Instruction Manual Charmec MF 605 DA

Contents
1. Technical Data Sheet

2. Operator’s Manual
3. Control System User Interface Manual
4. Service Schedule
5. Maintenance Manual
6. Mobile Elevating Work Platform
7. Charging Module
8. Safety Instructions
9. Engine Supplement Information
10. Reverse Camera
11. Compressor
12. Portable Fire Extinguisher
13. Schemas
Original instructions
Normet Oy Tel. +358 (0)17 83 241
Ahmolantie 6 E-mail: info@normet.com
FI-74510 IISALMI Web: www.normet.com
FINLAND
Technical data sheet
100063155
Charmec MF 605 DA 06.06.2016
Pictured machine may include options and additional equipment.
Features
Charmec MC 605 ANFO charger with diesel hydraulic drive is designed for face and production charging
in underground mines and tunnels up to 65 m2 cross sections where max face height is 8.4 m.
ANFO vessels options of 2 x 250 / 360 / 500 / 720 / 1000 litres provides enough explosive storage volume
for several faces without need for refuelling. Ready designed place for stick powder boxes, primers and
detonators makes it possible to bring all the needed materials to the workplace at once and eliminates
the need for an additional explosive service vehicle. Compressor option eliminates the need for external
pressure air line.
The liquid cooled turbo charged 120 kW Deutz or 110 kW MB TIER 3 approved engine provides clean and
efficient operation and gives maximum speed of 25 km/h and 8 km/h in upward 1:7 inclined tunnel.
The FOPS /ROPS approved safety canopy / cabin with pivotal operator's seat provides comfortable
compartment for the driver and his assistant. The enclosed cabin provides noise level < 75 dB.
Self extinguishing marine type wire harness with tinned wires and water tight conduits are specially
designed for safe and reliable operation in tough underground conditions. All daily checks can be done
from the ground level.
Normet reserves the right to change this specification without further notice.
Normet Oy 1/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
FI-74510 IISALMI, FINLAND info@normet.com www.normet.com
100063155
Charmec MF 605 DA 06.06.2016
Technical specification
CHARGING SYSTEM BRAKES

2 ANFO vessels and work stand, 1 charging operator Service brake: hydraulically powered dual-circuit oil
500 liter stainless steel ANFO kettle immersed multidisc brakes in both axles
Pressure max. 7 bar Safety/Parking brake: spring applied hydraulically
Extra air for charging released fail-safe -type brake. Brake testing possible from
Pneumatic hand and foot control for charging cabin
and blowing
Pneumatic control in basket to switch between vessels TYRES
Anfo hose 19 x 25 mm
12.00 - 20 PR 20
Earth straps front and rear
Storage area for stick powder boxes FUEL TANK
Storage boxes for primers and detonators
Capacity 112 L
NBB3XS BOOM
HYDRAULIC SYSTEM
2-men hanging square tube basket
Lifting capacity 500 kg Variable displacement pump system,
Boom lift -11º...+ 60º 190 bar, 95 L/min/2200 rpm
Max. Lifting height (basket floor) 6.5 m Hydraulic oil tank capacity 115 L
Max. Vertical reach 8.8 m Return oil filtration 10 μm
Boom slew +/- 30° Indication of level, filtration and temperature
Automatic levelling of basket
24 VDC ELECTRICAL SYSTEM
Diesel start/stop from basket
Battery operated emergency pump for lowering the boom Exposed components are min IP 65 standard
Battery 2 x 115 Ah
ENGINE Alternator 100 A
Liquid cooled turbo charged Deutz TCD 2013 L4, Halogen driving lights (4 + 2 pcs) 70 W
120 kW/2300 rpm, TIER 3 approved Halogen work lights (2 + 2 pcs) 70 W
LED work lights in basket (2 pcs)
EXHAUST SYSTEM LED parking, brake and indicator lights
LED side lights; amber
Catalytic exhaust gas purifier and muffler
Side reversing halogen lights 70 W
TRANSMISSION Rotating beacon; amber
Wire harness (self extinguishing) with tinned wires and water
Dana 24 000 series power shift with pump drive group tight conduits
3 speeds forward and reverse
4-wheel drive DRIVER’S COMPARTMENT
AXLES Open 2-man cabin FOPS/ROPS approved

Air suspended driver’s seat
Planetary type Seats with retractable lap seat belt
Dana 123 Forward and side seating for the driver with two
Load end axle fixed sets of pedals (brake and accelerator)
Engine end axle oscillation +/- 10° MID 070 S Multifunctional Display with:
• Meters; e.g. speed, RPM, operating hours
PERFORMANCE • Status indicators; e.g. fluid levels, temperatures,
1st gear max. 6 km/h pressures, alarms, faults
2nd gear 12 km/h
3rd gear 25 km/h GREASING SYSTEM
Max. tractive effort 133 kN Centralized grease fittings for the carrier
Max speed in 1:7 inclined tunnel 8 km/h
Performance curve 100018584 OTHER
STEERING 12 kg hand held fire extinguisher (2 pcs)

Standard symbol labels
Hydraulic frame steering
Extendable support legs at the load end
Orbitrol type
Frame articulation +/- 40°
Normet Oy 2/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
100063155
Charmec MF 605 DA 06.06.2016
Optional equipment Additional equipment
CHARGING SYSTEM CHARGING SYSTEM

ANFO system: Additional pneumatic charging controls: For toe
• 2 charging operators holes and ground level charging work
ANFO module: 4 m3/min onboard diesel-hydraulic compressor
• ANFO filling system with filling hopper
ANFO vessel size: SUSPENSION
• 250 L Front axle suspension
• 360 L • Hydraulic front support legs
• 720 L
• 1000 L (see dimensional drawing) FOR ENCLOSED CABIN
Radio controlled charging and blowing in basket: CD/Radio system
Optional for pneumatic control Cabin ventilation:
ANFO hose diameter: • Cabin heating
• For manual hose feeding • Air conditioning
22x28 / 26.5x33.5 / 41.5x51 mm
ANFO hose length: FOR NBB BASKET BOOM
• 30 / 60 m Safety bar
Safety roof with hydraulic lift:
ENGINE • 400 kg = 240 kg + 2 persons
Liquid cooled turbo charged Mercedes-Benz OM 904 LA, Safety roof with hydraulic lift and slide:
110 kW/2200 rpm, TIER 3 approved • 300 kg = 140 kg + 2 persons
1st gear max. 6 km/h LED working lights on safety roof / safety bar (2 pcs) 43 W
2nd gear 13 km/h
3rd gear 25 km/h FIRE SUPPRESSION SYSTEM
Max. tractive effort 120 kN Fogmaker: Manually actuated
Max speed in upward 1:7 inclined tunnel 8 km/h Fogmaker: Automatically actuated
Performance curve 100018584 Ansul: Manually actuated
Ansul: Automatically actuated
DRIVER’S CABIN Tempus: Manually actuated (Non CE)
Enclosed cabin, ROPS/FOPS
Air suspended T-back seat for driver and passenger GREASING SYSTEM
Automatic lubrication system for carrier: Lincoln
OTHER Automatic lubrication system for carrier and lifter: Lincoln
LED driving lights (4 + 2 pcs) 18 W
LED work lights (2 + 2 pcs) 43 W OTHER
Warning lights, 1 unit: Fast fuel filling system: Wiggins
• Rotating beacon; red Oil evacuation kit with sample points
• Rotating beacon; blue Extra hand held fire extinguisher (12 kg)
Hydraulic front support legs
Warning lights, 1 unit:
• Rotating beacon; amber
• Rotating beacon; red
• Rotating beacon; blue
• Strobe light; white
Text labels in: Fin / En / Por / Swe / Rus / Nor / Ger / Fra /
Spa/ Ita
2 wheel chocks with brackets
Reversing camera
Spare wheel
Normet Oy 3/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
100063155
Charmec MF 605 DA 06.06.2016
LTC services
RECOMMENDED SPARE PARTS FOR EARLY LIFE TRAINING AND EXPERTISE SERVICES
Spare parts package: A complete package to make sure Available before and at the equipment delivery – and during
your machine runs with optimal uptime up to 1000 opera- the whole equipment life-time!
tion hours*.
Product training:
Includes periodical maintenance parts and most critical Operation and Maintenance
spare parts related to e.g.: Automation - NorSmart
- Engine (e.g. filters, belts) Foundation of electrics, hydraulics and mechanics
Trouble-shooting
- Chassis (e.g. wiper blades, throttle pedal connector)
- Hydraulics (e.g. filters) Process & operator improvement audit for:
- Electrics (e.g. sensors, work lights, solenoid coils, Concrete spraying
contactors) Charging
- Boom (e.g. sliding parts, bearings, cylinders, seals, pins) Scaling
- Charging equipment (e.g. charging hoses) Audit services to improve:

