CLAAS SCORPION 9040 Model: 404-03 Operator's manual- PDF DOWNLOAD

SCORPION 9040 Model: 404-03

from serial no. 404 03 0167

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 Contents ...................................................................................................................I-10 EC declaration of conformity (model 404-03) .........................................................EG-1 Introduction 1 General information on the Operator's Manual ........................................................ 1-1 Abbreviations/symbols ....................................................................................... 1-1 General information on machine safety ............................................................. 1-1 Machine overview .................................................................................................... 1-2 Model designation – trade names ............................................................................ 1-3 Brief description of telehandler ................................................................................ 1-3 General information on the machine ................................................................. 1-3 Main components of machine ............................................................................ 1-3 Hydrostatic drive ................................................................................................ 1-4 Work hydraulics and 4 wheel steering ............................................................... 1-4 Cooling system .................................................................................................. 1-4 Telehandler warranty ............................................................................................... 1-4 Information on warranty ..................................................................................... 1-4 Fields of application and using a telehandler with an attachment ........................... 1-5 Attachments with certified material densities ..................................................... 1-5 Regulations .............................................................................................................. 1-7 Driving licence ................................................................................................... 1-7 Licence/identification ......................................................................................... 1-7 Adjusting the headlights .................................................................................... 1-7 Machine inspections .......................................................................................... 1-8 On-board equipment .......................................................................................... 1-8 Documents ........................................................................................................ 1-8 Warning identification of telehandler on public roads (option) ........................... 1-8 Type labels and component numbers ...................................................................... 1-9 Serial number .................................................................................................... 1-9 Cab number ....................................................................................................... 1-9 Engine number .................................................................................................. 1-9 Hydraulic pump number .................................................................................. 1-10 Variable displacement motor number .............................................................. 1-10 Variable displacement motor number (high speed option) .............................. 1-10 Front and rear axle numbers ........................................................................... 1-10 Description of labels .............................................................................................. 1-11 Labels on the outside of the machine .............................................................. 1-11 Labels on the inside of the machine ................................................................ 1-12 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 Trailers and attachments ................................................................................... 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

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Contents 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 Overview of control elements ................................................................................... 3-1 Cab overview ........................................................................................................... 3-2 Instrument panel, multifunctional lever, switch consoles: overview ........................ 3-4 Telltales and warning lights: description .................................................................. 3-6 Telltale and warning light – indicating instrument .............................................. 3-6 Telltale and warning light – instrument panel .................................................... 3-7 Putting the machine into operation for the first time ................................................. 3-8 Safety instructions regarding commissioning .................................................... 3-8 Important information for the operating staff ...................................................... 3-8 Running-in period .............................................................................................. 3-8 Start-up checklist ............................................................................................... 3-9 Operation checklist .......................................................................................... 3-10 Parking checklist .............................................................................................. 3-10 Cab ........................................................................................................................ 3-11 Locking and unlocking the door ....................................................................... 3-11 Closing and opening the side window (to a gap) ............................................. 3-12 Completely opening and locking the side window ........................................... 3-12 Opening/closing the rear window ..................................................................... 3-13 Rear window emergency exit ........................................................................... 3-13 Engine cover .......................................................................................................... 3-13 Opening/closing the engine cover ................................................................... 3-13 Putting the diesel engine into operation ................................................................. 3-14 Preparing to start the engine ........................................................................... 3-14 Starting the engine ........................................................................................... 3-15 Avoiding running the engine under low-load conditions .................................. 3-16 Stopping the engine ......................................................................................... 3-16 Battery master switch ............................................................................................. 3-16 Switching the battery master switch ON and OFF ........................................... 3-16 Error code displays (103 kW diesel engine) .......................................................... 3-17 Reading out the flash code .............................................................................. 3-17 Warning limit – coolant temperature ................................................................ 3-17 Warning limit – charge-air temperature ........................................................... 3-18 Warning limit – engine oil pressure .................................................................. 3-18 Overview of flashing codes .............................................................................. 3-19 Key-based drive interlock (option) ......................................................................... 3-22 Coding (“training”) new ignition keys ............................................................... 3-22 Enabling (locking) the drive interlock ............................................................... 3-23 Disabling (releasing) the drive interlock ........................................................... 3-23 Deleting coded keys ........................................................................................ 3-23 Safety functions ............................................................................................... 3-23

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Contents Drive interlock with code input (option) .................................................................. 3-24 Entering/changing the personal code .............................................................. 3-25 Enabling the drive interlock ............................................................................. 3-25 Disabling the drive interlock ............................................................................. 3-26 Putting the drive interlock out of operation ...................................................... 3-27 Putting the drive interlock back into operation again ....................................... 3-27 Interruption of drive interlock power ................................................................ 3-27 Drive interlock maintenance ............................................................................ 3-27 Oil and fuel preheater (option) ............................................................................... 3-28 Oil preheater (option) ....................................................................................... 3-28 Fuel preheater (option) .................................................................................... 3-28 Jump-starting the engine (external battery) ........................................................... 3-29 Safety instructions regarding external starting aids ......................................... 3-29 Providing external starting aid ......................................................................... 3-29 Before moving off ................................................................................................... 3-30 Special instructions for driving on public roads ............................................... 3-30 Carry out a functional check of brakes, steering system and lights ................. 3-31 Raising the telescopic boom to transport position ........................................... 3-31 Locking the control lever (joystick) and the 3rd control circuit (attachments) .. 3-31 Steering system ..................................................................................................... 3-32 Steering column height and angle adjustment ................................................ 3-32 Checking the steering system ......................................................................... 3-32 Synchronising the steering system .................................................................. 3-33 Changeover to front axle steering ................................................................... 3-34 Changing over to 4 wheel steering .................................................................. 3-34 Changing over to diagonal steering (crab steering option) .............................. 3-35 Accelerator pedal ................................................................................................... 3-36 Manual throttle (option) .......................................................................................... 3-36 Brake/inching pedal ............................................................................................... 3-37 Specific information on brake/inching pedal actuation .................................... 3-37 Inching with the brake/inching pedal ............................................................... 3-37 Braking with the brake/inching pedal ............................................................... 3-37 Parking brake ......................................................................................................... 3-38 General information on the parking brake ....................................................... 3-38 Applying the parking brake .............................................................................. 3-38 Moving off the telehandler ..................................................................................... 3-39 Selecting the drive range 0 – 20 kph (30/40 kph option) ................................. 3-39 Changing direction (forwards/reverse) ............................................................ 3-40 Selecting a speed range (low-speed control option) ....................................... 3-41 Stopping/parking the machine ............................................................................... 3-42 Decommissioning the machine for a longer time ............................................. 3-42 Load stabiliser ........................................................................................................ 3-43 General instructions regarding the load stabiliser function .............................. 3-43 Switching the load stabiliser ON or OFF ......................................................... 3-44 Differential lock ...................................................................................................... 3-45 Important information on the differential lock ................................................... 3-45 Switching the differential lock ON and OFF ..................................................... 3-45 Backup warning system (option) ............................................................................ 3-46 Information on the backup warning system ..................................................... 3-46 Electric mirror adjustment (option) ......................................................................... 3-46 Adjusting the rearview mirror ........................................................................... 3-46 Machine lights ........................................................................................................ 3-47 General instructions regarding the machine lights .......................................... 3-47 Machine lights operation .................................................................................. 3-47 Working lights operation .................................................................................. 3-48 Interior light operation (cab) ............................................................................. 3-48

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Contents Signalling system ................................................................................................... 3-49 Turn indicator operation ................................................................................... 3-49 Hazard warning system operation ................................................................... 3-49 Rotating beacon operation (option) ................................................................. 3-49 Cab heating and ventilation ................................................................................... 3-50 Operation of the heating and ventilation system .............................................. 3-50 Air conditioning (option) ......................................................................................... 3-51 Air conditioning operation ................................................................................ 3-51 Washer system ...................................................................................................... 3-52 Washer system operation ................................................................................ 3-52 Tank for washer system ................................................................................... 3-52 Seat ........................................................................................................................ 3-53 Seat adjustment: overview ............................................................................... 3-53 Weight adjustment ........................................................................................... 3-53 Height adjustment (air-suspension seat, option) ............................................. 3-54 Backrest adjustment ........................................................................................ 3-54 Horizontal adjustment ...................................................................................... 3-54 Seat belt (lap belt) .................................................................................................. 3-55 Specific instructions regarding the seat belt .................................................... 3-55 Fastening the seat belt .................................................................................... 3-55 Unfastening the seat belt ................................................................................. 3-56 Longer/shorter lap belt adjustment: ................................................................. 3-56 Fire extinguisher (option) ....................................................................................... 3-57 Fire extinguisher operation .............................................................................. 3-57 Reversing fan (option) ............................................................................................ 3-57 Towing the machine ............................................................................................... 3-58 Safety instructions for towing away ................................................................. 3-58 Getting ready for towing ................................................................................... 3-58 Towing the machine ......................................................................................... 3-59 Once towing is over ......................................................................................... 3-59 Loading and transporting the telehandler on a transport vehicle ........................... 3-60 General safety instructions regarding loading ................................................. 3-60 Loading and tying down the machine .............................................................. 3-61 Crane handling the machine .................................................................................. 3-62 Safety instructions regarding crane handling ................................................... 3-62 Crane handling ................................................................................................ 3-62 Telescopic boom control lever: overview ............................................................... 3-63 Operating the control lever for the lift, tilt and push-out rams .......................... 3-63 Operating and securing the 3rd control circuit ....................................................... 3-64 Locking and unlocking the quickhitch or an attachment .................................. 3-64 Releasing the pressure on the quick couplers ................................................. 3-64 Safe load indicator for telescopic boom ................................................................. 3-65 General safety instructions regarding the safe load indicator .......................... 3-65 Safe load indicator display ............................................................................... 3-66 Functional check of the safe load indicator ...................................................... 3-67 Disabling/enabling the overload cutoff (option) ...................................................... 3-67 Operating the telescopic boom .............................................................................. 3-68 Raising/extending the telescopic boom ........................................................... 3-68 Retracting/lowering the telescopic boom ......................................................... 3-68 Emergency lowering of telescopic boom in case of diesel engine breakdown ...... 3-69 Lower or raise as follows: ................................................................................ 3-69 Equipping the machine with a standard bucket ..................................................... 3-70 General information on buckets ....................................................................... 3-70 Pressure relief on the quickhitch couplers ....................................................... 3-70 Fitting a standard bucket onto the quickhitch .................................................. 3-71 Removing a standard bucket from the quickhitch ............................................ 3-72

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Contents Working with the standard bucket .......................................................................... 3-73 Safety instructions regarding work with the bucket ......................................... 3-73 Driving on public roads with a standard bucket ............................................... 3-74 Transport position of standard bucket ............................................................. 3-74 Standard bucket payload ................................................................................. 3-75 Safety instructions for transporting material in a full bucket ............................ 3-75 Loading loose material .................................................................................... 3-76 Loading if the material is hard to penetrate ..................................................... 3-76 Removing material/digging in soft soil ............................................................. 3-77 Removing material/digging in hard soil ............................................................ 3-78 Grading ............................................................................................................ 3-78 Loading vehicles .............................................................................................. 3-79 Freeing the machine ........................................................................................ 3-79 Fitting a multipurpose bucket ................................................................................. 3-80 General information on the multipurpose bucket ............................................. 3-80 Picking up a multipurpose bucket with the quickhitch ..................................... 3-80 Hydraulic connections on the multipurpose bucket: overview ......................... 3-80 Connecting hydraulic lines to the 3rd control circuit ........................................ 3-81 Removing the multipurpose bucket from the quickhitch .................................. 3-82 Working with the multipurpose bucket ................................................................... 3-83 Safety instructions regarding work with the bucket ......................................... 3-83 Driving on public roads with the multipurpose bucket ..................................... 3-84 Transport position of multipurpose bucket ....................................................... 3-84 Multipurpose bucket payload ........................................................................... 3-85 Safety instructions for transporting material in a full bucket ............................ 3-85 Grading and scraping ...................................................................................... 3-86 Removing and spreading material in thin layers .............................................. 3-86 Pulling out material from slopes ...................................................................... 3-87 Moving material with longer reach ................................................................... 3-87 Picking up remaining material completely ....................................................... 3-87 Grabbing bulky material ................................................................................... 3-88 Pulling out and setting posts ............................................................................ 3-88 Backfilling round gravel and precise unloading ............................................... 3-89 Unloading from the bottom of the bucket for increased dump heights ............ 3-89 Fitting pallet forks ................................................................................................... 3-90 Fitting pallet forks onto the quickhitch ............................................................. 3-90 Removing pallet forks from the quickhitch ....................................................... 3-90 Driving on public roads with the pallet forks .................................................... 3-90 Working with the pallet forks .................................................................................. 3-91 General safety instructions regarding the pallet forks ..................................... 3-91 Specific safety instructions .............................................................................. 3-92 Brief instructions for fork arms ......................................................................... 3-93 Load diagram for pallet forks (EN 1459/1998) ................................................. 3-94 Pallet forks payload ......................................................................................... 3-94 Pallet forks transport position without load ...................................................... 3-94 Adjusting the fork arms of the pallet forks ....................................................... 3-95 Picking up loads with the pallet forks ............................................................... 3-96 Transporting loads with the pallet forks ........................................................... 3-97 “Hose burst valve” safety feature ........................................................................... 3-98 Hose burst valve function ................................................................................ 3-98 Mechanical oscillating axle interlock (rear axle) .................................................... 3-99 Mechanically locking the oscillating axle ......................................................... 3-99 Hydraulic rear oscillating axle interlock (option) .................................................... 3-99 Hydraulically locking the oscillating axle .......................................................... 3-99 Frame levelling feature on front axle (option) ...................................................... 3-100 Switching the frame levelling ON and OFF ................................................... 3-100

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Contents Working with a crane jib (option) .......................................................................... 3-101 General safety instructions for working with a crane jib ................................. 3-101 Continuous operation of 3rd control circuit (option) ............................................. 3-102 Switching continuous operation of 3rd control circuit ON/OFF ...................... 3-102 Tilt ram lock (option) ............................................................................................ 3-102 Switching the tilt ram lock ON and OFF ......................................................... 3-102 Electric changeover valve for operation of 3rd control circuit as additional front control circuit (option) .................................................................. 3-103 Switching the additional control circuit ON or OFF ........................................ 3-103 Front/rear hydraulic additional control circuit (option) .......................................... 3-104 General information on the additional control circuit ...................................... 3-104 Connecting an attachment onto the additional control circuit ........................ 3-104 Additional control circuit operation ................................................................. 3-105 Automatic bucket repositioning (option) ............................................................... 3-106 General information on automatic bucket repositioning ................................. 3-106 Tipping trailer connection (option) ........................................................................ 3-106 Operating the tipping trailer connection ......................................................... 3-106 Operation of the Autohitch trailer coupling (option) .............................................. 3-107 General information on the Autohitch trailer coupling .................................... 3-107 Unlocking and opening the Autohitch trailer coupling .................................... 3-107 Locking the Autohitch trailer coupling ............................................................ 3-108 Automatic trailer coupling (option) ....................................................................... 3-109 General information on the trailer coupling .................................................... 3-109 Attaching a trailer ........................................................................................... 3-109 Compressed-air brake system (option) ................................................................ 3-110 General safety instructions regarding the compressed-air braking system ... 3-110 Coupling and uncoupling compressed-air hoses (dual-circuit brake system) ............................................................................. 3-110 Compressed-air gauge .................................................................................. 3-111 Hydraulic trailer brake (option) ............................................................................. 3-111 General information on the hydraulic trailer brake ......................................... 3-111 Fitting attachments from other manufacturers onto the quickhitch (option) ......... 3-112 General information on quickhitches ............................................................. 3-112 Example: inspection plan for attachments other than Kramer ....................... 3-113 Troubleshooting 4 Diesel engine malfunctions ...................................................................................... 4-1 Malfunctions in the air conditioning system (option) ................................................ 4-3 Maintenance 5 Introduction .............................................................................................................. 5-1 Safety prop for telescopic boom .............................................................................. 5-1 Fuel system .............................................................................................................. 5-2 General safety instructions for refuelling ........................................................... 5-2 Diesel fuel specification ..................................................................................... 5-2 Stationary fuel pumps ........................................................................................ 5-2 Refuelling ........................................................................................................... 5-3 Bleeding the fuel system .................................................................................... 5-3 Checking/replacing the fuel prefilter (water separator) ...................................... 5-4 Replacing the fuel filter ...................................................................................... 5-5 Cleaning the fuel cooler (option) ........................................................................ 5-5 Engine lubrication system ........................................................................................ 5-6 Checking the engine oil level daily ..................................................................... 5-6 Filling up engine oil ............................................................................................ 5-6 Replacing the engine oil (every 500 service hours) ........................................... 5-7 Replacing the engine oil filter (every 500 service hours) ................................... 5-8

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Contents Engine and hydraulics cooling system ..................................................................... 5-9 Specific information on cooling system maintenance ........................................ 5-9 Temperature gauge: engine coolant ................................................................ 5-10 Checking the coolant level and quality ............................................................ 5-10 Filling up coolant .............................................................................................. 5-11 Draining coolant ............................................................................................... 5-12 Cleaning the radiator fins ................................................................................. 5-13 Cleaning the radiator with the reversing fan (option) ....................................... 5-14 Air filter ................................................................................................................... 5-15 Checking air filter contamination ..................................................................... 5-15 Checking the dust collector once a day ........................................................... 5-15 Replacing the air filter cartridge at 500 s/h (service hours) ............................. 5-16 V-belts .................................................................................................................... 5-17 Checking the V-belts ....................................................................................... 5-17 Retightening the V-belts .................................................................................. 5-17 Hydraulic system ................................................................................................... 5-18 Specific safety instructions regarding the hydraulic system ............................ 5-18 Monitoring the hydraulic oil and the reflux filter ............................................... 5-19 Checking the hydraulic oil level once a day ..................................................... 5-20 Filling up hydraulic oil ...................................................................................... 5-20 Important information for the use of biodegradable oil .................................... 5-21 Checking hydraulic pressure lines ......................................................................... 5-22 Specific safety instructions regarding pressure line checks ............................ 5-22 Lubrication work ..................................................................................................... 5-23 General safety instructions .............................................................................. 5-23 Lubricating the front and rear axle oscillation-type bearings ........................... 5-23 Lubricating the planetary drive bearing ........................................................... 5-23 Lubrication points on the telescopic boom: overview ...................................... 5-24 Lubricating the telescopic boom ...................................................................... 5-24 Checking and adjusting the wear plates .......................................................... 5-24 Lubricating with the central lubrication system (option) ......................................... 5-25 General functional description of the central lubrication system ..................... 5-25 Time control ..................................................................................................... 5-25 Setting the lubrication and break times ........................................................... 5-26 Filling the central lubrication system ................................................................ 5-26 Maintenance of the brake system .......................................................................... 5-27 Specific safety instructions regarding the brake system .................................. 5-27 Checking/filling up the brake fluid level ........................................................... 5-27 Maintenance: compressed-air brake system (option) ............................................ 5-28 Checking the compressed-air tank and lines ................................................... 5-28 Checking compressor attachment and drive ................................................... 5-28 Tyres ...................................................................................................................... 5-29 Daily tyre checks ............................................................................................. 5-29 Changing wheels ............................................................................................. 5-30 Heating and ventilation system maintenance ........................................................ 5-31 Cleaning/replacing the fine-dust filter .............................................................. 5-31 Cleaning/replacing the recirculated-air filter .................................................... 5-31 Air conditioning (option): maintenance .................................................................. 5-32 General safety instructions regarding the air conditioning system .................. 5-32 Filling up the air conditioning system ............................................................... 5-32 Daily functional and visual checks of the air conditioning ................................ 5-33

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Contents Maintenance of the electrical system ..................................................................... 5-34 General instructions ......................................................................................... 5-34 Specific safety instructions regarding the electrical system and the battery .... 5-34 Checking/replacing the battery ........................................................................ 5-35 Checks at regular intervals .............................................................................. 5-36 Cables, bulbs and fuses .................................................................................. 5-36 Alternator ......................................................................................................... 5-36 Checking/replacing relays and fuses ............................................................... 5-37 Maintenance: automatic trailer coupling ................................................................ 5-38 Cleaning and lubricating the trailer coupling .................................................... 5-38 Check the trailer coupling for wear .................................................................. 5-38 General maintenance work .................................................................................... 5-39 Specific safety instructions regarding cleaning ................................................ 5-39 Cleaning inside the cab ................................................................................... 5-40 Cleaning the seat belt ...................................................................................... 5-40 Cleaning the exterior of the machine ............................................................... 5-40 Cleaning the engine and the engine compartment .......................................... 5-41 Screw connections ........................................................................................... 5-41 Pivots and hinges ............................................................................................ 5-41 Maintenance: diesel particle filter (option) ............................................................. 5-42 Checking the electronic filter monitoring .......................................................... 5-42 Maintenance and service of the attachments ........................................................ 5-42 Maintenance work “Aggressive Media” (option) ..................................................... 5-43 Anticorrosion protection applied in the factory ................................................. 5-43 Components coated with anticorrosive wax .................................................... 5-43 Measures for maintaining anticorrosive protection .......................................... 5-44 Applying the protective anticorrosion coating .................................................. 5-45 Treatment of oxidised surfaces ........................................................................ 5-45 Maintenance plan (overview) ................................................................................. 5-47 Fluids and lubricants ............................................................................................. 5-51 Maintenance label .................................................................................................. 5-52 Explanation of symbols on the maintenance label ........................................... 5-52 Maintenance label ............................................................................................ 5-53 Specifications 6 Model and trade names: overview ........................................................................... 6-1 Frame ....................................................................................................................... 6-1 Engine ...................................................................................................................... 6-1 Oil/water fan ............................................................................................................. 6-2 Power train ............................................................................................................... 6-2 Variable displacement pump ............................................................................. 6-2 Variable displacement motor ............................................................................. 6-2 Axles ........................................................................................................................ 6-3 Front axle ........................................................................................................... 6-3 Rear axle ........................................................................................................... 6-3 Service and parking brake ....................................................................................... 6-4 Steering system ....................................................................................................... 6-4 Work hydraulics ....................................................................................................... 6-5 Hydraulic pump .................................................................................................. 6-5 Hydraulic ram protection .................................................................................... 6-5 Lift, tilt and push-out rams: velocity ................................................................... 6-5 Hydraulic pilot control ........................................................................................ 6-6 Additional control circuit (option) ........................................................................ 6-6

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Contents Electrical system ...................................................................................................... 6-7 Fuses: overview ................................................................................................. 6-7 Electric components .......................................................................................... 6-8 Main fuse box with relays (88 kW diesel engine) .............................................. 6-9 Main fuse box with relays (103 kW diesel engine) ............................................ 6-9 Relays (overview) ............................................................................................ 6-10 Tyres ...................................................................................................................... 6-11 Weights .................................................................................................................. 6-11 Trailer weight/drawbar load: trailer couplings (option) ........................................... 6-11 Noise levels ........................................................................................................... 6-12 Vibrations, oscillation and acceleration value ........................................................ 6-12 Tightening torques ................................................................................................. 6-13 General tightening torques .............................................................................. 6-13 Specific tightening torques .............................................................................. 6-13 Coolant compound table ........................................................................................ 6-13 Payloads model 404-03 ......................................................................................... 6-14 Rigid front axle without oscillating axle interlock (rear axle) ............................ 6-14 Rigid front axle with mechanical or hydraulic oscillating axle interlock (rear axle) .......................................................................................... 6-15 Front axle with frame levelling and without oscillating axle interlock (rear axle) .......................................................................................... 6-16 Front axle with frame levelling and hydraulic oscillating axle interlock (rear axle) .......................................................................................... 6-17 Dimensions with bucket ........................................................................................ 6-18 Dimensions with pallet forks ................................................................................. 6-19

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Contents

Contents Verzeichnisse

Contents Symbole “Hose burst valve” safety feature (option).................................3-98 A Abbreviations ..............................................................................1-1 Adjusting the bucket repositioning..........................................3-106 Adjusting the fork arms .............................................................3-95 Adjusting the headlights when using superlightweight material bukkets..........................................................................1-7 Adjusting the height of the control lever base...........................3-36 Air conditioning (option) ............................................................3-51 Air filter......................................................................................5-15 Cleaning the dust collector .................................................5-15 Dust valve...........................................................................5-15 Applications with lifting gear .......................................................2-8 Avoiding running the engine under low-load conditions ...........3-16 B Battery ......................................................................................5-35 Battery master switch (option) ..................................................3-16 Biodegradable oil ......................................................................5-21 Brake system ............................................................................5-27 Brake fluid...........................................................................5-27 Safety instructions ..............................................................5-27 C Cab ...........................................................................................3-11 Closing and opening the side window (to a gap)................3-12 Completely opening and locking the side window ..............3-12 Locking and unlocking the door..........................................3-11 Opening/closing the rear window .......................................3-13 Central lubrication system (option) ...........................................5-25 Changeover valve for operation of 3rd control circuit as additional control circuit .....................................................3-103 Cleaning and maintenance Maintenance work if the machine is used in a saline environment........................................................................5-42 Compressed-air brake system..................................................5-28 Compressed-air brake system (option)...................................3-110 Coolant temperature .................................................................3-17 Crane handling .........................................................................3-62 Crane jib (option) ....................................................................3-101 D Designated use and exemption from liability ..............................2-2 Diagnosis tip switch function Charge-air temperature ......................................................3-18 Overview of flashing codes.................................................3-19 Documents..................................................................................1-8 Driving licence ............................................................................1-7 Driving on public roads with standard bucket...........................................................3-74 With the multipurpose bucket .............................................3-84 With the pallet forks ............................................................3-90

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E Electrical system .........................................................................6-7 Emergency lowering of the telescopic boom in case of a diesel engine breakdown .......................................................3-69 Engine oil pressure ...................................................................3-18 Equipping the machine with a standard bucket ........................3-70 Error code displays (103 kW diesel engine) .............................3-17 F Fire extinguisher .......................................................................3-57 Fitting a multipurpose bucket....................................................3-80 Fitting an attachment onto the quickhitch .................................3-71 Fitting attachments other than Kramer onto the quickhitch (option)...................................................................3-112 Fitting pallet forks......................................................................3-90 Fluids and lubricants.................................................................5-51 Front/rear additional control circuit (option) ............................3-104 Fuel cooler ..................................................................................5-5 Fuel preheater (option) .............................................................3-28 Fuel system Bleeding................................................................................5-3 Cleaning the water separator ...............................................5-4 H Hazard warning system ............................................................3-49 Heating .....................................................................................3-50 Heating, fresh air ................................................................3-50 Heating, mixed mode..........................................................3-50 Heating, recirculated air mode............................................3-50 Recirculated-air filter...........................................................5-31 Hose burst valve .......................................................................3-98 Hydraulic connection of multipurpose bucket ...........................3-81 Hydraulic oscillating axle interlock ............................................3-99 I Important information On this Operator's Manual....................................................1-1 Interior light ...............................................................................3-48 K Key-based drive interlock (option) ............................................3-22 L Legal regulations ........................................................................1-7 Licence, identification .................................................................1-7 Light system..............................................................................3-47 Load diagram............................................................................3-94 Load stabiliser Switching ON/OFF..............................................................3-44 Loading and transporting ..........................................................3-60 Locking and unlocking the engine cover...................................3-13

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Contents M Machine Brief description....................................................................1-3 Fields of application..............................................................1-5 Overview ..............................................................................1-2 Machine inspections, regulations for accident prevention ..........1-8 Machine lights........................................................................... 3-47 Maintenance Biodegradable oil................................................................5-21 Brake system......................................................................5-27 Changing wheels................................................................5-30 Checking the coolant level .................................................5-10 Checking the engine oil level................................................5-6 Checking the hydraulic oil level ..........................................5-20 Cleaning .............................................................................5-39 Compressed-air brake system (option) ..............................5-28 Diesel particle filter (option)................................................5-42 Electrical system ................................................................5-34 Engine and hydraulics cooling system .................................5-9 Engine lubrication system ....................................................5-6 Filling in engine oil................................................................5-6 Filling up coolant ................................................................5-11 Filling up hydraulic oil .........................................................5-20 Fluids and lubricants ..........................................................5-51 Fuel system ..........................................................................5-2 Heating...............................................................................5-31 Hydraulic pressure lines .....................................................5-22 Hydraulic system ................................................................5-18 Maintenance of attachments ..............................................5-42 Maintenance work if the machine is used in a saline environment .............................................................5-43 Pivots and hinges...............................................................5-41 Replacing the air filter cartridge..........................................5-16 Replacing the engine oil filter cartridge ................................5-8 Screw connections .............................................................5-41 Service and maintenance work ..........................................5-39 Service and maintenance work at regular intervals............5-36 Trailer couplings.................................................................5-38 Tyre care ............................................................................5-29 V-belts ................................................................................5-17 Maintenance plan .....................................................................5-47 Mechanical oscillating axle interlock.........................................3-99 Model designation – trade names ..............................................1-3 Multipurpose bucket payload....................................................3-85

O Oil preheater (option)................................................................3-28 On-board equipment................................................................... 1-8 Operation Additional control circuit with switch .................................3-105 Before moving off ...............................................................3-30 Driving direction (forwards/reverse) ...................................3-40 Fire extinguisher (option)....................................................3-57 Hose burst valve on tilt ram (option)...................................3-98 Load stabiliser ....................................................................3-43 Moving off...........................................................................3-39 Parking the machine...........................................................3-42 Reversing fan (option) ........................................................3-57 Speed range selection........................................................3-39 Starting the engine .............................................................3-14 P Pallet forks................................................................................3-91 Brief instructions for fork arms............................................3-93 Picking up loads ................................................................. 3-96 Safety instructions ..............................................................3-91 Specific safety instructions.................................................3-92 Transporting loads..............................................................3-97 Parking brake ...........................................................................3-38 Putting into operation Putting the machine into operation for the first time ............. 3-8 Safety instructions ................................................................ 3-8 R Radiator Draining coolant ................................................................. 5-12 Rear window emergency exit ...................................................3-13 Refuelling.................................................................................... 5-3 Releasing the pressure on the quick couplers.................3-64, 3-70 Removing a standard bucket from the quickhitch.....................3-72 Removing the multipurpose bucket from the quickhitch ...........3-82 Rotating beacon .......................................................................3-49 Running-in period ....................................................................... 3-8

N Noise levels ..............................................................................1-11

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I-11

Contents S Safe load indicator ....................................................................3-65 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 ......................................................2-9 Transport ..............................................................................2-9 Transporting with a full multipurpose bucket ......................3-85 Transporting with a full standard bucket.............................3-75 Seat Backrest adjustment ...........................................................3-54 Height adjustment (air-suspension seat, option) ................3-54 Horizontal adjustment.........................................................3-54 Seat adjustment..................................................................3-53 Weight adjustment..............................................................3-53 Seat adjustment........................................................................3-53 Seat belt....................................................................................3-55 Adjustment..........................................................................3-56 Fastening the seat belt .......................................................3-55 Service brake............................................................................3-37 Signalling system......................................................................3-49 Signs and symbols....................................................................1-11 Specific information for driving on public roads ........................3-30 Specifications..............................................................................6-1 Additional control circuit (option) ..........................................6-6 Axles.....................................................................................6-3 Brakes ..................................................................................6-4 Coolant compound table.....................................................6-13 Dimensions with bucket......................................................6-18 Dimensions with pallet forks ...............................................6-19 Drive .....................................................................................6-2 Electric components .............................................................6-8 Engine ..................................................................................6-1 Frame ...................................................................................6-1 Front axle..............................................................................6-3 Hydraulic pump.....................................................................6-5 Hydraulic ram protection.......................................................6-5 Main fuse box with relays .....................................................6-9 Model and trade names........................................................6-1 Noise levels ........................................................................6-12 Oil/water fan .........................................................................6-2 Pilot control...........................................................................6-6 Rear axle ..............................................................................6-3 Relays (overview) ...............................................................6-10 Steering system....................................................................6-4 Tightening torques..............................................................6-13 Trailer couplings .................................................................6-11 Variable displacement motor ................................................6-2 Variable displacement pump ................................................6-2 Vibration .............................................................................6-12 Weights...............................................................................6-11 Work hydraulics....................................................................6-5 I-12

Speed Lift, tilt and push-out rams ....................................................6-5 Standard bucket payload ..........................................................3-75 Starting aid................................................................................3-29 Steering mode 4 wheel steering .................................................................3-34 Diagonal steering (crab steering option).............................3-35 Front axle steering..............................................................3-34 Switching the differential lock ON and OFF..............................3-45 T Telescopic boom Checking the transport position of the bucket ....................3-74 Checking the transport position of the multipurpose bucket ...........................................................3-84 Checking the transport position of the pallet forks..............3-94 Extending/raising ................................................................3-68 Lubrication ..........................................................................5-24 Overview of lubrication points.............................................5-24 Retract/lower ......................................................................3-68 Telltales ......................................................................................3-6 Temperature gauge ..................................................................5-10 Tilt ram lock.............................................................................3-102 Towing and transporting the machine.......................................3-58 Trailer coupling .......................................................................3-109 Trailer weight/drawbar load.......................................................6-11 Turn indicators ..........................................................................3-49 Tyre care...................................................................................5-29 V Ventilation .................................................................................3-50 Ventilation, fresh air............................................................3-50 W Warning identification..................................................................1-8 Warranty .....................................................................................1-4 Warranty claims ..........................................................................1-4 Washer system Front window washer pump................................................3-52 Front window wiper.............................................................3-52 Rear window washer pump ................................................3-52 Rear wiper ..........................................................................3-52 Tank....................................................................................3-52 Wheel change...........................................................................5-30 Working Freeing the machine...........................................................3-79 Grading...............................................................................3-78 Loading loose material .......................................................3-76 Practical hints .....................................................................3-79 Removing material/digging in hard soil...............................3-78 Removing material/digging in soft soil ................................3-77 With a crane jib (option)....................................................3-101 With the multipurpose bucket .............................................3-83 With the pallet forks ............................................................3-91 Working lights ...........................................................................3-48

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EC Declaration of Conformity

EC Declaration of Conformity EC declaration of conformity (model 404-03) Manufacturer Kramer-Werke GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf

Product Machine designation

404

Model/version

404-03 (9040)

Serial number

404 03 _ _ _ _ _

Output kW

88 (103)

Measured sound power level dB(A)

105.6 (103.8)

Guaranteed sound power level dB(A)

106 (104)

Conformity assessment procedure The following inspection body was involved in the procedure: Fachausschüsse Bau und Tiefbau (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 (old 98/37 EC), 2000/14 EC, and EN ISO 3744: 1995, 2004/108/EC (old 89/336/EEC), 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, (date) i. A.

