Wacker Neuson WL28 Wheel loader Operating Manual - PDF DOWNLOAD

Operating Manual Wheel loader

April 2013 Edition Original operating manual

You have opted for a Wacker Neuson loader – thank you very much for putting your trust in us.

Your Wacker Neuson loader is a powerful product with robust technology and a wide range of applications to aid you in your day-to-day work. In order to familiarise yourself with your loader in a quick, comprehensive manner, please read this operating manual attentively.

In addition to the information regarding operation, this operating manual also contains important maintenance and operating instructions for conserving the value of your loader. Furthermore, we will show you how to operate your loader in an environmentally sound manner.

Should you have any questions or problems relating to your loader, please contact your Wacker Neuson partner or importer. They will be happy to respond to your questions, suggestions or criticisms at any time.

We are confident that you will be very satisfied with your new Wacker Neuson loader.

Wacker Neuson SE

Contents

Table of contents

Preface 1 1.1 1.2 1.3 1.4 2

2

............................................................................................................................................................... 9

Basic information.................................................................................................................................... 10 Notes about this operator’s manual..................................................................................................... 11 Explanation of the symbols used in this operator’s manual................................................................. 12 Warranty and liability........................................................................................................................... 13 Proper use........................................................................................................................................... 16

Basic safety instructions................................................................................................................... 18 2.1 Organisational measures..................................................................................................................... 19 Selection and qualification of personnel / basic duties........................................................................ 21 2.2 Safety instructions for certain operating phases................................................................................. 22 2.3 Safety instructions for normal operation........................................................................................... 22 2.3.1 2.3.2 Safety instructions for other operating modes.................................................................................. 24 2.4 Safety instructions for special types of hazard.................................................................................... 27 2.4.1 Transport of large bales or packaged goods.................................................................................... 27 2.4.2 Working in the vicinity of overhead power lines................................................................................ 28 2.4.3 Electrical power................................................................................................................................ 29 2.4.4 Fire hazard........................................................................................................................................ 29 2.4.5 Gas, dust, vapor, smoke................................................................................................................... 30 Hydraulic systems, pneumatic systems............................................................................................ 30 2.4.6 2.4.7 What to do if the loader tips over...................................................................................................... 31 2.4.8 Noise................................................................................................................................................. 31 2.4.9 Oil, grease and other chemical substances...................................................................................... 31

Contents

2.5 Transporting and towing/restarting...................................................................................................... 32 2.6 Final decommissioning/dismantling..................................................................................................... 32 Safety stickers used............................................................................................................................. 33 2.7 2.8 Safety devices...................................................................................................................................... 37 2.8.1 Fire extinguisher............................................................................................................................... 37 2.8.2 Rotating beacon................................................................................................................................ 37 Lowering brake valves on lifting and tipping cylinders...................................................................... 38 2.8.3 2.8.4 Battery disconnect switch................................................................................................................. 39 2.8.5 Safety belt......................................................................................................................................... 40 2.8.6 Seat contact switch........................................................................................................................... 40 2.8.7 Emergency exit................................................................................................................................. 41 2.8.8 Audible reverse warning device........................................................................................................ 41 2.8.9 Locking mechanism for the lift frame................................................................................................ 42 3

Technical data........................................................................................................................................... 43 3.1 Technical description........................................................................................................................... 43 3.2 Loader data.......................................................................................................................................... 45 3.3 Dimensions.......................................................................................................................................... 50 3.3.1 Dimensions (Loaders with driver’s canopy)...................................................................................... 50 3.3.2 Dimensions (Loaders with cab)........................................................................................................ 52 3.4 Factory signs........................................................................................................................................ 54

3

Contents

4 Description of the indicator, warning and control elements.......................................... 56 4.1 Operating elements and instruments................................................................................................... 56 4.2 Control and warning lights................................................................................................................... 58 4.3 Switches / toggle switches................................................................................................................... 62 4.4 Indicator devices.................................................................................................................................. 66 5

4

Operating and operation..................................................................................................................... 68 5.1 Before starting up................................................................................................................................ 68 5.1.1 Fueling.............................................................................................................................................. 68 5.1.2 Getting in.......................................................................................................................................... 70 5.1.6 Doors and windows.......................................................................................................................... 73 5.1.3 Adjusting the steering column........................................................................................................... 75 5.1.4 Adjusting the driver‘s seat................................................................................................................. 76 5.1.5 Seat belt............................................................................................................................................ 78 5.2 Starting up........................................................................................................................................... 81 5.2.1 Lighting system and signal horn....................................................................................................... 82 5.2.2 Headlights......................................................................................................................................... 83 5.2.5 Rotating beacon................................................................................................................................ 85 5.2.6 Wipers and windscreen washer system........................................................................................... 86 5.2.7 Ventilation and heating of the cab..................................................................................................... 87 5.2.3 Before starting the engine................................................................................................................ 89 5.2.4 Starting the engine........................................................................................................................... 89

Contents

5.3 Driving.................................................................................................................................................. 94 5.3.1 Parking brake.................................................................................................................................... 94 Preparation for driving in public traffic.............................................................................................. 95 5.3.2 5.3.3 Description of the drive hydraulics.................................................................................................... 96 5.3.4 Driving............................................................................................................................................... 97 5.3.5 Stopping and parking...................................................................................................................... 101 Work operation................................................................................................................................... 102 5.4 5.4.1 Control lever for the lift frame......................................................................................................... 104 5.4.2 Locking mechanism for the lift frame.............................................................................................. 106 5.4.3 Operating lever for additional hydraulics........................................................................................ 108 5.4.4 Differential lock................................................................................................................................112 5.4.5 Changing attachments.....................................................................................................................114 5.4.6 Bucket............................................................................................................................................. 125 5.4.7 Manure fork..................................................................................................................................... 131 5.4.8 Pallet fork........................................................................................................................................ 133 5.4.9 Measures in the event of the loader tipping over............................................................................ 138 5.4.10 Precaution measures for various weather conditions..................................................................... 139 5.5 Additional equipment..........................................................................................................................141 5.6 Optional equipment - collapsible driver’s canopy.............................................................................. 150 5.6.1 Folding down the collapsible driver’s canopy................................................................................. 153 5.6.2 Bringing the collapsible driver’s canopy into the protection ON position........................................ 157

5

Contents

6 6.1 6.2

Towing and transporting.................................................................................................................. 158 Towing................................................................................................................................................ 158 Transporting....................................................................................................................................... 161

7 Measures in the event of power loss.......................................................................................... 169 8 Discharging residual pressure in the hydraulic system................................................... 170 9 10

6

Securing the loader............................................................................................................................ 173 Servicing and inspection.....................................................................................................................174 10.1 Basic safety instructions for servicing and inspection........................................................................174 10.2 Servicing and inspection intervals..................................................................................................... 180 10.3 Lubrication schedule.......................................................................................................................... 192 10.4 Cleaning the loader............................................................................................................................ 194 10.5 General safety check......................................................................................................................... 196 10.6 Specifications and filling quantities.................................................................................................... 196 10.7 Servicing and inspection work........................................................................................................... 198 10.7.1 Preparation for maintenance and inspection work......................................................................... 199 10.7.2 Servicing the engine....................................................................................................................... 204 10.7.3 Servicing the fuel system................................................................................................................ 210 10.7.4 Servicing the air filter system.......................................................................................................... 215

Contents

10.7.5 Servicing the cooling system.......................................................................................................... 218 10.7.6 Servicing the hydraulic system....................................................................................................... 226 Servicing the axles......................................................................................................................... 235 10.7.7 10.7.8 Servicing the brakes....................................................................................................................... 239 10.7.9 Maintaining the collapsible driver’s canopy.................................................................................... 242 10.7.10 Servicing the tires and wheels........................................................................................................ 244 Servicing the cab vent filter............................................................................................................ 248 10.7.12 10.7.13 Filling the container for the windscreen washer system................................................................. 249 10.7.11 Servicing the electrical system....................................................................................................... 250 10.8 Jump-starting / emergency starting................................................................................................... 258 10.9 Shutting down and restarting the loader............................................................................................ 260 11

Troubleshooting and emergency maintenance....................................................................... 262

12

Safety instructions for repairs.................................................................................................... 266 12.1 General safety regulations for repairs............................................................................................... 266 12.2 Engine................................................................................................................................................ 269 12.3 Welding work..................................................................................................................................... 269 12.4 Hydraulic system................................................................................................................................ 271 12.5 Brakes................................................................................................................................................ 271

7

Contents

13

Final shutdown of the loader / decommissioning.................................................................. 272

14

Appendix..................................................................................................................................................... 274 Ordering replacement parts................................................................................................................................ 274 Index ........................................................................................................................................................... 276 List of figures....................................................................................................................................................... 282

8

Preface

Preface

This operator’s manual describes how to operate and service the loader. They provides operating and maintenance personnel with the necessary knowledge of the loader’s functional characteristics in order to allow them to handle, properly service/inspect, clean and look after the loader safely and without danger, and to ensure that the technical safety regulations for the loader are complied with.

Observing the requirements in this operator’s manual ensures: • • •

proper, safe and professional operation of the loader professional maintenance, cleaning and care for the loader compliance with the necessary technical safety regulations

If required, the user/operator of the loader should supplement the operator’s manual with instructions and regulations regarding environmental protection and national health and safety regulations relating to accident prevention.

NOTE This operator's manual must always be kept either on the loader or at the point of use.

The operator’s manual must be read and applied by all persons involved in work with or on the loader, for example with regard to: •

• •

Operation including setup, remedying faults during operation, care, disposal of auxiliary materials and operating materials (lubricants, fluids and oils) as well as disposal of the entire loader Servicing (inspection, maintenance, care) Transport NOTE This operator's manual does not contain instructions on how to carry out extensive servicing or repairs. This type of work must only be performed by qualified specialists.

If you have any questions about this operator’s manual, please contact your dealer; the Wacker Neuson Service department will be glad to assist.

9

Basic information

1

Basic information

In Germany, the following rules must be followed when driving on public roads: Loaders with a maximum speed of up to 20 km/h require no approval. They do however require an operating license, which is issued by the motor vehicles registration office.

In addition, the name (first name and surname) and the place of residence or the company name and the location of the company’s registered office must be clearly displayed on the left-hand side of the loader in non-smudging lettering (§64b of the German Road Traffic Licensing Regulations, StZVO).

The operator is responsible for ensuring that appropriate insurance cover is in place. The operator must check with his insurance provider whether or not the loader is covered under the terms of his public liability insurance, or whether he needs to take out separate third party insurance for this purpose.

Every new user must be instructed before using the loader for the first time.

10

Notes on using the operator’s manual: • • • • •

Read the operator’s manual carefully before using the loader.

Observe all safety instructions.

Follow the regulations and laws which are applicable in the place of use.

Follow the regulations of the federal association of statutory accident insurances (VGB).

Always keep the operator’s manual in a clean and orderly state together with the loader.

Symbols will he used to highlight any hazards to persons or material which cannot be ruled out during the course of normal work which is carried out in accordance with the proper use of the loader. Descriptions relate to the direction of travel of the loader, so directional information should always be interpreted looking in the direction of travel.

Basic information

1.1

Notes about this operator’s manual

All of the information about technical data in this operator’s manual relates to series models which have been tested under standard operating conditions for Central Europe; all such data relates to the standard functions of these series models. The equipment and its functional modalities and accessories depend on the relevant model and the product options, as well as on the national requirements which apply specifically in the country of sale. Illustrations may show products which are not mentioned in the text or which are not supplied as standard.

product and its surroundings special functions can be implemented. If you have concerns about the load capacity or mode of operation of our products because of special circumstances, we recommend carrying out test work under controlled framework conditions.

The descriptions, illustrations, weight information and technical data are not binding and correspond to the state of the art at the time of printing. We must reserve the right to make changes without prior notice in the areas of design, equipment, appearance and technology on account of the ongoing further development of the products.

Despite taking the greatest care, we cannot rule out the possibility of deviations from drawings or dimensions, calculation errors, printing errors or incompleteness in this operator’s manual. As a result, we accept no liability for the correctness and completeness of the information we have provided in this operator’s manual. We guarantee that our products will work properly and without problems within the framework of our General Terms and Conditions of Business. As a matter of principle we do not offer more far-reaching guarantees. We do not accept liability beyond the scope of our liability as defined in our General Terms and Conditions of Business.

Please get in touch with us if you require any special functions which can only be made available with the aid of additional components and/or which require special framework conditions. We will be happy to answer your questions and let you know whether and under which conditions for the

Please make sure that you always follow without fail all safety instructions in this operator’s manual and the statutory and regulations of the federal association of statutory accident insurances at the point of use.

11

Basic information

1.2

Explanation of the symbols used in this operator’s manual

To ensure safe operation and maintenance of the loader, it is necessary for you to follow all of the instructions in this operator’s manual.

Throughout the text, you will be warned about hazards and provided with special information using the following symbols and the signal words DANGER, WARNING, CAUTION and NOTE as well as the adjacent phrases.

Warning symbol: Warns about potential dangers. ►► Follow all instructions which are linked to this symbol.

Warning symbol: Warning information on risk of injury or accident caused by electric shock. ►► Follow all instructions which are linked to this symbol.

12

DANGER The word DANGER is used to warn about hazards with high levels of risk which could directly result in death or serious injury if they are not avoided.

WARNING The word WARNING is used to warn about hazards with moderate levels of risk which could possibly result in death or serious injury if they are not avoided.

CAUTION The word CAUTION is used to warn about hazards with low levels of risk which could possibly result in minor or moderately serious injuries if they are not avoided.

Basic information

1.3

Warranty and liability The CE mark shows that the loader has been manufactured in accordance with the applicable EC directives.

NOTE Warning information about the risk of possible technical damage.

NOTE The manufacturer / supplier cannot be held liable for damages resulting from improper use of the loader. In such cases the full risk is borne by the operator / user.

NOTE Important general information.

ENVIRONMENTAL NOTE Important general information for protection of the environment.

Please note the following points:

Read the operator’s manual before using the loader.

•

• •

• • • •

Do not make any changes to the loader.

Only use attachments approved by WEIDEMANN for your loader.

The loader must only be started up, operated and serviced in the manner described in the operator’s manual.

Only use the loader if all of the safety devices and protection devices are intact.

Observe the monitoring systems during operation.

Repairs must only be carried out by trained specialists.

Closely follow all instructions in the operator’s manual.

13

Basic information

NOTE This operator's manual must always be kept either on the loader or at the point of use.

Place the operator's manual in the document pocket at the side of the driver's platform.

Fig. 1 Document pocket Loader with drivers canopy

Loader with cab

14

WL28 1160

Type/Version Trade name

99,9 98,4 101 101

measured sound power level dB(A) Guaranteed sound power level dB(A)

Translation of the Original declaration of conformity

Hans Heinrich Schmidt director

Bernd Apfelbeck director

diemelsee-Flechtdorf, 28.09.2012

Jolanthe Wydra, secretary to the head of technology Weidemann GmbH mühlhäuser Weg 45-49 34519 diemelsee Germany

authorised representative for the compilation of the technical file

2006/42/eg, 2000/14/eg, 2004/108/eg, diN eN iSo 12100 and dIN EN 474-1 and 3

We hereby declare that this product satisfies the relevant provisions of these directives:

Directives and standards applied

europäisch notifzierte Stelle, Kenn-Nr. 0515 dguV Test, Prüf- und Zertifizierungsstelle, Fachbereich Bauwesen Landsberger Straße 309, 80687 münchen, Germany

Office named in the procedure

in accordance with 2000/14/ec annex Vi

conformity assessment procedure

35,7 23,4

Power kW

chassis number

Wheel loader 1370 rL20

Vehicle designation

Product

Weidemann GmbH, mühlhäuser Weg 45-49, 34519 diemelsee, Germany

Manufacturer

ec Declaration of conformity

Basic information

15

Basic information

1.4

Proper use Improper use of the loader can put people's lives at risk and cause serious injuries or extensive material damage.

The loader has been built according to the state of the art and in accordance with the recognized technical safety rules. Nonetheless, use of the loader can endanger the life and limb of the user or third parties and/or cause damage to the loader or other property.

The loader must only be operated in accordance with its proper intended purpose, with full awareness for safety and potential hazards and taking into account the operator’s manual, with the device in technically perfect condition. In particular, any faults which could have an adverse effect on safety must be rectified immediately.

16

The loader is used to pick up and load material through forward motion of the loader, taking into account the safety instructions / regulations and intervals detailed by WEIDEMANN in the operator’s manual. One work cycle consists of picking up, lifting, transporting and unloading the material.

Uses of the loader for similar, related purposes with alternative attachments which do not affect the safety requirements for the loader but which change the way in which it is used are only permitted with the attachments which have been expressly approved by WEIDEMANN for this purpose.

Special conditions apply when using additional attachments from WEIDEMANN. Proper use also includes compliance with the operator’s manual and satisfaction of maintenance, inspection and servicing intervals.

Basic information

Any other use of the loader or use of the loader which exceeds the described scope, e.g.: • • • • • •

to lift or transport people as a working platform to lift or transport loads without the attachment which is required for this purpose being provided to tow trailer loads after improper/unprofessional rectification of faults/repairs after making major changes to the loader

is deemed to be improper.

17

Basic safety instructions

2

Basic safety instructions NOTE Loaders may only be used on suitable terrain in farmyards or, with an operating license according to the Road Traffic Licensing Regulations, on suitable public land.

• • • • •

18

Use the loader and attachments only as intended and in a technically faultless state.

Observe the safety regulations precisely.

Follow the operating manual and the inspection regulations.

Observe the permissible payloads.

Please observe that, when using the loader outside the sphere of responsibility of the agricultural trade association, the regulations applicable for the responsible trade association shall apply.

NOTE Should the loader be used by a private person or by other persons who are both operators and users, then they must also observe all safety instructions.

Observance of the organizational safety instructions and the safety instructions relating to the selection and qualification of personnel in particular are basic duties. If there are no trained personnel for the various tasks, the operator/user must attend to this. In case you require training sessions or instruction/training personnel, Wacker Neuson Service and our agents will be happy to help you.

Basic safety instructions

2.1

Organisational measures

The following safety instructions are directed at the operator / user of the loader.

• •

• •

Always keep the operating manual on hand at the place of operation of the machine, for example in the tray provided for it.

As a supplement to the operating manual, universally valid legal and other binding regulations relating to road traffic, compulsory coverage, accident prevention and environmental protection must be observed, and users must be instructed to observe them. This applies in particular to the maximum speed, depending on the model and the permissible total weight of the loader.

If required, instruct that personal protective equipment be worn. This applies particularly to the handling of harmful substances at the location of use.

Supplement the operating manual with instructions, including supervisory and reporting requirements, taking into account differences between various companies, e.g. with regard to the organization of work, work processes or personnel used.

•

• • • •

Personnel who have been assigned duties using the loader/users must have read the operating manual before starting work, especially the chapter Basic Safety Instructions. This applies particularly to personnel used only occasionally, for machine setup or servicing, for example.

Observe all safety instructions and danger warnings on the loader and in the operating manual.

Make sure that all safety instructions and danger warnings on the machine are legible.

Should the loader change its operating behaviour in a way that affects safety, shut down the loader immediately and correct the malfunction or have it corrected.

Do not make any changes, attachments or conversions to the loader that will adversely affect safety without the consent of Wacker Neuson. This also applies to the installation and adjustment of safety devices and valves as well as welding work on load-bearing parts.

19

Basic safety instructions

•

• • • •

20

Replacement parts and operating and auxiliary materials must conform to the technical requirements specified

by Wacker Neuson. This is always the case for original replacement parts.

Replace the hydraulic hose lines at the specified time intervals, even if no defects are discernible which could adversely affect safety.

Adhere to the compulsory time limits specified in the operating manual for regular checks/inspections.

Workshop equipment appropriate for the work is absolutely mandatory for carrying out servicing and repairs.

Make the location and means of operation of the fire extinguishers known, and consider the options for fire detection and fighting.

•

The operator is solely responsible for requirements and obligations resulting from the accident prevention regulations, the environmental regulations, the maximum speed depending on the model, the permissible total weight and the dimensions of the loader, and which do not concern the state of the loader (basic requirements according to MRL 2006/42/EC). This applies particularly to the requirements of the road traffic regulations (registration number requirement), and the driving license and insurance requirements.

Basic safety instructions

2.2 •

•

• •

Selection and qualification of personnel / basic duties

Work on or with the loader may only be performed by reliable personnel.

Please observe the minimum legal age.

Please particularly observe the legal regulations for driving license requirements regarding the maximum speed depending on the model and the permissible total weight of the loader.

Only trained, instructed personnel may be used. The responsibilities of the personnel for operating, setting up, servicing and repairing the loader must be clearly defined.

Ensure that only personnel assigned to work on or with the loader do so.

The operator must define the responsibility of the machine driver, also regarding traffic regulations, and allow him/her to reject unprofessional instructions from third parties.

•

•

• •

Personnel being trained, educated, instructed or participating in a general training program may only work on or with the machine under constant supervision of an experienced, authorized supervisor.

Work on the machine‘s electrical equipment may only be carried out by an electrician or by trained persons under the direction and supervision of an electrician in accordance with electronic rules.

Work on the chassis, brakes and steering system may only be performed by trained, specialized personnel.

Only trained, specialized personnel with specific knowledge of and experience in hydraulics may work on hydraulic units.

21

Basic safety instructions

2.3

Safety instructions for certain operating phases

The safety instructions are directed at all persons involved in work on or with the loader.

2.3.1

• •

• •

22

• •

Safety instructions for normal operation

• Refrain from any measures that could put safety into question.

Before starting work, familiarize yourself with the working environment in which you will be using the loader.

The working environment includes, for example, obstacles in the working and traffic area, the bearing capacity of the ground and the necessary safeguarding of the location to allow it to be used as a public traffic area.

Take precautions to ensure that the loader is operated only in a secure, functioning state.

Only operate the loader if all the protection devices and safety devices, e.g. detachable protection devices, sound absorbers and exhaust equipment, are present and functioning.

• • • • •

Check the loader at least once a day for visible defects.

Should any changes occur (including changes in the operating behaviour), shut down the loader immediately, secure it and correct the defects right away.

In the case of malfunctions, shut down the loader immediately, secure it and correct the malfunctions right away.

Start and operate the loader only from the driver‘s seat.

When switching on and off, observe the indicator displays in accordance with the operating manual.

Make sure no one is located in the danger area of the loader before you start the engine.

Before beginning to work/drive, check whether the brakes, steering, signal and lighting systems are functional.

Before driving the loader away, always check that the accessories are placed so that they will not cause accidents.

Basic safety instructions

• • •

• •

When driving on public roads, lanes and squares, observe the valid road traffic regulations and put the loader into a condition permissible for the road beforehand.

As a matter of principle, turn on the lights when dark or the visibility is poor.

When driving through underpasses, gates, bridges, tunnels, overhead lines, etc., always make sure that you have enough clearance above and on both sides and a sufficient safety margin.

Always keep sufficient distance to excavations, embankments and the edges of piled up material.

Refrain from any method of working that could adversely affect the loader‘s stability. This also includes the duty to pass on information regarding the approved carrying capacity (=payload) for the relevant loader attachments. (carrying capacity / approved payload are specified in the operating manual)

• •

• •

Do not drive transversely on slopes; always keep work equipment and load near the ground, especially when driving down slopes.

When driving down a slope, always adjust your driving speed to take account of the respective conditions.

Always reduce your speed before reaching a downhill slope, and not after you have reached it.

The load must be located on the uphill side during driving on downhill or uphill slopes.

As a matter of principle, always secure the loader from accidentally rolling away and against unauthorized use.

Turn off the engine, put on the parking brake, lower the work equipment, take the key out of the ignition and, if necessary, employ a wheel chock.

23

Basic safety instructions

2.3.2

Safety instructions for other operating modes

These safety instructions refer to special tasks relating to the use of the loader and servicing tasks - as well as emergency maintenance during operation or work concerning disposal of the auxiliary and operating materials.

•

• • •

24

Observe the adjustment, maintenance and inspection tasks and deadlines as specified in the operating manual, including the specifications regarding replacing parts / partial equipment.

Adjustment, maintenance and inspection tasks such as replacing parts may only be carried out by specialized personnel.

Before maintenance work or other work can begin, operating personnel must be informed.

Appoint a supervisor.

For all work relating to the operation, conversion or adjustment of the loader and its safety devices, make sure that all switching on and off is performed according to the instructions in the operating manual.

•

• •

For all work relating to servicing, maintenance and repairs, observe the instructions in the operating manual for maintenance work and adhere to the time limits specified.

Secure the maintenance area, allowing as large a space as required.

If the loader is being completely shut off during servicing and maintenance work, please observe the following (see the chapter „Securing the Loader“): --Secure the loader from being accidentally turned back on by taking the key out of the ignition.

--Attach a warning note to indicate that the loader is being worked on.

--Only carry out servicing and maintenance work if the loader is parked on an even, hard surface and secured from rolling away and buckling.

--If maintenance work can only be carried out when the work equipment (= lift frame) is raised, support it with a suitable safety support.

Basic safety instructions

•

•

•

•

When they are replaced, individual parts and larger assemblies should be carefully attached and secured to the lifting gear. Use only suitable, technically faultless lifting gear and load-handling equipment with sufficient lifting capacity. Do not stand or work under suspended loads.

Only experienced persons may be assigned the tasks of slinging loads and instructing crane operators. The instructor must be within view of the operator or within speaking distance of him or her.

For assembly above head height, use only climbing aids and working platforms which are intended for this purpose, or which are safe for use in this situation. Do not use machine parts as climbing aids. Keep all handles, steps, pedestals, platforms and ladders free of dirt, snow and ice.

Clean the entire loader, especially the connections and threaded connections, with oil, fuel or care products when beginning maintenance and servicing work.

Use lint-free cleaning rags and no aggressive cleaning agents.

•

Before cleaning the loader with water or by steam jet (high-pressure cleaner) or with other cleaning agents, cover up / seal off all the openings into which water, steam and cleaning agents are not permitted to enter.

Electrical components, inlets and outlets for the engine‘s combustion air and tank openings are particularly at risk.

Completely remove the covers / seals after you have finished cleaning.

• Before restarting, retighten any threaded connections loosened during servicing and repairs, in particular for oil or fuel lines. When carrying out maintenance and servicing work, check all the lines and threaded connections for leaks and tight fit.

25

Basic safety instructions

ROPS/FOPS protective structures • •

Should it be necessary to remove safety devices during setup, servicing or repairs, reinstall and check the safety devices immediately after finishing the work.

Make sure that operating and auxiliary aids and replacement parts are disposed of safely and in an environmentally sound way.

