Gehl Wheel Loader 418T Operator’s Manual(909879) - PDF DOWNLOAD by www.heydownloads.com

OPERATOR’S MANUAL Form No. 

909879

418T Wheel Loader

GEHL CONSTRUCTION WARRANTY

GEHL CONSTRUCTION DIVISION of the GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl construction equipment to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months from the Warranty

Start Date:

GEHL CONSTRUCTION WARRANTY INCLUDES:

Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer’s business location.

GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT.

GEHL WARRANTY SERVICE DOES NOT INCLUDE:

1.Transportation to selling dealer’s business location or, at the option of the Original Retail Purchaser, the cost of a service call.

2.Used equipment.

3.Components covered by their own non-Gehl warranties, such as tires, trade accessories and engines.

4.Normal maintenance service and expendable, high wear items.

5.Repairs or adjustments caused by: improper use; failure to follow recommended maintenance procedures; use of unauthorized attachments; accident or other casualty.

6.Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment.

No agent, employee or representative of Gehl has any authority to bind Gehl to any warranty except as specifically set forth herein. Any of these limitations excluded by local law shall be deemed deleted from this warranty; all other terms will continue to apply.

Thecompletedocumentationconsistsof:

Description

Partnumber

Operator’sManual909879

Operator’sManual(Engine)

Sparepartscatalogue909880

Legend

Edition Issued

ASeptember2002

©Copyright–2002GehlCompany

PrintedintheUnitedStatesofAmerica

Allrightsreserved

Nopartofthispublicationmaybereproduced,translatedorusedinanyformorbyanymeans–graphic,electronic ormechanicalincludingphotocopying,recording,tapingor informationstorageorretrievalsystems–withoutprior permissioninwriting.

Thecoverfeaturesthemachinewithpossibleoptionalequipment.

GehlCompany

P.O.Box179

WestBend,WI53095U.S.A.

Document:909879

Partno.:909879

Edition:A

Introduction Introduction....................................................................................................................1-1 Notesonthisoperator’smanual.............................................................................1-1 Machine:Overview...................................................................................................1-2 Briefdescription........................................................................................................1-3 Applications..............................................................................................................1-4 Regulations...............................................................................................................1-5 Machinedata............................................................................................................1-6 Typelabelsandcomponentnumbers.......................................................................1-7 Safetysignsandsymbols.......................................................................................1-8 Safetyinstructions Safetyinstructions..........................................................................................................2-1 Identificationofwarningsanddangers...................................................................2-1 Designateduses.......................................................................................................2-2 Generalconductandsafetyinstructions...................................................................2-3 Safetyinstructionsregardingoperation....................................................................2-5 Safetyinstructionsforserviceandmaintenance......................................................2-9 Warningofspecialhazards...................................................................................2-11 Operation Operation.......................................................................................................................3-1 Overviewofcab.......................................................................................................3-2 Overview:Multifunctionalleverandconsoles.........................................................3-4 Placingintoservice..................................................................................................3-5 Safetyinstructions.............................................................................................3-5 Placingthemachineintoserviceforthefirsttime.............................................3-5 Checklists..........................................................................................................3-6 Drivingthemachine..................................................................................................3-8 Overviewofcontrols:........................................................................................3-8 WarningLights:overview................................................................................3-13 Beforestartingtheengine...............................................................................3-16 Startingtheengine..........................................................................................3-16 Beforedrivingthemachine...............................................................................3-20 Driving.............................................................................................................3-22 Driveranges.....................................................................................................3-23 Differentiallock.................................................................................................3-25 Stoppingthemachine......................................................................................3-25 Parkingthemachine.........................................................................................3-26 Lightsystem.....................................................................................................3-27 Signallingsystem..............................................................................................3-28 Cabheatingandventilation..............................................................................3-29 Windowwashsystem.......................................................................................3-30 Seatadjustment................................................................................................3-31 Seatbelt...........................................................................................................3-33 Driver'sdoorandsidewindow..........................................................................3-35 Othercontrols...................................................................................................3-38 Towingandtransportingthemachine..............................................................3-39 Workingwiththemachine......................................................................................3-42 Generalsafetyinstructions..............................................................................3-42 Loaddiagram...................................................................................................3-42 Safeloadindicator............................................................................................3-43 Controlvalveforthetelescopicunit:overview.................................................3-45 Tableofcontents

I-2 AP0902 Tableofcontents Loweringthetelescopicunitwiththeengineswitchedoff................................3-47 Relievingpressurethequickcouplersonthetelescopicunit.........................3-47 Installinganattachment...................................................................................3-48 Connectingpressurizedquickcouplers...........................................................3-51 Operationofthetelescopicunit........................................................................3-53 Safetydevice“Hoseburstvalve“......................................................................3-55 Workingwithstandardbucketandpalletforks.................................................3-58 Workingwithpalletforks...................................................................................3-66 Troubleshooting Troubleshooting.............................................................................................................4-1 Enginetrouble..........................................................................................................4-2 Possiblecausesformalfunctions.......................................................................4-3 Maintenance Maintenance...................................................................................................................5-1 Introduction..............................................................................................................5-1 Fuelsystem..............................................................................................................5-1 Specificsafetyinstructions................................................................................5-1 Refuelling............................................................................................................5-2 Cleaningthefueltank........................................................................................5-3 Changingthefuelfilter........................................................................................5-4 Cleaningthefuel/waterseparator.......................................................................5-5 Bleedingthefuelsystem.....................................................................................5-6 Enginelubricationsystem.........................................................................................5-7 Checkingtheengineoillevel.............................................................................5-7 Toppinguptheengineoil..................................................................................5-7 Changingtheengineoil......................................................................................5-8 Changingtheengineoilfiltercartridge...............................................................5-9 Engineandhydraulicscoolingsystem....................................................................5-10 Specificsafetyinstructions..............................................................................5-10 Checkingthecoolantlevel/toppingupthecoolantlevel..................................5-11 Cleaningthecoolingfins..................................................................................5-12 Airfilter...................................................................................................................5-13 V-belt.......................................................................................................................5-15 CheckingtheV-belttension.............................................................................5-15 Re-tensioningtheV-belt..................................................................................5-15 Hydraulicsystem.....................................................................................................5-16 Specificsafetyinstructions..............................................................................5-16 Checkingthehydraulicoillevel.......................................................................5-16 Toppingupthehydraulicoil..............................................................................5-17 Changingthehydraulicoil...............................................................................5-17 Hydraulicoilreturnfilter....................................................................................5-20 Replacingthebreatherfilter.............................................................................5-21 Hydraulicpressurelines..................................................................................5-21 Gearboxesandaxles.............................................................................................5-22 Rearaxletransfergearbox..............................................................................5-22 Frontandrearaxledifferentials........................................................................5-24 Frontandrearaxleplanetarydrives................................................................5-25 Lubricatingtherearaxleoscillation-typebearing.............................................5-26

AP0902 I-3 Tableofcontents Maintenanceofthebrakesystem...........................................................................5-27 Specificsafetyinstructions..............................................................................5-27 Checking/toppingupbrakefluid......................................................................5-27 Telescopicunit........................................................................................................5-28 Lubricatingthepivotpointsofthetelescopicunit............................................5-28 Lubricatingthetelescopicunit.........................................................................5-28 Adjustingthewearpads...................................................................................5-29 Tirecare.................................................................................................................5-30 Inspectionwork................................................................................................5-30 Wheelchange...................................................................................................5-31 Heating...................................................................................................................5-32 Cleaningthedustfilteroftheheatingsystem..................................................5-32 Electricalsystem.....................................................................................................5-33 Specificsafetyinstructions..............................................................................5-33 Serviceandmaintenanceworkatregularintervals.........................................5-33 Instructionsconcerningspecificcomponents...................................................5-34 Generalmaintenancework.....................................................................................5-36 Cleaning..........................................................................................................5-36 Boltedconnections...........................................................................................5-38 Pivotsandhinges............................................................................................5-38 Enginefluidsandlubricants..................................................................................5-39 Maintenancekits....................................................................................................5-40 Helpfulinformationforusingtheservicepartslist Helpfulinformationforusingtheservicepartslist.........................................................6-1 Introduction..............................................................................................................6-1 Compositionofservicepartslist..............................................................................6-1 Groups...............................................................................................................6-1 Groupoverview..................................................................................................6-2 Figures................................................................................................................6-3 Numberindex....................................................................................................6-3 Symbolsandabbreviations......................................................................................6-4 Descriptionofsymbols......................................................................................6-4 Abbreviations......................................................................................................6-6 Machinedata...........................................................................................................6-6 Helpfulinformationfororderingserviceparts...........................................................6-7 Orderinformation...............................................................................................6-7 Addressforyourservicepartorder....................................................................6-8 Specifications Specifications................................................................................................................. 7-1 Frame......................................................................................................................7-1 Engine.....................................................................................................................7-1 Powertrain...............................................................................................................7-2 Axles.......................................................................................................................7-2 Brakes.....................................................................................................................7-3 Steering..................................................................................................................7-3 Workhydraulics......................................................................................................7-3 Telescopicunit........................................................................................................7-4 Electricalsystem......................................................................................................7-5 Fuseboxesinsideconsole...............................................................................7-5 Mainfusesinenginecompartment....................................................................7-6 Relays................................................................................................................7-6 Tires.......................................................................................................................... 7-7

I-4 AP0902 Tableofcontents Weights...................................................................................................................7-7 Noiselevels.............................................................................................................7-7 Vibration...................................................................................................................7-8 Dimensions.............................................................................................................7-8 Coolanttable.............................................................................................................7-9 Tighteningtorques...................................................................................................7-9 Generaltighteningtorques................................................................................7-9 Specifictighteningtorques................................................................................7-9 Conversiontables..................................................................................................7-10 Conversionfactors...........................................................................................7-10 Specificconvertedvalues................................................................................7-11 Annex Proofsofmaintenance..................................................................................................A-1 Maintenanceplanmodel418T(overview)....................................................................A-3 Maintenanceplanmodel 418T(maintenancelabel).............................................................................................A-5 Explanationofsymbolsusedinmaintenanceplan..................................................A-5 Legendforhydraulicsdiagram, model418T ❙➜ 418T0001.....................................................................................A-6 Hydraulicsdiagrammodel418T...................................................................................A-7 Electricaldiagram418T................................................................................................A-9

Fuelsystem....................................................................................5-1

Gearboxesandaxles...................................................................5-22

Generalmaintenancework..........................................................5-36

Heating.........................................................................................5-32

Hydraulicoilreturnfilter................................................................5-20

Hydraulicpressurelines...............................................................5-21

Hydraulicsystem..........................................................................5-16

Instructionsconcerningspecificcomponents...............................5-34

Lubricatingtheoscillation-typebearing........................................5-26

Lubricatingthetelescopicunit......................................................5-28

Maintenanceplan...........................................................................A-3 Pivotsandhinges.........................................................................5-38

Planetarydrives............................................................................5-25

Proofsofmaintenance...................................................................A-1

Replacingthefillerandbreatherfiltersonthehydraulicoiltank..5-21

Screwconnections.......................................................................5-38

Serviceandmaintenanceworkatregularintervals......................5-33 Telescopicunit.............................................................................5-28

Toppingupthe

Coolantlevel......................................................................5-11

Engineoil.............................................................................5-7

Hydraulicoil.......................................................................5-17

Transfergearbox..........................................................................5-22

Tirecare.......................................................................................5-30

V-belt............................................................................................5-15

Wheelchange..............................................................................5-31

AP0902 I-5 Index A Abbreviations.........................................................................................1-1 Acceleratorpedal...................................................................................3-9 Applications Attachments....................................................................................1-4 B Backupwarningsystem(option)..........................................................3-24 Biodegradableoil.................................................................................5-19 Brakeinchingpedal...............................................................................3-9 Brakesystem.......................................................................................5-27 Brakefluid.....................................................................................5-27 Safetyinstructions.........................................................................5-27 C Changingdirection...............................................................................3-24 Changingdirection,Tipswitchfor........................................................3-24 Checklists..............................................................................................3-6 Controlelements....................................................................................3-8 Controlleverforattachmentsand3rdcontrolcircuit...........................3-46 Conversionfactors...............................................................................7-10 Convertedvalues.................................................................................7-11 D Designateduseandexemptionfromliability.........................................2-2 Differentiallock....................................................................................3-25 Documents.............................................................................................1-5 Drivingdirectionselectorswitch............................................................3-8 Drivinglicence.......................................................................................1-5 Drivingonpublicroads........................................................................3-20 Drivingthemachine...............................................................................3-8 Dustfilter..............................................................................................5-32 E Electricaldiagram.................................................................................A-9 Enginecoolantpreheater(option).......................................................3-18 Enginepreheater(option)....................................................................3-18 Equipmentofthemachine.....................................................................1-5 F Fieldsofapplication Possibleattachments......................................................................1-4 Fuellevelindicator...............................................................................3-15 Fuelpreheater(option)........................................................................3-18 G Generalconduct....................................................................................2-3 H Hazardwarningsystem.......................................................................3-28 Heating................................................................................................3-29 Highbeam...........................................................................................3-27 Hydraulicoilpreheater(option)............................................................3-18 J Jump-startingtheengine.....................................................................3-19 L Lightsystem.........................................................................................3-27 Loaddiagram.............................................................................1-12,3-42 Loaderunit Checkingthetiltpositionofthebucket.........................................3-58 Lockfordrivingonpublicroads...........................................................3-46 Loweringthetelescopicunitwiththeengineswitchedoff...................3-47 M Machine Briefdescription..............................................................................1-3 Data................................................................................................1-7 Fieldsofapplication........................................................................1-4 Overview........................................................................................1-2 Machineinspections..............................................................................1-5 Maintenance Airfilter.........................................................................................5-13 Biodegradableoil..........................................................................5-19 Bleedingthefuelsystem................................................................5-6 Brakesystem................................................................................5-27 Changingthe Engineoil.............................................................................5-8 Engineoilfiltercartridge......................................................5-9 Fuelfilter..............................................................................5-4 Hydraulicoil.......................................................................5-17 Checkingthe Coolantlevel......................................................................5-11 Engineoillevel.....................................................................5-7 Hydraulicoillevel...............................................................5-16 Cleaning.......................................................................................5-36 Cleaningthe Fueltank..............................................................................5-3 Cleaningthecoolingribs..............................................................5-12 Cleaningthefuel/waterseparator..................................................5-5 Differentials..................................................................................5-24 Electricaldiagram...........................................................................A-9 Electricalsystem..........................................................................5-33 Engineandhydraulicscoolingsystem.........................................5-10 Enginelubricationsystem..............................................................5-7

Index I

I-6 AP0902 Index

Multifunctionallever.............................................................................3-11 O Operation...............................................................................................3-1

Beforemovingoff..........................................................................3-20 Beforestartingtheengine.............................................................3-16 Changingdirection........................................................................3-24 Driveranges.................................................................................3-23

Parkingthemachine.....................................................................3-26

Startingtheengine........................................................................3-16 Stoppingthemachine...................................................................3-25 Operationmanual Notes..............................................................................................1-1 P Palletforks...........................................................................................3-66 Approachingthematerial..............................................................3-66 Loadingthematerial.....................................................................3-67 Safetyinstructions........................................................................3-66 Settingdownthematerial.............................................................3-68 Parkingbrake.......................................................................................3-10 Preheatingstartswitch..........................................................................3-8 R Refuelling...............................................................................................5-2 Regulations............................................................................................1-5 Rotatingbeacon(option).....................................................................3-28 Running-inperiod..................................................................................3-5 S Safeloadindicator...............................................................................3-43 Adjustingsignalvolume................................................................3-44 Overview.......................................................................................3-43 Whattodoif.................................................................................3-44 Safetyinstructions.................................................................................2-1 Identification....................................................................................2-1 Operation........................................................................................2-6 Specialhazards............................................................................2-13 Seatadjustment...................................................................................3-31 Armrestsetting..............................................................................3-32 Backrestsetting............................................................................3-32 Heightsetting................................................................................3-31 Longitudinalsetting.......................................................................3-32 Weightsetting...............................................................................3-31 Seatbelt...............................................................................................3-33 Servicebrake.......................................................................................3-22 Signallingsystem.................................................................................3-28 Signsandsymbols.................................................................................1-9 Specifications.........................................................................................7-1 Axles...............................................................................................7-2 Brakes.............................................................................................7-3 Conversionfactors........................................................................7-10 Coolantcompoundtable.................................................................7-9 Dimensions.....................................................................................7-8 Electricalsystem.............................................................................7-5 Engine.............................................................................................7-1 Frame.............................................................................................7-1 Noiselevels....................................................................................7-7 Powertrain.....................................................................................7-2 Specificconvertedvalues.............................................................7-11 Steering..........................................................................................7-3 Telescopicunit...............................................................................7-4 Tighteningtorques..........................................................................7-9 Tires...............................................................................................7-7 Vibration.........................................................................................7-8 Weights..........................................................................................7-7 Workhydraulics..............................................................................7-3 Startingwithstartingaid......................................................................3-24 Steering...............................................................................................3-21 Symbols................................................................................................1-1 T Takingintoservice................................................................................3-5 Checklists.......................................................................................3-6 Overviewofthecontrolelements...................................................3-8 Safetyinstructions..........................................................................3-5 Takingthemachineintoserviceforthefirsttime...........................3-5 Telescopicunit Checkingthetransportpositionofthebucket..............................3-58 Depressurizingthequickcouplersonthetelescopicunit.............3-47 Loweringthetelescopicunitwiththeengineswitchedoff............3-47 Lubrication....................................................................................5-28 Re-equippingthetelescopicunit..................................................3-48 WarningLights....................................................................................3-13 Towingandtransportingthemachine.................................................3-39 Transportingwithafullbucket............................................................3-59 Turnindicators....................................................................................3-28 Typelabelsandcomponentnumbers...................................................1-8 Tirecare..............................................................................................5-30 Tireinflationpressuretable.................................................................1-11 Tires......................................................................................................7-7 V Ventilation...........................................................................................3-29 Ventilation,freshair......................................................................3-29 W Warningidentification(option)...............................................................1-5 Warranty................................................................................................2-1 Washerpump......................................................................................3-30 Washersystem Tank.............................................................................................3-30 Wheelchange.....................................................................................5-31 Wheelsynchronizationposition...........................................................3-21 Windowwashsystem..........................................................................3-30 Wipers.................................................................................................3-30 Working ...withpalletforks.........................................................................3-66 Approachingthematerial.............................................................3-66 Loadingthematerial.....................................................................3-67 Safetydevice"Hoseburstvalve".................................................3-55 Settingdownthematerial.............................................................3-68 Workinglight(option)..........................................................................3-27 Workingwiththemachine Freeingthemachine.....................................................................3-65 Grading.........................................................................................3-65 Loadingheapedmaterial..............................................................3-64 Loadingloosematerial.................................................................3-60 Practicalhints...............................................................................3-65 Removingmaterial/digginginhardsoil........................................3-63 Removingmaterial/digginginsoftsoil..........................................3-62

Maintenancekits..................................................................................5-40

Backupwarningsystem(option)...................................................3-24

Movingoff.....................................................................................3-22 Overviewofcab..............................................................................3-2 Overviewofinstrumentpanel,multifunctionalanddrivelever........3-4

Selectingdriverange....................................................................3-23

Section1 Introduction

1.1Notesonthisoperator’smanual

Thisoperator’smanualcontainsimportantinformationonhowtoworksafely,correctlyand economicallywiththewheelloadermodel418T.Therefore,itaimsnotonlyatnewoperators,butitisalsoareferenceforexperienced ones.Ithelpstoavoiddangeroussituations, andreducerepaircostsanddowntimes.Furthermore,thereliabilityandtheservicelifeof themachinewillbeincreasedbyfollowingtheinstructionsintheoperator’smanual.Thisis whytheoperator’smanual must alwaysbekeptinthemachine.

Yourownsafety,aswellasthesafetyofothers,dependstoagreatextentonhowthe machineismovedandoperated.Therefore,carefullyreadandunderstandthisoperator’s manualpriortothefirstuse.Thisoperator’smanualwillhelptofamiliarizeyourselfmore easilywiththemachine,therebyenablingyoutouseitmoresafelyandefficiently.

GeneralsafetyinstructionsaregiveninPart2ofthisoperator’smanual.Carefullyread andunderstandthempriortothefirstdrive.Asarule,keepthefollowinginmind: Carefulandprudentworkingisthebestwaytoavoidaccidents!

Specialsafetyinstructionswithdirectreferencetoservice,functionandoperator’softhe machinearegivenbeforetheproceduretofollowintherespectivechapters.Thesesafety instructionsmustalwaysbeobservedandfollowed.

Operationalsafetyandreadinessofthemachinedonotonlydependonyourskill,butalso onmaintenanceandserviceofthemachine.Thisiswhyregularmaintenanceandservice workisabsolutelynecessary.Extensivemaintenanceandrepairworkshouldalwaysbe carriedoutbyanexpertwithappropriatetraining.Insistonusingoriginalserviceparts whenperformingmaintenanceandrepairwork.Thisensuresoperationalsafetyandreadinessofyourmachine,andmaintainsitsvalue.

Yourdealerwillbepleasedtoansweranyfurtherquestionsregardingthemachineorthe operator’smanual.

Abbreviations/symbols

• Thissymbolstandsforalist

• Thissymbolstandsforthesubdivisionofanenumerationoranactivity.Followthe stepsintherecommendedsequence.

☞ Thissymbolrequiresyoutocarryouttheactivitydescribed.

➥ Descriptionoftheeffectsorresultsofanactivity.

n.s.=notshown

SO=option

Statedwhenevercontrolsorothercomponentsofthemachineareinstalledasanoption.

Thissymbolshowsthedirectionoftravel–forbetterorientationinfiguresand graphics.

AP0902 1–1 1 1Introduction

Introduction

1–2 AP0902 Introduction 1.2Machine:Overview

308b0070.eps 308b0060.eps

31100b0190.eps

1 Workinglight(option) 2 Dangerlabel 3 Fronteyehooks–liftingandstrappingdownthemachine 4 Wheelchock 5 Horn 6 Mark–telescopicunitpositionforlong-haultravel 7 Accesshandle 8 ProtectiveFOPSscreen 9 Noiseemissionlabel 10 ECsign 11 Maximumdrivingspeedlabel 12 Fuelfillerinlet 13 Drawbarpin 14 Reareyehooks–liftingandstrappingdownthemachine 15 Step 16 Workinglight(option) 17 Turnindicator 18 Headlights 19 Enginecoverlock 20 Label–“Donotopenenginecoverbeforeengineisata standstill!” Donottouchanymovingorturningparts! 21 Brakelight,rearlight,turnindicator 22 Rearviewmirror 2 20 6 8 9 4 5 10 11 13 14 21 21 2 20 11 1 16 22 17 18 17 18 7 15 19 12 22 3 20 14 !

Fig.1:Machineoutsideviews

1.3Briefdescription

Thewheelloadermodel418Tisaself-propelledworkmachine. Thismachineisaversatileandpowerfulhelperformovingearth,gravelanddebrisonconstructionsitesandelsewhere.Thewiderangeofattachmentsaccountsforthenumerous applicationsofthemachine:asaforklift,asnowplow,aspreaderforsand,saltetc.,a sweeperoratreereplanter.Seepart 1.4Applications forfurtherapplications.Fitthe machinewiththerespectivesafetydeviceswhenusingitasaliftingmachine(see“Applicationswithliftingaccessories”inPart2SafetyInstructions).

Themaincomponentsofthewheelloadermodel418Tare:

• ROPStestedoperator’scab

• Water-cooledfourcylinderPERKINSdieselengine,58hp(43.1kW)at2400rpm(as perDINISO9249)

• Sturdysteelsheetframeintorsion-resistantbox-typedesign

• Hydrostaticdrivewithelectroniccontrol,inching;12mph(20km/h)max.speed

• Hydrostaticfour-wheelsteeringwithemergencysteeringfeatures

• Frontandrearplanetaryaxles,rearaxlewithoscillation

• Servicebrake(mechanicalorhydrostatic),mechanicaldisk-typeparkingbrake

• Telescopicunitwithsafeloadindicator

Hydrostaticdrive

Thedieselenginedrivesahydraulicpump,whoseoilflowissenttoahydraulicmotorconnectedtotherearaxle.Theforceofthehydraulicmotoristransmittedtotherearaxlevia thetransfergearbox.Atthesametime,thefrontaxleisdrivenbythecardanshaft,ensuringpermanentfourwheeldrive.

Workhydraulicsandhydrostaticfourwheelsteering

Thedieselenginealsodrivesthejointgearpumpforworkhydraulicsandhydrostaticfourwheelsteering.Theoilflowofthispumpdependsonthedieselenginespeedonly.

Whenthemachineisinoperation,theentiredieselengineoutputcanbetransmittedtothe gearpumpforworkhydraulicsandsteering.Thisismadepossiblebytheso-calledinching whichrespondsassoonastheinchingbrakeisused,reducingorcuttingoffpowerinputof thedrive.Therefore,engineoutputisfullyavailableforthetelescopicunitbypressingthe acceleratorpedalandtheinchingbrakepedalatthesametime.

Coolingsystem

Acombinedoil/watercooler(forthedieselengineandthehydraulicoil)islocatedatthe rearofthemachine.Thewarninglightsintheinstrumentpanel 17 ensureconstantmonitoringofthecoolantandhydraulicoiltemperature.Inaddition,anaudiblesignalsoundsin themachinecabassoonasthereisdangerofcoolantorhydraulicoiloverheatingandin caseoflowengineoilpressure.

AP0902 1–3 Introduction

Introduction 1.4Applications

Theattachmentswilldeterminewhereandhowthemachinecanbeused. Thefollowingtablegivesanoverviewofthepossibleattachments.

1–4 AP0902

DescriptionandModel ModelNo. Use Standardbucketw/teeth –normalmaterial 418T 810136Loosening,pickingup,transportingandloadinglooseor solidmaterial(materialdensity ≤ 2700lbs/yd³(18kg/m³)) Palletforks 418T 810135Pickingupandtransportingpalletsperloaddiagram

1.5Regulations

Drivinglicense

Earthmovingmachineryshouldbedrivenonpublicroadsonlyifthedriverhasadrivers license.

Getinformedonandfollowthelegalregulationsofyourcountry.

Equipment

Thehighwayregulationsofyourstate/provincemayrequireyoutoequipyourmachine with:

• Slow-MovingVehicle(SMV)emblem

• warninglights

Becomeinformedonandfollowthelocalhighwayregulations.

GehlwillsendyoutheoriginalcopyofthisDeclarationofManufactureratyourrequest. Pleasestatenameofproduct,modelandidentificationnumber(seetypelabelofthe attachment).

AP0902 1–5 Introduction

Introduction

1.6Machinedata

Thefollowingdataprovideadetaileddescriptionofyourmachine.Pleasesupplyyour dealerwiththesedataforallcorrespondenceortelephoneinquiries.

Pleasereadthedatavalidforyourmachineofftheserialnumberplates,andenterthis datainthelist.Theywillimmediatelybeathandforallinquiriesorservicepartsorders.

Machinemodel:

Dateofregistration:

Servicehours/kilometerreading: ......................................................................................................................................

Serialnumber:

Cabnumber:

Engineno.: ......................................................................................................................................

Variabledisplacementpumpmodel–identificationno.:

Variabledisplacementmotormodel–identificationno.:

Frontaxleno.:

Rearaxleno.: ......................................................................................................................................

Cabno.:

Optionalattachments:

Yourlocaldealer:

• Address:

• Telephone:

1–6 AP0902

1.7Typelabelsandcomponentnumbers

Typelabel

Thetypelabel(Fig.3)islocatedatthefrontrightofthemachineframe(Fig.2 /1)

Serialnumber

Theserialnumberisstampedonthemachineframe(Fig.2/2).Itisalsostampedonthe typelabel(Fig.3)

Exampleforwheelloadermodel418T: 418T0005

Enginenumber

Theenginenumberislocatedonthelabelatthefrontoftheengineblock(arrow,Fig.4)

Example: 073305

Numberofhydraulicpump

Thetypelabel(arrow,Fig.5)islocatedonthepump,belowtheairfilter

Hydraulicmotornumber

Thetypelabel(arrow,Fig.6)islocatedonthelowersideofthehydraulicmotor,abovethe cardanshaft

AP0902 1–7

Introduction

Fhzg-Typ Model Modèle 308 311 10 311 10 0003 2001 Typ Ausf. Version Version Fg.-Nr. Serial no. No. de série Baujahr Model year Anné e fabr. Zul. Achslast vorn Front GAWR PNBE AV Zul. Achslast hinten Rear GAWR PNBE AR Zul. Ges. Gew. GWR PTAC Leistung Output Performance [ kg ] [ kg ] [ kg ] [ kW ] 3750 3750 6000 43,5 31100b0230.eps

Fig.2:Typelabel:location

1 2

Fig.3:Typelabelmodel418T Fig.4:Dieselenginenumber Fig.5:Hydraulicpump:typelabel Fig.6:Hydraulicmotor:typelabel

Front/rearaxlenumber

Theaxlenumberislocatedonthetypelabel,ontherightsideofeachaxle(arrow,Fig.7)

1.8Safetysignsandsymbols

Thefollowingexplainssignsandsymbolsthatdonotcontainexplanatorytext.

...ontheoutsideofthemachine

Meaning

Generalindicationofdanger:

Thissign(Fig.9)warnspersonsstandingorworkingnearthemachineofincreaseddangeraroundthemachine.

Location

Frontleftandrightofmachineframe,andatrearofmachine(Fig.8/3)

Meaning

Eyehooks/limit(Fig.10)stopsonthemachine. Theeyehooksareusedforliftingorstrappingdownthemachine.

Location

Attherearofthecounterweight(Fig.8/2),aswellas atthefrontabovethefrontaxle,leftandrightontheframe

Meaning

1(Fig.11)Donotopenenginecoverbeforeengineisstopped!

2(Fig.11)Donottouchanymovingorturningparts!

Location

Attherearontheenginecover(Fig.8/1),aswellasontheengineblock.

1–8 AP0902 Introduction

Fig.7:Typelabelonthefrontaxle

3 3 2

Fig.8:Decalsattherear 308b0360.eps Fig.9:Dangersign 308b0680.eps Fig.10:Decal:eyehooks Fig.11:Prohibitorysign

Meaning

Readandobservetheoperator’smanualbeforecarryingoutmaintenancework!

Location

Ontheengineblock(Fig.12)

AP0902 1–9 Introduction

Fig.12:Pleaserefertooperator’smanual

Introduction

...insidetheoperator’scompartment

Meaning

Cabtypelabel(Fig.13)

Location

OnleftsideofB-column

Meaning

Reifenluftdrucktabelle

Tire pressure

Pression pneumatiques

Tireinflationpressuretable (Fig.14)

Listofauthorizedtypesoftireswithprescribedtireinflationpressure

Tires Pneumatiques

Reifenbezeichnung vorn (bar) front (bar) AV (bar)

hinten (bar) rear (bar) AR (bar)

Bei Stapelbetrieb Luftdruck vorne um 0,5bar erhöhen! Increase tire pressure by 0,5 bar during pallet forks operation! Augmenter la pression pneumatique de 0,5bar en service porte-palette!

Location

Insidethecab,onleftsideoffrontwindow

Meaning

Loaddiagram (Fig.15foroperationwithpalletforks(forkarms):

Theframednumbersindicatethemaximumauthorizedloadontheforkarmsforindustrial (S=1.25)andoff-road(S=1.67)applicationsrespectively.Themaximumloadvaries accordingtothehorizontalandverticaldistanceoftheloadcenter,inthediagramdepicted ontheforkarmswithadistanceof500mmtotherearoftheforkarms.Thetelescopicunit withforkarmsmoveswithinthedottedrange.

Readingexampleforattachmentno.810135:

Off-roadapplication ➝ safetyfactorS=1.67

Distanceofloadtorearofforkarms=20inches(500mm)

Heightofforkarmabovetirecontactarea=61inches(1.56m)

Distancetotirefront=132inches(3.36m)

Maximumloadis2061lbs(935kg)!