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

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EG-1

EC Declaration of Conformity Notes:

EG-2

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Introduction

Introduction

1

Introduction

1.1 General information on the Operator's Manual This Operator's Manual contains important information on how to work safely, correctly and economically with your telehandler. Therefore, it aims not only at new operators, but it also serves as a reference for experienced ones. It helps to avoid dangerous situations and reduce repair costs and downtimes. Furthermore, the reliability and the service life of the machine will be increased by following the instructions in the Operator's Manual. This is why the Operator's Manual must always be kept at hand in proper condition in the machine.

The Operator's Manual is stored in the storage compartment on the backrest of the seat.

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

Abbreviations/symbols • 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 n. s. = not shown “Option” = optional equipment

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

General information 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. Therefore, carefully read and understand this Operator's Manual prior to the first drive. The Operator's Manual will help to familiarise yourself more easily with the machine, thereby enabling you to use it more safely and efficiently. (see also Selection and qualification of staff, basic responsibilities on page 2-5) Prior to the first drive, carefully read chapter “Safety Instructions” as well, in order to be prepared for possible dangerous situations, as it will be too late for it during operation. As a rule, keep the following in mind: Careful and prudent working is the best way to avoid accidents!

Operational safety and readiness of the machine do not only depend on your skill, but also on maintenance and servicing of the machine. This is why regular maintenance and service work is absolutely necessary. Extensive maintenance and repair work must always be carried out by an expert with appropriate training. Insist on using original spare parts when carrying out maintenance and repair work. This ensures operational safety and readiness of your machine, and maintains its value.

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1-1

Introduction 1.2 Machine overview 5

6

7

8

9

10

11

12

13

14

11 4

15 16

3

17

2

18

19

Fig. 1:

Machine outside views

Pos.

1

Description

4

Pos.

1 Front eye hook for towing/tying down the machine 2

9

20

5

Description

14 Trailer coupling (option) 15 Numberplate fixture (option)

3 Boom working lights (option)

16 Brake, rear and turn indicator lights

4 Light with turn indicator

17 Door arrester

5 Rearview mirrors

Mechanical oscillating axle interlock with pin 18 (standard) Hydraulic oscillating axle interlock (option)

6 Rear clearance light 7 Air filter

19 Rear eye hook for tying down the machine

8 Eye hook1 for installing/removing the cab

20 Handle

9 Front/rear working light (standard)

21 Cab access

10 Rotating beacon (option)

22 Battery (battery master switch option)

11 Working light (front/rear option)

1-2

21

13 Hydraulic connections (quick couplers, option)

Brace on the right on front axle (standard) Frame levelling ram (option)

12 Rearview mirror (rear, option)

22

1.

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

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Introduction 1.3 Model designation – trade names Telehandler model

Trade name

404-03

9040

1.4 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 1-5.

Main components of machine • Sturdy steel sheet frame; rubber-mounted engine • ROPS/FOPS tested cab (roll-over/falling object protection) • Water-cooled turbocharged Deutz four-cylinder in-line engine ➥ Exhaust emissions according to Directive 2004/26 EC • Automotive drive, infinitely variable hydrostatic axial-piston gearbox; maximum speed 20 kph (30/40 kph options) • Hydraulic power steering with emergency steering features (front wheel/four wheel/ diagonal steering) • Planetary steering axles, rear axle with oscillation (option frame levelling with oscillating axle interlock) • Service brake (multidisc brake) • Parking brake and auxiliary brake (spring-loaded brake effect on multidisc brake) • Telescopic boom

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1-3

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

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

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

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

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

1.5 Telehandler warranty Information on 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.

1-4

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Introduction 1.6 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 below have been certified for installation on the machine. ☞ See table “Attachments with certified material densities” on page 1-5 Mounting attachments other than Kramer is only allowed if they correspond to the description in chapter “Operation” Fitting attachments from other manufacturers onto the quickhitch (option) on page 3-112.

Note that not all the indicated attachments comply with local traffic regulations. The attachments complying with German road traffic regulations and the applicable provisions are listed in the General Certification for Vehicles (Germany) or the data confirmation (Germany)!

Attachments without ABE (General Certification for Vehicles) require an EBE (separate certification for vehicles) made out by the competent authority!

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

Attachments with certified material densities Attachment type no.

Dimensions

Struck/heaped

1000150361 1000150491

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

1.0/1.2 m3

1000151088 1000151089

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

1.3/1.6 m3

Standard bucket – lightweight material 1, 2

10001587303

2500 mm

1.5/1.8 m3

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

Standard bucket – superlightweight material1, 2, 5

10001766453 10001717283

2500 mm

2.5/3.0 m3

Picking up, transporting and loading grain (material density ≤ p = 0.7 t/m³)

Attachment

Standard bucket – normal material1

1.45 m3

1000174575 Silage bucket with hydraulic clamp1, 4

1000166717

2400 mm

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

1.90 m3

1000174577

1.3 m3

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

1.6 m3

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

2400 mm 1000174578

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

1000166718

Heavy duty bucket with hydraulic clamp1, 4, 6

Multipurpose bucket (with exchangeable blade)1, 6

2.40 m3

Use

1000185558

2400 with teeth

1.1/1.2 m3

Grading, removing and scraping vegetation, for example; picking up and evenly spreading material; grabbing bulky material; loading trucks (material density ≤ p = 1.8 t/m³)

1-5

Introduction Attachment type no.

Dimensions

1000171857

1200 mm

1000178248

1500 mm

1000165368

2000 mm

Floating pallet forks (floating fork arms)1, 4, 5, 6

1000171735

1200 mm

Floating pallet forks (floating fork arms with hydraulic side shift)1, 4, 5, 6

1000171736

Attachment

Pallet forks1, 4, 5, 6

Struck/heaped

Use

Load diagram Picking up and transporting pallets

1200 mm

Load diagram

Picking up, transporting and side-shifting pallets

Pallet forks (fork arms with hydraulic side shift) 1, 4, 5, 6

1000174576 1000174581

1600 mm

Crane jib1, 4, 5

1000157237

1300 mm

Load diagram

Picking up and transporting loads with lifting gear (cables, chains, belts)

Bale spike (3 tines)1, 5

1000166754

Length 1100 mm Width 1250 mm

Load diagram

Picking up and transporting hay and straw bales

Bale grapple1, 5

1000166756

Clamping width 800 – 1800 mm

–

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

1000166758

Length 1000 mm Width 2300 mm

2.3 m³

1000166765

Length 1000 mm Width 2500 mm

2.5 m³

Beet basket1, 5, 6

1000166760

2400 mm

2.0 m³

Rotary broom6

1000174580

–

Street cleaning

6

1000174579

–

Winter service

1, 5, 6

Manure and silage forks

Snow plough 1.

2.

3.

4.

5.

6.

Picking up and transporting manure and silage Picking up and transporting beets

Bear in mind the safe load indicator when working with this attachment When using this bucket on public roads, mount the right and left-hand side headlights in a higher position and readjust them - see “Adjusting the headlights” on page 1-7 With screwed-on bucket blade Only with load diagram for telehandler Not authorised for use on public roads See the Operator's Manual of the attachment for putting the attachment into operation and using it

Get informed on the legal regulations of your country for further information on mounting attachments

1-6

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Introduction 1.7 Regulations 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 ein 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.

Adjusting the headlights If a lightweight or superlightweight material bucket (Attachments with certified material densities on page 1-5) is fitted onto the machine, the headlights are covered by the buckets in transport position!

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

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1-7

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.

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.

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

Warning identification of telehandler 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.

1-8

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Introduction 1.8 Type labels and component numbers Serial number The serial number is stamped on the machine frame A (next to the front axle attachment, on the front right in driving direction). It is also located on the type label.

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

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

A

Type label indications (example)

C

B 1 2 3 4 5

Fig. 2:

6 7 8 9 10

1

Machine model

404

2

Version

404 03

3

Serial no.

404 03 0036

4

Year of construction

2010

5

Output (kW)

88

6

Front gross axle weight rating (kg)

6500

7

Rear gross axle weight rating (kg)

6500

8

Gross weight rating (kg)

10000

9

Dead weight (kg)

–

10

Maximum payload (kg)

–

Type label: location

Other data: – see Specifications on page 6-1

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

Fig. 3:

Cab type label

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

Example: Deutz TCD 2012 L04 2V kW 88 or 103

Fig. 4:

Diesel engine number

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1-9

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

Fig. 5:

Hydraulic pump type label

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

Fig. 6:

Variable displacement motor type label

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

Fig. 7:

Variable displacement motor type label (option)

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

Fig. 8:

1-10

Rear axle and gearbox type label

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Introduction 1.9 Description of labels 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 crane-lifting the machine.

Fig. 9:

Location Cab roof (4x).

Eye hook label

A

B

Fig. 10: Label for points used for tying down the machine

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 ➥ – see Machine overview on page 1-2 and “Loading and transporting the telehandler on a transport vehicle” on page 3-60 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)

Machine noise level label Noise levels produced by the machine.

LWA = sound power level Other information – see chapter 6 “Noise levels” on page 6-12 Location Rear window

XX Fig. 11: Noise level label

20

30

Fig. 12: Speed label

Fig. 13: Danger label

Fig. 14: Prohibitory label

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40

Machine top speed label Design-specific max. machine speed 20 kph (30/40 kph option).

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

Label: general indication of danger All persons must stay clear of the hazard zone of the telehandler Location Front left and right of machine frame, and at rear of machine.

Label: do not open the engine cover Do not open engine cover before engine is at a standstill!

Do not touch any moving or turning parts!

Location Laterally on the engine cover of the machine.

1-11

Introduction

1 2 3

Battery master switch label In order to avoid malfunctions of the electronic fuel injection, do not immediately turn the battery master switch out of the notched position after stopping the engine!

Bear the correct order in mind as you stop the engine (see label) – see chapter 3 “Battery master switch” on page 3-16 Location Near the battery master switch (cab access)

Fig. 15: Battery master switch label

Labels on the inside of the machine Pallet forks load diagram label Load diagrams with maximum load indications for buckets, pallet forks or crane jib in telescopic boom operation!

Example: ➥ – see chapter 3 “Load diagram for pallet forks (EN 1459/1998)” on page 3-94 Location Inside the cab on the front window.

Fig. 16: Example: pallet forks load diagram

Crane jib load diagram label Load diagrams with maximum payload indications for crane jib applications in telescopic boom operation!

Example: ➥ – see chapter 3 “Working with a crane jib (option)” on page 3-101 Location Inside the cab on the front window.

Important!

The affixed load diagrams only apply to the authorised pallet forks or the crane jib!

• – see Attachments with certified material densities on page 1-5

Fig. 17: Example for Crane jib load diagram

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Introduction Tyre pressure table label List of authorised types of tyres with prescribed tyre inflation pressures. ➥ For more details, see “Specifications” on page 6-11 Location Inside the cab on the front window.

Fig. 18: Tyre pressure table

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 5-51.

Location On the brake-fluid tank

A B Fig. 19: Brake fluid label

Label: locking the control lever (joystick) against unintentional operation • A = lock open • B= lock closed ➥ – see Locking the control lever (joystick) and the 3rd control circuit (attachments) on page 3-31 Location On the stop cock on the control lever console

A

B Fig. 20: Control lever lock label

B A

C

D

E

Fig. 21: Label: control lever operation: overview

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Label: control elements on control lever (joystick) • A = driving direction: (F) forwards/(R) reverse and (N) neutral position ➥ – see chapter 3 “Changing direction (forwards/reverse)” on page 3-40 • B = differential lock ➥ – see chapter 3 “Differential lock” on page 3-45 • C = telescopic boom extension and retraction • D = telescopic boom: raise/lower and dump in/out ➥ – see chapter 3 “Telescopic boom control lever: overview” on page 3-63 ➥ – see chapter 3 “Raising/extending the telescopic boom” on page 3-68 • E = lock: attachment in quickhitch ➥ – see chapter 3 “Operating and securing the 3rd control circuit” on page 3-64 Location On the right on the side window

1-13

Introduction

A

B

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

Fig. 22: Additional control circuit potentiometer

Label for operation of tipping trailer connection or Autohitch trailer coupling ➥ – see chapter 3 “Tipping trailer connection (option)” on page 3-106 ➥ – see chapter 3 “Operation of the Autohitch trailer coupling (option)” on page 3-107 Location On the right on the side window

Fig. 23: Label: tipping trailer/Autohitch trailer coupling operation

1 Stop

2 1000157829

Label for differential lock operation • 1 First stop the telehandler, then • 2 enable the differential lock! ➥ – see chapter 3 “Differential lock” on page 3-45 Location On the right on the side window

Fig. 24: Differential lock label

Label: avoiding danger in general Label for avoiding danger of serious injuries or of injuries resulting in death!

Read and understand the Operator's Manual under all circumstances before putting the machine into operation!

Location On the right-hand side member inside the cab

Fig. 25: Label: avoiding danger

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Introduction Seat belt label ➥ – see chapter 3 “Seat belt (lap belt)” on page 3-55 Location On the right on the side window

Fig. 26: Seat belt label

Label for air conditioning system refill (option) Use only the refrigerants R 134a indicated on the label (see arrow) for refilling the air conditioning system.

Refill may be carried out by an authorised workshop only.

Fig. 27: Label for air conditioning refill

Label: stopping the machine • 1 = at telehandler standstill • 2 = set driving direction to neutral with tip switch N on control lever (joystick) ➥ – see chapter 3 “Changing direction (forwards/reverse)” on page 3-40 • 3 = service and/or parking brake operation ➥ – see chapter 3 “Brake/inching pedal” on page 3-37 ➥ – see chapter 3 “Parking brake” on page 3-38 Location On the right of the ignition lock

Fig. 28: Label: stopping the telehandler

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Introduction Notes:

1-16

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Safety instructions

Safety instructions

2

Safety instructions

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

Danger!

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

☞ Measures for avoiding danger

Caution!

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

Important!

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

• Carrying or transporting persons in the attachments (e.g. bucket, pallet forks) is not allowed either!

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

• 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, Attachments with certified material densities on page 1-5!

• 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/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!

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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.Immediately rectify any functional disorders, especially those affecting the safety of the attachment!

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Safety instructions Selection and qualification of staff, basic responsibilities • Any work on or with the machine must be carried out by reliable staff only. Do not let unauthorised persons drive or work with the machine! Observe statutory minimum age limits!

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

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

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

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

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

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

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

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

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

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

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

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

• Take the necessary precautions to make sure 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 telltales!

• Before putting the machine/attachment into operation (start-up/moving), make sure 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, make sure 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!

• Persons accompanying the driver must be seated on the passenger seats provided for this purpose!

• 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.

Always contact Kramer-Werke GmbH for installation!)

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

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

• When working in buildings or in enclosed areas, look out for: • Height of the ceiling/clearances • Width of entrances • Maximum load of ceilings and floors • Sufficient room ventilation – danger of poisoning!

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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!

• Before 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 engine and remove the ignition key • Before starting work check whether • all safety devices are properly installed and functional • the warning triangle • the approved warning light and • the first-aid kit are at hand, or other equipment required by the regulations of your country, such as fire extinguishers, rotating beacons etc.!

• Before moving the machine or before taking up work: • Make sure 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!

Make sure 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 Definition: 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 e.g.: • Safe possibilities of slinging and securing lifting gear (attachment/load hook) • Load diagram!

• 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!

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Safety instructions Trailers and 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 “Attachments with certified material densities” on page 1-5!

• Get informed on the legal regulations of your country which deal with the use and applications of trailers towed by the machine! ➥ 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.! ➥ See the General Certification for Vehicles (Germany) for agriculture and forestry • Trailer operation with the towing device of the machine is not permitted!

• 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 engine • Release the pressure in the hydraulic system. In order to do so, move the control levers of the hydraulic control units back and forth a couple of times!

• Coupling attachments requires special care!

• Secure the attachments against unintentional movement!

• 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, telltales etc., must be provided for and functional!

• Mount the attachments only if the engine and the drive have been switched off!

• Especially when driving or working with machines equipped with a quickhitch for the attachments, make sure the attachment is safely locked in the quickhitch. The lock pin must be visible on either side of the bores on the attachment. Check before starting work!

• Prior to fitting attachments to the quickhitch, secure the control lever of the hydraulic control unit against unintentional movement!

• Be careful when coupling attachments to the quickhitch: danger of personal injury due to crushing and shearing. Make sure nobody is between the machine and the attachment without 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!

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

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

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Safety instructions 2.5 Safety instructions for maintenance • 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!

• 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.

• The maintenance plan indicates when the maintenance work mentioned below must be carried out.– see Maintenance plan (overview) on page 5-47 • 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 • 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 service, maintenance and repair work only if the • machine is positioned on firm and level ground • forwards-reverse lever (tip switch on control lever) is in neutral position • parking brake is applied • all hydraulically movable attachments and working equipment have been lowered to the ground • engine is stopped • ignition key is removed and the • machine has been secured against unintentional movement!

• Should maintenance or repair be inevitable with the 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 assembly work on the machine, make sure 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!

• The brake and steering systems are crucial to safety. Maintenance work must be carried out by trained staff and an authorised workshop only!

• 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!

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Safety instructions • 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!

• Make sure 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!

• Before taking up work on machine parts dangerous for life and limb (bruising, cutting), always ensure safe blocking/support of these areas!

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

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

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

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

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

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Safety instructions 2.6 Maintenance work on protective ROPS and FOPS structures 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, make sure 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 make sure the premises are adequately ventilated – danger of explosions!

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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. Make sure 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. Therefore carry out regular checks of the tyres for • Prescribed tyre 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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Safety instructions Notes:

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Operation

Operation

3

Operation

3.1 Overview of control elements This chapter describes the controls, and contains information on the function and the handling of the telltales 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 numbers if they are placed to the left of the text.

Cab overview: see overleaf

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 n. s. = not shown

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3-1

Operation 1

2

3

4

5

3.2 Cab overview

6

Pos. 45

7

6 8 44 9

43 42

10

00000 00h

AUTO OFF

41 11

0

I II 1

0

40

2

3

12

39 38

13

37 14 36 15

35 34

16

33 17 32 18

31 30

19

29 20

19 20

21 40001_Draufsicht.iso

21

28

27

26

25

24

23

22

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

Operator's compartment

For more information see page

Front wiper......................................................................................................................................................................... 3-52 Storage compartment Front window air vents....................................................................................................................................................... 3-50 Preheating start switch (ignition lock) ............................................................................................................................... 3-15 Steering column adjustment .............................................................................................................................................. 3-32 Side window air vents........................................................................................................................................................ 3-50 Instrument panel.................................................................................................................................................................. 3-4 Safe load indicator............................................................................................................................................................. 3-65 Fire extinguisher (option)................................................................................................................................................... 3-57 Heating switches ............................................................................................................................................................... 3-50 Accelerator pedal Control lever (joystick) ......................................................................................................................................................... 3-4 Stop cock – control lever lock during road travel............................................................................................................... 3-31 Interior light Switch panel – side console (right)...................................................................................................................................... 3-4 Drink holder Storage net for Operator's Manual Prepared installation for radio (option) Loudspeakers (option) Rear window air vents ....................................................................................................................................................... 3-50 Working light (standard on left/option on right).................................................................................................................. 3-48 Steering electronics Drive electronics (Susmic) Central electrics (relays, fuse box etc.)................................................................................................................................ 6-7 Rear wiper ......................................................................................................................................................................... 3-52 Rotating beacon ................................................................................................................................................................ 3-49 Aerial (option) Proportional electronics Rotary switch – fresh air/recirculated air............................................................................................................................ 3-50 Fresh air filter..................................................................................................................................................................... 5-31 Seat belt ............................................................................................................................................................................ 3-55 Hook Brake fluid tank.................................................................................................................................................................. 5-27 Bracket for first aid kit Tank – washer system....................................................................................................................................................... 3-52 Seat ................................................................................................................................................................................... 3-53 Bracket for side window lock (upper door option).............................................................................................................. 3-12 Roller sun-visor Steering wheel................................................................................................................................................................... 3-33 Brake/inching pedal ........................................................................................................................................................... 3-37 Lock on cab ....................................................................................................................................................................... 3-12 Inside door lock ................................................................................................................................................................. 3-12 Multifunctional lever – turn indicators, headlights, wipers.................................................................................................. 3-49 Switch panel – side console (left)........................................................................................................................................ 3-4 Front working light (option) ................................................................................................................................................ 3-48

Fig. 29: Cab overview

3-2

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Operation

Instrument panel, multifunctional lever and drive lever (overview)

Instrument panel, multifunctional lever and drive lever (overview)

00 0290 174 1 – BA SCORPION

3-3

Operation 59 51

52

60

61

62

63

64

65

66

3.3 Instrument panel, multifunctional lever, switch consoles: overview

67

Pos.

53

50

54

49

55

48

56

68

00000

47

57

46

58

00

h

69

78

70

79 80

Fig. 30: Indicating instrument

81 2

0

1

3

82

Nr_7_2.iso

77

76

74

72

73

72

83

71

Fig. 31: Instrument panel

84

85

86

87

88

89

100

90

101 102 91

103

AUTO

104

OF F

99

92 98

105

97

106 96

95

118 94

Fig. 32: Switch panel – side console (left)

107 93

12

117

119

116

108

122

121

43

120

110 111

0

I

For more information see page

46 47 48 49 50 51 52 53 54 55 56 57 58

Hour meter Cold starter telltale (yellow) ............................................................................................................................................... 3-15 High beam telltale (blue).................................................................................................................................................... 3-47 Coolant level telltale (red) .................................................................................................................................................. 5-11 Hydraulic oil filter telltale (red) ........................................................................................................................................... 5-20 Air filter telltale (yellow)...................................................................................................................................................... 5-15 Alternator charge function telltale (red) ............................................................................................................................. 3-15 Parking brake telltale (red) ................................................................................................................................................ 3-38 Engine oil pressure telltale (red) ........................................................................................................................................ 3-15 Telltale (red) – 3rd control circuit, continuous operation.................................................................................................. 3-102 Right/left turn indicators telltale (green) for rear attachments............................................................................................ 3-49 Telltale (green) – fuel/water separator................................................................................................................................. 5-4 Fuel level indicator Instrument panel For more information see page

59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78

Telltale (red) – hydraulic system overheating.................................................................................................................... 5-19 Telltale (red) – hydraulic oil level ....................................................................................................................................... 5-20 Telltale (green) – differential lock ...................................................................................................................................... 3-45 Right/left turn indicators telltale (green)............................................................................................................................. 3-49 Telltale (yellow) – hose burst valve .................................................................................................................................. 3-98 Telltale (green) – front axle steering .................................................................................................................................. 3-34 4 wheel steering telltale (green) ........................................................................................................................................ 3-34 Telltale (green) – diagonal steering (crab steering option) ................................................................................................ 3-35 Steering synchronisation telltale (red) ............................................................................................................................... 3-40 Forwards driving direction telltale (green) ......................................................................................................................... 3-40 Reverse driving direction telltale (green) ........................................................................................................................... 3-40 Speedometer (high speed option) Temperature indicator – diesel engine (115 °C ON/110 °C OFF)....................................................................................... 5-9 Indicating instrument Manual throttle potentiometer (option)............................................................................................................................... 3-36 Tip switch with error code display (103 kW diesel engine) ................................................................................................ 3-17 Crawler gear potentiometer (option) Tip switch with error code displays – particulate filter (diesel exhaust particulate filter option) ......................................... 5-42 Tachometer (engine) Telltale (red) – disabling/enabling the overload cutoff ....................................................................................................... 3-67 Heating switch console, mirror adjustement For more information see page

79 80 81 82 83

Rotary switch – heating temperature................................................................................................................................. 3-50 Rotary switch – heater fan................................................................................................................................................. 3-50 Switch – tilt ram lock (option)........................................................................................................................................... 3-102 Acoustic indication – particulate filter (diesel exhaust particulate filter option) .................................................................. 5-42 Mirror adjustment switch (option) ...................................................................................................................................... 3-46

109 115

Indicating instrument

112 113

Fig. 33: Multifunctional lever

Fig. 34: Control lever (joystick)

114 Fig. 35: Switch panel – side console (right)

3-4

00 0290 174 1 – BA SCORPION

Operation

Pos.

Operation Switch panel on the left

For more information see page

84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99

Hazard warning system switch (red) ..................................................................................................................................3-49 Switch (grey) – machine lights (low beam and rear lights).................................................................................................3-47 Switch (grey) – rotating beacon (option) ............................................................................................................................3-49 Switch (grey) – front working light ......................................................................................................................................3-48 Switch (grey) – rear working light.......................................................................................................................................3-48 Switch (grey) – boom working light (option) .......................................................................................................................3-48 Switch with lock (green) – continuous operation of 3rd control circuit (option) ................................................................3-102 Switch (green) – front/rear additional control circuit (option)............................................................................................3-107 Switch (grey) – heated rear window + mirror heating (option) Switch (grey) – fuel preheater (option)...............................................................................................................................3-28 Switch (grey) – front socket for electric attachments (option) ..........................................................................................3-103 Switch with lock (green) – 3rd control circuit lock ..............................................................................................................3-64 Air compressor pressure gauge (option)................................................................................................................ 3-110, 5-28 Switch (green) – Autohitch trailer coupling (option) .........................................................................................................3-107 Switch (green) – quickhitch release and emergency lowering ...........................................................................................3-64 Switch (green) – load stabiliser (option).............................................................................................................................3-43 Switch panel on the right For more information see page

100 101 102 103 104 105 106 107 108 109

Switch with lock (red) – parking brake ...............................................................................................................................3-38 Switch with lock (blue) – 4 wheel/front axle steering..........................................................................................................3-34 Switch with lock (blue) – diagonal (crab) steering..............................................................................................................3-35 Tip switch (blue) – steering synchronisation ......................................................................................................................3-33 Switch (blue) – work/drive range........................................................................................................................................3-39 Switch (grey) – rear wiper ..................................................................................................................................................3-52 Switch (grey) – reversing fan operation (engine) ..................................................................................................... 3-57, 5-14 Switch (grey) – air conditioning system (option) ...................................................................................................... 3-51, 5-32 Switch (green) – hydraulic tipping trailer connection (opton) ...........................................................................................3-106 Tip switch (green) – hydraulically adjustable trailer coupling (Autohitch) or hydraulic connection for tipping trailer (option) ...................................................................................................................................... 3-106, 3-107 Switch (green) – additional control circuit (option) ...........................................................................................................3-104 Switch (green) – frame levelling (option)..........................................................................................................................3-100 Tip switch (green) – hydraulic rear oscillating axle interlock (option).................................................................................3-99 Switch with lock (green) – disabling/enabling the overload cutoff ......................................................................................3-67 Potentiometer – rotary switch for additional control circuit (option)....................................................................................3-67 Control lever (joystick) For more information see page

110 111 112 113 114 115 116 117 118 119 120

Tip switch – driving direction in neutral ..............................................................................................................................3-40 Switch – extend/retract telescopic boom............................................................................................................................3-68 Tip switch – front socket or bucket repositioning (option) Switch – unlock/lock 3rd control circuit ..............................................................................................................................3-64 Tip switch – differential lock ...............................................................................................................................................3-45 Switch – forwards/reverse driving direction........................................................................................................................3-40 Multifunctional lever For more information see page

121 122

Rotary switch and tip switch – front wiper, washer pump ..................................................................................................3-52 Horn tip switch....................................................................................................................................................................3-49

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3-5

Operation 3.4 Telltales and warning lights: description Telltale and warning light – indicating instrument Cold starter telltale (yellow) Comes on when the key in preheating start switch (fig. 29/4) is in position 1.