WARNING Never use the loader without properly attached ROPS/FOPS protective structures. ►► Never drill holes in ROPS/FOPS protective structures, do not perform welding work on them, and do not straighten (bend) ROPS/FOPS protective structures. ►► ROPS/FOPS protective structures which are damaged should be replaced as a complete unit; this should only be done by authorized specialists.

•

•

26

Repairs to ROPS or FOPS protective structures may only be carried out by authorized specialized personnel.

In case of doubt, always completely replace ROPS or FOPS protective structures.

If the loader is equipped with a cab / driver canopy, it must be checked with the Category 1 FOPS.

Basic safety instructions

2.4

Safety instructions for special types of hazard

2.4.1

Transport of large bales or packaged goods

WARNING Risk of accidents due to falling objects. Falling objects, large bales or falling stacks of bales can cause serious or even fatal injuries. ►► Never transport more than one large bale or crate at once. ►► It is prohibited to load large bales or packaged goods with loaders which do not have a protective roof for the driver or driver's cab.

It is only permitted to use loaders with driver canopy or cabin for large bales or packaged goods.

Fig. 2

Transport of large bales or packaged goods

27

Basic safety instructions

2.4.2

Working in the vicinity of overhead power lines

DANGER Risk of fatal electrical shock due to contact with overhead power lines! ►► Keep the loader and attachments at a safe distance to overhead power lines and other electrical lines with a voltage of more than 50 V. ►► Read the information about the relevant safety distances which need to be maintained.

Rated voltage

Safety distance

Up to 1000 V

1m

3.3 ft.

Above 1 kV and up to 110 kV

3m

9.8 ft.

Above 110 kV and up to 220 kV

4m

13.1 ft.

Above 220 kV and up to 380 kV

5m

16.4 ft.

Unknown rated voltage

5m

16.4 ft.

28

•

•

If it is not possible to maintain a sufficient distance to overhead power lines, the owner/operator must put alternative safety measures in place in conjunction with the owner or operator of the power lines, for example by arranging to have the electrical power switched off.

What to do after contact with cables carrying high voltage current: --Do not get out of the loader.

--Drive the loader away from the danger area.

--Warn any people around the loader not to come any closer or touch the vehicle.

--Arrange to have the power switched off.

--Do not get out of the loader until you are sure that the cable you came into contact with and which is now damaged has been disconnected from the electrical supply and is definitely no longer carrying a live voltage.

Basic safety instructions

2.4.3

• • •

Electrical power

Check the electrical equipment of the loader at regular intervals. Defects such as loose plug connections or burnt cables must be immediately rectified.

Shut down the loader immediately if there are any defects in the electrical system.

Only use original fuses with the required current rating.

2.4.4

Fire hazard

WARNING Hot parts of the machinery, e.g. the exhaust system, exhaust gases and the electrical system, represent particular dangers as they can cause explosions and fires. ►► Keep a safe distance from flammable materials like hay and straw. ►► Do not work in enclosed rooms which contain flammable materials, explosive vapors or dusts. ►► Only park the loader in designated areas which are protected against the risk of fire.

29

Basic safety instructions

2.4.5

•

• •

•

30

Gas, dust, vapor, smoke

Due to the exhaust gases which are emitted from the diesel engine, the loader must only be used in sufficiently well ventilated areas. Before starting up the vehicle in enclosed spaces, make sure that there is sufficient ventilation.

Comply with the regulations which apply at the particular site of use.

Do not carry out any welding, burning or grinding work unless it is expressly permitted. There must not be any risk of fire or explosion. Ensure that adequate ventilation is provided before carrying out welding, burning or grinding work and clean the loader and its surroundings of dust and combustible materials.

Wear appropriate personal protection equipment (breathing filters, protective overalls) for protection against specific hazards, e.g. as a result of poisonous gases, corrosive vapors, poisonous surroundings of the vehicle (i.e. containing toxins) etc.

2.4.6

•

•

•

Hydraulic systems, pneumatic systems

Any oil which sprays out can cause burns and result in injuries. Regularly check all lines, hoses and screwed connections for leaks and damage which can be seen from the outside. Leaks and damage must be rectified immediately.

Do not open hydraulic or pneumatic systems unless they have been depressurized. Always depressurize system sections and high-pressure lines before starting any repair work. Refer to the corresponding instructions in this operator’s manual for more information about doing this.

Hydraulic and pneumatic lines must be properly routed and installed. This work must only be carried out by an authorized expert. Make sure that none of the connections get mixed up. The hydraulic lines and pneumatic lines must meet the requirements in terms of the fittings, their length and quality, in particular with regard to pressure and temperature resistance.

Basic safety instructions

2.4.7

What to do if the loader tips over

2.4.8

WARNING Risk of injury!

If the loader tips over it can injure the driver. ►► Always fasten the seat belt when working with the loader. ►► Keep the lift frame lowered when traveling.

•

DANGER Risk of engine damage!

Failure to comply with the following instructions can result in extreme engine damage. ►► Switch the engine off immediately if the loader slips into an extremely tilted position or tips over as a result of inappropriate or careless operation. ►► Do not restart the engine once the loader has been returned to the proper upright position. ►► Inform a specialist workshop. The engine will need to be checked by a qualified specialist before it can be released for continued use.

While the loader is in operation, all of the noise protection devices of the loader must be in the protection ON position.

2.4.9

• • • •

Noise

Oil, grease and other chemical substances

Observe the applicable safety regulations for the product when handling oil, grease and other chemical substances.

Take care when handling hot operating materials (fluids, lubricants, oils etc.) and auxiliary materials - risk of burns or scalding.

Smoking and naked flames are prohibited during refueling. Risk of fire and explosion!

Caution - extreme risk of fire and explosion! It is prohibited to add petrol to the fuel mixture. At low outside temperatures use standard commercially available winter diesel fuel.

31

Basic safety instructions

2.5 • • • •

32

Transporting and towing/restarting

Always follow the instructions in the operator’s manual when towing, loading and transporting the loader.

When towing the loader, adhere to the specified transport position, the maximum permitted speed and the maximum permitted towing distance.

Only use suitable transport vehicles and lifting equipment with sufficient load-bearing capacity.

Always follow the instructions in the operator’s manual when restarting the loader.

2.6 •

• •

Final decommissioning/dismantling During final decommissioning or dismantling of the vehicle all operating materials (oils, lubricants, fluids etc.) and auxiliary materials must be drained and disposed of in accordance with relevant environmental legislation.

It must be ensured that it is not possible to take the loader back into operation.

The remaining machine body must be disposed of via suitable, specialized companies or disposal sites.

Basic safety instructions

2.7

Safety stickers used Fig. 3 Safety stickers

Never remove the safety stickers. Damaged stickers must be replaced. New stickers can be ordered from: www.wackerneuson.com

5

9

10

4

3 8 2 1

1

6

11

7

33

Basic safety instructions

34

Safety sticker 1

Safety sticker 3

Warning

Warning

Risk of injury!

Do not stand in the danger area of the loader during operation.

Do not step underneath the lift frame when it is lifted up.

Remove the ignition key before carrying out maintenance or repair work.

Follow the operator’s manual when carrying out maintenance and repair work.

Safety sticker 2

Safety sticker 4

Warning

Warning

Risk of injury due to moving parts.

Never open the protective devices while the engine is running.

Risk of injury!

Do not stand near the bending region during operation.

Basic safety instructions

Safety sticker 5

Safety sticker 7

Important

Warning

Risk of technical damage.

Grease the centre joint daily before placing into operation.

Additional details can be found in the operating manual.

Never stand in the unsecured danger area.

Use the safety supports.

Safety sticker 6

Safety sticker 8

Important

Warning

Information stickers: The battery disconnect switch is located here.

Please observe the description in the operator’s manual.

Escaping pressurized hot coolant or hot steam can cause scalding on the hands.

Never open the radiator when it is hot.

Follow the operator’s manual.

15 PSI 1 BAR

35

Basic safety instructions

Safety sticker 9

Safety sticker 10

Warning

Warning

Risk of accidents due to falling objects.

Never transport more than one large bale or crate at once.

It is prohibited to load large bales or packaged goods with loaders which do not have a protective roof for the driver or driver’s cab.

Follow the operator’s manual.

Always fasten the seat belt when performing any work with the loader.

Risk of injury!

Fasten the safety belt for all work with the loader!

Safety sticker 11

Important Risk of technical damage.

Close both doors before tilting the cab.

36

Basic safety instructions

2.8

Safety devices

2.8.1

Fire extinguisher

Fig. 4 Fire extinguisher

A fire extinguisher can be fitted to cab / driver’s canopy rail to the right or left of the driver‘s seat (Fig. 4).

2.8.2

Rotating beacon

Additional equipment!

Note Use the yellow rotating beacon according to the legal regulations.

The mounting for a rotating beacon is located at the rear of the driver’s canopy (Fig. 5).

Fig. 5 Attaching the rotating beacon

To switch the rotating beacon on and off, see the chapter „Switches / toggle switches“.

37

Basic safety instructions

2.8.3

Lowering brake valves on lifting and tipping cylinders

Additional equipment!

CAUTION For loaders with lowering brake valves (Fig. 6), the lift frame may only be lowered and the residual pressure discharged exclusively by trained specialized personnel as described in the chapter „Relieving residual pressure in the hydraulic system“.

The lowering brake valves prevent the lift frame from dropping uncontrollably in the event of a sudden decrease of pressure in the hydraulic system.

38

Fig. 6 Lowering brake valve

Basic safety instructions

2.8.4

Battery disconnect switch

Note Ensure that you cover the opening with a protective cap when you pull off the switch head so that moisture cannot penetrate into the switch.

Never switch the battery disconnect switch under load! Activate the switch first before inserting the ignition key. Proceed in the reverse sequence when stopping!

The switch can be used to quickly disconnect the entire electrical system from the battery in the event of an emergency.

Switch off the battery overnight to prevent it from potential discharge or damage. You can also use the switch as an additional anti-theft device by pulling off the switch head.

Fig. 7 Battery disconnect switch

• Turn the switch lever to the left: –– The battery is disconnected from the electrical system • Turn the switch lever to the right: –– The battery is connected to the electrical system.

39

Basic safety instructions

2.8.5

Safety belt

Note Fasten the safety belt for all work with the loader!

The loader is equipped with a safety belt on the driver‘s seat (Fig. 8).

2.8.6

Seat contact switch

Note The loader is equipped with a seat contact switch.

The seat contact switch ensures that the engine can only be started if the driver is sitting in the driver’s seat.

If the engine is running and the driver gets up from the seat, the engine automatically cuts out after approximately 20 seconds.

40

Fig. 8 Safety belt

Basic safety instructions

2.8.7

Emergency exit

Note The cab has two doors. Use only the door on the left when entering and leaving the cab. The door on the right is only to be used as an emergency exit.

2.8.8

Fig. 9 Emergency exit

Audible reverse warning device

Additional equipment!

An acoustic warning signal sounds when reverse gear is engaged. This acoustic signal is intended to warn anybody who is in the vicinity of the loader that the loader is backing up.

41

Basic safety instructions

2.8.9

NOTE The lift frame can be secured against inadvertent operation by means of a locking device.

When the locking mechanism is engaged it is no longer possible to activate the lift frame.

The fact that the lift frame is blocked is not shown via indicator lamps, but instead can be seen from the position of the switching lever (Fig. 10).

CAUTION Danger due to inadvertent activation of the lift frame while traveling on roads. ►► Before driving the loader on public roads, always block the lift frame by engaging the locking mechanism. ►► Always block the lift frame before getting out of the loader. ►► Do not disengage the locking mechanism until you have sat down in the driver's seat and wish to start work.

42

1

Locking mechanism for the lift frame

Fig. 10 Lever for locking the lift frame

ON Off

Apply the locking system for the lift frame by shifting the lever located to the right of the driver‘s seat Item 1 (Fig. 10).

• Move the switching lever to the rear: –– The locking system is now on.

• Move the switching lever forwards: –– The locking system is now off.

Technical data

3

Technical data

3.1

Technical description

The loader consists of the vehicle frame, the drive and the axles. The vehicle frame contains all the drive and control units for the standard configuration. The vehicle frame consists of the front carriage with the lift frame, and the rear carriage, in which the drive unit is situated. They are connected by an articulated swivel joint.

Brakes The drive also functions as the service brake. It acts on the front and rear axles. The brake is activated via the brakinginching pedal. Furthermore, the braking-inching pedal is used to activate the hub brake on the differential. The parking brake also operates mechanically on this hub brake.

Steering

Drive The loader is driven by a diesel engine, which powers the steering and working hydraulics and the driving hydraulics.

The fully hydraulic articulated swivel steering system operates via a dual action cylinder.

The driving hydraulics power the transfer case, which transfers the force to the rear axle, and to the front axle (via the propeller shaft).

The axles are designed as rigid axles.

43

Technical data

Hydraulics The loader has two hydraulic systems supplied by a hydraulic fluid tank: –– hydrostatic drive –– steering and working hydraulics The hydrostatic drive consists of an axial piston variable displacement pump, which drives an axial piston diesel engine. The axial piston variable displacement pump is flanged onto the diesel engine, while the axial piston diesel engine is flanged onto the transfer case.

Displacement is automatic and continuous, but depends on speed and load. The driving speed depends on the engine speed and the machine load. The driving application begins with the target engine speed, and ends with the maximum speed of the engine, achieved by means of the accelerator

44

pedal. Depending on load, the variable displacement pump is automatically adjusted so that the most favourable speed is maintained. The more the loader is burdened (when carrying a load or driving uphill), the lower the driving speed will be. This adjustment control allows the entire range of performance to be utilised optimally. Actuating the inching pedal (inching delay, left pedal in relation to direction of travel) also influences the control, allowing the loader to be slowed down by fine reductions in the engine speed, right down to the loader coming to a standstill.

A gear hydraulic pump supplies the steering and working hydraulics with oil. The gear pump is flanged to the drive‘s variable displacement pump.

The hydraulic system is equipped with relief valves, filters and oil coolers.

Technical data

Electrical system

3.2

Loader data

The electrical system has an operating voltage of 12 volts.

The consumers and their supply lines are fused.

Engine

Equipment

Type

404 D – 22

Displacement

2216 cm³

Cooling

water-cooled

rpm

2600 rpm

Output

35,7 kW / 49 hp

The loading equipment consists of the lift frame with an integrated mechanical or hydraulic quick-change receptacle, lifting and tipping cylinders and the appropriate attachments.

The loader is fitted with a ROPS/FOPS structure. ROPS: Structure to protect the driver should the loader tip over.

FOPS: Structure to protect the driver against falling objects.

4-cylinder Perkins diesel engine

Electrical system Working voltage

12 volts

Battery

77 Ah

45

Technical data

Hydraulics

Brick Master

Driving hydraulics

Steering Fully hydraulic articulated swivel steering

Flow rate

73 l/min

73 l/min

Rotating angle

± 12°

Working pressure

450 bar

450 bar

Turn angle

± 50° / ± 44°

Flow rate

49 l/min

49 l/min

Drive (driving speed)

Working pressure

210 bar

250 bar

1. gear

0 – 7 kph

2. gear

0 – 20 kph

Working hydraulics

Steering hydraulics Flow rate

49 l/min

49 l/min

Working pressure

175 bar

175 bar

46

Noise values dB(A) average noise output level LwA

99,4

guaranteed noise output level LwA

101

specified sound power level LpA

82

Technical data

Weight specifications (With driver’s canopy)

Brick Master

Operating weight

2780 kg

2780 kg

Permissible total weight

3200 kg

3200 kg

Permissible axle load per axle

2400 kg

2400 kg

Permissible payload with shovel

777 kg

936 kg

Permissible payload with pallet fork

759 kg

840 kg

Max. drivable uphill/downhill gradient

< 20°

Weight specifications (With cab) Operating weight

2880 kg

Permissible total weight

3200 kg

Permissible axle load per axle

2400 kg

Permissible payload with shovel

851 kg

Permissible payload with pallet fork

812 kg

47

Technical data

Vibrations (weighted effective value) Hand/arm vibrations:

Full-body vibrations:

Hand-arm vibrations do not exceed 2.5 m/s².

This loader is equipped with a driver’s seat which complies with EN ISO 7096:2000 requirements.

Assuming proper usage, full-body vibrations vary from less than 0.5 m/s² up to a momentary maximum value.

When calculating the vibration values in accordance with ISO/TR 25398:2006, you are advised to use the values specified in the table. Here the actual conditions of use must be taken into account.

Loaders and teleloaders are classified according to their operating weight.

48

Technical data

Average value Loader type Compact loader (operating weight < 4,500 kg)

Loader (operating weight > 4,500 kg)

Typical operating conditions

Standard deviation (s)

1.4*aw,eqx 1.4*aw,eqy aw,eqz

1.4*sx

1.4*sy

sz

[m/s²]

[m/s²]

[m/s²]

[m/s²]

[m/s²]

[m/s²]

Load & carry

0.94

0.86

0.65

0.27

0.29

0.13

Load & carry

0.84

0.81

0.52

0.23

0.20

0.14

Use in extraction (harsh conditions of use)

1.27

0.97

0.81

0.47

0.31

0.47

Transfer journey

0.76

0.91

0.49

0.33

0.35

0.17

V-shape operation (loading)

0.99

0.84

0.54

0.29

0.32

0.14

49

Technical data

3.3

Dimensions

3.3.1

Dimensions (Loaders with driver’s canopy)

Fig. 11 Dimensions (Loaders with driver’s canopy)

50

Technical data

Dimensions with 10.0/75 – 15.3AS tyres Item Designation

Unit Value

Item Designation

Unit Value

A

Overall length with standard bucket

mm 4563

N

Max. dumping angle at max. lift height

°

43

A‘

Overall length without bucket

mm 3586

O

Reverse roll angle on ground

°

52

B

Axle centre to bucket pivot-point

mm 560

P

Reverse roll angle at max. lift height

°

43

C

Wheelbase

mm 1732

Q*

Inside turning radius

mm 1327

D

Rear overhang

mm 1182

R*

Overall width

mm 1044

E*

Overhead loading height

mm 2681

S*

Radius at outer edge

mm 2531

F*

Max. height of bucket pivot point

mm 3000

T*

Ground clearance

mm 256

G*

Height of seat

mm 1245

U

Turn angle

°

H*

Max. dumping height

mm 2024

V

Width across driver’s canopy

mm 839

I*

Scraping depth

mm 89

W* Track width

mm 780

Overall width driver’s canopy

mm 1021

Maximum turning radius (depends on bucket width)

mm 2879

K*

Reach at H

mm 339

X

L*

Height to driver’s canopy

mm 2225

Z

M* Total working height

mm 3687

± 50

*In the event of deviating tires or reverse wheel rims the dimensions will change

51

Technical data

3.3.2

Dimensions (Loaders with cab)

Fig. 12 Dimensions (Loaders with cab)

52

Technical data

Dimensions with 10.0/75 – 15.3AS tyres Item Designation

Unit Value

Item Designation

Unit Value

A

Overall length with standard bucket

mm 4719

N

Max. dumping angle at max. lift height

°

37

A‘

Overall length without bucket

mm 3743

O

Reverse roll angle on ground

°

50

B

Axle centre to bucket pivot-point

mm 722

P

Reverse roll angle at max. lift height

°

56

C

Wheelbase

mm 1732

Q

Inside turning radius*

mm 1812

Overall width*

mm 1124 mm 3011

D

Rear overhang

mm 1182

R

E

Overhead loading height*

mm 2865

S

Radius at outer edge*

F

Max. height of bucket pivot point*

mm 3194

T

Ground clearance*

mm 250

G

Height of seat*

mm 1245

U

Turn angle

°

H

Max. dumping height*

mm 2283

Width across driver’s canopy*

mm 840

I

Scraping depth*

mm 150

Width across cab*

mm 870

K

Reach at H*

mm 496

W Track width*

Height to cab*

mm 2230

Total working height*

mm 3927

Z

M

V

Maximum turning radius (depends on bucket width)

± 44

mm 860 mm 3419

*In the event of deviating tires or reverse wheel rims the dimensions will change

53

Technical data

3.4

Factory signs Fig. 13 Vehicle ID no.

A factory sign is permanently attached to the loader on the right side of the front carriage (Fig. 13).

It lists the following information:

1 Weidemann GmbH Mühlhäuser Weg 45-49 D-34519 Diemelsee-Flechtdorf

1 Art.-Nr. Fahrzeug-Ident-Nr. Typ Motorleistung kW Betriebsgewicht kg zul. Ges Gew. kg Hom.-Nr

54

2 4 5 6 7 9 11 13

Baujahr

3

8 zul. Achslast hinten kg 10 zul. Anhängelast kg 12 zul. Achslast vorn kg

Made in Germany

Radlader

Item

Designation

1

Manufacturer

2

Vehicle description

3

Year built

4

Article number

5

Vehicle ID no.

6

Type

7

Engine power kW

8

Permissible front axle load kg

9

Operating weight kg

10

Permissible rear axle load kg

11

Permissible total weight kg

12

Permissible trailer load kg

13

Homologation number

Technical data

In addition, the vehicle ID is engraved on the right side of the rear end near the entry area (Fig. 13/1).

In addition, the following loader components each have their own rating plate: • • • •

The diesel engine The axial piston variable displacement pump (hydraulic transmission pump) The oil motor (hydraulic traction engine) The axles

55

Description of the indicator, warning and control elements

4

Description of the indicator, warning and control elements

4.1

Operating elements and instruments Fig. 14 Operating elements

1 3 2 12

11

5 4

10

6

8 9

56

7

Description of the indicator, warning and control elements

Item Designation 1

Steering wheel turning knob

2

Instrument panel

3

Steering wheel

4

Accelerator

5

Engine speed adjustment for cold starting

6

Operating lever for lift frame / drive

7

Operating lever for additional hydraulics

8

Operating lever for parking brake

9

Driver‘s seat

10

Braking-inching pedal

11

Operating lever for adjusting the steering column

12

Operating lever for lighting, blinkers and signal horn

57

Description of the indicator, warning and control elements

4.2

Control and warning lights 1

2

3

4

5

6

Danger of accidents from malfunctions! ►► Should a red indicator light be illuminated when the engine is running, turn off the engine immediately. ►► Resolve the fault (see troubleshooting and emergency maintenance). Do not continue working with the loader until the fault has been resolved.

Note Immediately turn off the engine if a light marked with this * symbol is illuminated in the adjacent table.

Fig. 15

58

Control and warning lights

7

8

9

Description of the indicator, warning and control elements

Item Designation

Function

1

Not used

No function

2

Heater indicator light

Illuminates during preheating

3

Not used

No function

4*

Warning light for engine oil pressure

Illuminates when engine oil pressure is too low (Additionally a warning tone sounds)

5*

Warning light for generator

Illuminates if the battery is not charged

6*

Warning light for engine temperature

Illuminates when engine temperature (Additionally a warning tone sounds)

7

Indicator light for forward drive

Illuminates when gear is set to forward drive

8

Indicator light for reverse drive

Illuminates when gear is set to reverse drive

9

Indicator light for crawler gear

Illuminates when crawler gear is engaged

Symbol

59

Description of the indicator, warning and control elements

Control and warning lights Danger of accidents from malfunctions! ►► Should a red indicator light be illuminated when the engine is running, turn off the engine immediately. ►► Resolve the fault (see troubleshooting and emergency maintenance). Do not continue working with the loader until the fault has been resolved.

Note Immediately turn off the engine if a light marked with this * symbol is illuminated in the adjacent table.

10 Fig. 15

60

11

12

13

14

15

Control and warning lights

16

17

18

Description of the indicator, warning and control elements

Item Designation

Function

10

Indicator light for parking brake

Illuminates when the parking brake is on

11

Not used

No function

12

Indicator light for main beam

Illuminates when the main beam is switched on

13

Not used

No function

14

Air filter indicator light

Illuminates when the air filter is contaminated

15

Turn signal indicator light

Illuminates when a turn signal is on

16

Warning light for return filter

Illuminates if the pressure at the return filter is too high

17 *

Warning light for hydraulic oil temperature

Illuminates when hydraulic oil temperature is too high

18

Indicator light for overdrive

Illuminates when overdrive is engaged

Symbol

61

Description of the indicator, warning and control elements

4.3

Switches / toggle switches Note Loader with driver‘s canopy: The switch for the signal horn is in position 3 for loaders without lighting system.

1 Fig. 16

62

2

3

4

5

Switches / toggle switches

6

7

8

Description of the indicator, warning and control elements

Item Designation

Function

1

Combination switch

For switching lighting and signal horn

2

Toggle switch for hydraulic locking for attachments

Releases the additional hydraulics in order to release the hydraulic locking device for attachments

3

Toggle switch for hazard warning lights

For switching hazard warning lights ON/OFF

4 * Available for additional equipment

For switching Electrical outlet on the lift frame

5 * Available for additional equipment

Loaders with driver‘s canopy: For switching Rotating beacon ON/OFF

6 * Available for additional equipment

No function

7

Headlight toggle switch

Loaders with driver‘s canopy: For switching the headlights ON/OFF

8

Engine ignition switch

For switching the engine ON/OFF

Symbol

63

Description of the indicator, warning and control elements

Switches / toggle switches (Loaders with cab) Switches / toggle switches

9

64

10

11

12

13

14

Description of the indicator, warning and control elements

Item Designation

Function

9

Toggle switch for front windscreen wipers

For switching front windscreen wipers ON/OFF

10

Toggle switch for rear windscreen wipers

For switching rear windscreen wipers ON/OFF

11

Toggle switch for front headlights (Loader with cab)

For switching front headlights ON/OFF

12

Toggle switch for rear headlights (Loader with cab)

For switching rear headlights ON/OFF

13

Toggle switch for rotating beacon

For switching rotating beacon ON/OFF

14

Available for additional equipment

No function

Symbol

* The position of the switches can vary depending on the combination of different additional equipment

65

Description of the indicator, warning and control elements

4.4

Indicator devices Item Designation

1 Fig. 17

66

2 Indicator devices

3

4

Function

Symbol

1

Fuel gauge

Shows the fuel quantity

2

Tachometer

Shows the diesel engine‘s speed

3

Time meter

Adds up the loader‘s operating time. Plan your service work and inspection work according to the meter reading.

4

Engine temperature

Shows the engine‘s temperature

Description of the indicator, warning and control elements

67

Operating and operation

5

Operating and operation

5.1

Before starting up Read the operator's manual before starting up the loader. ►► Only operate the loader from the driver‘s seat. ►► Observe the safety regulations. ►► Receive instruction from expert personnel before you drive the loader the first time. Your first attempts at driving should be carried out on spacious premises. ►► Check the condition of the loader before beginning work. ►► Have the loader checked by specialized personnel before restarting it following long periods of disuse.

68

5.1.1

Fueling

Caution Fire hazard – diesel fuel is flammable! ►► Do not smoke and avoid fire and open flames when fueling. ►► Do not use petrol. Use only diesel fuel. Do not add petrol.

