Wacker KRAMER 5509 TELEHANDER Repair Manual - PDF DOWNLOAD

Repair Manual Telehandler

5509

Machine model

416-06

From serial no.

416 06 0001

Version

1.0

Document number

1000344605

Language

[en]

Documentation

Further documents

Order no.

Order no.

[de]

1000344601

[en]

1000344602

[fr]

1000344603

[de en fr]

1000311561

Operator’s Manual Spare parts catalogue model 416-06

Legend Version Date Document

1.0 02/2014 RHB 416-06 *

Copyright – 2014 Kramer-Werke GmbH Printed in Germany All rights reserved, in particular the copyright, the right of reproduction and the right of distribution applicable worldwide.

No part of this publication may be reproduced, translated or used in any form or by any means – graphic, electronic or mechanical including photocopying, recording, taping or information storage or retrieval systems – without prior permission in writing from the manufacturer.

No reproduction or translation of this publication, in whole or part, without the written consent of KRAMER-WERKE GmbH. Violations of legal regulations, in particular of the copyright protection, shall be subject to civil and criminal prosecution.

KRAMER-WERKE GmbH keep abreast of the latest technical developments and constantly improve their products. For this reason we are reserved the right to changes in the pictures and descriptions in this documentation without any obligation to alter any machines previously delivered.

Technical specifications, measurements and weights are not binding. Responsibility for errors or omissions not accepted.

The cover features the machine with possible optional equipment.

Kramer-Werke GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf Tel. 0080090209020 E-mail info@kramer.de www.kramer.de

Table of contents

Table of contents

Table of contents 0 Foreword / Safety 0.1 Repair Manual ......................................................................................................................................

0.2 General instructions..............................................................................................................................

0.3 Safety symbols and signal words .........................................................................................................

0.4 General safety and accident prevention regulations.............................................................................

0-2 0-6 0-6 0-7

1 Maintenance 1.1 Tightening torques ................................................................................................................................ 1-2 1.2 Battery master switch ........................................................................................................................... 1-3 1.3 Information on maintenance ................................................................................................................. 1-4 1.4 Maintenance overview .......................................................................................................................... 1-6 1.5 Fluids and lubricants........................................................................................................................... 1-12 1.6 Maintenance accesses ....................................................................................................................... 1-18 1.7 Cleaning and maintenance ................................................................................................................. 1-23 1.8 Lubrication work ................................................................................................................................. 1-27 1.9 Central lubrication system (option) ..................................................................................................... 1-36 1.10 Fuel system ........................................................................................................................................ 1-38 1.11 Engine lubrication system................................................................................................................... 1-45 1.12 Valve clearance .................................................................................................................................. 1-50 1.13 Cooling system ................................................................................................................................... 1-53 1.14 Air filter ............................................................................................................................................... 1-61 1.15 V-belt/flat belt...................................................................................................................................... 1-64 1.16 Hydraulic system ................................................................................................................................ 1-66 1.17 Electrical system................................................................................................................................. 1-77 1.18 Heating, ventilation and air conditioning system................................................................................. 1-81 1.19 Washer system ................................................................................................................................... 1-88 1.20 Axles/travelling drive........................................................................................................................... 1-89 1.21 Maintenance of the brake system....................................................................................................... 1-96 1.22 Maintenance of compressed-air brake system (option)...................................................................... 1-98 1.23 Tyres................................................................................................................................................... 1-99 1.24 Maintenance and care of attachment devices .................................................................................. 1-102 1.25 Maintenance of options .................................................................................................................... 1-103 1.26 Exhaust gas treatment...................................................................................................................... 1-105 1.27 Machine preservation ....................................................................................................................... 1-108 2 Engine 2.1 Technical data ...................................................................................................................................... 2-2 2.2 Complete engine .................................................................................................................................. 2-4 2.3 Alternator ............................................................................................................................................ 2-17 2.4 Fuel sensor ......................................................................................................................................... 2-19 2.5 Accelerator pedal................................................................................................................................ 2-21 2.6 Starter ................................................................................................................................................. 2-23 3 Cooling 3.1 Radiator ................................................................................................................................................ 3-2 3.2 Replace fan motor .............................................................................................................................. 3-12 3.3 Reversing valve .................................................................................................................................. 3-12 4 Drive 4.1 High speed gearbox ............................................................................................................................. 4-2 4.2 Maintenance operations for the high-speed gearbox ......................................................................... 4-13 4.3 Additional variable displacement motor .............................................................................................. 4-50

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I-1

Table of contents 5 Axles 5.1 Oscillating axle interlock ....................................................................................................................... 5-2 5.2 Front axle.............................................................................................................................................. 5-4 5.3 Rear axle ............................................................................................................................................ 5-11 5.4 Steering cylinder ................................................................................................................................. 5-20 5.5 Adjust the steering sensors ................................................................................................................ 5-27 5.6 Type plate – front/rear axle................................................................................................................. 5-28 5.7 Threaded fittings ................................................................................................................................. 5-29 5.8 Threadlocker – tightening torques ...................................................................................................... 5-30 5.9 Drain, filler and check plugs................................................................................................................ 5-33 5.10 Sealing work ....................................................................................................................................... 5-34 5.11 Special tools ....................................................................................................................................... 5-85 6 Brakes 6.1 Brake system maintenance .................................................................................................................. 6-2 6.2 Brake pedal........................................................................................................................................... 6-7 6.3 Brake valve ........................................................................................................................................... 6-9 8 Work hydraulics 8.1 Control unit ........................................................................................................................................... 8-2 8.2 Dismantle pumps .................................................................................................................................. 8-4 8.3 Tilt cylinder............................................................................................................................................ 8-8 8.4 Seal-tighten cylinder ........................................................................................................................... 8-15 8.5 Tightening torque of oil container ....................................................................................................... 8-24 9 Electrical system 9.1 Board .................................................................................................................................................... 9-2 9.2 Starter ................................................................................................................................................... 9-4 9.3 Load sensor .......................................................................................................................................... 9-6 Index Index ..............................................................................................................................................................S-1

I-2

RHB 416-06 * 1.0 * RHB_41606_en_V1IVZ.fm

Table of contents

Foreword / Safety

Index

0Foreword / Safety

0 Foreword / Safety

0.1

Repair Manual

handling This repair book is intended to help ensure continual operational functionality. Subsequently, this assures the high value of the vehicle thanks to careful care and customer-service monitoring.

The experiences of our customer service technicians as well as experience gathered from our sites are summarised in this repair book.

The sequence of images illustrates the repair procedure.

The text provides the necessary information for making adjustments, using special tools, etc.

The main types of maintenance work are listed in such a way that individual tasks and more minor tasks are comprehendible and easily found.

The book is supplemented to reflect the technical further development of the vehicle and is therefore always up to date as a means of reference.

To be on the safe side, please always compare the adjustment values and capacities with the current operating manual of the respective machine.

Technical data, dimensions and weights are only given as an indication.

Responsibility for errors or omissions not accepted.

Some pictures can differ visually from the actual object.

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

0-2

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Foreword / Safety 0

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

Symbols

Explanation

•

Identifies a general list

1 2 1.

2.

RHB 416-06 * 1.0 * 41605_R_Vorwort.fm

Identifies a list in a table (position numbers) Identifies activities that must be performed in a certain order

➥

Identifies results

►

Identifies things to be avoided in the warning and safety instructions

Abbreviations

Explanation

poss.

possibly

if nec.

if necessary

min.

minimum

max.

maximum

e.g.

for example

resp.

respectively

Fig.

Figure

o/h

Operating hours

Order no.

Order, item or part number

(opt)

Option

SW

Quickhitch facility (load system)

LoF-approval

Agricultural or forestry-use approval (German: Land- oder Forstwirtschaftliche Zulassung)

ROPS

Roll Over Protective Structure

FOPS

Falling Object Protective Structure

0-3

0 Foreword / Safety

General Repair Instructions Technical Specifications Technical data, dimensions and weights are only given as an indication.

Subject to technical modifications. Responsibility for errors or omissions not accepted.

Cause of Damage Detect cause of damage, limit damage and secure the machine.

Spare Parts Use original Kramer spare parts and the relevant Kramer special tools.

With regard to all orders of spare parts and technical queries, please specify the machine number of the vehicle and for diesel engines, the respective serial numbers of any attachment devices.

This is necessary in order to avoid incorrect deliveries of spare parts.

Only use spare parts, accessories and additional equipment which originate from Kramer and which have been checked and approved by Kramer. This is essential to preserve the design characteristics and functionality of your vehicle. Original parts also preserve the vehicle's active and/or passive driving safety as well as its operational safety.

Kramer for damages resulting from the use of non Kramer original parts, Kramer accessories or Kramer additional equipment is excluded.

Diesel engine Before carrying out any work on the diesel engine, always disconnect the battery cable or cut off the power with the battery isolating switch.

Gearbox When disassembling the gearbox, always drain the gear oil first before removing the gears. Separate parts that are interlocked with a soft-metal or plastic hammer.

0-4

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Foreword / Safety 0

Required tools and screw connections • • • • • • • • • • •

Standard tools, electric power tools, pit 2 x 60 bar pressure gauge 2 x 600 bar pressure gauge 1 x 250 bar pressure gauge 2 x micro screw connection 7/16 UNF with O-ring 2 x micro screw connection M12x1.5 with O-ring 2 x micro screw connection S25 (high pressure up to 600 bar) 2 x plug S25 (high pressure, up to 600 bar) 1 x diesel engine speed sensor (or diagnosis system) 1 x multimeter (or diagnosis system) Allen key set with spherical lock (retaining function)

Procedure to follow after components have been replaced or after warranty handling Basically, approval is required for replacing the variable displacement pump or the high-speed gearbox. Please always make a note of the name of the person giving the approval and the date of it on the test report. If you are replacing a pump or the gearbox, the following documents must be sent back in paper form together with the old part: • • • •

RHB 416-06 * 1.0 * 41605_R_Vorwort.fm

Standard test report “Before troubleshooting” Hydraulic pump report High-speed gearbox report (only if high-speed gearbox is replaced) Standard test report "After troubleshooting"

0-5

Foreword / Safety

0 Foreword / Safety

0.2

General instructions Pay particular attention to the following The information in this repair handbook must be read and observed in order to avoid risks to all persons who use, maintain, repair, service or inspect this machine.

In particular, please read this section on safety.

0.3

Safety symbols and signal words

Explanation The following symbol identifies safety instructions. It is used for warning against potential personal risk or danger.

DANGER DANGER identifies a situation causing death or serious injury if it is not avoided.

Consequences in case of nonobservance. ► Avoidance of injury or death.

WARNING WARNING identifies a situation that can cause death or serious injury if it is not avoided.

Consequences in case of nonobservance. ► Avoidance of injury or death.

CAUTION CAUTION identifies a situation that can cause injury if it is not avoided.

Consequences in case of nonobservance. ► Avoidance of injury.

NOTICE NOTICE identifies a situation that causes damage to the machine if it is not observed. ► Avoidance of damage to property.

The warning labels on the machine provide important information about how to operate the machine safely. Complying with these labels is for your safety!

0-6

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Foreword / Safety 0

0.4

General safety and accident prevention regulations • • • •

• •

• • • • • • • • • • •

In addition to these instructions, please also always observe the operating manual for this vehicle.

Comply with all general safety and accident prevention regulations.

When using public roads, observe the respective regulations!

Before starting the diesel engine, please ensure that no gear is engaged and that all safety devices are attached and set at the safety position.

Before starting the diesel engine and before switching on the main drive, hoot the horn.

Start the diesel engine only from the driver's seat. The diesel engine may not be started by short circuiting the electric connections in the motor starter, as otherwise the vehicle may start moving!

Do not leave the diesel engine running in closed rooms!

The assemblers clothes should be close-fitting.

Avoid loose-fitting clothing!

Caution is required when handling fuel. – Increased risk of fire.

Do not smoke during refuelling, and avoid fire and sparks.

Do not smoke when refuelling!

Before refuelling, always switch off the diesel engine and remove the key from the ignition. Do not refuel in closed rooms.

Wipe away fuel spills immediately!

Keep the vehicle clean to avoid risk of fire!

Caution is required when handling brake fluids and battery acid.

Battery acid is toxic and caustic!

Work underneath the raised vehicle only if secure bracing elements are in place.

After maintenance work or servicing, reattach the safety devices!

Leaving the vehicle •

• • •

Before getting out of the vehicle secure it against inadvertently rolling away (parking brake, wheel chock). Switch off the engine, remove the key from the ignition and lock the cab as required!

If the vehicle is not going to be moved for a longer period, switch off the battery circuit breaker.

Never leave the vehicle unattended when the engine is running!

Before leaving the vehicle, lower the boom completely!

Adjustment and maintenance work The drives in the machine are not automatically secured when the engine is shut down.

In addition, adjustment work can require that the drives are rotated.

The following must be observed:

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0-7

0 Foreword / Safety •

•

• • •

• • • • •

Before any adjustment, cleaning or maintenance work and before rectifying any functional faults: - Shut down the engine.

- Disconnect the battery circuit breaker.

Before any adjustment, cleaning or maintenance work or before rectifying any functional faults in the hydraulic system, lower the attachment and/or infeed unit.

When working on the electric system, always disconnect the battery circuit breaker.

You must ensure that no-one can start the vehicle or cause the drives to start rotating.

Fluids emitted under high pressure (fuel hydraulic oil, etc.) can penetrate the skin and cause serious injuries, therefore call a doctor immediately as otherwise serious infections can be caused!

Repairs to the hydraulic system may only be carried out by specialist workshops.

Caution when opening the cooler lock. When the engine is hot, the cooler is under pressure!

Fitting tyres requires sufficient know-how and the proper installation tools!

Oil, fuel and filters have to be disposed of properly!

Tighten wheel nuts at regular intervals!

Risk of injury from hydraulic fluids

WARNING Risk of injury from fluids under high pressure.

Fluids penetrate the skin and can cause death or serious injuries. ► Work to the hydraulic system may only be carried out by authorised specialist workshops. ► Check hose lines at regular intervals. ► Look for leaks with a piece of wood or card. ► Make sure that the jet of oil does not flow towards the body. ► Replace damaged hose lines. ► Replace hose lines after a maximum of 6 years after the date of manufacture. ► If hydraulic fluids penetrate skin or eyes, this must be treated by a specialist doctor immediately.

Air conditioning

Environment The air conditioning system is filled with HFC refrigerant.

This can damage the atmosphere. Particular caution is required when handling the air conditioning system. All maintenance and repair work may only be carried out by specialist air conditioning workshops.

The coolant generally has to be suctioned off and disposed of for recycling

0-8

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Foreword / Safety 0 Pressure accumulator

WARNING Risk of injury from fluids under high pressure.

Fluids penetrate the skin and can cause serious injuries. ► Work on the hydraulic system may only be carried out by specialist workshops.

First-aid measures Breathing: • •

Make sure the person has enough fresh air and, depending on the symptoms, consult a doctor.

Remove the person from the danger area.

Eye contact: Rinse thoroughly for several minutes with plenty of water.

Seek medical attention if necessary.

Skin contact: Wash thoroughly with plenty of water and soap. Take off any contaminated, soaked items of clothing immediately and in the event of a rash on the skin (e.g. redness), consult a doctor.

Swallowing: Do not induce vomiting, immediately seek medical attention.

Battery master switch – see “Switch off the battery master switch” on page 1-3 Safety strut for telescopic boom – see “Installing the safety prop onto the lift ram” on page 1-5 Jack up the machine

WARNING Risk of crushing due to incorrectly jacked up vehicle.

If the vehicle sinks or crashes to the ground, this can cause serious injuries or even death to any persons underneath. ► Use hydraulic jack/trestle with sufficient carrying capacity. ► Use hydraulic jacks/trestles that function reliably. ► Use hydraulic jacks/trestles on a firm and even surface. ► Position the jack/trestle at a suitable location at the vehicle.

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0-9

0 Foreword / Safety

Shut down the vehicle Before work can be carried out on the machine, the following work steps need to be performed: • • • • • • •

0-10

Stop the diesel engine.

Apply the parking brake.

Remove the starting key.

Remove key from main battery switch.

Wait until moving machine parts come to a standstill.

Secure vehicle with wheel chocks.

Ensure that the machine cannot be started by a third person.

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Maintenance

Table of contents

1 Maintenance

1 Maintenance

1.1

Tightening torques Screw dimensions

1.

1-2

Tightening torques in Nm1 8.8

10.9

12.9

M4

3

4

5

M5

5.5

8

10

M6

10

14

16

M8

23

34

40

M10

46

67

79

M12

79

115

135

M14

125

185

220

M16

195

290

340

M18

280

400

470

M20

395

560

660

M22

540

760

890

M24

680

970

1150

M27

1000

1450

1700

M30

1350

1950

2300

These values are valid for screws with untreated, non-lubricated surfaces.

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Maintenance 1

1.2

Battery master switch Switch off the battery master switch

1.

A

2.

NOTICE In order to avoid damage from functional disorders in the electronic motor regulation of the diesel engine, after switching off the engine, do not immediately take the battery main switch out of the lock!

Follow the correct order (see label)!

3.

An external auxiliary heater (option) cannot be operated if the battery master switch is removed.

Fig. 1

1. First stop the diesel engine with the ignition key.

2. Wait at least 30 seconds.

3. Then turn key A out of the notched position and remove it. ➥ The entire electrical system is out of operation.

Switch on the battery master switch 1. Put the key A in the battery main switch and turn in lock. ➥ The entire electrical system is in operation.

2. Start the diesel engine.

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1-3

1 Maintenance

1.3

Information on maintenance

Responsibilities and prerequisites • • •

•

Operational readiness and the service life of the telehandler are heavily dependent on maintenance.

Daily and weekly service and maintenance work must be performed by a specifically trained driver.

All other maintenance operations (e.g. changing oil) may only be carried out by trained and qualified personnel from a specialist workshop.

The manufacturer shall not be liable for damage or personal injury caused by failure to observe instructions!

Information Insist on using original spare parts for repairs.

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

Important safety instructions regarding maintenance work CAUTION Risk of injury due to maintenance work.

Injury hazard! ► Lock the service brake. ► Stop the engine and remove the starting key. ► Observe the danger indications and safety instructions during maintenance. ► Always park the machine on firm and level ground and secure it to prevent it from rolling away. ► Secure the raised loader unit against unintentional lowering. ► Remove the key if the machine is equipped with the “Battery master switch” option. ► Follow the maintenance and safety instructions given in the Operator’s Manuals of the attachments.

1-4

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Maintenance 1

Safety prop for telescopic boom Installing the safety prop onto the lift ram A

WARNING Crushing hazard! Assembly and maintenance on the raised telescopic boom not secured by a prop!

Causes serious injury or death.

B

► Install safety prop A (supplied with the machine) onto the extended lift ram and secure it with pin B (or a screw, see figure).

The safety prop is located at the front left of the machine chassis over the axle mounting.

1.

2.

3.

4.

5.

6.

Park the machine on firm and level ground.

Empty the attachment (bucket).

Tilt in the attachment.

Retract the telescopic boom.

Raise the telescopic boom.

Take the safety prop from its storage place. ➥ Remove the safety pin in order to be able to turn pin B out of the threaded bore.

7. Install the safety prop over the piston rod of the extended lift ram.

8. Lock the safety prop with pin B and secure it with the safety pin.

A

NOTICE Install it as shown in Fig. 2 in order to avoid damage to the piston rod and the safety prop.

A

► Opening showing downward!

B

Information Before putting the machine into operation, remove the safety prop from the lift ram and fasten it in its storage place again (front left machine frame)!

A

Fig. 2

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1-5

1 Maintenance

1.4

Maintenance overview

Maintenance plan Important information on the maintenance plan For servicing and maintenance on the attachment, please also refer to the operator’s and maintenance manuals provided by the attachment manufacturer.

In order to be able to claim on the warranty, maintenance operations, handover-inspection, 1st review at 100 hours of operation, 2nd review every 500 hours of operation and after every 1500 hours of operation (annually) the inspection has to be carried out by an authorised workshop.

“A”, “B” and “C” refer to the respective maintenance kits .

Work description (o/h = operating hours)

Service center

User/operator

Service center

“B” every 500 o/h

“C” every 1500 o/h once a year

●

●

Engine oil filter

●

●

●

Fuel filter

●

●

●

Replace the fuel prefilter

●

●

Air filter insert 1

●

●

Every 20 o/h

“A” 1st Inspection at 100 o/h

every 10 hours of operation (daily)

●

Delivery inspection

Engine oil

Oil and filter changes ( ) (check the oil levels after a test run):

cartridge2

Air filter insert – safety

●

Gearbox oil in front and rear axle differential

●

3

● ●

Gearbox oil in gearbox

Gearbox oil in front and rear axle planetary drives (left and right)

●

●

Hydraulic oil4

● ●

Hydraulic oil filter insert/return filter Hydraulic oil reservoir breather filter

●

●

2

Hydraulics suction filter5 (boost pressure, intake via hydraulic oil tank)

● ●

●

Heating fine-dust filter (outside the cabin)

●

●

Heating recirculated-air filter (inside the cabin)

●

●

1.

2.

3.

4.

5.

Replace the filter insert as indicated by the maintenance display, and more frequently in an acidic environment.

Depending on operation and dust conditions, and in an acidic environment it can be necessary to replace the filters more frequently Every 500 hours of operation, change oil after taking into service for first time and afterwards, every 1500 hours of operation.

Only when using biodegradable oil (before the cold season).

Clean the filter at the control valve input

1-6

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Maintenance 1

Work description (o/h = operating hours)

“C” every 1500 o/h once a year

Service and parking brake: check the linings

“B” every 500 o/h

●

Service center “A” 1st Inspection at 100 o/h

●

Every 20 o/h

Service and parking brake: check the function

every 10 hours of operation (daily)

):

User/operator

Delivery inspection

Functional check, inspection work (

Service center

●

●

●

●

●

●

Accelerator and brake/inching pedals: check them for dirt, clean them if necessary, apply spray oil to the joints

●

●

●

●

●

Compressed-air brake system (option)

●

●

●

●

●

Steering system: steering column adjustment, synchronous position of wheels

●

●

●

●

●

Light and electrical system

●

●

●

●

●

●

●

Battery: check charge condition Immobiliser (option)

●

●

●

●

●

Telescopic boom safe load indicator

●

●

●

●

●

Operator seat, seat belt

●

●

●

●

●

Control lever (joystick): lock for road travel

●

●

●

●

●

Hose burst valve safety feature

●

●

●

●

Load stabiliser (option): check the function

●

●

●

●

●

●

●

Load stabiliser (option): check the pressure accumulator, correct the pressure level if necessary Quickhitch lock

●

●

●

●

●

Hydraulic oscillating axle interlock (option)

●

●

●

●

●

Frame levelling (option)

●

●

●

●

●

Additional control circuits (option)

●

●

●

●

●

Trailer couplings/Autohitch (option): function, damage, wear

●

●

●

●

●

Condition of paint coating

●

Engine oil: check the level

●

●

●

●

●

Hydraulic oil: check the level

●

●

●

●

●

Check the gearbox oil level

●

●

●

Front/rear axle differential: check the oil levels

●

●

●

Front/rear axle planetary drives (left/right): check the oil levels

●

●

●

●

●

●

●

●

●

●

●

●

●

●

Coolant: check the level, add coolant if necessary1

●

Water/oil radiator (engine/hydraulic oil): check for dirt, clean if necessary2

●

Charge-air cooler: check for dirt, clean if necessary

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1-7

1 Maintenance Work description (o/h = operating hours)

Service center “C” every 1500 o/h once a year

“B” every 500 o/h

“A” 1st Inspection at 100 o/h

Every 20 o/h

):

User/operator every 10 hours of operation (daily)

Delivery inspection

Functional check, inspection work (

Service center

●

Charge-air cooler: drain the condensation water 3

●

●

●

●

●

●

●

●

Hydraulic oil reservoir: drain the condensation water 4, 5

●

Air filter: clean the dust collector (cyclone preliminary separator)

●

Air filter: clean the dust valve

Operating hydraulics: clean the filter insert (pressure line between pump and control valve)

●

Diesel particulate filter: have it cleaned or replaced if necessary

● Every 3000 o/h

Flat belt (alternator): check, retighten and replace if necessary

●

●

●

●

●

V-belt (air conditioning, compressed-air brake option): check, retighten and replace if necessary

●

●

●

●

●

●

●

●

Valve clearance (diesel engine): check and adjust if necessary

●

●

●

Line filter (LS drive – control valve): clean the filter insert

●

●

Fuel prefilter: drain the water

●

Heating: Clean the recirculated-air filter (inside the cabin)6 Clean the fine-dust filter (outside the cabin)6

●

●

●

●

Air conditioning system (option): check the coolant level, clean the condenser7

●

●

●

●

Compressed-air brake (option): check for leaks (sound of escaping air) and damage

●

●

●

●

●

Tyres: damage, inflation pressure, tread depth

●

●

●

●

●

Trailer coupling: damage, wear

●

●

●

●

●

Warning and information labels: check for damage, loss

●

●

●

●

●

●

●

●

●

●

Slide and wear plates 1.

2.

3.

4.

5.

6.

7.

8.

on telescopic boom: check, adjust8

Replace the coolant every 2 years Depending on operation and dust conditions, it can be necessary to clean the radiator more frequently.

Only when using biodegradable oil (before the cold season).

Replace the filter insert as indicated by the maintenance display, and more frequently in an acidic environment.

Automatically cleaned on machines equipped with the “Vacuum-operated preliminary separator” option.

Replace more frequently when used in applications with increased dust development.

The dehumidifier must be replaced every 2 years or during any intervention on the refrigeration circuit Replace slide and wear plates under the minimum thickness

1-8

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Maintenance 1

Work description (o/h = operating hours)

Service center

User/operator

Service center

Every 20 o/h

“A” 1st Inspection at 100 o/h

“B” every 500 o/h

“C” every 1500 o/h once a year

every 10 hours of operation (daily)

●

●

●

●

●

Fastening screws of steering system

●

●

●

●

●

Fastening screws of hydraulic system

●

●

●

●

●

Fastening screws of loader unit (pin locking), quickhitch lock

●

●

●

●

●

Axle mounting, axle suspension

●

●

●

●

●

Counterweight fastening screws

●

●

●

●

●

Fastening screws of cardan shafts

●

●

●

●

●

Cabin fastening screws

●

●

●

●

●

Wheel nuts

●

●

●

●

●

Electrical system: check electric and ground connections, chafing on wiring harness, battery terminals

●

●

●

●

●

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Delivery inspection

Fastening screws of engine and engine suspension

Check screws and nuts or threaded fittings for tightness on the following assemblies/components.

Retighten if necessary

1-9

1 Maintenance

Work description (o/h = operating hours)

Service center

User/operator

Service center

Every 20 o/h

“A” 1st Inspection at 100 o/h

“B” every 500 o/h

“C” every 1500 o/h once a year

every 10 hours of operation (daily)

●

●

●

●

●

Front/left axle planetary drive bearing (left/right)

●

●

●

●

●

Hinges, joints, fittings (door arresters, for example)

●

●

●

●

Door hinges

●

●

●

●

Trailer coupling (option)/autohitch (option)

●

●

●

●

):

Delivery inspection

Front/rear axle oscillating bearing

Lubrication1 (

● ● ●

Loader unit – see “Lubricating the telescopic boom” on page 1-30 Telescopic boom slide plates

●

●

●

●

●

Compensating ram bearing

●

●

●

●

●

Boom bearing

●

●

●

●

●

Tilt lever bearing, tilt rod bearing

●

●

●

●

●

Lift cylinder bearing

●

●

●

●

●

Tilt cylinder bearing

●

●

●

●

●

Quickhitch: bearing on boom

●

●

●

●

●

Hydraulic ram bearing of oscillating axle interlock (option)

●

●

●

●

●

Hydraulic ram bearing of frame levelling (option)

●

●

●

●

●

1.

Lubricate attachment according to manufacturer’s instructions!

1-10

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Work description (o/h = operating hours)

Service center

User/operator

Service center

every 10 hours of operation (daily)

“A” 1st Inspection at 100 o/h

“B” every 500 o/h

“C” every 1500 o/h once a year

●

●

●

●

●

Engine lubrication (engine – filter)

●

●

●

●

●

Fuel lines1

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

Hydraulic system/loader unit: flexible lines, rams2

●

●

●

●

●

Additional control circuit quick couplers, 3rd control circuit, tipping trailer connection (option)

●

●

●

●

●

Braking system3: flexible lines

●

●

●

●

●

Compressed-air brake (option)

●

●

●

●

●

Air conditioning system (option): flexible lines, condenser, evaporator

●

●

●

●

●

):

Cooling system (engine – hydraulic oil) Steering system: flexible lines, rams

1.

2.

3.

2

Every 20 o/h

Delivery inspection

Air intake line: air filter, turbocharger, engine charge-air cooler

Leakage check (

Replace flexible fuel leak oil lines every 2 years Replace flexible lines every 6 years (UVV, DIN 20066 part 5) Clean the filter at the control valve input

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-11

1 Maintenance

1.5

Fluids and lubricants

Overview of lubricants Component/application

Diesel engine

Fluid/lubricant

SAE grade/specification

Temperature

Capacities1

Engine oil2 with filter

CLAAS AGRIMOT PROTECT FE 10W-30 PROTECT 10W-40 SRS Turbo-Rekord plus FE 10W-40 ACEA E9/API CJ-4/SN3

Year-round

10.5 l

Gearbox Left/right planetary drives, Front/rear axle

Gearbox oil

Differential Front/rear axle Hydraulic system, hydraulic oil reservoir, braking system

SAE 85 W 90 CLAAS Agrishift MT (API GL4 MIL L-2105) (API GL5 MIL 2105-B)

About 3.5 l Year-round

SAE 90 LS (hypoid gear oil) Hydraulic oil4 Biodegradable oil

0.75 l each 7.1 l each

CLAAS Agrihyd HVLP-D 46 HVLPD 46 (HYD0530)

Year-round

About 100 l5,6

AVIA Syntofluid 46 PANOLIN HLP Synth 46

Multipurpose grease

CLAAS Agrigrease EP 2 Lithium-saponified brand-name grease MPG-A33

Year-round

As required

Special grease

Optimoly paste “TA” White-Paste

Year-round

As required

Battery terminals

Acid-proof grease

SP-B33

Year-round

As required

Fuel system, fuel tank

Diesel fuel8

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

Year-round −40 °C

About 235 l

Year-round

Water 12 l (55 %) Antifreeze 11 l (45 %)

Year-round

Water 1.0 l (33 %) Antifreeze 2 l (67 %)

Grease zerks Telescopic boom slide plate, installation of shafts/pins7

Engine cooling

Washer system

Antifreeze

9,10,11

Cleaning agent11

HAVOLINE XLC

Water + antifreeze

1.

2.

3.

4.

5.

6.

7.

The capacities indicated are approximate values; the oil level check alone is relevant for the correct oil level MIL-L-2104C; API CD/CE/CF4; CCMC-D4 Abbreviation for lubricants (Hauptverband der Deutschen Bauindustrie e. V. – German construction engineering association) DIN 51 524 Total capacity of hydraulic system about 190 l Middle of the sight glass Note: bolts and shafts (hard-chrome plated or coated with Molycote 3400 A) are inserted during installation in a dry state.

Once assembly is over, lubricate shafts and pins with multipurpose grease via grease nipples.

8. If fuels that do not comply with DIN EN or ASTM (USA) are used, warranty rights shall not apply in case of diesel engine damage 9. See manufacturer's instructions on packaging 10. The coolant must be replaced every 2 years by an authorised service centre 11. See manufacturer’s indications on the packaging and bear in mind the antifreeze compound table

1-12

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Component/application

Fluid/lubricant

SAE grade/specification

Temperature

Capacities1

Aggressive media (option)

Anticorrosion protection

Anticorit BW 3662

Year-round

As required

Air conditioning (option)3

Refrigerant4

R 134a/DIN 9860

Year-round

About 1300 g

1.

2.

3.

4.

The capacities indicated are approximate values; the oil level check alone is relevant for the correct oil level TI 8030-015/K 19/MIL-C-16 173 C-Grade 4 Maintenance work may only be performed by trained personnel Bear in mind the safety data sheet during maintenance

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-13

1 Maintenance

Lubrication plan/maintenance plan label

1-14

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Explanation of symbols on the maintenance label Affixed on the cabin Symbol

Explanation Before starting maintenance, follow the safety instructions in the Operator’s Manual!

Before starting maintenance, read the “Maintenance” chapter in the Operator’s Manual!

Perform a functional check of the light system!

Check tires for damage, inflation pressure and tread depth!

Check hydraulic oil level. Add oil if necessary!

Check engine oil level. Add oil if necessary!

Compress the dust valve Check radiator for engine coolant and hydraulic oil for dirt. Clean if necessary!

Check condition and initial tension of V-belt. Retension or replace it if necessary!

Visual check!

Check wear parts and threaded fittings at regular intervals Retighten loose connections immediately and replace worn wear parts!

Leakage check: Check the fuel/water separator. Drain water if necessary!

Lubrication service: Lubricate the assemblies concerned!

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-15

1 Maintenance

Diesel fuel specification According to the legal exhaust-gas regulations, diesel engines equipped with exhaust-gas treatment systems must be operated with sulphur-free diesel fuel only.

CAUTION Health hazard due to diesel fuel!

Diesel fuel and fuel vapors are harmful to health! ► Avoid contact with the skin, eyes and mouth. ► Seek medical attention immediately in case of accidents with diesel fuel. ► Wear protective equipment.

NOTICE In order to avoid damage to the diesel engine and the exhaust-gas treatment system, use only those diesel fuels specified in the table! ► If other fuels are used, warranty rights shall not apply in case of damage (guarantee)! ► When mixing additives (additives or supplementary materials) into diesel fuel, only those permitted by DEUTZ may be used. ► Operation with RME/PME fuel (biodiesel) or vegetable oils is prohibited! ► Please contact your dealer if you require more information on fuel.

Fuel specification

Cetane number

Use (°C)

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

Min. 49

Up to -44 °C outside temperature

Coolant Environment Dispose of throwaway containers according to national regulations.

1-16

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Important information on operation with biodegradable oils •

•

•

•

•

• •

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Use only the tested and approved biodegradable hydraulic fluids – see “Fluids and lubricants” on page 1-12. Always contact the manufacturer for the use of products other than those that have been recommended. In addition, ask the oil supplier for a written declaration of guarantee. This guarantee is applicable to damage occurring on the hydraulic components that can be proved to be due to the hydraulic fluid.

Use only biodegradable oil of the same type for adding oil. In order to avoid misunderstandings, a label providing clear information is located on the hydraulic oil reservoir (next to the filler inlet) regarding the type of oil currently used! Replace missing labels!

The joint use of two different biodegradable oils can affect the quality of one of the oil types. Therefore, ensure that the remaining amount of initial hydraulic fluid in the hydraulic system does not exceed 8 % when changing biodegradable oil (manufacturer indications).

