GHH Fahrzeuge GmbH Operating Instructions Load Haul Dumper LF -6 Webicte Nex 394827 Lee Lee ' Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 1 Contents “Introduction” 11) Mawta use the operating insta stions wae Reecand of rewisior's waa 12 Pretace 1281 1.3. Warranty Candifions far hiring and Tunnelling Vehicle Aieport EQuIpMeM eee 14-4 1.4 ehite identification taal Namepistes ....... aed 1.6 Technical Data .... 18-1 Main dimensions ......... 18-1 eights 14.1 Tramming capacities 18-1 Engine... 18-1 “Tree chive writ 18-2 Wheels and Gres... 18-2 Brakes 14-3 ‘Steering 1603 Hydronic system 1603 ‘Steering hydraulic system 16.4 Blectical equipment 16.4 Lighting system oe eee 14-4 Fling WORMS eee 18-4 Birmensions of webicle 1668 Sounderessure level 1868 1.8 Carcise descigtion oftmahicle See Awe Properuse oft Fpe coders powered by dascterginectsbockic makers... 1-2 Fornter Lee tel sa Escaneado con CamScannerGHH Fahrzeuge GmbH 1.4 How to use the operating instructions ‘Secuons The operating imstuckons comprise four sections. 1 = Introduction 2 = Operation 3= Maintenance 4 = System drawings ‘Subsectons ‘Sectiona 1 90 3 are dnaded imo the necessary chapters. A table of contents 1s provided at the begannng of every main secton. Pages The pages of each subsection ars numbered, | = ‘Subseckon Sechon“Operanon* Example: 2. Fortes ur ated suse Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Page numbers (Each page has the number of the main secicnichapter andia page number parted in the kotiars fine cf page. Each chapter begins with page cumber"!" The indhvigual pages of the respective chapter are ‘consecutively numbered, ‘Code mumberr / tmsue dane ‘The cade mumberindicated in theletihand comer at the boftore ofeach page isusedfcrimiernalider Biica- Sion. ft may be igrcrad by fe uter cf the operating instructions. Tre tne rt Pron pe) cocoate roar te fe near CAUTION, Wiening. Note (Caution — The ward “Caution” is used to draw afterfaon to methods, prasecures or threshakds which must be caretuily observed in ander to avcic injury to perzars, Waring ‘Tre word Warring” dranes atienicn to methods and procedures that rmustbe adhered tain order to avoid damage to the equipment, Nae The mcrd Nae dans alison fa paricuat iechracel maiers which the diever sual ‘observe and which alsa sim pty the ware, lustratore, ‘The illustrations usedlin fhe operating instrucSerms serve to enplain etext Vibile hey may wary fom he actual vebicl design, they mil nat bnsically change the tachudl infor ation Patent, trademarks The interration ineuded in these operating instructions is publeshed regard less of ary patert rights. Trademaris are used without any warranty thet they may ke used freely, Lisitey ‘The tets and itu strations were com piled with greatcare, Nevertieless, erors carat exchded comple- fely. GHE FFahroeuge GmbH and the authors cannot ether assume arylegal resparmitity or arty ality for anformaton and fhe consequences there af Please contact our Service Departrnert ifycu have technical queries orf yau notice any discrepancies. ‘The contents of these cpeniing instructions are regularly revised te incude techrical innovations. We reserve the mght of technical changes due tc ongeing develogmert without prior notice. ‘Copyright Repreducton in any fore ct translation and storage on clechanic media in net permitted without pricr write ten consent ty GHH Fahtzeuge GmbH, This abso applies to extracts. AN nghis under cary knw are specifically esersed by GHH Fahceuge GmbH Fortes ur tek suse Escaneado con CamScannerGHH Fahrzeuge GmbH Record af revisions ‘Altresisions insusd are liste: inthis table, Each rewision is num baned consecutively togethes with the date ‘af sue. The date ard the rame ef fhe person who inserted the sheets in this manual are alse shewn in FAHRZEUGE the table Rev. | Revision | Ome | Name | Rev. | Revision | Dato Name Na. Date | inserted Na. Date | Inserted Webicle no, 384027 Fornten ea wea Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 1.2 Preface ‘These operating instructions inciude im portantinfarmation on how to cperate and keepyyour wehicke mace ty GH Fahraeuge GmbH in working crder. ‘One copy each of theinstructars should at aliens be available tc both the criverand the mairterance personnel, Each operation carried aut on the vehide presupposes that the contents af te operating in- shuchons are inaun and striefly achered ta, ‘Therefore, please read these instructions carctully and terrorize yourself wih the vehide, in parficular before puting the wehide infa cperation fr the first tise. Proper operaticr and raintersnce make for lasting operational reliatilty, Any doantirmes which are cue to zvcidatle maintenance workcan be minirized ifspecial attention is paid fic the oll ge + Never ster with outaporoval any parameters whact are either permanently set or specified by the ma- nufteiurer, such as hydronic pressures, Sghiering torques, eke, = Perform af specified maintenance ard inspection warts completely and in good time, Use onty oil brands ard grease types mitch are in compliance with curseoormmendaticns. instal onty oniginatspare pans, ‘Should you have any toutle cr questions, ar i'you wish to order spare parts, please contact: ‘GMM Fahezeuge GmbH Abtedung & Postiach 1¢ 0942 (D-45808 Gelsenkirchen Telephone: +4940)208 38807 300 Tele: +49(0)208 38807-2149 car the represer tative responsible for your area Please state fre vehicle type and serial number in all writer queries or phone calls. When mating out spare parts orders, please adhere'to the ordering instructions included in the spare parts est. Never have repairs or alterations canied cut by third parties without cur: we cannct be held responsible in arty case of nonscomplarce wih Ee roa. You wil appeciate that cee Please nee our “Wianrarty Candiicrs” tor Wining and Tunneling Vehicles, Aipost Equigmert. Fortes ur tae suse Escaneado con CamScannerGHH Fahrzeuge GmbH 4.3 Warranty and Tunnelling Vehicles, Airport Equipment 1 nmamaet er aupy on tate mote aw hat at ‘ape athe rasa rupee ya oe we (soot car fan arte at hk becarrs utarnoeae yj Hh weary pad das a i gh aan. ta seechortor wares. we ace mst fer prperves expe guaran ‘Orth anes er ad ay nara air maplacereer ssepphea- preade!, Parch ana? cam ven dad Sea in an igs cre pats a accu, (aver cea Shad Ba Purchase, sear Meer cea ar rarer re a ala atar arr he Inte es pars hy ng Pac char acid ea cer ot rap Th does on dee a bn pte a ming meds 2 2 sary Canvcr ais aba be ‘serum sen Parchane's ome ml rer ‘Sbigaterm spac ay ctmaron qa praeoor anaes ‘spree. un cea vargas pa pacers ch pe a Be ar a at a a ay a tt ane ny cthacs Pat hacen abdul ooesert ts do Tha eran ai sara te ate it aa (2, peeps, cements he eral paride ‘BOG watery a Fer SOD ays ae vere re ‘eeetecar nour et Then wanes prt sta epee ‘cae ed a Cy fe ac fe Pang ‘seers Parca, ‘wha cer and te ard utes cern ‘ara ae cr cree Be adv wana peas aa The ruber effeacha vate ha te re ecard se Be apne aura eels Ba ‘sateca tr Pes spec te guopane. Tha dan on eos the ‘200 oy ORE ser oe as ech opt ara aa vee at tg dy Lio, ‘ata cx tas bie erie mab Ut pa be male. Fareepar minh, chadeng emplacerrt he mata (pata al ba oe dal cas in of a ad ‘dn fer gy ot ng ad ara an! FB Sepct ofa. Fornten sate Conditions for Mining "ML Tes Petree Ra ag Ml cathe eee, proved he decaf cur gama ppd bag prey ena her euapacts Pacha a ree tea, sae anseealta vekvehor parca pr, ‘VE Madea so, Pc a eee 8 ty Su aa er dare agi Bi mae ‘Sas, spec tla el damage, eb aed aneng es tea Harr ee owe ‘or Mou acelal pata fa, paca ha laa ‘Ts aoe ue aa ay 8 tare pega at pa of ec a ga all, ‘Sepacat) na eithe goat ot eaccutae cereaanat of Sec. Any ty acts saat tate oe AOL a ars Cie dest Sue VAL OT, es ier tars Pa tanar scape ery ea wat Escaneado con CamScannerGHH Fahrzeuge GmbH 1.4 Vehicle identification For the specific data of yeur webicie please see of the nameplates shown below. Namoplates ‘The wehice nameptate is iccated in the chiver's compartment. Ail equipmentauch as engine, torque can ‘verter, transmission, axles, etc, have nameptates and may bear stamped equicment numbers. Gt Faneemuge nb SHH se (S851 Gebserichon ‘isc te ‘en of cmatucher Seaine, Fei poms ag rig by Paton 3 and ENGINE NC: Please record here VEHICLE Nr... your weticke. The Sire pressure plateindicates the tine ype ard therelevartipressure ol the fies crithe nespective antes, ; 5 PA lease note here Tie pressure drive rit bar for Gre type: Tee pressure payloadunit .........,.bar for bre type: .. ct your vehicle. Fortes ur tat Escaneado con CamScannerGHH Fahrzeuge GmbH 1.5 Technical Data Main dimensions Lenght ‘Wi at the ve ait ‘With at the bucket Height, athe ckive unit (gabowe criveris cancpyh Bucket capacity (SAE, heared) Weights Beadight Payiaad Fronteande lead, untacen Rsarcanie bad, urtader Fronieande load, laden isaranle baad, laden Tramming capacities \Manirurn trarerning spec tader forward / reverse, on a bowel roaceay Istgear 2nd gear ‘nd gear sath gear IManic ur acmessitie: gradist (Manic urn active Se Fornten sate § 483 con 188m 2640mm 168m 22mm aan 17209 bg 000 kg #880 kg #380 kg 17459 bg 380 kg 4.5emh 23am 15.0 kwh 248 kewh 250% 160 kN DEUTZ reo2013 Water cccled chesal engine 128 KAW29C0 mit” ey ir fier Catabyst sence sa kiwi 2a V5 A comm ea 1d Escaneado con CamScannerGHH Fahrzeuge GmbH Teawal drive unit Torque converter Manufacturer ‘Type Design Power sift transmission Manufacturer Tres ‘Tire filing pressure Fornten sate FAHRZEUG Gare meas C270 singe-stage industria! type with 2uxi- idrrves for steening and dump sist ba beinpteriony Gak seses 22 O00 paver if transmission with 4 forse and 4 reverse gears Kessler DE) PLAC NL rigid planetary ates with differential ger Kessler 081 PLAta NL fighd planetary andes with differential gen 28 00. 281,6 1A RA 2.0 20.1 bor 14.00. 2801,6 TTA Raa 50201 be ea Escaneado con CamScannerGHH Fahrzeuge GmbH Desige oftrake syster ‘Service brake Design ‘Stoonng Besige ‘Steering ange Outer clearance crcie inner Gearance crcte Mydaulie system ‘Ourmpfhosst yea uc system Purp delivery flowrate System pressure Number of hoist cylinder Number of dump cylinder Boom rasing Bucket raising, thom dumping pasion Stosring hydraulic system Purp celtvery flowrate System pressure Nuniter of stsening cinder Electncal equipment Operating weitage Battery Lighting system Main reversing hezelights ‘Adcional hesdigtes Fornten sate FAHRZEUGE ‘Multi disk brake, hypdr. actuated, ext cocled (Mut disk spring rake (SAME) ‘paieelsoiet ydrandic p omer stoerieng 24x 5£102200mm 22202 200mm 20.8440 5 om 190 bar 2 1 Stsec asses 08 on 150 bam aw 2anz wnat an msn aw 14-3 Escaneado con CamScannerGHH Fahrzeuge GmbH Filing wotames Fuel tank Hyraulic tak Engine wit cil fiver ‘Contant ‘Torque conveneripawer shift transmission cincuit From ante cificrential gene Front axie planetary gear Rear ade cities gear sar ade planetary gear Fornten sate att 1801 wal moat zal 16.11 2x621 16.11 2x621 ea 1a Escaneado con CamScannerGHH Fahrzeuge GmbH Dimensions af wabicle Fontan ur 14-8 Escaneado con CamScannerWap eyaquary uUsBunvapuy ayos tuysay 9-31 qua 1ss4aqnq Bunuusueg eee pagneye6 Sas o0z? $908 ¥ Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE ‘Sound-pressure level ‘Ta determine the soundeoressure levelithe vehicle is placed outdcors on a reflecting base. The sound- pressure levels measured in accordance mith DIN 45626 underthe folowing condiSars. The indicated mesuurement values are the average vatues trom thee sound measurements. Note Na relecting chjecis mustite present cn either side af fre venice, Measuring ports - Diagram @ @ Mesnsuring distance Measuring points 1-4 lnteral distance te vehicle = 2.0 m measuring point