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

47

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

48

49

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

50

Hydraulic oil filter telltale (red) Indicates that the resistance of the oil flow in the reflux filter is too high. ☞ – see chapter 5 “Monitoring the hydraulic oil and the reflux filter” on page 5-19

51

Air filter telltale (yellow) Indicates air filter contamination.

Alternator charge function telltale (red) The telltale 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 telltale comes on with the engine running. The battery is no longer charged.

52

53

54

3-6

P

Parking brake telltale (red) Comes on if the switch (fig. 35/101) is pressed.

Speed ranges and the driving direction cannot be selected if the parking brake is applied.

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

55

Telltale (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).

56

Right/left turn indicators telltale (green) for rear attachment (option) Flashes intermittently if the turn indicators (fig. 29/43) are used and if there is an electric connection to a front or rear attachment.

57

Telltale (red) – water separator (fuel system) Indicates that the water separator of the fuel prefilter contains water: ☞ Drain water 00 0290 174 1 – BA SCORPION

Operation Telltale and warning light – instrument panel 59

Hydraulic oil temperature telltale (red) Indicates that the temperature in the hydraulic system is too high. ➥ – see chapter 5 “Monitoring the hydraulic oil and the reflux filter” on page 5-19

60

Telltale (red) – hydraulic oil level Indicates that the hydraulic oil level in the tank is too low: ➥ – see chapter 5 “Checking the hydraulic oil level once a day” on page 5-20

61

Telltale (green) – differential lock Indicates that the differential lock is switched on

62

Right/left turn indicators telltale (green) Flashes intermittently when turn indicators 29/43 are used Load stabiliser/hose burst valve telltale (yellow) Indicates that the load stabiliser is switched on, and that the hose burst valve is disabled – see chapter 3 “Load stabiliser” on page 3-43.

63

64

Telltale (green) – front axle steering Indicates that front axle steering is switched on

65

4 wheel steering telltale (green) Indicates that 4 wheel steering is switched on

66

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

67

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

69

68

78

71

Telltale (green) – driving direction Indicates forwards/reverse driving direction Telltale (red) – disabling/enabling the overload cutoff Indicates that the hydraulic functions “Raising, Lowering, Dumping In/Out and Extending” locked by the safe load indicator are available again Engine coolant temperature indicator Indicates the engine temperature detected by a sensor.

Important!

Engine temperature should be between 80 and 105 °C • Max. admissible temperature is 110 °C. • The acoustic warning sounds from 115 °C – see chapter 5 “Monitoring the hydraulic oil and the reflux filter” on page 5-19

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3-7

Operation 3.5 Putting the machine into operation for the first time Safety instructions regarding commissioning • • • •

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 • Never get on or off a moving machine! Never jump off the machine • Refer to the load diagrams for the pallet forks on the telescopic boom

Important information for the operating staff • The machine may be put into service by instructed and authorised staff only – see chapter 1 “Driving licence” on page 1-7 and “Selection and qualification of staff, basic responsibilities” on page 2-5 of this Operator's Manual • The operating staff must have read and understood this Operator's Manual before putting the machine into operation • The machine may only be put into operation when the driver is seated • Never get on or off a moving machine! Never jump off the machine • Stop the diesel engine and apply the parking brake before leaving the telehandler • Carrying or transporting 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 • Bear in mind the checklists on the following pages • – see chapter 3 “Start-up checklist” on page 3-9 • – see chapter 3 “Operation checklist” on page 3-10 • – see chapter 3 “Parking checklist” on page 3-10

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

The future performance and service life of the machine are heavily dependent on the observance of the following recommendations during the running-in period.

• Do not overload the machine, but at the same time do not drive too cautiously either, as the machine will never reach its proper operating temperature • Do not run the engine at high speed for extended periods • Increase the load gradually while varying the engine speed • Strictly observe maintenance schedules and carry out (or have carried out) the specified maintenance work – see chapter 5 “Maintenance plan (overview)” on page 5-47

3-8

00 0290 174 1 – BA SCORPION

Operation Start-up checklist These checklists cannot claim to be exhaustive; they are merely intended as an aid for you in fulfilling your duties as a conscientious operator.

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

Questions are explained on the pages indicated below.

Example: Enough fuel in the tank? See page 5-2 (➠ 5-2) No. Engine start checklist 1

Enough fuel in the tank? (➠ 5-2)

2

Engine oil level OK? (➠ 5-6)

3

Oil level in hydraulic tank OK? (➠ 5-20)

4

Water level in washer tank OK? (➠ 3-52)

5

V-belt condition and tension checked? (➠ 5-17)

6

Telescopic boom lubricated? (➠ 5-24)

7

Brake system (including parking brake) OK? (➠ 3-38, 5-27)

8

Tyre condition and inflation pressure OK? (➠ 5-29, 6-11)

9

Wheel nuts safely tightened (especially after a wheel change)? (➠ 5-30, 6-13)

✔

10 Lights, signals, indicators, warning lights and telltales OK? (➠ 3-47, 3-49, 3-6) 11 Windows, mirrors, lights and steps clean?

12 Attachment on the telescopic boom safely locked? (➠ 3-71) 13 Engine cover safely locked? (➠ 3-13) 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? (➠ 1-7)

16 Seat position and rearview mirror correctly adjusted?

17 Seat belt fastened? (➠ 3-55)

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3-9

Operation Operation checklist After starting the engine and during operation, check and observe the following points: ✔

No. Checklist for putting the machine into service 1

Telltales for engine oil pressure and alternator gone out? (➠ 3-6)

2

Braking effect sufficient? (➠ 3-37)

3

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

4

Steering system working properly? (➠ 3-32)

5

Anyone dangerously close to the machine? (➠ 2-5, 3-30)

6

Safe load indicator checked and OK? (➠ 3-65)

7

3rd control circuit locked? (➠ 3-64, 3-71)

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

Telescopic boom completely retracted? (➠ 3-68)

9

Telehandler levelled horizontally (frame levelling)? (➠ 3-100)

10 Bucket and attachments in transport position? (➠ 3-30) 11 Transport locks installed? (➠ 3-30) 12

Control lever for lift and tilt hydraulics of the telescopic boom locked with the stop cock? (➠ 3-31)

13 Front-edge protection fitted to bucket? (➠ 3-30)

Parking checklist ➥ Check and observe the following points when parking the machine: ✔

No. Parking checklist 1

Attachments on the telescopic boom lowered to the ground? (➠ 3-42, 3-68)

2

Parking brake applied? (➠ 3-38)

3

Cab locked, especially if the machine cannot be supervised?

When parking on public roads: 4

Machine adequately secured? (➠ 3-42)

When parking on slopes: 5

3-10

Machine additionally secured with chocks under the wheels to prevent it from rolling away? (➠ 3-42)

00 0290 174 1 – BA SCORPION

Operation

Operation 3.6 Cab Locking and unlocking the door Danger!

A

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

☞ Close the door before moving the machine ☞ Secure the upper cab door with door arrester 41 ☞ Outside: press button A ☞ Inside: pull handle B upwards B

D

Opening the upper door (option) The upper door can be opened to improve cab ventilation. ☞ Press lever C down ☞ Open the upper door and secure it in door arrester 41 Closing the upper door (option) ☞ From outside: press lever B forwards ☞ From the inside: press the button

➥ The door is released from the lock by spring action

☞ Safely lock the upper door in lock D of the main door

Important!

C

37

Lubricate the catch bolt of lock 37 at regular intervals.

41

B

Fig. 36:

Opening and locking the door

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3-11

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

A

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

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

A a

b Fig. 37: Locking, unlocking and opening the side window to a gap

Completely opening and locking the side window The side window can fully opened to the rear and locked with the door closed. ☞ Remove the end of lever a from the guide (arrow) ☞ Open the side window completely and press it against arrester 41

➥ The side window locks into place and is locked

a

Important!

Lubricate the catch bolt of lock 37 at regular intervals.

37

41

Unlocking the open side window ☞ From outside: press lever B forwards ☞ From the inside: press button B

➥ The side window is released from the lock by spring action ☞ Close and safely lock the side window ➥ – see Closing the side window on page 3-12

B

Fig. 38: Fully opening the side window

3-12

00 0290 174 1 – BA SCORPION

Operation Opening/closing the rear window Danger!

A

In order to avoid danger of injury, lock the open rear window with the lock lever! The lock lever may be pulled out of the guide only in an emergency!

☞ Lock the rear window with the lock lever ☞ Remove the lock lever from the guide only in case of an emergency ☞ Do not use the side window as an exit unless in case of emergency!

Opening the rear window ☞ Unlock lock lever A in the direction of the arrow ☞ Open the rear window ☞ Engage lock A in the end of lever B with an audible click (arrow) Closing the open rear window ☞ Lock the rear window in the reverse order

B

Fig. 39: Rear window lock

Rear window emergency exit In case of an emergency, the rear window can be used to exit from the cab if the door can no longer be used. ☞ Unlock lock lever A in the direction of the arrow ☞ Remove the end of lever B from the guide (arrow) ☞ Open the rear window ☞ Engage the end of the lever in the guide before resuming normal operation

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

Fig. 40:

• Stop the engine and remove the ignition key • Pull handle A up • Pull the engine cover upwards ➥ The engine cover opens with the help of gas struts ☞ Close the engine cover • Firmly press down the engine cover until the lock engages with an audible click • Press handle A down ☞ Lock the engine cover • Close the engine cover with the ignition key (a padlock can be used in addition)

Engine cover lock

00 0290 174 1 – BA SCORPION

3-13

Operation 3.8 Putting the diesel engine into operation Preparing to start the engine • Run through the “Start-up checklist” on page 3-9 • Switch on the battery master switch – see Battery master switch on page 3-16 • Adjust steering wheel position – see Steering column height and angle adjustment on page 3-32 • Adjust the mirrors • Adjust the correct seat position – see Seat on page 3-53

Important!

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 Make sure the “Parking brake” on page 3-38 is applied Make sure the control lever (joystick) for the telescopic boom is in neutral position The motor will not start unless the parking brake is applied – see Parking brake on page 3-38 • the “Key-based drive interlock (option)” on page 3-22 or “Drive interlock with code input (option)” on page 3-24 is enabled • The starter cannot be actuated if the engine is already running (start repeat interlock) • Interrupt the start attempt after a max. 10 seconds so that the battery can recover • Repeat the start attempt only after about 1 minute

Important!

The engine cannot be started by tow starting the machine, as there is no driving connection between the engine and the gearbox (e.g. cardan shaft).

(Hydrostatic drive).

Important!

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 Oil and fuel preheater (option) on page 3-28

3-14

00 0290 174 1 – BA SCORPION

Operation Starting the engine

0

1

☞ Apply the parking brake ☞ Turn the ignition key (preheating start switch 4) to position “1” ☞ The following telltales must come on

2 3

• Telltale 54 for the engine oil pressure comes on (88 kW diesel engine only)

4

Important!

Fig. 41: Preheating start switch

52

53

47 Fig. 42: Indicating instrument telltales

00000

00 h

54

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Fig. 43: Error code display tip switch (103 kW diesel engine)

74

54

Due to the electronic fuel injection, telltale 54 (engine oil pressure, 103 KW diesel engine) does not come on when starting the engine!

Diesel engine errors are indicated in tip switch 74 by means of a flashing code!

• – see Error code displays (103 kW diesel engine) on page 3-17 • Telltale 53 comes on if the parking brake is applied • Telltale 52 for alternator charge function comes on • Cold starter telltale 47 comes on for about 5 – 10 seconds at normal temperatures (up to 0 °C) and for about 15 – 60 seconds at low temperatures (below 0 °C) ➥ The intake air is preheated via a temperature-dependent time lag relay ➥ Telltale 47 goes out as soon as the temperature is reached ☞ 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 telltales have gone out: • Telltale 54 (88 kW diesel engine only) • Telltale 52 • Telltale 47

Caution!

If the telltales indicated above do not go out, stop the engine immediately and have the reason checked by an authorised workshop! ☞ Replace defective telltales 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 when starting. ☞ Let the engine warm up at low idling speed (for about 30 seconds)

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3-15

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

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

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

Stopping the engine

0

1

Caution!

2 3

4

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

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

Fig. 44: Stopping the engine

the ignition key

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

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

Interrupting power supply

1 2 A

3

Fig. 45: Battery master switch

Caution!

In order to avoid malfunctions of the electronic fuel injection, do not immediately turn the battery master switch out of the notched position after stopping the engine!

Bear the correct order in mind (see label) 1 = first stop the engine with the ignition key (Fig. 44/4) 2 = wait at least 30 seconds 3 = turn key A out of the notched position and remove out Switching on power supply ☞ Insert the key in the battery master switch ☞ Turn the key to the notched position

3-16

00 0290 174 1 – BA SCORPION

Operation 3.10 Error code displays (103 kW diesel engine) Reading out the flash code

00000

The tip switch with the error code displays 74 (integrated telltale) is located on the instrument panel.

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

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

Error display: the integrated telltale comes on continuously, or the telltale flashes ☞ Read out the error display with tip switch 74. To do this: press tip switch about 1 second

00 h

➥ The telltale displays the error by means of the different lengths of the flashing signals (– see Overview of flashing codes on page 3-19)

74

☞ Error codes are read out as follows

Nr_7_2.iso

Fig. 46: Reading out the error code display

2

3

1

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

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

Warning limit – coolant temperature Error display

Caution!

Tip switch 74 comes on continuously

Coolant temperature 111 °C (see also temperature indicator 71 on the instrument panel)

Danger!

Tip switch 74 flashes

Tip switch 74 goes out

00 0290 174 1 – BA SCORPION

Coolant temperature 119 °C (see also temperature indicator 71 on the instrument panel) Coolant temperature below 109 °C (see also temperature indicator 71 on the instrument panel)

Troubleshooting

☞ Stop the machine as quickly as possible ☞ Read out the error with the ignition switched on ➥ – see Overview of flashing codes on page 3-19 ☞ Let the diesel engine run briefly at idling speed so it can cool down, then stop the engine ☞ Check the coolant level or fill up the coolant ☞ Check the cooling circuit for leaks ☞ Have repair work carried out by an authorised workshop if necessary

☞ Stop the machine and the diesel engine immediately ☞ Read out the error with the ignition switched on ➥ – see Overview of flashing codes on page 3-19 ☞ Check the coolant level or fill up the coolant ☞ Check the cooling circuit for leaks ☞ Have repair work carried out by an authorised workshop if necessary ☞ Start the diesel engine ☞ Check the cooling system for leaks and correct function

3-17

Operation Warning limit – charge-air temperature Error display

Tip switch 74 comes on continuously

Troubleshooting

Caution!

Charge-air temperature 95 °C

Dirty radiator ☞ Stop the machine and the diesel engine immediately ☞ Read out the error with the ignition switched on

➥ – see Overview of flashing codes on page 3-19 ☞ Clean the radiator from the engine side with compressed air or with the reversing fan (option) ☞ Have repair work carried out by an authorised workshop if necessary

Tip switch 74 flashes

Danger!

Charge-air temperature 110 °C

Very dirty radiator ☞ Stop the machine and the diesel engine immediately ☞ Read out the error with the ignition switched on

➥ – see Overview of flashing codes on page 3-19 ☞ Clean the radiator from the engine side with compressed air or with the reversing fan (option)

Tip switch 74 goes out

Charge-air temperature below 90 °C

☞ Have repair work carried out by an authorised workshop if necessary ☞ Start the diesel engine ☞ Check the cooling system for leaks and correct function

Warning limit – engine oil pressure Error display

Troubleshooting

Tip switch 74 comes on continuously

Caution!

Engine oil pressure too low

Tip switch 74 flashes

Danger!

No engine oil pressure

Tip switch 74 goes out

3-18

–

☞ Stop the machine and the diesel engine as quickly as possible ☞ Read out the error with the ignition switched on ➥ – see Overview of flashing codes on page 3-19 ☞ Fill up engine oil or replace it according to the maintenance plan ☞ Have repair work carried out by an authorised workshop if necessary ☞ Stop the machine and the diesel engine immediately ☞ Read out the error with the ignition switched on ➥ – see Overview of flashing codes on page 3-19 ☞ Fill up engine oil or replace it according to the maintenance plan ☞ Check the diesel engine for oil loss ☞ Have repair work carried out by an authorised workshop if necessary ☞ Start the diesel engine and check for correct function

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Operation Overview of flashing codes Flash code

Component

Description

1-2-3

Coolant temperature telltale

Open wiring or short circuit

1-2-6

Manual throttle

Open wiring or short circuit, signal not plausible

1-2-8

Charge-air temperature sensor

Open wiring or short circuit

1-3-3

Customer-specific sensor

Open wiring or short circuit (sensor 1)

1-3-3

Customer-specific temperature

Not within specified system reaction range (temperature 1)

1-3-4

Rail pressure

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

1-3-5

Fuel metering unit

Flow rate not within specified range

1-3-5

Oil pressure telltale

Open wiring or short circuit

1-3-6

Air filter

Pressure beyond specified system reaction range

1-3-7

Main relay

Short circuit (relay 1)

1-4-2

Engine operation telltale

Open wiring or internal error of control unit

1-4-3

Multiple position switch

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

1-4-4

Oil temperature sensor

Open wiring or short circuit

1-4-4

Oil temperature

Below specified system reaction range

1-4-5

Jumper switch

Jammed switch

1-4-6

Rail pressure relief valve

Opening error

1-4-7

Rail pressure sensor

Open wiring or short circuit

1-4-7

Rail pressure sensor

Signal divergence when starting or after run, beyond specified range

1-5-1

Several injectors

Short circuit (row of cylinders 1)

1-5-4

Separate injector

Short circuit (injector 1)

1-5-4

Separate injector

Open wiring (injector 1)

1-5-5

Separate injector

Short circuit (injector 2)

1-5-5

Separate injector

Open wiring (injector 2)

1-5-6

Separate injector

Short circuit (injector 3)

1-5-6

Separate injector

Open wiring (injector 3)

1-6-1

Separate injector

Short circuit (injector 4)

1-6-1

Separate injector

Open wiring (injector 4)

2-1-2

Revs sensor

Motor runs only with camshaft speed signal

2-1-2

Revs sensor

Bad or missing camshaft speed signal

2-1-2

Revs sensor

Bad or missing crankshaft speed signal

2-1-3

Revs sensor

Phase displacement of crankshaft and camshaft speed signals

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3-19

Operation 2-1-4

Overspeed

Overspeed due to error with system reaction

2-1-4

Overspeed

Overspeed in overrun (trailing throttle) with system reaction

2-1-6

Fuel low-pressure sensor

Open wiring or short circuit

2-1-6

Low fuel pressure

Below specified range with system reaction

2-1-9

Engine brake flap (actuator)

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

2-2-3

Charge-air pressure sensor

Open wiring or short circuit

2-2-3

Charge-air pressure

Not within specified range with system reaction

2-2-4

Oil pressure sensor

Open wiring or short circuit

2-2-5

Coolant temperature sensor

Open wiring or short circuit

2-2-6

Drive pedal/analog potentiometer

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

2-2-7

Fuel temperature sensor

Fuel temperature sensor: open wiring or short circuit

2-2-8

Fuel filter water level

Open wiring or short circuit

2-2-8

Water level in fuel filter

Beyond specified range

2-3-1

Oil pressure

Beyond specified range

2-3-1

Oil pressure

Below specified range

2-3-2

Coolant temperature

Not within specified range with system reaction

2-3-3

Charge-air temperature

Beyond specified system reaction range

2-3-5

Coolant level

Not within specified range with system reaction

2-3-7

Fuel temperature

Beyond specified system reaction range

2-3-8

Fan actuator

Fan actuator: open wiring or short circuit

2-3-8

Fan speed

Beyond specified system reaction range

2-4-1

Separate cylinder

Misfiring (cylinder 1)

2-4-1

Separate cylinder

Misfiring (cylinder 2)

2-4-1

Separate cylinder

Misfiring (cylinder 3)

2-4-1

Separate cylinder

Misfiring (cylinder 4)

2-4-1

Several cylinders

Misfiring

2-4-1

Misfiring

Misfiring with system reaction

2-6-1

Misfiring

Short circuit against earth or emergency stop (relay 2)

2-6-3

Preheating relay

Open wiring or short circuit

2-6-3

Preheating solenoid valve

Open wiring or short circuit

2-7-1

CAN bus switched off

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

2-9-2

Control unit, internal error

Defective environmental pressure sensor

3-1-8

Battery

Voltage below specified range

3-1-8

Battery voltage

Beyond specified system reaction range

3-20

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Operation 3-2-8

Preheating telltale

Open wiring or short circuit

3-4-1

Engine stop demand

Engine stop demand ignored by operator

4-1-4

EGR positioner (external)

Short circuit

5-1-2

Starting relay

Starting relay (+ side): short circuit

5-1-3

Diagnostics telltale

Open wiring or short circuit, prevented by control unit

5-1-4

Terminal 15

Ignition ON not detected

5-1-5

Terminal 50

Engine start, jammed switch

5-2-1

Machine speed signal

Speed over specified range, missing signal or not plausible

5-2-6

CAN message

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

5-2-8

Engine brake (internal)

Internal engine brake: open wiring or short circuit

5-3-1

Solenoid valve dwell period

Not within specified range or missing (cylinder 1)

5-3-2

Solenoid valve dwell period

Not within specified range or missing (cylinder 2)

5-3-3

Solenoid valve dwell period

Not within specified range or missing (cylinder 3)

5-3-4

Solenoid valve dwell period

Not within specified range or missing (cylinder 4)

5-5-5

Engine performance indication output

Engine performance indication output: open wiring or short circuit

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3-21

Operation 3.11 Key-based drive interlock (option) The drive interlock is integrated in the ignition lock and can be enabled only with the blue ignition keys!

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

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

Caution!

The 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

3-22

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Operation Enabling (locking) the drive interlock ☞ Apply the parking brake ➥ – see Parking brake on page 3-38 ☞ 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 3-15 “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 3-15

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

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

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

Safety functions The drive interlock remains enabled for 15 minutes and does not accept any valid keys if more than 5 keys with different invalid codes are inserted and turned in the ignition lock within 1 minute. This function avoids 'finding' the correct key by chance by trying different keys. It is only available if the control valve relay is connected in addition with terminal 30.

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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3-23

Operation 3.12 Drive interlock with code input (option) The drive interlock is enabled or disabled with “personal” codes entered via the keypad.

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

Caution!

LED

We recommend using the personal code for disabling the system. ☞ Keep the main code in a safe place.

Fig. 47: 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 telltale) • 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

3-24

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Operation Entering/changing the personal code 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 the ignition ON position

➥ The LED comes on for 2 seconds ☞ Enter the 4, 5 or 6-digit new personal code and confirm with the (*) key within

20 seconds 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 OFF 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.

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

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

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3-25

Operation Disabling the drive interlock ☞ Enter the personal code or main code (6 digits). ☞ Press the (*) key. ➥ Confirmation: 2 long acoustic signals, long LED flashing, LED OFF = drive interlock

is disabled ➥ Diesel engine can be started The diesel engine will not start if a wrong code has been entered ➥ Confirmation: 4 short acoustic signals, flashing LED = wrong code, re-enter the code ☞ Turn the ignition key and 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 ☞ The LED comes on briefly when turning the ignition key to the engine start position

3-26

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Operation 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 “ON” 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 the OFF position and remove it 7 The engine can be started without entering the code. The system is out of service even if electric power is interrupted.

Caution!

If the system is out of operation, the LED flashes slowly even if the ignition key is in the ON position. ☞ 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 service again”) to leave the out-of-service status again.

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

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

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

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

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

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

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

Protect the keypad and the control unit from heat and humidity

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3-27

Operation 3.13 Oil and fuel preheater (option) This equipment serves as a starting aid at temperatures below -5 °C and is located in the engine compartment, on the left in driving direction.

Oil preheater (option) The oil is heated by means of two heating elements with a capacity of 750 W in the engine oil circuit and in the hydraulic oil tank (according to the gravity principle: warm oil rises and is replaced by cold oil).

The oil can only be thoroughly warmed up to operating temperature if the oil preheater is connected over a longer period of time – preferably over night. ☞ Connect the oil preheater as follows: • Park the machine near a 220 V socket • First connect the special cable (supplied with the machine) with the machine socket, then insert the plug into the 220 V socket ☞ Before starting the engine: • Remove the plugs from the 220 V socket and from the machine socket • Close the engine cover ☞ Start the engine

Important!

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

Fuel preheater (option)

AU TO

93

OF F

A B Fig. 48: Switch for fuel preheater (option)

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

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

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

Important!

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

3-28

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Operation 3.14 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 ☞ Proceed as follows:

Flat battery

12 V

12 V Starting battery

• 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, remove the jump leads in the reverse order • In order to avoid sparking, first disconnect the cable on the – terminal, then the one on the + terminal

Fig. 49: Starting aid with jump leads 34001b710_05.eps

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3-29

Operation 3.15 Before moving off Special instructions for driving on public roads • The machine is subject to the applicable national legal regulations (e.g. StVZO German road traffic regulations) and to the provisions laid down in the General Certification for Vehicles (Germany), the data confirmation (Germany) or the machine certification papers • Read and understand the Operator's Manual under all circumstances before putting the machine into operation!

• Carrying or transporting persons in the cab or on the telehandler is not allowed!

• Only the attachments are certified for use on public roads that are described in the General Certification for Vehicles (Germany), the data confirmation (Germany), licence certificate or in this Operator's Manual on page 1-5 “Attachments with certified material densities” (the footnotes must be taken into account).

• Remove inadmissible attachments • Driving on public roads with a loaded attachment is prohibited!

• 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. Remove attachments.

• Dump in the quickhitch and the bucket as far as it will go and raise the telescopic boom to transport position ➥ – see Raising the telescopic boom to transport position on page 3-31 • Mount the front-edge protection on the leading edge of the bucket • Remove the protective screen (option) from the front window • Readjust the lights when fitting lightweight material buckets ➥ – see chapter 1 “Adjusting the headlights” on page 1-7 • Switch off the working lights when driving on public roads ➥ – see Working lights operation on page 3-48 • High speed version (25 – 40 kph): switch the steering system to front axle steering ➥ – see Changeover to front axle steering on page 3-34 • 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 3-31 • Switch on the load stabiliser ➥ – see Load stabiliser on page 3-43 • Fasten your seat belt ➥ – see Seat belt (lap belt) on page 3-55

Caution!

When driving downhill, use the brake pedal to support the braking effect of the drive. This avoids damage to the drive due to excessive engine speed. In addition, shift to 1st speed first on extremely steep slopes! ☞ – see Selecting the drive range 0 – 20 kph (30/40 kph option) on page 3-39

3-30

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Operation Carry out a functional check of brakes, steering system and lights • • • •

– see Steering system on page 3-32 – see Brake/inching pedal on page 3-37 – see Machine lights on page 3-47 – see Signalling system on page 3-49

Raising the telescopic boom to transport position Telescopic boom operation – see Operating the telescopic boom on page 3-68 ☞ Empty and dump in the bucket

B

➥ – see Working with the standard bucket on page 3-73 ☞ Retract the telescopic boom fully and raise it to transport position until the red marks B on the telescopic bomm and the frame coincide

➥ – see Telescopic boom control lever: overview on page 3-63 ➥ If both marks B coincide, ground clearance in connection with the standard bucket

and standard tyres is about 200 mm. ☞ Cover the blade or teeth of the bucket across their entire width with the protection provided

200 mm A Fig. 50: Transport position

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

13

B

A

Danger!

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

The lock (stop cock) for the control lever (joystick) is located on the console of the control lever base to the right of the seat.

Locking the control lever (joystick): ☞ Push stop cock 13 lever forwards A

➥ The control valve is cut off from the hydraulic oil circuit C 95 A B Fig. 51: Control lever lock

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Unlocking the control lever (joystick): ☞ Push stop cock 13 lever backwards B

➥ The control lever (joystick) is connected with the hydraulic oil circuit Locking the 3rd control circuit: As soon as an attachment is picked up with the quickhitch, the 3rd control circuit is automatically secured to avoid unlocking the attachment. However, it must be fully locked when driving on public roads. ☞ Slide lock C on switch 95 in the direction of the arrow and press the switch to position A at the same time ☞ Release lock C ➥ 3rd control circuit is fully locked – see Operating and securing the 3rd control circuit on page 3-64

3-31

Operation 3.16 Steering system Steering column height and angle adjustment The steering column height and angle can be set to the driver's individual size.

5

Danger!

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. 52: Steering column adjustment

Function Height adjustment

Angle adjustment

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

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

Important!

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)

3-32

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Operation Synchronising the steering system Danger!

Do not synchronise the steering system when driving on public roads –

☞ Synchronise the steering system before driving on public roads

67

101

A

B

Fig. 53: Steering synchronisation

103

104

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

Synchronisation is over as soon as both steering rams of the front and rear axles have passed through the straight-ahead position from both directions. Telltale 67 on the instrument panel goes out

Important!

Only the work range is active during synchronisation – telltale 67 on the instrument panel flashes!

The drive range (switch 104) can be selected but is not active until synchronisation is over.

If the wheels of the machine no longer follow the same track when driving straight-ahead on level ground, the steering system must be synchronised.

Tip switch 103 for steering synchronisation is on the switch console on the right. ☞ Proceed as follows: • Switching from front axle steering to 4 wheel steering with switch 101 in position A: • Press switch 104 to position A (selects the work range) • Drive at walking pace on level ground and press tip switch 103 to position B • Drive on at walking pace while steering to the left and right until telltale 67 goes out ➥ The wheels of the front and rear axles are parallel to each other (synchronised) • Carry out a functional check of the steering system and select the steering mode ➥ – see Changeover to front axle steering on page 3-34 ➥ – see Changing over to 4 wheel steering on page 3-34 ➥ – see Changing over to diagonal steering (crab steering option) on page 3-35

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3-33

Operation Changeover to front axle steering

65

64

Danger!

66

Do not change the steering mode when driving the machine, and on public roads!

101

S

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

A

☞ Slide lock S in switch 101 in the direction of the arrow and press the switch to position A

B Fig. 54:

Steering mode selection (front axle steering)

at the same time ☞ Release lock S ☞ Turn the steering wheel to the left and/or right until the wheels of the front and rear axles have passed through the straight-ahead position from both directions

➥ Telltale 64 for front axle steering comes on ➥ Telltales 65 (4 wheel steering) and 66 (diagonal steering, option) go out ➥ Front axle steering is in operation

Changing over to 4 wheel steering Danger!

65

64

66 S

101

A

☞ Slow down the machine to less than 20 kph under all circumstances ☞ Speed is automatically reduced to 20 – 30 kph if the machine is equipped with the high speed option

☞ Slide lock S in switch 101 in the direction of the arrow and press the switch to position B

B Fig. 55:

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

Steering mode selection (4 wheel steering)

at the same time ☞ Release lock S ☞ Turn the steering wheel to the left and/or right until the wheels of the front axle have passed through the straight-ahead position from both directions

➥ Telltale 65 for 4 wheel steering comes on ➥ Telltales 64 (front axle steering) and 66 (diagonal steering, option) go out ➥ 4 wheel steering is in operation

3-34

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

Driving in diagonal steering mode (crab steering) on public roads is prohibited!

☞ Change over to 4 wheel steering mode, or to front axle steering in the case of the optional high speed mode, before driving on public roads! ☞ – see Changing over to 4 wheel steering on page 3-34or“Changeover to front axle steering” on page 3-34

Caution!