Do not add mineral oil – the content of mineral oil should not exceed 2 % by weight in order to avoid foaming problems and to ensure biological degradability.

When running the machine with biodegradable oil, the same oil and filter replacement intervals are valid as for mineral oil – see maintenance plans in the appendix.

The condensate in the hydraulic oil tank has to be emptied after every 500 hours in operation; and in any case before the cold season starts.

The water content must not exceed 0.1 % by weight.

Also, when using organic oils, all the information about environmental protection provided in this repair manual applies as well.

If additional hydraulic attachments are installed or operated, use the same type of biodegradable oil for these attachments to avoid mixtures in the hydraulic system.

1-17

1 Maintenance

1.6

Maintenance accesses

Engine cover lock CAUTION Injury hazard due to rotating parts!

Rotating parts can cause serious injury. ► Stop the engine before opening the engine cover ► Switch off the starter and remove the starting key ► Switch off the battery master switch ► Enabling the parking brake Opening the engine cover: 1. Stop the engine and remove the starting key.

2. Pull handle A up. ➥ The engine cover opens with the help of gas struts.

Closing the engine cover:

A

1. Press the engine cover down firmly and press handle A ➥ The engine cover can be locked with the ignition key and/or a padlock.

Fig. 3

Maintenance accesses on the engine vat

A

B

C

Fig. 4

A Maintenance access (at rear right of engine vat) ➥ Fuel prefilter B Maintenance accesses (at bottom of engine vat): ➥ Engine oil change, oil filter, fuel filter, radiator C Maintenance access (at front right of engine vat) ➥ Engine electronics (air conditioning)

1-18

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1 Dismantle the maintenance access (engine vat) 1. Secure covers A from falling off.

2. Remove screws B (socket 13).

3. Remove covers A.

A B

Mount the maintenance access (engine vat, bottom) 1. Position the covers A and secure them from falling off.

2. Screw the screws B into the covers A (socket 13).

Fig. 5

Underride protection (opt.) underneath frame Remove the cardan shaft joint guard A

WARNING Risk of injury from the weight of the underride protection!

B D C

Risk of serious injuries in the event of the underride protection folding open by itself. ► Never dismantle the underride protection on your own, but only with two people.

1. Unscrew the screws B on the underride protection A (socket 13).

2. Hold the underride protection in position A and unscrew the screws C on the lock (socket 13).

3. Open lock and fold down the underride protection A. 4. Hold the underride protection in position A and unscrew the screws D. 5. Put down the underride protection A.

A

Mount the underride protection

WARNING Fig. 6

Risk of injury from the weight of the underride protection!

Risk of serious injuries in the event of the underride protection folding open by itself. ► Never mount the underride protection on your own but always with two people.

1. Position the underride protection A and tighten the screws D. 2. Fold down the underride protection A and close the lock.

3. Hold the underride protection in position A and tighten the screws C on the lock (socket 13).

4. Unscrew the screws B on the underride protection A (socket 13).

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-19

1 Maintenance

Covers between the driver's cab and the engine vat Remove the covers

A B C

1. Lift boom and secure the lifting cylinder with safety struts – see “Installing the safety prop onto the lift ram” on page 1-5.

2. Loosen the screws A on the rubber cover B between the driver's cab and engine vat.

3. Remove the rubber cover.

4. Loosen the screws D on the cover sheet C between the driver's cab and engine vat.

5. Remove the cover sheet C. Mount the covers back on again

D

1. Position the cover sheet C. 2. Tighten the screws D on the cover sheet C between the driver's cab and engine vat.

3. Position the rubber cover.

4. Tighten the screws A on the rubber cover B between the driver's cab and engine vat.

Fig. 7

1-20

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1 Maintenance access at the rear of the machine Open the cover: 1. Stop the engine and remove the starting key.

2. Unscrew knurled screws A. 3. Raise cover B upward.

Close the cover: A

1. Hitch cover B from above.

2. Screw knurled screws A.

Fig. 8

B

Fig. 9

Fig. 10

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-21

1 Maintenance

Access to machine fuses Open the cover:

A

1. Stop the engine and remove the starting key.

2. Raise quick fastener A upward.

3. Tilt cover B backward and remove it.

Close the cover: 1. Hitch cover B at the bottom and close it toward the front.

2. Press quick fastener A and tilt it downward.

Fig. 11

B Fig. 12

1-22

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

1.7

Cleaning and maintenance

Important information on cleaning and maintenance The wrong choice of cleaning equipment and agents can impair the operating safety of the machine on the one hand, and on the other put the health of the persons in charge of cleaning the machine at risk.

Therefore always observe the following instructions.

NOTICE Damage to machine due to cleaning work. ► Pay attention to the lower side in particular when cleaning the machine. Do not allow dirt to collect on the engine or gearbox. ► Ensure that the spaces between the radiator fins are clean and not blocked. ► Do not damage the radiator fins when cleaning with a high-pressure cleaner. ► Always cover the intake connection of the air filter before washing the engine. ► Do not point the water jet of the high-pressure cleaner at the seals of hydraulic cylinders. ► Do not clean sensitive electrical components (instrument panel, alternator, compact connectors, control levers, etc.) with a high-pressure cleaner.

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

Environment In order to avoid damage to the environment, clean the machine only in wash bays and places provided to this effect.

Cleaning with washing solvents • • •

Ensure appropriate room ventilation Wear suitable protective clothing Do not use flammable liquids, such as gasoline or diesel

Cleaning with compressed air • • • •

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Work carefully Wear safety glasses and protective clothing Do not aim the compressed air at the skin or at other people Do not use compressed air for cleaning your clothing

1-23

1 Maintenance

Cleaning with a high-pressure cleaner or steam jet • • •

Electrical components and damping material must be covered and not directly exposed to the jet Cover the vent filter on the hydraulic oil reservoir and the filler caps for fuel, hydraulic oil, etc.

Protect the following components from moisture: - Engine - Electrical components such as the alternator, oil pressure switches, wiring, electric/electronic parts, etc.

- Control devices and seals - Air intake filters, etc.

Cleaning with flammable anticorrosion agents and sprays • • •

1-24

Ensure appropriate room ventilation Do not use unprotected lights or open flames Do not smoke

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Cleaning inside the cabin NOTICE Never use high-pressure cleaners, steam jets or high-pressure water to clean inside the cabin. ► Water under high pressure can penetrate into the electrical system and cause short circuits ► Damage seals and disable the controls!

The following aids are recommended for cleaning: • • • • •

Broom Vacuum cleaner Damp cloth Bristle brush Water with mild soap solution

Cleaning the seat belt (lap belt) •

Clean the seat belt (which remains fitted in the machine) only with a mild soap solution; do not use chemical agents as they can destroy the fabric!

CAUTION Injury hazard! Dirty or malfunctioning automatic safety belts can prevent them from rolling up properly and impair the operator’s safety!

Can cause injury. ► Clean the seat belt with water and a mild soap solution ► Only wind the seat belt when it is dry! ► Replace defect belts immediately

Cleaning the exterior of the machine NOTICE In order to avoid the formation of rust (lacquering, joints, screw connections, etc.) clean the vehicle thoroughly with water whenever it has been used on salty terrain, roads or after transportation!

The following aids are recommended for cleaning: • •

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

High-pressure cleaner Steam jet

1-25

1 Maintenance

Cleaning the engine and the engine compartment CAUTION Injury hazard due to rotating parts!

Rotating parts can cause serious injury. ► Stop the engine before opening the engine cover ► Switch off the starter and remove the starting key ► Switch off the battery master switch ► Enabling the parking brake

NOTICE When cleaning the engine with a water or steam jet, humidity penetrating the electronics can cause them to fail and damage the engine! ► The engine must be cold ► Do not point the water jet directly at any of the electric sensors such as temperature and oil pressure switches or control valves. ► Protect all electric parts, such as the alternator, connectors, relays etc. from humidity ► If the water jet is unintentionally pointed at electrical components, dry them with compressed air and apply contact spray to them

The following aids are recommended for cleaning: • •

High-pressure cleaner Steam jet

•

All threaded fittings must be checked regularly, even if they are not listed in the maintenance plans.

Retighten loose connections immediately.

Refer to chapter “Technical data” for the tightening torques.

Checking threaded fittings

•

Checking pivots and hinges •

•

1-26

Lubricate all mechanical pivot points on the machine (for example door hinges, joints) and fittings (for example door arresters) regularly, even if they are not listed in the lubrication plan.

Check the accelerator and brake/inching pedals for dirt, clean them if necessary, apply spray oil to the joints.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

1.8

Lubrication work

Preparing lubrication • • • • •

Park the telehandler on level ground Apply the parking brake and secure the machine with additional wheel chocks Only raise the boom until all grease nipples can be accessed without any risk Stop the engine and remove the starting key Switch off the battery master switch

Information Lubricate all lubrication points mentioned below with lithium-saponified brand-name grease

Lubricating the rear axle oscillation-type bearing

Information A

The machine has an oscillation-type rear axle.

Both grease nipples A are located on the rear left side of the frame and are routed to the axle bearing via hoses. ► Maintenance intervals – see “Maintenance plan” on page 1-6. ► Specifications and fill quantities – see chapter 1 “1.5 Fluids and lubricants” on page 1-12.

•

Lubricate grease nipples A (2 x).

Fig. 13

Lubricating the front axle oscillation-type bearing

A

Information The machine has an oscillation-type front axle.

Both grease nipples A are located at the front right of the frame and are routed to the axle bearing via hoses. ► Maintenance intervals – see “Maintenance plan” on page 1-6. ► Specifications and fill quantities – see chapter 1 “1.5 Fluids and lubricants” on page 1-12.

Fig. 14

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

•

Lubricate grease nipples A (2 x).

1-27

1 Maintenance Lubricating the planetary drive bearing (front and rear axles)

Information Maintenance intervals – see “Maintenance plan” on page 1-6.

Specifications and fill quantities – see chapter 1 “1.5 Fluids and lubricants” on page 1-12.

B

•

Lubricate grease nipples B (2 x) on each planetary drive bearing.

Fig. 15

Lubricating the hydraulic ram bearing of the hydraulic oscillating axle interlock (option)

Information C

Maintenance intervals – see “Maintenance plan” on page 1-6.

Specifications and fill quantities – see chapter 1 “1.5 Fluids and lubricants” on page 1-12.

•

Lubricate grease nipples C (2 x).

Fig. 16

Lubricating the hydraulic ram bearing of the frame levelling (option)

Information D

Maintenance intervals – see “Maintenance plan” on page 1-6.

Specifications and fill quantities – see chapter 1 “1.5 Fluids and lubricants” on page 1-12.

•

Lubricate grease nipples D (2 x).

Fig. 17

1-28

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1 Lubricating the door •

Lubricate grease nipples C (4 x) every 20 service hours or once a week

C

C

Fig. 18

Information

45

Maintenance intervals – see “Maintenance plan” on page 1-6.

Specifications and fill quantities – see chapter 1 “1.5 Fluids and lubricants” on page 1-12.

•

Lubricate the door arrester 45.

Fig. 19

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-29

1 Maintenance

Lubricating the telescopic boom

A

B

C

D

E

F

D

E

F

Fig. 20

Overview of lubrication points A B C D E F

Tilt lever bearing Quickhitch bearing Tilt cylinder bearing Boom bearing Compensating cylinder bearing Lift cylinder bearing

Lubricating the telescopic boom 1. Set the quickhitch to a horizontal position 2. Only raise the boom until all grease nipples can be accessed without any risk 3. Stop the engine 4. Enabling the parking brake 5. Switch off the starter and remove the starting key 6. Lubricate the lubrication points every 20 operating hours or daily if the work is considerable, using a suitable tool to do so 7. Always lubricate the slide plates regularly on the inside and outside boom sections with a suitable tool.

1-30

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Checking the slide plates The slide plates are located between the inside and outside boom sections.

Slide plate wear limits At wear and tear greater than 1 mm, adjust the slide plates with filler plates.

If they go below the minimum thickness, both slide and wear plates have to be replaced!

– see “Changing the side plates / Readjusting the filler plates” on page 1-32 B

Pos. Location

Slide plates minimum thickness

A

Lower front Upper rear

15 mm

> 12 mm

B

Left/right Upper front Lower rear

12 mm

> 10 mm

C

Lower rear centre

34 mm

> 28 mm

Fig. 21

B

Slide plates in new condition

A Fig. 22

A B B

C

Fig. 23

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-31

1 Maintenance

Changing the side plates / Readjusting the filler plates The slide plates are located between the inside and outside boom sections.

Information The slide plates and filler plates at bottom front and rear top have to be of the same thickness The slide plates and filler plates at side left/right and top front have to be of the same thickness If the slide plates are not below the minimum thickness – see “Checking the slide plates” on page 1-31 all that needs to be done is to readjust them with additional filler plates, inserted between the outer telescopic boom and the slide plates themselves.

Dismount the front stripper (opt.)

A

B C D

1. Lower the boom and extend it a little.

2. Remove the cable ties D. 3. Remove the screws C on both sides, remove holder B with the work lights and put to the side.

4. Pull out stripper A.

C

Fig. 24

Replace front slide plates A B C

1. Lower the boom and extend it a little.

2. Unscrew screw A and remove together with disk and plate B. 3. Pull out slide plate C and any filler plates that are in place inside the boom.

4. Insert the new slide plate C and insert any required filler plates into the boom.

5. Tighten slide plate C with screw A, as well as disk and plate B.

Fig. 25

1-32

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1 Mount front stripper (opt.)

A

1. Insert stripper A. 2. Position holder B and work lights on both sides and mount using screws C. 3. Secure the cable with cable ties D. 4. Retract the boom.

B C D C

Fig. 26

Replace the rear top slide plates A

B

1.

2.

3.

4.

C

Loosen screw C and remove with disk and plate B Pull out side plate A and any filler plates that are in place inside the boom Insert the new slide plate A and any required filler plates into the boom Tighten the slide plate A with screw C, as well as disk and plate B

Fig. 27

Replace the rear side slide plate 1. Loosen screws D and remove with guide sheet E 2. Loosen screw C and remove with disk and plate B 3. Pull out side plate A and any filler plate(s) that are in place inside the boom 4. Insert the new slide plate A and any required filler plates into the boom 5. Tighten the slide plate A with screw C, as well as disk and plate B 6. Tighten the guide sheet E using the screws D to do so

B

A E

D

C

Fig. 28

Replace rear bottom slide plate A

B

F E

C D

1. Loosen the screws D and remove holder C together with limit switch B and disks 2. Loosen and remove nuts A and the setscrew 3. Pull out slide plate F, limit switch plate E and any existing filler plates from the boom 4. Insert the new slide plate A, limit switch plate E and any required filler plates into the boom 5. Tighten slide plate A with the setscrew and nuts A 6. Tighten holder C with limit switch B using the disks and screws D to do so

Fig. 29

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-33

1 Maintenance

Spraying oil onto the slide plates after a salt application (with a spray lance) NOTICE Corrosion on the slide plates of the telescopic boom causes damage to the machine. ► Apply an oil coating to them after washing and drying the telescopic boom.

Environment Risk for the environment due to spray oil! ► When spraying oil onto the machine, position it only on surfaces with oil separators. ► When applying spray oil, place a container to collect the oil as it drips. ► If possible, use biodegradable oil for spraying – see chapter 1 “1.5 Fluids and lubricants” on page 1-12.

Preparing the machine:

B

1.

2.

3.

4.

5.

6.

Park the machine on level ground with an oil separator.

Apply the parking brake.

Before spraying, extend the telescopic boom completely Stop the engine.

Disengage the starter and remove the starting key.

Unscrew the cover B from the rear of the vehicle.

Fig. 30

1-34

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Spraying oil to the telescopic boom:

C

A

C

B

Fig. 31

1. Spray oil onto all lateral, upper and lower slide plates B inside the telescopic boom.

2. Spray oil onto all lateral, upper and lower slide plates C outside the telescopic boom.

3. Check the quantity of sprayed oil: the spray oil must neither run nor drip.

After spraying oil: 1. Retract and extend the telescopic boom several times.

2. Screw on the cover at the rear of the machine.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-35

1 Maintenance

1.9

Central lubrication system (option)

Functional description of the central lubrication system The central lubrication system allows you to lubricate all lubrication points of the telescopic loader in one single step.

•

•

The yellow LED illuminates for 1.5 seconds upon switching on ignition to indicate functional readiness of the controls (switch-on check).

It stays lit during the entire lubrication procedure.

The integrated electronic control unit has a data memory for saving the times that have been set or that have elapsed. The time is taken and saved if the starter is disengaged during lubrication or during a break.

The remaining lubrication time or break time is read from the memory upon engaging the starter again, and lubrication is resumed where it was interrupted.

Time control •

Break and lubrication times can be set with the time-dependent control of the central lubrication system. Break times are the periods between two lubrication times.

Information

A Fig. 32

Pressing the push button A on the side of the pump starts intermediate lubrication at any time if the starter is engaged.

This also serves as a functional check.

The pump then immediately starts with a lubrication cycle.

The lubrication or break time that has elapsed so far or that has been saved is reset and starts over again.

A lubrication system malfunction can also be reset by pressing the intermediate lubrication switch, and the pump restarts lubrication.

Repair work Repair work on the central lubrication system may be performed only by qualified service centres!

1-36

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Lubrication with central lubrication system Setting the lubrication and break times Break times and lubrication times are set with the notched switches S and P in the window of the controls.

Break time

1. Remove the red chassis on the protective motor housing of the pump with a flat screwdriver to set the time 2. Slacken the four cross-slotted screws and remove the transparent cover 3. Set the break time P and the lubrication time S with a flat screwdriver 4. Install the transparent cover (window) once the settings are performed

Lubrication time

Lubrication times (S) • • S

P

1 to 16 minutes (16 notches, 1 minute each) 2 to 32 minutes (16 notches, 2 minutes each)

Break time (P)

L

• B A Fig. 33

0.5 to 8 h (16 notches, 0.5 h each)

Yellow LED (L) • •

(B) lubrication system in operation (A) lubrication in progress: 0.5 seconds LED ON/0.5 seconds LED OFF

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

Filling the central lubrication system max.

A

The lubrication system is filled via conical grease nipple A or a fill coupling with a manual or pneumatic grease gun.

NOTICE Only fill up to the maximum level in order to ensure the ventilation of the central lubrication system.

NOTICE Fig. 34

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

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

1-37

1 Maintenance

1.10 Fuel system Important safety instructions for refuelling WARNING Danger of explosions and fire when handling fuel!

Can cause serious burns or death. ► Wear protective equipment. ► Before refuelling, stop the engine and remove the ignition key. ► Never perform work on the fuel system near open flames or sparks. ► Do not smoke. ► Keep the maintenance area clean. ► Do not refuel in closed rooms.

Environment Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner! Keep the machine clean to reduce the risk of fire and wipe away fuel spills immediately!

1-38

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Diesel fuel specification Diesel engines must fulfill the following conditions in order to comply with the legal exhaust-gas regulations: They must only be operated with sulphur-free diesel fuel if they are equipped with exhaust-gas treatment systems.

NOTICE In order to avoid damage to the diesel engine and the exhaust-gas treatment system, use only those diesel fuels specified in the table! ► If other fuels are used, warranty rights shall not apply in case of damage (guarantee)! ► When adding additives to the diesel fuel, only use the ones authorized

by DEUTZ ► Please contact your dealer if you require more information on fuel

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Fuel specification

Cetane number

Use (°C)

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

Min. 49

Up to -44 °C outside temperature

1-39

1 Maintenance

Stationary fuel pumps NOTICE In order to avoid damage in the fuel system, only refuel from stationary fuel pumps. ► Fuel from barrels or cans is usually contaminated and causes increased engine wear ► Malfunctions in the fuel system and reduced effectiveness of the fuel filters

Incorrect

Correct

✓

✗

If refueling from barrels cannot be avoided, note the following points: • • • • •

Barrels must neither be rolled nor tilted before refueling Protect the suction pipe of the barrel pump with a fine-mesh strainer Immerse it down to a max. 15 cm above the floor of the barrel Only fill the tank using refueling aids (funnels or filler pipes) with integral microfilter Keep all refueling containers clean at all times

Fig. 35

Refueling Filler inlet A of the fuel tank is located on the left in travel direction, behind the cabin (refer to the label affixed near the filler opening) Refuel as follows: A

1.

2.

3.

4.

Lower the loader unit to the ground Stop the diesel engine and remove the starting key Clean the area around the filler opening before opening the filler cap Open the tank cap and refuel the fuel tank via the filling screen

1.

2.

3.

4.

5.

Lower the loader unit to the ground Stop the diesel engine and remove the starting key Clean the area around the filler opening before opening the filler cap Open tank cap A and remove filling screen Pump off the fuel into one or more barrels, using a pump to do so. ➥ Capacity approx. 235 l.

Fig. 36

Drain fuel

1-40

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Check/clean fuel prefilter CAUTION Injury hazard due to rotating parts!

Rotating parts can cause serious injury. ► Stop the engine before opening the engine cover ► Switch off the starter and remove the starting key ► Switch off the battery master switch ► Enabling the parking brake

Information Drain the condensation water in the fuel prefilter at the latest if the indicator light on the instrument panel illuminates

NOTICE Condensate in winter-diesel can cause defects in the event of frost. ► Drain off condensate regularly Drain the condensation water as follows: 1.

2.

3.

4.

A B Fig. 37

5.

6.

7.

8.

9.

Lower the loader unit to the ground Stop the diesel engine and remove the starting key Enabling the parking brake Remove the servicing lid – see “Maintenance accesses on the engine vat” on page 1-18 Place a container to collect the fuel Open the drain cock on the fuel prefilter.

To do this: turn the cock to the left A Draining condensation water Close the drain cock on the fuel prefilter.

To do this: turn the cock to the right B Start the diesel engine and check the fuel prefilter for leaks

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

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-41

1 Maintenance Replacing the fuel prefilter CAUTION Injury hazard due to rotating parts!

Rotating parts can cause serious injury. ► Stop the engine before opening the engine cover ► Switch off the starter and remove the starting key ► Switch off the battery master switch ► Enabling the parking brake

A B

Fig. 38

1.

2.

3.

4.

Lower the loader unit to the ground Stop the diesel engine and remove the starting key Enabling the parking brake Remove the servicing lid – see “Maintenance accesses on the engine vat” on page 1-18 5. Place a container to collect the fuel 6. Disconnect the water level sensor cable connection 7. Loosen the drain plug B and let off fluid 8. Loosen filter cartridge A in a clockwise direction 9. Clean the filter housing and sealing areas of the new filter cartridge B 10.Dampen the seal face of the new filter cartridge A lightly with fuel and screw to the filter housing by turning the screw in a clockwise direction ➥ Tightening torque 17-18 Nm 11.Screw drain plug B into position ➥ Tightening torque 1.6 ±0.3 Nm 12.Connect the water level sensor cable connection 13.Bleed the fuel system – see “Bleeding the fuel system” on page 1-43 14.Mount maintenance lid

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

1-42

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Bleeding the fuel system WARNING Explosion and fire hazard when handling fuel!

Can cause serious burns or death. ► Bleed the fuel system only if the engine is cold. ► Wear protective equipment. ► Never perform work on the fuel system near open flames or sparks. ► Do not smoke. ► Keep the maintenance area clean.

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

The fuel system has to be bled after a repair or if the tank has been driven empty. The vent pump is on the fuel prefilter.

Bleed the fuel system as follows: A

B

Fig. 39

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1. Remove the servicing lid below on the engine vat – see “Maintenance accesses on the engine vat” on page 1-18 2. Place the container under the engine 3. Fill the fuel tank 4. Loosen the vent screw B 5. Unlock the vent pump A, do this by pressing the pump handle against the filter housing and turning in an anticlockwise direction 6. Pump the vent pump A vigourously by hand until no more air comes out of the vent screw B 7. Tighten the vent screw B ➥ Tightening torque 6.5 ±1.3 Nm 8. Lock the vent pump A, do this by pressing the pump handle against the filter housing and turning it in a clockwise direction until it snaps into place 9. Starting the engine 10.Start the engine and operate it at idling speed or under little load for about 5 minutes. ➥ Check the prefilter for leaks 11.Install the servicing lid below on the engine vat.

1-43

1 Maintenance

Replacing the fuel filter WARNING Explosion and fire hazard when handling fuel!

Can cause serious burns or death. ► Never bleed the fuel system if the engine is hot!

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

Proceed as follows: 1.

2.

3.

4.

5.

6.

7.

A Fig. 40:

B A

Park the machine on level ground Lower the telescopic boom fully Apply the parking brake Stop the engine Switch off the starter and remove the starting key Opening the engine cover Place a suitable container underneath the engine to collect the fuel as it drains 8. Slacken and unscrew filter cartridge A with a commercially available filter spanner 9. Clean the inside of the filter head 10.Apply a thin coat of fuel to rubber seal B of the new filter cartridge 11.Tighten the new filter cartridge by hand until the gasket makes contact 12.Tighten the filter cartridge A ➥ Tightening torque 10 - 12 Nm 13.Bleed the fuel system – see “Bleeding the fuel system” on page 1-43 Let the engine run and check the filter cartridge for leaks

A Fig. 41

1-44

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

1.11 Engine lubrication system Important safety instructions regarding the engine lube oil system CAUTION Injury hazard due to rotating parts!

Rotating parts can cause serious injury. ► Stop the engine before opening the engine cover ► Switch off the starter and remove the starting key ► Switch off the battery master switch ► Enabling the parking brake

CAUTION Risk of burns when working next to the hot diesel engine!

Can cause serious injury. ► No smoking, no open flames! ► Ensure extreme cleanliness.

Carefully clean the area around the components affected!

• • • •

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Follow the safety instructions and country-specific regulations when handling lube oil!

Dispose of drained lube oil correctly.

Do not allow used oil to seep into the ground!

Perform a test run every time work has been performed!

Check for leaks and correct lube oil pressure, and then check the lube oil level in the diesel engine!

1-45

1 Maintenance

Checking the engine oil level CAUTION Injury hazard due to rotating parts!

Rotating parts can cause serious injury. ► Stop the engine before opening the engine cover ► Switch off the starter and remove the starting key ► Switch off the battery master switch ► Enabling the parking brake

NOTICE Insufficient engine oil will cause damage and impair the performance of the engine! ► Add engine oil.

Check the engine oil as follows: A

1.

2.

3.

4.

5.

6.

Park the machine on level ground and stop the engine Switch off the starter and remove the starting key Enabling the parking brake Opening the engine cover Pull out oil dipstick A and wipe it with a lint-free cloth Push in the oil dipstick as far as possible, pull it back out and read off the oil level 7. Add oil if the oil level is near the MIN mark Example: oil dipstick with 2 notches

Fig. 42

➥ 1st notch = MIN mark ➥ 2nd notch = MAX mark Example: oil dipstick with 4 notches ➥ Cold engine – 1st notch = MIN mark, 3rd notch = MAX mark ➥ Warm engine – 2nd notch = MIN mark, 4th notch = MAX mark

1-46

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Adding engine oil CAUTION Injury hazard due to rotating parts!

Rotating parts can cause serious injury. ► Stop the engine before opening the engine cover ► Switch off the starter and remove the starting key ► Switch off the battery master switch ► Enabling the parking brake

NOTICE Too much or incorrect engine oil can result in engine damage! ► Do not add engine oil above the MAX mark of the oil dipstick A ► Use only the specified engine oil

Environment OIL

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

Add engine oil as follows:

A

B

1.

2.

3.

4.

5.

6.

7.

8.

9.

Clean the area around oil filler cap A with a lint-free cloth Open filler cap A Pull out oil dipstick B and wipe it with a lint-free cloth Adding engine oil Wait a moment until all the oil has run into the oil sump Check the oil level with oil dipstick B Add oil if necessary and check the oil level again Close filler cap A Completely remove all oil spills from the engine

Fig. 43

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-47

1 Maintenance

Changing engine oil 58

CAUTION Risk of burns during maintenance work with hot engine oil!

Failure to observe this can cause serious injury. ► Wear protective gloves and eye protection.

+80 °C

Environment

OIL

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

Fig. 44

D

E

Drain engine oil 1.

2.

3.

4.

C

Fig. 45

D E F

G

Park the machine on level ground and stop the engine Lower the telescopic boom fully Enabling the parking brake Let the engine run until it reaches its operating temperature (about 70 – 80 °C) 5. Switch off the starter and remove the starting key 6. Opening the engine cover 7. Remove the servicing lid under the engine vat 8. Place a container (about 20 l capacity) under the opening to collect the oil as it drains 9. Unscrew filler cap C of oil drain valve D 10.Place the drain coupling with a sufficiently long hose F into container G 11.Screw drain coupling E onto oil drain valve D ➥ The engine oil is drained Refill engine oil

Fig. 46

1-48

1. Unscrew drain coupling E from oil drain valve D. 2. Screw cap C of the oil drain valve back on again.

3. Replace the engine oil filter – see “Replacing the engine oil filter” on page 1-49.

4. Add engine oil and check oil level – see “Checking the engine oil level” on page 1-46.

5. Start the engine and let it run briefly at low speed.

6. Check the engine oil pressure control lamp 58.

7. Stop the engine and wait (about 10 seconds) until all the oil has run into the oil sump.

8. Check the oil level again.

9. Add if necessary and check again.

10.Completely remove all oil spills from the engine.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Replacing the engine oil filter Engine oil filter A is located in the engine vat at the rear left.

It is accessed through the maintenance opening.

CAUTION Risk of burns due to hot engine oil when replacing the oil filter!

Failure to observe this can cause serious injury.

A

► Wear protective gloves and eye protection. ► Use suitable tools (filter spanners, torque wrenches are commercially available)

Fig. 47

Environment Collect the drained engine oil in a suitable container.

Dispose of used oil and filters in an environmentally friendly manner!

Replace the engine oil filter as follows:

58

A

B

A

Fig. 48

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1.

2.

3.

4.

5.

6.

7.

8.

Park the machine on level ground.

Lower the telescopic boom fully.

Apply the parking brake.

Stop the engine and remove the key.

Open the engine cover.

Remove the servicing lid (access to oil filter).

Place a suitable container under the oil filter.

Slacken and unscrew oil filter A with a commercially available filter spanner.

9. Clean the inside of the filter head.

10.Apply a thin coat of fresh engine oil to rubber seal B of the new oil filter.

11.Tighten the oil filter by hand until the gasket makes contact.

12.Tighten the oil filter with a (commercially available) torque wrench ➥ Torque = 15 – 17 Nm 13.Change the engine oil – see “Changing engine oil” on page 1-48.

14.Check the oil level and add engine oil if necessary.

15.Let the engine run briefly.

16.Check the engine oil pressure control lamp 58.

17.Stop the engine and check the seal on oil filter A. 18.Check the oil level and add engine oil if necessary.

19.Completely remove all oil spills from the engine.

20.Dispose of the used oil filter in an environmentally friendly manner.

1-49

1 Maintenance

1.12 Valve clearance Valve clearance diagram for engine 4.1 Crankshaft setting 1 1. Turn the crankshaft until both valves overlap on cylinder 1 ➥ The exhaust valve not closed yet ➥ The intake valve starts to open 2. Set the valves marked black.

3. Mark the set valves with chalk

Fig. 49

Crankshaft setting 2 1. Turn the crankshaft one revolution (360°) 2. Set the valves marked black.

Fig. 50

1-50

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Preparations for setting the valve clearance CAUTION Risk of burns during maintenance on a hot diesel engine.

Risk of burns on hot parts. ► Wait until the engine has cooled down before taking up work. ► Wear protective clothes.

1.

2.

3.

4.

5.

6.

7.

Park the machine on level ground Lower the telescopic boom fully Enabling the parking brake Stop the engine Switch off the starter and remove the starting key Opening the engine cover Allow the engine too cool down for at least 30 minutes ➥ Lube oil temperature below 80 °C 8. Dismount the electric line that leads to the injectors 9. Remove the cylinder-head cover 10.Turn the crankshaft until the valves overlap – see “Valve clearance diagram for engine 4.1” on page 1-50 The cylinders that need to be set can be seen on the configuration diagram.

Valve overlap

Adjustment

1

4

3

2

4

1

2

3

Valve clearance

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

IN

Intake valve

75° ±15°

EX

Exhaust valve

120° ±15°

1-51

1 Maintenance

Setting valve clearance EX

A

B Fig. 51

C

D

E

IN

1. Attach the pivot bracket disk C to the setting screw A using the socket wrench insert D to do so 2. Secure the pivot bracket disk magnet C 3. Turn the pivot bracket disk C in a clockwise direction to the system ➥ Rocker arm is without play 4. Set scale to zero 5. Turn pivot bracket disk C in an anticlockwise direction until it reaches the predefined angle of twist 6. Secure the pivot bracket disk C against being rotated 7. Turn the pivot bracket disk C in a clockwise direction to the system ➥ Rocker arm is without play 8. Set scale to zero 9. Tighten the locknut B ➥ Tightening torque 20 Nm 10.Next, adjust the other two valves on the rocker arm as described in steps 1 to 10 11.Complete the adjustment procedure at each cylinder 12.Mount the cylinder-head cover with new seal 13.Tighten the screws ➥ Tightening torque 22 Nm

Fig. 52

1-52

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

1.13 Cooling system Safety instructions regarding the cooling system The combined water/oil cooler is located in the engine compartment.

It cools the diesel engine and the hydraulic oil of the drive and work hydraulics.

WARNING Burn hazard! The cooling system is hot and under high pressure!

Never open the coolant reservoir or drain coolant if the diesel engine is hot!

Failure to observe this can cause serious injury or death. ► Wear protective gloves and eye protection. ► Wait at least 10 minutes after stopping the diesel engine, then open the filler cap of the radiator to the first notch and release the pressure

WARNING Danger of caustic injury! Risk of swallowing antifreeze when handling it!

Can cause serious injury or death ► Seek medical attention immediately if antifreeze has been swallowed ► Keep antifreeze out of reach of children

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-53

1 Maintenance

Information on inspection and cleaning work on the cooling system Dirt on the radiator fins reduces the radiator’s heat dissipation capacity!

To avoid this: • • • • • • • • •

Clean the outside of the radiator at regular intervals.

Refer to the maintenance plan for the cleaning intervals In dusty or dirty work conditions, clean more frequently than indicated in the maintenance plans An insufficient coolant level reduces the heat dissipation capacity as well and can cause engine damage! Therefore: Check the coolant level once a day.

If extra coolant needs to be added frequently, check the cooling system does not have a leak!

Never add cold water/coolant if the engine is warm!

After filling the radiator, make a test run with the engine and check the coolant level again after stopping the engine Add enough antifreeze to the coolant Use brand-name antifreeze compounds with anticorrosion additives

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

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

1-54

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Checking the coolant level The cooling system is monitored by the temperature readout 12 (with acoustic signal) in the instrument panel.