height = upper edge af drive unit Measuring point 6 measuring point height = height of carvers head Measuring points 7 arc & imeasuning point height = 2 m above upper edge cf drive urit ‘Operating state + senvion Brae actuated = Righest reverse gear engaged + Sor 30 seconds, dining engine at ful lead/and dump het hydrauiie again st fhe stop. \Mesasure ment result Measuring port | 1 z a 4 4 4 ? a cb) a ae a a a ae a a8 Fortes ur 14e Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUG 1.6 Concise description of vehicle ‘The lload haul dumper is a vehicle with suiveljait steering and hydrodynamic drive system, consisting cof the drive unit and payload unit. ‘The deve unitthouses the deve spstem ccmparertts, engine, converter, transmission, 25 well 2s the cil ‘cooler, tanks, hydrautic system components, brates and the electrical equipment, ‘The driven auies are designed as rigid axles with diffrential gear and planetary gears in the axle enc. ‘The driver's cabin weih its controls ardinsiruments is amanged an the lefistiand side of the wehicle, trans ‘verse to the ramming direction. The driver's seat is sprung and hyckaudically cushioned, ‘The vehide is steered by ab ytraubs power stemsing system with one or fino doublewacting steering cyline ders. ‘The service brake and the parking brake actor all fourwheets. The sence brake is executed as 2 hist ‘Growl braking system with a separate Brake circu forthe front ard rear aude, The parking brake spring-achiated brake whose brake circuit wor indepedertty of the service braze, ‘The bucket and boom are linked to fe pay ad urit, The buckets tited forscart and backward by hdrani= ‘cally cperated cumphoes! cylinders. Gentrcllevers in the driver's cain aperate the boar and bucket. ‘The ‘wehicte chasaisis of welded construction, manufectired according ta the applicable DIN standards andthe German Federal Raiheays' DS 882 Cade ea Fornten sate Escaneado con CamScanner E 1sGHH Fahrzeuge GmbH FAHRZEUGE Proper use of L-type toaders powered by diesol enginesietoctric motors (LFotype leaders made by GHM Fahrzsuge Grit which are powered either ty a diesetergine cretectsic motor are suitable for urdergrourdiaacing, having arddumping of minerals ir nenvexplomensharae ous ‘areas and in areas bere ro risk of mine gas formation exists. Proper use means fat the losers are ‘operated exctusivety within speciaihy identtied and demarcated areas of work, ax well a3 inarezsnctac- ‘censitle to unauthorised stall. Leaders must te eperated anly by specialy tained and instructed sia8. ‘The nctes ard techricaldata contained ir the qperaiing and maintenance instructors form fhe tenis for ‘tafe cpematicn of the loader anc are partafthe Cesonpiion for proper use of the loaders. For apphcatiors other than those listed above ardintre operating and maintersnceinstncticrs, the loading andcpersting livits vill imindieidual cases need to be agrend with fre manuiacturer and confirmed by Pam in weiing Fortes ur 18-2 Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 2 Contents “Operation” 2.1 Saaty inetuctions for the operation cf wehbicies made 2tat by GHH Fabrreuge GmbH ‘Safety marking (Sichesheitsbeschilderang) 0.0.0... Growing 908-4064995 Functional marking (Furktiansteschidenng) droning SO8ati08 4998 22 Driver's seat 22.1 Adjustment. : 2241 2:3 Drivers at, operating elements ard comat instr ems 2a Spain are corel eamscert se 2a 24 Checks... viet etee eta seeeneee Bat 3A Ene steding, engine sath Bhat Engine starting Bet Engine snitch se pig eee SPN ete horace 28.2 Autarvatic engine shutctl .. 28-2 26 Tramming operation exh sya oat 2861 Setup 28.1 ‘Ohanging Bre tearwming direction 28.1 ‘Steering contra lever 2801 ints on the torque comestes and power arsmiission 26.2 Teaming on dowrtil sizes 28-3 Dawrhill driving in converter made... 28 ening the wetucle : 28-5 Fling efoace system for toeang of wenice 28-8 2.7 Dumphoist operation 0... 234 Cartref damit quip ent « 2364 Bucket ing ee 2742 Emptying the Suchet cose coeiesssimsermssen eee 2742 28 Winker qperation 28.1 Engine ast Caching system aa Jiirtaie system aa Fuel systere 2a? Pode gem ee 2-2 Hydraulic system . 28-2 Blecinea! syste 28.2 28 Strtdcwn of vehicle 284 ‘Shutoff cf wahidie 2a Stuncown cfvatide ....... 2a Paning verice bacin cpersicn sfersntdown secs... 28-2 210 Loading, attachment parts, transpartabar 2101 Loading, attachment paints 2101 Transportation 2101 Fortes ur ae4 Escaneado con CamScannerGHH Fahrzeuge GmbH 2.1 Safety instructions for the operation of vehicles made by GHH Fahrzeuge GmbH ‘Goneral safoty instructions: lease read these salty instructinrs aswell as the ‘operating instructions carefully before tne first tar fing af the machine and every now and then afher- words Handing of GHH Fatmeuge GmbH wetides and the necessary operating material ix uncomplicated if you as the ower have trained the staff respansi- bble for operation, maintenance and atiendarce accandngiy ‘This survey car, af course, only contain general instructors. Operations! specialities may rset dewjations cr adkdficnal amendments, For thes reason these instructions have fa be studied thos oughly by operators, supervisory staf, mainte: nance staff anc safety speciatists of the comespcre ding plants together and must be adapted anc amended where necessary. Deviations fom these general safety instructions prepared by GHH Fahrreuge Gers are especialy ‘explaines ir the crerating mstrectiors. Wf there are ary uncertainties in understanding these instructions. please da natiresitate fe contact ‘dur senice department (SHH Fahrreuge GmbH: phone +43(0)203 24907 206 fax: +45 (0208 38907-348), lin adeition ta these general safety instructors he ‘special safely instruc refenang fo the operating mode aflengre ard of the weticle are tc be oiser- ‘ved, For afl work comied cut an the vehicle please ‘observe special the safely instructors for maictes ance wot. When operating the velicle the local aaddent pre ‘vention codes are ta be ctserved. The owner anc dimer are respersitle for compliance with such codes. Hinecessary, fhe cumertasto amend such accident (Brevention codes te reflect the bocal cardigans at ‘operaticr. isferring to the conditions af operation, the satety instructors of the comescending employer's litte lity insurance association hare to be observed. ie recommend the owner tainsest on a written car ir- mation fat fe stall has read the cpersting and maintenance insirudicrs, these safetyinatructicns ‘as well as the accdent preverticn codes and the Fornten sate FAHRZEUG additional requtations itch are tabe applied loc Zed tat 8 have been oorwa sctoeinghy 1 addticn to thes stat! members should ahwanys have the above mentioned regulaticns at hardta reseed them Because of he relatvely high noise level ger erally found at alrost all aperating places cf our wehickes caused by surcunding concigons, peroepeve faculty may be reduced. For ts nenson vehicles are to be operated expecially carefully at such pla- Get used to Handling atthe machine arc its control and safety equipment as wellas to oriticaliplaces”. Fiend in operating instructions where these places are and how'they are mare. Before each staring check the vaticte's tuncticrat and operational safety Mf cpereticnat tritures cour fd cul the reason immesdaniely. Came far imene dante remedy af discos wered faults in ander to prevent possibée accident hazends and major damage of fhe wetide oF its systems, In case cf sericus detects (lature offbreke system etc) shut down the vehicle immediately nt the remedy of such 2 tuft is camied aut. Switch aff electrical components where risks have teen dhccuered, especialy fault curert, undue nise intempersture, appearance ofsmoke and elec- tricarcs orwhichhavebecomeinaccessible, interme next supendsor or specialist far electrical equips ment as scori2s possible Suiteh off ce ctrieca equipment which is not atowed tobe cperated ard secure against'staring at least by means of warning signs.in places where those instalistions could be started Furthermore make means fer propuicn or exniral cf sctustors ct remcte controlled smfiches inetlecive. Faulty clectical equipment and operator material may not be stanec or ued betore bang repaired. Maite sure that nobacy without spacial knowledge vil ewer cperate, maintain, repair or ciherwise hands the machine Before leaning the drivers compartment abwxys appiyparking brawe. Pak the vehicle af 2 piace wit plane surface mittout descent and witicut disture king ofher operations. Never alowihe engines! the machine mn unatien- ded ea Escaneado con CamScanner atedGHH Fahrzeuge GmbH ‘The chiver's undivided atiertion i necessary for ‘optimal warkingresits andreiatle operator of fe machine. For this reaser never slow persons te ‘operate the machine whaze reacSuity is reduced The influence of alcchdic beweages, medcines andather agents will reduce capability to react a5 ‘well a3 oversredness will co and tus the risk af acodents wil imerease Abua ys maintain themachine intechnicaly futons ‘candiion = terauiicin evel efepereirg matin, coe gears, andes, oxriverters, brake Stns bptouiearel aamcaion ccpapess so alsin cotieg cnc. ‘Undue modifications and insu ficient maintenance ‘will mpair the machine's function, operation safety andserfosatle like For thes reason care for come ppltnce win required maintenant ard inspection itervats. ifycurvannt to camry out technical modifica fans of the machine, please contact GHH Fahr- -reuge GmbH in any case in aduance The machine is equipped with waming signs or ‘euipment af speciic places of danger, Take care fier proper condifian of this warming squioment mace een case of darrage crillegibie ‘Tasee special care af the proper conciar cf afl pro- tection and safety equipment cn the machine. De nt remove and repiace immediately ir case af damage ‘Safety equipment and protectin 2nd control instal- lations cf the wehicke necessary far safety may nat bbe made inetiectve nor unduly adjusted ar crodie ‘Tate care mat parts fhe body. chores. witnat center dangerarea ofmeving parts. 7 mabe use of acdticnal personal pro- ection dcthes (protection relmet, protecacn gias- ‘sen, car protection, protectan shoes etc) IMain tain your driver's carepuatiment clear, dry and ear. Keep all perscre not nected for the warking pro- (cess away from the machine when operating When qperafing the machine take care that nobody andincthing is i its range cf action (driving ways, ofmerahes and sinene sina cme chareas aahihgh ange? te). T sf crushing Fornten sate FAHRZEUGE War people in ange of danger with the hom. Stop morking, # pecple co not leave danger area in sei: ef waming. Newer stay below ltted and unsecured Jaats or machine parts, For climbing up anc down use handles and meas. Darctgive peopte itton hemachinecradkddicrst equpmertif tere ira dewce especaaly designed Purpose by the manufacturer. Keep all the wehicle clean fer ditt, residual ai, utreart, fuel and, if necessary, from srawcand ioe etc. especialy treads, plationns, actuation places, (glass panes etc, (Only operate contrcis in criver's compartment fram dnrver's set. Only operate the machine within the load lite (giver by the manufacturer Undue avertaading il reduce the operating safely and senaos lide cfthe machine. (Bo not soc of the webice inne dia ely after high oad butllet tide tora certain sme if possible, £2 that the terrperature of systems ard components can be compensated. 