1–10 AP0902

Fig.13:Cabinspectionlabel 31100b0010.eps Fig.14:Tyreinflationpressuretablemodel31100 Fig.15:Loaddiagram

S=1,25/ 1100 kg S=1,67/ 820 kg S=1,25/ 1270 kg S=1,67/ 950 kg S=1,25/ 1500 kg S=1,67/ 1120 kg S=1,25/ 1800 kg S=1,67/ 1345 kg 311-00 311-10

charges Gültig

Anbaugerät

for attachment Valable pour équipement Nr. 10103-00 Nr. 10149-00 Nr. 10162-00 Nr. 10165-00

31100b0210.eps

Traglastdiagramm Load diagram Diagramme de

für

Valid

Section2

Safetyinstructions 2

2Safetyinstructions

2.1Identificationofwarningsanddangers

Importantindicationsregardingthesafetyoftheoperatingpersonnelandthemachineare indicatedinthisoperator’smanualwiththefollowingtermsandsymbols:

DANGER!/WARNING!/CAUTION!

Failuretoobservetheinstructionsidentifiedbythissymbolmayresultin personalinjuryordeathfortheoperatororotherpersons.

☞ Measuresforavoidingdanger

IMPORTANT

Failuretoobservetheinstructionsidentifiedbythissymbolmayresultin damagetothemachine.

☞ Measuresforavoidingdangerforthemachine

NOTE:

Thissymbolidentifiesinstructionsforamoreefficientandeconomicaluseofthe machine.

Environment!

Failuretoobservetheinstructionsidentifiedbythissymbolmayresultindamagetothe environment. Theenvironmentisindangerifenvironmentallyhazardousmaterial(e.g.wasteoil)isnot subjecttoproperuseordisposal.

AP0902 2–1 2

Safetyinstructions

2.2Designateduses

• Themachineisintendedfor:

• Movingearth,gravel,coarsegravelorballastandrubbleaswellas

• Workingwiththeattachmentmentionedinthepresentoperator’smanual Everyotherapplicationisregardedasnotdesignatedfortheuseofthemachine.Gehl willnotbeliablefordamageresultingfromuseotherthanmentionedabove.Theuser alonewillbeartherisk.

Designatedusealsoincludesobservingtheinstructionsintheoperator’smanualand observingtheconditionsofmaintenanceandservice

• Observethepertinentregulationsrelevanttoaccidentprevention,othergenerally acknowledgedregulationsregardingsafetyandoccupationalmedicine,aswellasthe regulationsandstandardsrelevanttomotormachinesandtraffic.Themanufactureris notliablefordamageresultingfromthefailuretoobservetheseregulations

• Thesafetyofthemachinecanbenegativelyaffectedbycarryingoutmachinemodificationswithoutproperauthorityandbyusingspareparts,equipment,attachmentsand optionalequipmentwhichhavenotbeencheckedandapprovedbythemanufacturer. Themanufacturerwillnotbeliablefordamageresultingfromthis

• Themanufacturerwillnotbeliableforpersonalinjuryand/ordamagetoproperty causedbyfailuretoobservethesafetyinstructionsandtheoperator’smanual,andby thefailuretoexerciseduecarewhen:

• Handling

• Operating

• Servicingandcarryingoutmaintenancework

• Repairing themachine.Thisisalsoapplicableinthosecasesinwhichspecialattentionhasnot beendrawntothedutytoexerciseduecare,inthesafetyinstructionsaswellasinthe operator’sandmaintenancemanuals(machine/engine).

Readandunderstandtheoperator’smanualbeforestarting,servicingorrepairingthe machine.Observethesafetyinstructions!

• Themachinemaynotbeusedfortransportjobsonpublicroads

• Inapplicationswithliftingaccessories,themachineistobeusedaccordingtoitsdesignateduseonlyiftherequiredsafetydevicesareinstalledandfunctional

2–2 AP0902

2.3Generalconductandsafetyinstructions

Organizationalmeasures

• Themachinehasbeendesignedandbuiltinaccordancewithcurrentstandardsand therecognizedsafetyregulations.Nevertheless,itsusemayconstitutearisktolifeand limboftheuserorofthirdparties,orcausedamagetothemachineandtoother materialpropertyifitisnotusedproperly.

• Themachinemustonlybeusedinmechanicallygoodconditioninaccordancewithits designateduse(s)andtheinstructionssetoutintheoperator’smanual,andonlyby safety-consciouspersonswhoarefullyawareoftherisksinvolvedinoperatingthe machine.Anymalfunctions,especiallythoseaffectingthesafetyofthemachine,must thereforebecorrectedimmediately!

Basicrule:

Beforestartingthemachine,inspectthemachineforsafetyinworkandroadoperation!

• Carefulandprudentoperationisthebestwaytoavoidaccidents!

• Theoperatinginstructionsmustalwaysbeavailable,andmustthereforebekeptinthe storagecompartmentprovidedforinthecab.

Immediatelycompleteorreplaceanincompleteorillegibleoperator’smanual.

• Inadditiontotheoperatinginstructions,observeandinstructtheoperatorinallapplicablelegalandmandatoryregulationsrelevanttoaccidentpreventionandenvironmentalprotection.

Thesecompulsoryregulationsmayalsodealwiththehandlingofhazardous substances,issuingand/orwearingofpersonalprotectiveequipment,ortrafficregulations.

• Withregardtospecificoperationalfeatures,e.g.thoserelevanttojoborganization, worksequencesorthepersonsdoingthework,supplementtheoperator’smanualby correspondinginstructions,includingthoserelevanttosupervisingandreportingduties.

• Personswhowithworkonthemachinemusthavereadandunderstoodtheoperator’s manualandinparticular,Section2“SafetyInstructions”beforebeginningwork.This appliesespeciallytopersonsworkingonlyoccasionallyonthemachine,e.g.set-upor maintenance.

• Theuser/ownermustcheck–atleastfromtimetotime–whetherthepersonsdoing operationormaintenanceofthemachineareworkingincompliancewiththeoperator’s manualandareawareofrisksandsafetyfactors.

• Theuser/ownercommitshimselftooperateandkeepthemachineinagoodoperating condition,and,ifnecessaryorrequiredbylaw,torequiretheoperatingorservicing personstowearprotectiveclothingetc.

• Intheeventofsafety-relevantmodificationsorchangesonthemachineorofits behavior,stopthemachineimmediatelyandreportthemalfunctiontothecompetent authority/person. Safety-relateddamageormalfunctionsofthemachinemustbecorrectedimmediately.

• Nevermakeanymodifications,additionsor conversionstothemachineanditssuperstructure(cab,telescopicunitetc.),aswellastotheattachments,whichmightaffect safetywithouttheapprovalofthemanuufacturer!Thisalsoappliestotheinstallation andtheadjustmentofsafetydevicesandvalves,aswellastoweldingworkonloadbearingelements.

• Servicepartsmustcomplywiththetechnicalrequirementsspecifiedbythemanuufacturer.Originalservicepartsfromthemanuufacturercanbereliedtodoso.

• Replacehydraulichoseswithinstipulatedandappropriateintervalsevenifnosafetyrelateddefectshavebeendetected.

AP0902 2–3

Safetyinstructions

• Beforeworkingonorwiththemachine,take offjewelry,suchasrings,wristwatches, bracelets,etc.,andtiebacklonghair,and donotwearloose-fittinggarments,suchas unbuttonedorunzippedjackets,tiesorscarves. Injurymayresultfrombeingcaughtupinthemachineryorfromringscatchingon movingparts!

• Keepthemachineclean.Thisreduces:

• Firehazard,e.g.duetooil-soakedragslyingaround

• Dangerofinjury,e.g.duetodirtordebrisonthesteps,and

• Dangerofaccidente.g.duetodirtordebrisonthebrakeoracceleratorpedal!

• Observeallsafety,warningandinformationsignsanddecalsonthemachine.

• Adheretoprescribedintervalsorthosespecifiedintheoperator’smanualforroutine checks/inspectionsandmaintenancework!

• Forservice,inspection,maintenanceorrepairwork,toolsandworkshopequipment adaptedtothetaskinvolvedareabsolutelyindispensable.

Selectionandqualificationofpersonnel,basicresponsibilities

• Anyworkonorwiththemachinemustbeperformedbyreliablepersonnelonly.Donot letunauthorizedpersonsdriveorworkwiththemachine!Observestatutoryminimum agelimits!

• Employonlytrainedorinstructedstaffonthemachine,andsetoutclearlyandunequivocallytheindividualresponsibilitiesofthepersonnelforoperation,set-up,maintenance andrepair!

• Definethemachineoperator'sresponsibilities –includingobservingtrafficregulations. Givetheoperatortheauthoritytorefuseinstructionsbythirdpartiesthatarecontraryto safety.

• Donotallowpersonstobetrainedorinstructed,orpersonstakingpartinageneral trainingcourse,toworkonorwiththemachinewithoutbeingsupervisedbyanexperiencedperson!

• Workontheelectricalsystemandequipment,onthechassisandonthesteeringand brakesystemsmaybecarriedoutonlybyskilledpersonnelwhohasbeenspecially trainedforsuchwork.

Workonthehydraulicsystemofthemachinemustbecarriedoutonlybypersonnel withspecialknowledgeandexperienceofhydraulicequipment!

• Sealofftheareaofdangershoulditnotbepossibletokeepasafedistance. Stopworkifpersonsdonotleavetheareaofdangerinspiteofwarning!Keepoutof theareaofdanger!

Areaofdanger : Theareaofdangeristheareainwhichpersonsareindangerduetothemovementsof the

• Machine

• Workequipment

• Additionalequipment,or

• Material

Thisalsoincludestheareaaffectedbyfallingmaterial,equipment,orbypartsthatare thrown.

2–4 AP0902

2.4Safetyinstructionsregardingoperation

Normaloperation

• Beforebeginningwork,familiarizeyourselfwiththesurroundingsandcircumstancesof theworksite.Theseare,e.g.,obstaclesintheworkingandtravellingarea,thesoil bearingcapacityandanynecessarybarriersseparatingtheworksitefrompublicroads.

• Takethenecessaryprecautionstoensurethatthemachineisusedonlywheninasafe andreliablecondition!

• Operatethemachineonlyifallprotectiveandsafety-relateddevices,e.g.,removable safety-devices,soundproofingelementsandmufflersetc.,areinplaceandfully functional!

• Checkthemachineatleastoncedaily/perworkingshiftforvisibledamageanddefects. Reportanychanges(suchaschangesinthemachine’sworkingbehavior)tothe competentorganization/personimmediately!Ifnecessary,stopthemachineimmediatelyandlockit!

• Intheeventofmalfunctions,stopthemachineimmediatelyandlockit!Haveany defectscorrectedimmediately!

• Startandoperatethemachinefromtheoperator’sseatonly!

• Carryoutstart-upandshut-downproceduresinaccordancewiththeoperator’smanual, andobservethewarninglights!

• Beforeputtingthemachine/attachmentintooperation(start-up/moving),makesure nobodyisatrisk!

• Beforedrivingthemachine,andalsoafterstoppingwork,checkwhetherthebrakes, steering,signallingandlightsystemsarefunctional!

• Beforemovingthemachinealwayscheckwhetherthesupplementaryequipmentand theattachmentshavebeensafelystowedawayorattached!

• Whendrivingonpublicroads,observethetrafficregulationsand,ifnecessary,make surebeforehandthatthemachineisincompliancewiththeseregulations!

• Inconditionsofpoorvisibilityandafterdarkalwaysswitchonthelights!

• Nolifting,loweringorcarryingofpersonsinthe workequipment/attachments!

• Nomountingofamanbasketorpersonalworkplatform!

• Whencrossingunderpasses,bridgesandtunnels,orwhenpassingunderoverhead lines,alwaysmakesurethereissufficientclearance!

• Alwayskeepatasafedistancefromtheedgesofexcavationsandslopes!

• Whenworkinginbuildingsorinenclosedareas,lookoutforthe

• Heightoftheceiling/clearances

• Widthoftheentrancesand

• Maximumloadofceilingsandfloors Provideforsufficientroomventilation–dangerofpoisoning!

AP0902 2–5

Safetyinstructions

• Avoidanyoperationthatmightbearisktostability!

• Duringoperationonslopes,driveorworkuphillordownhill.Ifdrivingacrossaslope cannotbeavoided,bearinmindthestabilitylimitofthemachine! Alwayskeeptheattachments/worktoolclosetotheground.Thisalsoapplieswhen drivingdownhill!

Whendrivingorworkingacrossaslope,theloadmustbeontheuphillsideofthe machine.

• Onslopingterrainalwaysadaptyourdrivingspeedtotheprevailinggroundconditions. Neverchangetoalowergearonaslope,butalwaysbeforereachingit!

• Beforeleavingthemachine

• Lowertheworktool/attachmentstotheground

• Beforeleavingtheoperatorseat,alwayssecurethemachineagainstinadvertent movementandunauthorizeduse!

• Beforestartingwork,checkwhether

• Allsafetydevicesareproperlyinstalledandfunctional

• SlowMovingVehicle(SMV)embleminstalledasneeded

• Warninglightsinstalledasneeded,and

• AFirst-aidkitisonhand

• Beforemovingthemachineorbeforestartingwork:

• Makesurevisibilityissufficient(donotforgetrearviewmirrors!)

• Adjustcorrectseatposition(brakepedalmustbedepressedtothelimit). Neveradjusttheoperatorseatwhendrivingorworking!

• Fastenyourseatbelt

• Inspecttheimmediatearea(children!).Intheworkareatheoperatorisresponsible forthirdparties!

• Cautionwhenhandlingfuel–increaseddangeroffire!

Makesurefueldoesnotcomeintocontactwithhotparts!Stoptheengineduringrefuelling!Donotsmokeduringrefuelling,andavoidfireandsparks!

• Nevergetonoroffamovingmachine!Neverjumpoffthemachine!

• Ifthelightsofthemachinearenotsufficientforthesafeexecutionofcertainwork processes,provideadditionallightingoftheworkarea.

• Installedrearworklightsmustnotbeswitchedonfortravelonpublicroads.Theycan beswitchedoninworkoperationifusersofpublicroadsarenotdazzled.

• Hydrostaticfour-wheelsteeringtakestimegettingusedto.Therefore,adjustthedriving speedtoyourabilitiesandthecircumstances.Selectionandchangesteeringmodeof machineatstandstillonly!

WARNING!

Exposuretocrystallinesilica(foundinsand,soilandrocks)hasbeen associatedwithsilicosis,adebilitatingandoftenfatallungdisease.A HazardReview(Pub.No.2002-129)bytheU.S.NationalInstitutefor OccupationalSafetyandHealth(NIOSH)indicatesasignificantrisk(at least1in100)ofchronicsilicosisforworkersexposedtoinhaledcrystallinesilicaoveraworkinglifetime.NIOSHrecommendsanexposurelimit of0.05mg/m3 asatime-weightedaverageforuptoa10-hrworkdayduringa40-hrworkweek.NIOSHalsorecommendssubstitutinglesshazardousmaterialswhenfeasible,usingrespiratoryprotection,andregular medicalexaminationsforexposedworkers.

2–6 AP0902

Safetyinstructions

ApplicationswithliftingaccessoriesDefinition:

Applicationswithliftingaccessoriesareunderstoodasproceduresinvolvingthelifting, transportingandloweringofloadswithhelpofslingsandload-securingdevices(e.g. ropes,chains).Indoingso,thehelpofpersonsisnecessaryforsecuringanddetaching theload.Thisapplies,forexample,toliftingandloweringofpipes,shaftringsorcontainers.

• Themachinemaybeusedforapplicationswith liftingaccessoriesonlyiftheprescribed safetydevicesareinplaceandfunctional. Theseare,e.g.:

• Accessoriesforslingingandsecuringaliftingattachment(loadhook)

• Loaddiagrams

• Theloadmustbesecuredsoastopreventitfromfallingorslipping.

• Personsguidingtheloadorsecuringitmuststayinvisualcontactwiththemachine operator.

• Themachineoperatormustguidetheloadasnearaspossibletotheground,andavoid anyoscillatingorswingingmovements.

• Themachinemaybemovedwitharaisedloadonlyifthepathofthemachineislevel.

• Thepersonsattachingorsecuringloadsmayapproachtheboomfromthesideonly, andonlyafterthemachineoperatorhasgivenpermission.Themachineoperatormay givehispermissiononlyafterthemachineisatastandstillandthetool/attachmentis notmoving.

• Donotuseanydamagedliftingattachmentsorsuchliftingaccessories(ropes,chains) thatarenotsufficientlysized.Alwayswearprotectivegloveswhenworkingwithlifting accessories.

AP0902 2–7

Safetyinstructions

Trailersandattachments

• Itisnotpermittedtouseatrailerwiththetowingdeviceofthemachine!

• Attachmentsandcounterweightsaffecthandling,aswellasthesteeringandbrake capabilityofthemachine!

• Fittheattachmentswiththespeciallyrequireddevicesonly!

• Beforeuncouplingorcouplinghydrauliclines(hydraulicquickcouplers):

• Turnofftheengine,and

• Relievetheoilpressureinthehydraulicsystembymovingthecontrolleversofthe hydrauliccontrolunitsbackandforthacoupletimes.

• Couplingofattachmentsrequiresspecialcare!

• Securetheattachmentsagainstinadvertentmovement!

• Operatethemachineonlyifallsafetydevicesareinstalledandarefunctional,andifall brake,lightandhydraulicconnectionsareconnected!

• Ifoptionalequipmentisinstalled,alladditionallyrequiredlightinstallations,warning lights,etc.,mustbeprovidedforandfunctional.

• Mounttheattachmentsonlyiftheengineisstoppedandthedrivesystemisswitched off.

• Relievepressureinthehydraulicsystembeforeconnectingordisconnectinghydraulic lines.

• Especiallywhendrivingorworkingwithmachineswithaquickhitchfacilityforthe attachments,besurethattheattachmentissecurelylockedinthequickhitchfacility. Thelockpinmustbevisibleonbothsidesoftheboresontheattachment.Check beforestartingwork.

• Priortoconnectingattachmentstotheloader,securethecontrolleverofthehydraulic controlagainstunintentionalmovement.

• Becarefulwhenconnectingattachmentstotheloadert:becauseofthedangerof personalinjuryduetocrushingandshearing.Besurenobodyisbetweenthemachine andtheequipmentwithoutsecuringthemachineandtheattachmentagainst movement. Transport

• Themachinemustbetowed,loadedandtransportedonlyinaccordancewiththe operator’smanual!

• Fortowingthemachineobservetheprescribedtransportposition,speedand procedure.

• Useonlyappropriatemeansoftransport,anduseliftinggearofadequatecapacity!

• Safelysecurethemachineonthetransportmachine!Usesuitablemountingpointsand load-securingdevices.

• Thestartupproceduremustbestrictlyinaccordancewiththeoperator’smanual!

2–8 AP0902

2.5Safetyinstructionsforserviceandmaintenance

• Avoidanyunsafeoperationalmode!

• Observetheadjusting,maintenanceandinspectionactivitiesandserviceintervalsset outintheoperator’smanual,includinginformationonthereplacementofparts/partial equipment.

Theseactivitiesmaybeperformedbyskilledpersonnelonly.

• Themachinemaynotbeserviced,repairedortest-drivenbyunauthorizedpersonnel.

• Informoperatingpersonnelbeforebeginningspecialoperationsandmaintenancework! Appointapersontosupervisetheactivities!

• Inanyworkconcerningtheoperation,conversionoradjustmentofthemachineandits safetydevices,oranyworkrelatedtomaintenance,inspectionandrepair,observethe start-upandshut-downproceduressetoutintheoperator’smanual,andtheinformationonmaintenancework.

• Ifrequired,securethemaintenanceareaappropriately!

• Priortoperformingservice,maintenanceandrepairwork,attachawarninglabel,such as“Repairwork–donotstartmachine!”,totheignitionlock/steeringwheelortothe controlelements.

Removetheignitionkey!

• Performservice,maintenanceandrepairworkonlyif:

• machineispositionedonfirmandlevelground

• Transmissioncontrolleverisinneutralposition

• Parkingbrakeisapplied

• Allhydraulicallymovableattachmentsandworkingequipmenthavebeenloweredto theground

• Engineisstopped

• Ignitionkeyisremoved,and

• machinehasbeensecuredagainstunintentionalmovement

• Ifmaintenanceorrepairisrequiredwiththeenginerunning:

• Onlyworkingroupsoftwo

• Bothpersonsmustbeauthorizedtooperatethemachine

• Onepersonmustbeseatedontheoperatorseatandmaintainvisualcontactwiththe otherperson

• Observethespecificsafetyinstructionsintherespectiveworkmanual

• Keepasafedistancefromallrotatingandmovingparts,e.g.fanblades,V-belt drives,PTOshaftdrives,fans,etc.

• Priortoperformingassemblyworkonthemachine,besurenomovablepartswillroll awayorstartmoving.

• Toavoidtheriskofaccidents,individualpartsandlargeassembliesbeingmovedfor replacementpurposesmustbecarefullyattachedandsecuredtoliftingtackle. Useonlysuitableliftinggearandsuspensionsystemsinagoodconditionwith adequateliftingcapacity!

Neverworkorstandundersuspendedloads!

AP0902 2–9

Safetyinstructions

• Thefasteningofloadsandtheinstructingofliftoperatorsmustbedonebyexperienced personsonly!

Thepersongivingtheinstructionstotheoperatormustbewithinsightorsoundofhim.

• Foroverheadassemblywork,alwaysusespeciallydesignedorotherwisesafetyorientedladdersandworkplatforms.

Neverusemachinepartsorattachments/superstructuresasaclimbingaid! Wearasafetyharnesswhencarryingoutmaintenanceworkatgreaterheights! Keepallhandles,steps,handrails,platforms,landingsandladdersfreefromdirt,snow andice!

• Cleanthemachine,especiallyconnectionsandthreadedunions,ofanytracesofoil, fuelorpreservativesbeforecarryingoutmaintenance/repairwork! Donotuseaggressivedetergents!

Uselint-freecleaningrags!

• Beforecleaningthemachinewithwater,steamcleaning(high-pressurecleaning)or usingdetergents,coverortapeupallopeningsthat–forsafetyandfunctionalreasons –mustbeprotectedagainstwater,steamordetergents.Specialcaremustbetaken withtheelectricalsystem.

• Aftercleaning,removeallcoversandtapesappliedforthatpurpose!

• Aftercleaning,examineallfuel,lubricantandhydraulicoillinesforleaks,chafemarks anddamage!

Anydefectsfoundmustbecorrectedwithoutdelay!

• Tightenanyscrewconnectionsthathavebeenloosenedduringmaintenanceand repair!

• Anysafetydevicesremovedforset-up,maintenanceorrepairpurposesmustbe refittedandcheckeduponcompletionofthemaintenanceandrepairwork.

• Ensurethatallfluidsandreplacedpartsaredisposedofsafelyandwithminimum environmentalimpact!

• Donotusetheworktoolsasliftingplatformsforpersons!

• Beforeworkingonamachineparts/attachmentsmoveandcauseinjury(bruising, cutting),alwaysensuresafeblocking/supportofthesecomponents.

• Performmaintenanceandrepairworkbeneatharaisedmachine,worktool/attachmentsoradditionalequipmentonlyifasafeandsecuresupporthasbeenprovided (Theuseofhydrauliccylinders,jacks,etc.doesnotsufficientlysecureraisedmachines orequipment/attachments).

• Avoidcontactwithhotparts,suchastheengineblockortheexhaustsystemduringthe operationofthemachineandforsometimeafterwards–dangerofburns!

• Retainerpinscanflyoutorsplinterwhenstruckwithforce–becarefultoavoid personalinjury!

• Donotusestartingfluid(ether)!Thisespeciallyappliestothosecasesinwhicha heaterplug(intake-airpreheating)isusedatthesametime–becauseofthedangerof explosions!

• Usespecialcarewhenworkingonthefuelsystem–becauseoftheincreaseddanger offire!

2–10 AP0902

2.6Warningofspecialhazards

Electricalhazards

• Useonlyoriginalfuseswiththespecifiedcurrentrating! Turnoffthemachineimmediatelyandcorrectthemalfunctioniftroubleoccursinthe electricalsystem!

• Whenworkingwiththemachine,maintainasafedistancefromoverheadelectriclines! Ifworkistobecarriedoutclosetooverheadlines,theequipment/attachmentsmustbe keptwellawayfromthem.Learntheprescribedsafetydistances!

• Ifyourmachinecomesintocontactwithanelectricalwire:

• Donotleavethemachine

• Drivethemachineoutoftheareaofdanger,ifpossible

• Warnothersagainstapproachingandtouchingthemachine

• Havetheelectrifiedwirede-energized

• Donotleavethemachineuntiltheelectrifiedwirehasbeensafelyde-energized!

• Workontheelectricalsystemmayonlybeperformedbyaskilledtechnician,inaccordancewiththeapplicableelectricalsystemrepairprocedures.

• Inspectandchecktheelectricalsystemofthemachineatregularintervals.Defects suchaslooseconnectionsorburnedcablesmustbecorrectedimmediately.

• Observetheoperatingvoltageofthemachine!

• Alwaysremovethegroundstrapfromthebatterywhenworkingontheelectricalsystem orwhenperformingweldingwork!

• Startingwithabatteryjumpcablecanbedangerousifperformedimproperly.Observe thesafetyinstructionsregardingthebattery!

• Operatethemachineonlyinadequatelyventilatedlocations!Beforestartinginternal combustionenginesinenclosedlocations,makesurethatthereissufficientventilation!

• Carryoutwelding,flame-cuttingandgrindingworkonthemachineonlyifithasbeen expresslyauthorized,becausetheremaybeariskofexplosionorfire.

• Beforecarryingoutwelding,flame-cutting andgrindingwork,cleanthemachineandits surroundingsfromdustandotherflammablesubstances,andbesurethatthe premisesareadequatelyventilated–becauseofthedangerofexplosions!

AP0902 2–11

Safetyinstructions

Gas,dust,steam,smoke

Safetyinstructions

Hydraulicequipment

• Workonthehydraulicequipmentofthemachinemaybedoneonlybypersonshaving knowledgeandexperienceinhydraulicsystems!

• Checkalllines,hosesandconnections regularlyforleaksanddamage!Repairany damageandleaksimmediately!Leakingoilmaycauseinjuryandfire.

• Inaccordancewiththeoperator’smanual/instructionsfortheassembly,relievethe pressureinallsystemsectionsandpressurepipes(hydraulicsystem,)tobeopened beforedoinganyrepairwork!

• Hydrauliclinesmustberoutedandfittedproperly.Ensurethatnoconnectionsareinterchanged.Thefittings,lengthsandqualityofthehosesmustcomplywiththedesign specifications.

Noise

Oil,greaseandotherchemicalsubstances

• Wearhearingprotectionifnecessary!

• Whenhandlingoil,greaseandotherchemicalsubstances(e.g.,batteryelectrolyte— sulfuricacid),observetheproduct-relatedsafetyregulations(materialsafetydatasheet MSDS)!

• Becarefulwhenhandlingfluids,becauseoftheriskofburningorscalding!

Battery Whenhandlingthebattery,observethespecificsafetyinstructionstoavoidinjury.Batteriescontainsulfuricacid.

• Especiallywhenchargingbatteries,aswellasduringnormaloperation,ahydrogen-air mixtureisformedinthecellswhichhasadangerofexplosion!

• Inthecaseofafrozenbatteryorofaninsufficientelectrolytelevel,donottrystart-up withjumpercables.Thebatterycanburstorexplode.

Tires

• Repairworkontiresandrimsmaybecarriedoutbyskilledpersonalorbyanauthorizedworkshoponly!

• Damagedtiresand/orwrongtirepressurereducetheoperationalsafetyofthe machine.Thereforeconductregularchecksofthetiresfor

• Prescribedtirepressureand

• Damage

• Donotinflatetireswithinflammablegas–dangerofexplosion!

• Conductregularchecksofthewheelnutsfortightness,atleastevery600service hours.Afterchangingtirescheckthewheelnutsafter10servicehours–tightenif necessary!

2–12 AP0902

Section3 Operation

3Operation

Thischapterdescribingthecontrolscontainsinformationonthefunctionandtheuseoftheindividualwarninglightsandcontrolsinthe operatorcab.

Thepageslistedinthetablerefertothedescriptionofthecorrespondingcontrols. Theidentificationofthecontrolswithacombinationofdigitsoracombinationofdigitsandletters,e.g.40/18 or40/A,means:Figureno. 40/controlelementno.18orposition A infigureno.40. Afigurecarriesnonumberwhenitisplacedtotheleftofthetext.

Unfoldpages3-2and3-4forabetteroverview.

Thesymbolsusedinthedescriptionhavethefollowingmeanings:

• Thissymbolstandsforalist

• Thissymbolstandsforthesubdivisionofanenumerationoranactivity.Followthestepsintherecommendedsequence

☞ Thissymbolrequiresyoutocarryouttheactivitydescribed

➥ Descriptionoftheeffectsorresultsofanactivity

n.s.=notshown

SO=option

Statedwhenevercontrolsorothercomponentsofthemachineareinstalledasanoption.

AP0902 3-1

Overview:seeoverleaf

3.1Overviewofcab

31110b0062.eps 308b0950.eps 308b0960.eps Operation 3-2 AP0902 1 2 3 19 21 22 6 8 9 10 25 7 Fig.16:Cab:overview

Ref.no. Description Formoreinformationseepage 1Doorlock..................................................................................................................................................................................................3-35 2Washerfluidtank.....................................................................................................................................................................................3-30 3Brakeinchingpedal...................................................................................................................................................................................3-9 4Brakefluidtank.......................................................................................................................................................................3-6,5-27,5-39 5Hydrostaticsteering.................................................................................................................................................................................3-21 6Acceleratorpedal.......................................................................................................................................................................................3-9 7Multifunctionallever...........................................................................................................................................................................3-4,3-11 8Sunvisor 9Interiorlight..............................................................................................................................................................................................3-27 10Rearwiper–rockerswitch......................................................................................................................................................................3-30 11Hook 12Doorholderleftandright.........................................................................................................................................................................3-35 13Driveelectronics.......................................................................................................................................................................................3-9, 14Electronicloadindicator...........................................................................................................................................................................3-43 15Frontwiper...............................................................................................................................................................................................3-30 16Sidewindow,locking...............................................................................................................................................................................3-35 17Controlpanel....................................................................................................................................................................................3-4,3-13 18Heatercontrol..........................................................................................................................................................................................3-29 19Controlflapforfan...................................................................................................................................................................................3-29 20Cabtypelabel............................................................................................................................................................................................1-7 21Controllever–telescopic.................................................................................................................................................................3-4,3-45 22Controllever–3rdcontrolcircuit/attachment.........................................................................................................................................3-46 23Lockforcontrollever 22 ..........................................................................................................................................................................3-45 24Sideconsole..............................................................................................................................................................................................3-4 25Parkingbrake...........................................................................................................................................................................................3-10 26Smallstoragecompartment 27Largestoragecompartment 28Operator'sseat........................................................................................................................................................................................3-31 29Seatbelt...................................................................................................................................................................................................3-33 30Toolkit 4 5 17 18 20 23 11 16 24 26 27 30 12 13 15 28 14 29

Overview:seeoverleafO verview:seeoverleaf

AP0902 3-3

3.2Overview:Multifunctionalleverandconsoles

Multifunctionallever

31Lever–turnindicator,highbeam,headlightflasher.............................................................................................................3-11,3-27,3-28

32Rotaryswitch–lights(parkinglightandlowbeam)........................................................................................................................3-11,3-27

33Tipswitch–washerpump..............................................................................................................................................................3-11,3-30

34Tipswitch–horn.............................................................................................................................................................................3-11,3-28

Controlpanel

35WarningLight(red)–alternatorchargefunction.....................................................................................................................................3-13

36WarningLight(red)–coolanttemperature..............................................................................................................................................3-13

37WarningLight(yellow)–airfilter.............................................................................................................................................................3-14

38WarningLight(red)–hydraulicoiltemperature.......................................................................................................................................3-14

39WarningLight(red)–hydraulicoilfilter...................................................................................................................................................3-14

40WarningLight(red)–engineoilpressure................................................................................................................................................3-14

41WarningLight(red)–parkingbrake........................................................................................................................................................3-14

42WarningLight(green)–right/leftturnindicator.......................................................................................................................................3-15

43WarningLight(blue)–highbeam............................................................................................................................................................3-15

44Notassigned 45Hourmeter...............................................................................................................................................................................................3-15 46Fuellevelgauge......................................................................................................................................................................................3-15

49Notassigned Sideconsole 50FuseboxesA,BandC..............................................................................................................................................................................7-5 51Socket/cigarettelighter..............................................................................................................................................................................7-5

52Preheatingstartswitch.....................................................................................................................................................................3-8,3-16

53Rockerswitch–hazardwarningsystem.................................................................................................................................................3-28

54Tipswitch–lockforquickhitchfacility.....................................................................................................................................................3-50

55Rockerswitch–frontwiper......................................................................................................................................................................3-30

56Rockerswitch–fan.................................................................................................................................................................................3-29

57Rockerswitch–frontandrearworkinglights(option).............................................................................................................................3-27

58Rockerswitch–driverange....................................................................................................................................................................3-23

Telescopicunit:controllever

59Tipswitch(green)–forwardtravel...................................................................................................................................................3-8,3-24

60Tipswitch(yellow)–reversetravel...................................................................................................................................................3-8,3-24

61LED(green)–forwardtravel............................................................................................................................................................3-8,3-24

62LED(yellow)–reversetravel.................................................................................................... ........................................................3-8,3-24

63Tipswitch–extendtelescopicunit..........................................................................................................................................................3-53

64Tipswitch–retracttelescopicunit...........................................................................................................................................................3-53

Operation 3-4 AP0902 30864b0091.eps 30864b0060.eps 7 31 33 34 35 36 37 38 39 40 41 42 43 44 46 45

Fig.17:Multifunctionallever Fig.18:Controllever Fig.19:Controlpanel Fig.20:Sideconsole

Page

Ref.no. Description

47Rockerswitch–rotatingbeacon(option)................................................................................................................................................3-28 48Rockerswitch–electricallyoperatedattachments(option).....................................................................................................................3-49

32 51 52 17 24 63 21 22 23 59 64 60 61 62 48 47 49 53 55 56 57 54 50 58 A B C

3.3Placingintoservice

3.3.1Safetyinstructions

• Onlyusethestepsandhandlesprovidedwhenenteringandleavingthecab

• Neverusethecontrolsormovablelinesandcablesashandles

• Neverjumponoroffamovingmachine

• Refertothecorrespondingloaddiagramsfortheloaderunitpalletforks

3.3.2Placingthemachineintoserviceforthefirsttime

Importantinformation

• Themachinemaybeplacedintoservicebyauthorizedpersonnelonly

• Theoperatingpersonnelmusthavereadandunderstoodthisoperator’smanualbefore placingthemachineintoservice

• Themachinemayonlybeusedingoodconditioninaccordancewithitsdesignateduse andtheinstructionssetoutintheoperator’smanual,andonlybypersonswhoarefully awareoftherisksinvolvedinoperatingthemachine

• Gothroughthe“Start-up”checklistinthefollowingsection

Running-inperiod

Operatethemachinecarefullyduringitsfirst100operatinghours.

