Claas Telehandlers Scorpion–Australia 6030 COMPACT 408-01 Operator's Manual - PDF DOWNLOAD

SCORPION – AUSTRALIA 6030 COMPACT Model: 408-01

Operator's Manual

Original Operator's Manual

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Translation of original Operator's Manual

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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 .................................................................................EG-1 Introduction 1 Operator's Manual ................................................................................................... 1-1 Important notice on this Operator's Manual ....................................................... 1-1 Important notice on machine safety ................................................................... 1-1 Explanation of safety symbols ........................................................................... 1-2 Explanation of abbreviations and symbols ........................................................ 1-2 Machine overview .................................................................................................... 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 Fields of application and using a telehandler with an attachment ........................... 1-6 Authorised attachments ..................................................................................... 1-6 Legal regulations regarding telehandler operation .................................................. 1-8 Principal regulations for the operating staff ....................................................... 1-8 Driving licence ................................................................................................... 1-8 Licence/identification ......................................................................................... 1-8 Machine inspections .......................................................................................... 1-9 Documents ........................................................................................................ 1-9 On-board equipment .......................................................................................... 1-9 Warning identification of machine 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 work pump number .......................................................................... 1-11 Variable displacement pump number .............................................................. 1-11 Variable displacement motor number .............................................................. 1-12 Gearbox number (standard 30 kph) ................................................................ 1-12 Gearbox number (optional 40 kph) .................................................................. 1-12 Front and rear axle numbers ........................................................................... 1-12 Description of signs and labels .............................................................................. 1-13 Important notice on signs and labels ............................................................... 1-13 Labels on the outside of the machine .............................................................. 1-13 Labels on the inside of the machine ................................................................ 1-14 Labels in the engine compartment .................................................................. 1-17

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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 Cab, roll-over bar, protective screen ................................................................ 2-12 Warning of special hazards .................................................................................... 2-12 Electric energy ................................................................................................. 2-12 Gas, dust, steam, smoke ................................................................................. 2-12 Hydraulic equipment ........................................................................................ 2-13 Noise ................................................................................................................ 2-13 Oil, grease and other chemical substances ..................................................... 2-13 Battery ............................................................................................................. 2-13 Tyres ................................................................................................................ 2-13 Operation 3 General information regarding the description of the control elements ................... 3-1 Inside of cab: overview ............................................................................................ 3-2 Instrument panel, multifunctional lever, switch consoles: overview ......................... 3-4 Indicator and warning lights: description .................................................................. 3-6 Indicator light check ........................................................................................... 3-6 Indicator light and warning light on indicating instrument .................................. 3-6 Indicator lights and indicators on the instrument panel ...................................... 3-8 Important notice on putting the machine into operation ......................................... 3-10 Operating staff ................................................................................................. 3-10 Running-in period ............................................................................................ 3-10 “Diesel engine start” checklist .......................................................................... 3-11 Checklist “Putting the machine into service” .................................................... 3-12 “Parking” checklist ........................................................................................... 3-12 Cab ........................................................................................................................ 3-13 Safety instructions regarding cab entrance and exit ........................................ 3-13 Safety instruction – side window (right) ........................................................... 3-13 Locking and unlocking the door ....................................................................... 3-13 Opening the upper cab door to a gap .............................................................. 3-14 Opening/closing the rear window ..................................................................... 3-15 Interior light operation (cab) ............................................................................. 3-15 Cab emergency exit ............................................................................................... 3-16 Information on emergency exit via the rear window ........................................ 3-16 Fire extinguisher (option) ....................................................................................... 3-16 Fire extinguisher operation .............................................................................. 3-16 Seat ........................................................................................................................ 3-17 Important notice on seat operation .................................................................. 3-17 Seat adjustment without options (overview) .................................................... 3-17 Weight adjustment ........................................................................................... 3-18 Backrest adjustment ........................................................................................ 3-18 Horizontal adjustment ...................................................................................... 3-18 Lumbar support adjustment (option) ................................................................ 3-19 Adjustment of horizontal suspension (option) .................................................. 3-19 I-2

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Contents Adjustable seat suspension damper (option) .................................................. 3-19 Heated seat (option) ........................................................................................ 3-19 Air-suspension seat (option) .................................................................................. 3-20 Important notice on air-suspension seat operation .......................................... 3-20 Air-suspension seat operation ......................................................................... 3-20 Seat belt (lap belt) .................................................................................................. 3-21 Important notice on the seat belt ..................................................................... 3-21 Fastening the seat belt .................................................................................... 3-21 Unfastening the seat belt ................................................................................. 3-22 Longer/shorter seat belt adjustment ................................................................ 3-22 Engine cover .......................................................................................................... 3-23 Opening/closing the engine cover ................................................................... 3-23 Battery master switch ............................................................................................ 3-23 Switching the battery master switch ON and OFF ........................................... 3-23 Electronic key-based drive interlock (option) ......................................................... 3-24 Description of electronic drive interlock ........................................................... 3-24 Coding (“training”) new ignition keys ............................................................... 3-24 Enabling (locking) the drive interlock ............................................................... 3-25 Disabling (releasing) the drive interlock ........................................................... 3-25 Deleting coded keys ........................................................................................ 3-25 Safety functions ............................................................................................... 3-25 Electronic drive interlock with code input (option) .................................................. 3-26 Description of electronic drive interlock ........................................................... 3-26 Entering/changing the personal code .............................................................. 3-27 Enabling the drive interlock ............................................................................. 3-27 Disabling the drive interlock ............................................................................. 3-28 Putting the drive interlock out of operation ...................................................... 3-28 Putting the drive interlock back into operation again ....................................... 3-29 Interruption of drive interlock power ................................................................ 3-29 Drive interlock maintenance ............................................................................ 3-29 Fuel, diesel engine and hydraulic oil preheating (option) ...................................... 3-30 Putting the coolant and oil preheater into operation ........................................ 3-30 Fuel preheater operation ................................................................................. 3-30 Putting the diesel engine into operation ................................................................. 3-31 Preparing to start the engine ........................................................................... 3-31 Starting the engine .......................................................................................... 3-32 Avoiding running the engine under low-load conditions .................................. 3-33 Stopping the engine ......................................................................................... 3-33 Jump-starting the engine (external battery) ........................................................... 3-34 Safety instructions regarding external starting aids ......................................... 3-34 Providing external starting aid ......................................................................... 3-34 Preparing to put the machine into operation .......................................................... 3-35 Important notice regarding driving on public roads .......................................... 3-35 Preparing for driving on public roads ............................................................... 3-36 Carrying out a functional check of the machine ............................................... 3-36 Locking the control lever (joystick) and the 3rd control circuit (attachments) .. 3-37 Putting the machine into operation ........................................................................ 3-38 Selecting the speed range 0 – 30 kph (40 kph option) .................................... 3-38 Driving direction selection (reversing operation forwards/reverse) .................. 3-39 Steering system ..................................................................................................... 3-40 Steering column height and angle adjustment (option) ................................... 3-40 Checking the steering system ......................................................................... 3-40 Selecting the steering modes .......................................................................... 3-41 Steering synchronisation (wheels front/rear axles) ................................................ 3-42 Important notice on steering synchronisation .................................................. 3-42 Wheel synchronisation .................................................................................... 3-42 Accelerator pedal ................................................................................................... 3-43 00 0291 629 0 - BA SCORPION – AUSTRALIA

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Contents Accelerator pedal lock (option) .............................................................................. 3-43 Switching the accelerator pedal lock ON/OFF ................................................. 3-43 Brake/inching pedal ............................................................................................... 3-44 Important notice on brake/inching pedal actuation .......................................... 3-44 Inching with the brake/inching pedal ................................................................ 3-44 Braking with the brake/inching pedal ............................................................... 3-44 Parking brake ......................................................................................................... 3-45 Information on the parking brake ..................................................................... 3-45 Applying the parking brake .............................................................................. 3-45 Low-speed control (option) .................................................................................... 3-46 Selecting the drive speed ................................................................................ 3-46 Differential lock ...................................................................................................... 3-46 Important notice on the differential lock function ............................................. 3-46 Load stabiliser ........................................................................................................ 3-47 Information regarding the load stabiliser function ............................................ 3-47 Switching the load stabiliser ON or OFF .......................................................... 3-48 Backup warning system (option) ............................................................................ 3-48 Information on the backup warning system ..................................................... 3-48 Machine lights ........................................................................................................ 3-49 Machine lights operation .................................................................................. 3-49 Working lights operation .................................................................................. 3-50 Signalling system ................................................................................................... 3-51 Turn indicator operation ................................................................................... 3-51 Hazard warning system operation ................................................................... 3-51 Rotating beacon operation (option) ................................................................. 3-51 Cab heating and ventilation ................................................................................... 3-52 Operation of the heating and ventilation system .............................................. 3-52 Rear window heating (option) ................................................................................ 3-52 Rear window heating ....................................................................................... 3-52 Reversing fan (option) ............................................................................................ 3-52 Reversing fan operation ................................................................................... 3-52 Air conditioning (option) ......................................................................................... 3-53 Information on putting the air conditioning into operation ................................ 3-53 Air conditioning operation ................................................................................ 3-53 Washer system ...................................................................................................... 3-54 Front window wiper operation .......................................................................... 3-54 Rear window wiper operation .......................................................................... 3-54 Washer pump operation .................................................................................. 3-54 Tank for washer system ................................................................................... 3-54 Telescopic boom control lever: overview ............................................................... 3-55 Operating the control lever for the lift, tilt and push-out rams .......................... 3-55 Safe load indicator for telescopic boom ................................................................. 3-56 Important notice on the safe load indicator ...................................................... 3-56 Important notice on the safe load indicator overload display ........................... 3-57 Functional check of the safe load indicator ...................................................... 3-57 Overview of indicator lights on overload display .............................................. 3-57 What to do when the indicator lights come on ................................................. 3-58 Switching the overload cutoff ON and OFF ..................................................... 3-59 Operating and securing the 3rd control circuit ....................................................... 3-60 Locking and unlocking the quickhitch or an attachment .................................. 3-60 Operating the telescopic boom .............................................................................. 3-61 Raising/extending the telescopic boom ........................................................... 3-61 Retracting/lowering the telescopic boom ......................................................... 3-61 Emergency lowering of telescopic boom in case of diesel engine breakdown ...... 3-62 Lower or raise as follows: ................................................................................ 3-62

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Contents Equipping the machine with a standard bucket ..................................................... 3-63 Field of application of bucket ........................................................................... 3-63 Mounting an attachment on a quickhitch with a hydraulic lock ........................ 3-63 Mounting an attachment on a quickhitch with a mechanical lock .................... 3-64 Removing a standard bucket from the quickhitch ............................................ 3-65 Working with the standard bucket .......................................................................... 3-66 Important notice on bucket use ....................................................................... 3-66 Driving on public roads with a standard bucket ............................................... 3-67 Moving with the bucket fully dumped out ......................................................... 3-67 Safety instructions regarding work with a full bucket ....................................... 3-68 Standard bucket payload ................................................................................. 3-69 Loading loose material .................................................................................... 3-70 Loading if the material is hard to penetrate ..................................................... 3-70 Removing material/digging in soft soil ............................................................. 3-71 Removing material/digging in hard soil ............................................................ 3-72 Grading ............................................................................................................ 3-72 Loading vehicles .............................................................................................. 3-72 Fitting pallet forks ................................................................................................... 3-73 Picking up pallet forks with the quickhitch ....................................................... 3-73 Removing the pallet forks from the quickhitch ................................................. 3-73 Pallet forks transport position without load ...................................................... 3-73 Driving on public roads with the pallet forks .................................................... 3-74 Working with the pallet forks .................................................................................. 3-75 Safety instructions regarding the use of the pallet forks .................................. 3-75 Brief instructions for fork arms ......................................................................... 3-77 Adjusting the fork arms of the pallet forks ....................................................... 3-78 Description of load diagram for pallet forks and bucket ................................... 3-79 Picking up material with the pallet forks .......................................................... 3-80 Transporting material ....................................................................................... 3-81 Setting down the material ................................................................................ 3-81 “Hose burst valve” safety feature ........................................................................... 3-82 Emergency lowering of the telescopic boom with the hose burst valve .......... 3-82 Retrofitting to attachments with hydraulic functions ............................................... 3-83 Important notice on fitting attachments from other manufacturers .................. 3-83 Pressure relief on the quickhitch couplers ....................................................... 3-84 Mounting an attachment from another manucturer on the quickhitch ............. 3-84 Hydraulic connections: attachments from other manufacturers on the 3rd control circuit .................................................................................. 3-85 Removing attachments from other manufacturers from the quickhitch ........... 3-86 Tilt ram lock (option) .............................................................................................. 3-86 Switching the tilt ram lock ON and OFF .......................................................... 3-86 Continuous operation of 3rd front control circuit (option) ....................................... 3-87 Switching continuous operation of 3rd control circuit ON/OFF ........................ 3-87 Electric changeover valve for operation of 3rd control circuit as additional front control circuit (option) ............................................................... 3-88 Switching the additional control circuit ON or OFF .......................................... 3-88 Rear hydraulic additional control circuit (option) .................................................... 3-89 Description of the additional control circuit ...................................................... 3-89 Connecting an attachment onto the additional control circuit .......................... 3-89 Additional control circuit operation ................................................................... 3-90 Tipping trailer connection (option) ......................................................................... 3-91 Operating the tipping trailer connection ........................................................... 3-91 Operation of the Autohitch trailer coupling (option) ............................................... 3-92 Important notice on the Autohitch trailer coupling ........................................... 3-92 Operation of Autohitch trailer coupling ............................................................ 3-93

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Contents Automatic trailer coupling (option) ......................................................................... 3-94 Trailer coupling description and use ................................................................ 3-94 Attaching a trailer ............................................................................................. 3-94 Uncoupling the trailer ....................................................................................... 3-95 Compressed-air brake system (option) .................................................................. 3-96 Safety instructions regarding the compressed-air braking system .................. 3-96 Coupling and uncoupling compressed-air hoses (dual-circuit brake system) .. 3-96 Compressed-air gauge .................................................................................... 3-97 Hydraulic trailer brake (option) ............................................................................... 3-97 Information on the hydraulic trailer brake ........................................................ 3-97 Fitting attachments from other manufacturers (option) .......................................... 3-98 Quickhitches for attachments from other manufacturers ................................. 3-98 Important notice on fitting attachments from other manufacturers .................. 3-98 Fitting attachments from other manufacturers ................................................. 3-99 Example: inspection plan for attachments from other manufacturers ............ 3-100 Towing the machine ............................................................................................. 3-101 Safety instructions for towing away ............................................................... 3-101 Getting ready for towing ................................................................................. 3-101 Towing the machine ....................................................................................... 3-102 Once towing is over ....................................................................................... 3-102 Decommissioning the machine temporarily ......................................................... 3-103 Stopping/parking the machine ....................................................................... 3-103 Decommissioning the machine for a longer time ........................................... 3-103 Loading the machine on a transport vehicle ........................................................ 3-104 Safety instructions regarding loading ............................................................. 3-104 Loading the vehicle ........................................................................................ 3-105 Tying down the machine ................................................................................ 3-105 Crane handling the machine ................................................................................ 3-106 Safety instructions regarding crane handling ................................................. 3-106 Crane handling .............................................................................................. 3-107 Final decommissioning of machine ...................................................................... 3-108 Information on decommissioning ................................................................... 3-108 Preparing disposal ......................................................................................... 3-108 Disposal ......................................................................................................... 3-108 Troubleshooting 4 Information on troubleshooting ................................................................................ 4-1 Diesel engine malfunctions ...................................................................................... 4-1 Drive malfunctions ................................................................................................... 4-4 Malfunctions in the air conditioning system (option) ................................................ 4-5 Maintenance 5 Important notice on maintenance work .................................................................... 5-1 Maintenance staff .............................................................................................. 5-1 Important notice on maintenance work .............................................................. 5-1 Safety prop for telescopic boom .............................................................................. 5-2 Mounting the safety prop onto the lift ram ......................................................... 5-2 Fuel system .............................................................................................................. 5-3 Important safety instructions for refuelling ......................................................... 5-3 Diesel fuel specification ..................................................................................... 5-3 Stationary fuel pumps ........................................................................................ 5-3 Refuelling ........................................................................................................... 5-4 Checking/cleaning the additional fuel filter (water separator, option) ................ 5-4 Bleeding the fuel system .................................................................................... 5-5 Replacing the fuel filter ...................................................................................... 5-6

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Contents 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 Information on inspection and cleaning work on the cooling system ............... 5-12 Temperature gauge: engine coolant ................................................................ 5-13 Checking the coolant level ............................................................................... 5-13 Filling up coolant .............................................................................................. 5-14 Draining coolant ............................................................................................... 5-15 Cleaning the radiator fins ................................................................................. 5-16 Cleaning the radiator with the reversing fan (option) ....................................... 5-17 Air filter ................................................................................................................... 5-18 Checking air filter contamination ..................................................................... 5-18 Replacing the filter cartridge ............................................................................ 5-19 V-belts .................................................................................................................... 5-20 Checking the V-belts ....................................................................................... 5-20 Retightening the V-belts .................................................................................. 5-20 Hydraulic system ................................................................................................... 5-21 Important safety instructions regarding the hydraulic system .......................... 5-21 Monitoring the hydraulic oil and the return filter ............................................... 5-22 Checking the hydraulic oil level once a day ..................................................... 5-23 Filling up hydraulic oil ...................................................................................... 5-23 Important notice regarding the use of biodegradable oil ................................. 5-24 Checking hydraulic pressure lines ......................................................................... 5-25 Specific safety instructions regarding pressure line checks ............................ 5-25 Lubrication work ..................................................................................................... 5-26 General safety instructions regarding lubrication work .................................... 5-26 Lubricating the rear axle oscillation-type bearing ............................................ 5-26 Lubricating the planetary drive bearing (front and rear axles) ......................... 5-26 Lubrication points on the telescopic boom: overview ...................................... 5-27 Lubricating the telescopic boom ...................................................................... 5-27 Checking and adjusting the slide plates .......................................................... 5-27 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 Compressed-air tank and lines ........................................................................ 5-31 Compressor attachment and V-belt ................................................................. 5-31 Tyres ...................................................................................................................... 5-32 Daily tyre checks ............................................................................................. 5-32 Changing wheels ............................................................................................. 5-33 Heating/cab ventilation .......................................................................................... 5-34 General information on the heating system ..................................................... 5-34 Cleaning/replacing the fine-dust filter .............................................................. 5-34

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Contents Air conditioning (option): maintenance ................................................................... 5-35 Important safety instructions regarding the air conditioning system ................ 5-35 Filling up the air conditioning system ............................................................... 5-35 Functional and visual checks of the air conditioning ........................................ 5-36 Cleaning the heat exchanger (condenser) ....................................................... 5-37 Maintenance of the electrical system ..................................................................... 5-38 General instructions ......................................................................................... 5-38 Safety instructions regarding the electrical system and the battery ................. 5-38 Checking/replacing the battery ........................................................................ 5-39 Inspection and maintenance work on the electrical system at regular intervals ............................................................................... 5-40 Checking the alternator .................................................................................... 5-40 Checking/replacing relays and fuses on the board .......................................... 5-41 Checking/replacing the main fuse box and the switching relays ..................... 5-41 Maintenance of the automatic trailer coupling (option) .......................................... 5-42 Cleaning and lubricating the trailer coupling .................................................... 5-42 Check the trailer coupling for wear .................................................................. 5-42 General maintenance work .................................................................................... 5-43 Specific safety instructions regarding cleaning ................................................ 5-43 Cleaning inside the cab ................................................................................... 5-44 Cleaning the seat belt (lap belt) ....................................................................... 5-44 Cleaning the exterior of the machine ............................................................... 5-44 Cleaning the engine and the engine compartment .......................................... 5-45 Checking screw connections ........................................................................... 5-45 Checking pivots and hinges ............................................................................. 5-45 Maintenance: particulate-soot filter (option) ........................................................... 5-46 Checking the electronic filter monitoring .......................................................... 5-46 Maintenance of attachments and of the work equipment ...................................... 5-46 Maintenance work “Aggressive Media” (option) ..................................................... 5-47 Important notice on anticorrosion protection applied in the factory ................. 5-47 Components coated with anticorrosive wax .................................................... 5-47 Measures for maintaining anticorrosive protection .......................................... 5-48 Applying the protective anticorrosion coating .................................................. 5-49 Treatment of oxidised surfaces ........................................................................ 5-49 Maintenance plan (overview) ................................................................................. 5-50 Fluids and lubricants ............................................................................................. 5-55 Maintenance label and maintenance plan under preparation ................................ 5-56 Explanation of symbols on the maintenance label ........................................... 5-56 Maintenance label ............................................................................................ 5-57

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Contents Specifications 6 Model and trade names: overview ........................................................................... 6-1 Frame ...................................................................................................................... 6-1 Engine ...................................................................................................................... 6-1 Power train ............................................................................................................... 6-2 Variable displacement pump, boost pump ........................................................ 6-2 Variable displacement motor ............................................................................. 6-2 Oil/water fan ............................................................................................................. 6-3 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 ................................................................... 6-6 Hydraulic pilot control ........................................................................................ 6-6 Usable consumer pressure at additional control circuit (option) ........................ 6-6 Electrical system ...................................................................................................... 6-7 Electric components .......................................................................................... 6-7 Fuses: overview ................................................................................................. 6-7 Main fuse box with relays .................................................................................. 6-8 Relays (overview) .............................................................................................. 6-9 Tyres ...................................................................................................................... 6-10 Weights .................................................................................................................. 6-10 Trailer couplings: trailer weight/drawbar load ........................................................ 6-10 Noise levels ........................................................................................................... 6-11 Vibration ................................................................................................................. 6-11 Coolant compound table ........................................................................................ 6-11 Tightening torques ................................................................................................. 6-12 General tightening torques .............................................................................. 6-12 Specific tightening torques .............................................................................. 6-12 Pallet forks payload ............................................................................................... 6-13 Payload: bucket ..................................................................................................... 6-13 ......................................................................................................................... 6-13 Dimensions with bucket ........................................................................................ 6-14 Dimensions with pallet forks ................................................................................. 6-15 Index S Index S-1

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EC Declaration of Conformity

EC Declaration of Conformity EC Declaration of Conformity

EC Declaration of Conformity Manufacturer Kramer-Werke GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf

Product Machine designation

408

Model/version

408-01 (6030 cp)

Serial number

408 01 _ _ _ _ _

Output kW

58/55.1 (74.9 option)

Measured sound power level dB(A)

103.9

Guaranteed sound power level dB(A)

104 (58/55.1 kW) 106 (74.9 kW)

Conformity assessment procedure The following inspection body was involved in the procedure: Fachausschüsse Bau und Tiefbau (Notified body number (EU): 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/EC, 2000/14EC and EN ISO 3744: 1995, 2004/108/EC, 2002/44/EC, DIN EN 1459, DIN EN ISO 12100-1 and 2, DIN EN 474-1 and 3, DIN EN 14121, DIN EN 3471, DIN EN 13510, EN ISO 3744, EN ISO 3746, DIN EN ISO 3449

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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EC Declaration of Conformity Notes:

EG-2

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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 model 408-01 telehandler.

It is primarily designated for the operator and provides instructions on the use, the adjustment, the operation and the maintenance of the machine.

The operator must 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 (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. Read this Operator's Manual carefully prior to the first drive.

• Basic rule: 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.

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. ➥ – see chapter 5 “Maintenance plan (overview)” on page 5-50

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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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.

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

Explanation

•

Identification of general enumerations

☞

Identification of activities to carry out •

Identification of subdivision and order of activities

➥

Identification of the results of an enumeration

➥

Identification of results of activities

Abbreviations

Explanation

max.

maximum

e.g.

for example

Fig.

Figures

S/h

Service hour

Order no.

Order or part number

(opt)

Option This symbol shows the driving direction – for better orientation in figures and graphics

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Introduction 1.2 Machine overview 3

4

5

6

7

8

9

13

10

11

9

12 13 2

13

1

1

14

2 Fig. 1:

17

16

4

15

Machine outside views

Pos. Description

Pos. Description

1

Hooks for loading/tying down the machine (front left/right of frame)

11

Autohitch, automatic or adjustable trailer coupling (options)

2

Headlight with turn indicator

12

Toolbox

3

Rearview mirror

13

4

Front working light (option)

Hooks for loading/tying down the machine (rear left/right of frame)

5

Boom working light

14

Door arrester

6

Engine cover lock

15

Handle in cab

7

Eye hook1 for installing/removing the cab

16

Door opener

8

Rear working light

17

Cab access

9

Brake, rear and turn indicator lights

10

Hydraulic ports (additional control circuit, tipping trailer, unpressurised return, leak oil options)

00 0291 629 0 - BA SCORPION – AUSTRALIA

1.

