If the fuel, as it drains, comes into contact with hot engine parts or the exhaust system, there is an increased fire hazard!

☞ Never bleed the fuel system if the engine is hot!

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!

A

B Fig. 176: Checking the fuel/water separator

4 3 2 1 Fig. 177: Replacing the fuel/water separator

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Draining condensation water ☞ Proceed as follows: • Stop the engine • Apply the parking brake with the switch • Switch off ignition and remove the ignition key • Open the engine cover • Place a container to collect the fuel • Remove the cover plate • Unscrew drain plug B on sight glass A of the fuel prefilter • Drain the water until the fuel that flows out is clean • Tighten drain plug B • Test run the engine and check for leaks • Mount the cover plate Replace the fuel prefilter every 500 s/h (service hours) ☞ Proceed as follows: • Place a container to collect the fuel • Remove cable 1 from the plug on the water receptacle • Remove water receptacle 2 (arrow) • Remove filter cartridge 3 with a slight rotation • Clean filter housing 4 • Insert a new filter cartridge 3 • Clean and install water receptacle 2 • Install cable 1 on the plug of the water receptacle • Test run the engine and check for leaks • Mount the cover plate

5-5

Maintenance Replacing the fuel filter Danger!

If the fuel, as it drains, comes into contact with hot engine parts or the exhaust system, there is an increased fire hazard!

☞ Never bleed the fuel system if the engine is hot!

Environment!

A

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!

Fig. 178: Fuel filter position

☞ Proceed as follows: B A

A Fig. 179: Replacing the fuel filter

• • • • • • • • • • • • • •

Park the machine on level ground Lower the telescopic boom fully Apply the parking brake with switch Fig. 44/100 Stop the engine Switch off ignition and remove the ignition key Open the engine cover Place a suitable container underneath the engine to collect the fuel as it drains Slacken and unscrew filter cartridge A with a commercially available filter spanner Clean the inside of the filter head Apply a thin coat of fuel to rubber seal B of the new filter cartridge Tighten the new filter cartridge by hand until the gasket makes contact Tighten filter cartridge A by hand by about a further half revolution Bleed the fuel system – see Bleeding the fuel system on page 5-4 Let the engine run and check the filter cartridge for leaks

Cleaning the fuel cooler (option) Check fuel cooler A daily for dirt, and clean it if necessary ☞ Proceed as follows: • Remove the complete fuel cooler with bracket B • Blow compressed air from either side to clean the fuel cooler • Mount fuel cooler B

A

B

Fig. 180: Cleaning the fuel cooler

5-6

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Maintenance 5.4 Diesel engine lubrication system Important safety instructions for working on the lube oil system Danger!

In order to avoid danger of injury, do not carry out work on a hot and running diesel engine!

• No smoking, no naked flames!

• Caution when handling hot lube oil. Danger of burns!

• Ensure utmost cleanliness when working on the lube oil system. Carefully clean the area around the components affected!

• Follow the safety instructions and country-specific regulations when handling lube oil!

• Dispose of drained lube oil correctly. Do not allow used lube oil to seep into the ground!

• Carry out a test run every time work has been carried out!

• Check for leaks and correct lube oil pressure, and then check the lube oil level in the diesel engine!

Checking the engine oil level daily Caution!

max min

If the engine oil level is too low or if an oil change is overdue, this can cause engine damage or loss of output! ☞ Change the oil ☞ – see Maintenance plan (overview) on page 5-48 A

☞ Proceed as follows: Fig. 181: Checking the oil level

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• • • • • • •

Place the telehandler horizontally and fully lower the telescopic boom Stop the engine and remove the key Apply the parking brake Open the engine cover Pull out oil dipstick A and wipe it with a lint-free cloth Push in the oil dipstick as far as possible, pull it back out and read off the oil level However if necessary, fill up the oil at the latest when the oil reaches the MIN mark on the oil dipstick A – see Filling up engine oil on page 5-8

5-7

Maintenance Filling up engine oil OIL

A

Caution!

B

Too much or incorrect engine oil can result in engine damage! For this reason: ☞ Do not add engine oil above the MAX mark of oil dipstick A ☞ Use only the specified engine oil ☞ – see Fluids and lubricants on page 5-53

Environment!

Fig. 182: Filling up engine oil

Use a suitable container to collect the engine oil as it drains and dispose of it in an environmentally friendly manner!

☞ Proceed as follows: • • • • • • • •

5-8

Clean the area around oil filler cap B with a lint-free cloth Open filler cap B Pull out oil dipstick A and wipe it with a lint-free cloth Fill in engine oil ➥ Wait a moment until all the oil has run into the oil sump Check the oil level ➥ – see Checking the engine oil level daily on page 5-7 Fill up if necessary and check the oil level again Close filler cap B Completely remove all oil spills from the engine

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Maintenance Replacing the engine oil (every 500 service hours) 55

Danger!

Caution when draining hot engine oil Danger of burns!

☞ Wear protective gloves ☞ Use suitable tools

+80 °C

Environment!

OIL

Use a suitable container to collect the engine oil as it drains and dispose of it in an environmentally friendly manner!

Fig. 183: Optimum engine oil temperature

D

E

☞ Proceed as follows: • • • • • • • • • • •

C

Fig. 184: Oil drain plug

D E F

Fig. 185: Drain coupling with hose

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G

Park the machine on level ground Lower the telescopic boom fully Apply the parking brake Let the engine run until it reaches its operating temperature (about 70 – 80 °C) Stop the engine and remove the key Open the engine cover Remove the servicing lid (access to drain plug) Place a container (about 12 l capacity) under the opening to collect the oil as it drains Unscrew filler cap C of oil drain valve D Place the drain coupling with a sufficiently long hose F into container G Screw drain coupling E onto oil drain valve D ➥ The engine oil is drained ☞ Once the oil is completely drained • Unscrew drain coupling E from oil drain valve D • Screw cap C of the oil drain valve back on again • Replacing the engine oil filter ➥ – see Replacing the engine oil filter (every 500 service hours) on page 5-10 • Fill in engine oil and check the oil level – see Checking the engine oil level daily on page 5-7 • Start the engine and let it run briefly at low speed • Check engine oil pressure indicator light 55 • Stop the engine and wait (about 10 seconds) until all the oil has run into the oil sump • Check the oil level again • Fill up if necessary and check again • Completely remove all oil spills from the engine

5-9

Maintenance Replacing the engine oil filter (every 500 service hours) Engine oil filter H is located at the rear right in the engine vat.

It is accessed through the maintenance opening.

Danger!

A

Careful when replacing the oil filter! Hot engine oil carries a danger of burns!

☞ Wear protective gloves ☞ Use suitable tools (filter spanners, torque wrenches are commercially available)

Fig. 186: Engine oil filter position

Environment!

Collect the drained engine oil in a suitable container. Dispose of used oil and filters in an environmentally friendly manner!

☞ Proceed as follows:

55

A

B

A

Fig. 187: Replacing the engine oil filter

• • • • • • • • • • • • • • • • • • • •

5-10

Park the machine on level ground Lower the telescopic boom fully Apply the parking brake Stop the engine and remove the key Open the engine cover Remove the servicing lid (access to oil filter) Place a suitable container under the oil filter Slacken and unscrew oil filter A with a commercially available filter spanner Clean the inside of the filter head Apply a thin coat of fresh engine oil to rubber seal B of the new oil filter Tighten the oil filter by hand until the gasket makes contact Tighten the oil filter with a (commercially available) torque wrench ➥ Torque = 15 – 17 Nm Changing engine oil ➥ – see Replacing the engine oil (every 500 service hours) on page 5-9 Check the oil level and fill in engine oil if necessary Let the engine run briefly Check engine oil pressure indicator light 55 Stop the engine and check the seal on oil filter A Check the oil level and fill in engine oil if necessary Completely remove all oil spills from the engine Dispose of the used oil filter in an environmentally friendly manner

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Maintenance 5.5 Engine and hydraulics cooling system Safety instructions regarding cooling system maintenance The combined water/oil cooler is located in the engine compartment. It cools the diesel engine and the hydraulic oil of the drive and work hydraulics.

Danger!

The cooling system is hot and under high pressure! Never open the coolant tank or drain coolant if the diesel engine is hot!

☞ Wait at least 10 minutes after stopping the diesel engine, then open the

filler cap to the first notch and release the pressure – see Filling up coolant on page 5-13 ☞ Wear protective gloves and clothing

Danger!

Danger of swallowing antifreeze when handling it!

☞ Seek medical attention immediately if antifreeze has been swallowed ☞ Keep antifreeze out of reach of children

Notice on inspection and cleaning work Dirt on the radiator fins reduces the radiator's heat dissipation capacity!

To avoid this: • Clean the outside of the radiator at regular intervals. Refer to the maintenance plans for the cleaning intervals • In dusty or dirty work conditions, clean more frequently than indicated in the maintenance plans • An insufficient coolant level reduces the heat dissipation capacity as well and can lead to engine damage • Check the coolant level at regular intervals.

• If the coolant must be replace frequently, have the cooling system checked for leaks by an authorised workshop!

• Never fill in cold water/coolant if the engine is warm!

• After filling the expansion tank, make a test run with the engine and check the coolant level again after stopping the engine • Add enough antifreeze to the coolant • Use brand-name antifreeze compounds with anticorrosion additives – see Coolant compound table on page 6-12 • Do not use salt, lake, river, brackish or industrial water • Do not use radiator cleaning compounds if an antifreeze compound has been added to the coolant – otherwise this causes sludge to form that can damage the engine • Use a suitable container to collect the coolant as it drains and dispose of it in an environmentally friendly manner

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5-11

Maintenance Temperature gauge: diesel engine coolant Temperature gauge (with acoustic warning) 73 on the instrument panel monitors the cooling system.

73

Caution!

Engine operating temperature is between 80 and 105 °C (the maximum admissible cooling temperature is 110 °C). ☞ If the acoustic warning sounds (115 °C), let the engine run briefly at idling speed until the temperature drops back to 110 °C (acoustic warning no longer sounds) ☞ Stop the engine and check the coolant level, or clean the radiator fins ➥ – see Filling up coolant on page 5-13 ➥ – see Cleaning the radiator fins on page 5-15

Fig. 188: Temperature gauge

Checking the coolant level and quality Notice!

Check the coolant level every 10 s/h (service hours) or once a day.

• Check before starting the engine • Check the antifreeze at temperatures below 4 °C

Caution!

Replace the coolant every 2 years to ensure that the diesel engine is cooled correctly!

☞ Check the coolant level as follows D

C

MAX

A

B MIN

Fig. 189: Checking the coolant expansion tank

5-12

• Park the machine on level ground • Lower the telescopic boom fully • Apply the parking brake • Stop the engine • Switch off ignition and remove the ignition key • Open the engine cover • Check the coolant level in the expansion tank A If the coolant level is below the MIN mark B of the expansion tank: • Fill up coolant to the MAX mark C ☞ Check the coolant quality (antifreeze) with suitable testing equipment (antifreeze tester) – see Fluids and lubricants on page 5-53 and “Coolant compound table” on page 6-12

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Maintenance Filling up coolant Danger!

Danger of burns! The cooling system is hot and under high pressure!

Never open the coolant tank or drain coolant if the engine is hot!

☞ Wait at least 10 minutes after stopping the engine! ☞ Wear protective gloves and clothing ☞ Always actuate the safety valve first on the filler cap of the expansion tank ☞ Open the cap to the first notch and release the pressure ☞ Fill up coolant as follows: D

C

MAX

A

MIN

Fig. 190: Filling up coolant in the expansion tank

• • • • • • • • • • • •

• • • •

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Park the machine on level ground Lower the telescopic boom fully Apply the parking brake Switch off ignition and remove the ignition key Allow the engine/cooling system to cool down Release the overpressure in coolant expansion tank A. To do this: open cap D to the first notch and release the pressure Open filler cap D fully Fill up coolant to the MAX mark C Use brand-name antifreeze compounds with anticorrosion additives – see Fluids and lubricants on page 5-53 and – see chapter 6 “Coolant compound table” on page 6-12 Close filler cap D Start the engine and warm it up to operating temperature (86 – 90 °C or about 186 – 194 °F) Open the heating circuit fully – see chapter 3 “Cab heating and ventilation” on page 3-58 ➥ The thermostat must be open and the operating temperature must be reached Stop the engine and remove the key Allow the engine/cooling system to cool down Check the coolant level again and fill up coolant if necessary. Repeat the procedure until the correct coolant level is reached Check the cooling system and the heating water circuit for leaks ➥ Have leaks immediately repaired by qualified and trained staff

5-13

Maintenance Draining coolant Danger!

The cooling system is hot and under high pressure!

Never open the coolant tank or drain coolant if the engine is hot!