Thefutureperformanceandservicelifeofthemachineareheavilydependentonthe observanceofthefollowingrecommendationsduringtherunning-inperiod.

• Donotoverloadthemachine,butatthesametimedonotdrivetoocautiouslyeither,as themachinewillneverreachtheproperoperatingtemperature

• Donotruntheengineathighspeedsforextendedperiods

• Increasetheloadgraduallywhilevaryingtheenginespeed

• StrictlyobservethemaintenanceschedulesintheAnnex

AP0902 3–5 Operation

Operation

3.3.3Checklists

Thechecklistsbelowareintendedtoassistyouincheckingandmonitoringthemachine before,duringandafteroperation.

Thesechecklistscannotclaimtobeexhaustive;theyaremerelyintendedasanaidfor youinfulfillingyourdutiesasaconscientiousoperator.

Thecheckingandmonitoringjobslistedbelowaredescribedingreaterdetailinsubsequentsections.

IftheanswertooneofthefollowingquestionsisNO,firstrectifythecauseofthefault beforecommencingorcontinuingwork.

Start-upchecklist

Checkthefollowingpointsbeforetakingthemachineintoserviceorstartingtheengine: No. Question ✔

1Sufficientfuelinthetank?(➠ 5-1)

2CoolantlevelOK?(➠ 5-10)

3Engineoillevelinorder?(➠ 5-7)

4Oillevelinhydraulicoiltankinorder?(➠ 5-16)

5BrakefluidlevelOK?(➠ 5-27)

6Waterlevelinwindscreenwashertankinorder?(➠ 3-30)

7Telescopiclinkagelubricated?(➠ 5-28)

8TireconditionOK?(➠ 5-30)

9Lights,signals,indicators,andwarninglightsOK? (➠ 3-27,3-28,3-13)

10Windows,mirrors,lightsandstepsclean?

11Istheattachmentonthetelescopiccorrectlyconnected?( ➠ 3-48)

12Istheenginecoverfirmlylocked?(➠ 3-38)

13Especiallyaftercleaning,maintenanceorrepairwork: Rags,toolsandotherlooseobjectsremoved?

14ApprovedSMVemblem,hazardwarninglightsinthemachine?(➠ 1-5)

15Seatpositionandrearviewmirrorcorrectlyadjusted?(➠ 3-16)

16Seatbeltfastened?(➠ 3-33)

3–6 AP0902

Operationchecklist

Afterstartingtheengineandduringoperation,checkandobservethefollowingpoints:

No. Question

1WarningLightsforengineoilpressure,coolantlevelandalternatorgoneout? (➠ 3-13)

2Brakingeffectsufficient?(➠ 3-21)

3Temperatureindicatorforenginecoolantinnormalrange?( ➠ 3-13)

4Isthesteeringworkingproperly?(➠ 3-21)

5Isanyonedangerouslyclosetothemachine?( ➠ 2-7)

6SafeloadindicatortestedandOK?(➠ 3-44)

Whentravellingonpublicroads,particularattentionshouldbepaidtothe followingpoints:

7Telescopicunitcompletelyretracted?(➠ 3-53)

8Bucketandattachmentsintransportposition?(➠ 3-20)

9Transportlocksinstalled?(➠ 3-20)

10Controlleverforliftandtilthydraulicsofthetelescopiclocked?(➠ 3-20)

Parkingchecklist

Checkandobservethefollowingpointswhenparkingthemachine:

No. Question ✔

1Attachmentsonthetelescopicunitloweredtotheground?(➠ 3-26,3-45)

2Parkingbrakeapplied?(➠ 3-10)

3Machinecablocked(especiallyifthemachinecannotbesupervised)?( ➠ 3-35)

Whenparkingonpublicroads:

4Machineadequatelysecured?(➠ 3-26)

Whenparkingonuphillanddownhillgradients:

5Machineadditionallysecuredwithchocksunderthewheelstopreventitfrom rollingaway?(➠ 3-26)

AP0902 3–7

Operation

✔

Operation

3.4Drivingthemachine

3.4.1Overviewofcontrols:

NOTE:

Thejoystickisinneutralwhenyoustarttheengine.Neutralisselectedwhenyou applytheparkingbrakeorturnofftheengine.Drivingdirectioncanbeselected onlyafterreleasingtheparkingbrake!

3–8 AP0902

Selectionofdrivingdirection/neutralpositionofdrive ☞ Selectionofdrivingdirection/neutralposition:

Preheatingstartswitch[52] NOTE: Theenginewillstartonlyifparkingbrake16/25 isapplied. DrivingdirectionselectorswitchFunction •

1 0 2 3 52 Fig.21:Preheatingstartswitch P Position Function Powerconsumer P NofunctionNone 0 InsertingorremovingignitionkeyNone 1 ON/driveposition ➥ Allfunctionsareoperational ➥ WarningLight19/41 comesonif parkingbrake16/25 isapplied 2 Preheatingengine(withcoldstartingat<0°C:10–15seconds) 3 Starttheengine ➥ Starterisactuated ➥ WarningLightsmustgoout 21 59

60 61 62 Function Operation Effect • Forward ☞ Pressgreentipswitch 59 ➥ GreenLED 61 comeson • Reverse ☞ Pressyellowtipswitch 60 ➥ YellowLED 62 comeson • Neutralposition ☞ Pressbothtipswitchesatthe sametime ➥ BothLEDsgoout

Fig.22:Drivingdirectionselectorswitch

Driverangeselector[58]Function

• Selectionofdriverangewithrockerswitch 58

Acceleratorpedal[6]

•

☞ Pressrockerswitch 58 in B (above) Long-haultransport,road travel

Theacceleratorpedal 6 controlsthedrivespeedasfollows:

• Presspedal

•

Brakeinchingpedal[3]Function

• Tobrakethemachineirrespectiveofthebrakingeffectofthedriveandthepositionof theacceleratorpedal 6

• Intheinchingrangeofthebrakepedal(pedalpressedinlightly),thepedalcanbeused likeacar’sclutch.Thedrivesystemissuppliedwithlesshydraulicoil,whichmeansthe entireengineoutputisavailabletotheworkhydraulics.Thisallowstheloadertoraise morerapidly

Braking

☞ Pressthebrakeinchingpedal 3 downwithforce

Inching

☞ Pressthebrakeinchingpedal 3 downlightly

AP0902 3–9

Operation

58 B A Driverange

Recommendedfor:

Fig.23:Driverangeswitch

Rockerswitch58

0–3mph (0–5km/h)

• Low

Heavywork

☞ Pressrockerswitch 58 in A (below)

0–12mph

High

(0–20km/h)

Fig.24:Acceleratorpedal

➥ Drivespeedisincreased

➥ Drivespeedisreduced

• Releasepedalslowly

Releasepedalfully ➥ Hydrostaticbraking

Fig.25:Brakeinchingpedal

NOTE:

Adrivinginterlockpreventsthemachinefromdrivingwiththeparkingbrake applied.

Theforward/reversedrivingdirectioncanbeselectedviatipswitches1859/and 18/60 andonlyiftheparkingbrakeisreleased.Applyingtheparkingbrakeautomaticallyinterruptsforward/reversedrivingdirection,whichissettoneutral(LEDs onjoystickgoesout).

• Preventsthemachinerollingaway

• Emergencybrakeincaseofservicebrakebreakdown

WARNING!

Usetheparkingbrake 25 insteadoftheservicebrakeonlyinanemergency, i.e.incaseofabreakdownoftheservicebrake.Thebrakelightsdonotlight up,andthemachinestopsabruptly,whichcanbehazardous

☞ Innormaloperation,onlyusebrakeinchingpedal 16/3 asaservicebrake

Topreventthemachinerollingaway

☞ Pulluplever 25 tothelastnotch

➥ WarningLight19/41 comeson

Toreleasetheparkingbrake

☞ Pulluplever 25 slightly

☞ Depressbutton a

☞ Movelever 25 allthewaydown

3–10 AP0902

Parkingbrake[25]Function

Operation

Fig.26:Parkingbrake

Fig.27:Applyingandreleasingtheparkingbrake

Tousetheparkingbrakeasemergencybrakewhendrivingthemachine

WARNING!

Operatingtheparkingbrake 25 whendrivingcausesthemachinedriveto disengage.Thiscausessuddendecelerationatfullspeed,whichcanbe hazardous.

☞ Usetheparkingbrake 25 asservicebrakeonlyincaseofemergency

☞ Beforeusingtheparkingbrake 25 reducedrivingspeedifpossible

☞ Pulluplever 25

Multifunctionallever[7]Function

• Switchontheturnindicatorswithlever 31

• Switchhighbeamonandoffwithlever 31

• Flashheadlightflasherwithlever 31

• Switchlights(parkinglightandlowbeam)onandoffwithrotaryswitch 32

• Switchonfrontwindowwasherpumpwithtipswitch 33

• Soundhornwithtipswitch 34

Switchesonhighbeamandheadlightflasherwithlever31

Lever31

☞ Centralposition 0

☞ Lowerposition I

☞ Raisetoposition II andholdinthis position

Turnindicationwithlever31

Lever31

☞ Pullupward

☞ Incenterposition

☞ Pullbackward

Effect

➥ Highbeamandheadlightflasher OFF

➥ Lowbeam ON

➥ Highbeam ON iflowbeamisswitched onwithrotaryswitch 32.WarningLight 43 comeson

➥ Headlightflasher ON,warninglight 43 comeson

Effect

➥ Leftturnindicatorsactuated,warning light 42 flashes

➥ None

➥ Rightturnindicatorsactuated,warning light 42 flashes

AP0902 3–11 Operation

31 7 32 33

34 7

Fig.28:Multifunctionallever

31 II 0 I

Fig.29:Switchingonhighbeamandheadlightflasher

31 L R

Fig.30:Turnindicators

3–12 AP0902 Operation Actuatewasherpumpwithtipswitch33 Soundhornwithtipswitch34

33 Tipswitch33 Effect ☞ Slidetotheleftandhold ➥ Washerpump ON ☞ Release ➥ Washerpump OFF

Fig.31:Actuatingthewasherpump

34 Tipswitch34 Effect ☞ Press ➥ Horn ON ☞ Release ➥ Horn OFF

Fig.32:Actuatingthehorn

3.4.2WarningLights:overview

Unfoldpage3-4forabetteroverview!

35WarningLight(red)–alternatorchargefunction

Thewarninglightcomesonwhentheignitionisturnedonandgoesoutassoonasthe engineisrunning.

TheV-beltforthealternator,orthechargingcircuitofthealternatorisfaultyifthewarning lightcomesonwiththeenginerunning.Thebatteryisnotchargedanymore (➠ page 5-15

Important!

ThecoolantpumpnolongerrunsiftheV-beltisfaulty. Possibilityofengineoverheatingorbreakdown!

Ifwarninglight1935 comesonwiththeenginerunning:

☞ Switchofftheengineimmediatelyandrepairorhavethecauserepaired

36WarningLight(red)–coolanttemperature

Comesonifcoolanttemperatureistoohigh.Abuzzersoundsatthesametime.Thewarninglightandthebuzzergooutassoonasthecoolanttemperatureisbackintheacceptablerange.

WARNING!

Neveropenthecoolanttankandneverdraincoolantiftheengineiswarm, becausethecoolingsystemisunderhighpressure–

Dangerofburns!

☞ Waitatleast10minutesafterturningofftheengine!

☞ Wearprotectiveglovesandclothing

☞ Alwaysstartbyactuatingthesafetyvalveinthecapoftheexpansiontank. Todothis:Turnthecaptothefirstnotchandallowthepressuretoescape

Important!

Possibilityofenginebreakdownifwarninglight19/36 comesonwiththe enginerunning!

☞ Afterextremeworkload: Lettheenginerunatidleuntilthewarninglightgoesout

☞ Afternormalworkloadorifthewarninglightdoesnotgooutasdescribed above:

Turnofftheengineimmediately

☞ Checkandcorrectthecoolantlevel(➠ page5-10)

AP0902 3–13

Operation

37WarningLight(yellow)–airfilter

Indicatesairfiltercontamination.Inthiscase:

☞ Cleanorreplacetheairfilter(➠ page5-13)

38WarningLight(red)–hydraulicoiltemperature

Comesonifhydraulicoiltemperatureistoohigh.

Important!

Possibilityofhydraulicdamageassoonaswarninglight19/38 comeson!

☞ Reducetheloadontheworkanddrivehydraulics.Todothis:

•Stopthemachineinasuitableplace

•Movecontrollever16 /21 oftheloadertoneutralposition

•Setdriveswitchtoneutral–seeDrivingdirectionselectorswitchon page3-8

•Runtheengineatincreasedspeedsuntilwarninglight 19/38 goesout

39WarningLight(red)–hydraulicoilfilter

Indicatesanunacceptablyhighpressureinthehydraulicreturnlinetothetank.Inthis case:

☞ Replacethehydraulicoilreturnfilter(➠ page5-20)

Incoldweatherwarninglight19/39 maycomeonimmediatelywhentheengineisstarted. Thisisduetoincreasedoilviscosity.Inthiscase:

☞ Lettheenginerunatidlingspeedforabout2minutes

40WarningLight(red)–engineoilpressure

Comesoniftheengineoilpressureistoolow.Inthiscase:

☞ Stopthemachine

☞ Turnofftheengineimmediatelyandchecktheoillevel(➠ page5-7)

Thewarninglightcomesonwhentheignitionisturnedonandgoesoutassoonasthe engineisrunning.

41WarningLight(red)–parkingbrake

PComesonwhenparkingbrakelever16/25 isapplied. Theelectricdrivinginterlockpreventsdrivingthemachinewiththeparkingbrakeapplied.

3–14 AP0902

42WarningLight(green)–right/leftturnindicator Flashesintermittentlywhentheturnindicatorsareused(lever17/ 31)

43WarningLight(blue)–highbeam

Comesonifhighbeamisswitchedon,orduringheadlightflashing

44Notassigned

45Hourmeter

Countstheengineservicehourswiththeenginerunning

46Fuellevelgauge

AP0902 3–15

Operation

3.4.3Beforestartingtheengine

3.4.4Startingtheengine

General

Procedure

1 ☞ Runthroughthe“Start-up”checklistonpage3-6

☞ Adjustseatpositionandrearviewmirror CAUTION!

Allcontrolsmustbewithineasyreach.Youmustbeabletomovethebrakeand acceleratorpedalstotheirlimitpositions!

☞ Fasteningtheseatbelt

☞ Besurethat:

–Parkingbrake16/25 isapplied;and –Controllever16/21 and16/22 areinneutral

• Theenginewillstartonlyifparkingbrake16/25 isapplied

• Thestartercannotbeoperatediftheengineisalreadyrunning(startrepeatinterlock)

• Donotrunthestarterformorethan10seconds

• Waitforabout1minutetoletthebatteryrecoverbeforetryingagain

• Theenginecannotbestartedbytowingthemachine,becausethereisnodriving connectionbetweentheengineandgearboxwhentheengineisoff

☞ Afteryouhavecompletedthestartingpreparationsinaccordancewith3.4.3Before startingtheengine

• Inserttheignitionkeyintothepreheatingstartswitch33/52

• Turntheignitionkeytoposition“1”

• Checkwhetherthefollowingwarninglightscomeon:

•WarningLight 40 forengineoilpressure

•WarningLight 35 foralternatorchargefunction

•WarningLight 41 iftheparkingbrakeisapplied

•Duringthewarninglightcheck,warninglights 36, 37, 38 and 39 mustcomeonaswell,andthewarningbuzzermustsound

• Replacedefectivewarninglightsimmediately

• Presstheacceleratorpedal16/6 throughaboutaquarterofitstravel

• Turntheignitionkeytoposition“3”andholditinthispositionuntiltheenginestarts

• Releasetheignitionkey

Whentheenginehasstarted...

☞ Checkthatthefollowingwarninglightshavegoneout:

• WarningLight34/35

• WarningLight34/40

• WarningLights34/36, 37, 38 and 39

☞ Runtheenginewarm

3–16 AP0902

Operation

1 0 2 3

52 35 40 41

Fig.33:Preheatingstartswitch

36 37 38 39 44 Operation

Fig.34:WarningLights

Startingattemperaturesbelow 32°F(0°C)

☞ Startingattemperaturesbelow32°F(0°C):

• Turntheignitionkeytoposition2andholditinthispositionforabout15seconds

• Presstheacceleratorpedal16/6 allthewaydown

• Turntheignitionkeytoposition“3”andholditinthispositionuntiltheenginestarts

• Releasetheignitionkey

Whentheenginerunssmoothly(increasedenginespeed):

• Releaseacceleratorpedal16/6

NOTE:

Ingeneral,abatterydeliverslessenergyincoldconditions.Asaresult,youmust besurethebatteryisalwayswellcharged.

...foracoldstartatoutsidetemperaturesbelow32°F(0°C):

☞ Lettheenginerunatincreasedidlingspeedforabout1minute

☞ Donotexceedtheaverageenginespeedfor10minutes, howeverdriveandworkhydraulicsmaybestartedgently.Donotextendorretractthe hydrauliccylinderstothelimitsifpossible

☞ Increasethedieselenginespeedandhydraulicforcesgradually

...foracoldstartatoutsidetemperaturesbelow50°F(10°C):

☞ Increasetheenginespeedslowly

☞ Donotruntheengineatfullloadforthefirst10minutes

AP0902 3–17

Operation

Enginepreheater(option)

Thisequipmentisforcold-startingattemperaturesbelow29°F(–5°C).

Thefollowing“enginepreheater”versionsareavailableforthemachine:

–Enginecoolantpreheater(option)

–Hydraulicoilpreheater(option)

–Coolantpreheater(option)andhydraulicoilpreheater(option)

Theoperationofthedifferentversionsisthesame.

Heatingelementsintheengineblockand/orinthehydraulicoiltankwarmuptheengine coolantcircuitand/orthehydraulicoilaccordingtothegravityprinciple(warmfluidrises andisreplacedbycoldfluid).Thecoolantortheoilcanonlybethoroughlywarmedupto servicetemperatureiftheenginepreheaterisconnectedoveralongerperiodoftime–preferablyovernight.

Connectingtheenginepreheater(option)

☞ Connectthe enginepreheater asfollows:

• Parkthemachineneara220Vsocket

• Firstconnectspecialcable A tomachinesocket B ontheservicepanelontheleft sideofthemachine,then

• Inserttheplugintothe220Vsocket

☞ Beforestartingtheengine:

• Pullouttheplugfromthe220Vsocket

• Unplugspecialcable A frommachinesocket B

NOTE:

Theenginepreheater(option)reducesengineemissionsduringthewarm-up phasebyupto50%,savingfuelatthesametime.

3–18 AP0902

A B

Fig.35:Enginepreheater(option)

Jump-startingtheengineSafetyinstructions

• Neverjump-starttheengineifthebatteryofthemachineisfrozenbecauseoftheriskof explosion!

• Themachinemustnottouchthejump-startingmachinewhenconnectedwithjumper cablesbecauseoftheriskofsparking!

• Theexternalpowersourcemustdeliveraratedvoltageof12V;highersupplyvoltages willdamagetheelectricalsystemofthemachine!

• Useonlyjumpercablesthatareingoodcondition!

• Thejumpercableconnectedtothepositive(+ )terminalofthestartingbatterymust nevercontactmetalmachinepartsbecauseoftheriskofshortacircuit!

• Routethejumpercablessotheycannotcatchonrotatingcomponentsintheengine compartment!

Proceedasfollows:

• Drivethejump-startingmachinecloseenoughtothemachinesothatthejumper cablescanreachtoconnectthetwobatteries.

• Starttheengineofthejump-startingmachine.

• Firstconnectoneendoftheredjumpercable(+ )tothe(+ )terminalofthe dischargedbattery,thencliptheotherendtothe(+ )terminalofthestartingbattery.

• Connectoneendoftheblackjumpercable(–)tothe(–)terminalofthestarting battery.

• Cliptheotherendoftheblackjumpercable(–)ontoasolidmetalcomponent connectedtotheengineblockorontotheengineblockitself.Donotconnectittothe negativeterminalofthedischargedbattery,becauseexplosivegasfromthebattery mayigniteifsparksoccur!

• Starttheengineofthemachinewiththedischargedbattery

Oncetheenginehasstarted:

☞ Withtheenginerunning,disconnectthejumpercablesinexactlythereversesequence (firstremove(–)terminal,then(+ )terminal)–thispreventssparkinginthevicinityof thebattery!

AP0902 3–19

Operation

3.4.5Beforedrivingthemachine

Beforedrivingthemachine:

• Checkthefunctionof:

•Brakes

•Steeringand

•Lighting

• Dumpoutthebucket

• Adjustthebuckettotransportposition.Todothis:

•Retractthetelescopicunitcompletely

•Tiltthefrontbuckettotherear(36/B)and

•Raisethetelescopicunitsothatbothredmarks D ontheliftframeandthe bulkheadarealigned

NOTE:

Intransportposition,tworedmarks D ontheliftframeandonthebulkheadare aligned(figure37).Thesemarkingsarevisiblefromtheoperator'scab. Withbothmarks D aligned,transportgroundclearanceamountstoatleast9inches (230mm)(36/C),withstandardbucketandstandardtires(12.5-20).

• Securethecontrolleverforthetelescopicunit 21 againstunintentionaloperation.To dothis:

Pushcontrollever 21 downinneutralposition

➥Thecontrolleverislockedinthisposition,itcannotbemoved

• Securethecontrolleverforthe3rdcontrolcircuit/attachments 22 againstunintentionaloperation.Todothis:

•Turnsafetysleeve 23 clockwiseuntilitispulleddownbyspringaction.

•Letcontrollever 22 lockintoplaceincentralposition.

➥Thecontrolleverislockedinthispositionandcannotbemoved.Thelockcanonly bereleasedbyliftingthesafetysleeve

3–20 AP0902

C B

Fig.36:Drivingonpublicroads

Fig.37:Marksfortransportposition

Fig.38:Securingthecontrolleverforthetelescopicunit

22 23

Fig.39:Securingthecontrolleverfortheattachments

NOTE:

Thesteeringsystemisonlyoperationalwhentheengineisrunning! Intheeventofafailureofthedieselengineorofthehydraulicsteeringpump(e.g. failureofthepumpdrive),themachinecanstillbesteered(emergencysteering feature).

WARNING!

Incaseoffailureofsteeringpumpordrive: Turningthesteeringwheelrequiresgreateffort!Takethisintoaccount especiallywhentowingthemachine!

☞ Adapttowingspeedtothealteredsteeringbehavior!

☞ Useatowingrod!

☞ Functionalcheck:Movethesteeringwheeltotheleftandright Wheelsynchronizationposition Important!

Carefullysteeringthefrontandrearwheelstotheirlimitsautomaticallysynchronizesthesteeringsystemofthemachine.

Ifyounoticefromthedrivingcharacteristicsofthemachinethatthewheelsofbothaxles arenotrunninginexactlythecorrecttrack:

☞ Driveatlowspeed,turningthesteeringwheelslowlytotheleftandrighttothelimit,and trytokeeponturningthesteeringwheelbrieflyinbothfinalpositions

☞ Slowlyturnbackthesteeringwheeltostraight-aheadposition

☞ Contactyourdealerifthisdoesnotsynchronizethewheels

AP0902 3–21

Operation

Inspectionofimportantfunctional units Steering

3.4.6Driving

Servicebrake

WARNING!

Thebrakelightsattherearofthemachinedonotlightupwhenthe

•Parkingbrakeisapplied

•Machineisbrakedwithitshydrostaticbrakingeffect

☞ Whendrivingonpublicroadsandduringworkoperation,especiallyfor abruptbrakemaneuvers,usethebrakeinchingpedal16/3 tobrakethe machine.Onlythiscausesthebrakelightstolightup.

Dirtaccumulationintheareaofthebrakepedalcanresultinbrake malfunctions–

☞ Keepthebrakeinchingpedal16/3 clean!

☞ Checktheservicebrakeactionasfollows:

• Beforedrivingmachine,pressdownthebrakeinchingpedal16/3 tocheckwhether

•Afteramaximumofhalfthepedaltravelthereisafirmresistancetobefelt

•Brakelightscomeonifthebrakepedalispresseddown

• Aftermovingmachine,checkintherearviewmirrorthatnoonewillbehinderedbya brakemaneuver

• Checkthebrakeactionatlowspeed

NOTE:

Themachinecanbemovedonlyafterreleasingparkingbrake16/25.

☞ Afterstartingtheengine,proceedasfollows:

• Selectdrivingdirectionwithtipswitch18/59 or18/60

• Releaseparkingbrake16/25

➥WarningLight19/41 goesout

• Graduallydepressacceleratorpedal16/6

➥Machinemovesoff

• Testthebrakesatlowspeed

3–22 AP0902

Operation

3.4.7Driveranges

Selectingdriverange

Themachinehas2driveranges.

☞ Stopthemachinewithbrakeinchingpedal 16/3

☞ Pressbothtipswitches 18/59 and 18/60 atthesametime

☞ Selectionofdriverangewithrockerswitch 58

WARNING!

Donotswitchfromhightolowdriverangeatfullspeed–

➥ Machinedrivesystemalsomaybedamaged!

☞ Switchdriverangeswiththemachinedrivingatlowspeedonly

forworkrequiringprecisespeedadjustment,e.g.rotarybroomapplications

•

☞

AP0902 3–23

Operation

58 B A Driverange Rockerswitch58

Fig.40:Selectionofdriverangewithrockerswitch

Recommendedfor: • Low 3mph 0–5km/h ☞ Pressrockerswitch 58 in A (below) Especiallyforshortloading/unloading cycles,truckloading,e.g.,ontoalorry,and

High 12mph 0–20km/h

Pressrockerswitch 58 in B (above) Long-haultransport,roadtravel

Operation

Changingdirection

WARNING!

Changingdirectionathighspeedandhighenginespeedscausesthemachine tostopabruptly–

➥ Machinedrivesystemalsomaybedamaged!

☞ Switchdirectiononlywhenmachineusstopped.

☞ Stopthemachine.Takeyourfootoffacceleratorpedal16/6

☞ Selectnewdrivingdirectionasfollows:

Function

•

Backupalarm(option)

•

NOTE:

Thejoystickisinneutralwhenyoustarttheengine.Neutralisselectedafterapplyingparkingbrake16/25 orswitchingofftheengine.Drivingdirectioncanbe selectedonlyafterreleasingtheparkingbrake!

DANGER!

Whenbackingupwiththemachine: Accidenthazard!

☞ Makesurethatnobodyiswithintheareaofdangerofthemachinewhen changingthedrivingdirection!

☞ Donotrelyexclusivelyonthebackupwarningsystem(option)!

Thebackupalarm A,isfittedtothereartopleftofthecab.Thealarmsoundswhen shiftingintoreverse.Thesoundlevelis: 103dB(A)atadistanceof40inches(1m),andatafrequencyof2800Hz.

3–24 AP0902

21 59 60 61 62

Fig.41:Drivingdirectionselectorswitch

Operation Effect

☞ Pressthegreentipswitch 59 ➥ GreenLED 61

Forward

comeson

☞ Pressyellowtipswitch 60 ➥ YellowLED 62

Reverse

comeson

Neutralposition ☞ Pressbothtipswitchesatthe sametime ➥ BothLEDsgoout A

Fig.42:Backupalarm(option)

3.4.8Differentiallock

NOTE:

Adifferentiallockneutralizesthecompensatingeffectofthedifferential,i.e.tractionisdistributedevenlytothefrontandrearwheels.Boththefrontandrearaxles ofthemachinearefittedwithself-lockingdifferentials.Thelockingvalueis40%for eachaxle.Thedifferentialsarelockedautomatically.Thedifferentiallockcannot beengagedordisengagedbytheoperator!Ifawheellosescontactwiththe ground,thedifferentiallockontherespectiveaxleisnolongereffective!

3.4.9Stoppingthemachine

☞ Proceedasfollows:

• Throttlebacktheengine:Takeyourfootoffacceleratorpedal16/6

• Stopthemachinewithservicebrake16/3

• Movedrivelevertoneutral–see Drivingdirectionselectorswitch onpage3-8

• Applytheparkingbrake.Todothis: Pulluplever16/25 tothelastnotch

➥WarningLight19/41 comeson

AP0902 3–25

Operation

3.4.10Parkingthemachine

WARNING!

Machinesparkedonslopesmayrollaway.

☞ Usetheparkingbraketoparkthemachinesafelyandtopreventitrolling away!

SeeSection3.4.9„Stoppingthemachine”

☞ Additionallysecurethemachinebyplacingchocksunderthedownhillsides ofthewheels!

Donotparkthemachinewiththeloadliftedorthetelescopicunitextended–Accidenthazard!

☞ Beforeleavingthecab,retractthetelescopicunitcompletelyandlowerthe loadtotheground!

☞ Proceedasfollows:

• Stopthemachine

• Movedriveswitchtoneutral.Todothis: Pressdownswitches 59 and 60 atthesametime(bothLEDs 61and62 goout)

• Applytheparkingbrakepermanently–see Section3.4.9„Stoppingthemachine”

• Retractthetelescopicunit.Todothis: Presstipswitch 64 untilthetelescopicunitiscompletelyretracted

• Lowerthetelescopicunit.Todothis: Pushcontrollever 21 forward,outofneutral( C)

Afteroperationatfullpower:

• Allowtheenginetoidleandwithoutloadforawhilesothatthetemperaturecan stabilize

• Cutofftheengine.Todothis: Turntheignitionkeytoposition“0”

• Removetheignitionkey

• Lockthedoorsoftheoperator’scompartmentafterleavingthecab

Onuphillanddownhillgradients:

• Additionallysecurethemachinebyplacingchocksunderthedownhillsidesofthe wheels!