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

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.

This machine is a versatile and powerful helper on construction sites, in agriculture and for recycling applications. The wide range of attachments accounts for the numerous applications of the machine: as a snow plough, a construction machine, a fork lift for applications with palletised goods, or as a tractor for transport applications in agriculture.

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 Telehandler model

Trade name

408-01

6030 cp

Main components of machine • • • • • • • • • •

1-4

Sturdy steel sheet frame; rubber-mounted engine Telescopic boom (onefold) ROPS/FOPS tested cab (roll-over/falling object protection) Water-cooled Deutz four-cylinder turbocharged in-line engine, exhaust emissions according to 2004/26/EC standard Automotive drive, infinitely variable hydrostatic axial-piston gearbox; maximum speed 30 kph (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 (brake disc on front and rear axle drive shaft) Parking brake (brake disc on front axle drive shaft) Telescopic boom (onefold)

00 0291 629 0 - BA SCORPION – AUSTRALIA

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 transfer gearbox. The output of the hydraulic motor is transmitted to the front and rear axles via the transfer gearbox (at the centre of the machine) and the cardan shaft connection. This creates a permanent 4 wheel drive transmission.

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 an 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/inching 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, as well as of the coolant temperature and level.

1.4 Telehandler warranty 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 in the first place how the telehandler is used.

Caution!

In order to avoid damage to the machine, only the attachments listed in the table have been authorised for installation on the machine.

Mounting attachments from other manufacturers is only allowed if they correspond to the description in chapter “Operation” Retrofitting to attachments with hydraulic functions on page 3-83 and Fitting attachments from other manufacturers (option) on page 3-98.

Note that not all specified attachments are allowed to be used on public roads Germany.

Please refer to the General Certification for Vehicles (Germany) or the data confirmation (Germany) for information on the authorised attachments and the specific requirements!

Attachments without a General Certification for Vehicles (Germany) or data confirmation (Germany) require a Separate Certification for Vehicles (Germany) made out by the competent authority!

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

Authorised attachments Attachment type no.

Dimensions

Heaped

Standard bucket – normal material

1000241488 1000241489

2300 mm (with teeth) 2300 mm (without teeth)

1.0 m3

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

408-01

Standard bucket – lightweight material

1000242365

2300 mm (without teeth)

1.4 m3

Picking up, transporting and loading lightweight material (material density ≤ p = 1.3 t/m³)

408-01

Standard bucket – superlight1000242366 weight material2

2400 mm (without teeth)

2.0 m3

Picking up, transporting and loading very lightweight material (material density ≤ p = 0.9 t/m³)

408-01

Picking up and transporting large stones, e.g. flags

408-01

Picking up and transporting silage or recycling material (material density ≤ p = 1.1 t/m³)

408-01

1

Attachment

Stone bucket

1000249312

2300 mm

–

Silage bucket with hydraulic clamp4, 5

1000249266

2400 mm

1.45 m3

1-6

Telehandler model

Use

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Introduction Attachment type no.

Dimensions

Heaped

Use

Manure forks 4, 5 with hydraulic grab

1000249314 1000249480

2300 mm 2500 mm

–

Silage cutter4, 5

1000249317

800 mm

–

Picking up and transporting manure and silage

Pallet forks3, 4, 5

1000146909 1000238331

1200 mm

Bale grapple4, 5

1000166756

Clamping width 800 – 1800 mm

–

1000249268

–

–

1000249269

–

–

1000249270

1000 mm

–

1

Attachment

Bale grapple V404, 5 Bale grapple W500

4, 5, 6

Bale grapple V60004, 5 1.

2.

3.

4.

5.

6.

Load diagram Picking up and transporting pallets

Telehandler model 408-01 408-01 408-01 408-01

Picking up and transporting hay and straw bales (load-bearing capacity 1500 kg)

408-01 408-01 408-01

Bear in mind the safe load indicator when working with this attachment With screwed-on blade Only with authorised load diagram for telehandler Authorised for public roads if the distance between the front edge of the bucket, or the pallet forks with fork arm protection, and the centre of the steering wheel is not over 3500 mm in transport position(see “Merkblatt für Anbaugeräte“ (leaflet with specific instructions for attachments) § 30, 11 of the StVZO German road traffic regulations See the Operator's Manual of the attachment for putting the attachment into operation and using it Attachment can be operated only with a switchable 3rd control circuit.

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1-7

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 for the machine, 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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Introduction Machine inspections

A

Fig. 1:

Example: inspection label

In Germany, legislation requires all machine operators to have all machines and equipment inspected regularly.

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) 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.)

This requirement is met, for instance, if the results are documented in a test logbook, a test log file or in a test report; see also policy of German employers' liability insurance association for construction engineering “Inspection of vehicles by experts” (BGG 916) 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 BGV D29 § 57 clause 2 (safety and health regulations of German employer's liability insurance association) • Operator's Manual Get informed on and follow the legal regulations of your country.

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 machine on public roads (option) According to § 52 clause 4.1 of StVZO German road traffic regulations, from 01.10.1998 onwards machines that are used on public roads for the construction, maintenance and cleaning of roads or facilities can be fitted with the red and white warning identification as per DIN 30 710, also in connection with a yellow rotating beacon (option).

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

00 0291 629 0 - BA SCORPION – AUSTRALIA

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 right mudguard attachment). 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

6 7 8 9 10 11

Fig. 3:

Serial number and type label position

1 Machine model 2 Version 3 Serial no.

4 Year of construction 5 Output (kW) 6 Front gross axle weight rating (kg) 7 Rear gross axle weight rating (kg) 8 Gross weight rating (kg) 9 Dead weight (kg) 10 Maximum payload (kg) 11 Check number of EU approval

408 408-01 (6030 cp) 408 01 0023 2010 58 (74.9 option) 5500 5500 8500 – – e1*2003/37*0374*00

Other data: – see chapter 6 “Specifications” on page 6-1

Cab number The cab type label (arrow) is located on the side console, on the right in driving direction (near the seat).

Fig. 4:

1-10

Cab type label

00 0291 629 0 - BA SCORPION – AUSTRALIA

Introduction Engine number The engine number is located on the type label on the engine valve cover (arrow A) and is stamped on the side of the engine block (arrow B).

Fig. 5:

Engine number type label

Hydraulic work pump number Seen on lower side of machine The type label (arrow) is located on the hydraulic work pump housing (next to the where the variable displacement pump is mounted)

Fig. 6:

Hydraulic work pump type label

Variable displacement pump number Seen on upper side of machine between cab and engine vat The type label (arrow) is located on the hydraulic pump housing (next to where the pump is installed on the diesel engine)

Fig. 7:

Hydraulic pump type label

00 0291 629 0 - BA SCORPION – AUSTRALIA

1-11

Introduction Variable displacement motor number Seen on upper side of machine between cab and engine vat The type label (arrow) is located on the housing of the variable displacement motor.

Fig. 8:

Variable displacement motor type label

Gearbox number (standard 30 kph) Seen on lower side of machine The type label (arrow) is located on the gearbox housing.

Fig. 9:

Gearbox type label

Gearbox number (optional 40 kph) Seen on access side of cab The type label (arrow) is located on the housing of the variable displacement motor.

Fig. 10: Variable displacement motor type label

Front and rear axle numbers Seen on lower side of machine The type label (arrow) is located on the axle tube (inside) Rear axle (on the left in driving direction) Front axle (on the right in driving direction)

Fig. 11: Rear and front axle type label

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00 0291 629 0 - BA SCORPION – AUSTRALIA

Introduction 1.8 Description of signs and 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!

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. 12: Eye hook label

A

B

Fig. 13: Label for points used for tying down the machine

Machine noise level label Noise levels produced by the machine.

LWA = sound power level

XX

Location On the rear window.

Fig. 14: Noise level label

30

40

Fig. 15: Speed label

Machine top speed label 30 kph (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.

Fig. 16: Danger label

A

Slinging point labels for loading and tying down the machine A slinging points for crane handling B slinging points for tying down the machine for transport 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).

B

Label: filler opening for hydraulic oil A = hydraulic oil or B = biodegradable hydraulic oil Location Next to the filler opening (hydraulic oil tank)

Fig. 17: Label: filler opening for hydraulic oil

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1-13

Introduction Labels on the inside of the machine

pa r

at

io n

Load diagram label Load diagrams with maximum payload indications for pallet forks applications in telescopic operation!

Location On the inside right on the side window

rp re

Notice!

Un de

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

Fig. 18: Load diagram

Tyre pressure table label Example List of authorised types of tyres with prescribed tyre inflation pressures.

Location On the inside right on the side window

Fig. 19: 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 5-55.

Location Next to the brake-fluid tank

Fig. 20: Brake fluid label

A

B

B

Fig. 21: Steering mode label

A

B

Steering mode label Steering mode information – see chapter 3 “Selecting the steering modes” on page 3-41 • A = diagonal steering (crab steering) • B= front axle steering • C = 4 wheel steering Location Next to the steering mode control lever

Label for operation of additional hydraulic control circuit (rotary switch – proportional controls) • A small flow capacity • B large flow capacity Location On the switch console on the right, at the rear

Fig. 22: Additional control circuit potentiometer

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Introduction A

B

C

F

D

E

N R

F

G

1000241649

Label: control elements on control lever (joystick) • A = not assigned (option) • B = front socket operation (option) • C = operation of control lever lock (road travel) • D = driving direction: (F) forwards/(R) reverse and (N) neutral position • E = telescopic boom extension and retraction • F = telescopic boom: raise/lower and dump in/out • G = locking/unlocking: attachment in quickhitch and hydraulic control circuit – attachment Location On the right on the side window (next to the control lever)

Fig. 23: Label: control lever operation overview

Label for operation of tipping trailer connection or Autohitch trailer coupling – see chapter 3 “Tipping trailer connection (option)” on page 3-91 – see chapter 3 “Operation of the Autohitch trailer coupling (option)” on page 3-92 Location On the right on the side window Fig. 24: Label: tipping trailer/Autohitch trailer coupling

Label: stopping the machine • 1 = at telehandler standstill • 2 = set driving direction to neutral with tip switch N on control lever (joystick) • 3 = service and/or parking brake operation Location On the right of the ignition lock Fig. 25: Label: stopping the machine

Label: “Danger in case of broken side window” Caution!

In order to avoid danger of crushing or accidents, stop the machine immediately if the side window is broken!

• Stop the diesel engine and remove the ignition key • Apply the parking brake • Have the side window replaced by an authorised workshop Location On the upper right member inside the cab

Fig. 26 : Label: Danger in case of broken side window

Operator's Manual label Caution! Read and understand this Operator's Manual before putting the machine into operation, and before servicing or repairing it.

Location On the left-hand side member inside the cab.

Fig. 27: Operator's Manual label

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1-15

Introduction Label: seat belt and machine stability • Operate the machine only from the seat • Fasten the seat belt before operating the machine • Ensure machine stability • 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: 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. 29: 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. 30: Prohibitive label: no transport of persons

1-16

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Introduction Labels in the engine compartment

Fig. 31: Prohibitory label

Fig. 32: 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: Container under pressure, danger of scalding!

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

• 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 • Wear protective gloves and clothing 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. 33: Label: hot surface

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

00 0291 629 0 - BA SCORPION – AUSTRALIA

1-17

Introduction Notes:

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00 0291 629 0 - BA SCORPION – AUSTRALIA

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!

00 0291 629 0 - BA SCORPION – AUSTRALIA

2-3

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!

2-4

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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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2-5

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!

• 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!

2-6

00 0291 629 0 - BA SCORPION – AUSTRALIA

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

• 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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2-7

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 6-10 • 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!

2-8

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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 3-60 • 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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2-9

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 5-50.

• 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 5-50 • 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!

2-10

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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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2-11

Safety instructions 2.6 Maintenance work on protective ROPS and FOPS structures 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!

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!

2-12

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Safety instructions 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!

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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2-13

Safety instructions Notes:

2-14

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Operation

Operation

3

Operation

Inside of cab: overview see overleaf

3.1 General 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.

The symbols used in the description have the following meanings: • This symbol stands for a list • Subdivision within lists or an activity. Follow the steps in the recommended sequence ☞ This symbol requires you to carry out the activity described

➥ Description of the effects or results of an activity

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3-1

Operation 3.2 Inside of cab: overview Inside of cab (overview) 1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

D PF

11

!

1

43

x100 0min

16

-1

4 6 AIR 2

42

8 10

0 bar

6 0 3 0 b li d 3 _ 0 1 . si o

41

17 N

0

18

I

A UT O 6 03 0 b

40

i o id l 3 _ 04 . s

OF F

19

39

20

38 37

21

36

22

35 34 33 32 31 30 29

28 Fig. 35: Inside of cab: overview

3-2

27

19

26

25

24

23

For more information see page

1 Aerial (option) 2 Front window wiper motor ..............................................................................................................................................................3-54 3 Front working light (option).............................................................................................................................................................3-50 4 Instrument panel switch console (left) 5 Level indicator (option)...................................................................................................................................................................3-79 6 Radio (option) 7 Roller sun-visor 8 Socket (electrical system) 9 Switch – tilt ram lock (option) .........................................................................................................................................................3-86 10Steering column adjustment...........................................................................................................................................................3-40 11Air vents – front window/side window 12Instrument panel with indicators 13Interior light.....................................................................................................................................................................................3-15 14Work hydraulics/reversing fan electronics 15Switch panel – working light, rotating beacon, rear wiper (on the right on the cab ceiling) 16Control lever (joystick)....................................................................................................................................................................3-55 17Instrument panel – speed range switch panel................................................................................................................................3-38 18Radio loudspeakers in cab ceiling (option) 19Working light (standard on left/option on right)...............................................................................................................................3-50 20Steering mode lever .......................................................................................................................................................................3-41 21Rear attachment switch panel 22Drink holder 23Emergency hammer 24Fire extinguisher (option)................................................................................................................................................................3-16 25Rear window wiper motor...............................................................................................................................................................3-54 26Storage net for documents 27Door arrester ..................................................................................................................................................................................3-14 28Bracket for first aid kit 29Tank – washer system ...................................................................................................................................................................3-54 30Seat belt .........................................................................................................................................................................................3-21 31Parking brake .................................................................................................................................................................................3-45 32Seat................................................................................................................................................................................................3-17 33Accelerator pedal (solenoid for accelerator pedal lock option).......................................................................................................3-43 34Hook 35Brake/inching pedal with inching potentiometer.............................................................................................................................3-44 36Fresh air/recirculated-air filter (cab) ...............................................................................................................................................3-52 37Steering wheel................................................................................................................................................................................3-40 38Proportional electronics – additional control circuit (option) 39Central electrics (relays, fuse box etc.) ..........................................................................................................................................5-41 40Multifunctional lever – turn indicators, high and low beam, wiper, horn .........................................................................................3-51 41Relay bracket – brakes, air conditioning (option), etc. ...................................................................................................................5-41 42Preheating start switch (ignition lock)............................................................................................................................................ 3-32 43Brake fluid tank...............................................................................................................................................................................5-30

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Operation Instrument panel, multifunctional lever, switch consoles: overview see overleaf

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3-3

Instrument panel, multifunctional lever, switch consoles: overview see overleaf

Operation 50

49

57

51

58

59

60

61

62

63

64

65

66

67

52

48 47 46

Indicating instrument

DPF

53

1

55

44

56 x1000min

-1

71

Fig. 36: Indicating instrument

4

AIR

6

2

8 0

86

87

88

10 bar

70 Fig. 37: Instrument panel with indicators

74 73

72

Instrument panel with indicator lights and indicators

40

69

75 85

68

76 96

77

97

Fig. 38: Multifunctional lever

79

98 99

78

84

8

100

16

DPF !

AUTO

83

80

OFF

4AIR6 2 8 0 bar10

9 Fig. 39: Instrument panel switch console (left)

89

82

81

42

90

91

92

94

6030bild3_04.iso

102

106

107

108

109

110

103

104

For more information see page

57Temperature indicator – diesel engine..................................................................................................................................3-32, 5-13 58Indicator light (red) – overload cutoff (option) ................................................................................................................................3-57 59Indicator light (yellow) – accelerator pedal lock (option) ................................................................................................................3-43 60Indicator light (red) – Caution! (option) 61Indicator light (red/yellow/green) – diesel particle filter (option) or additional fuel filter (option)..............................................5-46, 5-3 62Indicator light (red) – hydraulic system overheating....................................................................................................................... 5-22 63Indicator light (red) – drive boost pressure monitoring.....................................................................................................................3-8 64Indicator light (green) – front socket (option) .................................................................................................................................3-87 65Indicator light (yellow) – hose burst valve, load stabiliser ..............................................................................................................3-82 66Reverse driving direction indicator light (green)............................................................................................................................. 3-39 67Forwards driving direction indicator light (green) ...........................................................................................................................3-39 68Safe load indicator ......................................................................................................................................................................... 3-56 69Air compressor indicator (option) ...................................................................................................................................................3-97 70Speedometer (high speed option) 71Diesel engine tachometer Multifunctional lever

For more information see page

72Rotary switch – front wiper, washer pump ..................................................................................................................................... 3-54 73Horn tip switch................................................................................................................................................................................ 3-51

Fig. 41: Side console switch panel for rear attachments

93

Fig. 42: Instrument panel – speed range switch panel

3-4

Fig. 40: Control lever (joystick)

6030blid3_01.iso

105

95

101

1

-1 x1000 min

For more information see page

44Hour meter 45Right/left turn indicator light (green) for rear attachments..............................................................................................................3-51 46Right/left turn indicator light (green) ...............................................................................................................................................3-51 47Coolant level indicator light (red)....................................................................................................................................................5-13 48Hydraulic oil filter indicator light (red) .............................................................................................................................................5-22 49Air filter indicator light (red) ............................................................................................................................................................5-19 50Alternator charge function indicator light (red) ............................................................................................................................... 3-32 51Parking brake indicator light (red) ..................................................................................................................................................3-45 52Engine oil pressure indicator light (red)...................................................................................................................................3-32, 5-7 53Indicator light (red) – 3rd control circuit, continuous operation (option) .........................................................................................3-89 54High beam indicator light (blue) ..................................................................................................................................................... 3-49 55Indicator light (yellow) – preheating time lag relay .........................................................................................................................3-32 56Fuel level indicator

!

54

45

3.3 Instrument panel, multifunctional lever, switch consoles: overview

Fig. 43: Switch panel in cab ceiling

00 0291 629 0 - BA SCORPION – AUSTRALIA

Operation

Operation Instrument panel switch console (left) 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88

Not assigned (option) Tip switch (green) – disable/enable hydraulics overload cutoff....................................................................................................3-59 Not assigned (option) Not assigned (option) Switch with lock (green) – additional front and/or rear control circuit (option)..............................................................................3-88 Switch with lock (green) – continuous operation of 3rd control circuit (option) ............................................................................3-87 Switch (green) – Autohitch trailer coupling (option) .....................................................................................................................3-93 Switch (green) – quickhitch unlocking/emergency lowering (option) ..........................................................................................3-60 Switch (green) – load stabiliser (option).......................................................................................................................................3-48 Switch with lock (green) – locking/unlocking the 3rd control circuit .............................................................................................3-86 Switch – hazard warning system..................................................................................................................................................3-51 Switch (grey) – machine lights (headlights) .................................................................................................................................3-49 Rotary switch – heating temperature ........................................................................................................................................... 3-52 Rotary switch – heater fan settings..............................................................................................................................................3-52 Tachometer (engine) switch – air conditioning (option) ...............................................................................................................3-53

Instrument panel – speed range switch panel 89 90 91 92 93 94 95

For more information see page

For more information see page

Potentiometer – low-speed control (option) .................................................................................................................................3-46 Indicator light – centre position of front axle wheels (option) Tip switch (grey) – reversing fan (option).....................................................................................................................................3-52 Tip switch – accelerator pedal lock (option) .................................................................................................................................3-43 Potentiometer – additional control circuit (option) ........................................................................................................................3-90 Indicator light – centre position of wheels (rear axle)...................................................................................................................3-42 Switch (blue) – speed range

Control lever (joystick)

For more information see page

96 Switch – locking/unlocking attachments – quickhitch and 3rd control circuit ...............................................................................3-60 97 Not assigned (option) 98 Tip switch – front socket (option) .................................................................................................................................................3-55 99 Switch – extend/retract telescopic boom......................................................................................................................................3-61 100Switch – forwards/reverse driving direction..................................................................................................................................3-39 101Tip switch – driving direction in neutral ........................................................................................................................................3-39 Switch panel for rear attachments

For more information see page

102Switch (green) – tipping trailer switchover/Autohitch (option) ......................................................................................................3-93 103Tip switch (green) – hydraulically adjustable trailer coupling (Autohitch) or hydraulic connection for tipping trailer (option).......3-91 104Switch (green) – additional control circuit (option) .......................................................................................................................3-88 Switch panel on cab ceiling

For more information see page

105Switch (grey) – boom working light (option) .................................................................................................................................3-50 106Switch (grey) – front working light................................................................................................................................................3-50 107Switch (grey) – rear working light.................................................................................................................................................3-50 108Switch (grey) – rotating beacon (option) ......................................................................................................................................3-51 109Tip switch (grey) – heated rear window (option) ..........................................................................................................................3-52 110Switch (grey) – rear window wiper ...............................................................................................................................................3-54

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3-5

Operation 3.4 Indicator 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.

50

Notice!

51

52

P

Indicator lights 50/51/52 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 on indicating instrument 55

54

47

48

49

50

3-6

Indicator light (yellow) – preheating time lag relay Comes on when the key in preheating start switch (Fig. 35 on page 3-2)/4 is in position 2.

A glow plug preheats the air in the combustion chamber of the engine when the key is in this position.

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

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 the coolant Hydraulic oil filter indicator light (red) Indicates inadmissibly high pressure in the hydraulic return line to the tank. ➥ The filter element is dirty and must be replaced – see chapter 5 “Monitoring the hydraulic oil and the return filter” on page 5-22 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 V-belt or the charging circuit of the alternator is faulty if the indicator light comes on with the engine running. The battery is no longer charged.

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Operation 51

52

Parking brake indicator light (red) Comes on when the parking brake is applied.

An electric driving interlock prevents starting the diesel engine when the parking brake is not applied!

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.

Comes on if the engine oil pressure is too low. In this case: ☞ Stop the machine ☞ Stop the engine immediately and check the oil level

53

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).

46

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.

45

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

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3-7

Operation Indicator lights and indicators on the instrument panel 62

63

61

61

Indicator light (red) – hydraulic oil temperature Indicates that the temperature in the hydraulic system is too high.

Indicator light (red) – drive boost pressure monitoring If this indicator light comes on with a running engine and a released parking brake, and/or during machine operation, this is a sign of a boost pressure drop in the drive!

• Stop the machine immediately to avoid further damage to the drive • Stop the engine and apply the parking brake • Have the error repaired by an authorised workshop

Indicator light (red/yellow/green) – diesel particle filter (option) The LED indicates the status in the exhaust gas particulate filter system.

Indicator light (red) – fuel system water separator (option) Indicates that the water separator of the fuel prefilter contains water: ➥ – see chapter 5 “Checking/cleaning the additional fuel filter (water separator, option)” on page 5-4 Indicator light (red) – Caution! (option)

60

59

58

3-8

Indicator light (yellow) – accelerator pedal lock (option) Indicates that the accelerator pedal lock (manual throttle) is switched on.

Indicator light (red) – overload cutoff (option) Indicates that the hydraulic functions “Raising, Lowering, Dumping In/Out and Extending” locked by the safe load indicator are available again.

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Operation 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 “Switching the load stabiliser ON or OFF” on page 3-48

65

66

67

57

Indicator light (green) – driving direction Indicates forwards/reverse driving direction

Temperature gauge with acoustic warning – engine (coolant) Indicates the engine temperature detected by a sensor. ➥ Engine temperature should be between 80 and 105 °C. Max. admissible temperature is 110 °C. The acoustic warning sounds from 115 °C

90

Indicator light (green) – front axle wheel position Indicates that the front axle wheels are parallel to the centre line of the machine.

94

Indicator light (green) – rear axle wheel position Indicates that the rear axle wheels are parallel to the centre line of the machine.