Performance, availability, maintenance & repair efficiency,
- Compressor, if applicable (e.g. filters) safety, quality, environmental aspects
*) In challenging operating environment 1000h of usage
SERVICE CONTRACTS FOR
may not be reached with this spare parts package.
Spare parts supply
EXTENDED WARRANTY Scheduled inspection
Extended warranty extends the standard warranty period (12 Supervision
months or 2000 usage hours) up to total 24 months or 3000 Scheduled maintenance
usage hours, whichever is reached first. Preventive maintenance
ELECTRONIC MANUALS ON THE WEB

LinkOne electronic spare parts and instruction manuals
EQUIPMENT HAND-OVER SERVICES
Start-up training Commissioning
1. Operator training
1.1 Classroom training
General introduction and operation of machine Comprehensive
Safety instructions Comprehensive
Use of manuals Comprehensive No classroom training
Technical introduction of equipment Comprehensive included in commissioning
Hands-on service and pre-operation checks Comprehensive
Controls and driving (starting, driving, stopping, parking) Comprehensive
Work method Comprehensive
1.2 Practical training
Pre-operation checks Comprehensive Basic
Driving, starting, stopping, parking Comprehensive Basic
Preparing the machine for specific operation conditions Comprehensive Not covered
Operation Comprehensive Basic
Washing the machine Comprehensive Basic
Troubleshooting Comprehensive Basic
2. Maintenance and repair training

General operation of machines Comprehensive Basic
Symbols of drawings and codes Comprehensive Not covered
Understanding hydraulic and electric schematics Comprehensive Basic
Control systems Comprehensive Basic
Function of main components (depending on equipment) Comprehensive Basic
Locations of components in the machine Comprehensive Not covered
Periodical maintenance Comprehensive Basic
Troubleshooting Comprehensive Not covered
Use of manuals Comprehensive Basic
Connection of hydraulic and electrical equipment Comprehensive Not covered
Normet Oy 4/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
100063155
Charmec MF 605 DA 06.06.2016
Dimensions
SIDE VIEW
Basic machine
SIDE VIEW
Machine with options and enclosed cabin
DIMENSIONS TURNING RADIUS

Length 10450 mm Outer 7750 mm
Width 2150 mm Inner 4850 mm
Height 2500 mm
Wheel base 4450 mm WEIGHT
Track 1650 mm Operating weight: 17 000 kg
Ground clearance 360 mm

Normet Oy 5/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
100063155
Charmec MF 605 DA 06.06.2016
Dimensions
TOP VIEW
TURNING RADIUS
Normet Oy 6/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
100063155
Charmec MF 605 DA 06.06.2016
Dimensions
BOOM REACH
Normet Oy 7/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
100063155
Charmec MF 605 DA 06.06.2016
Tractive efforts
DEUTZ TCD 2013 L4 120 kW

Performance curve 100018584
MERCEDES-BENZ OM 904 LA 110 kW

Normet Oy 8/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
100063155
Charmec MF 605 DA 06.06.2016
Tractive efforts
DEUTZ D914 L6 86,5 kW

Normet Oy 9/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
Declaration of conformity for machinery
Manufacturer: Normet Oy
Address: Ahmolantie 6
FI-74510 IISALMI
FINLAND
Name and address of the person authorised to compile the technical file.
Normet Oy
Design department
Ahmolantie 6
FI-74510 IISALMI
FINLAND
Herewith declares that anfo charging machine:
Charmec MF 605 DA, DJ305
– is in conformity with following (parts/clauses of) technical standards and spec-

ifications:
EN ISO 12100:2010
EN 474-1:2007+A5:2018
EN 1889-1:2011
EN ISO 3449:2009
EN ISO 3471:2009
AD2000
– the following (parts/clauses of) national technical standards and specifications

have been used -
Place and date: Iisalmi 06.09.2018
Signature: Timo Rask

President
Normet Oy
3 EN - Original
Operator’s Manual
CHARMEC MF 605 DA
Code: . . . . . . . . . . . . . . . . . . . . 100121643
Carrier No: . . . . . . . . . . . . . . . . DJ305
This manual is a guide to the proper and safe operation of the carrier. The information
contained in this manual is current for this carrier. In the interest of continually improving its
products, Normet reserves the right to update or modify information contained in this manual.
Illustrations shown in this manual were produced during the development stages and may
differ from the actual product.
Normet Oy Tel. +358 (0)17 83 241

FINLAND
Operator’s Manual
About this manual

Read this manual carefully before operating the carrier. Follow the instructions
presented in the manual to ensure the safety of operators and others.
The following warnings are found in the text:
Danger!
Immediate risk of serious injury or death.
Warning!
Risk of injury.
Caution!
Risk of damage to property.
Note!
Important information related to servicing or repair work.

Operator’s Manual
CONTENTS
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1. Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2. Carrier identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3. Frame Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.1. Engine end Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.2. Load end Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.3. Oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4.2. Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4.3. Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4.4. Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4.5. Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5. Hydrodynamic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.2. Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5.3. Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5.4. Transmission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6. Mechanical Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6.2. Driveshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6.3. Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7. Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.7.1. Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.7.2. Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7.3. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2. Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1. General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2. Operating Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3. Label locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Operator’s Manual
3. Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1. Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.1. Switches TB7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.2. TB7b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.3. Norsmart Control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.4. Automatic Brake Application System . . . . . . . . . . . . . . . . . . . . . 34
3.1.5. Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2. Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.3. Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4. Driving Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.5. Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.6. Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.7. Fire Suppression System(optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4. Operation and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.1. Commissioning on Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2. Daily Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2.1. Daily Maintenance Operations . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2.2. Instrumentation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2.3. Testing the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.3. Driving the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.3.2. Before Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.3.3. Engine Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.3.4. Gear Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.3.5. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.3.6. Setting The Carrier In Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.3.7. Driving on Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.3.8. Road Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.3.9. Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.4. Carrier Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.4.1. Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.4.2. Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4.3. Lowering the Carrier Down a Mine . . . . . . . . . . . . . . . . . . . . . . . 64
4.5. Special Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.5.1. Winter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.5.2. High Ambient Temperature, High Altitude . . . . . . . . . . . . . . . . . 68
4.5.3. Jump Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.5.4. Engine Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Operator’s Manual
1. INTRODUCTION
1.1. Carrier
The carrier is a four wheel drive, centrally articulating frame steering carrier powered
by a diesel engine. The power from the engine is transmitted through a torque
converter to a three speed, full reversing, powershift transmission.
From the transmission, driveshafts with universal slip type joints transmit the power to
the deep reduction, inboard planetary drive axles. The wheel axles are equipped with
built-in brakes immersed in an oil bath and serve as both driving brakes and the carrier
safety/parking brake.
The steering system as well as the braking system are operated hydraulically.
Steering is full hydraulic power type, utilizing a flange-mounted, direct drive hydraulic
pump which provides hydraulic fluid to an orbital valve operated by the steering wheel.
This activates the two steering cylinders located at the articulating joint.
A 24 V electrical system supplies the carrier with voltage for carrier start-up, operation
and control panel monitoring functions. The instruments and controls to monitor and
operate all of the systems are located in the operator’s area. A description of each is
listed in this manual. Become familiar with the position and operation of each.
To obtain the best performance from your carrier, it is important that the carrier func-
tions as well as the operating procedures are well understood. Read this manual care-
fully, and then use it as a reference until complete proficiency is achieved.
Before initial operation and before each work shift, inspect and service the carrier.
100121643 1 - 1 EN 0918 ettekma 5 (76)