3–26 AP0902

Operation

21 59 60 62 61 C

Fig.43:Movethedriveswitchtoneutral

21 63 64

Fig.44:Retractingandloweringthetelescopicunit

3.4.11Lightsystem

NOTE:

Onlytheparkinglightstayslitiftheignitionisswitchedoff(withlowbeamswitched

AP0902 3–27 Operation

on)–keyinpreheatingstartswitch20/52 inposition 0!

☞ Donotusetheworkinglightsfortravelonpublicroads,andinworkoperationonlyifnootherpersonsaretemporarilyblind! 32

Parkinglights ON ☞ Turnrotaryswitch 32 toposition I ➥ WarningLight19/43comesonwith highbeamswitchedon OFF ☞ Turnrotaryswitch 32 toposition 0 ➥ Highbeamandwarninglight19/43 go out Lowbeam ON ☞ Turnrotaryswitch 32 toposition II ➥ WarningLight19/43comesonwith highbeamswitchedon OFF ☞ Turnrotaryswitch 32 toposition 0 ➥ Highbeamandwarninglight19/43 go out 31

WARNING! Theworkinglightsmaytemporarilyblindmotoristsonpublicroads.

Fig.45:Lightsystem:switches

II 0 I Highbeam ON ☞ Withlowbeamswitchedon,move leverdownwarduntilitlocksin position I ➥ WarningLight19/43 comeson OFF ☞ Movelever 31 uptoposition 0 ➥ Highbeamandwarninglight19/43 go out Headlightflasher ON ☞ Pushlever 31 uptoposition II ➥ WarningLight19/43 comeson

Fig.46:Switchingonhighbeamandheadlightflasher

A B 57 Workinglight(option) ON ☞ Pressrockerswitch 57 downwardsin A (down) ➥ WarningLightinrockerswitch 57 comeson OFF ☞ Pressrockerswitch 57 downwardsin B (above) ➥ WarningLightinrockerswitch 57 goesout Interiorlight ON ☞ Pressinteriorlight16/ 9 OFF ☞ Pressinteriorlight16/ 9 downasecondtime

Fig.47:Switchforworkinglight

3.4.12Signallingsystem

Important!

3–28 AP0902

Operation

Checkthefrontandrearindicatorsimmediately

A B 53 Hazardwarningsystem ON ☞ Pressrockerswitch 53

A (down) ➥ WarningLightinrocker switch 53 flashes OFF ☞ Pressrockerswitch 53 downwardsin B (above) ➥ WarningLightinrocker switch 53 goesout Fig.49:Turnindicators 31 L R Turnindicators LEFT ☞ Pushlever 31 forward ➥ WarningLight19/42 flashes RIGHT ☞ Pulllever 31 totherear ➥ WarningLight19/42 goes out

A B 47 Rotatingbeacon(option) ON ☞ Pressrockerswitch 47 in A (below) ➥ WarningLightinrocker switch 47 flashes OFF ☞ Pressrockerswitch 47 in B (above) ➥ WarningLightinrocker switch 47 goesout

Theturnindicatorsystemisnotfunctioningproperlyifwarninglight19/ 42 flashesabouttwiceasfastasnormally! ☞

Fig.48:Signalingsystem:switches

downwardsin

Fig.50:Switchforrotatingbeacon

3.4.13Cabheatingandventilation

Theheaterofthemachinecanbesettotwooperatingconditions:

•Ventilation

•Heating

Theflowofairisdirectedtothewindscreenviaadefrosterventandtotheoperator compartmentviaafootvent16/19 Thefootventcanbeclosedanddirectedseparately.

Ventilation,freshair

1stfanlevel ☞ Pressrockerswitch 56 downin A (below)byonestep

2ndfanlevel ☞ Pressrockerswitch 56 downin A (below)bytwosteps

FanOFF ☞ Pressrockerswitch 56 allthewaydownin B (above)

Heating

Colder ☞ Slidelever 18 toposition B

Warmer ☞ Slidelever 18 toposition A

AP0902 3–29 Operation

A B

Fig.51:Fanswitch 56

B 18

Fig.52:Heatingadjustment

NOTE: Fillwithcleantapwateronly!Addasuitablecleaningagentifrequired.Inwinter: Addantifreezeforwashersystemstothewater.Refertotheinstructionsforusing theantifreeze,whichgiveinformationaboutconcentrations.

3–30 AP0902

Tankforwashersystem2

Operation 3.4.14Windowwashsystem

A B 55

Frontwiper ON ☞ Pressrockerswitch 55 in A (below) OFF ☞ Pressrockerswitch 55 in B (above) 33

Fig.53:Frontwiper:switch

A B Washerpumpforfrontandrearwindow ON ☞ Presstipswitch 33 toposition A OFF ☞ Releasetipswitch

Fig.54:Washerpumptipswitch

33 (

)

10 Rearwiper ON ☞ Pressrockerswitch 10 toposition I OFF ☞ Pressrockerswitch 10 toposition 0 2

Fig.55:Rearwiper:rockerswitch Fig.56:Tankforwashersystem

3.4.15Seatadjustment

WARNING!

Neverchangetheseatpositionwhendrivingorworkingtoavoidandaccident.

☞ Adjusttheseatbeforemovingthemachine

Theseatcanbesettothefollowingpositions:

• Weightsetting a withweightindicator b

• Heightsetting c

• Armrestangle d

• Backrestsetting(dependingonversion) e

• Fore-and-aftsetting f

Weightsetting

Heightsetting

Important!

Adjusttheseatsuspensioncorrectlytoensurecomfort.Uselever a toadjustthe seatsuspensiontotheoperator'sweight.Theweightindicator b showstheset operatorweightinkg.

☞ Sitdownontheoperator’sseat

Toadjusttoahigheroperatorweight:

☞ Turnlever a clockwise

Toadjusttoaloweroperatorweight:

☞ Turnlever a counterclockwise

Upwards:

☞ Raiseseatasrequireduntilitengageswithanaudibleclick

Downwards:

☞ Raiseseatasfaraspossibleand

☞ Lowerseattobottomposition

AP0902 3–31 Operation

b c a f d e

Fig.57:Seatadjustment

a b

Fig.58:Weightadjustment

Fig.59:Heightsetting

Operation

Armrestsetting

Thearmrestcanbefoldedbackasrequired.Setthearmrestasfollows:

Upwards:

☞ Turnhandwheel d clockwiseasrequired

Downwards:

☞ Turnhandwheel d counterclockwiseasrequired

Backrestsetting

☞ Sitdownontheoperator’sseat

☞ Pulllever e upwardsandatthesametime

☞ Leanbacktopushthebackrestintotherequiredposition

☞ Letlever e lockintoplace

Fore-and-aftsetting

☞ Sitdownontheoperator’sseat

☞ Pulllever f upwardsandatthesametime

☞ Movetheoperator’sseatforwardorbackward

3–32 AP0902

Fig.60:Armrestsetting d

Fig.61:Backrestsetting

Fig.62:Fore-and-aftsetting

3.4.16Seatbelt

WARNING!

Donotoperatemachinewiththeseatbeltunbuckledtoavoidpersonalinjury.

☞ Buckleupbeforemovingorusingthemachine!

•Seatbeltmustnotbetwisted!

•Seatbeltmustrunoverthehips–notoverstomach–andmustalways beappliedtightly!

•Donotplaceseatbeltoverhardedgedorfragileitems(tools,glasses, pen)carriedinsideyourclothes!

•Neverbuckleup2persons(children!)withasingleseatbelt!

•Checkseatbeltsregularly.Havedamagedpartsimmediatelyreplaced!

•Alwayskeepseatbeltclean,asdirtmayimpairproperfunctioning!

•Seatbeltbucklemustnotbeobstructedotherwisethebucklelatchcannotlockintoplace!

WARNING!

Afteranaccidentthebeltstrapmaybestretched,andisnolongerserviceable. Inanaccident,theseatbeltwillnotprovideadequateprotection!

☞ Replacetheseatbeltafteranaccident

☞ Havefasteningpointsandseatfixturecheckedforloadingcapacity!

Theseatbelt 29 isdesignedforthedriver'ssafetyduringworkonconstructionsitesand duringroadtravel.

Tofastenseatbelt29

☞ Beforestarting,fastenseatbelt 29 asfollows:

• Holdbeltonthebucklelatch A andrunitslowlyandsteadilyoverthehipstothe buckle B

• Insertbucklelatch A intothebuckle B untilitengagesaudibly( pulltest )

• Tightenseatbeltbypullingatitsend

➥Theseatbeltmustalwaysbetightlyinplaceoverthehips!

AP0902 3–33 Operation

30763b0007.eps

29 B A

Fig.63:Fasteningtheseatbelt

Operation

Tounfastenseatbelt29:

☞ Unfastenseatbelt 29 asfollows:

• Holdtheseatbelt

• Pressredbutton C onthebuckle B

➥Thelatch A isreleasedfromthebuckle B byspringpressure

• Slowlyreturntheseatbelttheretractor(option)

Longer/shorterlapbeltsetting29:

☞ Lengthenthelapbeltasfollows:

• Holdthebucklelatchatarightangletotheseatbeltandpulltheseatbelttothe requiredlength–seeFig.65

☞ Toshortenthelapbelt,justpullonthefreeend D ofthebelt–seeFig.65

NOTE:

Whenpulledslowly,theautomaticseatbelt(option)offersfullfreedomofmovement.Itlockshoweverduringabruptbraking. Theautomaticseatbelt(option)mayalsolockwhenpassingthroughpotholesor uneventerrain.

3–34 AP0902

30763b0006.eps

29 B A C

Fig.64:Tounfastenseatbelt 30763b0005.eps

A D

Fig.65:Longer/shorterseatbeltsetting

3.4.17Driver'sdoorandsidewindow

Accessto/exitfromthecabispossiblethroughthedriver'sdoor(left).Incaseof emergencyhowever,thesidewindowontherightmaybeusedasemergencyexit.

Openingfromoutside:

• Pressdoorbutton a

Lockdoor:

• Turnignitionkey b indoorlocktotheright

Unlockdoor:

• Turnignitionkey b indoorlocktotheleft

Openingfrominside:

• Pulllever 1 up

Driver'sdoorin“open”positionwiththedoorarrester

☞ Presstheoperator'sdooragainstthedoorholder16/12 untilitengages

NOTE: Greasethedoorholderatregularintervals(min.every600servicehours)!

Unlockingthedoorarrester

☞ Pressthereleasebuttoninthecab(16/12)

➥ Doorisreleasedbyspringaction

AP0902 3–35

Operation

Driver'sdoor

b a

Fig.66:Doorlockontheoutside

Fig.67:Doorlockontheinside

Operation

SidewindowNormaloperation

Lock

• Turnlever 16 downward

Unlock

• Turnlever 16 upward

Openingthehingedsidewindow

• Turnlever 16 upward

• Pushlever 16 horizontallytowardstheoutside

• Tofixthewindowinitslimitposition: Pushtheendoflever a downwardinguide b

Fullyopeningthesidewindow

☞ Turnlever 16 upward

☞ Pushlever 16 horizontallytowardstheoutside

☞ Fullyopenthewindowasfollows: Pulltheendoflever a totherear,outofguide b

Sidewindowin“open”positionwithdoorholder 16/12

☞ Openthesidewindowcompletelyandpushagainstdoorholder16/12 untilthedoor locksintoplace

NOTE: Greasethedoorholderatregularintervals(min.every600servicehours)!

Unlockingthedoorholder 16/12

☞ Pressbutton16/12 inthecabattherightoractuatetheleveroutsidethemachine

➥ Sidewindowisreleasedbyspringaction

3–36 AP0902

Fig.68:Locking/unlockingthesidewindow

16 b a

Fig.69:Openingthehingedsidewindow

16 b a

Fig.70:Fullyopeningthesidewindow

Fig.71:Fullyopeningthesidewindow

Emergencyexit

Incaseofemergency,thesidewindowmaybeusedasaccessto/exitfromthecab.

WARNING!

Toavoidpersonalinjury,donotusethesidewindowasanaccessorexit exceptincaseofanemergency.Therightsideofthemachinedoesnothave footholdsorhandlesthatensureasafeaccess/exit.Moreover,theside windowcannotbeheldin“open”positioniflockinglever69/16 isliftedoutof guide69/b –

Dangerofpersonalinjury!

☞ Donotusethesidewindowasaccessorexitexceptincaseofemergency!

☞ Beforetakingupnormaloperationagain,besurethattheendoflever69/a isengagedinguide69/b

☞ Toopenthesidewindowcompletely:

• Pushendoflever69/a upwardsinguide69/ b

• Pullendoflever69/a gentlyoutofguide69/b

AP0902 3–37

Operation

3.4.18Othercontrols

Fueltank

Unlocking:

• Turnthekeytotheright

Closing:

• Turnthekeytotheleft

Enginecover

Theenginecovercanonlybeopenedbykey.

Unlocking:

• Turnthekeytotheright

• Pulltheenginecoverupwards

Closing:

• Presstheenginecoverfirmlydown

• Turnthekeytotheleftandremoveitfromthelock

3–38 AP0902

Fig.72:Fillercaplock Fig.73:Enginecoverlock

3.4.19Towingandtransportingthemachine

Safetyinstructions

• Themachinemayonlybetowedusingsuitabletowingequipment(towingbarorcable) andsuitabletowingfacilities,suchasatowingcoupling,hooksandeyes!

• Driveoffslowly!Besurenooneisdangerouslyclosetothetowingbar.

• Themachinemayonlybetowedwithacableiftheservicebrakesandsteeringarefully operational!

Whenloadingandtransportingthemachine:

• Thetransportmachinemustbeofadequatesize–refertosection Specifications forthe dimensionsofthemachine!

• Removeanymud,snoworicefromthetyressothatthemachinecansafelybedriven ontotheramps

• Securethemachineagainstunintentionalmovement!

• Beforetransportingthemachinethrough heavyrain:Closetheoutletoftheexhaust silencerwithasimplecaporsuitableadhesivetape

AP0902 3–39

Operation

WARNING!

Turningthesteeringwheelrequiresgreatereffortifthedieselenginebreaks down.Takethisintoaccount,especiallywhentowingthemachine!

☞ Useatowingrod! Important!

Thehydrostaticdrivemaybedamagedifthemachineistowedinthis condition!

☞ Switchofftheengine!

☞ Short-circuitthehydrauliccircuitbeforetowing(seebelow)

☞ Donottowthemachineformorethan100yards(100meters)anddonot towitfasterthan2-3mph(3–4km/h)!

☞ Towthemachineasfollows:

• Movedrivelevertoneutral–see Drivingdirectionselectorswitch onpage3-8

• Applytheparkingbrake(➠ page3-10)

• Switchofftheengine

• Attachanadequatelysizedtowingrodtothetowingfacilities

☞ Changeoverthevalvesonhydraulicpump A .Todothis:

• Depressbuttons B

NOTE:

TheHPvalvechangeoverisautomaticallyreversedwhenthemachineisplaced backintoservice,assoonastheengineisstarted.

3–40 AP0902

Operation Towing

A B

Fig.74:Hydraulicpumpwhentowingthemachine

WARNING!

Toavoidinjury,themachinemustbeloadedandtransportedproperly:

☞ Itisessentialthatyoureadthesafetyinstructionsatthebeginningofthis chapterandfollowthem!

☞ Loadasfollows:

• Securethetransportmachinewithchockstopreventitfromrolling

• Attachtherampssothattheaccessangleisassmallaspossible,andensurethat theycannotslip

• Ensurethattheloadingareaisclearandaccesstoitisnotobstructed.

• Ensurethattherampsandthewheelsofthewheelloaderarefreeofoil,grease andice

• Starttheengineofthewheelloader

• Raisethefrontbucketenoughsothatitwillnottouchtheramps

• Carefullydrivethewheelloaderontothetransportmachine

• Movedrivelevertoneutral–see Drivingdirectionselectorswitch onpage3-8

• Applytheparkingbrakeofthewheelloader

• Lowerthebuckettotheloadingareawiththetelescopicunitretracted

• Ensurethattheauthorizedmaximumheightisnotexceeded

• Cutofftheengineofthewheelloader

• Securealltyresofthewheelloaderwithchocksinfrontof,behindandatthesidesof eachwheel

• Securelylashthewheelloaderontotheloadingareausingstrapsandchainsof adequatesizeatthelashingpointsprovided–seesection1.2 Machine:Overview on page1-2

• Beforetransportingthemachinethroughheavyrain: Closetheoutletoftheexhaustsilencerwithasimplecaporsuitableadhesivetape

• Makecertainthatthedriverofthetransportmachineknowstheoverallheightofhis machinebeforedeparture!

AP0902 3–41

Operation

Loadingandtransportingthe machine:

3.5Workingwiththemachine

3.5.1Generalsafetyinstructions

• Neverlowertheextendedtelescopicunitfromahighposition,becauseofthechanceof tipping!Retractthetelescopicunitbeforeloweringit!

• Exerciseextremecautioninoff-roadoperation: Workonsolidgroundwheneverpossible!

• Neverdriveuptotheedgeofapitfromoutside,becauseofthechanceofcave-in!

• Neverunderminethefoundationsofwalls,becauseofthechanceofcollapse!

• Operationofthemachinebyunauthorizedpersonsisprohibited!

• Whenexcavating,lookoutforhigh-voltage cables,undergroundcables,gasandwater pipes!

• Whenusingliftingaccessoriessuchaspalletforks,complywiththeloaddiagramsfor thismachine

• Thehydraulicsystemofthemachineremainspressurizedevenwhentheengineisnot running!Relievethepressureinthesectionsofthesystemandhydrauliclinesthatare tobeopenedbeforestartingsetuporrepairwork,e.g.fitting/removinganattachment withhydraulicfunctions–see Section3.5.6„Relievingpressurethequickcouplerson thetelescopicunit”

3.5.2Loaddiagram

Observetherelevantloaddiagramwhenusingpalletforkswithforkarmsonthetelescopic.Thisdiagramspecifiesmaximumloadontheforkarms–seesection1.8 Safety signsandsymbols onpage1-8.Themaximumloadvariesaccordingtothedistancefrom theloadcenter.

NOTE:

Theloaddiagramsonthefrontwindowarevalidonlyforapplicationswithpallet forks.Observethespecificloaddiagramsofotherattachmentsused,e.g.rotaryjib boom!

3–42 AP0902 Operation 3

Overview

WARNING!

Thesafeloadindicatorhasbeenadjustedforindustrialapplication(S=1.25). Donotrelyonthesafeloadindicatorwhenworkingoff-road.

☞ Workinroughterrainwithevenmorecarethanusual!Adaptyourdrive speedandloadstotheterrain.Refertotheloaddiagramforthemaximum authorizedloads!

Adefectivesafeloadindicatororworkingatmorethan100%ofthesafework loadmaycausethemachinetotiltandmayresultinanaccident.

☞ Checkthesafeloadindicatordaily!

☞ Aflashingindicatorandanaudiblesignalwarnofloadsexceeding100%. Theoperatormustreducetheloadbelowthe100%limitbyretractingthe telescopicunit!

Yourmachineisequippedwithanelectronicloadindicator 14 whichcontinuouslymonitors theweightvariationsontherearaxleduringoperation. Visibleandaudiblesignalswarntheoperatorof criticalloadsonthetelescopicunitwhich mightcausethemachinetotilttothefront. Criticalsideloadshoweverarenotmonitored, i.e.theoperatorisnotwarnedinthiscase!

TheLEDs a, b and c indicatetheloadeffectiveonthetelescopicunit–inpercentofthe safeworkload.

a 6greenLEDs–indicationofloadsbetween45%and85% of thesafeworkload

b 2yellowLEDs–indicationofloadsupto100%of thesafeworkload

c 2redLEDs–indicationofloadsupto110%of thesafeworkload

d GreenLEDstosignalreadiness

e Tipswitchforcheckingthesystem

f Tipswitchforadjustingthevolumeoftheaudiblesignal

AP0902 3–43 Operation

3.5.3Safeloadindicator

c b a d e f 14

Fig.75:Electronicloadindicator

Operation

Whattodoif...

• GreenLED d comeson?

➥ OK;loadindicatorisready

• GreenLEDs a (1-6)comeon?

➥ OK;theloadisbetween 45% and 90% of thesafeworkload

• YellowLEDs b (7-8)comeoninaddition?

➥ Workwithcaution;theloadisbetween 85% and 100% ofthe safeworkload

• Green a andyellowLEDs b areflashing,theacousticsignalisgiven?

➥ Workwithextremecaution!100% ofthe safeworkload isreachedcorrespondingtotheloaddiagram

• RedLEDs c comeon?

➥ OVERTURNINGHAZARD! Reducetheloadimmediatelybyretractingthe telescopicunit!Theloadisbetween 100% and 110% ofthe safeworkload!

• Thecompleteindicatorisflashing,theacousticsignalisgiven,althoughtheTESTtip switchhasnotbeenactivated?

➥ Theloadindicatorisdefective.Haveitimmediatelycheckedandrepairedbyan expert!

Functionalcheck

NOTE: Thecheckmaybeperformedatanytime,evenduringoperation.

☞ Proceedasfollows:

• PressTESTtipswitch e

AllLEDsareflashingandtheacousticsignalisgiven:

➥ Inworkingorder

Acousticsignalsoundsuninterruptedlyfor10seconds,then2redand1,2or3green LEDscomeoninaddition:

➥ Systemerror;havethesafeloadindicatorimmediatelybecheckedandrepairedby anexpert!

Adjustingsignalvolume

☞ Proceedasfollows:

• PressTESTtipswitch e

Whiletheacousticsignalisgiven:

• PresstheMUTEtipswitch f untilthedesiredvolumeisset

3–44 AP0902

3.5.4Controlvalveforthetelescopicunit:overview

WARNING!

Unintentionaloperationofthecontrollever76/21maycauseanaccidentwhen drivingonpublicroads

☞ Lockthecontrollever–seeBeforedrivingthemachineonpage3-20

•

Securingthecontrolleverfordrivingonpublicroads

Toengage:

☞ FollowtheinstructionsgiveninSection3.4.5„Beforedrivingthemachine”

☞ Pushcontrollever 21 downinneutralposition

➥Thecontrolleverislockedinthisposition,itcannotbemoved

Disengagingthelock:

☞ Pulllever 21 up

AP0902 3–45 Operation

Controlleverforhydraulicsofliftand tiltcylinderoftelescopicunit

A B C D Position Symbol Lever21 Function • A ☞ Totheleft ➥ Rollbackattachment

B ☞ Totheright ➥ Tiltoutattachment

C ☞ Forward ➥ Lowerstheliftarm

Fig.76:Telescopicunit:controllever

•

D ☞ Backward ➥ Raisestheliftarm

Fig.77:Securingthecontrolleverfordrivingonpublic roads

Operation

Controlleverforattachmentsand3rd controlcircuit

Position Lever22 Function

A ☞ Forward ➥ Unlocksquickhitchfacility

Attachmentwithhydraulicfunction: ➥ E.g.opensthemultipurposebucket

B ☞ Backward ➥ Locksquickhitchfacility

Attachmentwithhydraulicfunction: ➥ E.g.closesthemultipurposebucket

Lockfordrivingonpublicroads

Toengage:

☞ Turnlocksleeve 23 untilitispulleddown

➥ Lever 22 islocked

Toopenpermanently:

☞ Pulllocksleeve 23 uptothelimitandturnituntilitstaysinthetopposition

➥ Lever 22 canbemovedforwardandbackward

Toopenbriefly:

☞ Pulllocksleeve 23 uptothelimitandholditinthisposition

➥ Aslongaslocksleeve 23 isbeingpulledupward,lever 22 canbemoved.

3–46 AP0902

Fig.78:Controlleverforattachments

23 B A

23 22

Fig.79:Securingthecontrolleverfordrivingonpublic roads

3.5.5Loweringthetelescopicuni twiththeengineswitchedoff

☞ Proceedasfollows:

• Makesurethatno-oneisdangerouslyclosetothetelescopicunit

• Pushcontrollever 21 forward(C),untilthetelescopicunitisfullylowered

• Returncontrollever 21 toneutral

NOTE:

Thehydraulicsystemofthe3rdcontrolcircuit/attachmentisstillpressurizedeven whentheengineisnotrunning!Thehydraulicquickcouplerscanbereleased, howevertheycannotbere-attachedbecausethepressureinthehydrauliclinesis toohigh.Therefore:

☞ Depressurizesectionsofthesystemandhydrauliclineswhicharetobe openedbeforestartingsetuporrepairwork,e.g.fitting/removinganattachment!

☞ Depressurizeasfollows:

• Applyparkingbrake16/25 –see Parkingbrake[25] onpage3-10

• Switchofftheengine

• Movelever 22 forwardandbackwardseveraltimes

➥Hydraulicpressureisreleased

AP0902 3–47 Operation

3.5.6Relievingpressurethequickcouplersonthetelescopicunit

C 21

Fig.80:Loweringthetelescopicunitwiththeengine switchedoff Fig.81:Depressurizinghydrauliclines

Operation

3.5.7Installinganattachment

Installinganattachmentonthetelescopicunitisdescribedbelowforthestandardbucket! Ifyouarefittingorremovingattachmentswithhydraulicfunctions–e.g.multipurposeor sidedumpbucket–youmustfollowthespecialinformationgivenintheoperator’smanual ofthecorrespondingattachment.

Fittingattachmentsontothequick hitchfacility

WARNING!

Theattachmentmustalwaysbesafelylockedontothequickhitchfacilityto avoidaccidents.

☞ Beforestartingwork,besurethattheattachmentissecurelylockedonto thequickhitchfacilitybymeansofthelockcylinder.Youmustbeableto seethelockpinsonbothsidesofthemountingholes.

☞ Proceedasfollows:

• Drivethemachineuptotheattachment

• Tiltthequickhitchfacilityallthewayforward.Todothis: Pushlever 21 totheright( B)

• AdjusttheheightofthepinshanksLofthequickhitchfacilitysothattheyareunder thecatchhooks K oftheattachment.Todothis:

• Driveforwarduntilthepinshanks L ofthequickhitchfacilityaredirectlybeneaththe catchhooksoftheattachment K

3–48 AP0902

Fig.82:Drivinguptotheattachment 21 K L Telescopicunit Lever21 • Lower ☞ Pushforward(C) or • Lift ☞ Pullbackward( D)

L K

Fig.83:Pickingupanattachment

• Raiseloaderlinkage().Todothis: Pulllever 21 backward( D)and

• Tiltinthequickhitchfacility().Todothis: Pushlever 21 totheleft(A )

• Securetheattachmentwiththelockpinofthequickhitchfacility.Todothis: Pulllever 22 backward( F)

➥Lockpin G engagesinthemountingboresoftheattachment

• Makesurethatthetool/attachmentissecurelylockedontothequickhitchfacility!

NOTE:

Youmustbeabletoseecatchbolt G on bothsides ofthemountingboresonthe attachment,asinfigure86/G

Attachmentswithhydraulicfunction:

• Switchofftheengine

• Attachthehydraulicand,ifused,electricalconnectionsfortheattachmentinaccordancewithitsoperator’smanual

Themachinecanbeequippedwitha4polefrontsocket(option).Withrockerswitch 48, thepowersupplyforelectricallyoperatedfrontattachments,e.g.aspraywaterpumpfora rotarybroom,canbepermanentlyswitchedONandOFF.

AP0902 3–49 Operation

Connectionofelectricallyoperated attachments(option)

Fig.84:Liftingtheattachment

22 G

Fig.85:Securingtheattachment

Fig.86:Checkingthelockpins

48 B A Powersupplyforfrontattachments(option) ON ☞ Pressrockerswitch 48 in position A

➥ Thepowersupplyatthefrontsocketis switchedon ➥ WarningLightinswitchcomeson OFF ☞ Pressrockerswitch 48 in position B (above) ➥ Powersupplyisinterrupted ➥ WarningLightgoesout

Fig.87:Switchforattachments(option)

(down)

Operation

Takinganattachmentoffthequick hitchfacility

WARNING!

Toavoidinjury,theattachmentmustbeplacedonthegroundsothatitwillnot falloverwhenremoved

☞ Positiontheattachmentsothatafterremovalitwillstandsafelyandwillnot tipover.

☞ Taketheattachmentoffthequickhitchfacilityasfollows:

• Drivethemachinewithemptyattachmentuptothestoragelocation.

• Rollbackthequickhitchfacility().Todothis: Pushlever 21 totheleft(A )

• Lowertheloader()untiltheattachmentisabout2–4in(5-10cm)abovethe ground.Todothis: Pushlever 21 forward( C)

Attachmentswithhydraulicfunction:

• Switchofftheengine

• Changeroundthehydraulicconnections(figure89)fromtheattachmenttothelock cylinder,inaccordancewiththeoperator’smanualoftheattachment

• Releasethelockonthequickhitchfacility.Todothis: Keeptipswitch 54 inposition A depressedandsimultaneously

• Retractthelockpinofthequickhitchfacility.Todothis: Pushleverforward88/22 forward(88/E)

• Tiltquickhitchfacilityslightlyforward().Todothis: Pushlever 21 totheright( B)

• Lowerthebucketfully().Todothis: Pushlever 21 forward( C)

3–50 AP0902

Fig.88:Loweringandtiltingintheattachment Fig.89:Changingroundthehydraulicconnections

54 B A

Fig.90:Unlocksthequickhitchfacility

21 22

Fig.91:Takingofftheattachment

Assoonasthepinshanks L ofthequickhitchfacilityarebeneaththecatchhooks K ofthe attachment:

• Reverseawayfromtheattachment

3.5.8Connectingpress urizedquickcouplers

WARNING!

Toavoidinjury,useextracarewhenconnectingpressurizedquickcouplers.

☞ Depressurizesectionsofthesystemandhydrauliclinesthataretobe openedbeforestartingsetuporrepairwork,e.g.fitting/removinganattachment!

seeRelievingpressurethequickcouplersonthetelescopicunitonpage 3-47.

☞ Neverconnectpressurizedquickcouplersbyforce

NOTE:

Oiltemperatureandpressureinthecylindercanriseifanattachment(e.g.side dumpbucketormultipurposebucket)orthequickhitchfacilityisexposedtothe sunforalongperiodoftime,withoutbeingconnectedtothemachine.Thispressurecannotbeloweredbymeansofdepressurization(asdescribedin section3 “Relievingpressurethequickcouplersonthetelescopicunit” onpage3-47 )

Thefollowingdescribeshowtoconnectapressurizedquickhitchfacility.Proceedaccordinglyforconnectionofpressurizedattachments.

Connectpressurizedquickcouplersasfollows:

☞ Fittheattachmentontothequickhitchfacility(pressurizedattachment),orremovethe hydrauliclinesfromtheattachment(pressurizedquickhitchfacility)

☞ Switchofftheengine

☞ Depressurizeasdescribedinsection3“Relievingpressurethequickcouplersonthe telescopicunit”onpage3-47

☞ Pulllever 22 backwardandlockit.Todothis:

• Turnlocksleeve 23 untilitispulleddown

AP0902 3–51 Operation

L K 22

Fig.92:Reversingfromtheattachment

Fig.93:Lockingthecontrollever

☞ Connecthydraulicline A (ontheright)onthemachine,toblueplug C ofthequickhitch facility(ontheleft,crosswise!)

☞ Removehydraulicline A again

☞ Connecthydraulicline A toblueplug D ofthequickhitchfacility(ontheright)

☞ Connecthydraulicline B toredplug C ofthequickhitchfacility(ontheleft)

☞ Releaselockoflever 22

☞ Returnlever 22 backtoneutral

☞ Locktheattachment–seesection3.5.7Installinganattachmentonpage3-48

3–52 AP0902

Operation

A C

Fig.94:Depressurization

A B C D 22

Fig.95:Connectinghydrauliclines

Fig.96:Releasingthelock

3.5.9Operationofth etelescopicunit

WARNING!