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3-9

Operation 3.5 Important notice on putting the machine into operation Operating staff • The machine may be put into service by instructed and authorised staff only – see chapter 1 “Driving licence” on page 1-8 and “Personalauswahl und -qualifikation, grundsätzliche Pflichten” 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 • Carrying or transporting accompanying persons in the cab and/or on the telehandler 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 “Diesel engine start” checklist on page 3-11 – see Checklist “Putting the machine into service” on page 3-12 – see “Parking” checklist on page 3-12

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 5-50

3-10

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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.

“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?

5-21

4

Water level in washer tank OK?

3-54

5

V-belt condition and tension checked?

5-7

6

Telescopic boom lubricated?

5-26

7

Brake system (including parking brake) OK?

3-44, 3-45

8

Tyre condition and inflation pressure OK?

9

Wheel nuts safely tightened (especially after a wheel change)?

10 Lights, signals, indicators, warning lights and indicator lights OK? 11 Windows, mirrors, lights and steps clean?

12 Attachment on the telescopic boom safely locked?

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See page ✔

5-32 3-49 – 3-60

13 Engine cover safely locked?

–

14 Especially after cleaning, maintenance or repair work: Rags, tools and other loose objects removed?

–

15 Approved warning triangle, hazard warning light and first aid kit in the machine?

–

16 Seat position and rearview mirrors correctly adjusted?

3-17

17 Seat belt fastened?

3-21

3-11

Operation Checklist “Putting the machine into service” After starting the engine and during operation, check and observe the following points: Checklist “Putting the machine into service”

See page

1 Indicator lights for engine oil pressure and alternator gone out?

3-31

2 Braking effect sufficient?

3-44

3 Temperature gauge for engine coolant in normal range?

3-6

4 Steering system working properly?

3-40

5 Anyone dangerously close to the machine?

–

6 Safe load indicator checked and OK?

3-56

7 3rd control circuit locked and secured?

3-60

When driving on public roads, particular attention should be paid to the following points: 8 Telescopic boom completely retracted?

3-61

9 Bucket and attachments in transport position?

10 Transport guards (front-edge protection) put in place?

11 Control lever for lift and tilt hydraulics of the telescopic boom locked?

– 3-60

“Parking” checklist Check and observe the following points when parking the machine: Parking checklist

See page

1 Attachments on the telescopic boom lowered to the ground?

3-61

2 Parking brake applied?

3-45

3 Diesel engine stopped?

3-31

4 Cab locked, especially if the machine cannot be supervised?

–

When parking on public roads: 5 Machine adequately secured?

–

When parking on slopes: 6 Machine additionally secured with chocks under the wheels to prevent it from rolling away?

3-12

–

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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 – or stop the machine immediately – if the side window on the right is brocken!

Fig. 44: Danger in case of broken side window

Keep a safe distance to the telescopic boom as you lower it to the ground carefully – see Operating the telescopic boom 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

Locking and unlocking the door Danger!

A

In order to avoid danger of accidents, safely lock the upper and lower doors when using the machine!

Lock the upper cab door with the lower door, or secure it in the door arrester of the cab Lock the lower cab door Outside: pull handle A outwards Inside: press door opener B upwards To open the upper cab door (side window) – see Opening the upper cab door to a gap on page 3-14

B

Notice!

Apply grease to the door lock at regular intervals.

Fig. 45:

Opening and locking the door

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3-13

Operation Opening the upper cab door to a gap With the lower door closed, the upper door half can be opened to a gap to improve cab ventilation.

D

Danger!

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

C

E

Close the upper cab door fully with the lower door, or open it to a gap with the arrester on the lower door Open the upper cab door fully and secure in the lock on the cab Opening the upper cab door to a gap • Unlock the upper cab door out of the lower door. To do this: pull lever C (inside the cab on the door) backwards • Open the cab door and fold out spacer D • Make the cab door engage in the lock of the lower door (see arrow) with spacer D Opening the upper cab door completely • Unlock the upper cab door out of the lower door. To do this: pull lever C (inside the cab on the door) backwards • Open the upper cab door completely to the rear and make it engage in door arrester E

Notice!

Lubricate the catch bolt of the lock at regular intervals.

Fig. 46: Locking, unlocking and opening the side window to a gap

3-14

Closing the upper cab door • From the outside or inside: press lever E forwards The side window is released from the lock by spring action • Safely lock the upper cab door in the lower door and lock the complete cab door

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Operation Opening/closing the rear window Danger!

A

In order to avoid crushing and injury, close the rear window when driving the machine!

Lock the rear window with the lock lever Remove the lock lever from the guide only in case of an 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. 47: Rear window lock

Interior light operation (cab) The interior light is switched on via a contact switch when opening the door.

Switch the light on/off permanently • See the switch on the interior light

Fig. 48: Switch for interior light

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3-15

Operation 3.7 Cab emergency exit Information on emergency exit via the rear window The rear window can be smashed with the emergency hammer and used as an emergency exit if the cab door can no longer be used.

The hammer is located on the right of the seat.

Danger!

Caution! Smashing the rear window pane sends glass splinters flying around – danger of injury!

Protect face and eyes before smashing the window pane If possible, ask for help before smashing the window pane Fig. 49: Emergency hammer

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 • Smash the rear window with the emergency hammer and carefully exit the cab

Notice!

Before taking the machine back into service, put the emergency hammer back in place and seal it!

Have the damaged rear window replaced by an authorised workshop!

3.8 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 it checked at regular intervals and refilled!

• See inspection tag on fire extinguisher 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

3-16

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Operation 3.9 Seat Important notice on seat operation 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. suspension • of seat), contact a workshop immediately for repair.

• Failure to do this can result in health hazards and increased danger of accidents!

•

Seat adjustment without options (overview) Danger!

Never change the seat position when driving or working!

Adjust the seat before moving the machine Ensure that the levers for seat adjustment are safely engaged The seat can be set to the following positions: a = horizontal adjustment b = weight adjustment c = weight indication d = backrest adjustment a

b

c

d

Fig. 50: Overview of seat adjustments

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3-17

Operation Weight adjustment Notice!

Adjust the seat suspension correctly to ensure a high level of ride comfort, and to avoid or minimise physical disorders related to bad posture. Use lever b to adjust the seat suspension to the operator's weight. The weight indicator c shows the set operator weight [kg]. b

Adjust as follows: 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. 51: 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

D

Fig. 52: Backrest adjustment

Horizontal adjustment Adjust 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

a Fig. 53: Horizontal seat adjustment

3-18

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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. 54: 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. 55: 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, with lever 3.

Four levels ranging from soft to hard are possible.

• Position a = soft • Position b = hard

3

a

b

Fig. 56: Adjustment of horizontal suspension

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

4

Fig. 57: Heated seat

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3-19

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 4

Seat height changes Upon reaching the upper or lower limit, the height is automatically adjusted to ensure a minimum spring travel

Caution!

Fig. 58: Air-suspension seat

3-20

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

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Operation 3.11 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

A

Fasten the seat belt as follows: • Sit down on the seat • Hold the seat belt at buckle latch A and run it 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 not be twisted and must run tightly over the hips!

B

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

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3-21

Operation Unfastening the seat belt

A

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)

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

Longer/shorter seat belt adjustment Extend/shorten the seat belt as follows: • 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

A

Notice!

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

3-22

When pulled slowly, the automatic seat belt (option) 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.

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Operation 3.12 Engine cover Opening/closing the engine cover D

Fig. 62:

Engine cover lock

Open the engine cover • Stop the engine and remove the ignition key • Turn handle A to the left and pull up the engine cover The engine cover opens with the help of gas struts Close the engine cover • Press the engine cover down firmly and turn handle A to the right Lock the engine cover • The engine cover is locked with the ignition key

3.13 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.

Before carrying out repair work on the electrical system, separate the battery from the electrical system with the battery master switch.

The battery master switch is located above the battery in the engine compartment.

Caution!

Do not switch off the battery master switch if the engine is running!

• Voltage peaks can destroy electric components Fig. 63: Battery master switch

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Interrupting power supply • Turn and remove the key of the battery master switch (notched position) Switching on power supply • Insert the key in the battery master switch • Turn the key to the notched position

3-23

Operation 3.14 Electronic key-based drive interlock (option) Description of electronic drive interlock The electronic drive interlock protects the machine against operation by unauthorised persons.

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.

Caution!

Each drive interlock has only one master key!

The drive interlock must be replaced 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

3-24

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Operation Enabling (locking) the drive interlock Apply the parking brake – see Parking brake on page 3-45 Stop the engine Remove the ignition key (blue) The drive interlock is enabled in 30 seconds

Caution!

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 3-32 “Starting the engine”.

The system is enabled 5 seconds after the ignition key is inserted in the ignition lock Start the engine – see Starting the engine on page 3-32 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 60 seconds.

This function avoids 'finding' the correct key by chance by trying different keys. The drive interlock remains enabled for 15 minutes and does not accept any valid keys if several invalid keys have been detected without having set the ignition lock to position '0'.

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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3-25

Operation 3.15 Electronic drive interlock with code input (option) Description of electronic drive interlock The electronic drive interlock protects the machine against operation by unauthorised persons.

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

Caution!

LED

We recommend using the personal code for disabling the system.

Keep the main code in a safe place.

Fig. 64: Drive interlock (code input option)

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

3-26

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Operation Entering/changing the personal code Caution!

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: 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 as soon as the LED goes out 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)

00 0291 629 0 - BA SCORPION – AUSTRALIA

3-27

Operation Disabling the drive interlock Enter the personal code or the main code (6 digits) and confirm with the (*) key Confirmation: 2 long acoustic signals and long LED flashing.

LED out = the drive interlock is disabled and the diesel engine can be started If the diesel engine cannot be started: Wrong code has been entered Confirmation: 4 short acoustic signals, flashing LED = wrong code Re-enter the code Turn the ignition key and switch on the engine before the LED flashes again (30 seconds)

Caution!

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 entry The LED comes on briefly when turning the ignition key to position 1

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.

1 Disable the system by entering the personal or main code and by confirming with the (*) key 2 Turn the ignition key to position 0 as soon as the LED goes out 3 The LED comes on for 2 seconds 4 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) 5 The LED now flashes very slowly, and the keypad is disabled 6 Turn the ignition key to 0 and remove it 7 The system is out of operation. The engine can be started without entering the code

Caution!

If the system is out of operation, the LED flashes slowly even if the ignition key is in position 1 Entering the personal or main code does not have the effect of putting the system back into operation again (the acoustic signals for confirmation are still given). See the following procedure (“Putting the drive interlock back into operation again”) to leave the out-of-service status again.

3-28

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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 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 drive interlock does not require any maintenance.

Protect the keypad and the control unit from heat and humidity

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3-29

Operation 3.16 Fuel, diesel engine and hydraulic oil preheating (option) This equipment is for cold-starting at temperatures below -5 °C. The socket is installed 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 operation The fuel preheater prevents paraffin crystals forming, which otherwise clog the fuel filter at low temperatures.

• An integrated temperature sensor automatically switches on a heating element in the fuel line between the tank and the fuel prefilter when ignition is switched on at temperatures below + 10 °C.

3-30

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Operation 3.17 Putting the diesel engine into operation Preparing to start the engine Danger In order to avoid injury or danger of accidents, the machine may be put into operation only when the operator is seated on the seat!

• • • •

• •

• •

Run through the “Diesel engine start” checklist on page 3-11 Switch on the battery master switch – see Battery master switch on page 3-23 Adjust the rearview mirror correctly to ensure visibility to the rear Adjust the correct seat position – see Seat on page 3-17 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 3-45 is applied The motor will not start unless the parking brake is applied – see Parking brake on page 3-45 Enable Electronic key-based drive interlock (option) on page 3-24 or Electronic drive interlock with code input (option) on page 3-26 Ensure that the control lever (joystick) for the telescopic boom is in neutral position

Notice!

The starter cannot be actuated if the engine is already running (start repeat interlock).

• If the engine does not start, interrupt the start attempt after a max. 20 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)!

Caution!

Danger of engine damage!

Do not use additional starting aids (e.g. injection with start pilot) • If the machine is used for extended periods at outside temperatures under -10 °C, we recommend retrofitting the machine with a fuel and/or engine preheater (option) – see Fuel, diesel engine and hydraulic oil preheating (option) on page 3-30.

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3-31

Operation Starting the engine Notice!

When ignition is switched on, all indicator lights on the indicating instrument come on briefly – indicator light check!

0

1

2 3

42 Fig. 65: Preheating start switch

50

51

52

55

Fig. 66: Indicator lights on indicating instrument

Start the diesel engine as follows: • Apply the parking brake to the last notch • Turn the ignition key (preheating start switch 42) to position “1” • The following indicator lights must come on Engine oil pressure indicator light 52 Indicator light 51 if the parking brake is applied Indicator light 50 alternator charge function Indicator light 55 for the cold starter (preheating) – Comes on for about 5 – 10 seconds at normal temperatures (up to 0°) – Comes on for about 15 – 60 seconds at low temperatures (below 0°) The intake air is preheated via a temperature-dependent time lag relay, and indicator light 55 goes out once the temperature is reached After indicator light 55 (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 in this position until the engine starts • Release the ignition key • Check that the following indicator lights have gone out: Engine oil pressure indicator light 52 Alternator charge function indicator light 50 Indicator light 55 for the cold starter

Caution!

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

Replace defective indicator lights immediately

Caution!

In order to avoid damage to the engine and the exhaust turbocharger due to insufficient lube oil supply, do not run the cold engine at full throttle as you start it!

Let the engine warm up at low idling speed (for about 30 seconds)

3-32

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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 idling speed or high speed and at less than 20 % of the load.

Effects: • Operating temperature is not reached • Increased lube oil consumption • Lube oil in exhaust system • Engine contamination • Blue smoke in exhaust We recommend running the engine at loads of over 20 % during regular operation

Stopping the engine

0

1

Caution!

2 3

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

42 Fig. 67: Stop the engine

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Proceed as follows: • Apply the parking brake to the last notch • Turn the ignition key (preheating start switch 42) to position “0” and remove the ignition key

3-33

Operation 3.18 Jump-starting the engine (external battery) Safety instructions regarding external starting aids Danger The jump lead connected to the positive (+) terminal of the starting battery must never be brought into connection with electrically conductive vehicle parts – danger of short circuit!

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 cannot catch on rotating components in the engine compartment!

Providing external starting aid

Flat battery

12 V

12 V Starting battery

Fig. 68: Starting aid with jump leads 34001b710_05.eps

3-34

Proceed as follows: • Drive the jump-starting vehicle close enough to the telehandler 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, disconnect both jump leads from the batteries in the reverse order

Notice!

In order to avoid sparking, first disconnect the jump lead on the – terminal, then the one on the + terminal of the batteries!

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Operation 3.19 Preparing to put the machine into operation Important notice regarding driving on public roads • Carrying or transporting accompanying persons in the cab or on the telehandler is not allowed.

• 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) or the data confirmation (Germany).

• On the machine, only the attachments are certified for use on public roads that are described in the General Certification for Vehicles (Germany), in the data confirmation (Germany) or in this Operator's Manual on page 1-6 “Fields of application and using a telehandler with an attachment” (the footnotes must be taken into account).

• Driving on public roads with an attachment is allowed if the distance between the front edge of the pallets forks or bucket and the centre of the steering wheel is not over 3500 mm in transport position.

• In trailer operation the provisions laid down in the General Certification for Vehicles (Germany), or the data confirmation (Germany) must be observed – also see Trailer operation on page 2-8 • Securely tie down loads on the trailer • Bear in mind the trailer and drawbar loads – see chapter 6 “Trailer couplings: trailer weight/drawbar load” on page 6-10

Caution!

When driving downhill, the brake pedal must be used to support the braking effect of the drive. This avoids damage to the drive due to excessive speed. In addition, shift to 1st speed first on extremely steep slopes!

– see Selecting the speed range 0 – 30 kph (40 kph option) on page 3-38

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3-35

Operation Preparing for driving on public roads • In addition, bear in mind the mandatory regulations relevant to accident prevention • Empty the attachment Driving on public roads with loaded attachments is prohibited.

• Retract the telescopic boom fully and dump in the quickhitch as far as it will go • Raise the telescopic boom to transport position and mount the protection on the pallet forks or the leading edge of the bucket – see Driving on public roads with a standard bucket on page 3-67 and – see Driving on public roads with the pallet forks on page 3-74 • In trailer operation: Check the trailer coupling for proper locking and the hydraulic or compressed-air brake (option) for secure connection with the tractor • Remove the protective screen (option) from the front window • Adjust the steering column height and inclination (option) – see Steering column height and angle adjustment (option) on page 3-40 • Switch off the working lights when driving on public roads – see Working lights operation on page 3-50 • High speed version (40 kph): switch the steering system to front axle steering – see Selecting the steering modes on page 3-41 • 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 3-37 • Switch on the load stabiliser – see Load stabiliser on page 3-47 • Lock the cab door and the hinged window – see Locking and unlocking the door on page 3-13 • Fasten your seat belt – see Seat belt (lap belt) on page 3-21

Carrying out a functional check of the machine • • • •

3-36

– see Steering system on page 3-40 – see Brake/inching pedal on page 3-44 – see Machine lights on page 3-49 – see Signalling system on page 3-51

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

16

S

Secure the control lever (joystick) • Push control lever 16 down vertically in neutral position The control lever is locked in this detent and can no longer be moved 83

A

B Fig. 69: Control lever lock

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Notice!

After the attachment has been picked up, the 3rd control circuit is automatically locked against unintentional unlocking of the attachment. When driving on public roads however, it must be fully secured with switch 83 on the switch console on the left.

Lock the 3rd control circuit • Slide lock C on switch 83 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

3-37

Operation 3.20 Putting the machine into operation Selecting the speed range 0 – 30 kph (40 kph option) 95 A

B

The telehandler has two speed ranges.

The switch for selecting the speed ranges is located on the switch console on the right After starting the engine: Select the 1st speed range • Press switch 95 to position A • Select the required driving direction with switch 100 on the control lever (joystick) Select the 2nd speed range • Press switch 95 to position B • Select the required driving direction with switch 100 (on the joystick)

100 101

Fig. 70: Switch for speed range selection

Symbol

30 kph gearbox

40 kph gearbox (option)

1st speed range

1st speed range

0 – 7 kph

0 – 15 kph

2nd speed range

2nd speed range

0 – 30 kph

0 – 40 kph

Recommended 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.

For long-haul travel

Notice!

In order to avoid damage to the drive hydraulics, the setting of the drive at the factory ensures full machine dynamics only when the temperature of the drive is about 20 – 30 °C!

3-38

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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

F

100

101

R

67

66

Move off the machine • Release the parking brake (Fig. 35 on page 3-2) • Select the driving direction with switch 100 on the control lever (see table) • Press the drive pedal (Fig. 35 on page 3-2) slowly • Perform a brake test after looking in the rearview mirror and at low speed Reversing operation (change the driving direction) • Reduce the drive speed (0 – 12 kph) • Select the driving direction with switch 100 on the control lever (see table) F = forwards R = reverse Neutral position (stopping the machine) • Reduce the drive speed (0 – 12 kph) • Press tip switch 101 on the control lever (joystick) • Brake the machine to a standstill with the service brake • Apply the parking brake (Fig. 35 on page 3-2) Indicator light on instrument panel

Driving direction

Operation

Forwards

Press switch 100 on the control Indicator light 67 comes on lever (joystick) forwards F

Neutral

Press tip switch 101 on the conIndicator light 66/67 goes out trol lever (joystick)

Reverse

Press switch 100 on the control Indicator light 66 comes on lever (joystick) backwards R

Driving direction is rejected

The driving direction has been Indicator light 66/67 flashes selected at speeds over 12 kph

Fig. 71: Changing direction

Notice!

If the driving direction selection is rejected (no function): • The driving direction was selected at a speed of more than 12 kph, or switch 101 (drive – neutral position) was unintentionally actuated!

• Further possible causes – see chapter 4 “Drive malfunctions” on page 4-4

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3-39

Operation 3.21 Steering system Steering column height and angle adjustment (option) The steering column height and angle can be set to the driver's individual size 10

Danger Do not adjust the steering column when driving or working.

A

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

B

Fig. 72: Steering column adjustment

Function

Operation

Height adjustment

Angle adjustment

• Pull lever 10 upwards A and pull or push the steering column to the correct position.

• Release lever 10.

Steering column is locked • Press lever 10 downwards B and tilt the steering column to the correct position.

• Release lever 10.

Steering column is locked

Checking the steering system Functional check: move the steering wheel to the left and right

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)

3-40

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Operation Selecting the steering modes Danger In order to avoid danger of accidents, do not change the steering mode when driving the machine or on public roads!

Stop the machine and change the steering mode as described below After selecting the steering mode, safely lock the lever against unintentional operation (press lock S downwards)

Caution!

In order to avoid possible damage to the steering valve, select a steering mode only when the machine is at a standstill and without turning the steering wheel!

V = front axle steering (centre position) • Pull lock S on lever 20 out of the detent and select the “Front axle” steering mode (V) • Lock the lever in this position and release lock S

D F 4

Lock S is spring-loaded and locks into place automatically as soon as a steering mode has been selected.

S

20

Fig. 73:

Notice!

Steering mode selection

A = 4 wheel steering (rear position) • Pull lock S on lever 20 out of the detent and select the “Four wheel” steering mode (4) • Lock the lever in this position and release lock S D = diagonal steering (crab steering) (front position) • Pull lock S on lever 20 out of the detent and select the “Diagonal steering” steering mode (D) • Lock the lever in this position and release lock S

Danger Driving on public roads with diagonal steering (crab steering) is prohibited!

30 kph machine: switch over to 4 wheel steering or front axle steering 40 kph (option) machine: switch over to front axle steering

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3-41

Operation 3.22 Steering synchronisation (wheels front/rear axles) Important notice on steering synchronisation 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, synchronising the steering is not allowed when working off-road or when driving on public roads! .

Notice!

Steering synchronisation is only possible in the “4 wheel” steering mode!

Wheel synchronisation D F

94

4 S

20

Proceed as follows: • Pull lock S on lever 20 out of the detent, move and lock the lever to “4 wheel” steering mode (A) • Press lock S down • At walking speed of the machine, turn the steering wheel to the left and/or right until indicator light 94 on the instrument panel (drive mode switch panel) comes on The wheels of the rear axle are synchronised in straight-ahead position • With lever 20, select the front axle steering mode (V), and at walking speed of the machine, turn the steering wheel to the left and/or right until the front axle wheels are parallel to the rear axle Wheel synchronisation (front and rear axles) is now over • Select the required steering mode with lever 20 and lock the lever • Press lock S down

Fig. 74: Steering synchronisation

Notice!

Contact your dealer if this does not synchronise the wheels.

3-42

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Operation 3.23 Accelerator pedal The drive speed is set continuously with the accelerator pedal (Fig. 35 on page 3-2)

Notice!

Maximum speed depends on the speed range selected!

• – see Selecting the speed range 0 – 30 kph (40 kph option) on page 3-38.

3.24 Accelerator pedal lock (option) Switching the accelerator pedal lock ON/OFF 95

92

The accelerator pedal lock replaces the manual throttle and is especially useful for operation of hydraulic attachments in order to ensure a continuous hydraulic oil supply and/or drive speed.

Danger In order to avoid danger of accidents, driving on public roads with a locked accelerator pedal is not allowed!

Before driving on public roads, disable the accelerator pedal lock 100

Fig. 75: Disabling/enabling the accelerator pedal lock

Enable the accelerator pedal lock (bear in mind the correct order) During drive operation • Select a speed range with switch 95 (turtle or hare) • Select the driving direction with switch 100 on the joystick • Select and hold the required engine or drive speed with the accelerator pedal • Press tip switch 92 on the switch panel The required engine or drive speed is set Disable the accelerator pedal lock With 1st speed range engaged • Press tip switch 92 on the switch panel With the 2nd speed range engaged • Press the brake/inching pedal (inching, braking), • or press tip switch 92 on the switch panel

Notice!

In the first speed range it is not possible to disable the accelerator pedal lock with the brake/inching pedal!

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3-43

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

Dirt accumulation and objects in the area of the brake/inching pedal can 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 (Fig. 35 on page 3-2) down with force until the braking effect is felt.

Inching with the brake/inching pedal Press the brake/inching pedal (Fig. 35 on page 3-2) 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!

The brake lights do not come on in the inching range!

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

Braking with the brake/inching pedal Check before moving off: • A firm resistance must be felt after half the pedal travel, and the brake lights must come on • After looking in the rearview mirror and at low speed, press down the brake/inching pedal 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

3-44

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Operation 3.26 Parking brake Information on the parking brake An electric driving interlock prevents starting the diesel engine when the parking brake is not applied.