☞ Wait at least 10 minutes after stopping the engine! ☞ Wear protective gloves and clothing ☞ Open filler cap D to the first notch of the expansion tank and release the pressure

☞ Drain the coolant as follows: D C

A

MAX MIN

E

Fig. 191: Draining coolant

5-14

• • • • • •

Park the machine on level ground Lower the telescopic boom fully Apply the parking brake Stop the engine Switch off ignition and remove the ignition key Set the temperature controller of the heating to maximum temperature ➥ This also drains the coolant from the heating circuit – see chapter 3 “Cab heating and ventilation” on page 3-58 • Open the engine cover • Allow the engine/cooling system to cool down • Place a suitable container underneath the outlet of the radiator to collect the coolant as it drains • Release the overpressure in coolant expansion tank A. To do this: open cap D to the first notch and release the pressure • Open filler cap D fully • Open the lower screw plug on the radiator E and drain the coolant ☞ Fill up coolant as follows: • Close the outlet on radiator E with the screw plug and a new seal • Fill up coolant up to about 30 mm below filler cap D of the expansion tank ➥ Use brand-name antifreeze compounds – see Fluids and lubricants on page 5-53 and – see chapter 6 “Coolant compound table” on page 6-12 • Close filler cap D fully • Open the heating circuit fully – see chapter 3 “Cab heating and ventilation” on page 3-58 • Start and warm up the engine until the thermostat opens • Stop the engine • Check the cooling system and the heating water circuit for leaks ➥ Have leaks immediately repaired by qualified and trained staff • Check the coolant level MAX in the expansion tank • If necessary, fill in coolant and repeat the procedure until reaching the correct coolant level

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Maintenance Cleaning the radiator fins Danger!

Maintenance work on a hot engine and radiator carries a danger of burns!

☞ Wait at least 10 minutes after stopping the engine! ☞ Wear protective goggles, gloves and clothing!

Caution!

Dirt on the radiator fins reduces the radiator's heat dissipation capacity and can cause damage to the engine and the hydraulic system! ☞ Check and clean the outside of the radiator once a day ☞ Clean the radiator more frequently in dusty or dirty work conditions

☞ Clean the radiator as follows: • • • • • • • • Fig. 192: Cleaning the radiator

Park the telehandler on level ground Lower the telescopic boom fully Apply the parking brake Stop the engine and let it cool down Switch off ignition and remove the ignition key Open the engine cover Clean the radiator fins by blowing compressed air from either side of the radiator Remove dirt in the intake area of the radiator

Caution!

In order to ensure the radiator's optimal cooling capacity, do not damage the radiator fins as you clean them with a compressed-air gun!

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5-15

Maintenance Cleaning the radiator with the reversing fan (option) The telehandler can be fitted with a reversing fan.

Pressing tip switch 106 (switch console on the right on the instrument panel) reverses the fan's direction of rotation and cleans the radiator.

106 A

Notice!

B

The radiator can be cleaned at any time with the reversing fan during machine operation and only with the diesel engine running.

Caution!

A

Fig. 193: Tip switch for reversing fan

Dirt on the radiator fins reduces the radiator's heat dissipation capacity and can cause damage to the engine and the hydraulic system! ☞ Check and clean the radiator once a day. ☞ Clean the radiator more frequently in dusty or dirty work conditions ☞ Do not clean in closed premises

☞ Operate the reversing fan as follows: • Press tip switch 106 briefly to position B ➥ The fan rotates the other way round with a certain delay, ➥ The fan is in cleaning mode and dirt is removed from the radiator ➥ Check: dust is blown out A from the intake screen of the engine cover ➥ The fan automatically switches back to cooling mode after about 1 minute

Notice!

When working in especially dusty environment, clean the radiator repeatedly and more frequently!

5-16

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Maintenance 5.6 Air filter Checking air filter contamination ☞ Clean the dust valve once a day as follows: • • • • • • •

A

Stop the engine Apply the parking brake Switch off ignition and remove the ignition key Open the engine cover Squeeze the discharge slot of dust valve E Remove hardened dust by compressing the upper area of the valve Clean the discharge slot if necessary

Notice!

The machine can be fitted with a vacuum-operated preliminary separator (option). In this case, hardened dust does not need to be removed manually.

It is automatically aspirated via a flexible line in the area of the radiator.

52

H D F Fig. 194: Air filter – dust valve

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Weekly check: filter cartridge contamination Indicator light 52 on the indicating instrument monitors the filter cartridge.

If this indicator light comes on, the air filter D is very dirty and has to be replaced! ➥ At the latest after 500 service hours (however once every year) ➥ – see Replacing the filter cartridge at 500 s/h (service hours) on page 5-18

Caution!

Filter cartridges degrade prematurely when in service in acidic air for longer periods of time! ☞ Replace filter cartridge D and safety cartridge F at the latest at 500 service hours!

5-17

Maintenance Checking the dust collector (option) once a day ☞ Clean the dust collector as follows: • • • • • •

1 2

Stop the engine Apply the parking brake Fig. 44/100 Switch off ignition and remove the ignition key Remove cover 1 from the dust collector Remove and empty the dust container 2 Insert the dust container and mount the cover

Caution!

Ensure that the dust in the container is no higher than 25 mm under the cover otherwise the engine is damaged!

When working in especially dusty environment, clean repeatedly and more frequently!

Fig. 195: Air filter – dust valve

Replacing the filter cartridge at 500 s/h (service hours) Caution!

G

The filter cartridge will be damaged if it is washed or brushed out!

Bear in mind the following to avoid premature engine wear!

• Do not clean the filter cartridge • Replace the filter cartridge when the indicator light comes on • Never reuse a damaged filter cartridge • Ensure cleanliness when replacing the filter cartridge • Do not put the diesel engine into operation without a filter cartridge

H

307b0700.ai

D

☞ Replace the filter as follows:

307b0710.ai

H D F

• • • • • • • •

Stop the engine Apply the parking brake Switch off ignition and remove the ignition key Open the engine cover Fold both locks G on air filter housing H to the outside Remove lower housing section H Carefully remove filter cartridge D with slightly turning movements In addition, every 3rd time the filter is replaced, carefully remove the safety cartridge F with slightly turning movements • Ensure that all contamination (dust) inside the upper and lower housing sections has been removed • Insert a new safety cartridge F and filter cartridge D in the upper housing section • Position lower housing section H (ensure that it is properly seated) and close it with both locks G

Fig. 196: Removing the filter element

5-18

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Maintenance 5.7 V-belts Checking the V-belts Danger!

In order to avoid danger of injury, check, retighten or replace V-belts only at engine standstill!

☞ Stop the engine ☞ Switch off ignition and remove the ignition key C

☞ Check the V-belts once a day as follows (every 10 service hours) A

A B

C

C

• • • • • •

Stop the engine Switch off ignition and remove the ignition key Apply the parking brake with the switch Open the engine cover Carefully check the V-belts for damage through slots B of V-belt cover A Press with your thumb to check whether the V-belt can be deflected between the pulleys by no more than about 10 mm • Retighten the V-belts if necessary (see “Retightening the V-belts”) ➥ Have a damaged V-belt replaced by authorised staff

Caution!

Cracked and stretched V-belts can cause engine damage! ☞ Have the V-belts replaced by an authorised workshop

Fig. 197: Checking V-belt tension

Retightening the V-belts D

Fig. 198: Retightening the V-belts

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☞ Retighten a V-belt as follows: • • • • • • •

Stop the engine Apply the parking brake with the switch Switch off ignition and remove the ignition key Open the engine cover Remove V-belt cover A (see Fig. 197, screws C) Slacken fastening screws 1, 2 + 4 of alternator 5 Turn set screw 3 on the alternator in the direction of arrow D until you reach the correct V-belt tension • Firmly retighten fastening screws 1, 2 + 4 of alternator 5 • Check V-belt tension again • Mount V-belt cover A

5-19

Maintenance 5.8 Hydraulic system Specific safety instructions regarding the hydraulic system Danger!

Danger of burns! Do not carry out maintenance work on a hot diesel engine and hydraulic system!

☞ Wait at least 10 minutes after stopping the diesel engine until the hydraulic system has cooled down! ☞ Wear protective gloves and clothing during maintenance work

• Release the pressure in all lines carrying hydraulic oil prior to any maintenance and repair work. To do this: Lower all hydraulically controlled attachments to the ground, stop the engine and switch off ignition • Use the parking brake to park the machine safely and to prevent it from rolling away!

• Move all control levers of the hydraulic control valves several times • Secure the lift ram of the raised telescopic boom with a prop to prevent unintentional lowering • Wear protective clothes during maintenance work

Important notice on hydraulic oil • Contaminated hydraulic oil, lack of oil or wrong hydraulic oil carries a danger of severe damage to the hydraulic system • If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has penetrated the hydraulic system. This can cause damage to the hydraulic pump • Have the hydraulic oil changed only by an authorised workshop ☞ Observe the following instructions: • Take care to avoid contamination when working!

• Always fill up hydraulic oil in time using the filling screen!

• Only use authorised oils of the same type – see Fluids and lubricants on page 5-53 • If the hydraulic system is filled with biodegradable oil, then only use biodegradable oil of the same type for filling up – observe the sticker on the hydraulic oil tank • Have the hydraulic oil replaced by an authorised workshop only – see chapter 5 “Maintenance plan (overview)” on page 5-48

5-20

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Maintenance Monitoring the hydraulic oil and the return filter The red indicator light 51 on the indicating instrument monitors the return filter.

51

60

Caution!

61

00000

00

h

Indicator light 51 on the indicating instrument comes on if the resistance of the oil flow in the filter is too high ☞ Replace the filter element • Drain the hydraulic oil in case of increased contamination, however after 1500 s/h at the latest or once a year • Have the filter element and the hydraulic oil replaced by an authorised workshop only!

If indicator lights 60 and 61 on the instrument panel come on: • Not enough oil in the tank – check the hydraulic oil level • Dirty filter – the filter element must be replaced by an authorised workshop

Notice!

Fig. 199: Indicator light for return filter

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Indicator light 51 on the indicating instrument can come on in cold weather immediately after starting the engine. This is caused by increased oil viscosity.

In this case: • Set engine speed so that indicator light 51 on the indicating instrument goes out • Bear in mind the instructions concerning warmup – see chapter 3 “Starting the diesel engine” on page 3-30

5-21

Maintenance Checking the hydraulic oil level once a day

B A

Fig. 200: Oil level sight glass on the hydraulic oil tank

The oil level sight glass is located on the hydraulic oil tank behind the cab. ☞ Clean the hydraulic oil level as follows: • Park the telehandler on level ground • Retract all hydraulic rams • Stop the engine • Apply the parking brake • Switch off ignition and remove the ignition key • Check the hydraulic oil level in sight glass A ➥ If the oil level is visible in the lower half of the oil level sight glass, the quantity is OK ➥ If the oil level is not visible in the oil level sight glass (not enough oil), add hydraulic oil

Filling up hydraulic oil Caution!

Do not fill up the hydraulic oil unless the diesel engine is stopped!

• Hydraulic oil runs out of the filler opening on the hydraulic tank

☞ Add hydraulic oil as follows:

B A

Fig. 201: Hydraulic oil tank

• Park the telehandler on level ground • Retract all hydraulic rams • Stop the engine • Apply the parking brake • Switch off ignition and remove the ignition key • Clean the area around the filler and breather filter B with a cloth • Open breather filter B by hand With the filter insert in place: • Fill up the hydraulic oil ➥ Only use authorised oils – see Fluids and lubricants on page 5-53 • Check the hydraulic oil level on oil level sight glass A • Fill up if necessary and check again • Firmly close breather filter B by hand

Notice!

Any excess quantity of hydraulic oil in the tank escapes via the breather B as soon as the temperature rises!

The oil level is no longer visible in the upper half of the oil level sight glass A! • Drain hydraulic oil

5-22

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Maintenance Important notice regarding the use of biodegradable oil • Use only the tested and approved biodegradable hydraulic fluids – see Fluids and lubricants on page 5-53. Always contact the manufacturer for the use of other products which have not been recommended. In addition, ask the oil supplier for a written declaration of guarantee. This guarantee is applicable to damage occurring on the hydraulic components, which can be proved to be due to the hydraulic fluid • Use only biodegradable oil of the same type for filling up. In order to avoid misunderstandings, a label providing clear information is located on the hydraulic oil tank (next to the filler inlet) regarding the type of oil currently used! Replace missing labels!

The joint use of two different biodegradable oils can affect the quality of one of the oil types. Therefore, ensure that the remaining amount of initial hydraulic fluid in the hydraulic system does not exceed 8 % when changing biodegradable oil (manufacturer indications) • Do not fill up with mineral oil – the content of mineral oil should not exceed 2 % in order to avoid foaming problems and to ensure biological degradability • When running the machine with biodegradable oil, the same oil and filter replacement intervals are valid as for mineral oil – see maintenance plans in the appendix • Have the condensation water in the hydraulic oil tank drained by an authorised workshop every 500 service hours, in any case before the cold season. The water content must not exceed 0.1 % by weight • The instructions in this Operator's Manual concerning environmental protection are also valid for the use of biodegradable oil • If additional hydraulic attachments are mounted or operated, use the same type of biodegradable oil for these attachments to avoid mixtures in the hydraulic system

Notice!