Adefectivesafeloadindicatororworkingatmorethan100%ofthesafework loadmaycausethemachinetotiltandmayresultinanaccident.

☞ Checkthesafeloadindicatordaily!

☞ Aflashingindicatorandanaudiblesignalwarnofloadsexceeding100%. Theoperatormustreducetheloadbelowthe100%limitbyretractingthe telescopicunit!

Lift

☞ Proceedasfollows:

• Raisetheretractedtelescopicunittotherequiredheight.Todothis: Pulllever 21 backward( D)

• Extendthetelescopicunit.Todothis: Pressthetipswitch 63 andholdinthispositionuntilthetelescopicunitisextendedto therequiredlength

AP0902 3–53 Operation

1 21

Fig.97:Liftingthetelescopicunit

2 63

Fig.98:Retractthetelescopicunit

Lower

☞ Proceedasfollows:

• Retractthetelescopicunit.Todothis: Presstipswitch 64 untilthetelescopicunitiscompletelyretracted

• Lowertheretractedtelescopicunit.Todothis: Pushlever 21 forward( C)

3–54 AP0902

Operation

64 21

Fig.99:Retractthetelescopicunit

Fig.100:Loweringthetelescopicunit

3.5.10Safetydevice“Hoseburstvalve“

NOTE:

Whenworkingwithliftinggearandcertainattachments,thehydrauliccylinderof thetelescopicunitmustbeequippedwith“hoseburstvalves”–see Applications withliftingaccessories onpage2-7. Theypreventthetelescopicunitfromsuddenlyloweringordumpingoutwhena hoseorpipebursts.

WARNING!

Damagetothehydraulicsystemleadstoactivationofthe“hoseburstvalve andmayresultinanaccident–

☞ Unlocktheemergencyloweringofthehoseburstvalveonlyinanemergency.

☞ Havedamagetothehydraulicsystemandtothehoseburstvalveimmediatelyrepairedandcheckedbytrainedpersonnel

Intheeventofdamagetothehydraulicsystem:

☞ Immediatelystopthemachine

☞ Applytheparkingbrake

☞ Firstretractthepush-outcylinderifpossible

☞ Switchofftheengine

☞ Removetheignitionkey

☞ Blockthemachine

Environment!

Collectthedrainedhydraulicoilinasuitablecontainer.Disposeofdrainedhydraulicoilin anecologicallysafemethod!

Alwayscontacttherelevantauthoritiesorcommercialestablishmentsinchargeofoildisposalbeforedisposingofbiodegradableoil.

☞ Collectthedrainedoilanddisposeofitinanecologicallysafemethod!

AP0902 3–55 Operation

Emergencyloweringontheliftcylinder

WARNING!

Emergencyloweringoftelescopicunitmayresultinanaccident.

☞ Firstretractthepush-outcylinderifpossible!

☞ Keepclearofthehazardzoneunderthetelescopicunit,alwaysapproach fromthesides!

☞ Donotactuatetheemergencyloweringoftheliftcylinderfromthefront,but throughthelateralboreintheframe!

☞ Alwaysactuateemergencyloweringwithextremecare

☞ Actuatetheemergencyloweringontheliftcylinderasfollows:

• Firstcarefullyretractthepush-outcylinder

• Removelocknut A

• Carefullyturnoutscrew B by1to2turnsuntilthetelescopicunitstartslowering

• Collectthedrainedoilanddisposeofitbyanecologicallysafemethod!

• Carefullylowerthetelescopicunittotransportposition

• Tightenscrew B again,counteringitwithlocknut A

• Drivethemachineoutofthehazardzonewiththebucketlowered

☞ Havethesettingofthehoseburstvalvecheckedbyaspecialist.Havethehoseburst valvereplacedifnecessary

Emergencyloweringonthepush-out cylinder

☞ Actuatetheemergencyloweringonthepush-outcylinderasfollows:

• Donotretracttheliftcylinder!

• Carefullyturnoutscrew A byabout1/2turnuntilthetelescopicunitstartsretracting

• Carefullyretractthetelescopicunitagainstthelimitstop

• Firmlyretightenscrew A

• Carefullylowerthetelescopicunitwiththeliftcylinderintotransportposition

• Drivethemachineoutofthehazardzonewiththebucketlowered

☞ Havethesettingofthehoseburstvalvecheckedbyaspecialist.Havethehoseburst valvereplacedifnecessary

3–56 AP0902

Operation

A B

Fig.101:Hoseburstvalveforliftcylinder(option)

Fig.102:Hoseburstvalveonpush-outcylinder(option)

☞ Actuatetheemergencyloweringonthetiltcylinderasfollows:

• Firstcarefullyretractthepush-outcylinder

• Carefullylowerthetelescopicunittotransportposition

• Carefullyextendthepush-outcylinderuntiltheboreontheleftsideofthetelescopic unitcanbeaccessed

• Carefullyturnoutscrew A byabout1/2turnuntiltheattachmentstartsdumping

• Retightenscrew A

• Drivethemachineoutofthehazardzonewiththebucketlowered

☞ Havethesettingofthehoseburstvalvecheckedbyaspecialist.Havethehoseburst valvereplacedifnecessary

AP0902 3–57 Operation

Emergencyloweringonthetiltcylinder

Fig.103:Hoseburstvalveontiltcylinder(option)

Operation

3.5.11Workingwithstandardbucketandpalletforks

Standardbucket

Thefollowingsectiondescribesworkoperationswiththemachineequippedwiththestandardbucket.

Thestandardbucketismainlyusedfordiggingearth,andforloosening,lifting,transportingandloadinglooseorsolidmaterials.

Checkingthetiltpositionofthebucket

NOTE:

Angleofredmarking A ontopofthebucketisthesameastheangleofthecutting blade B

Checkingthetransportpositionofthebucket

NOTE:

Thebucketisintransportpositionwhenthe

•Telescopicunitisfullyretractedand

•Bucketisrolledbackincompletely(A )and

•Marks C ontheliftframeandthemachineframearelinedup(figure106)

Withbothmarks C aligned,transportgroundclearancewillbeatleast10in (230mm).(105/B ),withstandardbucket(810136)andstandardtires(12.5-20).

3–58 AP0902

A B B A

Fig.104:Tiltpositionofthebucket Fig.105:Transportpositionofthebucket

Fig.106:Marksfortransportposition

Transportingwithafullbucket

WARNING!

Itishazardoustotransportfullbucketsintheraisedposition.Beespecially carefulwhenturningordrivingonslopes.Thelowerthebucketandthecenter ofgravity,thelesschancethereisoftippingover.

☞ Toavoidaccidents:

•Completelyretractthetelescopicunit

•Rollbackthebucketalltheway

•Raisethebuckettothetransportposition

☞ Proceedasfollows:

• Completelyretractthetelescopicunit

• Rollbackthebucketalltheway(105/A )

• Lowerorraisethetelescopicunittotransportposition(105/B)

AP0902 3–59

Operation

Loadingloosematerial

WARNING!

Donotloadorpushmaterialwiththetelescopicunitextendedasthismay resultinanaccident.

☞ Completelyretractthetelescopicunitforloadingorpushingmaterial!

☞ Proceedasfollows:

• Completelyretractthetelescopicunit

• Selectlowdriverange

• Alignthebladeparallelwiththeground(A )–seealso“Checkingthetiltpositionofthe bucket”

• Lowerthebuckettotheground( B ).Todothis: Pushlever 21 forward( C)

• Driveforwardintothematerial(108/A)

Whentheenginespeeddecreases:

• Raisethebucketslightly B ).Todothis: Pulllever 21 backward(D)

3–60 AP0902

B 21

Fig.107:Horizontalloweringofthetelescopicunit

B A 21

Fig.108:Drivingintothematerial

Ifthematerialishardtopenetrate:

☞ Proceedthesameasforloadingloosematerial,butinaddition:

• Tiltthebucketgentlyinandout.Todothis: Movelever 21 totheleftandright(A and B)

Endingloading:

☞ Proceedasfollows:

• Rollbackinbucket( C).Todothis: Pushlever 21 totheleft(A )

• Reduceenginespeed

• Reverseoutofthematerial(A)

• Raisethebuckettotransportposition(B )

AP0902 3–61

Operation

Fig.109:Loading,ifthematerialishardtopenetrate

C 21

Fig.110:Rollbackinthebucket

B A

Fig.111:Reversingoutofthematerial

Operation

Removingmaterial/digginginsoftsoil

WARNING!

Donotunderminefoundationsorwallsbecauseofthechanceofcollapse!

☞ Neverunderminefoundationsorwalls!

☞ Proceedasfollows:

• Completelyretractthetelescopicunit

• Selectlowdriverange

• Placebuckettotheground( B ).Todothis: Pushlever 21 forward( C)

• Setdiggingangle α (113/1).Todothis: Pushlever 21 totheright( B)

• Drivethemachineforward(114/1) Oncethebuckethaspenetratedthesoil:

• Setdiggingangle α slightlyflatter(114/2).Todothis: Pushlever 21 totheleft(A ),sothat: •Layerbeingremovedisasevenaspossibleand •Toreducewheelspin

• Proceedthesameasforloadingloosematerial

3–62 AP0902

B 21

Fig.112:Loweringthetelescopicunit

1 1 21

Fig.113:Settingthediggingangle

2 1 21

Fig.114:Removinganevenlayer

Removingmaterial/digginginhardsoil

Proceedasfollows:

• Completelyretractthetelescopicunit

• Selectlowdriverange

• Lowerbuckettotheground(115/1).Todothis: Pushlever 21 forward(C)

• Setdiggingangle α slightlyflatter(115/ 2)thanfordigginginsoftsoil.Todothis: Pushlever 21 totheleft(A )

• Drivethemachineforward(115/3)and

• Pressthebucketdownwardslightly.Todothis: Pushlever 21 slightlyforward( C)

Oncethebuckethaspenetratedthesoil:

• Setdiggingangle α slightlyflatter(116/ 1).Todothis:

Pushlever 21 totheleft(A ),sothat:

•Layerbeingremovedisasevenaspossibleand

•Toreducewheelspin

• Pushlever 21 totheleft(A ),ormoveitalternatelytotheleftandright( A and B),to loosenthematerial

• Proceedthesameasforloadingmaterialthatishardtopenetrate

AP0902 3–63

Operation

2 1 3 21

Fig.115:Removinghardsoil

1 21

Fig.116:Settingthediggingangleflatter

Loadingheapedmaterial(non-compactedmaterial)

WARNING!

Diggingunderheapedmaterialcancauseittocollapse.

☞ Neverundermineheapedmaterial!

☞ Proceedasfollows:

• Completelyretractthetelescopicunit

• Selectlowdriverange

• Setthecuttingbladeofthebucketparalleltotheground.Todothis: Pushlever 21 totheleftorright( A and B)

• Lowerthetelescopicunithorizontaltotheground.Todothis: Pushlever 21 forward( C)

• Driveforward

Afterpenetratingtheheapedmaterial:

• Smoothlyliftthetelescopicunit

• Keepthebucketlevel

Whenthetelescopicunitstopsraising:

• Rollbackthebucket(118/1)

• Raisethetelescopicunit(118/2)

• Reverseawayfromtheheapedmaterial(118/3)

• Lowerthetelescopicunittotransportposition

Loadingheapedmaterial(compactedmaterial)

Proceedasfollows:

• Completelyretractthetelescopicunit

• Selectlowdriverange

• Proceedasfornon-compactedmaterial,howeverwhenraisingthetelescopicunit throughtheheapedmaterial:

• Rollbackthebucketinandoutslightly(119/1).Todothis: Movelever 21 alternatelytotheleftandright(A and B)

➥Materialisloosened

3–64 AP0902

Operation

Fig.117:Penetratingtheheapedmaterial

1 3 2 21

Fig.118:Reversingawayfromheapedmaterial

1 21

Fig.119:Heapedcompactedmaterial

Grading

Afterhavingfinishedremoving/loadingthematerial:

• Selectlowdriverange

• Lowerthetelescopicunittotheground(120/1)

• Reverseacrossthesurfacetobegraded(120/2)

Furtherpracticalhintsfordigging

Whenplanningandcarryingoutdiggingwork,werecommendthatyouobservethefollowingpoints:

• Exitsfrompitsshouldbeoutsidethedigginglineandshouldbeaslevelaspossible

• Digbyremovingadjacentstripsifpossible

• Makesureyoucandriveforwardwhendrivingoutofthediggingareawithafully loadedbucket

• Wheneverpossible,driveinreversewhentransportingafullbucketdownasteepslope

Loadingmachines

Whenloadingmachines,werecommendtotakeintoaccountthefollowing:

• Selectlowdriverange

• Ifpossible,thelorryandtheworkingdirectionofthemachineshouldformanangleof 45°(figure121)

• Onlyraisethefullbuckettothedumpingheightwhenyouaredrivinginastraightline towardthelorry

• Withdustymaterials: Ifpossibledumpwiththewindbehindyoutokeepthedustawayfromyoureyes,air filtersandfans

Freeingthemachine

☞ Ifyourmachinegetsstuckintheground:

• Selectlowdriverange

• Dumpoutthebucketuntilthecuttingedgeisverticalabovetheground

• Lowerthebucketalltheway

• Graduallyrollbackthebucket

➥Themachinewillbepushedbackward

• Reverseslowly

• Repeatthisprocedureuntilthewheelsreachfirmground

• Reversethemachineaway

AP0902 3–65

Operation

1 2

Fig.120:Grading Fig.121:Loadingmachines

Operation

3.5.12Workingwithpalletforks

Safetyinstructions

• ObservetheinstructionsinSection 3.5.3„Safeloadindicator” onpage3-43.Thedriver mustbeawareofthesignalsgivenbythesafeloadindicator

• Followthespecialinstructionsintheattachment'soperator’smanual!

• Donotlowertheextendedtelescopicunitfromahighforkarmposition–alwaysretract thetelescopicunitfirst

• Moveascloseaspossibletothematerialtobeloaded

• Movetothematerialtobeloadedwiththewheelsalignedstraightahead!

• Ifpossible,loadthematerialwiththetelescopicunitretracted,asloadingwiththe extendedunitmayaffectthestabilityofthemachine!

• Alwaysworkonfirmandlevelgroundwithsufficientbearingcapacity(forafullyloaded machine)!

• Neverlifttheloadwithonlyoneforkarm!

• Keepaminimumdistanceof6mbetweentelescopicunit/loadandtowerlines!

• Beforecommencingwork,makesurethattheforkarmsontheforkframearesafely locked!

• Donotoperatetelescopicunitorattachmentswhendrivingathighspeed!

• Donotleavethemachinewiththeloadliftedandthetelescopicunitextended!

Approachingthematerial

☞ Proceedasfollows:

• Stopthemachineimmediatelyinfrontofthematerial

• Applyparkingbrake16/25

• Setdriveswitchtoneutral–see Drivingdirectionselectorswitch onpage3-8

• Aligntheforkarmsparallelwiththeground

• Checkthedistanceoftheforkarmstothecenterline(dashedlineinfigure123) Theforkarmsmustbe:

•Atthesamedistancetothecenterline

312b0850.eps

•Asfarapartaspossible

3–66 AP0902

Fig.122:Positionofmachineandtinestowardsthematerial Fig.123:Checkforkspacing

Loadingthematerial

☞ Proceedasfollows:

• Adjusttheheightoftheforkarmssothatthepalletcanbecorrectlyloaded

• Movecarefullyforwarduntiltheforkframeisincontactwiththematerial

• Makesurethatthepalletissafelyloadedontheforkarms

• Applyparkingbrake25

• Movedrivelevertoneutral–see Drivingdirectionselectorswitch onpage3-8

• Liftthetelescopicunit slowly andmakesurethatthelimitsofloaddiagramandsafe loadindicatorarenotexceeded!

• Incaseofdoubtordanger,lowertheloadimmediately!

• Tilttheforkframebackwards( 1)

• Completelyretractthetelescopicunit( 2)

• Intransportposition,lowerthetelescopicunitasfaraspossible(3)

• Makesurethatnothing/nobodyisinthewaywhenreversing

• Engagereversegear

• Releaseparkingbrake16/25

• Reverseslowlyfromthestack(4)

AP0902 3–67

Operation

Fig.124:Loadthematerial Fig.125:Liftthetelescopicunit(

1 2 3 4

Fig.126:Movethematerialtotransportposition

Fig.127:Reversefromthestack

Operation

Settingdownthematerial

☞ Proceedasfollows:

• Movestraightaheadtothestackwiththetelescopicunitretractedandloweredto transportposition,andtheforkframeslightlytiltedback

• Applyparkingbrake16/25

• Setdriveswitchtoneutral–see Drivingdirectionselectorswitch onpage3-8

• Raisethetelescopicunit(1)

• Carefullyextendthetelescopicunit(2)untiltheloadispositionedpreciselyabovethe stack

• Puttheforkarmslevelagain(3)

• Lowerthetelescopicunit slowly (4),makingsurethatthepresetlimitsofload diagramandsafeloadindicatorarenotexceeded!Incaseofdoubtordanger,stop stackingimmediately!Todothis:

•Firstretractthetelescopicunitandthen

•Lowerthetelescopicunit

• Toaligntheloadwiththestack,carefullyretract/extendthetelescopicunit

• Lowertheload

• Makesurethattheforkarmsarefreefromloadandthatnothing/nobodyisinyour way,beforereversingfromthestack

• Retractthetelescopicunit

• Lowerthetelescopicunittotransportposition

• Tilttheforkframetotheback

3–68 AP0902

4 3 2 1

Fig.128:Liftthetelescopicunit

Section4

Troubleshooting

Theinformationgiveninthissectionisintendedformaintenancepersonnelwhencarrying outrepairwork.Itallowsforfastandreliabledetectionoferrorsandmalfunctionssothat appropriatemeasurescanbetakenfortroubleshooting. Thedetaileddescriptionofrepairworkislimitedtotheworkthatcanbecarriedoutbypersonswithoutspecialtraining.

AP0902 4–1 Troubleshooting 4 4Troubleshooting

Troubleshooting

4.1Enginetrouble

4–2 AP0902

Problem Possiblecauses Checkedbyoperator Checkedbyworkshop Starterturnstooslowly1,2,3,4 Enginedoesnotstart5,6,7.8,9,10,12,13,14,15,1734,35,36,37.38,42,43,44 Enginenoteasytostart 5,7.8,9,10,11,12,13,14,15,16, 17.19 34,36,37.38,40,42,43,44 Insufficientoutput 8,9,10,11,12,13,16,17.18,19,20, 21 34,36,37.38,39,42,43,44,63 Interruptedengineoperation8,9,10,12,13,15,20,2234,36,37.38,39,40,41,43 Highfuelconsumption11,13,15,17.18,19,21,2234,36,37.38,39,40,42,43,44,63 Blacksmoke11,13,15,17.19,21,2234,36,37.38,39,40,42,43,44,63 Blueorwhitesmoke4,15,21,2336,37.38,39,42,44,45,52,58,62 Oilpressuretoolow4,24,25,2646,47.48,50,51,59 Engineknocks9,13,15,17.20,22,2336,37.40,42,44,46,52,53,60 Irregularenginespeeds 7.8,9,10,11,12,13,15,16,18,20, 22,23 34,38,40,41,44,52,60 Vibrations13,18,20,27.2834,38,39,40,41,44,52,54 Oilpressuretoohigh4.2549 Enginetemperaturetoohigh11,13,15,19,27.29,30,32,6534,36,37.39,52,55,56,57 Pressureincrankcasetoohigh31,3339,42,44,45,52 Compressiontoolow11,2237.39,40,42,43,44,45,53,60 Enginestartsandstopsrightafter10,11,12

4.1.1Possiblecause sformalfunctions

tionpump

37Incorrectvalvetiming

38Compressiontoolow

39Cylinder-headgasketleaks

40Blockedvalves

41Wronginjectionlines

42Cylinderboresworn

43Valveseatsleak

44Pistonringblocked,wornorbroken

45Valvestemsand/orguidesworn

46Crankshaftbearingwornordamaged

47Oilpumpworn

48Pressurereliefvalvedoesnotclose

49Pressurereliefvalvedoesnotopen

50Springinpressurereliefvalvebroken

51Defectiveoilsuctionpipeofoilpump

52Damagedpiston(s)

53Incorrectprojectionofpiston(s)

54Flywheelhousingorflywheelnotcorrectlyaligned

55Defectivethermostatorwrongthermostat

56Coolantchannelsconstricted

57Defectivecoolantpump

58Damagedvalvestemsealing

59Oilscreenfouled

60Valvespringbroken

61Notassigned

62Notassigned

63Intakesystemleaks

64Notassigned

65Drivebeltforcoolantpumpisloose

AP0902 4-3 Troubleshooting

3Defectivestarter 4Wrongoilgrade 5Starterturnstooslowly 6Fueltankempty 7Defectiveshutoffunit 8Fuellinesclogged 9Defectivefuelpump 10Fuelfilterfouled 11Intakesystemconstricted/airfilter fouled 12Airinfuelsystem 13Injectionnozzlesdamagedorwrong injectionnozzles

tem 15Defectivecoldstartingsystem 16Badfueltankventilation 17Wrongfuelgrade 18Limitedactionofcontrolsforspeed regulation 19Defective/cloggedexhaustsystem 20Enginetemperaturetoohigh 21Enginetemperaturetoolow 22Wrongsettingofvalveclearance

withtoomuchoiloroilwithwrong grade 24Engineoilleveltoolow 25Defectiveoilpressuresensor 26Oilfilterfouled 27Defectivebreather 28Defectiveenginesuspensionorflywheelhousing 29Engineoilleveltoohigh 30Limitedcirculationofairorcoolant throughradiator 31Breatherlineconstricted 32Coolantleveltoolow 33Vacuumlineleaksordefectivevacuum pump 34Defectivefuelinjectionpump 35Defectivedriveoffuelinjectionpump 36Incorrectstartofdeliveryoffuelinjec-

1Deadbattery 2Electricalconnectionsarenotinorder

14Incorrectoperationofcoldstartingsys-

23Oilbathaircleaner(ifinstalled)filled

Troubleshooting

Notes

4–4 AP0902

Maintenance 5

Section5

5.1Introduction

Beforecarryingoutserviceandmaintenancework,alwaysread,understandandfollow theinstructionsgivenin

• Part2“SAFETYINSTRUCTIONS”ofthisoperator’smanual

• Theoperator’smanualfortheengine

Dailyserviceandmaintenancework,andmaintenanceworkaccordingtomaintenance planA,canbecarriedoutbyspeciallytrainedoperators.Allothermaintenanceworkmust becarriedoutbyqualifiedmechanicsonly.

Theintervalsforthemaintenanceworkdescribedbelowarelistedinthemaintenance plansintheannex.

5.2Fuelsystem

5.2.1Specificsafetyinstructions

• Extremecautionisessentialwhenhandlingfuelbecauseoftheriskoffire!

• Neverworkonthefuelsystemiftheengineishot–e.g.forbleeding,changingfiltersor cleaningthewaterseparator!

• Neverperformworkonthefuelsystemnearopenflamesorignitablesparks!

• Donotsmokewhenworkingonthefuelsystemorwhenrefuelling!

• Beforerefuellingswitchofftheengineandremovetheignitionkey!

• Donotrefuelinenclosedareas!

• Wipeawayfuelspillsimmediately!

• Keepthemachinecleantoreducetheriskoffire!

AP0902 5–1 Maintenance 5

5Maintenance

Maintenance

5.2.2Refuelling

WARNING!

Allworkinvolvingfuelcarriesanincreasedriskoffireandpoisoning!

☞ Donotrefuelinenclosedareas

☞ Neverperformworkonthefuelsysteminthevicinityofnakedflamesor sparks

Environment!

Useasuitablecontainertocollectthefuelasitdrainsanddisposeofitinanenvironmentallyfriendlymanner!

NOTE:

Donotrunthefueltankcompletelydry.Otherwise,airisdrawnintothefuelsystem.Thisrequiresbleedingthefuelsystem–seesection5.2.6 Bleedingthefuel system onpage5-6.

StationaryfueltanksGeneral

Ifpossible,onlyrefuelfromstationaryfueltanks.Fuelfrombarrelsorcansisusuallycontaminated.

Eventhesmallestparticlesofdirtcancause

• Increasedenginewear

• Malfunctionsinthefuelsystemand

• Reducedeffectivenessofthefuelfilters

Refuellingfrombarrels

Ifrefuellingfrombarrelscannotbeavoided,notethefollowingpoints(seefigure130):

• Barrelsshouldneitherberollednortiltedbeforerefuelling

• Protectthesuctionpipeopeningofthebarrelpumpwithafine-meshstrainer

• Immerseitdowntomax.6in(15cm)abovethebottomofthebarrel

• Onlyfillthetankusingrefuellingaids(funnelsorfillerpipes)withanintegralmicrofilter

• Keepallrefuellingcontainerscleanatalltimes

5–2 AP0902

Maintenance

wrong right ✓ ✗

Fig.129:Fuelfillerinlet Fig.130:Refuellingfromabarrel

Specificationfordieselfuel

Onlyusehigh-gradefuels:

Fortemperaturesbelow20°F(6°C)orfor operationabove1640yd(1500m)altitude

5.2.3Cleaningthefueltank

Environment!

Useasuitablecontainertocollectthefuelasitdrainsanddisposeofitinanenvironmentallyfriendlymanner!

Depositsofdirtparticlesandwaterinthetankcannotbeentirelyavoided.Thefueltank shouldthereforebecleanedoccasionally, particularlybeforewinteroperation. Cleanthefueltankwhenthefuellevelinthetankisaslowaspossible!

☞ Cleanthefueltankasfollows:

• Placeadriptrayunderfueltank A

• Unscrewreturnconnectionpiece B

• Flushoutthefueltankwithfuel,severaltimesifnecessary

• Screwreflexconnectionpiece B backin,tothelimit

• Unscrewreflexconnectionpiece B again,untilthecorrectpositionis reached–max.1turn!

• Fillthetank

• Checkreflexconnectionpiece B forleakage

AP0902 5–3 Maintenance

Grade Cetane number Application • No.2-D Min.45 Fornormaltemperatures

No.1-D

•

A B

Fig.131:Drainplugonfueltank

Maintenance

5.2.4Changingthefuelfilter

WARNING!

Ifthefuel,asitdrains,comesintocontactwithhotenginepartsortheexhaust system,thereisanincreasedriskoffire.

☞ Neverchangethefuelfilteriftheengineishot!

Environment!

Useasuitablecontainertocollectthefuelasitdrainsanddisposeofitinanenvironmentallyfriendlymanner!

☞ Changefuelfilter132/C asfollows:

• Thoroughlycleantheoutsidesurfacesofthefuelfilter

• Firmlyholdlowercover133/6 ofthefilterandunscrewscrew133/1 onthefilterhead

• Pulllowercover133/6 ofthefilterdownward

• Removeanddisposeoffilter133/4

• Cleantheinsideofthefilterheadandthelowercover

• Replaceseals133/2 and133/5 andO-ring133/3 andapplyathincoatofcleanfuel

• Holdthelowercoverunderthenewfilterandplacethefilteronthefilterhead.Ensure correctpositionofthefilterontheO-ringinthefilterhead

• Placeandtightenscrew133/1

• Bleedthefuelsystem–seesection5.2.6 Bleedingthefuelsystem onpage5-6

• Makeatestrun–andcheckfortightness!

5–4 AP0902

Fig.132:Fuelfilterposition Fig.133:Removingthefuelfilter

5.2.5Cleaningthefuel/waterseparator

WARNING!

Ifthefuel,asitdrains,comesintocontactwithhotenginepartsortheexhaust system,thereisanincreasedriskoffire

☞ Nevercleanthefuel/waterseparatoriftheengineishot!

☞ Proceedasfollows:

• Placeadriptrayunderthefuel/waterseparator

• Unscrewthedrainplugonthelowerside

• Drainthewateruntilcleanfuelrunsout

• Screwinthedrainplugonthelowerside

• Testruntheengine

AP0902 5–5 Maintenance

Fig.134:Positionoffuel/waterseparator

5.2.6Bleedingthefuelsystem

WARNING!

Ifthefuel,asitdrains,comesintocontactwithhotenginepartsortheexhaust system,thereisanincreasedriskoffire

☞ Neverbleedthefuelsystemiftheengineishot!

Bleedthefuelsysteminthefollowingcases:

• Afterremovingandfittingthefuelfilterandthefuellinesbackonagain,or

• Afterrunningthefueltankempty,or

• Ifthefuelsystemleakswiththeenginerunning,or

• Afterrunningtheengineagain,afterithasbeenoutofserviceforalongperiodoftime

☞ Bleedthefuelsystemasfollows:

• Fillthefueltank

• Unscrewtheventscrew135/1 onthesideofthefuelinjectionpump

• Actuatethehandpumpleveronthefuelsupplypump135/2untilthefuelrunsoutfree ofairfromthebleedopening

• Tightenbleedscrew135/1

• Turntheignitionkeytothe“ON”position(1)

• Turnthestarteruntiltheenginestarts(15secondsmaximum) Iftheenginerunssmoothlyforawhile,andthenstops;orifitdoesnotrunsmoothly:

• Checkonceagainifthereisanyairinthefuelsystem Thepresenceofairinthefuelsystemisasignofleakageonthelow-pressuresideofthe fuelsystem!

• Switchofftheengine

• Turntheignitionkeytothe“OFF”position(0)

5–6 AP0902

Maintenance

Fig.135:Bleedingthefuelsystem

5.3Enginelubricationsystem

5.3.1Checkingtheengineoillevel

NOTE:

Checktheoillevelevery10servicehoursoreveryday.Werecommendchecking theoillevelbeforestartingtheengine;afterswitchingoffawarmengine,waitat least5minutesbeforechecking.

☞ Checktheoillevelasfollows:

• Parkthemachineonlevelground

• Switchofftheengine!

• Oildipstick136/1

•Pullitoutandwipeitwithalint-freecloth

•Pushitbackinasfaraspossible

•Withdrawand

•Readtheoillevel

• Topuptheoillevelifnecessary (atlatestwhentheoilreachestheMINmarkonthedipstick)

Important!

Excessiveorincorrectengineoilmayresultinenginedamage!Forthis reason:

☞ DonotaddengineoilabovetheMAXmark136/2 oftheoildipstick

☞ Useonlythespecifiedengineoil–seesection5.15Enginefluidsandlubricantsonpage5-39

Environment!

Collectthedrainedengineoilinasuitablecontaineranddisposeofitbyanecologically safemethod!

☞ Topuptheoillevelasfollows:

• Cleantheareaaroundoilfillercap A withalint-freecloth

• Opencap A

• Raiseoildipstick B slightlytoallowanytrappedairtoescape

• Addengineoil

• Waitamomentuntilalltheoilhasrunintotheoilsump

• Checktheoillevel–seesection5.3.1 Checkingtheengineoillevel onpage5-7

• Topupifnecessaryandchecktheoillevelagain

• Closeoilfillercap A

• Pushinoildipstick B intothefillerinletasfarasitwillgo

• Completelyremovealloilspillsfromtheengine

AP0902 5–7 Maintenance

5.3.2Toppinguptheengineoil Fig.136:Checkingtheoillevel Fig.137:Toppingupengineoil

A B

5.3.3Changingtheengineoil

WARNING!

Useextracautionwhendraininghotengineoil,becauseoftheriskofburns.

☞ Wearprotectivegloves

☞ Usesuitabletools

Environment!

Collectthedrainedengineoilinasuitablecontaineranddisposeofitbyanecologically safemethod!

☞ Changetheengineoilasfollows:

• Parkthemachineonlevelground

• Lettheenginerununtilreachingoperatingtemperature[oiltemperatureabout180°F (80°C)]

• Switchofftheengine

• Removemaintenancepanel A underthemachinerearend.Todothis: Releasescrews B

• Placeanoildriptray[withacapacityofabout8quarts(8liters)]undertheopening

• Unscrewfillercap C ofoildrainvalve E

• Unscrewoildraincoupling D withasufficientlylonghose,makingsuretheendofthe hoseisintheoildriptray

➥Oildrainvalve E opensandtheengineoildrains

• Completelydraintheoil

• Unscrewoildraincoupling D

• Screwonfillercap C oftheoildrainvalve

• Fitmaintenancepanel A

• Fillwithengineoil–seesection5.3.2 Toppinguptheengineoil onpage5-7

• Starttheengineandrunitatlowspeedforashorttime

• Switchofftheengine

• Waitamomentuntilalltheoilhasrunintotheoilsump

• Checktheoillevelagain

• Topupifnecessaryandcheckagain

• Completelyremovealloilspillsfromtheengine

5–8 AP0902

Maintenance

A B

Fig.138:Maintenancepanel

C C D E

Fig.139:Engineoildrainplug

5.3.4Changingtheengineoilfiltercartridge

WARNING!