Selecting the driving direction with the switch on the control lever is not possible unless the parking brake is released completely.

Notice!

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 Danger When driving the machine, apply parking brake 31 only in an emergency if the service brakes break down.

31

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

A 51

Apply the parking brake • Pull parking brake lever 31 up Indicator light 51 on the indicating instrument comes on The engine can be started Release the parking brake • Pull parking brake lever 31 up a little • Press button A and lower the parking brake lever as far as it will go Indicator light 51 on the indicating instrument goes out

1

Notice!

Fig. 76: Parking brake

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The brake lights at the rear of the machine do not come on when the parking brake is applied!

• Press the brake/inching pedal (Fig. 35 on page 3-2) down with force in order to brake the machine

3-45

Operation 3.27 Low-speed control (option) Selecting the drive speed 89

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 manually via potentiometer 89 at constant engine speed.

Notice!

A

Continuous setting of the drive speed with the potentiometer is only possible in the 1st speed range “Turtle” !

B

95 Fig. 77: Low-speed control

Select the drive speed as follows: • Press switch 95 to position A Potentiometer 89 is enabled • Set the drive speed with potentiometer 89 With a 30 kph gearbox: drive speed 0 – 7 kph With a 40 kph gearbox: drive speed 0 – 15 kph

Notice!

Important! Once the low-speed control is no longer needed, turn potentiometer 89 to “Hare” so you can reach maximum drive speed again in the 1st speed range “Turtle” .

3.28 Differential lock Important notice on the differential lock function Both the front and rear axles of the machine are equipped with self-locking differentials, i.e. when required, the traction is automatically and evenly distributed to the front and rear wheels with a lock value of 45 %!

The differential is locked automatically and cannot be switched on or off!

3-46

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Operation 3.29 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 and increases drive comfort and safety!

Notice!

When driving on public roads, the machine may become unstable if the load stabiliser is not switched on.

• Always switch on the load stabiliser when driving on public roads – see Switching the load stabiliser ON or OFF on page 3-48

65 Fig. 78: Indicator light – load stabiliser, hose burst valve

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Caution!

Switching on the load stabiliser automatically switches off the hose burst valve!

There is no protection in the event of pipe or line damage!

Indicator light 65 “Hose burst valve” comes on Switch off the load stabiliser when working with the machine • – see “Hose burst valve” safety feature on page 3-82

3-47

Operation Switching the load stabiliser ON or OFF Switch 82 for the load stabiliser is located on the switch console on the left.

65 82

A

AUTO

B

OFF

C Fig. 79: Load stabiliser switch

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 before carrying out work with the telescopic boom, especially stacking jobs.

• Switch on the load stabiliser when driving longer transport distances Automatic load stabiliser function • For driving on public roads, lighter work and off-road transport.

Switch on as follows: • Press switch 82 to position A The load stabiliser is automatically switched on if the machine moves faster than 7 kph Indicator light 65 on the instrument panel comes on (the hose burst valve is switched off) Load stabiliser in continuous operation • For lighter work and off-road transport.

Switch on as follows: • Press switch 82 to position C The load stabiliser is immediately in continuous operation (no drive speed control) Indicator light 65 on the instrument panel goes out (the hose burst valve is switched on) Switch off the load stabiliser • For heavy-duty work, e.g. picking up excavated material Switch on as follows: • Press switch 82 to centre position B Indicator light 65 on the instrument panel goes out (the hose burst valve is switched on)

3.30 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 when reversing with the machine!

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

Fig. 80: Backup warning system

3-48

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Operation 3.31 Machine lights Machine lights operation The switch for the machine lights is located on the left on the instrument panel 54

Side marker light operation

Function

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

1

Low beam operation 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

A B

Function

Notice!

85

II

40

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

I 0

High beam operation

I

II

Fig. 81: Machine lights

With low beam switched on, pull lever 40 to position II towards the steering wheel and release

High beam and indicator light 54 on the indicating instrument come on

OFF

Pull lever 40 to position II towards the steering wheel and release

High beam and indicator light 54 on the indicating instrument go out

Headlight flasher operation ON

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Function

ON

Lenkstockschalt_il.iso

Function

Pull lever 40 briefly upwards to posi- High beam and indicator light 54 on the tion I indicating instrument come on

3-49

Operation Working lights operation The switches are located at the top right in the cab roof lining.

Danger Impaired visibility – danger of accidents! The working lights can dazzle motorists on public roads – Switch off the working lights when driving on public roads When operating the machine, only switch on the working lights when noone can be dazzled by them

Front and/or rear working light operation Press switch 106 to position B

Working light Cab at front

Press switch 107 to position B

Working light Cab at rear left (right option)

Press switches 106 and/or 107 to position A

Indicator light in switch goes out

ON

OFF 105

106

A

107

Front boom working light operation (option) ON

Press switch 105 to position B

OFF

Press switch 105 to position A

Working light Telescopic boom at front

B Fig. 82: Working light switches

3-50

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Operation 3.32 Signalling system Turn indicator operation l

Turn indicator operation 46

45 40

R

RIGHT

Push lever 40 forwards R

Indicator light 45/46 on the indicating instrument flashes

LEFT

Pull lever 40 to the rear L

Indicator light 45/46 on the indicating instrument flashes

0 I

I

Caution!

Lenkstockschalt_il.iso

L

The turn indicator system is not in order if indicator light 45 flashes about twice as fast as normally!

Check the indicator system, have it repaired by an authorised workshop if necessary

Fig. 83: Turn indicators

Hazard warning system operation The hazard warning switch is located on the switch console on the left 45

84

A B

Hazard warning system operation ON

Press hazard warning switch 84 to position B

The indicator light in the switch and indicator light 45 on the indicating instrument both flash

OFF

Press hazard warning switch 84 to position A

The indicator light in the switch and indicator light 45 on the indicating instrument both go out

Fig. 84: Switch for hazard warning system

Rotating beacon operation (option) The switch is located at the top right in the cab roof lining.

Rotating beacon operation (option) 108

A B Fig. 85: Switch for rotating beacon

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ON

Press switch 108 to position B

Indicator light in switch comes on

OFF

Press switch 108 to position A

Indicator light in switch goes out

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.

3-51

Operation 3.33 Cab heating and ventilation Operation of the heating and ventilation system 86

87

W

C

AUT O

OFF

Fig. 86: Heating switches

The air flow is directed to the front window via 2 defroster vents and to the cab via a footwell vent.

The vents can be closed and adjusted separately The heater can be set to 2 operating modes.

• Ventilation • Heating Rotary switches 86/87 are located on the heating switch console on the right.

Rotary switch 36 is located on the side console on the left next to the seat.

Ventilation, fresh air Turn rotary switch 87 to positions 1 – 3 Heating Turn rotary switch 87 to positions 1 – 3 Set the required temperature with rotary switch 86 C = cold/W = warm

3.34 Rear window heating (option) Rear window heating The switch is located at the top right in the cab roof lining.

The rear window heating prevents the rear window from fogging.

Press tip switch 109 to position B

109 A

Indicator light in switch comes on The rear window heating is switched off automatically after about 5 minutes via a time lag relay, and the indicator light in the switch goes out

B Fig. 87: Rear window heating tip switch

Notice!

The rear window heating is only active if the engine is running!

3.35 Reversing fan (option) Reversing fan operation 91 A

B Fig. 88: Reversing fan

3-52

Pressing switch 91 reverses the direction of rotation of the fan, cleans the radiator and the intake screen of the engine cover, and maintains the temperature of the engine and hydraulic oil radiator at an optimal level.

Tip switch 91 for automatic cleaning is located on the switch panel on the left on the instrument panel Cleaning the radiator – see chapter 5 “Cleaning the radiator with the reversing fan (option)” on page 5-17

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Operation 3.36 Air conditioning (option) Information on putting the air conditioning into operation The air conditioning system supplies cool and dehumidified air to the cab during the hot season.

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 at least once a month • This prevents the seals in the compressor from drying and becoming brittle Check V-belt tension and clean the condenser • – see Functional and visual checks of the air conditioning on page 5-36 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 left.

88

Notice!

A B

The air conditioning system allows you to select the 2 same operating modes as for normal heating and ventilation!

• – see Operation of the heating and ventilation system on page 3-52 Press switch 88 to position B

Fig. 89: Air conditioning switch

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Indicator light in switch comes on Air conditioning in operation

3-53

Operation 3.37 Washer system Front window wiper operation Operating the front window wiper ON

Turn rotary switch 72 on the lever to Intermittent wipe the first position

ON

Turn rotary switch 72 on the lever to Continuous wiping the second position

OFF

Turn rotary switch 72 on the lever completely back

72 Fig. 90: Switch for front and rear wipers

Function

Wipers return to base position

Rear window wiper operation 110

l

The switch is located at the top right in the cab roof lining.

Rear window wiper operation

A B

Function

ON

Press switch 110 to position B

Rear wiper is on

OFF

Press switch 110 to position A

Rear wiper returns to base position

Fig. 91: Rear window heating tip switch

Washer pump operation A

Front window washer pump operation

72

ON

Press and hold rotary switch 72 on the lever to the right A

OFF

Release rotary switch 72 on the lever

Rear window washer pump operation OFF

Fig. 92: Washer pump

Press switch 110 beyond position B (tip switch function)

Tank for washer system The tank filler inlet 29 is located to the left of the seat.

29 A

Notice!

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 also – see chapter 5 “Fluids and lubricants” on page 5-55 • Tank capacity: see sight glass A

Fig. 93: Tank for washer system

3-54

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Operation

Operation 3.38 Telescopic boom control lever: overview Operating the control lever for the lift, tilt and push-out rams 98

Danger

C B

96

In order to avoid injury or danger of accidents, the control lever (telescopic boom) and the switch (3rd control circuit) must be locked against unintentional actuation before leaving the seat and before driving on public roads!

99

A

Lock the control lever (joystick) and the 3rd control circuit – see Locking the control lever (joystick) and the 3rd control circuit (attachments) on page 3-37 – see Operating and securing the 3rd control circuit on page 3-60

D

Notice!

Fig. 94: Control lever for telescopic boom

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

• – see Emergency lowering of telescopic boom in case of diesel engine breakdown on page 3-62

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

96

Switch (scroll wheel for pro- 3rd control circuit for locking/unlocking the portional controls) quickhitch or for hydraulic attachment

98

Tip switch

99

Switch (scroll wheel for proRetracts/extends the telescopic boom portional controls)

Front socket – attachment (option)

3-55

Operation 3.39 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.

It is equipped with an electronic load indicator for continuously monitoring weight changes on the rear axle during operation Visible and acoustic signals warn the operator of critical loads on the telescopic boom that might cause the machine to tilt to the front.

The display is installed on the right on the instrument panel.

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!

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, 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 Observe the maximum authorised loads indicated in the load diagram – see Description of load diagram for pallet forks and bucket on page 3-79

3-56

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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 of tipping over, regularly check the safe load indicator for proper functioning!

– see Functional check of the safe load indicator on page 3-57 • Have a defective safe load indicator immediately repaired by an authorised workshop

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 flash and an alarm sounds: 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. 95: 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!

Overview of indicator lights on overload display c b a

a b c d e

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

e d Fig. 96: Overview of safe load indicator display

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3-57

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

Fig. 97: Display of safe load indicator functions

d

See page 3-61 for telescopic boom operation • Green diode d (readiness) comes on The safe load indicator is in operation • Green LEDs a (1 – 4) come on OK! = the loads are between 45 and 90 % of the safe work load • Green LEDs a (1 – 4) and the orange LED b flash Work with extreme caution! Loads are between 90 and 100 % of the safe work load • 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 telescopic boom is overloaded. The load is too heavy The hydraulic functions “Raise, Lower, Dump In/Out and Extend” of the telescopic boom are automatically disabled If possible, retract the telescopic boom and carefully lower the load within the safety range (see load diagram) If the telescopic boom cannot be fully retracted for some reason, for instance due to an obstacle or because the retracted telescopic boom is overloaded, the disabled hydraulic functions have to be enabled with the overload cutoff to reduce the load!

– see Switching the overload cutoff ON and OFF on page 3-59

Notice!

Overload cutoff with “Limit switch” on telescopic boom (option)!

The hydraulic functions disabled by overload are automatically enabled again by a limit switch by retracting the telescopic boom as far as it will go!

If this option is not installed on the machine, the disabled hydraulic function must be enabled with the overload cutoff to reduce the load!

• – see Switching the overload cutoff ON and OFF on page 3-59

3-58

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Operation Switching the overload cutoff ON and OFF 58 A 75

B

Notice!

C A

Functional description of the overload cutoff Pressing tip switch 75 causes indicator light 58 to come on and enables the disabled hydraulic functions “Raise, Lower, Dump in/out and Extend/Retract telescopic boom” again Tip switch 75 for the overload cutoff is located in the switch panel (left-hand side instrument panel).

B

99 D

For reasons of safety, the overload cutoff can be operated only with two hands!

• Press tip switch 75 to position B and move scroll wheel 99 and/or the control lever (joystick) at the same time

Danger In order to avoid danger of tipping over with the machine, the overload cutoff may be overridden only in situations of extreme emergency, e.g. to set down the load within the safety range (see load diagram)!

Fig. 98: Overload cutoff

• Set down the load only when the diesel engine is running at idling speed • Do not continue working if the lock function is disabled (tip switch pressed) Switch off the lock function as follows: If possible, retract the telescopic boom first • Press and hold tip switch 75 in position B and at the same time, move scroll wheel 99 on the control lever backwards until the telescopic boom is fully retracted If this reduces the overload, only the green LEDs are on in the display of the safe load indicator – see Overview of indicator lights on overload display on page 3-57 • Release tip switch 75 Indicator light 58 goes out and the disabled hydraulic functions are enabled again • Carefully lower the load within the safety range (see load diagram) If this measure does not reduce the overload: All LEDs (a, b, c) flash and an alarm sounds. Caution, danger of tipping over!

The telescopic boom is overloaded. The load is too heavy • With tip switch 75 pressed and moving the control lever at the same time, lower the load within the safety range (see load diagram)

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3-59

Operation 3.40 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 96 on the control lever.

The attachment can only be unlocked by pressing switch 81 in addition.

81 AUTO

OFF

96

C A B 83 1

53 Fig. 99: Operation of 3rd control circuit

3-60

Unlock the 3rd control circuit • Slide lock C in switch 83 in the direction of the arrow and press it to position B • Release lock C Indicator light 53 on the indicating instrument comes on 3rd control circuit is unlocked Unlock the attachment • Press switch 81 and scroll wheel 96 (on the control lever) to the right at the same time The attachment on the quickhitch is unlocked Locking the attachment • Press scroll wheel 96 (on the control lever) to the left The attachment is locked in the quickhitch and automatically secured against unlocking 3rd control circuit – hydraulic attachment • The attachment is operated with the 3rd control circuit after having changed over the flexible lines from the quick couplers of the quickhitch to the attachment (e.g. multipurpose bucket)!

– see Switching continuous operation of 3rd control circuit ON/OFF on page 3-87

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Operation 3.41 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!

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

Bear in mind the safe load indicator – see Safe load indicator for telescopic boom on page 3-56 Observe the load diagram. Refer to the label affixed on the side window and to the description on page 3-79 of this Operator's Manual

99 D

Raise the retracted telescopic boom to the required height. To do this: • Pull the control lever backwards D • Extend the telescopic boom. To do this: • Scroll potentiometer wheel 99 on the control lever forwards until the required telescopic boom length is reached

Fig. 100: Raising/extending the telescopic boom

Retracting/lowering the telescopic boom Danger The safe work load can be exceeded when lowering the extended telescopic boom. This can cause the machine to tip forwards!

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 3-56

C

99

Retracts the telescopic boom • Scroll potentiometer wheel 99 on control lever 13 backwards until the telescopic boom is fully retracted Lower the retracted telescopic boom • Push control lever forwards C

Fig. 101: Retracting/lowering the telescopic boom

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3-61

Operation 3.42 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 or raised 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

C

B

99 D

81 AUTO

OFF

Fig. 102: Emergency lowering of telescopic boom

For emergency lowering proceed as follows: Before 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: • Completely retract the telescopic boom with auxiliary means (pulley block). To do this: press switch 81 and at the same time, press and hold potentiometer scroll wheel 99 on the control lever fully backwards • Lower the telescopic boom. To do this: press and hold switch 81 and at the same time, slowly push the control lever forwards C until the telescopic boom is lowered to transport position • Raise the telescopic boom to transport position with lifting gear (crane). To do this: press switch 81, and pull and hold the control lever backwards D until the telescopic boom is lowered to transport position

Notice!

If an emergency lowering has to be carried out with the attachment raised and tilted to the limit, the pressure on the tilt ram has to be released, too, in order to lower the telescopic boom. To do this: • Press and hold switch 81 and at the same time, slowly push the control lever forwards C and to the right B until the telescopic boom is lowered to transport position

Caution!

In case of diesel engine breakdown, have an authorised workshop carry out checks and repair work!

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Operation 3.43 Equipping the machine with a standard bucket 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.

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

Mounting an attachment on a quickhitch with a hydraulic lock Danger

C

B

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.

96

A

The lock pin must be visible on either side in the bores on the attachment D

3

1

2 2

Mount and lock the bucket hydraulically • Release the hydraulic pressure on the 3rd control circuit, and unlock the circuit – see Pressure relief on the quickhitch couplers on page 3-84 • Approach the telehandler to the attachment • Lower the telescopic boom. To do this: push the control lever forwards C • Tilt the quickhitch forwards 1. To do this: push the control lever 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 the control lever to the left A • Scroll potentiometer wheel 96 on the control lever to the left Lock pin E engages in the mounting bores of the attachment and is automatically secured against unintentional unlocking Ensure that lock pin E can be seen on either side of the attachment

E

Fig. 103: Hydraulic lock

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3-63

Operation Mounting an attachment on a quickhitch with a mechanical lock Mount and lock the bucket hydraulically • Remove safety pin F from lock pin G, and remove the lock pin completely out of the quickhitch by hand • Approach the telehandler to the attachment and carefully pick it up with the catch hooks of the quickhitch • Fully dump in the quickhitch and the attachment • Slide lock pins G through the mounting bores of the attachment and of the quickhitch, and secure them with safety pins F on the quickhitch • Ensure that lock pin G on the opposite side is visible in the mounting bore of the attachment

C B

96

A D

3

Notice!

1

2

If an attachment is not installed on the quickhitch, fasten lock pin G in the fixture on the side of the boom and secure it with a safety pin! !

2

F

G

G

Fig. 104: Mechanical lock

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Operation Removing a standard bucket from the quickhitch 96

Notice!

C

Position the attachment so that after unlocking it will stand safely and not tip over.

81

B A

AUTO

D

Removing an attachment with hydraulic locking • Release the hydraulic pressure on the 3rd control circuit, and unlock the circuit – see Pressure relief on the quickhitch couplers on page 3-84 • Drive the telehandler to the drop-off position • Lower telescopic boom 5. To do this: push the control lever to position C until the attachment is about 5 – 10 cm horizontal above the ground • Press and hold switch 81 and at the same time, scroll potentiometer wheel 96 to the right on the control lever • Lock pin E moves out of the mounting bores of the attachment • Slightly tilt the quickhitch forwards 4. To do this: push the control lever to position B • Lower the telescopic boom completely 5. To do this: press the control lever to position C • Reverse the telehandler away from the attachment Removing an attachment with mechanical locking • Remove safety pin F from lock pin G, and remove the lock pin completely out of the quickhitch by hand • 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 • Reverse the telehandler away from the attachment and fully tilt in the quickhitch • Slide lock pins G into the quickhitch and secure them with safety pins F

OFF

4

5 E

Caution!

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 – see Removing the pallet forks from the quickhitch on page 3-73

F

G

Fig. 105: Removing a standard bucket

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3-65

Operation 3.44 Working with the standard bucket Important notice on bucket use • Bear in mind the safety instructions given in chapter 2 before working with the machine.

– see chapter 2 “Designated use and exemption from liability” on page 2-2, – see chapter 2 “General conduct and safety instructions” on page 2-3, – see chapter 2 “Safety instructions regarding operation” on page 2-6 • Never drive up to the edge of a pit from outside – danger of cave-in!

• Never undermine the foundations of walls – danger of collapse!

• When working with a bucket, pallet forks or other attachments, bear in mind the load diagram and the safe load indicator Both are located in the cab.

• Operation of the machine by unauthorised staff is prohibited!

• When working with the machine, look out for high-voltage cables, underground cables, gas and water pipes!

• Release the pressure in the sections of the system and hydraulic lines which are to be opened before starting setup or repair work, e.g. fitting/removing an attachment with hydraulic functions – see Pressure relief on the quickhitch couplers on page 3-84 • Switch off the load stabiliser before working with the telescopic boom – otherwise it will yield very easily, making it difficult to carry out any precise lifting movements – see Load stabiliser on page 3-47

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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Operation Driving on public roads with a standard bucket Notice!

B

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!)

Furthermore, driving on public roads is prohibited if the distance between the front edge of the bucket and the centre of the steering wheel is over 3500 mm in transport position.

320 mm A Fig. 106: Transport position with bucket

Proceed as follows: • Empty and dump in the standard bucket • Retract the telescopic boom completely and set it to transport position Transport position is reached as soon as the telescopic boom is fully retracted and the bucket is dumped in to the limit.

See marks B on the lift frame and the machine frame The distance between the bucket and the ground A is about 320 mm • Cover the blade or teeth of the bucket across their entire width with the protection provided

Notice!

Before driving on public roads, switch off the working lights and remove the protective screen (option) if it is mounted on the cab!

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 quickhitch and lower it to transport position Fig. 107: Tyre damage in transport position

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3-67

Operation Safety instructions regarding work with a full bucket Danger In order to avoid danger of accidents, do not transport loads with a telescopic boom raised higher than in the transport position!

A

Wrong

B

Right

Always dump in the attachment a little towards the machine, carry it as 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)!

Slightly readjust the bucket if necessary (Fig. 108 on page 3-68) In case of a bulky load: • Secure the load and if necessary, 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 Safe load indicator for telescopic boom on page 3-56

Danger Fig. 108: Safety instructions for transporting material

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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Operation Standard bucket payload The load diagram affixed in the cab (right-hand side window) is valid only for use with the buckets as specified and released in Authorised attachments on page 1-6.

Maximum authorized bucket payloads – see chapter 6 “Payload: bucket” on page 6-13

Danger In order to avoid danger of tipping over, ensure the telehandler's stability when picking up loads!

The weight of the attachment and the load must not exceed the specified payload range!

– see Description of load diagram for pallet forks and bucket on page 3-79 Pay attention to the front and rear angle of inclination and to the lateral angle of inclination Bear in mind the safe load indicator (see page 3-56)

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3-69

Operation Loading loose material C

Caution!

B

A

In order to avoid damage to the telescopic boom, push and pull material only with the telescopic boom completely retracted!

D

1 Fig. 109: Driving into the material

Load as follows: • Align the blade parallel with the ground 1 • Lower the telescopic boom to the ground. To do this: push the control lever forwards C • Drive forwards into the material When the engine speed decrease due to too much material: • Raise the telescopic boom a little. To do this: pull the control lever backwards D

Loading if the material is hard to penetrate C

B

A D

Load as follows: • Proceed 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 • Reduce engine speed • Reverse out of the material • Raise the bucket to transport position

C Fig. 110: Loading if the material is hard to penetrate

3-70

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Operation Removing material/digging in soft soil Load as follows: • Place the bucket horizontally on the ground. To do this: push the control lever forwards C

C

B

A D

Fig. 111: 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. 112: 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. 113: Removing an even layer

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3-71

Operation Removing material/digging in hard soil C

B

A D

3

1

Load as follows: • 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 downward a little. To do this: push the control lever forwards C a little

2 Fig. 114: Removing hard soil

C

B

A D

3

Once the bucket has penetrated the soil: • Set the digging angle a little flatter 1. 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 • Push control lever to the left A, or move it alternately to the left and right A and B to loosen the material • Proceed as for loading material hard to penetrate

1 Fig. 115: Adjusting the digging angle flatter

Grading After having finished removing/loading the material, proceed as follows: • Lower the telescopic boom horizontally to the ground (1) • Reverse across the surface to be graded (2)

1 2

Fig. 116: Grading

Loading vehicles

Fig. 117: Loading vehicles

3-72

When loading vehicles, take the following into account: • 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 3.45 Fitting pallet forks Picking up pallet forks with the quickhitch The pallet forks are picked up and mounted on the quickhitch in the same way as the standard bucket – see Mounting an attachment on a quickhitch with a hydraulic lock on page 3-63

Danger Before starting work, ensure that (visual check) 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

Fig. 118: Checking the lock pins

Removing the pallet forks from the quickhitch 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 3-65

Caution!