NOTICE Engine temperature should be between 80 and 105 °C (the maximum admissible cooling temperature is 110 °C, see arrow). ► If the acoustic warning sounds (115 °C),

13

► let the engine run briefly at idling speed until the temperature drops back to 110 °C (acoustic warning no longer sounds) ► Stop the engine and check the coolant level Fig. 53

► Clean the radiator fins

Information Check the coolant level every 10 o/h (operating hours) or once a day.

Check before starting the engine.

Check the antifreeze at temperatures below 4 °C Check the coolant as follows: A

MAX MIN

1.

2.

3.

4.

5.

6.

7.

Park the machine on level ground Lower the telescopic boom fully Enabling the parking brake Stop the engine Switch off the starter and remove the starting key Opening the engine cover Check the coolant level in the inspection window ➥ If the coolant level is below the MIN mark, add coolant up to the MAX mark

Fig. 54

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-55

1 Maintenance

Adding coolant WARNING Burn hazard! The cooling system is hot and under high pressure!

Never open the coolant reservoir or drain coolant if the diesel engine is hot!

Failure to observe this can cause serious injury or death. ► Wear protective gloves and eye protection. ► Wait at least 10 minutes after stopping the diesel engine, then open the filler cap of the radiator to the first notch and release the pressure Preparations A

MAX MIN

Fig. 55

1.

2.

3.

4.

5.

Park the machine on level ground Lower the telescopic boom fully Enabling the parking brake Switch off the starter and remove the starting key Allow the engine/cooling system to cool down

Adding coolant 1. Release the overpressure in the radiator.

To do this: open cap A to the first notch and release the pressure 2. Open filler cap A fully 3. Add coolant up to the MAX mark ➥ Use brand-name antifreeze compounds with anticorrosion additives 4. Close filler cap A Leakage check 1. Start and warm up the engine 2. Set the temperature regulator (rotary switch) for the heating to the maximum temperature ➥ Heating regulator is open 3. Stop the engine and remove the key 4. Check the cooling system and the heating water circuit for leaks 5. Check the coolant level again 6. If necessary, add coolant and repeat the procedure until reaching the correct coolant level

1-56

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Draining/replacing coolant WARNING Burn hazard! The cooling system is hot and under high pressure!

Never open the coolant reservoir or drain coolant if the diesel engine is hot!

Failure to observe this can cause serious injury or death. ► Wear protective gloves and eye protection. ► Wait at least 10 minutes after stopping the diesel engine, then open the filler cap of the radiator to the first notch and release the pressure Drain coolant as follows D A

MAX MIN

E

1.

2.

3.

4.

5.

6.

Park the machine on level ground Lower the telescopic boom fully Apply the parking brake Stop the engine Switch off the starter and remove the starting key Set the temperature regulator (rotary switch) for the heating to the maximum temperature ➥ Heating regulator is open ➥ This also drains the coolant from the heating circuit 7. Opening the engine cover 8. Allow the engine/cooling system to cool down 9. Place a suitable container underneath the outlet of the radiator to collect the coolant as it drains 10.Release the overpressure in the coolant expansion tank A. To do this: open cap D to the first notch and release the pressure 11.Open filler cap D fully 12.Open the lower screw plug on the radiator E and drain the coolant

Fig. 56

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-57

1 Maintenance

D A

MAX

Add coolant as follows: 1.

2.

3.

4.

MIN 5.

6.

7.

8.

E

Close the outlet on radiator E with the screw plug Add coolant up to about 30 mm below filler cap D of the expansion tank Close filler cap D fully Set the temperature regulator (rotary switch) for the heating to the maximum temperature ➥ Heating regulator is open Take engine up to operating temperature Stop the engine Check the cooling system and the heating water circuit for leaks Check the coolant level MAX in the expansion tank

If necessary, add coolant and repeat the procedure until reaching the correct coolant level

Fig. 57

1-58

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Clean the radiator once a day CAUTION Burn hazard during maintenance on a hot engine and radiator!

Failure to observe this can cause injury. ► Wear protective gloves and eye protection. ► Let the radiator cool down at least 10 minutes after stopping the diesel engine

NOTICE Dirt on the radiator fins reduces the radiator’s heat dissipation capacity and can cause damage to the engine and the hydraulic system! ► Check and clean the outside of the radiator once a day. ► Clean the radiator more frequently in dusty or dirty work conditions.

Clean as follows: 1.

2.

3.

4.

5.

6.

7.

Park the telehandler on level ground Lower the telescopic boom fully Enabling the parking brake Stop the engine and let it cool down Switch off the starter and remove the starting key Opening the engine cover Clean the radiator fins by blowing compressed air from either side of the radiator 8. Remove dirt in the intake area of the radiator

Information Fig. 58

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

In order to ensure the radiator’s cooling capacity, do not damage the radiator fins as you clean them with a compressed-air gun!

1-59

1 Maintenance

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

By activating the button 134 (instrument panel, right) you can reverse the direction of rotation of the cooling fan and the cooler is blown free of deposits of dirt.

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

NOTICE Dirt on the radiator fins reduces the radiator’s heat dissipation capacity and can cause damage to the engine and the hydraulic system! ► Check and clean the radiator once a day. ► Clean the radiator more frequently in dusty or dirty work conditions ► Do not clean in closed premises

134 A B

Clean as follows with the reversing fan: •

While the engine is running, tap the button 134 briefly moving it into position B ➥ The fan rotates the other way round with a certain delay, ➥ The fan is in cleaning mode and dirt is removed from the radiator ➥ This can be seen by the dust blown out from the intake screen on the engine cover ➥ The fan automatically switches back to normal cooling mode after about 1 minute

Information When working in especially dusty environment, clean the radiator repeatedly and more frequently!

Fig. 59

1-60

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

1.14 Air filter Important information on cleaning the air filter NOTICE In order to avoid damage to the engine due to dirty intake air, bear in mind the following: ► The air-filter elements have to be changed if the display indicates that dirt has accumulated or the indicator light lights up. ► Do not clean air-filter elements, replace them completely. ► Never reuse damaged air-filter elements. ► Do not clean the air-filter elements with compressed air or a brush. ► Ensure cleanliness in the entire filter area when replacing the air-filter elements! ► Do not operate the engine without the air-filter elements.

Clean the dust valve once a day Cleaning the dust valve:

A

1.

2.

3.

4.

5.

6.

7.

Stop the engine.

Apply the parking brake.

Disengage the starter and remove the starting key.

Open the engine cover.

Squeeze the discharge slot of dust valve A. Remove hardened dust by squeezing the upper area of the valve.

Clean the discharge slot if necessary.

Information The machine can be fitted with a vacuum-operated preliminary separator (option). In this case, hardened dust does not need to be removed manually. It is automatically aspirated via a flexible line in the area of the radiator.

Check the filter cartridge once a week for dirt: • B

•

Indicator light on the indicating instrument monitors the filter cartridge.

Replace filter cartridge B if this indicator light illuminates.

Replace the filter cartridge after 500 service hours at the latest.

Fig. 60:

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-61

1 Maintenance

Replacing the filter cartridge NOTICE In order to avoid damage to the engine due to dirty intake air, bear in mind the following: A

► Do not clean the air-filter elements with compressed air or a brush. ► Replace the air-filter elements when the indicator light illuminates. ► Never reuse damaged air-filter elements. ► Ensure cleanliness in the entire filter area when replacing the air-filter elements! ► Do not operate the engine without the air-filter elements.

Fig. 61:

Replacing the filter cartridge and safety cartridge: 1.

2.

3.

4.

5.

6.

7.

8.

9.

Stop the engine.

Apply the parking brake.

Disengage the starter and remove the starting key.

Open the engine cover.

Pull lock A on the housing cover outward.

Turn the housing cover anticlockwise.

Remove the housing cover.

Carefully remove filter cartridge B with slightly turning movements.

In addition, every 3rd time the filter is replaced, carefully remove the safety cartridge C with slightly turning movements.

10.Ensure that all the dirt (dust) inside the filter housing and the housing cover has been removed.

11.Insert a new safety cartridge C into the filter housing.

12.Insert a new filter cartridge B into the filter housing.

13.Position the housing cover (ensure that it is properly seated) and press lock A.

Fig. 62:

NOTICE B

Air-filter elements degrade prematurely when in service in acidic air for longer periods of time. ► This risk is present, for example, in acid production facilities, steel and aluminium mills, chemical plants and other nonferrous-metal plants. ► Replace air-filter elements every 500 service hours at the latest regardless of the dirt indicator!

C

Fig. 63:

1-62

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Checking/cleaning the dust collector (option) Clean the dust collector as follows: 1 2

1.

2.

3.

4.

5.

6.

Stop the engine Apply the parking brake Switch off the starter and remove the starting key Remove cover 1 from the dust collector Remove and empty the dust container 2 Insert the dust container and install the cover

NOTICE Fig. 64

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Ensure that the dust in the container is no higher than 25 mm under the cover otherwise the engine is damaged!

When working in especially dusty environment, clean repeatedly and more frequently!

1-63

1 Maintenance

1.15 V-belt/flat belt Checking/retightening the V-belt and flat belt CAUTION Injury hazard due to rotating parts!

Rotating parts can cause serious injury. ► Stop the engine before opening the engine cover. ► Only check or retighten the V-belt and flat belt when the engine is stopped.

Check the flat belt (diesel engine) as follows: 1.

2.

3.

4.

5.

A

Stop the engine Enabling the parking brake Switch off the starter and remove the starting key Opening the engine cover Carefully check the flat belt through inspection slot A for damage and correct tension ➥ The flat belt is automatically tightened!

NOTICE

Fig. 65

A cracked and stretched flat belt causes engine damage! ► Replace damaged flat belts Check the V-belt (air conditioning) as follows: 1.

2.

3.

4.

5.

A

Stop the engine Enabling the parking brake Switch off the starter and remove the starting key Opening the engine cover Press with your thumb to check through inspection slot A whether the V-belt can be deflected between the pulleys by no more than about 10 mm. ➥ Replace cracked or over-stretched V-belts

Fig. 66

1-64

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1 Retighten the V-belt (air conditioning) as follows: A

1. Loosen the screws A and remove together with the shielding plate B 2. Remove cover C

B C

1.

2.

3.

4.

5.

Loosen fastening D Press the air conditioning compressor outward with setting screw E Tighten fastening D Check the V-belt tension Mount cover C

D

E Fig. 67

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-65

1 Maintenance

1.16 Hydraulic system Important information on the hydraulic system WARNING Burn hazard during maintenance on a hot engine and hydraulic system!

Risk of burns. ► Do not add hydraulic oil unless the diesel engine is stopped. ► Wait at least 10 minutes after stopping the engine ► Wear protective gloves and clothing during maintenance •

Release the pressure in all lines carrying hydraulic oil prior to any maintenance and repair work. To do this: - Lower all hydraulically controlled attachments to the ground, stop the engine and switch off the ignition - Use the parking brake to park the machine safely and to prevent it rolling away - After shutting off the diesel engine, operate all of the control levers for the hydraulic control devices in order to relieve pressure - Secure the lift ram of the raised telescopic boom with a strut to prevent unintentional lowering - Wear protective clothes during maintenance work

NOTICE Contaminated hydraulic oil, lack of oil or wrong hydraulic oil poses a risk of serious damage to the hydraulic system! ► Take care to avoid dirt when working! ► Always add hydraulic oil using the filling screen! ► Only use authorised oils of the same type ► Always add hydraulic oil before the level gets too low ► If the hydraulic system is filled with biodegradable oil, then only use biodegradable oil of the same type for adding oil – observe the sticker on the hydraulic oil tank

1-66

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Monitoring the hydraulic oil filter The red indicator light 95 on the indicating instrument monitors the hydraulic oil filter.

NOTICE Indicator light 95 on the indicating instrument illuminates if the resistance of the oil flow in the return filter is too high!

95

► The filter element is dirty and must be replaced. ► The filter element and the hydraulic oil may be replaced by an authorized service centre only!

Fig. 68

Information In cold weather indicator light 95 can illuminate immediately when the engine is started. This is caused by increased oil viscosity. In this case regulate the engine speed so that indicator light 95 does not illuminate.

Bear in mind the instructions concerning warmup.

Hydraulic oil level monitoring (option) The red indicator light 94 on the indicating instrument monitors the hydraulic oil level during machine operation.

NOTICE If the consumed volume is too high (for example with a tipping trailer) or if the level in the hydraulic oil reservoir is too low, indicator light A illuminates (in the indicating instrument)!

94

Fig. 69

► Hydraulic oil has to be added – see “Adding hydraulic oil” on page 1-69. ► Always check the hydraulic-oil level at the oil level sight glass in transport position – see “Checking the hydraulic oil level” on page 1-68. ► Have leaks repaired by an authorized service centre if necessary!

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-67

1 Maintenance

Checking the hydraulic oil level The oil level sight glass is located on the hydraulic oil reservoir behind the cabin (on the left in travel direction).

Check the hydraulic oil level as follows: A

Fig. 70

1.

2.

3.

4.

5.

6. ➥

Park the machine on level ground Retract all hydraulic rams Enabling the parking brake Stop the engine Switch off the starter and remove the starting key Clean oil level sight glass A and check the oil level If the oil level is visible in the lower half of the oil level sight glass: oil level is OK. ➥ If the oil level is no longer visible in the lower half of the oil level sight glass: not enough oil! ➥ Fill hydraulic oil – see “Adding hydraulic oil” on page 1-69 ➥ If necessary, uncouple the hydraulic hoses from the consumers.

NOTICE Damage to hydraulic system due to incorrect hydraulic oil level. ► The hydraulic-oil level must never drop below the middle of the oil level sight glass. ► Do not fill above the oil level sight glass when adding hydraulic oil.

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

1-68

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Adding hydraulic oil NOTICE Contaminated or the wrong hydraulic oil and lack of oil can severely damage the hydraulic system. ► Do not add hydraulic oil unless the diesel engine is stopped. ► Take care to avoid dirt when working. ► Add oil with a screen to avoid dirt. ► Only use authorised oils of the same type. ► Add hydraulic oil before the level gets too low. ► If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has penetrated the hydraulic system. ► If the hydraulic system is filled with biodegradable oil, then use only biodegradable oil of the same type for filling up – observe the sticker on the hydraulic oil reservoir.

Add hydraulic oil as follows:

B

Fig. 71

1. Park the machine on level ground 2. Retract all hydraulic rams 3. Stop the engine 4. Enabling the parking brake 5. Switch off the starter and remove the starting key 6. Clean the area around the filler and breather filter B 7. Place a container under the hydraulic oil tank to collect the oil 8. Open breather filter B by hand 9. Add hydraulic oil with the filter insert in place 10.Check the hydraulic oil level in sight glass A 11.Add if necessary and check again 12.Firmly close breather filter B by hand

Information Excess hydraulic oil is released via the breather filter during loader unit operation. ► Drain the oil in a suitable container until the oil level is visible in the oil level sight glass.

Environment Dispose of drained hydraulic oil by an ecologically safe method.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-69

1 Maintenance

Change the hydraulic oil NOTICE Contaminated or the wrong hydraulic oil and lack of oil can severely damage the hydraulic system. ► Only change the hydraulic oil when the diesel engine is shut off. ► Take care to avoid dirt when working. ► Add oil with a screen to avoid dirt. ► Only use authorised oils of the same type. ► If the hydraulic system is filled with biodegradable oil, then use only biodegradable oil of the same type for filling up – observe the sticker on the hydraulic oil reservoir.

Follow this procedure to change the hydraulic oil

A

B C

1. Park the machine on level ground 2. Retract all hydraulic rams 3. Stop the engine 4. Enabling the parking brake 5. Switch off the starter and remove the starting key 6. Clean the area around the filler and breather filter A 7. Place a container under the hydraulic oil tank to collect the oil 8. Open breather filter A by hand 9. Place a suitable container under the hydraulic oil tank 10.Open the lid C to the oil drain valve B 11.Place the end of the hose connected with the oil drain coupling in the container 12.Screw the oil drain coupling to the oil drain valve B ➥ The oil drain valve opens and the oil runs into the container 13.Close the lid to the oil drain valve 14.Add hydraulic oil with the filter insert in place 15.Check the oil level in sight glass D 16.Add if necessary and check again 17.Firmly close breather filter A by hand

Information Excess hydraulic oil is released via the breather filter during loader unit operation.

D

► Drain the oil in a suitable container until the oil level is visible in the oil level sight glass.

Environment Dispose of drained hydraulic oil by an ecologically safe method.

Fig. 72

1-70

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Replacing the hydraulic oil return filter Follow this procedure to change the reflux filter A B

Fig. 73

1.

2.

3.

4.

5.

6.

Park the machine on level ground Retract all hydraulic rams Stop the engine Enabling the parking brake Switch off the starter and remove the starting key Clean the area around the filling and breather filters A and the reflux filter C 7. Open breather filter A by hand 8. Unscrew cover C 9. Pull out the filter element with the bow clip 10.Install new filter element ➥ Before installing the new filter check whether the designation corresponds to the dismantled filter 11.Screw cover C back on again 12.Firmly close breather filter A by hand 13.Check the level of hydraulic oil and refill if necessary – see “Adding hydraulic oil” on page 1-69

Hydraulic tank - change breather filter Proceed as follows to change the breather filter A

Fig. 74

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1.

2.

3.

4.

5.

6.

7.

8.

Park the machine on level ground Retract all hydraulic rams Stop the engine Enabling the parking brake Switch off the starter and remove the starting key Clean the area around the filler and breather filter A Unscrew the breather filter A by hand Install new breather filter A ➥ Before installing the new filter check whether the designation corresponds to the dismantled filter 9. Check the level of hydraulic oil and refill if necessary – see “Adding hydraulic oil” on page 1-69

1-71

1 Maintenance

Changing the suction filter - hydraulic equipment CAUTION There is a risk of being scalded from hot hydraulic oil when replacing the filter element!

Failure to observe this can cause serious injury. ► Wear protective gloves and eye protection.

Proceed as follows to change the suction filter A

B C D

1.

2.

3.

4.

5.

6.

Park the machine on level ground Retract all hydraulic rams Stop the engine Enabling the parking brake Switch off the starter and remove the starting key Open the breather filter A by hand in order to relieve the pressure in the hydraulic oil tank ➥ There must be no pressure in the hydraulic oil system 7. Place a suitable container underneath the suction filter (in a central position underneath the telescopic boom) (capacity of at least 10 litres) 8. Dismount the housing E 9. Replace the filter cartridge D 10.Check seals B – C and replace parts as required 11.Open the housing E by unscrewing it 12.Firmly close breather filter A by hand 13.Carry out a test run and check the filter element for leaks 14.Check the level of hydraulic oil and refill if necessary – see “Adding hydraulic oil” on page 1-69

E

Environment Dispose of drained hydraulic oil by an ecologically safe method.

Fig. 75

1-72

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Checking the hydraulic system for leaks Safety instructions regarding pressure line checks

WARNING Burn and injury hazard if hot hydraulic oil escapes under high pressure!

Hydraulic oil escaping under high pressure can catch fire, damage property, penetrate the skin, and cause serious burns. ► Do not operate the machine with leaking or damaged hydraulic system components. ► Never search for leaks with your bare hands, wear protective gloves and clothes ► Wear safety glasses to protect the eyes. If oil contacts the eye flush immediately with clean water and seek emergency medical treatment. ► Seek immediate medical attention if oil penetrates the skin.

Oil can cause serious infections. ► Retighten leaking threaded fittings and hose connections only when the hydraulic system is not under pressure. In other words, release the pressure before working on pressurized lines. ► Never weld or solder defect or leaky pressure hoses and screw connections, but replace defect parts. ► Do not check for leaks with an open flame due to explosive fire risk from vaporized oil mist.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-73

1 Maintenance

Checking the condition and age of hydraulic hoses Important information for the owner of the machine: The entrepreneur/owner of the machine must ensure that flexible lines are replaced in appropriate intervals, even if no safety-relevant malfunctions can been detected on the flexible line.

Flexible lines must be inspected by a technician (competent person) before the first commissioning, and then at least once a year for safe working condition.

4 Q/12

•

•

Fig. 76

Leaking and damaged pressure hoses have to be removed immediately.

This not only increases the operating safety of your machine but also helps to protect the environment Replace hydraulic hoses every 6 years from the date of manufacture, even if they do not seem to be damaged

In this respect, we also recommend that you observe all the relevant safety regulations for hydraulic lines, as well as the safety regulations regarding accident prevention and occupational health and safety in your country. Also observe DIN 20066, part 5.

The date of manufacture (month or quarter and year) is indicated on the flexible line.

Example: •

1-74

The indication “4 Q/12” means manufactured in the 4th quarter of 2012.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Clean the line filter (control unit) strainer Remove the line filter A

1. Loosen sleeve nut A. 2. Remove the pressure control valve 144 (B) and seal with plugs.

B

Fig. 77

3. Loosen the sleeve nuts A and C at the line filter B, holding an open-end wrench at the filter to counter the movement.

A

B

C

Fig. 78

4. Dismantle the screw connection B on the line filter A. A

B

Fig. 79

A

5. Remove the filter element B from the housing A. 6. Wash the filter element B with petroleum benzine or cold cleaner.

B

Fig. 80

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-75

1 Maintenance

A

Mount the line filter 1. Insert the filter element B into the housing A.

B

Fig. 81

A

B F

2. Lubricate the O-ring E on the screw connection D. 3. Insert the spring C and centering piece F as shown between the screw connection D and the filter element B. 4. Screw the screw connection D into housing A with a tightening torque of 180 Nm.

C

E D Fig. 82

5. Tighten the sleeve nuts A and C at the line filter B, holding an open-end wrench at the filter to counter the movement.

A

B

C

Fig. 83

6. Remove the plugs and position the pressure control valve 144 (B).

7. Tighten the sleeve nut A.

A

B

Fig. 84

1-76

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

1.17 Electrical system Qualification of maintenance personnel Replacement and repair work on the electrical system may be performed only by trained technical personnel and/or qualified service centres!

Checks and service work, as well as the replacement of light bulbs, fuses and the battery, must be performed by a specifically trained driver

Safety instructions regarding the battery WARNING Hazardous material. Batteries contain caustic sulfuric acid.

Danger of serious injury. ► This acid must not be allowed to come into contact with the skin, the eyes, clothing or the machine. ► Always wear safety glasses and protective clothing with long sleeves. ► If acid has been spilt: immediately rinse all affected surfaces thoroughly with water. ► Thoroughly wash any part of the body touched by the sulphuric acid immediately with plenty of water and seek medical attention at once.

WARNING Explosion hazard. An easily flammable oxyhydrogen mixture forms in batteries during normal operation and especially when charging.

Danger of serious injury. ► Always wear gloves and eye protection when working with batteries. ► Avoid open lights and sparks in the vicinity of open battery cells and do not smoke. ► In case of a frozen battery or of an insufficient electrolyte level, do not try starting the machine with battery jumper cables.

Dispose of the battery immediately.

NOTICE Charge a low battery with a regulated battery charger equipped with an automatic shutoff. ► Refer to the Operator’s Manual of the battery charger.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-77

1 Maintenance

Checking/replacing the battery The battery is located under the cabin to the left of the access.

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

Preparing battery replacement: 1.

2.

3.

4.

5.

6.

Park the machine on level ground Lower the loader unit Enabling the parking brake Switch off the starter and remove the starting key Remove the key from the battery master switch Remove the protective cover

NOTICE In order to avoid a short circuit, when you are disconnecting the battery cable it is important to observe the order in which the cables are dismantled!

Replace the battery as follows: +

Fig. 85

1-78

-

1. First remove the black battery lead from the negative terminal (−), then the red battery lead from the positive terminal (+) 2. Remove the battery fixture 3. Replace the battery with a new one 4. Install the battery fixture 5. First connect the battery lead to the positive terminal (+), then to the negative terminal (−)

NOTICE In order to avoid damage to the machine electronics, only use batteries of the specified capacity!

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Regular checks and maintenance of the electrical system Daily checks before operating the machine • •

Is the light system OK? Is the signaling and warning system OK?

Weekly checks •

•

• •

Electric fuses: if malfunctioning, use only the specified load capacity (amperage) ➥ Blown fuses indicate overloading or short circuits.

Therefore, the electrical system should be checked by a qualified technician before installing the new fuse Electric and ground connections: When performing maintenance on the electrical system, pay particular attention to ensuring good contact in leads and fuses Battery charge condition and condition of battery terminals Check that the electric cables are positioned securely and show no signs of wear and tear. If necessary replace them.

Checking the alternator • • • •

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Only test run the engine with the battery connected When connecting the battery, ensure that the poles (+/−) are not inverted Always disconnect the battery before performing welding work or connecting a quick battery charger Have malfunctioning charge indicator lights immediately replaced

1-79

1 Maintenance

Checking/replacing relays and fuses on the board The board with the fuses and relays is located to the bottom left of the leg room area of the cab.

Checking/replacing fuses and switching relays 1. Switch off ignition and remove the black battery lead from the negative terminal (−) of the battery or switch off the battery master switch.

2. Remove the trim and the defective fuses or relays from the relay bracket, and replace them by new ones

NOTICE Blown fuses indicate overloading or short circuits. The electrical system must therefore be checked before installing the new fuse! ► Only use fuses with the specified load capacity (amperage).

Fig. 86

Checking/replacing fuses in the main fuse box Main fuse box with switching relays The main fuse box is installed in front of the air filter in the engine compartment.

Main fuse box with switching relays (overview) • • • •

Fig. 87

Main fuses Ignition lock and preheating fuse Engine control unit fuse The high current relay for preheating, the high current relay for starting and the switching relay for the engine electronics are located below the main fuse box.

Check/replace relays as follows 1. Switch off ignition and disconnect the negative lead (−) from the battery, or switch off the battery master switch (option).

2. Remove the fuse box cover.

3. Remove the fuses from the control panel and use a multimeter to check them.

4. Replace defect fuses with new fuses of the exact same type.

5. Replace defect relays with new relays of the exact same type.

6. Install the fuse box cover.

7. Check the electrical system for correct function.

1-80

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

1.18 Heating, ventilation and air conditioning system Important information on cabin ventilation The cabin is equipped with a fine-dust filter and recirculated-air filter.

Clean the filters as required, however replace them every 500 s/h at the latest.

CAUTION Health hazard! Filter installed incorrectly or damaged!

Penetration of dust in cabin causing damage to health. ► In order to be able to comply with the required safety measures regarding occupational safety and health, malfunctioning or dirty filters must be replaced by new ones! ► The machine may not be used in an environment requiring protection against aerosols and vapors!

Clean/replace filter Cleaning the recirculated-air filter: The recirculated-air filter is located underneath the cover to the left of the operator seat in the cabin.

B C

Fig. 88

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1. Remove screws B 2. Remove the cover and recirculated-air filter C 3. Clean recirculated-air filter C with compressed air or water, replace it with a new one if necessary ➥ Replace the recirculated-air filter every 500 s/h (service hours) ➥ Replace or clean the filter more frequently if the machine is used in severe dust conditions 4. Clean the inside of the filter housing and insert the filter ➥ Ensure that it is positioned properly ➥ Install the cover

1-81

1 Maintenance Cleaning the fine-dust filter: The fresh-air filter is located behind the door on the left on the outside of the machine.

A

Fig. 89

1.

2.

3.

4.

5.

Unscrew screw A. Remove cover B. Remove fine-dust filter C and check for damage.

Knock filter element C on a plate on either side.

Blow compressed air from the inside to the outside to clean the filter, or wash it with water and dry it. ➥ Replace the fine-dust filter every 500 service hours. ➥ Replace or clean the filter more frequently if the machine is used in severe dust conditions.

6. Clean the inside of the filter housing and insert the filter. ➥ Ensure that it is seated properly.

7. Install the cover.

B

Fig. 90

C

Fig. 91

1-82

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Air conditioning (option) Functional and visual checks must be performed by the operator/ user!

All kinds of maintenance and repair operations may only be carried out by trained specialist personnel with knowledge about air-conditioning systems.

Important safety instructions regarding the air conditioning system CAUTION Injury hazard due to rotating parts!

Rotating parts can cause serious injury. ► Stop the engine before opening the engine cover ► Switch off the starter and remove the starting key ► Switch off the battery master switch ► Enabling the parking brake

CAUTION Injury hazard during inspection work!

The evaporator and heat exchanger have sharp-edged fins.

Lines and hoses containing coolant can be hot!

Failure to observe this can cause injury. ► Wear protective equipment (protective gloves and safety glasses) ► Do not perform maintenance unless the heating and air conditioning systems are switched off ► Observe the pertinent regulations relevant to accident prevention, other generally acknowledged regulations regarding safety and occupational medicine

WARNING Risk of injury from outflowing refrigerant!

This can cause serious frost bite or bodily injury. ► Before replacing components from the air-conditioning system, the refrigerant has to be emptied properly.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-83

1 Maintenance Air conditioning The air conditioning system must be checked and serviced twice a year by trained personnel with expert knowledge about air-conditioning systems!

•

For the first fill, see the air conditioning label inside the cabin on the door

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

Fig. 92

Empty the air conditioning system .

WARNING A

B

Poisonous gases can be incurred during welding work or in the event of open flames close to the refrigerant circuit.

Risk of poisoning from poisonous gas. ► Avoid open flames in the proximity of the refrigerant circuit. ► Do not weld close to the refrigerant circuit.

Use an air conditioning service centre to drain the air conditioning system.

Observe the relevant operating instructions!

Fig. 93

1.

2.

3.

4.

Stop the engine Enabling the parking brake Switch off the starter and remove the starting key Connect the (red) high pressure service line to the high pressure connection B 5. Connect the (blue) low pressure service line to the lower pressure connection A 6. Drain the air conditioning system with the respective program from the air conditioning service centre

Filling the air conditioning system WARNING A

B

Poisonous gases can be incurred during welding work or in the event of open flames close to the refrigerant circuit.

Risk of poisoning from poisonous gas. ► Avoid open flames in the proximity of the refrigerant circuit. ► Do not weld close to the refrigerant circuit.

Fig. 94

Use an air condition service centre to fill the air conditioning system.

Observe the relevant operating instructions!

1. Stop the engine 2. Enabling the parking brake 3. Switch off the starter and remove the starting key

1-84

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1 4. Connect the (red) high pressure service line to the high pressure connection B 5. Connect the (blue) low pressure service line to the lower pressure connection A 6. Fill the air conditioning system with the respective program from the air conditioning service centre

Visual check of the air conditioning system A

CAUTION Risk of burns during maintenance on a hot diesel engine.

Risk of burns on hot parts. ► Wait until the engine has cooled down before taking up work. ► Wear protective clothes.

The driver must perform the following visual checks once a day 1.

2.

3.

4.

5.

B Fig. 95

Stop the engine Enabling the parking brake Switch off the starter and remove the starting key Remove the protective cover Check V-belt tension B and if necessary, retighten the V-belt ➥ Press with your thumb to check whether the V-belt can be deflected between the pulleys by no more than about 10 mm (arrow) ➥ Replace defect V-belts 6. Check the hoses for tightness and chafing 7. Check the electric connections for correct condition and tightness 8. Check the level of the refrigerant ➥ With the air conditioning system switched on, the refrigerant must be visible and free of air in the sight glass A of dehumidifier ➥ If there is air in sight glass A, the system must be checked for leaks and refilled by an authorised workshop

NOTICE The air conditioning system must be checked and serviced twice a year by trained personnel in a qualified service centre! ► Replace dehumidifier A every two years

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-85

1 Maintenance

Replace the dehumidifier A

B

F C

1.

2.

3.

4.

5.

D E Fig. 96

6.

7.

8.

Stop the engine Enabling the parking brake Switch off the starter and remove the starting key Empty the air conditioning system – see “Empty the air conditioning system .” on page 1-84.

Loosen the plug-in connections of the pressure switch A on the dehumidifier C Remove the compressed air hoses B and F Loosen the screw connection D at the collar and remove the dehumidifier C Insert a new dehumidifier into the collar and screw the screw connection D tight

CAUTION There is a risk of injury should installation of the compressed air hoses at the dehumidifier not be carried out properly.

Outflowing refrigerant can cause serious frost bite or bodily injury. ► Counter movement of the connections at the dehumidifier when securing the compressed air hoses.

9. Connect compressed air hoses B and F to the dehumidifier C, countering movement of the connections as you do so 10.Insert connector E into pressure switch A 11.Filling the air conditioning system – see “Filling the air conditioning system” on page 1-84.

1-86

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Cleaning the heat exchanger (condenser) A

CAUTION Risk of burns during maintenance work on a hot diesel engine and radiator!

Risk of burns on hot parts. ► Wait at least 10 minutes after stopping the diesel engine until the air conditioning has cooled down. ► Wear protective clothes.

Clean the condenser as follows: 1.

2.

3.

4.

5.

6.

7.

8.

Fig. 97

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

•

Park the machine on level ground Lower the telescopic boom to the ground Stop the diesel engine Enabling the parking brake Switch off the starter and remove the starting key Opening the engine cover Slacken lock A on the condenser and tilt it forward Clean the condenser with compressed air or by spraying water (do not use a high-pressure cleaner) Tilt back the condenser and safely lock it A in the bracket once cleaning is over

1-87

1 Maintenance

1.19 Washer system Washer system reservoir 39

The filler neck of the store tank 39 is on the left side of the driver's cab, next to the driver's seat.

The level in the tank can be checked via inspection window A.

Information Add only clean tap water!

A

Add a suitable cleaning agent if required. In winter: add antifreeze for washer systems to the water. Refer to the antifreeze instructions for further information on concentrations – see “Fluids and lubricants” on page 1-12

Fig. 98

1-88

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

1.20 Axles/travelling drive Check/refill gear lubricant oil CAUTION Risk of burns when emptying hot gear lubricant oil!

Can cause serious injury. ► Wear protective gloves! ► Use suitable tools, e.g. to unscrew the oil drain plug!

A

1. Place the vehicle with gears at operating temperature on level ground

Fig. 99

2.

3.

4.

5.

6.

Lower the telescopic boom fully Enabling the parking brake Stop the engine Switch off the starter and remove the starting key Unscrew the oil-fill screw and check plug A and B holding a cloth underneath the opening as you do so

If the oil level is below the opening or if the oil level cannot be seen at all: B

•

Add oil until the filling orifice overflows

Environment Fig. 100

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

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

1-89

1 Maintenance Change gear oil in high speed gearbox CAUTION Risk of burns when emptying hot gear lubricant oil!

Can cause serious injury. ► Wear protective gloves! ► Use suitable tools, e.g. to unscrew the oil drain plug!

A

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

B Fig. 101

1. Park the vehicle on level ground with gears at operating temperature.

2. Lower the telescopic boom fully.

3. Apply the parking brake.

4. Stop the engine.

5. Disengage the starter and remove the starting key.

6. Place a suitable container under the gears at the rear axle.

7. Unscrew the oil-fill screw and check plug A. 8. Unscrew oil drain plug B. 9. Drain old gear oil completely.

10.Tighten the oil drain plug B with the new sealing ring and with a tightening torque of 100 ± 10 Nm.