Useextracautionwhendraininghotengineoil,becauseoftheriskofburns.

☞ Wearprotectivegloves

Environment!

Useasuitablecontainertocollecttheengineoilasitdrains. Disposeofusedoilandfiltersinanenvironmentallyfriendlymanner!

☞ Changethefilterasfollows:

• Stoptheengine

• Placeasuitablecontainerundertheoilfiltertocollecttheoil

• Releaseandunscrewtheoilfiltercartridgeusingacommerciallyavailabletool

• Besurethethreadadapter140/1 iscorrectlyplacedinthefilterhead

• Cleantheinsideofthefilterhead

• Applyathincoatoffreshengineoiltotherubberseal140/2 ofthenewoilfilter cartridge

• Tightenthenewfiltercartridgebyhanduntilthegasketmakescontact

• Tightentheoilfiltercartridgebyhandwithafurtherhalforthree-fourthsofa revolution

• Makesuretheoilleveliscorrect!

• Runtheengineforashorttime

• Switchofftheengine

• Checkthesealoftheoilfiltercartridgeandretightenbyhand

• Checktheoillevelandaddengineoilifnecessary

• Completelyremovealloilspillsfromtheengine

• Disposeoftheusedoilfilterinanenvironmentallyfriendlymanner

AP0902 5–9 Maintenance

Fig.140:Engineoilfiltercartridge

5.4Engineandhydraulicscoolingsystem

Thecombinedoil/watercoolerislocatedintheenginecompartment,ontherightsideof theengine.Itcoolsthedieselengine,andthehydraulicoilofthedriveandwork hydraulics.

Theexpansiontankforthecoolantisalsolocatedintheenginecompartment,abovethe cooler.

5.4.1Specificsafetyinstructions

• Dirtonthecoolingfinsreducesthecooler’sheatrejectioncapacity!

Toavoidthis:

• Cleantheoutsideofthecooleratregularintervals.Refertothemaintenanceplansin theAnnexforthecleaningintervals

• Industyordirtyworkconditions,cleanmorefrequentlythanindicatedinthemaintenanceplans

• Aninsufficientcoolantlevelreducestheheatrejectioncapacityaswell,andcanleadto enginedamage!Therefore:

• Checkthecoolantlevelatregularintervals.Refertothemaintenanceplaninthe Annexfortheintervals

• Ifcoolantmustbeaddedfrequently,checkthecoolingsystemforleakagesand/or contactyourdealer!

• Neverfillincoldwater/coolantiftheengineiswarm!

• Afterfillingtheexpansiontank,conductatestrunwiththeengineandcheckthe coolantlevelagainafterswitchingofftheengine

• Theuseofthewrongcoolantcandestroytheengineandthecooler.Therefore:

• Addsufficientantifreezetothecoolant–butnevermorethan50%.Ifpossibleuse brand-nameantifreezethathaveanticorrosionadditives

• Observethecoolanttableinsection“Specifications”

• Donotusecoolercleaningcompoundsifantifreezehasbeenaddedtothecoolant–otherwisethiscausessludgetoform,whichcandamagetheengine

Environment!

Useasuitablecontainertocollectthecoolant asitdrainsanddisposeofitinanenvironmentallyfriendlymanner!

5–10 AP0902 Maintenance

5.4.2Checkingthecoolantlevel/toppingupthecoolantlevel

NOTE:

Checkthecoolantlevelevery10servicehoursordaily.Werecommendchecking theoillevelbeforestartingtheengine;

Checkingthecoolantlevel

WARNING!

Neveropenthecoolanttankandneverdraincoolantiftheengineiswarm, becausethecoolingsystemisunderhighpressureandthereisariskofburns

☞ Waitatleast10minutesafterswitchingofftheengine!

☞ Wearprotectiveglovesandclothing

☞ Alwaysstartbyactuatingthesafetyvalveinthecapoftheexpansiontank. Todothis: Openthecaptothefirstnotchandallowthepressuretoescape

☞ Proceedasfollows:

• Switchofftheengine

• Opentheenginecover

• Checkthecoolantlevelinthetransparentexpansiontank A IfthecoolantlevelisbelowMINmark B:

• Addcoolant–seeToppingupthecoolantlevel

AP0902 5–11 Maintenance

A D B C

Fig.141:Expansiontankforcoolant

Toppingupthecoolantlevel

WARNING!

Neveropenthecoolanttankandneverdraincoolantiftheengineiswarm, becausethecoolingsystemisunderhighpressureandthereisariskofburns

☞ Waitatleast10minutesafterswitchingofftheengine!

☞ Wearprotectiveglovesandclothing

☞ Alwaysstartbyactuatingthesafetyvalveinthecapoftheexpansiontank. Todothis: Openthecaptothefirstnotchandallowthepressuretoescape

☞ Proceedasfollows:

Aftertheenginehascooleddown:

• Reducetheoverpressureinexpansiontank A .Todothis: Openfillercap D byhalfarevolution

Afterreleasingthepressure:

• Openfillercap D completely

• FillupcoolantuptoMAXmark C

• Closefillercap D

Afterfillinginalargeamountofcoolant,e.g.firstfill:

• Starttheengineandletitwarmup

• Switchofftheengineandletitcooldown

• Checkthecoolantlevelagain

• Ifnecessary,addcoolantandrepeattheprocedureuntilthecoolantlevelremains constant

5.4.3Cleaningthecoolingfins

☞ Proceedasfollows:

• Switchofftheengine

• Opentheenginecover

• Blowcompressedairfromtheenginesidetoremovedirtfromthecoolingfins E.

5–12 AP0902

Maintenance

A D B C

Fig.142:Expansiontankforcoolant

Fig.143:Cleaningthecooler

Important!

Donotcleantheairfiltercartridge.Theairfiltercartridgewillbedamagedifit iswashedorbrushedout!Dustonthecleansideofthefiltercausesacceleratedenginewear!

☞ Replacethefiltercartridgewhenthewarninglightcomeson!

☞ Neverreusedamagedfiltercartridges.Replacethemifyouareunsure!

☞ Ensurecleanlinesswhenreplacingthefiltercartridge!

WarningLight19/ 37 ontheinstrumentpanelmonitorsthefiltercartridge.Thefiltercartridgemustbereplaced:

• Ifwarninglight19/37 comeson,or

• Atthelatestafter1200servicehoursoronceeveryyear.

NOTE:

Theairfiltercanbefittedwithanoptionalsafetycartridgefor applicationsin especiallydustyenvironment.Itisnotpossibletocleanthesafetycartridge. Replacethesafetycartridgeeverythirdtimemaintenanceworkiscarriedout!

Important!

Thefiltercartridgemaydegradeprematurelywhenusedinacidicairforlong periodsoftime.Thisriskispresentforexampleinacidproductionfacilities, steelandaluminiummills,chemicalplantsandothernonferrous-metalplants.

☞ Useoptionalinductionsystemwhenworkinginanenvironmentwith increaseddust(option)

☞ Replacethefiltercartridgeandthe safetycartridge (option)asperwarning light19/37,orafter300servicehoursatthelatest!

☞ Cleandustvalve A regularlyaccordingtothemaintenanceplan!

AP0902 5–13 Maintenance 5

5.5Airfilter

A C

B D Maintenance

Fig.144:Airfilter

Maintenance

Functionalcheckofthedustvalve, everyweek

☞ Proceedasfollows:

• Switchofftheengine

• Opentheenginecover

• Compressthedischargeslotofdustvalve A

• Removehardeneddustbycompressingtheupperareaofthevalve

☞ Cleanthedischargeslotifnecessary

Important!

Donotcleantheairfiltercartridge.Theairfiltercartridgewillbedamagedifit iswashedorbrushedout!Dustonthecleansideofthefiltercausesacceleratedenginewear!

☞ Replacethefiltercartridgewhenthewarninglightcomeson!

☞ Neverreusedamagedfiltercartridges.Replacethemifyouareunsure!

☞ Ensurecleanlinesswhenreplacingthefiltercartridge!

☞ Replaceasfollows:

• Switchofftheengine

• Opentheenginecover

• Openthethreebowclips145/B onthelowerhousingsection145/C

• Removethelowerhousingsection145/C

• Removefiltercartridge146/E withaslightturningmovement

• Additionallyafterevery3rdreplacementofprimaryfiltercartridge E:

•Removesafetycartridge F (option),turningitslightlyasyoudoso

•Carefullyinsertthenewsafetycartridge F (option)intothetophousingsection

• Carefullyinsertfiltercartridge E intotheupperhousingsectiond145/D

• Putthelowerhousingsection145/C backintoplaceandsecurewith the3bowclips145/B

➥Thefilterelementisthenautomaticallypressedintothecorrectposition

• Putthelowerhousingsection144/Cbackintoplaceandsecurewith the3bowclips144/B

➥Thefilterelementisthenautomaticallypressedintothecorrectposition

5–14 AP0902

Replacingthefiltercartridge

A C

B D

Fig.145:Airfilter

308b1040.eps E

Abb.146:Removingthefiltercartridge

F E

Fig.147:Airfilterwithsafetycartridge(option)

5.6V-belt

WARNING!

Toavoidinjury,onlycheckorre-tension/replacetheV-beltwhentheengineis switchedoff.

☞ Switchofftheenginebeforecarryingoutmaintenanceworkintheengine compartment!

ChecktheV-belteverydayorevery10hoursofoperationandre-tensionitifnecessary. NewV-beltsshouldbere-tensionedafterabout15minutesofoperatingtime.

5.6.1CheckingtheV-belttension

☞ Checkasfollows:

• Switchofftheengine

• Preventthemachinefromrollingawayandremovetheignitionkey

• Opentheenginecover

• CarefullyinspecttheV-beltfordamage

IftheV-beltisdamaged:

☞ ReplaceV-belt

• Presswithyourthumbinthemiddleofthelongestsectionbetweentwopulleys(figure 148)tocheckwhethertheV-beltcanbedeflected,bynomorethanabout0.4in(10 mm)

• Re-tensiontheV-beltifnecessary–seeSection 5.6.2„Re-tensioningtheV-belt”

5.6.2Re-tensioningtheV-belt

☞ Re-tensionasfollows:

• Switchofftheengine

• Preventthemachinefromrollingawayandremovetheignitionkey

• Opentheenginecover

• Unscrewswivelscrews148/3 onthealternatorandthesetscrewon adjustmentbracket148/2

• UseasuitabletooltomovethealternatoruntilthecorrectV-belttensionisobtained

• Keepthealternatorinthisposition

• Firmlytightenswivelscrew148/3 onthealternatorandthesetscrewon adjustmentbracket148/2

• ChecktheV-belttensiononceagain.ChecktheV-belttensionagainafterthefirst25 servicehoursifanewV-beltismounted

AP0902 5–15 Maintenance

Fig.148:CheckingtheV-belttension

5.7Hydraulicsystem

5.7.1Specificsafetyinstructions

• Alllinescarryinghydraulicoilmustbedepressurizedpriortoanymaintenanceand repairwork.Todothis:

☞ Lowerallhydraulicallycontrolledattachmentstotheground

☞ Actuatethecontrolleversofthehydrauliccontrolvalvesseveraltimes

• Applytheparkingbraketopreventthemachinefromrollingawaybeforeyoucarryout serviceandmaintenancework

• Hydraulicoilescapingunderhighpressurecanpenetratetheskinandcauseserious injuries.Alwaysconsultadoctorimmediatelyevenifthewoundseemsinsignificant–otherwiseseriousinfectionscouldsetin!

• Ifthehydraulicoilinthelevelglassiscloudy,thisindicatesthatwaterorairhasentered thehydraulicsystem.Thismaycausedamagetothehydraulicpump!

☞ Contactyourdealerimmediately

• Insufficientorincorrecthydraulicoilwill resultindamagetothehydraulicsystem!For thisreason:

• Onlyuseauthorizedoilsofthesametype–see Enginefluidsandlubricants on page5-39

• Alwaystopupthehydraulicoilbeforethelevelgetstoolow

• Contactcustomerserviceifthehydraulicsystemfilteriscontaminatedwithmetal chippings.Otherwise,additionaldamagemayresult!

5.7.2Checkingthehydraulicoillevel

☞ Proceedasfollows:

• Parkthemachineonlevelground

• Retractallthehydrauliccylyinders

• Switchofftheengine

Whenalltheoilhasreturnedtothehydraulicoiltank:

• Opentheenginecover

• Checkthehydraulicoillevel149/Ainthesightglass:

5–16 AP0902 Maintenance

A ✓ Iftheoillevelis

IsvisibleinthesightglassOK

Belowthesightglass ☞ Topupthehydraulicoil

Abovethesightglass ☞ Drainthehydraulicoil

Fig.149:Oillevelsightglassonthehydraulicoiltank

•

5.7.3Toppingupthehydraulicoil

Donottopupthehydraulicoilunlesstheengineisswitchedoff.

☞ Topupasfollows:

• Parkthemachineonlevelground

• Retractallthehydrauliccylinders

• Switchofftheengine

• Applyparkingbrake16/25

Whenalltheoilhasreturnedtothehydraulicoiltank:

☞ Opentheenginecover

☞ Cleantheareaaroundbreatherfilter B ofthehydraulicoiltankwithacloth

☞ Openbreatherfilter B

Withthefilterinstalled:

☞ Topupthehydraulicoil

☞ Checkthehydraulicoillevelonoillevelsightglass A

☞ Topupthehydraulicoilifnecessaryandcheckagain

WARNING!

Draininghothydraulicoilandremovingthefilterelementcanbehazardous becauseoftheriskofburns

☞ Wearprotectivegloves

☞ Fitasufficientlylonghosetotheoildraincoupling

☞ Proceedasfollows:

• Parkthemachineonlevelground

• Lowerthetelescopicunitfully.Todothis:Pushlever16/21 forward

• Rollbackthebucketalltheway.Todothis:Pushlever16/21 totheleft

• Switchofftheengineandpreventthemachinefromrollingaway

• Opentheenginecover

• Removecover150/B ofhydraulicoiltank

AP0902 5–17 Maintenance

5.7.4Changingthehydraulicoil

B A

Fig.150:Hydraulicoiltank

Undertherearendofthemachine:

• Placeasuitablecontainertocollecttheoilasitdrains,withaminimumcapacity of15gallons(55liters)

• Removefillercap C oftheoildrainvalve

• Screwoildraincoupling D ontotheoildrainvalve,withasufficientlylonghose, makingsuretheendofthehoseisinthecontainer

➥Oildrainvalve E opensandtheoildrainsintothecontainer

• Flushoutthehydraulicoiltankwithasmallamountofhydraulicoil

• Removeoildraincoupling D onoildrainvalve E

• Screwonfillercap C oftheoildrainvalve

• Replacethehydraulicoilreturnfilter–see Hydraulicoilreturnfilter onpage5-20

• Checkthewhetherthefillingscreenisintact

Important!

Ifthehydraulicoiliscontaminated,thereisariskofseveredamageinthe hydraulicsystem.

☞ Alwaysaddhydraulicoilusingthefillingscreen!

• Fillthesystemwithfreshhydraulicoiluptothemiddle149/ A oftheoillevelsight glass

• Screwoncover150/B ofthehydraulicoiltank

• Starttheengine

Atalowenginespeed:

• Fullyextendtheliftandtiltcylindersonthetelescopicunit

• Turnthesteeringwheeltotheleftandrightseveraltimes,fromlocktolock

• Retractallthehydrauliccylindersagain

• Switchofftheengine

• Checkthehydraulicoillevelagainandtopupagainifnecessary

5–18 AP0902 Maintenance

C D E

Fig.151:Oildrainvalvewithcap

Importantinformationconcerningthe useofbiodegradableoil

• Useonlythebiodegradablehydraulicfluidsthathavebeenapprovedbythemanufacturer–see Enginefluidsandlubricants onpage5-39.Alwayscontactthemanufacturer fortheuseofotherproducts.Inaddition,asktheoilsupplierforawrittendeclarationof guarantee.Thisguaranteeisapplicabletodamageoccurringtothehydrauliccomponents,whichcanbeprovedtobeduetothehydraulicfluid

• Theremainingamountofinitialhydraulicfluidinthehydraulicsystemmustnotexceed 8%whenusinganothertypeofbiodegradableoil(manufacturerindications)

• Donottopupwithmineraloil–thecontentofmineraloilmustnotexceed2%inorder toavoidfoamingproblemsandtoensurebiologicaldegradability(hazardouswaste!)

• Whenrunningthemachinewithbiodegradableoil,thesameoilandfilterreplacement intervalsareusedasformineraloil–seemaintenanceplansintheAnnex. Inaddition,takeasampleofthehydraulicoilevery600servicehoursatthelatest,and haveitanalyzed(orderno.foroilsampleset:0004400014).Furtheractiondepends ontheresultsoftheoilanalysis

• Drainthecondensationwaterinthehydraulicoiltankevery600servicehours,andin anycasebeforethecoldseason.Thewatercontentshouldnotexceed0.1%byweight

• Theinstructionsinthisoperator’smanualconcerningenvironmentalprotectionalsofor theuseofbiodegradableoil

• Ifadditionalhydraulicattachmentsaremountedoroperated,usethesametypeof biodegradableoilfortheseattachmentstoavoidmixturesinthehydraulicsystem

Subsequentchangefrommineraloiltobiodegradableoil

☞ Completelyflushthehydrauliccomponents.Todothis:

• Parkthemachineonlevelgroundwhenitisatoperatingtemperature

• Retractallthehydrauliccylinders

• Switchofftheengine

Whenalltheoilhasreturnedtothehydraulicoiltank:

• Completelydrainthehydraulicoil

• Fillthehydraulicsystemwiththenewoiltype

• Starttheengine

• Operateallthecomponentsofthehydraulicsystem,suchascylinders,to“flush”the lines,cylindersandpumps

• Retractallthehydrauliccylinders

Whenalltheoilhasreturnedtothehydraulicoiltank:

• Switchofftheengine

• Completelydrainthehydraulicoilagain

• Replacethehydraulicoilreturnfilter(insert)–see Hydraulicoilreturnfilter on page5-20

• Fillthehydraulicsystemwithfreshoiltotherequiredlevel

• Checktheoillevelandtopupifnecessary

AP0902 5–19 Maintenance

Fig.152:Label:biodegradableoil

5.7.5Hydraulicoilreturnfilter

Theredwarninglight19/39 ontheinstrumentpanelmonitorsthefilter.Thefilterelement mustbereplaced:

• Ifwarninglight19/39 comesonwhenthehydraulicoilisatoperatingtemperature

• Atthelatestafter1200servicehoursoronceeveryyear.

Incoldweatherwarninglight19/39 maycomeonimmediatelywhentheengineisstarted. Thisisduetoincreasedoilviscosity.Inthiscase:

☞ Setenginespeedsothatthewarninglightgoesout

☞ Bearinmindtheinstructionsconcerningwarmup–seeWhentheenginehasstarted... onpage3-16

Changingthefilterelement

Important!

Contaminationmaycauseseveredamageinthehydraulicsystem!

☞ Takecaretoavoidcontaminationwhenworking!

☞ Proceedasfollows:

• Switchofftheengine

• Opentheenginecover

• Openbreather A onthehydraulicoiltank

• Unscrewcaps F and154/1 ofthefilterbyabout2turnsandwaitfortheoillevelinthe filterhousingtofalltothelevelinthetank

• Completelyunscrewandremovecovers F and154/1 ofthefilter

• Pulloutthefillerpipe154/2 withthefilterelement154/3,turningthemslightly

• Pullthefilterelement154/3 offthefillerpipe154/2 anddisposeofthefilterelement

• Checkthattheflatgasket154/4 onthefiltercap154/1 andtheO-ring154/ 5 onthe fillerpipeareingoodcondition

• FitnewO-ringsiftheoldonesaredamaged

• Slidethefillerpipe154/2 ontoanewfilterelement154/3 andinserttheassemblyinto thefilter

• Tightencaps153/F and154/1 byhand[Torque:15ft-lbs(20Nm)]

• Tightenbreatherfilter153/A byhand

• Carryoutatestrunofthehydraulicsystem

Withtheengineswitchedoff:

• Checkthefilterforleakage

5–20 AP0902 Maintenance

A F 308b1100.eps

Fig.153:Positionofhydraulicoilreturnfilter

2 1 2 3 4 5

Fig.154:Returnsuctionfilter:explodedview

5.7.6Replacingthebreatherfilter

Replacebreather A forthehydraulicoiltankevery1200servicehours,oratleastoncea year

☞ Proceedasfollows:

• Unscrewbreather A

• Screwinthenewbreatherfilter A

5.7.7Hydraulicpressurelines Specificsafetyinstructions

WARNING!

Useextracautionwhencheckinghydrauliclines,especiallywhensearching forleaks.Hydraulicoilescapingunderhighpressurecanpenetratetheskin andcauseseriousinjuries.Alwaysconsultadoctorimmediately,evenifthe woundseemsinsignificant–otherwise seriousinfectionscouldsetin!Never searchforleakswithyourbarehands,butwearprotectivegloves!Usepaper orwoodtocheckforminorleaks.Neveruseanunprotectedlightornaked flame!

☞ Alwaysobservethefollowinginstructions:

•Retightenleakingfittingsandhoseconnectionsonlywhenthesystemis notunderpressure;i.e.relievethepressurebeforeworkingonpressurizedlines!

•Neverweldorsolderfaultyorleakingpressurelinesandconnections. Replacedamagepartswithnewones!

•Whenreplacinghoselines,ensurethattheyarenottwisted!

• Leaksanddamagedlinesmustberepairedorreplacedasquicklyaspossible.Thisnot onlyincreasestheoperatingsafetyofthemachine,butalsohelpstoprotectthe environment

AP0902 5–21 Maintenance

Fig.155:Breatherfilteronthehydraulicoiltank

5.8Gearboxesandaxles

Maintenanceofthesecomponentsislimitedtocheckingtheoillevelsandtochangingthe oilatprescribedintervals–seemaintenanceplansintheAnnex.

NOTE: Onlyusenewsealingringsforoilfilleranddrainplugs.Drainoilonlyafterrunning themachineforalongperiodoftime!

5.8.1Rearaxletransfergearbox

Checkingtheoillevel

☞ Proceedasfollows:

•Parkthemachineonlevelgroundwhenthegearboxisatoperatingtemperature

•Cleanandunscrewplug A ontransfergearbox B

Iftheoillevelisbelowtheopeningoriftheoillevelcannotbeseenatall:

•Topupwithoil –seesection5.15Enginefluidsandlubricants onpage5-39

Iftheoilleveliscorrect:

•Tightenplug A withanewsealingringtoensureanoil-tightseal

☞ Proceedasfollows:

•Parkthemachineonlevelgroundwhenthegearboxisatoperatingtemperature

•Cleanandunscrewplug156/A ontransfergearbox156/B

•Fillwithoiluntilitrunsoutofthefilleropening –seesection5.15Enginefluidsand lubricants onpage5-39

Ifthegearboxoillevelremainsconstant:

•Tightenplug156/A withanewsealingringtoensureanoil-tightseal

5–22 AP0902 Maintenance 5

A B C Maintenance

Fig.156:Rearaxletransfergearbox

Changingtheoil

WARNING!

Draininghothydraulicoilandremovingthefilterelementscanbehazardous becauseoftheriskofburns.

☞ Wearprotectivegloves

☞ Usesuitabletools,e.g.forunscrewingtheoildrainplug

☞ Proceedasfollows:

•Parkthemachineonlevelgroundwhenthegearboxisatoperatingtemperature

•Placeasufficientlylargecontainerunderthetransfergearboxtocollecttheoil

•Cleanandunscrewplug A ontransfergearbox B

•Unscrewplug C ontransfergearbox B

•Completelydraintheoldgearboxoil

•Tightenplug C withanewsealingringtoensureanoil-tightseal

•Fillwithoiluntilitrunsoutofthefilleropening –seesection5.15Enginefluidsand lubricants onpage5-39

Ifthegearboxoillevelissufficient:

•Tightenplug A withanewsealingringtoensureanoil-tightseal

Afterconductingatestrun:

•Checktheoillevelagainafterabout5minutes,andtopupifnecessary

AP0902 5–23

Maintenance

A B C

Fig.157:Rearaxletransfergearbox

Maintenance

5.8.2Frontandrearaxledifferentials

Environment!

Collectthedrainedgearoilinasuitablecontaineranddisposeofitbyanecologicallysafe method!

NOTE:

Onlyusenewsealingringsforoilfilleranddrainplugs.Drainoilonlyafterrunning themachineforalongperiodoftime!

Checkingtheoillevel

☞ Proceedasfollows:

•Parkthemachineonlevelground

•Cleanandunscrewplugs A

Iftheoillevelisbelowtheopeningoriftheoillevelcannotbeseenatall:

•Topupwithoil –seesection5.15Enginefluidsandlubricants onpage5-39

Iftheoilleveliscorrect:

•Tightenplug A withanewsealingringtoensureanoil-tightseal

Topuptheoillevel

☞ Proceedasfollows:

•Parkthemachineonlevelground

•Cleanandunscrewplug158/A

•Fillwithoiluntilitrunsoutofthefilleropening –seesection5.15Enginefluidsand lubricants onpage5-39

•Tightenplug158/A withanewsealingringtoensureanoil-tightseal

Changingtheoil

☞ Proceedasfollows:

•Parkthemachineonlevelgroundwhenitisatoperatingtemperature

•Placeadriptrayunderplug158/B tocollecttheoil

•Cleanandunscrewplug158/A

•Cleanandunscrewplug158/B

•Completelydraintheoldoil

•Tightenplug158/B withanewsealingringtoensureanoil-tightseal

•Fillwithfreshoilatopening158/A untilitrunsoutofthefilleropening –seesection5.15Enginefluidsandlubricants onpage5-39

•Tightenplug158/A withanewsealingringtoensureanoil-tightseal

5–24 AP0902

Rearaxle:againstthedirectionoftravel!

A B

Fig.158:Checkingtheoillevelonthefrontandrearaxle differentials

A B

Frontaxle:seeninthedirectionoftravel!

5.8.3Frontandrearaxleplanetarydrives

NOTE:

Fitnewsealingrings!Drainoilonlyafterrunningthemachineforalongerperiodof time!

Checkingtheoillevel

☞ Proceedasfollows:

•Parkthemachineonlevelground

•Turnplug A andoillevelmark B toahorizontalposition

•Cleanandunscrewplug A

Iftheoillevelisbelowopening C oriftheoillevelcannotbeseenatall:

•Topupwithoil –seesection5.15Enginefluidsandlubricants onpage5-39

•Tightenplug A withanewsealingring A toensureanoil-tightseal

Topuptheoillevel

☞ Proceedasfollows:

•Parkthemachineonlevelground

•Turnplug159/A andoillevelmark159/B toahorizontalposition

•Cleanandunscrewplug159/A

•Fillwithfreshoiluptotheoillevelmark159/2(overflow) –seesection5.15Engine fluidsandlubricants onpage5-39

•Tightenplug159/A withanewsealingring159/D toensureanoil-tightseal

Changingtheoil

☞ Proceedasfollows:

•Parkthemachineonlevelgroundwhenitisatoperatingtemperature

•Placeasuitablecontainerunderplug A

•Turnplug A tothetopmostposition

•Cleanandunscrewplug A

Never raisethemachineononesideonlyforthefollowingwork!

•Turnplug A tothelowestposition

•Completelydraintheoldoil

•Turnplug A andoillevelmark B toahorizontalposition

•Fillwithfreshoiluptooillevelmark B (overflow) –seesection5.15Enginefluidsand lubricants onpage5-39

•Tightenplug A withanewsealingring A toensureanoil-tightseal

AP0902 5–25 Maintenance

2 A

B C D 2 A

Fig.159:Checkingtheoillevelintheplanetarygear

B C D

Fig.160:Checkingtheoillevelintheplanetarygear

5.8.4Lubricatingtherearaxleoscillation-typebearing

NOTE:

Theoscillationbearinguses“Longlife”lubrication.Lubricatethebearingevery 1200servicehours(maintenanceplanC).

☞ Greaseoscillation-typebearing A ongreasenipple B withlithiumbasedmultipurpose grease–seesection5.15Enginefluidsandlubricantsonpage5-39

5–26 AP0902

Maintenance

Abb.161:Rearaxleoscillation-typebearing

B A

5.9Maintenanceofthebrakesystem

Environment!

Useasuitablecontainertocollectthebrakefluidasitdrainsanddisposeofitinanenvironmentallyfriendlymanner!

5.9.1Specificsafetyinstructions

• Brakesaretopprioritysafetycomponents.Incorrectworkcancausebrakefailure.For thisreason,allmaintenanceandrepairworkperformedonthebrakesmustbecarried outbytrainedpersonnel.Butthisdoesnotincludethefollowingactivities,whichmust beperformedbythedriverofthemachine:

• Dailycheckofthelevelinthebrake-fluidtank

• Newbrakepadsneedrunninginiftheoptimumbrakingeffectistobeachieved.Torun inthebrakepads,brakethemachinemorefrequentlythanusualusingtheservice brakesbutavoidfullbraking!

• Replacedamagedbrakelinesorhosesimmediatelybecauseoftheriskofaccidents!

5.9.2Checking/toppingupbrakefluid

WARNING!

Maintainthebrakesystemproperly.Thesafetyofthebrakingsystemcanbe reducedbyimproperbrakefluidqualityorincorrectbrakefluidlevel–

☞ Checkthebrakefluidintank 4 atregularintervals

☞ Topupthebrakefluidtotheupperedgeofthesightglass

☞ ThebrakefluidmustcomplywiththeSAEspecification–see“Enginefluids andlubricants”onpage5-39

☞ Changethebrakefluideverytwoyears

Ifthefluidlevelisbelowtheupperedgeofthesightglass:

• Opentankcover A

• Topupthebrakefluidtotheupperedgeofthesightglass

AP0902 5–27 Maintenance

4 A MAX MIN

Fig.162:Checkingthebrakefluidlevelinthebrakefluid tank

5.10Telescopicunit

5.10.1Lubricatingthepivotpointsofthetelescopicunit

Ifmachineisinuninterrupteduse

☞ Lubricatethegreasenipples(circlesinfigure163) every10servicehour (ordaily) withgrease

Ifmachineisinoccasionaluse

☞ Lubricatethegreasenipples(circlesinfigure163) every50servicehours (oroncea week)withgrease

5.10.2Lubricatingthetelescopicunit

Lubricatethepadtracksatregularintervals. Recommendedlubricant–seesection5.15 Enginefluidsandlubricants onpage5-39

☞ Beforelubricating: Completelyextendthetelescopicunit

☞ Ifmachineisinuninterrupteduse

• Greasethepadtracksevery10hours

☞ Ifmachineisinoccasionaluse

• Greasethepadtracksonceaweek

5–28 AP0902 Maintenance

A B C D A B

Fig.163:Telescopicunitwithlubricationpoints Fig.164:Wearpadsofthetelescopicunit

5.10.3Adjustingthewearpads

NOTE:

The(green)wearpadsarelocatedbetweentheinner163/C andouterboomsection163/D

Thewearpadscanbereadjustedastheyweardown–toaminimumthicknessof 0.25in(6mm)only–bymeansofsetscrews163/A and163/B.

Donotovertightenthesetscrews,otherwisethetelescopicunitisimpairedand doesnotworksmoothlyanylonger. Replacethewearpadsuponreachingorfallingbelowaminimumthicknessof 0.25in(6mm)!Inthiscasepleasecontactyourdealer.