Have a subsequent change from mineral oil to biodegradable oil carried out only by an authorised workshop or dealer!

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5-23

Maintenance 5.9 Checking hydraulic pressure lines Safety instructions regarding pressure line checks Danger!

Caution when checking hydraulic lines, especially when searching for leaks.

Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries.

☞ Always observe the following instructions: • Wait at least 10 minutes after stopping the diesel engine until the hydraulic system has cooled down!

• Wear protective goggles, gloves and clothing!

• Never search for leaks with your bare hands, but wear protective gloves!

• Always consult a doctor immediately, even if the wound seems insignificant – otherwise serious infections could set in!

• Retighten leaking screwed fittings and hose connections only when the system is not under pressure; i.e. release the pressure before working on pressurised lines!

• Have defective or leaking pressure lines replaced by an authorised workshop!

Notice for the entrepreneur/owner The entrepreneur/owner of the machine must ensure that flexible lines are replaced in appropriate intervals, even if no safety-relevant defects can been detected on the flexible line.

• Flexible lines must be inspected by an expert (competent person) before the first commissioning, and then at least once a year for safe working condition.

• Leakages and damaged pressure lines must be immediately repaired or replaced by an authorised workshop or after-sales staff.

• Replace hydraulic hoses every 6 years from the date of manufacture, even if they do not seem to be damaged

4 Q/10

Fig. 202: Identification of flexible line

5-24

Notice!

In this respect, we recommend that you observe all the relevant safety regulations for hydraulic lines, as well as the safety regulations regarding accident prevention and occupational health and safety in your country. Also observe DIN 20066, part 5.

The date of manufacture (month or quarter and year) is indicated on the flexible line.

Example: “4 Q/10” means manufactured in the 4th quarter of 2010.

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Maintenance 5.10 Lubrication work Preparing lubrication • Park the telehandler on level ground • Secure the telehandler with the parking brake and wheel chocks • Extend and lower the telescopic boom until all lubrication points can be accessed from the ground • Stop the diesel engine and remove the key • Remove the key from the battery master switch (option)

Notice!

Lubricate all lubrication points mentioned below with lithium-saponified brandname grease – see Fluids and lubricants on page 5-53!

Lubricating the rear axle oscillation-type bearing Notice!

A

The machine has an oscillation-type rear axle. Lubricate the oscillating bearing every 20 service hours at the latest.

• Lubrication point A (2 x) is located at the rear left of the frame.

Lubrication is connected with the axle bearing by means of flexible lines.

☞ Apply grease to grease nipple A Fig. 203: Grease nipples for oscillation-type bearing

Lubricating the planetary drive bearing (front and rear axles) ☞ Lubricate grease nipples B (2 x) on each planetary drive bearing every 20 service hours

B

Fig. 204: Grease nipples on planetary drive bearings

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5-25

Maintenance Lubrication points on the telescopic boom: overview

C

C A

A

A

A

D

B

Fig. 205: Lubrication points on telescopic boom

Description of lubrication points A = direct lubrication B = grease nipple block at the right above the rear axle (grease nipples with flexible lines) C = slide plates (plastic)

5-26

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Maintenance Lubricating the telescopic boom Danger!

In order to avoid danger of accidents, do not carry out lubrication work under a raised telescopic boom!

☞ Raise the telescopic boom until the lubrication points can be accessed normally from the ground

A

Fig. 206: Lubrication points on quickhitch

☞ Lubricate every 20 service hours as follows: • Extend and lower the telescopic boom until all lubrication points can be accessed from the ground • Dump out the quickhitch horizontally • Stop the engine • Apply the parking brake • Switch off ignition and remove the ignition key • Lubricate lubrication points A and B, or once a day in heavy-duty operation (Fig. 205/A) • Lubricate the slide plates on the inside section of the telescopic boom as required

Checking and adjusting the slide plates Slide plates are located between the inside and outside telescopic sections, and outside on the telescopic boom (Fig. 205/D).

The wear plates can be readjusted with compensating panels – but only up to a minimum thickness of 8 mm.

Replace the slide plates if they are below the minimum thickness!

Notice!

Have the slide plates readjusted or replaced by an authorised workshop only.

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5-27

Maintenance 5.11 Lubricating with the central lubrication system (option) General functional description of the central lubrication system The central lubrication system allows you to lubricate all lubrication points of the telehandler in one single step.

• The yellow LED or the green indicator light in the cab (option) comes on for 1.5 seconds upon switching on ignition to indicate functional readiness of the controls (switch-on check). It stays lit during the entire lubrication procedure.

• The integrated electronic control unit has a data memory for saving the times that have been set or that have elapsed. The time is taken and saved if ignition is switched off during lubrication or during a break. The remaining lubrication time or break time is read from the memory upon switching ignition on again, and lubrication is resumed where it was interrupted.

Time control • Break and lubrication times can be set with the time-dependent control of the central lubrication system • Break times are the periods between two lubrication times.

Notice!

A Fig. 207: Filling the central lubrication system

Pressing the tip switch A on the side of the pump starts intermediate lubrication at any given time if ignition is switched on.

• The pump then immediately starts with a lubrication cycle. The lubrication or break time that has elapsed so far or that has been saved is reset and starts over again • A lubrication system malfunction can also be reset by pressing the intermediate lubrication switch, and the pump restarts lubrication

Repair work Repair work on the central lubrication system may be carried out only by authorised workshops!

5-28

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Maintenance Setting the lubrication and break times Break time Lubrication time

S

P

L B A

Break times and lubrication times are set with the notched switches S and P in the window of the controls. ☞ Set the break times as follows: • Remove the red frame on the protective motor housing of the pump with a flat screwdriver to set the time • Slacken the four cross-slotted screws and remove the transparent cover • Set the break time P and the lubrication time S with a flat screwdriver Lubrication times (S): 1 to 16 minutes (16 notches, 1 minute each) 2 to 32 minutes (16 notches, 2 minutes each) Break time (P): 0.5 to 8 h (16 notches, 0.5 h each) Yellow LED (L) (B) lubrication system in operation (A) lubrication under progress: 0.5 seconds LED ON/0.5 seconds LED OFF • Install the transparent cover (window) once the settings are carried out

Caution!

Fig. 208: Setting the lubrication times

Close the cover watertight!

• If the cover is not closed correctly, water penetrates into the controls and damages them!

Filling the central lubrication system The lubrication system is filled via conical grease nipple 1 or a fill coupling with a manual or pneumatic grease gun.

1

Caution!

In order to avoid damage to the central lubrication system, use only commercially available greases for filling up! ☞ – see Fluids and lubricants on page 5-53

Notice!

Fig. 209: Filling the central lubrication system

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Have maintenance and repair work on the central lubrication system carried out by an authorised workshop only!

5-29

Maintenance 5.12 Maintenance of the brake system Important safety instructions regarding the brake system • Brakes are crucial to safety • Incorrect maintenance can cause brake failure • All maintenance and repair work on the brakes must be carried out by trained staff and authorised workshops.

• An exception to this is the following work which must be carried out by the driver/ operator: • Daily check of the level in the brake fluid tank ➥ The brake-fluid tank is located inside the cab to the left of the seat • Daily check of the brake lines

Danger!

Defective brake lines or hoses carry a danger of accidents!

☞ Damaged brake lines or hoses must immediately be replaced by an authorised workshop

Checking/filling up the brake fluid level Danger!

A

MAX

An incorrect brake fluid grade or an insufficient brake fluid level impairs the safety of the brake system!

MIN

☞ Check the brake fluid in the tank at regular intervals • The brake fluid must comply with the SAE specification (LHM) • – see Fluids and lubricants on page 5-53 ☞ Contact an authorised workshop immediately if the fluid level is lower than allowed ☞ The brake fluid must be replaced every 2 years by an authorised workshop

Fig. 210: Checking the brake fluid level in the tank

☞ If the fluid level is below the MAX mark: • • • • •

5-30

Clean the area around the cover Open tank cover A Fill up brake fluid up to the MAX mark Close the tank cover Check the brake system for leaks and correct function

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Maintenance 5.13 Maintenance: compressed-air brake system (option) Checking the compressed-air tank and lines ☞ Check the compressed-air brake once a day for leaks (sound of escaping air) and damage

➥ Have leaky hose and screw connections repaired by an authorised workshop

Notice!

The water in the pressure accumulator is automatically drained

Fig. 211: Water drain valve of compressed-air tank

Checking compressor attachment and drive ☞ Check as follows: • Remove V-belt cover B • Check the attachment of the compressor console once a day • Check V-belt tension C of the compressor drive once a day by pressing with your thumb ➥ You must not be able to deflect the V-belt between the pulleys by more than about 10 mm

B

C

Fig. 212: Water drain valve of compressed-air tank

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5-31

Maintenance 5.14 Tyres Daily tyre checks Danger!

In order to avoid danger of accidents, have repair work on tyres and rims carried out by an authorised workshop only!

Notice!

Regular inspections of the tyres • Improve operating safety • Increase the service life of the tyres • Reduce machine downtimes • Refer to chapter “Specifications” on page 6-11 for the authorised tyre types and the correct tyre pressures • A sticker is also affixed on the side window in the cab

☞ Check the tyres as follows: • • • •

5-32

Check tyre pressure Check tyres and rims for damage (cracks, ageing etc.) – also on the inside Remove foreign bodies from the tyre tread Remove traces of oil and grease from the tyres

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Maintenance Changing wheels Danger!

In order to avoid damage to property and danger of accidents, use only the tyres that have been released for the machine!

☞ See released Tyres for models 401-03/402-03/403-03 on page 6-11 ☞ Check the wheel nuts for tightness after every wheel or tyre change

Caution!

The threads on the wheel studs can be damaged when mounting the heavy wheels! ☞ Use suitable assembly tools, such as covering sleeves for the studs, a jack etc.

☞ Remove the wheels as follows: • Park the telehandler on level and firm ground and prevent it from rolling away – see chapter 3 “Stopping/parking the machine” on page 3-43 • Loosen the wheel nuts a little of the wheel you want to remove • Place a jack under the axle beam, making sure it is standing firmly • Raise the side of the axle from which you want to remove the wheel • Secure the machine with a suitable trestle • Check the machine is standing firmly • Completely remove the wheel nuts • Remove the wheel ☞ Mount the wheels as follows: • Place the wheel onto the wheel bolts • Tighten all wheel nuts part-way • Lower the raised axle • Tighten the wheel nuts to the prescribed tightening torque – see chapter 6 “Specific tightening torques” on page 6-13

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5-33

Maintenance 5.15 Heating and ventilation system maintenance General information on the heating system The heating system of the machine is equipped with a recirculated-air filter (inside the cab) and a fine-dust filter (outside the cab).

Clean them as required, however replace them every 500 s/h at the latest.

Depending on operation and dust conditions, and in an acidic environment it can be necessary to replace the filters more frequently.

The access to the fine-dust filter is located on the outside left of the cab.

Cleaning/replacing the fine-dust filter ☞ Clean the filter as follows: • • • •

Remove the cover Remove fine-dust filter A and check for damage Knock the filter element on a plate on either side Blow compressed air from the inside to the outside to clean the filter, or wash it with water and dry it ➥ Replace the fine-dust filter every 500 s/h (service hours) ➥ Replace or clean the filter more frequently if the machine is used in severe dust conditions • Clean the inside of the filter housing and insert the filter ➥ Ensure that it is seated properly • Install the cover

A

Fig. 213: Fresh-air fine-dust filter

Cleaning/replacing the recirculated-air filter B

C

The recirculated-air filter is located underneath the cover to the left of the seat in the cab. ☞ Clean the filter as follows: • Remove screws B • Remove the cover and recirculated-air filter C • Clean recirculated-air filter C with compressed air or water, replace it with a new one if necessary ➥ Replace the recirculated-air filter every 500 s/h (service hours) ➥ Replace or clean the filter more frequently if the machine is used in severe dust conditions • Clean the inside of the filter housing and insert the filter ➥ Ensure that it is seated properly • Install the cover

Fig. 214: Recirculated-air filter of the heating system

5-34

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Maintenance 5.16 Air conditioning (option): maintenance Safety instructions regarding the air conditioning Functional and visual checks must be carried out by the driver/user!

All maintenance and repair work may be carried out by trained staff only.