Diesel fuel is hazardous to your health. ►► Wear appropriate gloves. ►► In the event of an accident involving fuel, immediately inform the persons responsible.

Note Use only clean, conventional high-grade diesel fuel to operate the loader.

If at all possible, use a fine filter in the filling line.

Operating and operation

Environment Note Diesel fuel is hazardous to the environment. ►► Do not allow it to be released uncontrollably into the environment. ►► Immediately soak up with binding material any fuel that has leaked, overflowed or been spilled, and dispose of it in an ecologically sound manner. ►► Immediately inform the persons responsible if fuel has been released into the environment.

The diesel tank is located in the front carriage of the loader.

The tank‘s filler neck is located on the right side of the front carriage (Fig. 18).

Fig. 18 Fuel filler neck

1. Lower the lift frame and turn off the engine to fuel the loader.

2. Remove the lid of the filler neck.

3. Fuel the loader‘s tank through the filler neck.

4. Carefully close the tank lid after fueling.

69

Operating and operation

5.1.2

70

Getting in

Check before getting in

WARNING Danger of accidents from defects! ►► Do not work with the loader if defects put the operational safety of the loader at risk. Correct any defects immediately. ►► Check that the safety devices are present and operative each time before you start up the loader.

Danger of accidents from damaged tyres! ►► Check the tyres each time before commencing work.

Danger of accidents due to jamming or slipping! ►► Remove or tighten loose objects located in the cab. Keep the operating elements clean. ►► Follow the daily servicing schedule.

• • • • • • •

Check that the loader is clean and undamaged.

Check that the handles and steps are in good condition and clean.

Check that all safety components are present and fully functional.

Check that the rods, cylinders, hinge pins and coolers are clean.

Check that all the screws, joints and hinge pins are firmly seated.

Check that all the signs are present and in good condition.

Check the loader for oil, fuel and coolant leaks.

Operating and operation

Check: • • • • •

•

Engine oil level Hydraulic fluid level Coolant level Fuel level Check the condition of the tyres, check for cuts or signs of wear, for example. Check the tyre pressure! Ensure that the tyres are inflated to the proper pressure (see tire pressure table).

Ensure that the engine covers and the caps for the fuel tank and hydraulic fluid tank are present and have been tightened.

71

Operating and operation

Getting in Fig. 19 Getting in

CAUTION Risk of accident due to slipping when entering the loader. ►► Check the condition and cleanliness of the handles and steps. ►► Enter the cabin from the left-hand side only. ►► Use the attached handles and steps (Fig. 19)! ►► Always face the loader when climbing in and out.

Risk of injury due to restraining bar slamming shut! ►► When working with the loader, ensure that the side restraining bars are always locked in position.

The driver’s cab is equipped with side restraining bars for the driver item 1 (Fig. 20). Open the restraining bars by pushing down the unlocking lever item 2 (Fig. 20).

1

2

72

Fig. 20 Locking the restraining bar

Operating and operation

5.1.6

Doors and windows

CAUTION Danger of injury from falling cab doors! ►► Make sure that the cab doors are always locked tightly in place.

Fig. 21 Cab door locking mechanism Illustration 1 outside

The cab has one door on the left and one on the right. The right-hand door is intended for use as an emergency exit.

• •

Open the cab door from the outside by pulling the door opener (Fig. 21/1).

Open the door from the inside by pulling the unlocking lever downwards (Fig. 21/2).

Illustration 2 inside

73

Operating and operation

The cab doors can be locked in two positions:

Fig. 22 Cab door locking

1. Closed 2. Open (Fig. 22) The cab door can be locked in „Open“ position by releasing the lever (Fig. 23).

Always check that the cab doors and windows are closed before leaving the loader.

Fig. 23 Releasing locked cab doors

74

Operating and operation

5.1.3

Adjusting the steering column

Only for loader equipment with lighting system!

Warning Danger of accidents from distractions! ►► Do not adjust the steering column while driving, but rather only when the loader is shut down.

Fig. 24 Adjusting the steering column

You can adjust the position of the steering column lengthwise so that it fits your height and posture.

1. Operate the adjustment lever (Fig. 24).

2. Adjust the steering column as needed.

3. Let go of the adjustment lever.

75

Operating and operation

5.1.4

Adjusting the driver‘s seat

Adjusting the driver‘s seat

WARNING Danger of accidents from distractions! ►► Do not adjust the driver‘s seat while driving; only adjust it when the loader is stopped!

1. Height adjustment:

You can adjust the driver‘s seat to fit your height and posture. This keeps your muscles relaxed and prevents fatigue while working.

Adjust the seat so that you can comfortably reach the levers and pedals with your back against the backrest.

You can adjust the seat in the following ways (Fig. 25):

76

There are three levels of height adjustment. Adjust the height while sitting in the seat by turning the height adjustment handle. In each case the position set is the one indicated on the bottom of the handle. Re-adjust the weight setting after each height adjustment.

2. Weight adjustment: Adjust the weight while sitting in the seat by turning the weight adjustment handle. The weight is set correctly if the height position that has been set via the height adjustment handle can be seen in the view window Item 2a. The middle position of the spring‘s range for the respective height setting will be indicated.

Operating and operation

4 3. Backrest adjustment: Adjust the backrest via the locking lever. The locking lever should lock in the desired position. The backrest should not move again after it has been locked in place.

3

2 Fig. 25 Adjusting the driver‘s seat

4. Lengthwise adjustment: Adjust the length setting by pulling the locking lever upwards. After you have made the adjustment, the locking lever should lock in the desired position. The driver‘s seat should not move again after it has been locked in place.

2a

1

77

Operating and operation

5.1.5

78

Seat belt

Fastening the seat belt

WARNING Risk of injury.

The driver can be injured if the seat belt is not fastened or if the seat belt is damaged. ►► In order to work with the loader you must be sitting on the driver's seat and have properly fastened the seat belt. ►► Keep the seat belt and the seat belt buckle free from dirt in order to ensure that they work properly. ►► Check the seat belt and the seat belt buckle for damage before starting work. ►► If either the seat belt or the seat belt buckle are damaged they must be replaced immediately.

1. Sit yourself on the driver’s seat with all of your back touching the backrest.

2. Place the seat belt over your lap.

3. The seat belt must not be twisted.

4. Place the tongue item 1 in the seat belt buckle item 3 (Fig. 26).

5. If necessary, adjust the seat belt to your body size (refer to the section “Adjusting the seat belt”).

Releasing the seat belt 1. Press the red button item 2 on the seat belt buckle.

Operating and operation

Adjusting the seat belt Fig. 26 Fastening the seat belt

1 2

WARNING Risk of injury or material damage.

Attempts to adjust the seat belt while operating the loader can result in inadvertent movement of the operating elements. ►► Do not attempt to adjust the seat belt while operating the loader. ►► Stop the loader first and then adjust the seat belt.

NOTE Adjust the seat belt so that it is not too tight and not too loose.

Do not position the seat belt over solid or fragile objects (e.g. glasses, bunches of keys).

3

79

Operating and operation

Lengthening the seat belt •

Fig. 27 Adjusting the seat belt

Pull the tongue clasp to lengthen the seat belt to the desired length.

Shortening the seat belt • •

Lengthening

With the seat belt fastened, pull on the free end of the seat belt until the seat belt lies snugly across your lap.

Move the plastic clasp as required to secure the excess belt webbing item 1 (Fig. 27).

Shortening

1

80

Operating and operation

5.2

Starting up WARNING Danger of accidents! ►► Do not drive the loader if the entire lighting system or individual functions are not working.

Note The warning and indicator lights display fault messages from the equipment.

All the toggle switches are switched on by moving them to the down position.

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Operating and operation

5.2.1

Lighting system and signal horn Fig. 28 Lighting / signal horn

Note The switch for the signal horn is in position 5a for loaders without lighting system.

Check the lighting, blinker and signal horn each time before driving.

The lever (Fig. 28) is used to control the three functions, lighting, blinker, and signal horn: • Press the lever forwards (position 1): –– The blinker blinks to the right.

1

4

5 2 3

5a

• Pull the lever backwards (position 2): –– The blinker blinks to the left.

• Press the lever upwards (position 3): –– The low beam switches on.

• Turn the lever forwards: –– The parking light switches on with level 1.

• Press the lever downwards (position 4): –– The high beam switches on.

• Continue turning the lever forwards: –– The parking light switches on with level 2.

• Press the symbol for the signal horn (5): –– The signal horn is activated.

82

Operating and operation

5.2.2

Headlights Fig. 29 Switch for work lights (Loaders with driver‘s canopy)

WARNING Danger of accidents from drivers who are blinded by the high-beam lights! ►► Do not drive on public roads with the work lights switched on.

Loaders with driver‘s canopy: The loader is equipped with front and rear headlights. The work lights are switched on/off using the toggle switches on the right next to the steering wheel (Fig. 29).

5

7

• Put the toggle switch item 7 into position 1: –– The front headlights switch on.

• Put the toggle switch item 7 into position 2: –– The front headlights and rear headlights switch on.

• Put the toggle switch item 7 into position 0: –– The headlights switch off.

83

Operating and operation

Loaders with cab: Fig. 30 Switch for work lights (Loaders with cab)

The loader is equipped with front and rear headlights. The switches for switching on the headlights are located in the cab to the right above the driver‘s seat item 11 and 12.

Front headlights: • Put the toggle switch Item 11 in position 1: –– The headlights switch on.

9 • Put the toggle switch Item 11 in position 0: –– The headlights switch off.

Rear headlights: Note Operate the rear headlights using the toggle switch Item 12 (Fig. 30) the same way you would the front headlights.

84

10

11

12

13

14

Operating and operation

5.2.5

Rotating beacon Fig. 31 Switch for rotating beacon

(additional equipment) Note Use the yellow rotating beacon according to the legal regulations.

(Loaders with driver‘s canopy)

If you want to use a rotating beacon, mount it on the fastener provided (Fig. 5).

• Put the toggle switch item 5/13 into position 1: –– The rotating beacon switches on.

5

• Put the toggle switch item 5/13 into position 0: –– The rotating beacon switches off.

(Loaders with cab)

9

10

11

12

13

14

85

Operating and operation

5.2.6

Wipers and windscreen washer system Fig. 32 Switches for windscreen wipers

The wipers and windscreen washer system are switched on/off using the toggle switches in the cab roof on the right next to the driver‘s seat Item 9 and 10 (Fig. 32).

(Loaders with cab)

Front window: • –– • –– • ––

Put the toggle switch Item 9 in position 1: The windscreen wiper switches on.

Put the toggle switch Item 9 in position 2: The front windscreen washer system switches on.

Put the toggle switch Item 9 in position 0: The windscreen wipers and windscreen washer system switch off.

Rear window: • –– • –– • ––

86

Put the toggle switch Item 10 in position 1: The back wiper switches on.

Put the toggle switch Item 10 in position 2: The back washer system switches on.

Put the toggle switch Item 10 in position 0: The windscreen wiper and windscreen washer system switch off.

9

10

11

12

13

14

Operating and operation

5.2.7

Ventilation and heating of the cab Fig. 33 Heating controller

Ventilation The cab is ventilated via the doors and rear window. The doors must be locked in open condition (Fig. 22): Heating

W

The cab heater is located on the right next to the steering column.

G

Temperature

Fan

Use the left regulator Item W to adjust the temperature continuously (Fig. 33):

Adjust the fan by turning the right regulator Item G (Fig. 33).

The fan speed can be switched to three levels:

• –– • ––

• • • •

Turn the left regulator Item W to the left: The temperature rises.

Turn the left regulator Item W to the right: The temperature decreases.

Level „0“ Level „1“ Level „2“ Level „3“

– Fan „OFF“ – Low speed.

– Medium speed.

– High speed.

87

Operating and operation

Ventilation jets Fig. 34 Ventilation jets

You can use the jets (Fig. 34) to control air flow into cab. In cold weather, warm air supply keeps the windows free of ice and heats the cab in the process.

88

Operating and operation

5.2.3

Before starting the engine

Danger of injury! ►► Check that no one is on or near the loader!

Danger of injury from slipping! ►► Keep the operating elements clean and dry, as they could slip out of your grasp, causing you to lose control of the loader.

Danger of accidents from poor visibility! ►► Make sure that the cab windows and exterior mirrors are clean and position the exterior mirrors so that you have a good view from your seat of the area immediately behind the loader.

Danger of accidents from missing safety devices! ►► Ensure that all safety devices are fitted, and that (after repairs) all tools have been removed, and that the engine hood is closed.

5.2.4

Starting the engine

Caution Danger of injury! ►► Check that no one is in the loader‘s danger area! ►► Do not use any combustible starting aids (e.g.

Startpilot)!

Danger of accidents! ►► Do not use the loader if the „starter lock/driving lock“ does not function. ►► Only start the loader from the driver‘s seat.

1. Perform the „Check before getting in“ prior to starting the engine (see the chapter „Getting in“).

2. Adjust the driver‘s seat and the steering column as needed.

3. Adjust the rear view mirror / exterior mirror.

4. Fasten your safety belt.

89

Operating and operation

Note Danger of technical damage!

Due to the high viscosity in the hydraulic system and engine oil circuit at temperatures below 0°C, major technical damage can occur if the speed is increased immediately. ►► Let the engine run for a certain period of time at low speed at temperatures below 0°C. The lower the outside temperature, the longer the warm-up phase. ►► Do not under any circumstances tow-start the loader to start the engine. This could damage the hydraulic system. ►► Turn off the engine immediately if the warning lights do not go out when the engine is running.

Have the malfunction rectified immediately. Do not use the loader again until the malfunction has been rectified. ►► Do not suddenly turn off the engine at full load, but rather allow it to idle for 3 minutes before turning it off it to equalise the temperature.

90

Note The loader is equipped with a „starter lock/drive lock“. The engine can only be switched on when the shift is switched to „neutral“ or the parking brake is on.

Loader with driver‘s canopy: The loader is equipped with a seat contact switch.

The seat contact switch ensures that the engine can only be started if the driver is sitting in the driver’s seat.

If the engine is running and the driver gets up from the seat, the engine automatically cuts out after approximately 20 seconds.

Operating and operation

Description of the starting process Fig. 35 Ignition key

Use the ignition key to start the loader‘s engine (Fig. 35).

1. Depress the accelerator foot pedal.

2. Insert key - level 0 = no operating voltage.

3. Turn the key to the right - level I = operating voltage; The indicator lamps must light up.

Preheating: --The heating process is automatically activated when level I is switched on --The heater indicator light Item 2 (Fig. 15) lights up.

--Start the engine at level II as soon as the heater indicator light goes out.

0 I

II

4. Turn the key further to the right against the spring force - level II = starting.

5. Let go of the key as soon as the engine starts - the key returns to level I - the indicator lamps go out.

Check that all of the indicator lamps have gone out. Rectify any potential problems before driving off with the loader.

Note Switch off the engine: ►► Turn the key anti-clockwise to position "0"

.

91

Operating and operation

Idle speed adjustment for cold starting WARNING Danger of accidents! ►► Observe that, at high idle speeds, the loader will immediately move when the drive switch is actuated.

This adjustment allows you to set the idle speed a little higher for a cold start: 1. Push the accelerator.

2. Turn the adjustment knob Item 1 (Fig. 36) to the left to the stop and hold it in place.

3. Let go of the accelerator first and then the adjustment knob: –– The engine will run at a higher speed.

4. Once the warm-up phase is over, push the accelerator again: –– The engine will run at normal speed.

92

Fig. 36 Idle speed adjustment

1

Operating and operation

If the engine does not start Note Danger of technical damage In no way is it possible to start the engine by towstarting the loader. This could damage the hydraulic system.

• • • •

Attempt to start the loader for a maximum of 20 seconds.

Wait one minute.

Repeat the starting process.

If the engine will not start after two attempts, look for the cause in the malfunction table („Troubleshooting and emergency maintenance“) or contact a specialist garage.

93

Operating and operation

5.3

Driving

5.3.1

Parking brake

Note When the parking brake is set the loader‘s drive is switched off (driving lock). This is shown by the illuminated parking brake indicator. It is not possible to drive again until the parking brake has been released and the indicator light has gone out.

Operate the parking brake to secure the loader so that it cannot roll away inadvertently. Operate the parking brake with the lever item H (Fig. 37). The lever is located to the left of the driver’s seat.

• Set the lever Item H to position 1: –– The parking brake is activated.

To release the lever item H pull it slightly upwards and then press the button item K with your thumb.

• Set the lever Item H to position 0: –– The parking brake is released.

94

Operating and operation

5.3.2 Fig. 37 Operating lever for parking brake

(1) ON

Preparation for driving in public traffic

Fork prongs of pallet forks must be dismantled before undertaking trips in public traffic!

H (0) OFF

Note Before you start driving, make sure that the machine complies with the relevant local regulations and has a valid operating licence.

1. Secure the attachment: --Ensure that the bucket has been emptied and has been lowered to transport position.

--Put the tooth guard on the bucket.

K

2. Check the lighting system, and if applicable, the function of the rotating beacon.

3. Switch off the work lights.

4. Put all the hydraulic control valves in 0 position.

5. Always block the lift frame by engaging the arrest prior to driving on streets.

6. Fasten your safety belt.

7. Make sure that you can drive off safely.

95

Operating and operation

5.3.3

Description of the drive hydraulics

The hydrostatic drive consists of an axial piston variable displacement pump, which drives an axial piston diesel engine. The axial piston variable displacement pump is flanged onto the diesel engine, while the axial piston diesel engine is flanged onto the transfer case.

Displacement is automatic and continuous, but depends on speed and load. The driving speed depends on the engine speed and the machine load. The driving application begins with the target engine speed; the maximum speed is attained when the engine reaches maximum speed, which is dependent upon operation of the accelerator. Depending on load, the variable displacement pump is automatically adjusted so that the most favourable speed is maintained. The more the loader is burdened (when carrying a load or driving uphill), the lower the driving speed will be. This adjustment control allows the entire range of performance to be utilised optimally.

96

Actuating the inching pedal (inching delay, left pedal in relation to direction of travel) also influences the control, allowing the loader to be slowed down by fine reductions in the engine speed, right down to the loader coming to a standstill.

Operating and operation

5.3.4

Driving

Warning Danger of accidents from the loader tipping over! ►► Keep the lift frame lowered while driving. ►► Adjust your speed to the particular work and conditions. Always keep the loader under control while driving. ►► Watch for people or obstructions in the danger area.

Note Indicator lights will show you the drive directions and gears selected.

When the parking brake is set the loader‘s drive is switched off (driving lock). This is shown by the illuminated parking brake indicator. It is not possible to drive again until the indicator light has gone out.

Drive direction switch ►► Be careful when driving in snowy and icy conditions – reduce your driving speed considerably in the event of bad weather. ►► When driving downhill, always reduce your driving speed before reaching the slope, rather than on it. ►► Do not rest your feet on the braking-inching pedal. ►► Stop driving immediately if you detect malfunctioning of the drive, steering or brakes. Do not restart the loader until the malfunction has been rectified.

97

Operating and operation

WARNING Danger of accidents from incorrect actuating of the drive direction switch! ►► Never activate the drive direction switch while driving. The loader will move in the opposite direction without any warning. Use the switch only according to the manual. Change the drive direction and the gears only when the loader is stopped. ►► Observe each of the indicator lights when changing direction / gears.

Note If the loader is equipped with the additional equipment „Warning buzzer for reverse drive“, a warning buzzer sounds when reverse gear is engaged. The sound is to warn persons who are in the vicinity of the loader that the loader is going into reverse.

98

Use the slide switch item 1 (Fig. 38) to change the loader‘s drive direction. After the engine has been started, the gear changer is in 0 position.

• –– • ––

Drive direction switch in middle position: Gear changer in Neutral Push the drive direction switch forward: The indicator light „7“ (Fig. 15) is illuminated. The loader drives forward.

• Push the drive direction switch back: –– The indicator light „8“ (Fig. 15) is illuminated. The loader drives in reverse.

Operating and operation

Switching gears Fig. 38 Changing direction

1

The loader has an overdrive and a crawler gear. Use the button item 2 (Fig. 41) to shift the loader‘s gears.

• Press the button: –– The loader shifts from crawler gear to overdrive.

Indicator light „18“ (Fig. 15) lights up.

• Press the button again: –– The loader shifts from overdrive to crawler gear.

Indicator light „9“ (Fig. 15) lights up.

2

12V

1 2

99

Operating and operation

Driving off with the loader

Braking and stopping

1. Release the parking brake after the engine has warmed up.

–– The parking brake indicator light will shut off. The loader is ready to be driven.

2. Select the drive direction by actuating the drive direction switch.

–– The indicator light shows the drive direction selected.

You can drive off.

3. Push the accelerator.

–– The loader will smoothly come up to speed.

Activate the braking-inching pedal to left of the steering column in order to change the driving speed independently from the engine RPMs. The first part of the pedal‘s path adjusts the drive back down, then the brake system is activated.

Pushing the braking-inching pedal allows you to continuously reduce the pump flow rate until the loader has come to a halt without wearing out the material. This also allows you to drive very slowly at a high engine speed.

The loader‘s driving speed is proportional to the accelerator‘s displacement.

• •

low engine speed = low driving speed high engine speed = high driving speed

100

1. Reduce the loader‘s driving speed by decreasing the engine speed.

2. To brake the loader, step on the braking-inching pedal.

3. To stop, step on the braking-inching pedal until the loader has come to a stop.

4. Shift to neutral.

5. Activate the parking brake.

Operating and operation

Changing the drive direction

5.3.5

Stopping and parking

Warning Danger of accidents from incorrect actuating of the drive direction switch! ►► Never activate the drive direction switch while driving. The loader will move in the opposite direction without any warning. ►► Use the switch only according to the instructions in the manual.

Caution Danger of accidents due to people in the danger area. ►► Make sure that there are not any people in the loader‘s danger area when you stop and park the loader. ►► Park the loader only in fire safe places provided for it.

Note It is not necessary to depress the inching pedal fully every time you change direction.

Note Bring the loader smoothly to a halt by easing up on the accelerator or actuating the braking-inching pedal and secure it as described in the chapter „Securing the loader“.

1. Reduce the driving speed until the loader has come to a halt.

2. Move the drive direction switch in the other direction.

3. Push the accelerator so that the loader starts moving.

101

Operating and operation

5.4

Work operation Read and observe the „Basic safety instructions“.

Danger of accidents due to people in the danger area. ►► Make sure that no-one is in the loader‘s danger area. ►► Before beginning work, check the control elements for function!

Danger of accidents from wrong attachments! ►► Use only attachments approved by Wacker Neuson. ►► Before beginning work, check that attachments are undamaged, fit tightly, and that they are locked correctly to the lift frame.

Danger of accidents from the lift frame making sudden, uncontrolled movements! ►► Before beginning work, with the parking brake on, activate all the lift frame‘s functions several times until the stop, to remove a possible vacuum in the hydraulic cylinders.

102

Warning Danger of accidents from falling objects! ►► In the event of power loss (failure of the engine and/or driving or working hydraulics), lower the lift frame to the ground immediately and relieve the control circuits and hydraulic lines of pressure. Read the chapter „Measures in the event of power loss“!

Operating and operation

Each time before starting work • • • • •

Examine the loader for visible defects prior to each work shift.

Check the function of the operating equipment.

Check the function of the brakes and warning devices.

Report any defects to the supervisor and, when changing shifts, to the driver taking your place.

Perform the „Check before getting in“ prior to getting in (see the chapter „Getting in“).

103

Operating and operation

5.4.1

Control lever for the lift frame

Warning Danger of accidents from the loader tipping over! ►► Keep the lift frame lowered while driving. ►► Danger of accidents from the lift frame making uncontrolled movements! Never change to „float position“ with the lift frame raised. The float position may only be switched on when the lift frame is lowered.

Danger of accidents! ►► Actuate the lift frame and attachment only from the driver‘s seat. ►► Only work when you are calm and able to act carefully. Abrupt, quick operation results in accidents. ►► Always lower the lift frame when interrupting and ending work.

104

Note The lift frame float position is located on the »Lower« and »Tilting out« function. When the multifunction lever is released, it automatically returns to the 0 position (except when in float position).

Use the control lever to control the movements of the lift frame Item A (Fig. 39). The control lever is located adjacent to the driver‘s seat on the right.

Operating and operation

Float position ( ) • Move the multi- function lever item A (Fig. 39) forward past the resistance until it engages: –– The float position switches on.

• Pull back the multi- function lever item A past the resistance: –– The float position switches off.

A

Fig. 39 Control lever for the lift frame

Lift frame • Move the multi- function lever item A backwards: –– The lift frame rises.

• Move the multi- function lever item A forwards: –– The lift frame lowers.

Attachment • Move the multi- function lever item A to the left: –– The attachment tilts in.

• Move the multi- function lever item A to the right: –– The attachment tilts out.

105

Operating and operation

5.4.2

Locking mechanism for the lift frame

NOTE The lift frame can be secured against inadvertent operation by means of a locking device.

When the locking mechanism is engaged it is no longer possible to activate the lift frame.

The fact that the lift frame is blocked is not shown via indicator lamps, but instead can be seen from the position of the switching lever (Fig. 40).

CAUTION Danger due to inadvertent activation of the lift frame while travelling on roads. ►► Before driving the loader on public roads, always block the lift frame by engaging the locking mechanism. ►► Always block the lift frame before getting out of the loader. ►► Do not disengage the locking mechanism until you have sat down in the driver's seat and wish to start work.

106

Apply the locking system for the lift frame by shifting the lever located to the right of the driver‘s seat Item 1 (Fig. 40).

• Move the switching lever to the rear: –– The locking system is now on.

• Move the switching lever forwards: –– The locking system is now off.

Operating and operation

1 Fig. 40 Lever for locking the lift frame

ON OFF

107

Operating and operation

5.4.3

Operating lever for additional hydraulics

Note Risk of technical damage. ►► Avoid dirt. Make sure that the hydraulic connections are clean.

Note The control lever for the additional hydraulics must return automatically to the zero position. Unless it is equipped with a detent mechanism (optional equipment).

108

You can activate the lift frame‘s hydraulic connections (Fig. 42) using the control lever for the additional hydraulics item Z (Fig. 41).

•

Pull the control lever for the additional hydraulics to the left (L): –– The connection on the left is the pressure side, while the one on the right is for return flow.

• Pull the control lever for the additional hydraulics to the right (R): –– The connection on the right is the pressure side, whereas the one on the left is for return flow.

Operating and operation

Float position ( Fig. 41 Operating lever for additional hydraulics R

Z

)

•

Move the control lever for the auxiliary hydraulics to the right beyond the resistance until it engages: –– The float position is activated.

• Move the control lever for the auxiliary hydraulics back beyond the resistance: –– The float position is deactivated.