Operator’s Manual
1.2. Carrier identification

Check the model and serial numbers in order to identify the carrier and its components
correctly for technical purposes or when ordering spare parts.
2 3 4
Fig. 1. Plate locations
1. Machine plate
2. Engine type plate
3. Powershift transmission type plate
4. Axle type plate
100121643 1 - 1 EN 0918 ettekma 6 (76)

Operator’s Manual
1.3. Frame Structure

The carrier is specially designed for modern mining techniques. Its construction and
components have been engineered to give long, trouble-free service under the most
adverse conditions.
The carrier consists of two module frames, the engine end and the load end frame.
Hydraulic steering cylinders are mounted for pivoting motion between the frames.
The frames are joined near the centre of the unit in the frame joint, which is movable
+/-40o about a vertical shaft through two hinge pins for steering. This enables the
carrier to maneuver in the tightest spaces and to position itself with high accuracy
Fig. 1. Frame
1.3.1. Engine end Frame

The engine end frame of the carrier is constructed from welded steel plate and incor-
porates the power unit, transmission, operator’s space and engine end drive axle as
main components.
1.3.2. Load end Frame

Is also of welded steel plate construction and incorporates the load end drive axle and
accessories, such as basket booms, cassettes and lift frames.
100121643 1 - 1 EN 0918 ettekma 7 (76)

Operator’s Manual
1.3.3. Oscillation
The engine end axle oscillation allows the carrier to be turned along the longitudinal
axis. This arrangement makes it possible for the carrier to maintain full tractive power
on all four wheels on uneven surfaces.
Fig. 2. Axle oscillation
100121643 1 - 1 EN 0918 ettekma 8 (76)

Operator’s Manual
1.4. Engine
1.4.1. General
Power between 60 and 170 kW at speeds between 1500 and 2400/min are available
for turbo charged four and six cylinder engines, whilst adhering to the standards of 97/
68 EU level III and EPA TIER III. The displacement is around 1.0 liters per cylinder.
The 2012 series has the designation TCD 2012 L4 / L6 2V and the 2013 series has
the designation TCD 2013 L4 / L6 4V for emission level III. The fundamental change
from the level II engine to the level III engine regarding emissions is the changeover
of the injection system from the current mainly mechanically controlled injection
system to electronically controlled systems. The current basic engine series are thus
equipped with the DCR (DEUTZ Common Rail) injection system.
In order to achieve emission level III, it was necessary to rework the inlet and exhaust
channels. The whole combustion process was optimized. An increase in ignition pres-
sure was also necessary, requiring the crankcase also to be optimized.
All existing characteristics of the 2012 and 2013 engines have, to a large extent, been
retained. With the TCD 2012 series a maximum torque of up to 850 Nm is available.
As previously, several gear-driven power take-off points are also available. Up to 100
% of the engine power output can be delivered to both ends of the crankshaft. An inex-
pensive V-belt is supplied as standard for the drive on add-on units. Alternatively, an
easy-to-maintain V-ribbed belt can be supplied.
Thanks to its low-level sound emission, this drive offers a high degree of comfort in
the driver’s cab and a low level of environmental pollution. In some special cases
noise capsules may be necessary, although the requirement for these is low. Low fuel
consumption and long maintenance intervals ensure high operational efficiency.
1.4.2. Fuel Injection

The major technological change for Deutz from Stage 2 to Stage 3 engines is the
adoption of a common rail fuel injection system. The TCD 2012/2013 engines will be
equipped with Deutz’s own DCR (Deutz Common Rail) injection system, which uses
modified unit pumps in two of the camshaft actuation bores previously occupied by
standard unit injection pumps to pressurize the fuel accumulator rail.
100121643 1 - 1 EN 0918 ettekma 9 (76)

Operator’s Manual
1.4.3. Cooling
TCD 2012/2013 power units are liquid-cooled engines. TCD 2012/2013 engines with
integrated cooling can accommodate both an engine cooling system and additional
torque converter or hydraulic fluid coolers within the engine envelope – no extra space
is required.
1.4.4. Benefits
– Good cost-effectiveness thanks to simple and inexpensive installation, good
durability and long service intervals.
– Low noise emission ensures further savings due to reduced sound proofing
measures.
– Lean engine structure and variable design of the engine’s front end offer max-
imum flexibility.
– Very low exhaust emissions actively contribute towards environmental protec-
tion.
– High running smoothness, thanks to mass balancing shafts in the 4-cylinder
engine, guarantee high operating comfort.
– The 2012 series complies with 2004/26/EU level III A emission standards and
EPA TIER III for mobile working carriers.
Fig. 3. Engine layout
100121643 1 - 1 EN 0918 ettekma 10 (76)

Operator’s Manual
1.4.5. Exhaust system
The Catalytic Exhaust Gas Purifier

The ECS diesel purifier consists of a metallic honeycomb coated with a precious metal
catalyst enclosed in stainless steel housing. The catalyst serves to oxidize hazardous
carbon monoxide (CO) and hydrocarbons (HC) to form harmless carbon dioxide
(CO2) and water (H2O). The ECS diesel purifier is also capable of reducing overall
particulate emissions by 25 – 30 % by oxidizing the soluble organic fraction (SOF) of
the particulate.
Silencer
Silencer is installed along the exhaust pipe as part of the exhaust system of an internal
combustion engine to reduce its exhaust noise. On internal combustion engines, the
engine exhaust blows out through the silencer.
Fig. 4. Exhaust pipe
100121643 1 - 1 EN 0918 ettekma 11 (76)

Operator’s Manual
1.5. Hydrodynamic Transmission

1.5.1. General
The transmission is of the hydrodynamic type. The diesel engine drives the torque
converter transmission via the drive plate. From the transmission, the power is further
transmitted to both axles by a propeller shaft.
The system consists of a hydrodynamic torque converter and a multi-speed transmis-
sion. The functions of the transmission and the torque converter are coordinated, and
they are operated by a common hydraulic system.
Fig. 5. Basic design of the transmission
100121643 1 - 1 EN 0918 ettekma 12 (76)

Operator’s Manual
1.5.2. Torque Converter

A torque converter is a device that adjusts torque steplessly. The power is transmitted
from the impeller to the turbine by hydraulic fluid.
A torque converter consists of three elements and their related parts to multiply engine
torque.
There is no mechanical connection between the impeller and turbine; the fluid flow
from the impeller rotates the turbine. The impeller acts as a centrifugal pump, featuring
curved blades that direct the fluid flow through the inner ring against the turbine, in the
direction of rotation.
The blades of the turbine and impeller are curved in opposite directions. The force
generated by the fluid flow acts on the turbine in the same direction as the impeller
rotation; when the resistance is equal, the impeller and turbine act as a simple clutch.
The curvature of the blades of the turbine generates a return flow that creates the
maximum multiplication of force. Fluid flows out of the turbine against the impeller’s
direction of rotation. To prevent the return oil that comes from the turbine from working
against the impeller, the stator directs the flow into the impeller vanes with the
impeller’s direction of rotation rather than against it
1 2 3
Fig. 6. Basic design of the torque converter
1. Impeller
2. Turbine
3. Stator
100121643 1 - 1 EN 0918 ettekma 13 (76)

Operator’s Manual
Impeller
The engine power is transmitted from the engine flywheel to the impeller. This
element, constituting the pump portion of the hydraulic torque converter, is the primary
component that starts the oil flow to the other components, resulting in multiplication
of torque. The impeller gives the oil its movement, forcing it into the turbine.
Turbine
The turbine is mounted opposite the impeller and connected to the output shaft of the
torque converter. The turbine is the driven member of the torque converter. Fluid is
directed at the outer perimeter of this element. It discharges the fluid at its center and
also transfers the hydraulic force to the transmission.
Stator
The stator, the torque converter’s reaction member, is located between the impeller
and turbine. Its function is to redirect the fluid exiting the inner portion of the turbine to
the impeller element for recirculation.
The stator has strongly curved blades, and its hub features an overrunning clutch that
prevents the stator from turning against the engine’s direction of rotation. The stator
changes the direction of the oil flow such that the oil returns to the impeller in the direc-
tion of rotation of the impeller. The overrunning clutch prevents the stator from running
against the direction of rotation of the impeller and turbine by the force of the flow.
100121643 1 - 1 EN 0918 ettekma 14 (76)