0 of the complete machine or single devices thereof may lead to damage and reductan of ser twice Be and means in any case: loss cf warranty claims arc raise of risk of zecidents. Take special care of appropriate speed witen di teing arcondbends. Besides tis, amas adhust pour ‘driving speed te surrounding conditions. esceciay to suriace concitions When dinang around tends, avo! high socelers- ficn acd wiskert steering movements wbach ray ead to ety sliding, reduction oristanility, anc ever todamage. Take care for sufficient carrying capacity cithe sub- structing, especially cn bridges, waufts, and wher Passing aver tubes placed urderthe travel wary arc devin in areas wich are laterally declining, Before using the machine, check is fitness for use especialy af working places previously uninoen, ‘Alnays heep emergency call equiprent.and emer. gency materia (frst box, fie extinguishing equipment, etc.) ready for use in your immediate weirtty (Only authorized people may operate. use, andact- uate ee Gincal ristalaicns and comesparding opes rafing rratienal Aa for as waming signs anetixed or cases ct elects cal mstalaiors, their ules are tabe observed. ea Escaneado con CamScanner atkGHH Fahrzeuge GmbH When toning another wehide please tke care of the specislinstrackons in the operating instructions oftotn vehides fe.g. hycrostatics, brake, etc) anc ‘Sutra lov snare Take cae of persion ed fo ent, Take care of fhe roquned higher brake poston ance cf fie toning ‘vehide, ‘on decining ways with braker deve Brake systers of fhe towed vehicle. ‘Only we crignal additional carts and spare parts hom GHH Fabreuge GmbH and lubricants and Fornten sate FAHRZEUGE u process materials authorized by GHH Fahromuge ath tsmarton ae operabar Acti and aes Atay of your machine GHH Fahreeuge GmbH is not responsible for Gamage ciused fy instalation or applicator cf “equiislent’ parts af another engin. See po co be pik el hem cor semen tepartmert (GHH Fabmeeuge GmbH; phone Scogeyaon San occa seSpyane S807 45) Let at. Escaneado con CamScannerGHH Fahrzeuge GmbH ‘Special satety instructions for combustion ‘engines: Eshaust gases fem combustion engines are toric! Forhisreason do orhyaperatecombustanengines in places with sufiiert fresh sir, Observe reguia- fans for instaison and operation af engines in do Fornten sate FAHRZEUGE sed roams. Take care of suffciest werilation ard suction andexiracton ordeaning of gases. When nefifing the machine, sudich off engine and hesing, co nat srrase, avaid cpen flames or sout- ces of sparks or heat nearty. Switch aff electrical instalation. lemcve spilled fuel immediately. Ontyuse specified, unpollutedard antydraustusts. Let at. Escaneado con CamScannerGHH Fahrzeuge GmbH imstructions for miming and les: stb a hey hao iid Sir sine Gp loopy dbtiec BU geal safety instructors as well as the sate tyinstrucicns: ‘which come spond to aperating mode of fhe engine. pene es sew eee een aay Sects Drive up ascents uptil if possitle and aeckd drning feanserely © the slope wr crcer © 2vod sipping and averuring of the machine. ‘Take care that the acknissitle bareswerse ard longie tudinal indinzticn cf the machine vail nate excze ded ‘Abwa ys maintain safety distances te stockpiles pits, etc Pay stienan te the condiion of stope faces and especialy afterbooks andpossible danger caused by falling or breaking rocks Maintain travelsans as plane ard boulderless. as pessite, Infom yourself about locations ofl dangerous and ‘endangering instaltaions in your working area, 25 for exemple high-veltage cables. pipework, eecin- oy ra, ote ‘Care for tac high water levels being pumped aut. |Whendenving uphifand downhill care for areascna bble selection cf gear respectively speed and thus acid superfluous rises of acciderts, camage yawere hewing, and wear gut afbrates ard rhing comzo- nents, Toahigh gears may overstrein drive systers (ite, nanos, deine) Tao gt gems during dowrtill diving require excessive use cflbrae lees, Too high gearsduring uphid criving, expeciaty ‘wilh igh loading, resuitin an excessive rise cftem = perature ofdming compcnents. Forthesmeason pay ‘atfentan to terepesafture incboatars ard select ext bower gear, ifnmecessary. ‘Camry cut transportjourneys onty in transpartmade, iz, mth completely lowered bodybocm retracted bucket, Sore, te piles in body cr bucket aretco steep, this mayllead fi falingcut of rocks or corweyed= aerial ard thus Fornten sate ea FAHRZEUGE increase the risk of accidents ard danger of tire damage caused by urrew=n trawehaa ys Hinecersary, secure your load so that uncontrolled siding and connected risks cf accidents ¢lsiling down offload, tumover of the wehide, etc} 25 veel as shiing of fe conte cf gravity wall be avciced, Ensure sutfdent height in fhe dumping place sc that crashing of bed, bucket cr dum pinctstlinkage agans! fhe rocf ail be awoided ‘titer dumping dda ct leave the dumping place before bucket fork andior body ane Brough intz ‘rarspertaticn pasion again. Working places with special dangers, e.g. caused by tilling artices, nequire special salty measures a5 eg. remote control for unmanned cperaticn ct the machine When wotking under ited kody, Bucket or fork, always apely Safety belts or supports prowded for safety. Safety bots are located in the area ol! ody or boore bearing. Hinecessaryaapplythesaive amesterscfthe saved hinge to reduce danger cf crushing. Svvel ares Ses ave prowaded arth area cf fre sel Rng Park the machine fully ucswiveBed in straights ahepd positicr, preferably cr plane surfaces with cul slopes. Vihen standing on slopes, alvenys park the machine in a manner such fhatuncontroled nl- fing wall be avoided ewer if holding devices are loos sered unintentionally (e.g.. wit the sive of the wehicle fern the Grver's cat sunelled towards the material face) Beforelenvingthe machine apoly parkinglbrate ard snitch cif engne, In addition ta tres make sure tt Lnauthcrized operation wil be impassitie, ¢.g. by igrifon key. Wher leaving loaders for a longtime, put bucket cr fork ta the ground and in addiicn tc fis secure against mling (eg. put necks in trant of whects) Seeure yeur parked vehide especialy st Bind pis. ces with much tratic cptically to avcid accents 2g. cashes, For decinically operated machines cbserve corres- ponding safety instructions Escaneado con CamScanner ate8GHH Fahrzeuge GmbH ‘Special salety instructions for LF type loaders It posaitle, camy our loacing crty with 2 complctety sketched machine. Viitt suivelled machine, wor. angers ul bs reduced and the risk of ic gal Fay abertion especially during loading, tor sliding and tslin grocks orboaded ma terial from the lasting place 25 weil as from the bucket ‘Camry out loacing princaty with lowered ting ‘equipment and lowered bucket Dang thes yeu wil wold fhe nei of tacts falling trem fhe bucket arte the dhiver's cam partment [Emptying the loading place tram sites cere wl avoid mteral siding of Inading mateal ta fhe Fornten sate FAHRZEUGE machine, which coud encutiber the wheels ard ould ining you closer fo the dangerous area. Empty the loading place as continucusty 25 possi Ble ard witha straight front so fat acing material may slide doar sicwly and cartirucushy Hipassitle, execute dumping only at pisces without transverse indinafon and with a stretched machine. ‘Wh raised bacr avoid high acosteration and deceleration by starfng and braking as wells Wwolert steering movements. if thene insamuciores are notabserved, stabilty can olanger be guaran- food sger of eg fot ade ot wf this, danger caused ty leading materia fling dome from the bucket will increase Let ate Escaneado con CamScanner10 1 6,7,8,9,19 5 141617 3 Fasten 8B] seat beit! ‘Staying in danger area of vehicle is forbidden ! 1 [Gar 15 ar 13 auf] 2 1) artneen ae Wp, Legato her OF catia Lr@aSiCHE.cOR| a z Featl a (2 geinaer aaa ie bec variant [Bena | Anzant ‘at dor Arcenang, Tag BeatiGerr [CAD-Zeichnun ToingeNed Emetinges [Werte uLAba ON 716) rite doer im Gren DIN ISG 1307 Typ LF-8.3 ates ohne: [Geach GEWICHT kg | TA. Ori FAHRZEUGE IHEZ S08 EZ ES ema ist | eng —=§ ——1® jerening SICHERHEITSBESCHILDERUNG in englincher Spracke 7 909-4-064995A [|] Escaneado con CamScanner4 [HYORAULIC On| 5 [DIESEL FUEL 8 Aor] 11 7 [=] 8 [ces] soeouer os 9 [=a] ‘AC TYPENNEU_2010:.COR wnisw 10 E:SYSTUENLCOR wale 4+ FLUIDECOR wise 6. Mi: SYSTUEB1COR weirw ‘1: FILTMINWCOR welew 12 ng Ase luau nse Y Uré3FUNKE.COR ——— [can Temegitcdinptinges [wemaiom Tuas: ON 7160 - el Mociesehc estar oper DIN 1S 1302 iy tF-8.3 ‘fieadetas kg | ez 908 luez i [isiwedingabeseich lNenesnang FUNKTIONSBESCHILDERUNG. oHH in englischer Sprache FAHRZEUGE —[eichrungedir x 909-4-064996 TZ 909-4-0533 Es. far Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 2.2 Driver's seat ‘The driver's cab is equipped wilt « mech arscally suspended driver's seat. To prevertihealth damage, the driver's seat omust be adjusted tc the ditver's body Eelore stasting the wehbde, ‘Theeestraintbelt mustbbe usec atalltimes, The belt stouidbe mam sight as passe tothe body. ater can zocident the restraint belt must ibe replaced and the diver's seat and the festering cf the chiver's seat inspected by qualited personnel. 1 Lever for backnest adjustment 2 Lever for height and it adjuster ent 2 Marduieel for seting the weight 4 Lever for horizontal adjustment Fortes ur aae4 sate Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 2.3 Driver's cab, operating elements and control instruments AIL he instruments ard contra instruments necessary fo eperaie the vehicle are amanged in the cbiver's ‘cab, The speed adjustmert ofthe dining engine ard therefore the adjustment of the driving speed is of flected via the night-hand pedal and the operation of he service trae via the leftard pedal. The gearshi mechanism is operated wiih the lever Sd in the middle ef feinstrumert bax. To the left ofthes lever sts fhe stenang lever. The levers for operating the bacm and fre Eucke! are located in the driver's cak te fe right of the insinemert box. The dining engine is stopped via the twist suiich S84 "kotor Start Ming" ‘Operating and contro! instruments 4 aged Fornten Escaneado con CamScannerGHH Fahrzeuge GmbH + kinetin disp MED The MED is a display system with indicator messages. ts soar as an alamn lewelis Getected in ane of the systems, fe inccmect wave is autor aticay faded in the display anc indscated addtional by a warring light, NOTICE ‘Ateach fault indication sepert ta Maintenance and deterrtine the cause. Symbols of the operating display [Atiemuaticr charge contrcl Goes cut when three-phase stematcr and controller are working. [Lights up during operation in cme ofa detect in fhe generator ar charging circu Terminate the operation as quicsly 25 possible and snitch of the engine Parking brake cict release [Lights up when the parking brake is applied or is rot fuby released. it goes cut 2s soar as fhe parking brake ts lly released. [Service brake [Lights up mhen the sencice brake ts activated or when your foot rests lightly on the oraice pects. Myarads a level Lights up ifthe ai level inthe hydauiic oil reserwcir Graps below minimum, /Chvsck mycrauic system for lezks, thn visible leaks are preser, Sepp oll to fhe maxx mark on the cillevel indicator. In case of visible leaks, stom the operation Fortes ur 24-2 Escaneado con CamScannerGHH Fahrzeuge GmbH nm A x) a iN mi ei a mi Symbols of the operating displsy ES: temperature Step fhe veticle, shit fre ransrisaion to newtal position, briny allow fhe engine ta un aticle without lear, ard abserve the tersperature incicator in the graphic display. tthe temperature increases, saiich off the engine immediately. if Be temperature decreazes afow fe engine ts keep runing. Operaicn ft excessively igh coclart ier parature resus in engine camage. [Ergine ail pressure ire penne reached. The engine output is reduced by appro. 