65 101

64 S

66 102

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

☞ Slide lock S in switch 101 in the direction of the arrow and press the switch to position A A

B Fig. 56:

Steering mode selection (diagonal steering)

at the same time ☞ Release lock S ☞ Slide lock S in switch 102 in the direction of the arrow and press the switch to position B at the same time ☞ Release lock S ☞ Turn the steering wheel to the left and/or right until the wheels of the front and rear axles have passed through the straight-ahead position from both directions

➥ Telltale 66 for diagonal steering comes on ➥ Telltales 64 (front axle steering) and 65 (4 wheel steering) go out ➥ Diagonal steering (crab steering) is in operation

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3-35

Operation 3.17 Accelerator pedal Accelerator pedal Fig. 29/11 controls the drive speed as follows:

☞ Press the accelerator pedal down ➥ Drive speed is increased ☞ Release the accelerator pedal slowly ➥ Drive speed is reduced ☞ Release the accelerator pedal fully ➥ Hydrostatic braking

Important!

Maximum speed depends on the speed range selected.

• – see Selecting the drive range 0 – 20 kph (30/40 kph option) on page 3-39

3.18 Manual throttle (option)

A B

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

Mechanical manual throttle • The manual throttle is located on the right of the side console Electronic manual throttle (103 kW diesel engine only) • Manual throttle 73 (potentiometer) is installed on the instrument panel

Danger!

In order to avoid danger of accidents, setting engine speed with the manual throttle is prohibited when driving on public roads!

Fig. 57: Mechanical manual throttle (option)

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

Position A

A

Engine speed Idling speed = minimum engine speed

B

Full throttle = maximum engine speed

73 B Fig. 58: Electronic manual throttle (option)

3-36

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Operation 3.19 Brake/inching pedal Specific information 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 pedal can result in brake malfunctions.

• Keep the brake/inching pedal clean and remove all objects in the area of the pedal • Caution when stopping on slopes: press brake/inching pedal Fig. 29/40 down with force until the braking effect is felt

Danger!

The brake lights at the rear of the machine neither come on when applying the parking brake, nor when braking hydrostatically with the drive.

☞ Press the brake/inching pedal down with force in order to brake the machine

Inching with the brake/inching pedal ☞ Press brake/inching pedal Fig. 29/40 down slightly ➥ In the inching range of the brake pedal (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

Braking with the brake/inching pedal ☞ Check before moving off: • Whether after half the pedal travel, there is a firm resistance to be felt, and whether the brake lights come on when pressing the brake pedal.

• Check by looking back in the rearview mirror that no-one is hindered by the brake manoeuvre.

• Press the brake/inching pedal Fig. 29/40 down at slow speed and check the brake effect

Caution!

When driving downhill, the brake pedal must be used to support the braking effect of the drive. This avoids damage to the drive and/or the diesel engine due to excessive speed. ☞ Reduce engine speed: remove your foot from the accelerator pedal ☞ Reduce your drive speed with the brake/inching pedal

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3-37

Operation 3.20 Parking brake General information on the parking brake Important!

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

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

Applying the parking brake S

Danger!

A

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

☞ Only apply the parking brake in an emergency if the service brake breaks

B 100

53

down ☞ The brake lights do not come on in this case ☞ In normal operation only use brake/inching pedal Fig. 29/40 as a service brake

Apply the parking brake The switch is located on the switch console on the right ☞ Press lock S in switch 100 in the direction of the arrow and at the same time, press the switch to position B

➥ Telltale 53 on the indicating instrument comes on ➥ Selection of forwards/reverse driving direction (drive) is automatically cancelled and

Fig. 59: Parking brake

neutral activated ➥ The engine can be started Releasing the parking brake ☞ Press lock S in switch 101 in the direction of the arrow and at the same time, press the switch to position A

➥ Telltale 53 on the indicating instrument goes out ➥ The machine is ready to move off

Caution!

If telltale 53 does not go out with the engine running and the parking brake released, or if this telltale comes on when driving or working with the machine – Possible boost pressure loss in the drive! ☞ Stop the machine immediately to avoid damage ☞ Stop the engine ☞ Apply the parking brake ☞ Have the error repaired by an authorised workshop

3-38

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Operation 3.21 Moving off the telehandler Selecting the drive range 0 – 20 kph (30/40 kph option)

120 64 115

S

Selecting the speed range

(0 – 7 kph)

☞ Press switch 104 to position A ☞ Select the required driving direction with switch 120 on the control lever (joystick)

Joyst ic. iso

101

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: ☞ Set the driving direction to neutral with tip switch 115 on the control lever

104

A

B

Selecting the speed range

(0 – 30 kph or 0 – 40 kph option)

☞ Press switch 104 to position B ☞ Select the required driving direction with switch 120 (on the joystick)

Important!

The 40 kph speed range is active only if front axle steering is switched on.

Fig. 60: Switch for speed range selection

☞ Press switch 104 to position B ☞ Press lock S in switch 101 in the direction of the arrow and at the same time, press the switch to position B ☞ Release lock S

➥ Front axle steering is enabled ➥ Also refer to “Changeover to front axle steering” on page 3-34 ☞ Select the required driving direction with switch 120 on the control lever Symbol

Drive speed

Recommended

Speed range = 0 – 7 kph

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

Drive range = 0 – 30 kph (standard) Drive range = 0 – 40 kph (option)

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For long-haul travel

3-39

Operation Changing direction (forwards/reverse) ☞ Release parking brake Fig. 35/100 ☞ Select the driving direction with switch 120 on the control lever (joystick) ➥ Telltales 68 or 69 come on ☞ Slowly press accelerator pedal Fig. 29/11 ➥ Machine moves off ☞ Test the brakes at low speed

F 120 R

Important!

115

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

• The telltale flashes at speeds over 12 kph

Joystic.iso

68

Fig. 61: Changing direction

69

☞ Reduce engine speed ☞ Slow down your drive speed to less than 12 kph ☞ Select the new driving direction with switch 120 on the control lever as follows: Driving direction

Operation

Telltale

Forwards

Press switch 120 on the control lever (joystick) forwards F

Telltale 68 comes on

Reverse

Press switch 120 on the control lever (joystick) backwards R

Telltale 69 comes on

Neutral

Press tip switch 115 on the conTelltale 68/69 goes out trol lever (joystick)

Caution!

When driving downhill, use the brake pedal to support the braking effect of the drive and/or the diesel engine. This avoids damage (excessive speed) to the drive and/or the diesel engine! ☞ Reduce engine speed: remove your foot from the accelerator pedal ☞ Reduce your drive speed with the service brake

3-40

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

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

The crawler gear potentiometer 75 is active only if the drive range

is selected.

☞ Press switch 104 to position A ☞ Continuous setting of the drive speed with crawler gear potentiometer 75 Symbol

75 A

104

Drive speed

Recommended

Speed range = 0 – 7 kph

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

Drive range = 0 – 20 kph (standard) Drive range = 0 – 30 kph (option)

B Fig. 62: Crawler gear potentiometer

For long-haul travel

Drive range = 0 – 40 kph (option)

Important!

Once the function is no longer needed, set crawler gear potentiometer 75 to “Hare” for maximum speed in normal operation.

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3-41

Operation 3.22 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 – see Parking brake on page 3-38! ☞ In addition to the parking brake, secure the machine by placing chocks under the downhill sides of the wheels!

☞ Reduce engine speed: remove your foot from the accelerator pedal ☞ Stop the machine with the service brake ☞ Set the machine to neutral with tip switch (Fig. 34/115) on the joystick ☞ Press the parking brake switch – see Parking brake on page 3-38 ☞ Lower the telescopic boom completely and set the bucket horizontally with the ground – see Operating the telescopic boom on page 3-68

☞ Stop the engine. To do this: turn the ignition key to “0” and remove it ➥ The drive interlock (option) is enabled

Caution!

After operation at full power: ☞ Allow the engine to run for a while so that the temperature can stabilise, then stop the engine

☞ Close and lock the windows and the door as you leave the cab ☞ Lock the engine cover securely ☞ Remove the key from the battery master switch

– see Battery master switch on page 3-16 On slopes: Additionally secure the machine by placing chocks under the downhill sides of the wheels

Decommissioning the machine for a longer time ☞ If possible, retract the piston rods of the hydraulic rams to protect them against

damage. If this is not possible, apply grease to the piston rods and to the bare parts of the hydraulic rams that are not paint-coated ☞ Before putting the machine into operation, do not clean the piston rods with a grease solvent or a high-pressure cleaner

➥ The scraper is not water-tight ➥ Water in the guide bushing causes corrosion and damage to the piston rod

3-42

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Operation 3.23 Load stabiliser General instructions 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!

Important!

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

In order not to impair the load stabiliser function in transport position of the telescopic boom, do not retract the tilt ram to the limit!

• Briefly release the hydraulic pressure on the tilt ram after tilting in the bucket

Caution!

Switching on the load stabiliser automatically switches off the hose burst valve, and the hydraulic lines and pipes are no longer protected against possible damage! ☞ Telltale 63 on the instrument panel comes on ☞ – see “Hose burst valve” safety feature on page 3-98 ☞ Switch off the load stabiliser during pallet forks operation

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3-43

Operation Switching the load stabiliser ON or OFF Switch 99 for the load stabiliser is located on the switch console on the left 99 63 A B

AUTO

Important!

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

• Switch off the load stabiliser during pallet forks operation

OFF

C Fig. 63: Switch for load stabiliser (option)

Automatic load stabiliser function For driving on public roads, for lighter work with the telescopic boom and for light off-road transport ☞ Press switch 99 to position A

➥ The load stabiliser is automatically switched on if the machine moves faster than

7 kph ➥ Telltale 63 on the instrument panel comes on (the hose burst valve is switched off) Load stabiliser in continuous operation ☞ Press switch 99 to position C

➥ The load stabiliser is immediately in continuous operation (no drive speed control) ➥ Telltale 63 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 ☞ Press switch 99 to centre position B

➥ The load stabiliser is switched off ➥ Telltale 63 on the instrument panel goes out (the hose burst valve is switched on)

3-44

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Operation 3.24 Differential lock Important information on the differential lock The 100 % front axle differential lock neutralises the compensating effect of the differential, i.e. traction is distributed evenly to both front wheels.

Caution!

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

Switching the differential lock ON and OFF

119

61

Switching on the differential lock In order to avoid damage to the differential lock when switching it on, it can only be enabled by pressing tip switch 119 on the control lever and the brake/inching pedal! ☞ Stop the machine ☞ Press and hold tip switch 119 on the control lever ☞ Press the brake/inching pedal 29/40 briefly (3 – 5 sec) until telltale 61 on the instrument panel comes on

➥ The differential lock is enabled ☞ Carefully move off the machine with tip switch 119 pressed Joystic.iso

Fig. 64: Tip switch for differential lock

Switching off the differential lock ☞ Reduce drive speed and engine speed ☞ Release tip switch 119 on the control lever

➥ Telltale 61 on the instrument panel goes out, the differential lock is disabled

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3-45

Operation 3.25 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!

Do not rely on the backup warning system when reversing with the machine!

☞ Make sure nobody is within the danger area of the machine when changing the driving direction!

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

U F

R

L R D

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

Switch 83 is located on the right-hand side console ☞ Turn the switch to position F (right-hand side mirror) ☞ Turn the switch to position R (rear mirror) ☞ Press the switch laterally to position ...

➥ U = mirror moves upwards ➥ D = mirror moves downwards ➥ R = mirror moves to the right L = mirror moves to the left

Fig. 65: Electric mirror adjustment (option)

3-46

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Operation 3.27 Machine lights General instructions regarding the machine lights The machine lights (main headlights) can be equipped with optional screens for protection against damage (falling rocks).

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

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

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

Parking lights ☞ Press switch 85 to the ON 1st position B OFF ☞ Press switch 85 to position A

48

A

Low beam ☞ Press switch 85 to the ON 2nd position B OFF ☞ Press switch 85 to position A

➥ Telltale in switch comes on ➥ Telltale in switch goes out

➥ Telltale in switch comes on ➥ Telltale in switch goes out

B

Important!

43

85

II I

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

0

I

II

Fig. 66: Machine lights

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Lenkst ockscha lt _li .i so

High beam ☞ With low beam switched on, pull ➥ High beam and telltale 48 on the ON lever 43 to position II towards the indicating instrument come on steering wheel and release ☞ Pull lever 43 to position II towards ➥ High beam and telltale 48 on the OFF the steering wheel and release indicating instrument go out Headlight flasher ☞ Pull lever 43 briefly upwards to ➥ High beam and telltale 48 on the ON position I indicating instrument come on

3-47

Operation Working lights operation Danger!

The working light can dazzle motorists on public roads.

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

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

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

88

89

A

B Fig. 67: Working light switch

Front and/or rear working lights on the cab (option) ☞ Press switches 87 and/or 88 to ➥ Telltale in switch comes on ON position B ☞ Press switches 87 and/or 88 to ➥ Telltale in switch goes out OFF position A Front boom working light (option) ➥ Telltale in switch comes on ON ☞ Press switch 89 to position B OFF ☞ Press switch 89 to position A

➥ Telltale in switch goes out

Interior light operation (cab) Interior light without door contact ☞ Switch to the left L

14

L

0 T Fig. 68: Switch for interior light

➥ Interior light ON (continuous operation)

☞ Move the switch to the centre position 0 ➥ Interior light OFF Interior light with door contact (option) ☞ Switch to the right D

➥ The interior light is switched ON and OFF by opening and closing the door (door contact)

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

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Operation 3.28 Signalling system Turn indicator operation l

43

62

R

Turn indicators ☞ Push lever 43 forwards R RIGHT

➥ Telltale 62 on the

☞ Pull lever 43 to the rear L

➥ Telltale 62 on the

LEFT

instrument panel flashes instrument panel flashes

0

Caution!

I II

Lenkstockschalt_li.iso

The turn indicator system is not in order if telltale 62 flashes about twice as fast as normally! ☞ Check the front and rear turn indicators immediately ➥ Have the turn indicator system repaired if necessary

L Fig. 69: Turn indicators

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

62

Hazard warning system ☞ Press hazard warning switch 84 to ➥ The telltale in the switch and telltale ON position B 62 both flash ☞ Press hazard warning switch 84 to ➥ The telltale in the switch and telltale OFF position A 62 both go out

A B Fig. 70: Switch for hazard warning system

Rotating beacon operation (option) The switch is located on the switch console on the left Rotating beacon (option) ON ☞ Press switch 86 to position B

➥ Telltale in switch comes on

OFF ☞ Press switch 86 to position A

➥ Telltale in switch goes out

86

Important!

A B Fig. 71: Switch for rotating beacon

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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.

3-49

Operation 3.29 Cab heating and ventilation Operation of the heating and ventilation system The air flow is guided to the front window via the two defroster vents Fig. 29/3, to one leg room vent and to the rear window via the two defroster vents Fig. 29/20.

Each nozzle can be closed and directed separately.

Important!

The machine heater can be set to 4 operating modes: • Ventilation, fresh air • Heating, fresh air • Ventilation and heating in mixed mode • Ventilation and heating in recirculated-air mode

79

80

Fig. 72: Heating switches

29

D E

Rotary switches 79/80 are located on the heating switch console on the right.

Rotary switch 29 is located on the side console on the left next to the seat. ☞ Ventilation, fresh air • Rotary switch 80 in positions 1 – 3 • Rotary switch 29 in position D ☞ Heating, fresh air • Rotary switch 80 in positions 1 – 3 • Set rotary switch 79 to the required temperature C = cold/W = warm • Turn rotary switch 29 fully to position D ☞ Ventilation and heating in mixed mode • Rotary switch 80 in positions 1 – 3 • Set rotary switch 79 to the required temperature C = cold/W = warm • Turn rotary switch 29 to between positions D and E ☞ Ventilation and heating in recirculated-air mode • Rotary switch 80 in positions 1 – 3 • Set rotary switch 79 to the required temperature C = cold/W = warm • Turn rotary switch 29 fully to position E

D

E Fig. 72: Mixed mode switch

3-50

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Operation 3.30 Air conditioning (option) Air conditioning operation The air conditioning system supplies cool and dehumidified air to the cab during the hot season.

107

Important!

A

B Fig. 73: Air conditioning switch

Close the door and the windows to achieve best air conditioning results.

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

➥ Telltale in switch comes on ➥ Air conditioning in operation

Important!

The air conditioning system allows you to select the 4 same operating modes as for normal heating and ventilation!

• – see Ventilation, fresh air on page 3-50 • – see Heating, fresh air on page 3-50 • – see Ventilation and heating in mixed mode on page 3-50 • – see Ventilation and heating in recirculated-air mode on page 3-50

Caution!

In order to avoid functional errors and possible loss of the refrigerant: ☞ run the air conditioning system once a month • This prevents the seals in the compressor from drying and becoming brittle ☞ Check V-belt tension – see chapter 5 “Air conditioning (option): maintenance” on page 5-32 ☞ Clean the condenser – see chapter 5 “Air conditioning (option): maintenance” on page 5-32 ☞ The air conditioning system must be repaired, serviced and filled with a refrigerant by trained staff and an authorised workshop only

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3-51

Operation 3.31 Washer system Washer system operation Front window wiper ☞ Turn rotary switch 121 on the ON lever to the first position ☞ Turn rotary switch 121 on the ON lever to the second position ☞ Turn rotary switch 121 on the OFF lever fully back

121

➥ Intermittent wipe ➥ Continuous wiping ➥ Wipers return to base position

Fig. 74: Switch for front and rear wipers

Front window washer pump ON ☞ Press rotary switch 121 on the lever to the right A and hold

A

OFF ☞ Release rotary switch 121 on the lever 121 Fig. 75: Washer pump

105

A

Rear wiper ON ☞ Press switch 105 to position B

➥ Rear wiper is on

OFF ☞ Press switch 105 to position A

➥ Rear wiper returns to base position

Rear window washer pump OFF ☞ Press switch 105 beyond position B (tip switch function)

B Fig. 76: Rear wiper switch

Tank for washer system Tank filler inlet 35 is located in the cab underneath the cover on the left next to the seat

Important!

35

Fill with clean tap water only!

Add a suitable cleaning agent if required.

In winter: add antifreeze for washer systems to the water. Refer to the antifreeze instructions for further information on concentrations.

• – see chapter 5 “Fluids and lubricants” on page 5-51

Fig. 77: Tank for washer system

3-52

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Operation 3.32 Seat Seat adjustment: overview Always adjust the seat to your individual needs. This will help avoid or minimise physical disorders related to bad posture

Danger!

Never change the seat position when driving or working!

☞ Adjust the seat before moving the machine ☞ Make sure the levers for seat adjustment are safely engaged

a

b

c

d

e

The seat can be set to the following positions: • Horizontal adjustment without control lever base a • Weight adjustment b (height adjustment with air suspension, option) • Weight indication c • Longitudinal adjustment with control lever base d (option) • Backrest adjustment e

Fig. 78: Seat adjustment

Weight adjustment Important!

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

c

Fig. 79: Weight adjustment

☞ Sit down on the seat To adjust to a higher weight: ☞ 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

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3-53

Operation Height adjustment (air-suspension seat, option) The air-suspension seat height can be adjusted continuously ☞ Pull or press lever b (arrow)

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

Caution! b

Do not run the air compressor longer than 1 minute to avoid damage!

Fig. 80: Weight adjustment

Backrest adjustment ☞ Sit down on the seat ☞ Pull lever e up and at the same time ☞ Lean back to push the backrest into the required position ☞ Allow lever e to engage

e

Fig. 81: Backrest adjustment

Horizontal adjustment With control lever base ☞ Sit down on the seat ☞ Pull lever d up and at the same time ☞ Move the seat forwards or backwards

➥ The control lever base is adjusted as well ☞ Allow lever d to engage in required position Without control lever base ☞ Sit down on the seat ☞ Pull lever a up and at the same time ☞ Move the seat forwards or backwards

d

➥ The control lever base remains in its position ☞ Allow lever a to engage in required position

a Fig. 82: Horizontal seat adjustment

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Operation 3.33 Seat belt (lap belt) Specific instructions regarding the seat belt Danger!

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

☞ Buckle up before moving or working with the machine!

• Seat belt must not be twisted!

• 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 seat belts regularly. Have damaged parts 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!

Fastening the seat belt 31 A

B

The seat belt is for the driver's safety during work on construction sites and during road travel. ☞ Fasten seat belt 31 as follows before moving off: ☞ Hold the belt at buckle latch A and run it slowly and steadily over the hips to buckle B ☞ Insert buckle latch A into buckle B until it engages audibly (pull test) ☞ Tighten the seat belt by pulling at its end

➥ The seat belt must always be tightly in place over the hips!

0763b0007.eps Fig. 83: Fastening the seat belt

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3-55

Operation Unfastening the seat belt Unfasten seat belt 31 as follows: ☞ Hold the seat belt ☞ Press red button C on buckle B

➥ Latch A is released from buckle B by spring action A

☞ Slowly return the seat belt to the retractor (option)

C B 30763b0006.eps Fig. 84: Unfastening the seat belt

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

A

• 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

Important!

D

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

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

30763b0005.eps Fig. 85: Longer/shorter seat belt adjustment

3-56

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Operation 3.34 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 the inspection tag ☞ Remove the fire extinguisher from the cab in an emergency only ☞ After the fire extinguisher has been used: have it filled by an authorised workshop, or replace it with a new one

Fig. 86: Fire extinguisher (option)

3.35 Reversing fan (option) 106 A

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

Tip switch 106 for automatic cleaning is located on the instrument panel on the right ☞ Cleaning the radiator – see chapter 5 “Cleaning the radiator with the reversing fan (option)” on page 5-14

B Fig. 87: Reversing fan

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3-57

Operation 3.36 Towing the machine Safety instructions for towing away • 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!

• Make sure 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 Disable the variable displacement pump (neutral position) ☞ Apply the parking brake ☞ Stop the diesel engine ☞ Switch off ignition and remove the ignition key ☞ Switch over HP relief valves B on the hydraulic pump A to towing. To do this: ☞ Unscrew the HP valves B 3 – 4 turns with an allen key

B

A

Caution!

Fig. 88: Disabling hydraulic pump TMP 89

Reset the variable displacement pump to drive operation once towing the machine is over! ☞ – see Once towing is over on page 3-59

A B

Fig. 89: Disable hydraulic pump H1 P 078

1

A Fig. 90: Releasing the parking brake for towing

3-58

Disabling (releasing) the brake discs in the front axle If the diesel engine or the hydraulic pump breaks down, the brake discs in the axle are automatically enabled (spring-loaded brake system is blocked)!

The spring-loaded brake system must be opened mechanically in order to be able to tow away the machine. ☞ Slacken lock nut A on set screw 1 (2 on either side of the axle tube) with a hexagon socket spanner (13 mm) and unscrew by about 8 mm ☞ Evenly screw in set screws 1 (2 on either side of the axle tube) alternately until you can feel a resistance ☞ Evenly screw in set screws 1 (2 on either side of the axle tube) alternately by a max. 1 turn against the pressure of the spring-loaded brake

➥ The service brake is released

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Operation Towing the machine B

Danger!

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

☞ If the diesel engine is broken down, tow the machine only with a towing bar ➥ See chapter “Specifications” on page 6-1 for the machine's dimensions

A

and weights! ☞ Eye hooks for towing the machine – see chapter 1 “Machine overview” on page 1-2 ☞ If possible, run the diesel engine at idling speed when towing the machine ➥ Steering and braking requires greater effort if the diesel engine breaks down. ☞ Tow away the machine from the danger area only after you have opened the HP pressure relief valves and the brake discs ➥ Towing distance and speed => max 300 m at a max. 8 kph

Fig. 91: Disabling hydraulic pump TMP 89

A B

Fig. 92: Disable hydraulic pump H1 P 078

Once towing is over

1

Enabling drive A (variable displacement pump) ☞ Screw in high pressure valves B by 3 – 4 turns and tighten the locknut to 85 Nm (see Fig. 91 or Fig. 92) Enabling the brake discs in the front axle

30 mm

Danger!

A Fig. 93: Releasing the parking brake for towing

After having been opened mechanically, the brake discs in the axle must be enabled once towing is over.

☞ Unscrew set screws 1 (2 on either side of the axle tube) evenly and alter-

nately until reaching 30 mm between the end of the screw head and the contact area (lock nut – axle tube) ☞ Secure the set screw with lock nut A (2 on either side of the axle tube) ➥ Important! Do not modify the dimension of 30 mm as you secure the set screw ➥ The service brake is enabled Once you have enabled the parking brake: ☞ Check the service and parking brake for correct function

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3-59

Operation 3.37 Loading and transporting the telehandler on a transport vehicle General safety instructions regarding loading • The transport vehicle must be of adequate size • See chapter “Weights” on page 6-11 for the telehandler's dimensions and weights!

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

• When placing the load on the platform, make sure the load is at the lowest possible position and that the centre of gravity of the load is in the centre line of the 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.

• Make sure the load does not fall short of the minimum axle load of the steering axle, otherwise the steering behaviour of the transport vehicle is affected • Place partial loads so as to ensure an even load on all axles.

• Store or secure the load 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.

• Use auxiliary means such as anti-slip bases and linings, load-securing straps and chains, clamping beams, protective paddings, nets, edge protectors • 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.

• Depending on the load, adapt your drive speed to the road and traffic conditions and to the handling of the transport vehicle.

• Always use the existing lashing points when using belts and chains – see chapter 1 “Machine overview” on page 1-2.

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

3-60

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Operation Loading and tying down the machine Danger!

The machine must be loaded and transported properly, otherwise there is danger of accidents!

☞ Use only suitable means of transport and lifting gear of adequate

capacity/payload! ☞ Safely secure the machine on means of transport! Use suitable slinging points and load-securing devices! ➥ – see chapter 1 “Machine overview” on page 1-2

☞ Load as follows: • • • •

20˚ 30864brampe.eps

Fig. 94: Access ramps

Fig. 95: Tying down the telehandler

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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.

Make sure the loading area is clear and access to it is not obstructed – e.g. by superstructures • Make sure 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 engine of the machine • Raise the telescopic boom enough so that it will not touch the access ramps • Carefully drive the machine onto the middle of the transport vehicle • Set the drive to neutral – see Changing direction (forwards/reverse) on page 3-40 • Lower the telescopic boom to the loading area • Stop the engine • Apply the parking brake – see Parking brake on page 3-38 • Remove the ignition key • Do not allow anyone to stay in the cab, lock the door and the engine cover ☞ Tie down the machine as follows: • Make sure the authorised maximum height is not exceeded • 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 1-2 – with sufficiently dimensioned belts or chains onto the platform • Before transporting the machine through heavy rain: close the outlet of the exhaust silencer with a simple cap or suitable adhesive tape • Make sure 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!

3-61

Operation 3.38 Crane handling the machine Safety instructions regarding crane handling • The crane and the lifting gear must have suitable dimensions ➥ Overall weight of machine – see chapter 6 “Weights” on page 6-11 • Secure the machine against unintentional movement!

Crane handling Danger!

Bear in mind the following instructions when crane handling the machine!

Danger of accidents! ☞ Make sure no-one is in the machine! ☞ Have loads fastened and crane operators instructed by experienced per-

sons only! The person giving the instructions to the crane operator must be within sight or sound of him ☞ Make sure the crane and the lifting gear (cables, chains) have sufficient load-bearing capacity. ☞ Load the machine only with the standard bucket empty and in transport position! ☞ 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! ☞ The slinging points are marked with the symbol A

☞ Load the machine as follows • Mount and safely lock the standard bucket – see Equipping the machine with a standard bucket on page 3-70 • Empty and dump in the standard bucket, and lower it to transport position – see Special instructions for driving on public roads on page 3-30 • Set the drive to neutral – see Changing direction (forwards/reverse) on page 3-40 • Stop the engine and remove the ignition key • Apply the parking brake – see Parking brake on page 3-38 • Lock the cab and the engine cover • Fasten the machine at the 4 slinging points A with sufficiently dimensioned lifting gear – see chapter 1 “Machine overview” on page 1-2

Caution!

A Fig. 96: Label for crane handling

3-62

B

Do not use the slinging points B on the cab for loading the machine – see chapter 1 “Machine overview” on page 1-2.

• Carefully raise the machine

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Operation

Operation 3.39 Telescopic boom control lever: overview Operating the control lever for the lift, tilt and push-out rams 118

Danger!

Before leaving the seat, and when driving on public roads, lock the control lever for the telescopic boom and the 3rd control circuit (quickhitch) against unintentional actuation!

117 C

☞ Lock the control lever (joystick) and the 3rd control circuit ➥ – see Locking the control lever (joystick) and the 3rd control circuit

B

A

116

(attachments) on page 3-31

D

➥ – see Operating and securing the 3rd control circuit on page 3-64

Important!

12 Joystic.iso

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

Fig. 97: Control lever for telescopic boom

Position Operation

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Function

A

To the left

Tilts in the attachment

B

To the right

Dumps out the attachment

C

Forwards

Lowers the telescopic boom

D

Backwards

Raises the telescopic boom

116

Potentiometer wheel

Retracts and extends the telescopic boom

117

Tip switch

Front socket for attachment (option) or bucket repositioning (option)

118

Switch

3rd control circuit for locking and unlocking the quickhitch or for hydraulic attachment

3-63

Operation 3.40 Operating and securing the 3rd control circuit Locking and unlocking the quickhitch or an attachment Important!

The attachment locked onto the quickhitch is secured against unintentional operation of tip switch 118 on the control lever. The attachment can only be unlocked by pressing switch 98 in addition.

118

98 AUTO

OFF

C A Joystic. iso

B 95 55 Fig. 98: Operation of 3rd control circuit

Unlocking the 3rd control circuit ☞ Slide lock C in switch 95 in the direc- ➥ Telltale 55 comes on tion of the arrow and press it to ➥ 3rd control circuit is unlocked position B ☞ Release lock C Locking the attachment ☞ Scroll wheel 118 (on the control ➥ The attachment is locked in the quickhitch lever) upwards and automatically secured against unlocking Unlocking the attachment ☞ Press switch 98 and scroll wheel 118 ➥ The attachment on the quickhitch is (on the control lever) downwards at unlocked the same time 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 Fitting a standard bucket onto the quickhitch on page 3-71 ) ➥ – see Picking up a multipurpose bucket with the quickhitch on page 3-80 ➥ – see Switching continuous operation of 3rd control circuit ON/OFF on page 3-102

Releasing the pressure on the quick couplers 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. ➥ – see Pressure relief on the quickhitch couplers on page 3-70

3-64

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Operation 3.41 Safe load indicator for telescopic boom General safety instructions regarding the safe load indicator The safe load indicator has been installed for bucket and pallet forks operation with varying reaches (telescopic boom according to DIN EN 1459).

It is equipped with an electronic load indicator for continuously monitoring weight changes on the rear axle during operation (the indicator is installed inside the cab at the upper right.)

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

Caution!

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!

Lateral loads are not monitored by the safe load indicator.