L

R

L Fig. 42 Hydraulic connections

109

Operating and operation

Hydraulic locking mechanism for attachments The hydraulic locking mechanism of the quick-change system for the attachments can also be operated using the control lever for the additional hydraulics item Z (Fig. 41).

Fig. 43 Releasing the hydraulic locking mechanism for attachments

•

Move the control lever for the additional hydraulics to the right (R): –– The quick-change system is locked.

• Press and hold the switch item 2 (Fig. 43) and move the control lever for the additional hydraulics to the left (L): –– The quick-change system is released.

2

110

Operating and operation

Detent mechanism for the control lever for the additional hydraulics NOTE Risk due to overheating of the hydraulic system. ►► Make sure that the control lever for the additional hydraulics is always moved to the "zero position" when the detent mechanism is not required.

(Optional equipment)

•

Move the control lever for the additional hydraulics over the resistance point to the right until it engages: –– The detent mechanism is switched on.

• Move the control lever for the additional hydraulics forward again over the resistance point: –– The detent mechanism is switched off.

With the aid of this function you can operate the additional hydraulic connections in continuous use. This function is required for certain attachments which have a hydraulic fluid motor which requires continuous power (e.g. road sweeper).

In this case you will then not need to continuously hold on to the control lever for the additional hydraulics.

111

Operating and operation

5.4.4

Differential lock

NOTE Avoid damage to the transmission. ►► Only switch on the differential lock if the wheels are not moving. ►► Only use the differential lock for loading work on loose or slippery surfaces.

After releasing the button item 1 (Fig. 44), the differential can be locked occasionally. This is noticeable by more effort for steering. Try to release the differential lock by slight right / left steering movements or by changing the direction of travel.

112

Activate the differential lock using the button, item 1, on the multi-function lever (Fig. 44). With the differential lock you can block the differential and thus prevent non-uniform wheel slip.

• Press the button item 1 (Fig. 44): –– The differential lock switches on.

• Release the button item 1 (Fig. 44): –– The differential lock switches off.

Operating and operation

1

Fig. 44 Switch for differential lock

1 12V

113

Operating and operation

5.4.5

Changing attachments

This operating manual describes only the use of the following the attachments: • • • • •

Light cargo buckets Earth buckets Earth buckets with digging teeth Manure fork Pallet fork

If you wish to use additional attachments with your loader, please observe the following: Should you use other attachments, observe the operating manuals for these attachments. Request the relevant operating manuals from the following address: www.wackerneuson.com

114

Use only Wacker Neuson approved attachments for your loader. Wacker Neuson is not liable in the event of other attachments being used.

Avoid overworking the loader. For heavy loads, do not use buckets that are too big.

Should new hydraulic hoses need to be routed for a new attachment, please contact a specialist. Only specialised personnel may route hydraulic hoses.

Various high-pressure hoses are used. Note the DIN designations on the hose and/or fitting when ordering replacements.

Observe the safety instructions for changing attachments.

Operating and operation

Warning Danger of accidents from wrong attachments! Use only Wacker Neuson approved attachments for your loader. Unapproved attachments could overload the loader. This could result in loader instability.

Danger of accidents from the loader tipping over! When the tool is used, the loader‘s weight changes! Do not exceed the approved payloads!

Drive only with the lift frame lowered.

When loading, adjust your driving speed to the material being loaded and environmental conditions.

Danger of injury from pressurised hydraulic fluid escaping (e.g. when hydraulic hoses are damaged)! Should you get hydraulic fluid on your skin or in your eyes, go to a doctor immediately.

Danger of accidents due to people in the danger area. Make sure that no-one is in the loader‘s danger area.

Danger of accidents from the uncoupled attachment tipping over! Only personnel with sufficient specialised knowledge may replace attachments – should knowledge be lacking, experienced personnel must carefully train the responsible individuals.

Danger of injury from damaged attachments! Do not use damaged attachments.

Before beginning work, check that attachments are undamaged, fit tightly and are locked correctly. Do not carry out work if the receptacle / locking mechanism for the attachments is damaged.

Carry out work on the attachments only if the loader is secured as described in the chapter „Securing the loader“.

115

Operating and operation

Note Unapproved attachments could overload the loader.

This can result in damage to the loader.

Note Wacker Neuson is not liable for changes made without its approval.

1. Before assembly, start-up or maintenance, read the operating manual for the relevant attachment.

2. Consult a Wacker Neuson dealer or Wacker Neuson itself to receive approval for the conversion, if the hydraulic system has to been converted for the attachment that will be used (e.g. depressurised return).

3. Select the attachment that will be used according the type of work that will be carried out.

4. Practice using the attachment before working with it the first time. Familiarise yourself ahead of time with all the functions and control elements.

The loader is equipped with a hydraulic quick-change system for the various attachments. Thus the operator can couple and uncouple attachments in a quick and uncomplicated manner from the driver‘s seat.

116

Operating and operation

Coupling attachments Warning Danger of accidents due to people in the danger area! ►► Make sure that no one is in the loader‘s danger area.

Danger of accidents from releasing the hydraulic locking mechanism unintentionally! ►► Always check that the locking bolts are correctly locked (Fig. 45 + 48).

Danger of injury from pressurised hydraulic fluid escaping (e.g. when hydraulic hoses are damaged)! ►► Should you get hydraulic fluid on your skin or in your eyes, go to a doctor immediately.

Environment Note Hydraulic fluid is hazardous to the environment. ►► Do not allow it to be released uncontrollably into the environment.

Note Danger of technical damage! ►► Avoid dirt. Make sure that the hydraulic connections are clean.

117

Operating and operation

Coupling with hydraulic quick-change system

1

2 Fig. 45 Coupling - hydraulic locking mechanism

1. Drive the loader up to the attachment (Fig. 45).

2. Position the mounting pin (item 1) under the mounting hook (item 2).

3. Raise the lift frame and tilt the attachment inward.

4. Use the control lever for the additional hydraulics to extend the locking pins (item 4).

5. Check that both pins are engaged in the locking bores (item 3).

4

3

R

Z

118

Operating and operation

For hydraulically operated attachments: 6. Switch the control lever for the auxiliary hydraulics to “float position”. This depressurises the lines for the auxiliary hydraulics. This depressurises the lines for the additional hydraulics.

7. Plug the attachment‘s quick couplers in the appropriate connections for the additional hydraulics on the lift frame (Fig. 46).

8. Check that there are no leaks in the attachment‘s hydraulic system and the quick couplers of the additional hydraulics. Carefully activate the attachment.

Fig. 46 Connecting the additional hydraulics

119

Operating and operation

Coupling and uncoupling the connections for additional hydraulics Note Danger of technical damage! ►► Avoid dirt. Make sure that the hydraulic connections are clean.

Environment Note Hydraulic fluid is hazardous to the environment. ►► Do not allow it to be released uncontrollably into the environment.

Coupling: 1. Depressurize the additional hydraulics.

2. Remove the protective caps from the connections. To do so, on the connection on the loader, push forward the quick coupling with the hose.

3. Push the connection of the attachment device into the opening of the connection on the loader.

4. To check whether the quick coupling has engaged correctly, pull on the hose of the attachment. The quick coupling must not come loose.

Uncoupling: 1. Depressurize the additional hydraulics.

2. Place a container beneath the quick couplings of the additional hydraulics to catch any oil that may escape.

3. To release the connection on the loader, push forward the quick coupling with the hose, simultaneously pulling on the hose of the attachment.

4. Fit the protective caps onto the connections.

120

Operating and operation

Coupling with mechanical quick-change system

2 Fig. 47 Coupling - mechanical locking mechanism

1. Drive the loader up to the attachment (Fig. 47).

2. Position the mounting pin (item 1) under the mounting hook (item 2).

3. Raise the lift frame and tilt the attachment inward.

4. Insert the locking pins item 3 (Fig. 48). To do so, push down the handles of the locking pins item 4.

5. After locking, ensure that the handles of the locking pins item 4 are engaged in position.

1

For hydraulically operated attachments: NOTE ►► Proceed as described from point 6 onwards under "Coupling with hydraulic quick-change system".

4 Fig. 48 Locking of the mechanical locking mechanism

3

121

Operating and operation

Uncoupling attachments Caution Danger of accidents due to people in the danger area! ►► Make sure that no-one is in the loader‘s danger area.

Danger of accidents from the uncoupled attachment tipping over! ►► Close attachments that have moving parts (e.g. crocodile grippers). Make sure that the attachment is tightened. If necessary, secure the attachment with the supports provided. Place the attachment only on a hard, even surface.

Environment Note Hydraulic fluid is hazardous to the environment. ►► When uncoupling the hydraulic connections, hold a pan under the additional hydraulics‘ quick couplers to catch any oil that might run out.

Dispose of it in an ecologically sound way.

122

Uncoupling with hydraulic quick-change system NOTE Points 2-5 refer to the uncoupling of hydraulically operated attachments.

1. Lower the attachment to just before it sits down on the ground.

2. Switch the control lever for the auxiliary hydraulics to “float position”. This depressurises the lines for the auxiliary hydraulics. This depressurizes the lines for the additional hydraulics.

3. Pull the quick couplings apart.

4. Push on the protective caps.

5. Lay the hydraulic hoses over the attachment.

Operating and operation

Fig. 49 Uncoupling - hydraulic locking mechanism

6. Press and hold the switch item 2 (Fig. 49) and move the control lever for the additional hydraulics to the left (L).

–– The locking pins engage.

7. Lower the lift frame and tilt the attachment out. (this will release the mounting pins from the mounting hooks).

8. Back the loader away from the attachment once the mounting hooks have been released.

2

Z L

123

Operating and operation

Uncoupling with mechanical quick-change system 4 Proceed as described up to point 5 under “Uncoupling with hydraulic quick-change system”. Then insert the locking pins item 3 (Fig. 50). To do so, push down the handles of the locking pins item 4.

Fig. 50 Uncoupling mechanical locking mechanism

3

124

Operating and operation

5.4.6

Bucket

Proper use

►► Avoid overloading the loader. Observe the maximum permitted payload. ►► Operate the control lever slowly and cautiously.

The attachments light cargo buckets / earth buckets are intended for loosening, picking up, transporting and dumping materials.

Attaching the bucket

NOTE The light cargo bucket is used for lightweight materials, such as corn, maize and pellet feed.

The earth bucket is used for heavy materials, such as gravel, sand, soil and stones/rocks.

Read the section entitled “Coupling attachments”.

Operating element Operate the bucket with the control lever for the lift frame.

Read the section entitled “Control lever for the lift frame”.

125

Operating and operation

Operation Note Before carrying out work for the first time, practice handling the load bucket.

2a 2a

When tilting out the bucket and loading vehicles, you can perform two work movements at the same time if necessary, e.g. lifting and tilting out or lowering and tilting in. To do so, you have to overlay the movement on the control lever (Fig. 51).

0 = Zero position 1 = Lift 2 = Lower 2a = Float position 3 = Tilt in 4 = Tilt out 4a = Float position

126

Fig. 51

2/3

2 2

2/4

3 3

0

4 4

1/3

1 1

1/4

4a 4a

Control lever movements

The float position facilitates stripping during resurfacing work. To do so, lower the bucket with the tip to the ground.

Then engage the control lever in position 2a. The bucket now lies on the ground, free to move and burdened only by its own weight.

Operating and operation

Level indicator (Additional equipment!)

Fig. 52 Level indicator

Note If different attachments are used, you can add a marking on the guide tube for each attachment (Fig. 52 a + b). This will enable you to adjust the level display quickly when changing attachments.

a

b

Observe the level display (Fig. 52) so that you can judge the tilt position of the attachment better from the driver’s seat.

Setting the level display: 1. Lower the attachment to the ground in a parallel position.

2. Release lever item 1 by turning it to the left.

3. Adjust the guide tube item 2 in such a way that the display rod item 3 aligns with the end of the guide tube.

4. Lock the lever by turning it to the right.

5. Now you can align the attachment according to the display position during your work.

3 1 2

127

Operating and operation

Working with the bucket Warning Danger of accidents from the loader tipping over! ►► Drive only with the lift frame lowered. Especially when turning if the loader is jack-knifed, there is a danger of tipping. ►► Drive at an appropriate speed. ►► Do not use the loader if downhill slopes are too steep.

Note Adjust your driving speed when driving into the loading material depending on the type of material and the given conditions.

Make sure that no excessive wheel slip occurs.

Tyre wear and fuel consumption will increase unnecessarily and the loader‘s performance will not be fully utilised.

128

Loading work Fig. 53 Loading work 1

Lower the bucket to pick up loose material so that it is parallel to the ground and move it into the material to be loaded. In doing so, the driving speed conforms to the type of material and the given working conditions (Fig. 53).

Operating and operation

Now lift the lift frame slightly so that the weight is on the loader‘s front axle. This is to avoid excess wheel slip. You can also manually restrict wheel slip by inching.

Fig. 54 Loading work 2

If the bucket is filling up, tilt it in. You can now drive off with the filled bucket to the unloading site (Fig. 54).

Drive straight up to the unloading site and do not lift the bucket until just before you have reached the unloading site.

Fig. 55 Loading work 3

If material will be loaded that is not easy for the bucket to break into, you can generate an up-and-down movement with the scraping edge of the bucket. This makes it easy for the bucket to break into the material (Fig. 55).

129

Operating and operation

Excavation work Soft foundation:

Fig. 56 Excavation work 4

Lower the bucket to the ground to lift out soft material and tilt the bucket forward until you have a digging angle. If you start driving the loader forward now, the bucket‘s digging edge will break into the ground. Now make the tilting angle flat to remove as even a layer as possible and to avoid a large wheel slip (Fig. 56).

Hard foundation: Lower the bucket to the ground to lift out hard material and tilt the bucket forward until you have a digging angle. If you drive the loader forward now, lightly press the bucket downwards so that it can break into the ground. Should the bucket‘s digging angle break into the ground, make the tilting angle flatter. Use the control lever to produce an up-anddown movement of the digging edge of the bucket (Fig. 57).

130

Fig. 57 Excavation work 5

Operating and operation

5.4.7

Manure fork

Operating element

►► Avoid overloading. Observe the maximum permissible payload. ►► Operate the control lever carefully.

Operate the manure fork attachment with the control lever for the lift frame. Read the section entitled “Control lever for the lift frame”.

Proper use The manure fork attachment is used to loosen, pick up, transport and load materials like silage, hay, round bales, green fodder and manure.

Operation Note Before carrying out work for the first time, practice handling the manure fork.

Attaching the manure fork Read the section entitled “Coupling attachments”.

131

Operating and operation

Working with the manure fork

132

Loading work

Warning Danger of accidents from the loader tipping over! ►► Drive only with the lift frame lowered. Especially when turning if the loader is jack-knifed, there is a danger of tipping. ►► Drive at an appropriate speed. ►► Do not use the loader if downhill slopes are too steep.

To pick up material, lower the manure fork so that the tines are parallel to the ground. Drive into the material to be loaded. Here the driving speed should be determined on the basis of the type of material and the given working conditions.

Note Adjust your driving speed when driving into the loading material depending on the type of material and the given conditions.

Make sure that no excessive wheel slip occurs.

Tyre wear and fuel consumption will increase unnecessarily and the loader‘s performance will not be fully utilised.

For solid materials such as stamped-down pen manure, you can loosen the load by tilting in the manure fork.

Now lift the lift frame slightly so that the weight is on the loader‘s front axle. This is to avoid excess wheel slip. You can also manually restrict wheel slip by inching.

Drive straight up to the unloading site and do not lift the manure fork until just before you have reached the unloading site. Tilt out the manure fork to unload.

Operating and operation

5.4.8

Pallet fork

Attaching the pallet fork

►► Avoid overloading. Observe the maximum permissible payload. ►► Operate the control lever carefully.

Read the section entitled “Coupling attachments”.

Proper use The pallet fork attachment is used to lift, transport and set down loads. The pallet fork is not intended for any other use. The forks must always be used in pairs as delivered.

The driver of the loader requires special training before he his allowed to use the pallet fork.

Operating element Operate the pallet fork attachment with the control lever for the lift frame. Read the section entitled “Control lever for the lift frame”.

Operation Note Before carrying out work for the first time, practice handling the pallet fork.

133

Operating and operation

Adjusting the fork arm spacing Ensure the fork arm spacing is correct. Otherwise, the load may fall down! ►► Adjust the fork arms such that they are arranged symmetrically about the centre of the wheel loader. ►► Adjust the fork arms such that they are spaced apart from each other as far as possible (Fig. 58).

134

Fig. 58 Correct fork arm spacing

Operating and operation

Fig. 59 Adjusting the fork arm spacing

Caution Risk of injury!

Be careful not to crush your fingers or hands between the fork arm carrier and the fork hook. ►► Do not touch the gliding surfaces of the fork arm carrier while moving the fork arms.

1



1. Lift the pallet fork to 10–30 cm above the ground.

2. Put the arresting lever of the fork arms to the vertical position (Fig. 59 / 1).

–– The locking mechanism is released.

3. Move the fork arms to the position required. Hold the fork arms at top and bottom (Fig. 59 / 2).

4. Put the arresting lever of the fork arms to the horizontal position (Fig. 59 / 3).

5. Move the fork arms until the locking mechanism is engaged.

–– The locking mechanism is fixed.

2



3

135

Operating and operation

Working with the pallet fork Fork prongs of pallet forks must be dismantled before undertaking trips in public traffic!

Warning Danger of accidents from falling objects! Falling objects, large bales or stacks of bales can cause serious or fatal injuries. ►► Never transport several large bales or crates simultaneously! ►► It is prohibited to use loaders without driver canopy or cabin for large bales or packaged goods.

Danger of accidents from the loader tipping over! ►► Drive only with the lift frame lowered. ►► Drive at an appropriate speed. ►► Do not use the loader if downhill slopes are too steep.

136

Picking up a load 1. Check whether the permissible load carrying capacity of the loader and the pallet fork is appropriate for the weight of the load.

2. Adjust the fork arm spacing and arrest the fork arms.

3. Approach the load in straight direction.

4. Put the pallet fork to the height required and align it horizontally.

5. Drive forward until the load abuts on the rear of the fork.

6. Lift the load a little and tilt it back a little.

7. Drive back and set the load to transport height.

Operating and operation

Transporting a load

Putting down a load

1. Lower the load to transport height. Keep the load as low as possible. Select the transport height such that the pallet fork can just pass across uneven floor surfaces.

2. Tilt the pallet fork back a little to secure the load against slipping off during travelling. Transport the load on the side facing uphill while driving down or up a slope. If necessary, secure the load with ratchet straps.

3. Adjust your driving speed. Always start, turn and stop gently.

4. If necessary, transport large bulky loads backwards to ensure better vision.

1. Approach the place where you wish to put down the load in straight direction.

2. Do not lift the load to the height required before you have reached the unloading site.

3. Drive forward until the load is positioned above the unloading site.

4. Put the pallet fork in horizontal position, lower the load, and put it down.

5. Drive back until you can lower the pallet fork freely.

Lower the pallet fork.

6. Drive away from the unloading site in reverse gear.

137

Operating and operation

5.4.9

Measures in the event of the loader tipping over

Warning Risk of injury!

The driver may be injured by an overturning loader. ►► Always fasten your safety belt while working with the loader. ►► Keep the lift frame lowered while driving.

Note Danger of engine damage!

Make sure you observe the following instructions because, otherwise, there may be the risk of extreme damage to the motor! ►► Turn off the engine immediately if the loader gets into an extremely inclined position or tips over due to improper or careless operation. ►► Do not start the engine after the loader has been righted again. ►► Inform a specialist garage. The engine must be checked by trained, specialised personnel and be authorized to be operated again.

138

Environment Note Danger of environmental damage! ►► Right the loader as soon as possible so that oil and fuel cannot escape. ►► Immediately soak up with binding material any oil or fuel that has leaked, and dispose of it separately from other waste, in an ecologically sound manner.

Operating and operation

5.4.10

Precaution measures for various weather conditions

At high outside temperatures Take the following precautions at high temperatures to prevent the loader from being damaged: •

Regularly check the cooling system: --Keep the water and oil coolers clean --Make sure that the coolant level is always correct --Use the proper coolant mix.

--Regularly check the cooling system for leaks --Regularly check the condition and tension of the fan pulley

• •

Use engine lubricating oil of the proper viscosity class.

Regularly check the engine air filter.

At low outside temperatures Danger of accidents due to a change in ground conditions. Snow, mud and ice can result in accidents.

Danger of accidents from poor visibility! Clear the cab windows of ice before beginning work.

Note At particularly low temperatures, i.e. –18°C or less, an additional starting aid may be necessary. Examples of this are a fuel, oil and coolant heater and additional batteries. Consult a specialist distributor.

139

Operating and operation

Note Danger of technical damage!

Due to the high viscosity in the hydraulic system and engine oil circuit at temperatures below 0°C, major technical damage can occur if speed is increased immediately. ►► Let the engine run for a certain period of time at low speed at temperatures below 0°C. The lower the outside temperature, the longer the warm-up phase. ►► Do not switch two batteries in series to produce a starting voltage of 24 V.

140

Take the following precautions at low temperatures to prevent the loader from being damaged and to make the loader easier to start: • • • • • •

Use the proper coolant mix.

Use engine lubricating oil of the proper viscosity class.

Use diesel fuel for low temperatures.

Fill the fuel tank at the end of the work shift.

Make sure the battery is always fully charged.

Install the cold starting aid (see note above!).

Operating and operation

5.5

Additional equipment

Foldable rollover bar Warning Danger of accidents from the loader tipping over. ►► The rollover bar should always be locked in protection position, insofar as this is possible given the working conditions. Only fold the rollover bar back if this is absolutely necessary in order to allow work to be carried out (e.g. if it is necessary to drive through low doorways).

Safety sticker 1

Warning The rollover bar should always be locked in protection position, insofar as this is possible given the working conditions.

Safety sticker 2

Note Loaders with collapsible anti-roll bar may only be operated with special authorization.

If you have any questions about this special authorization for collapsible anti-roll bars, please contact your dealer; the Wacker Neuson Service department will be happy to assist.

Danger Never transport several large bales or crates simultaneously!

It is prohibited to use loaders without driver canopy or cabin for large bales or packaged goods!.

Read the operating manual before starting up the loader.

Fasten the safety belt for all work with the loader.

141

Operating and operation

Fig. 60 Foldable rollover bar

Fold the rollover bar backwards, insofar as this is possible given the working conditions: 1. Remove the screws Item 1 (Fig. 60/A).

2. Fold the rollover bar backwards (Fig. 60).

3. Secure the rollover bar with a screw Item 1 (Fig. 60) to the tab Item 2 (Fig. 60).

When the folded position is no longer necessary, fold the rollover bar back by repeating the actions in the reverse order. Retighten the screw securing nuts, Item 1 (Fig. 60), in such a way that they cannot become loose of their own accord.

Dimensions with 10.0/75-15.3AS tyres: In the event of deviating tires or reverse wheel rims the dimensions will change

1 Designation

Unit Value

Height to rollover bar

mm

2394

Height to rollover bar, folded

mm

1807

A

142

B

Operating and operation

Changeover valve applies tilting in/out function to additional hydraulics Fig. 61 Switch for changeover valve

The function is switched using the switch, Item 1 (Fig. 61), on the multi- function lever. You can use this function to switch actuation of the hydraulic connections to the multi- function lever. Then you do not need to let go of the multi- function lever to activate the additional hydraulics.

1

Switching the changeover valve: • Press the button Item 1 (Fig. 61): –– The „tilting in“ function actuates the left hydraulic connection.

–– The „tilting out“ function actuates the right hydraulic connection.

• Let go of the button Item 1 (Fig. 61): –– The „tilting in“ function tilts the attachment in.

–– The „tilting out“ function tilts the attachment out.

1

143

Operating and operation

Hydro connection additionally via changeover valve Fig. 62 Additional hydraulic connections

This function allows you to activate additional hydraulic connections using the multi- function lever. This function is necessary if the standard hydraulic connections do not suffice for certain attachments. You can activate the standard hydraulic connections using the control lever for the additional hydraulics and the additional hydraulic connections using the multi- function lever.

The function is switched using the switch, Item 1 (Fig. 61), on the multi- function lever.

The changeover valve is switched in the same way as in „Changeover valve applies tilting in/out function to additional hydraulics“.

1

144

Operating and operation

Hydro connection additionally via additional control device Fig. 63 Additional control lever

The function is switched using an additional control lever (Fig. 63) adjacent to the driver‘s seat on the right.

This function allows you to actuate additional hydraulic connections (Fig. 62). This function is necessary if the standard hydraulic connections do not suffice for certain attachments.

Depressurized return line Fig. 64 Depressurized return line

For some attachments, a depressurized return line is required. The connection for the depressurized return line is located on the front left of the load arm (Fig. 64). The connection is designed in such a way that it is not possible to confuse it with the normal connections for the additional hydraulics.

145

Operating and operation

Electrical outlet on the lift frame Fig. 65 Electrical outlet on the lift frame

Note If the loader is equipped with an electrical outlet and changeover valve, the electrical outlet is actuated via the toggle switch Item 4 (Fig. 66).

The electrical outlet on the lift frame is used to connect attachments for which certain functions must be activated electrically.

The electrical outlet (Fig. 65) on the lift frame is switched using the switch item 1 (Fig. 67) on the multi-function lever.

Fig. 66 Switch for the electrical outlet on the lift frame (1)

4

146

Operating and operation

Version 27 km/h Fig. 67 Switch for the electrical outlet on the lift frame (2)

1

1

Note Loaders built for a maximum speed of more than 20 km/h have special requirements for users/operators regarding licence requirements and required insurance.

It is still possible that registration and a licence plate may be required when driving on public roads.

The operator is solely responsible for meeting these requirements/obligations.

12V

147

Operating and operation

Optional multi-function lever for multiple functions If the loader is equipped with an electrical socket and reversing valve, the functions will be activated by another multi-function lever (Fig. 68).

1.

2.

3.

4.

Differential lock Changeover valve No function (free for other additional functions) Electrical outlet

Fig. 68 Optional multi-function lever

3

1

4 2

1 2 4 12V

148

Operating and operation

149

Operating and operation

5.6

Optional equipment - collapsible driver’s canopy

Safety information for collapsible driver’s canopy WARNING Risk of accidents due to falling objects (Fig. 69)!

Falling objects or falling stacks of bales can cause serious or even fatal injuries. ►► The loading of large bales or packaged goods is only allowed when the protective roof for the driver or driver's cab is in place! ►► Always engage the protective roof for the driver in the protection ON position, providing the working conditions allow. ►► Only fold down the protective roof for the driver if this is essential in order to carry out the work at hand (e.g. due to low access heights). ►► In areas where large bales or packages goods are stored, the protective roof for the driver must always be in the protection ON position! ►► Never transport or stack more than one large bale or crate at once.