20% cf the rated outzurt, Sturt ctf fengine immediately a3 scon.as the signal larg lights. [Engine Giterperatire Lights up when tre engine ol temperature is too high. ais Lights up when the engine cl has fallen below the sirimusn level. The errine cil Revel, haweves, is cry monhared when the engine is standing stil ard the operating fucitage suitchod on. Check engine forleaks. Hna viitle leak fase of ei) i present op up cilte the max, mars an the cil digstick. tn case cf visbte leas, ston lapersticn Diagnosis aa Lights up mhen the engine monfioning system (EMS) has detected deviations from the detauit engine cperating data. Is used ia indicate the fault messages that are [stored in the engine cingnesis system. See DEUTZ &imetonal descripicn of elecioric engine monitoring apstemn (EMS), Terminate the cperaticn 25 quicily 25, pessibte and switch aff the engine. ae Filter [Lights up when the air fer diferemtial pressure at an engine speed cf<00rpm Jexceeds the admissible value, Replace fier insert in the air siter. [Lights up tec, when the sevice hours forthe nest engine maintenance have been reached fapticr all, Ta reset the mdicatar. see DEUTZ Functional Description cf the Blectroric Engine Moritosing Sistem (EMIS). Codartievs Lights up when the codtantin the engine cooling circuit has fallen below the minimum level. Stop the engine, stow cooling gyster ta cocldown and check for Reales. If no waite leak is presertt, top up coolant fo the man. rack crithe expansion fark. tn case of visible leaks, stop operation Preheat inckcator Goes cut when the engine i pretest, Fontan ur aa-43 Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Symbols of the operating displsy CAN-Bus Exar Beach cients graanganages Terminate the cperation as quickly 25 pesaible and swatch of the engine Aruadable brake pressure indicator incicates the aveilobie pressure of the brave system I the available brake pressure craps below 100 bar, stop wehicle immediatoly, [apply parking brake ard stag operation, Mushrecm pushbutton emengenay OFF i released [Depressing the pushbumcn in an emergency switches cifte diesel engine and lactuates the parking brake. To release, pull out the pustbutten and press the Flenet Button emnergency-SFE. tsee belo) =: emengency-OFF Press tis button tc reset te emengency-CFF functions. The emergencwOFF sign goes cut Brae reserves pressure iste how Operation wihaut cooing of the brates, ard waiout an assured gag cf the brake disks! Corweter ol temperatone Lights up when tre converter oll temperature fises abave | 20% [Step wehiole, shift gear inc neutral and let fhe engine ile briefly at no toad. tr the muliturcion cksplay, maricr the “converter ci temperature” incicatan. Whe terpersnure tises, stop the engine immediately; if © terpercture fas, let the fengine confirwe fo run. If necessary, check the crvertentrarescrssion cil level Drive tne vehicle with less corwerter sip. Transmession chiich pressure Tesminats the operation as quicsly 25 possible ard snitch offte engine [Retum pressure titer [Lights up mhen the retum pressure rises above 1 3 bar, replace regu iter of hycraubc ofl rexervcir. high bear igre up ifthe high beam is on licw Beam Lights up ifthe tew'beam is on. Emer Steesing system Lights up when an emar in te stecring system has detected .fe 9. steering watve or Joysck). Terminate the operation as quickly as possible ard switch af the ange Fontan ur aa-4 Escaneado con CamScannerGHH Fahrzeuge GmbH nm A x) a iN mi ei a mi [Symbols of the operating displsy Tarik tved| Indicate if fuel seserve has been reached The resadual query is 2pproxmmately 10% afithe fuel quamity. [Cckart temperature Lights up when the coctant temperature in the cating crcuft cf me engine exceeds. ihe admissible value. The engee outputis reduced Ey appra. 30% cf the rated Jauiput. Stop wehiche, shift gear into neutral and bet the engine ile Erithy witout Road in the multifunction dsptay, canitar fie “coolant temperature" indication. tf the terepersnure rises, stop the engine immediately; ifthe terpersture fas, let the Jengine contiwe to run. Opereticn at too nigh a coer temperate will cause damage ta the engine [Date and time adjustment Press tes button te set fre date and the time Service Press mis button tc get ints the service ment, taming [Lights up in aciisian with 2 tat indication in the Disptay. Checc the respective: jcomponents and repair / nepiace them [Emer [Lights up in addin with ar emorinchoaticn in the Display. Terminate the operation as quickly as possible and switch off the engine. Ring butler error messages and warring messages ‘Ths eror-and warming messages arestored in aringtutler. Tadispay the specitc messages, i thefuno- fan mer "Service" call up the “Messages” screen. (Gc are step left, in te service main menue) The ast message wil be Gisplayed in the screen. The cther stored messages will be crlled up bry actnating the LAST ct NEXT" buttons on the soren Eq MEMORY [Main | >| # 03-821 temperature hydraulic oll Date: 2014-05-13-09- 16-47. jengine hours: 132 Waring «Ear messages are safety.rolevant. ‘Stop the veinicie immediately and follow the handling instruct oer Init ate appropriate measures! Fontan ur 24-8 Escaneado con CamScannerGHH Fahrzeuge GmbH PM SH S44 S721 Sm2 Sat Fornten ea aa-6 Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Note ‘The abbreviations used are: (OT = push ution, ML = sagnal lamp, ST = ccnfrcl switch, ‘SH = dst switch, SL = koey switch, AN'= analog incicatcr [Warming At each fault indicabon report ta lilaintenance and determine the ciuse. een Descxigian (AN Bervolutions counter ‘An engine speed cf2¢#0+40 min must never te exossded. (ADI dwaitathe brave presume indicator ingicates the 2wailatie brace pressure in the brake circuit cf te service and parking brake, ifthe avaitsbee brase pressure drops betow 100 bat, stop vehicle immadia- fly. arply rating brace ard stan operation. Ka hkl uncon disptay MED P12 MU avaiable braking pressure Lights up ifthe avaiatte brake pressure drops fa less than 101 bar. ‘Stop vebicie immediately. arply carking brake and stop operon, PE Mit Fatt Pee ML Warning ene Pressure gauge ight. su OT Emergency pump sa Lever brake ‘Serves to release orto apply the paving broice, release amcwe to upper posiicn acply -mcve talawer poxisar sas ‘Ger switch ste ‘SLignisortstarter owtch Turing pasigen'@: OFF Tees gata S08 BT engine startstog sts ‘SL Radke remote conral farticr smd ‘SK light front eued tc switch on the tart headlamps and material face lighting. sn ‘SH light wear 1s used te switch on fhe tear headiamps and material face ighting sm ‘SK Rictating beacan (option) sma Panel air conxdiicn (eption) sac SK Flecelights Fortes ur 24-7 Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE tern Descigtan sa ‘ST stessing jeystick su Bosom 1 bucket joystick set ‘SK Windsoren wipentwasher su Mushroom pushbutton emengency OFF for the cider for the cabin protection) Depressing the pustitution in an emerpency switches ofthe chesel engine and actus aes the parking brake. To release, pull cut Ee p S882u. 982 Mushroom pusttoutton emengency OFF for tre right and lethare side on fhe engine part) Pressing this pushtutior in adanger stuator fe. woh is aling rss ar tice) causes te ciaal engine and he ‘peraiing valiage ta be caffard the packing brake to be applied. To urilock, pull cuf the pushbutton ea aa.a Fornten sate Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 2.3.1 Radio remote control (option) For further infommatians se= manuel in the appencia, ‘The radio nemete control system consists ot a Battery operated portable transmitter with timo replaceable btiies, 8 a receiver maurted an tte left foritcfthe tender af the engine comparis ent and twa rod antennas mounted onthe instrument pans ua changer for charging the batteries, Transmitior Fontan ur aad Escaneado con CamScannerGHH Fahrzeuge GmbH iy ‘ten Cescnptar at CheceLED functional merigosing st ey Rartemitter ONIGEE SZ Mushroom pushoutton STOP transmitter release and switch=at st Pushbutton system ON F hom Sa ST Speed adjustment, drivingssteesing, release service brake St ‘ST Boom-buctet st Teggle eaitich parking baie, apely /release st Pushbutton rete ase parking brave su Toggle eaitch engine starting J saitch-oft se Pushbutton avtomatic fre extinguishing syst Technical Data ‘Transeitier “Typ at protection Pas ‘Service temperaure 20 bis 400°C Voltage supply 12° 600 mAb replaceable accu ‘Senice lite cf accumutstorer appr. han confrmaus operation Fontan ur 241-2 Escaneado con CamScannerGHH Fahrzeuge GmbH ‘Teanseritter powes ‘STAND-BY automatic isceiver ‘Typ at protection ‘Service temperaure ‘Weltage supehy ‘Ouiput darvernetams: © 12x FAHRZEUGE an appt. after four minutes Pes -20bis 480°C operating voltage 24 OC sominal woltage 2VDE ‘saiiched curent 2a ‘Output criver ansiog: teay.1eV0C 2e-10V-0V-+10V0C tx-8v OV. 410¥ 0G te The fined camier frequency of fie transmnifier and recehes is indicated or the names piste ‘Charging device Mains veltage 220-20 v- ‘Typatpretecion Pas ‘Acoumulatoren te 12 Vreplaceabie accu ‘Capacity 00 mah Permissible senice temperature 120.60°C. Fornten sate 231-3 Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Remote cantral mode In remote control mode, the wehidte is deiven ont in 1 gear, Caution —_inremete conmot mode, the driver must have constant visual contact'with the vericle (Caution — an areas ofthe company gecunds that are intended ternegular trai, tre vehicle must rat be operated in remote cominal mode ‘Switching ta radio contral mode Nate ‘Suatichang te rade Control mode is alsa possible when the engine is rurring = Emengency stzp swfiches in the driver's cat and onthe rear cf the vehade (SS8/1-2) ane released 1 Saiiching cn the operating wattage + Stith gear lever ($4) to neutal pasiicn. Apply the parking brake: (E43) ‘= nsert key in key sraitch (S62) ard tum tc positicn “Radia nemete conteal ON". ‘Sigal larng (2) ) lights up = All;contral elements cn trartifer in zero position, i. not activated. = On transmiter, insert key (51). + Unlock the transmitter by pulling the STOP muster pushbutton Note nat al elements are in zene position, an audible signal sounds and te indicater LED Saahes, Unlocking cf the transmitter is indicated by the lighting of the indicator LED ¢H1). «Unlock the mecniver by pressing the pushbutton (3) “Syste ON | hon" Atereach EMERGENCY ‘STOP or interruption af the radio link, again uricck the receiver with te gushbution (53) Note Each time receiver uricokec, the ham souncs bristly. [Warming Ar aucible signal and capid fasting of the indicator LED inchcates fal the battery is aimast er pty and the system wil autarcaically saitch of alter 10 seconds Waring the device is nat switched alfalier automatic sudicholf of fre karsciBer due to low batterycharge, deepidischarge cle ceils ren becomesunawadatie Deep discharge can rent ir damaged cr cefectve calls, ea Fornten sate aad Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Engine staring te reheating the diesel engine wih the radio remote contral is not possible, Theretcre, fhe deve engne must be af aperaing fem perafure before sechng te remcte conta mode 1 Startengre by moving the toggle seaich (S8} upwards, = Apsoon as the engine is rurring, refeaze the tagge switch, Engine switchoott = Settcontel switch (£4) te neutral pesiion = Appty parking brake by moving the toggle smitch (58) upwards. = Sitch of engine by meving the togute switch (SH) dowrreards. + Saitch offtrarsmitier ty pressing the STOP mushroom pushbutier (S2} and pulling #ekey (S1)aut. Waring Neverleave tre tarmmitier uraiterded ard alaayssuitchitetlduring breaks and wher leaving the work site, Remove theleey ofthe key switch (S53) in the driver's cab as pac against unauthorised use. ‘STANDCBY mode: tne commands executed on the transmifter fora peice cfazprex. 