• Careful when carrying out maintenance and repair work – sharp-edged fins on the condensor and the heat exchanger • Wear protective equipment (protective gloves and goggles) during maintenance and repair work • Lines and hoses containing refrigerants and cooling fluids are under pressure and can be hot • Avoid touching parts containing refrigerants • Do not carry out maintenance work unless the heating and air conditioning systems are switched off • Bear in mind the pertinent regulations relevant to accident prevention, other generally acknowledged regulations regarding safety and occupational medicine.

Filling up the air conditioning system The air conditioning system must be checked and serviced twice a year by trained staff in an authorised workshop!

• For the first fill, see the air conditioning label inside the cab on the door

Notice!

Use only the refrigerants indicated on the label for refilling the air conditioning system (R 134a, see arrow)!

Fig. 215: Label for air conditioning refill

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5-35

Maintenance Checking the function, visual check and cleaning once a day B

Danger!

Maintenance work on a hot engine and radiator carries a danger of burns!

☞ Wait at least 10 minutes after stopping the engine! ☞ Wear protective goggles, gloves and clothing!

A

☞ The driver must carry out the following visual checks once a day • • • • • • •

D

C

C

Stop the engine Apply the parking brake Fig. 44/100 Switch off ignition and remove the ignition key Check for damage of the refrigerating and heating lines Check the hoses for tightness, leaks and chafing Check the electric connections for correct condition and tightness Check the level of the refrigerant ➥ With the system switched on, the refrigerant must be visible and free of air in sight glass B of dehumidifier A • If there is air in sight glass B, the system must be checked for leaks and refilled by an authorised workshop ☞ Clean the dirty condenser C • Open lock D • Tilt the condenser forwards ➥ Clean the condensor with compressed air or by spraying water (do not use a highpressure cleaner) • Tilt back the condenser and safely lock it D once it is clean • Check V-belt tension E and if necessary, retighten the V-belt ➥ Press with your thumb to check whether the V-belt can be deflected between the pulleys by no more than about 10 mm (arrow) ➥ Have a defective V-belt replaced by an authorised workshop

Caution!

In order to avoid damage to the air conditioning system, have it checked and serviced by trained staff in an authorised twice a year!

Dehumidifier A must be replaced every 2 years!

E

Fig. 216: Air conditioning: evaporator, dehumidifier

5-36

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Maintenance 5.17 Maintenance of the electrical system Important notice Maintenance and repair work on the electrical system (including the battery) may be carried out only by trained staff and/or authorised workshops!

Safety instructions regarding the electrical system and the battery The battery contains sulphuric acid! This acid must not be allowed to come into contact with the skin, the eyes, clothing or the machine. Therefore when recharging or working near the battery: always wear goggles and protective clothing with long sleeves!

If acid is spilt: • Thoroughly wash any part of the body touched by the acid immediately with plenty of water and seek medical attention at once • Immediately rinse acid splashes in the eyes with clear water for several minutes! Then seek medical attention at once • Immediately neutralise acid splashes on skin or clothing with an acid neutraliser or soap, and rinse with plenty of water • Immediately seek medical attention if acid has been swallowed • Thoroughly rinse all affected surfaces immediately with plenty of water Battery maintenance – danger of explosion!

• Avoid naked flames and sparks and do not smoke in the vicinity of open battery cells, otherwise gas can ignite • When charging batteries, as well as during normal operation of batteries, an oxyhydrogen mixture is formed in the battery cells • Do not attempt to jump-start the machine if the battery is frozen or if the acid level is low. The battery can rupture or explode • Disconnect the negative (-) battery terminal from the battery before starting repair work on the electrical system Jump-starting • Use only 12 V power sources. Higher voltages will damage the electric components • When connecting the battery leads, ensure that the poles +/- are not inverted, otherwise sensitive electric components will be damaged • Danger of sparking! Do not interrupt voltage-carrying circuits at the battery terminals • Never place tools or other conductive articles on the battery – danger of short circuit!

Putting the machine out of operation • Remove the battery, store it in a dry and frost-free place • If the machine is put out of operation for extended periods, charge the battery every 2 months or use a battery charge maintainer • Always charge the battery when storing it. The sulphation of the electrodes causes lasting damage! A flat battery must be recharged as soon as possible Before putting the machine into operation • Charge the battery and clean the terminals before installing it Disposal of old battery • For safe transport to a recycling point, place the protective cap on the positive terminal of the old battery and dispose of if properly

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5-37

Maintenance Checking/replacing the battery Battery A is located in the engine compartment, on the left next to the hydraulic oil tank.

It is low in maintenance and no fluid needs to be refilled under normal operating conditions.

However have the battery checked at regular intervals.

+

Danger!

When charging batteries, as well as during normal operation of batteries, an oxyhydrogen mixture is formed in the battery cells with danger of explosions or causticisation!

A

Therefore when recharging and/or working near the battery: Fig. 217: Battery

☞ Always wear goggles and protective clothing with long sleeves ☞ Open the caps of the battery openings by half a revolution before recharging the battery

☞ Always disconnect the negative terminal (-) from the battery before starting repair work on the electrical system!

☞ Replace the battery as follows: • • • •

Apply the parking brake with switch Fig. 44/101 Switch off ignition and remove the ignition key Remove the key from the battery master switch (option) Remove the battery fixture

Caution!

In order to avoid short circuits when disconnecting the battery leads, always bear in mind the order for removing the leads under all circumstances!

• Disconnecting the leads: First the small terminal at the negative pole (-), then the big terminal at the positive pole (+) • Replace the battery with a new one • Install the battery fixture • Connecting the leads: First the big terminal at the positive pole (+), then the small terminal at the negative pole (-)

5-38

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Maintenance Checks at regular intervals ☞ Daily checks before operating the machine • Is the light system OK? • Is the signalling and warning system OK? • Do the indicator lights work? ☞ Weekly checks • Electric fuses ➥ Replace defective fuses by new ones of the specified load capacity (amperage) – see chapter 6 “Fuse assignment” on page 6-7

Alternator Always observe the following instructions: • Only test run the engine with the battery connected • When connecting the battery, ensure that the poles (+/-) are not inverted • Always disconnect the battery before carrying out welding work or connecting a quick battery charger • Replace defective charge indicator lights immediately

Checking/replacing relays and fuses The fuses and relays are located on the board underneath the cover behind the seat. ☞ Check/replace fuses and switching relays as follows: • Switch off ignition and disconnect the negative lead (-) from the battery, or switch off the battery master switch (option) • Remove the trim • Remove defective fuses from the relay bracket and replace them by new ones • Check the correct function of the electrical system

Caution!

Fig. 218: Fuse board

Blown fuses indicate overloading or short circuits. Have the electrical system checked before installing new fuses! ☞ Only use fuses with the specified load capacity (amperage) – see chapter 6 “Fuse assignment” on page 6-7

☞ Checking/replacing switching relays • Switch off ignition and disconnect the negative lead (-) from the battery, or switch off the battery master switch (option) • Remove the cover • Remove defective relays from the relay bracket and replace them by new ones ➥ Relay descriptions and output indications – see chapter 6 “Switching relay assignment” on page 6-10 • Install the cover • Check the correct function of the electrical system

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5-39

Maintenance Main fuse box with switching relays K7

F 40

K6

K5

F 39

K7 F40

F39

Fig. 219: Main fuse box (88 kW engine)

K5

K42

K7

F40 F39

The main fuse box is installed on the rear wall in the engine compartment Overview: main fuse box with switching relays (88 kW diesel engine) • Main fuses F40 • Ignition lock and preheating fuse F39 • The high current relay K5 for preheating, the high current relay K7 for starting and the time lag relay K6 for preheating are located below the main fuse box.

Overview: main fuse box with switching relays (103 kW diesel engine) • Main fuses F40 • Ignition lock and preheating fuse F39 • Engine control unit fuse F41 • The high current relay K5 for preheating, the high current relay K7 for starting and the switching relay K42 for the engine electronics are located below the main fuse box. ☞ Check/replace fuses/relays as follows: • Switch off ignition and disconnect the negative lead (-) from the battery, or switch off the battery master switch (option) • Remove the fuse box cover • Remove defective fuses from the relay bracket and replace them by new ones ➥ Main fuse and relay descriptions and output indications – see chapter 6 “Main fuse box with relays (88 kW diesel engine)” on page 6-9 • Install the fuse box cover • Check the correct function of the electrical system

F41 Fig. 220: Main fuse box (103 kW engine)

5-40

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Maintenance 5.18 Maintenance of the automatic trailer coupling (option) Cleaning and lubricating the trailer coupling Notice!

In order to ensure the full functionality of the trailer coupling, close the coupling pin in the trailer coupling before cleaning with high-pressure cleaning equipment!

☞ Clean as follows: • Close the trailer coupling • After cleaning, apply tough water-proof grease (EP3) to the coupling pin, the base ring and the drawbar eye • Apply tough waterproof grease (EP3) to the lower bearing of the coupling jaw • Apply grease to the grease nipple on the joint

Check the trailer coupling for wear A 3.0 mm

Danger!

Worn coupling pins, too much play in the bearing or a worn base ring carries a danger of accidents!

2.5 mm

36.5 mm B

☞ Check the trailer coupling once a day for wear and play ☞ Apply grease to the base ring ☞ Have an authorised workshop replace a defective trailer coupling by a new one

36.5 mm

☞ Checking the bearing and longitudinal play A of the coupling head

C

2.5 mm

7 mm

E

Fig. 221: Trailer coupling

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D

• Move the uncoupled coupling head with force in driving direction ☞ Checking the height-wise play of the coupling head • Open the coupling • Move the coupling head up and down with a suitable tool (mounting lever) ➥ Play A in the centre axis of the coupling head = max. 3 mm ☞ Checking the coupling pin C/D • Measure wear by means of a slide gauge on the thickest section of the coupling pin C ➥ Diameter C may not drop below 36.5 mm ➥ Height-wise play B max. 2.5 mm • Check pin play D in the base ring and thickness E of the base ring ➥ Pin play max. 2.5 mm ➥ Thickness of base ring min. 7 mm

5-41

Maintenance 5.19 Cleaning and maintenance work Specific safety instructions regarding cleaning The wrong choice of cleaning equipment and agents can impair the operating safety of the machine on the one hand, and on the other undermine the health of the persons in charge of cleaning the machine.

Cleaning with washing solvents • Ensure adequate room ventilation • Wear suitable protective clothing • Do not use flammable liquids, such as petrol or diesel Cleaning with compressed air • Work carefully • Wear goggles and protective clothing • Do not aim the compressed air at the skin or at other people • Do not use compressed air for cleaning your clothing Cleaning with a high-pressure cleaner or steam jet • Electric components and damping material must be covered and not directly exposed to the jet • Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.

• Protect the following components from moisture: • Engine • Electric components such as the alternator, pressure switches, wiring, electric/ electronic parts etc.

• Control devices and seals • Air intake filters etc.

Cleaning with volatile and easily flammable anticorrosion agents and sprays • Ensure adequate room ventilation • Do not use unprotected lights or naked flames • Do not smoke

Environment!

In order to avoid damage to the environment, clean the machine only in wash bays and places provided to this effect!

Notice!

A machine with anticorrosion protection (“aggressive media”) must be cleaned separately! – see Maintenance work “Aggressive Media” (option) on page 545! l

5-42

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Maintenance Cleaning inside the cab Caution!

Never use high-pressure cleaners, steam jets or high-pressure water to clean inside the cab!

Water under high pressure can penetrate into the electrical system, cause short circuits, damage seals and disable the controls!

We recommend using the following aids to clean the cab: • Broom • Vacuum cleaner • Damp cloth • Bristle brush • Water with mild soap solution

Cleaning the seat belt • Clean the seat belt (which remains fitted in the machine) only with a mild soap solution; do not use chemical agents as they can destroy the fabric!

Danger!

Danger of personal injury! If the machine is equipped with automatic seat belts (option), soiled belts hinder winding and jeopardise the driver's safety!

☞ Clean dirty belt straps and wind them only when they are dry! ☞ Have defective belts replaced

Cleaning the exterior of the machine We recommend using the following aids to clean the machine: • High-pressure cleaner • Steam jet

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5-43

Maintenance Cleaning the engine and the engine compartment Danger!

Caution, danger of injury! Rotating parts!

☞ Clean the engine only when it is at a standstill!

Caution!

When cleaning the engine with a water or steam jet, the humidity penetrating the electronics causes it to fail and leads to engine damage! ☞ Allow the engine to cool down before cleaning ☞ Protect all electric sensors such as temperature and oil pressure switches or control valves against humidity. ☞ Protect the alternator, connectors, fuses and relays against humidity ☞ If the water jet is unintentionally pointed at electric components, dry them with compressed air and apply contact spray to them.

☞ Clean the engine compartment as follows: • • • • • •

Park the machine in a wash bay or place Lower the telescopic boom Stop the diesel engine Switch off ignition and remove the ignition key Apply the parking brake Clean after the diesel engine has cooled down

Checking screw connections All screw connections must be checked regularly for tightness, even if they are not listed in the maintenance plans.