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 Fig. 119: Driving without an attachment

Pallet forks transport position without load Caution!

320 mm

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 the telescopic boom to transport position • The distance between the pallet forks and the ground is about 320 mm

Fig. 120: Moving the machine without load

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3-73

Operation Driving on public roads with the pallet forks B A

320 mm

Fig. 121: Transport position with 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 Driving on public roads with a standard bucket on page 3-67 • – see chapter 1 “Authorised attachments” on page 1-6 Proceed as follows: • Empty the pallet forks, fully retract the telescopic boom and lower or raise it to transport position.

See marks B on the left on the lift frame and the machine frame The distance between the fork arms and the ground is about 320 mm • Cover the fork arms across their entire width with the protection 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.

3-74

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Operation 3.46 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!

• Ensure the stability of the machine – see Safe load indicator for telescopic boom on page 3-56 – see Description of load diagram for pallet forks and bucket on page 3-79 • 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!

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.

– see Switching the load stabiliser ON or OFF on page 3-48 • Increase the tyre pressure by 0.5 bar

126801d0.ai

Fig. 122: Loading the pallet forks

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3-75

Operation Transporting load • 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 3-60!

• 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 • Observe 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!

• Observe 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

3-76

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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 • No cable-laying work 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!

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3-77

Operation Adjusting the fork arms of the pallet forks Danger In order to prevent the fork armss from slipping or sliding sideways, the safety pins of the fork arms must be correctly locked in the notches on the fork frame.

Before using the pallet forks, check whether both locking levers (a) on the fork arms are folded down and safely engaged in the fork frame!

126801f0.ai

Fig. 123: Fork arms position

When the fork arms are moved under the load, they must have the biggest possible spacing between them, or be introduced at the positions or in the fixtures provided for to this effect.

The fork arms must always be evenly aligned with the fork frame.

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. 124: Locking the fork arms

3-78

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Operation Description of load diagram for pallet forks and bucket

1

2

The load diagram affixed in the cab (right-hand side window) is valid only for use with the buckets and pallet forks as specified and released in Authorised attachments on page 1-6.

Danger In order to avoid danger of tipping over, ensure the telehandler's stability when picking up loads!

The weight of the attachment 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 3-56)

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3-79

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!

Work carefully! 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 – see Safe load indicator for telescopic boom on page 3-56 Observe the load diagram. Refer to the label affixed on the side window and to the description on page 3-79 of this Operator's Manual Proceed as follows: • Switch off the load stabiliser before working – see Switching the load stabiliser ON or OFF on page 3-48 • Pick up the load. To do this: stop the telehandler right before the load and align 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. 125: 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. 126: Picking up the load

2 1 3 Fig. 127: Raising the telescopic boom

4

• 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 320 mm above the ground

Fig. 128: Transport position – pallet forks

3-80

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Operation Transporting material Danger In order to avoid danger of accidents when driving or manoeuvring on slopes, in strong wind or in conditions of poor visibility with fully loaded pallet forks, do not transport loads with a telescopic boom raised higher than in the transport position!

A Wrong

Lower the telescopic boom to transport position and tilt in the pallet forks Avoid high storage positions for material which should not be exposed to wind Whenever possible, drive in reverse when transporting pallet forks loaded with material down a steep slope

Caution!

B

If they are dumped in, the pallet forks are moved parallel to their initial position as the telescopic boom is raised! If the pallet forks are unintentionally dumped in to the limit in the raised position, material can fall over the rear of the pallet forks!

Right

Transport material as follows: • Slightly readjust the pallet forks if necessary (Fig. 129 on page 3-81)/B In case of a bulky load: • Secure the load and if necessary, fit the rear of the pallet forks 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 Safe load indicator for telescopic boom on page 3-56

Fig. 129: Transporting material

Setting down the material 3 2 1

4

5

Lower the material to the ground as follows: • 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 • Bear in mind the safe load indicator • 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!

• After setting down the material, ensure that the area behind the machine is clear • Reverse carefully (5) until the telescopic boom can be lowered to transport position • Lower the telescopic boom and tilt in the fork frame

Fig. 130: Setting down the material

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3-81

Operation 3.47 “Hose burst valve” safety feature Emergency lowering of the telescopic boom with the hose burst valve

C

99 D

81 AUTO

OFF

Fig. 131: Hose burst valve emergency lowering

The hose burst valve prevents the telescopic boom from being lowered and/or dumped out without being braked, in the event of a bursting hose or pipe!

Preparing 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 81 and at the same time, press potentiometer scroll wheel 99 on the control lever backwards and hold • Fully retract the telescopic boom with auxiliary means (pulley block) Lower the telescopic boom • Press and hold switch 81 and at the same time, slowly push the control lever forwards C until the telescopic boom is lowered to transport position Raise the telescopic boom • Press switch 81, and slowly pull and hold control lever backwards D • Raise the telescopic boom to transport position with lifting gear (crane) • Release switch 81 and control lever Secure the machine • Switch off ignition and remove the ignition key • Lock the cab • Secure the machine and the attachment • Have a burst hose or pipe, and the hose burst valve, immediately repaired by a workshop with 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.

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Operation 3.48 Retrofitting to attachments with hydraulic functions Important notice on fitting attachments from other manufacturers 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 and must meet the requirements indicated on page 1-6 “Authorised attachments”!

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 Fitting attachments from other manufacturers (option) on page 3-98 Get informed on and follow the legal regulations of your country!

Notice!

Refer to the attachment's Operator's Manual for information on how to use and operate attachments from other manufacturers!

Working with e.g. a multipurpose bucket – see “Standard bucket” on page 3-66 (by way of analogy).

Before connecting the hydraulics of the attachment from another manufacturer to the 3rd control circuit, ensure that the pressure on the quickhitch couplers is released!

• – see Pressure relief on the quickhitch couplers on page 3-84

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3-83

Operation Pressure relief on the quickhitch couplers Notice!

96 81

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 sections of the system and hydraulic lines which are to be opened before fitting or removing an attachment.

AUTO

OFF

Fig. 132: Releasing the pressure in the hydraulic lines

Release the pressure as follows: • Lower the telescopic boom • Apply the parking brake – see Parking brake on page 3-45 • Unlock the 3rd control circuit – see Operating and securing the 3rd control circuit on page 3-60 • Stop the engine, but do not switch off ignition • Press and hold switch 81 , and at the same time, scroll and hold potentiometer wheel 96 on control lever to the left or right about 8 seconds in either position Pressure in hydraulic lines is released • Switch off ignition and remove the ignition key • Remove the quick couplers from the quickhitch and mount them on the attachment – see Mounting an attachment on a quickhitch with a hydraulic lock on page 3-63

Mounting an attachment from another manucturer on the quickhitch The attachment is picked up and mounted on the quickhitch in the same way as the standard bucket – see Mounting an attachment on a quickhitch with a hydraulic lock on page 3-63

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. 133: Checking the lock pins

3-84

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Operation Hydraulic connections: attachments from other manufacturers on the 3rd control circuit 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 3-84

Caution!

D

C

Fig. 134: 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 3-84 • 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

3-85

Operation Removing attachments from other manufacturers from the quickhitch

B

A

D

C

Proceed as follows: • 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 3-84 • 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

Attachments from other manufacturers are lowered in the same way as a standard bucket – see Removing a standard bucket from the quickhitch on page 3-65

C

Danger Position the attachment so that after unlocking it will stand safely and not tip over.

Fig. 135: Connecting the hydraulic lines to the quickhitch

3.49 Tilt ram lock (option) Switching the tilt ram lock ON and OFF

9

Fig. 136: Operation of key-operated switch

3-86

This option is used for securing the tilt ram if it is not supposed to be operated (e.g. when setting down material on high piles).

The key-operated switch is located on the left on the instrument panel next to the indicating instruments.

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 9 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 9 to the symbol The tilt ram is unlocked and can be operated again

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Operation 3.50 Continuous operation of 3rd front control circuit (option) Switching continuous operation of 3rd control circuit ON/OFF 53 S

S A

B 81

D

79

C

By means of quick couplers C/D of the 3rd control circuit, this option is 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 81 and 79 (switch console on the left) as follows: Switching on continuous operation • Slide switch 81 (lock S) in the direction of the arrow and press it to position B 3rd control circuit switched ON Indicator light 53 on the indicating instrument comes on • Slide switch 79 (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 79 (lock S) in the direction of the arrow and press it to position A Continuous operation of the 3rd control circuit is switched OFF

Caution!

Fig. 137: Continuous operation of 3rd control circuit

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Clean the quick couplers carefully before connecting an attachment in order to ensure proper function and sealing features!

3-87

Operation 3.51 Electric changeover valve for operation of 3rd control circuit as additional front control circuit (option) Switching the additional control circuit ON or OFF 96 53 S

Notice!

A B 83

V

Fig. 138: Hydraulic connections of additional control circuit

3-88

This option allows the operation of hydraulic front attachments without changing over hydraulic hoses (e.g. quickhitch lock on attachment).

Quick couplers V on the quickhitch are used for this operation.

The additional control circuit is switched on with switch 83 and tip switch 96 on the control lever.

The attachments are mounted and removed in the same way as a standard bucket!

• – see Mounting an attachment on a quickhitch with a hydraulic lock on page 3-63 • – see Removing a standard bucket from the quickhitch on page 3-65 • For operation also see the Operator's Manuals of the attachment manufacturers Switching on the additional control circuit • Slide switch 83 (lock S) in the direction of the arrow and press it to position B 3rd control circuit switched ON Indicator light 53 on the indicating instrument comes on • Press tip switch 98 on the control lever • Operate the additional control circuit with scroll wheel 96 on the control lever Switching OFF the additional control circuit • Press tip switch 98 on the control lever Additional control circuit switched OFF

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Operation 3.52 Rear hydraulic additional control circuit (option) Description of the additional control circuit Quick couplers are mounted at the rear of the machine for operating hydraulic attachments with additional hydraulic functions The additional control circuit is supplied with hydraulic oil by pressing switch 78 (switch console on the left) and switch 104 (switch console on the right).

The quantity of oil (litres) is continuously set with potentiometer 93 (rotary switch on the switch console on the right).

Connecting an attachment onto the additional control circuit A

S

B

78

Quick couplers on rear frame: overview • 2 quick couplers HZ (return with/without pressure, red protective cap, not usable for single action tipping trailer connection) • Quick couplers HR (single action, blue protective cap, e.g. for tipping trailer connection)

A

AUTO

OFF

B

Caution!

81

104

Clean the quick couplers carefully before connecting an attachment in order to ensure proper function and sealing features!

Notice!

93 A

B

HR HZ

Fig. 139: Additional control circuit connections: overview

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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 reattached because the pressure in the hydraulic lines has not been released.

• Release the pressure in the sections of the system and hydraulic lines which are to be opened before fitting or removing an attachment.

Connect the additional control circuit as follows: • Lower the telescopic boom and apply the parking brake • Stop the engine, but do not switch off ignition • Switch on the additional control circuit. To do this: slide lock S downwards in switch 78 and press the switch • Release lock S • Release the hydraulic pressure in the quick couplers. To do this: press and hold switch 81 and at the same time, press switch 104 in either position for about 8 seconds Pressure in quick couplers is released • Switch off ignition and remove the ignition key • Connect the attachment to quick couplers HZ at the rear of the frame (return with/ without pressure, red protective cap) or to quick coupler HR (single action, blue protective cap)

3-89

Operation Additional control circuit operation A

S

B

78

Operate as follows if an attachment is connected: • Slide lock S on switch 78 in the direction of the arrow and press the switch to position B • Press switch 104 to position A or B (control circuit selection) • Turn potentiometer 93 (rotary switch on switch console on the right) as required A => less, B => more oil

A

AUTO

OFF

B 81

104

93 A

B

Notice!

If switches 78 and/or 104 are still switched on when starting the diesel engine, the additional control circuit is locked for reasons of safety.

Furthermore, the quantity of oil is automatically reset to minimum when starting the diesel engine.

• Switch off switches 78 and 104 and switch them on again (see above) • Turn back potentiometer 93 (rotary switch) to minimum A and then reset the required quantity of oil • Before stopping the engine, turn back potentiometer 93 (rotary switch) to minimum A and switch off switch 78 If switch 78 is unintentionally switched off and on during operation, the quantity of oil previously adjusted remains unchanged.

Notice!

HR HZ

Quick coupler HR (single action, blue protective cap) is used for tipping trailers with an unpressurised return!

Fig. 140: Operation of additional control circuit

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Operation 3.53 Tipping trailer connection (option) Operating the tipping trailer connection Quick couplers HR (blue protective cap) for operation of hydraulic tipping trailers.

A

S

B

78

S

102

103

A

Notice!

Only tipping trailers with single-action tilt ram can be operated with this option.

The tipping trailer connection is operated as follows, via switch 78 (on the switch console on the left) and via switch 102 (only with optional Autohitch trailer coupling) and tip switch 103 (both on the switch console on the right).

Caution!

B

Clean the quick couplers carefully before connecting an attachment in order to ensure proper function and sealing features!

HR Fig. 141: Operation of tipping trailer connection (option)

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Operate the tipping trailer connection as follows: • Connect the flexible line of the hydraulic tipping trailer to quick coupler HR (blue protective cap) • Slide switch 78 (lock S) in the direction of the arrow and press it to position A Additional control circuit switched OFF • If the machine is equipped with an Autohitch trailer coupling: slide switch 102 (lock S) in the direction of the arrow and press the switch to position B • Press tip switch 103 to position A Raises the tipping trailer • Press switch 103 to position B Lowers the tipping trailer

3-91

Operation 3.54 Operation of the Autohitch trailer coupling (option) Important notice on the Autohitch trailer coupling The Autohitch trailer coupling H allows you to hitch a trailer onto the telehandler while remaining seated.

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.

Gross trailer weight rating: – see chapter 6 “Trailer couplings: trailer weight/drawbar load” on page 6-10

Danger If the trailer is not coupled correctly, there is an extreme danger of accidents!

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

Notice!

Open and close the trailer coupling when the diesel engine is running at low speed (up to about a max. 1500 rpm)!

• The increased oil quantity that flows at higher engine speed causes the pressure relief valve to respond, and the locking/unlocking functions to be performed more slowly, and not faster. This in turn results in a higher energy consumption (fuel)!

Putting the Autohitch into operation – see Operation of Autohitch trailer coupling on page 3-93

3-92

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Operation Operation of Autohitch trailer coupling Notice!

Switch off the additional control circuit before putting the Autohitch trailer coupling into operation!

Press switch 81 to position A

80

102

S

103

A

AUTO

OFF

B

G

O H

Fig. 142: Opening the Autohitch trailer coupling

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The Autohitch trailer coupling is operated via tip switch 80 (switch console on left) and switch 103 (switch console on the right) as follows.

Unlock the trailer coupling lock • Slide switch 102 (lock S) in the direction of the arrow and press the switch to position A • Press tip switch 80 to position B and at the same time, press switch 103 in the direction of the arrow A Towing pin H moves fully upwards to the final position and automatically unlocks the safety lock Opening the trailer coupling • Press and hold tip switch 80 in position B and at the same time, press switch 103 in the direction of the arrow B Towing gear H moves downwards Coupling the trailer onto the trailer coupling • Use the mirror (option) to carefully approach to the trailer until the towing pin appears below the eyelet of the trailer drawbar • Press tip switch 80 to position B and at the same time, press switch 103 in the direction of the arrow A until the trailer coupling audibly encounters hydraulic resistance Towing pin H moves upwards to the final position (arrow G) • Caution! Check whether the trailer is safely locked Uncoupling the trailer from the trailer coupling • Press switch 102 to position A • Press tip switch 80 to position B and at the same time, press switch 103 in the direction of the arrow A Towing pin H moves fully upwards to the final position and automatically unlocks the safety lock • Press tip switch 80 to position B and at the same time, press switch 103 in the direction of the arrow B Towing pin H moves downwards

3-93

Operation 3.55 Automatic trailer coupling (option) Trailer coupling description and use • 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)!

• Trailer and drawbar loads – see chapter 6 “Trailer couplings: trailer weight/drawbar load” on page 6-10 • Have a damaged or defective trailer coupling immediately repaired or replaced by an authorised workshop Get informed on and follow the legal regulations of your country.

Attaching a trailer

A

Danger In order to avoid danger of accidents by not coupling a trailer correctly, always carry out a visual check to ensure that the lock pin is coupled into the lower bore of the coupling jaw!

B

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 replaced by an authorised workshop

Fig. 143: Trailer coupling (option)

Couple the trailer as follows: • Before coupling the trailer, press lever A upwards until it engages audibly • Check that the coupling jaw is locked horizontally • 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 connection 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 Uncouple the trailer from the trailer coupling – see Uncoupling the trailer on page 3-95

3-94

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Operation Uncoupling the trailer

A

B Fig. 144 : Trailer coupling (option)

Uncoupling the trailer from 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

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3-95

Operation 3.56 Compressed-air brake system (option) 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 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 (dual-circuit brake system) B

A

Danger Follow the correct order for uncoupling the pressure hoses under all circumstances to prevent the trailer rolling away!

Uncoupling the pressure hose: First uncouple the pressure hose from the red coupling head A (tank), then the pressure hose from the yellow coupling head B (brake) Coupling the pressure hose: Fig. 145: Compressed-air brake couplings (option)

3-96

First couple the pressure hose onto the yellow coupling head B, then the pressure hose onto the red coupling head A

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Operation Compressed-air gauge Danger Before moving off with a trailer, pressure gauge 69 must show a system pressure of at least 5 bar. Danger of accidents if the system pressure is below 5 bar!

69 Fig. 146: Compressed-air brake gauge (option)

Let the diesel engine run at machine standstill until the compressed-air brake system is filled 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

3.57 Hydraulic trailer brake (option) Information on the hydraulic trailer brake A

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!

Notice!

Fig. 147: Hydraulic trailer brake connection

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

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3-97

Operation 3.58 Fitting attachments from other manufacturers (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 stability, load capacity and other tests according to DIN EN 474 must be carried out for attachments used with the quickhitches indicated above.

For more information – see Example: inspection plan for attachments from other manufacturers on page 3-100 Follow the safety regulations of your country regarding accident prevention during operation of machines and attachments.

In Germany, legislation requires all machine operators 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.

3-98

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Operation Fitting attachments from other manufacturers • Refer to the Operator's Manual of the attachment for installing and connecting the hydraulic hoses onto the quickhitch.

Also refer to Equipping the machine with a standard bucket on page 3-63 Retrofitting to attachments with hydraulic functions on page 3-83

Caution!

Important! In order to ensure machine stability, the dimensions (length/width), the material density and the loads of attachments from other manufacturers must correspond to the authorised attachments – see chapter 1 “Fields of application and using a telehandler with an attachment” on page 1-6!

Notice!

Stability must be assessed 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 from other manufacturers” on page 3-100 to assess stability Get informed on and follow the legal regulations of your country.

Fig. 148: Attachments from other manufacturers: data

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3-99

Operation Example: inspection plan for attachments from other manufacturers 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:

3-100

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Operation 3.59 Towing the machine Safety instructions for towing away Danger 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 may be towed with a cable if the service brakes and steering are fully operational!

Getting ready for towing Caution!

A

Fig. 149: Disabling the variable displacement pump (30/40 kph)

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!

Disabling the variable displacement pump (neutral position) • Lower or raise the telescopic boom to transport position • Apply the parking brake • Stop the diesel engine • Switch off ignition and remove the ignition key • Switch over the variable displacement pump to towing. To do this: • Unscrew the two HP valves A 3 – 4 turns Wrench size 22 mm

Notice!

Reset the variable displacement pump to drive operation once towing the machine is over!

• – see Once towing is over on page 3-102

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3-101

Operation Towing the machine Danger In order to avoid danger of accidents, the towing vehicle must have enough tractive power and be fitted with a safe brake system.

It may be advisable to order a recovery service or authorised staff to tow the machine away If the diesel engine is defective, always use a towing bar for towing Eye hooks for towing the machine – see chapter 1 “Machine overview” on page 1-3 If possible, run the diesel engine at idling speed when towing the machine Tow away the machine from the danger area only after you have opened the HP valves

Notice!

Steering and braking requires greater effort if the diesel engine of the towed machine breaks down!

• Towing distance => 300 m max.

• Towing speed => 6 kph max.

Once towing is over

A

Enabling the variable displacement pump • Screw in and tighten both HP valves A with a torque wrench (wrench size 22 mm) Torque 85 Nm • Check the drive for correct operation

Fig. 150: Enabling the variable displacement pump H1 P 078

3-102

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Operation 3.60 Decommissioning the machine temporarily Stopping/parking the machine Danger Machines parked on slopes can roll away!

Use the parking brake to park the machine safely and to prevent it rolling away!

In addition to the parking brake, secure the machine by placing chocks under the downhill sides of the wheels!

Caution!

In order to avoid heat accumulation and damage to the exhaust gas turbocharger, do not stop the diesel engine from full throttle!

Let the diesel engine run at idling speed for about 2 minutes and then switch it off To decommission the machine temporarily, proceed as follows: • Park the machine on level ground • Set the machine to neutral with tip switch 101 on the joystick (Fig. 40 on page 3-4) • Apply the parking brake (Fig. 35 on page 3-2) • Telescopic boom: set the attachment horizontally with the ground and lower the telescopic boom completely to the ground – see Operating the telescopic boom on page 3-61 • Stop the diesel engine and remove the ignition key • Close the windows and the door as you leave the cab • Close and lock the engine cover • In addition to the parking brake, secure the machine on slopes by placing chocks under the wheels The wheel chocks are stored on the machine frame behind the cab

Decommissioning the machine for a longer time 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, clean the piston rods, however not with a grease solvent or a high-pressure cleaner The scrapers are not water-tight, therefore water can penetrate into the guide bushing, and cause corrosion and damage to the piston rod

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3-103

Operation 3.61 Loading 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 6-1!

• Remove any mud, snow or ice from the tyres so that the machine can be safely driven onto the ramps • Secure the transport vehicle against unintentional movement!

• When placing the load 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) • Do not exceed the gross weight rating and the gross axle weight rating of the transport vehicle when loading and transporting the machine.

• 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 overview” on page 1-3.

• 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

3-104

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Operation Loading the vehicle

20˚ 30864brampe.eps

Fig. 151: Access ramps

Load as follows: • 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 • Check that the attachment is safely locked onto the quickhitch • Carefully drive the machine onto the middle of the transport vehicle • Switch the drive to neutral position – see Driving direction selection (reversing operation forwards/reverse) on page 3-39 • Apply the parking brake – see Applying the parking brake on page 3-45 • Lower the telescopic boom to the loading area • Stop the diesel engine • Remove the ignition key • Leave the cab, close and lock the cab door and the engine cover • Ensure that the authorised maximum height is not exceeded

Tying down the machine Tie down the machine as follows: • Secure all tyres of the telehandler with chocks in front of, behind and at the sides of each wheel • Firmly tie down the machine at the eye hooks – see chapter 1 “Machine overview” on page 1-3 – with tested and sufficiently dimensioned belts, chains or shackles 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 of his vehicle (including the telehandler) before moving off, and the legal transport regulations of the country or countries in which transport will take place!

Fig. 152: Tying down the machine

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3-105

Operation 3.62 Crane handling the machine Safety instructions regarding crane handling In order to avoid injury or danger of accidents, observe the following instructions when loading the telehandler!

• Seal off the danger area!

• The crane and the lifting gear must have suitable dimensions!

• Take into account the machine's overall weight – see page 6-10!

• Use only tested ropes, belts, hooks and shackles (lockable brackets with screws or socket pins) for fastening!

• 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!

• Ensure that no-one is in or on the machine!

• Stay clear of suspended loads!

• Bear in mind the safety instructions of this Operator's Manual on page 2-1 and the safety-specific legal regulations of your country under all circumstances!

3-106

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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 3-63 • Empty and dump in the standard bucket, and lower it to transport position – see Driving on public roads with a standard bucket on page 3-67 • Set the drive to neutral – see Driving direction selection (reversing operation forwards/reverse) on page 3-39 • Stop the diesel engine and remove the ignition key • Apply the parking brake – see Parking brake on page 3-45 • Lock the cab and the engine cover • Fasten the machine to the slinging points with tested and sufficiently dimensioned lifting gear (ropes, belts, hooks, shackles) Slinging points on the machine, see labels A on the left and right, and at the front and rear of the frame – see chapter 1 “Machine overview” on page 1-3 • Carefully raise the machine with the crane A

B

Fig. 153: Label for crane handling

Caution!