4 minvtes,the transrviter wl gainto ‘energy saving mace. Thismade indicated by an inehostor fa ing af Sseeirtervaks and am audible wae. ing signal every 20 sec. tthe transmitter goes ints STANOABY made, the diving engine is automatically suiiched of, (Cancel STANDABY made + Press the pushbumcn (83) “System ON i hart + Move toggle suiich (SR) denenamds, ic fhe cfracian of Engne OFF. = Startengre agsic by maxing the toggle suitch (Si) upacres Activating the fire extinguishing system he fe exingushing system = The acivabon cecal ofthe fre exingusting system which i ‘assigned to fhe “Aufreatic” lighted pushbuticn, i evemidden by bath pushbuttons (25). As a result itis ‘also possible be activate an extinguishing uit via the radio nemcbe cart ‘The extinguishing unit is activated when totn pushbutton ($2) are pressed simultaneously Ware the extinguisting was aleady aclwvated via the "Automatic" ighted pushbuftion in the = sua ad bs can hs tot ccn meena pot re freeextinguishing achoricar bbe iebisted via the racko remote control Fontan ur 241-8 Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Sriving operation ‘Control of the farwardineverse and leftright driving direction is by means of the contrcl switch (54), the ane ef fhe saitch is proportional te the speed cfthe dming or steering mavementic fe furtherthe corral swiéch ism ovedavay fromnits central position, the fasterthe required driving orsteening ‘operation is camied out Release parking brake tyrm oving the toggle saiich (S6}domneands and simultaneously pressing the push ikumton (57). = Move contrel itch (54) into the desired driving direction unl the engine speed moreates. Then, to release the parking brake, breddy press dew the lewerand further move the contol saiich accarderg to the tuncticn to Ee camied cut. -G. vie — eg fig.t [Garirel seth tar Furdioniranning Grecian we eamesing ebrectan Fig. 1 [eve downward Eachaard bamming drecion | posison | eve tupware's Sernare framing directan Fenition 2 ence abt steering eft position 3 ence ta right teeing right Position 4 lapring-centered middle position and the service brake applied Fosition ewer nat pressed dawn lpness. down the ewer release service brake Fortes ur 24 Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE ‘Changing the dawing direction = Mowe contral switch (4) inte its mike position Wait forthe wetide ta stop, Mowe contral switch {84} ina onpesite driving direction unl the engine speed increases. Then, to m= lease the service brat, brietly depress the lever and furthermave the cortrel switch acconting te the SuncSan tate cared aut Note ‘When suitching rectly am ane driving drecton tc another, the serdoe brats is ap- lied and the gear shill mechanism putas neviral pasion, Sumpiaist operation The boom and tucket operations are controled by the contra switch (SS). The stroke of the control switch is prapertianal tc the speed at which the dump dnoist operation is peor medi. thefurtherthe control saiich ts shifted ou from its middle positon, the faster the desired bors! bucket qperaton is performed {ue {og tog {oe atk 2 [Conard switch for Effet ee lbccrmtucket Ecomfeucket Fig.2 Jmewe downwards bucked Gited back positon 1 Jc we UPVC bucket timed forward position 2 Jenciwe to ett com kwerec Fosison 3 lmmewe fa ight com ramsed posifion 4 |sonrg-cerberee mickdle pcatbon boom / bucket hele in positier | posifion 6 Fortes ia 23 Escaneado con CamScannerGHH Fahrzeuge GmbH ‘Switching ta driver's cab operation = Mowe contral switch (4) inte its mike position Sophy parking trake by mening the toggle saitch (8) upwards. = Seitch of engine by moving fhe toggle witch (SH) daversards. Shaich off transmitter by pressing the STOP musteacm pushbutton ($2) and remowe the key (51) Turn the heyin key sodtch (SAS)in the divar's cabto gestion "Radionemote contra! OFF" and remove the key. Signal tara (F21) goes out (Brake ! fault lamp ved vearring lamp (648) cn the rearlett of the wehicle mar ecd lights steady when the parking brace i appted, lin radia remote contel mode, wher the parking brake is released, the warring lamp dashes to incicate ‘a vehicle maliunction, inthis casa, carefully chive the vaticiairta an accessible area, mutch ofthe trans. iitter and rese cut fe mslfuratien im fhe eab, Fortes ur 241-8 suse Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Ropiace battery [Waring Rleplace battery only when the ranriter is switched cif = Saitch off mansmitter by pressing the STOP mushrocm pushbutton (£2) and remove the ey ¢S1) = Sightly tt cover of battery compartment and remove battery by the handle, = insert new bamery. Note (Make sure thet fre battery chcks wits place ar exnpy battery is inserted, this i mchcated by Se fashing indicator LED, Recharging battery Recharging sheulcbe caried cutata rocm temperature of 18e0 20°C. At wery how temperatures. akonger time is required for com peste recharging. Note (Use ir stone the Battery changer arly ina dry roam and newer ouldcars, Ta awaid heat ‘accumulation, the Eatiery charger must rat be covered = GCommectbatiery charger toa 220-220 secketoutletandinerta battery in the charger carspartmert. + TheindicaterLEDin the batery charyerindicates that the battery is being changed. Recharging takes appraa. 14 baurs. Note Please note that the full battery capacity can only be sel ater 2 number af changing ycies. [Waring __Dielociive battesies must notbe openedby force or bumed, but must disposed clin ace ‘cordance with local regutatians Fortes ur 24 suse Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 24 Checks Before daily eperaticn for reasons of solely ard reliability ofthe vehicle pericrm the felloning checks: = Engine ofl ewe «© Corverter and transmission oil ewes = Cillewelin mydrantic tari Tightress af all components and systems = Maintertance inicatr of cry aie ters Tre pressure and conden Function of brake Function of steering Function of lighting = Function ef bucket:and becm, ratsingilewering Funcion ctindcator controls and sign lamps cre ‘Al maintenance work an the vehicte trarne, sub-assembes and systems shailite car- fied cut in accordance with the checklists im section 3.4 Daily checks after operation: + Lawes work equipment Park wehicle on allewel, dry suriace, cample tly leweiled. On orackeris, park with the side ofthe wehile amway from the driver's cab, siveliad towards the material face. + Aga nde, the parting brake applies via fhe ‘parking braive" cortiral lever (S43). ‘Set afl contol bevers to neutral position Deactivate battery switch «Protect wehidle against unauthorized use = Gear vehicle (Check vehicle tor enteral damage, loose belts, ef Fornten Lea sate ade Escaneado con CamScannerGHH Fahrzeuge GmbH 2.5 Engine starting, engine switch-off Engine starting Tum on battery suitch. = sert fey in ignnition / starter snitch and tum ‘ta positiar Power ON". Selease emergency OFF (SAN jn divers cab ‘ne (35412) nd (SHAE) ne gene ‘Shift gear jeystick ta neutral positicn (As soon as the engine isrurring.release the igriticn Jstarter switch and ease back the spesd adstmert pedal such an extent that the engine nuns smoothly at rreckum speed. [Warning Dc notstattlorger than 20 seconds; peat the staring sequence # necessary Leave 2 one-rrarnte between twa staring sequences. If fe engme has nct started after fwe staring sequences, infarn maritenance and determine the cause. Theta engine should not be operated at high speeds. ce Inthe evertof faults see the engine cperating instructions andthe azpertaining sections of there operating instructions. Fortes ur 2a Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Engine swich-otf (Caution —Theparkingbrake isnot agpbed automaticaly when switching alithe engine tis here: fore impertart io apply the patking brake manually via the contre lever to aacure the ‘vehicde against ring away. u Setlengine speed te idling + Putlthe gear shit (S44) in neutral pasion and disconnect all cemumers. ply the parking brake, press the “parking brake” pushbutton = Tum the ignition start switch (984) ta position OFF" and remave the key. The criving engine anc the ‘operating vltage wil be ssefiched off Turn offignaticn and veihiéra key. = Deactivate the battery snitch. Note Unless theme is an emergency, do not swiich cif engire sudderty from fulllaad Allow engine ta cooldown Ey runring ita idling spreed for afew mites, Warming iiduring operation the indicator in the multifunction display indicates toc tow a'vehide ‘voltage, switch off all consumers that are not sticty necessary, enc the operation as soon 23 possible and seiich olf the engine, Wher trohigh 2 wehide valtage isitisplayed, stop the driving engine and switch offthe ‘rehide woliage. Stzp the aperaton ea Fornten sate Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 2.6 Tramming operation [Caution Tre wehicie's steanng system is inoperative when fe engine has been stopped ‘Start-up = Setigear shift mechanism to neutral pasiticn. « Statengre. = Settengine speed te icing Engage first gear. Release parking brake ((fihen the patting raise has bon fully relensed, the sigraliamp goes out) = Incrense fhe engine speed. ‘Changing the tramming direction. Apply service brace to brake tne loader to stands, Keep reraos brave pedal depressed. © Set gear shilt mech anisrr to neutral pasiicn. = Engage fest gear of cppasite tramming dinecticn + Release service brake. ‘Stenting control iever The steering is controled via the left jopstick lever Pressing the joystick forward (1) the lander escwesty fiorecard runring ta the night. By pulling the joystick (2) tte baader meves to the lef The travel of tre joystick lever is proportion alta the speed ofithe steering movement, ie. the taeteritte cperating lever is moved avary from its certrat positon, the faster the steering mover entis camied aut When the levers retumed ta ts spang-centred central pasifian, the steering angie is mantainec Fontan ur 2a Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE ints on the tarque converter and power transmission ‘The torque convener acts as 2 hydraulic connection of the engine and power shift transmission. ‘Since improper converter cperation may lead tt unnecessary healinque atthe converter transmission ‘system, the tilowing shauld ke observed: = Abvarys startin frst gear. 1 Utiize all gears ta shiting point ‘The point for changing fo a higher gearhias been reached if, i fl throttle position, the speeds iste below ant reached he inhcdval gear stops. . a Point tor changing: 12 pear 2 ort ger tat goa 22 kmh 68 koh 11 nt + ifthe system is excessively loaded, change tc alower gear. ‘The peint for changing ta.a lower gear has Benn reached i, in full tre Ble positon, the speeds ited! below are reached in the indrédual gear steps. Bort for charging: yt gear igo mo 11 0h 65 em 12k Waring the speedsin the indhidual gear steps fall below the rirircum walues epeciied fox fie charg paint, Rin wliconse xaoansies hesing Wiha aires hlatrctomain clcall and consequently cause damage tc the carvener and the rarsminsion. + accordance with te shiting paints tor shiting down, fe ellawing gradient ranges car be travelled ine indhadual gear steps: see annex, gradeeatiity ciagrar "EOS:Sk6 50530 14", page 3) gear 2 gear 2 gear ah gear 25% oe 2h Nee ee OK «the laader should be braked cr stopped ta standsill by changing te 2 lamer gear, the paint forchane ging tt a lower gemr is at an engine speed af < 800 mir! Fontan ur 24-2 Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Tramming an downhill stopes ‘Tramening on downhia stopesis preferably comiec outwith the engine partur front, During dawnhilldetving this cehding direction slows for abetier destribubar fhe mie lads and alsa pre verts ade litctfeaused