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

☞ Reduce the load immediately by retracting and lowering the telescopic

boom! ☞ Work carefully! Adapt your drive speed and loads to the terrain. ☞ Refer to the load diagram for the maximum authorised loads! ➥ Load diagram for pallet forks (EN 1459/1998)Load diagram for pallet forks (EN 1459/1998) – see Load diagram for pallet forks (EN 1459/1998) on page 3-94

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3-65

Operation Safe load indicator display Danger!

A defective safe load indicator or working at more than 100 % of the safe work load can cause the machine to tip over. Do not rely on the safe load indicator when working off-road!

☞ Work carefully! Adapt your drive speed and loads to the terrain. Refer to the load diagram for the maximum authorised loads! ☞ Check the safe load indicator once a day! ☞ A flashing indicator and an acoustic continuous signal warn of loads exceeding 81 % ☞ Reduce the load ☞ Retract the telescopic boom

c b a

e d Fig. 99: 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.

Safe load indicator (overview) a 4 green LEDs = indication of loads between 45 and 85 % of the safe work load b 1 orange LED = indication of loads up to 100 % of the safe work load c 1 red LED = indication of loads up to 110 % of the safe work load d Green LED = readiness e Tip switch (TEST) for checking the system Measures to be taken if ...

• Green diode d (readiness) comes on? ➥ OK; the safe load indicator is in operation • Green LEDs a (1 – 4) come on? ➥ OK; load is between 45 and 85 % of the safe work load • Orange LED b comes on in addition to the 4 green LEDs? ➥ Work with caution; the load is between 85 and 100 % of the safe work load • All green LEDs a and the orange LED b flash? ➥ Work with extreme caution! 100 % of the safe work load is reached ➥ Reduce the load immediately, retract the telescopic boom • All LEDs flash and the acoustic signal is given? ➥ DANGER OF TIPPING OVER! The load is between 100 and 110 % of the safe work load ➥ Reduce the load immediately, retract the telescopic boom

Important!

The overload cutoff option automatically locks the “Raise, Lower and Retract/extend telescopic boom” functions in case of overload (over 110 % of the safe work load) and can be overridden manually under certain conditions!

• – see Disabling/enabling the overload cutoff (option) on page 3-67!

3-66

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Operation Functional check of the safe load indicator c

Important!

b

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

a

Proceed as follows: ☞ Press TEST tip switch e ➥ The safe load indicator is OK when all LEDs (green, orange, red) flash and the alarms sounds

e d Fig. 100: Functional check – safe load indicator display

Caution!

If the first LED (green) and the last two LEDs (orange and red) flash and the alarm sounds: System error ☞ The safe load indicator must be immediately checked and repaired by a trained and authorised technician! ☞ If repair work cannot be performed immediately and the warning sound bothers, the alarm can be switched off with tip switch e until the machine is started again!

3.42 Disabling/enabling the overload cutoff (option) 78 S

Danger!

A B

The hydraulic functions “Raise, Lower, Dump in/out and Extend the telescopic boom”, locked due to overload (100 and 110 % of the safe work load), can be re-activated with switch 113 (on the right on the switch console). ➥ Switch 113 is located on the switch console on the right ➥ Telltale 78 is located in a bracket at the front on the instrument panel

113

Fig. 101: Overload cutoff

In order to avoid danger of tipping over, override the overload cutoff only in situations of extreme emergency!

☞ e.g. to lower the telescopic boom in case of danger of tipping over due to overload ☞ Do not continue working if the lock function of the safe load indicator has been overridden ☞ Enable the lock function of the safe load indicator after lowering the telescopic boom

☞ Unlock switch 113 with lock S (arrow) and lock it into position B ➥ Telltale 78 (at the front above the instrument panel) comes on ➥ The hydraulic functions “Raise, Lower, Extend” are enabled ☞ Press the switch to position A and lock it with lock S ➥ Telltale 78 (at the front above the instrument panel) goes out ➥ The overload cutoff “Raise, Lower, Dump In/Out and Extend” is enabled

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3-67

Operation 3.43 Operating the telescopic boom Raising/extending the telescopic boom Danger!

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

☞ Reduce the load immediately by retracting and lowering the telescopic D

boom! ☞ Bear in mind the safe load indicator ➥ – see Safe load indicator for telescopic boom on page 3-65

12

Joysti c.iso

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

A

116 12

Joystic. iso

Fig. 102: 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!

C

116

☞ Always retract the telescopic boom before you lower it! ☞ Bear in mind the safe load indicator • – see Safe load indicator for telescopic boom on page 3-65

12 Joystic. iso

Fig. 103: Retracting/lowering the telescopic boom

3-68

☞ Retract the telescopic boom. To do this: ☞ Scroll potentiometer wheel 116 on control lever 12 backwards until the telescopic boom is fully retracted ☞ Lower the retracted telescopic boom. To do this: ☞ Push control lever 12 forwards C

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Operation 3.44 Emergency lowering of telescopic boom in case of diesel engine breakdown Lower or raise as follows: Important!

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

• The telescopic boom can only be lowered as follows!

C

116 98 12 D

AUTO

OFF

Joyst ic.iso

Danger!

Do not lower the telescopic boom if it is extended!

☞ Retract and lower the telescopic boom as described below

Fig. 104: Emergency lowering of telescopic boom

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

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3-69

Operation 3.45 Equipping the machine with a standard bucket General information on buckets • 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 “Fields of application and using a telehandler with an attachment” on page 1-5 • In addition, bear in mind the mandatory regulations relevant to accident prevention.

Important!

Readjust the lights when fitting lightweight material buckets (– see chapter 1 “Adjusting the headlights” on page 1-7).

Pressure relief on the quickhitch couplers A

Important!

118 B

98 AUTO

OFF

Joysti c.iso

Fig. 105: Releasing the pressure in the hydraulic lines

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.

☞ Lower the telescopic boom and apply the parking brake ➥ – see Parking brake on page 3-38 ☞ Unlock the 3rd control circuit ➥ – see Operating and securing the 3rd control circuit on page 3-64 ☞ Stop the engine, but do not switch off ignition ☞ Press and hold switch 98, and at the same time, scroll and hold potentiometer wheel 118 on control lever 12 upwards and downwards about 8 seconds in either position

➥ Pressure in hydraulic lines is released

☞ Switch off ignition and remove the ignition key ☞ Remove the quick couplers from the quickhitch ➥ – see Fitting a standard bucket onto the quickhitch on page 3-71 ➥ – see Picking up a multipurpose bucket with the quickhitch on page 3-80

3-70

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Operation Fitting a standard bucket onto the quickhitch 118 C

Danger!

E

Before starting work, make sure the attachment is safely locked onto the quickhitch by means of the lock ram on either side.

B A

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

12

D

Picking up and locking hydraulically ☞ Release the hydraulic pressure on the 3rd control circuit, and unlock the circuit

Joystic.i so

3

1

➥ – see Pressure relief on the quickhitch couplers on page 3-70

☞ Approach the telehandler to the attachment ☞ Lower the telescopic boom. To do this: push control lever 12 forwards C ☞ Slightly tilt the quickhitch forwards 1. To do this: push control lever 12 to the right B ☞ Raise the telescopic boom 2 until the mount of the quickhitch engages in the mount of

2 2

the attachment. To do this: pull the control lever backwards D ☞ Tilt in the quickhitch fully 3. To do this: push control lever 12 to the left A ☞ Scroll potentiometer wheel 118 on control lever 12 downwards

➥ Lock pin E engages in the mounting bores of the attachment and is automatically

E

secured against unlocking

➥ Make sure lock pin E can be seen on either side of the attachment Picking up and locking mechanically ☞ Remove safety pin A from lock pin B, and remove the lock pin completely out of the quickhitch by hand

Important!

Lock pin B can be fastened laterally on the telescopic boom for storage!

☞ Approach the telehandler to the attachment and carefully pick up the attachment with A

C

B

the catch hooks ☞ Dump in the attachment completely ☞ Slide lock pins B through the mounting bores of the attachment and of the quickhitch, and secure them with safety pins A on the quickhitch ☞ Make sure lock pin B on the opposite side is visible in the mounting bore of the attachment

Fig. 106: Picking up a standard bucket

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3-71

Operation Removing a standard bucket from the quickhitch 118

Danger!

C

In order to prevent the attachment from tipping over, place it on the ground ensuring stability!

98

B A

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

AUTO

12

D

over

OFF

Joysti c.iso

Removing an attachment with hydraulic locking ☞ Release the hydraulic pressure on the 3rd control circuit, and unlock the circuit

4

➥ – see Pressure relief on the quickhitch couplers on page 3-70

☞ Drive the telehandler to the drop-off position ☞ Lower telescopic boom 5. To do this: push control lever 12 to position C until the attachment is about 5 – 10 cm horizontal above the ground

☞ Press and hold switch 98 to position B and at the same time, scroll potentiometer wheel 118 on control lever 12 downwards

5

➥ Lock pin E moves out of the mounting bores of the attachment

☞ Slightly tilt the quickhitch forwards 4. To do this: push control lever 12 to position B ☞ Lower the telescopic boom completely 5. To do this: press control lever 12 to position C ☞ Reverse the telehandler away from the attachment

E

Removing an attachment with mechanical locking ☞ Remove safety pin A from lock pin B, remove the lock pin completely out of the quickhitch by hand and insert it in the bracket on the side of the boom ☞ Tilt the quickhitch forwards 4 and at the same time, lower the telescopic boom 5 until the attachment is on the ground without applying any pressure ☞ Tilt in the quickhitch completely 6 ☞ Reverse the telehandler away from the attachment Slide lock pins B into the quickhitch and secure them with safety pins A A

C

B

Fig. 107: Removing a standard bucket

3-72

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Operation 3.46 Working with the standard bucket Safety instructions regarding work with the bucket • Bear in mind the safety instructions given in chapter 2 before working with the machine.

• – see Designated use and exemption from liability on page 2-2, • – see General conduct and safety instructions on page 2-3, • – see Safety instructions regarding operation on page 2-6 • Before starting work, check whether the attachment is safely locked onto the quickhitch by means of the lock ram! ➥ You must be able to see the lock pins on either side (left/right) in the mounting bores on the attachment • Never drive up to the edge of a pit from outside – danger of cave-in!

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

• 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 3-70 • Machine fitted with load stabiliser: • 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 3-43

Caution!

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

If the bucket is very full, the material may fall over the rear of the bucket and the slide surfaces of the extended telescopic boom may become dirty. ☞ Do not completely tilt in a full bucket if the telescopic boom is extended

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3-73

Operation Driving on public roads with a standard bucket German road traffic regulations prohibit driving on public roads if the distance between the front edge of the bucket and the centre of the steering wheel is over 3500 mm in transport position. ➥ – see chapter 1 “Fields of application and using a telehandler with an attachment” on page 1-5 Get informed on and follow the legal regulations of your country!

Get informed on and follow the legal regulations of your country! ☞ Empty and dump in the standard bucket ☞ Retract the telescopic boom completely and set it to transport position ☞ Lock the control lever (joystick) and the 3rd control circuit – see Operating and securing the 3rd control circuit on page 3-64 ☞ Cover the blade or teeth of the bucket across their entire width with the protection provided

Important!

Driving on public roads with a full bucket is not allowed in Germany!

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

☞

Transport position of standard bucket Caution!

In order to avoid damage to the tyres, do not move the machine with the bucket fully dumped out! ☞ Tilt in the bucket and lower it to transport position B

Important!

Transport position is reached as soon as the bucket is fully tilted in • the marks on the telescopic boom and the machine frame are lined up B • The distance between the bucket and the ground A is about 200 mm with standard tyres.

200 mm A Fig. 108: Transport position with bucket

3-74

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Operation Standard bucket payload Maximum authorized bucket payloads = pallet forks payloads – bucket weight. ➥ Weight: see bucket type label Example of calculation: ➥ 3800 kg pallet forks payload – 700 kg bucket => 3100 kg actual bucket payload

Safety instructions for transporting material in 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!

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 (dump out) the bucket if necessary ☞ In case of a bulky load: secure the load and if necessary, fit the rear of the

bucket with a protection ☞ Install a protective FOPS screen (option) onto the front window ☞ 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 3-65

Danger!

In order to avoid danger of tipping over when driving or manoeuvring on slopes with a full bucket, dump in the bucket fully and and set the telescopic boom to transport position!

☞ Whenever possible, drive in reverse when transporting a bucket loaded with material down a steep slope

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3-75

Operation Loading loose material C

Caution!

B

A

12

D

B

Joystic.iso

A Fig. 109: Horizontal lowering of the telescopic boom

In order to avoid damage to the telescopic boom, push material with the bucket only if the telescopic boom is 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

☞ Align the blade parallel with the ground A ☞ Lower the telescopic boom to the ground B. To do this: push control lever 12 forwards C

☞ Drive forwards into the material A

C

When the engine speed decrease due to too much material: ☞ Slightly raise telescopic boom B. To do this: pull control lever 12 backwards D

B

A

12

D Joystic.iso

B

A

Fig. 110: Driving into the material

Loading if the material is hard to penetrate ☞ Proceed as for loading loose material, but in addition: ☞ Tilt the bucket in and out slightly. To do this: move control lever 12 to the left and

C

B

A D

12

oyJstic.iso

A

right A and B Ending loading: ☞ Tilt in bucket C. To do this: push control lever 12 to the left A ☞ Reduce engine speed ☞ Reverse out of the material A ☞ Raise the bucket to transport position B

C B

Fig. 111: Loading if the material is hard to penetrate

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Operation Removing material/digging in soft soil C

Danger!

B

A

12

D

Danger of collapse when undermining foundations or walls!

☞ Never undermine foundations or walls!

Joystic.iso

☞ Place the bucket horizontally on the ground B. To do this:

B

push control lever 12 forwards C

Fig. 112: Lowering the telescopic boom horizontally to the ground

☞ Set the digging angle 1. To do this: push control lever 12 to the right B

C

B

A

12

D Joystic.iso

1

1 Fig. 113: Adjusting the digging angle

☞ Drive the machine forwards 1 C

B

A

12

D Joysict .iso

1

Once the bucket has penetrated the soil: ☞ Set the digging angle slightly flatter 2. To do this: push control lever 12 to the left A, so that • Layer being removed is as even as possible and • Wheel spin is reduced ☞ Proceed as for loading loose material

2 Fig. 114: Removing an even layer

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Operation Removing material/digging in hard soil ☞ Lower the bucket horizontally to the ground 1. To do this: C

B

A

12

D Joytsic.iso

push control lever 12 forwards C ☞ Set the digging angle flatter 2 than for digging in soft soil. To do this: push control lever 12 to the left A ☞ Drive the machine forwards 3 and ☞ Press the bucket down slightly. To do this: slightly push control lever 12 forwards C

3 1

2 Fig. 115: Removing hard soil

C

B

A

12

D Joyst.iciso

Once the bucket has penetrated the soil: ☞ Set the digging angle slightly flatter 1. To do this: push control lever 12 to the left A, so that • Layer being removed is as even as possible and • Wheel spin is reduced ☞ Push control lever 12 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. 116: Adjusting the digging angle flatter

Grading

2

1

After having finished removing/loading the material: ☞ Lower the telescopic boom horizontally to the ground (1) ☞ Reverse across the surface to be graded (2)

Fig. 117: Grading

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Operation Loading vehicles

Fig. 118: Loading vehicles

When loading vehicles, we recommend taking 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!

Freeing the machine Caution!

In order to avoid damage to the telescopic boom, do not use it to free the machine!

If your telehandler gets stuck in the ground: ☞ Fully retract the telescopic boom ☞ Dump out the bucket until the blade is vertical above the ground ☞ Lower the telescopic boom all the way ☞ Gradually tilt in the bucket

➥ The telehandler is pushed backwards ☞ Reverse slowly ☞ Repeat this procedure until the wheels reach firm ground Reverse the telehandler away

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Operation 3.47 Fitting a multipurpose bucket General information on the multipurpose bucket • The multipurpose bucket is mainly used for digging earth, and for loosening, picking up, transporting, loading and pushing 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 “Fields of application and using a telehandler with an attachment” on page 1-5 In addition, bear in mind the mandatory regulations relevant to accident prevention.

Picking up a multipurpose bucket with the quickhitch ☞ The multipurpose bucket is picked up and mounted on the quickhitch in the same way as the standard bucket

➥ – see Fitting a standard bucket onto the quickhitch on page 3-71

Danger!

Before starting work, make sure the attachment is safely locked onto the quickhitch by means of the lock ram on either side.

☞ The lock pin must be visible on either side in the bores on the attachment Fig. 119: Checking the lock pins

Hydraulic connections on the multipurpose bucket: overview D

C

Hydraulic connection

Function

C Pressurised

Opens the multipurpose bucket

D Pressurised

Closes the multipurpose bucket

Fig. 120: Hydraulic connections on the multipurpose bucket

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Operation Connecting hydraulic lines to the 3rd control circuit

B

A

D

C

☞ Stop the engine ☞ Apply the parking brake ☞ Release the pressure in the hydraulic lines ➥ – see Pressure relief on the quickhitch couplers on page 3-70 ☞ Clean the hydraulic connections on the quickhitch ☞ Connect flexible lines A and B of the multipurpose bucket onto the quick couplers of the quickhitch

➥ Flexible line A onto quick coupler C ➥ Flexible line B onto quick coupler D

Caution!

D

C

Connect the hydraulic connections correctly avoiding dirt. Do not connect the flexible lines crosswise in order to ensure correct hydraulic functions and to avoid squeezing the flexible lines when tilting in or dumping out an attachment (– see Working with the multipurpose bucket on page 3-83).

☞ Check the multipurpose bucket for correct function

Fig. 121: Connecting the hydraulic lines between the Fig. 121: Connecting the hydraulic lines to the quickhitch quickhitch and the multipurpose bucket

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Operation Removing the multipurpose bucket from the quickhitch Danger!

In order to prevent the attachment from tipping over, place it on the ground ensuring stability!

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

B

A

D

C

D

C

Important!

If the attachment is placed in direct sunlight after having been taken off, the oil in the hydraulic rams will warm up. This leads to a pressure increase in the hydraulic rams that will make it difficult to attach the hydraulic lines to the hydraulic connections.

☞ Empty the multipurpose bucket and tilt it in fully ☞ 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 3-70 ☞ Remove flexible lines A and B of the multipurpose bucket from the quick couplers of the quickhitch, and close them with the caps provided to this effect ☞ Start the engine and lower the multipurpose bucket to the ground

Important!

The multipurpose bucket is lowered in the same way as the standard bucket – see Removing a standard bucket from the quickhitch on page 3-72 Fig. 122: Remove the hydraulic lines between the quickhitch Fig. 122: Connecting the hydraulic lines to the quickhitch and the multipurpose bucket

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Operation 3.48 Working with the multipurpose bucket Safety instructions regarding work with the bucket • Bear in mind the safety instructions given in chapter 2 before working with the machine.

• – see Designated use and exemption from liability on page 2-2, • – see General conduct and safety instructions on page 2-3, • – see Safety instructions regarding operation on page 2-6 • Before starting work, make sure the attachment is safely locked onto the quickhitch.

• The lock pin must be visible on either side in the bores on the attachment • Never drive up to the edge of a pit from outside – danger of cave-in!

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

• 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 3-70 • If the machine is equipped with a load stabiliser (option): • 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 3-43

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 the multipurpose bucket German road traffic regulations prohibit driving on public roads if the distance between the front edge of the bucket and the centre of the steering wheel is over 3500 mm in transport position. ➥ – see chapter 1 “Fields of application and using a telehandler with an attachment” on page 1-5 Get informed on and follow the legal regulations of your country! ☞ Empty, close and tilt in the multipurpose bucket ☞ Retract the telescopic boom completely and set it to transport position ☞ Lock the control lever (joystick) and the 3rd control circuit – see Operating and securing the 3rd control circuit on page 3-64 ☞ Cover the blade or teeth of the bucket across their entire width with the protection provided

Important!

Driving on public roads with a full multipurpose bucket is not allowed in Germany!

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

Transport position of multipurpose bucket Caution!

In order to avoid damage to the tyres, do not move the machine with the bucket fully dumped out! ☞ Tilt in the bucket and lower it to transport position B

Important!

Transport position is reached as soon as the bucket is fully tilted in • the marks on the telescopic boom and the machine frame are lined up B • The distance between the bucket and the ground A is about 200 mm with standard tyres.

200 mm A Fig. 123: Transport position with bucket

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Operation Multipurpose bucket payload Maximum authorized bucket payloads = pallet forks payloads – bucket weight. ➥ Weight: see bucket type label Example of calculation: 3800 kg pallet forks payload – 900 kg bucket => 2900 kg actual bucket payload.

Safety instructions for transporting material in 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!

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!

☞ Slightly readjust (dump out) the bucket if necessary ☞ In case of a bulky load: secure the load and if necessary, fit the rear of the

bucket with a protection ☞ Install a protective FOPS screen (option) onto the front window ☞ 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 3-65

Danger!

In order to avoid danger of tipping over when driving or manoeuvring on slopes with a full bucket, dump in the bucket fully and and set the telescopic boom to transport position!

☞ Whenever possible, drive in reverse when transporting a bucket loaded with material down a steep slope

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Operation Grading and scraping Caution!

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

Caution! 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

Fig. 124: Grading work with a multipurpose bucket

Grading ☞ Fold up the front half of the bucket ☞ Set the depth of the layer you want to remove with the lift hydraulics ☞ Set the angle of the rear cutting edge Drawing material backwards ☞ Dump out the multipurpose bucket ☞ Raise the bucket with the lift hydraulics ☞ Fold up the front half of the bucket ☞ Lower the multipurpose bucket to the ground ☞ Set the angle of the bucket ☞ Surfaces are graded or scraped when driving in reverse

Removing and spreading material in thin layers Removing material in thin layers ☞ Set a flat digging angle ☞ Fold up the front half of the bucket by about 10 to 15 cm ☞ Move off the machine

➥ The material rolls into the bucket and is picked up at the same time ➥ This position allows to strip e.g. grass turf down to a thickness of about 8 cm Fig. 125: Removing material in thin layers with a multipurpose bucket

Spreading material in thin layers ☞ Set the rear cutting edge parallel to the ground ☞ Fold up the front half of the bucket until the required quantity of material is emptied onto the ground ☞ Move off the machine ☞ Lower the multipurpose bucket to the ground

➥ The rear cutting edge grades the material as it is emptied by opening the front half of

the bucket. This position allows to spread material without driving on the lower layer with the machine (e.g. applying the first bituminous base onto sensitive antifrost layers, applying granulated material onto plastic coatings)

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Operation Pulling out material from slopes Important!

This position allows to pull material out of slopes or roadside ditches with maximum safety and to spread it as required.

Fig. 126: Pulling out material with a multipurpose bucket

Moving material with longer reach Important!

This position allows to move material without damaging slopes or structures.

➥ Backfilling with maximum safety and without damaging slopes

Fig. 127: Filling in material with a multipurpose bucket

Picking up remaining material completely Important!

Both bucket halves must touch the ground so that all the material is picked up.

Fig. 128: Picking up remaining material with the multipurpose bucket

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☞ Fold up the front half of the bucket (multipurpose bucket) ☞ Dump out the bucket ☞ Lower the bucket to the ground. Make sure both bucket halves touch the ground ☞ Close and dump in the multipurpose bucket at the same time ☞ Raise the bucket with the lift hydraulics

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Operation Grabbing bulky material ➥ The multipurpose bucket allows to safely grab, pick up and transport building timber, reinforcement bars, packaging bands, wire etc. ➥ The multipurpose bucket allows to safely grab, pick up and transport large objects

Fig. 129: Picking up bulky material with a multipurpose bucket

Pulling out and setting posts ☞ Open the multipurpose bucket and lower it over the post. Close the bucket to grip the post firmly ☞ Loosen the post with careful up-and-down movements

Fig. 130: Moving posts with a multipurpose bucket

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Operation Backfilling round gravel and precise unloading ➥ Precise dosing and placement of pourable material ➥ Bucket teeth move back from the wall as the bucket opens

Fig. 131: Backfilling and unloading material with a multipurpose bucket

Unloading from the bottom of the bucket for increased dump heights ➥ Increases the dump height by at least 55 cm (depending on bucket size), as compared to dumping with a standard bucket

Important!

Smaller dump reach is compensated by pushing the material with the open multipurpose bucket as shown

Fig. 132: Unloading from the bottom of a multipurpose bucket

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Operation 3.49 Fitting pallet forks Fitting pallet forks onto the quickhitch Danger!

Before starting work, make sure the attachment is safely locked onto the quickhitch by means of the lock ram on either side.

☞ The lock pin must be visible on either side in the bores on the attachment ☞ The pallet forks are picked up and mounted on the quickhitch in the same way as the standard bucket

Fig. 133: Checking the lock pins

➥ – see Fitting a standard bucket onto the quickhitch on page 3-71

Removing pallet forks from the quickhitch Danger!

In order to prevent the attachment from tipping over, place it on the ground ensuring stability!

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

☞ The pallet forks are removed from the quickhitch in the same way as the standard bucket

➥ – see Fitting a standard bucket onto the quickhitch on page 3-71

Driving on public roads with the pallet forks Danger!

In Germany, driving on public roads with the pallet forks fitted is prohibited!

Do not transport the pallet forks in a bucket fitted onto the machine!

☞ Remove the pallet forks and transport them with an adequate means of transport when driving on public roads! ➥ – see Special instructions for driving on public roads on page 3-30

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

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Operation 3.50 Working with the pallet forks General safety instructions regarding the pallet forks

a

b

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Fig. 134: Loading the pallet forks

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• The machine may be used for applications with lifting gear only if the prescribed safety devices are in place and functional. e.g. safe possibilities of slinging and securing lifting gear (load hook) ➥ – see chapter 2 “Applications with lifting gear” on page 2-8 ➥ – see Working with a crane jib (option) on page 3-101 ➥ Bear in the mind the load diagram • Follow the special instructions in the Operator's Manual of the attachment!

• 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 (for a fully loaded machine)!

• Never raise a load with only one fork arm!

• Maintain a distance of a minimum 6 m between the telescopic boom/load and overhead lines!

• Before starting work, make sure the fork arms on the fork frame are safely locked!

• Never operate the telescopic boom and the attachments at higher machine speed!

• Never leave the machine with the load raised!

• Always transport the load close to the ground!

• Make sure only authorised persons handle and work with the attachment • Do not transport persons in the attachment • Stay clear of suspended loads a!

• Never use the controls or movable lines and cables as handles • Never use bent, cracked or otherwise damaged fork arms/pallet forks!

• Do not drive on public roads with an attachment fitted on the machine!

• 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!

• Lock the adjustable fork arms with the locking lever before moving the machine with loaded or unloaded pallet forks, to prevent the fork arms from moving (slipping, sliding) sideways!

• 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 • Always tilt in the attachment a little (towards the machine) for transport!

• Lower the bucket the nearest possible to the ground for transport. Observe minimum ground clearance!

• Drive slowly with a raised load, especially in off-road applications, to avoid strong swinging movements of the load!

• 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!

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Operation • Bear in mind the clearances of underpasses, tunnels, gates etc. before driving through or under them!

• Do not overload the attachment or the machine, observe the load diagram!

• Set down loads only in places where they will stand safely without tilting, falling down or sliding • 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.

• Set down loads only in the areas provided for within the construction site. Affix appropriate marks to loads which have been set down, especially in the area of public and private traffic • 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

Specific safety instructions • Lock the 3rd control circuit – see Operating and securing the 3rd control circuit on page 3-64.

• Ensure the stability of the telehandler ➥ – see Safe load indicator for telescopic boom on page 3-65 ➥ – see Load diagram for pallet forks (EN 1459/1998) on page 3-94 ➥ Never exceed the maximum load!

• Follow the special instructions in the Operator's Manual of the pallet forks!

• Do not lower the extended telescopic boom from a high fork arm position – always retract the telescopic boom first!

• 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!

• Maintain a distance of a minimum 6 m between the telescopic boom/load and overhead lines!

• Before starting work, make sure the fork arms on the fork frame are safely locked!

• Never operate the telescopic boom and the attachments at higher machine speed!

• Never leave the machine with the load raised!

• Always transport the load close to the ground!

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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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Operation Load diagram for pallet forks (EN 1459/1998) The load diagram in the cab is valid only for use with the pallet forks with fork arms as specified and released in Fields of application and using a telehandler with an attachment on page 1-5.

Observe the specific load diagrams of other attachments (e.g. crane jib) used!

Danger!

Observe the load diagram under all circumstances in order to ensure the telehandler's full stability with the pallet forks fitted, Maximum load depends on how the telehandler is equipped!

Fig. 135: Load diagram (example)

☞ The weight of the attachment and the respective maximum load may not

exceed the payload specified in the load diagram for the specific range! ➥ – see Safe load indicator for telescopic boom on page 3-65 ☞ The centre of gravity of the attachment/payload may be located horizontally at a maximum 650 mm in front of the lock pin and vertically at a maximum 250 mm over the lock pin.

Pallet forks payload Pallet forks payloads are described in chapter “Specifications” • – see chapter 6 “Payloads model 404-03” on page 6-14

Pallet forks transport position without load Caution!

In order to avoid damage to the tyres, do not move the machine with the pallet forks fully dumped out! ☞ Tilt in the pallet forks and lower them to transport position

Fig. 136: Moving the machine without load

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Operation Adjusting the fork arms of the pallet forks Danger!

If the fork arms are not secured so as to avoid lateral sliding or slipping, the load risks sliding sideways!

☞ Before using the pallet forks with or without load, check whether both lock-

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ing levers on the fork arms are folded down. This correctly locks the safety pins of the fork arms in the notches on the fork frame, and prevents the fork arms from slipping or sliding sideways

Fig. 137: 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

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

b c

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Fig. 138: Locking the fork arms

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Operation Picking up loads with the pallet forks Check whether the hose burst valve is enabled before starting work!

• Switching off the load stabiliser automatically enables the hose burst valve – see Switching the load stabiliser ON or OFF on page 3-44

Danger!

When working with the pallet forks, always observe the safe load indicator and the load diagram – danger of tipping over and of accidents!

☞ Work carefully! Adapt your drive speed and loads to the terrain. Refer to the load diagram for the maximum authorised loads ☞ Bear in mind and check the safe load indicator ➥ – see Safe load indicator for telescopic boom on page 3-65 ☞ In case of an alarm: retract and lower the telescopic boom

Check whether the hose burst valve is enabled before starting work • Switching off the load stabiliser automatically enables the hose burst valve – see “Hose burst valve” safety feature on page 3-98 ☞ Proceed as follows: • Stop the telehandler immediately in front of the material • Set the fork arms parallel to the ground • Check the distance of the fork arms to the centre line (dashed line) • The fork arms must be at the same distance from the centre line and as far apart as possible

Fig. 139: 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 • Make sure the pallet is safely loaded on the fork arms

Fig. 140: Loading material

2 4 1 3 Fig. 141: Raising the telescopic boom

• Raise the telescopic boom slightly (3), making sure that the preset limits of the load diagram and the safe load indicator are not exceeded!

• In case of doubt or danger, lower the load immediately!

• Tilt the fork frame backwards a little (1) • Retract the telescopic boom completely (2) • Make sure 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 250 mm above the ground)

Fig. 142: Transport position – pallet forks

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Operation Transporting loads with the pallet forks Danger!