Tighten loose connections immediately. Refer to chapter “Specifications” for the tightening torques.

Checking pivots and hinges Lubricate all mechanical pivot points on the machine (e.g. door hinges, joints) and fittings (e.g. door arresters) regularly, even if they are not listed in the lubrication plan.

5.20 Maintenance of attachments and of the work equipment Correct maintenance and service is absolutely necessary for smooth and continuous operation, and for an increased service life of the attachments. Observe the lubrication and maintenance instructions in the Operator's Manuals of the attachments!

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Maintenance

Maintenance 5.21 Maintenance work “Aggressive Media” (option) Important notice on anticorrosion protection The machine is specially protected against corrosion for work in aggressive media (e.g. a saline environment).

However, this anticorrosion protection is affected by external factors e.g. dirt, cleaning etc.

This is why it only has ongoing effect if checked at regular intervals and renewed or reapplied as required.

If no anticorrosion protection is applied to the machine, for instance for work in a saline environment, we recommend retrofitting your machine with the “Aggressive Media” option by a sales partner.

The following anticorrosive wax has been used in the factory: Description:

ANTICORIT BW 366

Manufacturer:

FUCHS MINERALOELWERKE GMBH/Mannheim

Specification:

TI 8030-015/K 19/MIL-C-16 173 C-Grade 4

Components coated with anticorrosive wax Component

All electric plug-and-socket, earthing and crimp connections

All parts of the machine, e.g.

Axles, gearbox, trim panels, servicing lids, telescopic boom, quickhitch

Flange surfaces

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Remarks Before applying the wax: • Apply contact spray to contact surfaces and connect the plug-and-socket connections again • Apply a particularly thick anticorrosion layer to the connecting parts of the fuel level transmitter Except: • Piston rods (chromium layer) • Cab, cab bearings • Engine cover, engine mounting • Air filter • Counterweight • Fastening surfaces for mounting parts on frame • Radiator and insulating mats • Mudguards, rubber and plastic parts • Light elements E.g. axles, diesel engine and cab bearing: • Seal gaps with anticorrosion wax after assembly

5-45

Maintenance Measures for maintaining anticorrosive protection Safety instructions • When handling chemical substances of any kind, such as solvents, wax etc., observe the specific product-related safety regulations (safety data sheet)!

• Ensure adequate room ventilation!

• Do not use unprotected lights or naked flames!

• Do not smoke!

• Corrosion on electric connections or components can lead to dangerous operating malfunctions • Carry out work on the electrical system only with the battery disconnected and the diesel engine stopped!

Cleaning • If the machine is used in corrosive environment over a longer period of time, remove the floor mat in the cab to avoid the accumulation of corrosive humidity.

• Thoroughly clean machines that are put out of operation over a longer period of time.

• Clean the machine at least once a week. In particular, remove corrosive deposits (such as salt crusts) as fast as possible.

• Clean the machine with cold running water preferably.

Caution!

Contrary to the instructions given in Chapter “General maintenance work” in the Operator's Manual of the machine, neither clean the machine with a bristle brush nor with a steam jet or a high-pressure cleaner! ☞ If cleaning the machine with these means cannot be avoided, check the wax coating very carefully and have it renewed or reapplied as required

5-46

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Maintenance Applying the protective anticorrosion coating Bear in mind the following instructions as you apply the anticorrosive wax:

Notice!

Carefully cover all fastening surfaces and elements to which the anticorrosive protection may not be applied – see Components coated with anticorrosive wax on page 5-45 • ANTICORIT BW 366 can be applied with a brush, by means of immersion or with all commercially available spray guns.

• ANTICORIT BW 366 protective coating can be removed with petrol, RENOCLEAN E/K or FUCHS MULTICLEAN as required.

• ANTICORIT BW 366 spots are difficult to remove on clothing.

• Affix a “Wet paint!” or a similar sign to newly coated machines.

Treatment of oxidised surfaces ☞ If in spite of all precautionary measures some components should be affected by corrosion (oxidised), treat the oxidised area follows: Electric connections • Remove the remaining protective wax in the oxidised area with petrol, RENOCLEAN E/K or FUCHS MULTICLEAN • Treat the affected area with an oxide solvent, such as KONTAKT 60, and rinse it with e.g. KONTAKT WL • Treat the contact surfaces of the connection with e.g. KONTAKTSPRAY WD 40 • Establish the connection • Apply/spray anticorrosion wax onto the electric connection from all sides Sheet-metal parts • Remove the remaining protective wax in the oxidised area with petrol, RENOCLEAN E/K or FUCHS MULTICLEAN • Remove all remaining corrosion and paint coating from the affected area down to the bare material, otherwise the paint coating will not adhere properly!

• Clean the affected area with a cleaning solvent, and then apply a 2-component prime coating and a 2-component paint coating to it • Then preserve the area with anticorrosion wax

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5-47

5-48

plan (overview)

Condition of paint coating Check engine oil level Check hydraulic oil level Check gearbox oil level in gearbox (on rear axle 20 kph) (Bibus 30/40 kph) Check gearbox oil level in front and rear axle differential Check gearbox oil level in front and rear axle, left and right planetary drives Check brake fluid level7, fill up if necessary (use LHM brake fluid) Check coolant level, fill up if necessary 8 Check water/oil radiator (engine/hydraulic oil) for dirt, clean if necessary9

): ● ● ● ● ● ● ●

● ● ●

● ● ●

●

●

●

●

●

at 100 s/h2

● ●

Every 10 s/h (daily)

• • • • • • • • •

Inspection work (

“A” 1st Inspection ● ● ●

● ● ● ● ●

●

● ●

● ●

● ● ● ● ●

“B” every 500 s/h2

Engine oil Engine oil filter Fuel filter Replace the fuel prefilter Air filter insert3 Air filter insert – safety cartridge4 Gearbox oil in front and rear axle differential Gearbox oil in gearbox flanged on rear axle (20 kph) Gearbox oil in gearbox, Bibus high speed 5 (30/40 kph) Gearbox oil in front and rear axle planetary drives (left and right) Hydraulic oil6 Hydraulic oil filter insert/return filter Hydraulic oil tank breather filter 4 Line filter in drive (boost pressure) Heating fine-dust filter (outside the cab) Heating recirculated-air filter (inside the cab)

Workshop

● ● ●

● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

“C” every 1500 s/h once a year

• • • • • • • • • • • • • • • •

) (check the oil levels after a test run):

Operator/driver

Delivery inspection

Oil and filter changes (

For service and maintenance work on the attachment, refer to the Operator's and Maintenance Manual of the attachment manufacturer.

5.22

1Maintenance Every 20 s/h

Workshop Maintenance

Maintenance

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plan (overview)

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● ● ● ●

● ●

● ● ● ●

Every 10 s/h (daily) ● ● ●

●

● ● ● ● ● ● ● ● ●

● ● ● ● ● ●

●

“A” 1st Inspection

● ● ● ●

●

● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ●

●

“B” every 500 s/h2

Check charge air cooler (diesel engine) for dirt, clean if necessary Drain condensation water in charge air cooler (diesel engine) Drain condensation water in hydraulic oil tank 6 Air filter – clean dust valve on air filter3, 10 Clean the dust collector (option) on the air filter Check the V-belts (fan wheel, alternator), retighten and replace if necessary 11 Check the V-belt (air conditioning, compressed-air brake option), retighten and replace if necessary 11 Drain the water in the fuel prefilter Check valve clearance (diesel engine) and adjust if necessary Check battery charge condition Clean the line filter (LS drive – control valve) filter insert Clean the heating fine-dust filter (outside the cab)4 Clean the heating fine-dust filter (inside the cab)4 Check the level in the air conditioning system (option) at the sight glass on the dehumidifier, clean the condenser 12 Check the service and parking brake linings13 Check the compressed-air brake (option) for leaks (sound of escaping air) and damage Tyre check (damage, air pressure, tread depth) Trailer coupling (damage, wear) Check and readjust slide plates on telescopic boom. Replace if necessary 14

Workshop

● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

“C” every 1500 s/h once a year

• • • • • • • • • • • • • • • • • • •

):

Operator/driver

Delivery inspection

Other inspection work (

For service and maintenance work on the attachment, refer to the Operator's and Maintenance Manual of the attachment manufacturer.

5.22

1Maintenance Every 20 s/h

Workshop

Maintenance

at 100 s/h2

5-49

5-50

plan (overview)

● ● ● ● ● ● ● ● ● ●

“A” 1st Inspection ● ● ● ● ● ● ● ● ● ●

Workshop “B” every 500 s/h2 ● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

“C” every 1500 s/h once a year

Check screws and nuts or screw connections for tightness on the following assemblies/components. Retighten if necessary • Fastening screws of engine and engine suspension ● • Fastening screws of steering system ● • Fastening screws of hydraulic system ● • Fastening screws of telescopic boom (pin locking), quickhitch lock ● • Axle mounting, axle suspension ● • Counterweight fastening screws ● • Fastening screws of cardan shafts ● • Cab fastening screws ● • Wheel nuts ● • Electrical system: check electric and earth connections, chafing on wiring harness, battery terminals ●

):

Operator/driver

Delivery inspection

Other inspection work (

For service and maintenance work on the attachment, refer to the Operator's and Maintenance Manual of the attachment manufacturer.

5.22

1Maintenance Every 20 s/h

Workshop

Maintenance

at 100 s/h2

Every 10 s/h (daily)

00 0291 628 0 - BA SCORPION – AUSTRALIA

plan (overview)

00 0291 628 0 - BA SCORPION – AUSTRALIA

• • • • • • • • • • • •

Service and parking brake Compressed-air brake system (option) Steering system: steering column adjustment, synchronous position of wheels Lights and electrical system Drive interlock (option) Safe load indicator of telescopic boom Seat adjustment, seat belt Control lever lock (joystick) for road travel Hose burst valve safety feature Load stabiliser Quickhitch lock Additional control circuits (option)

): ● ● ● ● ● ● ● ● ● ● ● ●

● ● ●

● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ●

● ● ● ●

“A” 1st Inspection

Functional check (

Every 10 s/h (daily) ● ●

● ●

● ● ● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ●

● ● ● ●

“B” every 500 s/h2

● ● ● ● ● ● ● ●

● ● ● ●

Workshop

● ● ● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ●

● ● ● ●

“C” every 1500 s/h once a year

• Rear axle oscillating bearing • Front and rear axle planetary drive bearings (left and right) • Hinges, joints and fittings (e.g. door arrester) • Trailer coupling (option) Telescopic boom – see Lubricating the telescopic boom on page 5-27 • Telescopic boom slide plates • Compensating ram bearing • Telescopic ram bearing (push-out ram) • Boom bearing • Tilt lever bearing and tilt rod bearing • Lift ram bearing • Tilt ram bearing • Quickhitch: bearing on boom

)

Operator/driver

Delivery inspection

Lubrication service15 (

For service and maintenance work on the attachment, refer to the Operator's and Maintenance Manual of the attachment manufacturer.

5.22

1Maintenance Every 20 s/h

Workshop

Maintenance

at 100 s/h2

5-51

5-52

plan (overview)

Have repair work carried out by an authorised workshop only Have maintenance carried out by an authorised workshop (acknowledgement of warranty claims) Replace the filter insert as indicated by the maintenance display, and more frequently in an acidic environment.

Depending on operation and dust conditions, and in an acidic environment it can be necessary to replace the filters more frequently At 500 s/h. Oil change after putting the machine into operation for the first time, then every 1500 s/h.

Only when using biodegradable oil (before the cold season).

Have the brake fluid (LHM) replaced every 2 years by an authorised workshop Have the coolant replaced every 2 years by an authorised workshop Depending on operation and dust conditions, it can be necessary to clean the radiator more frequently Automatically cleaned on machines equipped with the “Vacuum-operated preliminary separator” option Have the V-belts replaced by an authorised workshop after 2 years at the latest Dehumidifier must be replaced by an authorised workshop every 2 years or after maintenance and repair work on the refrigerating circuit Brake pads may be replaced by an authorised workshop only Have slide plates below the minimum thickness of 8 mm replaced by an authorised workshop Lubricate attachment according to manufacturer's instructions!

Replace flexible fuel leak oil lines every 2 years Have flexible lines replaced by an authorised workshop every 6 years (UVV, DIN 20066 T5)

Every 10 s/h (daily) ● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

“A” 1st Inspection

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

“B” every 500 s/h2

Air intake line (air filter, turbocharger, engine charge-air cooler) Engine lubrication (engine – filter) Fuel lines16 Cooling system (engine – hydraulic oil) Steering system (flexible lines and rams) 17 Hydraulic system/telescopic boom (flexible lines and rams)17 Additional control circuit quick couplers, 3rd control circuit, tipping trailer connection (option) Brake system7 (flexible lines) Check the compressed-air brake (option) for leaks (sound of escaping air) Air conditioning system (option) – flexible lines, condenser, evaporator

Workshop

● ● ● ● ● ● ● ● ● ●

“C” every 1500 s/h once a year

• • • • • • • • • •

):

Operator/driver

Delivery inspection

Leakage check (

For service and maintenance work on the attachment, refer to the Operator's and Maintenance Manual of the attachment manufacturer.