bby frantecranping ‘Tramering on downhill slopes always begins with thellomest gear appropriate for the gracie: ‘Via Se drive train the engine will keep the vehide ata unite sped Never allow vehicle tc rol apposite the selected tearmming cirecton = Trareming cn downhill slopes must newer be dane using the service brake. The brake will avert! On aitranges of downbit siopes, forthe same toad yer pryliaden), masimum the same gear anda. mum the same cing space si an upha slopes shale selected = = When the speed increases change ta rent lower gear. nthe indiicual gears the manium scesed indicated in the technical cata must not be exceeded When changing dawn ta 2 lover gear, first bate bc the switching gear using the sendce brat Waring = After changing ta a lewer gear, the rotaboral speod at the converter outpuifiansrrise ssicr input ts doubled (at least for a short frre. 4s a reference, the engine speed far changing ta.a lower gear is 800 mi! Fontan ur 24-3 Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Bownhl! dawring in converter mode When dining dawrtull ir converter mace the engine ides which means the speed acjusting mech anism is nat qpersied. in fe process, fhe engine braises the cormerter's pump wheel This causes Se burbire mbool ta rotate faster than fhe pump wheel, with fhe torque converter rewersing and the dum per braked ‘va he engine, torque converter, mansmissicn, crivelnes and axles. [Waring ‘Tre Brate peweris corverterints heat and fe converter.tansminsicn al Rested up The “comverendranemiesion oi" temperatuen indicator therekore has to be seach ‘Shoubd the vehicle's maximure converter oiltemperature be exceeded, braisaitby oper ming the service trace ard alowengre t ord down atidiing speed. in pushing mode, the converter outputhrarsrission input speed is substerniaily higher than the engine ‘speed, ag indicated af the meveluticn counter, ¥ me [Warming in pushing mode, the speed af the oowerter ouiputlransmissan inputs ab out baice as fagh 23 the engre speed ‘Therefore, the manimum admissible engine speed is 1500 mire! . Note Fetemtensie ching on down spe su sin echacia Eres (exhaust bres o- tarderraices} beused, orcise a detriment neatup within the converter-rans- sion eysters may aFise, You must not exceed the speed at the several gears atove the lenis 2s ksted below 1 gear 2 gear am! gear gem 40k 80 kth 1 keh 22.0kmb Fontan ur aed Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Towing the wehiche Note ‘Tew the wehicle onty at walking speed and aver short cistances. tn he evert oftoning avers ang distance or ever atand gratent secon prece edie complionce wi he inescaborw on paged <8 Warming = When the engine is mot running. the vehade cannot ke sheared. Fortcwing use onfy the towing hugs prvides and suticientiy dim ensioned ting aids Make sure thet the irwing vehide has the required brake power. Waring «Te aveid chating afthe parking brake incase of toa lewarclease pressure, amancm = fer must be installed at test connectors B7.1 and B72. if the mdkozted pressure fas below 120 bar, this causes severe chafing. whict may resultin healingcrevendestnuce fon of fhe brake Tevang in compliance with the indications on page 2 6 «6 [Warning During tasing, moritorine brats pressure presert or he servioe and parking brake cr fhe mancmetars in the chwer's cab and on test canractors 81.1 ard B72. [Caution ithe brake pressure tor the arvice barke crops below 100 bar, a sate stop with the sere ‘vice brates iz nalanget quarartend. The tasing preechire must be immediately inter rupted andifnecessary executed in accordance with the indications on page 26 + Agpreconcidan for toning is an operational brate system and a sufficiert avaiable brake pressure in the lbraie reuits of the service brake = Secure wehide against any selbinitisted movernerts, = Gheck brake pressure on the mancmeters in the dever's cab andtest axnnectors 87.1 andie7.2. esming The avast brave pressure for te serdce ard paring rakes must be gremer mar ba = Phace gearshittin neuteal postin Switch cn aperating woltage ard release parking brake + Remove vehile Blocks and tewithe vehicle (Caution — Safe taningis notpossitte when the brake system isnot operational ive. when fre avail atte brake pressure for the sence brake is insufficient, wher She faadng vehicke as diferent brake system cr as 2 result cfremaved component parts, Waring the dining engi tals but the brake system is cperational, fhe parting brake can be released via the emengency release function (see 3.16 4) for towing and single stops fing of the wehice with the parking trates, Fontan ur 24-8 Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Filling of brake system for towing of wehicte ‘The brydraufic brake system is supplied trom the nydrautic reservoir via a hydraulic pump fanged ontothe terque commerter Fartoning a vehide whase brake systemdoes not cartain suificentibrake pressure, the wehicte’s brake ‘system canbe filed by that cf the ttming wehidie Warming Provided both vehicles are fitted wath the sare brave system ‘Old is fled in via the B4 testfitings, AN 4 hose with suitable commecting couplers ix recqired Sar this purpese ‘The following wore operations are required: Secure wehide against any selbiritisted sm cremerts on fhewhicle foe tomed, toprup hyceaudic il on the Frydeaniic tare ba reamircuam lewel Waring With each Braking operation hychalicalis pumpedizam thetrake system ofthe toaing ‘vehide intothatcfihe towed vehicle. ttis eretire impartartts ensure thatthe hydrau- coir te hycraucreserei fe towing vehicle does al fll Below the mira + Decrease avaiable brave pressure cf brake system by pumsing vith the brake pedal, This has to be dare on both vehicles. = First connect fing hose tc conrecticn 6 of the vehicle being towed and wert hase by staréng the ‘engine. (Hydraufic of comes cul ubblenee), = Connect hase tates! fitting 84 of wehicle tae towed. = Restart engine oftoning vetide and charge brake syster of both wehictes, «Tur on theelectical master and control saiich cfithe veticle tc be towed. The service and parking brass ane naw ready for operation. = Remave the protections provided to secure fhe vehicle against rofing away «Place gearshift in neutral pasion .Rilease parking brake and towthe wehicle [Caution At fhe end cfthe towing operation the pdkaubc cil lewel on the hycraulic tank has to be conected onibeth vehicles Note Before the fling hoses removed, fe brake pressure inthe brake system of both wo fides must be reduced simultaneously by pumping with the parking or service brake. Fontan ur 24-6 Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 2.7 Dumpihoist operation ‘Contra! of dumplboist equi penest ‘Thelbcom anc the bucket are controlled by the joystick bever arranged on the fight side of fe instrument box ‘The aircke afthejaysichlever is propargonal ts the specd atwhich the dumplhciste poration is performed, i.e. he furtherthe levers shtted out fre mits middle position. the fasterthe desired boom/buceeteperaticn i pedarmed a Fig. ‘e Mave ta position 1 Lowering boxe “ie Mave ts pasion 2 Raise boom Re Move ta positon 3. Bucset tipping torward ad, Mave to position 4 Bucket lipping back Fortes ur ane Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Bucot filling = Grate londer in straightaahend positir in front cf the pile, Lames the boom taits stop, Bp bucket forward uni itis a few Confimeters above the gecund = Engage foreard gear. = rive everty into the pile. Give full acceleration when the bucket penetrates the pile [Waring Avoid ramming the pile, The bucket should be introduced a farinnc the pile axis neces ary Hit decid spinning cfwdeels, Observe ont whests. if tey start to spin, tip back bucket by inducing light jeraing movements cn the cantrl swfichtep erating lever. Thes vill rechuoe penetration resistance and increase the lad on the witects. Before the thant wheels enter the pile, the bucket should be fully oped back ard ionded. Bucket filing (floating position) Forloading cr uneven ground fully depress contal switchioperating lever ornespectwely, press button incentrclswitch fsee2.J~ 1), These set the bucket tothe faating position, in tis positicn the cinectiona ‘control valve is on free flow, The bucket adapts ta the uneven graund as 2 result of the extemal fcroes acting anit Emptying the bucket = Travelto the cumping point Before rezching the dumping point use service brake tc brace the koader ‘and raise the buctetto the necessary height tertipping it forward. + Set gear shit lever to neutral positon + Tig bucket torment Tig back empty bucket and at the same time lower the boom Fontan ur 20-2 Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 2.8 Winter operation Lew temperatures will aggravae the wehicke's operating conditions. To ensure troubledres epanatien in ‘winter, special maintenance and care are required. Preparing forthe cold saazan ingecd time is ofspecial importance Engine Engine ai ‘Too wscous engine af vill ead to starting problerss and fawaut increased wear, Note the ol grades: and ‘change intervals specified in the engine marulacturer's operating instructions! Injection nazzies Have injection nazzies inspected regularly. ster ts engine manufacturer's operating insiructicns. ‘Compressicn Mave compression checked befare the winter begins. insufficient compression will atiect starting ofthe ‘engine, especially in cold weather. ‘Cadcestarting ecuigment ‘Check existing ccléstaring equipment regularly, Rieter to the engine manulactuea's operating instruc+ ‘ian, ‘Costing system ‘Contant ‘Add a lbrand-name antireaze tc the coclant af Bquid-cocled engines in good time, Rieter to engine manufacturer's operating insiuctions. Air intake system (Oilebath air iter fi irsttied) Fill of bath of cithath a Ser with fhe same ell as used for the engine. Al extremly lou temperatures, use a muture af ail and winter diesel fuel Rieter engine sm anulactirer's operating instructions. (Dry aie fer stated Refer ta engine manufackirer's cperating instructions. Fontan ur 2a Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Fucl system us (At ambient temperatures below (FE fillup winter diesel fuel. Atlow temperatures diesel luc will separate pparatin, Paratin, in tum, will cog the tuellines, For the appication ofdhlferernt fusts refer toengne mami Ecauers cperasrginsvetors! Fuel tank \Wiken fre fuel ters are unduly selec, clean fe fuel tak ‘Water separator installed, crain water separator day Fuel pump ‘Clean fuel puma strane Gf installed) weeldy, Axle gear Bale geareil Fil up ande gear oil soconding to the lutricant tabie, Mydnaulie system ycraulic a Fi up hydraulic it acocraing to the hubricar tate Electncal system Batesies ‘The starting capzaty af the battetes depends on the charge state and tre armibient temperature. Check ‘aod density regulary, charge batienes ifireozssary. Check far proper contact of terminats. Attenratce ‘The proper changing capacity of the attemator is especialy important in witer, Check condition and ersion ofthe Vobeits regutorly, Mave afteriict checked in good time (ey sreciaist wersshon}. ‘Starter Have siatter checkedif necessary by aspeciaiist workshop. Grease trated gear rir itfer peratures deop below -20 Rieter to engine manufacturer's operating instructions. Fornten Lea sate Escaneado con CamScannerGHH Fahrzeuge GmbH 2.5 Shutdown of vehicle ‘Shutoff of vehicle (Caution The parkingbrake is not agpbed automaticaly wt en switching allthe engine tis theres Sore impertart io apply the patking trake manually via the contre lever to secure the ‘vehicle against ling away. (Lower dumpinoist equioment, be.netract all bycrauiic cyinders. + Park vehicle on allewel, dry suritee carmpletely