Operator’s Manual
1.5.3. Transmission
The transmission has clutch discs that engage the gears. The multi-speed transmis-
sion can be engaged under load. The control system adjusts the speed and load and
directs the hydraulic oil to the clutch pack, which selects the optimal gear for each
operating situation.
The speed and direction clutch assembly is fixed to the transmission case and
connected to the output shaft of the converter. The purpose of the speed and direc-
tional clutches is to direct the power through the gear train to provide the desired
speed range and direction.
1.5.4. Transmission Controls

The carrier has three speed ranges for each direction. The drive direction selection
and gear changing are electro-hydraulic. The gear shifter is connected to the electric
control unit that operates the magnetic valves connected to the transmission shift
control valve.
The transmission shift control valve is mounted directly on the side of the converter
housing. The function of the control valve is to direct the oil under pressure to the
desired directional and speed clutch.
The speed and directional clutch assemblies are mounted inside the transmission
case and connected to the output shaft of the converter either by direct gearing or via
driveshaft. The purpose of the speed and directional clutches is to direct the power
through the gear train such that the machine can be driven at the intended speed in
the desired direction.
100121643 1 - 1 EN 0918 ettekma 15 (76)

Operator’s Manual
1.6. Mechanical Transmission

1.6.1. General
The diesel engine runs a powershift transmission, from which the power is further led
to the both axles.
1.6.2. Driveshafts
The driveshaft assembly consists of a driveshaft, a slip joint, and one or more
universal joints. This assembly provides a flexible connection through which power is
transmitted from the transmission to the live axle.
There are two driveshafts in the power train. The two output shafts connect the lower
part of the powershift transmission case to the rear and front axles.
1.6.3. Axle Assemblies

Both axles are driving. The power is transmitted from the drive / differential gear to the
wheel hubs, which incorporate planetary gear units. The axles are of the double
reduction type having primary reduction by spiral bevels and secondary reduction
through planetary gears in the hub ends.
Power is transmitted from the drive shaft to the sun gear which is fitted to the end of
the drive shaft. By means of the planet pinions, the sun gear rotates the planetary
carrier which is fastened to the wheel hub.
The brake assemblies are oil immersed multi-plate disc type mounted within the
centre casing and are operated hydraulically. As they are enclosed and running in oil,
they are free from the ingress of dirt and foreign matter and are thus ideally suited to
off-highway applications. The centre casing has been designed to give adequate oil
capacity for heat dissipation.
Fig. 7. Axle assemblies
100121643 1 - 1 EN 0918 ettekma 16 (76)

Operator’s Manual
1.7. Hydraulics
This section contains general information concerning the carrier hydraulic system.
Detailed information is available in carrier schemas.
1.7.1. Pumps
General
The carrier has a common hydraulic system for steering and operation of accessories.
A hydraulic pump connected to a power outlet on the diesel engine supplies fluid to
the accessories system and also to the steering system. Simultaneous operation of
steering and accessories is possible.
Pumps
The hydraulic system comprises hydraulic pumps powered by a diesel engine. The
hydraulic fluid is distributed from the hydraulic pumps to the various parts of the carrier
by directional control valves.
Filtering
To provide good operational reliability and to maximize the lifespan of the components
included in the hydraulic system, a high degree of filtration has been implemented. All
of these filters are fitted with indicators to indicate when the filter cartridges should be
changed.
100121643 1 - 1 EN 0918 ettekma 17 (76)

Operator’s Manual
1.7.2. Brakes
General
Inside the axle assemblies, in the drive housing, oil bath type disc brake packs have
been fitted for both drive shafts.The brakes are hydraulically operated.
Function of the dual-circuit brake valve

The output pressures are strictly independent. A failure in one of the circuits does not
affect the operation of the other circuit.
The service brake valve is a mechanically-controlled, three-way, graduated release
double pressure reducing valve. The valve provides precisely controlled output pres-
sures proportional to the pedal stroke and therefore to the force applied to the pedal.
In a braking circuit, the brake valve is usually associated with the dual-circuit accumu-
lator charging valve.
Pressure accumulator
A hydraulic accumulator is a pressure storage reservoir in which a non compressible
hydraulic fluid is retained under pressure from an external source. Its main function is
to store hydraulic energy and is necessary, make the energy available again to the
system.
The main reasons that an accumulator is used in a hydraulic system are so that the
pump doesn't need to be so large to cope with extremes of demand, so that the supply
circuit can respond more quickly to any temporary demand and to smooth pulsations.
Function of the accumulator loading valve

Accumulators store energy to supply the brake valves even when the usual source of
hydraulic flow is not available. It stores hydraulic fluid at a pressure higher than the
brake pressure. The accumulators run at an operating pressure between 120 and 150
bar. When the accumulator pressure falls below the switch-on pressure of the loading
valve, the accumulators are loaded until the switch-off pressure is reached. The
switch-off pressure of the standard loading valve is set to 150 bar. The switch-on pres-
sure is approx. 120 bar.
The pressure accumulator loading valve controls the hydraulic accumulator process,
for systems with variable displacement pumps.
Safety/parking brake valve

Serving as a safety/parking brake in the carrier there are spring cylinders. When the
safety/parking brake is operated, braking occurs by means of the spring loaded cylin-
ders. When the safety/parking brake is released, oil flows from the charging valve into
the spring loaded cylinders and releases the brake. Releasing pressure is 25 bar.
100121643 1 - 1 EN 0918 ettekma 18 (76)

Operator’s Manual
1.7.3. Steering
General
The engine end and load end part of the centrally articulated carrier are joined in the
frame joint, which is movable about a vertical shaft for steering and is operated by two
hydraulic cylinders. Simultaneous operation of the steering and the accessories is
possible. Steering valve is Orbitrol type.
Load sensing
In load sensing steering systems both the steering system and the working hydraulics
can be supplied from just one pump. In addition LS steering systems make energy
saving possible by the use of an LS pump. Load sensing steering units have an extra
connection for load sensing (LS), so that a load pressure signal can be directed via
the steering unit to an LS pump. The load sensing signal controls the oil flow from the
LS pump to the steering unit.
Main components
– Hydraulic pump, which supplies the pressure fluid required.
– Steering device, to which the steering wheel is connected, controls the hydrau-
lic pump-supplied fluid flow to the cylinders so that a turning direction and
speed corresponding to the steering wheel movements is obtained for the car-
rier. The function of the steering device is also to act as a stand-by steering
pump in situations of reduced pressurized fluid supply to the steering system.
In this case, the required steering force is produced manually.
– Steering cylinders, which turn the carrier via its centre hinge upon the effect of
the pressure fluid.
100121643 1 - 1 EN 0918 ettekma 19 (76)

Operator’s Manual
2. SAFETY RULES
2.1. General Safety Rules
1. Learn to recognize and avoid potential hazard areas.