5.22

1Maintenance Every 20 s/h

Workshop

Maintenance

at 100 s/h2

00 0291 628 0 - BA SCORPION – AUSTRALIA

Wartung

Wartung 5.23 Fluids and lubricants Component/application

Engine/machine fluid

Engine oil2 with filter

Diesel engine

SAE grade/Specification

Temperature

CLAAS Argimot Ultratec 10W-40 HD-C 10W-40; EO1040B3 HD-C 15W-40; EO1540B3

Year-round

SAE 10W; EO103

Below -5 °C

SAE 20W20; EO203

-10 to +10 °C

3

SAE 30; EO30 20 kph gearbox 30/40 kph gearbox (option) Planetary drives – left and right, front/rear axle

Gearbox oil

Front and rear axle differentials Hydraulic system, hydraulic oil tank

SAE 85 W 90 CLAAS Agrishft MT (API GL4 MIL L-2105) (API GL5 MIL 2105-B)

Biodegradable oil

CLAAS Agrihyd HVLP-D 46 HVLPD 46 (HYD0530) AVIA Syntofluid 46

12.5 l

5 to 30 °C About 0.8 l About 4.0 l Year-round

SAE 90 LS (hypoid gear oil) Hydraulic oil4

Capacities1

0.75 l each 7.1 l each

Year-round

About 100 l5

PANOLIN HLP Synth 46

Multipurpose grease

CLAAS Agrigrease EP 2 lithium-saponified brand-name grease MPG-A3

Year-round

As required

Acid-proof grease

SP-B3

Year-round

As required

Aggressive media (option)

Anticorrosion protection

Anticorit BW 3666

Year-round

As required

Mounting 7 of pins, shafts

Special grease

Optimoly paste “TA” White paste

Year-round

As required

Fuel system, fuel tank

Diesel fuel8

DIN 51628/DIN EN 590 (EU) ASTM D975-94 (USA)

Year-round - 40 °C

About 190 l

Brake system

Brake fluid9

Agip LHM Super/Shell LHM

Year-round

0.5 l

R 134a/DIN 9860

Year-round

About 1300 g

Year-round

Water 7.5 l (55 %) Antifreeze 7.0 l (45 %)

Year-round

Water 1.0 l (33 %) Antifreeze 2 l (67 %)

Grease nipples, telescopic boom slide plates Battery terminals

10

Air conditioning (option) Engine cooling

Washer system

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Refrigerant

11

Antifreeze12,13

Cleaning agent11

HAVOLINE XLC

Water + antifreeze

The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level MIL-L-2104C; API CD/CE/CF4; CCMC-D4 Abbreviation for lubricants (Hauptverband der Deutschen Bauindustrie e. V. – German construction engineering association) DIN 51 524 Total capacity of hydraulic system about 170 l TI 8030-015/K 19/MIL-C-16 173 C-Grade 4 Important! Pins (hard-chromium plated or coated with Molykote 3400A) are inserted in dry state. Lubricate via grease nipples once assembly is over If fuels that do not comply with DIN EN or ASTM (USA) are used, warranty rights shall not apply in case of diesel engine damage Do not mix this brake fluid with other brake fluids (standards: B 71 2710 and ISO 7308) Maintenance work must be carried out by trained staff only Bear in mind the safety data sheet during maintenance work See Coolant compound table on page 6-12 and manufacturer indications on the packaging The coolant must be replaced every 2 years by an authorised workshop

00 0291 628 0 - BA SCORPION – AUSTRALIA

5-53

Wartung 5.24 Maintenance label Affixed on the cab

Explanation of symbols on the maintenance label Symbol

Explanation Before starting maintenance work, follow the safety instructions in the Operator's Manual!

Before starting maintenance work, read the “Maintenance” chapter in the Operator's Manual!

Carry out a functional check of the light system!

Check tyres for damage, pressure and tread depth!

Carry out a functional check and synchronise the steering system!

P

Carry out a functional check of the brake system!

Check hydraulic oil level. Fill up if necessary!

Check engine oil level. Fill up if necessary!

Compress the dust valve Check radiator for engine coolant and hydraulic oil for contamination. Clean if necessary!

Check condition and initial tension of V-belts. Retighten or replace if necessary!

Leakage check: Check for tightness, leaks and chafing: pipes, flexible lines and screw connections. Rectify if necessary!

Visual check!

Check wear parts and screw connections at regular intervals Retighten loose connections immediately and replace worn wear parts!

Leakage check: Check the fuel/water separator. Drain water if necessary!

Lubrication service: Lubricate the assemblies concerned!

5-54

00 0291 628 0 - BA SCORPION – AUSTRALIA

Wartung Maintenance label overview

1000153091

Pflege- und Wartungsarbeiten Service and maintenance work Travaux de maintenance Täglich Daily Tous les jours

10 h

20 h

Täglich Daily Tous les jours

P

10 h 20 h Typ 400/ 401/ 402/ 403/ 404

00 0291 628 0 - BA SCORPION – AUSTRALIA

5-55

Wartung Notes:

5-56

00 0291 628 0 - BA SCORPION – AUSTRALIA

Specifications

Specifications

6

Specifications

6.1 Model and trade names: overview Telehandler model

Trade name

401-03

7030

402-03

7040

403-03

7045

6.2 Frame Sturdy steel sheet frame, rubber-mounted engine

6.3 Engine Telehandler model

401-03/402-03

Type Output (as per ISO 14396) Max. torque (counterclockwise rotation) Specific minimum fuel consumption Number of cylinders Displacement Bore and stroke

403-03

TCD 2012 L04 2V 88 kW at 2400 rpm with charge-air cooler

103 kW at 2400 rpm with charge-air cooler

420 Nm 1500 rpm

520 Nm 1500 rpm

215 g/kWh

205 g/kWh 4 4038 cm³ 101 x 126 mm

Compression ratio Fuel injection system

PDL (pump, line, nozzle)

DCR (Deutz Common Rail)

Firing order

1-3-4-2

Starting aid

Glow plug

Max. inclined position (engine no longer supplied with oil) Oil pressure Valve clearance1 Control plunger play1 exhaust gas recirculation 1.

00 0291 628 0 - BA SCORPION – AUSTRALIA

1:18

Max. lateral left/right inclination: 30° (57 %) Max. uphill/downhill inclination: 30° (57 %) Observe the tilting limit of the machine!

Forced feed lubrication Intake valve 75° Exhaust valve 120° Control plunger play 144°

Adjust the play when the engine is cold

6-1

Specifications 6.4 Oil/water fan Telehandler model

401-03/402-03/403-03 Gear pump

Hydraulic pump Displacement

17 cm³/rev

Fan motor Capacity

14 cm³/rev

6.5 Power train Variable displacement pump Telehandler model Design Displacement

401-03/402-03/403-03 Automotive, infinitely variable hydrostatic axial-piston gearbox 0 – 78 cm³/rev (20 kph) 0 – 90 cm³/rev (30 or 40 kph) 450+30 bar

Max. operating pressure Starting engine speed

1050 – 1150 rpm/50 bar HP 2100±100 rpm 250 bar HP

Droop Boost pump Design

Gear pump

Displacement

17 cm³/rev

Charging/boost pressure

30 bar at max. rpm

Control

Electronic

Driving direction

Electrohydraulic control

Inching

Electric (potentiometer)

Variable displacement motor Telehandler model Design Capacity (30 or 40 kph) Work range/drive range forwards/reverse Traction force1 1.

6-2

401-03/402-03/403-03

402-03/403-03

Axial piston motor

Axial piston motor + fixed displacement motor

233 cm³/rev

233+45 cm³/rev

Work range: 0 – 7 kph Drive range: 0 – 40 kph 65 kN

75 kN

With 17.5LR24 tyres

00 0291 628 0 - BA SCORPION – AUSTRALIA

Specifications 6.6 Axles Front axle Telehandler model Design Differential lock

401-03/402-03/403-03 Planetary steering and drive axle, screw connection with frame 100 % differential

King-pin inclination

0°

Camber

0°

Steering angle Toe-in Track width

Max. 45° 0 mm 1920 mm

Rear axle Telehandler model Design

Planetary steering and drive axle, oscillating bearing on frame

Differential lock

No

King-pin inclination

0°

Camber

0°

Oscillation Steering angle Toe-in Track width

00 0291 628 0 - BA SCORPION – AUSTRALIA

401-03/402-03/403-03

± 10° Max. 45° 0 mm 1920 mm

6-3

Specifications 6.7 Service and parking brake Service brake 30 or 40 kph version (option) • Foot-operated dual-circuit hydraulic multidisc powerbrake 30 or 40 kph version (option) • Front and rear axles On both axles via cardan shaft Special hydraulic fluid based on basic mineral oil (LHM) – see chapter 5 “Fluids and lubricants” on page 5-53

Design Location Effect Brake fluid Parking brake

Actuated via switch on instrument panel, electrohydraulic multidisc spring-loaded brake

Design1 1.

On left and right between the axle tube and the front axle differential housing

6.8 Steering system Telehandler model

401-03/402-03/403-03 Hydrostatic 4 wheel steering with emergency steering features

Design Steering mode: 20 kph

4 wheel steering, front axle steering, optional diagonal steering (crab steering)

Steering mode: 30/40 kph (option)1

4 wheel steering, front axle steering, optional diagonal steering (crab steering) (front axle steering automatically engaged when switching over to high speed range)

Assemblies

Hydraulic pump, priority valve, servostat with safety valves, 1 steering ram per axle, electronically synchronised

Max. pump pressure2

205 – 235 bar 3

Max. steering pressure 1.

2.

3.

6-4

200 bar

30/40 kph version: high speed range only possible with front axle steering!

Measured after the pump Measured after the servostat

00 0291 628 0 - BA SCORPION – AUSTRALIA

Specifications 6.9 Work hydraulics Hydraulic pump Telehandler model Hydraulic pump Design Displacement Location on diesel engine Control valve

401-03/402-03

402-03/403-03

44 cm³/rev

60 cm³/rev

Fixed displacement pump

Variable displacement pump (LS)

110 l/min at 2400 rpm

150 l/min at 2400 rpm

88 kW

88 kW and 103 kW 4 – 7-fold pilot control

Hydraulic oil filter

Return filter

Hydraulic ram protection Telehandler model

401-03

402-03/403-03

Max. operating pressure Tilt ram Secondary protection: Rod side

210 bar

250 bar

260 bar

300 bar

Base side Lift ram Secondary pressure limiting Base side Push-out ram Secondary protection: Rod side

260 bar

300 bar

260 bar

300 bar

260 bar

300 bar

200 bar

200 bar

210 bar

210 bar

401-03/402-03

402-03/403-03

Fixed displacement pump 44 cm³/rev

Variable displacement pump 60 cm³/rev

Lift ram Raise Lower

9.5 sec 6.0 sec

7.5 sec.

5.6 sec.

Tilt ram Dump in Dump out

3.6 sec 3.0 sec

2.5 sec 2.5 sec

Push-out ram Retract Extend

6.0 sec 7.5 sec

5.5 sec 6.5 sec

Base side Quickhitch ram (3rd control circuit) Max. operating pressure

Lift, tilt and push-out rams: velocity Telehandler Hydraulic pump

00 0291 628 0 - BA SCORPION – AUSTRALIA

6-5

Specifications Hydraulic pilot control Pilot control pump = boost pump of hydraulic pump Displacement

17 cm³/rev

Charging/boost pressure

30 bar at 2400 rpm

Pilot control unit

Control lever (joystick)

Lock against unintentional operation (for long-haul travel and transport)

• Four-way lever Lift and tilt ram operation • Push-out ram via potentiometer scroll wheel • Lock ram or attachment via potentiometer scroll wheel (electrohydraulic control) Stop cock in pilot-control line and switch for 3rd control circuit lock (electric)

Usable consumer pressure at additional control circuit (option) Location

Rear additional control circuit

Function

Rpm / l/min / bar

Rpm / l/min / bar

Electric control (solenoid valve) 5fold control valve

1500/53/210 2000/77/185 240/102/170

1500/80/195 2000/100/180 240/100/110

Electric control (solenoid valve) 3rd control circuit

1500/53/200 2000/77/160 2400/102/127

1500/80/160 2000/100/145 2400/115/120

1500/53/210 2000/77/180 2400/102/160

1500/80/170 2000/100/165 2400/115/150

–

1500/70/193 2000/105/150 2400/140/140

Front additional Electric control control circuit (solenoid valve) 3rd installed on outcontrol circuit with side of telescopic external return boom 4th control circuit with external return

6-6

Fixed displacement Variable displacement pump 44 cm³/rev pump 60 cm³/rev

00 0291 628 0 - BA SCORPION – AUSTRALIA

Specifications 6.10 Electrical system Fuse assignment The fuse board is located underneath the cover behind the seat.