levelled On graven, park with the side ofthe wehicie samay frm the driver's cab, swivelled towards the matesal face. Spply patiing brake and sf gear shiftlever te neutal ‘Shut off engine ard withdraw igrticn key. = Set battery sich te “OFF = Protect wehiche against unauthorised use ‘Shutdown of vebicie ithe weticie is fo be shut coum for a longer period cf time, the foliaadng wark is to be Gumied aut ack up webicte softhat the fires de not touch the ground, Rielease parking brake = Sct alllevers to zero position. = Lawes dumpéhast equipment, ie referee all hycraube cylinders. Goat bright machinery campanents wit acidres grease, = Protectithe engine in line with the engine operating instructions. + Remove balleries and store in 2 dey room at apprene, 20°C. For batery care ncte the following: Check acie density and ne-change battery, ifnecessary. «se¢ 3.221 Keep batteries ean ard dey an the outside Never athow bamerios ta be stored discharged Fontan ur aged Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE Putting vehicle back in operation after shutdown Before putting the wehicie back in cperaticn again atter an extended peice of shutdown: = Deepreserve engine in ine with engine manu factures's operating instructions, = Fibup thesn engine oil, = Riemave grease trom bright machinery carrponerts. (Check battery change state are liquid level + Ghecitine pressure, «Check funefion ef brake system + Check Suneion of rydrauiie system Check function of alectical system, [Warming Generally, the usual preparations as for iniial startup af the vehicle cust be made Fontan ur 2a-2 Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 2.40 Loading, attachment points, transportation Loading, attachment points Tabood the wehicte by means of a crane, attachment points are provided atite front snd rearenc Beare iting the Wehicke, insertiscking hare arranged in suivel Fange area Permissibte load of transport rings see section 2.1, Drawing-saiety marsing. Caution Secure wehide against any setf-aitiated movernents and damaye. Transporation ‘To ensure marfienance of the landing dimensions, we recommend that a company expesenced in this field be consulied for transport Before transport the vehicle must be protectedin a sufatle way tc prevent damage Waring Fornten sate Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 3 Contents “Maintenance* 1 Safety imstructions for maintenance ard servicing aiet 2) Maimarance arc sending 0.0.2... alt Regular maintenance ard sersicing .... ane irregular maintenance and serdicing .... az General remacks . x aaa Cold sriiing by regen ce a2.a 2.3. regular maintenance and servicing ... aaet rir to itil operation... aaet ‘Aber irtial operation... aa 24 istofhuricarts avd opersing agerts aad 46 Checttict Vahicte ma ; a8 Maierance tervals: daly Pootbss mecgeaotecrdne . AMA Martenance intervals: deve engine, fuel fiter 38-2 Maiterance intervals: 1S0/3008680/780 Bh 38.3 Mairterance intervals: GOO! 2000 4002400 Bh. tb 48-8 Maiterance ifervals: acorrding to maintenance indicator... as-30 Mensuring-paiet pian, lacatar af the contal valves ag-21 LLufrication paints feet tet atten enaeiee as-2 26 Msitenance werk canted cut 38-1 3.7 Engine cperating rstructors amet 4A dicintake systers Saat 49 Exhaust gas system: age1 Exhanst bas pressure MeMSUreEMeNt eee ee cee eee aa ‘Stencer, exaust gas catalyst ........ aa ‘OO.measurement aget 2.10 Fuel systere an.t ‘Chectang of fuel level aio.2 Fiting up fuel. a10-2 Draining full o.oo 310-2 ‘Gearing the imske fet. a10-2 lection pump, tel fiter 10-2 : anet aN2 an-2 Z an-2 4.12 Torque converter, power shit teanemission an2et Maimerance of cxrvertertrantmission 312-2 ‘Checking of cil teva oat ER SRO 312-2 Ghangeg al an2.a ‘Cleaning the irtake strainer AN2.3 ‘Changing the Ser clerentin the pressure Sher an2 Fortes ur asf suse Escaneado con CamScannerGHH Fahrzeuge GmbH 313 Deivaines Marnerance af creaines: Lufrication ltnstallation drawing of drivetines 314 ade Planetary gear ail change (Diflerential gear cil change ...... Checking cf aleve, Tapping up planetary gear ai ‘Checking of cildewel, Topping up cifterential gear oil... ‘Vesting the differential gear sates 18 Brake system ee ‘Units off the brake systere Bleeding of hyde brake sipseen (HEE) (Biapihragen accumulator (Biaphragen aocumulater in brace system Pressure reduction armature and fling device ‘Checking the gas preload pressure cn the chaphragm eccumufator ‘Comecting the gas prelcad pressure... si ace ‘Changing ofineline titer element... ‘Seneca braiee - Checking for disk wear . ESSLER+C0 installation instructions . Mounting brakes. Dismounting brakes... 4.16 Brake system desciption Legend ta brake systers Fureficnal desorption ef Pydraulic rate system Pressure sungly system ‘Service brake . Resichal ae pressure mentee « Mantoring offine finer... External oxaling of muliecisk rakes . Parking brake te Emergency rele see ot pasting Erk 17 Mydrandic system . ‘Steering and dump hoist ironic system - Hyco tonic ‘Checking of aillewel Topping up trydraulic cit Retin iter ..... Monioning or pressure Ser ‘hanging of hycraulic al . ‘esting the mydrauiic system... Steering and dumphhaist iydrauic system presnure test | ‘Changing the ier elerertin the retum finer cbs ‘Changing the titer elererntin the pressure ie Ola cooling system Fortes ur a2 suse Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 9.18 Steering and chumpMaist rydranuiic system descipiion .. atest Legend ta steering an epee yl era ‘ wast Pressure af suppiy * A182 Fitesing of rycrauic ofl A182 ‘Stpering hydronic system .. a1a-2 Durephhoist hydraulic system a1a-3 Directional contrel uate... aaa Float positicn .... ataa Primary-cressure relist... a1aa Socondary-gressure relict ad atorsucion ata.a Durephhoist mydrauikc - Side cumping function ata.a Pressure all suppty eae aed Girectinral corel uahue amd 9.19 Converterransrission hydrauike syster: description ang.t Converter chagirg pump anget Pressure fier atget Torque comester ANget Bicol... ae ana-t ower ait rarsirissin « ana-t 3.20 Tenque convester operation . ant Description af fonque corwester 20.2 an agat 322 Becticalegupmert ....... 42.1 lectical ecqapment compere amet Botany... 4.1 Three-ghase atematar 122.2 ‘Groult breakers/Ptugan fuses... 422-2 Battery switch .. a 422-2 Lighting system . 422-2 Warning equiom ert 122-2 az 12.1 2:24 Fee eaegaanagoyoem sre entagaaner azaat 3.25 Faulttinding table .. 128-1 Brake system LOB 128-1 Hydrate system 328.2 Terque corvester.power shit ranemissior 128.3 3.28 Appendia 13801 cradeabilty diagrams “E06i8.081 4211 OF", page 3 Fortes ur 1.3 suse Escaneado con CamScannerGHH Fahrzeuge GmbH 3.1 Safety instructions for maintenance and servicing [Warning The warranty is immediately wid any ani-tomper seats cr paint seats ‘amached tthe vericle systems are detached er destroyed ‘The general safety instructions de prin apally apply for this chapter as well. The ef consists, ‘af impartant regulations ard adotional msteuctions ‘ior maimerance in order taintacucs the necessary lmawledge ta prevent acdcerts with camage af people, materia, and envrormest. Besides these Regulations also observe requistions which refer te ‘operation made offme mactine and typs of vehi War accident happens in spite off al precaubars, especialy caused by contact with coustic 20d, peneirabon ct vel into thessin, scakdirg with hata, anfireeze compound in the eyes, cfc. attend doctor immediatoly. Please let only authorized ard tained persoral used fo necessary working procedures camry out ‘adjusting, lubricaring, and maintenance wort. (Do onty use sate tacts anc working equipment Keep dean working place, tock, and operating eguierment, Park vehicle on glare, dry surface without slopes. ‘Secure vehide against selbconisined movements andunauthorized starting. ‘Camy out lutricating ard maintenance work only ‘wilh stopped machine. Swatch cffall propulsion tems, Enng addfional equipment in inccent position (Camry anf lubricating and maintenance wark using stich ail and gremse cay drains the machine only in places ecuicped with a separttors, of use suit- able lange ard unmistakably icerfiied wenseds IMake absolutely sure that a fuel, caclant etc de ‘net penetrate the soil or pass ints the sewage syS- fem, Danger ct chanking water pofubon Used fier elements er cartidges, coslants and rebigerants, batteries ard other substances haze andous to humans arc the ernironert must be handled as special waste according te gevernmen. falregalabars. monaica Ensure envicormertaly iienity disposal or recycle ing cf waste mates Ensure adequate installation cf al parts, Replace ‘morn out, damaged, and unsafe parts Fornten sate FAHRZEUG Any changes toload-beanng companents. i, parts locatedinthe tomaf toroes exerted byloads tirame, ivematc linkage, etc.) must onfy be made ater waitin consent cf MAN GHH Fahrzcuge GmbH. ‘This apoies in carticuar to repar welds, torchcute fing and the amangement off addisonal or medilied mounting parts. Switch of the engine for al mamtenarce wark whict does not necessarily require 2 working machine ard withcraw igriticr key. Alawenachine te cool down. Hi the aperation of certain components of the machine is necessary for mamtenance work, cay ‘special ater Gen to the related riscs fours, scald, Foiscring, cauterizafion, crushing, mtating pasts, chain and belt chives, ets) Seoure deers and gates prowded for camying aut marrtenance work after opening. Secure turin: swivel ard perdhfum hinges and joints witn pr vided bots, rackets, or supports. ‘Support cr mark parts ofthe mactine which hae tc be litted for reaintenance wars, Cty apply ing ecupment ae supeering stars me apy copia tans po Newer stay under pending toacs When maintaining or repaking the machine take care for parts of the machine wbich are supported by aunitory force (ol pressure, compressed air) or by force. Reduce pressures and spring pow ch ard secure parte ageist urcesed Tews: ments, Crly work en dapressurized Rycraube and prev matic systerns. Take alsa care for seoandary store agesysiems Clo neither ighten narloaser pressure ined screwed connection cf pinework or texibie hubes! (Only drain liquids at places provided for this pute pose cut of depressurized installations into suitable Containers and dump wiéhouthamn far ermine Be cancha with units which become wary hat wher ‘tperating ard thus reed a long time ta cecl own, danger of buring! ‘Only work on de-mnengized ele crical instatiaticns. Pullout switch lever atbartery main switchers witch affrmain siich.crdisconnectearth cable af the bate tery. ea Escaneado con CamScanner E atedGHH Fahrzeuge GmbH asia te long mos appt rma on aac Inical anstatiabors = Disconnect from power supply Secure against reconnection Determining dead voltage = Eartting and sharting Coverup any adjacent tive parts + Plug re socket connector shuld only cise Caeecd rd soncrmedtad il Be sale spadiched off, itis prahioited af any timerta store ary parts esce ‘cally tools, instalaticn material, cithes, ete. wn fhe dangerous vicirity of unsecured, uninsulaied parts satich are connected to the powsr supphy ‘The use cfrrended or bypassed fuses is prohibited. Itisnet allowed to conmectparts i thefeeder catle ‘af machines fitted wath cable reel. Bamaged feeder catles must be replaced ioume iste. Before starting work on high-voltage capacitors make sure + The capacitors hawe cocked dawnt = Make abschuety sure they ave telly discharged = Golore tcuching active parts earth and short ‘each capaciiorlead (phasefs) with the nelevant dewces | (Sex CaSdeTaNGSd and IEC aM toi 21), = Dismanted capachors for tarsport ar storage, pemnarerfly short the connections and connect fo the capacitor housing = nthe