Information If too much oil is added, it will be pushed out when travelling at speed in order to be vented!

11.Add oil to a maximum level, underneath the filling orifice (fill oil-fill screw and check plug A). ➥ Max. oil level 3.5 l oil. ➥ Min. oil level 6 mm below the filling orifice (oil-fill screw and check plug A).

12.Tighten the oil-fill screw and check plug A with new sealing ring and a tightening torque of 100 ± 10 Nm.

1-90

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Change the gear oil in a high speed gear box with four-wheel cut-off (opt.)

CAUTION Risk of burns when emptying hot gear lubricant oil!

Can cause serious injury. ► Wear protective gloves! ► Use suitable tools, e.g. to unscrew the oil drain plug!

A

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

1.

2.

3.

4.

5.

6.

7.

Park the vehicle on level ground with gears at operating temperature.

Lower the telescopic boom fully.

Apply the parking brake.

Stop the engine.

Disengage the starter and remove the starting key.

Place a suitable container under the four-wheel cut-off at the rear axle.

Unscrew the oil-fill screw and check plug A at the high speed gear box and the oil-fill screw and check plug C at the four-wheel cut-off.

B Fig. 102

8. Remove the oil drain plug B at the high speed gear box and the oil drain screw D at the four-wheel cut-off.

9. Drain old gear oil completely.

10.Tighten oil drain plugs B and D with new sealing rings and a tightening torque of 100 ± 10 Nm. C

Information If too much oil is added, it will be pushed out when travelling at speed in order to be vented!

D

11.Add oil to a maximum level, underneath the filling orifice (fill oil-fill screw and check plug A). ➥ Max. oil level 4.2 l oil. ➥ Min. oil level 6 mm below the filling orifice (oil-fill screw and check plug A).

12.Tighten the oil-fill screws and check plugs A and B with new sealing rings and a tightening torque of 100 ± 10 Nm.

Fig. 103

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-91

1 Maintenance

Check/refill oil at differential (rear axle) 1. Place the vehicle with differential at operating temperature on level ground 2. Clean and unscrew screw A , holding a cloth underneath the opening as you do so.

If the oil level is below the opening or if the oil level cannot be seen at all: • • A

Add fresh oil through opening A until it runs out of the filler opening Tighten plug A with a new sealing ring to make an oil-tight seal

If the oil level is correct: •

Tighten plug A with a new sealing ring to make an oil-tight seal

Fig. 104

Oil change on the differential (rear axle) CAUTION Risk of burns when emptying hot gear lubricant oil!

Can cause serious injury. ► Wear protective gloves! ► Use suitable tools, e.g. to unscrew the oil drain plug!

A

B Fig. 105

1. Place the vehicle with differential at operating temperature on level ground 2. Lower the telescopic boom fully 3. Enabling the parking brake 4. Stop the engine 5. Switch off the starter and remove the starting key 6. Place a suitable container under the differential at the rear axle.

7. Clean and unscrew plug A 8. Unscrew oil drain plug B 9. Completely drain the old gearbox oil 10.Tighten drain plug B with a new sealing ring to make an oil-tight seal 11.Fill in oil through opening A until it runs out If the oil level in the differential remains constant: •

Tighten plug A with a new sealing ring to make an oil-tight seal

After performing a test run: •

Check the oil level again after about 5 minutes, and add oil if necessary

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

1-92

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Maintenance 1

Check/refill oil in differential (front axle) 1. Place the vehicle with differential at operating temperature on level ground 2. Clean and unscrew screw A , holding a cloth underneath the opening as you do so.

If the oil level is below the opening or if the oil level cannot be seen at all: • • A

Add fresh oil through opening A until it runs out of the filler opening Tighten plug A with a new sealing ring to make an oil-tight seal

If the oil level is correct: •

Tighten plug A with a new sealing ring to make an oil-tight seal

Fig. 106

Oil change on the differential (front axle) CAUTION Risk of burns when emptying hot gear lubricant oil!

Can cause serious injury. ► Wear protective gloves! ► Use suitable tools, e.g. to unscrew the oil drain plug!

A

B Fig. 107

1. Place the vehicle with differential at operating temperature on level ground 2. Lower the telescopic boom fully 3. Enabling the parking brake 4. Stop the engine 5. Switch off the starter and remove the starting key 6. Place a suitable container under the differential at the front axle.

7. Clean and unscrew oil filler and inspection plug A 8. Unscrew oil drain plug B 9. Completely drain the old gearbox oil 10.Tighten drain plug B with a new sealing ring to make an oil-tight seal 11.Fill in oil through opening A until it runs out If the oil level in the differential remains constant: •

Tighten plug A with a new sealing ring to make an oil-tight seal

After performing a test run: •

Check the oil level again after about 5 minutes, and add oil if necessary

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

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1-93

1 Maintenance

Check/refill oil in planetary gearing NOTICE Fit new sealing rings! Drain oil only after running the machine for a longer period of time!

A

1.

2.

3.

4.

5.

6.

7.

8.

9.

Fig. 108

Park the vehicle, at operating temperature, on level ground.

Lower the telescopic boom fully Enabling the parking brake Stop the engine Switch off the starter and remove the starting key Place a suitable container under drain plug A Position the screw A as shown Fig. 108 (the screw must be at the top) Clean and unscrew plug A (to release possible overpressure) Position the opening A as shown Fig. 109 (the opening must be horizontal)

If the oil level is below the opening or if the oil level cannot be seen at all: 10.Add fresh oil through opening A until it runs out of the filler opening 11.Tighten plug A with a new sealing ring to make an oil-tight seal

A Fig. 109

1-94

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

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Oil change on the planetary drives CAUTION Risk of burns when emptying hot gear lubricant oil!

A

Can cause serious injury. ► Wear protective gloves! ► Use suitable tools, e.g. to unscrew the oil drain plug!

1. Park the vehicle, at operating temperature, on level ground.

2. Lower the telescopic boom fully Fig. 110

3.

4.

5.

6.

7.

8.

Enabling the parking brake Stop the engine Switch off the starter and remove the starting key Place a suitable container under drain plug A Position the screw A as shown Fig. 110 (the screw must be at the top) Clean and unscrew plug A (to release possible overpressure)

Never raise the machine on one side only for the following work!

A Fig. 111

9. Turn the planetary drive downward (plug must be at the bottom) 10.Remove plug A 11.Completely drain the old oil 12.Position the opening A as shown Fig. 111 (the opening must be horizontal) 13.Add fresh oil through opening A until it runs out of the filler opening 14.Tighten plug A with a new sealing ring to make an oil-tight seal

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

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-95

1 Maintenance

1.21 Maintenance of the brake system Important safety instructions regarding the braking system The brakes are a safety part of the first level; improper maintenance can cause the brakes to fail. Therefore all maintenance and repair work on the brakes must be performed by trained personnel.

An exception to this is the following work that must be performed by the operator: •

Daily check of the brake lines

WARNING Malfunctioning brake lines or hoses carry an accident hazard!

Can cause serious injury or death. ► Defect brake lines or hoses have to be replaced immediately

Bleeding the service brake Bleeding the service brake on the rear axle 1. Connect the bleed container C and hose B to the bleed valve A of the right rear axle 2. Start the diesel engine and let it run at idling speed 3. Press down the brake pedal and open the bleed valve with an open-end wrench SW 7 4. Press the brake pedal until there is no more air in the bleed hose 5. Close the bleed valve with the open-end wrench SW 7 6. Repeat steps 1 – 5 on the left side of the rear axle

A

C

B

Fig. 112

Bleeding the service brake on the front axle

A

C

B

1. Connect the bleed container C and hose B to the bleed valve A of the right front axle - The outside bleeder valves are for the service brake 2. Press down the brake pedal and open the bleed valve with an open-end wrench SW 7 3. Press the brake pedal until there is no more air in the bleed hose 4. Close the bleed valve with the open-end wrench SW 7 5. Repeat steps 1 - 4 on the left side of the rear axle

Fig. 113

1-96

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1 Bleeding the parking brake Bleeding the parking brake on the front axle

A

B C Fig. 114

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1. Connect the bleed container C and hose B to the bleed valve A of the right front axle - The inside bleeder valves are for the parking brake 2. Release the parking brake at switch S011 3. Open the bleed valve with an open-end wrench SW 7 until no more air bubbles can be seen at the bleed hose 4. Close the bleed valve with the open-end wrench SW 7 5. Repeat steps 1 - 4 on the left side of the front axle 6. Carry out a brake test. Repeat the procedure and bleed the brake system again if the braking effect is bad.

1-97

1 Maintenance

1.22 Maintenance of compressed-air brake system (option) Compressed-air tank and lines The compressed-air brake is a safety part; improper maintenance can cause it to fail. Therefore all maintenance and repair work on the compressed air brakes must be performed by trained personnel.

An exception to this is the following work that must be performed by the operator: •

Check once a day: - For leaks (sound of escaping air) - For damage (compressed-air lines, tank, compressor and valves) - Have leaky hose and screw connections repaired by an authorised workshop - The water in the pressure accumulator is automatically drained

WARNING Malfunctioning brake and compressed-air lines constitute an accident hazard!

Can cause serious injury or death. ► Defect brake and compressed air lines have to be repaired immediately

1-98

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

1.23 Tyres Important information on the tires WARNING Accident hazard if wheels are used that have not been released for the machine!

Can result in fatal or serious injury. ► Install only released tyres/wheels ► Change the wheel

WARNING Danger of crushing when raising the machine.

Can result in fatal or serious injury. ► Park the vehicle on level, horizontal and stable ground ► Use suitable lifting gear under all circumstances with a corresponding lift capacity. ► Use one or more trestles instead of a jack to stabilise the machine ► Never start the engine if the machine is on trestles or if it is raised with a jack.

Information Repair operations to tyres and rims must be carried out by trained personnel.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-99

1 Maintenance

Tire check WARNING Tires risk bursting during inflation!

Risk of serious or fatal injury. ► Wear gloves and safety glasses. ► Check the tyres and rims for damage before inflating the tyres ► Stay clear of the tires when checking the inflation pressure and/or inflating the tires. ► Observe the prescribed inflation pressure

Activities that have to be performed by the driver / operator • • • • • •

1-100

Check the tyre pressure once a day Check tyres and rims for damage (cracks, ageing, etc.)

– also on the inside Remove foreign bodies from the tire tread Remove traces of oil and grease from the tires Changing wheels Check the wheel nuts for correct seating and retighten them if necessary

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Changing wheels Remove the wheels as follows: 1. Park the machine on level and firm ground and prevent it from rolling away 2. Lower the telescopic boom to the ground 3. Enabling the parking brake 4. Stop the engine and switch off the ignition 5. Loosen the wheel nuts a little of the wheel you want to remove 6. Place a jack under the axle body, making sure it is standing firmly 7. Raise the side of the axle from which you want to remove the wheel 8. Secure the raised axle with a suitable trestle

NOTICE The trestle must be positioned so as to avoid machine damage.

9. Completely remove the wheel nuts 10.Remove the wheel with a suitable means Fit the wheels as follows:

NOTICE The threads on the wheel bolts can be damaged when fitting the heavy wheels! ► Use suitable assembly tools, such as covering sleeves for the wheel bolts 1.

2.

3.

4.

5.

6.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Place the covering sleeves onto the wheel bolts Place the wheel onto the wheel bolts with a suitable means Remove the covering sleeves Fit all the wheel nuts and tighten them part-way Lower the raised axle Tighten the wheel nuts to the specified tightening torque

1-101

1 Maintenance

1.24 Maintenance and care of attachment devices Correct maintenance and servicing is absolutely necessary for smooth and continuous operation, and for an increased service life of the attachments. Observe the lubrication and maintenance instructions in the Operator’s Manuals of the attachments!

1-102

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

1.25 Maintenance of options Automatic trailer coupling (option) Cleaning and lubricating the trailer coupling

NOTICE In order to ensure the full functionality of the trailer coupling, close the coupling pin in the trailer coupling before cleaning with high-pressure cleaning equipment!

Clean as follows: 1. Close the trailer coupling 2. After cleaning, apply tough waterproof grease (EP3) to the coupling pin, the base ring and the drawbar eye 3. Apply tough waterproof grease (EP3) to the lower bearing of the coupling jaw 4. Apply grease to the grease nipple on the joint Check the trailer coupling for wear A 3.0 mm

WARNING Risk of accidents in case of worn coupling pins, too much play in the bearing or a worn base ring

2.5 mm

36.5 mm

Can cause injury. ► Check the trailer coupling once a day for wear and play

B

► Apply grease to the base ring ► Replace a malfunctioning trailer coupling with a new one

36.5 mm Checking the bearing and longitudinal play A of the coupling head

C

•

Move the uncoupled coupling head with force in travel direction

Checking the height-wise play of the coupling head 2.5 mm

D

7 mm

E

• •

Checking the coupling pin C/D •

Fig. 115:

•

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Open the coupling Move the coupling head up and down with a suitable tool (mounting lever) ➥ Play A in the centre axis of the coupling head = max. 3 mm Measure wear by means of a slide gauge on the thickest section of the coupling pin C ➥ Diameter C may not drop below 36.5 mm ➥ Height-wise play B max. 2.5 mm Check pin play D in the base ring and thickness E of the base ring ➥ Pin play max. 2.5 mm ➥ Thickness of base ring min. 7 mm

1-103

1 Maintenance

Ball trailer coupling ø 80 mm (option) Cleaning and lubricating the trailer coupling

A

Fig. 116

Information Maintenance intervals – see “Maintenance plan” on page 1-6.

Specifications and fill quantities – see chapter 1 “1.5 Fluids and lubricants” on page 1-12.

1. After cleaning, apply tough waterproof grease (EP3) to trailer ball A and the trailer cap.

2. Apply grease to the grease nipple under the trailer ball.

3. Lubricate all moving parts of the height adjustment.

Autohitch trailer coupling (option) Cleaning and lubricating the trailer coupling

Information Maintenance intervals – see “Maintenance plan” on page 1-6.

Specifications and fill quantities – see chapter 1 “1.5 Fluids and lubricants” on page 1-12.

1. Apply grease to the grease nipple.

2. Lubricate all moving parts of the Autohitch.

Fig. 117

1-104

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

1.26 Exhaust gas treatment Important information on the diesel particulate filter If the indicator light 58 starts to flash and the warning light 57 turns on, the diesel particulate filter has to be regenerated.

56

The soot is burnt at higher engine speed in the diesel particulate filter.

The exhaust gas reaches a temperature of 600 °C at the exhaust outlet during this process.

%

WARNING The diesel particulate filter gets very hot, fire and burn hazard!

Can cause serious injury.

Fig. 118

58

57

► Keep your hands clear of the exhaust outlet! ► During machine operation, ensure that there is no easily flammable material in the immediate vicinity of the exhaust system, in particular near the exhaust pipe! ► When stopping the machine while the engine is running, ensure that there is no flammable or combustible material in the immediate vicinity of the exhaust opening (for example paper, dry grass, straw, wood, wood ceilings, oil, fuel, etc.). ► Do not park the machine in high dry grass or straw. ► Never use corrosion-protection agents for exhaust pipes, heat shields or the diesel particulate filter. They can catch fire if the engine is hot.

Information Maintenance intervals – see “Maintenance plan” on page 1-6.

For a successful regeneration of the diesel particulate filter, the following conditions must be fulfilled: • • • • • •

Required time is about 30 minutes.

The machine cannot be used during this time.

Engine coolant at least 70 °C. Park the machine on firm, non-flammable ground.

The machine must not move during regeneration.

Apply the parking brake.

Lock the operating hydraulics.

Information If these conditions are not fulfilled, regeneration cannot be performed or is interrupted, and must be performed again.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-105

1 Maintenance

Regenerating the diesel particulate filter

56

1.

2.

3.

4.

%

Run the machine warm (at least 70 °C).

Operate the parking brake 42.

Activate the joystick lock 113.

Operate the 118 Regeneration button.

Regeneration operation ON

58

57

Press 118 button to Symbol A

Abortion Press 118 button again

Function ➥ Warning light 58 (DPF) turns on. ➥ Engine speed is increased. ➥ Warning light 58 is flashing quickly. ➥ Warning light 57 is on. ➥ Reduction of output

Information A

Regeneration must be performed again if it is aborted.

118 Fig. 119

Regeneration has finished successfully if:

56

• • • •

%

Engine speed is reduced to idling speed, the warning light 58 (DPF) turns off, the warning light 57 turns off, and the information display 56 indicates a (DPF) 0% load (ideal value when new).

Information 58 Fig. 120

1-106

57

During its entire life span, the DPF also collects ashes that are not removed by regeneration. Accumulation of ash results in shorter regeneration intervals, and replacing the filter during maintenance then becomes necessary – see chapter 1 “ Cleaning/replacing the diesel particulate filter” on page 1-107.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1

Cleaning/replacing the diesel particulate filter During its entire life span, the DPF also collects ashes that are not removed by regeneration. Accumulation of ash results in shorter regeneration intervals, and replacing the filter then becomes necessary.

Information Maintenance intervals – see “Maintenance plan” on page 1-6.

The diesel particulate filter has to be cleaned and, if necessary, replaced by a service centre when the accumulation of ash reaches 100 % at the latest.

Perform regeneration when the indicator lights illuminate – see “Important information on the diesel particulate filter” on page 1-105.

Information Repair work to the diesel particulate filter may only be carried out at specialist workshops authorised by Deutz and by trained personnel.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-107

1 Maintenance

1.27 Machine preservation Important notice on anticorrosion protection The machine is specially protected against corrosion for work in aggressive media (for example in a saline environment).

However, this anticorrosion protection is affected by external factors, for example dirt, cleaning, etc. This is why it only has ongoing effect if checked at regular intervals and renewed or reapplied as required.

If no anticorrosion protection is applied to the machine, for example for work in a saline environment, we recommend retrofitting your machine with the “Aggressive Media” option by a sales partner.

The following anticorrosive wax has been used in the factory: Designation:

ANTICORIT BW 366

Manufacturer:

FUCHS MINERALOELWERKE GMBH/Mannheim

Specification:

TI 8030-015/K 19/MIL-C-16 173 C-Grade 4

Components coated with anticorrosive wax Component

Remarks

All electric plug-and-socket, grounding and crimp connections

Before applying the wax: • Apply contact spray to contact surfaces and connect the plug-and-socket connections again.

• Apply a particularly thick anticorrosion layer to the connecting parts of the fuel level transmitter.

All parts of the machine, for example Axles, gearbox, trim panels, servicing lids, loader unit, quickhitch

Except: • Piston rods (chromium coating) • Cabin, cabin bearings • Engine cover, engine mounting • Air filter • Counterweight • Fastening surfaces for installing parts on chassis • Radiator and insulating mat • Mudguards, rubber and plastic parts • Light elements

Flange surfaces for example axles, diesel engine and cabin bearing: • Seal gaps with anticorrosion wax after assembly

1-108

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Maintenance 1 Measures for maintaining anticorrosive protection WARNING Special hazards during anticorrosion protection!

Can cause serious injury or death. ► When handling chemical substances of any kind, such as solvents, wax, etc., observe the specific product-related safety regulations (safety data sheet)! ► Ensure appropriate room ventilation! ► Do not use unprotected lights or open flames! ► Do not smoke! ► Corrosion on electric connections or components can cause hazardous operating malfunctions. ► Perform work on the electrical system only with the battery disconnected and the diesel engine stopped!

Information Maintenance intervals – see “Maintenance plan” on page 1-6.

Specifications and fill quantities – see chapter 1 “1.5 Fluids and lubricants” on page 1-12.

Cleaning •

• • •

If the machine is used in corrosive environment over a longer period of time, remove the floor mat in the cabin to avoid the accumulation of corrosive humidity.

Thoroughly clean machines that are put out of operation over a longer period of time.

Clean the machine at least once a week. In particular, remove corrosive deposits (such as salt crusts) as fast as possible.

Clean the machine with cold running water preferably.

NOTICE Contrary to the instructions given in Chapter “General maintenance” in the Operator’s Manual of the machine, neither clean the machine with a bristle brush nor with a steam jet or a high-pressure cleaner! ► If cleaning the machine with these means cannot be avoided, check the wax coating very carefully and have it renewed or reapplied as required.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

1-109

1 Maintenance

Applying the protective anticorrosion coating Bear in mind the following instructions as you apply the anticorrosive wax:

Information Carefully cover all fastening surfaces and elements to which the anticorrosive protection may not be applied – see “Components coated with anticorrosive wax” on page 1-108!

• • • •

ANTICORIT BW 366 can be applied with a brush, by means of immersion or with all commercially available spray guns.

ANTICORIT BW 366 protective coating can be removed with petrol, RENOCLEAN E/K or FUCHS MULTICLEAN as required.

ANTICORIT BW 366 spots are difficult to remove on clothing.

Affix a “Wet paint!” or a similar sign to newly coated machines.

Treatment of oxidised surfaces If in spite of all precautionary measures some components should be affected by corrosion (oxidised), treat the oxidised area follows: Electric connections • • • • •

Remove the remaining protective wax in the oxidised area with petrol, RENOCLEAN E/K or FUCHS MULTICLEAN. Treat the affected area with an oxide solvent, such as KONTAKT 60, and rinse it with KONTAKT WL, for example.

Treat the contact surfaces of the connection with KONTAKTSPRAY WD 40, for example.

Establish the connection.

Apply/spray anticorrosion wax onto the electric connection from all sides.

Sheet-metal parts • •

• •

1-110

Remove the remaining protective wax in the oxidised area with petrol, RENOCLEAN E/K or FUCHS MULTICLEAN. Remove all remaining corrosion and paint coating from the affected area down to the bare material, otherwise the paint coating will not adhere properly!

Clean the affected area with a cleaning solvent, and then apply a 2-component prime coating and a 2-component paint coating to it.

Then preserve the area with anticorrosion wax.

RHB 416-06 * 1.0 * 41605_R_1_Wartung_a4.fm

Engine

2Engine

2 Engine

2.1

Technical data

Designation Operating principle Charging Type of cooling Cylinder arrangement Number of cylinders Hole/Stroke Total displacement

TCD 4.1 L4 Four-stroke diesel engine Exhaust turbocharger with charge air cooling Water-cooled in rows 4 101/126

mm

4038

cm3

Combustion process

Direct fuel injection

Fuel injection system

Common Rail

Exhaust-gas treatment Valves per cylinder Engine ignition order Direction of rotation in terms of flywheel

Diesel particulate filter DPF 2 1–3–4–2 Left

Motor capacity in accordance with ISO 3046 Rotational speed (rated speed)

kW see motor type plate

Injection time Quantity of coolant (only engine content without cooler/hoses and tubes) Industrial engines/agricultural technology Permitted permanent coolant temperature Difference in temperature between coolant inlet and outlet

2-2

min-1 °BTDC l

About 5,9/5,0 max. 110

°C

4-8

°C

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

Engine 2 Designation

TCD 4.1 L4

Thermostat starts to open Thermostat fully opened Quantity of lubricant oil for replacement (with filter)

1

Maximum lube oil temperature in the lube oil sump Minimum lube oil pressure (low idling speed, engine warm) Maximum permitted combustion air temperature after charge air cooler V-belt tension V-belt AVX 13 (width: 13 mm) Poly-V-belt tension Weight excl. cooling system as per DIN 70020-A 1.

86

°C

102

°C

About 15,5 125 80/0,8

l °C kPa/bar

50

°C

Pretensioning/Retensioning 650±50/400±50

N

Automatic spring-loaded tensioning roller About 400

kg

The specified fill quantities for lube oil apply to standard models. With engines that deviate from the standard, for example, engines with different lube oil sumps/ lube oil level gauges and/or special angled models, the lube oil fill quantity may vary. The basis is always the lube oil gauge level.

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

2-3

2 Engine

2.2

Complete engine

Disassemble complete engine WARNING Risk of injury lifting heavy components.

Death or serious injuries. ► Use lifting tackle with a sufficient bearing load ► Use functionally-safe lifting tackle ► Use the lifting tackle on firm and level ground ► Move the lifting tackle to predefined or suitable position on the component

Preparatory steps 1. Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3.

2. Drain coolant Draining/replacing coolant on page 1-57 Remove the engine cover 1.

2.

3.

4.

5.

6.

7.

A

B

C

D

Open the engine cover.

Remove a screw D respectively from both hinges (socket 13 mm).

Pull out the safety clips B. Have 2nd person hold the front lid of the engine in position.

Disconnect the attenuator A from the holding device C. Remove the second screw E respectively from both hinges (socket 13 mm).

Remove the front lid of the engine with 2 people.

E

Fig. 121

Remove the V-belt cover A

1. Remove 3 Allen head screws A (Allen key SW17).

2. Take off the V-belt cover B.

B

A

A Fig. 122

2-4

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

Engine 2 Dismount hoses and cables

A

1. Loosen the screws at both collars B (socket 10).

2. Remove hose A at the combustion air inlet and at the charge air cooler.

3. Close the opening to the combustion air inlet.

B

B Fig. 123

4.

5.

6.

7.

A B

Remove the cable A from the connections at the hose.

Loosen the screws at both collars B (socket 10).

Remove the hose C from the air filter and the exhaust turbocharger.

Close the opening at the exhaust turbocharger.

C

Fig. 124

8. Remove nut B (socket 8).

9. Remove white cable A from connection (D+) of the generator E. 10.Remove nut C (socket 13).

11.Remove red cable D from connection (B+) of the generator E.

A B D C

E Fig. 125

A D

Dismount exhaust B C

1.

2.

3.

4.

Open the cable tie C. Unplug cable B. Remove screws D (Allen key SW3).

Remove connection A.

B

C

Fig. 126

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

2-5

2 Engine 5. Remove screws A (socket 13).

6. Remove sheet B. A

B

Fig. 127

7. Disconnect cables A and B from the motor control.

A B

Fig. 128

Information A B

C

There is a sealing ring between the exhaust silencer A and the exhaust hose C. During disassembly make sure that the sealing ring does not drop down and get lost.

8. Unscrew the Allen head screw B on the collar D (Allen key SW6).

9. Remove the exhaust hose C from the exhaust silencer A. 10.Remove the sealing ring.

D

Fig. 129

11.Unscrew the Allen head screw C from the collar B (Allen key SW8).

12.Take out the exhaust silencer A.

A B

C

Fig. 130

2-6

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

Engine 2 Dismount the exhaust turbocharger hose

A

1. Unscrew Allen head screw C from collar B (Allen key SW5).

2. Remove the exhaust turbo-charge hose D from the exhaust turbocharger A.

B

C

D

Fig. 131

A

Remove V-belt

B

1. Remove screw E from belt tightener D (socket 10).

2. Remove screw C from belt tightener D (socket 13).

3. Remove screw F from the coolant compressor B (SW17 and counter movement with the Allen key SW8).

4. Remove V-belt A.

C

D E

F Fig. 132

Dismantle cable holder A

E

1. Remove screw C (SW13).

2. Take off support D. 3. Remove screw A from the cable B on the motor starter E (SW15).

B

D

C

A

B Fig. 133

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

2-7

2 Engine Dismantle the coolant hoses 1. Remove the screws A and D on the coolant hoses B and C (Allen key SW10).

2. Open the O-clip E on the coolant hose F. 3. Remove the coolant hoses B, C andF.

A B

F E

C D Fig. 134

Dismantling the fuel and heating lines

A

D

1.

2.

3.

4.

5.

Unscrew the screws on the fuel lines A and D (SW27).

Detach the fuel lines and close them with screw terminals.

Unscrew the screws on the heating lines C and B (SW32).

Detach the heating lines and close them with screw terminals.

Close all open connections.

B C

Fig. 135

Dismantle the engine cover lock

A

1. Remove the screws B and C from the support A (SW17).

2. Remove support A.

B C

Fig. 136

Dismantle cable holder A

1. Remove screw B (SW19).

2. Remove support A.

B

Fig. 137

2-8

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

Engine 2 Separate motor from pump unit

B

A

D

1. Secure the pump unit A in its mounted position, using a tension belt B to attach it to the vehicle frame E. 2. Remove the screws C and the ground strap D (Allen key SW8).

C

B

E

Fig. 138

Remove the motor from the engine vat 1. Attach suitable hoisting gear to the prespecified places A. 2. Loosen the screws on the motor bearings B (socket 19).

3. Lift out motor with hoisting gear.

A A

B Fig. 139

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

2-9

2 Engine

Install complete motor WARNING Risk of injury lifting heavy components.

Death or serious injuries. ► Use lifting tackle with a sufficient bearing load ► Use functionally-safe lifting tackle ► Use the lifting tackle on firm and level ground ► Move the lifting tackle to predefined or suitable position on the component Install motor in engine vat 1. Attach suitable hoisting gear to the prespecified places A. 2. Lift motor into the engine vat using the hoisting gear.

3. Screw the screws on the motor bearings B into place (socket 19).

Tighten screws with 79 Nm.

A A

B Fig. 140

Attach motor to pump unit

B

A

D

1. Attach the screws C and ground strap D (Allen key SW8).

Tighten screws with 46 Nm. 2. Remove the tension belt B from the pump unit A and the vehicle frame E.

C

B

E

Fig. 141

2-10

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

Engine 2 Attach the cable holders A

1. Position support A. 2. Screw the screw B into position (SW19). Tighten screw with 79 Nm.

B

Fig. 142

Install engine cover lock 1. Position support A. 2. Use the screws B and C to screw the support A into position (SW17).

A

B C

Fig. 143

Install fuel and heating lines

A

D

1. Open all closed connections.

2. Remove the screw terminals from the heating lines.

3. Attach the heating lines C and B (SW32).

Tighten sleeve nut C with 70 Nm and sleeve nut B with 50 Nm. 4. Remove the screw terminals from the fuel lines.

5. Screw the fuel lines A and D into position (SW27).

Tighten the sleeve nuts with 70 Nm.

B C

Fig. 144

Mount the coolant hoses A F

B

1. Insert the coolant hoses B, C and F .

2. Clamp the collar E to the coolant hose F. 3. Secure the coolant hoses B and C with collars A and D (Allen key SW10).

E

C D Fig. 145

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

2-11

2 Engine Attach the cable holders A

E

1. Use screw A to secure cable B to the motor starter E (SW15).

2. Screw holder D into position with screw C (SW13).

B

D

C

A

B Fig. 146

A

Tensioning the V-belts

B C

D E

F

1. Position the toothed belt A. 2. Use screw F to secure the coolant compressor B, but do not tighten the screw F (SW17 and Allen key SW8 are used to counter the movement).

3. Use screw E to screw into the belt tightener D (socket 10).

4. Use screw C to screw into belt tightener D (socket 13).

5. Tighten toothed belt.

6. Tighten screws C, E, F .

Fig. 147

Mount exhaust turbocharger hose

A B

C

1. Insert the exhaust turbocharger hose D into the exhaust turbocharger A. 2. Tighten the Allen head screw C on the collar B (Allen key SW5).

D

Fig. 148

2-12

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

Engine 2 Mount the exhaust

A

1. Insert the exhaust silencer A between the collars B .

2. Tighten the Allen head screw C on the collar B with 18 Nm (Allen key SW8).

B

C

Fig. 149

A B

C

3. Insert sealing ring between exhaust silencer A and the exhaust hose C. 4. Attach the exhaust hose C to the exhaust silencer A. 5. Tighten the Allen head screw B on the collar D (Allen key SW6).

D

Fig. 150

6. Connect cables A and B to motor control.

A B

Fig. 151

7. Screw sheet B into position with screws A (socket 13).

A

B

Fig. 152

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

2-13

2 Engine

A

8. Screw connection A into place with screws D (Allen key SW3).

9. Connect cable B and secure with cable clips C .

B

D

C B

C

Fig. 153

Install the air filter

A

1. Secure the holder B with mounted air filter A into position using the screws C to do so (socket 13).

B

C Fig. 154

2. Secure the holder A with mounted control panel C using the nuts A to do so (socket 13).

A

C

B

A Fig. 155

3. Place cable A in collar C. 4. Tighten nut B.

C

A B

Fig. 156

2-14

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

Engine 2 Install the hoses and cables A B D

1. Screw the white cable A to the connection (D+) on the generator E using nut B to do so (socket 8).

2. Screw the red cable D to the connection (B+) on the generator E using nut C to do so (socket 13).

C

E Fig. 157

3.

4.

5.

6.

A B

Remove the cover on the exhaust turbocharger.

Connect the hose C to the air filter and exhaust turbocharger.

Tighten the screws on both collars B (socket 10).

Connect cable A to the connections on the hose.

C

Fig. 158

7. Connect the charge air cooler hose A to the combustion air inlet and to the charge air cooler.

8. Tighten the screws on both collars B (socket 10).

A

B

B Fig. 159

Mount the V-belt cover A

1. Position the V-belt cover B. 2. Tighten the 3 Allen head screws A (Allen key SW17)

B

A

A Fig. 160

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

2-15

2 Engine Install the engine cover 1. Position the engine lid, taking 2 people to do so.

2. Screw one screw each to both hinges D (socket 13).

3. Insert the attenuator A into the holding device C and then add the safety clips B. 4. Screw the second screw respectively into both hinges E (socket 13).

5. Close the engine cover.

A

Next steps B Fig. 161

2-16

C

D

E

1. Fill coolant – see “Adding coolant” on page 1-56.

2. Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3.

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

Engine 2

2.3

Alternator

Dismount alternator Preparatory steps A

Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3

B

Remove the V-belt cover

A

1. Remove 3 Allen head screws A (Allen key SW17).

2. Take off the V-belt cover B.

A Fig. 162

Remove flat belt A

1.

2.

3.

4.

5.

D

Loosen sleeve nut A (SW27).

Remove fuel line C and seal with filler plug (15L).

Close open connection on diesel feed pump with filler plugs (15L).

Push down the belt tightener pulley B. Remove flat belt D.

C

B Fig. 163

A

Dismantle electric lines B

C

F

E

1.

2.

3.

4.

Remove nut B (socket 8).

Disconnect cable A from connection (D+) on generator D. Remove nut E (socket 13).

Remove the red D and black cable F from connection (B+) of the generator D.

D

Fig. 164

Dismantle the generator

A

B

1.

2.

3.

4.

Remove screws B (socket 17).

Remove generator A. Remove nuts C. Remove roller D.

C D

B Fig. 165

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

2-17

2 Engine

Install the generator Mount the generator

A

B

1.

2.

3.

4.

Position the roller D. Tighten nuts C. Position generator A. Tighten screws B (socket 17).

C D

B Fig. 166

A

Mount the electric lines B

C

F

E

1. Screw cable A to connection (D+) on the generator D with nuts B (socket 8).

2. Screw the red C and black cables F to connection (B+) on the generator D with nuts E (socket 13).

D

Fig. 167

Position the flat belt A

1.

2.

3.

4.

5.

D

Push down the belt tightener pulley B. Put the flat belt D into position.

Remove the filler plugs on the diesel conveyor pump.

Remove the filler plugs on the fuel line C and put it into position.