2. Use recommended safety equipment, i.e. gloves, safety boots, hard hats,
goggles and ear protection, and wear protective clothing when and where
required.
3. Study the Operator, Lubrication and Maintenance Manuals for the carrier.
4. Familiarize yourself with the carrier's capabilities, limitations and correct
operating techniques.
5. Operating the carrier when physically unfit or under the influence of alco-
hol or drugs is strictly forbidden.
6. Only appropriately trained and qualified operators are permitted to operate
the carrier.
7. Keep floors, steps and running boards clean and free of oil, ice, mud and
loose objects.
8. Never remove engine exhaust system components or carrier safety covers
or devices while the carrier is operational.
9. Do not mount or dismount the carrier while it is moving.
10. Do not stand near the carrier when the engine is running.
11. Keep a well maintained, serviceable first aid kit in the carrier.
12. Comply at all times with the instructions in this manual and your com-
pany's regulations regarding operation of the carrier.
100121643 1 - 1 EN 0918 ettekma 20 (76)

Operator’s Manual
2.2. Operating Safety Rules
1. Keep the work site clear of personnel while the engine is running.
2. Shut off the engine when refuelling, servicing or carrying out repairs. The
engine may be left running for adjustment/tuning purposes only.
3. Read this manual thoroughly before operating the carrier.
4. Check the area around the carrier before entering the operator's cab.
5. With the exception of the co-operator, no other passengers are allowed in
the cab.
6. Before starting the carrier, make sure that the transmission is in neutral
and the safety/parking brake is applied.
7. Before starting to drive, always make sure that all equipment controls and
functions are in working order.
8. Maintain a safe operating distance between the carrier and other person-
nel.
9. Repair or report any irregular functions or damage immediately.
10. Never use the safety/parking brake to stop the carrier other than in emer-
gency situations.
11. Always reduce speed when travelling downhill.
12. Follow all auxiliary equipment instructions before operating.
13. Strictly observe all work site regulations regarding operation of the carrier.
14. Park on level ground wherever possible. Turn the wheels towards a bank
or berm, or block the wheels when parking on a slope.
15. Shift the transmission to neutral during idle periods.
16. Never stop the engine immediately after running at high revs if the engine
is hot.
17. Do not open the main switch while the engine is running.
18. Always make sure that the safety/parking brake is engaged before leaving
the carrier for any reason.
100121643 1 - 1 EN 0918 ettekma 21 (76)

Operator’s Manual
19. Never exceed maximum inclination values

• longitudinal 9°
• lateral 4°
Fig. 8. Warning
100121643 1 - 1 EN 0918 ettekma 22 (76)

Operator’s Manual
2.3. Label locations
1 2 3
6 5
Fig. 9. Label locations
1. Cabin
– Safety label - Fall over danger
– ROPS/FOPS label
– Safety label - Engine use
– Safety label - General
2. Warning - High pressure hydraulic oli
3. Warning - Danger of crushing
4. Fire suppression
5. Danger of crushing / Staying on area restricted
6. Pressurized vessel
100121643 1 - 1 EN 0918 ettekma 23 (76)

Operator’s Manual
3. OPERATOR CONTROLS
3.1. Dashboard
3.1.1. Switches TB7
1 2 3 4 5 6 7
14
15
8 9
16
10 11
17
12
13
Fig. 10. Switches
1. Turn signal 10. Hand throttle +/-

2. Beacon 11. Hand throttle ON/OFF
3. Head light front 12. Horn by-pass
4. Head light rear 13. Horn
5. Work light front 14. Safety/parking brake
6. Work light rear 15. Safety/parking brake release
7. Work light 16. Current key switch
8. Engine override switch 17. Engine stop
9. Fire suppression system test
(optional)
100121643 1 - 1 EN 0918 ettekma 24 (76)

Operator’s Manual
1. Turn signal
Use
– Turning the switch to left or right causes a left-turn light or a right-
turn light to blink.
2. Rotating beacon
Purpose
– Warns persons being exposed under normal conditions of carrier
use to the hazards of impact or crushing and its movements.
Switch operation
– On / Off.
3. Head light – front
Switch operation
– High beam / Low beam / Off
4. Head light – rear
Switch operation
– On / Off
5. Work light – front
Switch operation
– On / Off
6. Work light – rear
Switch operation
– On / Off
7. Work light
Switch operation
– On / Off
100121643 1 - 1 EN 0918 ettekma 25 (76)

Operator’s Manual
8. Engine override switch
Use
– Allows the carrier operator to override the automatic engine shut-
down when the switch is used during starting the engine.
– Must be used only in an emergency to start the engine and to drive
the carrier to a safe place.
Note!
Must be used only in an emergency to start the engine

and to drive the carrier to a safe place.
Note!
Faulty and unnecessary use makes the fault indicator

light to light up and an error code is displayed on the mul-
ti information display.
9. Fire suppression system test (optional)
Switch operation
– Audible signal will be heard.
– Visual signal will be seen.
– Engine stops.
10. Hand throttle + / -
Purpose
– Engine speed can be adjusted after switching the hand throttle ON.
Switch operation
– Right – increase the engine speed.
– Left – decrease the engine speed.
100121643 1 - 1 EN 0918 ettekma 26 (76)

Operator’s Manual
11. Hand throttle On / Off
Purpose
– Used to set the engine speed during stationary operations.
– Use the “hand throttle + / -” switch to get the desired rpm.
Switch operation
– On / Off
12. Horn by-pass
Purpose
– Used to by-pass horn when starting the engine.
Switch operation
– On / Off
13. Horn
Purpose
– A warning device
14. Safety/parking brake
To engage
– Push the safety/parking brake button.
Event sequence
– Safety/parking brake warning indicator lights up.
To reset
– Pull the safety/parking brake button up.
– Push the safety/parking brake release button.
Should be used when
– On-job parking is required.
– Leaving the carrier unmanned.
– The service brake fails.
– Emergency circumstances require its use.
100121643 1 - 1 EN 0918 ettekma 27 (76)

Operator’s Manual
15. Safety/parking brake releasing
Brake release conditions

– Emergency stop button released.
To reset
– Pull the safety/parking brake button up.
– Push the safety/parking brake release button.
Course of events
– Safety/parking brake release button light goes out.
– Safety/parking brake warning indicator goes out.
– Safety/parking brake is disengaged.
Lap belt with automatically locking retractor
– Lap belt must be engaged before releasing the safety/parking
brake.
100121643 1 - 1 EN 0918 ettekma 28 (76)

Operator’s Manual
16. Current key switch - engine start
Engine start
– Prevents accidental startup of the engine by unauthorized persons
when the operator is absent.
– Insert the switch key and turn clockwise.
– Turn the current key switch further to startup position.
– Horn sounds three seconds.
– Once the engine fires, release the current key switch.
Engine stop
– A solenoid stops the engine when turning the current key switch
anti-clockwise.
– Reduce speed to idling for a few minutes to allow the engine tem-
perature to equalize when stopping the engine.
– Engine shutdown is electrical.
Caution!
Possible carrier damage.

Stop the engine immediately if any of the following occur:
• significant drops or fluctuations in oil pressure
• falling power output and engine speed with the position sensor
(accelerator pedal) in the same position
• large amounts of exhaust smoke emitted from the exhaust
• significant increases in coolant and oil temperature
• sudden, unusual noises from the engine or exhaust gas
turbocharger
17. Engine Stop
Purpose
– Stops the engine.
100121643 1 - 1 EN 0918 ettekma 29 (76)

Operator’s Manual
3.1.2. TB7b
1 2 3
4 5
Fig. 11. Controls
1. Engine end support leg - raising and lowering.
Switch operation
– Move the lever up or down.
2. Load end left support leg - raising and lowering.
Switch operation
3. Load end right support leg - raising and lowering.
Switch operation
100121643 1 - 1 EN 0918 ettekma 30 (76)

Operator’s Manual
4. Load end left support leg - extension in and out.
Switch operation
– Move the lever left or right.
5. Load end right support leg - extension in and out.
Switch operation
100121643 1 - 1 EN 0918 ettekma 31 (76)

Operator’s Manual
3.1.3. Norsmart Control system.