evert of damage itis possibte the capaci- for housing may crack, Rhenefore procsed ‘ith exmeme cre When camying out welding work an the machine, disconnect battery and elecireric contr urits Waring Plug ard socket connectors cn fhe diver postion and cr deckorsc caporets feo tik, ante units of the engine electra should be sezarated before welding. ‘When welding take came that the earthing texrinal af he aratus is near the weiting point ‘and that welding current isnctled through keanngs, earthing wire of the whicle, ef Fornten sate FAHRZEUGE Wren canying out welding, culting and , special sacri tobe po to amet yl intaremable materiots (ail, grease, fuel, vamist, rubber, che.) When removing protective castings, zinc layers, ete.bymeans ct grinding, buming.cr when welcing aris whichare covered with such ocmasicnpratec- fcr layers, health endangering gases, smokes, ard floating pamticies may ane, Use necessary protec- ficr ecuiereent and, possible, work outside, in well ventilated moms and with suction instoltaBars. Please see tunherinstructonsfor wetdinginspecist instruction sheets and regulations for prevention cf acerdents for welders. Cbsene manctackuresinstuctions for handing ot bemeries. Accumulator acid is caustic and tamio, batter gases are explosive. Observe regulations tor cperation of three-phase (Generators, see subsection Electical equement™ and engine manufacturer's operating instructions. (Change oft at operating temperature. Migh dar etbuinig a aaidng wir Pat ek of ramage screws anda fitter! Open coclart crait only when engine is cocked down, Cooling systems are pressurized when hot ef coslants ray lead te scaicing. If epening at epersing temperature is absolutely necessary, see engine maruiactirers operating instructors. Mf these ts danger cf freezing, drain coclart and ater ceculatar pumpifrecessary, wher engines not inuse Newer fi colt cooing liquid ants an overhetied engi When using com pressed ait.¢ 9, forctsaring airtl- ters cle, wear protective glosses When esting with damage or checking highepres- Sune systems, @.g. injectors, keep parts of your ody, espesiaily hands and face away trom pres sune jets. Liquids under high pressure may hawelthe same etiects as outing tosis. Reepioce demmaged flexible protection tubes cr ex ible pressure Gsbes immediatly, uty flenble tubes represent especially high danger af bursting and seating and danger tar pressune jets. The peried of use of.a fenible tube, inckuding ary storage petbod of the Henible-tube line, shoude mt exceed sic years, wit the period of storage alone ot tc exceed tied years. Da nict intale oll anc Sel mist, battery gzses, cack ant and vapours from exhaust scretber. Newer operate wehidie components without pre- sctibed operating sraterial, Taiee care far filing beve ea Escaneado con CamScanner ategGHH Fahrzeuge GmbH hots conta, te esreciatyn gia, gene box, cornerier, axes, brake system, hrdcaudic arc ibricaticn installatian as well as coatant circuits Never exceed ting levels, especialy for motor ai Never operate pumps umhubricated and without pumped duids. Abways make sure that check and supervisory devices work fautiessly (charge control, oll pres ‘sure, coclart tereperature, etc (De ony demand a5 much from She engine as ithas fie perform when properly employed. Please see detailed information in sales coouments Modifications of setpcints preset by the marutace uner, expecally infection pumps, current rviters, pressure limiters cfhydreniic units, ma'y ony be euecuted atter waiter cornet cfiGHH Fahrzeuge Geb Fornten sate FAHRZEUGE When fling the tires never stand beside the whet Recause you may be endangered by snap rings coming off awe onty specially rained ponte camy cutrepairs ffires, especially maunfing ard cismnanting te are from mboel rims. Snap rings may olen be pre stressed to a very fagh exter and are ic be hanced with special care Newer cory out work with cpen fares, welding, culling and Rame-cuting of wheel rims a long as tines are sfil mounted Scme of the parts or aperating materiats in the machines mfch are absohiiely necessary for peration are hazardous for humane and the envi ronment Therefore observe operating instructions and marnfactorer's instuctions an endasures, stickers and marusis. ea Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE 3.2. Maintenance and servicing [Waring = Trauble-ee operation and aang service ie require regular anc proper mamtenarce and senicing. Waring The warrartyisieumedisiely woid any arthtamper seals cr pair seals altached tc the \vehicde systems are detached or destroyed Roguiar maintenance and servicing ‘The firme for camying aut this type of werk depends on the vehicle operating Hours. See Chschlisteeguisr maintenance accoraing ba sarace hours Inmeguiar maintenance and servicing ‘The irregular mark is divided ints the folloadng subgroups: + Maintenance and seniangcfnew vehicles, afters hasscoverhaulaterinstallation ofinaplaced armas ents, ete up ta the fie at whack reguisr work is te be camed out, + Maintenance and sender ge finchidual eumporertts which are paricularly atiected ky varying opera. ‘sng cordisors Maintenance and Senicing work which cancaf either be desermined by the ruemiter af aperating hours, ‘or whose intervals Ceviat! fem tte usual apportioning into the number of operating hours. © Special measures fer cperatcn at low ter: peratures see 2.8« 1 winter operation. ‘General remarks ‘The wt specified inthe checklists wilive cetaiec in the various sections of the maintenance and send ong matucticrs. ‘Various items of the speciied werk may involve identical wars steps. Ta avoid repetitions in the descrip ons, these werk steps are desorbed below Safety at mark Mote safety instructions tar maintenancs and sersicing. = leaning the weticte Betcre starsng any work, dean components Iccated inthe respective work area. The selecton atthe properdesning agectdezends crite material ofthe parts ta be eared, For example, rubber cree ‘rical parts should not be dleaned with benzene ar steam jet. + Alter desring with sear je, hibrieate all bearings. = Covering all meurting areas ‘Toavaidthe ingress afcint, cover all openiberes, cormectons andhcusing sin a suitable manneriremne- cy. Fontan ur ane Escaneado con CamScannerGHH Fahrzeuge GmbH FAHRZEUGE = Comasion protection ‘Touch up damaged painted surlaces, grease bight spots regularly, = Exchanging parts (rvshrunk bushings sex Section 32 - 3) Exchange defective parts in good time to avcic major damage. = Protecting the electrical system Where the dangerafelecticconducters comingints coriact with tooks, spare carts, vehicle tram 2ystc exists, tur aff fhe main sadich «Checking of ail level Unless inckeatied cthonsise, the oillevelis to be checked imamiably an an even suriace ard atterthe ‘engine has been at steeds for agprea. 14 rriutes. Od change (Drain cil from ware componentsonly. Giean suncunding ofthe iting port, Félup off rem clean conta ers onty. Oc not rer owe strainers frac iling ports. ‘Check oil evel after 2 bret inal run, ‘Check sealing cements |Wherremeving caps, lug screws, atc. jay afterticrnta existing sealing elements. Reptace realnings, if required. Upon reassembly mae sure that they are properly seated ‘Check sealing faces Pricr ic reeassemly, chean all seating surfaces and check for leaks ater assembly. = Check locking elements Pay aftertion ta existing lacking ements while disassembling parts Sock washers, coffer gas, ofc) ‘Check locking elements arc replace, ifeequired = Lubrication ‘Gear grease fitings before and ater kibsication. Ftemove any eacess grease fram lubrication points. Fornten Lea sate ag-2 Escaneado con CamScannerGHH Fahrzeuge GmbH nm =| x) a iN mi ei a mi ‘Cold shnaking by nitrogen Fonthe processing af parts which are made from steel bronze and polyester resin tabric-type ocmpourd materials and which are tobe caldsshrunk by licuid nitrogen, abservsticr of the following saiety notes ‘and processing sequences is mandatory: ‘Satety notes uid nitogenhas a tem peratureats| 96°C, which ts: nitrogen and undenac abe d tera fale mceicd Todosn, pou die cle, sub te ropmet cris otal a presse ‘geggees and rotective gloves) shall bs wom. guid nitrogen mayite processed in mefvertiisted rooms only, 90.5 to aveid lack of cxygen caused by the breathing ar being enriched with to much nifroger, Gasecus ritregen is 2 colourless, tasteless arc adeuless g35 corisined in fhe namnal ambient stasghere at rate af 78%. Provided that suthciently lange amcurts of fresh air are supsbed, the nitroger, which upon heating af the Sigorilic misture has changed to Bie gaseous phase, poses na special risk’ Inserting and witidrawing work pieces shoudl peeteratiy be done with the help ofequipment mace trom materials tough at suboera temperatures, suct as hemp ropes, ccpper mine, kenge ard hacks made of ssuitable stainless stool grades (1.4547), a3 farasthese are subjected to theinduence offiguic nitsager ‘Whertexposedic sufimesc temperatures ordinary structural stenis lose Sheiricughness ardibecomecckis nite Preparation and execution af shrink joint: ‘Thedimensions of fhe insulating tarictobe used should preferably aich the werk piece. The work paoce fic be canled downs submerged inte liquid ritragen. Gn accourt of the high difteren tial temperature this ‘will rst cause vigorous Ealing cf the rifrogen bath. White the bath coots dawn, tre shnrinifoint surtace must nemain evenly wetted win quad nitrogen. As soon 23 baling stops, te work pimce nas steinkage temperature any may be neme ved fram the bath. Cocing-cawn times depend cn the matesal and an the work piece drrensions. For sted, eg..the eximmative ales in the table below apply: Wil thicknee ftir in ort 2 100 200 liemersicn tna in reiru tes 8 1 x fWaming The maximum admissible immersion time for sleeves mace of poly stenee sin fabrics ype compaune materiais is 1¢ miewtes, Rites its eemereal fromm the bath, the wark piece mustbe processed inimedisiely, Le. positioned 2s'shawn inthe fatricaticn¢ocuments and fied in v= spectted position if any. What mustbe chserved expecially ‘wilh sevaller, thin-walled work pieces is thatthese may adjust ta the ambient temperature and therefore long netton ably se pen a undercosiod materiats, na im pacts mustite applied ta fhe were pites, a Pas wouldincre ase Ge mmbienals soraity& baile ick ra Fontan ur ana Escaneado con CamScannerGHH Fahrzeuge GmbH 3.3. Irregular maintenance and servicing Prior te initial operation Check al cil levels (Check hvtrication of all oticating points. Check all tanks, howsngs, lines, etc, far beaks, Check lightening torques af wheel nuts. (Check tine pressure, Check function of electical system ‘= (Gheck function of operating elem ents and contral struments, + Cheek function of brake system. = Check function of dumpthoist and sheeting hpdeaniic system. After initial operation cof the compote vehicle or ofinchickal components, up tc the start cf reguisr maintenance. Engine ister to engine operating instructions. ‘heed ts ‘Check tightening tongue atter 10 cpersting hours. ‘in finer For air iter maintertance see 3 But intake system Lubrication ‘The Rubmication intervals ofthe grease lubrication paints depend cn the operating conditions (see regular maintenance and serncing). Lubricate vehide ater each steam jet clearing Fuel tarke Extract sludge af the bottom of the fuel tank orice a year. Flush the tark and clean the intake fier Mycraulic oil return fiter ‘Change fiterif with mydrantic system at crerating temperature the “Fistum pressure” signal larep lights Up oF Bhe “Retum pressure" araleg indicator indicates apressure of'> 1 Aber Waning Fiter element cannct be washed. Fontan ur aad Escaneado con CamScanner