Tighten the sleeve nut A (SW27).

C

B Fig. 168

Mount the V-belt cover A

1. Position the V-belt cover B. 2. Tighten the 3 Allen head screws A (Allen key SW17).

B

A

Next steps Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3.

A Fig. 169

2-18

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

Engine 2

2.4

Fuel sensor

Dismantle the tank sensor Preparatory steps Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3 Remove cover 1. Open the flap behind the driver's seat.

2. Remove cover A.

A

Fig. 170

Dismantle the tank sensor A

C

1.

2.

3.

4.

Pull out cable B. Disconnect the connector C. Loosen the nut A on the tank sensor (SW32).

Pull out the tank sensor.

B

Fig. 171

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

2-19

2 Engine

Install the tank sensor Mount the tank sensor A

1.

2.

3.

4.

Insert the tank sensor.

Loosen the nut A on the tank sensor (SW32).

Connect the connector C. Push the cable B into the opening.

B

C

Fig. 172

Close cover 1. Close cover A. 2. Close flap behind the driver's seat.

Next steps A

Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3.

Fig. 173

2-20

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

Engine 2

2.5

Accelerator pedal

Dismantle accelerator pedal 1. Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3.

2. Remove foot mat.

3. Remove Allen head screws A (AF3).

4. Remover cover B from over the accelerator pedal C.

A

C

B

Fig. 174

5. Disconnect the connector A. 6. Remove screws B (SW3).

7. Remove accelerator pedal C. A

B

C

B Fig. 175

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

2-21

2 Engine

Install accelerator pedal 1. Position gas pedal C. 2. Tighten screws B (SW3).

3. Plug in connector A. A

B

C

B Fig. 176

4.

5.

6.

7.

Position cover B over the accelerator pedal C. Tighten the Allen head screws A (AF3).

Place the foot mat on the floor of the driver's cab.

Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3.

8. Calibrate the accelerator pedal with CDS.

A

B

C

Fig. 177

2-22

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

Engine 2

2.6

Starter

Dismount the motor starter Preparatory steps A

Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3.

B

Remove the V-belt cover

A

1. Remove 3 Allen head screws A (Allen key SW17).

2. Take off the V-belt cover B.

A Fig. 178

A

Remove V-belt

B

1. Remove screw E from belt tightener D (socket 10).

2. Remove screw C from belt tightener D (socket 13).

3. Remove screw F from the coolant compressor B (SW17 and counter movement with the Allen key SW8).

4. Remove V-belt A.

C

D E

F Fig. 179

Dismount the motor starter A B

1. Remove screw C from cable holder B (SW13).

2. Remove screw A from motor starter D (socket 10).

3. Remove cable B.

C

D

Fig. 180

4. Remove the 3 screws A on the motor starter B (socket 13).

5. Take out motor starter B.

A

B

Fig. 181

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

2-23

2 Engine

Install motor starter Mount motor starter 1. Position the motor starter B. 2. Tighten the 3 screws A on the motor starter B (socket 13).

A

B

Fig. 182

3. Position cable B. 4. Tighten screw A on motor starter D (socket 10).

5. Tighten screw C on cable holder B (SW13).

A B

C

D

Fig. 183

A

Tensioning the V-belts

B C

D E

F

1. Position the toothed belt A. 2. Use screw F to secure the coolant compressor B, but do not tighten the screw F (SW17 and Allen key SW8 are used to counter the movement).

3. Use screw E to screw into the belt tightener D (socket 10).

4. Use screw C to screw into belt tightener D (socket 13).

5. Tighten toothed belt.

6. Tighten screws C, E, F .

Fig. 184

Mount the V-belt cover A

1. Position the V-belt cover B. 2. Tighten the 3 Allen head screws A (Allen key SW17)

B

A

Next steps Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3.

A Fig. 185

2-24

RHB 416-06 * 1.0 * 41605_R_2_Motor_a4.fm

Cooling

3 Cooling

3 Cooling

3.1

Radiator

Dismantle radiator WARNING Risk of injury lifting heavy components.

Death or serious injuries. ► Use lifting tackle with a sufficient bearing load ► Use functionally-safe lifting tackle ► Use the lifting tackle on firm and level ground ► Move the lifting tackle to predefined or suitable position on the component

Preparatory steps 1. Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3.

2. Drain coolant or Draining/replacing coolant on page 1-57.

Remove the engine cover 1.

2.

3.

4.

5.

6.

7.

A

B

C

D

Open the engine cover.

Remove a screw from each hinge D (socket 13).

Pull out the safety clips B. Have 2nd person hold the front lid of the engine in position.

Disconnect the attenuator A from the holding device C. Remove the second screw on both hinges E (socket 13).

Remove the front lid of the engine with 2 people.

E

Fig. 186

3-2

RHB 416-06 * 1.0 * 41605_R_3_Kuehlung_a4.fm

Cooling 3 Dismount hoses and cables 1. Loosen the screws on both collars A and B (socket 10), and remove the hoses.

A B

Fig. 187

B

A

2.

3.

4.

5.

C

D F

E

Loosen the sleeve nut A (SW36), and remove the hydraulic line.

Loosen the sleeve nut B (SW22), and remove the hose.

Disconnect the connector C of the temperature probe E (B015).

Loosen screw D (SW13), and remove hoses and cable from the holder.

6. Dismantle the temperature probe E (B015) (SW27) and put to one side.

7. Loosen the screw on the collar F (socket 10), and remove hose.

Fig. 188

8. Loosen the screw on the collar A (socket 10), and remove hose.

A

Fig. 189

9. Disconnect connector A on the temperature probe (B016).

10.Loosen the screw on the collar B (socket 10), and remove hose.

A B

Fig. 190

RHB 416-06 * 1.0 * 41605_R_3_Kuehlung_a4.fm

3-3

3 Cooling Dismantle the side sheet 1. Cut open the cable ties holding the line that runs on the inside of the side sheet D. 2. Remove edge protection A. 3. Remove screws B (socket 13).

4. Remove screws C (socket 13).

5. Remove side sheet D.

B

A

C D

Fig. 191

6. Cut open cable ties B and remove line C. 7. Remove screw A and take off collar D. A

D C

B

Fig. 192

Dismantle the hydraulic oil lines on the fan motor (III) A

C

1. Loosen the 2 sleeve nuts B (SW 27) and remove the hydraulic oil lines from the fan motor A. 2. Loosen the sleeve nut C (SW 19) and remove the hydraulic oil line from the fan motor A.

B

Fig. 193

3-4

RHB 416-06 * 1.0 * 41605_R_3_Kuehlung_a4.fm

Cooling 3 Mount the eyelet 1. Mount the eyelet B to the radiator A.

A

B Fig. 194

2.

3.

4.

5.

6.

A

B

Remove screws B on engine frame (socket 17).

Remove nuts C from radiator (socket 17).

Remove holder A with rubber insert.

Mount eyelet D to radiator.

Hook suitable hoisting gear into the eyelet.

C

B

D

Fig. 195

RHB 416-06 * 1.0 * 41605_R_3_Kuehlung_a4.fm

3-5

3 Cooling Dismantle air conditioning cooler 1. Loosen sleeve nut B on hydraulic oil line (SW36).

2. Remove hydraulic oil line from oil cooler A. B A

Fig. 196

3. Loosen and remove the thumb nuts B.

B A

Information Do not open the lines from the air conditioning cooler!

4. Remove screws A on the air conditioning cooler frame (SW10).

5. Put the air conditioning cooler on the front axle to the side.

C

A Fig. 197

A

6. Lift out cooler B using hoisting gear A to do so.

B Fig. 198

3-6

RHB 416-06 * 1.0 * 41605_R_3_Kuehlung_a4.fm

Cooling 3

Install cooler WARNING Risk of injury lifting heavy components.

Death or serious injuries. ► Use lifting tackle with a sufficient bearing load ► Use functionally-safe lifting tackle ► Use the lifting tackle on firm and level ground ► Move the lifting tackle to predefined or suitable position on the component Mount air conditioning cooler

A

1. Position cooler B, aided by hoisting gear A inside the motor frame.

B Fig. 199

2. Position air conditioning cooler on cooler.

3. Tighten screws A on air conditioning cooler frame (SW10).

4. Tighten thumb nuts B.

B A

C

A Fig. 200

5. Position hydraulic oil lines on oil cooler A. 6. Tighten sleeve nut B on hydraulic oil line with 85 Nm (SW36).

B A

Fig. 201

RHB 416-06 * 1.0 * 41605_R_3_Kuehlung_a4.fm

3-7

3 Cooling Dismantle eyelet

A

1.

2.

3.

4.

5.

B C

B

Take hoisting gear out of eyelet.

Dismantle eyelet D from cooler.

Position holder A with rubber insert.

Tighten screws B on engine frame (socket 17).

Tighten nut C on cooler (socket 17).

D

Fig. 202

6. Dismantle eyelet B on cooler A.

A

B Fig. 203

Install hydraulic oil lines on fan motor A

C

1. Position the hydraulic oil lines on fan motor A and tighten the 2 sleeve nuts B with 60 Nm (SW 27).

2. Position the hydraulic oil line on fan motor A and tighten the sleeve nut C with 28 Nm (SW 27).

B

Fig. 204

3-8

RHB 416-06 * 1.0 * 41605_R_3_Kuehlung_a4.fm

Cooling 3 Mount the side sheet 1. Position collar D and tighten screw A. 2. Secure line C with cable tie B.

A

D

B

C

Fig. 205

A

B

C

3.

4.

5.

6.

7.

Position side sheet D. Tighten screws C (socket 13).

Tighten screws B (socket 13).

Mount edge protection A. Secure the line that runs on the inside of the side sheet D with cable ties.

D

Fig. 206

RHB 416-06 * 1.0 * 41605_R_3_Kuehlung_a4.fm

3-9

3 Cooling Install the hoses and cables 1. Connect connector A of the temperature probe.

2. Position hose and tighten screw on collar B with 20 Nm (socket 10).

A B

Fig. 207

3. Position hose and tighten screw on collar A with 12 Nm (socket 10).

A

Fig. 208

A

B

C

D F

4.

5.

6.

7.

8.

9.

Position hose and tighten screw on collar F (socket 10).

Mount temperature probe E (SW27).

Position hoses and cable at holder and tighten screw D (SW13).

Plug in connector C of the temperature probe E. Position hose and tighten sleeve nut B with 40 Nm (SW22).

Position hydraulic oil line and tighten sleeve nut A with 85 Nm (SW36).

E

Fig. 209

10.Position hoses.

11.Tighten screw on collar A (socket 10).

12.Tighten screw on collar B with 12 Nm (socket 10).

A B

Fig. 210

3-10

RHB 416-06 * 1.0 * 41605_R_3_Kuehlung_a4.fm

Cooling 3 Install the engine cover 1. Position the engine lid, taking 2 people to do so.

2. Screw one screw each to both hinges D (socket 13).

3. Insert the attenuator A into the holding device C and then add the safety clips B. 4. Screw the second screw respectively into both hinges E (socket 13).

5. Close the engine cover.

A

Next steps B

C

D

E

Fig. 211

RHB 416-06 * 1.0 * 41605_R_3_Kuehlung_a4.fm

1. Fill coolant Adding coolant on page 1-56.

2. Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3.

3-11

3 Cooling

3.2

Replace fan motor 1.

2.

3.

4.

A

B

Dismantle cooler – see “Dismantle radiator” on page 3-2.

Loosen the 4 screws A and remove fan motor B. Position fan motor B and tighten the 4 screws A. Install the cooler – see “Install cooler” on page 3-7.

A

Fig. 212

3.3

Reversing valve

Remove reversing valve

A

B

1. Disconnect the connectors C and E from the reversing valve B. 2. Loosen the sleeve nuts A and D and remove the hoses (SW27, SW32).

3. Close the hoses and connections on the reversing valve B with filler plugs.

C

E

D Fig. 213

A

4. Loosen the sleeve nuts A and D on the reversing valve C and remove the hoses (SW27, SW32).

5. Close the hoses and connections on the reversing valve C with filler plugs.

6. Remove the 3 screws B and take out the reversing valve C.

D B C Fig. 214

3-12

RHB 416-06 * 1.0 * 41605_R_3_Kuehlung_a4.fm

Cooling 3

Install reversing valve

A

1. Position the reversing valve C and tighten the 3 screws B. 2. Remove the filler plugs from the hoses and connections of the reversing valve C. 3. Position the hoses and tighten the sleeve nuts A and D on the reversing valve C (SW27, SW32).

D B C Fig. 215

A

B

C

4. Remove the filler stops in the hoses and connections of the reversing valve B. 5. Position the hoses and tighten the sleeve nuts A and D on the reversing valve C (SW27, SW32).

6. Insert the connectors C and E for the reversing valve B.

E

D Fig. 216

Setting the upper fan speed A

D

C

B Fig. 217

RHB 416-06 * 1.0 * 41605_R_3_Kuehlung_a4.fm

1.

2.

3.

4.

Heat oil temperature up to 50 °C. Disconnect the connector A from the solenoid valve D. Accelerate the diesel engine to its maximum rotational speed.

Measure the rotational speed of the fan impeller ➥ If the measuring result is greater or smaller than 2200 min-1, continue with step 5 5. Change the rotational speed with the setting screw B: Screw setting screw in -> rotational speed increases Unscrew setting screw -> rotational speed decreases 6. Repeat steps 4 and 5 until the rotational speed is set correctly.

7. Secure the setting with the locknut C.

3-13

3 Cooling Notes:

3-14

RHB 416-06 * 1.0 * 41605_R_3_Kuehlung_a4.fm

Drive

4 Drive

4 Drive

4.1

High speed gearbox

Remove the high-speed gearbox DANGER Risk of injury lifting heavy components.

Death or serious injuries. ► Use lifting tackle with a sufficient bearing load ► Use functionally-safe lifting tackle ► Use the lifting tackle on firm and level ground ► Move the lifting tackle to predefined or suitable position on the component

Preparatory steps 1. Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3.

2. Dismantle covers – see “Remove the covers” on page 1-20.

Mount eyelet 1. Remove screw plug A (M20x1.5) on high-speed gearbox B (X) (Allen key SW10).

A

B

Fig. 218

A

2. Screw the eyelet A (M20x1.5) into position at this location.

Environment Place a suitable container underneath the high-speed gearbox to catch any hydraulic oil that comes out and dispose of it in an environmentally-friendly manner.

Fig. 219

4-2

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Remove the electrical connections B

A

1. Disconnect the connector A from the proportional valve B (Y002).

Fig. 220

2. Disconnect the connector A an from the vehicle direction detector D (Y010).

3. Disconnect the connector B from the proportional valve C (Y098).

A

B D

C

Fig. 221

Dismantle hydraulic lines A

1. Loosen sleeve nuts A (SW36).

2. Loosen sleeve nut B (SW17).

3. Remove the hydraulic lines from the high-speed gearbox C (X).

B C

Fig. 222

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-3

4 Drive Dismantle the high-pressure lines 1. Dismantle the drain line A of the variable displacement motor (VII) by loosening the screw B (SW13).

A B

Fig. 223

2. Remove the screws B at the upper half-shells of the variable displacement motor A (VIII) (SW17).

3. Remove the upper half-shells.

4. Remove and close the high-pressure lines C. 5. Loosen the sleeve nut D on the drain line.

6. Remove and close the drain line.

B

A

B

D

C

Fig. 224

7. Remove the screws B from the upper half-shells of the high-speed gearbox C (X) (SW17).

8. Remove the inner half-shells.

9. Remove and close the high-pressure lines A.

A

B C B

Fig. 225

Dismantle the piston accumulator 080

WARNING Risk of injury from hydraulic pressure!

Can cause injury.

A

B

A

► Do not open the connections to the piston accumulator 080!

1. Loosen the 2 screws A (Allen key SW5).

2. Put the piston accumulator B to one side.

Fig. 226

4-4

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Dismantle the cardan shaft B

A

F

C

1. Remove the screws D from the front cardan shaft B on the front axle C (Allen key SW8).

2. Remove the screws E (Allen key SW8) and the self-locking nuts F (SW17) from the front cardan shaft B on the high-speed gearbox A (X).

3. Place the front cardan shaft B to one side.

D

E

Fig. 227

4. Remove the screws C (Allen key SW8) and the self-locking nuts D (SW17) from the rear cardan shaft B on the high-speed gearbox A (X).

A

D

B

C

Fig. 228

A

5. Remove the screws B from the rear cardan shaft A on the rear axle C (Allen key SW8).

6. Place the cardan shaft to one side.

B

C Fig. 229

7. Hook suitable hoisting gear A into the eyelet B. A B

Fig. 230

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-5

4 Drive Dismantle the high-speed gearbox support

A

1. Remove the screws A and B from the high-speed gearbox support C (X) on right in the direction of travel (SW24).

B

C Fig. 231

2. Remove the nuts B on the high-speed gearbox support A (X) on left in the direction of travel (SW24).

A

B Fig. 232

3. Slowly lower then high-speed gearbox A (X) using the hoisting gear B to do so.

A

B

Fig. 233

4-6

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4

Remove the old high-speed gearbox High-speed gearbox X H1

A1

G1

B1

Install the test connections from the old high-speed gearbox into the new one.

C F1 E

D Fig. 234

J

I Fig. 235

1.

2.

3.

4.

5.

Replace test connection A1 and screw-in connection A1 with plugs A2.

Replace test connection B1 and screw-in connection B1 with plugs B2.

Replace test connection G1 and screw-in connection G1 with plugs G2.

Replace test connection H1 and screw-in connection H1 with plugs H2.

Tighten the screw-in connections (AF19) in the new high-speed gearbox with 40 Nm. 6. Tighten the test connections in the new high-speed gearbox as follows: - Test connections A1 and B1 with 40 Nm - Test connection G1 with 28 Nm - Test connection H1 with 50 Nm 7. Mount eyelets in the new high-speed gearbox instead of the plugs K – see “Mount eyelet” on page 4-2.

8. Remove the sleeve nut F1 and screw-in connections on the hydraulic line E. 9. Remove the sleeve nut J and screw-in connection on the drain line I. 10.Remove the screws C on the variable displacement motor D (VII).

11.Secure the servomotor D (VII) by tightening the screws C on the new high-speed gearbox with 79 Nm. 12.Tighten the sleeve nut F1 with 28 Nm and the screw-in connection at 35 Nm on the hydraulic line E of the new high-speed gearbox.

13.Tighten the sleeve nut J to 110 Nm and the screw-in connection to 190 Nm of the drain line I on the new high-speed gearbox.

A

G2 H2 B2 A2

K

F2

Fig. 236

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-7

4 Drive

Install new high-speed gearbox A

DANGER Risk of injury lifting heavy components.

B

Death or serious injuries. ► Use lifting tackle with a sufficient bearing load ► Use functionally-safe lifting tackle ► Use the lifting tackle on firm and level ground ► Move the lifting tackle to predefined or suitable position on the component

Fig. 237

Mount the supports for the high-speed gearbox 1. Mount eyelet – see “Mount eyelet” on page 4-2 2. Slowly raise the high-speed gearbox A (X) with the hoisting gear B. 3. Tighten the nuts B on the high-speed gearbox support A (X) to 195 Nm on left in the direction of travel (SW24).

A

B Fig. 238

A

4. Tighten screw A on the high-speed gearbox support C (X) to 120 Nm on right in direction of travel (SW24).

5. Tighten screws B on the high-speed gearbox support C (X) to 195 Nm on right in direction of travel (SW24).

B

B

C Fig. 239

4-8

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Mount cardan shaft B

A

C

CAUTION There is a risk of injury if the cardan shafts are not installed correctly!

If the joints of the cardan shaft are not aligned to each other, the shaft can be destroyed. People in direct proximity could subsequently sustain serious injuries. The vehicle can be damaged.

F

D

E

► Align cardan shafts to marking.

Fig. 240

1. Position the front cardan shaft B, paying attention to both markings.

2. Tighten the screws D on the front cardan shaft B on the front axle C to 49 Nm (Allen key SW8).

3. Tighten the screws E (Allen key SW8) and the new self-locking nuts F (SW17) of the front cardan shaft B on the high-speed gearbox A (X) to 49 Nm. 4. Position the rear cardan shaft G, paying attention to both markings.

5. Tighten the screws H (Allen key SW8) and the new self-locking nuts I (SW17) of the rear cardan shaft G on the high-speed gearbox A (X) to 49 Nm.

G A

I

H

G

Fig. 241

6. Tighten the screws B of the rear cardan shaft A on the rear axle C to 49 Nm (Allen key SW8).

A

C

B

Fig. 242

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-9

4 Drive 7. Detach the hoisting gear A from the eyelet B. A B

Fig. 243

Mount high-pressure lines 1. Position the high-pressure lines A and the interior half-shells.

2. Tighten the screws B on the upper half-shells of the high-speed gearbox C (X) 79 Nm (SW17).

A

B C B

Fig. 244

B

A

D

3. Position the high-pressure lines C and the upper half-shells.

4. Tighten the screws B on the upper half-shells of the variable displacement motor A (VIII) to 46 Nm (SW17).

5. Tighten the sleeve nut on the drain line.

B

C

Fig. 245

6. Position the high-pressure line mounts A for the variable displacement motor (VII) 7. Tighten the screws B (AF13).

A B

Fig. 246

4-10

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Install the hydraulic lines 1. Position the hydraulic lines on the high-speed gearbox C (X).

2. Tighten the sleeve nuts A (SW36).

3. Tighten the sleeve nut B (SW17).

A

B C

Fig. 247

Set up the electrical connections B

A

1. Plug in connector A on proportional valve B (Y002).

Fig. 248

2. Plug in connector A on the vehicle direction detector D (Y010).

3. Plug in connector B on the proportional valve C (Y098).

A

B D

C

Fig. 249

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-11

4 Drive

A

Dismantle eyelet 1. Remove eyelet A.

Fig. 250

2. Tighten the screw plug A on the high-speed gearbox B to 80 Nm (Allen key SW10).

A

Next steps

B

1. Dismantle covers – see “Mount the covers back on again” on page 1-20.

2. Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3.

NOTICE Fig. 251

The gearbox will sustain damage if there is no hydraulic oil in the highspeed gearbox when you drive off. ► Add hydraulic oil to vehicle when it is at idling speed.

3. Allow the vehicle to run for about 2 minutes at idling speed, but do not drive, so that the high-speed gearbox can be filled with hydraulic oil.

4. Check the level of hydraulic oil in the gearbox – see “Check/refill gear lubricant oil” on page 1-89 5. Adjusting the high-speed gearbox - see system manual.

4-12

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4

4.2

Maintenance operations for the high-speed gearbox

Tools Tools for repair • • •

Commercially available tools Commercially available compression mechanism Assembly stand

Component

Part number

Press-out tool (new control cover of high-speed gearbox)

1 304 897.0

Slotted-nut key

1 305 189.0

Slotted-nut key

1 305 190.0

Securing wire

1 305 191.0

Adapter for taper roller bearing

1 305 192.0

Adapter for rotary shaft lip seal

1 305 193.0

Adapter for rotary shaft lip seal

1 305 194.0

Cpl extractor

1 305 195.0

Adapter for gear unit assembly

1 305 196.0

Extractor

1 305 197.0

Adapter for gear unit bearing

1 305 198.0

Adapter for gear unit profile shaft

1 305 199.0

Pressure plate

1 305 200.0

Intermediate ring assembly sleeve

1 305 201.0

Control cylinder assembly sleeve

1 305 202.0

Control cylinder assembly sleeve

1 305 203.0

Screw plugs Torque

Designation

Part number

20 Nm

Screw plug M10 x 1

13038160

35 Nm

Screw plug M12 x 1.5

13043100

45 Nm

Screw plug M14 x 1.5

2130990

55 Nm

Screw plug M16 x 1.5

2131001

80 Nm

Screw plug M20 x 1.5

3037910

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-13

4 Drive

Overview Control cover

Gear unit bearing Auxiliary motor

Swivel yoke

Gear unit

Output shaft

4-14

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4

Remove the gearbox cover Removing the cardan-shaft flanges 1. Remove the hexagon head screw (wrench size 17)

2. Remove the cardan-shaft flanges from the output shaft with an extractor 3. Remove the rotary shaft lip seals

Removing the cap 1. Remove the circlip

2. Removing the cap ➥ The cap is destroyed when removed

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-15

4 Drive Opening the slotted nut 1. Open the lock of the slotted nut

A

2. Open the slotted nut with slotted-nut key 1 305 190.0 and the adapter for the gear unit profile shaft 1 305 199.0 3. Remove fastening screws A from the gearbox cover (wrench size 19)

Remove the gearbox cover

B

1. Rethread the shearing screws with an M10 screw tap 2. Press the gearbox cover out of the gearbox housing with shearing screws B ➥ Shearing screws M10 x 50 3. Remove the gearbox cover from the gearbox housing

4. Remove the speed sensor

4-16

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Removing output shaft C

C

1. Remove the output shaft with the bearing and the gear

2. Remove output shaft C from the gearbox housing with extractor D 1 305 195.0

C D

Old version with rear-axle fastening Remove the output shaft as described above

1. Dismantle the gear wheel and bearings from the output shaft on one parking brake

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-17

4 Drive

Removing the control cover from the gearbox housing Removing control cover version 1 from the housing

A

1. Remove fastening screws B 2. Press out the control cover with screw A 3. Shearing screw M12 x 1.5 and 90 mm long

B

C

Removing control cover version 2 from the housing 1. Remove press-out tool C for the new control cover 1 304 897.0 2. Remove fastening screws B 3. Press out the control cover with screw C

B

4. Screw the shearing screw into the control cover 5. Press out the control cover 6. Keep the control cover straight as you press it out

4-18

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4

Removing the gear unit Opening the slotted nut of the gear unit 1. Open the lock of the slotted nut

A 2. Remove the slotted nut from the shaft ➥ Open the slotted nut with slotted-nut key 1 305 189.0

3. Remove the gear from the shaft with a commercially available extractor

4. Remove circlip B

B

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-19

4 Drive 5. Remove gear unit C from the housing with extractor 1 305 195.0 6. Take gear unit C out of the gearbox housing

C

D

Intermediate ring D for sealing the hydraulic part and the gear part 1. Remove the intermediate ring from the shaft

2. Remove the taper roller bearing from the shaft

3. Swivel yoke E can now be removed from the gearbox housing 4. Remove rolling bearings F

E

F

4-20

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4

Dismantling the control cover Control cover (overview) Proportional regulator

Setting screw control initiation

Proportional valve Y010

Control cylinder end plate

Stroke adjustment housing Qmin

Forward-reverse spool valve Y002 driving direction identification solenoid valve

Flush valve

Scouring slide valve

Removing the scouring slide valve 1. Remove screw plugs A (wrench size 17)

A 2. Remove the spring, spring seat and scouring slide valve B

B C

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Removing the flush valve 1. Remove flush valve C (wrench size 27)

4-21

4 Drive Solenoid valve Y002 D of driving direction identification 1. Remove solenoid valve Y002 D 2. Remove valve insert E (wrench size 22)

E

Information Valve insert E has three versions

D Version 1

Version 2

2 mm Version 1 Ø 2 mm

Version 3

4 mm

O-ring

Version 2 Ø 4 mm

Version 3 O-ring version

Version 1 and version 2 can be exchanged without any restrictions

Version 3 Is not compatible with version 1 and version 2

Removing the forward-reverse spool valve 1. Remove the screw plug (Allen key 8)

F

H

4-22

G

F

2. Take out forward-reverse spool valve F with a magnetic lifter 3. Take out spring G with a magnetic lifter 4. Take out thrust washer H with a magnetic lifter

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Remove the proportional regulator 1. Remove proportional valve I (Allen key 3)

I

J

2. Remove proportional regulator J (Allen key 4) 3. Remove the springs with the large and small diameters from spring seat K

K

Removing proportional regulator J

J

1. Remove the circlip on the proportional regulator 2. Take out proportional regulator J ➥ Ensure that it is placed in the correct position

J

Removing the control initiation set screw

L

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

1. Measure the control initiation set screw L 2. Open the locknut (wrench size 19) 3. Unscrew set screw L (Allen key 6)

4-23

4 Drive Removing the control piston 1. Remove end plate M (Allen key 8)

M

2. Remove pressure relief valve N on end plate M (wrench size 24)

M N 3. Remove the orifice (Allen key 5) ➥ Orifice 0.7 mm

4. Remove stroke adjustment housing O (wrench size 55)

5. Remove spring mount P (Allen key 5)

P

4-24

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 6. Push out control cylinder Q

Q

7. Remove the seal and the O-ring from control cover R

R

8. Remove the seal and the O-ring from control cylinder S

S

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-25

4 Drive Removing the high-pressure seal

T

1. Remove the high-pressure seal and O-ring T from the control cover

Removing the shuttle throttle

U

1. Remove screw plug U (Allen key 6)

2. Remove the screw plug from the throttle pin (Allen key 5) ➥ Use an Allen key with a holding function

3. Take out throttle pin V with a magnetic lifter

F

4. Remove the throttle screw from the throttle pin (Allen key 6) ➥ Use an Allen key with a holding function

4-26

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4

Set up steering cover Information Use only original spare parts for installation!

Clean all components thoroughly before assembly. Sealing surfaces must not have any damage or irregularities. Screw plugs have to be renewed after disassembly.

Overview

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-27

4 Drive Installing the high-pressure seals

B

A

C

1. Install O-ring A 2. Install high-pressure seal B as shown ➥ Do not bend the high-pressure seal

Installing the piston rod seal in the control cover 1. Install O-ring C in the control cover

2. Give the piston rod seal D its shape

D

D

4-28

3. Install piston rod seal D in the control cover

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Installing the piston rod seal on the control cylinder

D

1. Install the O-ring on the piston rod 2. Install piston rod seal D on the piston rod with assembly sleeve 1 305 203.0

3. Calibrate the piston rod seal with assembly sleeve E 1 305 202.0

E

4. Carefully install the piston rod in the control cover ➥ Apply a thin coat of grease to the seals

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-29

4 Drive Installing the spring mount (position indication)

E

1. Install spring mount E on the piston rod (Allen key 5) ➥ Adjust to a tightening torque of 11+2 Nm and secure with Loctite 242 ➥ Turn the spring mount downward in the control cover

11 Nm

Installing the control initiation set screw 1. Use a new collar nut and adjust it to the dimension measured before ➥ Tightening torque 84+3 Nm

Installing forward-reverse spool valve I • •

I

Forward-reverse spool valve I (overview) Steel washer H

H H

1. Secure forward-reverse spool valve I, spring G and steel washer H with grease, and install them together in the control cover bore

G

I Checking the forward-reverse spool valve

12 mm

1. Check the forward-reverse spool valve for smooth running once it is installed 2. The distance between the control cover and the forward-reverse spool valve must be 12 mm 3. Install a new screw plug with an O-ring (Allen key 8) ➥ Tightening torque 55+4 Nm

Information Repeat the installation of the forward-reverse spool valve if this dimension is not reached.

4-30

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Installing scouring slide valve J •

Scouring slide valve J (overview)

J 1. Install scouring slide valve J in the control cover

J

K

L

M

N

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

2. Install spring seat M on the scouring slide valve 3. Position and screw in spring L with screw plug K (wrench size 17) 4. Use new screw plugs and O-rings ➥ Tightening torque 35+3 Nm

5. Install flush valve N (wrench size 24) ➥ Tightening torque 30+5 Nm

4-31

4 Drive Installing the solenoid valve of driving direction identification O

O

1. Install valve insert O and a new O-ring (wrench size 22) ➥ Tightening torque 45+5 Nm 2. Install the solenoid valve ➥ Tightening torque 5+2 Nm

2 mm Version 1 Ø 2 mm

4 mm Version 2 Ø 4 mm

Version 1 and version 2 can be exchanged without any restrictions

O-ring Version 3 O-ring version Version 3 Is not compatible with version 1 and version 2

Installing the shuttle throttle

P S R

S

R

P

1. Install throttle screw P (Allen key 6) 2. Assemble throttle screw R and throttle pin S with grease and install them in the bore (Allen key 5) ➥ Tightening torque of both throttle screws 5+2 Nm 3. Use a new screw plug and O-ring ➥ Tightening torque of throttle screw 35+3 Nm ➥ The tip of the throttle pin must show toward the bore

Information The tip and the notch of throttle pin S must not be damaged

Information Install pressure regulator T, proportional valve Y010, end plate S and the pressure relief valve on the gearbox housing only once the control cover is installed

T S

4-32

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4

Installing the gearbox housing Information Use only original spare parts for installation In order to avoid errors during assembly work, perform all work carefully ensuring cleanliness Clean all components thoroughly before assembly.

The sealing surface must not have any damage or irregularities, and it must be free of oil and grease.

Overview Control cover Gear unit bearing Auxiliary motor (option)

Swivel yoke

Gear unit

Output shaft

Information Mount the swivelling yoke first followed by the control cover.

In the next step, install the gear unit and the gear wheel.

Afterwards, install the output shaft, gear wheel and gearbox cover.

Inserting the swivel yoke 1. Install swivel yoke A in the gearbox housing with new bearings

A

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-33

4 Drive

B

Positioning the seal and the sliding block 1. Position the seal 2. Sliding block B must face the swivel joint with the short side

Installing the control cover

C

CAUTION The risk of crushing when positioning the control cover!