Norsmart Control system is based on the smart distributed IO-units. The units commu-
nicate with each other and the MID-unit through the CANbus.
System is operated with its own controllers and navigation keyboard.
Keyboard is mainly used to control the carrier’s user interface.
System contains also HC-modules which can be used to expand the CANbus easily
and effectively.
For more information see instructions for NorSmart Control System User Interface
Manual.
Fig. 12. User interface
1. USB-connector
2. Remote display
3. Navigation keyboard
100121643 1 - 1 EN 0918 ettekma 32 (76)

Operator’s Manual
1. USB connector
Purpose
– To update the software.
– To take software backup.
Definition
– Main switch closed.
2. Multi information display
Purpose
– Provides all the necessary information.
3. Navigation keyboard
Purpose
– To control the system.
100121643 1 - 1 EN 0918 ettekma 33 (76)

Operator’s Manual
3.1.4. Automatic Brake Application System
Definition
– The braking system is equipped with hydraulic accumulators.
– The system automatically applies the safety/parking brakes and stops the car-
rier before the hydraulic accumulators reach the critical level to stop the car-
rier.
Warning
– Warning system because of the hydraulic accumulators used for the applica-
tion of the service brake.
– Warning attracts the operator’s attention by providing a continuous visible
warning.
– System warns the operator that the hydraulic accumulator pressure is
approaching the critical level of the accumulator pressure so that the carrier
can be safely stopped or the operator prepares himself/herself for the applica-
tion of the safety/parking brakes.
Warning light and audible alarm

– Hydraulic accumulator pressure drops below 100 bar.
– Hydraulic reservoir fluid level too low.
– Transmission oil pressure below 10 bar.
Fig. 13. Warning light
100121643 1 - 1 EN 0918 ettekma 34 (76)

Operator’s Manual
The safety/parking brakes will be automatically engaged when:

– Engine stops.
– Transmission clutch pressure drops below 4,5 bar.
– Service brake pressure drops below 75 bar.
Automatic brake application override

1. Press the safety/parking brake pilot lamp push button once if the pressure drop
is momentary.
2. Press the safety/parking brake pilot lamp push button all the time if the pressure
drop is not momentary.
– Enables the operator to override automatic brake application.
– Must only be used in an emergency situation to drive the carrier to a safe
place.
– Park the carrier on a level surface if possible.
– Jack-knife the carrier if parking on a slope.
100121643 1 - 1 EN 0918 ettekma 35 (76)

Operator’s Manual
3.1.5. Engine Control System

The engine is equipped with an electronic control system that monitors both the
engine and itself.
If a malfunction is detected, it is immediately evaluated and one of the following meas-
ures is automatically initiated:
– A malfunction is indicated by the maintenance- and fault indicator warning
lights on the multi information display.
– The fault codes are shown on the drive display screen.
– The engine is switched to the appropriate back-up function for continued oper-
ation.
Fig. 14. Multi-information display
Maintenance indicator – yellow indicator light

Lights up
– if servicing is needed.
– The diesel engine is in impermissible operating state and the ve-
hicle should be taken into service as soon as possible.
Fault indicator – red indicator light

Lights up
– Engine control system has detected a fault.
– Stop engine immediately. The engine might shut down automati-
cally depending on engine controller configuration.
100121643 1 - 1 EN 0918 ettekma 36 (76)

Operator’s Manual
3.2. Main Switch
Fig. 15. Main switch
Main switch
– The main switch in the carrier switches off and on the supply of electricity to
the carrier.
– It is vital that the main switch is opened before any electrical inspection or work
is carried out such as replacing a blown fuse.
– Isolates the battery from the rest of the circuit for fire protection when the
engine is stopped and the carrier is left unattended.
– Do not open the switch while the engine is running.
– After turning the current key switch anti-clockwise to shut down the engine,
wait at least 40 seconds before opening the main switch.
– Wait one minute before starting procedure.
Note!
The engine can be stopped only in emergency situation

by opening the main switch.
100121643 1 - 1 EN 0918 ettekma 37 (76)

Operator’s Manual
3.3. Circuit Breakers
Fig. 16. Circuit breakers
Circuit breaker
– A circuit breaker is an automatically-operated electrical switch designed to
protect an electrical circuit from damage caused by overload or short circuit.
– The centre of the circuit breaker pops up in response to excessive temperature
or current rise.
– Can be reset manually to resume normal operation.
100121643 1 - 1 EN 0918 ettekma 38 (76)

Operator’s Manual
3.4. Driving Controls
1 2
3
4
4
3
Fig. 17. Driving controls
1. Steering wheel
2. Gear selector
3. Accelerator pedal
4. Service brake pedal
100121643 1 - 1 EN 0918 ettekma 39 (76)

Operator’s Manual
1. Steering Wheel
– As the steering system is hydraulic, the engine must be running in

order to make the system fully operational.
– The steering valve controls the direction and volume of the fluid
flow to the steering cylinders.
2. Gear shifter
– Desired situation-specific driving speed range and direction.

– “F” position for forward movement.
– “R” position for reverse movement.
– ”N” position for neutral.
– Three gears in both directions.
– Gear shifting is possible while the carrier is in motion.
Danger!
Never leave the carrier unattended with the gear shifter

in either the forward or reverse position while the engine
is running. Always make sure that the safety/parking
brake is engaged before leaving the carrier for any
reason.
3. Accelerator pedal
– Foot-pedal on the far right at floor level.

– Controls the engine revolutions.
– Depress the pedal to increase engine speed.
4. Service brake pedal
– Foot-pedal located to the left of the accelerator pedal.

– Depress the pedal to activate the service brakes.
– Always use the service brakes as required to stop the carrier.
– Use the engine to slow down.
– The brakes are applied on all wheels when the pedal is depressed.
– The braking force depends on how far the pedal is depressed.
100121643 1 - 1 EN 0918 ettekma 40 (76)

Operator’s Manual
3.5. Seat
3 4
2
1
5 6
Fig. 18. Seat
1. Weight adjustment.
– to increase or decrease the suspension resistance.
2. Seat cushion angle adjustment.
3. Backrest regulation.
4. Seat belt.
– Always use the seat belt for all kinds of driving.
– A sudden application of the brakes could have serious consequences if the
belt is not used.
– Withdraw a sufficient length of strap from the retractor in a smooth and steady
movement.
– Insert the locking tongue into the buckle until a click is heard.
5. Fore-and-aft adjustment.
– Pull the lever.
– Slide the seat forward or backwards to required position.
– Release the lever after adjustment.
6. Seat rotating.
100121643 1 - 1 EN 0918 ettekma 41 (76)

Operator’s Manual
Danger!
Ensure the seat is locked when driving.

• Do not attempt to drive when swivelled as this may result in
injury.
• Lock the seat to its extreme positions after turning the seat.
• The seat will swivel when the lever is pulled up.
• The seat will lock when the lever is pushed down.
7. Locking lever
100121643 1 - 1 EN 0918 ettekma 42 (76)

Operator’s Manual
3.6. Emergency Stop
Fig. 19. Emergency stop
1. Emergency stop - mushroom head button
Purpose
– To deflect or minimize the risk as quickly as possible.
– To provide safety for man and the carrier in emergency situations.
– In the event of operational malfunction.
– For fast stoppage of movement.
To engage
– Push the button down.
To reset
– Release the emergency stop button.
100121643 1 - 1 EN 0918 ettekma 43 (76)

Operator’s Manual
3.7. Fire Suppression System(optional)
Fig. 20. Controls
1. Manual activation device

– Pre-engineered, fixed nozzle system for protection of carrier.
– Discharge of the system is initiated from the remote actuator.
– More information from the operation and maintenance manual for the fire sup-
pression system.
2. Test Button (optional)

The fire suppression system is equipped with a test feature which allows verification
of proper function of the audible alarm, visual alarm and engine shutdown features.
To use the test features, depress and hold the button.
When the test button is pressed,
– audible signal will be heard.
– visual signal will be seen.
– engine stops.
On a weekly basis
– On carriers equipped with test features, depress the test button to confirm
proper shutdown operations.
100121643 1 - 1 EN 0918 ettekma 44 (76)

Operator’s Manual
4. OPERATION AND USE
4.1. Commissioning on Delivery

The following inspections must be performed during the delivery check-up.
1. Make a ”walk-around” inspection of the carrier.
2. Check the engine oil level.
3. Check the transmission oil level.
4. Check the coolant level.
5. Check the axle oil level.
6. Check the hydraulic fluid level.
7. Check the fuel level.
8. Clean the air filter / check air cleaner oil.
9. Check tyre pressure and condition.
10. Check the wheel nuts.
11. Check the gauges and warning lights.
12. Check the safety/parking and service brake function.
13. Check the engine belts for tension and condition.
14. Check the steering function.
15. Check the engine revolutions.
16. Check the hydraulic circuit.
17. Check the safety symbols and warnings.
18. Check the fire extinguisher pressure.
19. Check the carrier for leakages.
100121643 1 - 1 EN 0918 ettekma 45 (76)