150

Fig. 69 Transporting large bales or packaged goods (collapsible driver’s canopy)

Operating and operation

Safety stickers

Caution Risk of injury due to crushing between moving parts. ►► Do not touch the hinges when folding the collapsible driver’s canopy. ►► Follow the operator’s manual.

Dimensions with 10.0/75-15.3AS tyres: In the event of deviating tires or reverse wheel rims the dimensions will change Item Designation

Unit Value

L

Height to driver’s canopy

mm

2339

Lgh

Height to driver’s canopy when collapsed - rear

mm

1823

Lgv

Height to driver’s canopy when collapsed - front

mm

1800

Fig. 70

Dimensions (collapsible driver’s canopy)

151

Operating and operation

Description

1

Fig. 71 Components (collapsible driver’s canopy)

The collapsible driver’s canopy can if necessary be folded down. This enables the loader to pass through low-clearance areas that it would otherwise not be able to access.

The driver’s canopy consists of 2 movable roof sections attached to each other by hinges. The roof sections are held in place by 3 pillars. The 2 front pillars are individually folded forward. The rear pillar is folded backwards together with the roof sections. The rear pillar also functions as a ROPS protective structure. The roof sections protect the driver against falling objects when the protective roof for the driver is in the protection ON position. The front roof section is secured by 2 pins. 2 gas struts assist the folding process.

152

2

3

Item Description 1

Securing pins

2

Roof sections

3

Front pillars

4

Gas struts

5

Rear pillars

4

5

Operating and operation

5.6.1

Folding down the collapsible driver’s canopy Fig. 72 Preparations for folding down the driver’s canopy (collapsible driver’s canopy)

WARNING Risk of accidents due to falling objects. ►► Only fold down the protective roof for the driver if this is essential in order to carry out the work at hand (e.g. due to low access heights).

Preparations 1.

2.

3.

4.

Park the loader on firm, level ground (Fig. 72).

Fully lower the lift frame.

Apply the parking brake.

Switch off the engine.

Fig. 73 Releasing the securing pins (collapsible driver’s canopy)

Releasing the securing pins 1. Remove the pin item 1 (Fig. 73) from the retaining clip by pulling it downwards.

2. Remove the pin.

3. Insert the pin into the other retaining clip.

1

153

Operating and operation

Folding down the front pillars forwards

3 Fig. 74 Folding down the front pillars forwards (collapsible driver’s canopy)

1. Hold the front roof section by the handle item 2 (Fig. 74) and lift it slightly.

2. Fold forward the front pillars item 3 (Fig. 74).

3. Clip the front pillars in the folded position into the retainers item 4 (Fig. 74).

2

4

154

Operating and operation

Fold in the roof sections Caution Risk of injury due to crushing between moving parts. ►► Do not touch the hinges when folding the collapsible driver’s canopy. ►► Follow the operator's manual.

1. Hold the front roof section item 1 (Fig. 75) by the handle and pull downwards.

2. Fold the front roof section under the lower roof section.

3. Once folded, pull the roof downwards and fold it down between the rear pillar.

1 Fig. 75 Fold in the roof sections (collapsible driver’s canopy)

1

2

3

155

Operating and operation

Folding down the rear pillar Fig. 76 Folding down the rear pillar (collapsible driver’s canopy)

1. Remove the securing pins item 2 (Fig. 76) from the rear pillars.

2. Fold down the rear pillars item 3 (Fig. 76) until they rest against the rubber buffers.

3. Reinsert and secure the securing pins of the rear pillars.

2

3

156

Operating and operation

5.6.2

Bringing the collapsible driver’s canopy into the protection ON position

WARNING Risk of accidents due to falling objects. ►► When bringing the collapsible driver’s canopy into the "protection ON" position, always ensure that all securing pins (including those in the rear pillars) are correctly located and secured!

Fig. 77 Inserting the front securing pins (collapsible driver’s canopy)

NOTE ►► To insert the front securing pins, pull the front pillars towards each other.

The collapsible driver’s canopy is brought into the protection ON position in the reverse order as that described under “Folding down the collapsible driver’s canopy”.

157

Towing and transporting

6

Towing and transporting

6.1

Towing Warning Danger of accidents! ►► Only tow the loader if the steering and brakes are functional, and if it cannot be transported in any other way. ►► Only tow the loader using a tow bar or a tow cable. ►► Do not allow people in the danger area of the tow bar or tow cable while the loader is being towed. ►► Do not allow the tow bar or tow cable to become damaged; the fracture load must be at least three times as great as the tractor‘s pulling power. ►► The tractor must have sufficient pulling power.

The tractor driver and the loader driver must agree on their intentions and proceed carefully. ►► Secure the loader from rolling away and from unauthorized use after it has been towed.

158

NOTE Danger of damage from the hydraulic system overheating! ►► Tow the loader only as far as necessary to retrieve it from the danger area, however only a maximum of 500 metres! ►► The towing speed may not exceed 5 km/h. ►► Use a transport machine for longer stretches or repair the loader on site.

Towing and transporting

Towing equipment

Short-circuiting the drive

Warning Danger of accidents! ►► Do not use the towing equipment to pull trailer loads.

Fig. 78 Towing equipment

Warning Danger of accidents due to the driver‘s platform tipping over! ►► Do not tow the loader until the driver‘s platform has been secured.

NOTE Danger of damaging the hydraulic system! ►► Do not screw in the stud bolts item 1 (Fig. 79) further than described in point 3, otherwise important valve parts of the axial piston variable displacement pump could be destroyed. ►► After towing the loader, unscrew the stud bolts again up to the stop and secure them with the hexagon nuts item 2 (Fig. 79). Otherwise the loader cannot be driven.

159

Towing and transporting

High-pressure control valves Fig. 79 Short-circuiting the drive

1

To tow the loader, it is necessary for you to disconnect the drive. In this case the drivetrain is switched from power transmission to freewheeling. For this purpose the variable displacement pump is equipped with high-pressure control valves with bypass function. The variable displacement axial piston pump can be accessed from the underside of the loader.

2

4 mm 13 mm

1. Tilt the driver‘s platform (see the chapter Maintenance and inspection work).

2. Unscrew the hexagon nuts Item 2 (Fig. 79): 3. Screw in the stud bolts Item 1 (Fig. 79) until they lock with the hexagon nuts.

4. Tilt back the driver‘s platform and retighten it for towing.

After towing: 1. Unscrew the studs item 1 (Fig. 79) again as far as the stop.

2. Tighten the hexagon nuts item 2 (Fig. 79) to a torque of 22 Nm.

Activating the bypass Deactivating the bypass

160

Towing and transporting

6.2

Transporting Load and transport the loader only if all the safety regulations have been met.

Only experienced, trained specialised personnel may load and transport the loader. The carrier is always responsible for loading and transporting.

Moving the loader onto a transport vehicle Warning Danger of accident through improper loading! ►► Clean large dirt off the loader before loading and transporting it. ►► Use transport machine with appropriate loadbearing capacity (observe the operating weight of the loader).

Danger of accidents from falling or slipping when loading the loader! ►► Exercise caution when loading and transporting under snowy and icy conditions.

161

Towing and transporting

Blocking the articulated joint ►► Always block the articulated joint before the loader is lashed. ►► Do not actuate the steering when the articulated joint is blocked. ►► After transporting the loader, release the buckling guard first.

Fig. 80 Buckling guard Articulated joint free

The buckling guard Item 1 (Fig. 80) is fitted to the front carriage on the bolts attached for it and secured with spring cotters.

1.

2.

3.

4.

Drive the loader so that it stands straight.

Unscrew the spring cotters.

Move the buckling guard Item 1.

Secure the buckling guard with the spring cotters.

Release the blocking in the reverse order.

162

1

Articulated joint blocked

Towing and transporting

Independent driving onto the transport device Warning Danger of accident through improper loading! ►► Use only sufficiently dimensioned loading ramps that are not damaged (observe the operating weight of the loader). ►► There should not be any oil or grease on the transport surface and the loading ramps. ►► After driving the loader onto the transport machine, secure it as described in the chapter „Securing the loader“. ►► Block the articulated joint using the buckling guard as described in the chapter „Blocking the articulated joint“.

Fig. 81 Independent driving onto the transport device

< 20°

163

Towing and transporting

Loading with crane Warning Danger of accident due to improper loading! ►► Block the articulated joint before applying the hoisting tackle, using the buckling guard as described in the chapter „Blocking the articulated joint“. ►► Use only sufficiently dimensioned hoisting gear which is not damaged (observe the operating weight of the loader). ►► Never stand beneath the loader when it is raised off the ground. ►► After loading on the transport machine, secure the loader as described in the chapter „Securing the loader“.

164

Use the attachment points (Fig. 83) that are marked with stickers (Fig. 82) to hook in the hoisting tackle. To do this, unscrew the screw which is holding the rear attachment eyelets, in order to turn these.

Fig. 82 Attachment point stickers

Towing and transporting

Fig. 83 Attachment points front

Fig. 84 Loading with crane

Attachment points rear

165

Towing and transporting

Lashing the loader Warning Danger of accident due to improper loading! ►► Always block the articulated joint before the loader is lashed. ►► Use wheel chocks to prevent the loader from slipping or rolling away. ►► Lash the loader only to the special attachment points as depicted in Fig. 87. ►► Use lashing equipment with appropriate loadbearing capacity (observe the operating weight of the loader).

166

Use the attachment points (Fig. 86) marked with the stickers (Fig. 85) to lash the loader.

Fig. 85 Lashing point stickers

Towing and transporting

Fig. 86 Lashing points front

Lashing points rear

167

Towing and transporting

Fig. 87

168

Lashing the loader

Measures in the event of power loss

7

Measures in the event of power loss Warning Danger of accidents due to uncontrolled lift frame movements! ►► Should the loader experience power loss, for example if the engine, the driving hydraulics or the working hydraulics fail, immediately but carefully lower the lift frame to the ground and relieve the individual control circuits of the working hydraulics from residual pressure by activating the control lever.

For loaders with countersunk brake valves, the lift frame may only be lowered and the residual pressure discharged exclusively by trained specialized personnel as described in the chapter „Relieving residual pressure in the hydraulic system“.

169

Discharging residual pressure in the hydraulic system

8

Discharging residual pressure in the hydraulic system Caution Caution! Danger of injury! A fine jet of hydraulic fluid under high pressure can pierce the skin. ►► Go to a doctor immediately should you get hydraulic fluid in your eyes or on your skin. ►► Open only depressurized hydraulic systems.

Even for a loader parked on a horizontal surface with its lift frame completely lowered and engine turned off, there can still be considerable residual pressure in parts of the hydraulic system. Residual pressure reduces gradually at first. ►► If a hydraulic system is to be opened immediately after being shut down, the system must be depressurized ahead of time.

170

Discharging residual pressure in the hydraulic system

Proceed as follows to reduce the residual pressure in the hydraulic circuits (adhere to the order of the individual work steps):

Fig. 88 Reducing residual pressure

1. Lower the lift frame as far as it will go.

2. Turn off the engine.

3. Immediately after turning off the engine, actuate all the control levers and pedals for the hydraulic system several times in all directions.

4. Relieve the hydraulic tank by opening the filler neck, illustration 1 (Fig. 88).

5. Remove the preload from the drive‘s system by opening the return filter, illustration 2 (Fig. 88).

Illustration 1

Illustration 2

171

Discharging residual pressure in the hydraulic system

Opening the lowering brake valves Only trained personnel may open the lowering brake valves.

After maintenance/repairs, close the lowering brake valves again and return them to their original state.

For loaders with lowering brake valves on the lifting and tipping cylinder, open the valves (Fig. 89).

Fig. 89 Opening the lowering brake valves

For machines with lowering brake valves on the lifting and tipping cylinder which can be electrically unblocked, the ignition must be turned on and the switch for unblocking actuated so that the work equipment can be lowered to the ground.

1

2

172

1. Unscrew the nuts Item 1.

2. Unscrew the screw Item 2 until the lift frame slowly lowers.

Should the lift frame not lower due to friction or insufficient bulk, you will have to support the process using a control cable or ratchet straps.

3. Screw the screw Item 2 back in as soon as the lift frame is completely lowered and retighten the nuts Item 1.

Securing the loader

9

Securing the loader Note The following instructions apply to stopping and parking the loader after daily operation, transporting the loader and to all servicing, inspection and repair work!

• • • • • • • •

Place the loader on an even, dry surface that can support sufficient weight.

Lower the lift frame.

Pull the parking brake and stop the motor.

Switch off all electrical switches.

Depressurize all control circuits and put all control levers in zero position.

Secure the loader with the wheel chock.

Clean dirt off the loader.

Perform a visual inspection to make sure there are no leaks: --in the hydraulic system --in the cooling system --in the fuel system

• • •

Perform a visual inspection for damage to the loader, especially on the tires, attachments and locking mechanism for the attachments.

Fill the fuel tank and check the other operating materials.

Secure the loader against unauthorized use: --Remove the ignition key --Close the windows, doors, tank lid and engine hood.

173

Servicing and inspection

10

Servicing and inspection

10.1

Basic safety instructions for servicing and inspection Follow all instructions in this chapter.

Personnel

Operating manual

•

•

• •

Maintenance and inspection personnel must have specialised knowledge of servicing and inspection work on the loader. The specialised knowledge required can be obtained at training sessions from Wacker Neuson Service.

Carry out servicing and inspection work only with suitable work clothing and personal protective equipment.

Wear hearing protection should there be noise pollution.

174

• •

•

Carry out servicing and inspection work only if you have read and understood the operating manual.

Observe the basic safety instructions and all the warning signs attached to the loader.

The operating manual describes the work to be carried out. However, the descriptions of work processes provide the necessary instructions only for experienced specialised personnel.

Keep the operating manual with the loader at all times.

Servicing and inspection

Securing the loader and attachment

Tools

•

•

•

• • •

•

Carry out servicing and inspection work only if the loader is secured as described in the chapter „Securing the loader“.

Caution! Danger of injury! If the lift frame is raised, it could suddenly lower and cause serious bodily injury.

Should it be essential to carry out servicing and inspection work under a raised lift frame, the lift frame must be secured with a suitable support.

Position the attachments on the ground so that no movements can occur when mechanical or hydraulic connections are released.

Secure the articulated joint with the buckling guard when working in the bending region.

Secure equipment or components that should be attached, removed or changed in their install position, against unintended movement, slipping or falling, by means of suitable lifting gear, or suspension or support equipment.

Clean dirt from steps and handles and keep them ready for use.

Work only with fully functional, suitable hand tools.

Cleaning •

Clean units in the work area before beginning work. Your choice of cleaning agent depends on the material of the parts to be cleaned. Do not clean rubber or electrical parts with solvents or steam. Water can result in short circuits in the electrical system and cause new hazards.

Do not use cleaning agents which give off hazardous or highly flammable vapours. Avoid skin contact with cleaning agents. Wear protective gloves.

175

Servicing and inspection

Handling combustible fluids

Handling fuel, oil and grease

•

•

• •

Do not smoke when handling combustible fluids and avoid fire or open flames.

Do not use water to extinguish fires on the loader or burning fluids. Use suitable extinguishing agents such as powder, carbon dioxide or foam extinguishers.

Always call the fire department in the event of a fire.

• • • • • •

176

Caution! Danger of scalding from hot lubricating oil or hydraulic fluid.

Avoid skin and eye contact with oils and greases. Wear protective gloves and safety goggles.

Do not use fuel or solvents to clean your skin.

Eliminate any oil or fuel leaks immediately.

Avoid environmental damage. Do not allow oil and waste containing oil to spill on the ground or get into bodies of water!

Immediately soak up with binding material any oil or fuel that has leaked, and dispose of it separately from other waste, in an ecologically sound manner.

Even biodegradable „environmentally friendly“ oil must be disposed of separately, just like other oil.

Servicing and inspection

Residual pressure in the hydraulic system

Threaded connections, pipes, hydraulic hoses

•

• •

• •

• •

Caution! Danger of injury! A fine jet of hydraulic fluid under high pressure can pierce the skin. Go to a doctor immediately should you get hydraulic fluid in your eyes or on your skin.

Open only depressurised hydraulic systems.

Even for a loader parked on a horizontal surface with its lift frame completely lowered and engine turned off, there can still be considerable residual pressure in parts of the hydraulic system.

Residual pressure reduces gradually at first. If a hydraulic system is to be opened immediately after being shut down, the system must be depressurised ahead of time.

For loaders with lowering brake valves on the lifting and/or tipping cylinder, you must open the valves as described in the chapter „Discharging residual pressure in the hydraulic system“ in order to lower the lift frame.

• •

Eliminate any leaks in the pipework immediately.

Caution! Danger of injury! A fine jet of hydraulic fluid under high pressure can pierce the skin. Go to a doctor immediately should you get hydraulic fluid in your eyes or on your skin.

Do not use your hands to look for leaks. To look for leaks, use a piece of cardboard or paper on which you can identify leaking oil spillings.

Do not repair damaged pipes and hydraulic hoses; rather, replace them immediately with new ones even if only moisture penetration is visible.

177

Servicing and inspection

Engine exhaust fumes

Batteries

•

•

•

Caution! Danger of poisoning! Engine exhaust fumes are hazardous to your health. Do not inhale any engine exhaust fumes.

For servicing and inspection work carried out in a closed room, extract the exhaust fumes using an extraction system and ventilate the room well.

•

•

• •

178

Caution! Danger of explosion! Batteries give off explosive gases! Avoid smoke, fire or open flames near batteries.

Caution! Danger of explosion! Do not place any tools on the battery - danger of short-circuiting! In the event of a short circuit of the poles, sparks will arise and ignite the leaking battery acid fumes.

Caution! Danger of injury! Battery acid is corrosive. Prevent battery acid from coming into contact with your skin, eyes, mouth or clothing. Wear protective gloves and safety goggles. If you make contact with battery acid, rinse the contaminated spot on your body immediately with plenty of clean water. Go to a doctor!

Always take off jewellery and metal watches before working on the battery or the electrical system.

Dispose of old batteries in an ecologically sound way, separate from other waste.

Servicing and inspection

Electrical system

After maintenance

•

•

Always observe the correct order when disconnecting the battery: --Disconnecting: First the negative pole and then the positive pole!

--Connecting: First the positive pole and then the negative pole!

• •

Always disconnect the battery before working on the electrical system if tools, spare parts, etc. with electrical components or contacts could touch it.

Always disconnect the battery before welding.

• • •

After completing maintenance and inspection work, always reattach all the safety devices.

Do not start the engine until the loader is no longer being worked on and everyone has left the danger area.

Only start the engine from the driver‘s seat.

Perform a functional test with the loader after completing servicing and inspection work.

179

Servicing and inspection

10.2

Servicing and inspection intervals

Daily servicing Carry out the following tasks: • • • • • • • • • • • • • •

Clean the machine Clean the air filter Check for general damage Check the coolant level/condition Check the engine oil level/condition Check the engine leakage Check the hydraulic fluid level Check the hydraulic system Check the brake fluid level Check the condition of the tyres and the tyre pressure Make sure all screws fit tightly Check the wheel bolts Check that the brake system is functional Check the windscreen washer system

180

• • • • • • • • • • •

Check the seat belt Check the instruments, indicator lights and audible warning devices Check the electrical system Check the foot brake Check the hydraulic steering Check that the hydraulic power units are functional Check the attachments Check the exhaust pipe for defects or excessive smoke emission Grease lubrication according to lubrication drawing Grease the tools Check ROPS structure (all mounting screws must be present and tightened)

Servicing and inspection

Weekly servicing Carry out the following tasks: • • • • • • • • • •

Clean fuel filter for the presettling tank (if present) Check axles for leaks Check hydraulic fluid cooler and water radiator for leaks and dirt Check exterior condition of the radiators, i.e. the hoses Check the tension and condition of the fan belt Check the acid level of the battery Check the attachments Check the piston rods for the hydraulic cylinders Check the routing of the hoses and pipes Check the air filter hose

• • • • • • •

Check the routing of the electrical wiring (rubbing/damage) Oil lubrication for all the levers Oil lubrication for all the cables and hinges Retighten all the screws Observe in particular the engine suspension and the axle mounting Perform the general safety check Check the sliding surfaces of the telescopic fork for damage and use dry lube spray or grease to protect them against corrosion

181

Servicing and inspection

Inspection after 30 operating hours (First inspection) Note Servicing and inspection personnel must have specialised knowledge of maintenance and inspection work on the loader. ►► Follow the operating manual for the engine.

Work to be carried out (please check)

Note To assure proper functioning of the machine, it is required that the first inspection be carried out after 30 operating hours, but at the latest 3 months after initial start-up, by a Wacker Neuson dealer or a mechanic at a Wacker Neuson factory agent.

Inspection after 30 operating hours (First inspection)

Check the transmission, engine and hydraulic system for leaks Check the hydraulic, water and engine oil coolers for dirt Check the coolant level and antifreeze Check the tension and condition of the V-belt Make sure all hoses and pipes fit tightly Check the routing of the hoses and pipes Check the piston rods for the hydraulic cylinders Check the routing of the bowden cables and electrical wiring Retighten all the screws. Observe in particular the engine suspension, axle mounting and propeller shaft Check: Instruments + audible warning devices

182

Servicing and inspection

Work to be carried out (please check)

Inspection after 30 operating hours (First inspection)

Check the electrical system Check the foot brake and parking brake, adjust if necessary Check the hydraulic steering Check the lighting system (if present) Check the idle speed Check the valve clearance, adjust if necessary (only Perkins 1004-4) Check the functioning of the door and engine hood mechanisms Check ROPS / cab Check the condition of the tires Change the engine oil and filter Clean the air filter, replace if necessary Change the hydro return filter Have all the grease nipples been lubricated? Lubricate if necessary Lubricate the propeller shafts (universal joint) Lubricate all the levers, cables and hinges with oil Check all oil levels, also the transmission and axles

183

Servicing and inspection

Inspection after 500 operating hours Note Servicing and inspection personnel must have specialised knowledge of maintenance and inspection work on the loader. ►► Follow the operating manual for the engine.

Work to be carried out (please check)

Note Perform this inspection once after the first 500 operating hours. Should the loader not reach 500 operating hours during the first year of operation, perform this inspection once 12 months after starting up the loader.

500 hours inspection

Check transmission, engine and hydraulic system for leaks Check the hydraulics, water and hydraulic fluid radiators for dirt Check the coolant level and antifreeze Check the tension and condition of the V-belt Check the routing of hoses and pipes Check the piston rods for the hydraulic cylinders Check the air filter hose Examine the intake muffler for damage or obvious wear Check routing of bowden cables and electrical wiring Retighten all screws, observing in particular the engine suspension, the axle mounting and the propeller shaft

184

Servicing and inspection

Work to be carried out (please check)

500 hours inspection

Check the engine suspension‘s rubber pad Check the acid level of the battery Check: Instruments, indicators + audible warning devices Check the electrical system Check the foot brake and parking brake, adjust if necessary Check the hydraulic steering Check the lighting system – (if present) Check the exhaust system Check the hinge pins and joint bushings Check the centre pivot bolts and bearings Check the idle speed Check the functioning of the engine hood and door locking mechanisms, adjust if necessary Check the condition of the tyres and the tyre pressure Change the engine oil and filter Change the fuel filter – clean the prefilter Clean the fuel feed pump (Deutz engines only)

185

Servicing and inspection

Work to be carried out (please check) Clean the air filter, replace if necessary Set the valve clearance Change the hydraulic fluid Change the hydro return filter Change the hydro pressure filter Change the oil in the transfer case Change the oil in the axles Are all the grease nipples lubricated? Lubricate if necessary Lubricate the propeller shafts Lubricate all the levers, cables and hinges with oil Check all the oil levels

The following inspection intervals apply after this inspection:

186

500 hours inspection

Servicing and inspection

Inspection intervals Note Servicing and inspection personnel must have specialised knowledge of maintenance and inspection work on the loader. ►► Follow the operating manual for the engine.

Note Carry out the service work listed in the inspection schedule depending on which interval has been reached first, that is, if either the number of operating hours have been reached or the time specified in the schedule has elapsed..

187

Servicing and inspection

Operating hours: 250, 750, 1000, 1250, 1750, 2000, 2250, 2750, 3000, etc.

Operating hours: 1500, 2500, 3500, 4500, etc.

monthly

annually

Check transmission, engine and hydraulic system for leaks

X

X

X

X

Check the hydraulic and water radiators for dirt

X

X

X

X

Check the coolant level and antifreeze

X

X

X

X

Check the tension and condition of the V-belt

X

X

X

X

Work to be carried out

Check the routing of hoses and pipes

X

Check the piston rods for the hydraulic cylinders Check the air filter hose

X

X X

X

X X

X

Examine the intake muffler for damage or obvious wear

X

Check routing of bowden cables and electrical wiring

X

X

Retighten all screws, observing in particular the engine suspension, the axle mounting and the propeller shaft

X

X

Check the acid level of the battery

X

Clean the battery terminals/check the acid density

X

X

X

X X

Check: Instruments, indicators + audible warning devices

X

X

X

X

Check the electrical system

X

X

X

X

188

Servicing and inspection

Operating hours: 250, 750, 1000, 1250, 1750, 2000, 2250, 2750, 3000, etc.

Operating hours: 1500, 2500, 3500, 4500, etc.

monthly

annually

Check the foot brake and parking brake, adjust if necessary

X

X

X

X

Check the hydraulic steering

X

X

X

X

Check the lighting system – (if present)

X

X

X

X

Work to be carried out

Check the exhaust system

X

X

Check the hinge pins and joint bushings

X

X

Check the centre pivot bolts and bearings

X

X

Check the pressure relief valves in the hydraulic system

X

X

Check the idle speed

X

X

X

X

Check max. speed when loaded and unloaded

X

X

Check the starter and dynamo (engine manual)

X

X

Check the heater plugs and fuel injectors (engine manual)

X

X

Check the valve clearance, adjust if necessary

X

For Deutz engines: Check the timing belt for engine timing and, if available, for auxiliary drive system (do not retighten, change every 5 years or after 4500 op. hours)

X

X

Check the fuel injectors (every 3000 operating hours)

189

Servicing and inspection

Work to be carried out

Check the functioning of the engine hood locking mechanism, adjust if necessary

Operating hours: 250, 750, 1000, 1250, 1750, 2000, 2250, 2750, 3000, etc.

Operating hours: 1500, 2500, 3500, 4500, etc.

monthly

annually

X

X

X

X

Check ROPS/FOPS structures Check the condition of the tyres and the tyre pressure

X X

X

X X

Change the engine oil and filter (every 500 engine hours)

X

Change the fuel filter – clean the prefilter

X

Clean the fuel feed pump (for Deutz engines) Clean the air filter, replace if necessary

X X

X X

X

X X

X

Change the hydraulic fluid

X

Change the ventilation filter of the hydraulic oil tank

X

Change the hydro return filter

X

X

Change the oil in the transfer case

X

X

Change the oil in the axles

X

X

X

Pressure filter (first change after 500 op. hours, further changes as needed*)

Change the coolant – every 2 years

190

Servicing and inspection

Work to be carried out

Operating hours: 250, 750, 1000, 1250, 1750, 2000, 2250, 2750, 3000, etc.