Do not use the slinging points B (eyelets) on the cab for loading the machine!

• They are used for removing the cab only • – see chapter 1 “Machine overview” on page 1-3

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3-107

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 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!

3-108

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Troubleshooting

Troubleshooting

4

Troubleshooting

4.1 Information on troubleshooting The information given in this chapter is provided for the fast and reliable detection of malfunctions and their appropriate repair.

Please contact your dealer if the malfunction cannot be remedied.

Notice!

Repairs may be carried out only by authorised workshops and trained staff.

4.2 Diesel engine malfunctions Diesel engine malfunctions

Possible causes

Remedy

Parking brake not applied

• Release the parking brake

Wrong SAE grade of engine lubrication oil

• Contact an authorised workshop

Fuel grade does not comply with specifications

• Observe fuel specification when filling up

Insufficient fuel supply

• Contact an authorised workshop

Diesel engine does not start or Defective or flat battery is not easy to start Loose or oxidised cable connections in starter circuit Defective starter, or pinion does not engage

– 5-55 – 5-38 –

• Contact an authorised workshop

– –

Defective fuel injector

– • Observe fuel specification when filling up

Wrong valve clearance Injection line leaks Defective fuel injector

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3-45

Wrong valve clearance

Fuel grade does not comply with specifications Diesel engine starts, but does not run smoothly or faultless

• Replace the battery with a new one

See page

5-55 –

• Contact an authorised workshop

– –

4-1

Troubleshooting Diesel engine malfunctions

Possible causes

Remedy

Oil level too low

• Fill up engine oil • Observe engine oil specification

5-8

Oil level too high

• Contact an authorised workshop

–

Diesel engine overheats. Tem- Dirty air filter perature warning system Defective air filter maintenance switch or gauge responds Dirty oil/water radiator fins

See page

• Replace air filter • Contact an authorised workshop • Clean the radiator

Defective fan, torn or loose V-belt Defective fuel injector

• Contact an authorised workshop

• Observe fuel specification when filling up

5-55

Dirty air filter

• Replace air filter

5-19 –

Wrong valve clearance

–

Injection line leaks

– • Contact an authorised workshop

–

Injection line leaks

–

Insufficient fuel supply

–

Defective fuel injector

–

Oil level too low Insufficient or no diesel engine Machine inclination too high oil pressure Wrong SAE grade of engine lubrication oil Oil level too high

4-2

–

Fuel grade does not comply with specifications

Defective fuel injector

Blue diesel engine smoke

5-16

–

Insufficient diesel engine output Defective air filter maintenance switch or gauge

Diesel engine oil consumption too high

–

–

Oil level too high

Diesel engine does not run on all cylinders

5-19

Defective piston rings

• Fill up engine oil • Observe engine oil specification

5-8

• Move machine out of inclination

–

• Contact an authorised workshop • Observe engine oil specification

5-55

• Contact an authorised workshop

– –

Diesel engine inclination too high

• Move machine out of inclination

–

Low-load operation of diesel engine

• Avoid too long engine idle times

–

Oil level too high

• Contact an authorised workshop

–

Diesel engine inclination too high

• Move machine out of inclination

–

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Troubleshooting Diesel engine malfunctions

White diesel engine smoke

Possible causes

Remedy

Engine starting temperature too low

• Contact an authorised workshop

Fuel grade does not comply with specifications

• Observe fuel specification when filling up

Wrong valve clearance Defective fuel injector Dirty air filter Black diesel engine smoke

• Replace air filter

Defective air filter maintenance switch or gauge Wrong valve clearance Defective fuel injector

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• Contact an authorised workshop

See page – 5-55 – – 5-18 5-18

• Contact an authorised workshop

– –

4-3

Troubleshooting 4.3 Drive malfunctions Notice!

Basically, proceed as follows when the driving direction selection does not work: • Press tip switch “Neutral position” on the joystick and select the driving direction again • If this does not work: start diesel engine again, then select the driving direction again • If the malfunction persists, have the drive immediately checked or repaired by an authorised workshop • For further possible causes, see table

Drive malfunctions

Possible causes

Remedy

Parking brake applied – arrows on the joystick flash

•

The tip switch (neutral position) was unintentionally actuated when the driving direction was selected

1 Start the diesel engine again 2 Release the parking brake 3 Select the driving direction again

3-39

If the diesel engine runs at idling speed: 1 Press tip switch “Neutral position” on the joystick 2 Release the parking brake 3 Select a driving direction 4 Press the accelerator pedal

3-39

The driving direction was selected and at the same time, the accelerator pedal Driving direction selection does not work was pressed and the parking brake after new start released

See page

Release the parking brake

3-45

The driving direction was selected and at the same time, the accelerator pedal was pressed, the diesel engine was started and the parking brake released

1 2 3 4 5 6 7

Stop the diesel engine Switch off ignition Apply the parking brake Start the diesel engine Release the parking brake Select the driving direction again Press the accelerator pedal

3-32, 3-39

Unable to change driving direction – arrows on the joystick flash

The driving direction has been selected at speeds over 12 kph

1 Slow down your drive speed to less than 12 kph 2 Select the driving direction again

3-39

Maximum drive speed is not reached

Drive temperature is below 20 °C

Drive without full output

4-4

The drive electronics has detected an error and switches to “Limited Mode” (extremely limited drive output)

•

Increase drive temperature to over 20 °C

–

1 Stop the diesel engine 2 Switch off ignition 3 Apply the parking brake 4 Start the diesel engine 5 Release the parking brake 6 Select the driving direction again 7 Check the drive output If this measure does not work, contact an authorised workshop

–

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Troubleshooting 4.4 Malfunctions in the air conditioning system (option) Notice!

Filling up and repair work on the air conditioning system may be carried out only by authorised workshops! l

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

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V-grooved pulley does not turn even though magnetic clutch is attracted

• Contact an authorised workshop

–

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

4-5

Troubleshooting Malfunctions in the air conditioning system Loss of refrigerant

Possible causes

System cools with interruptions

See page

Refrigerating-agent line interrupted

–

System leak

–

Clogged fan duct Insufficient refrigerating output

Remedy

•

Contact an authorised workshop

Level of refrigerant too low

–

Humidity in system

–

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

4-6

–

– 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 notice 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 5-50.

• 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 5-50 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 notice on maintenance work • 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 • Follow all safety instructions given in this Operator's Manual • 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 onto the lift ram The safety prop is located at the front left on the machine frame.

B

Danger 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!

A

Mount safety prop A (supplied with the machine) onto the extended lift ram and secure it with pin B (see figure) 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 (see Fig. 154) • Lock the safety prop with pin B and secure it with the safety pin

A

Caution!

A

Mount it as shown in Fig. 154 in order to avoid damage to the piston rod and the safety prop.

B

Notice!

Fig. 154: 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 left machine frame)!

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Maintenance 5.3 Fuel system Important 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

Fuel 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. 155: Refuelling from a barrel

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General Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually contaminated.

Even the smallest particles of dirt can cause • Increased engine wear • Malfunctions in the fuel system and • Reduced effectiveness of the fuel filters 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 (refer to the label affixed near the filler opening) A

Danger Do not refuel in closed rooms – danger of fire and suffocation!

☞ Before refuelling: • • • •

Fig. 156: 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!

Checking/cleaning the additional fuel filter (water separator, option) Notice!

61

Drain the condensation water in the additional fuel filter at the latest if indicator light 61 on the instrument panel comes on – see Maintenance plan (overview) on page 5-50.

B Fig. 157: Checking the additional fuel filter

The additional fuel filter is installed on the air filter bracket. ☞ Proceed as follows: • Lower the telescopic boom to the ground • Stop the diesel engine and remove the ignition key • Apply the parking brake • Place a container to collect the fuel • Open drain cock B on the additional fuel filter and drain the condensation water • Close drain cock B • Start the diesel engine and check the additional fuel filter for leaks

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!

5-4

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Maintenance Bleeding the fuel system Danger If the fuel, as it drains, comes into contact with hot engine parts or the exhaust system, there is an increased fire hazard!

A

☞ Never bleed the fuel system if the engine is hot! ☞ Wear protective gloves

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!

B

Bleed the fuel system in the following cases: • After replacing the fuel (pre)filter • After cleaning the fuel lines • After running the fuel tank empty ➥ After running the diesel engine again, after it has been out of operation for a longer period of time

☞ Bleed the fuel system as follows: Fig. 158: Bleeding the fuel system

• • • • • • • • •

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Place the container under the engine Fill the fuel tank Slacken bleed screw A on the injection pump by a few turns Press button B on the fuel pump with your hand (pumping movement) until the fuel comes out free of air from the slackened bleed screw A Tighten bleed screw A Start the engine If the engine runs smoothly for a while, and then stops; or if it does not run smoothly: Stop the engine and bleed the fuel system again as described above Have this checked by authorised staff if necessary

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! ☞ Wear protective gloves!

A

Environment!

Fig. 159: Fuel filter position

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!

☞ Proceed as follows: B A

A Fig. 160: Replacing the fuel filter

5-6

• • • • • • • • • • • • • •

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 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 5-5 Let the engine run and check the filter cartridge for leaks

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Maintenance 5.4 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 (black engine oil), this can cause engine damage or loss of output! ☞ Drain the oil ☞ – see Maintenance plan (overview) on page 5-50 A

☞ Proceed as follows: Fig. 161: 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

Caution!

B

Too much or incorrect engine oil can result in engine damage! ☞ 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 5-55

A

Environment!

Fig. 162: 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) 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. 163: Optimum engine oil temperature

A B

D

C

Fig. 164: Oil drain plug

B D E

F

Proceed as follows: • 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 A below on the engine vat (access to drain plug) • Place a container (about 15 l capacity) under the opening to collect the oil as it drains • Unscrew filler cap C of oil drain valve B • Place the drain coupling with a sufficiently long hose E into container F • Screw drain coupling D onto oil drain valve B The oil drain valve opens and the oil is drained as the drain coupling is screwed onto the valve Once the oil is completely drained • Unscrew drain coupling D from oil drain valve B • Screw cap C of the oil drain valve back on again • Replace 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 the engine oil pressure indicator light (Fig. 36 on page 3-4)/52 (must go out when the engine runs) • 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 and the oil sump

Fig. 165: Drain coupling with hose

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5-9

Maintenance Replacing the engine oil filter (every 500 service hours) Engine oil filter G is located next to the engine oil cooler.

Danger Careful when replacing the filter. Hot engine oil carries a danger of burns!

Wear protective gloves Use suitable tools (filter spanners, torque wrenches are commercially available)

G

Proceed as follows: • 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 A below on the engine vat (access to oil filter) • Place a suitable container under the oil filter • Slacken and unscrew oil filter G with a commercially available filter spanner • Clean the inside of the filter head

A Fig. 166: Engine oil filter position

H

• • • •

G • • •

G Fig. 167: Replacing the engine oil filter

• •

Apply a thin coat of fresh engine oil to rubber seal H of the new oil filter Tighten the oil filter by hand until the gasket makes contact Tighten the oil filter to 15 – 17 Nm with a (commercially available) torque wrench Drain the 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 the engine oil pressure indicator light (Fig. 36 on page 3-4)/52 The indicator light must be out if the engine is running Stop the engine and check the seal on the oil filter Completely remove all oil spills from the engine and the engine vat

Environment!

Collect the drained engine oil in a suitable container. Dispose of used oil and filters in an environmentally friendly manner!

5-10

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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 5-14 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

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5-11

Maintenance Information on inspection and cleaning work on the cooling system 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! Therefore: • Check the coolant level at regular intervals. Refer to the maintenance plan for the intervals – see Maintenance plan (overview) on page 5-50 • 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 6-11

Caution!

In order to avoid sludge in the cooling system that damages the engine, do not use radiator cleaning compounds if an antifreeze compound has been added to the coolant.

Environment!

Use a suitable container to collect the coolant as it drains and dispose of it in an environmentally friendly manner!

5-12

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Maintenance Temperature gauge: engine coolant Temperature gauge 57 (with acoustic warning) on the instrument panel monitors the cooling system.

57

Caution!

Engine temperature should be between 80 and 105 °C (the maximum admissible cooling temperature is 110 °C, see arrow).

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 • Clean the radiator fins

Fig. 168: Temperature gauge

Checking the coolant level 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

MAX

A

MIN

Fig. 169: Checking the coolant expansion tank

Checking the coolant level • 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 of the expansion tank: • Fill up coolant to the MAX mark Check the coolant quality (antifreeze) with suitable testing equipment (antifreeze tester) – see Fluids and lubricants on page 5-55 and – see chapter 6 “Coolant compound table” on page 6-11

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5-13

Maintenance Filling up coolant Danger The cooling system is under high pressure!

Never open the coolant tank or drain coolant on a running and hot engine!

Wait at least 10 minutes after stopping the engine!

Wear protective gloves and clothing Actuate the safety valve in the filler cap of the expansion tank Open the cap to the first notch and release the pressure

B

MAX

A

MIN

Fig. 170: Filling up coolant in the expansion tank

5-14

Fill up coolant as follows: • 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 the coolant expansion tank A. To do this: • Open cap B to the first notch and release the pressure • Open filler cap B fully • Fill up coolant to the MAX mark • Use brand-name antifreeze compounds with anticorrosion additives – see Fluids and lubricants on page 5-55 and – see chapter 6 “Coolant compound table” on page 6-11 • Close filler cap B • Start and warm up the engine • Open the heating circuit fully – see chapter 3 “Cab heating and ventilation” on page 3-52 • Stop the engine and remove the key • Check the cooling system and the heating water circuit for leaks • Have leaks immediately repaired by qualified and trained staff • Check the coolant level again • If necessary, fill in coolant and repeat the procedure until reaching the correct coolant level

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Maintenance Draining coolant Danger Never open the coolant tank or drain coolant on a running and warm engine!

The cooling system is under high pressure!

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

B

MAX

A

MIN

C Fig. 171: Draining coolant

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Drain the coolant as follows: • 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 heating temperature controller to max. temperature in order to drain the coolant from the heating circuit as well – see chapter 3 “Cab heating and ventilation” on page 3-52 • 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 the coolant expansion tank A. To do this: • Open cap B to the first notch and release the pressure • Open filler cap B fully • Remove servicing lid C below on the engine vat • Open the drain plug below on the radiator and drain the coolant Fill up coolant as follows: • Close the outlet on the radiator • Fill up coolant up to about 30 mm below the opening of the expansion tank Use brand-name antifreeze compounds with anticorrosion additives – see Fluids and lubricants on page 5-55 and – see chapter 6 “Coolant compound table” on page 6-11 • Close the expansion tank with filler cap B • Open the heating circuit fully – see chapter 3 “Cab heating and ventilation” on page 3-52 • 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 the trained staff of an authorised workshop • Check the coolant level MAX in the expansion tank • If necessary, fill in coolant and repeat the procedure until reaching the correct coolant level

5-15

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. Refer to the maintenance plan for the intervals In dusty or dirty work conditions, clean more frequently than indicated in the maintenance plan

Fig. 172: Cleaning the radiator

Proceed as follows: • 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

Notice!

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!

5-16

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Maintenance Cleaning the radiator with the reversing fan (option) 91

The telehandler can be equipped with a reversing fan (option).

Pressing tip switch 91 (on the right on the instrument panel) reverses the fan's direction of rotation and cleans the radiator.

Notice!

A

The radiator can be cleaned with the reversing fan during machine operation and only with the diesel engine running.

B

Caution!

A

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 Briefly press tip switch 91 to position B with a running engine

Fig. 173: Tip switch for reversing fan

The fan rotates the other way round with a certain delay, The fan is in cleaning mode and dirt is removed from the radiator This can be seen by the dust A blown out from the intake screen on 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!

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5-17

Maintenance 5.6 Air filter Checking air filter contamination Clean the dust valve once a day • 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

49

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.

A

D F

Fig. 174: Air filter – dust valve

5-18

Check the filter cartridge once a week for dirt Indicator light 49 on the indicating instrument monitors the filter cartridge. Replace filter cartridge D if this indicator light comes on Replace the filter cartridge after 500 service hours at the latest, however at least once a year – see Maintenance plan (overview) on page 5-50

Caution!

Filter and safety cartridges degrade prematurely when in service in acidic air for longer periods of time. This risk is present for example in acid production facilities, steel and aluminium mills, chemical plants and other nonferrousmetal plants.

Replace filter cartridge D and safety cartridge F at the latest after 500 service hours!

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Maintenance Replacing the filter cartridge Replacing the filter cartridge at 500 s/h (service hours) at the latest

Caution!

G

H

307b0700.ai

D

307b0710.ai

H D F

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!

Proceed as follows: • Stop the engine • Apply the parking brake • Switch off ignition and remove the ignition key • Open the engine cover • Fold both locks G on lower housing section 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 into the upper housing section • Insert new filter cartridge D into the upper housing section • Position lower housing section H (ensure that it is properly seated) • Close both locks G

Caution!

Fig. 175: Removing the filter element

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In order to avoid engine damage, do not operate the diesel engine without a filter insert!

5-19

Maintenance 5.7 V-belts Checking the V-belts Danger Only check or retighten/replace the V-belt when the engine is stopped!

A

Stop the engine Switch off ignition and remove the ignition key Check the V-belts once a day and retighten them if necessary.

• Stop the engine • Apply the parking brake • Switch off ignition and remove the ignition key • Open the engine cover • Remove V-belt guard A • Carefully inspect the V-belts for damage Have a damaged V-belt immediately replaced by authorised staff • 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-belt if necessary

Fig. 176: Checking V-belt tension

Caution!

Cracked and stretched V-belts cause engine damage Have the V-belt replaced by authorised staff

Retightening the V-belts D

Fig. 177: Retightening the V-belts

5-20

Retighten as follows: • Stop the engine • Apply the parking brake • Switch off ignition and remove the ignition key • Open the engine cover • Remove V-belt guard A (see Fig. 176) • Slacken fastening screws 1, 2 + 4 of alternator 5 • Turn screw 3 to move alternator 5 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 guard A (see Fig. 176)

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Maintenance 5.8 Hydraulic system Important safety instructions regarding the hydraulic system Danger Danger of burns! Do not carry out maintenance work on a hot engine and hydraulic system!

Wait at least 10 minutes after stopping the engine 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 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 • 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 replaced by an authorised workshop only

Caution!

Contaminated hydraulic oil, lack of oil or wrong hydraulic oil carries a danger of severe damage to the hydraulic system!

Take care to avoid contamination when working!

Always fill in hydraulic oil using the filling screen!

Only use authorised oils of the same type – see Fluids and lubricants on page 5-55 Always fill in hydraulic oil before the level gets too low 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

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5-21

Maintenance Monitoring the hydraulic oil and the return filter 48

The red indicator light 48 on the indicating instrument monitors the return filter.

62

Caution!

DPF !

1

x1000min

-1

4

AIR

6

2

8 10

0 bar

Indicator light 48 on the indicating instrument comes on if the resistance of the oil flow in the return filter is too high!

The filter element is dirty and must be replaced Drain the hydraulic oil in case of increased contamination, after 1500 s/h at the latest or once a year The filter element and the hydraulic oil may be replaced by an authorised workshop only!

The hydraulic oil temperature is too high if indicator light 62 on the instrument panel comes on!

Check the hydraulic oil level (not enough oil in the tank) Replace the filter element (highly contaminated filter)

Fig. 178: Indicator light for return filter

Notice!

Indicator light 48 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 48 on the indicating instrument goes out • Bear in mind the instructions concerning warmup – see chapter 3 “Starting the engine” on page 3-32

5-22

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Maintenance Checking the hydraulic oil level once a day

A

Fig. 179: Oil level sight glass on the hydraulic oil tank

The oil level sight glass is located on the hydraulic oil tank behind the cab (on the left in driving direction).

Proceed as follows: • Park the telehandler on level ground • Retract all hydraulic rams • Stop the engine and apply the parking brake • Switch off ignition and remove the ignition key • Clean oil level sight glass A and check the oil level If the oil level is visible in the lower half of the oil level sight glass • Oil level is OK If the oil level is no longer visible in the lower half of the oil level sight glass • Not enough oil, fill up hydraulic oil – see Filling up hydraulic oil on page 5-23 If the oil level is no longer visible in the upper half of the oil level sight glass • Drain the hydraulic oil into a suitable container until the oil level is visible in the lower half

Notice!

Any excess quantity of hydraulic oil in the tank escapes via the breather B as soon as the temperature rises!

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

B A

Fig. 180: Hydraulic oil tank

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Fill up 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 • Clean the area around the filler and breather filter B with a cloth • Place a suitable container under the hydraulic oil tank • Open breather filter B by hand With the filter insert in place: • Fill up the hydraulic oil and check the oil level at the oil level sight glass A • Fill up if necessary and check again • Firmly close breather filter B by hand

5-23

Maintenance Important notice regarding the use of biodegradable oil • Use only the tested and approved biodegradable hydraulic fluids – see Fluids and lubricants on page 5-55. 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 Subsequent change from mineral oil to biodegradable oil must be carried out by an authorised workshop or by a dealer.

5-24

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Maintenance 5.9 Checking hydraulic pressure lines Specific 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 consult a doctor immediately, even if the wound seems insignificant – otherwise serious infections could set in!

Always observe the following instructions: • 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!

• Never weld or solder damaged or leaking pressure lines and screw connections. Replace damaged parts with new ones!

• Never search for leaks with your bare hands, but wear protective gloves!

• Have damaged flexible lines replaced by authorised workshops only!

3 Q/10

Fig. 181: Identification of flexible line

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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.

This not only increases the operating safety of your machine but also helps to protect the environment • Replace hydraulic hoses every 6 years from the date of manufacture, even if they do not seem to be damaged 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: • The indication “3 Q/10” means manufactured in the 3rd quarter of 2010.

5-25

Maintenance 5.10 Lubrication work General safety instructions regarding lubrication work • Park the telehandler on level ground and prevent it from rolling away by applying the parking brake and placing wheel chocks • Raise the telescopic boom and secure it with the safety prop on the lift ram – see Safety prop for telescopic boom on page 5-2 • Stop the engine and remove the ignition key

Caution!

Lubricate all lubrication points mentioned below with lithium-saponified brandname grease – see Fluids and lubricants on page 5-55

Lubricating the rear axle oscillation-type bearing Notice!

A

The machine has an oscillation-type rear axle. Grease the bearing at the latest after every 20 service hours or once a week.

• Both grease nipples A are located on the rear left side of the frame and are routed to the axle bearing via hoses.

Lubricate grease nipples A (2 x)

Fig. 182: Grease nipples for oscillation-type bearing

Lubricating the planetary drive bearing (front and rear axles) Lubricate grease nipples B (2x) on each planetary drive bearing every 20 service hours or once a week

B

Fig. 183: Grease nipples on planetary drive bearings

5-26

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Maintenance Lubrication points on the telescopic boom: overview A

A

A

A

A

C

D

B

C

Fig. 184: Lubrication points on telescopic boom

Lubricating the telescopic boom A

Fig. 185: Lubrication points on quickhitch

Lubricate the telescopic boom as follows: • Dump out the quickhitch horizontally • Raise the telescopic boom and secure it with the safety prop on the lift ram – see Safety prop for telescopic boom on page 5-2 • Stop the engine and apply the parking brake • Switch off ignition and remove the ignition key • Lubrication points A and B Lubricate every 20 service hours or once a day in heavy-duty operation – see Maintenance label and maintenance plan under preparation on page 5-56 • Also apply grease to the slide plates on the inside boom section at regular intervals.

Checking and adjusting the slide plates Slide plates (Fig. 184 on page 5-27)/C are located between the inside and outside telescopic sections, and slide plates (Fig. 184 on page 5-27)/D are located outside on the telescopic boom.

The slide plates can be readjusted with compensating panels – up to a minimum thickness of 8 mm.

Replace the slide plates if they are below the minimum thickness!

Important! Have the slide plates readjusted and 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 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. 186: 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. This also serves as a functional check.

• 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

Break times and lubrication times are set with the notched switches S and P in the window of the controls.

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

A

Caution!

Fig. 187: Setting the lubrication times

Water can penetrate into the controls and cause lubrication system failure if the cover is not fitted and closed correctly!

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!

Use only commercially available greases up to NLGI-Kl. 2 to avoid damage to the lubrication system and the lubrication points!

– see Fluids and lubricants on page 5-55

Fig. 188: Filling the central lubrication system

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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. Therefore all repair work on the brakes must be carried out by trained staff.

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 • Daily check of the brake lines Fig. 189: Brake fluid label

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 The brake-fluid tank is located on the left underneath the instrument panel trim.