No.

(A)

Protected circuit

F1

7.5

Brake light

F2

15

F3

10

F4

15

F5

10

Front socket Mirror adjustment, mirror heating, solenoid valve: additional circuit raise/lower, emergency lowering OFF, overload cutoff Proportional electronics Preheating time control unit, preheating indicator light, preheating switching relay, engine electronics Turn indicators Steering electronics, 4 wheel steering/front axle steering/diagonal steering solenoid valve, 4 wheel steering/front axle steering/ diagonal steering/synchronism indicator light Susmic (drive electronics) Solenoid valve: load stabiliser, hose burst valve, reversing fan, load stabiliser indicator light Air-suspension seat (option) Solenoid valve: additional control circuit, tilt ram lock, bucket repositioning, quickhitch lock, load stabiliser relay, Autohitch unlocking Cutoff solenoid Forwards/reverse driving direction indicator light, hold electronics, front socket relay, bucket repositioning relay, parking brake solenoid valve Driving direction identification solenoid valve, rear horn, reversing light, reversing light, float position solenoid valve Hour meter, indicator light: 3rd control circuit, parking brake, air filter, engine oil pressure, water separator, preheating, hydraulic oil filter, alternator, hydraulic oil level, hydraulic oil temperature, coolant temperature, fuel level indication, speedometer Front and rear axle sensors, speed sensor, indicator light for water in fuel, level amplifier, reversing fan tip switch, coolant level indicator light Window heating

F6 F7

7.5

F8 F9 F10

10

F11 F12

5

F13

3

F14

7.5

F15 3 Fig. 222: Fuse box

00 0291 628 0 - BA SCORPION – AUSTRALIA

F16 F17

30

F18

25

F19

15

F20

10

F21

5

F22

20

F23

3

Heater fan, magnetic coupling compressor Main fuse: right/left low beam, right/left high beam, high beam indicator light Rear wiper, washer pump Safe load indicator, window heating time lag relay, window heating switching relay, bucket repositioning sensor, mini switching relay for overload cutoff Switching relay wiper 1st/2nd speed, intermittent wipe relay, front wiper, washer pump, horn Radio

6-7

Specifications No. F24 F25 F26 F27

(A)

F32 F33 F34 F35 F36 F37

7.5

Protected circuit High beam (right) High beam (left) Low beam (right) Low beam (left) Side marker lights (right), rear light (right), rear clearance light (right), numberplate lights, switch lights Side marker lights (left), rear light (left), rear clearance light (left), instrument lights, light for cigarette lighter High current relay, start switching relay Main fuse: parking light, rear light, rear socket for additional lights, front socket for additional lights, switch lights, instrument lights, light for cigarette lighter, interior light Drive interlock/auxiliary heater Rotating beacon Telescopic boom working light Rear working light Front working light Turn indicator relay, turn indicators, radio

F38

15

Socket (cigarette lighter)

7.5

F28 5 F29 F30 F31

3 15

10

Electric components Description Alternator Starter Battery

6-8

Output 12 V 95 A 12 V 3.0 kW 12 V/135 Ah

00 0291 628 0 - BA SCORPION – AUSTRALIA

Specifications Main fuse box with relays (88 kW diesel engine) The main fuse box is located in the engine compartment K7

Fuse no.

F 40

K6

K5

F 39

K7 F40

F39

Rated current (A)

Protected circuit

F39

125 A

Preheating/start fuse (starter)

F40

100 A

Main fuse

Relay no.

Protected circuit

K5

Preheating high current relay

K6

Preheating time lag relay

K7

Start high current relay

Fig. 223: Main fuse box (88 kW engine)

Main fuse box with relays (103 kW diesel engine) The main fuse box is located in the engine compartment K5

K42

K7

F40 F39

F41 Fig. 224: Main fuse box (103 kW engine)

00 0291 628 0 - BA SCORPION – AUSTRALIA

Fuse no.

Rated current (A)

Protected circuit

F39

125 A

Preheating/start fuse (starter)

F40

100 A

Main fuse

F41

25 A

Main fuse (engine control unit)

Relay no.

Protected circuit

K5

Preheating high current relay

K7

Start high current relay

K42

Engine electronics switching relay

6-9

Specifications Switching relay assignment The relays are located underneath the cover behind the seat.

Switching relay no.

Protected circuit

K1

High current relay

K2

High current relay

K3

Reverse driving switching relay

K10

Turn indicator relay

K16

Front socket switching relay

K21

Differential lock

K22

Load stabiliser (option)

K23

Wiper switching relay (1st speed)

K25

Interval relay (wiper)

K27

Time lag relay for rear window heating (option)

K10

K28

Switching relay for bucket repositioning (option) or front socket (option)

K28

K30

Brake lights switching relay

K31

Fuel preheater switching relay (option, installed in engine compartment)

K32

Reversing fan (option) switching relay

K33

High current relay for rear window heating (option)

K34

Switching relay for overload cutoff

K25 K23

K33

K1

K3

K27

K2

Fig. 225: Relays

Fig. 225: Relays

6-10

K22

K38

K32

K36

K16

K37

K30

K35

K35

Switching relay for overload cutoff

K21

K34

K36

Drive signal switching relay

K37

Drive signal switching relay

K38

Switching relay for other options

00 0291 628 0 - BA SCORPION – AUSTRALIA

Specifications 6.11 Tyres for models 401-03/402-03/403-03 Tyre pressure

Tyre size

405/70-24 MPT01 152 B 15.5-25 EM60 149 B 15.5 R25 TL VSDL L5

Wheel rims

Front/rear

Wheel rim

3.25 bar

DW13x24

4.5 bar

12.00/1.3 x 25

Wheel offset Minus (-)

17.5LR24 A-570 150 A8 460/70 R24 159 A8 XMCL 460/70-24IND 159 A8 TR01 460/70 R24 159 A8

TW14Lx24

0

3.25 bar

19.5 LR24 149A8 A-570 500/70 R24 164A8 XMCL

1.

2.

DW16Lx24

500/70 R24 157A8 IT530

2.5 bar

440/70 R28 IND 152A8 AC70G1

4.0 bar

W15Lx28

-5

600/50-22.5 16PR 153 A8 2

2.6 bar

22.5x20 TH2

-25

Applies only to telehandler model 403-03 Steering angle must be reduced from 45° to 40° on the front and rear axles if these tyres are mounted

6.12 Machine weights, axle loads Telehandler

401-03

402-03

403-03

1

7200 kg

7800 kg

8100 kg

Kerb weight

Gross weight rating

10000 kg

Front/rear gross axle weight rating

6500 kg

1.

00 0291 628 0 - BA SCORPION – AUSTRALIA

Without attachment, with driver and full fuel tank

6-11

Specifications 6.13 Noise levels Diesel engine

Sound power level

dBA

Measured value

105.6

Guaranteed value

106

Measured value

103.8

Guaranteed value

104

Driver-perceived noise level

78

88 kW 103 kW 88/103 kW

Notice!

Measurement of sound power level according to EC Directive 2000/14 EC and according to the modified EC Directive 2005/88 EC. Driver-perceived noise level measured according to EC Directives 84/532/ EEC, 89/514/EEC and 95/27/EEC. Measurements carried out on asphalted surface.

6.14 Vibrations, oscillation and acceleration value Vibration 1 Overall vibration value for upper extremities of the body

< 2.5

m----s2

Maximum effective value of weighted acceleration for body

< 0.5

m----s2

1.

Instruct or inform the operator of danger arising from vibrations

6.15 Coolant compound table

1.

2.

6-12

Outside temperature

Water1

Antifreeze2

Up to °C

% by volume

% by volume

4

99

–

- 10

79

20

- 20

65

34

- 25

59

40

- 35

55

45

- 42

50

50

Water quality at 20 °C = 6.5 – 8.5 ph/total hardness 3 – 20 °dGH (do not use salt, lake, river, brackish or industrial water) SeeFluids and lubricants on page 5-53

00 0291 628 0 - BA SCORPION – AUSTRALIA

Specifications 6.16 Tightening torques General tightening torques Screw dimensions

1.

Tightening torques in Nm1 8.8

10.9

12.9

M4

3

4

5

M5

5.5

8

10

M6

10

14

16

M8

23

34

40

M10

46

67

79

M12

79

115

135

M14

125

185

220

M16

195

290

340

M18

280

400

470

M20

395

560

660

M22

540

760

890

M24

680

970

1150

M27

1000

1450

1700

M30

1350

1950

2300

These values are valid for screws with untreated, non-lubricated surfaces

Specific tightening torques Description Wheel nut

Tightening torque 400 ±20 Nm

6.17 Trailer couplings: trailer weight/drawbar load Gross trailer weight rating: Trailer without brakes

Tractors and agriculSelf-protural or forestry pelled work machinery machines Directive 2003/37 EC 1000 kg

Trailer (one axle braked)

3500 kg

Trailer (all axles braked)

8000 kg

Trailer with hydraulic or pneu20000 kg 15000 kg matic brakes Control mark e4D077/e4D0157 (see machine documentation) Max. authorised load for towing 4000 kg facility on machine 1.

00 0291 628 0 - BA SCORPION – AUSTRALIA

Gross drawbar load rating

1000 kg1

1000 kg

2000 kg, in consideration of the axle loads and the overall weight of the telehandler. See EC certificate of conformity or indications on the type labels of the trailer couplings

6-13

Specifications 6.18 Payload: load diagram model 401-03 (without counterweight) Load centre 600 mm

Notice!

Payload indications with authorised tyres • – see Tyres for models 401-03/402-03/403-03 on page 6-11

6-14

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Specifications 6.19 Payload: load diagram model 401-03 (with counterweight 2 x 150 kg) Load centre 600 mm

Notice!

Payload indications with authorised tyres • – see Tyres for models 401-03/402-03/403-03 on page 6-11

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6-15

Specifications 6.20 Payload: load diagram model 402-03 (with counterweight 2 x 150 kg) Load centre 600 mm

Notice!

Payload indications with authorised tyres • – see Tyres for models 401-03/402-03/403-03 on page 6-11

6-16

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Specifications 6.21 Payload: load diagram model 402-03 (with counterweight 2 x 300 kg) Load centre 600 mm

Notice!

Payload indications with authorised tyres • – see Tyres for models 401-03/402-03/403-03 on page 6-11

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6-17

Specifications 6.22 Payload: model 403-03 load diagram Load centre 600 mm

Notice!

Payload indications with authorised tyres • – see Tyres for models 401-03/402-03/403-03 on page 6-11

6-18

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Specifications 6.23 Dimensions with bucket

d

f

920

e e a

b

c 45° 47 °

430 2850 4760

Fig. 226: Machine dimensions 1940

– – – – – – – a b c d e f – – – – – – – 1.

2.

3.

4.

5.

00 0291 628 0 - BA SCORPION – AUSTRALIA

2650

c

2450

b

1710

a

200 1920 2320

900 5690

Telehandler models 401-03/402-03/403-03 Overall length1 (without standard bucket) Overall height 2 Overall height with rotating beacon 2 Overall height of telescopic bearing2 Cab floor access height2 Overall width without bucket3 Cab width Bucket pin height 2 retracted extended 2, 4 Load-over height retracted extended Dump height2, 4 retracted extended 2, 4 Dump reach extended Telescopic boom length2 retracted extended 4 Dump-in angle /dump-out angle 4 Departure angle Transport position Ground clearance underneath axle and gearbox5 Track width, front/rear Wheelbase centre Turning radius between kerbs Turning radius between walls4

5690 mm (4760 mm) 2450 mm 2650 mm 1710 mm About 910 mm 2320 mm 920 mm 4900 mm 7350 mm 4600 mm 7050 mm 3920 mm 6370 mm 290 mm 5079 mm 7527 mm 45°/45° 47 ° 200 mm 430 mm 1920 mm 2850 mm 3600 mm 4550 mm

With Autohitch trailer coupling (+ 250 mm) With tyres 405/70-24 MPT01 (with tyres 425/75R20 and 405/70-20 (- 50 mm) 17.5LR24, 400/80R24 and 460/70R24 (+ 20 mm), 15.5-25 and 15.5-80-24 (+ 40 mm), 19.5LR24 and 500/70R24 (+ 60 mm) With tyres 17.5LR24 (+ 70 mm), 15.5-24 TR01 (- 25 mm), 19.5LR24 A-570 and 500/70 R24 (+ 100 mm) 2400 mm wide with standard bucket Ground clearance 405 mm with cardan shaft guard (option)

6-19

Specifications 6.24 Dimensions with pallet forks

d

a

b

a b

c Fig. 227: Machine dimensions

Telehandler models 401-03/402-03/403-03 a b c d – 1.