Operating hours: 1500, 2500, 3500, 4500, etc.

monthly

annually

Are all the grease nipples lubricated? Lubricate if necessary

X

X

X

X

Lubricate the propeller shafts (universal and slip joint)

X

X

X

X

Lubricate all the levers, cables and hinges with oil

X

X

X

X

Check all the oil levels Clean cab vent filter, replace as needed Inspect according to the accident prevention regulations

X X

X X

X

* Required if there is a damage in the hydraulic system which is supposed to be caused by strong abrasive wear

Valve clearance for Perkins 400 series: 0.2 mm inlet and outlet for a cold engine Valve clearance for Perkins 1000 series: 0.2 mm inlet and 0.45 mm outlet for a cold engine Valve clearance for Deutz 2011 series: 0.3 mm inlet and 0.5 mm outlet for a cold engine

191

Servicing and inspection

10.3 1

Lubrication schedule 2

17

192

3

4

5

6

7

8

18

19

20

21

22

23

9

10

11

12

13

14

15

Fig. 90

16 Points of lubrication

Servicing and inspection

Item Point of lubrication

Number of nipples

Item Point of lubrication

Number of nipples

1

Engine hood hinges

[2]

13

Bearing for reversing lever

[1]

2

Hinges of restraining bar Door hinges (Loaders with cab)

[2] [4]

14

Pivot point of tool attachment

[2]

15

Tie rod, front

[1]

3

Brake pedal bearing

[1] 16

Tool locking bolts

[2]

4

Brake lever bearing

[1] 17

Driver‘s platform hinge, rear

[1]

5

Accelerator

[1] 18

Steering cylinder, rear

[1]

6

Middle joint bearing, top

[2] 19

Propeller shaft, rear

[1]

7

Tipping cylinder, rear

[1] 20

Driver‘s platform hinge, front

[1]

8

Lift frame bearing

[2] 21

Middle joint bearing, bottom

[1]

9

Lifting cylinder, rear

[2] 22

Steering cylinder, front

[1]

10

Lifting cylinder, front

[2] 23

Propeller shaft, front

[1]

11

Tipping cylinder, front

[1]

12

Tie rod, rear

[1]

Lubricate all the points of lubrication daily with water-resistant multi- purpose grease. Lubricate all other moving parts such as the handbrake lever, foot pedals, cables, etc. using the oil can.

193

Servicing and inspection

10.4

Cleaning the loader Caution Danger of accidents and injury! ►► Daily cleaning is necessary to keep the loader in a secure, technically faultless state. Observe in particular the handles, steps and operating elements.

Environment Note Avoid environmental damage. ►► Clean the loader only in a suitable place where the waste water can be collected in an ecologically sound manner. ►► Collect contaminated waste water and dispose of it in an ecologically sound manner.

194

Note Danger of technical damage! ►► When cleaning the loader, pay particular attention to its underside. Do not allow mud to collect on the engine and transmission. ►► Make sure that the radiator is thoroughly clean all over. ►► Do not damage the radiator fins when cleaning the radiator with a high-pressure cleaner. ►► Always cover up the suction connection of the air filter before washing the engine. ►► Do not clean sensitive electrical components (instrument panel, dynamo, compact plug, multifunction lever, etc.) with a high-pressure cleaner.

Servicing and inspection

Note When the loader is new (in the first three months), only clean it with a sponge.

As the paintwork on the underside is not fully hardened, the paintwork can be damaged if cleaned with a high-pressure cleaner.

Note when cleaning the loader with a high-pressure cleaner: Maximum water pressure 130 bar.

Maximum water temperature 80°C. When cleaning, do not hold the jets of the highpressure cleaner too close to the labels and other sensitive parts, so that nothing gets damaged!

195

Servicing and inspection

10.5

General safety check Immediately rectify any damage detected during the safety check. Damaged parts must be immediately repaired or replaced. Do not use the loader again until the damage has been rectified professionally.

Check: • • • • • • • • •

all steel parts for damage and loose screws/bolts, particularly the ROPS/FOPS protective structures the condition of the safety belt, the quick-change system for the attachments, that all the hinge pins are in the correct position and are secured by their locking devices, that the step and handles are OK and fit well, cab windows for cracks and flaws, the condition of the reflectors and the lighting including the work lights, the tyres for damage and any sharp-edged objects that have penetrated them, the condition of all warning and instruction stickers.

196

10.6

Specifications and filling quantities Note When filling oil, the oil level must correspond to the dip stick or control screw markings!

Servicing and inspection

Position

Capacity (in litres)

Fluid / grease nipple

Specification

Fuel tank

50

Diesel fuel

DIN 51601 conventional, see engine manual

Engine oil with filter

8,0

Engine oil SAE 10 W 40 Ambient temperature -20°C to +40°C

API CG-4 / API CH-4 see engine manual

Cooling system contents

9,0

Water with conventional HD coolant / antifreeze

HD coolant / antifreeze: ASTN D4985

Front axle Rear axle

3,2 3,9

Transmission SAE 90 GL 5

API GL 5 - MIL 2105

Complete hydraulic system Hydraulic tank

38 30

Hydraulic fluid HLP

ISO VG 46

Multi-purpose grease

water-resistant

Lubrication points Brake system

0,5

ATF oil

197

Servicing and inspection

10.7

Servicing and inspection work Carry out servicing and inspection work only if the loader is secured as described in the chapter „Securing the loader“.

Note To be able to better carry out maintenance and inspection work, it is possible to tilt the driver‘s platform to the right.

198

Servicing and inspection

10.7.1

Preparation for maintenance and inspection work

Opening the engine bonnet Caution Danger of injury from hot and moving parts! ►► Never open the engine bonnet when the engine is running. ►► Let the engine cool off or use protective gloves.

Note Danger of technical damage! ►► Remove all tools and objects from the engine and the engine compartment before closing the engine bonnet.

Fig. 91 Handle for the engine bonnet

Open and close the engine bonnet using the handle provided. The handle is lockable.

199

Servicing and inspection

Tilting the driver‘s platform Warning Danger of injury from the driver‘s platform accidentally tipping over! ►► Do not unscrew the screws which hold the bearing for the driver‘s platform in place. ►► Always immediately secure the tilted driver‘s platform from tilting back by using the safety support. ►► Always screw in the mounting screws immediately after tilting the driver‘s platform back in place. ►► Do not use the loader if the driver‘s platform is not secured.

200

Note Danger of technical damage!

Avoid damage to the cab doors. ►► Either close the doors or remove them.

Note Loader with cab: To facilitate tilting of the driver‘s platform, there is a lever in the cab item 1 (Fig. 92). To tilt the driver‘s platform, place the lever in the holder, item 2 (Fig. 92).

Servicing and inspection

Fig. 92 Cab tilt lever

1

2

201

Servicing and inspection

Tilting the driver‘s platform: 1. Remove any loose objects from the driver‘s platform.

2. Make sure there is sufficient room to the right of the loader.

3. Open the engine bonnet.

4. Remove the mounting screw from the driver‘s platform bearing at the front on the left (Fig. 94).

5. Remove the mounting screw from the driver‘s platform bearing at the rear on the left (Fig. 95).

Caution! Do not unscrew the screws which are holding the driver‘s platform bearing in place!

6. Tilt the driver‘s platform to the right by hand.

7. Secure the tilted driver‘s platform immediately from tilting back using the safety support (Fig. 96).

The safety support is to be found on the crosspiece under the driver‘s platform.

202

Fig. 93

Position of the driver‘s platform mounting screws

Servicing and inspection

Fig. 94 Driver‘s platform mounting screw, front

Fig. 95 Driver‘s platform mounting screw, rear

Fig. 96 Driver‘s platform safety support

Tilting back the driver‘s platform: 1. Remove the safety support and attach this to the crosspiece underneath the driver‘s platform.

2. Tilt back the driver‘s platform by hand. Ensure that the upper sections of the bearing for the driver‘s platform lie precisely on the lower sections.

3. Screw in the mounting screws immediately after tilting the driver‘s platform back in place.

203

Servicing and inspection

10.7.2

Servicing the engine

Caution Danger of injury from hot and moving parts! ►► Never open the engine bonnet when the engine is running. ►► Let the engine cool off or use protective gloves.

Checking the engine oil level Note Danger of technical damage! ►► The oil level must never be allowed to drop below the “Minimum” marking on the oil dipstick. ►► When adding oil, the level must never be higher than the “Maximum” marking on the oil dipstick.

Note Danger of technical damage! ►► Remove all tools and objects from the engine and the engine compartment before closing the engine hood. ►► Service the engine according to the inspection intervals specified in this operating manual and observe in particular the operating manual for the engine.

Maximum

Minimum

204

Fig. 97 Engine oil dipstick

Servicing and inspection

1. Stop the loader on a horizontal surface and set the parking brake.

2. Lower the lift frame as far as it will go.

3. Turn off the engine.

4. Wait one minute.

5. Open the engine hood.

6. Pull out the dip stick out again (left side of the engine: Item 1 (Fig. 98)).

7. Wipe the dip stick with a clean, lint-free cleaning rag.

8. Put the dip stick back in.

9. Pull the dip stick out again.

10. Check the oil level. The oil level must be between the „minimum“ and „maximum“ marks.

11. Put the dip stick back in after checking the oil level.

Fig. 98 Checking the engine oil / filling the oil

2

1

205

Servicing and inspection

Topping up engine oil Note Danger of technical damage! ►► Use the correct oil grade (see the chapter „Specifications and filling quantities“). ►► Use a funnel with tube extension as aid for filling.

If the fluid level is under the „Maximum“ mark, the fluid must be added: Open the oil filler neck item 2 (Fig. 98).

Add the engine oil.

Check the oil level.

Add engine oil until the oil level is at the „Maximum“ mark.

5. Close the oil filler neck item 2 (Fig. 98).

1.

2.

3.

4.

206

Changing the engine oil Caution Danger of scalding from hot engine oil! ►► Let the engine cool off or use protective gloves.

Environment Note Danger of environmental damage! ►► Avoid environmental damage. Collect old engine oil and dispose of it in an ecologically sound manner.

Note Use a sufficiently dimensioned receptacle for the old engine oil and use the correct oil grade (see the chapter „Specifications and filling quantities“).

Servicing and inspection

1. Bring the engine to operating temperature.

2. Stop the loader on a horizontal surface and set the parking brake.

3. Lower the lift frame as far as it will go.

4. Turn off the engine.

5. Put a sufficiently dimensioned receptacle under the drain opening.

6. Unscrew the sealing plug Item 1 (Fig. 99) and attach the supplied hose Item 2 (Fig. 99). The oil will now flow out of the engine.

1

Fig. 99 Engine oil drain opening

2

207

Servicing and inspection

Changing the engine oil filter Once the engine oil has been drained: 1. Change the engine oil filter (see the section „Changing the engine oil filter“) 2. Unscrew the discharge hose item 2 (Fig. 99) and screw on the sealing plug.

3. Open the oil filler neck.

4. Add engine oil into the filler neck until the oil level has reached the „Maximum“ mark.

5. Start the engine and let it idle until the engine oil indicator light goes out.

6. Check the oil level and, if necessary, fill to the „Maximum“ mark.

7. Close the oil filler neck.

8. Dispose of the old engine oil in an ecologically sound manner.

208

Caution Danger of scalding from hot engine oil! ►► Let the engine cool off or use protective gloves.

Environment Note Danger of environmental damage! ►► Avoid environmental damage! Collect old engine oil and dispose of it in an ecologically sound manner. ►► Dispose of the old engine oil filter in an ecologically sound manner.

Note The engine oil filter contains a bypass valve that opens when the filter is clogged.

Servicing and inspection

The engine oil filter is located on the left side of the engine (Fig. 100).

1. Put a receptacle for draining oil under the engine oil filter.

2. Unscrew the engine oil filter item 1 (Fig. 101).

3. Clean the sealing surface of the filter holder Item 2 (Fig. 101).

4. Lightly oil the rubber seal of the new engine oil filter item 3 (Fig. 101).

5. Screw on the new engine oil filter until it rests well against the rubber seal.

6. Tighten the new engine oil filter by hand by another half rotation.

7. Check the oil level and, if necessary, fill to the „Maximum“ mark.

8. Dispose of the old engine oil filter in an ecologically sound manner.

Fig. 100 Location of the engine oil filter

2 Fig. 101 Engine oil filter

3 1

209

Servicing and inspection

10.7.3

Servicing the fuel system

Warning Danger of injury from hot and moving parts! ►► Never open the driver‘s platform when the engine is running!

Danger of explosion and fire! ►► Do not smoke when handling fuel and avoid fire and open flames. ►► Do not use gasoline as an additive to the diesel fuel.

Note Danger of technical damage! ►► Service the fuel system according to the inspection intervals specified in this operating manual. ►► Always replace all the fuel filters at the same time. ►► Use only clean, high-grade diesel fuel. Do not use gasoline. ►► After working on the fuel system, clean the engine and engine bearings thoroughly from any fuel that may stick

210

Environment Note Danger of environmental damage! ►► Avoid environmental damage. Collect leaking fuel and dispose of it in an ecologically sound manner.

The fuel passes from the tank through a pre-filter and a sieve with water separator and is then conveyed by an electric feed pump through the main filter to the fuel injection pump.

The filters and the feed pump are located in the engine compartment. To access them, open the engine bonnet and tilt the driver‘s platform.

Servicing and inspection

Servicing the water separator 1. Place a receptacle under the water separator Item 1 (Fig. 102).

2. Unscrew the drain plug from the inspection glass Item a (Fig. 102).

3. The collected water now runs out.

4. Retighten the drain plug when the collected water has run out.

Fig. 102 Water separator

1

Check the filter screen in the water separator. If required: 1.

2.

3.

4.

Remove the inspection glass and clean it.

Clean or replace the filter screen.

Screw the inspection glass back on.

Venting the fuel system.

a

211

Servicing and inspection

Changing the fuel pre-filter

a

Fig. 103 Fuel pre-filter, main fuel filter

Note The fuel prefilter Item 2 (Fig. 103) can only be replaced together with the entire housing.

1.

2.

3.

4.

5.

6.

7.

Place a receptacle under the fuel prefilter.

Remove the hose clamps from the fuel prefilter.

Pull out the fuel hoses.

Replace the fuel prefilter.

Connect the fuel hoses.

Attach the hose clamps for the fuel prefilter.

Venting the fuel system.

212

2

3

Servicing and inspection

Changing the main fuel filter 1. Place a receptacle under the main fuel filter item 3 (Fig. 103).

2. Unscrew the screw Item 1 (Fig. 103).

3. Remove the main fuel filter Item 3 (Fig. 104).

4. Clean the sealing surfaces of the filter holder and the filter cover Item c (Fig. 104).

5. Replace the gaskets Item b (Fig. 104). Moisten the new gaskets with diesel fuel and make sure that they fit correctly.

6. Replace the main fuel filter.

7. Put on the filter cover.

8. Tighten the screw Item a (Fig. 103).

9. Venting the fuel system.

Fig. 104 Changing the main fuel filter

b 3

c

213

Servicing and inspection

Venting the fuel system 1. Fill the fuel tank.

2. Switch the ignition key to position I (operation) so that the electrical fuel feed pump is working.

3. Wait 1 minute; the system will exhaust itself automatically.

4. The engine can now be started.

Fig. 105 Venting the fuel system

0 I

II

214

Servicing and inspection

10.7.4

Servicing the air filter system

Caution Danger of injury from hot and moving parts! ►► Never open the engine bonnet when the engine is running. ►► Let the engine cool off or use protective gloves.

Note Danger of technical damage! ►► Service the air filter according to the inspection intervals specified in this operating manual. ►► If the engine takes in unclean air, the engine could be damaged. ►► Never let the engine run if parts of the air intake system are removed. ►► Replace damaged air filters immediately.

Environment Note Risk of damage to the environment!

The main air filter element must be replaced at an early stage. If it is allowed to get too dirty, exhaust gas emissions will increase.

The loader is equipped with a dry air filter for filtering the engine intake air. The dry air filter consists of a main filter and a safety filter element. To access it, open the engine bonnet.

215

Servicing and inspection

Check main air filter element / clean / replace

Air filter dust valve Check if the outlet slot on the dust valve Item 1 (Fig. 106) is clear. Remove dust accumulation by pinching the valve.

Note Danger of technical damage! ►► Clean or replace the main filter element Item 4 (Fig. 107) during inspections or if the indicator light for the air filter on the instrument panel is illuminated between inspection intervals Item 14 (Fig. 15).

5 Fig. 106 Location of the air filter

Fig. 107 Air filter elements

2

1

4

216

Servicing and inspection

Checking / changing the safety filter 1. Remove the fasteners on the cover Item 2 (Fig. 106) and take off the cover.

2. Pull out the main filter element Item 4 (Fig. 107). Do not remove the safety filter element in the process.

3. Perform a visual inspection of the intake manifold between the filter and the engine for leaks and tight fit. The intake manifold must not display any exterior damage.

4. Clean the main filter element (knock off lightly and blow out with compressed air from the inside to the outside).

Should the main filter element be too dirty or damaged, replace it.

Install a new or cleaned main filter element, repeating the steps in the reverse order.

After a new or a cleaned main filter element has been installed, the indicator light in the instrument panel Item 14 (Fig. 15) should no longer light when the engine is running.

Should this nevertheless be the case, replace the safety filter.

Note Danger of technical damage! ►► Replace the safety filter if necessary, and at least after cleaning the main filter for the fifth time.

Should it be apparent while servicing the dry air filter that a maintenance fault was present or that the main filter element is damaged, replace the safety filter element Item 5 (Fig. 107).

1. Remove the three fasteners on the cover Item 2 (Fig. 106).

2. Remove the cover Item 2 (Fig. 106): 3. Pull out the main filter element Item 4 (Fig. 107).

4. Pull out the safety filter element Item 5 (Fig. 107).

5. Insert a new safety filter element.

Assembly takes place in the reverse order.

217

Servicing and inspection

10.7.5

Servicing the cooling system

Caution Danger of injury from hot and moving parts! ►► Never open the engine bonnet when the engine is running!

Danger of scalding from hot coolant! ►► Never open the cooling system when the engine is hot or the cooling system is under pressure. ►► Let the engine cool off or use protective gloves.

218

Note Danger of technical damage! ►► Service the cooling system according to the inspection intervals specified in this operating manual. ►► Turn off the engine immediately if the temperature indicator in the instrument panel item 6 + 17 (Fig. 15) is illuminated.

Servicing and inspection

Fig. 108 Radiator

Should the loader get too hot during long drives on the road or at high outside temperatures, check the following: • • • •

Is there enough coolant in the radiator and is it the correct coolant mix?

Is the fan‘s V-belt taut and in good condition?

Are the radiators continuously clean at all points?

Are all seals fitted near the radiator? (Hot air must not flow around the radiators and be drawn back in again!).

The radiator is installed behind the diesel engine. The left part contains hydraulic oil; the right part is intended for cooling the engine (Fig. 108).

219

Servicing and inspection

Checking V-belt tension / Tensioning the V-belt CAUTION Risk of injury due to moving parts. ►► Never open the engine hood while the engine is running.

Risk of scalding due to hot coolant. ►► Never open the cooling system while the engine is hot. Never open the cooling system while it is pressurized. ►► Allow the engine to cool off, or wear protective gloves.

NOTE Risk of technical damage.

Cracked or stretched V-belts will lead to engine damage. ►► The V-belts must be maintained at the inspection intervals stated in this operator's manual. ►► Observe the operating instructions for the engine! ►► The V-belt must only be replaced by an authorized specialist workshop.

220

Preparations 1. Park the loader on a horizontal surface and apply the parking brake.

2. Lower the lift frame all the way to the bottom.

3. Switch off the engine.

4. Wait one minute.

5. Open the engine hood.

Checking the V-belt tension Using your thumb, check that the V-belt cannot be depressed by more than approximately 10 mm between the belt pulleys (Fig. 109).

Servicing and inspection

Tensioning the V-belt

ca. 10 mm

Fig. 109 Checking the V-belt tension

Fig. 110

1 V-belt 2 G 1

1. Loosen the fixing bolts item 2 and adjusting screw (item 1) of the generator item G (Fig. 110).

2. Using a suitable tool, apply pressure to the generator until the correct V-belt tension is obtained (Fig. 111).

3. Hold the generator in this position and re-tighten the adjusting screw item 1 (Fig. 110). Next, re-tighten the fixing bolts item 2 (Fig. 110).

Fig. 111 Tensioning the V-belt

G

221

Servicing and inspection

Checking the coolant level / refilling the coolant Caution Danger of scalding from hot coolant! ►► Never open the cooling system when the engine is hot or the cooling system is under pressure.

Environment Note Danger of environmental damage! ►► Avoid environmental damage! Do not allow antifreeze and coolant to be released uncontrollably into the environment. ►► Collect antifreeze and coolant and dispose of it in an ecologically sound manner.

222

Note Danger of technical damage! ►► The coolant must consist of equal parts of water and antifreeze. This mix guarantees an optimal ratio of cooling performance and corrosion protection. ►► Do not pour in the coolant too quickly if the full amount is to be poured in, e.g. when changing the coolant. Pour in at a maximum of 5 l/ min. If the cooling system fills up too quickly, air pockets in the cooling system could form, causing the engine to overheat.

Servicing and inspection

Checking the antifreeze mix Fig. 112 Radiator opening

Check the coolant level at regular intervals. If you look into the radiator opening (Fig. 112) from above, the radiator fins should be covered with coolant.

Make sure that enough antifreeze is always present in the coolant, even in summer, as antifreeze also prevents internal corrosion of the radiator and the engine.

Fig. 113 Checking the antifreeze mix

Antifreeze prevents the coolant from freezing at temperatures below zero and protects the engine block and the radiator from internal corrosion. Under normal conditions, the antifreeze concentration is sufficient for protection down to between –20° and –30° C. You can determine the antifreeze concentration by using a conventional antifreeze tester (Fig. 113).

223

Servicing and inspection

Changing the coolant Note Danger of technical damage! ►► Put in new coolant every 2 years. ►► The coolant must consist of equal parts of water and antifreeze. This mix guarantees an optimal ratio of cooling performance and corrosion protection. ►► Do not pour in the coolant too quickly! Pour in at a maximum of 5 l/min. If the cooling system fills up too quickly, air pockets in the cooling system could form, causing the engine to overheat.

1. Stop the loader on a horizontal surface and set the parking brake.

2. Lower the lift frame as far as it will go.

3. Turn off the engine.

4. Place a sufficiently dimensioned receptacle under the lower radiator hose (see the chapter „Specifications and filling quantities“).

5. Open the radiator opening.

6. Remove the lower radiator hose (remove the hose clamp and pull off the hose).

If the coolant has run out: 1. Correctly reattach the lower radiator hose.

2. Mix new coolant using equal parts of clean tap water and new antifreeze.

3. Add new coolant into the radiator opening until the radiator fins are covered with coolant. Pour in at a maximum of 5 l/min.

4. Close the radiator opening.

5. Check the coolant level once again after half an hour of operation.

224

Servicing and inspection

Cleaning the cooling system Fig. 114 Cleaning the cooling system

Note Danger of technical damage! ►► The greater the amount of dust in the air, the more frequently the radiator has to be checked and cleaned. ►► Always cover up the suction connection of the air filter before cleaning the radiator. ►► Do not damage the radiator fins when cleaning the radiator. Straighten any twisted radiator fins carefully.

Environment Note Danger of environmental damage! ►► Avoid environmental damage! Clean the loader only in a suitable place where the waste water can be collected in an ecologically sound manner. ►► Collect contaminated waste water and dispose of it in an ecologically sound manner.

Clean the dirty radiator with compressed air (Fig. 114). You can also clean heavily contaminated radiators with water under high pressure.

Clean • • •

the engine‘s radiator the hydraulic fluid cooler the dynamo (with compressed air only!)

225

Servicing and inspection

10.7.6

Servicing the hydraulic system

Caution Danger of injury from moving parts!

Never open the engine bonnet when the engine is running.

Danger of scalding from hot hydraulic fluid!

Danger of injury from hydraulic fluid escaping under pressure!

A fine jet of hydraulic fluid under high pressure can pierce the skin. Go to a doctor immediately should you get hydraulic fluid in your eyes or on your skin.

Open hydraulic systems only if they have been depressurised. Even if a loader is parked on a horizontal surface with its lift frame completely lowered and engine turned off, there can still be considerable residual pressure in parts of the hydraulic system. Residual pressure reduces gradually at first. If a hydraulic system is opened immediately after shutting down, the system has to be depressurised as described in the chapter „Discharging residual pressure in the hydraulic system“.

226

Note Danger of technical damage! ►► Service the hydraulic system according to the inspection intervals specified in this operating manual. ►► Exercise extreme cleanliness when carrying out service work on the hydraulic system. Impurities in the hydraulic fluid in the form of dirt or water can result in premature wear or failure of the entire system.

Servicing and inspection

Hydraulic fluid cooler The oil radiator is installed behind the diesel engine (Fig. 115). The left part contains hydraulic oil; the right part is intended for cooling for the engine. Should the loader get too hot during long drives on the road or at high outside temperatures, check whether the fan‘s V-belt is taut and in good condition and whether the radiator is thoroughly clean all over.

Fig. 115 Hydraulic fluid cooler

227

Servicing and inspection

Ventilation filter / hydraulic fluid filler neck Note Replace the ventilation filter after 1000 operating hours.

The ventilation filter is located on the hydraulic fluid tank item 1 (Fig. 116). It ensures that the hydraulic tank is ventilated and exhausted when the hydraulic fluid level fluctuates. The air filter contains a filter element which prevents dust and dirt from penetrating and oil spills from escaping.

The air filter has a valve that keeps the tank pressure at approx. 0.5 bar. This pressure will escape if the hydraulic fluid filler neck is opened.

Checking the hydraulic fluid level Note Danger of technical damage!

Never let the oil level drop below the „Minimum“ mark on the dip stick.

When pouring in oil, never let the „Maximum“ mark on the dip stick be exceeded. ►► Check the hydraulic fluid level at regular intervals. Do not use the loader if the hydraulic fluid level is not correct. ►► Oil cloudiness means that water or air is in the system, which could damage the hydraulic pump. Contact trained specialized personnel to eliminate the fault. Do not drive the loader until the fault has been eliminated.

The hydraulic oil tank is located on the left side of the rear carriage. To access it, open the engine bonnet.