Careful when transporting material – with the telescopic boom raised and extended, – with the upright fork frame tilted too far back, – in strong wind and poor visibility –

Danger of accidents and injury! ☞ Transport material only with the telescopic boom lowered ☞ Align the fork frame with the material parallel to the surface where you want

3

to set down the material ☞ Avoid high storage positions for material which should not be exposed to wind ☞ Ensure good visibility of the material you want to pick up and of the work and travel range

2 1

☞ Proceed as follows: 4

Fig. 143: Setting down the material

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5

• Approach the storage position ensuring the material is in the middle of the stack • Raise the telescopic boom (1) • Extend the telescopic boom (2) carefully until the load is positioned precisely above the stack • Adjust the inclination of the fork arms (3) • Lower the telescopic boom slowly (4), making sure that the preset limits of the load diagram and the safe load indicator are not exceeded! In case of doubt or danger, stop stacking immediately! ☞ Make sure the fork arms are no longer under load: • Make sure the area behind the machine is clear • Carefully reverse from the stack (5) until the telescopic boom can be lowered to the transport position • Tilt the fork frame backwards

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Operation 3.51 “Hose burst valve” safety feature Hose burst valve function Important!

The “Hose burst valve” safety feature prevents the telescopic boom from being lowered or dumped out without being braked, in the event of a bursting hose or pipe.

Caution!

Switching on the load stabiliser automatically switches off the hose burst valve! ☞ Switch off the load stabiliser to make sure the the hose burst valve works correctly! ☞ – see Load stabiliser on page 3-43

Danger!

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

☞ Proceed as follows: • • • • •

Stop the machine immediately Apply the parking brake – see Parking brake on page 3-38 Stop the engine Do not switch off ignition With the engine stopped, carefully lower the telescopic boom to transport position • Remove the ignition key and 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 3.52 Mechanical oscillating axle interlock (rear axle) Mechanically locking the oscillating axle During pallet forks/loader operation at greater lift heights, the rear axle can be locked only on level ground with the oscillating axle interlock located laterally on the frame! ➥ – see Load diagram for pallet forks (EN 1459/1998) on page 3-94 ➥ – see chapter 6 “Payloads model 404-03” on page 6-14 ☞ Place the telehandler on level ground ☞ Lower the telescopic boom to transport position ☞ Apply the parking brake ☞ Remove pin A from its fixture and ☞ insert it in bracket B of the oscillating axle interlock (see arrow) ☞ Secure the pin with the safety pin

A

Caution!

B

In order to avoid damage to the frame and the axle, handle pallets with the locked oscillating axle on level ground only! ☞ Unlock the oscillating axle once pallet forks operation is over

Fig. 144: Mechanical oscillating axle interlock (rear axle)

3.53 Hydraulic rear oscillating axle interlock (option) Hydraulically locking the oscillating axle N K

We recommend using the oscillating axle interlock when working at greater heights in pallet forks/load operation!

• – see chapter 3 “Load diagram for pallet forks (EN 1459/1998)” on page 3-94 or Front axle with frame levelling and hydraulic oscillating axle interlock (rear axle) on page 6-17 ☞ Press switch 112 to position B

➥ Rear axle oscillation is locked via the solenoid valve on interlock ram D

Fig. 145: Level indicator

☞ Press switch 112 to position A ➥ Rear axle oscillation is unlocked via the solenoid valve on interlock ram D ➥ The red telltale K comes on (next to the level indicator in the cab at the front on the

112 A

instrument panel)

B

Caution!

In order to avoid damage to the frame and the axle, handle pallets/work with the bucket with the locked oscillating axle on level ground only! ☞ Once pallet forks operation is over: • Disable the hydraulic or mechanical oscillating axle interlock • Set the telehandler horizontally (see level indicator in the cab) D

Fig. 146: Hydraulic oscillating axle interlock (rear axle)

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3-99

Operation 3.54 Frame levelling feature on front axle (option) Switching the frame levelling ON and OFF 111

98 A

The telehandler can be set horizontally on slopes with the “Frame levelling” option in the case of a max. 10° (±) lateral inclination of the longitudinal axis!

Danger!

Do not use frame levelling when driving on public roads –

B

Danger of accidents! ☞ Before driving on public roads: • Set the telehandler horizontally with the level indicator (at the front on the instrument panel)

Caution!

C

In order to avoid damage to the frame and the axle, disable the hydraulic or mechanical oscillating axle interlock under all circumstances during frame levelling operation! ☞ – see Mechanical oscillating axle interlock (rear axle) on page 3-99 ☞ – see Hydraulic rear oscillating axle interlock (option) on page 3-99 N

☞ Stop the telehandler in the required position with the load and the telescopic boom lowered ☞ Press and hold tip switch 98 (unlocking, on the instrument panel on the left) and at the same time, press tip switch 111 (frame levelling, on the instrument panel on the right) to position A or B

➥ The frame levelling ram C sets the telehandler horizontally in its longitudinal axis to

Fig. 147: Frame levelling display

the right or left ➥ See level indicator N in the cab (at the front on the instrument panel) ☞ Enable rear axle oscillation (option)

➥ During pallet forks/loader operation at greater lift heights, the rear axle can be

locked only on level ground with the oscillating axle interlock located laterally on the frame ➥ – see Hydraulic rear oscillating axle interlock (option) on page 3-99 ☞ Carefully raise and set down the load

➥ – see chapter 6 “Payloads model 404-03” on page 6-14

3-100

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Operation 3.55 Working with a crane jib (option) General safety instructions for working with a crane jib Shaft rings, containers, pipes etc., can be repositioned and transported with a crane jib and suitable lifting gear (belts, cables, chains).

Bear in mind the following precautionary measures!

• Check whether the hose burst valve is enabled before starting work ➥ Switching off the load stabiliser automatically enables the hose burst valve – see Switching the load stabiliser ON or OFF on page 3-44 • Bear in mind the instructions in chapter Safety Instructions Applications with lifting gear on page 2-8 • Pick up and place loads on firm and level ground only • Wear safety gloves • Make sure the ratchet safely engages in the hook as you hook up the lifting gear (belts, cables, chains) • Do not use damaged lifting gear • Bear in mind the load diagram (on the front window) before raising a load • Adapt your speed to the load as you move it near to the ground • Persons guiding the load must stay in visual contact with the machine operator • Do not transport loads on public roads

Danger!

Before starting work, make sure the attachment is safely locked onto the quickhitch by means of the lock ram on either side.

☞ The lock pin must be visible on either side in the bores on the attachment ➥ – see Fitting a standard bucket onto the quickhitch on page 3-71

Fig. 148: Checking the lock pins

☞ Hook up the lifting gear in the mounts (eyelets, shackles) provided for transporting the load ☞ Carefully raise the load and transport it near the ground ☞ Do not exceed the load capacity

➥ See load diagram A in the cab (front window) ➥ – see Safe load indicator display on page 3-66 ➥ – also refer to the Operator's Manual of the attachment (crane jib)

Fig. 149: Crane jib load diagram (example)

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3-101

Operation 3.56 Continuous operation of 3rd control circuit (option) Switching continuous operation of 3rd control circuit ON/OFF 55

S

S A

B 95

90

Quick couplers D of the 3rd control circuit can also be used for continuous operation of attachments with hydraulic motors (e.g. rotary brooms) or of attachments with their own hydraulic circuits and control valves.

After an attachment has been fitted and safely locked onto the quickhitch, continuous operation is operated by means of switches 95 and 90 (switch console on the left) as follows: Switching on continuous operation ☞ Slide switch 95 (lock S) in the direction of the arrow and press it to position B

➥ 3rd control circuit switched ON ➥ Telltale 55 on the indicating instrument comes on ☞ Slide switch 90 (lock S) in the direction of the arrow and press it to position B ➥ 3rd control circuit is in continuous operation Switching off continuous operation ☞ Slide switch 90 (lock S) in the direction of the arrow and press it to position A

D

➥ Continuous operation of the 3rd control circuit is switched OFF

Fig. 150: Continuous operation of 3rd control circuit

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

81

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 switch console on the right.

Switching on the tilt ram lock ☞ With the telescopic boom in transport position, set the tilt ram and the material to the required position ☞ Turn the key-operated switch 81 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 Fig. 151: Operation of key-operated switch

3-102

Switching off the tilt ram lock ☞ Turn the key-operated switch 81 to the symbol ➥ The tilt ram is unlocked and can be operated again

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Operation 3.58 Electric changeover valve for operation of 3rd control circuit as additional front control circuit (option) Switching the additional control circuit ON or OFF 55

S

117

A 118

B

95

Quick couplers V for operation of hydraulic front attachments with additional hydraulic functions.

Functions enabled with switch 118 on the control lever can be carried out without changing over hydraulic hoses The additional control circuit is switched on with switch 95 or, depending on machine options, with switch 94 (switch console on the left) or tip switch 117 on the control lever.

Switching on the additional control circuit ☞ Slide switch 95 (lock S) in the direction of the arrow and press it to position B

➥ 3rd control circuit switched ON ➥ Telltale 55 on the indicating instrument comes on

94

☞ Depending on machine options: press switch 94 to position B or tip switch 117 on the

Joystic.i so

control lever

V

➥ Additional control circuit in operation ➥ Telltale in switch comes on Switching OFF the additional control circuit ☞ Depending on machine options: press switch 94 to position B or tip switch 117 on the control lever

➥ Additional control circuit switched OFF ➥ Telltale in switch goes out

Important!

Fig. 152: Hydraulic connections

See the Operator's Manuals of the attachment manufacturers for installing and operating the attachments!

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3-103

Operation 3.59 Front/rear hydraulic additional control circuit (option) General information on the additional control circuit Quick couplers are mounted at the rear of the machine and/or on the outside of the telescopic boom for operating hydraulic attachments with additional hydraulic functions The additional control circuit is supplied with hydraulic oil by pressing switch 91 (switch console on the left) and switch 110 (switch console on the right).

The quantity of oil (litres) is continuously set with potentiometer 114 (rotary switch on the switch console on the right).

Connecting an attachment onto the additional control circuit AUTO

S

OFF

98

91

Caution!

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

110

Important!

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.

B 114 A

☞ Lower the telescopic boom and apply the parking brake ➥ – see Parking brake on page 3-38 ☞ Stop the engine, but do not switch off ignition ☞ Slide lock S in switch 91 downwards and press the switch ☞ Release lock S ☞ Press and hold switch 98 and at the same time, press and hold switch 110 in either

HR

HZ

position about 8 seconds

➥ Pressure in hydraulic lines is released ☞ Switch off ignition and remove the ignition key ☞ Connect the attachment to quick couplers HZ at the rear of the frame or to quick couVR

VS

VZ

plers VZ / VS on the telescopic boom Quick couplers on rear frame: overview • 2 quick couplers HZ (1 x pressure, switchable, 1 x reflux via hydraulic filter) • 1 quick coupler HR (leak oil line direct to the tank) Overview of quick couplers on upper side of telescopic boom • Quick couplers VS (pressure, switchable) • Quick couplers VZ (reflux via hydraulic filter) • Quick couplers VR (leak oil line direct to the tank)

Fig. 153: Additional control circuit: overview

3-104

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Operation Additional control circuit operation ☞ Connect the attachment (at the rear on the frame) onto the HZ quick couplers (reflux with/without pressure)

A

S

B

91

A

110

B

➥ – see Connecting an attachment onto the additional control circuit on page 3-104 ☞ Slide lock S on switch 91 in the direction of the arrow and press the switch to position B ☞ Press switch 110 to position A or B (control circuit selection) ☞ Turn potentiometer 114 (rotary switch on switch console on the right) as required ➥ A => less, B => more oil ➥ The HZ and VS quick couplers are pressurised

Important!

B

If switches 91 and/or 110 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 91 and 110 and switch them on again (see above) • Turn back potentiometer 114 (rotary switch) to minimum A and then reset the required quantity of oil • Before stopping the engine, turn back potentiometer 114 (rotary switch) to minimum A and switch off switch 91 If switch 91 is unintentionally switched off and on during operation, the quantity of oil previously adjusted remains unchanged.

114 A

HR

Caution!

No operation of attachments at the front and rear quick couplers at the same time! ☞ Uncouple the attachment if it is not used • See the Operator's Manuals of the attachment manufacturers for installing and operating the attachments!

HZ

VR

Important!

The rear HR and front VR quick couplers are used for attachments with an unpressurised reflux!

VS

VZ

Fig. 154: Operation of additional control circuit

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3-105

Operation 3.60 Automatic bucket repositioning (option) General information on automatic bucket repositioning The bucket repositioning function can be used for carrying out cyclical work (e.g. loading trucks) efficiently and with minimum impact to the material: by pressing a button, the attachment is automatically positioned from the dump-out position to the preset work position (e.g. leading edge of bucket aligned parallel to the ground).

Programming the base position ☞ Set the bucket to the base position by means of the tilt ram (see figure) ☞ Press both tip switch 117 on the control lever and switch 98 on the switch console on the left at the same time about 10 seconds and then release them

117 98 AUTO

OFF

Joystic. iso

➥ The base position is programmed ☞ After loading a truck, for instance, press tip switch 117 briefly on the control lever ➥ The bucket automatically returns to the programmed base position and material can be picked up

Fig. 155: Operating the bucket repositioning

3.61 Tipping trailer connection (option) Operating the tipping trailer connection

A

S

B S

Important!

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

91 108

109

A B

Quick couplers K for operation of hydraulic tipping trailers.

The tipping trailer connection is operated as follows, via switch 91 (on the switch console on the left) and via switch 108 (only with optional Autohitch trailer coupling) and tip switch 109 (both on the switch console on the right). ☞ Connect the flexible line of the hydraulic tipping trailer to quick coupler K ☞ Slide switch 91 (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 108 (lock S) in the direction of the arrow and press it to position B

K

☞ Press tip switch 109 to position A ➥ The tipping trailer is raised ☞ Press switch 109 to position B ➥ The tipping trailer is lowered

Fig. 156: Operation of the additional control circuit (option)

3-106

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Operation 3.62 Operation of the Autohitch trailer coupling (option) General information on the Autohitch trailer coupling Important!

Autohitch trailer couplings with EC acceptance are certified for use on public roads in Germany (StVZO German road traffic regulations).

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

Get informed on and follow the legal regulations of your country. ☞ Gross trailer weight rating: – see chapter 6 “Trailer weight/drawbar load: trailer couplings (option)” on page 6-11 The Autohitch trailer coupling H allows you to hitch a trailer onto the telehandler while remaining seated.

The Autohitch trailer coupling is operated via switch 97 (switch console on the left) and switch 109 (switch console on the right) as follows.

Unlocking and opening the Autohitch trailer coupling AU TO

97

OFF

Unlocking the towing gear ☞ Press tip switch 97 to position B and at the same time, press switch 109 in the direction of the arrow A

➥ Towing gear H moves upwards to the final position (arrow G) and automatically

B 109

A B

unlocks the safety lock Opening the towing gear ☞ Press and hold tip switch 97 to position B and at the same time ☞ Press switch 109 in the direction of the arrow B

➥ Towing gear H moves downwards (arrow O)

H G

O

Fig. 157: Opening the Autohitch trailer coupling

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3-107

Operation Locking the Autohitch trailer coupling AU TO

97

OFF

B

Danger!

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

109

A B

☞ Check the proper function of the safety lock once a day ☞ Do not exceed the load values for the Autohitch coupling (see type label) ☞ Adjust the rearview mirror correctly to ensure visibility to the rear ☞ Remove dirt from the towing pin ☞ After you have coupled the trailer onto the telehandler, check whether the towing gear is safely locked

Coupling the trailer onto the towing gear ☞ Use the mirror to carefully approach to the trailer until the towing pin appears below the eyelet of the trailer drawbar ☞ Press and hold switch 109 in the direction of the arrow A until the towing gear audibly encounters hydraulic resistance

➥ Towing gear H moves upwards to the final position (arrow G) ➥ Check whether the trailer is safely locked

H G

O

Uncoupling the trailer from the towing gear ☞ The trailer is uncoupled in the reverse order

Fig. 158: Locking the Autohitch trailer coupling

3-108

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Operation 3.63 Automatic trailer coupling (option) General information on the trailer coupling Caution!

Under certain conditions, German traffic regulations (StVZO) allow trailer operation on public roads*. ☞ Please refer to the machine documentation for information on specific requirements. ☞ Get informed on and follow the legal regulations of your country.

• • • •

Gross unbraked trailer weight rating = 1000 kg Gross braked trailer weight rating = 15000 kg Gross drawbar load rating = 1000 kg Other trailer weights and drawbar loads – see chapter 6 “Trailer weight/drawbar load: trailer couplings (option)” on page 6-11

Attaching a trailer Danger!

Always check that the trailer is correctly and safely coupled. The lock pin must be correctly coupled in the lower bore of the coupling jaw!

☞ Drive the machine forwards about 1 m and then reverse again, and check whether the trailer is correctly coupled ☞ Keep your hands clear of the coupling jaw when checking (danger of crushing!) ☞ Repeat the procedure if necessary

A

A

☞ In order to attach a trailer, press lever A upwards until it engages ☞ Check whether the coupling jaw is locked ☞ Release the front axle brake of the trailer ☞ 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

B

➥ The trailer is locked in the coupling jaw as the drawbar touches release trigger B Closing the coupling by hand (e.g. for a tow cable) ☞ Carefully pull the pommel of lever A in closing direction by hand

Fig. 159: Trailer coupling (option)

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3-109

Operation 3.64 Compressed-air brake system (option) General 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, make sure the sealing rings of the coupling heads are clean and that they are not damaged • Coupling head colours ➥ Single-circuit brake system C = black ➥ Dual-circuit brake system A = red (tank), B = yellow (brake) • Before moving off, set the lever of the trailer brake-power controller to the position corresponding to the load (empty, half empty, full) • Trailers allowed to drive over 25 kph must undergo specific inspections as required by German road traffic regulations.

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

• Do not exceed the maximum gross weight rating of the trailer • The maximum drive speed of the tractor/trailer combination is always the maximum speed of the slowest trailer • Check the drive belt on the compressed-air compressor at regular intervals for correct tension and damage • Have repair and adjustment work on the brake system carried out by an authorised workshop only

Coupling and uncoupling compressed-air hoses (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!

C Fig. 160: Compressed-air brake couplings (option)

3-110

Uncoupling: ☞ First uncouple the pressure hose from the red coupling head A (tank), then the pressure hose from the yellow coupling head B (brake) Coupling: ☞ 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 96 must show a system pressure of at least 5 bar. Danger of accidents if the system pressure is below 5 bar!

96

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

➥ Specified value: 6 – 8 bar

Fig. 161: Compressed-air brake gauge (option)

☞ 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 5-28

3.65 Hydraulic trailer brake (option) General information on the hydraulic trailer brake Important!

A Fig. 162: 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.

☞ Quick coupler A for the hydraulic trailer brake is mounted at the rear of the machine (on the right in driving direction). ☞ The trailer brake valve is operated together with the service brake.

Caution!

Clean the quick coupler carefully before connecting the flexible line of the trailer in order to ensure proper function and sealing features!

Pressure settings may only be carried out by an authorised workshop. ☞ Maximum oil pressure (brake pressure) on the quick coupler may not exceed 150 bar at maximum brake pedal pressure.

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3-111

Operation 3.66 Fitting attachments from other manufacturers onto the quickhitch (option) General information on quickhitches Quickhitch: Volvo TBV, Manitou, Matbro, Sanderson, Q-fit JCB

Caution!

Attachments listed in this Operator's Manual cannot be fitted onto the quickhitches listed above! ☞ – see chapter 1 “Attachments with certified material densities” on page 1-5 ☞ When fitting attachments other than Kramer 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 1-5 “Attachments with certified material densities”! ☞ Pallet forks = safety factor = S 1.25/S 1.67 Max. moment = (FL+XL) + 362.0 daN + (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.

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

Fig. 163: Attachments other than Kramer: data

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 other than Kramer on page 3-113 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. ☞ Refer to the Operator's Manual of the attachment for installing and connecting the hydraulic hoses onto the quickhitch ☞ Coupling the hydraulic hoses onto the quickhitch

➥ – see Equipping the machine with a standard bucket on page 3-70 ➥ – see Fitting a multipurpose bucket on page 3-80

3-112

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Operation Example: inspection plan for attachments other than Kramer Machine model: Serial no.: Job no.: Stability

Attachment type: Attachment no.:

Date:

Actual value

Remarks

Checked by:

Wheelbase [mm] Front left wheel [N]

[N]

Front right wheel [N]

Front axle =

Rear left wheel [N] Rear right wheel [N]

Rear axle =

Proof of stability as per DIN EN 474

Required

Yes

No

Existing

Yes

No

Stability (calculated)

S=

With gamma =

Specifications

Specified

Actual value

Remarks

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

No

Hydraulically OK

Yes

No

Electrically OK

Yes

No

Mechanical stops

Dump out/tilt in

OK

Yes

No

Yes

No

Hose routing OK Nominal width of pressure line [mm]

10

Nominal width of reflux line [mm]

10

Pressures

Specified

Actual value

Remarks

At idling speed

[bar]

Oil 50 °C

Under full load

[bar]

Oil 50 °C

Admissible hydraulic pressures not exceeded at nominal load of boundary states [bar] Other remarks:

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3-113

Operation Notes:

3-114

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Troubleshooting

Troubleshooting

4

Troubleshooting

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

Caution!

Diesel engine repairs may be carried out only by authorised workshops and trained staff.

Diesel engine malfunctions

Engine does not start or is not easy to start

Possible causes

See page

Parking brake not applied

3-38

Drive lever not in neutral

3-40

Wrong SAE grade of engine lubrication oil

5-51

Fuel grade does not comply with specifications

5-51

Insufficient fuel supply

–

Defective or flat battery

5-35

Loose or oxidised cable connections in starter circuit

–

Defective starter, or pinion does not engage

–

Wrong valve clearance

–

Defective fuel injector

–

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

Engine overheats. Temperature warning system responds

Wrong valve clearance

–

Injection line leaks

–

Defective fuel injector

–

Oil level too low

5-6

Oil level too high

5-6

Dirty air filter

5-16

Defective air filter maintenance switch or gauge

5-15

Dirty oil/water radiator fins

5-13

Defective fan, torn or loose V-belt

5-17

Defective fuel injector

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5-51

–

4-1

Troubleshooting Diesel engine malfunctions

Insufficient engine output

Engine does not run on all cylinders

Possible causes

See page

Oil level too high

5-6

Fuel grade does not comply with specifications

5-51

Dirty air filter

5-16

Defective air filter maintenance switch or gauge

5-15

Wrong valve clearance

–

Injection line leaks

–

Defective fuel injector

–

Injection line leaks

–

Insufficient fuel supply

5-4, 5-5

Defective fuel injector

–

Oil level too low Insufficient or no engine oil pressure

Engine inclination too high

Engine oil consumption too high

White Engine smoke

Black

4-2

–

Wrong SAE grade of engine lubrication oil

5-51

Oil level too high

5-6

Engine inclination too high Blue

5-6

Oil level too high

– 5-6

Engine inclination too high

–

Engine starting temperature too low

–

Fuel grade does not comply with specifications

5-51

Wrong valve clearance

–

Defective fuel injector

–

Dirty air filter

5-15

Defective air filter maintenance switch or gauge

5-15

Wrong valve clearance

–

Defective fuel injector

–

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Troubleshooting 4.2 Malfunctions in the air conditioning system (option) Repairs must be carried out only by authorised and trained staff Malfunctions in the air conditioning system

Possible causes Defective or loose fuse

Fan does not run

Fan cannot be switched off

Reduced fan output

No or insufficient heating output

See page 6-7

Interrupted line

–

Defective fan motor

–

Defective fan switch

3-51

Short circuit in cable or in fan switch

–

Dirty contacts

–

Size of electric lines too small

–

Heat exchanger extremely dirty

5-33

Flow temperature too low

–

Defective thermostat

–

Dirty heat exchanger fins

5-33

Loose hose connection Loss of refrigerant on equipment

Damaged hose Damaged heat exchanger Interruption in solenoid coil of compressor Loose or torn V-belt

Compressor does not run

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

5-33

Compressor clutch slips Defective controls Evaporator overflow Iced-up evaporator

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Expansion valve is stuck in open position Thermostat sensor in wrong position Defective expansion valve or thermostat

4-3

Troubleshooting Malfunctions in the air conditioning system

Possible causes

Clogged evaporator

Dirty radiator fins

Loss of refrigerant

See page

Refrigerating-agent line interrupted System leak Clogged fan duct

Insufficient refrigerating output

Level of refrigerant too low Humidity in system

System cools with interruptions

Line interruption, insufficient ground connections or loose contacts in solenoid coil of compressor

5-33

Defective fan motor Loose or excessively worn V-belt Loud clutch Very loud system

Loose condensor bracket or inside parts of compressor Excessive wear of fan motor System overfill Not enough refrigerant in the system

4-4

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Maintenance

Maintenance

5

Maintenance

5.1 Introduction Operational readiness and the service life of your telehandler are heavily dependent on maintenance.

Caution!

Before carrying out service and maintenance work, always bear in mind the following: ☞ chapter 2 “SAFETY INSTRUCTIONS” of this Operator's Manual ☞ the instructions given in the Operator's Manuals of the attachments ☞ Make sure the lift ram of the telescopic boom is secured with a prop so the telescopic boom cannot be lowered unintentionally if you need to carry out maintenance work with the telescopic boom raised 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.

The maintenance plan indicates when the maintenance work mentioned below must be carried out. ➥ – see Maintenance plan (overview) on page 5-47

5.2 Safety prop for telescopic boom Safety prop A is located at the rear right on the machine frame

Danger!

A

Do not carry out assembly and maintenance work if the telescopic boom is raised and not secured, otherwise there is a danger of crushing and injury!

☞ Raising the telescopic boom ☞ Fit safety prop A over the piston rod on the extended lift ram ☞ Turn safety strut 180° and secure it with pin B (see figure)

A

A B Fig. 164: Safety prop for telescopic boom

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5-1

Maintenance 5.3 Fuel system General safety instructions for refuelling • • • • •

Extreme caution is essential when handling fuel – high risk of fire!

Never carry out work on the fuel system in the vicinity of naked flames or sparks!

Do not smoke when working on the fuel system or when refuelling!

Before refuelling, stop the engine and remove the ignition key!

Do not refuel in closed rooms!

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner! Keep the machine clean to reduce the risk of fire and wipe away fuel spills immediately!

Diesel fuel specification Caution!

Use only the diesel fuels listed in the table below! ☞ If other fuels are used, warranty rights shall not apply in case of diesel engine damage (guarantee)! ☞ Do not use diesel fuel with additives

Specification

Cetane number

Use (°C)

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

Min. 49

Up to -44 °C outside temperature

Stationary fuel pumps Wrong

Right

✓

Fig. 165: Refuelling from a barrel

5-2

✗

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

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Maintenance Refuelling Filler inlet A of the fuel tank is located on the left in driving direction, behind the cab A

Danger!

Do not refuel in closed rooms – danger of intoxication!

☞ Never carry out work on the fuel system in the vicinity of naked flames or sparks

Fig. 166: Fuel filler inlet

Bleeding the fuel system

1

2

Fig. 167: Bleeding the fuel system

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Bleed the fuel system in the following cases: • After removing and fitting the fuel filter, prefilter or the fuel lines back on again • After running the fuel tank empty • After running the engine again, after it has been out of service for a longer period of time ☞ Bleed the fuel system as follows: • Stop the engine • Apply the parking brake with the switch (fig. 35/101) • Switch off ignition and remove the ignition key • Fill the fuel tank • Place the container under the engine • Open the engine cover • Slacken bleed screw 1 on the injection pump by a few turns • Press button 2 on the fuel prefilter with your hand (pumping movement) until the fuel comes out free of air from the slackened bleed screw • Tighten bleed screw 1 • Clean the engine vat • Start the engine If the engine runs smoothly for a while, and then stops; or if it does not run smoothly: • Stop the engine • Check once again if there is any air in the fuel system • Bleed the fuel system again as described above • Have this checked by authorised staff if necessary

5-3

Maintenance Checking/replacing the fuel prefilter (water separator) ☞ Drain the condensation water in the fuel prefilter every 50 s/h (service hours) ☞ At the latest when telltale (Fig. 30/57) on the instrument panel comes on

Danger!

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

☞ Never bleed the fuel system if the engine is hot! ☞ Proceed as follows:

A

B Fig. 168: Checking the fuel/water separator

4 3 2 1 Fig. 169: Replacing the fuel/water separator

5-4

• Stop the engine • Apply the parking brake with switch Fig. 35/100 • Switch off ignition and remove the ignition key • Open the engine cover • Place a container to collect the fuel • Remove the lower cover plate and the one on the side • Unscrew drain plug B on sight glass A of the fuel prefilter • Drain the water until the fuel that flows out is clean • Tighten drain plug B • Test run the engine and check for leaks • Install the lower cover plate and the one on the side Replacing the fuel prefilter every 500 s/h (service hours) ☞ Proceed as follows: • Place a container to collect the fuel • Remove the lower cover plate and the one on the side • Remove cable 1 from the plug on the water receptacle • Remove water receptacle 2 (arrow) • Remove filter cartridge 3 with a slight rotation • Clean filter housing 4 • Insert a new filter cartridge 3 • Clean and install water receptacle 2 • Install cable 1 on the plug of the water receptacle • Test run the engine and check for leaks • Install the lower cover plate and the one on the side

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Maintenance Replacing the fuel filter Danger!

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

☞ Never bleed the fuel system if the engine is hot!

Environment!

A

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

Fig. 170: Fuel filter position

☞ Proceed as follows: B A

A Fig. 171: Replacing the fuel filter

• • • • • • • • • • • • • • •

Park the machine on level ground Lower the telescopic boom fully Apply the parking brake with switch Fig. 35/100 Stop the engine Switch off ignition and remove the ignition key Open the engine cover Place a suitable container underneath the engine to collect the fuel as it drains Slacken and unscrew filter cartridge A with a commercially available filter spanner Clean the inside of the filter head Apply a thin coat of fuel to rubber seal B of the new filter cartridge Tighten the new filter cartridge by hand until the gasket makes contact Tighten filter cartridge A by hand by about a further half revolution Bleed the fuel system – see Bleeding the fuel system on page 5-3 Let the engine run and check the filter cartridge for leaks Clean the engine vat

Cleaning the fuel cooler (option) Check fuel cooler A daily for dirt, and clean it if necessary ☞ Remove the complete fuel cooler with bracket B ☞ Blow compressed air from either side to clean the fuel cooler ☞ Mount fuel cooler B A

B

Fig. 172: Cleaning the fuel cooler

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5-5

Maintenance 5.4 Engine lubrication system Checking the engine oil level daily Caution!

max min

If the engine oil level is too low or if an oil change is overdue, this can cause engine damage or loss of output! ☞ Drain the oil ☞ – see Maintenance plan (overview) on page 5-47 A

☞ Proceed as follows: • • • • • • • •

Fig. 173: Checking the oil level

Place the telehandler horizontally Lower the telescopic boom fully Stop the engine and the ignition, and remove the key Apply the parking brake with the switch (fig. 35/101) 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 5-6

Filling up engine oil OIL

A

Caution!