Operator’s Manual
4.2. Daily Operation

4.2.1. Daily Maintenance Operations
1. Make a walk–around inspection of the carrier.
2. Take a few minutes to correct any minor problems.
– Doing so now can prevent major repairs at a later date.
3. Perform the following checks before starting the engine at the beginning of each
shift.
– Check the fuel level.
– Check the hydraulic fluid level.
– Check the transmission oil level.
– Check the engine oil level.
– Check the coolant level
– Check the air cleaner.
– Check the heated fuel pre–filter.
– Check the safety/parking and service brakes.
– Check the warning lights and gauges.
– Check there are no leaking or hanging hoses.
– Check the tyres visually.
4.2.2. Instrumentation Checks

The engine will reach normal operating values after a few minutes of operation with a
moderate load and varying speed.
Stop the engine and investigate the problem if any of the values do not read within the
normal operating ranges. Check the values from the display.
100121643 1 - 1 EN 0918 ettekma 46 (76)

Operator’s Manual
4.2.3. Testing the Brakes

The operation and holding capacity of the brakes must always be ensured before
driving.
Start up the engine and let it run until the transmission oil temperature reaches normal.
Danger!
Do not operate the carrier with a faulty service or safety/

parking brakes. Damage to the carrier or serious per-
sonal injury may result.
Pressure accumulators
Hydraulic pressure accumulators are energy storage devices. They hold hydraulic
pressure in the hydraulic brake circuit only for emergency assistance if the hydraulic
pump fails or the engine quits altogether.
1. Start and run the engine for 1 minute to charge the accumulators.
2. Switch off the engine.
3. Turn the current on with the current key switch.
4. Apply and hold the service brake foot pedal for 10 seconds and release.
5. Repeat pressing and releasing.
– Service brake warning light lights up at 100 bar.
– This should take at least 3 applications.
Danger!
Do not operate the carrier if the following occurs:

• Less than 3 applications are required to illuminate the brake
pressure indicator light.
• Brake pressure indicator light does not illuminate at all.
100121643 1 - 1 EN 0918 ettekma 47 (76)

Operator’s Manual
Safety/Parking Brakes
The holding effect of the safety/parking brakes depends both on the condition of the
brake discs and that there is no pressure acting on the safety/parking brake circuit.
1. Start the engine.
2. Push the safety/parking brake mushroom head button down.
3. Pull the safety/parking brake mushroom head button up.
Note: Don’t push safety/parking brake releasing button.
4. Set the gear shifter into 2nd gear.
5. Apply full throttle.
6. The carrier should not move. Do not operate if the carrier moves.
Service Brakes
The holding effect of the service brakes depends both on the condition of the brake
discs and on the pressure acting on the service brake circuit.
2. Press the service brake pedal down.
3. Pull the safety/parking brake mushroom head button up.
4. Push the safety/parking brake pilot lamp button to release the brake.
5. Set the gear shifter into 2nd gear.
6. Apply full throttle.
7. The carrier should not move. Do not operate if the carrier moves.
Note!
If the carrier fails any of the above tests, tag and remove
from service. Report to maintenance personnel.
100121643 1 - 1 EN 0918 ettekma 48 (76)

Operator’s Manual
4.3. Driving the Carrier

4.3.1. General
Before commencing actual productional use of the carrier, familiarize yourself thor-
oughly with its operation, behaviour in different situations and the location of its
controls. Continued operation of the carrier without regular inspection or maintenance
schedules will greatly reduce its efficiency and life-span, and its therefore forbidden.
Danger!
1. Read this manual thoroughly before operating the carrier.

2. Always make sure that all carrier controls and functions are in working order
before driving.
3. Follow all auxiliary equipment instructions before operating.
4. Keep the operator’s cab clean and free of foreign objects.
5. Check to ensure that all travel paths are clear of obstruction.
6. Ensure proper side clearances are maintained.
7. Maintain a safe operating distance between the carrier and other personnel.
8. Repair or report any irregular operations or damage immediately.
9. Strictly observe all work site regulations.
10. Shut down the engine when fuelling, servicing or repairing.
100121643 1 - 1 EN 0918 ettekma 49 (76)

Operator’s Manual
4.3.2. Before Start
Note!
Check the area around the carrier before entering the operator’s cab.
– Make sure that the frame joint safety bar is not connected.
– Use the steps and hand rails provided to enter the cab safely.
– Do not grab the steering wheel when entering the cab.
– Keep all foot controls free of obstruction.
– Keep the operator’s cab clean and tidy.
Warning!
Lock the frame joint by the safety bar when lifting and
shipping the carrier. Stop the engine before inserting
and removing the safety bar.
Fig. 21. Safety bar
100121643 1 - 1 EN 0918 ettekma 50 (76)

Operator’s Manual
4.3.3. Engine Start
Caution!
Before starting, make sure the carrier's work danger area is free of personnel.
Check after repairs that all protective equipment is mounted and all tools have been
removed from the engine.
Do not use additional start aids (e.g. start pilot injection) when starting with heating
plugs/heating flange! Danger of accident!
1. Close the main switch.
2. Check that the carrier’s gear selector is in neutral.
3. Check that the safety/parking brake is engaged.
– Starting the engine is prevented if the safety/parking brake is not engaged.
4. Switch the current on with the current key switch on the instrument panel, where-
upon the indicator lights will light up.
5. Check all indicator lights are illuminated. If a light is not illuminated, change the
light. The engine must not be started if a warning light is not functioning.
6. Start the engine after the preheating indicator light extinguishes.
– Engine can be started right away if the light does not come on.
7. Start up the engine by turning the current key switch further round.
100121643 1 - 1 EN 0918 ettekma 51 (76)

Operator’s Manual
8. Engage the ignition continuously for a maximum of 20 seconds.

– If the engine fails to start, wait for one minute and then repeat the starting pro-
cess.
– The one minute interval is required for the batteries to restore their charge and
also to prolong their life.
– If the engine fails to start after two attempts, determine the cause by referring
to the troubleshooting table.
– The EMR3 system has activated the start lock to protect the engine if the
engine does not start and the fault indicator lamp flashes.
– Switch the system off with the ignition switch for about 30 seconds to disen-
gage the start lock.
9. Warm up the engine for approximately 30 seconds at a low idling speed.
– Do not run up the engine immediately to high idling speed / full load operation
from cold.
10. If the starter is connected by a relay on the EMR3:
– the maximum starting time is limited by the EMR3.
– the pause between two start attempts is given by the EMR3.
Danger!
No unauthorized persons are permitted in the operating

area while the engine is running.
100121643 1 - 1 EN 0918 ettekma 52 (76)

Operator’s Manual
4.3.4. Gear Shifting

Gear shifter operation
– The travel positions can be selected once the shift lever is lifted.
– The travel positions are Forward, Reverse and Neutral.
– Direction is selected by placing the shift lever in one of three positions.
– Gearshifts are made by rotating the twist grip handle either in the upshift posi-
tion or in the downshift position.
Note!
Shift the transmission to neutral during idle periods.
Fig. 22. Gear shifter
1. Shift lever
2. Twist grip handle
100121643 1 - 1 EN 0918 ettekma 53 (76)

Operator’s Manual
Definition of terms
Selecting neutral
– Place the shift lever into its central detented position.
Selecting forward - engine end
– Lift the shift lever.
– Push the shift lever away from the driver.
– The forward position is a stable shift lever position.
Selecting reverse - load end
– Lift the shift lever.
– Pull the shift lever towards the driver.
– The reverse position is a stable shift lever position.
Upshift - selecting up
– Rotate the twist grip handle counter clockwise.
Downshift - selecting down
– Rotate the twist grip handle clockwise.
Gear selection
First gear
– Use to set the carrier in motion.
– Load and ground conditions prohibit driving in a higher gear.
Second gear
– The carrier speed approaches the limit of the first gear.
– Load and ground conditions allow a higher travelling speed.
Third gear
– The carrier speed approaches the limit of the second gear.
– Load and ground conditions allow travelling at maximum speed.
Lower gear change
– Observe the carrier speed.
– Do not change gear if the carrier speed is higher than the maximum speed of
the gear you intend to select.
Drive direction change
– The carrier must be brought to a complete stop before the change.
100121643 1 - 1 EN 0918 ettekma 54 (76)