228

Servicing and inspection

1. Stop the loader on a horizontal surface and set the parking brake.

2. Lower the lift frame as far as it will go.

3. Turn off the engine.

4. Open the hydraulic oil filler neck Item 1 (Fig. 116) so that the pressure can escape from the tank.

5. The dip stick is located on the underside of the air filter.

Pull out the dip stick (Fig. 117).

6. Wipe the dip stick with a clean, lint-free cleaning rag.

7. Put the dip stick back in.

8. Pull the dip stick out again.

9. Check the oil level. The oil level must be between the „minimum“ and „maximum“ marks.

10. Put the dip stick back in after checking the oil level.

11. Close the hydraulic fluid filler neck item 1 (Fig. 116).

Fig. 116 Ventilation filter

1

Fig. 117 Hydraulic fluid dip stick

229

Servicing and inspection

Adding hydraulic fluid Note Danger of technical damage! ►► Use the correct fluid grade (see the chapter „Specifications and filling quantities“). ►► Open the hydraulic fluid filler neck item 1 (Fig. 116) carefully so that the pressure can escape from the tank.

If the fluid level is under the „Maximum“ mark, hydraulic fluid must be added: Open the hydraulic fluid filler neck Item 1 (Fig. 116).

Add hydraulic fluid.

Check the hydraulic fluid level.

Add hydraulic fluid until the fluid level is at the »Maximum« mark.

5. Close the hydraulic oil filler neck Item 1 (Fig. 116).

1.

2.

3.

4.

230

Changing the hydraulic fluid Caution Danger of scalding from hot hydraulic fluid! ►► Let the hydraulic oil cool down or use protective gloves.

Environment Note Danger of environmental damage! ►► Avoid environmental damage. Collect old hydraulic fluid and dispose of it in an ecologically sound manner.

Note Use a sufficiently dimensioned receptacle for the old hydraulic fluid and use the correct oil grade (see the chapter „Specifications and filling quantities“).

Servicing and inspection

Fig. 118 Hydraulic fluid drain plug

1. Stop the loader on a horizontal surface and set the parking brake.

2. Lower the lift frame as far as it will go.

3. Turn off the engine.

4. Depressurize the hydraulic system as described in the chapter „Relieving residual pressure in the hydraulic system“.

5. Place a sufficiently dimensioned receptacle under the lower drain opening of the hydraulic fluid tank (see the chapter „Specifications and filling quantities“).

6. Unscrew the sealing plug (Fig. 118).

Once the hydraulic fluid has been drained: 1. Remove the filter insert Item b (Fig. 120).

2. Clean the tank bottom and tank interior with hydraulic or detergent oil through the opening.

3. Replace the filter element of the return filter (see the section „Changing the return filter element“).

4. Screw on the plug (Fig. 118).

5. Pour the hydraulic oil into the hydraulic oil filler neck Item 1 (Fig. 116) until the oil level has reached the „Maximum“ mark.

6. Close the hydraulic fluid filler neck.

7. Vent the hydraulic system (see the section „Venting the hydraulic system“).

8. Check the hydraulic fluid level and top up the hydraulic fluid if necessary.

9. Dispose of the old hydraulic fluid in an ecologically sound manner.

231

Servicing and inspection

Changing the return filter element NOTE Risk of technical damage! ►► Replace the filter element of the return filter Item b. (Fig. 120) during inspections or if the indicator light for the return filter on the instrument panel is illuminated between inspection intervals item 16 (Fig. 15). After installing a new filter element, the indicator light on the instrument panel should no longer be illuminated. ►► Replace the filter element in a timely manner, as the filter‘s effect is overridden when the bypass valve is open.

232

Environment Note Danger of environmental damage! ►► Let the pressure from the hydraulic fluid tank escape by opening the hydraulic fluid filler neck Item 1 (Fig. 116) before you unscrew the lid of the filter housing Item a (Fig. 120). Otherwise, hydraulic fluid will be forced out of the filter housing and could get into the environment. ►► Dispose of the old filter element and any leaking hydraulic fluid in an ecologically sound manner.

The hydraulic system is equipped with a return filter Item 2 (Fig. 119). An installed bypass valve secures the return valve against positive pressure.

Servicing and inspection

1. Stop the loader on a horizontal surface and set the parking brake.

2. Lower the lift frame as far as it will go.

3. Turn off the engine.

4. Depressurize the hydraulic system as described in the chapter „Relieving residual pressure in the hydraulic system“.

5. Unscrew the cover of the filter housing Item 1 (Fig. 120).

6. Remove the filter element item b (Fig. 120).

7. Insert a new filter element.

8. Check the gasket Item c (Fig. 120). Replace the gasket if it is damaged.

9. Screw on the cover of the filter housing Item a (Fig. 120).

10. Close the hydraulic oil filler neck Item 1 (Fig. 116).

11. Vent the hydraulic system (see the section „Venting the hydraulic system“).

12. Check the hydraulic fluid level and top up the hydraulic fluid if necessary.

Fig. 119 Return filter

a

2 Fig. 120 Filter insert

b

c

233

Servicing and inspection

Venting the hydraulic system Warning Danger of the loader and lift frame moving uncontrollably!

Exhaust the hydraulic system each time after the hydraulic fluid or the return filter is changed, in the event of a malfunction in the hydraulic system, or following repairs or longer periods of shutdown. ►► Exhaust the system only from the driver‘s seat.

Danger of accidents due to people in the danger area. ►► Make sure that no one is in the loader‘s danger area while exhausting is being carried out.

234

1. Check the fluid level in the hydraulic fluid tank. If necessary, top up hydraulic fluid until the fluid level is at the „Maximum“ mark.

2. Start the engine and let it idle for a few minutes.

3. Drive the piston rod for all the hydraulic cylinders in and out several times.

4. With the engine running, turn the steering wheel to its maximum angle of turn in both directions until the steering can be actuated faultlessly and without any noises.

5. Check the oil level in the hydraulic fluid tank after exhausting has been completed. If necessary, top up hydraulic fluid until the fluid level is at the „Maximum“ mark.

Servicing and inspection

10.7.7

Servicing the axles

NOTE Risk of technical damage. ►► Service the transmission and the axles according to the inspection intervals specified in this operating manual.

Checking the axle oil level Note The complete axle (transfer case, differential, axle tube, wheel drives) shares a common oil supply.

You can check the oil level on the differential housing, the transfer case and on the wheel reduction gears.

Note Checking / filling and draining screws can be found in the same place on the front and rear axles.

The axial piston variable piston displacement motor for the driving hydraulics is mounted on the transfer case. The transfer case is connected to the rear axle of the loader.

The front axle is driven via the propeller shaft. The wheels are driven via two reduction gears on each axle.

Fig. 121 Differential

a b

235

Servicing and inspection

1. Stop the loader on a horizontal surface and set the parking brake.

2. Lower the lift frame as far as it will go.

3. Turn off the engine.

4. Remove the hex socket screws items a, c, e (Fig. 121/122/123).

For the wheel reduction gears raise the wheel with a jack first and turn it so that the hex socket screw Item e (Fig. 123) is precisely in the middle.

5. The transmission oil must be at or below the bottom edge of the filler neck.

6. If necessary, top up the transmission oil.

7. Replace the hex socket screws items a, c, e (Fig. 121/122/123).

Fig. 122 Transfer case

c d

Fig. 123 Wheel reduction

e

236

Servicing and inspection

Changing the axle oil Caution Danger of scalding from hot transmission oil! ►► Avoid contact with hot transmission fluid. Wear protective gloves.

Note The complete axle (transfer case, differential, axle tube, wheel drives) shares a common oil supply. If some of the oil must be changed, then afterwards, all oil levels must be checked to ensure that sufficient oil is in the axle.

Environment Note Danger of environmental damage! ►► Avoid environmental damage. Do not allow oil and oil-containing waste to spill on the ground or get into bodies of water! ►► Collect leaking transmission oil and dispose of it in an ecologically sound manner.

Note Use a sufficiently dimensioned receptacle for the old hydraulic fluid and use the correct oil grade (see the chapter „Specifications and filling quantities“).

The transmission oil is viscous. Replace the oil when it is warm and open the fill screws: this will allow it to drain more quickly.

237

Servicing and inspection

1. Stop the loader on a horizontal surface and set the parking brake.

2. Lower the lift frame as far as it will go.

3. Turn off the engine.

4. Place a sufficiently large receptacle under the drain opening of the differential housing item b (Fig. 121).

5. Remove the hex socket screw Item a (Fig. 121); the transmission oil will now drain more quickly.

6. Remove the hex socket screw Item b (Fig. 121).

7. The transmission oil drains off.

8. Lift the wheels with a jack and turn them so that the sealing screws Item e (Fig. 123) are down.

9. Place a receptacle under the sealing screws Item e (Fig. 123) and unscrew them.

238

Once the transmission oil has been drained: 1. First fill the wheel reduction transmission, after you have aligned the wheels as illustrated in (Fig. 123).

2. The transmission oil must be at or below the bottom edge of the opening.

3. Insert the sealing screw Item e.

4. Screw the hex socket screw on the differential housing Item b (Fig. 121) back in.

5. Pour new transmission oil through the filler neck into the axle Item a (Fig. 121).

6. The transmission oil must be at or below the bottom edge of the filler neck.

7. Screw the hex socket screw Item b (Fig. 121) on the differential housing back in.

8. Check the axle oil level once again after half an hour of operation on the transfer case housing, the differential housing, and the wheel reduction gears, and top up with transmission oil if necessary.

Servicing and inspection

10.7.8

Servicing the brakes

Warning Danger of accidents from defective brakes!

Defective brakes can cause fatal accidents. ►► Do not drive with defective brakes. Do not work with the loader again until the faults have been eliminated. ►► Only trained, experienced specialized personnel may work on the brake system. ►► Have the brake system checked regularly by trained, experienced specialized personnel during the inspections.

The hydrostatic drive is used as an operating brake and operates equally without wear resistance on all four wheels.

In addition, the loader has a foot brake and parking brake.

The foot brake and parking brake consists of a hub brake on the differential. The parking brake is actuated via a bowden cable, by means of the handbrake lever. The foot brake is activated hydraulically via brake lines and main brake cylinders by means of the braking-inching pedal.

239

Servicing and inspection

Checking the brake fluid level / topping up brake fluid Warning Danger of injury!

Brake fluid is hazardous to your health! ►► Avoid contact with skin and eyes. ►► Wear protective gloves.

NOTE Risk of technical damage!

Using the wrong brake fluid damages the brake system. ►► Only use brake fluid approved by Wacker Neuson for the braking system (see chapter „Specifications and fill quantities“).

240

Environment Note Danger of environmental damage! ►► Avoid environmental damage! Do not allow oil and waste containing oil to spill on the ground or get into bodies of water. ►► Collect leaking brake fluid and dispose of it in an ecologically sound manner.

Note If you are frequently topping up brake fluid between inspections, then a defect is present! Do not work with the loader again until the faults have been eliminated.

Servicing and inspection

The brake fluid container is on the left at the back, underneath the engine cover (Fig. 124). The control marks „MAX“ and „MIN“ are on the side of the container.

Fig. 124 Brake fluid container

If the brake oil level in the brake fluid container falls below the „MIN“ mark, then fill the prescribed brake fluid up to the „MAX“ mark and have the brake system checked by a trained specialist.

241

Servicing and inspection

10.7.9

Maintaining the collapsible driver’s canopy

(Additional equipment) Check the following during the visual inspection: WARNING Risk of accident due to damaged or incorrectly repaired ROPS/FOPS protective structures! ►► Carry out visual inspections regularly and every time the ROPS/FOPS protective structures come into use. ►► Have any damage rectified immediately. Repair work on ROPS or FOPS protective structures must only be carried out by authorized specialists. If in any doubt, always replace ROPS or FOPS protective structures as a complete unit. ►► Never drill holes in ROPS/FOPS protective structures.

242

• • • •

Are all securing pins in place and secured?

For screw connections, are all screws properly tightened?

Is there damage to any steel parts (flaking paint, cracks, etc.)?

Are all safety stickers present and clearly visible?

With the exception of any cleaning that may be necessary, the collapsible driver’s canopy does not require any special maintenance. However, it is advisable to grease the security pins (Fig. 125) every now and then, to prevent corrosion.

Servicing and inspection

Fig. 125 Greasing the front securing pins (collapsible driver’s canopy)

243

Servicing and inspection

10.7.10 Servicing the tires and wheels

Warning Danger of death or injury!

Fatal accidents can occur during incorrect installation of tires and wheels. ►► Only personnel trained for such work may install wheels and tires. ►► Welding and cutting of rims is prohibited. Replace damaged rims.

NOTE Risk of technical damage.

Different wheel or tire sizes can result in damage to the loader‘s differentials. ►► Install only wheels or tires from the same manufacturer which are the same size and have the same wear.

244

Inflating the tires ►► Use only filling devices with a calibrated pressure gauge to pump up tires. ►► Make sure that no one is in the danger area when you pump up tires.

NOTE These instructions refer to inflating in the event of loss of air pressure. Observe the air pressure specified for the loader‘s tire size (see air pressure table for tires).

In the case of complete air pressure loss, this work may only be carried by trained, experienced specialized personnel with appropriate equipment.

Servicing and inspection

Air pressure table for tires 1. Stop the loader on a horizontal surface and set the parking brake.

2. Lower the lift frame as far as it will go.

3. Turn off the engine.

4. Remove the protective cap on the tire valve.

5. Place the pneumatic chuck of the filling device on the tire valve so that it stays in place.

6. Inflate the tires to the specified pressure.

7. Remove the pneumatic chuck of the filling device from the tire valve.

8. Screw the protective cap back on the tire valve.

Tires

PR

Air pressure (bar)

7.00-12 AS

6

3,2

27x8.50-15 EM

8

4,2

27x10.50-15 EM

8

4,2

31x15.50-15 AS

8

3,1

10.0/75-15,3 AS

8

3,1

11.5/80-15,3 AS

10 8

4,5 3

10.5/80-18 AS

10

3,7

12.5/80-18 AS

12

4,7

10x16.5 EM

8

3,6

12x16,5 EM

10

4,5

15.5/55-18 EM

14

4,0

405/70 R18 EM 15.0/55-17 AS 405/70 R20 AS

4,0 10

3,5 3,5

245

Servicing and inspection

Changing wheels Warning Danger of death or injury!

If a wheel has been removed and the loader then slips off the jack, persons in the danger area can be trapped or crushed. ►► To change the wheels, stop the loader on a horizontal surface with a hard foundation. ►► Use only a safe, suitable jack with sufficient lifting capacity (observe the operating weight of the loader).

Danger of accidents due to wheels falling off.

Observe the following when bolting the wheels on: ►► Always tighten the wheel bolts with a torque wrench to the specified tightening torque. ►► Always alternately tighten the wheel bolts opposite each other. ►► After changing tires, check the tightening torque of the wheel bolts every two hours until they do not change anymore.

246

Note Observe the direction of the tread of the tires so that the greatest force of the loader is achieved during forward travel.

You will find the tightening torque in the table below: Wheel bolts / wheel nuts

Front wheels

Rear wheels

M18 x1,5

285 Nm

285 Nm

Servicing and inspection

1. Stop the loader on a horizontal surface with a hard foundation and set the parking brake.

2. Lower the lift frame as far as it will go.

3. Turn off the engine.

4. Position the jack under the axle next to the wheel to be changed. Make sure that the loader cannot slip off the jack.

5. Unscrew the wheel bolts.

6. Raise the jack just high enough so that the wheel does not touch the ground.

7. Remove the wheel bolts and take off the wheel.

8. Put on the new wheel and the wheel bolts.

9. Tighten the wheel bolts.

10. Lower the jack back down.

11. Alternately tighten the wheel bolts opposite each other to the specified tightening torque.

247

Servicing and inspection

10.7.12 Servicing the cab vent filter

Note Change the cab air filter annually, or more frequently under dusty conditions.

The loader is equipped with a dry air filter for filtering the engine intake air for cab ventilation. The filter is located on the front of the cab above the middle joint of the loader (Fig. 126).

1.

2.

3.

4.

Unscrew the lid of the filter housing.

Pull the filter out.

Insert a new filter.

Screw on the lid of the filter housing.

248

Fig. 126 Cab vent filter

Servicing and inspection

10.7.13 Filling the container for the windscreen washer system

Caution Danger of injury from hot and moving parts! ►► Never open the engine bonnet when the engine is running.

Fig. 127 Location of the windscreen washer container

Note Make sure that there is always enough water in the container for the windscreen washer system.

Mix in antifreeze with the water in winter.

The container for the windscreen washer system is located on the rear side of the cab to the left. Access it by opening the engine bonnet (Fig. 127).

249

Servicing and inspection

10.7.11 Servicing the electrical system

Danger of short-circuiting! ►► Always disconnect the battery before working on the electrical system if tools, spare parts, etc. with electrical components or contacts could touch it.

Note Danger of technical damage! ►► Do not clean sensitive electrical components (instrument panel, dynamo, compact plug, multifunction lever, etc.) with a high-pressure cleaner. ►► Do not touch incandescent lamps and headlight reflectors with your fingers.

Note Have malfunctions in the electrical system corrected by trained specialised personnel.

250

Fuse allocation Note ►► In the event of failure of electrical devices, check the fuses. If a fuse has blown, find the cause and correct the fault before replacing it. ►► Replace defective fuses only with fuses of the same power rating.

Note A 40 ampere fuse fused with the cab‘s electrical system is located at the battery.

The circuits are protected by various powerful fuses. These fuses are housed in the fuse box on the left side of the steering column (box 2) and in the switch strip on the right side in the cab (box 1).

Servicing and inspection

Fig. 128 Fuses

Item

Fused function for Box 1

Rating (A)

F021 Front headlights

15

F022 Front windscreen wipers

10

F023 Rear windscreen wipers

10

F024 Rear headlights

15

F025 Rotating beacon, radio

10

F026 Cab courtesy light, radio

10

Box 1 F021 F024 F022 F025 F023 F026

251

Servicing and inspection

F013 F014 F015 F016

FR 10

F012

FR 15

F011

FR 10

Box 2

FR 5

Fig. 129 Fuse box

F019 F020

FR: Reserve fuses

252

FR 7,5

F018

F009 F008 F007 F006 F005 F004

FR 20

F017

F010

F003 F002 F001

Servicing and inspection

Item

Fused function for Box 2

Rating (A)

Item

Fused function for Box 2

Rating (A)

F001 Turn signal (blinkers), hazard warning lights

15

F011 Available

F002 Signal horn, rotating beacon

10

F012

Electrical outlet on the lift frame, Options (AdF003 ditional equipment)

15

F013 Available

F004 Stopper, generator, fuel pump

10

F014 Available

F005 Available

10

F015 Available

F006 Options (Additional equipment)

10

F016 Left dipped beam

7,5

F007 Options (Additional equipment), tool locking

10

F017 Right dipped beam

7,5

F008 Instrument lighting, switch illumination

5

F018 Main beam

15

F009 Work lights

15

F019 Left-hand sidelight

7,5

F010 Available

7,5

F020 Right-hand sidelight

7,5

Turn signal (blinkers), hazard warning lights, Dashboard electrical outlet

20 15

10

253

Servicing and inspection

Battery Warning Danger of explosion!

Batteries give off explosive gases! ►► Avoid smoke, fire or open flames near batteries. ►► Do not place any tools on the battery – danger of short-circuiting! In the event of a short circuit of the poles, sparks will arise and ignite the leaking battery acid fumes.

Danger of injury!

Battery acid is corrosive! ►► Prevent battery acid from coming into contact with your skin, eyes, mouth or clothing. ►► Wear protective gloves and safety goggles. ►► If you make contact with battery acid, rinse the contaminated spot on your body immediately with plenty of clean water. Go to a doctor!

Environment Note Avoid environmental damage.

Dispose of old batteries in an ecologically sound way, separate from other waste.

254

Fig. 130 Location of the battery

1

The battery has a nominal voltage of 12 volts; the battery capacity is 77 Ah. The battery is located on the left side of the loader in the engine compartment Item 1 (Fig. 130).

To access it, open the engine bonnet and tilt the driver‘s platform.

Servicing and inspection

Servicing the battery

3

4 Fig. 131 Servicing the battery

Caution Danger of injury from hot and moving parts! ►► Never open the engine bonnet when the engine is running.

Note It is not necessary - or possible - to check the battery acid level and to refill distilled water.

Observe the battery’s operating instructions. You can find the battery’s operating instructions at the side of the battery Item 2 (Fig. 131).

2 • • •

Always keep the battery‘s pole heads and the connecting line terminals clean and lubricate them with anticorrosion grease.

Make sure that the cover for the positive pole is always present and closed item 3 (Fig. 131).

Observe the charge control indicator of the battery. You can find the charge control indicator on the upper side of the battery Item 4 (Fig. 131): --Green - battery charging condition OK --Black - charge battery --White - change battery

255

Servicing and inspection

Disconnecting and connecting the battery / changing the battery (+) Caution Danger of injury from hot and moving parts! ►► Never open the engine hood when the engine is running.

Danger of short-circuiting! ►► Always follow the correct sequence when disconnecting the battery.

–– Disconnecting: First the negative pole and then the positive pole!

–– Connecting: First the positive pole and then the negative pole!

6

Fig. 132 Removing the battery

5

256

(-)

Servicing and inspection

Removing the battery: 1. Stop the loader on a horizontal surface and set the parking brake.

2. Lower the lift frame as far as it will go.

3. Turn off the engine.

4. Before disconnecting the battery, switch off all electrical consumers (and the battery disconnect switch) and take out the ignition key.

5. Open the engine hood.

6. Tilt the driver‘s platform.

7. Unscrew the line from the negative pole item – (Fig. 132).

8. Unscrew the line from the plus pole item + (Fig. 132).

9. Unscrew the battery tray Item 5 (Fig. 132).

10. Take the battery by the grips Item 6 (Fig. 132) and lift it out.

Install the battery following the steps in the reverse order.

257

Servicing and inspection

10.8

Jump-starting / emergency starting Warning Danger of explosion!

Batteries give off explosive gases! ►► Avoid smoke, fire or open flames near batteries.

Danger of short-circuiting! ►► Make sure that the vehicle with the good battery and the loader do not touch. ►► Do not emergency start the loader if the battery is defective or frozen. ►► Do not switch two batteries in series. ►► Use only jump-starting batteries with the same voltage. ►► Use only tested jumper cables with insulated terminal clamps and a large enough cable cross-section. ►► Lay out the jumper cables so that they cannot be touched by turning engine parts.

258

r

2

V

1

Fig. 133 Connecting the jumper cables

L

3

s

4

Before jump-starting, check if the loader‘s dead battery is functional: 1. Switch off all the loader‘s electrical consumers.

2. Switch the ignition key to position 1 (operation). The warning lights must light up now!

3. If the warning lights do not light up, the battery is defective. In that case, do not start the loader! Install a functional battery.

Servicing and inspection

Getting ready

Starting the engines

1. Switch off all the loader‘s electrical consumers.

2. Switch the ignition key to position 0.

3. Drive the vehicle with the good battery (charged battery) up to the loader so that the vehicles are not touching but you can reach the batteries with the jumper cables.

4. Switch off all electrical consumers on the vehicle with the good battery and stop the engine.

1. Start the engine of the vehicle with the good battery and let it run at an increased speed.

2. Start the loader‘s engine.

3. If the engine does not start after 15 seconds, wait one minute before trying again.

4. Once the engine has started, let both engines continue to idle with the jumper cables connected for about another two minutes.

Connect the jumper cables (the correct sequence must be followed) 1. Connect the red jumper cable item r (Fig. 133) to the positive pole of the dead battery item L. 2. Connect the red jumper cable to the positive pole of the charged battery item V (Fig. 133).

3. Connect the black jumper cable item s to the negative pole of the charged battery.

4. Connect the black jumper cable to the negative pole of the dead battery.

Disconnect the jumper cables (As with connecting, follow the correct sequence) 1. Disconnect the black jumper cable first from the negative pole of the dead battery and then from the negative pole of the charged battery.

2. Disconnect the red jumper cable first from the positive pole of the charged battery and then from the positive pole of the dead battery.

259

Servicing and inspection

10.9

Shutting down and restarting the loader

The specified measures refer to shutting down and re-starting the loader over longer periods of time.

Note Follow the operating manual for the engine.

Shutting down the loader 1. Park the loader as described in the chapter „Securing the loader“.

2. Block the articulated joint.

3. Jack the loader so that the tires no longer touch the ground.

4. Release the parking brake.

5. Lower the lift frame as far as it will go.

6. Carry out the task „Discharging residual pressure in the hydraulic system“ and put the control lever in 0 position.

7. Spray bare metal parts of the loader (e.g.: the piston rods of the hydraulic cylinders if they are not retracted) with an anti-corrosion agent.

8. Preserve the engine.

260

Preserving the engine 1. Clean the engine in a suitable place using a high-pressure cleaner.

2. Bring the engine to operating temperature.

3. Drain the engine oil and dispose of it in an ecologically sound manner.

4. Pour anti-corrosion oil into the engine.

5. Drain the fuel from the tank.

6. Produce a mixture of 90% fuel and 10% anti-corrosion oil and pour it into the fuel tank.

7. Let the engine idle for 10 minutes before turning it off.

8. To preserve the cylinders and combustion chamber, crank the engine by hand several times.

9. Remove the fan belt and pack it for storage so that it is airtight and light-proof.

10. Spray the belt pulley contact surface with anti-corrosion agent.

11. Close the intake and exhaust opening of the engine.

Servicing and inspection

Storing the battery

Remove preservatives from the engine

1.

2.

3.

4.

1. Remove the closures from the intake and exhaust opening of the engine.

2. Remove the anti-corrosion agent from the pulley.

3. Install the fan belt.

4. Drain the preservative oil and pour in engine oil.

5. Start up the engine.

6. Check the V-belt tension after the first two operating hours.

Remove the battery.

Clean the battery.

Charge the battery.

Store the battery in a dry, well-ventilated room at approx. 20°C. 5. Check the acid level once a month.

6. Recharge the battery before installing it again.

Restarting the loader 1.

2.

3.

4.

5.

6.

7.

8.

9.

Remove the engine preservative.

Install the battery.

Check the air pressure of the tyres.

Remove the preservative for the hydraulic cylinders‘ piston rods.

Lower the loader.

Check the functioning of the electrical system.

Unblock the articulated joint.

Vent the hydraulic system.

Check the functioning of the steering and the brakes.