B

Too much or incorrect engine oil can result in engine damage! For this reason: ☞ Do not add engine oil above the MAX mark of oil dipstick A ☞ Use only the specified engine oil ☞ – see Fluids and lubricants on page 5-51

Environment!

Fig. 174: 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: • • • •

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 5-6 • Fill up if necessary and check the oil level again • Close filler cap B • Completely remove all oil spills from the engine

5-6

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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. 175: Optimum engine oil temperature

D

☞ Proceed as follows:

E

• • • •

C

Fig. 176: Oil drain plug

D E F

Fig. 177: Drain coupling with hose

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G

Park the machine on level ground Lower the telescopic boom fully Apply the parking brake with switch Fig. 35/100 Let the engine run until it reaches its operating temperature (oil temperature about 70 – 80 °C) • Stop the engine • Switch off ignition and remove the ignition key • Open the engine cover • Remove the cover plate • Place a container (about 12 l capacity) under the opening to collect the oil as it drains • Unscrew filler cap C of oil drain valve D • Place the drain coupling with a sufficiently long hose F into container G • Screw drain coupling E onto oil drain valve D • The engine oil is drained ☞ Once the oil is completely drained • Unscrew drain coupling E from oil drain valve D • Screw cap C of the oil drain valve back on again • Replace the engine oil filter – see Replacing the engine oil filter (every 500 service hours) on page 5-8 • Fill in engine oil – see Filling up engine oil on page 5-6 • Check the oil level – see Checking the engine oil level daily on page 5-6 • Start the engine and let it run briefly at low speed • Check the engine oil pressure telltale Fig. 30/54 • Stop the engine • Wait a moment 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

5-7

Maintenance Replacing the engine oil filter (every 500 service hours) Engine oil filter H is accessed via the maintenance flap in the rear right wheel well.

Danger!

Caution when handling hot engine oil Danger of burns!

H

☞ Wear protective gloves

Environment!

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

Fig. 178: Engine oil filter position

☞ Proceed as follows: I H

H Fig. 179: Replacing the engine oil filter

• • • • • • • • • • • • • • • • • • • • • •

5-8

Park the machine on level ground Lower the telescopic boom fully Apply the parking brake with switch Fig. 35/100 Stop the engine Switch off ignition and remove the ignition key Open the engine cover Remove the servicing lid Place a suitable container underneath the oil filter to collect the oil as it drains Slacken and unscrew oil filter A with a commercially available oil filter spanner Clean the inside of the filter head Apply a coat of fresh engine oil to rubber seal I 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 5-7 Check the oil level and fill in engine oil if necessary Let the engine run briefly Check the engine oil pressure telltale Fig. 29/54 Stop the engine Check the seal of oil filter H and retighten by hand Check the oil level and fill in engine oil if necessary Completely remove all oil spills from the engine Dispose of the used oil filter in an environmentally friendly manner

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Maintenance 5.5 Engine and hydraulics cooling system Specific information on 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!

Danger of swallowing antifreeze when handling it!

☞ Seek medical attention immediately if antifreeze has been swallowed ☞ Wear protective clothing and gloves ☞ Keep antifreeze out of reach of children • Dirt on the radiator fins reduces the radiator's heat dissipation capacity! To avoid this: • Clean the outside of the radiator at regular intervals. Refer to the maintenance plans for the cleaning intervals • In dusty or dirty work conditions, clean more frequently than indicated in the maintenance plans • An insufficient coolant level reduces the heat dissipation capacity as well and can lead to engine damage!

• Check the coolant level at regular intervals. Refer to the maintenance plan for the intervals – see Maintenance plan (overview) on page 5-47 • 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 • The use of the wrong coolant can destroy the engine and the radiator. Therefore: • Add enough antifreeze to the coolant.

• Use brand-name antifreeze compounds with anticorrosion additives – see Coolant compound table on page 6-13 • Do not use radiator cleaning compounds if an antifreeze compound has been added to the coolant – otherwise this causes sludge to form that can damage the engine

Environment!

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

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5-9

Maintenance Temperature gauge: engine coolant Temperature gauge (with acoustic warning) 71 on the instrument panel monitors the cooling system.

71

Caution!

Engine temperature should be between 80 and 105 °C (the maximum admissible cooling temperature is 110 °C). ☞ If the acoustic warning sounds (115 °C), let the engine run briefly at idling speed until the temperature drops back to 110 °C (acoustic warning no longer sounds) ☞ Stop the engine and check the coolant level, or clean the radiator fins ➥ – see Filling up coolant on page 5-11 ➥ – see Cleaning the radiator fins on page 5-13

Fig. 180: Temperature gauge

Checking the coolant level and quality Important!

Check the coolant level every 10 s/h (service hours) or once a day.

• Check before starting the engine • Check the antifreeze at temperatures below 4 °C

Caution!

Replace the coolant every 2 years to make sure the diesel engine is cooled correctly!

☞ Check the coolant level as follows D

C

MAX

A

B MIN

Fig. 181: Checking the coolant expansion tank

• Park the machine on level ground • Lower the telescopic boom fully • Apply the parking brake with switch Fig. 35/100 • Stop the engine • Switch off ignition and remove the ignition key • Open the engine cover • Check the coolant level in the expansion tank A If the coolant level is below the MIN mark B of the expansion tank: • Fill up coolant to the MAX mark C ☞ Check the coolant quality (antifreeze) with suitable testing equipment (antifreeze tester)

➥ – see Fluids and lubricants on page 5-51 and – see chapter 6 “Coolant compound table” on page 6-13

5-10

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Maintenance Filling up coolant Danger!

The cooling system is hot and under high pressure!

Never open the coolant tank or drain coolant if the engine is hot!

☞ Wait at least 10 minutes after stopping the engine! ☞ Wear protective gloves and clothing ☞ Always actuate the safety valve first on the filler cap of the expansion tank ☞ Open the cap to the first notch and release the pressure ☞ Fill up coolant as follows D

C

MAX

A

MIN

Fig. 182: Filling up coolant in the expansion tank

• Park the machine on level ground • Lower the telescopic boom fully • Apply the parking brake with switch Fig. 35/100 • 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 D to the first notch and release the pressure • Open filler cap D fully • Fill up coolant to the MAX mark C • Use brand-name antifreeze compounds with anticorrosion additives – see Fluids and lubricants on page 5-51 and – see chapter 6 “Coolant compound table” on page 6-13 • Close filler cap D • Start the engine and warm it up to operating temperature (86 – 90 °C or about 186 – 194 °F) • Open the heating circuit fully – see chapter 3 “Cab heating and ventilation” on page 3-50 ➥ The thermostat must be open and the operating temperature must be reached • Stop the engine and remove the key • Allow the engine/cooling system to cool down • Check the coolant level again and fill up coolant if necessary. Repeat the procedure until the correct coolant level is reached • Check the cooling system and the heating water circuit for leaks

Important!

Have leaks immediately repaired by qualified and trained staff!

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5-11

Maintenance Draining coolant Danger!

The cooling system is hot and under high pressure!

Never open the coolant tank or drain coolant if the engine is hot!

☞ Wait at least 10 minutes after stopping the engine! ☞ Wear protective gloves and clothing ☞ Open filler cap D to the first notch of the expansion tank and release the pressure

☞ Drain the coolant as follows: D C

A

MAX MIN

E

Fig. 183: Draining coolant

5-12

• • • • • •

Park the machine on level ground Lower the telescopic boom fully Apply the parking brake with switch Fig. 35/100 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 3-50 • 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 D to the first notch and release the pressure • Open filler cap D fully • Open the lower screw plug on the radiator E and drain the coolant ☞ Fill up coolant as follows: • Close the outlet on radiator E with the screw plug • Fill up coolant up to about 30 mm below filler cap D of the expansion tank ➥ Use brand-name antifreeze compounds with anticorrosion additives – see Fluids and lubricants on page 5-51 and – see chapter 6 “Coolant compound table” on page 6-13 • Close filler cap D fully • Open the heating circuit fully – see chapter 3 “Cab heating and ventilation” on page 3-50 • Start and warm up the engine until the thermostat opens • Stop the engine • Check the cooling system and the heating water circuit for leaks ➥ Have leaks immediately repaired by qualified and trained staff • Check the coolant level MAX in the expansion tank • If necessary, fill in coolant and repeat the procedure until reaching the correct coolant level

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Maintenance Cleaning the radiator fins Danger!

The cooling system is hot and under high pressure!

Never open the coolant tank or drain coolant if the engine is hot!

☞ Wait at least 10 minutes after stopping the engine! ☞ Wear protective gloves and clothing ☞ Open filler cap D to the first notch of the expansion tank and release the pressure

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 cleaning intervals ☞ In dusty or dirty work conditions, clean more frequently than indicated in the maintenance plan

☞ Proceed as follows: • • • • • • •

Fig. 184: Cleaning the radiator

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Park the telehandler on level ground Lower the telescopic boom fully Apply the parking brake with switch Fig. 35/100 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 the engine side

Caution!

In order to ensure the radiator's optimal cooling capacity, do not damage the radiator fins as you clean them with a compressed-air gun!

5-13

Maintenance Cleaning the radiator with the reversing fan (option) 106

The telehandler is fitted with a reversing fan. Pressing tip switch 106 reverses the fan's direction of rotation and cleans the radiator. The radiator can be cleaned at any time with the reversing fan during machine operation and with the diesel engine running.

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

B

Tip switch 106 for the reversing fan is located on the instrument panel on the right. ☞ Press tip switch 106 briefly to position B A

Fig. 185: Tip switch for reversing fan

➥ The fan rotates the other way round with a certain delay, ➥ the fan is in cleaning mode and the ➥ 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

Important!

When working in especially dusty environment, clean the radiator repeatedly and more frequently!

5-14

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Maintenance 5.6 Air filter Checking air filter contamination Cleaning the dust valve once a day ☞ Proceed as follows: • Stop the engine • Apply the parking brake with switch Fig. 35/100 • 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 Weekly check: filter cartridge contamination

51

Telltale 51 on the indicating instrument monitors the filter cartridge. ☞ Filter cartridge D must be replaced if: • Telltale 51 (on the indicating instrument) comes on • At the latest after 500 service hours (however once every year) • – see Replacing the air filter cartridge at 500 s/h (service hours) on page 5-16

A

H

Caution!

Filter cartridges degrade prematurely when in service in acidic air for longer periods of time! ☞ Replace filter cartridge D and safety cartridge F at the latest after 500 service hours!

D F

Fig. 186: Air filter – dust valve

Checking the dust collector once a day ☞ Proceed as follows: 1 2

Fig. 187: Air filter – dust valve

• • • • • •

Stop the engine Apply the parking brake with switch Fig. 35/100 Switch off ignition and remove the ignition key Remove cover 1 from the dust collector Remove and empty the dust container 2 Insert the dust container and mount the cover

Caution!

Make sure the dust in the container is no higher than 25 mm under the cover otherwise the engine is damaged!

When working in especially dusty environment, clean the radiator repeatedly and more frequently!

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5-15

Maintenance Replacing the air filter cartridge at 500 s/h (service hours) Caution!

G

H

307b0700.ai

D

307b0710.ai

H D F

The filter cartridge will be damaged if it is washed or brushed out!

Bear in mind the following to avoid premature engine wear! ☞ Do not clean the filter cartridge ☞ Replace the filter cartridge when the telltale 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 with the switch fig. Fig. 35/100 • 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 safety cartridge F with slightly turning movements • Make sure 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 (make sure it is properly seated) • Close both locks G

Fig. 188: Removing the filter element

5-16

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Maintenance 5.7 V-belts Checking the V-belts Danger!

In order to avoid danger of injury, check, retighten or replace V-belts only at engine standstill!

☞ Stop the engine before carrying out inspection work in the engine compartment!

C

A

A B

C

C

Check the V-belts once a day or every 10 service hours and retighten them if necessary. ☞ Retighten new V-belts after about 15 minutes of running time.

• Stop the engine • Apply the parking brake with switch Fig. 35/100 • Switch off ignition and remove the ignition key • Open the engine cover • Through slots B of V-belt cover A • Carefully inspect the V-belts for damage • 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 ☞ If the V-belt is damaged: • Have the V-belt replaced by authorised staff

Caution!

Fig. 189: Checking V-belt tension

Cracked and stretched V-belts cause engine damage ☞ Have the V-belts replaced by an authorised workshop

Retightening the V-belts D

Fig. 190: Retightening the V-belts

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☞ Retighten as follows: • • • • • • •

Stop the engine Apply the parking brake with switch Fig. 35/100 Switch off ignition and remove the ignition key Open the engine cover Remove V-belt cover A (see Fig. 189, screws C) 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 cover A

5-17

Maintenance 5.8 Hydraulic system Specific safety instructions regarding the hydraulic system • 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 the ignition • Move all control levers of the hydraulic control valves several times • Apply the parking brake to prevent the machine from rolling away before you carry out service and maintenance work • Make sure the lift ram of the telescopic boom is secured with a prop so the telescopic boom cannot be lowered unintentionally if you need to carry out maintenance work with the telescopic boom raised • 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!

• 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 5-51 ☞ 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

Environment!

Collect drained hydraulic oil and biodegradable oil in a suitable container!

Dispose of drained oil and used filters by an ecologically safe method.

Always contact the relevant authorities or commercial establishments in charge of oil disposal before disposing of biodegradable oil.

5-18

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Maintenance Monitoring the hydraulic oil and the reflux filter The red telltale 50 on the indicating instrument monitors the reflux filter.

50

59

Caution!

60

00000

00

h

Fig. 191: Telltale for reflux filter

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Telltale 50 on the indicating instrument comes on if the resistance of the oil flow in the filter is too high ☞ Replace the filter element ☞ Drain the hydraulic oil in case of increased contamination ☞ However after 1500 s/h at the latest or once a year ☞ The filter element and the hydraulic oil may be replaced by an authorised workshop only!

If telltales 59 (overheating) and/or 60 (oil level) come on on the instrument panel: ☞ Check the hydraulic oil level (not enough oil in the tank) ☞ Replace the filter element (highly contaminated filter) Telltale 50 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 telltale 50 on the indicating instrument goes out ☞ Bear in mind the instructions concerning warmup – see chapter 3 “Starting the engine” on page 3-15

5-19

Maintenance Checking the hydraulic oil level once a day

B A

Fig. 192: Oil level sight glass on the hydraulic oil tank

The red telltale Fig. 191/60 on the indicating instrument monitors the hydraulic oil level.

You can also check the hydraulic oil level at the oil level sight glass in the hydraulic oil tank behind the cab. ☞ Proceed as follows: • Park the telehandler on level ground • Retract all hydraulic rams • Stop the engine • Apply the parking brake with switch Fig. 35/100 • Switch off ignition and remove the ignition key • Check the hydraulic oil level in sight glass A ☞ If the oil level is visible in the lower half of the oil level sight glass

➥ OK ☞ If the oil level is not visible in the oil level sight glass (not enough oil) • Fill up the hydraulic oil

Filling up hydraulic oil Caution!

Do not fill up the hydraulic oil unless the engine is stopped. Otherwise, hydraulic oil will run out of the filler opening on the hydraulic tank.

☞ Fill up as follows:

B A

Fig. 193: Hydraulic oil tank

5-20

• Park the telehandler on level ground • Retract all hydraulic rams • Stop the engine • Apply the parking brake with switch Fig. 35/100 • Switch off ignition and remove the ignition key • Clean the area around the filler and breather filter B with a cloth • Open breather filter B by hand With the filter insert in place: • Fill up the hydraulic oil • Check the hydraulic oil level on oil level sight glass A • Fill up if necessary and check again • Firmly close breather filter B by hand

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Maintenance Important information for the use of biodegradable oil • Use only the tested and approved biodegradable hydraulic fluids – see Fluids and lubricants on page 5-51. 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, make sure 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 your dealer

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5-21

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!

• Use paper or wood to check for minor leaks. Never use an unprotected light or naked flame!

• Have damaged flexible lines replaced by authorised workshops only!

1 Q/10

5-22

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 “1 Q/10” means manufactured in the 1st quarter of 2010.

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Maintenance 5.10 Lubrication work General safety instructions • Park the telehandler on level ground • Raise the telescopic boom and secure it with the safety prop on the lift ram ➥ – see Safety prop for telescopic boom on page 5-1 • Stop the engine • Apply the parking brake with switch Fig. 35/100 • Secure the telehandler with chocks to prevent it from rolling • Switch off ignition and remove the ignition key

Caution!

Lubricate all lubrication points mentioned below with lithium-saponified brandname grease – see Fluids and lubricants on page 5-51

Lubricating the front and rear axle oscillation-type bearings Important!

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 lubrication points A are located on the rear left side of the frame and are routed to the axle bearing via hoses

☞ Apply grease to grease nipple A Fig. 194: Grease nipples for oscillation-type bearing

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

B

Fig. 195: Grease nipples on planetary drive bearings

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Maintenance Lubrication points on the telescopic boom: overview A

A

A

A

C

D

B

C

Fig. 196: Lubrication points on telescopic boom

Lubricating the telescopic boom A

☞ Fully extend the telescopic boom ☞ 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 5-1 ☞ Stop the engine ☞ Apply the parking brake with switch Fig. 35/100 ☞ Switch off ignition and remove the ignition key ☞ Apply grease to lubrication points A and B every 20 service hours, or once a day in heavy duty operation ☞ Also apply grease to the slide plates on the inside boom section at regular intervals

Fig. 197: Lubrication points on quickhitch

Checking and adjusting the wear plates Wear plates Fig. 196/C are located between the inside and outside telescopic sections, and wear plates Fig. 196/D are located outside on the telescopic boom.

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

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

Have the wear plates readjusted and replaced by an authorised workshop only.

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Maintenance 5.11 Lubricating with the central lubrication system (option) General functional description of the central lubrication system The central lubrication system allows you to lubricate all lubrication points of the telehandler in one single step.

• The yellow LED or the green telltale in the cab (option) comes on for 1.5 seconds upon switching on ignition to indicate functional readiness of the controls (switch-on check). It stays lit during the entire lubrication procedure.

• The integrated electronic control unit has a data memory for saving the times that have been set or that have elapsed. The time is taken and saved if ignition is switched off during lubrication or during a break. The remaining lubrication time or break time is read from the memory upon switching ignition on again, and lubrication is resumed where it was interrupted.

• A lubrication system malfunction can also be reset by pressing the intermediate lubrication switch, and the pump restarts lubrication.

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.

Important!

Pressing the tip switch on the side of the pump or the tip switch with telltale in the cab (option) 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.

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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. 198: Setting the lubrication times

Water can penetrate into the controls and damage them 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 5-51

Fig. 199: Filling the central lubrication system

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Maintenance 5.12 Maintenance of the brake system Specific safety instructions regarding the brake system Brakes are crucial to safety. Incorrect work can cause brake failure. Therefore all maintenance and 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 of the machine: • Daily check of the level in the brake fluid tank!

• Daily check of the brake lines • Check the quick coupler for the hydraulic trailer brake for leaks (option)

Danger!

Defective brake lines or hoses carry a danger of accident!

☞ Damaged flexible lines or brake lines must immediately be replaced by an authorised workshop

Checking/filling up the brake fluid level The brake-fluid tank is located inside the cab to the left of the seat.

Danger!

A MAX

An incorrect brake fluid grade or an insufficient brake fluid level can impair the safety of the brake system –

MIN

☞ Check the brake fluid in the tank at regular intervals ☞ The brake fluid must comply with the SAE specification

– see Fluids and lubricants on page 5-51 ☞ Contact an authorised workshop immediately if the brake fluid level is lower than allowed ☞ The brake fluid must be replaced every 2 years by an authorised workshop

Fig. 200: Checking the brake fluid level in the tank

☞ If the fluid level is below the MAX mark: • • • • •

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Clean the area around the cover Open tank cover A Fill up brake fluid up to the MAX mark Close the tank cover Check the brake system for leaks and correct function

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Maintenance 5.13 Maintenance: compressed-air brake system (option) Checking the compressed-air tank and lines ☞ Check the system once a day for leaks (sound of escaping air) and damage ➥ Have leaky hose and screw connections repaired by an authorised workshop

Important!

The water in the pressure accumulator is automatically drained

Fig. 201: Water drain valve of compressed-air tank

Checking compressor attachment and drive ☞ Remove V-belt cover B ☞ Check the attachment of the compressor console once a day ☞ Check V-belt tension C of the compressor drive once a day by pressing with your

thumb to check whether the V-belt can be deflected between the pulleys by no more than about 10 mm

B

C

Fig. 202: Water drain valve of compressed-air tank

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Maintenance 5.14 Tyres Daily tyre checks Danger!

All repair work on tyres and rims may only be carried out by authorised workshops.

Important!

Daily 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 6-11 for the authorised tyre types and the correct tyre pressures.

• A tyre table sticker is also affixed on the front window of the machine

☞ Carry out maintenance work once a day: • • • •

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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

5-29

Maintenance Changing wheels Danger!

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

☞ – see chapter 6 “Tyres” on page 6-11 ☞ Check the wheel nuts for tightness after every wheel or tyre change

Caution!

The wheels are heavy and can damage the threads on the wheel studs if they are handled incorrectly! ☞ 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 3-42 • 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 studs • Tighten all wheel nuts part-way • Lower the raised axle • Tighten the wheel nuts to the prescribed tightening torque – see chapter 6 “Specific tightening torques” on page 6-13

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Maintenance 5.15 Heating and ventilation system maintenance The machine's heating system is fitted with a recirculated-air filter and a fine-dust filter.

Clean the filter elements as required, however replace them every 500 s/h at the latest.

The access to the fine-dust or active charcoal filter (option) is located on the outside left of the cab.

Cleaning/replacing the fine-dust filter ☞ Clean the filter element as follows: • • • •

Remove the cover Remove fine-dust filter A or active charcoal filter (option) and check for damage Knock the filter element on a plate on either side Blow compressed air from the inside to the outside to clean the filter, or wash it with water and dry it ➥ Replace the filter element every 500 s/h (service hours) by a new one ➥ Replace the filter more frequently if the machine is used in severe dust conditions • Clean the inside of the filter housing and insert the filter ➥ Make sure it is seated properly • Install the cover

A

Fig. 203: Fresh-air fine-dust filter

Cleaning/replacing the recirculated-air filter B

C

The recirculated-air filter is located underneath the cover to the left of the seat in the cab. ☞ Clean the filter as follows: • Remove screws B • Remove the cover and recirculated-air filter C • Clean recirculated-air filter C with compressed air or water, replace it with a new one if necessary ➥ Replace the recirculated-air filter every 500 s/h (service hours) by a new one ➥ Replace the filter more frequently if the machine is used in severe dust conditions • Clean the inside of the filter housing and insert the filter ➥ Make sure it is seated properly • Install the cover

Fig. 204: Recirculated-air filter of the heating system

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Maintenance 5.16 Air conditioning (option): maintenance General safety instructions regarding the air conditioning system For your own safety, please bear the following instructions in mind: • 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.

• 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.

Danger!

Lines and hoses containing refrigerants and cooling fluids are under pressure and can be hot!

☞ Avoid touching parts containing refrigerants ☞ Switch off the air conditioning during checks and maintenance work ☞ Have repair work carried out by an authorised workshop with trained staff only

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 • Use only the refrigerants indicated on the label for refilling the air conditioning system (R 134a, see arrow)

Fig. 205: Label for air conditioning refill

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Maintenance Daily 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

☞ The driver must carry out the following visual checks once a day • • • • • • •

D

C

C

Stop the engine Apply the parking brake with switch Fig. 35/100 Switch off ignition and remove the ignition key Check for damage of the refrigerating and heating lines Check the hoses for tightness, leaks and chafing Check the electric connections for correct condition and tightness Check the level of the refrigerant ➥ With the system switched on, the refrigerant must be visible and free of air in sight glass B of dehumidifier A • If there is air in sight glass B ➥ The system must be checked for leaks and refilled by an authorised workshop • Clean the dirty condenser C • Open lock D • Tilt the condenser forwards • Clean the condensor with compressed air or by spraying water (do not use a highpressure cleaner) • Tilt back the condenser and safely lock it D once it is clean • Check V-belt tension E and if necessary, retighten the V-belt ➥ Press with your thumb to check whether the V-belt can be deflected between the pulleys by no more than about 10 mm (arrow) ➥ Have a defective V-belt replaced by an authorised workshop

Caution!

E

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

Fig. 206: Air conditioning: evaporator, dehumidifier

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Maintenance 5.17 Maintenance of the electrical system General instructions Maintenance and repair work on the electrical system (including the battery) may be performed only by trained staff and/or authorised workshops!

Specific 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 rinse all affected surfaces immediately with plenty of water • Thoroughly wash any part of the body touched by the acid immediately with plenty of water and seek medical attention at once!

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

• 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!

• Avoid naked flames and sparks and do not smoke in the vicinity of open battery cells – otherwise the gas produced during normal battery operation can ignite!

• Use only 12 V power sources. Higher voltages will damage the electric components • When connecting the battery leads, make sure the poles +/- are not inverted, otherwise sensitive electric components will be damaged • Do not interrupt voltage-carrying circuits at the battery terminals because of the danger of sparking!

• Never place tools or other conductive articles on the battery – danger of short circuit!

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

+

Battery A is located in the engine compartment, on the left next to the hydraulic oil tank.

The battery is low in maintenance and no fluid needs to be refilled under normal operating conditions.

However have the battery checked at regular intervals.

Always follow the specific battery safety instructions!

-

Danger!

A

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!

Fig. 207: Battery

Therefore 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 If acid is spilt:

☞ Thoroughly rinse all affected surfaces immediately with plenty of water ☞ Thoroughly wash any part of the body touched by the acid immediately with

plenty of water and seek medical attention at once! ☞ Avoid naked lights and sparks in the vicinity of the battery and do not smoke! ☞ 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! ☞ Always disconnect the negative terminal (-) from the battery before starting repair work on the electrical system!

☞ Replace the battery as follows: • • • •

Apply the parking brake with switch Fig. 35/100 Switch off ignition and remove the ignition key Remove the key from the battery master switch (option) Remove the battery fixture

Caution!

In order to avoid short circuits when disconnecting the battery leads, always bear in mind the order for removing the leads under all circumstances!

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

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Maintenance Checks at regular intervals Before driving the machine ☞ Check every time before driving the machine: • Is the light system OK? • Is the signalling and warning system OK? Every week ☞ Check once a week: • Electric fuses – see chapter 6 “Fuses: overview” on page 6-7 and Main fuse box with relays (88 kW diesel engine) on page 6-9 • Cable and earth connections • Charge condition of battery – See Checking/replacing the battery on page 5-35.

• Condition of battery terminals

Cables, bulbs and fuses Always observe the following instructions: • Defective components of the electrical system must always be replaced by an authorised expert. Bulbs and fuses may be changed by unqualified persons • When carrying out maintenance work on the electrical system, pay particular attention to ensuring good contact in leads and 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 and Main fuse box with relays (88 kW diesel engine) on page 6-9

Alternator Always observe the following instructions: • Only test run the engine with the battery connected • When connecting the battery, make sure the poles (+/-) are not inverted • Always disconnect the battery before carrying out welding work or connecting a quick battery charger • Replace defective charge telltales immediately

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Maintenance Checking/replacing relays and fuses Checking/replacing fuses and switching relays The fuse board with the relays is located underneath the cover behind the seat.

Caution!

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) Fig. 208: Fuse board

K7

F 40

K6

F 39

K5

K7 F40

F39

Fig. 209: Main fuse box (88 kW engine)

K5

K42

K7

F40 F39

Checking/replacing switching relays ☞ Switch off ignition and disconnect the battery leads ☞ Remove trim A ☞ Relay descriptions and output indications – see page 6-7 Main fuse box with switching relays (88 kW diesel engine) The main fuse box with the main fuse F40 and the ignition lock and preheating fuse F39 is located on the rear wall in the engine compartment.

The high current relay K5 for preheating, the high current relay K7 for starting and the time lag relay K6 for preheating are located below the main fuse box.

Main fuse box with switching relays (103 kW diesel engine) The main fuse box contains the main fuse F40, fuse F39 for the ignition lock and preheating, and fuse F41 for the engine control unit The high current relay K5 for preheating, the high current relay K7 for starting and the switching relay K42 for the engine electronics are located below the main fuse box.

Checking/replacing fuses and relays ☞ Switch off ignition and remove the battery leads or switch off the battery master switch (option) ☞ Remove the fuse box cover ☞ Main fuse and relay descriptions and output indications – see page 6-9

F41 Fig. 210: Main fuse box (103 kW engine)

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Maintenance 5.18 Maintenance: automatic trailer coupling Cleaning and lubricating the trailer coupling Caution!

Make sure 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

☞ 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

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)

36.5 mm C

2.5 mm

7 mm

E

Fig. 211: Rockinger trailer coupling

☞ Check the trailer coupling once a day for wear and play ☞ Apply grease to the base ring ☞ Have a defective trailer coupling replaced by a new one

D

➥ 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

Caution!

Repair work on the trailer coupling must be carried out by an authorised workshop only

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Maintenance 5.19 General maintenance work Specific safety instructions regarding cleaning Cleaning the machine is divided into 3 separate areas: 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 5-43 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 and cause short circuits and • damage seals and disable the controls!

We recommend using the following aids to clean the cab: • Broom • Vacuum cleaner • Damp cloth • Bristle brush • Water with mild soap solution

Cleaning the seat belt • Clean the seat belt (which remains fitted in the machine) only with a mild soap solution; do not use chemical agents as they can destroy the fabric!

Danger!

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

Danger of personal injury! ☞ Only wind the seat belt when it is dry! ☞ Have defective belts replaced

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

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Maintenance Cleaning the engine and the engine compartment Danger!

Clean the engine only when it is at a standstill –

Danger of personal injury! ☞ Stop the engine before cleaning ☞ Remove the ignition key ☞ Apply the parking brake with the switch (fig. 35/101) ☞ Switch off ignition and remove the ignition key

Caution!

The humidity penetrating the electronics causes it to fail and leads to engine damage!

When cleaning the engine with a water or steam jet ☞ The engine must be cold ☞ Do not point the 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 etc. from humidity ☞ If the water jet is unintentionally pointed at electric components, dry them with compressed air and apply contact spray to them.

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.

Pivots and hinges All mechanical pivot points on the machine (e.g. door hinges, joints) and fittings (e.g. door arresters) must be lubricated regularly, even if they are not listed in the lubrication plan.

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Maintenance 5.20 Maintenance: diesel particle filter (option) Checking the electronic filter monitoring The functional readiness or errors and malfunctions of the filter are indicated by the tip switch and the telltale 76 (LED display) on the instrument panel and the acoustic warning indicator.

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

00000

Caution!

00 h

If the red LED display (DPF) comes on or flashes, correct the error or the cause of the error before continuing to operate the machine! ☞ Have troubleshooting carried out only by an authorised workshop!