It can lead to the hands being injured. ► Wear protective gloves 1. Apply a thin coat of oil to the high-pressure seals of the swivel joint 2. Position the control cover on the parallel pins 3. Turn the control cover until the sliding block fits in the groove of the control cylinder 4. If the sliding block is in the control cylinder, install the control cover on the gearbox housing with a rubber hammer 5. Install the fastening screws ➥ Tightening torque 110+10 Nm 6. Install the end plate of the control piston 7. Lightly lubricate the O-rings with grease and insert them into position

4-34

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Installing an orifice in end plate F 1. Install the orifice (Allen key 5) ➥ Tightening torque 5+2 Nm

F 70 Nm

2. Install end plate F on the control cover (Allen key 8) ➥ Tightening torque 70+3 Nm

F

H

3. Install pressure relief valve H ➥ Tightening torque 60+5 Nm

Installing the stroke adjustment housing O-ring

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

1. Apply a thin coat of grease to the new O-ring and install it 2. Install the stroke adjustment housing (wrench size 55)

4-35

4 Drive

Installing the pressure regulator on the control cover Pressure regulator and proportional valve (overview)

1. Install start spring D on the set screw

D 2. Install spring E of the position indication

E

3. Install spring seat F

F G

4-36

4. Install pressure regulator G ➥ Ensure that it is placed in the correct position

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 5. Install the housing and pressure regulator G (Allen key 4) ➥ Pay attention to the bores when positioning the pressure regulator 6. Use new O-rings ➥ Tightening torque 8.5+1 Nm

G

G

7. Install proportional valve H on the housing of the pressure regulator ➥ Tightening torque 3+1 Nm

H

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-37

4 Drive

Installing the output shaft Overview

Output shaft Installing the output shaft 1. Install the long side of the bearing toward the gear

2. Install the new taper roller bearing 32209 with adapter 1 305 193.0

A

4-38

3. Install output shaft A in the gearbox housing

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Installing the gearbox cover 1. Install the fastening screws (wrench size 19) ➥ The cover must be removed later on

2. Install the new taper roller bearing 32209 B with adapter 1 305 193.0

B

C

3. Install the circlip ➥ Without spacers 4. Turn the high-speed gearbox 180°

B

5. Heat new tapered roller bearing to 80° – 120° 6. Install the taper roller bearing 30208 with adapter 1 305 193.0

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-39

4 Drive 7. Install the circlip 8. Turn the high-speed gearbox 180°

Installing the gearbox cover bearing

C B Measure X

Measure Y

1. Drive the output shaft downward with a plastic hammer ➥ Until the bearing touches the circlip on the opposite side 2. Remove the circlip and take the measurement with an external micrometer 3. Carefully fasten the bearing shell on the taper roller bearing with adapter 1 305 193.0 4. Install the circlip 5. Measure the distance between the circlip and the bearing shell with a depth gauge ➥ Dimension X – dimension Y + 0.1 mm (pretensioning) = spacer 6. Remove the circlip 7. Place the spacers 8. Install the circlip

•

The drag torque is adjusted with the spacers ➥ Drag torque about 0.3 Nm

9. Remove the gearbox cover

4-40

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4

Installing the gear unit Overview Synchronous joint

Taper roller bearing

Block cylinder

Shaft with pistons

Installing the gear unit 1. Warm up the taper roller bearing to 80 – 120 °C before installing

2. Install the new taper roller bearing on the shaft

8

9

7

6

5

3. Position the shaft with the synchronous joint bearing (see figure) facing oneself 4. Position pistons 1 – 4 facing oneself 5. Pistons 2 and 3 must be in the middle with regard to the synchronous joint bearing 6. Put pistons 5 – 6 a little aside 7. Put pistons 7 – 9 to the rear

4

1 2

3

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-41

4 Drive 8. Install supporting pin A with grease at the centre of the shaft

A 9. Install synchronous joint bearing B with grease on synchronous joint C

C B A

10.Install supporting pin A with grease at the centre of the block cylinder

11.Put the synchronous joint in the shaft and insert the block cylinder from above into the first 2 pistons (see figure) ➥ Ensure that the synchronous joint is in line with the 2 pistons ➥ The synchronous joint bearing of the block cylinder must be in line with the synchronous joint of the shaft (see figure)

A

4-42

12.Raise the block cylinder a little further to insert the next pistons ➥ Ensure that supporting pin A does not fall out of the block cylinder

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Securing the gear unit with securing wire 1 305 191.0 1. The securing wire is pushed into the shaft up to the supporting pin 2. The gear unit can now be installed in the gearbox housing ➥ Securing wire 1 305 191.0

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-43

4 Drive

Installing the gear unit in the swivel yoke Overview

Swivel yoke

Gearbox cover

Gear unit Seal

Gear Bearing

Installing the gear unit 1. Measure the set screw for the wheel speed 2. Unscrew the set screw for the wheel speed until the swivel yoke is straight in the gearbox housing

A

Information Securing wire A has to be removed before raising the gear unit from below into the gearbox housing

3. Install gear unit B from below into the swivel yoke ➥ Ensure that the gear unit does not tip over 4. After inserting it, turn the gearbox housing 180° without letting the gear unit slip out of the swivel yoke ➥ 2 persons are required for this

B

4-44

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4

Installing the bearing shell

NOTICE Make sure the shaft C is not hit or hammered. The supporting pins might otherwise fall out.

1. Lightly grease bearing shell C 1 and install carefully with adapter 1 305 196.0

C

C1

Information Only use intermediate plates with a web width of 4.5 mm.

4.50 mm

2. Fit assembly sleeve D 1 305 201.0 on the shaft

D

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-45

4 Drive Installing the rotary shaft lip seal 1. Press the rotary shaft lip seal into the bearing housing with adapter E 1 305 194.0 and apply a thin coat of grease to the sealing lips 2. Replace the O-ring seal and apply a thin coat of grease to it

E

3. Carefully slide intermediate ring F onto the shaft with assembly tool F1 1 305 201.0 4. Install the intermediate ring about 5 mm in the bore

F1

F 5. Install circlip G with the opening (see figure)

G 6. Press the circlip downward with assembly fixture 1 305 195.0 and adapter G1 1 305 196.0 until the circlip engages in the groove

G1

H1

Installing the gear 1. Warm up gear H to 120 °C 2. Press gear H onto the shaft with assembly fixture H1 1 305 195.0 and adapter G1 1 305 196.0

H

4-46

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Installing slotted nut I

J

I

•

Adapter for gear unit profile shaft J 1 305 199.0 for countering the shaft

1. Position slotted-nut key K 1 305 189.0 and install the slotted nut 2. Secure the slotted nut

J

K

Installing the gearbox cover 1.

2.

3.

4.

5. Install bearing shell L on the gearbox cover 6. Warm up taper roller bearing X32209 M to 80 – 120 °C before installing 7. Install taper roller bearing X32209 M on the shaft with adapter N 1 305 193.0

L

M

The sealing surfaces must be free of oil and grease before assembly Apply Loctite 518 to the sealing surface Position the gearbox cover Install the fastening screws (wrench size 19) ➥ Tightening torque 80 + 10 Nm

N

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-47

4 Drive 8. Install the slotted nut with slotted-nut key P 1 305 190.0 and the adapter for the gear unit profile shaft O 1 305 199.0

O

Information The drag torque of the gears is adjusted with the groove nut.

P 9. Check the drag torque 10.Tighten the slotted nut in increments up to a drag torque of about 7 Nm 11.Secure the slotted nut

Q

12.Install cap Q 13.Install the circlip

Installing rotary shaft lip seal R of the output shaft 1. Install rotary shaft lip seal R with adapter 1 305 193.0 2. Apply a thin coat of grease to the sealing lips

R

4-48

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Installing cardan-shaft flanges S

S

1. Warm up cardan-shaft flange S to 80 °C 2. Install cardan-shaft flange S on the output shaft 3. Insert new O-ring seals and install the screw with a washer ➥ Tightening torque 45+5 Nm

T

4. Install the speed sensor ➥ Tightening torque 24+5 Nm

T

5. Adjust the wheel speed set screw to the measure taken ➥ Tightening torque 84+3 Nm

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

The high-speed gearbox can now be installed in the machine.

Add gearbox oil as specified in the service manual and adjust the high-speed gearbox as specified in the test report.

4-49

4 Drive

4.3

Additional variable displacement motor

Remove variable displacement motor Preparatory steps 1. Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3.

2. Dismantle covers – see “Remove the covers” on page 1-20.

Disassemble front cardan shaft B

A

F

1. Remove the screws D from the front cardan shaft B on the front axle C (Allen key SW8).

2. Remove the screws E (Allen key SW8) and the self-locking nuts F (SW17) from the front cardan shaft B on the high-speed gearbox A (X).

3. Place the front cardan shaft B to one side.

C

D

E

Fig. 252

Remove the electrical connections A

B

1. Disconnect the connector A an from the vehicle direction detector D (Y010).

2. Disconnect the connector B from the proportional valve C (Y098).

D

C

Fig. 253

4-50

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Remove high-pressure lines and drain line B

A

D

B

C

E

1. Remove the screws B at the upper half-shells of the variable displacement motor A (VIII) (SW17).

2. Remove the upper half-shells.

3. Remove and close the high-pressure lines C. 4. Loosen the sleeve nut D on the drain line.

5. Remove and close the drain line.

6. Loosen sleeve nut E. 7. Remove and close hydraulic line.

8. Loosen sleeve nut G. 9. Remove and close the drain line.

10.Remove the 4 screws F and take out the variable displacement motor A (VIII).

F A

G

Fig. 254

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-51

4 Drive

Install variable displacement motor Install high-pressure lines and drain line B

A

B

D

C

1. Position the variable displacement motor A (VIII) and tighten the 4 screws F. 2. Position the drain line and tighten the sleeve nut G. 3. Position the hydraulic line and tighten the sleeve nut E. 4. Position the drain line and tighten the sleeve nut D. 5. Position the high-pressure lines C and the upper half-shells.

6. Tighten the screws B on the upper half-shells of the variable displacement motor A (VIII) (SW17).

E

F A

G

Fig. 255

Set up the electrical connections A

1. Plug in connector A on the vehicle direction detector D (Y010).

2. Plug in connector B on the proportional valve C (Y098).

B

D

C

Fig. 256

4-52

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Drive 4 Install front cardan shaft B

A

C

CAUTION There is a risk of injury if the cardan shafts are not installed correctly!

If the joints of the cardan shaft are not aligned to each other, the shaft can be destroyed. People in direct proximity could subsequently sustain serious injuries. The vehicle can be damaged.

F

E

D

► Align cardan shafts to marking.

Fig. 257

1. Position the front cardan shaft B, paying attention to both markings.

2. Tighten the screws D on the front cardan shaft B on the front axle C to 49 Nm (Allen key SW8).

3. Tighten the screws E (Allen key SW8) and the new self-locking nuts F (SW17) of the front cardan shaft B on the high-speed gearbox A (X) to 49 Nm. Next steps 1. Dismantle covers – see “Mount the covers back on again” on page 1-20.

2. Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3.

3. See the system manual for making adjustments.

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

4-53

4 Drive Notes:

4-54

RHB 416-06 * 1.0 * 41605_R_4_Fahrantrieb_a4.fm

Axles

5 Axles

5 Axles

5.1

Oscillating axle interlock

Front axle with mechanical oscillation interlock A front axle with a mechanical oscillation interlock cannot oscillate and therefore does not need to be locked.

Front axle with hydraulic frame levelling A front axle with hydraulic frame levelling cannot oscillate and therefore does not need to be locked.

Rear axle with mechanical oscillation interlock Locking the oscillating axle 1. Take lock pin (A) out of the equipment supplied with the machine.

2. Check whether the bores of the axle are fully flush with those of the frame.

3. Insert lock pin (A) and secure it with spring plug (B).

Fig. 258

A

Fig. 259

Unlocking the oscillating axle 1. Release spring plug (B) and remove lock pin (A).

2. Store lock pin (A) and spring plug (B) with the other equipment supplied with the machine.

B

A

Fig. 260

5-2

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Rear axle with hydraulic oscillating lock Locking the oscillating axle

91

1. Slide lock S in the direction of the arrow and press switch 139 to position B at the same time. ➥ Rear axle oscillation is locked via the solenoid valve on interlock ram C. ➥ Indicator light 91 on the instrument panel illuminates.

S

A

Unlocking the oscillating axle 2. Slide lock S in the direction of the arrow and press switch 139 to position A at the same time. ➥ Rear axle oscillation is unlocked via the solenoid valve on interlock ram C. ➥ The rear axle can oscillate freely again.

3. Indicator light 91 on the instrument panel goes out.

B 139

C

Fig. 261

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-3

5 Axles

5.2

Front axle

Remove front axle Preparatory steps 1. Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3.

2. Prevent uncontrolled movement of the oscillating axle – see “Oscillating axle interlock” on page 5-2.

Remove wheel covers 1. Remove 4 nuts each on both sides B (socket 27) 2. Remove wheel covers A and holders.

A B Fig. 262

Remove central lubrication hoses (opt.)

A

1. Remove hoses A on both planetary carriers.

2. Remove screws C from the planetary carrier collars (Allen key SW4).

3. Remove screws B from axle collar (SW17).

C B

A Fig. 263

4. Cut open cable tie A. 5. Fix hoses C of the central lubrication system to the attachment points B on the vehicle frame with cable ties.

A

B

C

Fig. 264

6. Remove screws A from cover B (SW13).

7. Take off cover B.

A

B Fig. 265

5-4

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Disassemble front cardan shaft B

A

F

1. Remove the screws D from the front cardan shaft B on the front axle C (Allen key SW8).

2. Remove the screws E (Allen key SW8) and the self-locking nuts F (SW17) from the front cardan shaft B on the high-speed gearbox A (X).

3. Place the front cardan shaft B to one side.

C

D

E

Fig. 266

Remove hoses 1.

2.

3.

4.

5.

6.

C A B

C

E

Remove hydraulic hoses C from the steering cylinders (AF22).

Remove hydraulic hoses E from the brake (AF17).

Remove hydraulic hose D from the differential lock (SW19).

Disconnect connector A from the differential lock.

Unplug the steering sensor connector B. Remove lubricating oil lines F.

E F

D

F

Fig. 267

Jack up the machine 1. Raise the vehicle with a suitable hydraulic jack B placing it centrally underneath the front axle A. 2. Place a secure support underneath the vehicle.

A B Fig. 268

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-5

5 Axles Remove bolts of the frame levelling (opt.)

1. Remove pin lock A. 2. Drive bolt B out of the frame levelling.

A

B

Fig. 269

Remove axle 1. Remove screws A and nuts B (AF32).

2. Slowly lower the front axle with the hydraulic jack.

A

B

A

Fig. 270

If necessary, release the parking brake (negative brake):

E A D

B C

3. Loosen lock nuts D on the set screws A – C approx. 1/2 turn.

4. Screw in set screws A, B, C on each axle tube side (3x) with Allen key E (8 mm) evenly, in alternation, until you feel some resistance.

5. Screw in set screws another 5 – 5.5 turns evenly, in alternation, against the resistance. ➥ The parking brake is released.

6. Roll the front axle away on wheels.

A

B

C Fig. 271

5-6

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5

Install front axle Mount axle 1. Roll the front axle underneath the vehicle on wheels.

2. Slowly raise the front axle with the hydraulic jack.

3. Tighten screws A and nuts B to 750 Nm on both sides (AF32).

A

B

A

Fig. 272

Jack up the machine 1. Raise the vehicle with a suitable hydraulic jack B placing it centrally underneath the front axle A. 2. Remove the support underneath the vehicle.

A B Fig. 273

Mount bolt of frame levelling (opt.)

A

1. Drive in bolt B of frame levelling.

2. Mount pin lock A.

B

Fig. 274

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-7

5 Axles Install the hoses 1.

2.

3.

4.

5.

6.

C A B

E

C

Tighten hydraulic hoses C of steering cylinders (AF22).

Tighten hydraulic hoses E of brake (AF17).

Tighten the differential lock hydraulic hose D (SW19).

Connect connector A of differential lock.

Connect the steering sensor connector B. Tighten lubricating oil lines F.

E F

D

F

Fig. 275

Mount cardan shaft B

A

C

CAUTION There is a risk of injury if the cardan shafts are not installed correctly!

If the joints of the cardan shaft are not aligned to each other, the shaft can be destroyed. People in direct proximity could subsequently sustain serious injuries. The vehicle can be damaged.

F

E

D

► Align cardan shafts to marking.

Fig. 276

1. Position the front cardan shaft B, paying attention to both markings.

2. Tighten the screws D on the front cardan shaft B on the front axle C to 49 Nm (Allen key SW8).

3. Tighten the screws E (Allen key SW8) and the new self-locking nuts F (SW17) of the front cardan shaft B on the high-speed gearbox A (X) to 49 Nm.

5-8

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Mount the central lubrication hoses (opt.)

1. Position cover B. 2. Tighten screws A on cover B (SW13).

A

B Fig. 277

3. Cut open the cable ties used to fix the hoses C of the central lubrication system to the attachment points B on the vehicle frame.

4. Fix hoses C to axis with cable tie A.

A

B

C

Fig. 278

5. Attach hoses A to both planetary carriers.

6. Attach the screws C to the collars on the planetary carriers (Allen key SW4).

7. Attach the screws B to the collars on the axle (SW17).

A

C B

A Fig. 279

Mount the wheel covers 1. Position the wheel covers A and holders.

2. Tighten the 4 nuts respectively on both sides B (socket 27).

A B Fig. 280

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-9

5 Axles Next steps

E A D

B C

A

B

1. Turn back all set screws A, B, C approx. 1 turn evenly, in alternation (3 on either side of the axle tube, see circles in diagram).

2. Counter all set screws with lock nut D (3 on either side of the axle tube, see circles in diagram). ➥ The parking brake is applied.

3. Vent brake – see “Bleeding the service brake on the front axle” on page 1-96 and – see “Bleeding the service brake on the rear axle” on page 1-96 Synchronising the steering system 1. Set the steering mode switch S022 to front-axle steering 2. Start the diesel engine 3. Press the steering mode switch S022 five times within 10 seconds - Front-axle steering is now activated 4. Turn the wheels in the opposite direction 5. Set the steering mode switch S022 to 4-wheel steering and confirm (press steering mode switch S022 once) 6. All three of the indicator lights for the steering modes now flash and the steering electronics D001 are synchronising 7. By steering via the neutral position, the steering system is synchronous again.

C Fig. 281

5-10

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5

5.3

Rear axle

Removing the rear axle Preparatory steps

A

1. Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3 2. Remove screws A. 3. Remove sheet B over rear axle C.

B C Fig. 282

4. Remove screws A from cover B (SW13).

5. Take off cover B.

A

B Fig. 283

6. Remove screws A from cover B (SW13).

7. Take off cover B.

A

B Fig. 284

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-11

5 Axles Remove wheel covers 1. Remove 4 nuts each on both sides B (socket 27) 2. Remove wheel covers A and holders.

A B Fig. 285

Remove central lubrication hoses (opt.)

A

C

1.

2.

3.

4.

Remove hoses A on both planetary carriers.

Remove screws C from the planetary carrier collars (Allen key SW4).

Remove screws B from axle collar (SW17).

Pull back hoses to centre.

B

A Fig. 286

5-12

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Remove the rear cardan shaft A

1. Remove the screws C (Allen key SW8) and the self-locking nuts D (SW17) from the rear cardan shaft B on the high-speed gearbox A (X).

B

C

D

Fig. 287

2. Remove the screws B from the rear cardan shaft A on the rear axle C (Allen key SW8).

3. Place the cardan shaft to one side.

A

B C Fig. 288

A

F

B

E

D

Remove hoses 1.

2.

3.

4.

5.

Remove hydraulic hoses C and E from the steering cylinders (AF22).

Remove hydraulic hoses D from the brake (AF17).

Disconnect connector F of the overload safety device sensor.

Disconnect the steering sensor connector A. Remove grease hoses B from the rear axle.

C

Fig. 289

Jack up the machine 1. Raise the vehicle with a suitable hydraulic jack B by placing it centrally underneath the counterweight A. 2. Place a secure support underneath the vehicle.

3. Position the hydraulic jack B at the back, underneath the centre of the rear axle and pump up to the level of the axle.

A B Fig. 290

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-13

5 Axles Remove the compressed air tank (opt.)

1. Drain the compressed air from the red coupling head

A

Fig. 291

2. Disconnect the connection marked brown A on the pressure tank B. A

B

Fig. 292

B

C

A

3. Disconnect the connections marked red and blue A and C. 4. Disconnect the connector B. 5. Loosen the screws E and remove the pressure tank D.

D

E Fig. 293

Remove bolt from hydraulic oscillating lock (opt.)

1. Remove pin lock A. 2. Drive out bolt B.

B A

A

Fig. 294

5-14

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Remove rear axle A B

1. Remove screws A and nuts B (AF32).

2. Slowly lower the front axle with the hydraulic jack.

3. Roll the rear axle away on wheels.

A

Fig. 295

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-15

5 Axles

Install rear axle Install rear axle A

1. Roll the rear axle underneath the vehicle on wheels.

2. Slowly raise the rear axle with the hydraulic jack.

3. Tighten screws A and nuts B to 750 Nm (AF32).

B

A

Fig. 296

Install axle oscillating lock 1. Put bolt A into bore.

2. Push the splint B into the bolt A so that it is held securely.

A B

Fig. 297

B

C

A

3. Position the pressure tank D and tighten the screws E. 4. Plug in connector B. 5. Attach the connections marked red and blue: A and C.

D

E Fig. 298

6. Attach the connection marked in brown A on the pressure tank B. A

B

Fig. 299

5-16

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Jack up the machine 1. Raise the vehicle with a suitable hydraulic jack B by placing it centrally underneath the counterweight A. 2. Remove the support underneath the vehicle.

3. Lower the hydraulic jack B.

A B Fig. 300

A

F

B

E

Install the hoses 1.

2.

3.

4.

5.

Tighten hydraulic hoses C and E of the steering cylinders (AF22).

Tighten hydraulic hoses D of brake (AF17).

Insert connector F of the overload safety device sensor.

Connect the steering sensor connector A. Tighten grease hoses B on the rear axle.

C

D

Fig. 301

Install the cardan shaft

CAUTION G A

There is a risk of injury if the cardan shafts are not installed correctly!

If the joints of the cardan shaft are not aligned to each other, the shaft can be destroyed. People in direct proximity could subsequently sustain serious injuries. The vehicle can be damaged.

G

I

H

► Align the cardan shaft to the marking.

1. Position the rear cardan shaft G, paying attention to both markings.

2. Tighten the screws H (Allen key SW8) and the new self-locking nuts I (SW17) of the rear cardan shaft G on the high-speed gearbox A (X) to 49 Nm.

Fig. 302

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-17

5 Axles 3. Tighten the screws B of the rear cardan shaft A on the rear axle C to 49 Nm (Allen key SW8).

A

B C Fig. 303

Mount the central lubrication hoses (opt.)

A

C

1. Pull the hoses through the axles and secure with cable ties.

2. Tighten the hoses A and C that are part of central lubrication at the distributor block B.

B

Fig. 304

A

C

3. Pull the hoses from the centre to the planetary carriers.

4. Attach the screws B to the collars on the axle (SW17).

5. Attach the screws C to the collars of the planetary carriers (Allen key SW4).

6. Attach hoses A to both planetary carriers.

B

A Fig. 305

Mount the wheel covers 1. Position the wheel covers A and holders.

2. Tighten the 4 nuts respectively on both sides B (socket 27).

A B Fig. 306

5-18

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Next steps 1. Position cover B. 2. Tighten screws A on cover B (SW13).

A

B Fig. 307

3. Position cover B. 4. Tighten screws A on cover B (SW13).

A

B Fig. 308

A

B C

5. Position sheet B over the rear axle C .

6. Tighten screws A (AF13).

7. Vent brake – see “Bleeding the service brake on the rear axle” on page 1-96.

8. Fill shaft with oil – see chapter 1 “ Check/refill oil at differential (rear axle)” on page 1-92 9. Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3 10.Synchronise steering – see “Synchronising the steering system” on page 5-10

Fig. 309

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-19

5 Axles

5.4

Steering cylinder

Remove the steering ram Remove ball rod end

A

1. Remove self-locking nut B. 2. Remove the ball rod end A with a normal extractor tool.

B Fig. 310

A

B

C

D

Remove intermediate joints 1. Heat piston rod at A and B with a hot air gun.

NOTICE Complete disassembly of the guide rod can damage the piston rod. ► First disconnect the intermediate joints before disassembling everything.

2. Hold the piston rod B to counter any movement (SW32) and then remove the intermediate joint A (SW50).

3. Hold the piston rod C to counter any movement (SW32) and then remove the intermediate joint D (SW50).

4. Disassemble the intermediate joints A and D completely.

Remove steering sensor

Fig. 311

1.

2.

3.

4.

A B

Mark the position f the steering sensor.

Loosen the screws A on the collars B. Remove the collars B. Remove the steering sensor C (B004 or B005).

C Fig. 312

5-20

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Remove the piston rod 1. Detach the screw-in connection A on the steering cylinder B.

A

B

Fig. 313

2. Remove the screws B from the steering cylinder A. 3. Use a plastic hammer to remove the steering cylinder, detaching it in the direction of the arrow.

B

A

B Fig. 314

4. Remove the circlip B from the guide bushing A. A

B

Fig. 315

5. Insert the guide bushing B into the cylinder jacket A using a plastic hammer.

A

B Fig. 316

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-21

5 Axles 6. Remove the circlip B from the cylinder jacket A using two screwdrivers.

A

B Fig. 317

7. With the help of a plastic hammer, remove the piston rod C together with the guide bushing A from the cylinder jacket B.

A

B

C

Fig. 318

5-22

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5

Install steering cylinder Install piston rod 1. Install the piston rod seals A, B and C in the cylinder jacket.

A

B

C

Fig. 319

2. Install the piston rod seals A, B and C in the guide bushing.

C

B

A

Fig. 320

3. Install sealing ring A in the guide bushing.

A

Fig. 321

4. Attach the sealing rings A, B and C and the guide tape D to the piston E. B

A

C

D

E

Fig. 322

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-23

5 Axles 5.

6.

7.

8.

B

A

Grease the sealing rings lightly with oil before assembling them.

Position the tool B on the piston rod A. Insert the piston rod A into the cylinder jacket C with a plastic hammer.

Remove tool B .

C

Fig. 323

9. Position tool B on the piston rod C and push the guide bushing A on to the piston rod.

10.Remove tool B.

B

C

A

Fig. 324

11.Insert circlip A into the groove on the cylinder jacket B.

A

B

Fig. 325

12.Push the guide bushing B outwards as far as it will go up to the circlip A. A

B Fig. 326

5-24

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 13.Insert the circlip B into the groove on the guide bushing A A

B

Fig. 327

A

Install the steering ram

B

1. Insert the steering cylinder A into the axle bridge.

2. Tighten screws B to 12 Nm.

B Fig. 328

3. Attach the screw-in connection A to the steering cylinder B. A

B

Fig. 329

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-25

5 Axles Mount the steering sensor 1. Position the steering sensor C (B004 or B005) at the marked location.

2. Place collars B around the steering cylinder.

3. Tighten the screws A on the collar B.

A B

C Fig. 330

A

B

C

D

Mount the intermediate joints 1. Smear both sides of the threaded spigots on the piston rod B and C with Loctite 242.

2. Counter the movement of the piston rod B (SW32) and tighten the intermediate joint A to 260 Nm (SW50).

3. Counter the movement of the piston rod C (SW32) and tighten the intermediate joint D to 260 Nm (SW50).

Fig. 331

Attach the ball rod end

A

1. Attach the ball rod end A. 2. Tighten new self-locking nut B to 260 - 290 Nm.

B Fig. 332

5-26

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5

5.5

Adjust the steering sensors 1.

2.

3.

4.

5.

6.

7.

8.

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Put the axle in a straight-ahead position (steering angle 0°).

Engage the starter.

If necessary, release the hose collar on the steering sensor.

Determine the scatter zone of the steering sensor (approx. 4 mm) by moving it on the steering cylinder. ➥ LED on steering sensor is on Push steering sensor to the left until the LED goes out. ➥ Draw a mark in this position Push steering sensor to the right until the LED goes out. ➥ Draw a mark in this position Position the steering sensor right in the centre of the scatter zone.

Tighten the hose collars on the steering sensor.

5-27

5 Axles

5.6

Type plate – front/rear axle

All information about the axles can be found on the type plate.

Axle type label Axle type

Carraro no.

Carraro-serial number Customer no.

Overall reduction gear

Rotational speeddrive shaft Differential type

Oil specification

Oil quantity in differential housing and transfer gearbox

5-28

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5

5.7

Threaded fittings

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-29

5 Axles

5.8

Threadlocker – tightening torques A1* = Loctite®510 * for rear axle only B2 = Loctite®270

5-30

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5

A5 = Loctite®5188 B1 = Loctite®542 B2 = Loctite®270 C2 = Loctite®638

Rear axle

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Front axle

5-31

5 Axles

B2 = Loctite®270 C3 = Loctite®542 Front axle

Rear axle

For rear axle only

5-32

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5

5.9

Drain, filler and check plugs

Rear axle

Front axle

Pos.

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Designation

1

Oil filler and check plug

2

Drain plug

3

Breather

4

Filler, drain and check plugs (planetary gearing)

5

Bleeder valve

6

Steering sensor

7

Grease zerks

5-33

5 Axles

5.10 Sealing work Drive flange

Remove drive flange 9. Unscrew the cardan shaft 10.Remove circlip 1 11.Remove flange 2 12.Remove O-ring 4 and disk 5

13.Remove shaft sealing ring 3

5-34

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Install drive flange 1. Mount the shaft sealing ring 3 when dry, using an adapter

2.

3.

4.

5.

6.

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Mount washer 5 and O-ring 4 Install flange 2 Mount circlip 1 Screw on the cardan shaft Fill in oil

5-35

5 Axles

Planetary gearing, joint housing for front/rear axle

Remove the planetary drive 1. Drain oil (see maintenance) 2. Remove lock screw 3 3. Remove planetary lid 2

3

2

4. Remove circlip 1 5. Remove lock washers 2 and 3

1

5-36

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 6. Remove the fastening screws 5 from the internal geared wheel 7 with an open-end wrench SW22 5 7

7. Press the internal geared wheel with two pull-off screws M16 5 7

8. In order to separate the drive disk 7 remove the circlip 8 and dismantle the internal geared wheel 4 9. If necessary, disconnect the guide bushings 6 with a hammer and an adapter

6

7 8 4

10.Dismantle the wheel hub with a mounting lever and a hammer

11.Place the wheel hub 11 on a level surface 12.Remove the sealing ring 13 with a mounting lever 13.Dismantle the bearing shells 9 and 12 with the help of a hammer and a soft mandrel

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-37

5 Axles

19

18

14

14.Remove the fastening screws 19 from the upper and lower bearing bolts 18 with an open-end wrench SW24 15.Remove the bearing bolts

16.Take the joint housing 14 out of the axle tube together with the double cardan shaft

17.Take the double cardan shaft 14 out of the shaft housing 14

18.Remove sealing ring

5-38

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Installing the planetary drive 1. Attach the sealing ring 23 to the shaft housing 14 using an adapter 2. Apply a thin coat of grease to the sealing ring

14 23

3. Place the thin belleville spring washer 25 and the thick belleville spring washer 27

27

25

NOTICE The planetary gearing leaks due to a defect sealing ring! ► Do not damage the sealing ring when assembling the shaft housing.

4. Install the double cardan shaft in the shaft housing 14 5. Mount the shaft housing to the axle tube

14

19 18

6. Mount the upper and lower bearing bolts 18 7. Install fastening screws 19 8. Pay attention to the tightening torque – see “Threadlocker – tightening torques” on page 5-30

9. Mount sealing ring 13 with an adapter 10.Place the sealing ring without grease, sealing compounds etc. (outside and inside) 11 13

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-39

5 Axles

14

12

6

11.Install the wheel hub 12 in the shaft housing 14 12.Mount taper roller bearing 9

9

13.Attach the guide bushings 6 in line with the drive disk 7 14.Allow 2 bushings to protrude by about 2 mm ➥ The projecting bushings are used as guides during assembly

7

15.Assemble the internal geared wheel 4 and the drive disk 7 and secure with the circlip 8

16.Mount the internal-geared wheel 17.Mount the two protruding bushings with two screws

6

5

18.Insert the protruding bushings 6 with the help of a hammer and an adapter 19.Attach the fastening screws 5 paying attention to the tightening torque. ➥ – see “Threadlocker – tightening torques” on page 5-30

20.Press the cardan shaft outward by means of a mounting lever.

5-40

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5

3

2 1

21.Mount washers 2 and 3 22.Insert the circlip 1 23.Attach the planetary lid (use new O-ring)

24.Install fastening screws 3 25.Fill in oil

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-41

5 Axles

Axle tube, front axle

Axle tube, remove front axle Disable (release) the negative-action brake before removing the double cardan shaft ➥ – see “Deactivating/activating the brake discs (front axle)” on page 6-5

13

11

1.

2.

3.

4.

Draining oil Hook planetary gearing into crane Remove guide rod 13 Remove the upper 11 and lower bearing bolts 12

12

5-42

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 5. Remove the planetary gearing 13 together with axle 10 from the axle tube 14 3

10 14

6. Apply the marks (see figure) ➥ Axle tube, brake cylinder and differential housing

7. Hook the axle tube 3 into the crane with the help of hoisting gear 8. Remove the fastening screws with the hexagon socket 14

9. Remove the axle tube 3 ➥ The brake can be accessed freely 10.Remove the O-ring 2

11.Take the seal 9 out of the axle tube

9

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-43

5 Axles Mount the axle tube, front axle 1. Mount a new sealing ring 9 with an adapter

Installation drawing of sealing ring 9 in the axle tube ➥ Dust lip faces outwards

2. Install a new O-ring 2

3. Flange mount the axle tube 3 to the differential housing 1 ➥ Bear in mind the mark

4. Mount the fastening screw with hexagon socket 14

5. Tighten the screws in sequence 6. Pay attention to the tightening torque – see “Threadlocker – tightening torques” on page 5-30

5-44

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 7. Place the thin belleville spring washer 25 and the thick belleville spring washer 27

27

25

3

NOTICE

10

Axle tube leaks due to defect sealing ring!

14

13

11

► Do not damage the sealing ring when installing the double cardan shafts.

8. Insert the planetary gearing 14 and double cardan shaft 10 into the axle tube 3 9. Attach the upper 11 and lower bearing bolts 12 10.Mount the guide rod 13 11.Fill in oil

12

12.Activate the negative brake function (parking brake) ➥ – see “Deactivating/activating the brake discs (front axle)” on page 6-5

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-45

5 Axles

Axle tube, rear axle

Remove the axle tube, rear axle

11

13

1.

2.

3.

4.

Draining oil Hook planetary gearing into crane Remove guide rod 13 Remove the upper 11 and lower bearing bolts 12

12

5. Remove the planetary gearing 13 together with axle 10 from the axle tube 14 3

10 14

5-46

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 6. Apply the marks (see figure) ➥ Axle tube and differential housing

7. Hook the axle tube 3 into the crane with the help of hoisting gear 8. Remove the fastening screws with the hexagon socket 14

9. Remove the axle tube 3 10.Remove the O-ring 2

11.Take the seal 9 out of the axle tube

9

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-47

5 Axles Mount the axle tube, rear axle 1. Mount a new sealing ring 9 with an adapter

Installation drawing of sealing ring 9 in the axle tube ➥ Dust lip faces outwards

2. Install a new O-ring 2

3. Flange mount the axle tube 3 to the differential housing 1 ➥ Bear in mind the mark

4. Mount the fastening screw with hexagon socket 14

5. Tighten the screws in sequence 6. Pay attention to the tightening torque – see “Threadlocker – tightening torques” on page 5-30

5-48

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 7. Place the thin belleville spring washer 25 and the thick belleville spring washer 27

27

25

3

NOTICE

10

Axle tube leaks due to defect sealing ring!

14

13

11

► Do not damage the sealing ring when installing the double cardan shafts.