☞ Adjustthewearpadsasfollows:

• Extendthetelescopicunitbyabout20cm,sothatthefrontwearpadscanbeeasily accessed

• Switchofftheengine

• Propthetelescopicunitsecurely

• Loosenthelocknutsatsetscrews163/A and163/B

• Firstaligntheinnerboomsection163/C horizontallywiththeouterboomsection163/ D .Todothis:

Screwinthesetscrews163A (hexagonsocket)

NOTE:

Screwinthesetscrewsuntilthewearpadstouchthepadtracksontheinner boomsection.Tightenthesetscrewbyturningitafurther1/4revolution.

• Firstaligntheinnerboomsection163/C horizontallywiththeouterboom section163/D .Todothis: Screwinthesetscrews163/B (hexagonsocket)

• Tightenthelocknutstosecureallsetscrews163A and B

AP0902 5–29 Maintenance

5.11Tirecare

WARNING!

Impropertirerepairsconstituteareapersonalinjuryhazard!

☞ Allrepairworkontiresandrimsmayonlybecarriedoutbyauthorizeddealers.

NOTE:

Regularinspectionofthetires

•Improvesoperatingsafety

•Increasestheservicelifeofthetires

•Reducesmachinedowntime

Refertothetableinsection“Specifications”onpage7-7fortheauthorizedtire typesandthecorrecttirepressures.Thistableisalsoonthelabelonthefrontwindow.

5.11.1Inspectionwork

Dailychecks

☞ Carryoutthefollowingmaintenanceworkdaily:

•Visualcheckofthetirecondition,especially:

•Tirepressure

•Outsideandinsidedamageoftiresandrims

•Wear

•Removeforeignbodiesfromthetiretread

•Removetracesofoilandgreasefromthetires

Weeklychecks

☞ Carryoutthefollowingmaintenanceworkeveryweek:

•Checkthetreaddepthofthetires

•Checkthetirepressure

5–30 AP0902

Maintenance

5.11.2Wheelchange

WARNING!

Useofwrongtiresorwheelscanbehazardous.

☞ Useonlythewheelsandtiresreleasedforyourmachine–seesection7 “Tires”onpage7-7

☞ Checkthewheelnutsfortightnessaftereverywheelortirechange

Important!

Thewheelsareheavyandcandamagethethreadsonthewheelstudsifthey arehandledincorrectly!

☞ Usesuitableassemblytools,suchascoveringsleevesforthestuds,ajack, etc.

Removingthewheels

☞ Proceedasfollows:

•Parkthemachineonlevelandfirmgroundandpreventitfromrollingaway.

•Slightlyloosenthewheelnutsofthetireyouwanttoremove.

•Placeajackundertheaxlebeam,makingsureitiswellsupported.

•Raisethesideoftheaxlefromwhichyouwanttoremovethetire.

•Checkthatthemachineiswellsupported.

•Completelyremovethewheelnuts

•Removethewheel

Installingthewheels

☞ Proceedasfollows:

•Placethewheelontothewheelstuds

•Tightenallthewheelnutspart-way

•Lowertheraisedaxle

•Tightenthewheelnutstotheprescribedtighteningtorque–seesection7.16.2 Specifictighteningtorques onpage7-9

AP0902 5–31 Maintenance

5.12Heating

Theheatingsystemofthemachineisequippedwithadustfilter,whichshouldbecleaned atregularintervalsandreplacedonceayear,asappropriate. Theheatingsystemislocatedontherightfrontofthecab.

5.12.1Cleaningthedustfilteroftheheatingsystem

Adustfiltercleanstheairtakeninbytheheater.Blowcompressedairthroughthefilteras oftenasnecessary,butatleastonceayear.Thevolumeofwarmairflowingoutoftheair ventsdecreasesasfiltercontaminationincreases.

☞ Cleanthefilterasfollows:

• Removecover A atthefrontrightofthecabasfollows:

☞ Removescrews B

• Removedustfilter C

• Cleanorreplacedustfilter C

• Re-insertthecleaneddustfilterandinstallcover C

5–32 AP0902 Maintenance

B A

Fig.165:Replacingthecoveroftheheatingsystem

Fig.166:Replacingthedustfilteroftheheatingsystem

5.13Electricalsystem

5.13.1Specificsafetyinstructions

• Thebatterycontainssulfuricacid!Thisacidmustnotbeallowedtocomeintocontact withtheskin,theeyes,clothingorthemachine. Thereforewhenrechargingorworkingnearthebattery:

☞ Alwaysweargogglesandprotectiveclothingwithlongsleeves

Ifacidisspilled:

☞ Thoroughlyrinseallaffectedsurfacesimmediatelywithplentyofwater

☞ Thoroughlywashanypartofthebodytouchedbytheacidimmediatelywithplentyof waterandseekmedicalattentionatonce!

• Duringcharginginparticular,butalsoduringnormalbatteryoperation,anoxygen/ hydrogenmixtureisformedinthebatterycellswhichhasariskofexplosion!

• Donotattempttojump-startthemachineifthebatteryisfrozenoriftheacidlevelis low.Thebatterymayruptureorexplode!

• Avoidsparksandunprotectedlightsources,andrefrainfromsmokinginthevicinityof openedbatterycells,becausethegasproducedduringnormalbatteryoperationmay ignite!

• Useonly12Vpowersources.Highervoltageswilldamagetheelectricalcomponents

• Whenconnectingthebattery,ensurethatthepolesarenotreversed,becausesensitive electricalcomponentswillbedamaged

• Donotinterruptvoltage-carryingcircuitsatthebatteryterminals,becauseofthedanger ofsparking!

• Neverplacetoolsorothermetalitemsonthebattery,becauseoftheriskofshort circuit!

• Disconnectthenegativebatteryterminalbeforestartingrepairworkontheelectrical system

• Disposeofusedbatteriesproperly

5.13.2Serviceandmaintenanc eworkatregularintervals

AP0902 5–33 Maintenance

Beforedrivingthemachine ☞ Checkeverytimebeforedrivingthemachine: • IsthelightingsystemOK? Everyweek ☞ Checkeveryweek: • Cableandgroundconnections

Chafingonwiringharnesses

Conditionofthebatteryterminals

•

Maintenance

5.13.3Instructionsconcer ningspecificcomponents

Cables,bulbsandfuses

• Defectivecomponentsoftheelectricalsystemmustalwaysbereplacedbyauthorized technicians,exceptthatbulbsandfusesmaybechangedbyotherpersons

• Whencarryingoutmaintenanceworkontheelectricalsystem,payparticularattention toensuringgoodcontactinconnectionsandfuses

• Blownfusesindicateoverloadingorshortcircuits.Theelectricalsystemmusttherefore becheckedbeforeinstallingthenewfuse

• Onlyusefuseswiththespecifiedcapacity(amperage)–see Electricalsystem on page7-5

Alternator

Alwaysobservethefollowinginstructions:

• Onlytesttheenginewiththebatteryconnected

• Whenconnectingthebattery,ensurethatthepolesarenotreversed

• Alwaysdisconnectthebatterybeforecarryingoutweldingworkorconnectingaquick batterycharger

• Replaceadefectivechargewarninglightasquicklyaspossible

Battery

NOTE: Thebatteryislocatedintheenginecompartment,ontheleftside. Evenso-called“maintenance-free”batteriesmustundergomaintenance,because theytooconsumewater. Alwaysfollowthespecificsafetyinstructions!

☞ Observethefollowinginstructionstoensurealongbatteryservicelife:

• Keepthesurfaceofthebatteryincleananddrycondition

• Checktheacidlevelatregularintervalsandifnecessary,fillupwithdemineralizedor distilledwater.Neverfillupwithacid!

Checktheregulatorvoltageofthemachineincaseofincreasedlossofwater

• Donotuseso-calledbatteryimprovingcompounds

• Checkthebatterychargeconditionbymeasuringtheaciddensity. (Exception: Inthecaseofclosedbatteriesbymeasuringtheoff-loadvoltage)

NOTE:

Rechargethedisconnectedbatteryifspecificgravityisbelow1.21.Atthislevelthe batterywillfreezeonlyattemperaturesbelow5°F(–15°C).

5–34 AP0902

Driveelectronics

Checkingthebatterychargecondition

☞ Checkthebatterychargeconditionasfollows:

• Parkthemachineonlevelground

• Switchofftheengine

• Opentheenginecover Afterremovingthebatterycaps:

• Measurethespecificgravitywiththehydrometer

Instructionsforrechargingthebattery

• Avoidsparksandshortcircuits

• Removethebatteryforrecharging.Ifthebatterymustrechargedinthemachine, alwaysdisconnectthebatteryleadsunderallcircumstances

• Unscrewthebatterycaps(Exception:Closedbatteries)

• Switchoffthebatterychargerbeforeconnectingthebattery!

• Chargebatterieswithdirectcurrentonly.Connectthepositive(+)terminalofthe batterytothepositive(+)terminalofthebatteryrecharger,andthenegative(–) terminalofthebatterywiththenegative(–)terminalofthebatterycharger

• Recommendedchargingcurrent:onetenthoftheamphourcapacity(e.g.,80Ah=8A chargingcurrent)

• Chargeclosedbatterieswithregulatedbatterychargersonly

• Makesureacidtemperaturedoesnotexceed120°F(55°C)duringrecharging.Stop rechargingthebatteryifthetemperaturerisesanyfurther. Thebatteryisfullychargedifspecificgravityandchargingvoltagedonotriseany furtherwithin2hours

• Rechargingclosedbatteriestakesatleast12to16hours,andisnotcompletedunless off-loadvoltageis ≥ 12.8Vseveralhoursafterrecharging

• Checktheacidlevelafterrechargingandifnecessary,fillupwithdemineralizedor distilledwateruptothemaximumacidlevelmarkor0.6inch(15mm)abovethebattery plates.Neverfillupwithacid!

• Donotopenclosedbatteries.Neveraddwater

Instructionsfortemporarystorageofthemachine

• Ensurefullbatterycharge(seeabove)

• Ifthebatteryremainsinthemachine,disconnectthenegative(–)terminal

• Checkthebatterychargeconditionatregularintervals(seeabove)

• Removethemainplugwhencarryingoutweldingwork,etc.

AP0902 5–35

Maintenance

5.14Generalmaintenancework

5.14.1Cleaning

Cleaningthemachineisdividedinto3separateareas:

• Insideoftheoperatorcompartment

• Exteriorofthemachine

• Enginecompartment

Thewrongcleaningequipmentandchemicalsmayimpairtheoperatingsafetyofthe machineandaffectthehealthoftheperson(s)cleaningthemachine.Itisthereforeessentialtoobservethefollowinginstructions.

Generalinstructionsforalltheareas

ofthemachine

Washingsolvents

• Ensureadequateroomventilation

• Wearsuitableprotectiveclothing

• Donotuseflammableliquids,suchasgasolineordieselfuel

Compressedair

• Workcarefully

• Weargogglesandprotectiveclothing

• Donotaimthecompressedairattheskinoratotherpeople

• Donotusecompressedairforcleaningyourclothing

Whenusingahigh-pressurecleanerorsteamcleaner

• Electricalcomponentsanddampingmaterialsmustbecoveredandnotdirectly exposedtothejet

• Covertheventfilteronthehydraulicoiltankandthefillercapsforfuel,hydraulicoiletc.

• Protectthefollowingcomponentsfrommoisture:

• Engine

• Electricalcomponents,e.g.,alternator,plugandsocketconnectionsetc.

• Controldevicesandseals

• Airfilters,etc.

Whenusingvolatileandeasilyflammableanticorrosionchemicalsandsprays:

• Ensureadequateroomventilation

• Donotuseunprotectedlightsoropenflames

• Donotsmoke!

5–36 AP0902

Insidetheoperatorcompartment

Important!

Neverusehigh-pressurecleaners,steamcleanersorhigh-pressurewaterto cleantheinsideoftheoperatorcompartment.Waterunderhighpressuremay •Penetrateintotheelectricalsystemsandcauseshortcircuitsand •Damagesealsanddisablethecontrols!

Forcleaningtheoperatorcompartment,werecommendusingthefollowingaids:

• Broom

• Vacuumcleaner

• Dampcloth

• Bristlebrush

• Bucketofwater

Cleaningyourseatbelt

• Cleantheseatbelt(whichremainsfittedinthemachine)onlywithamildsoapsolution; donotusechemicalagents,becausetheymaydestroythefabric!

WARNING!

Forautomaticseatbelts(option),soiledbeltsmayimpairwindingandthereby affectsafety.Onlywindseatbeltwhenitisdry!

Exteriorofthemachine

Enginecompartment

Thefollowingarticlesaregenerallysuitable:

• High-pressurecleaneror

• Steamcleaner

WARNING!

Toavoidinjury,cleantheengineonlywhenitisstopped.

☞ Switchofftheenginebeforecleaning

Important!

Whencleaningtheengineusingawaterjetorsteamcleaner,donotpointthe jetdirectlyatelectricalmeasurementsensorssuchastheoilpressureswitch, becauseotherwise,liquidpenetratingsuchunitscanleadtocorrosionand failureofthemeasuringfunction!

AP0902 5–37 Maintenance

5.14.2Boltedconnections

Allboltedconnectionsmustbecheckedregularly,eveniftheyarenotlistedinthemaintenanceschedules.

Tightenlooseconnectionsimmediately.Tighteningtorquescanbefoundinsection “Specifications”.

5.14.3Pivotsandhinges

Allmechanicalpivotpointsonthemachine(e.g.doorhinges,joints)andfittings(e.g.door holders)shouldbelubricatedregularly,eveniftheyarenotlistedinthelubricationplan.

5–38 AP0902 Maintenance

5.15Enginefluidsandlubricants

Component/

Dieselengine Engineoil2

HD-C5W-303

-4°Fto+86°F (-20°Cto+30°C)

HD-C10W-30 14°Fto+95°F (-10°Cto+35°C)

HD-C10W-40;EO1040B5

14°Fto+104°F (-10°Cto+40°C)

HD-C15W-40;EO1540B 5 32°Fto+104°F (0°Cto+40°C)

7.4quarts (7litres) 4

Rearaxletransfergearbox

SAE80W-90 1.6quarts (1.5litres) Planetarydrives–leftandright frontandrearaxle

Gearboxoil6

SAE90LS 3.9quarts (3.7litreseach)

0.7quarts (0.7litreseach) Differential–frontandrearaxle

SAE5W/303

-4°Fto+95°F (-20°Cto+35°C)

SAE10W/30 14°Fto+104°F (-10°Cto+40°C)

SAE10W/40;EO0540B5

SAE15W/40;EO1540B5 32°Fto+104°F (0°Cto+40°C)

Hydraulicoiltank

About52.8quarts (50litres)

ATF ATF66M/ATF86(ATF5) 14°Fto+86°F (-10°Cto+30°C)

Biodegradableoil

GreasenipplesMultipurposegrease

WearpadsofthetelescopicunitMultipurposegrease

Mountingofpins,shaftsetc.Speciallubricatinggrease

AVILUBSyntofluid46

PANOLINHLPSynth46

FIATIdraulicarBS68

AGIPArnicaS68

Lithium-saponifiedbrand-namegreases

MPG-A5 Year-roundAsrequired

1.Thecapacitiesindicatedareapproximativevalues;theoillevelcheckaloneisrelevantforthecorrectoillevel

2.MIL-L-2104C;APICD/CE/CF4;CCMC-D4

3.Onlywithoilpreheating

4.Withfilterchange

5.Abbreviationforlubricants(HauptverbandderDeutschenBauindustriee.V.–Germanconstructionengineeringassociation)

7.NecessaryadditionofFuchsLSconcentrate:20gr/ltr.

8.250grtube:orderno.:0004413210

AP0902 5–39 Maintenance 5

Engine/machinefluid SAEgrade Specification Season/ temperature Capacities1

application

6.MIL-L-2105B;API-GL5;ZFTE-ML-0.5 Year-round

SAE80W-90+LSconcentrate7

Engineoil2

Year-roundAsrequired BatteryterminalsAcid-proofgrease SP-B5 Year-roundAsrequired

Optimolypaste“TA”8

Year-roundAsrequired FueltankDieselfuelDIN51601,min45Cetan, 15.9gal (60ltr) Brakesystem BrakefluidSAEJ1703DOT3.4,SP-A5 RadiatorCoolant Water+antifreeze;SP-C5 Year-round About9.0quarts (8.5litres) WashersystemCleaningagentWater+antifreeze About1.3quarts (1.2litres) Maintenance

5.16Maintenancekits

5–40 AP0902 Maintenance

Maintenancekits PartnumberDescriptionQtyRemarks Maintenancekitfor“1stInspection” 0160030030Maintenancekit 1 MaintenancekitforMaintenanceplan“B” 0160030130Maintenancekit 1 MaintenancekitforMaintenanceplan“C” 0160030230Maintenancekit 1

0000805573Filterforheater1(notincludedinmaintenancekit)

Additionalpartsformaintenancekits 0000805188Airfilter1(option,notincludedinthemaintenancekit)

Section6 Helpfulinformationforusingtheservicepartslist

6.1Introduction

Thisoperator’smanualandaseparateservicepartslisthavebeenhandedovertoyou togetherwithyourmachine.

Pleasereadthissectioncarefully.Itwillmakeiteasierforyoutocarryoutyourworkand findserviceparts.

Theillustrationsintheservicepartslistarenotbindingfordesign. Subjecttofurtherdevelopment andtechnicalmodifications.

6.2Compositionofservicepartslist

6.2.1Groups

Theservicepartslistisdividedinfunctionalgroups. Groupsareidentifiedbynumbers(e.g.01=engine)

AP0902 6-1 Helpfulinformationforusingtheservicepartslist 6 6Helpfulinformationforusingtheservicepartslist

Group

Fig.167:Titlepageofagroup

6-2 AP0902

6.2.2Groupoverview Theservicepartslistcontainsthefollowinggroups: Group Description 01 Engine 08 Fuelsystem 10 Airfilter 15 Coolingsystem 17 Speedregulation 20 Machineframe 22 Hydrostaticdrive 23 Frontaxle 24 Brakesystem 26 Rearaxle 27 Steering 29 Operator'sseat 30 Sheet-metalparts 31 Wheelsandtyres 32 Exhaustsystem 33 Electricalsystem 34 Cab 36 Hydraulicsystem 41 Heatingandventilation 41/3 Buckets 41/4 Palletforks 43 Tools,labels A Numberindex

Helpfulinformationforusingtheservicepartslist

6.2.3Figures

Groupsconsistofoneormorefigures.Theyareidentifiedattheupperrightbythefigure number.

Thenumberbeforethehyphenidentifiesthegroup(e.g.01).

Thereferencenumbersinthefiguresidentifytheindividualserviceparts.Thecorrespondingpartnumbersarelistedinthenumberindex.

Thefiguresarereducedrepresentationsofassembliesandcomponentparts,andarenot bindingfordesign.

Subjecttofurtherdevelopment andtechnicalmodifications.

6.2.4Numberindex

Thenumberindexisincludedattheendoftheservicepartslistandcontainsallpartnumberscorrespondingtothereferencenumbersinthefigures.Partnumbersarelistedinthe orderoffigures,andofreferencenumber.

AP0902 6-3

Helpfulinformationforusingtheservicepartslist

01-58 20 19 17 18 21 22 21 19

Figurenumber

Fig.168:Exampleforfigure 01-7.......1..... 7571646012 01-7.......2..... 7578646001 01-7.......3..... 7578646002 01-7.......4..... 0003330367 01-7.......5..... 7571646041 01-7.......6..... 7571646042 01-7.......7..... 7571646043 01-7.......8..... 7578646011 01-7.......9..... 7578646012 01-7.......10.... 7578646013

Referencenumbers 01-7........11....7579641081 01-7........12....7579641082 01-7........13....7579642051 01-7........14....7577646040 01-7........15....7577646036 01-7........16....0003333065 01-7........17....0003332965 01-7........18....0003335166 01-7........19....0003334866 01-7........20....7572642006 08-1.......1..... 7572642012 08-1.......2..... 7572642052 08-3.......1..... 7572642502 08-3.......2..... 7572646515 08-3.......3..... 7572642510 08-3.......4..... 7572642505 08-3.......5..... 7572646517 10-1.......1..... 0003330256 10-1.......2..... 0003338266 10-1.......3..... 0003336265 23 2 1234567890 00-2 23 2 1234567890 00-2 23 2 1234567890 00-2 Figure Referencenumber Partnumber Fig.169:Detailofnumberindex

6.3Symbolsandabbreviations

Symbolsandabbreviationsareusedinthefiguresforclearidentificationofparts.Combinationsofsymbolsandabbreviationsarealsoused.

6.3.1Descriptionofsymbols

Symbolsmayhavethefollowingmeanings:

Identifiesacomponentpart.

Thecirclednumberidentifiesanassemblywhichmayconsistofseveralcomponent parts.

Assembliesaredeliveredasfinishedassemblies,orpreassembledwithallnecessary componentparts.

Componentpartscanbegroupedinbracketsorinboxes,orappearbelowthereference numberoftheassembly,e.g.referencenumbers18and19.

Acomponentpartcanconsistofseveralpartswhichmaybedeliverableasawholeonly, e.g.referencenumber19.

Componentpartsgroupedinabox,withoutreferencenumberfortheassembly,identify details.

6-4 AP0902

Helpfulinformationforusingtheservicepartslist

Symbol Description Referencenumber

22 17 20 19 17 18 21 22 21 19 1 3 4 5 6 2 8 10 11 12

Validity

➜❙

❙➜

Instructionsforassembly

Partsarevalidonly uptoandincluding the serialnumber stated,e.g.uptoandincludingserialnumber307630238

Partsarevalidonly uptoandincluding the identificationnumber statedforthe respectiveassembly,e.g.uptoandincludingcabnumber0237.Thiscanalsoinclude othersymbols,e.g.axle,engineetc.

Partsarevalidonly startingandincluding theserialnumberstated,e.g.startingand includingserialnumber307630239

Partsarevalidonly startingandincluding theidentificationnumberstatedforthe respectiveassembly,e.g.startingandincludingcabnumber0237.Thiscanalsoinclude othersymbols,e.g.axle,engineetc.

Symbolforaxle

Symbolforcab

Symbolforengine

Donotremoveparts,partscannotberepaired

Tightenpartswithatorquespannertotheprescribedtorque.Usestandardtorquesifno specifictorqueisstated–seesection7.16.1 Generaltighteningtorques onpage7-9and section7 “Specifictighteningtorques” onpage7-9

Safetypart!

Forreasonsofsafety,partsmaybedismantledorrepairedbyqualifiedmechanicsonly. Otherwisepartsmustbereplacedasawhole!

Checkpartsforwearbeforereassembly,e.g.bearings,rotaryshaftlipsealsetc.

Partsarenotreuseableandmustbereplacedduringrepairwork,e.g.sealingelements Payspecialattentiontodirectionofinstallationwhenremovingorfittingparts,e.g.rotary shaftlipseals,bearings,bushingsetc.

Usesecuringmeansandsealingcompoundsstated,e.g.Loctite242 Measurelength/thicknessofnewpart,e.g.shims,edgeguards,sealingstripsetc. Rounduptothefullmetreforordersbythemetre!

Measurethicknessofnewpart,duetoavailabilityinvarioussizes. Statealldimensionsinmm(millimetres).

Specialsymbols Symbolforspecialversionwithfloatposition

AP0902 6-5

Helpfulinformationforusingtheservicepartslist

Symbolforhydrauliccylinder Symbolforsealingkit Symbolfortoolkit Symbolfordocumentation

6 7 8 0.15 0.2 0.5

Symbol Description

Helpfulinformationforusingtheservicepartslist

6.3.2Abbreviations

Indicationofposition

Abbreviationsspecifypositionofserviceparton/inmachineindrivingdirection. Combinationsofabbreviationsarealsopossible,e.g. HLO (upperrearleft).

Application

Abbreviationsspecifyuseofserviceparton/inmachine.

6.4Machinedata

Alwaysincludetheexactmachinedatainyourorderstoensurecorrectdeliveryofservice partsrequired.

Seesection1 “Machinedata” onpage1-6and “Typelabelsandcomponentnumbers” on page1-7fortherelevantmachinedata.

6-6 AP0902

Abbreviation Description F Front H Rear L Left R Right O Upper U Lower M Centre A Outer I Inner Abbreviation Description BA Specifiesoperator’smanual ET Specifiesservicepartslist De German En English Fr French MC Specifiesmicrofiches SO Specifiesspecialequipment

6.5Helpfulinformationfororderingserviceparts

Deliveryofservicepartscashondelivery. Damagedsampleswillbescrappedifnorequestforreturnhasbeenforwardedwithin4 weeks.

ServicepartscanbereturnedonlyuponagreementwithourServicePartsDepartment. Returnexcludes:

Seals,O-rings,sealingkits,electricalparts,specialpurchasesandpartsorderedwithout exactmachinedata.

6.5.1Orderinformation

Alwaysincludethefollowinginformationinyourorderstoensurecorrectdelivery ofserviceparts:

• Customerandaddress

e.g.JasonMiller

HighStreet40

LeightonBuzzardLU58RT

• Deliveryaddress ifnotidenticalwithcustomer'saddress

e.g.Constructionsite:JeffMason

ChurchStreet41

HighWycombeHP93ER

• Modeofshipment

e.g.UnitedParcelService(UPS)

Shipmentwillbemadeatourowndiscretionifnoindicationsaremade

• Machinedescription

e.g.418T

• Modelandserialno. (seetypelabelonmachine)

e.g.418T,418T0239

• Servicepartslistandedition (seeservicepartslistcover)

e.g.EditionA

• Figure,reference (inservicepartslist)

e.g.01-8,reference15

• Partnumber (innumberindexinservicepartslist)

e.g.:0000801987

• Quantityandunit

e.g.1off

• Forcomponent,identificationnumber (seetypelabel)

e.g.engine:KubotaV1305–073248

AP0902 6-7

Helpfulinformationforusingtheservicepartslist

6.5.2Addressforyourservicepartorder

GehlCompany

143WaterStreet

WestBend,WI53095-0179

U.S.A

Telephone:262-334-9461

Fax:262-338-7517

6-8 AP0902

Specifications 7

Section7

7Specifications

7.1Frame

7.2Engine

Sturdysteelsheetframe,rubber-mountedengine

Engine Product

Perkinsdieselengine

Model 704-30DI

Design Vertical,water-cooled4-strokedieselengine

No.ofcylinders 4

Displacement 180in³(2955cm³)

Boreandstroke

Compressionratio

3.8x3.9in(97x100mm)

1:17.5

Output(asperISO9249) 58hp(43.1kW)at2400rpm

Max.torque 154.9lb-ft(210Nm)at1600min-1

Specificminimumfuelconsumption 288g/hp-hr(215g/kWh)

Fuelinjectionsystem

Directfuelinjection

Firingorder 1–3–4–2

Startingaid Glowplug

Max.inclinedposition(engineno longersuppliedwithoil):

25°inalldirections

Observetiltinglimitofthemachine!

Oilpressure 61lb/in2 (4.2bar)

Valvetipclearance

Intake,exhaustvalve 0.01in(0.35mm),engineatcoldtemperature respectively

Exhaustemissionsvaluesasper ISO/TR14396

EC97/68level1

US40CFRpart89

AP0902 7–1 7

Specifications

7.3Powertrain

Variabledisplacementpump

Design Axialpistonpump(swashplatedesign)

Displacement 0–2.5in³/rev(0–41cm³/rev)

Max.operatingpressurep 5584lb/in2 (385bar) StartingRPMs 1050 ±50

Droop 2250 ±50

Boostpump(integratedinvariabledisplacementpump)

Design Internalgearpump

Displacement 0.7in³/rev(11cm³/rev)

Charging/boostpressure 290lb/in2 (20bar) Control

7.4Axles

Drivingdirection

Forward–reverseoncontrollever Inching Electrically(potentiometer)

Variabledisplacementmotor

Design Axialpistonmotor(swashplatedesign) Capacity 0.9–3.7in³/rev(16–60cm³/rev

Drivespeed 0–12mi/h(0–20km/h),forwardandreverse Max.tractionforce 8543lbf(38kN)

Frontaxle(withself-lockingdifferential40%)

Rearaxle(with40%differentiallock)

1.Withstandardtyres12.5–20

7–2 AP0902

Specifications

Design Rigidsteeringanddriveaxle King-pininclination 6° Camber 0° Positive/negativewheelcastorSteeringangle 40° Toe-in 0in(0mm) Trackwidth 54in(1370mm)1

Design

King-pininclination 6° Camber 0° Totaloscillation +/-8.5° Positive/negativewheelcastor –Steeringangle 40° Toe-in 0mm Trackwidth 54in(1370mm)1

Steeringanddriveaxle,oscillating

7.5Brakes

Servicebrake

DesignFoot-operated,hydraulicdiscbrake+hydrostat

MountedinFrontaxle,drive(rearaxle)

EffectOnbothaxlesviacardanshaft

BrakefluidSeeEnginefluidsandlubricants

Parkingbrake

DesignManual,mechanicaldiscbrake

MountedinFrontaxleinput

EffectOnbothaxlesviacardanshaft

7.6Steering

Steering Design

7.7Workhydraulics

Hydrostaticfour-wheelsteeringwithemergency steeringfeatures(closedversion)

Steeringmode Fourwheelsteering

Assemblies

Hydraulicpump,steeringunitwithflangedpriority valve,steeringcylinder,automaticsynchronizationinleftandright-handfinalpositions

Max.pressureofhydrauliclines 2611lb/in2 (180bar)

Hydraulicpump Gearpump Displacement1.4in³/rev(23cm³/rev)

Workhydraulics

Hydraulicpump Gearpump Displacement 1.4in³/rev(23cm³/rev)=17g/min(66l/min) at2400rpm

Controlvalve 3sections

Max.servicepressure 3046+10 lb/in2(210 +10 bar)

Secondarypressurelimiting Secondarypressurereliefvalvefortiltram: rodside3481lb/in2(240bar) bottomside1450lb/in2(100bar)

Secondarypressurereliefvalveforliftram: bottomside3481lb/in2(240bar) Filter Returnsuctionfilter(7.3lb/in2 (0.5bar)initial stress)

Hydraulicoiltank 13.2gal(50l)

AP0902 7–3 Specifications

7.8Telescopicunit

7–4 AP0902 Specifications

Telescopicunitwithbucket 1, 2 1.Withstandardtyres12.5-20 2.Standardbucket810136 Telescopicunit BucketcapacityheapedasperISO 1.1yd³ (0.85m³) Tippingload 6557lb (2974kg) Payload 3278lb (1487kg) Liftloadatmax.height 6173lb (2800kg) Bucketwidth 69in (1750mm) Lengthoftelescopicextension 45in (1150mm) DumpheightwithstandardbucketRetracted 118in (3000mm) Extended 158in (4000mm) Fulcrumheightofquickhitchfacility 185in (4690mm) DumpingreachExtended 47in (1205mm) Scrapingdepth about2in (50mm) Tilt-backangle 40° Dump-outangle 40° Breakoutforce(liftcylinder) 6744lbf (30.0kN) Breakoutforce(tiltcylinder) 11015lbf (49.0kN) Forkarms3 (payloadsstatedfor20in(500mm)loaddistance) 3.Palletforks810135 Tippingload(ISO8313)Retracted 4982lb (2260kg) Payload(ISO8313) Extended(S=1.254) 4.Onfirmandlevelground 2425lb (1100kg) Extended(S=1.675) 5.Off-road 1808in (820kg) Retracted(S=1.254) 3968lb (1800kg) Retracted(S=1.675) 2965lb (1345kg) PalletheightRetracted 136in (3450mm) Extended 177in (4500mm) Movablepayloadintransportposition(S=1.254) 4850lb (2200kg)

7.9Electricalsystem

Alternator

Starter

12V/65A

12V/2.5kW

Battery 12V/80Ah

Socket E.g.forcigarettelighter;15Amax.

Thefuseboxesarelocatedinthesideconsoleinthecab.