2.

Pallet forks pin height1 retracted extended

4900 mm 7350 mm

Pallet height1, 2

4760 mm 7100 mm

retracted extended

Dump-in angle in transport position2

20 °

2

Dump-out angle

70° 2

Turning radius: with forks between walls

4550 mm

With tyres 405/70-24 MPT01, with tyres 425/75R20 and 405/70-20 (- 50 mm), 17.5LR24, 400/80R24 and 460/70R24 (+ 20 mm), 15.5-25 and 15.5-80-24 (+ 40 mm), 19.5LR24 and 500/70R24 (+ 60 mm) With pallet forks

➥ See page 6-19 for further dimensions

6-20

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Index

Index

Index Index Symbole “Hose burst valve” safety feature (option) ................................3-88 A Adjusting the bucket repositioning............................................3-94 Adjusting the fork arms.............................................................3-84 Adjusting the height of the control lever base...........................3-48 Air conditioning (option)............................................................3-59 Air filter .....................................................................................5-17 Cleaning the dust collector .................................................5-18 Dust valve........................................................................... 5-17 Air-suspension seat (option).....................................................3-21 Alternator ..................................................................................5-39 Applications with lifting gear .......................................................2-8 Avoiding running the engine under low-load conditions ...........3-31 B Battery ......................................................................................5-38 Battery master switch (option) ..................................................3-27 Biodegradable oil......................................................................5-23 Brake system............................................................................5-30 Brake fluid ..........................................................................5-30 Safety instructions ..............................................................5-30 C Cab ...........................................................................................3-12 Closing and opening the side window (to a gap)................3-14 Completely opening and locking the side window.............. 3-14 Locking and unlocking the door..........................................3-13 Opening/closing the rear window .......................................3-15 Safety instruction – side window (right)..............................3-12 Central lubrication system (option) ...........................................5-28 Changeover valve for operation of 3rd control circuit as additional control circuit.............................................3-90 Cleaning Exterior of the machine ......................................................5-43 Inside the cab .....................................................................5-43 Motor and engine compartment .........................................5-44 Seat belt .............................................................................5-43 Specific safety instructions .................................................5-42 Compressed-air brake system (option) ....................................3-99 Coolant and oil preheater (option) ............................................3-28 Coolant temperature.................................................................3-33 Crane handling .......................................................................3-111

D Description of telehandler........................................................... 1-4 Designated use and exemption from liability .............................. 2-2 Diagnosis tip switch function Charge-air temperature ......................................................3-34 Overview of flashing codes ................................................3-35 Documents ................................................................................. 1-8 Driving direction selection (forwards/reverse)...........................3-41 Driving licence ............................................................................ 1-7 Driving on public roads Safety equipment ...............................................................3-39 With standard bucket..........................................................3-74 With the pallet forks............................................................3-80 E Electrical system......................................................................... 6-7 Emergency lowering of the telescopic boom ............................3-88 Emergency lowering of the telescopic boom in case of a diesel engine breakdown ..........................................3-67 Engine oil pressure...................................................................3-34 Equipping the machine with a standard bucket ........................3-69 Error code displays (103 kW diesel engine) .............................3-33 F Fire extinguisher .......................................................................3-21 Fitting an attachment onto the quickhitch.................................3-70 Fitting attachments from other manufacturers onto the quickhitch (option) ....................................................3-101 Fitting pallet forks .....................................................................3-79 Fluids and lubricants................................................................. 5-53 Front/rear additional control circuit (option) ..............................3-91 Fuel preheater (option) .............................................................3-28 Fuel system Bleeding ............................................................................... 5-4 Cleaning the water separator ............................................... 5-5 Refuelling ............................................................................. 5-4 Fuse assignment ........................................................................ 6-7 H Hazard warning system ............................................................3-57 Heating .....................................................................................3-58 Fine-dust filter.....................................................................5-34 Heating, fresh air ................................................................3-58 Heating, mixed mode .........................................................3-58 Heating, recirculated air mode ...........................................3-58 Recirculated-air filter ..........................................................5-34 Hose burst valve.......................................................................3-88 Hydraulic connections of attachments from other manufacturers ............................................................... 3-105 I Indicator lights and warning lights .............................................. 3-6 Interior light ...............................................................................3-56 K Key-based drive interlock (option) ............................................3-22

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S-1

Index L Labels in the engine compartment .................................................1-20 Inside the cab ..................................................................... 1-15 On the outside of the machine............................................1-13 Legal regulations ........................................................................1-7 Licence, identification .................................................................1-7 Light system..............................................................................3-55 Load diagram ............................................................................3-85 Load stabiliser Switching ON/OFF..............................................................3-52 Loading and transporting ........................................................3-109 Locking and unlocking the engine cover...................................3-20 Lubrication points Planetary drive bearing of axle ...........................................5-25 Rear axle oscillation-type bearing ......................................5-25 Telescopic boom ................................................................5-26 M Machine Fields of application..............................................................1-6 Overview...............................................................................1-3 Machine decommissioning and disposal ................................3-114 Machine inspections, regulations for accident prevention ..........1-8 Machine lights...........................................................................3-55 Main components of machine.....................................................1-4 Maintenance Air filter cartridge ................................................................5-18 Biodegradable oil................................................................5-23 Brake system......................................................................5-30 Changing wheels................................................................5-33 Checking the coolant level..................................................5-12 Checking the engine oil level................................................5-7 Checking the hydraulic oil level ..........................................5-22 Compressed-air brake system (option) ..............................5-31 Electrical system.................................................................5-37 Engine and hydraulics cooling system ...............................5-11 Engine lubrication system.....................................................5-7 Explanation of symbols on the maintenance label .............5-54 Filling in engine oil ................................................................5-8 Filling up coolant.................................................................5-13 Filling up hydraulic oil .........................................................5-22 Fluids and lubricants...........................................................5-53 Fuel system ..........................................................................5-3 Heating ...............................................................................5-34 Hydraulic pressure lines .....................................................5-24 Hydraulic system ................................................................5-20 Maintenance label overview ...............................................5-55 Maintenance of attachments ..............................................5-44 Maintenance work if the machine is used in a saline environ-

S-2

ment....................................................................................5-45 Pivots and hinges ...............................................................5-44 Replacing the engine oil filter cartridge ..............................5-10 Screw connections .............................................................5-44 Service and maintenance work at regular intervals............5-39 Trailer couplings .................................................................5-41 Tyre care ............................................................................5-32 V-belts ................................................................................5-19 Maintenance plan .....................................................................5-48 Model designation – trade names...............................................1-4 O Operation Additional control circuit with switch ...................................3-93 Before moving off ...............................................................3-38 Decommissioning the machine for a longer time..............3-113 Hose burst valve.................................................................3-88 Load stabiliser ....................................................................3-51 Moving off ...........................................................................3-40 Parking the machine...........................................................3-43 Reversing fan (option) ........................................................3-54 Speed range selection........................................................3-40 Starting the engine .............................................................3-29 Operator's Manual ......................................................................1-1 Explanation of abbreviations and symbols ...........................1-2 Explanation of safety symbols ..............................................1-2 Overview of attachments ............................................................1-6 P Pallet forks ................................................................................3-81 Brief instructions for fork arms............................................3-83 Picking up loads .................................................................3-86 Safety instructions ..............................................................3-81 Transporting loads..............................................................3-87 Parking brake............................................................................3-50 Putting into operation Operating staff ......................................................................3-9 Putting the machine into operation for the first time .............3-9 Q Quickhitch with hydraulic lock...................................................3-70 Quickhitch with mechanical lock ...............................................3-71 R Radiator Draining coolant..................................................................5-14 Rear window emergency exit....................................................3-15 Regulations for the operating staff ..............................................1-7 Releasing the pressure on the quick couplers..........................3-69 Removing a standard bucket from the quickhitch.....................3-72 Removing the pallet forks from the quickhitch ..........................3-79 Rotating beacon........................................................................3-57 Running-in period .......................................................................3-9

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Index S Safe load indicator....................................................................3-62 Functional check ................................................................3-63 Note on the display.............................................................3-63 What to do when the indicator lights come on....................3-64 Safety instructions ......................................................................2-1 Applications with lifting gear .................................................2-8 General conduct ...................................................................2-3 Identification .........................................................................2-1 Maintenance.......................................................................2-10 Maintenance work on protective ROPS/FOPS structures..2-12 Operation..............................................................................2-6 Special hazards..................................................................2-12 Trailers and attachments......................................................2-8 Transport ..............................................................................2-9 Seat Backrest adjustment...........................................................3-17 Horizontal adjustment.........................................................3-17 Seat adjustment .................................................................3-16 Weight adjustment..............................................................3-17 Seat adjustment........................................................................3-16 Seat belt ...................................................................................3-19 Adjustment .........................................................................3-20 Fastening the seat belt .......................................................3-19 Service brake............................................................................3-49 Signalling system......................................................................3-57 Signs and symbols ...................................................................1-13 Specific information for driving on public roads ........................3-38 Specifications ............................................................................. 6-1 Axles.....................................................................................6-3 Brakes ..................................................................................6-4 Consumer pressure on additional control circuit (option) .....6-6 Coolant compound table ....................................................6-12 Dimensions with bucket......................................................6-19 Dimensions with pallet forks...............................................6-20 Drive.....................................................................................6-2 Electric components.............................................................6-8 Engine ..................................................................................6-1 Frame...................................................................................6-1 Front axle ............................................................................. 6-3 Fuse assignment ..................................................................6-7 Hydraulic pump ....................................................................6-5 Hydraulic ram protection ......................................................6-5 Lift, tilt and push-out ram velocity.........................................6-5 Main fuse box with relays .....................................................6-9 Model and trade names........................................................6-1 Noise levels........................................................................6-12 Oil/water fan .........................................................................6-2 Pilot control...........................................................................6-6 Rear axle..............................................................................6-3 Relays (103 kW diesel engine).............................................6-9 Relays (88 kW diesel engine)...............................................6-9 Steering system....................................................................6-4 Switching relay assignment................................................6-10 Tightening torques..............................................................6-13 Trailer couplings.................................................................6-13 Tyres ..................................................................................6-11 00 0291 628 0 - BA SCORPION – AUSTRALIA

Variable displacement motor................................................ 6-2 Variable displacement pump ................................................ 6-2 Vibration .............................................................................6-12 Weights ..............................................................................6-11 Work hydraulics.................................................................... 6-5 Starting aid ...............................................................................3-32 Steering mode 4 wheel steering ................................................................. 3-46 Diagonal steering (crab steering option) ............................3-47 Front axle steering..............................................................3-46 Switching the differential lock ON and OFF..............................3-53 Switching the overload cutoff ON and OFF ..............................3-65 T Telescopic boom Checking and adjusting the slide plates .............................5-27 Checking the transport position of the pallet forks ............. 3-80 Extending/raising................................................................3-66 Lubrication.......................................................................... 5-27 Retract/lower ......................................................................3-66 Tilt ram lock ..............................................................................3-89 Towing and transporting the machine ....................................3-107 Trailer coupling .........................................................................3-97 Trailer weight/drawbar load ......................................................6-13 Transport With full bucket ...................................................................3-75 Turn indicators.......................................................................... 3-57 Tyre care ..................................................................................5-32 V V-belts ......................................................................................5-19 Ventilation.................................................................................3-58 Ventilation, fresh air............................................................3-58 W Warning identification ................................................................. 1-9 Warranty..................................................................................... 1-5 Washer system Front window washer pump ...............................................3-60 Front window wiper ............................................................3-60 Rear window washer pump ................................................3-60 Rear wiper .......................................................................... 3-60 Tank ...................................................................................3-60 Wheel change...........................................................................5-33 Working With the pallet forks............................................................3-81 With the standard bucket....................................................3-73 Working lights ...........................................................................3-56

S-3

Index

S-4

00 0291 628 0 - BA SCORPION – AUSTRALIA

CLAAS KGaA mbH keep abreast of the latest technical developments and constantly improve their products. For this reason, we may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which have already been delivered and which will not be implemented on these machines.

Technical data, dimensions and weights are given as an indication only. Responsibility for errors or omissions not accepted.

No reproduction or translation of this publication, in whole or part, without the written consent of CLAAS KGaA mbH All rights under the provision of the Copyright Act are reserved.

CLAAS KGaA mbH D-33426 HARSEWINKEL Germany

Our contribution to the environment: this manual has been printed on 100 % chlorine-free paper.

CLAAS KGaA mbH Postfach 1163 33426 Harsewinkel Tel. +49 (0) 5247 12-0 www.claas.com

00 0291 628 0 BA SCORPION – AUSTRALIA en - 11/10 Printed in Germany