A MAX MIN

Fig. 190: Brake fluid level in the tank

Danger An incorrect brake fluid grade or an insufficient brake fluid level can impair the safety of the brake system – 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 5-55 Contact an authorised workshop immediately if the brake fluid level is lower than allowed (below MIN) The brake fluid must be replaced every 2 years by an authorised workshop Fill up the fluid if the level is below the MAX mark: • 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

5-30

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Maintenance 5.13 Maintenance: compressed-air brake system (option) Compressed-air tank and lines The compressed-air brake is a safety component. Incorrect maintenance can cause failure. Therefore all maintenance and repair work on the compressed-air brake must be carried out by trained staff.

An exception to this is the following work which must be carried out by the driver/operator: Daily check • For leaks (sound of escaping air) • For damage (compressed-air lines, tank, compressor and valves) Have leaky hose and screw connections repaired by an authorised workshop The water in the pressure accumulator is automatically drained

Danger Defective brake and compressed-air lines carry a danger of accident!

Damaged brake and compressed-air lines must immediately be replaced by an authorised workshop

Compressor attachment and V-belt Check once a day as follows: • Park the telehandler on level ground • Lower the telescopic boom • Stop the engine • Apply the parking brake • Switch off ignition and remove the ignition key • Remove V-belt guard A • Check the fastening of the compressor console • Check V-belt tension B of the compressor drive by pressing with your thumb to check whether the V-belt can be deflected between the pulleys by no more than about 10 mm

A

B

Fig. 191: Compressor attachment and V-belt

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5-31

Maintenance 5.14 Tyres Daily tyre checks Danger All repair work on tyres and rims may only be carried out by authorised workshops.

Notice!

Regular inspections of the tyres • Improve operating safety • Increase the service life of the tyres • Reduce machine downtimes • Refer to the table in chapter “Specifications” on page 6-10 for the authorised tyre types and the correct tyre pressures. A tyre table sticker is also affixed on the front window of the machine For the authorised tyre types and the correct tyre pressures – see chapter 6 “Tyres” on page 6-10 and the label on the front window.

Check the tyres as follows: • 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

5-32

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Maintenance Changing wheels Danger Use only the wheels and tyres that have been released for the machine.

– see chapter 6 “Tyres” on page 6-10 Check the wheel nuts for tightness after every wheel or tyre change

Caution!

The threads on the wheel bolts 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 3-103 • 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 6-12

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5-33

Maintenance 5.15 Heating/cab ventilation General information on the heating system The heating system of the machine is equipped with a fine-dust filter. Clean the filter as required, however replace it every 500 s/h at the latest.

Danger In order to be able to comply with the required safety measures regarding occupational safety and health, defective or dirty fine-dust filters must be replaced by new ones!

Cleaning/replacing the fine-dust filter

36

Fig. 192: Fresh-air fine-dust filter

5-34

The fine-dust filter access is located in the cab on the right between the front and side trims.

Clean the filter as follows: • Remove knurled screw (2x) • Pull out fine-dust filter 36 and check it 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 fine-dust filter Ensure that it is seated properly • Mount knurled screw (2x)

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Maintenance 5.16 Air conditioning (option): maintenance Important safety instructions regarding the air conditioning system 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 (see arrow).

Fig. 193: Label for air conditioning refill

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Maintenance Functional and visual checks of the air conditioning 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

E

Fig. 194: Air conditioning: dehumidifier, V-belt

The driver must carry out the following visual checks once a day • Stop the engine • Apply the parking brake • Switch off ignition and remove the ignition key • 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 • Check the hoses for tightness 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

Caution!

The air conditioning system must be checked and serviced twice a year by trained staff in an authorised workshop!

• Replace dehumidifier A every two years

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Maintenance Cleaning the heat exchanger (condenser) D

Danger Maintenance work on a hot diesel engine and radiator carries a danger of burns!

Wait at least 10 minutes after stopping the diesel engine until the air conditioning has cooled down!

Wear protective goggles, gloves and clothing!

C

C

Clean the condensor as follows: • Park the telehandler on level ground • Lower the telescopic boom to the ground • Stop the diesel engine • Apply the parking brake • Switch off ignition and remove the ignition key • Open the engine cover • Open lock D • Tilt the condenser forwards • Clean the condensor with compressed air or by spraying water (do not use a highpressure cleaner) • Safely lock the condenser in bracket D once cleaning is over

Fig. 195: Air conditioning: heat exchanger

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5-37

Maintenance 5.17 Maintenance of the electrical system General instructions 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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Maintenance Checking/replacing the battery A B

The battery is located in the engine vat in front of the radiator.

It is low in maintenance and no fluid needs to be refilled under normal operating conditions. However have it checked at regular intervals to ensure that the electrolyte level is between the MIN and MAX marks.

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!

When recharging and/or working near the 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 • Avoid naked lights and sparks in the vicinity of the battery and do not smoke!

• Always disconnect the negative terminal (-) from the battery before starting repair work on the electrical system!

Fig. 196: Battery master switch and cover

-

+ C Fig. 197: Battery

Replace the battery as follows: • Park the machine on level ground • Lower the telescopic boom • Apply the parking brake • Switch off ignition and remove the ignition key • Remove key A from the battery master switch • Remove protective cover B

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!

• Remove the battery leads: First the small terminal at the negative pole (-), then the big terminal at the positive pole (+) • Remove battery fixture C • Replace the battery with a new one • Mount battery fixture C • Install the battery leads: First the big terminal at the positive pole (+), then the small terminal at the negative pole (-)

Notice!

Use batteries only of the specified capacity!

• – see chapter 6 “Electric components” on page 6-7

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Maintenance Inspection and maintenance work on the electrical system at regular intervals Daily checks before operating the machine • Is the light system OK? • Is the signalling and warning system OK? • – see chapter 5 “Maintenance plan (overview)” on page 5-50 Weekly checks • Electric fuses: if defective, use only the specified load capacity (amperage) Blown fuses indicate overloading or short circuits. Therefore, the electrical system should be checked by an authorised technician before installing the new fuse – see chapter 6 “Fuses: overview” on page 6-7 • Electric and earth connections: When carrying out maintenance work on the electrical system, pay particular attention to ensuring good contact in leads and fuses • Battery charge condition and condition of battery terminals – see Checking/replacing the battery on page 5-39

Checking the 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

5-40

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Maintenance Checking/replacing relays and fuses on the board The board with the fuses and relays is located behind the trim under the instrument panel on the left (switch console).

Checking/replacing fuses and switching relays • Switch off ignition and disconnect the negative lead (-) from the battery, or switch off the battery master switch • Remove the trim and the defective fuses or relays from the relay bracket, and replace them by new ones Relay and fuse descriptions and output indications – see chapter 6 “Fuses: overview” on page 6-7 and Relays (overview) on page 6-9

Caution!

Fig. 198: Fuses

Blown fuses indicate overloading or short circuits. The electrical system must therefore be checked before installing the new fuse!

Only use fuses with the specified load capacity (amperage) – see chapter 6 “Fuses: overview” on page 6-7

Checking/replacing the main fuse box and the switching relays K05

F39

F40

K06

K07

F41

K29

The main fuse box with the main fuses F40, the ignition lock/preheating fuse F39, the preheating K05 and starting high current relay K07, the preheating time lag relay K06 and a relay K29 (option) is located on the side wall (above the battery) in the engine compartment Checking/replacing fuses and switching relays • Switch off ignition and disconnect the negative lead (-) from the battery, or switch off the battery master switch (option) • Remove the fuse box cover • Main fuse and relay descriptions and output indications – see chapter 6 “Main fuse box with relays” on page 6-8

Fig. 199: Main fuse box

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Maintenance 5.18 Maintenance of the automatic trailer coupling (option) Cleaning and lubricating the trailer coupling Caution!

Ensure that the coupling pin is engaged in the trailer coupling before cleaning with high-pressure equipment!

Apply a little more grease to the coupling pin and the base ring once cleaning is over Clean as follows: • Apply tough water-proof grease (EP3) to the coupling pin, the base ring and the drawbar eye after heavy use and before putting the coupling into operation • 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

36.5 mm C

2.5 mm

7 mm

E

Fig. 200: Trailer coupling

5-42

D

Check the trailer coupling once a day for wear and play Apply grease to the base ring Have a damaged and defective trailer coupling replaced by a new one Checking the bearing and longitudinal play A of the coupling head • 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 D max. 2.5 mm Thickness E of base ring min. 7 mm

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Maintenance 5.19 General 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. Therefore always observe the following instructions.

Caution!

Machines with anticorrosion protection (“aggressive media”) must be cleaned separately!

– see Maintenance work “Aggressive Media” (option) on page 5-47 l

Cleaning the machine is divided into 3 separate areas: • Inside the cab • Exterior of the machine • Engine compartment 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, oil 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!

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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 (lap 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 In the case of automatic seat belts, soiled belts can affect and impair winding and the driver's safety!

Only wind the seat belt when it is dry!

Defective belts must be replaced by an authorised workshop

Cleaning the exterior of the machine The following articles are generally suitable: • High-pressure cleaner • Steam jet

5-44

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Maintenance Cleaning the engine and the engine compartment Danger Caution, turning parts! Clean the engine only when it is at a standstill!

Stop the engine before cleaning Remove the ignition key Apply the parking brake Switch off ignition and remove the ignition key

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!

The engine must be cold Do not point the water jet directly at any of the electric sensors such as temperature and oil pressure switches or control valves.

Protect all electric parts, such as the alternator, connectors, relays etc. from humidity If the water jet is unintentionally pointed at electric components, dry them with compressed air and apply contact spray to them.

Checking screw connections All screw connections must be checked regularly, 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.

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Maintenance 5.20 Maintenance: particulate-soot filter (option) Checking the electronic filter monitoring 61

The functional readiness or errors and malfunctions of the filter are indicated by indicator light 61 (DPF LED display) on the instrument panel and the acoustic warning indicator.

Errors are indicated by means of a flashing or continuously lit indicator light 61 (see table).

DPF !

Caution!

If the red LED display (DPF) comes on or flashes, correct the error or the cause before continuing to operate the machine!

Have troubleshooting carried out only by an authorised workshop!

1

x1000min

-1

Fig. 201: Diesel particle filter indicator light 4

AIR

The following alarms can be displayed:

6

LED colour

Alarm

Green

Cause

Troubleshooting

The filter system is operational

Yellow flashHigh counterpressure ing

Drive under full load (30 minutes). If this does not help, this means that the filter is clogged with ash High counterpressure, Main alarm: very dirty Have the filter cleaned by threshold value a service technician filter reached Pre-alarm: dirty filter

Defective temperature sensor input Red flashing Sensor not plugged in Have the sensor replaced or defective by a service technician Defective temperature sensor output

Red and warning sound

Overdue service interval

Servicing must be carried out

Reset the service interval (service technician)

System error

Several possible causes

Service technician

5.21 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 5.22 Maintenance work “Aggressive Media” (option) Important notice on anticorrosion protection applied in the factory 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

5-47

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)!

• When using volatile and easily flammable anticorrosive agents and solvents: • 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. Therefore check the electric functions of the machine with special care.

Immediately put the machine out of operation if you detect any defects and have defects rectified immediately.

• 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, we recommend removing the floor mat in the cab to avoid collecting 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. Otherwise the anticorrosive protection will be heavily affected.

If cleaning the machine with these means cannot be avoided, check the wax coating very carefully and have it renewed or reapplied as required.

• Components to coat – see table on page 5-47

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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 5-47 • 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), proceed as 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 apply a 2-component prime coating and then a 2-component paint coating to it • Then preserve the area with anticorrosion wax

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5-50

• Heating fine-dust filter4 (in cab)

• Hydraulic oil tank breather filter

4

Air filter insert – safety cartridge4 Gearbox oil in front and rear axle differential Gearbox oil in gearbox (flanged on rear axle) Gearbox oil in front and rear axle planetary drives (left and right) Hydraulic oil Hydraulic oil filter insert/return filter

“A” 1st Inspection2 ●

● ● ●

● ● ●

Workshop

●

●

● ● ●

“B” every 500 s/h2 2nd Inspection

• • • • • •

) (check the oil levels after a test run):

Operator/driver

●

● ● ● ● ● ●

●

●

● ● ●

“C” every 1500 s/h once a year

• Air filter insert3

Oil and filter changes ( • Engine oil • Engine oil filter • Fuel filter

For service and maintenance work on the attachment, please refer to the Operator's and maintenance manual of the attachment manufacturer as well.

5.23 1Maintenance plan (overview)

Workshop Maintenance

Maintenance

at 100 s/h

Every 20 s/h (once a week)

Every 10 s/h (once a day)

Delivery inspection

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12

4

Check fan wheel/alternator V-belt for damage, retighten if necessary Check and adjust valve clearance (diesel engine) Check battery charge condition Clean the LS drive line filter (leak oil) (option) 13

• Air conditioning (option): check coolant level, clean compressor and condenser • Check the service and parking brake for correct function

• Heating – clean fine-dust filter for cab ventilation (in cab)

• • • •

• Replace toothed belt (diesel engine valve timing)

11

• Clean air filter dust valve • Clean the dust receptacle on the air filter (option)

3 , 10

• Drain condensation water in hydraulic oil tank

9

• Drain condensation water in charge air cooler (diesel engine)

●

●

●

●

●

● ●

● ●

● ●

● ● ●

●

Every 3000 s/h

●

●

●

●

●

●

●

● ● ● ●

●

●

●

●

●

●

●

●

●

●

at 100 s/h

●

●

●

Every 20 s/h (once a week)

8

• Check water/oil radiator (diesel engine/hydraulic oil) for dirt, clean if necessary • Check charge air cooler (diesel engine) for dirt, clean if necessary

●

●

“A” 1st Inspection2 ●

“B” every 500 s/h2 2nd Inspection

• Check coolant level, fill up if necessary 7

●

● ●

Workshop

● ●

● ● ●

●

●

●

●

●

●

●

●

“C” every 1500 s/h once a year

6

• Check brake fluid level, fill up if necessary5 (use LHM brake fluid)

Delivery inspection ● ● ● ● ● ●

Operator/driver Every 10 s/h (once a day)

Inspection work ( ): • Check condition of paint coating • Check engine oil level • Check hydraulic oil level • Check gearbox oil level in gearbox (Carraro 30 kph) (Bibus 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

For service and maintenance work on the attachment, please refer to the Operator's and maintenance manual of the attachment manufacturer as well.

5.23 1Maintenance plan (overview)

Workshop

Maintenance

5-51

5-52 Every 20 s/h (once a week) ●

● ● ● ● ● ● ● ● ● ●

●

●

Delivery inspection

● • Check slide plates on telescopic boom for wear. Readjust if necessary15 • Check quickhitch lock for correct function ● 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 ● • Fastening screws of cardan shafts ● • Fastening screws of cab ● • Wheel nuts ● • Electrical system: check electric and earth connections, chafing on wiring harness, battery terminals ●

Every 10 s/h (once a day) ● ● ●

at 100 s/h

● ● ●

● ● ● ● ● ● ● ● ●

“A” 1st Inspection2 ● ● ● ●

Workshop

● ● ● ● ● ● ● ● ●

●

●

● ● ● ●

“B” every 500 s/h2 2nd Inspection

Check service and parking brake pads14 Check compressed-air braking system (pressure gauge, compressor, couplings) for correct function Tyre check (damage, air pressure, tread depth) Check trailer coupling (damage, wear)

):

Operator/driver

● ● ● ● ● ● ● ● ●

●

●

● ● ● ●

“C” every 1500 s/h once a year

• • • •

Other inspection work (

For service and maintenance work on the attachment, please refer to the Operator's and maintenance manual of the attachment manufacturer as well.

5.23 1Maintenance plan (overview)

Workshop

Maintenance

00 0291 629 0 - BA SCORPION – AUSTRALIA

● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

Functional check ( ): • Service and parking brake • Compressed-air braking system (pressure gauge, compressor, couplings) • Steering system: steering column adjustment, synchronous position of wheels • Lights and electrical system • Drive interlock (option) • Safe load indicator with overload cutoff of telescopic boom • Seat adjustment, seat belt • Lock – control lever (joystick) and 3rd control circuit for road travel • Load stabiliser • Front and rear additional control circuits (option) • Cab – heating, ventilation, air conditioning (option)

Delivery inspection

Every 10 s/h (once a day)

00 0291 629 0 - BA SCORPION – AUSTRALIA

● ● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ●

● ● ● ●

“B” every 500 s/h2 2nd Inspection

● ● ● ● ● ● ● ●

● ● ● ●

Workshop

● ● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ●

● ● ● ●

“C” every 1500 s/h once a year

● ● ● ● ● ● ● ● ● ● ●

● ●

● ●

Every 20 s/h (once a week)

● ● ● ●

Operator/driver “A” 1st Inspection2

Lubrication service16 ( ) • 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 Lubrication points on the telescopic boom: overview 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

For service and maintenance work on the attachment, please refer to the Operator's and maintenance manual of the attachment manufacturer as well.

5.23 1Maintenance plan (overview)

Workshop

Maintenance

at 100 s/h

5-53

5-54 Operator/driver

Workshop

● ●

● ●

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

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 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 74.9 kW diesel engine only Only when using biodegradable oil (before the cold season) Automatically cleaned on machines equipped with the “Vacuum-operated preliminary separator” option Toothed belt may be replaced by an authorised workshop only 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 Have flexible lines replaced by an authorised workshop every 6 years (UVV, DIN 20066 T5)

• Brake system (flexible lines and cylinders) • Compressed-air braking system – flexible lines, tank, pressure gauge, compressor (option) • Air conditioning – flexible lines, compressor, condensor, attachment (option)

● ●

● ●

● ●

● ●

●

● ●

●

●

● ●

5

● ●

Delivery inspection ●

Every 10 s/h (once a day)

• Hydraulic system/telescopic boom (flexible lines and rams)17 • Additional control circuit quick couplers, 3rd control circuit, tipping trailer connection (option)

Every 20 s/h (once a week) ●

at 100 s/h

●

“A” 1st Inspection2

• Steering system (flexible lines and rams)17

“B” every 500 s/h2 2nd Inspection ● ● ● ●

● ●

● ●

●

●

● ● ● ●

“C” every 1500 s/h once a year

Leakage check ( ): Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify (or have rectified) if necessary • Air intake line (air filter, turbocharger, engine charge-air cooler) ● ● ● • Engine lubrication (engine – filter) ● ● ● • Fuel system (hoses and pipe lines) ● ● ● • Cooling system (engine – hydraulic oil) ● ● ●

For service and maintenance work on the attachment, please refer to the Operator's and maintenance manual of the attachment manufacturer as well.

5.23 1Maintenance plan (overview)

Workshop

Maintenance

00 0291 629 0 - BA SCORPION – AUSTRALIA

Maintenance

Maintenance 5.24 Fluids and lubricants Component/application Diesel engine

Engine/machine fluid

Specification

Temperature

Capacities 1

Engine oil2 with filter

CLAAS Argimot Ultratec 10W-40 HD-C 10W-40; EO1040B3 HD-C 15W-40; EO1540B3

Year-round

10.5 l

30 kph gearbox (standard)

1.3 l

40 kph gearbox (option) Front and rear axle differentials

Gearbox oil

Planetary drives – left and right, front/rear axle

4.0 l Year-round

8.0 l each 0.6 l each

Hydraulic oil4 Hydraulic system, hydraulic oil tank

CLAAS Agrishift MT SAE 85 W 90/API CL5 or SAE 90 LS (hypoid gear oil)

Biodegradable oil4

CLAAS Agrihyd HVLP-D 46 HVLPD 46 (HYD0530) AVIA Syntofluid 46

Year-round

About 105 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

Mounting 6 of pins, shafts

Special grease

Optimoly paste “TA” White-Paste

Year-round

As required

Fuel system, fuel tank

Diesel fuel7,8

DIN 51628/DIN EN 590 (EU) ASTM D975-94 (USA)

Year-round - 40 °C

About 123 l

Brake fluid9

Agip LHM Super/ Shell LHM

Year-round

0.5 l

R 134a/DIN 9860

Year-round

About 1100 g

HAVOLINE XLC

Year-round -35 °C

Water 7.5 l (55 %) Antifreeze 7.0 l (45 %)

Year-round

Water 1.0 l (33 %) Antifreeze 2.0 l (67 %)

Grease nipples, telescopic boom slide plates Battery terminals

Brake system 10

Air conditioning (option)

Refrigerant

11

12, 13, 14

Engine cooling

Antifreeze

Washer system

Antifreeze with cleansing agent13

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

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 (ISO 6743/4) 155 l in complete work hydraulics system Important! Pins are hard-chromium plated or coated with Molykote 3400A. They are inserted in a dry state. Lubricate via grease nipples once assembly is over.

In order to avoid engine damage, do not add additives to the diesel fuel!

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 specially trained staff only Bear in mind the safety data sheet during maintenance work SeeCoolant compound table on page 6-11 See manufacturer's indications on the packaging and bear in mind the antifreeze compound table The coolant must be replaced every 2 years by an authorised workshop

00 0291 629 0 - BA SCORPION – AUSTRALIA

5-55

Maintenance 5.25 Maintenance label and maintenance plan under preparation 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!

5-56

00 0291 629 0 - BA SCORPION – AUSTRALIA

Maintenance Maintenance label

1000237192

Affixed on front or side window

Pflege- und Wartungsarbeiten Service and maintenance work Travaux de maintenance

10 h

20 h

P

10 h

20 h Typ 408

00 0291 629 0 - BA SCORPION – AUSTRALIA

5-57

Maintenance Notes:

5-58

00 0291 629 0 - BA SCORPION – AUSTRALIA

Specifications

Specifications

6

Specifications

6.1 Model and trade names: overview Telehandler

Trade name

408-01

6030 cp

6.2 Frame Sturdy steel sheet frame, rubber-mounted engine

6.3 Engine Engine Product Type

TD 2011 L04

TCD 2011 L04

Output (kW) as per ISO 14396

58 or 55.1 kW at 2300 rpm

74.9 kW at 2300 rpm with charge-air cooler

270 Nm (58 kW) 257 Nm (55.1 kW) at 1600 rpm

350 Nm at 1600 rpm

Max. torque (counterclockwise rotation) Minimum idling speed with fixed displacement pump1

1100 rpm

Minimum idling speed with LS pump1

990 rpm

Specific minimum fuel consumption Number of cylinders Displacement Bore and stroke Compression ratio Fuel injection system

230 g/kWh (218 g/kWh)

215 g/kWh 4 3619 cm³ 96 x 125 mm 1:18

Direct fuel injection

Firing order

1-3-4-2

Starting aid

Glow plug

Max. inclined position (engine no longer supplied with oil) Oil pressure Exhaust emissions according to directives 1.

00 0291 629 0 - BA SCORPION – AUSTRALIA

Deutz diesel engine

Max. lateral left/right inclination: 30° (57 %) Max. uphill/downhill inclination: 30° (57 %) Observe the tilting limit of the machine!

(20° laterally) Forced feed lubrication 2004/26 EC

Hydraulic pump (work hydraulics)

6-1

Specifications 6.4 Power train Variable displacement pump, boost pump Variable displacement pump Design Displacement Max. operating pressure (high pressure)

Automotive, infinitely variable hydrostatic axial-piston gearbox 0 – 78 cm³/rev (30 or 40 kph) 450 – 480 bar

Starting speed (LS pump)

1000 – 1150 rpm/50 bar HP

Starting speed (fixed displacement pump)

1150 – 1300 rpm/50 bar HP

Max. engine droop1 speed

2100 – 2200 rpm/300 – 350 bar HP

Boost pump integrated in variable displacement pump Design

Gear pump

Displacement

17 cm³/rev

Charging/boost pressure Control

30 bar at max. rpm Electronic

Driving direction

Electrohydraulic control

Inching

Electric (potentiometer)

1.

Measured with machine jacked up

Variable displacement motor Variable displacement motor Design

Axial piston motor

Capacity (Sauer-Danfoss)1 (30 kph)

160 cm³/rev

Capacity (Bibus)2 (40 kph/option)

233 cm³/rev

Speed ranges 30 kph machines (forwards/reverse)

1st speed range: 0 – 7 kph 2nd speed range: 0 – 30 kph1

Speed ranges 40 kph machines (option) (forwards/reverse)

1st speed range: 0 – 15 kph 2nd speed range: 0 – 40 kph2

Traction force3 (58 kW/30 kph) Traction force3 (74.9 kW/30 kph)

53 kN

Traction force3 (74.9 kW/40 kph) 1.

2.

3.