8. Insert the planetary gearing 14 and double cardan shaft 10 into the axle tube 3 9. Attach the upper 11 and lower bearing bolts 12 10.Mount the guide rod 13 11.Fill in oil

12

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-49

5 Axles

Brake version 1

Remove brake version 1 1. Before disassembly, deactivate the negative brake (release) ➥ – see “Deactivating/activating the brake discs (front axle)” on page 6-5 2. Draining oil

3. Remove axle tube from brake cylinder ➥ – see “Axle tube, remove front axle” on page 5-42

5-50

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 4. Take the outer fins 3, inner fins 4 and fin holder 5 out of the axle tube

NOTICE

F

Damage incurred to the differential housing due to tension from the spring washer ► Ensure that the brake cylinder is pressurised Device with stopcock V (for pressure loading) Connection B for parking brake to be mounted to device V

5. Install a device with stopcock V in the parking brake connection B on the brake cylinder 13 and pressurise with 20 to 25 bar F

13

6. Mark installation position of brake cylinder 13 on the differential housing 24 7. Remove screws 11 8. Remove brake cylinder 13 from the differential housing 24

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-51

5 Axles 9. Remove the O-rings 14, 15 and 23 from the brake cylinder 13

10.Remove the self-adjustment 6 from the brake cylinder 13 11.Keep the individual parts that belong to the self-adjustment 6

12.Remove the service brake brake piston 8 with the help of 2 mounting levers 2 I from the brake cylinder 13

13.Remove the O-rings 9 and 10 from the brake piston 8

14.Remove the clamping sleeve 7, which is part of the self-adjustment, from the brake piston 8

5-52

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 15.Via the device with the stopcock V let off pressure from the brake cylinder 13 16.Dismantle the device with stopcock V from the brake cylinder 13

17.Place the brake cylinder 13 on a workbench 18.Position the special tool t1 on the spring washer 20 19.Use a press to push down on the thrust washer 21 until the circlip 22 can be removed

20.Remove circlip 22

CAUTION Spring washers are put under considerable pretension There is a risk of injury if the spring washer jumps out of position ► Release pressure slowly 21.Slowly release pressure from the press 22.Remove the circlip 22 and thrust washer 21

23.Remove the spring washers 19 and 20 from the brake cylinder 13

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-53

5 Axles 24.Turn the brake cylinder 13 on the workbench, so that the brake piston 17 can be removed from the parking brake

13 17

25.Remove the brake piston 17 with a suitable tool

26.Remove the O-rings 16 and 18 from the brake piston 17

Mount brake version 1

NOTICE Used O-rings are sometimes unable to seal properly. ► Use new O-rings!

1. Grease the O-rings 16 and 18 lightly and mount to the brake piston 17 on the parking brake 2. Place the brake cylinder 13 on a workbench 3. Press the brake piston 17 into the brake cylinder 13 with the help of a press and adapter

5-54

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 4. Insert the spring washers 19 and 20 into brake cylinder 13 5. Position the thrust washer 21 with the circlip on top of it 22 on the spring washer

Order of installing the internal components

6. Position the special tool t1 on the spring washer 20 7. Use a press to push down on the thrust washer 21 until the circlip 22 can be removed

8. Move the special tool t1 a few millimetres from the spring washer 20 9. Add about 20 bar of oil pressure to the brake cylinder and check that the circlip 22 is positioned securely and that the O-rings are leak-tight

Connection B for parking brake to be mounted to device with cockstop V

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-55

5 Axles 10.Install a device with cockstop V in the parking brake connection B on the brake cylinder 13 and pressurise with 20 to 25 bar

11.Insert clamping sleeves 7 into the pistons for the self-adjustment device, with the help of an adapter and hammer

The clamping sleeves 7 have to be aligned to the underside of the piston

NOTICE Used O-rings are sometimes unable to seal properly. ► Use new O-rings!

12.Lightly grease the O-rings 9 and 10 and mount to the brake piston 8 on the parking brake 13.Position the brake piston 8 in such a way that the infeed unit is in line with the hydraulic connection or the inspection hole 14.Insert the brake piston 8 into the brake cylinder 13 and position the special tool on the piston 15.Press the brake piston 8 into the brake cylinder 13 with the help of a press

8

13

5-56

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 16.Mount the self-adjustment 6 to the brake cylinder 13 under observation of the installation diagram 17.Pay attention to the tightening torque – see “Threadlocker – tightening torques” on page 5-30

Installation diagram for self-adjustment device: A B C D E

Screw Belleville spring washer Distance sleeve Bushing Washer

NOTICE Used O-rings are sometimes unable to seal properly. ► Use new O-rings!

18.Lightly grease the O-rings 14, 15 and 23 and mount to the brake cylinder 13 Installation position of O-rings 14, 15 and 23 on brake cylinder 13

NOTICE Damage incurred to the differential housing due to tension from the spring washer ► Ensure that the brake cylinder is pressurised 19.Pay attention to the markings made during disassembly indicating the installation position of the brake cylinder 13 20.Attach brake cylinder 13 to the differential housing 24 21.Smear screws 11 with sealant and screw into the brake cylinder 13 22.Pay attention to the tightening torque – see “Threadlocker – tightening torques” on page 5-30

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-57

5 Axles 23.Check the inner and outer fins as well as the fin holder for damage 24.Replace defect parts with new parts

NOTICE Damage incurred to the differential housing due to tension from the spring washer ► Ensure that the brake cylinder is pressurised Before replacing the defect fins, the brake cylinder 13 has to be put into the position described in the following steps: NOTICE Outflow of oil through bleed valve. ► Keep bleed valve closed.

25.Check that bleed valve A for the service brake is closed

26.Press the brake piston 8 right to the end of the stroke

27.Carefully clean the seat of the inner and outer fins in the axle tube

5-58

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 28.Mount the outer 3 and inner fins 4 as well as the fin holder 5 in the axle tube as follows

29.Insert the outer fins in such a way as to ensure that the recesses s are horizontally positioned in comparison with the outer diameter (see picture A) 30.Insert the inner fins in such a way as to ensure that they fit into the holes (see picture B)

Piston side

When assembling the brake fins, make sure they are positioned correctly on the fin holder 5: the holes of all of the inner fins each have to be in the same position in order to ensure an optimal flow of oil. The groove of the fin holder must be on the piston side.

open side

31.Flange mount the axle half to the brake cylinder, taking care to ensure the correct positioning of the brake fins

32.Once both axle halves have been mounted, release pressure from the brake cylinder via the cockstop device V 33.Dismantling the device with the cockstop V

34.Enable the negative-action brake ➥ – see “Deactivating/activating the brake discs (front axle)” on page 6-5 35.Fill in oil

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-59

5 Axles

Brake version 2

Remove brake version 2 1. Draining oil 2. Before disassembly, deactivate the negative brake (release) ➥ – see “Deactivating/activating the brake discs (front axle)” on page 6-5

3. Remove axle tube from brake cylinder 14

5-60

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 4. Take the outer and 24, 27 inner fins 25, 28 as well as the fin holder 26 out of the axle tube

5. Remove the self-adjustment 23 which is part of the brake piston 22 from the service brake 6. Keep the individual parts that belong to the self-adjustment 23 7. Remove the brake piston 22

8. Remove the O-rings 20 and 21 from the brake piston 22

9. Remove the screw plugs 19 10.Completely remove the parking brake screws 18 from these positions: A, B and C 11.Remove the studs alternately 16 until they have all been taken out 12.Remove O-rings 17 and bolts 15

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-61

5 Axles

13

13.Mark the installation position of the brake cylinder 14 on the differential housing 14.Secure the brake cylinder 14 with hoisting gear 15.Remove the brake cylinder 14 16.Remove the O-ring 13 from the brake cylinder 14

14

t2

17.Place the brake cylinder on a workbench 18.Position special tool t2 CA715056 on the thrust washer 3 19.Use a press to push down on the thrust washer 3 until the circlip 2 can be removed

20.Remove circlip 2

CAUTION Spring washers are put under considerable pretension!

There is a risk of injury if the spring washer jumps out of position ► Release pressure slowly 21.Slowly release pressure from the press 22.Remove the circlip 2 and thrust washer 3 23.Remove spring washers 4 and 5 from brake cylinder 14

CAUTION If the brake piston is operating sluggishly, a high level of pressure can build up!

Risk of injury due to brake piston jumping out of position ► Add press slowly 24.Via the hydraulic brake cylinder connection 14 slowly build up pressure until the parking brake brake piston 8 is pushed out of brake cylinder 14 25.Remove O-rings 6 and 12 from the brake piston 8 26.Remove the circlips 7 from the brake piston 8 27.Push out the thrust bolts 10 28.Remove the O-rings 9 and 11 from the thrust bolt 10

5-62

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Mount brake version 2

NOTICE Used O-rings are sometimes unable to seal properly. ► Use new O-rings!

1.

2.

3.

4.

5.

t2

Lightly grease the O-rings 9 and 11 and mount to thrust bolt 10 Insert thrust bolt 10 into the brake piston 8 of the parking brake In order to secure the thrust bolts 10 insert the circlips 7 Lightly grease the new O-rings 6 and 12 mount to brake piston 8 Push the brake piston 8 into brake cylinder 14 with the help of special tool t3 CA715056 and a press

t3

6. Position the spring washers 4 and 5 on top of each other, paying attention to the positioning of the concave side as seen in the next picture 7. Place the spring washers together with the thrust collar 3, the circlip 2 and the special tool t2 CA715056 into the brake cylinder 14 8. Position special tool t2 CA715056 on the spring washer 4 9. Use a press to push down on the thrust washer 3 until the circlip 2 can be removed

t2

Positioning of the concave side of the spring washers 4 and 5

4 5

t3

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

10.Move the special tool t2 CA715056 a few millimetres away from the spring washer 4 11.Add about. 20 bar of oil pressure to the brake cylinder and check that the circlip 2 is positioned securely and that the O-rings are leak-tight

5-63

5 Axles

BrakePiston

12.Insert bolts 15 into the brake cylinder 14 at the parking brake and positioned at A, B and C 13.Screw studs 16 into position until the bevelled side of the bolts 15 touch the brake piston of the parking brake 14.Tighten the studs 16 by a 1/4 turn

NOTICE Used O-rings are sometimes unable to seal properly. ► Use new O-rings!

15.Lightly grease new O-ring 17 and position next to screws 16

Information We recommend Loctite®518 as a sealant

t3

16.Apply sealant underneath the head of the screws 18 17.Tighten the screws 18 ➥ Tightening torque 50 Nm 18.Tighten screw plug 19 ➥ Tightening torque 30 Nm 19.Hit the clamping sleeve for the self-adjustment into the piston using a soft mandrel t3 CA715033 and a hammer

The clamping sleeves have to be aligned to the underside of the piston

5-64

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5

NOTICE Used O-rings are sometimes unable to seal properly. ► Use new O-rings!

20.Lightly grease the O-rings 20 and 21 and attach to the brake piston 22 of the service brake 21.Press the brake piston into the brake cylinder 14 with a special tool t2 CA715056 and a press t3

14

22.Assemble the self-adjustment 23 and tighten the screws ➥ Tightening torque 10 Nm

NOTICE Used O-rings are sometimes unable to seal properly.

13

14

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

► Use new O-rings!

23.Lightly grease the O-ring 13 and attach to the brake cylinder 14 24.Secure the brake cylinder 14 with hoisting gear 25.Pay attention to the markings made during disassembly indicating the installation position of the brake cylinder 14 26.Attach the brake cylinder 14 27.Check the inner and outer fins as well as the fin holder for damage 28.Replace defect parts with new parts

5-65

5 Axles 29.Pay attention to the correct positioning of the brake piston

30.Mount the outer fins 24, 27, inner fins 25, 28 and the fin support 26 as shown in the picture

When assembling the brake discs, make sure they are positioned correctly on fin holder 26: the holes of all the inner fins 25, 28 have to be in the same position in order to ensure an optimal flow of oil.

31.Flange mount the axle half to the brake cylinder

32.Enable the negative-action brake ➥ – see “Deactivating/activating the brake discs (front axle)” on page 6-5 33.Fill in oil

5-66

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5

Front axle differential lock 16

15 12 13

17

11 14 10 8

7

9 5 5 10

2

3 7 6 4

1

Remove the differential lock of the front axle 1.

2.

3.

4.

Remove the axle half (on left in the driving direction) Remove the brake cylinder Remove the intermediate plate (differential bearing) Remove the cylinder 3

3

5. Remove the end cap 14

14

6. Remove circlip 7

2

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-67

5 Axles 7. Pull off the piston 4 8. Take the springs 10 of the spindle 8 on both sides 9. Remove the circlip 7 on the side of the end cap

8

10 4

10.Remove spindle 8

8

11.Remove the differential cage 17 with fork 11 of the differential lock from the differential housing

11

17

5-68

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Mount differential lock at front axle 9

1. Mount the differential cage 17 with fork 11 of the differential lock inside the differential housing

15

2. Attach the spindle 8

8

3. Attach the circlip 7 to the side of the end cap 4. Take the springs 10 of the spindle 8 on both sides 5. Attach piston 4

8

10 4

6. Mount circlip 7

7

7. Attach end cap 14

14

1

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

8. Attach cylinder 3 9. Pay attention to the threadlocker – see “Threadlocker – tightening torques” on page 5-30 10.Attach the intermediate plate (differential bearing) 11.Attach the brake cylinder 12.Mount the axle half (on left in the driving direction)

5-69

5 Axles

Differential

5

1 4 2

7 3

8

9 10

6 13 14

11 12

15 16

19

18

17

20 22

21

23

5-70

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Remove differential 1. Remove both fastening screws 12 from the intermediate plate 10

2. Remove the intermediate plate 10 3. Remove the O-ring 9 from the differential housing 1

4. Remove the differential 7

5. Remove the O-rings 6 from the both sides of the differential housing 1

6. Remove the screw 14 and nut retention 13 belonging to the setting nut from the intermediate plate 10 7. Remove the setting nut 11 from the intermediate plate 10

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-71

5 Axles 8. Remove the bearing shell 8 from the intermediate plate 10 with a mandrel and hammer

In the event of considerable abrasion (only rear axle): 9. Remove the sealing rings 3 and 5 and the bushings 2 and 4 from the differential housing 1 using suitable tools

5-72

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Remove the angle drive 1. Open the lock of the groove nut 23 2. Remove the groove nut 23 with the special tools CA119099 and CA715022 3. Remove the disk 22 and bearing cone 21 22 23

21

4. Knock the drive shaft 15 out of the differential housing with a plastic hammer

15

5. Remove disk 6, O-bushing 5 and disk 4

6. Dismantle the bearing shells 3 and 8 with the help of a hammer and a mandrel

7. Remove the tapered roller bearing 17 with a standard extractor 8. Remove the setting disk 16 17 16 15

17 19

9. Check the components for abrasion or damage 10.Make sure to replace the groove nut 23, O-bushing 19 and tapered roller bearing 17

23

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-73

5 Axles Mount the new angle drive with the existing housing Calculate the new setting disk 1. Set the dial gauge to 30 mm

2. Measure the tapered roller bearing by turning it several times ➥ Example: "-265" on the dial gage means a thickness of D= 27.35 mm 3. Calculate size x : Example Required strength of tapered roller 27,25 mm bearing - Actual strength of tapered roller bearing

- 27,35 mm

Measure X

-0,1 mm

4. Place the differential housing on a workbench 5. Mount the bearing shells 3 and 8 with a special tool CA715380

6. Read off the value V from the head of the old and the new angle 7. Measure size y: Example Value V from the old angle drive

1 mm

- Value V from the new angle drive - 0,8 mm Measure Y

0,2 mm

8. Calculate size S: Example Measure X

-0,1 mm

+ size y

0,2 mm

S

0,1 mm

➥ The disk thickness increases by size S

5-74

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 9. Select the setting disk 16 from the following available disks Disk thicknesses Starch 2.5 2.6 2,7 2.8 2.9 3.0 3,1 3.2 3,3 3,4 Quan-tity

--

--

--

--

--

--

--

--

--

10.Mount the selected setting disk 16 with the chamfer facing the head of the drive shaft (as shown in the picture) 16

20 17

19

16

11.Mount the tapered roller bearing 17 with a special tool CA715179 and a press 12.Mount the disk 18, new O-bushing 19 and disk 20

18

15

15 19 17

20

13.Check the assembly sequence

18

14.Insert the drive shaft 15 into the differential housing 15.Mount the tapered roller bearing 21 on to the shaft with the adapter CA715179 21

15

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-75

5 Axles 16.Mount the disk 9 on to the drive shaft 17.Attach the groove nut 10 with the special tools CA119099 and CA715022

18.The tightening torque is determined by the drag torque

NOTICE Damage to the O-bushing due to groove nut that has been tightened too much. ► Tighten the groove nut gradually 19.Tighten the groove nut 10 gradually 20.Attention: If the groove nut 10 has been tightened too much, the O-bushing 5 has to be replaced and the procedure repeated 21.When the drag torque has been set, it is a good idea to use a plastic hammer to hit both sides of the drive shaft so that the tapered roller bearings settle properly 22.If you do not use the special tool to measure the drag torque, the reference diameter is the end of the drive shaft 23.The measured value has to be within the following range: FP = 92,0 – 137,9 N

24.Once the required value has been reached, secure the groove nut 10

5-76

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Mount the differential If removed (only rear axle): 1. Mount the sealing rings 3 and 5 and bushings 2 and 4 in the differential housing 1 using the tools shown in the following picture

The following tools must be used: • •

CA715163 for installing the bushings 2 and 4 CA715164 for installing the sealing rings 3 and 5

2. Mount the O-rings 6 on both sides of the differential housing 1

3. Place the intermediate plate 10 on a level surface 4. Mount the bearing shell 8 on the intermediate plate 10 using a hammer and the special tool CA715583 8

10

NOTICE Used O-rings are sometimes unable to seal properly. ► Use new O-rings!

5. Lightly grease the O-ring 9 and mount to the intermediate plate 10 6. When mounting the brake cylinder make sure that the markings made during disassembly between the brake cylinder and the differential housing 1 correspond.

7. Install right brake cylinder in the differential housing 1 8. Mount differential 7 in the differential housing 1 9. Always ensure the following: Front axle: ring gear is left, as in the driving direction Rear axle: ring gear is right, as in the driving direction

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-77

5 Axles 10.Install the left brake cylinder in the differential housing 1 11.Using the two fastening screws 12 mount the intermediate plate 10

12.Mount the setting screw 11 to the intermediate plate 10 with the special tool CA119030 13.Tighten until there is no more play and the differential bearing is at a slight tension

14.Mount the special tool CA715456 to the opening of the differential housing 15.Attach the dial gage with the magnetic foot to the differential housing, adjusting to an angle of 90° to the surface of the special tool plate, taking the reference value R into consideration

16.Move the special tool plate CA715456 back and forth by hand 17.Measure the play between the drive shaft and the ring gear and note this down 18.Turn the angle drive by a 1/4 turn and measure the play between the drive shaft and the ring gear, also noting down this measurement 19.Repeat step 18 several times in order to attain multiple values 20.Check whether the mean value of play is within the following range: 0.15 mm – 030 mm 21.Adjust the setting screw 11 with the special tool CA119030 as follows:

5-78

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 • •

If the flank clearance is below the defined tolerance, tighten the setting screw to the gear wheel and loosen the other setting screw respectively If the flank clearance is over the defined tolerance, tighten the setting screw to the side of the gear wheel and loosen the other setting screw respectively

22.Check whether a pre-tensioning force exists at the angle drive

23.If you do not use the special tool to measure the drag torque, the reference diameter is the end of the drive shaft 24.The measured value must be within the following range: 23,7 N – 35,6 N + FP

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-79

5 Axles

Front axle differential

Disassemble the differential front axle 1. Disassemble the sleeve 17 and round pin 16 of the differential lock

2. Place the differential into a vice

NOTICE Once the screws have been removed the two halves of the differential housing are loose 2

► Carefully remove the ring gear 3. Remove the screws 1 and take out the ring gear 2 enabling the differential cage to fall apart 4. Mark the installation position of the two housing halves 5. Completely disassemble the two housing halves 4 and 15 6. Check the condition of the individual parts 7. Replace any damaged or worn components

5-80

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 8. Remove the tapered roller bearings 3 and 18 from the housing halves 4 and 15 with a standard extractor

Assemble the differential front axle 4

1. Mount the tapered roller bearings 3 and 18 to the housing halves 4 and 15 with the special tool CA119230 and a hammer

18

15 3

2. Place the housing halves 4 and 15 on a workbench 3. Lightly grease the thrust washers 5 and 14 and insert them into position

6

13

11

9

8

4

15

10

4. Install the bevel wheels 6 and 13 in the housing halves 4 and 15 5. Lightly grease the thrust washers 10 and 11 6. Mount the satellite bevel wheels 9 and 12 to the hub with the thrust washers 10 and 11 8 7. Place the mounted hub on the housing half as shown 15

12

8. Hit the lockpin 7 into the hub with a hammer

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-81

5 Axles 9. Pay attention to the markings during assembly 10.Assemble the housing halves 4 and 15

11.Lubricate the seat of the round pins 12.Insert 4 round pins 16

16

13.Degrease the ring gear 2 and differential cage and clean with a suitable cleaning agent 14.Put the ring gear 2 on the differential cage 15.Smear the threads of the screws 1 with threadlocker – see “Threadlocker – tightening torques” on page 5-30 16.Secure the ring gear 2 to the differential cage with screws 1 17.Tighten the screws 1 18.Pay attention to the tightening torque – see “Threadlocker – tightening torques” on page 5-30 19.When assembling the sleeve 17 make sure it is positioned correctly 20.Insert sleeve 17 into the switch fork 21.Mount the differential paying attention to the installation position

5-82

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5 Rear axle differential

Disassemble the differential rear axle 1. Place the differential into a vice

NOTICE 2

Once the screws have been removed the two halves of the differential housing are loose ► Carefully remove the ring gear 2. Remove the screws 1 and take out the ring gear 2 carefully, so that the differential housing does not fall apart 3. Mark the installation position of the two housing halves 4. Disassemble the housing halves 4 and 12 completely 5. Check the condition of the individual parts 6. Replace any damaged or worn components

7. Disassemble the tapered roller bearings 3 and 13 from the housing halves 4 and 12 with a standard extractor

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-83

5 Axles Assemble the differential rear axle 1. Mount the tapered roller bearings 3 and 12 to the housing halves 4 and 12 with the special tool CA715083 and a hammer

2. Place the housing halves 4 and 12 on a workbench 3. Lightly grease the thrust washers 5 and 11 and insert them into position 4. Install the bevel wheels 6 and 10 in the housing halves 4 and 15 5. Lightly grease the thrust washer 9 6. Mount the satellite bevel wheel 8 together with the thrust washer 9 to the hub 7 7. Place the mounted hubs into the housing half 12 8. Degrease the ring gear 2 and differential cage and clean with a suitable cleaning agent 9. Put the ring gear 2 on the differential cage 10.Smear the threads of the screws 1 with threadlocker – see “Threadlocker – tightening torques” on page 5-30 11.Attach the ring gear 2 to the differential cage with screws 1 12.Tighten the screws 1 13.Pay attention to the tightening torque – see “Threadlocker – tightening torques” on page 5-30

5-84

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Axles 5

5.11 Special tools

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

5-85

5 Axles

5-86

RHB 416-06 * 1.0 * 41605_R_5_Achse_a4.fm

Brakes

6 Brakes

6 Brakes

6.1

Brake system maintenance Environment Use a suitable container to collect the hydraulic fluid as it drains and dispose of it in an environmentally friendly manner!

Specific safety instructions •

•

The brakes are a safety part of the first level; improper work can cause the brakes to fail. Therefore all maintenance and repair work on the brakes must be performed by trained personnel. An exception to this is the following work which must be performed by the driver of the machine: Damaged brake lines or hoses must immediately be replaced by an authorised workshop – danger of accidents!

Bleeding the parking brake

A

1. Start the engine.

2. Release the handbrake lever.

3. Attach vent hoses to vent valves A and place in an oil collecting container.

4. Carefully open the vent valves A on the front axle until no further air bubbles are visible in the vent hoses.

5. Close the vent valves A.

Fig. 333

Bleeding the service brake Bleeding the front axle

A

1. Start the engine.

2. Attach vent hoses to vent valves A and place in an oil collecting container.

3. Open the vent valves A on the front axle.

4. Slowly press the brake pedal down several times until no further air bubbles are visible in the vent hoses 5. Close the vent valves A.

Fig. 334

6-2

RHB 416-06 * 1.0 * 41605_R_6_Bremse_a4.fm

Brakes 6 Bleeding the rear axle 1. Start the engine.

2. Attach vent hoses to vent valves A and place in an oil collecting container.

3. Open the vent valves A on the rear axle.

4. Slowly press the brake pedal down several times until no further air bubbles are visible in the vent hoses 5. Close the vent valves A.

A

Fig. 335

Bleeding the service brake Bleed the service brake as follows: Bleeding the rear axle

Fig. 336

1. Connect the bleed container and the hose to the bleeder valve on the right of the rear axle 2. Start the diesel engine and let it run at idling speed 3. Press down the brake pedal and open the bleed valve SW 7 4. Press the brake pedal until there is no more air in the bleed hose 5. Close bleed valve SW 7 6. Repeat steps 1 – 5 on the left side of the rear axle Bleeding the front axle

Fig. 337

RHB 416-06 * 1.0 * 41605_R_6_Bremse_a4.fm

1. Connect the bleed container and the hose onto the bleeder valve on the right of the front axle - The outside bleeder valves are for the service brake 2. Press down the brake pedal and open the bleed valve SW 7 3. Press the brake pedal until there is no more air in the bleed hose 4. Close bleed valve SW 7 5. Repeat steps 1 - 4 on the left side of the rear axle

6-3

6 Brakes Bleeding the parking brake

Fig. 338

6-4

1. Connect the bleed container and the hose onto the bleeder valve on the right of the front axle - The inside bleeder valves are for the parking brake 2. Release the parking brake with switch S011 3. Open the bleed valve SW 7 until no more air bubbles can be seen at the bleed hose 4. Close bleed valve SW 7 5. Repeat steps 1 - 4 on the left side of the rear axle 6. Make a brake test. Repeat the procedure and bleed the brake system again if the braking effect is bad

RHB 416-06 * 1.0 * 41605_R_6_Bremse_a4.fm

Brakes 6

Deactivating/activating the brake discs (front axle) WARNING Risk of accidents due to machine rolling away!

Can cause serious injury or death. ► The machine can no longer be braked! ► The vehicle must be secured against rolling away before the brake discs are deactivated!

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

The spring-loaded braking system must be opened mechanically in order to be able to tow away the machine.

Disable brake discs

E A D

B C

1. Loosen lock nuts D on the set screws A – C approx. 1/2 turn.

2. Screw in set screws A, B, C on each axle tube side (3x) with Allen key E (8 mm) evenly, in alternation, until you feel some resistance.

3. Screw in set screws another 5 – 5.5 turns evenly, in alternation, against the resistance. ➥ The parking brake is released.

A

B

C Fig. 339

RHB 416-06 * 1.0 * 41605_R_6_Bremse_a4.fm

6-5

6 Brakes Enabling the brake discs

E A D

B C

1. Turn back all set screws A, B, C approx. 1 turn evenly, in alternation (3 on either side of the axle tube, see circles in diagram).

2. Counter all set screws with lock nut D (3 on either side of the axle tube, see circles in graph). ➥ The parking brake is applied.

3. Vent brake – see “Bleeding the front axle” on page 6-2.

A

B

C Fig. 340

6-6

RHB 416-06 * 1.0 * 41605_R_6_Bremse_a4.fm

Brakes 6

6.2

Brake pedal

Remove brake pedal 1. Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3.

2. Remove foot mat.

3. Remove Allen head screws A (AF3).

4. Remove cover B over the brake pedal C.

A

B C Fig. 341

5. Remove the 6 screws A. 6. Take off cover B.

A

B

Fig. 342

7. Disconnect the connector A. 8. Remove all hydraulic hoses at the brake valve B. 9. Remove 4 fastening screws C. 10.Pull out brake pedal.

A B

C Fig. 343

RHB 416-06 * 1.0 * 41605_R_6_Bremse_a4.fm

6-7

6 Brakes Install brake pedal 1. Position brake pedal.

2. Tighten the 4 fastening screws C. 3. Position all the hydraulic hoses at the brake valve B and tighten the sleeve nuts.

4. Plug in connector A.

A B

C Fig. 344

A

5. Position cover B. 6. Tighten the 6 screws A.

B

Fig. 345

7. Position cover B over the brake pedal C. 8. Tighten the Allen head screws A (AF3).

9. Place the foot mat on the floor of the driver's cab.

10.Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3.

A

B C Fig. 346

6-8

RHB 416-06 * 1.0 * 41605_R_6_Bremse_a4.fm

Brakes 6

6.3

Brake valve

Take out brake valve 1. Remove cover and dismantle hoses – see “Switch off the battery master switch” on page 1-3 work steps 5 to 8.

2. Remove fastening screws A and take off brake valve B. A

B

Fig. 347

Install brake valve 1. Position brake valve B and tighten fastening screws A. 2. Mount hoses and cover – see “Install brake pedal” on page 6-8 working steps 3 to 6.

3. Remove cover C. A

B C Fig. 348

RHB 416-06 * 1.0 * 41605_R_6_Bremse_a4.fm

6-9

6 Brakes

6-10

RHB 416-06 * 1.0 * 41605_R_6_Bremse_a4.fm

Work hydraulics

8 Work hydraulics

8 Work hydraulics

8.1

Control unit

Remove control unit 1. Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3.

2. Take off cover over control unit – see “Remove the covers” on page 1-20.

3. Mark all the installation positions of the hydraulic lines on the control unit A. 4. Remove all hydraulic lines (SW14, 19, 22, 32, 50) and seal with filler plugs (6L, 10L, 12L, 18L, 30S).

A

Fig. 349

5. Mark all the installation positions of the electric lines on the control unit A. 6. Take off all plugs.

A

WARNING

Fig. 350

Risk of injury from the weight of the control unit!

A

C

Risk of serious injuries from control unit pressing down.

B

► Do not dismantle the control unit alone, but in pairs.

7. Remove screw C on the left-hand side of the control unit A. 8. Remove the 2 screws B on the right-hand side of the control unit A. 9. Lift out control unit A; at least two people should be involved.

Fig. 351

8-2

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Work hydraulics 8

Install control unit WARNING

A

B

Risk of injury from the weight of the control unit!

Risk of serious injuries from control unit pressing down. ► Always involve two people when installing the control unit.

C

1. Position control unit A with two people.

2. Tighten the 2 screws B on the right-hand side of the control unit A. 3. Tighten the screw C on the left-hand side of the control unit A. Fig. 352

4. Plug in all connectors at the marked assembly positions on the control unit A.

A

Fig. 353

A

5. Remove all filler plugs and install all hydraulic lines in the positions marked on the control unit A .

6. Tighten sleeve nuts (SW14, 19, 22, 32, 50).

7. Install cover over control unit – see “Mount the covers back on again” on page 1-20.

8. Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3.

Fig. 354

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

8-3

8 Work hydraulics

8.2

Dismantle pumps Remove the rear cardan shaft A

D

C

1. Remove the screws C (Allen key SW8) and the self-locking nuts D (SW17) from the rear cardan shaft B on the high-speed gearbox A (X).

B

Fig. 355

A

2. Remove the screws B from the rear cardan shaft A on the rear axle C (Allen key SW8).

3. Place the cardan shaft to one side.

B

C Fig. 356

Dismantle tandem pump A

B

C F

E

1.

2.

3.

4.

5.

6.

Loosen sleeve nut A on the tandem pump D and remove hose.

Loosen sleeve nut B and remove hose.

Loosen sleeve nut C and remove hose.

Loosen sleeve nut F and remove hose.

Remove the 4 screws E and take off the tandem pump D. Dismantle all connections on the tandem pump D.

D

Fig. 357

8-4

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Work hydraulics 8 Dismantle variable displacement pump 1. Loosen sleeve nut A on the variable displacement pump D and remove hose.

2. Take the screws B off the half-shell and remove tube.

3. Loosen sleeve nut C and remove hose.

4. Remove the 4 screws E and take off the variable displacement pump D. 5. Dismantle all connections on the variable displacement pump D.

B

A

D

E

C Fig. 358

Dismantle hydraulic pump A

1.

2.

3.

4.

5.

C

B

Loosen sleeve nut A on the hydraulic pump E and remove hose.

Loosen sleeve nut B and remove hose.

Loosen sleeve nut C and remove hose.

Loosen sleeve nut D and remove hose.

Loosen sleeve nut F and remove hose.

D E

F Fig. 359

G

6. Loosen sleeve nut G on the hydraulic pump E and remove hose.

7. Loosen sleeve nut H and remove hose.

E

H

Fig. 360

8. Remove the 4 screws I and take off the hydraulic pump E. 9. Dismantle all connections on the hydraulic pump E.

E

I

Fig. 361

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

8-5

8 Work hydraulics Install hydraulic pump 1. Install all connections on the hydraulic pump E. 2. Position hydraulic pump E and screw the 4 screws I into place.

E

I

Fig. 362

G

3. Position hose and tighten sleeve nut G on the hydraulic pump E. 4. Position hose and tighten the sleeve nut H.

E

H

Fig. 363

A

5.

6.

7.

8.

9.

C

B

Position hose and tighten sleeve nut A on the hydraulic pump E. Position hose and tighten the sleeve nut B. Position hose and tighten the sleeve nut C. Position hose and tighten the sleeve nut D. Position hose and tighten the sleeve nut F.

D E

F Fig. 364

Install variable displacement pump B

A

E

1. Install all connections on the variable displacement pump D. 2. Position the variable displacement pump D and tighten the 4 screws E. 3. Position hose D on the variable displacement pump and tighten the sleeve nut C. 4. Position tube and tighten the screws B off the half-shell.

5. Position hose and tighten the sleeve nut A.

D C

Fig. 365

8-6

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Work hydraulics 8 Install tandem pump A

B

C F

1.

2.

3.

4.

5.

6.

Install all connections on the tandem pump D. Position the tandem pump D and tighten the 4 screws E. Position hose D on the tandem pump and tighten the sleeve nut F. Position hose and tighten the sleeve nut C. Position hose and tighten the sleeve nut B. Position hose and tighten the sleeve nut A.

D

E Fig. 366

Install rear cardan shaft

CAUTION There is a risk of injury if the cardan shafts are not installed correctly!

G A

If the joints of the cardan shaft are not aligned to each other, the shaft can be destroyed. People in direct proximity could subsequently sustain serious injuries. The vehicle can be damaged. ► Align the cardan shaft to the marking.

I

H

1. Position the rear cardan shaft G, paying attention to both markings.

2. Tighten the screws H (Allen key SW8) and the new self-locking nuts I (SW17) of the rear cardan shaft G on the high-speed gearbox A (X) to 49 Nm.

G

Fig. 367

Tighten the screws B of the rear cardan shaft A on the rear axle C to 49 Nm (Allen key SW8).

A

C

B

Fig. 368

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

8-7

8 Work hydraulics

8.3

Tilt cylinder

Remove tilt ram Preparatory steps

WARNING Crushing hazard! Assembly and maintenance operations on raised but not secured boom.