–Instrumentlighting

F1A7.5A

–Brakelights

F2A7.5A –Horn

–Wiper/washsystem

F3A10A –Heater

F4A7.5A

–Cutoffsolenoid

–Rearwiper

F5A10A –Frontwiper

F6A10A –Cigarettelighter

F7A7.5A –Interiorlighting

–Hazardwarningsystem

F8A7.5A –Switchlights

F9B10A

30864b0030.eps

–Turnindicators

–Driveswitch

–Driveelectronics

F10B15A –Lights

F11B7.5A –Highbeam(right)

F12B7.5A –Highbeam(left)

F13B7.5A –Lowbeam(right)

F14B7.5A –Lowbeam(left)

F15B7.5A

–Parkinglight(right)

–Rearlight(right)

F16B7.5A –Parkinglight(left) –Rearlight(left)

F17C10A

–Air-suspensionseat(option)

F18C7.5A –Telescopicunit

F19C7.5A

F20C7.5A

–Lockforquickhitchfacility(option) –Attachments(option)

–Notassigned

F21C25A –Workinglight(option)

F22C7.5A

–Rotatingbeacon(option)

C7.5A –Notassigned(spare)

C10A –Notassigned(spare)

AP0902 7–5 Specifications

7.9.1Fuseboxesinsideconsole Fig.170:Fuseassignmentinsideconsole 50 A B C A Fuse Row Ratedcurrent(A) Protectedcircuit

7.9.2Mainfusesinenginecompartment

Themainfusearelocatedabovethehydraulicoiltank,underneathcover D

Fuse Ratedcurrent(A) Protectedcircuit

F23100A –Mainfuse

F24100A –Mainfuse

7.9.3Relays

RelaysK1andK2arelocatedabovethehydraulicoiltank,underneathcover D RelaysK2toK9arelocatedunderneaththecoverplateontherightsideofthecab,inthe sideconsole.

Description Function

K1 Switchingrelay,cutoffsolenoid

K2 Switchingrelaypreheating

K3 Switchingrelaydriveinterlock

K4 Switchingrelaylowbeam

K5 Switchingrelayhighbeam

K6 Switchingrelay,retracttelescopicunit

K7 Switchingrelay,extendtelescopicunit

K8 Hazardlightindicator

0160081701.eps

7–6 AP0902

Specifications

Fig.171:Mainfusesinenginecompartment F24 F23 Fig.172:Relayassignment K2 K1 K8 K5 K4 K3 K6 K7

7.10Tires

Bearinmindthestickeratthefrontwindowofthemachine!

Tyresize Tirepressure1

Specifications

7.11Weights

Weights1

7.12Noiselevels

Important!

NoisemeasurementcarriedoutinaccordancewithECguidelines86/662EEC (dynamic),79/113EECatmaximumenginespeed.Thesurfacewherethemeasurementswerecarriedoutwasasphalted.

AP0902 7–7

Wheelrims FrontRearWheelrimWheeloffset 12.5-20MPT10PR 36lb/in2 (2.5bar) 29lb/in2 (2.0bar) 11x200mm 14.5-20MPT10PR 29lb/in2 (2.0bar) 25lb/in2 (1.7bar) 375/75R20136G 36lb/in2 (2.5bar) 29lb/in2 (2.0bar) 405/70R18141B

1.Increasetyrepressureby0.5barduringpalletforksoperation! 2

44lb/in2 (3.0bar) 36lb/in2 (2.5bar) 13x180mm 12.5-20MPT10PR 36lb/in2 (2.5bar) 29lb/in2 (2.0bar) 11x200mm

2.Overallwidthofmachinelargerthanstandardbucketwhenequippedwiththesetyres

Kerbweight 10913lb(4950kg) Frontaxleload 3968lb(1800kg) Rearaxleload 6945lb(3150kg) Grossweightrating 13228lb(6000kg) Frontaxleweightrating 8267lb(3750kg) Rearaxleweightrating 8267lb(3750kg) Max.authorizedloadfortowingfacility None Noiselevels Soundpowerlevel 99dB(A) Noiselevelinthecab 74dB(A)

1.Withstandardbucket810136andstandardtyres12.5-20

7.13Vibration

Effectiveaccelerationvalueforthe upperextremitiesofthebody <2.5

Effectiveaccelerationvalueforthe body <0.5

7.14Dimensions

d (underrearaxlegearbox)

e intransportpositionoftelescopicunit

7–8 AP0902

Specifications

Dimensions1

Overalllength

217in(5500mm) Overallheight

–WithFOPSscreen –WithFOPSscreenandrotatingbeacon(option) 100in(2530mm) 103in(2610mm) Overallwidth

71in(1800mm) Groundclearance

13in(340mm)

9in(230mm) Front/reartrackwidth

54in(1370mm) Wheelbase

75in(1910mm) Turningradius 156in(3950mm) m s 2 --m s 2 --a e g b c f 31100b0180.eps d

1.Withstandardbucket810136andstandardtyres12.5–20

Transportgroundclearance

Fig.173:Machinedimensions

AP0902 7–9 Specifications

Outsidetemperature Coolant Water Anticorrosionagent Antifreezeagent upto°C %by volume cm³/ltr. %byvolume %byvolume 39(4)99 10114(-10)7920 -4(-20)6534 -13(-25)5940 -22(-30)5544 Screwdimensions TighteningtorquesinNm 1

7.15Coolanttable 7.16Tighteningtorques 7.16.1Generaltighteningtorques 7.16.2Specifictighteningtorques

8.8 10.9 12.9 M42.2(3)3.0(4)3.7(5) M54.1(5.5)5.9(8)7.4(10) M67.4(10)10.3(14)11.8(16) M817.0(23)25.0(34)29.5(40) M1033.9(46)49.4(67)58.3(79) M1258.3(79)84.8(115)99.6(135) M1492.2(125)136.4(185)162.2(220) M16143.8(195)213.9(290)250.8(340) M18206.5(280)295.0(400)346.7(470) M20291.3(395)413.0(560)486.8(660) M22398.3(540)560.5(760)656.4(890) M24501.5(680)715.4(970)848.2(1150) M27737.6(1000)1069.5(1450)1253.9(1700) M30995.7(1350)1438.2(1950)1696.4(2300) Description Tighteningtorque Wheelnut309.8lb-ft(420Nm) Track-rodend(steeringcylinder)118.0lb-ft(160Nm) Pistonrod(steeringcylinder/trackrod)184.4lb-ft(250Nm) Frontaxlemounting442.5lb-ft(600Nm)

1.Valuesvalidforscrewswithslightlyoiledsurfaces.

Specifications

7.17Conversiontables

7.17.1Conversionfactors

Toconvert to metric, multiply bythefactorshown.Toconvert from metric, divide bythefactor.

Temperature

°C°F

Miles–kilometres(km)1.6093–30–22

Feet(ft)–metres(m)0.3048–20–4

Inches(in)–millimetres(mm)25.4–1014

Inches(in)–centimetres(cm)2.54032

Cubicfeet(cuft)–cubicmetres(m³)0.0283541

Cubicinches(cuin)–cubiccentimetres(cm³)16.38711050

Imperialgallons(Impgal)–litres(ltr)4.5461559

USgallons(USgal)–litres(ltr)3.7852068

Milesperhour(mph)–kilometresperhour(km/ hr) 1.60933086

Longtons–kilograms(kg)1016.0540104

Longtons–tonnes(t)1.016050122

Shorttons–kilograms(kg)907.260140

Shorttons–tonnes(t)0.907270158

Pounds(lb)–kilograms(kg)0.453680176

Ounces(oz)–grams(g)28.349590194

Pounds/in²(psi)–bar0.0689100212

Poundsxfeet(lbft)–Newtonmetre(Nm)1.35582110230

120248

ToconverttoFahrenheit,inserttheCelsiusvaluesintheequation: 1.8x...°C+32°C=...°F

ToconverttoCelsius,inserttheFahrenheitvaluesintheequation: x(...°F–32°F)=...°C 5 9 ---

7–10 AP0902

7.17.2Specificconvertedvalues

Thefollowingtablestatesthemostfrequentvaluesoccurringinthepresentoperator’s manual.Forabbreviationsandanyothervaluestobeconverted,pleaserefertotable 7.17.1Conversionfactors

AP0902 7–11 Specifications

. MassLength 820kg–1807.8lb0.35mm–0.014in 935kg–2061.3lb60mm–2.4in 1100kg–2425lb97mm–3.82in 1345kg–2965.2lb230mm–9in 1487kg–3278.2lb1150mm–45.3in 1800kg–3968lb1205mm–47.4in 2200kg–4850lb1290mm–50.8in 2260kg–4982.4lb1370mm–54in 2800kg–6172.8lb1560mm–61.4in 2974kg–6556.4lb1750mm–68.9in 3150kg–6994.4lb1910mm–75.2in 3750kg–8267lb2530mm–99.6in MassLength 4950kg–10,913lb3360mm–132.3in 5500kg–12.125lb3950mm–155.5in 4690mm–184.7in Volume 11cm³–0.67cuin0.85m³–30.03cuft 20cm³–1.22cuin 25cm³–1.53cuin 41cm³–2.5cuin 80cm³–4.88cuin 2955cm³–180.3cuin AccelerationVelocity 0.5m/s²–1.6ft/s²4km/hr–2.5mph 2.5m/s²–8.2ft/s²20km/hr–12.4mph Capacity 0.7ltr–0.15Impgal8ltr–1.76Impgal 0.18USgal2.1USgal 1.2ltr–0.26Impgal8.5ltr–1.87Impgal 0.32USgal2.25USgal 1.5ltr–0.33Impgal55ltr–12.1Impgal 0.4USgal14.5USgal 3.7ltr–0.81Impgal60ltr–13.2Impgal 0.98USgal15.9USgal 7ltr–1.54Impgal70ltr–15.4Impgal 1.85USgal18.5USgal

7–12 AP0902 Specifications Notes

Annex

AP0902 A–1 Annex Annex Proofsofmaintenance Afterservice hours Maintenance plan Date Service hourreading Company/ signature Delivery 50A 100 1st Inspection 150A 200A 250A 300A 350A 400A 450A 500A 550A 600 B 650A 700A 750A 800A 850A 900A 950A 1000A 1050A 1100A 1150A 1200 C 1250A 1300A 1350A 1400A 1450A 1500A 1550A 1600A 1650A 1700A 1750A 1800 B 1850A 1900A 1950A 2000A 2050A Proofsofmaintenance Afterservice hours Maintenance plan Date Service hourreading Company/ signature 2100A 2150A 2200A 2250A 2300A 2350A 2400 C 2450A 2500A 2550A 2600A 2650A 2700A 2750A 2800A 2850A 2900A 2950A 3000 B 3050A 3100A Proofsofmaintenance Afterservice hours Maintenance plan Date Service hourreading Company/ signature

Annex A–2 AP0902 3150A 3200A 3250A 3300A 3350A 3400A 3450A 3500A 3550A 3600 C 3650A 3700A 3750A 3800A 3850A 3900A 3950A 4000A 4050A 4100A 4150A Proofsofmaintenance Afterservice hours Maintenance plan Date Service hourreading Company/ signature 4200 B 4250A 4300A 4350A 4400A 4450A 4500A 4550A 4600A 4650A 4700A 4750A 4800 C 4850A 4900A 4950A 5000A 5050A 5100A 5150A 5200A Proofsofmaintenance Afterservice hours Maintenance plan Date Service hourreading Company/ signature 5250A 5300A 5350A 5400 B 5450A 5500A 5550A 5600A 5650A 5700A 5750A 5800A 5850A 5900A 5950A 6000 C 6050A 6100A 6150A 6200A 6250A Proofsofmaintenance Afterservice hours Maintenance plan Date Service hourreading Company/ signature

Forserviceandmaintenanceworkonthedieselengine/attachment,pleaserefertotheoperationand maintenancemanualoftheengine/attachmentmanufactureraswell.

ghtnessonthefollowingassemblies/components.

AP0902 A–3 Annex Annex Maintenanceplanmodel418T(overview) Workdescription

Maintenanceplan/servicehours Maintenancework every10hours (daily) Delivery inspection “A” every50hours everyweek 1stInspection1 at100hours “B” every600hours2 2ndInspection “C” every1200hours yearly Oilandfilterchanges(): Carryoutthefollowingoilandfilterchanges(checkoillevelsaftertestrun): ● Engineoil ●●● ● Engineoilfilter ●●● ● Fuelfilter ●● ● Airfilterinsert 3 ● ● Gearboxoilinfrontandrearaxledifferentials/gearbox ●● ● Gearboxoilinfrontandrearaxleplanetarydrives,leftandrightside ●● ● Hydraulicoil 4,5 ● ● Hydraulicoilfilterinsert 3 ●● ● Breather–hydraulicoiltank ● Inspectionwork(): Checkthefollowingmaterial.Refillifnecessary: ● Engineoil ●●● ● Coolant 6 ●●●●●● ● Hydraulicoil 4,5 ●●●●● ● Brakefluid 6 ●●●●●● ● Gearboxoilinfrontandrearaxledifferentials/gearbox ●● ● Gearboxoilinfrontandrearaxleplanetarydrives,leftandrightside ●● Checkcoolerforengineandhydraulicoilforcontamination.Cleanifnecessary 7 ●●●●● V-belt:checkconditionandpre-tension.Retightenorreplaceifnecessary 8 ●●●●● Ventilatethecrankcase 9 Checkglowplugs.Replaceifnecessary ●● Checkthefuel/waterseparator.Drainwaterifnecessary ●●●● Checkvalvetipclearance(enginetiming).Setifnecessary ●● Battery:Checkelectrolytelevelandchargecondition ●● Checkandsetparkingbrakepads.Replaceifnecessary ●●

●● Tyrecheck(damage,airpressure,treaddepth)Visual

●●●●● Heating:Cleandustfilterandreplaceevery1200servicehoursifnecessary ●● Checkscrewsandnutsorscrewconnectionsforti

Retightenifnecessary: ● Engineandenginesuspension ●● ● Steeringsystem ●● ● Hydraulicsystem ●● ● Telescopicunit(lockpin) ●● ● Axlemounting,axlesuspension ●● ● Counterweight(attachment) ●● ● Attachmentscrewsofthecardanshafts ●● ● Tankattachment(hydraulicoilandfueltanks) ●● ● Attachmentscrewsofthecab ●● ● Wheelnuts ●● Electricalsystem:wireandearthingleadconnections,chafingonwiringharness,batteryterminals ●●●●●

● Rearaxleoscillation-typebearing ● ● Telescopicunit–seesection5.10 Telescopicunit

● Wearpadsofthetelescopicunit ● 11 ● ● Compensatingcylinderbearing ● 11 ● ● Telescopzylinderlagerung ● 11 ● ● Liftframebearing ●●●●● ● Liftcylinderbearing ●●●●● ✩ Tiltcylinderbearing ●●●●● ✩ Tiltrodbearing ●●●●● ● Tiltleverbearing ●●●●● ● Quickhitchfacility:lockpins ●●●●● ● Quickhitchfacility:bearingonliftframe ●●●●● ● Hinges,jointsandfittings(e.g.doorholder) ●●

Checkandsetservicebrakepads.Replaceifnecessary

check

Lubricationservice():

Lubricatethefollowingassemblies/components:

onpage5-28

Maintenanceplanmodel418T(overview)

Maintenanceplan/servicehours 1stInspection1 at100hours

inspection “A” every50hours “C” every1200hours yearly ?

Workdescription

Delivery

every10hours (daily) “B” every600hours2 2ndInspection

Forserviceandmaintenanceworkonthedieselengine/attachment,pleaserefertotheoperationand maintenancemanualoftheengine/attachmentmanufactureraswell. everyweek

Maintenancework

Functionalcheck():

Checkfunctionofthefollowingassemblies/components.Rectifyifnecessary:

Serviceandparkingbrake

● ●●●●●●

Lightingsystem

Checkpipeandflexiblelines,aswellasscrewconnectionsofthefollowingassemblies/componentsfortightness, leakageandchafings.Rectifyifnecessary:

● ●●●●●

Airintakeline(airfilter–engine)

● ●●●●●

Fuellines

Coolingsystem(coolingwaterandhydraulicoil)

● ●●●●●

●●●●●

Steeringsystem(flexiblelinesandcylinder)

Hydraulicsystem/telescopicunit(flexiblelinesandcylinder)

1.Worktobecarriedoutonceonlyafterthefirst100servicehours.Mustbecarriedoutbyanauthorizedworkshopforwarrantyclaimstobeacknowledge

3.Clean/replacethefilterinsertasindicatedbythewarninglightintheinstrumentpanel,howeverreplaceatleastevery12monthsor1200serviceh ours.Whenworkinginanacidicenvironment,replacethefilterevery300servicehours!

4.Whenusingbiodegradableoil:Drainthecondensationwaterinthehydraulicoiltankevery600servicehours,inanycasebeforethecoldseason

5.Whenusingbiodegradableoil:Takeanoilsampleevery600servicehoursatthelatest,oilsampleset0004400014

6.Replaceevery2years

8.Replaceunderallcircumstanceseveryyearorevery1200servicehours

10.Lubricateattachmentaspermanufacturer'sinstructions!

11.Ifinuninterrupteduse

12.Replaceflexiblelinesevery6years(UVV,DIN20066T5)

Annex A-4 AP0902

● ●●●●●●

Steeringsystem

Leakagecheck():

Enginelubrication(engine–filter)

● ●●●●●

Brakesystem

●

2.Workafterthefirst600servicehours(2ndInspection)mustbecarriedoutbyanauthorizedworkshopforwarrantyclaimstobeacknowledged

7.Dependingonoperationanddustconditions,itmaybenecessarytocleanthecoolermorefrequently

9.Every2years

Explanationofsymbolsusedinmaintenanceplan

Symbol Description

Beforestartingmaintenancework,takenoteofthesafetyinstructionsintheoperator’smanual!

Beforestartingmaintenancework,takenoteoftheSection“Maintenance”intheoperator’smanual!

Carryoutafunctionalcheckofthelightsystem!

Checktyresfordamage,pressureandtreaddepth!

Carryoutafunctionalcheckofthesteering,synchronisethesteering!

Carryoutafunctionalcheckofthebrakesystem!

Checkbrakefluidlevel.Topupifnecessary!

Checkhydraulicoillevel.Topupifnecessary!

Checkengineoillevel.Topupifnecessary!

Checkcoolantlevel.Topupifnecessary!

Checkcoolerforengineandhydraulicoilforcontamination.Cleanifnecessary!

Cleandustvalveonairfilterhousing!

CheckconditionandinitialtensionofV-belt.Re-tightenorreplaceifnecessary!

Checkthefuel/waterseparator.Drainwaterifnecessary

Leakagecheck: Checkfortightness,leakageandchafing:pipes,flexiblelinesandscrewconnections. Rectifyifnecessary!

Lubricationservice: Lubricatetheassembliesconcerned!

AP0902 A-5 Annex Maintenanceplanmodel 418T(maintenancelabel) 10h Täglich Daily Tous les jours 50 h 418T 0001 0 00 435 22 89 31100w01_a.eps x x

Annex A

Legendforhydraulicsdiagram, model418T ❙➜418T0001

Ref.no. Description

1HydrostaticsteeringV=4.9in3 (80cm3) withinitialstressp=145lb/in2 (10bar)

2Nonreturnvalveblock2x145lb/in2 (10bar) +2x7.3lb/in2(0.5bar)

3Rearaxlesteeringcylinder

4Frontaxlesteeringcylinder

5Muffler

6WorkhydraulicspumpV=1.4in³/rev(23cm³/rev), Q=1.6gal/min(66l/min)

7Drivevariabledisplacementpump5584lb/in2(385bar)

8BoostpressurepumpV=0.7in³/rev(11cm³/rev), Q=6.6gal/min(25l/min)

9DrivevariabledisplacementmotorV=3.7in³(60cm³)

10Oiltemperaturecontroller

11Oilcooler29lb/in2 (2.0bar)

12Temperatureswitch212°F(100°C)+/-3°

13Returnsuctionfilter(initialstress7.3lb/in2 (0.5bar))

14HydraulicoiltankHydraulicoiltankVtotal =15.9gal(60l), Voillevel =13.2gal(50l)

15Pressureswitch29lb/in2 (2.0bar)

16Ventfilter

174foldcontrolvalvestandard –Mainpressurereliefvalve3046lb/in2 (210bar) –Secondarypressurereliefvalve: Push-outcylinder–bottomside3481lb/in2 (240bar)

18Tiltcylinder

19Hoseburstvalvefortiltcylinder

20Compensatingcylinder

21Secondarypressurereliefvalve fortiltcylinderandcompensatingcylinder rodside1740lb/in2 (120bar) bottomside3481lb/in2 (240bar)

22Liftcylinder

23Hoseburstvalveforliftcylinder

24Controlcylinderforquickhitchfacility

25Solenoidvalve–quickhitchlock

26Push-outcylinder

27Hoseburstvalveforpush-outcylinder

Annex A-6 AP0902 Annex A

AP0902 A-7 Annex A B L2 A M5 M4 B M2 M1 2 1 M3 L2 S L1 X M4 L1 M3 P A X X ) B 1 X B 2 P2 P1 A P 1 P X C V P T B4 A4 X B3 A3 A2 B2 A1 B1 P T X C V X 0260010325.eps A1 A2 V1 V2 C1C2M B1 B2 R L P T LS A(EF)LS ø = 0,5 ø = 0,5 1 7 8 6 9 10 11 12 13 14 16 17 24 22 18 3 4 Hydraulicsdiagrammodel418T validfromserialno.418T0001 0260010325(12/00) 5 20 26 2 27 25 23 21 15 19

B1Fuellevelsensor2B2Horn4+

B3Buzzer3S

B4Enginespeedtransmitter2*

B5Backupwarningsystem(option)5*

B6Safeloadindicatorsensor(option)6*

E1Frontparkinglight(left)4+

E2Frontparkinglight(right)4+

E3Highbeam,lowbeam(left)4+

E4Highbeam,lowbeam(right)4+

E5Rearlight(right)5+

E6Rearlight(left)5+

E7Interiorlightwithswitch5+

E8Rearworkinglight(right)5*

E9Frontleftworkinglight(option)5*

E10Frontrightworkinglight(option)5*

E11Instrumentpanellights3S

E12Cigarettelighter(withlighting)3/4S

F1...F22Fuses

F23Mainfuse(powersupply)1F24Fuse(preheating)1-

G1Alternatorwithcurrentregulator1-

G2Battery1-

H1Turnindicator(frontright)4+

H2Turnindicator(frontleft)4+

H3Turnindicator(rearright)5+

H4Turnindicator(rearleft)5+

H5,H6Brakelight5+

H7Rotatingbeacon(option)5*

H8WarningLight–parkingbrake3S

H9WarningLight–turnindicator3S

H10WarningLight–highbeam3S

H11Notassigned

H12WarningLight–engineoilpressure3S

H13WarningLight–hydraulicoilfilter3S

H14WarningLight–airfilter3S

H15WarningLight–coolanttemperature3S

H16WarningLight–hydraulicoiltemperature3S

H17WarningLight–alternatorchargefunction3S

K1Startingrelay,cutoffsolenoid2+

K2Switchingrelaypreheating4+

K3Switchingrelaydriveinterlock3+

K4Switchingrelaylowbeam4+

K5Switchingrelayhighbeam4+

K6Switchingrelay:retracttelescopicunit(option)6*

K7Switchingrelay:extendtelescopicunit(option)6*

K8Hazardlightindicator4+

K9Switchingrelayfloatposition(option)6M1Starter2*

M2Frontwipermotor(1speed)3+

M3Fanmotorheating(2speeds)4+

M4Washerpump4+

M5Rearwipermotorwithswitch5+

M6Fanmotor,air-suspensionseat(option)5*

P1Hourmeter3S

P2Fuellevelindicator3S

P3Safeloadindicator(option)6*

R1..R4Glowplugs2*

R5Potentiometer(inchingpedal)2+

R6Resistor1kΩ,¼W2+

R7Resistor1kΩ,¼W2+

S1Preheatingstartswitch2S

S2Hazardwarninglightswitchwithwarninglight4S

S3Switch–frontwiper3S

S4Switch–frontsocket(option)4*

S5Switch–rotatingbeacon(option)4*

S6Switch–heaterfan4S

S7Switch–workinglight(option)5*

S8Switch–quickhitchlock(option)6*

S9Switch–loadstabilizer(option)6S10Switch–lowdriverange2*

S11Temperatureswitch–hydraulicoil2S12Temperatureswitch–coolant2S13Pressureswitch–airfilter2S14Pressureswitch–oilreturnfilter2S15Oilpressureswitch–engine2S16Multifunctionallever(onsteeringcolumn,right)4+ S17Switch–parkingbrake5+

S18Brakelightswitch–servicebrake5+ S19Driveswitch–joystick(forward)2*

S20Driveswitch–joystick(reverse)2*

S21Tipswitch–extendtelescopicunit(option)2S22Tipswitch–retracttelescopicunit(option)2-

S23 Switch–floatpositionandhoseburstvalve (option) 6*

V1...V4Blockingdiodes2S

V5...V12Blockingdiodes6* F13Blockingdiode5S

V14...V17Blockingdiodes(indicator)3S

F18Blockingdiode6X12poleplugandsocketconnection1+

X2 17poleplugandsocketconnection(engine) naturalcoloured 2+

X317poleplugandsocketconnection(front)black3+

X4 21poleplugandsocketconnection(front)naturalcoloured 4+

X517poleplugandsocketconnection(rear)green5+

X6 3poleplugandsocketconnection(cutoffsolenoid)

X7 3poleplugandsocketconnection(inching pedal)

X8 3poleplugandsocketconnection(Susmiccentral)

X94poleplugandsocketconnection(joystick)2+ X103poleplugandsocketconnection(diagnosis)2+ X1142poleplugandsocketconnection(Susmic)2+

X12 3poleplugandsocketconnection(engine speedtransmitter)

X13Notassigned

X14 3poleplugandsocketconnection(telescopic unitoption,joystick)

2X162poleplugandsocketconnection(red)6X176poleplugandsocketconnection6X183poleplugandsocketconnection6XJ5poleplugandsocketconnection(indicator)3+ XK4poleplugandsocketconnection(indicator)3+ XX6poleplugandsocketconnection(indicator)3+ Y1Solenoidvalve–reversedriving2* Y2Solenoidvalve–forwarddriving2*

Y3 Solenoidvalve–hydraulicmotor(Vgmax.connection)

2* Y4Solenoidvalve–brakepressurecircuit2* Y5Solenoidvalve–cutoffsolenoid2* Y6Solenoidvalve–loadstabilizer(option)6Y7Solenoidvalve–loadstabilizer(option)6Y8Solenoidvalve–hoseburstvalve(option)6Y9Solenoidvalve–hoseburstvalve(option)6Y10Solenoidvalve–retracttelescopicunit(option)6Y11Solenoidvalve–extendtelescopicunit(option)6Y12Solenoidvalve–quickhitchlock(option)6Fusesizes

See Fuseboxesinsideconsole onpage7-5and “Mainfusesin enginecompartment” onpage7-6

Explanationofsymbols(locationinmachine)

+Cab

SSideconsoleandindicator

-Assignedtootherassemblies

*Cablingforoptionattachments(option)

Annex A-8 AP0902

Ref.no. Description Section Loc.

Ref.no. Description Section Loc.

Ref.no. Description Section Loc.

2.Startinganddrivesystem,Susmic/enginewiringharness

1.Powersupply3.17poleplugandsocketconnection(frontwiringharness)4.21poleplugandsocketconnection(frontwiringharness)

5.17poleplugandsocketconnection(roof&rearwireharness

6.Notintegratedinwiringharnessconsumers

Safeloadindicator(option)

Safeloadindicatorsensor (option)

AP0902 A-9 Annex 10 1 7 10 5 9 10 5 9 10 5 9 1 10 5 9 1 2 1 53 31 53a 8 9 10 53 31 53c 31 4 712 5112 8 14610 13115 30 15 17 19 50 2 4 5 8 691012 11 7 31613 15 A B C 9 8 12 10 11 134 14 87a 86 30 87 85 7 8 13 20 21 14 42 28 31 16 1 6 15 29 2 3 5 24 9 22 + GQ h 1 1 3 4 3 4 G4 3 2 1 1+ G B- B+ D+ 86 30 87 85 M 31 50 30 2 1 92131920102117 4 16 15 11 123114 18 C B A 85 87 30 86 87a 10 9 8 1 2 4 5 3 56 30 53c L R 56a 56b H 49 15 58 86 30 87 85 86 30 87 85 56a 56b 56b 56a 7 10 5 1 49a 49 C E11 5 10 1 2 85 87 30 86 86 30 87 85 1 2 CBA B A A B 1 2 1 2 10 9 5 7 6 8 86 30 87 85 10 5 7 K9 V18 S20 S19 X15 X9 X8 X12 X6 X14 S16 X17 S23 F17 M6 F5 S3 S10 S9 S4 S6 S2 S8 F4 F22 F21F19 F2 F8 F7 F10 F3 F6 F1 F20 R3 M4 S14 S15 S1 X10 J X X X K X V17 V16 V15 B3 H15 H16 H14 H12 H13 H10 H9 H8 E11 P1 P2 H17 V14 S22 S21 X2 R2 R4 R1 K2 R5 X7 R6 R7 Y2 Y1 B4 X11 X1 G1 G2 F23 F24 M1 Y5 K1 Kl. 31 F9 Y4 Y3 S13 S12 S11 Kl. 31 F18 V13 S17 K5 K4 E4 E3 S7 K8 B2 S5 E7 S18 E12 B1 M5 F16 F15 F14 F12 F13 F11 X3 X4 X5 E2 E1 H1E5E6H3H4 E8 E9 E10 H7 H5H6 B4 M3 M2 P3 X18 B6 X16 Y6Y7Y8Y9Y10Y11Y12 H2 K3 K6K7 V1 V2 V3 V4 V5V7V9V6V8V10 V11 0160010190_g.eps Indicator Controllever (joystick)

Cab/centralelectrics Chassis/wiringharness+consumers

Electricaldiagram418T validfromserialno.418T0001 0160010190–g(12/00)

Notes:

Annex A-10 AP0902

TORQUE SPECIFICATIONS

NOTE: Use these torque values when tightening GEHL hardware (excluding: Locknuts and Selftapping, Thread Forming and Sheet Metal Screws) unless specified otherwise.

All torque values are in Lb-Ft except those marked with an * which are Lb-In (For metric torque value Nm, multiply Lb-Ft value by 1.355 or Lb-In value by 0.113)

Unified National Thread Grade 2 Grade 5 Grade 8 Dry Lubed Dry Lubed Dry Lubed 8-32 19* 14* 30* 22* 41* 31* 8-36 20* 15* 31* 23* 43* 32* 10-24 27* 21* 43* 32* 60* 45* 10-32 31* 23* 49* 36* 68* 51* 1/4-20 66* 50* 9 75* 12 9 1/4-28 76* 56* 10 86* 14 10 5/16-18 11 9 17 13 25 18 5/16-24 12 19 14 20 3/8-16 20 15 30 23 45 35 3/8-24 23 17 35 25 50 7/16-14 32 24 50 35 70 55 7/16-20 36 27 55 40 80 60 1/2-13 50 35 75 55 110 80 1/2-20 55 40 90 65 120 90 9/16-12 70 55 110 80 150 110 9/16-18 80 60 120 90 170 130 5/8-11 100 75 150 110 220 170 5/8-18 110 85 180 130 240 180 3/4-10 175 130 260 200 380 280 3/4-16 200 150 300 220 420 320 7/8-9 170 125 430 320 600 460 7/8-14 180 140 470 360 660 500 1-8 250 190 640 480 900 680 1-14 270 210 710 530 1000 740 Metric Course Thread Grade 8.8 8.8 Grade 10.9 10.9 Grade 12.9 12.9 Dry Lubed Dry Lubed Dry Lubed M6-1 8 6 11 8 13.5 10 M8-1.25 19 14 27 20 32.5 24 M10-1.5 37.5 28 53 39 64 47 M12-1.75 65 48 91.5 67.5 111.5 82 M14-2 103.5 76.5 145.5 108 176.5 131 M16-2 158.5 117.5 223.5 165.5 271 200

This Operator’s Manual is provided for operator use. DO NOT REMOVE FROM THIS MACHINE.

DO NOT start, operate or work on this machine until you have carefully read and thoroughly understand the contents of this manual.

Failure to follow safety, operating and maintenance instructions could result in serious injury to the operator or bystanders, poor operation, and costly breakdowns.

If you have any questions on proper operation, adjustment or maintenance of this machine, contact your dealer or the Gehl Company Service Department before starting or continuing operation.

WARNING

 Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 U.S.A. (www.gehl.com)