6-2

30 kph with tyres 17.5 LR 28 kph with tyres 405/70-24 25 kph with tyres 405/70-20 40 kph with tyres 17.5 LR 40 kph with tyres 405/70-24 37 kph with tyres 405/70-20 With tyres 405/70-24

00 0291 629 0 - BA SCORPION – AUSTRALIA

Specifications 6.5 Oil/water fan Hydraulic pump/fan motor Hydraulic pump displacement

Gear pump 17 cm³/rev

Fan motor capacity

14 cm³/rev

Fan motor speed

2000 rpm

6.6 Axles Front axle Front axle Planetary steering and drive axle, rigid screw connection with frame

Design Differential lock

Self-locking differential 45 %

King-pin inclination

0°

Camber

0°

Steering angle Toe-in

0 mm 1

Track width 1.

Max. 40° 1860 mm

With tyres 405/70-20 or 24

Rear axle Rear axle Design Differential lock

No

King-pin inclination

0°

Camber

0°

Oscillation Steering angle Toe-in Track width1 1.

00 0291 629 0 - BA SCORPION – AUSTRALIA

Planetary steering and drive axle, oscillating bearing on frame

± 10° Max. 40° 0 mm 1860 mm

With tyres 405/70-20 or 24

6-3

Specifications 6.7 Service and parking brake Service brake Design

Foot-operated hydraulic disc brake

Location

Drive shaft (front and rear axle)

Brake fluid

Special hydraulic fluid based on basic mineral oil (LHM) – see chapter 5 “Fluids and lubricants” on page 5-55

Parking brake Design

Manual, mechanical disc brake on front axle drive shaft

6.8 Steering system Steering system Design Types of steering systems

4 wheel steering, front axle steering, diagonal steering (crab steering)

Assemblies

Hydraulic pump, priority valve, servostat with safety valves, 1 steering ram per axle with zero-position sensor on rear axle, changeover valve for steering mode “Front axle, diagonal and 4 wheel steering” Caution! When driving on public roads: 4 wheel steering allowed up to 30 kph (front axle steering recommended), front axle steering must be selected when travelling over 30 kph

Max. pump pressure1

180 bar

Max. steering pressure2

170 bar

1.

2.

6-4

Hydrostatic 4 wheel steering with emergency steering features

Measured after the pump Measured after the servostat

00 0291 629 0 - BA SCORPION – AUSTRALIA

Specifications 6.9 Work hydraulics Hydraulic pump Diesel engine

58/74.9 kW

74.9 kW (option)

Hydraulic pump

38 cm³/rev

60 cm³/rev

Fixed displacement pump (gear pump)

Variable displacement pump (LS)

84 l/min at 2300 rpm

135 l/min at 2300 rpm

Design Displacement Control valve

4-fold (standard)1 5-fold (optional)2

Hydraulic oil filter 1.

2.

Return filter

4-fold control valve (2x mechanical controls, 2x proportional controls) 5-fold control valve (2x mechanical controls, 3x proportional controls)

Hydraulic ram protection Hydraulic ram protection Hydraulic pump Max. operating pressure1

240 bar

Tilt ram Secondary pressure limiting

Rod side 260+10 bar Base side 260+10 bar

Lift ram Secondary pressure limiting

Base side 260+10 bar

Push-out ram Secondary pressure limiting

Rod side 260+10 bar Base side 200 bar

Quickhitch ram (3rd control circuit) Secondary pressure limiting 1.

00 0291 629 0 - BA SCORPION – AUSTRALIA

38 cm³/rev (60 cm³/rev option)

210 bar

Measured at control valve

6-5

Specifications Lift, tilt and push-out rams: velocity Lift, tilt and push-out rams: velocity Fixed displacement pump 38 cm³/rev

Variable displacement pump 60 cm³/rev

Raise

7.4 sec

5.2 sec

Lower

5.5 sec

4.2 sec

Dump in

4.1 sec

3.3 sec

Dump out

4.1 sec

3.2 sec

Retract

6.0 sec

4.4 sec

Extend

8.0 sec

5.0 sec

Hydraulic pump

Lift ram Tilt ram Push-out ram

Hydraulic pilot control Hydraulic pump boost pump Displacement

17 cm³/rev

Charging/boost pressure

30 bar at 2300 rpm

Pilot control unit Control lever (joystick)

Four-way lever – operation of lift and tilt rams, push-out ram via potentiometer scroll wheel and lock ram or attachment via potentiometer scroll wheel (electrohydraulic control)

Lock against unintentional oper- Control lever (joystick) mechanically locked by pushing ation (for long-haul travel and in centre position transport) 3rd control circuit electrically locked via switch

Usable consumer pressure at additional control circuit (option) Location

Rear additional control circuit

Function Electric control (solenoid valve) via 5-fold control valve

Electric control (solenoid valve) via Additional control 3rd control circuit circuit on front left Electric control side of telescopic (solenoid valve) via boom 3rd control circuit with external return

6-6

Fixed displacement Variable displacepump 38 cm³/rev ment pump 60 cm³/rev Rpm / l/min / bar

Rpm / l/min / bar

1500/45/165 2000/65/155 2300/75/145

1500/50/165 2000/100/120 2300/100/110

1500/45/175 2000/65/170 2300/75/170

1500/60/175 2000/100/150 2300/100/150

00 0291 629 0 - BA SCORPION – AUSTRALIA

Specifications 6.10 Electrical system Electric components Description

Output

Alternator

14 V 95 A

Starter

12 V 2.3 kW

Battery

12 V 88 Ah

Fuses: overview The fuses are located on the left behind the instrument panel trim.

F24 F25 F26 F27 F28 F29

F30 F31 F32 F33 F34 F35 F36 F37 F38

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

No.

(A)

Protected circuit

F1

7.5

Brake lights, rear socket

F2

15

Front socket (option)

F3

3

Manual throttle (accelerator pedal lock option), overload cutoff (option)

F4

15

Proportional electronics

F5

10

Fan (variable displacement pump electronics LS)

F6 F7

Fig. 202: Fuse box

00 0291 629 0 - BA SCORPION – AUSTRALIA

Turn indicators Speed range switch

F8

Drive electronics, brake lights switching relay

F9

Solenoid valve: load stabiliser, hose burst valve

F10

F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23

7.5

10

Solenoid valve: additional control circuit, tilt ram lock, quickhitch lock Tip switch: quickhitch lock, load stabiliser signal

F11 F12 F13 F14

Air-suspension seat (option), emergency lowering (option), central lubrication system (option)

5 7.5

F15 3

Cutoff solenoid, drive interlock (option) Joystick, compressed-air brake (option) Reversing light, backup warning system Engine oil temperature indicator, speedometer, tachometer, buzzer Indicator light: boost pressure, indicating instrument, hydraulic oil temperature, boost pressure Reversing fan tip switch, hydraulic oil level switch, rear axle steering sensor, speed sensor, coolant level amplifier

F16 F17

30

Window heating (option), mirror heating (option)

F18

25

Heating fan, air conditioning (option)

F19

15

Machine lights

F20

10

Rear wiper, rear washer pump

F21

5

Safe load indicator, window heating signal (option)

F22

20

Front wiper motor, horn, front wipe/wash pump

6-7

Specifications No.

(A)

Protected circuit

F23

3

Diagnosis connector, radio (option)

F24 F25 F26

High beam (right), high beam indicator light 7.5

High beam (left) Low beam (right)

F27

Low beam (left)

F28

Side marker light (left), switch lights

F29 F30 F31 F32

5

Side marker light (right), numberplate light, instrument lights, switch lights

3

Preheating start switch (ignition switch)

15

F33 F34 F35

Interior light, steering-column control lever Drive interlock (option) Rotating beacon (option)

10

F36

Telescopic boom working lights (option) Rear working light Front working light

F37

7.5

Hazard warning system, radio (option)

F38

15

Socket (cigarette lighter)

Main fuse box with relays The main fuse box is located in the engine compartment in front of the radiator Fuse

K5

K6

F39

K7

F40

K29

F41

Rated current Protected circuit (A)

F39

50 A

Preheating/start fuse (starter)

F40

50 A

Preheating (air-intake preheating)

F41

10 A

Excess fuel, minus compensation

F42

100 A

Main fuse

Relay no.

Protected circuit

K5

Preheating high current relay

K6

Preheating time control unit

K7

Start high current relay

K29

Excess fuel, minus compensation switching relay

Fig. 203: Main fuse box

6-8

00 0291 629 0 - BA SCORPION – AUSTRALIA

Specifications Relays (overview) The relays are located on the left behind the instrument panel trim.

K30

K35

K16

K22 K28 K10 K2

K27

K1

K3

K33

Switching relay no.

Protected circuit

K1

High current relay

K2

High current relay

K3

Reverse driving switching relay

K10

Turn indicator relay

K16

Switching relay – front socket (option)

K22

Load stabiliser switching relay

K23

Wiper switching relay (1st speed)

K25

Interval relay (wiper)

K27

Time lag relay for rear window heating (option)

K28

Front electronics socket (option)

K30

Brake lights switching relay

K33

High current relay for rear window heating (option)

K35

Overload cutoff switching relay (option)

K55

Brake lights switching relay

K56

Load stabiliser switching relay

K57

Compressed-air brake switching relay (option)

K59

K23

K60 K70

K25

Manual throttle switching relay (accelerator pedal lock option) Fuel pressure switching relay (option)

K55 K56 K57 K59 K60 K70

Fig. 204: Relays

00 0291 629 0 - BA SCORPION – AUSTRALIA

6-9

Specifications 6.11 Tyres Tyre pressure1

Tyre size

Wheel rims

Front/rear

Wheel rim

Wheel offset

DW13x24

20

TW14Lx24

60

405/70-24 14PR MPT-01 TBL 405/70 R24 SPT9 158 A2 405/70-20 14PR MPT-01 TBL

3.0 bar

2

460/70 R24 159A8 XMCL 17.5LR24 A-570 150 A8 1.

2.

Increase tyre pressure by 0.5 bar during pallet forks operation Steering angle must be checked and possibly readjusted by an authorised workshop if these tyres are mounted

6.12 Weights Weights Kerb weight1

5600 2 kg

Gross weight rating

8500 kg

Front/rear gross axle weight rating

5500 kg

1.

2.

Without attachment, with driver and full fuel tank Up to 6000 kg depending on equipment

6.13 Trailer couplings: trailer weight/drawbar load Gross trailer weight rating1 Trailer without brakes

1000 kg

Trailer with brakes (1 braked axle)

3500 kg

Gross drawbar load rating

1000 2kg

Trailer with brakes (all axles braked)

8000 kg

Trailer with hydraulic or pneumatic brakes

16000 kg

Towing facility Max. authorised load

4000 kg

1.

2.

6-10

Tractors and agricultural or forestry machinery Directive 2003/37 EC

1000 kg

Control mark: see machine documentation Maximum 1500 kg => taking the rear gross axle weight rating and the machine's overall weight into account

00 0291 629 0 - BA SCORPION – AUSTRALIA

Specifications 6.14 Noise levels Sound power level

Diesel engine (kW)

dBA

58 / 55.1 / 74.9

103.9

Guaranteed value

58 / 55.1

104

Guaranteed value

74.9

106

58 / 55.1 / 74.9

79

Measured value

Driver-perceived noise level

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 EN ISO 11201.

6.15 Vibration This machine is equipped with a seat complying with the requirements of EN ISO 7096:2000. The actual work conditions are taken into account.

Vibration 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

6.16 Coolant compound table

1.

2.

00 0291 629 0 - BA SCORPION – AUSTRALIA

Outside temperature

Water 1

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/overall hardness 3 – 20 °dGH – see “Fluids and lubricants” on page 5-55

6-11

Specifications 6.17 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

6-12

Tightening torque 400 ±20 Nm

00 0291 629 0 - BA SCORPION – AUSTRALIA

Specifications 6.18 Pallet forks payload

6.19 Payload: bucket

00 0291 629 0 - BA SCORPION – AUSTRALIA

6-13

Specifications 6.20 Dimensions with bucket

d

f a

b

930

c f

2510

c

2260

b

1600

a

e e

45°

415 2750

320 1860

730

4570

Fig. 205: Machine dimensions 1807

2250

5287

Dimensions with bucket

Retracted

Overall length1 (without attachment) Overall height

4570 mm

2

2260 mm

Overall height with rotating beacon 2

2510 mm

2

Overall height of telescopic bearing

1600 mm

Cab floor access height2

750 mm

Overall width without bucket

3

2250 mm

Cab width a Pin height

930 mm

2

b Load-over height 2, 4 c Dump height

2, 4

d Dump reach2, 4 2

e Length of telescopic extension f

6485 mm

4070 mm

5970 mm

3580 mm

5480 mm

–

310 mm

5670 mm

7570 mm 49°/41°

5

45° >

Transport position

320 mm 6

Ground clearance underneath axle and gearbox

415 mm

Track width: front/rear

1860 mm

Wheelbase: centre

2750 mm

Turning radius: between kerbs

3700 mm

4

4800 mm

Turning radius: between walls

6-14

4585 mm

Dump-in angle 4/dump-out angle4 Departure angle

1.

2.

3.

4.

5.

6.

extended

With Autohitch trailer coupling (+ 400 mm) Measured with tyres 405/70-24 MPT01 (with tyres 405/70-20 14PR MPT-01 (- 50 mm), 17.5LR24 (+ 20 mm)) Measured with folded-in mirrors With standard bucket 2300 mm With Autohitch coupling 32° Ground clearance 380 mm with cardan shaft guard (option)

00 0291 629 0 - BA SCORPION – AUSTRALIA

Specifications 6.21 Dimensions with pallet forks

d

a

b

a b

c Fig. 206: Machine dimensions

Dimensions with pallet forks

Retracted

extended

a Pallet forks pin height1

4585 mm

6485 mm

4150 mm

6050 mm

b Pallet height

1, 2

c Dump-in angle in transport position2

22°

2

68°

d Dump-out angle

Turning radius: with forks between walls2 1.

2.

4600 mm

Measured with tyres 405/70-24 MPT01 (with tyres 405/70-20 14PR MPT-01 (- 50 mm), 17.5LR24 (+ 20 mm)) With pallet forks

➥ See page 6-14 for further dimensions

00 0291 629 0 - BA SCORPION – AUSTRALIA

6-15

Specifications Notes:

6-16

00 0291 629 0 - BA SCORPION – AUSTRALIA

Index

Index

Index Index A Air conditioning (option)...................................................3-53, 5-35 Air filter .....................................................................................5-18 Air-suspension seat (option).....................................................3-20 Alternator ..................................................................................5-40 Applications with lifting gear .......................................................2-8 Attachments from other manufacturers Inspection plan .................................................................3-100 Mounting regulations ..........................................................3-99 Autohitch trailer coupling (option) .............................................3-92 B Battery master switch (option) ..................................................3-23 Biodegradable oil......................................................................5-24 Brake system............................................................................5-30 Brake fluid ..........................................................................5-30 Safety instructions ..............................................................5-30 C Cab ...........................................................................................3-13 Locking and unlocking the door..........................................3-13 Opening the upper door to a gap .......................................3-14 Opening/closing the rear window .......................................3-15 Safety instruction – side window (right)..............................3-13 Cab emergency exit..................................................................3-16 Cab heating and ventilation......................................................3-52 Central lubrication system (option) ...........................................5-28 Changeover valve for operation of 3rd control circuit as additional control circuit ............................................................................3-88 Checking/replacing the battery .................................................5-39 Cleaning Exterior of the machine ......................................................5-44 Inside the cab .....................................................................5-44 Motor and engine compartment .........................................5-45 Seat belt .............................................................................5-44 Specific safety instructions .................................................5-43 Continuous operation of 3rd control circuit (option)..................3-87 Coolant and oil preheater (option) ............................................3-30 Crane handling .......................................................................3-106 D Decommissioning of machine.................................................3-108 Designated use and exemption from liability ..............................2-2 Differential lock .........................................................................3-46 Disposal of machine ...............................................................3-108 Documents .................................................................................1-9 Drive interlock with code input (option).....................................3-26 Driving direction selection, reversing operation........................3-39 Driving licence ............................................................................1-8 Driving on public roads With standard bucket..........................................................3-67 With the pallet forks............................................................3-74

00 0291 629 0 - BA SCORPION – AUSTRALIA

E Electrical system......................................................................... 6-7 Emergency lowering after the hose burst valve has been enabled............................................................................3-82 Emergency lowering of the telescopic boom in case of a diesel engine breakdown...................................................3-62 Engine Avoiding running the engine under low-load conditions .....3-33 Start....................................................................................3-32 Stopping .............................................................................3-33 F Fields of application and using a telehandler with an attachment............................................................................. 1-6 Fire extinguisher (option)..........................................................3-16 Fitting pallet forks .....................................................................3-73 Fluids and lubricants................................................................. 5-55 Front window wiper...................................................................3-54 Front/rear additional control circuit (option) ..............................3-89 Fuel preheater (option) .............................................................3-30 Fuel system Bleeding ............................................................................... 5-5 Refuelling ............................................................................. 5-4 Water separator (option) ...................................................... 5-4 Fuel, diesel engine and hydraulic oil preheating (option) .........3-30 H Hose burst valve safety feature ................................................3-82 Hydraulic connections of attachments from other manufacturers ................................................................. 3-85 I Important notice regarding driving on public roads...................3-35 Indicator lights ............................................................................ 3-6 Information on putting the machine into operation ...................3-10 Interior light ...............................................................................3-15 K Key-based drive interlock (option) ............................................3-24 L Labels in the engine compartment.................................................1-17 Inside the machine .............................................................1-14 Outside on the machine .....................................................1-13 Licence, identification ................................................................. 1-8 Light system .............................................................................3-49 Load diagram............................................................................3-79 Loading and transporting........................................................3-104 Locking and unlocking the engine cover ..................................3-23 Lubrication points Planetary drive bearing of axle...........................................5-26 Rear axle oscillation-type bearing ......................................5-26 Telescopic boom ................................................................5-27

S-1

Index M Machine inspections, regulations for accident prevention ..........1-9 Maintenance Additional fuel filter (option) ..................................................5-4 Air filter cartridge ................................................................5-19 Biodegradable oil................................................................5-24 Brake system......................................................................5-30 Changing wheels................................................................5-33 Checking the coolant level..................................................5-13 Checking the engine oil level................................................5-7 Checking the hydraulic oil level ..........................................5-23 Compressed-air brake system (option) ..............................5-31 Diesel particle filter (option) ................................................5-46 Electrical system.................................................................5-38 Engine and hydraulics cooling system ...............................5-11 Engine lubrication system.....................................................5-7 Filling in engine oil ................................................................5-8 Filling up coolant.................................................................5-14 Filling up hydraulic oil .........................................................5-23 Fluids and lubricants...........................................................5-55 Fuel system ..........................................................................5-3 Heating ...............................................................................5-34 Hydraulic pressure lines .....................................................5-25 Hydraulic system ................................................................5-21 Lubrication ..........................................................................5-26 Maintenance of attachments ..............................................5-46 Maintenance work if the machine is used in a saline environment ..........................................................5-47 Pivots and hinges ...............................................................5-45 Replacing the engine oil filter cartridge ..............................5-10 Screw connections .............................................................5-45 Service and maintenance work ..........................................5-43 Service and maintenance work at regular intervals............5-40 Trailer couplings .................................................................5-42 Tyre care ............................................................................5-32 V-belts ................................................................................5-20 Maintenance plan ..................................................................... 5-50 Maintenance work.......................................................................5-1 Notice for maintenance staff.................................................5-1 Malfunctions Air conditioning (option)........................................................4-5 Diesel engine........................................................................4-1 Drive .....................................................................................4-4 Mounting and removing Attachments from other manufacturers (option) .................3-98 Pallet forks..........................................................................3-73 Standard bucket .................................................................3-63

Operation Additional control circuit with switch ...................................3-90 Before moving off ...............................................................3-35 Driving direction selection (forwards/reverse).....................3-39 Fire extinguisher (option)....................................................3-16 Load stabiliser ....................................................................3-47 Moving off ...........................................................................3-38 Parking the machine.........................................................3-103 Reversing fan (option) ........................................................3-52 Speed range selection........................................................3-38 Starting the engine .............................................................3-31 Operator's Manual ......................................................................1-1 Explanation of abbreviations and symbols ...........................1-2 Explanation of safety symbols ..............................................1-2 Overview Inside the cab .......................................................................3-2 Instrument panel, multifunctional lever, switch consoles......3-4 Outside of machine...............................................................1-3 Overview of attachments ............................................................1-6 P Pallet forks Adjusting the fork arms.......................................................3-78 Brief instructions for fork arms............................................3-77 Picking up loads .................................................................3-80 Safety instructions ..............................................................3-75 Transporting loads..............................................................3-81 Pallet forks payload ..................................................................6-13 Parking brake............................................................................3-45 Putting into operation Notice for operation staff ....................................................3-10 Preparing to put the machine into operation.......................3-35 Putting the diesel engine into operation....................................3-31 Putting the machine out of operation ......................................3-103 R Radiator Draining coolant..................................................................5-15 Rear window heating (option) ...................................................3-52 Rear wiper ................................................................................3-54 Regulations for the operating staff ..............................................1-8 Regulations regarding driving on public roads............................1-8 Releasing the pressure on the quick couplers..........................3-84 Reversing fan............................................................................3-52 Running-in period .....................................................................3-10

O Oil preheater (option)................................................................3-30

S-2

00 0291 629 0 - BA SCORPION – AUSTRALIA

Index S Safe load indicator....................................................................3-56 Functional check ................................................................3-57 Note on the display.............................................................3-57 Overload cutoff ...................................................................3-59 What to do when the indicator lights come on....................3-58 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 Operation and adjustment..................................................3-17 Seat belt .............................................................................3-21 Seat adjustment........................................................................3-17 Seat belt ...................................................................................3-21 Adjustment .........................................................................3-22 Fastening the seat belt .......................................................3-21 Service brake............................................................................3-44 Compressed-air brake system (option) ..............................3-96 Hydraulic trailer brake (option) ...........................................3-97 Signalling system......................................................................3-51

00 0291 629 0 - BA SCORPION – AUSTRALIA

Specifications ............................................................................. 6-1 Additional control circuit (option) .......................................... 6-6 Brakes .................................................................................. 6-4 Coolant compound table ....................................................6-11 Dimensions with bucket......................................................6-14 Dimensions with pallet forks...............................................6-15 Drive..................................................................................... 6-2 Electric components ............................................................. 6-7 Engine .................................................................................. 6-1 Frame ................................................................................... 6-1 Front axle ............................................................................. 6-3 Fuses.................................................................................... 6-7 Hydraulic pump .................................................................... 6-5 Hydraulic ram protection ...................................................... 6-5 Lift, tilt and push-out ram velocity......................................... 6-6 Main fuse box with relays..................................................... 6-8 Model and trade names........................................................ 6-1 Noise levels ........................................................................6-11 Oil/water fan ......................................................................... 6-3 Pallet forks payload............................................................6-13 Payload Bucket ..................................................................6-13 Pilot control........................................................................... 6-6 Rear axle.............................................................................. 6-3 Relays (overview) ................................................................. 6-9 Steering system.................................................................... 6-4 Tightening torques..............................................................6-12 Trailer couplings, trailer weight, drawbar load....................6-10 Tyres ..................................................................................6-10 Variable displacement motor................................................ 6-2 Variable displacement pump ................................................ 6-2 Vibration .............................................................................6-11 Weights ..............................................................................6-10 Work hydraulics.................................................................... 6-5 Standard bucket payload..........................................................3-69 Starting aid with external battery ..............................................3-34 Steering column height and angle adjustment .........................3-40 Steering system Selecting the steering modes .............................................3-41 Wheel synchronisation .......................................................3-42 Switching the load stabiliser ON and OFF................................3-48

S-3

Index T Telehandler Brief description....................................................................1-4 Overview...............................................................................1-3 Telescopic boom Checking and adjusting the slide plates .............................5-27 Extending/raising................................................................3-61 Lubrication ..........................................................................5-27 Retract/lower ......................................................................3-61 Tilt ram lock (option) .................................................................3-86 Towing and transporting the machine.....................................3-101 Trailer coupling (option) ............................................................3-94 Trailer weight/drawbar load ......................................................6-10 Tyre care...................................................................................5-32 W Warning identification .................................................................1-9 Warranty .....................................................................................1-5 Washer pump ...........................................................................3-54 Washer system Tank....................................................................................3-54 Wheel change...........................................................................5-33 Working With the pallet forks ............................................................3-75

S-4

00 0291 629 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 629 0 BA SCORPION – AUSTRALIA en - 09/10 Printed in Germany