Causes serious injury or death. ► Place telescopic boom on a stable support, making sure that no pressure is applied.

WARNING Burn and injury hazard!

Burn and injury hazard when working next to hot and/or pressurised hydraulic components! ► Allow the hydraulic system to cool down before removing components ► Wear protective gloves

NOTICE In order to ensure that the hydraulics function smoothly, all work must be executed carefully and cleanly. ► Before removing, thoroughly clean the parts of the machine where assembly work is to be performed. ► Clean all the hydraulic screw connections and ports before disassembly.

A

B Fig. 369

8-8

1.

2.

3.

4.

5.

Place the telehandler on a firm and level surface Apply the parking brake Extend the boom A a little way, as shown.

Move the quickhitch facility B into the position shown.

Place telescopic boom on to a support making sure that no pressure is applied 6. Release the pressure in the hydraulic system. To do this: ➥ Stop the engine, but leave the ignition switched on ➥ Keep emergency cut-off switch held down ➥ Move the control lever (joystick) in all directions repeatedly 7. Disengage the starter and remove the starting key.

8. Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Work hydraulics 8

A

9. Dismantle vent filter A on hydraulic tank B in order to vent any overpressure in the tank.

10.Connect the vacuum pump to the opening of the vent filter and place the hydraulic tank under vacuum (negative pressure).

B

Fig. 370

Remove tilt ram 1. Remove the 4 screws A on the cover B (socket 13).

2. Take off cover B.

A

B

A

Fig. 371

Environment Use a suitable container to collect the fluids as they drain and dispose of them in an environmentally friendly manner!

B

3. Relieve pressure via minimess connection.

4. Loosen sleeve nuts A and B on the hoses.

5. Seal hoses with filler plugs.

A

Fig. 372

6. Remove lock screw A from the pin B.

A

B

Fig. 373

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

8-9

8 Work hydraulics 7. Remove circlip A from right-hand side.

A

Fig. 374

8. Remove circlip A from left-hand side.

A

CAUTION

Fig. 375

Risk of crushing when disassembling the tilt ram!

A

Can cause injury. ► Dismantle the tilt ram only with suitable hoisting gear ► Wear protective gloves 9. Screw an eye bolt B into the thread A on the tilt ram.

10.Secure hoisting gear to eye bolt B.

B

Fig. 376

8-10

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Work hydraulics 8 11.Remove lower pin A. A

Fig. 377

12.Remove upper pin A. 13.Slowly lower it with the hoisting gear.

A

Fig. 378

14.Loosen sleeve nuts A and D. 15.Remove screw connection C from collar.

16.Remove hose burst valve B. 17.Remove eye bolt.

A

B C

D Fig. 379

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

8-11

8 Work hydraulics Install the tilt ram 1.

2.

3.

4.

A

Position hose burst valve B. Tighten screw connection C on collar.

Tighten sleeve nuts A and D. Attach eye bolt.

CAUTION Risk of crushing when assembling the tilt ram!

B

Can cause injury.

C

► Assemble the tilt ram only with suitable hoisting gear ► Wear protective gloves 5. Secure hoisting gear to eye bolt B.

D Fig. 380

A

6. Slowly raise it with the hoisting gear into the boom.

7. Lubricate bushings.

8. Install upper pin A.

Fig. 381

9. Install lower pin A. A

Fig. 382

8-12

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Work hydraulics 8

A

10.Remove hoisting gear from the eye bolt B. 11.Unscrew the eye bolt B from the thread A on the tilt ram.

B

Fig. 383

12.Install circlip A on the left-hand side.

A

Fig. 384

13.Install circlip A on the right-hand side.

A

Fig. 385

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

8-13

8 Work hydraulics 14.Install lock screw A for pin B.

A

B

Fig. 386

15.Remove filler plugs from the hoses.

16.Loosen sleeve nuts A and B on the hoses.

B

A

Fig. 387

A

17.Position cover B. 18.Remove the 4 screws A on the cover B (socket 13).

19.If necessary, install compensation disks A at the rotary joint B. Next steps

B

A

1.

2.

3.

4.

Check oil level and top up if necessary.

Lubricate pins.

Clean all hydraulic connections and ports.

Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3.

5. Vent tilt ram via mimimess port.

6. Tilt and dump out the tilt ram several times.

7. Check that there is no strain when the tilt ram is being tilted.

A

B Fig. 388

8-14

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Work hydraulics 8

8.4

Seal-tighten cylinder

Sealing the lift cylinder A B

C D

E

F

Fig. 389

Pos.

Designation

Tightening torque

A

Guide bushing

400 - 500 Nm

D

Piston

1000 ± 200 Nm

Dismantle lifting cylinder 1.

2.

3.

4.

5.

Unscrew guide bushing A with hooked wrench.

Pull piston rod F out of the cylinder jacket E. Remove headless screw B. Unscrew piston D from piston rod F. Remove ring C and guide bushing A from the piston rod F.

Install lifting cylinder 1.

2.

3.

4.

5.

Replace old seals with new ones.

Attach ring C and guide bushing A to the piston rod F. Lightly grease seals with oil.

Tighten pistons D to the prescribed tightening torque on the piston rod F. Insert headless screw B with Loctite®270 and tighten extremely securely.

6. Push piston rod F into the cylinder jacket E. 7. Tighten guide bushing A with the hooked wrench to the prescribed tightening torque.

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

8-15

8 Work hydraulics Seal tighten compensation cylinder

D A

B

E

C

F G

Fig. 390

Pos.

Designation

Tightening torque

C

Piston

900 ± 180 Nam

D

Guide bushing

400 - 450 Nam

Dismantle compensation cylinder 1.

2.

3.

4.

5.

6.

Unscrew guide bushing D with hooked wrench.

Pull piston rod G out of the cylinder jacket E. Remove headless screw F. Unscrew piston C from piston rod G. Remove rings A from the piston rod B. Remove guide bushing A from the piston rod G.

Install compensation cylinder 1.

2.

3.

4.

5.

6.

7.

8.

8-16

Replace old seals with new ones.

Insert rings A and B .

Attach the guide bushing D to the piston rod G .

Lightly grease seals with oil.

Tighten piston C to the prescribed tightening torque on the piston rod G. Insert headless screw F with Loctite®270 and tighten extremely securely.

Push piston rod G into the cylinder jacket E. Tighten guide bushing D with the hooked wrench to the prescribed tightening torque.

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Work hydraulics 8 Sealing the tilt cylinder A B C

D G

F E

Fig. 391

Pos.

Designation

Tightening torque

A

Guide bushing

400 - 500 Nm

C

Piston

1000 ± 200 Nm

Remove the tilt ram 1.

2.

3.

4.

5.

6.

Unscrew guide bushing A with hooked wrench.

Pull piston rod G out of the cylinder jacket D. Remove headless screw B. Unscrew piston C from piston rod G. Remove rings E and F. Remove guide bushing A from the piston rod G.

Install the tilt ram 1.

2.

3.

4.

5.

6.

7.

8.

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Replace old seals with new ones.

Insert rings E and F .

Attach the guide bushing A to the piston rod G .

Lightly grease seals with oil.

Tighten piston C to the prescribed tightening torque on the piston rod G. Insert headless screw B with Loctite®270 and tighten extremely securely.

Push piston rod G into the cylinder jacket D. Tighten guide bushing A with the hooked wrench to the prescribed tightening torque.

8-17

8 Work hydraulics

Seal-tighten push-out ram A B C

D

E

Fig. 392

Pos.

Designation

Tightening torque

A

Guide bushing

350 - 400 Nm

C

Piston

700 ± 140 Nm

Disassemble push-out ram 1.

2.

3.

4.

5.

Unscrew guide bushing A with hooked wrench.

Pull piston rod E out of the cylinder jacket D. Remove headless screw B. Unscrew piston C from piston rod E. Remove guide bushing A from the piston rod E.

Install push-out ram 1.

2.

3.

4.

5.

Replace old seals with new ones.

Attach the guide bushing A to the piston rod E. Lightly grease seals with oil.

Tighten piston C to the prescribed tightening torque on the piston rod E. Insert headless screw B with Loctite®270 and tighten extremely securely.

6. Push piston rod E into the cylinder jacket D. 7. Tighten guide bushing A with the hooked wrench to the prescribed tightening torque.

8-18

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Work hydraulics 8

Seal-tighten level cylinder B A

B C

E

D

I

M

K

F

G

J

H

I

Fig. 393

Pos.

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Designation

Tightening torque

A

Securing screw

20 Nm

K

Guide bushing

450 - 500 Nm

M

Piston

700 ± 140 Nm

Pos.

Designation

B

Guide band

C

Piston seal

D

O-ring seal between piston and piston rod

E

O-ring seal

F

Prop ring

G

O-ring seal

H

Dirt remover

I

Guide band

J

Piston rod seal

8-19

8 Work hydraulics

Description of level cylinder Disassemble level cylinder 1. Disassemble level cylinder 1.

2.

3.

4.

5.

Unscrew guide bushing K with hooked wrench.

Pull piston rod out of the cylinder jacket.

Remove lock screw A. Unscrew piston M from the piston rod.

Remove guide bushing K from the piston rod.

Install level cylinder 1.

2.

3.

4.

5.

6.

Replace old seals with new ones.

Lightly grease seals with oil.

Attach the guide bushing K to the piston rod.

Tighten piston M to the prescribed tightening torque on the piston rod.

Insert lock screw A with Loctite®270 and tighten extremely securely.

Push piston rod into the cylinder jacket.

- Lightly grease seals with oil.

7. Tighten guide bushing K with the hooked wrench to the prescribed tightening torque.

8-20

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Work hydraulics 8

Seal-tighten lock cylinder B A

B C

E

D

I

M

K

F

J

G

H

I

Fig. 394

Pos.

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Designation

Tightening torque

A

Securing screw

20 Nm

K

Guide bushing

450 - 500 Nm

M

Piston

700 ± 140 Nm

Pos.

Designation

B

Guide band

C

Piston seal

D

O-ring seal between piston and piston rod

E

O-ring seal

F

Prop ring

G

O-ring seal

H

Dirt remover

I

Guide band

J

Piston rod seal

8-21

8 Work hydraulics

Description of lock cylinder Disassemble lock cylinder 1. Disassemble lock cylinder 1.

2.

3.

4.

5.

Unscrew guide bushing K with hooked wrench.

Pull piston rod out of the cylinder jacket.

Remove lock screw A. Unscrew piston M from the piston rod.

Remove guide bushing K from the piston rod.

Install level cylinder 1.

2.

3.

4.

5.

6.

Replace old seals with new ones.

Lightly grease seals with oil.

Attach the guide bushing K to the piston rod.

Tighten piston M to the prescribed tightening torque on the piston rod.

Insert lock screw A with Loctite®270 and tighten extremely securely.

Push piston rod into the cylinder jacket.

- Lightly grease seals with oil.

7. Tighten guide bushing K with the hooked wrench to the prescribed tightening torque.

8-22

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Work hydraulics 8

Seal tighten control ram (quickhitch facility)

B A

C

D M16

Fig. 395

Dismantle control ram 1. De-pressurise control circuit for quickhitch cylinder.

2. Remove circlip A. 3. Hammer out piston rod B with the help of a slide hammer-puller M16.

Install control ram 1.

2.

3.

4.

5.

6.

Replace old seals on piston D and guide bushing C with new ones.

Lightly grease seals with oil.

Push piston B into place.

Attach circlip A. Replace screw plug (M12x1.5) with test port A. Connect hose B to test port.

B

Environment Place a suitable container underneath the quickhitch facility to catch any hydraulic oil that comes out and dispose of it in an environmentally-friendly manner.

A

7. Vent quickhitch cylinder by moving it.

8. Replace test port A again with screw plug (M12x1.5).

Fig. 396

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

8-23

8 Work hydraulics

8.5

Tightening torque of oil container A

Pos. Terminal marking

F

E

G I Fig. 397

8-24

D

C

B

H

J

Tightening torque

A

Oil level sensor

35 Nm

B

Hose burst valve boom lifting cylinder leak oil from outside

35 Nm

C

Trailer brake autohitch solenoid valve

35 Nm

D

Reflux memory pressure accumulator charge valve

35 Nm

E

Non-return valve

60 Nm

F

hydr. trailer brake

35 Nm

G

Reflux brake

35 Nm

H

Load sensing signal, leak oil

35 Nm

I

Drain plug

35 Nm

J

Reflex steering

60 Nm

RHB 416-06 * 1.0 * 41605_R_8_Arbeitshydraulik_a4.fm

Electrical system

9 Electrical system

9 Electrical system

9.1

Board

Disassemble board 1. Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3.

2. Remove foot mat.

3. Pull over lock A. 4. Take off cover B.

A

B

Fig. 398

5. Remove CDS-connection B from support A.

A

B

Fig. 399

6. Remove screws A left and right.

7. Remove screws B. 8. Remove support C.

A C B

Fig. 400

A

9. Remove screws A. 10.Remove board B. 11.Mark all positions of the connectors on the back.

12.Take off all plugs.

B Fig. 401

9-2

RHB 416-06 * 1.0 * 41605_R_9_Elektrik_a4.fm

Electrical system 9

Install board 1. Insert all connections into the positions marked on the back.

2. Position board B. 3. Remove screws A.

A

B Fig. 402

4. Position support C. 5. Tighten screws B. 6. Tighten screws A left and right.

A C B

Fig. 403

7. Insert CDS-connection B into support A.

A

B

Fig. 404

8. Insert cover A at bottom and push closed.

9. Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3.

A

Fig. 405

RHB 416-06 * 1.0 * 41605_R_9_Elektrik_a4.fm

9-3

9 Electrical system

9.2

Starter

Dismount the motor starter Preparatory steps A

Switch off the battery master switch – see “Switch off the battery master switch” on page 1-3

B

Remove the V-belt cover

A

1. Remove 3 Allen head screws A (Allen key SW17).

2. Take off the V-belt cover B.

A Fig. 406

A

Remove V-belt

B

1. Remove screw E from belt tightener D (socket 10).

2. Remove screw C from belt tightener D (socket 13).

3. Remove screw F from the coolant compressor B (SW17 and counter movement with the Allen key SW8).

4. Remove V-belt A.

C

D E

F Fig. 407

Dismount the motor starter A B

1. Remove screw C from cable holder B (SW13).

2. Remove screw A from motor starter D (socket 10).

3. Remove cable B.

C

D

Fig. 408

4. Remove the 3 screws A on the motor starter B (socket 13).

5. Take out motor starter B.

A

B

Fig. 409

9-4

RHB 416-06 * 1.0 * 41605_R_9_Elektrik_a4.fm

Electrical system 9

Install motor starter Mount motor starter 1. Position the motor starter B. 2. Tighten the 3 screws A on the motor starter B (socket 13).

A

B

Fig. 410

3. Position cable B. 4. Tighten screw A on motor starter D (socket 10).

5. Tighten screw C on cable holder B (SW13).

A B

C

D

Fig. 411

A

Tensioning the V-belts

B C

D E

F

1. Position the toothed belt A. 2. Use screw F to secure the coolant compressor B , but do not tighten the screw F (SW17 and Allen key SW8 are used to counter the movement).

3. Use screw E to screw into the belt tightener D (socket 10).

4. Use screw C to screw into belt tightener D (socket 13).

5. Tighten toothed belt.

6. Tighten screws C, E, F .

Fig. 412

Mount the V-belt cover A

1. Position the V-belt cover B. 2. Tighten the 3 Allen head screws A (Allen key SW17)

B

A

Next steps Switch on the battery master switch – see “Switch on the battery master switch” on page 1-3.

A Fig. 413

RHB 416-06 * 1.0 * 41605_R_9_Elektrik_a4.fm

9-5

9 Electrical system

9.3

Load sensor

Dismantle load sensor Remove sensor protection 1. Remove 2 screws B. Remove cover A. B

A

Fig. 414

2. Disconnect cable B from wiring harness.

B

Fig. 415

3. Remove screws A. 4. Cut open glue line B. 5. Carefully loosen the sensor from the installation surface.

C A B

Fig. 416

9-6

RHB 416-06 * 1.0 * 41605_R_9_Elektrik_a4.fm

Electrical system 9

Mount load sensor Generally one new load sensor has to be used with new screws!

WARNING Risk of injury due to incorrect functioning of load sensor!

If the load sensor is not installed properly this can lead to serious injuries. ► During assembly, basically always one new load sensor is used with new screws. ► The bushings may not be taken out of the sensor ► During assembly use only the assembly components and cleaning agents as indicated. ► Observe information and expiry date on packaging or containers of assembly components and cleaning agents! ► Shaft and sensor need to be at the same temperature for assembly (min. 10 °C).

• •

The surfaces may not be touched by the load sensor.

Make sure that the bushings from the load sensor do not fall out.

• •

When delivered, the bushings are affixed with a rubber band.

If the bushings fall out of the load centre, make sure there is no deformation or damage. If no damage or deformation can be seen, clean bushings and load sensor thoroughly.

Fig. 417

A

A1

Fig. 418

RHB 416-06 * 1.0 * 41605_R_9_Elektrik_a4.fm

9-7

9 Electrical system

It is essential that the following steps are observed:

A

A1

A

A1

Fig. 419

1. Rethread both threads A1 (M10) at 90 ° to the installation surface A on the rear axle.

2. Clean the installation surface A across to the axle with sandpaper (180 graining) (shiny metallic). See fig. 212 ➥ All remains of adhesive must be fully removed from the installation surface A. 3. Blow clean the threaded bores A1 thoroughly.

4. Check the depth of thread with a hexagon head cap screw M10 x 20mm. Screw the screw fully by hand. ➥ The thread length is OK if the screw head of the hexagon head cap screw rests completely on the installation surface A. 5. Use a lint-free cloth to wipe the installation surface A at the rear axle with Loctite® 7063, wiping away from the centre of the surface.

6. Blow clean the threaded bores A1 again thoroughly.

7. Use a lint-free cloth to wipe the installation surface A at the rear axle, wiping away from the centre of the surface.

8. Apply Loctite® Aktivator 7471 evenly to the installation surface and leave it to take effect for 4 minutes.

Fig. 420

9. Apply Loctite® 638 evenly to the installation surfaces B of the new load sensor.

10.Position the installation surfaces B of the new load sensor on the installation surface A of the rear axle.

B Fig. 421

C A B

11.Use new screws A (M10 x 35, 12.9). ➥ Pretension torque 20 Nm ➥ Tightening torque 70 Nm 12.Clean gap B between load sensor and rear axle with a clean brush and Terostat 450.

13.Seal gap B between load sensor and rear axle with Terostat MS 939.

Start in the middle of the long side of the load sensor.

14.Connect cable C to wiring harness.

Fig. 422

9-8

RHB 416-06 * 1.0 * 41605_R_9_Elektrik_a4.fm

Electrical system 9 15.Position cover A on rear axle.

16.Tighten the 2 screws B.

NOTICE B

If the vehicle is moved immediately after installation of the load sensor, the load sensor can become loose. ► Do not move the vehicle for at least 3 hours.

A

Fig. 423

RHB 416-06 * 1.0 * 41605_R_9_Elektrik_a4.fm

9-9

9 Electrical system

Safe load indicator Calibrating the 0 % point Perform 0 % calibration without an attachment 1.

2.

3.

4.

5.

6.

7.

8.

Park the machine on horizontal, level and firm ground.

Apply the parking brake.

Retract the telescopic boom as far as it will go.

Raise the telescopic boom as far as it will go (0 % load).

Disengage the starter.

Press and hold button B on the safe load indicator.

Start the engine.

Release button B ➥ 2 luminous bars can be seen on the display going inward from G1 to G3, and from O5 to G3. ➥ A warning sounds.

9. Wait until LED G3 illuminates.

10.Briefly press push button B. ➥ LED G1 illuminates.

11.Briefly press push button B. ➥ LEDs G1 to G4 illuminate.

12.Wait until LED R6 illuminates. ➥ The 0 % point is set.

Calibrating the 100 % point

R6 O5 G4 G3 G2 G1 B Fig. 424

E

P A Fig. 425

9-10

1. Pick up pallet forks with the quickhitch and lock them safely.

2. Pick up a load of about 1300 – 1800 kg with the forks in a horizontal position.

3. Park the machine on level and firm ground.

4. Extend the telescopic boon until the machine slightly tips forward, the rear wheels must still slightly touch the ground.

5. Measure the extension dimension A between the outside boom section and the goose neck.

6. Calculate setting dimension E ➥ Setting dimension E = extension dimension A – 40 % (P) 7. Retract the telescopic boom to the setting dimension E. 8. Briefly press push button B. ➥ All LEDs flash. ➥ The 100 % point is set. ➥ Calibration process over.

RHB 416-06 * 1.0 * 41605_R_9_Elektrik_a4.fm

Electrical system 9 LED colours

R6

G1 - G4 = green

O5

O5 = orange

G4

R6 = red

G3 G2 G1 Fig. 426

Error codes during normal operation G1 G2 G3 G4 O5 R6 Error

Cause

Time-out

Internal, program flow does not react within the expected time

Digital output error

Digital output does not react as expected

Redundancy

Difference of sensor current in cells A & B > 5 %

Control unit error

Control unit not found, no answer or incorrect answer

Calculation error

Internal, calculation beyond threshold value

Beyond range

Sensor current too high, sensor short circuit

Uncalibrated

System has not been calibrated

Boom angle supplies incorrect signal or none at all

See error display in diagnostic tool

Below range

Sensor current too low, sensor not connected

Limit switch supplies incorrect signal Incorrect on-board voltage Boom angle not or incorrectly calibrated Incorrect +5 V supply Release switch supplies incorrect signal

See error display in diagnostic tool

Limit switch not correct Malfunctioning proportional valve Release switch bypassed/ pressed too long

RHB 416-06 * 1.0 * 41605_R_9_Elektrik_a4.fm

9-11

9 Electrical system

Error codes in calibration mode G1 G2 G3 G4 O5 R6 Error

9-12

Cause

Calibration failed

Invalid measured value/difference between min and max too small/sensor current outside the tolerance

Beyond range

Sensor current too high, no compensation possible

Below range

Sensor current too low, no compensation possible

RHB 416-06 * 1.0 * 41605_R_9_Elektrik_a4.fm

Index

Index

Index Index A Abbreviations ......................................................... 0-3 Accelerator pedal disassemble .................................................... 2-21 Install ............................................................... 2-22 Accident prevention regulations general information ........................................... 0-7 Adding oil Differential (front axle) ..................................... 1-93 Differential (rear axle) ...................................... 1-92 Planetary drives .............................................. 1-94 Additional variable displacement motor disassemble .................................................... 4-50 Install ............................................................... 4-52 Air conditioning drain ................................................................ 1-84 fill ..................................................................... 1-84 Visual check .................................................... 1-85 Air filter ................................................................. 1-61 Cleaning the dust collector .............................. 1-63 Alternator check ............................................................... 1-79 disassemble .................................................... 2-17 Install ............................................................... 2-18 Anticorrosion protection Cleaning ........................................................ 1-109 Important information .................................... 1-108 Preservation .................................................. 1-109 Autohitch trailer coupling Clean ............................................................. 1-104 Lubricate ....................................................... 1-104 Automatic trailer coupling Clean ............................................................. 1-103 Lubricate ....................................................... 1-103 Axle tube Front axle ........................................................ 5-42 Rear axle ......................................................... 5-46

RHB 416-06 * 1.0 * RHB_41606_en_V1SIX.fm

B Ball trailer coupling Clean ............................................................. 1-104 Lubricate ........................................................ 1-104 Battery check ............................................................... 1-78 replace ............................................................. 1-78 Safety instructions ........................................... 1-77 Battery master switch ............................................. 1-3 switch off ........................................................... 1-3 switch on ........................................................... 1-3 Biodegradable oils ................................................ 1-17 Board disassemble ...................................................... 9-2 Install ................................................................. 9-3 Brake Version1 .......................................................... 5-50 Version2 .......................................................... 5-60 Brake discs (front axle) activate .............................................................. 6-5 deactivate .......................................................... 6-5 Brake pedal disassemble ...................................................... 6-7 Install ................................................................. 6-8 Brake valve disassemble ...................................................... 6-9 Install ................................................................. 6-9 Braking system ..................................................... 1-96 Maintenance ...................................................... 6-2 Safety instructions ........................................... 1-96

S-1

Index C Central lubrication system .................................... 1-36 Capacity .......................................................... 1-37 Lubrication ....................................................... 1-37 Changing the oil Differential (front axle) ..................................... 1-93 Differential (rear axle) ...................................... 1-92 Planetary drives .............................................. 1-95 Checking the oil Differential (front axle) ..................................... 1-93 Differential (rear axle) ...................................... 1-92 Planetary drives .............................................. 1-94 Clean Exterior of the machine ................................... 1-25 Inside the cabin ............................................... 1-25 Motor and engine compartment ...................... 1-26 Seat belt .......................................................... 1-25 Cleaning and maintenance ................................... 1-23 Compensation cylinder seal-tighten ...................................................... 8-16 Compressed-air braking system Maintenance .................................................... 1-98 Control ram (quickhitch facility) seal-tighten ...................................................... 8-23 Control unit disassemble ...................................................... 8-2 Install ................................................................. 8-3 Coolant refill .................................................................. 1-56 Coolant level check ............................................................... 1-55 Corrosion protection film apply .............................................................. 1-110 Covers between driver's cab and engine vat Assemble ................................................. 1-20 Remove ................................................... 1-20 Cylinder seal-tighten ...................................................... 8-15 D Dehumidifier replace ............................................................ 1-86 Diesel particulate filter Clean ............................................................. 1-107 Regenerating ...................................... 1-105, 1-106 replace .......................................................... 1-107 Differential Assemble ........................................................ 5-77 Remove ........................................................... 5-71 Differential (front axle) Adding oil ........................................................ 1-93 Changing the oil .............................................. 1-93 Checking the oil ............................................... 1-93 Disassemble .................................................... 5-80 Reinstall .......................................................... 5-81

S-2

Differential (rear axle) Adding oil ......................................................... 1-92 Changing the oil .............................................. 1-92 Checking the oil ............................................... 1-92 Disassemble .................................................... 5-83 Reinstall ........................................................... 5-84 Differential lock Front axle ........................................................ 5-67 Driver's cab ventilation Important information ...................................... 1-81 E Electrical system Fuses in the main fuse box check ....................................................... 1-80 replace ..................................................... 1-80 Fuses on board check ....................................................... 1-80 replace ..................................................... 1-80 Maintenance .................................................... 1-77 regular checks ................................................. 1-79 regular maintenance ........................................ 1-79 Relay to board check ....................................................... 1-80 replace ..................................................... 1-80 Engine disassemble ...................................................... 2-4 Install ............................................................... 2-10 Technical data ................................................... 2-2 Engine cover lock Assemble ......................................................... 2-11 Remove ............................................................. 2-8 Engine lubrication system Maintenance .................................................... 1-45 Engine oil refill .................................................................. 1-47 replace ............................................................. 1-48 Engine oil level check ............................................................... 1-46 Exhaust Assemble ......................................................... 2-13 Remove ............................................................. 2-5 Explanation of symbols ........................................... 0-3

RHB 416-06 * 1.0 * RHB_41606_en_V1SIX.fm

Index F Fan motor replace ............................................................ 3-12 Filter Clean ............................................................... 1-81 replace ............................................................ 1-81 Filter cartridge replace ............................................................ 1-62 Flat belt check ............................................................... 1-64 retighten .......................................................... 1-64 Front axle Activate brake discs .......................................... 6-5 Axle tube ......................................................... 5-42 Check plug ...................................................... 5-33 Deactivate brake discs ...................................... 6-5 Differential lock ................................................ 5-67 disassemble ...................................................... 5-4 Drain plug ........................................................ 5-33 Filler plug ......................................................... 5-33 Install ................................................................. 5-7 Type label ........................................................ 5-28 Fuel sensor disassemble .................................................... 2-19 Install ............................................................... 2-20 Fuel system Bleeding .......................................................... 1-43

H handling Repair book ....................................................... 0-2 Heat exchanger (Capacitor Clean ............................................................... 1-87 High speed gear box with four-wheel cut-off Changing the gearbox oil ................................ 1-91 High speed gearbox Changing the gearbox oil ................................ 1-90 disassemble ............................................... 4-2, 4-7 Repair .............................................................. 4-13 High-speed gearbox Repair .............................................................. 4-13 Hinges check ............................................................... 1-26 Hydraulic oil refill .................................................................. 1-69 replace ............................................................. 1-70 Hydraulic oil level check ............................................................... 1-68 Hydraulic pump Assemble ........................................................... 8-6 Remove ............................................................. 8-5 Hydraulic system Change the suction filter .................................. 1-72 Important information ...................................... 1-66 Maintenance .................................................... 1-66

G Gear drive Assemble ........................................................ 5-74 Remove ........................................................... 5-73 Gearbox oil check ............................................................... 1-89 refill .................................................................. 1-89 replace in high speed gear box with four-wheel cut-off ......................................... 1-91 in high speed gearbox ............................. 1-90 General regulations Accident prevention ........................................... 0-7 Safety ................................................................ 0-7 General Repair Instructions ................................... 0-4

I Important information Anticorrosion protection ................................. 1-108 Driver's cab ventilation .................................... 1-81 Hydraulic system ............................................. 1-66 Information on maintenance Requirements .................................................... 1-4 Responsibilities ................................................. 1-4

RHB 416-06 * 1.0 * RHB_41606_en_V1SIX.fm

S-3

Index L Level cylinder seal-tighten ...................................................... 8-19 Lift cylinder seal-tighten ...................................................... 8-15 Load sensor Assemble .......................................................... 9-7 Remove ............................................................. 9-6 Loader unit Spraying oil onto the slide plates .................... 1-34 Lock cylinder seal-tighten ...................................................... 8-21 Locking and unlocking the engine cover .............. 1-18 Lubricants Overview ......................................................... 1-12 Lubrication points Frame levelling ................................................ 1-28 Front axle oscillation-type bearing .................. 1-27 Hydraulic oscillating axle interlock ................... 1-28 Planetary drive bearing of axle ............... 1-28, 1-29 Rear axle oscillation-type bearing ................... 1-27 Telescopic boom ............................................. 1-30 Lubrication work ................................................... 1-27 M Machine fuses ...................................................... 1-22 Machine preservation ......................................... 1-108 Maintenance “Aggressive Media” ....................... 1-108 Maintenance access Rear of machine .............................................. 1-21 Maintenance access (engine bay, bottom) Assemble ........................................................ 1-19 Remove ........................................................... 1-19 Maintenance accesses ......................................... 1-18 Maintenance personnel Qualification .................................................... 1-77 Monitoring Hydraulic oil filter ............................................. 1-67 Hydraulic oil level ............................................ 1-67

P Parking brake bleed .................................................................. 6-2 Pivots check ............................................................... 1-26 Planetary drives Adding oil ......................................................... 1-94 Changing the oil .............................................. 1-95 Checking the oil ................................................................. 1-94 Pumps disassemble ...................................................... 8-4 Install ................................................................. 8-6 Push-out cylinder seal-tighten ...................................................... 8-18 R Radiator disassemble ...................................................... 3-2 Install ................................................................. 3-7 Rear axle Axle tube ......................................................... 5-46 Check plug ...................................................... 5-33 disassemble .................................................... 5-11 Drain plug ........................................................ 5-33 Filler plug ......................................................... 5-33 Install ............................................................... 5-16 Type label ........................................................ 5-28 Recirculated-air filter Clean ............................................................... 1-81 Reversing valve disassemble .................................................... 3-12 Install ............................................................... 3-13

N New high-speed gearbox Install ................................................................. 4-8 O Oil tank Tightening torques .......................................... 8-24 Oscillating axle interlock ............................................................. 5-2 Overview Lubricants ........................................................ 1-12 Oxidised surfaces treat ............................................................... 1-110

S-4

RHB 416-06 * 1.0 * RHB_41606_en_V1SIX.fm

Index S SAE grade ............................................................ 1-13 Safe load indicator ............................................... 9-10 Safety ..................................................................... 0-6 Safety instructions Battery ............................................................. 1-77 Maintenance ...................................................... 1-4 Safety regulations general information ........................................... 0-7 Safety symbols ....................................................... 0-6 Screw connections ................................................. 0-5 Screw dimensions .................................................. 1-2 Screw lock Tightening torques .......................................... 5-30 Sealing work Drive flange ..................................................... 5-34 Joint housing for front axle .............................. 5-36 Joint housing for rear axle ............................... 5-36 Planetary gearing ............................................ 5-36 Service brake bleed ................................................................. 6-3 Signal words ........................................................... 0-6 Slide plates check ............................................................... 1-31 replace ............................................................ 1-32 Special tools ......................................................... 5-85 Specification ......................................................... 1-13 Diesel fuel ....................................................... 1-16 Starter disassemble ..............................................2-23, 9-4 Install .........................................................2-24, 9-5 Steering cylinder disassemble .................................................... 5-20 Install ............................................................... 5-23 Steering sensor Adjust .............................................................. 5-27

T Tandem pump Assemble ........................................................... 8-7 Remove ............................................................. 8-4 Technical data Engine ............................................................... 2-2 Threaded fittings ................................................... 5-29 check ............................................................... 1-26 Tightening torques .................................................. 1-2 Oil tank ............................................................ 8-24 Tilt cylinder disassemble ...................................................... 8-8 Install ............................................................... 8-12 seal-tighten ...................................................... 8-17 Tire care ............................................................... 1-99 Tires ..................................................................... 1-99 Important information ...................................... 1-99 Tools ....................................................................... 0-5 Trailer coupling Clean ............................................................. 1-104 Lubricate ........................................................ 1-104 Treatment of oxidised surfaces .......................... 1-110 Type label Front axle ........................................................ 5-28 Rear axle ......................................................... 5-28 U Underride protection bottom frame Assemble ......................................................... 1-19 Remove ........................................................... 1-19 V Variable displacement pump Assemble ........................................................... 8-6 Remove ............................................................. 8-5 V-belt check ............................................................... 1-64 retighten .......................................................... 1-64 W Washer system ..................................................... 1-88 Wear limits Slide plates ............................................. 1-31, 1-32 Wheel change .................................................... 1-101 Wheels replace ........................................................... 1-101

RHB 416-06 * 1.0 * RHB_41606_en_V1SIX.fm

S-5

Index

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RHB 416-06 * 1.0 * RHB_41606_en_V1SIX.fm

KRAMER-WERKE GmbH keep abreast of the latest technical developments and constantly improve their products. For this reason we are reserved the right to changes in the pictures and descriptions in this documentation without any obligation to alter any machines previously delivered.

Technical specifications, measurements and weights are not binding.

Responsibility for errors or omissions not accepted.

No reproduction or translation of this publication, in whole or part, without the written consent of KRAMER-WERKE GmbH. All rights under the provision of the Copyright Act are reserved.

Kramer-Werke GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf Germany

Kramer-Werke GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf Phone 0080090209020 E-mail info@kramer.de www.kramer.de Order no. 1000344605 Language [en]