76 Nr_7_2.iso

Fig. 212: Diesel particle filter telltale

The following alarms can be displayed: LED colour

Alarm

Green

Yellow flashing

Cause

Troubleshooting

Filter OK and operational

High counterpressure

Drive under full load (30 minutes). If this does Pre-alarm: dirty filter not help: dirty filter: clean the filter (service technician)

Drive under full load High counterpressure, (30 minutes). If this does Main alarm: very dirty threshold value not help: dirty filter: clean filter reached the filter (service technician) Red flashing

Red and warning sound

Defective temperature Sensor not plugged in sensor input or defective

Replace the sensor (service technician)

Defective temperature Sensor not plugged in sensor output or defective

Replace the sensor (service technician)

Overdue service interval

Servicing must be carried out

Reset the service interval (service technician)

System error

Several possible causes

Service technician

5.21 Maintenance and service of the attachments 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) 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.

Anticorrosion protection applied in the factory 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, engine and cab bearing: • Seal gaps with anticorrosion wax after assembly

5-43

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 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.

If you replace components, check whether they are classified as in Components coated with anticorrosive wax on page 5-43 and whether they are subject to special treatment before assembly.

5-44

00 0290 174 1 – BA SCORPION

Maintenance Applying the protective anticorrosion coating Bear in mind the following instructions as you apply the anticorrosive wax:

Caution!

Carefully cover all fastening surfaces and elements to which the anticorrosive protection may not be applied – see Components coated with anticorrosive wax on page 5-43 • 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

00 0290 174 1 – BA SCORPION

5-45

Maintenance Notes:

5-46

00 0290 174 1 – BA SCORPION

00 0290 174 1 – BA SCORPION

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

● ● ●

● ● ●

● ●

●

●

●

●

●

● ● ● ●

● ●

●

●

●

● ●

●

• Clean the dust valve on the air filter3 • Clean the dust receptacle on the air filter (option) • V-belt: check condition and pre-tension, retighten and replace if necessary

●

●

● ●

● ●

● ● ●

●

● ● ●

●

●

●

● ●

● ●

at 100 s/h

• When using biodegradable oil: drain the condensation water in the hydraulic oil tank 5

• Check radiator (engine/hydraulic oil) for dirt, clean if necessary6, 7

• Brake fluid6 (level)

Delivery inspection ● ● ●

Maintenance work (once a day)

Condition of paint coating Engine oil (level) Hydraulic oil (level) Check the filter insert in the load sensing line (variable displacement pump) for dirt, clean it if necessary Gearbox oil in front and rear axle differentials and in rear axle gearbox (level) Gearbox oil in front and rear axle, left and right planetary drives (level)

Every 50 s/h once a week

• • • • • •

• Heating/fresh air: fine-dust fiter and recirculated-air filter8 Inspection work ( ):

• Hydraulic oil tank breather filter 4

• Hydraulic oil5 • Hydraulic oil filter insert/reflux filter • Line filter (power train)

Air filter insert 3,4 replace safety cartridge every 3rd time the air filter insert is replaced Gearbox oil in front and rear axle differentials and in rear axle gearbox Gearbox oil in gearbox Gearbox oil in front and rear axle planetary drives (left and right)

“A” 1st Inspection1 ● ● ●

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

• • • •

Operator/driver

● ●

●

●

●

●

●

●

● ● ●

●

● ● ● ●

● ● ●

“C” every 1500 s/h once a year

• Engine oil • Engine oil filter • Fuel filter (prefilter and main filter)

Oil and filter changes (

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

5.23 Maintenance plan (overview)

Workshop Maintenance

Maintenance

5-47

5-48

Air conditioning (option) check coolant level, clean compressor and evaporator Check the multidisc brake of the service and parking brake Compressed-air tank, compressed-air brake (option) Tyre check (damage, air pressure, tread depth) Trailer coupling (damage, wear)

● ● ● ● ● ●

● ● ● ● ● ●

• • • • • • • • • •

Engine and engine bearing Steering system Hydraulic system Telescopic boom (pin locking) Axle mounting, axle suspension Counterweight (attachment) Fastening screws of cardan shafts Fastening screws of cab Wheel nuts Electrical system: check electric and earth connections, chafing on wiring harness, battery terminals

● ● ● ● ● ● ● ● ● ●

• Check and readjust slide plates on telescopic boom. Replace if necessary 10 Check screws and nuts or screw connections for tightness on the following assemblies/components. Retighten if necessary

• • • • •

●

● ● ● ● ● ● ● ● ● ●

● ● ● ● ●

●

● ●

Every 50 s/h once a week

9

Maintenance work (once a day) ● ●

● ● ● ● ● ● ● ● ● ●

● ● ● ● ●

●

● ● ●

“A” 1st Inspection1

• Heating/fresh air: clean the fine-dust or active charcoal filter (option), replace it every 500 s/h if necessary

8

Delivery inspection ●

Workshop

● ● ● ● ● ● ● ● ● ●

● ● ● ● ●

●

●

●

● ●

“B” every 500 s/h2 2nd Inspection

Fuel system Check the fuel/water separator. Drain water if necessary Check valve clearance (engine management). Set if necessary Battery: check charge condition

):

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 operation and maintenance manual of the attachment manufacturer as well.

5.23 Maintenance plan (overview)

Workshop

Maintenance

at 100 s/h

00 0290 174 1 – BA SCORPION

00 0290 174 1 – BA SCORPION

):

• • • • • • •

Service and parking brake, compressed-air brake (option) Steering system: steering column adjustment, synchronous position of wheels Lights and electrical system Safe load indicator of telescopic boom Seat adjustment Frame levelling (option) Control lever lock (joystick) for road travel

Check the function of the following assemblies/components. Rectify if necessary:

Functional check (

● ● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ●

Delivery inspection ● ● ● ● ● ● ● ● ●

Maintenance work (once a day) ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

Every 50 s/h once a week ● ● ● ●

at 100 s/h

● ● ● ●

“A” 1st Inspection1

● ● ● ●

Workshop

● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

● ● ● ●

“B” every 500 s/h2 2nd Inspection

Rear axle oscillating bearing Front and rear axle planetary drive bearings (left and right) Hinges, joints and fittings (e.g. door arrester) Trailer coupling Telescopic boom – see Lubricating the telescopic boom on page 5-24 • Telescopic boom slide plates • Compensating ram bearing • Telescopic ram bearing (push-out ram) • Lift frame bearing • Tilt rod bearing • Tilt lever bearing • Lift ram bearing • Tilt ram bearing • Frame levelling ram on front axle (option) • Quickhitch: bearing on lift frame

)

Operator/driver

● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

● ● ● ●

“C” every 1500 s/h once a year

• • • • •

Lubrication service11 (

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

5.23 Maintenance plan (overview)

Workshop

Maintenance

5-49

5-50

):

Operator/driver Every 50 s/h once a week

Maintenance work (once a day)

Delivery inspection

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Work to be carried out once after the first 100 s/h. This work must be carried out by an authorised workshop for warranty claims to be acknowledged.

Work after the first 500 s/h (2nd Inspection) must be carried out by an authorised workshop for warranty claims to be acknowledged Replace filter insert as indicated by the telltale, however at least every 12 months or 1500 s/h.

When working in an acidic environment, replace the filter every 300 s/h!

When using biodegradable oil: drain the condensation water in the hydraulic oil tank every 500 s/h, in any case before the cold season.

Replace the coolant every 2 years (- see Fluids and lubricants on page 5-51) Depending on operation and dust conditions, it can be necessary to clean the radiator more frequently Depending on operation and dust conditions, it may be necessary to replace the dust filter more frequently Replace the dehumidifier every 2 years or after maintenance and repair work on the refrigerating circuit Minimum wear plate thickness (8 mm) Lubricate attachment according to manufacturer's instructions!

Replace flexible fuel leak oil lines every 2 years Replace flexible lines every 6 years (UVV, DIN 20066 part 5) Replace the brake fluid (LHM) every 2 years (- see Fluids and lubricants on page 5-51)

• Brake system (flexible lines and cylinders) • Air conditioning – flexible lines, compressor, evaporator, attachment

14

• Hydraulic system/telescopic boom (flexible lines and rams) ● ●

●

●

• Steering system (flexible lines and rams)13 13

● ●

• Fuel lines12 • Cooling system (engine – hydraulic oil)

● ●

●

●

● ●

● ●

●

●

● ●

● ●

● ●

●

●

● ●

● ●

“A” 1st Inspection1

● ●

● ●

●

●

● ●

● ●

“B” every 500 s/h2 2nd Inspection

● ●

Workshop

● ●

●

●

● ●

● ●

“C” every 1500 s/h once a year

• Air intake line (air filter, turbocharger, engine charge-air cooler) • Engine lubrication (engine – filter)

Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary:

Leakage check (

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

5.23 Maintenance plan (overview)

Workshop

Maintenance

at 100 s/h

00 0290 174 1 – BA SCORPION

Maintenance

Maintenance 5.24 Fluids and lubricants Component/ application

Engine/machine fluid

Engine oil2 with filter

Diesel engine

20 kph gearbox 30/40 kph gearbox (option) Planetary drives – left and right, front/rear axle

Gearbox oil

Front and rear axle differentials

Temperature

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

Year-round

SAE 10W; EO103

Below -5 °C

SAE 20W20; EO203

-10 to +10 °C

SAE 30; EO303

5 to 30 °C

SAE 85 W 90 (CLAAS Agrishft MT) (API GL4 MIL L-2105) (API GL5 MIL 2105-B)

CLAAS Agrihyd HVLP-D 46 HVLPD 46 (HYD0530)

Capacities 1

12.5 l

0.8 l 4.0 l Year-round

SAE 90 LS (hypoid gear oil) Hydraulic oil4

Hydraulic system, hydraulic oil tank

SAE grade/Specification

0.75 l each 7.1 l each

Year-round

About 100 l5

Multipurpose grease

CLAAS Agrigrease EP 2 lithium-saponified brand-name grease MPG-A3

Year-round

As required

Acid-proof grease

SP-B3

Year-round

As required

Aggressive media (option)

Anticorrosion protection

Anticorit BW 3666

Year-round

As required

Mounting 7 of pins, shafts

Special grease

Optimoly paste “TA” White paste

Year-round

As required

Fuel system, fuel tank

Diesel fuel8,9

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

Year-round - 40 °C

About 190 l

Brake system

Brake fluid10

Agip LHM Super/Shell LHM

Year-round

0.5 l

R 134a/DIN 9860

Year-round

About 1300 g

Year-round

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

Year-round

Water 1.0 l (33 %) Antifreeze 2 l (67 %)

Biodegradable oil

Grease nipples, telescopic boom slide plates Battery terminals

11

Air conditioning (option) Engine cooling

Washer system

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Refrigerant

12

Antifreeze13,14

Cleaning agent12

AVIA Syntofluid 46 PANOLIN HLP Synth 46

HAVOLINE XLC

Water + antifreeze

The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level MIL-L-2104C; API CD/CE/CF4; CCMC-D4 Abbreviation for lubricants (Hauptverband der Deutschen Bauindustrie e. V. – German construction engineering association) DIN 51 524 Total capacity of hydraulic system about 170 l TI 8030-015/K 19/MIL-C-16 173 C-Grade 4 Important! Pins (hard-chromium plated or coated with Molykote 3400A) are inserted in dry state. Lubricate via grease nipples once assembly is over DIN EN 590 If fuels that do not comply with DIN EN or ASTM (USA) are used, warranty rights shall not apply in case of diesel engine damage Do not mix this brake fluid with other brake fluids (standards: B 71 2710 and ISO 7308) Maintenance work must be carried out by trained staff only Bear in mind the safety data sheet during maintenance work See Coolant compound table on page 6-13 and manufacturer indications on the packaging Replace the coolant every 2 years!

00 0290 174 1 – BA SCORPION

5-51

Maintenance 5.25 Maintenance label Affixed on the cab

Explanation of symbols on the maintenance label Symbol

Explanation Before starting maintenance work, follow the safety instructions in the Operator's Manual!

Before starting maintenance work, read the “Maintenance” chapter in the Operator's Manual!

Carry out a functional check of the light system!

Check tyres for damage, pressure and tread depth!

Carry out a functional check and synchronise the steering system!

P

Carry out a functional check of the brake system!

Check hydraulic oil level. Fill up if necessary!

Check engine oil level. Fill up if necessary!

Compress the dust valve Check radiator for engine coolant and hydraulic oil for contamination. Clean if necessary!

Check condition and initial tension of V-belts. Retighten or replace if necessary!

Leakage check: Check for tightness, leaks and chafing: pipes, flexible lines and screw connections. Rectify if necessary!

Visual check!

Check wear parts and screw connections at regular intervals Retighten loose connections immediately and replace worn wear parts!

Leakage check: Check the fuel/water separator. Drain water if necessary!

Lubrication service: Lubricate the assemblies concerned!

5-52

00 0290 174 1 – BA SCORPION

Maintenance Maintenance label

1000153091

Pflege- und Wartungsarbeiten Service and maintenance work Travaux de maintenance Täglich Daily Tous les jours

10 h

20 h

Täglich Daily Tous les jours

P

10 h 20 h Typ 400/ 401/ 402/ 403/ 404

00 0290 174 1 – BA SCORPION

5-53

Maintenance Notes:

5-54

00 0290 174 1 – BA SCORPION

Specifications

Specifications

6

Specifications

6.1 Model and trade names: overview Telehandler

Trade name

404-03

9040

6.2 Frame Sturdy steel sheet frame, rubber-mounted engine

6.3 Engine Exhaust emissions according to Directive 2004/26EC/ level III Type

TCD 2012 L04 2V 88 kW at 2400 rpm with charge-air cooler

103 kW at 2400 rpm with charge-air cooler

Max. torque (counterclockwise rotation)

420 Nm 1500 rpm

520 Nm 1500 rpm

Specific minimum fuel consumption

215 g/kWh

205 g/kWh

Output as per ISO14396

No. of cylinders Displacement Bore and stroke

4 4038 cm³ 101 x 126 mm

Compression ratio Fuel injection system

PDL (pump, line, nozzle)

DCR (Deutz Common Rail)

Firing order

1-3-4-2

Starting aid

Glow plug

Max. inclined position (engine no longer supplied with oil) Oil pressure Valve clearance1 Control plunger play1 exhaust gas recirculation 1.

00 0290 174 1 – BA SCORPION

1:18

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

Forced feed lubrication Intake valve 75° Exhaust valve 120° Control plunger play 144°

Adjust the play when the engine is cold

6-1

Specifications 6.4 Oil/water fan Telehandler model Hydraulic pump Displacement Fan motor Capacity

404-03 Gear pump 17 cm³/rev 14 cm³/rev

6.5 Power train Variable displacement pump Telehandler model Design Displacement Max. operating pressure Starting engine speed Droop

404-03 Automotive, infinitely variable hydrostatic axial-piston gearbox 0 – 90 cm³/rev 450+30 bar 1050 – 1150 rpm 50 bar HP 2100±100 rpm 250 bar HP

Boost 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)

Variable displacement motor Telehandler model Design

Axial piston motor (bent axis design)

Capacity (20 kph)

160 cm³/rev

Capacity (30 kph option)

233 cm³/rev

Capacity (40 kph option)

233+45 cm³/rev

Work range forwards/reverse

0 – 7 kph

Drive range forwards/reverse

0 – 20 kph (Option) 0 – 30 kph (Option) 0 – 40 kph

Traction force1 1.

6-2

404-03

75 kN

With 17.5LR24 XM37 tyres

00 0290 174 1 – BA SCORPION

Specifications 6.6 Axles Front axle Telehandler model Design Differential lock

404-03 Oscillating planetary steering and drive axle, screw connection with frame with brace or frame levelling ram (option) 100 % differential

King-pin inclination

0°

Camber

0°

Maximum steering angle: Toe-in Track width Frame levelling angle of inclination (option)

Max. 40° 0 mm 1920 mm Max. ± 10°

Rear axle Telehandler model Design

Planetary steering and drive axle, oscillating bearing on frame with mechanical oscillating axle interlock (optional hydraulic oscillating axle interlock)

Differential lock

No

King-pin inclination

0°

Camber

0°

Oscillation Maximum steering angle: Toe-in Track width

00 0290 174 1 – BA SCORPION

404-03

± 10° Max. 40° 0 mm 1920 mm

6-3

Specifications 6.7 Service and parking brake Service brake Design

20 kph version ➥ Foot-operated hydraulic multidisc powerbrake 30/40 kph version (option) ➥ Foot-operated dual-circuit hydraulic multidisc powerbrake

Location

20 kph version ➥ Front axle only 30/40 kph version (option) ➥ Front and rear axles

Effect

On both axles via cardan shaft

Brake fluid

Special hydraulic fluid based on basic mineral oil (LHM) – see chapter 5 “Fluids and lubricants” on page 5-51

Parking brake Design

Actuated via switch on instrument panel, electrohydraulic multidisc spring-loaded brake

Location

Front axle1

1.

On left and right between the axle tube and the front axle differential housing

6.8 Steering system Telehandler model

404-03

Design

Hydrostatic 4 wheel steering with emergency steering features

Steering mode: 20 kph

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

Steering mode: 30/40 kph (option)1

4 wheel steering, front axle steering, diagonal steering (crab steering) (high speed automatically enabled when switching over to front axle steering)

Assemblies

Hydraulic pump, priority valve, servostat with safety valves, 1 steering ram per axle, electronically synchronised

Max. pump pressure2

205 – 235 bar 3

Max. steering pressure 1.

2.

3.

6-4

200 bar

30/40 kph version: high speed range only possible with front axle steering!

Measured after the pump Measured after the servostat

00 0290 174 1 – BA SCORPION

Specifications 6.9 Work hydraulics Hydraulic pump Hydraulic pump Design

60 cm³/rev Axial-piston variable displacement pump (LS)

Displacement

150 l/min at 2400 rpm

Location on diesel engine

88 or 103 kW

Control valve Hydraulic oil filter

4 – 7-fold pilot control Reflux filter

Hydraulic ram protection Telehandler model

404-03

Max. operating pressure

250 bar

Tilt ram Secondary protection: Rod side Base side

300 bar 300 bar

Lift ram Secondary protection: Base side

300 bar

Push-out ram Secondary protection: Rod side Base side

300 bar 200 bar

Quickhitch ram (3rd control circuit) Max. operating pressure

210 bar

Lift, tilt and push-out rams: velocity Telehandler model Hydraulic pump (LS axial-piston variable displacement pump)

404-03 60 cm³/rev

Lift ram Raise Lower

8.5 sec 6.5 sec

Tilt ram Dump in Dump out

2.5 sec 2.5 sec

Push-out ram Retract Extend

00 0290 174 1 – BA SCORPION

7.6 sec 8.5 sec

6-5

Specifications Hydraulic pilot control Pilot control pump = boost pump of hydraulic pump Displacement

17 cm³/rev

Charging/boost pressure

30 bar at 2400 rpm

Pilot control unit Control lever (joystick)

➥ Four-way lever – control 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 operation (for long-haul travel and transport)

Stop cock in pilot-control line and switch for 3rd control circuit lock (electric)

Additional control circuit (option) Location

Function

Variable displacement pump 60 cm³/rev Rpm / l/min / bar

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

1500/80/195 2000/100/180 240/100/110

Electric control (solenoid valve) via 3rd control circuit

1500/80/160 2000/100/145 2400/115/120

Electric control (soleFront additional control circuit noid valve) via 3rd coninstalled on outside of telescopic trol circuit with boom external reflux

1500/80/170 2000/100/165 2400/115/150

4th control circuit with external reflux

1500/70/193 2000/105/150 2400/140/140

Rear additional control circuit

6-6

00 0290 174 1 – BA SCORPION

Specifications 6.10 Electrical system Fuses: overview The fuse board is located underneath the cover behind the seat.

No.

(A)

Protected circuit

F1

7.5

Brake light

F2

15

Front socket

F3

10

Mirror adjustment, mirror heating, solenoid valve: additional circuit raise/lower, emergency lowering OFF, overload cutoff

F4

15

Proportional electronics

F5

10

Preheating time control unit, preheating telltale, preheating switching relay, engine electronics

F6 F7

Turn indicators 7.5

F8

Susmic (drive electronics)

F9

Solenoid valve: load stabiliser, hose burst valve, reversing fan, load stabiliser telltale

F10

10

Air-suspension seat (option) Solenoid valve: additional control circuit, tilt ram lock, bucket repositioning, quickhitch lock, load stabiliser relay, hydraulic oscillating axle interlock (option), frame levelling (option), Autohitch unlock (option)

F11 F12

5

Cutoff solenoid

F13

3

Forwards/reverse driving direction telltale, hold electronics, front socket relay, bucket repositioning relay, parking brake solenoid valve

F14

7.5

Driving direction identification solenoid valve, rear horn, reversing light, reversing light, float position solenoid valve

F15 Fig. 213: Fuse box

3

Hour meter, telltale: 3rd control circuit, parking brake, air filter, engine oil pressure, water separator, preheating, hydraulic oil filter, alternator, hydraulic oil level, hydraulic oil temperature, coolant temperature, fuel level indication, speedometer Front and rear axle sensors, speed sensor, telltale for water in fuel, level amplifier, reversing fan tip switch, coolant level telltale

F16

00 0290 174 1 – BA SCORPION

Steering electronics, 4 wheel steering/front axle steering solenoid valve, 4 wheel steering/front axle steering/diagonal steering/synchronism telltale

F17

30

Window heating

F18

25

Heater fan, magnetic coupling compressor

F19

15

Main fuse: right/left low beam, right/left high beam, high beam telltale

F20

10

Rear wiper, washer pump

F21

5

Safe load indicator, window heating time lag relay, window heating switching relay, bucket repositioning sensor, mini switching relay for overload cutoff

F22

20

Switching relay wiper 1st/2nd speed, intermittent wipe relay, front wiper, washer pump, horn

6-7

Specifications No.

(A)

Protected circuit

F23

3

Radio

F24 F25 F26

High beam (right) 7.5

High beam (left) Low beam (right)

F27

Low beam (left)

F28

Side marker lights (right), rear light (right), rear clearance light (right), numberplate lights, switch lights

5 F29 F30 F31

Side marker lights (left), rear light (left), rear clearance light (left), instrument lights, light for cigarette lighter

3

High current relay, start switching relay

15

Main fuse: parking light, rear light, rear socket for additional lights, front socket for additional lights, switch lights, instrument lights, light for cigarette lighter, interior light

F32

Drive interlock/auxiliary heater

F33

Rotating beacon

F34 F35

10

F36

Telescopic boom working light Rear working light Front working light

F37

7.5

Turn indicator relay, turn indicators, radio

F38

15

Socket/cigarette lighter

Electric components

6-8

Description

Output

Alternator

12 V 95 A

Starter

12 V 3.0 kW

Battery

12 V/135 Ah

00 0290 174 1 – BA SCORPION

Specifications Main fuse box with relays (88 kW diesel engine) The main fuse box is located in the engine compartment K7

Fuse no.

F 40

K6

F 39

K5

K7 F40

F39

Rated current (A)

Protected circuit

F39

125 A

Preheating/start fuse (starter)

F40

100 A

Main fuse

Relay no.

Protected circuit

K5

Preheating high current relay

K6

Preheating time lag relay

K7

Start high current relay

Fig. 214: Main fuse box

Main fuse box with relays (103 kW diesel engine) The main fuse box is located in the engine compartment K5

K42

K7

F40 F39 Fuse no.

F41 Fig. 215: Main fuse box (103 kW engine)

00 0290 174 1 – BA SCORPION

Rated current (A)

Protected circuit

F39

125 A

Preheating/start fuse (starter)

F40

100 A

Main fuse

F41

25 A

Main fuse (engine control unit)

Relay no.

Protected circuit

K5

Preheating high current relay

K7

Start high current relay

K42

Engine electronics switching relay

6-9

Specifications Relays (overview) The relays are located underneath the cover behind the seat.

K25 K23 K24 K33

K1

K3

K27

K2 K10

Switching relay no.

Protected circuit

K1

High current relay

K2

High current relay

K3

Reverse driving switching relay

K10

Turn indicator relay

K16

Front socket switching relay

K21

Differential lock

K22

Load stabiliser (option)

K23

Wiper switching relay (1st speed)

K24

Wiper switching relay (2nd speed)

K25

Interval relay (wiper)

K27

Time lag relay for rear window heating (option)

K28

Switching relay for bucket repositioning (option) or front socket (option)

K30

Brake lights switching relay

K31

Fuel preheater switching relay (option, installed in engine compartment)

K28

Fig. 216: Relays

Fig. 216: Relays

6-10

K22

K36

K32

K38

K16

K37

K30

K35

K32

Reversing fan (option) switching relay

K21

K34

K33

High current relay for rear window heating (option)

K34

Switching relay for overload cutoff

K35

Switching relay for overload cutoff

K36

Drive signal switching relay

K37

Drive signal switching relay

K38

Switching relay for other options

00 0290 174 1 – BA SCORPION

Specifications 6.11 Tyres Tyre pressure

Tyre size

Front/rear

Wheel rims Wheel rim

405/70-24 MPT01 152 B

Wheel offset

DW13x24

15.5-25 EM60 TBL 149B

12.00/1.3 x 25

15.5 R25 TL VSDL L5 17.5LR24 A-570 150 A8

3.25 bar

460/70 R24 159A8 XMCL

TW14Lx24

0

17.5L-24 IND 166/155A8 19.5LR24 A-570 149 A8

W15Lx24

500/70 R24 164A8 XMCL 500/70 R24 IND IT530 TL

2.50 bar

DW16Lx24

440/70 R28 IND 152A8 AC70G CGS

3.0 bar

W15Lx28

-5

6.12 Weights Weight Kerb weight1

8600 kg

Gross weight rating

10000 kg

Front/rear gross axle weight rating

6500 kg

Max. authorised load (towing facility) 1.

4000 kg/drawbar load 1000 kg

Without attachment, with driver and full fuel tank

6.13 Trailer weight/drawbar load: trailer couplings (option) Gross trailer weight rating: Trailer without brakes

Tractors and agriculGross tural or forestry machin- Self-propelled drawbar ery work machines load rating Directive 2003/37 EC 1000 kg

With brake (1 axle braked)

3500 kg

With brake (all axles braked)

8000 kg

Trailer with hydraulic or pneumatic brakes

20000 kg

1000 kg1

15000 kg

Control mark e4D077/e4D0157 (see machine documentation) 1.

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2000 kg, taking the axle loads and the overall weight of the telehandler into account. See EC certificate of conformity or indications on the type labels of the trailer couplings

6-11

Specifications 6.14 Noise levels Diesel engine 88 kW 103 kW –

Sound power level

dBA

Measured value

105.6

Guaranteed value

106

Measured value

103.8

Guaranteed value

104

Noise level in the cab

78

Important!

Measurement of sound power level according to EC Directive 2000/14 EC and according to the modified EC Directive 2005/88 EC. Noise level at the driver's ear measured according to EC Directives 84/532/EEC, 89/514/EEC and 95/27/EEC. Measurements carried out on asphalted surface.

6.15 Vibrations, oscillation and acceleration value Vibration 1 Overall vibration value for upper extremities of the body

< 2.5

m----s2

Maximum effective value of weighted acceleration for body

< 0.5

m----s2

1.

6-12

Instruct or inform the operator of danger arising from vibrations

00 0290 174 1 – BA SCORPION

Specifications 6.16 Tightening torques General tightening torques Screw dimensions

1.

Tightening torques in Nm1 8.8

10.9

12.9

M4

3

4

5

M5

5.5

8

10

M6

10

14

16

M8

23

34

40

M10

46

67

79

M12

79

115

135

M14

125

185

220

M16

195

290

340

M18

280

400

470

M20

395

560

660

M22

540

760

890

M24

680

970

1150

M27

1000

1450

1700

M30

1350

1950

2300

These values are valid for screws with untreated, non-lubricated surfaces

Specific tightening torques Description

Tightening torque 630 ±20 Nm

Wheel nut

6.17 Coolant compound table

1.

2.

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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/total hardness 3 – 20 °dGH (do not use salt, lake, river, brackish or industrial water) - see “Fluids and lubricants” on page 5-51

6-13

Specifications 6.18 Payloads model 404-03 Rigid front axle without oscillating axle interlock (rear axle)

Important!

Payload indications with authorised tyres • – see Tyres on page 6-11

6-14

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Specifications Rigid front axle with mechanical or hydraulic oscillating axle interlock (rear axle)

Important!

Payload indications with authorised tyres • – see Tyres on page 6-11

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6-15

Specifications Front axle with frame levelling and without oscillating axle interlock (rear axle)

Important!

Payload indications with authorised tyres • – see Tyres on page 6-11

6-16

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Specifications Front axle with frame levelling and hydraulic oscillating axle interlock (rear axle)

Important!

Payload indications with authorised tyres • – see Tyres on page 6-11

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6-17

Specifications 6.19 Dimensions with bucket d g

f

g

920

e e a

b

c

45°

50°

430 1480 Fig. 217: Machine dimensions

2330

3050 5590

b c d e f g

1.

2.

3.

4.

5.

6-18

1060

200 1920 2320

6440

Telehandler model Overall length1

a

2650

c

2450

b

1710

a

404-03 5590 mm 6440 mm 2450 mm 2650 mm 1760 mm 265 mm 2320 mm 920 mm 5850 mm 9120 mm 5555 mm 8825 mm 4810 mm 8080 mm 270 mm 5960 mm 9205 mm 45°/45° ± 10° 50° 200 mm 430 mm 1920 mm 3050 mm

without standard bucket with standard bucket

Overall height 2 Overall height with rotating beacon 2 Overall height of telescopic bearing2 Access height to cab2 Overall width without bucket3 Cab width Bucket pin height 2 retracted extended Load-over height2, 4 retracted extended Dump height2, 4 retracted extended Dump reach2, 4 extended Length of telescopic extension2 retracted extended 4 4 Dump-in angle /dump-out angle Frame levelling Departure angle Transport position Ground clearance underneath axle and gearbox5 Track width, front/rear Wheelbase: centre Turning radius without frame levelling: Between kerbs Between walls 4 Turning radius with frame levelling (option): Between kerbs Between walls 4

3650 mm 5050 mm 3850 mm 5250 mm

With Autohitch trailer coupling + 320 mm/with automatic trailer coupling + 130 mm With tyres 15.5-25 EM60 (+ 40 mm), 19.5LR24 (+ 60 mm) With tyres 460/70 R24 (+ 20 mm), 15.5-24 TR01 (- 25 mm), 19.5LR24 A-570 and 500/70 R24 (+ 100 mm) 2400 mm wide with standard bucket Ground clearance 405 mm with cardan shaft guard (option)

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Specifications 6.20 Dimensions with pallet forks

d

a

b

a b

c Fig. 218: Machine dimensions

Telehandler model a b c d

1.

2.

404-03 1

Pallet forks pin height retracted extended

5850 mm 9120 mm

Pallet height1, 2

5700 mm 8950 mm

retracted extended

Dump-in angle in transport position2

20 °

2

Dump-out angle

70°

Turning radius without frame levelling: With forks between walls2

5200 mm

Turning radius with frame levelling: With forks between walls2

5300 mm

With tyres 405/70-24 MPT01 (with tyres 405/70-20 (- 50mm), 17.5LR24 (+ 20 mm), 15.5-25 (+ 40 mm), 19.5LR24 (+ 60 mm) With pallet forks 1200 mm

➥ See page 6-18 for further dimensions

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6-19

Specifications Notes:

6-20

00 0290 174 1 – BA SCORPION

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 0290 174 1 BA SCORPION en - 01/10 Printed in Germany