261

Troubleshooting and emergency maintenance

11

Troubleshooting and emergency maintenance

Fault / malfunction

Possible cause

Remedy

Engine does not start

Driver not sitting in the driver's seat, seat contact switch faulty

Sit in the driver's seat, have the seat contact switch replaced

Handbrake not set, drive direction switched

Set the handbrake, shift to 0

Fuel tank empty

Fill up the tank and vent the fuel system if necessary

Fuel filter clogged, paraffin separation in winter

Change the fuel filter, use winter diesel

Release magnet on the engine does not attract

Check the fuses

Fuel line is leaky

Retighten all the threaded connections and clamps

Starting speed too low

Check and charge the battery, check that battery terminals fit tightly

Set the handbrake

Release the handbrake

Handbrake switch is defective

Replace the handbrake switch

Inch cartridge is not in 0 position

Check and, if necessary, repair the inch cartridge and brake shoe return spring

Engine is running but loader will not drive

The magnets on the transmission pump are not Check the fuses, getting any power and have the multi-function lever and the electronics checked at the garage

262

Troubleshooting and emergency maintenance

Fault / malfunction

Possible cause

Remedy

The engine is getting too hot

The water / oil cooler on the engine is dirty

Clean it

Coolant level is too low

Fill it up

The thermostat is jammed

Have the thermostat replaced at the garage

V-belt loosened from the fan blade

Tighten the V-belt

Oil level is too low or too high

Adjust the oil level

Hydraulic oil cooler is dirty

Clean it

V-belt loosened from the fan blade

Tighten the V-belt

Hydraulic fluid level is too low

Top up the hydraulic fluid

Load too high

Reduce the machine load, take breaks

Air filter is dirty

Replace it

Wrong fuel grade

Change the fuel

Inching is stuck

Check, repair

Engine speed is too low

Adjust it

The hydraulic system is getting too hot

Machine performance is too low

263

Troubleshooting and emergency maintenance

Filter

Tank

Oil Oil type Temperature Cooler/radiator

Wear

Direction of rotation

Suction hose

Troubleshooting on the driving pump / oil motor

Suction pressure "S" driving pump Measuring point Cause

System

Oil motor

Auxiliary pump Purge valve Purge needle

Cooler/radiator

Secondary consumers Brake/accumulator

Oil temperature

Oil motor

Oil motor

Cooler/radiator

Not blocked Clutch Brake Leak oil due to wear Oil temperature

Control wire

Supply pressure valve Wear

Supply pressure "G" driving pump Measuring point

Suction pressure Cause

Cooler/radiator

High-pressure valves Pressure cut-off Twisting Wear Oil temperature

Throttle Pressure cut-off Actuating unit/solenoid DA control valve/inching/rotary throttle

Bypass valve Oil temperature Rotational speed Connection (clutch), drive motor - pump Control pressure X1/X2 driving pump

Suction pressure Supply pressure

Measuring point

Cause

High pressure MA/MB driving pump

Supply pressure Control pressure

Measuring point

Cause

Diesel engine Max/min engine speed Diesel filter Air filter General power/performance

264

Driving pump

Driving pump

Driving pump

Cause

Vehicle speed is not attained

Cause

Loader

Diesel engine Engine speed

Control pressure Inching

Driving pump

Diesel engine Engine speed

Loader

Transmission ratio Tires

Tire diameter

Diesel engine Injection pump Fuel filter

High-pressure valves Wear Twisting

Throttle Suction pressure Control pressure Start of closed loop control Inching

Driving direction switch Start of closed loop control Mechanical zero position

Twisting Control pressure Pressure cut-off

Insufficient tractive power Driving pump

Cause

Severe overloading

Cause

Vehicle drives off too late

Cause

Diesel engine running, vehicle does not stop

Troubleshooting on the loader

Oil motor

Oil motor

Oil motor

Start of closed loop control Solenoid Swivel angle

Start of closed loop control Control cable X1/X2 Solenoid Swivel angle

Start of closed loop control Swivel angle

Troubleshooting and emergency maintenance

265

Safety instructions for repairs

12

Safety instructions for repairs 12.1 NOTE The section "Safety Instructions for Repairs" does not contain instructions which explain how the repairs are carried out. Instead, it details safety instructions which should be followed in addition to the general safety regulations for repair work and provides information about potential hazards which can be encountered while carrying out repair work.

It also contains information about certain things which should be avoided during repairs in order to prevent damaging the vehicle and its equipment.

This operator's manual do not contain specific repair instructions.

Operating manual: •

Carry out repairs only if you have read and understood the operating manual.

Observe in particular: • • • • •

266

General safety regulations for repairs

The basic safety instructions.

The basic safety instructions for servicing and inspection.

All warning signs and instructions attached to the loader.

That the descriptions of work processes provide the necessary instructions only for experienced specialised personnel.

That the operating manual is always kept with the loader.

Safety instructions for repairs

Repair personnel:

Removing components:

•

•

•

Repair personnel must have specialised knowledge and experience in repairing this or comparable loaders.

Should knowledge be lacking, experienced repair personnel must be trained carefully by Wacker Neuson Service, for example.

Blocking the articulated joint: • •

Always block the articulated joint with the buckling guard when carrying out repair work in the bending region.

Remove the blocking after completing the repair work.

• • • • •

Danger of burning from hot parts or fluids! Do not remove components when the loader is warm from operation.

Depressurise pipes and hoses, cylinders, coolers, the hydraulic tank, pressure tanks and other systems or aggregates before beginning work.

Replace defective components in a timely manner.

Clean components carefully before removing them.

Mark the parts removed in the correct order so that you do not make mistakes when installing them.

When removing a component, plug the cleared connections, open holes and housing carefully so that no dirt can infiltrate.

Pre- stressed aggregates: •

Do not open the defective pre- stressed aggregates (e.g. accumulators); always completely replace them.

267

Safety instructions for repairs

Do not remove seals or sealing wax:

After completing the repair:

•

•

•

Changing rated pressures for relief valves is prohibited without the express consent of Wacker Neuson.

Do not damage or remove seals and sealing wax on the engine, the pressure limiting valves and accumulators.

268

Put protective paint on all uncoated machine parts to prevent corrosion damage.

• Install the cab mounting screws again after the repair work has been completed.

• Reattach all safety devices, covers and noise/vibration insulation after repair work has been completed.

• Check the functioning of the loader, in particular the parts repaired in trial operation.

Make sure that no one is in the loader‘s danger area.

• Do not approve the loader for operation until all the loader‘s areas function properly.

Safety instructions for repairs

12.2 • • •

Engine

Carry out repair work only if the loader is secured as described in the chapter „Securing the loader“.

Danger of injury from rotating parts and hot parts. Let the engine cool off first, after stopping the loader.

Check the V- belt only when the engine is stopped.

12.3 • •

Welding work

Only people trained to weld may carry out welding work.

Only certain authorised individuals under the supervision of a competent person may weld containers which contain or have contained substances that are combustible, promote combustion, are explosive, or can produce vapour, gas, mist or dust when welding that are hazardous to health. Should you have problems or questions, it is imperative that you consult the Wacker Neuson Service.

269

Safety instructions for repairs

Before carrying out welding work on the loader

After welding has been completed:

•

•

• • • •

•

Disconnect the battery as described in this operating manual.

Disconnect the positive pole (terminal B+) on the generator.

Switch OFF the battery disconnect switch (if present).

Safeguard stripped terminals and connections against short-circuiting.

Attach the welding current terminal in the immediate vicinity of the welding site. Do not allow the welding current to pass through gears, bolts, articulated joints or hydraulic cylinders.

Do not do any welding work on components of the air conditioning system, or in their immediate vicinity.

270

•

Reconnect all the electrical connections and check that they function.

Connect the battery as described in this operating manual.

Safety instructions for repairs

12.4 • • • • •

Hydraulic system

Before carrying out repair work, depressurise the hydraulic system as described in the chapter „Discharging residual pressure in the hydraulic system“.

Replace damaged and leaky hydraulic lines and hoses with new ones. Do not use used hoses.

Replace hydraulic hoses after six years of use.

Dispose of any leaking oil and waste containing oil in an ecologically sound manner.

Observe the „Basic safety instructions for maintenance and inspection“.

12.5 •

• • •

Brakes

Repair work on brakes may only be carried out if the persons performing this work are suitably trained. In case of doubt, the work must be carried out by the Wacker Neuson Service.

Using a brake fluid other than the one specified by the manufacturer is prohibited.

Observe the notes on health hazards and environmental protection when working with brake fluid.

Carry out repair work on the brakes only if the loader is secured as described in the chapter „Securing the loader“.

271

Final shutdown of the loader / decommissioning

13

Final shutdown of the loader / decommissioning Environment Note Avoid environmental damage! Do not allow oil and waste containing oil to get into the ground or bodies of water.

Dispose of different materials and operating fluids/ auxiliary materials separately and in an ecologically sound manner.

Should you no longer plan to use the loader as intended, make sure that it is shut down, i.e. decommissioned, and disposed of according to the valid regulations.

Before disposing of the loader: • • • •

• • • •

272

Observe all the valid safety regulations regarding shutdown of the loader.

Make sure that the loader cannot be operated from the time of shutdown to further disposal.

Make sure that no environmentally hazardous operating fluids or fuel escape and that the machine poses no other dangers in the place where it is standing.

Protect the loader against unauthorised use. Close all openings (doors, windows, engine bonnet) and secure the loader as described in the chapter „Securing the loader“„.

Attach all the safety devices.

Eliminate leaks on the engine, tanks and hydraulic system.

Remove the battery.

Store the loader in a place protected against access by unauthorised persons.

Final shutdown of the loader / decommissioning

Disposing of the loader: •

• • •

Subsequent recycling of the loader must take place in accordance with the current state of the art at the time of recycling, taking into account the accident prevention regulations.

Dispose of all parts at the sites provided for them, depending on the material.

Take care to separate the materials when recycling.

Make sure that operating and auxiliary aids are disposed of in an ecologically sound manner.

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Appendix

14

Appendix

Ordering replacement parts Note Use only original Wacker Neuson replacement parts for your loader.

Note Please provide us with the following data for ordering replacement parts as a matter of principle. This is the only way we can assure smooth processing of your order and delivery of the replacement parts.

• • • • • • •

Wacker Neuson- machine type Specify the chassis number of the machine (see rating plate) For the engine, specify the respective engine number Item number and designation of the replacement part Address with telephone number (in the event of questions) Customer number (if available) Name of the orderer Shipping method (see below)

We reserve the right to change the replacement parts list.

If you are a new customer, please provide a correct address so that we can properly process future orders, etc. The first delivery is C.O.D. Do not forget to indicate the desired shipping method in your order.

• • •

274

Overnight shipping Parcel service Forwarding agent

Appendix

Importer (name; address): Note Enter the most important data for your loader on this page. In this way, you can quickly access the vehicle ID no. and other important data when ordering replacement parts.

Loader type:

Service garage (name; address):

Vehicle ID no.: Engine type: Engine no.: Delivery date:

275

Index

Index A

Adding hydraulic fluid.......................................................................................................................................... 230 Adjusting the driver‘s seat..................................................................................................................................... 76 Adjusting the driver‘s seat..................................................................................................................................... 76 Adjusting the fork arm spacing............................................................................................................................ 134 Adjusting the seat belt........................................................................................................................................... 79 Adjusting the steering column............................................................................................................................... 75 Air filter dust valve............................................................................................................................................... 216 Air pressure table for tires................................................................................................................................... 245 At high outside temperatures.............................................................................................................................. 139 At low outside temperatures................................................................................................................................ 139

B ........................................................................................................................................................... 254 Battery Blocking the articulated joint............................................................................................................................... 162 Braking and stopping.......................................................................................................................................... 100 C

Changeover valve applies tilting in/out function to additional hydraulics............................................................ 143 Changing attachments.........................................................................................................................................114 Changing the axle oil........................................................................................................................................... 237 Changing the coolant.......................................................................................................................................... 224 Changing the drive direction............................................................................................................................... 101 Changing the engine oil...................................................................................................................................... 206 Changing the engine oil filter............................................................................................................................... 208

276

Index

Changing the fuel pre-filter.................................................................................................................................. 212 Changing the hydraulic fluid................................................................................................................................ 230 Changing the main fuel filter............................................................................................................................... 213 Changing the return filter element....................................................................................................................... 232 Changing wheels................................................................................................................................................. 246 Checking / changing the safety filter................................................................................................................... 217 Checking the antifreeze mix................................................................................................................................ 223 Checking the axle oil level................................................................................................................................... 235 Checking the brake fluid level / topping up brake fluid........................................................................................ 240 Checking the coolant level / refilling the coolant................................................................................................. 222 Checking the engine oil level.............................................................................................................................. 204 Checking the hydraulic fluid level........................................................................................................................ 228 Checking V-belt tension / Tensioning the V-belt................................................................................................. 220 Check main air filter element / clean / replace.................................................................................................... 216 Cleaning the cooling system............................................................................................................................... 225 Control lever for the lift frame.............................................................................................................................. 104 Coupling and uncoupling the connections for additional hydraulics................................................................... 120 Coupling attachments..........................................................................................................................................117 Coupling with hydraulic quick-change system.....................................................................................................118 Coupling with mechanical quick-change system................................................................................................ 121

277

Index

D Daily servicing..................................................................................................................................................... 180 Depressurized return line.................................................................................................................................... 145 Description of the indicator, warning and control elements.................................................................................. 56 Description of the starting process....................................................................................................................... 91 Detent mechanism for the control lever for the additional hydraulics..................................................................111 Dimensions........................................................................................................................................................... 50 Disconnecting and connecting the battery / changing the battery...................................................................... 256 Doors and windows............................................................................................................................................... 73 Drive direction switch............................................................................................................................................ 97 Driving off with the loader................................................................................................................................... 100 E Each time before starting work........................................................................................................................... 103 EC Declaration of conformity................................................................................................................................ 15 Electrical outlet on the lift frame.......................................................................................................................... 146 F Fastening the seat belt.......................................................................................................................................... 78 Filling the container for the windscreen washer system...................................................................................... 249 Foldable rollover bar.............................................................................................................................................141 Fueling ............................................................................................................................................................. 68 Fuse allocation.................................................................................................................................................... 250 G Getting in ............................................................................................................................................................. 72

278

Index

H Headlights ............................................................................................................................................................. 83 Hydraulic fluid cooler........................................................................................................................................... 227 Hydraulic locking mechanism for attachments.....................................................................................................110 Hydro connection additionally via additional control device................................................................................ 145 Hydro connection additionally via changeover valve.......................................................................................... 144 I Idle speed adjustment for cold starting................................................................................................................. 92 If the engine does not start................................................................................................................................... 93 Independent driving onto the transport device.................................................................................................... 163 Inflating the tires.................................................................................................................................................. 244 Inspection after 30 operating hours (First inspection)......................................................................................... 182 Inspection after 500 operating hours.................................................................................................................. 184 Inspection intervals............................................................................................................................................. 187 J

Jump-starting / emergency starting.................................................................................................................... 258

L Lashing the loader............................................................................................................................................... 166 Lengthening the seat belt...................................................................................................................................... 80 Level indicator..................................................................................................................................................... 127 Lighting system and signal horn............................................................................................................................ 82 Loader data........................................................................................................................................................... 45 Loading with crane.............................................................................................................................................. 164 Lubrication schedule........................................................................................................................................... 192 M Measures in the event of the loader tipping over................................................................................................ 138 Moving the loader onto a transport vehicle......................................................................................................... 161

279

Index

O Opening the lowering brake valves..................................................................................................................... 172 Operating lever for additional hydraulics............................................................................................................. 108 Optional multi-function lever for multiple functions............................................................................................. 148 Ordering replacement parts................................................................................................................................ 274 R Releasing the seat belt.......................................................................................................................................... 78 S Safety information for collapsible driver’s canopy............................................................................................... 150 Seat belt ............................................................................................................................................................. 78 Servicing the air filter system.............................................................................................................................. 215 Servicing the axles.............................................................................................................................................. 235 Servicing the battery........................................................................................................................................... 255 Servicing the brakes............................................................................................................................................ 239 Servicing the cab vent filter................................................................................................................................. 248 Servicing the cooling system.............................................................................................................................. 218 Servicing the electrical system........................................................................................................................... 250 Servicing the engine........................................................................................................................................... 204 Servicing the fuel system.................................................................................................................................... 210 Servicing the hydraulic system............................................................................................................................ 226 Servicing the tires and wheels............................................................................................................................ 244 Servicing the water separator..............................................................................................................................211 Short-circuiting the drive..................................................................................................................................... 159 Shortening the seat belt........................................................................................................................................ 80 Specifications and filling quantities..................................................................................................................... 196 Starting the engine................................................................................................................................................ 89 Switching gears..................................................................................................................................................... 99

280

Index

T Technical description of the loader....................................................................................................................... 43 Tilting the driver‘s platform.................................................................................................................................. 200 Topping up engine oil.......................................................................................................................................... 206 Towing equipment............................................................................................................................................... 159 Troubleshooting and emergency maintenance................................................................................................... 262 Troubleshooting on the driving pump / oil motor................................................................................................. 264 Troubleshooting on the loader............................................................................................................................. 265 U Uncoupling attachments..................................................................................................................................... 122 Uncoupling with hydraulic quick-change system................................................................................................. 122 Uncoupling with mechanical quick-change system............................................................................................. 124 V Ventilation and heating of the cab......................................................................................................................... 87 Ventilation filter / hydraulic fluid filler neck........................................................................................................... 228 Venting the fuel system....................................................................................................................................... 214 Venting the hydraulic system............................................................................................................................... 234 Vibrations (weighted effective value)..................................................................................................................... 48 W Weekly servicing................................................................................................................................................. 181 Wipers and windscreen washer system................................................................................................................ 86 Working with the bucket...................................................................................................................................... 128 Working with the pallet fork................................................................................................................................. 136

281

List of figures

List of figures Fig. 1 Document pocket............................................................................................................................. 14 Fig. 2 Transport of large bales or packaged goods................................................................................... 27 Fig. 3 Safety stickers................................................................................................................................. 33 Fig. 4 Fire extinguisher.............................................................................................................................. 37 Fig. 5 Attaching the rotating beacon.......................................................................................................... 37 Fig. 6 Lowering brake valve....................................................................................................................... 38 Fig. 7 Battery disconnect switch................................................................................................................ 39 Fig. 8 Safety belt........................................................................................................................................ 40 Fig. 9 Emergency exit................................................................................................................................ 41 Fig. 10 Lever for locking the lift frame.......................................................................................................... 42 Fig. 11 Dimensions (Loaders with driver’s canopy)..................................................................................... 50 Fig. 12 Dimensions (Loaders with cab)....................................................................................................... 52 Fig. 13 Vehicle ID no.................................................................................................................................... 54 Fig. 14 Operating elements......................................................................................................................... 56 Fig. 15 Control and warning lights............................................................................................................... 58 Fig. 16 Switches / toggle switches............................................................................................................... 62 Fig. 17 Indicator devices ............................................................................................................................. 66 Fig. 18 Fuel filler neck.................................................................................................................................. 69 Fig. 19 Getting in......................................................................................................................................... 72 Fig. 20 Locking the restraining bar.............................................................................................................. 72 Fig. 21 Cab door locking mechanism.......................................................................................................... 73 Fig. 22 Cab door locking.............................................................................................................................. 74 Fig. 23 Releasing locked cab doors............................................................................................................. 74 Fig. 24 Adjusting the steering column.......................................................................................................... 75 Fig. 25 Adjusting the driver‘s seat................................................................................................................ 77 Fig. 26 Fastening the seat belt..................................................................................................................... 79

282

List of figures

Fig. 27 Adjusting the seat belt..................................................................................................................... 80 Fig. 28 Lighting / signal horn........................................................................................................................ 82 Fig. 29 Switch for work lights (Loaders with driver‘s canopy)...................................................................... 83 Fig. 30 Switch for work lights (Loaders with cab)........................................................................................ 84 Fig. 31 Switch for rotating beacon............................................................................................................... 85 Fig. 32 Switches for windscreen wipers...................................................................................................... 86 Fig. 33 Heating controller............................................................................................................................. 87 Fig. 34 Ventilation jets.................................................................................................................................. 88 Fig. 35 Ignition key....................................................................................................................................... 91 Fig. 36 Idle speed adjustment...................................................................................................................... 92 Fig. 37 Operating lever for parking brake.................................................................................................... 95 Fig. 38 Changing direction........................................................................................................................... 99 Fig. 39 Control lever for the lift frame.......................................................................................................... 105 Fig. 40 Lever for locking the lift frame.......................................................................................................... 107 Fig. 41 Operating lever for additional hydraulics......................................................................................... 109 Fig. 42 Hydraulic connections...................................................................................................................... 109 Fig. 43 Releasing the hydraulic locking mechanism for attachments.......................................................... 110 Fig. 44 Switch for differential lock................................................................................................................ 113 Fig. 45 Coupling - hydraulic locking mechanism......................................................................................... 118 Fig. 46 Connecting the additional hydraulics............................................................................................... 119 Fig. 47 Coupling - mechanical locking mechanism..................................................................................... 121 Fig. 48 Locking of the mechanical locking mechanism............................................................................... 121 Fig. 49 Uncoupling - hydraulic locking mechanism...................................................................................... 123 Fig. 50 Uncoupling mechanical locking mechanism.................................................................................... 124 Fig. 51 Control lever movements................................................................................................................. 126 Fig. 52 Level indicator.................................................................................................................................. 127

283

List of figures

Fig. 53 Loading work 1................................................................................................................................. 128 Fig. 54 Loading work 2................................................................................................................................. 129 Fig. 55 Loading work 3................................................................................................................................. 129 Fig. 56 Excavation work 4............................................................................................................................ 130 Fig. 57 Excavation work 5............................................................................................................................ 130 Fig. 58 Correct fork arm spacing................................................................................................................. 134 Fig. 59 Adjusting the fork arm spacing........................................................................................................ 135 Fig. 60 Foldable rollover bar........................................................................................................................ 142 Fig. 61 Switch for changeover valve............................................................................................................ 143 Fig. 62 Additional hydraulic connections..................................................................................................... 144 Fig. 63 Additional control lever.................................................................................................................... 145 Fig. 64 Depressurized return line................................................................................................................. 145 Fig. 65 Electrical outlet on the lift frame...................................................................................................... 146 Fig. 66 Switch for the electrical outlet on the lift frame (1)........................................................................... 146 Fig. 67 Switch for the electrical outlet on the lift frame (2)........................................................................... 147 Fig. 68 Optional multi-function lever............................................................................................................ 148 Fig. 69 Transporting large bales or packaged goods (collapsible driver’s canopy)..................................... 150 Fig. 70 Dimensions (collapsible driver’s canopy)......................................................................................... 151 Fig. 71 Components (collapsible driver’s canopy)....................................................................................... 152 Fig. 72 Preparations for folding down the driver’s canopy (collapsible driver’s canopy)............................. 153 Fig. 73 Releasing the securing pins (collapsible driver’s canopy)............................................................... 153 Fig. 74 Folding down the front pillars forwards (collapsible driver’s canopy)............................................... 154 Fig. 75 Fold in the roof sections (collapsible driver’s canopy)..................................................................... 155 Fig. 76 Folding down the rear pillar (collapsible driver’s canopy)................................................................ 156 Fig. 77 Inserting the front securing pins (collapsible driver’s canopy)......................................................... 157 Fig. 78 Towing equipment............................................................................................................................ 159 Fig. 79 Short-circuiting the drive.................................................................................................................. 160 Fig. 80 Buckling guard................................................................................................................................. 162

284

List of figures

Fig. 81 Independent driving onto the transport device................................................................................ 163 Fig. 82 Attachment point stickers................................................................................................................. 164 Fig. 83 Attachment points............................................................................................................................ 165 Fig. 84 Loading with crane........................................................................................................................... 165 Fig. 85 Lashing point stickers...................................................................................................................... 166 Fig. 86 Lashing points.................................................................................................................................. 167 Fig. 87 Lashing the loader........................................................................................................................... 168 Fig. 88 Reducing residual pressure............................................................................................................. 171 Fig. 89 Opening the lowering brake valves.................................................................................................. 172 Fig. 90 Points of lubrication......................................................................................................................... 192 Fig. 91 Handle for the engine bonnet.......................................................................................................... 199 Fig. 92 Cab tilt lever..................................................................................................................................... 201 Fig. 93 Position of the driver‘s platform mounting screws........................................................................... 202 Fig. 94 Driver‘s platform mounting screw, front........................................................................................... 203 Fig. 95 Driver‘s platform mounting screw, rear............................................................................................ 203 Fig. 96 Driver‘s platform safety support....................................................................................................... 203 Fig. 97 Engine oil dipstick............................................................................................................................ 204 Fig. 98 Checking the engine oil / filling the oil............................................................................................. 205 Fig. 99 Engine oil drain opening.................................................................................................................. 207 Fig. 100 Location of the engine oil filter......................................................................................................... 209 Fig. 101 Engine oil filter................................................................................................................................. 209 Fig. 102 Water separator............................................................................................................................... 211 Fig. 103 Fuel pre-filter, main fuel filter........................................................................................................... 212 Fig. 104 Changing the main fuel filter............................................................................................................ 213 Fig. 105 Venting the fuel system.................................................................................................................... 214 Fig. 106 Location of the air filter.................................................................................................................... 216 Fig. 107 Air filter elements............................................................................................................................. 216 Fig. 108 Radiator........................................................................................................................................... 219

285

List of figures

Fig. 109 Checking the V-belt tension............................................................................................................. 221 Fig. 110 V-belt................................................................................................................................................ 221 Fig. 111 Tensioning the V-belt....................................................................................................................... 221 Fig. 112 Radiator opening.............................................................................................................................. 223 Fig. 113 Checking the antifreeze mix............................................................................................................ 223 Fig. 114 Cleaning the cooling system............................................................................................................ 225 Fig. 115 Hydraulic fluid cooler....................................................................................................................... 227 Fig. 116 Ventilation filter................................................................................................................................ 229 Fig. 117 Hydraulic fluid dip stick.................................................................................................................... 229 Fig. 118 Hydraulic fluid drain plug.................................................................................................................. 231 Fig. 119 Return filter...................................................................................................................................... 233 Fig. 120 Filter insert....................................................................................................................................... 233 Fig. 121 Differential........................................................................................................................................ 235 Fig. 122 Transfer case................................................................................................................................... 236 Fig. 123 Wheel reduction............................................................................................................................... 236 Fig. 124 Brake fluid container........................................................................................................................ 241 Fig. 125 Greasing the front securing pins (collapsible driver’s canopy)........................................................ 243 Fig. 126 Cab vent filter................................................................................................................................... 248 Fig. 127 Location of the windscreen washer container................................................................................. 249 Fig. 128 Fuses............................................................................................................................................... 251 Fig. 129 Fuse box.......................................................................................................................................... 252 Fig. 130 Location of the battery..................................................................................................................... 254 Fig. 131 Servicing the battery........................................................................................................................ 255 Fig. 132 Removing the battery....................................................................................................................... 256 Fig. 133 Connecting the jumper cables......................................................................................................... 258

286

Best.-Nr.: 1000289673 Sprache: [au]