Operator’s Manual
4.3.5. Steering
The carrier has hydrostatically controlled frame joint steering. Notice that the steering
reaction speed diminishes as the engine’s rotation speed decreases. Take this into
account particularly when turning and when driving in higher gears. Pull back slightly
when you reach the steering stop to prevent excessive fluid heating. Use the hand-
knob when steering.
Fig. 23. Use of the steering wheel
4.3.6. Setting The Carrier In Motion
Note!
The following procedures must be followed accordingly

in order to get the carrier moving.
1. Ensure that any possible outside couplings to the carrier are disconnected.
2. Release the safety/parking brakes.
3. Set the gear shifter to the desired driving direction position.
4. Use first gear to set the carrier in motion.
5. Apply even pressure to the accelerator until the carrier starts to move.
6. Check to ensure that all travel routes are clear of obstruction.
7. Check the function of the steering.
100121643 1 - 1 EN 0918 ettekma 55 (76)

Operator’s Manual
4.3.7. Driving on Slopes

Select the speed range always according to the prevailing driving conditions. Watch
the transmission temperature. A suitable operating temperature is about 90 °C. If too
high a range is used, the transmission can rapidly overheat and can cause damage.
When driving downhill, select a gear that will enable you to make best possible use of
the transmission / engine braking. Avoid continuous use of the service brakes, as this
will cause unnecessary wear and heating.
When driving uphill, use a sufficiently low gear to avoid overheating of the transmis-
sion.
Danger!
Driving downhill with the gear disengaged in neutral is

forbidden. Never drive downhill at high speed.
4.3.8. Road Driving

Read the carrier-specific driving instructions carefully for special instructions
concerning driving the carrier.
1. Do not release the safety/parking brake until you have verified the following.
– The steering is working properly.
– The correct driving direction and driving speed has been selected.
– All equipment and functions operate normally.
– Transportation poses no danger to people or property.
2. Never try to drive the carrier from any other place than the actual operator’s
cabin.
3. Only trained personnel are allowed to drive the carrier.
4. It is forbidden to enter or leave the carrier while it is moving.
5. It is forbidden to transport passengers inside the carrier.
6. Beware of narrow passages and low underpasses.
7. If the driving instructions are not followed, this may cause the carrier to fall over
and cause serious damage.
8. Strictly apply all work site traffic regulations.
9. Lock all doors and latches that need not be open.
100121643 1 - 1 EN 0918 ettekma 56 (76)

Operator’s Manual
4.3.9. Stopping
1. Stop the carrier by decreasing the engine revolutions and using the service
brake.
– Avoid heavy braking when driving a loaded carrier.
Caution!
Never use the safety/parking brake to stop the carrier

other than in emergency situations.
2. Stop the carrier off the traffic lane.
– Preferably on level ground or turned towards a berm.
3. Engage the safety/parking brake.
– See that the safety/parking brake indicator light comes on.
4. Set the gear shifter to neutral.
– The transmission cannot be used as a braking device when parked.
5. Allow the engine to run at idling speed for a few minutes.
6. Check the following things if the carrier is left unattended on a slope.
– Safety/parking brake is set.
– Wheels are blocked.
– Or the wheels are turned into a bank or berm.
Caution!
Run the engine at idling speed for one or two minutes

without load after operation at full power or a high cool-
ant temperature.
100121643 1 - 1 EN 0918 ettekma 57 (76)

Operator’s Manual
7. Stop the engine by turning the current key switch anti-clockwise.

– Wait at least 40 seconds before opening the main switch.
Note!
The control unit remains active for about another 40 sec-

onds to save the system data and then switches itself
off.
8. Open the main switch.
Caution!
The main switch must not be opened while the engine is

running.
100121643 1 - 1 EN 0918 ettekma 58 (76)

Operator’s Manual
4.4. Carrier Transfer

4.4.1. Towing
To be noted
The carrier can not be started by towing. Attempts to start the carrier by towing
damages seriously the transmission circuit. Tow the carrier only in such cases where
it is judged necessary. Use always the tow bar.
Before towing is to start, remember to disengage the safety/parking brakes and
dismatle the cardan shafts. Make sure the towing carrier and the tow bar are robust
enough and dimensioned to tow the indended load.
Engine/pump combination is in working order.
– Towing can be carried out without any special measures.
– Start up the engine.
– Adjust the engine RPM to achieve normal transmission feed pressure.
– Towing can then be performed at normal driving speed.
Engine/pump combination is not functioning:
– Engine cannot be started.
– Steering does not function either.
– Release the safety/parking brakes mechanically
Note!
Due to the design of the hydraulic system, the engine

cannot be started by pushing or towing.
After towing test the brakes.
All towing points are painted red.
If the carrier is to be hoisted or transported on another carrier, the
frame section must be securely locked against movement by means
of the lock stays.
100121643 1 - 1 EN 0918 ettekma 59 (76)

Operator’s Manual
Disconnecting the steering cylinder

1. One end of the steering cylinders must be detached or the hydraulic hoses to the
cylinders disconnected.
2. If the hydraulic hoses to the cylinders are disconnected:
– Plug the ends of the hoses.
– Protect the cylinder against penetration of dirt by placing it in a plastic bag.
3. If the cylinder ends or the hydraulic hoses are not disconnected:
– The stiffness of the steering limits the towing speed.
– As no hydraulic pressure is available, steering is very stiff and slow.
Fig. 24. Steering cylinder.
100121643 1 - 1 EN 0918 ettekma 60 (76)

Operator’s Manual
Disconnecting the cardan shafts

Connect the tow bar between the carrier and the towing carrier before disengaging the
brakes and dismantling the driveshafts.
1. Mark the flanges on the cardan shafts.
– To faciliate identical reassembly later on.
2. Disconnect both the front and rear driveline.
3. Fasten the drivelines and support them properly.
– To avoid damage during towing.
Fig. 25. Disconnecting the driveline
100121643 1 - 1 EN 0918 ettekma 61 (76)

Operator’s Manual
Manual emergency release

1. Loosen the nuts of the screws provided for the mechanical and manual release
of the braking units. Move the nuts backwards by approximately 8 mm.
2. Tighten the screws so as to fasten them onto the pressure plate.
3. Using a wrench, tighten the screws in an alternate sequence 1/4 turn at a time so
as to compress the Belleville washers and disengage the braking disks. Tighten
max. by one turn.
Adjustment after manual release

1. Remove the screws complete with the nuts and seals. Replace the seals, apply
silicone–based Tecno Lube 101 grease to the screws and installall parts into the
arm.
2. Adjust the screws to obtain a jut of 35 mmin relation to the arm.
3. Lock into position with nuts. Hold the screws into position while locking the nuts.
4. After locking, check the jut of screws once more.
35 mm 35 mm
Fig. 26. Disconnecting the driveline
100121643 1 - 1 EN 0918 ettekma 62 (76)

Operator’s Manual
4.4.2. Lifting
Many countries have special laws and statutes related to lifting, hoisting cables and
lifting equipment. Always follow the safety regulations required by local laws.
Only a correct type of carrier with a sufficient lifting capacity can be used for lifting.
Fasten two hoists to the lifting points. Ensure that the carrier is properly fastened and
balanced by first lifting it a few centimeters from the ground. Continue the lifting only
after you are convinced that the carrier is in balance and safely fastened.
Warning!
Lock the frame joint by the safety bar when lifting the
carrier. All lifting points are painted red.
100121643 1 - 1 EN 0918 ettekma 63 (76)

Operator’s Manual
4.4.3. Lowering the Carrier Down a Mine

It may be necessary to dismantle the carrier into more manageable sections to enable
lowering the carrier down a mine shaft or similar.
Following points must be observed during disassembly, hoisting and reassembly of
the carrier.
1. Clean the carrier with water and suitable detergent before starting disassembly.
2. Observe strict cleanliness when disconnecting hydraulic, compressed air and
water lines and hoses.
3. Plug the open ends of the hoses, nipples and hydraulic oil lines immediately after
disconnection.
– Seal and protect them in some suitable manner from possible dirt contamina-
tion.
4. Mark all hoses, lines and other connections to facilitate subsequent, correct
reconnection and to avoid confusion.
5. Make sure:
– Hoisting equipment is of the correct size.
– Load capacity of the hoisting equipment.
– Hoisting equipment is securely anchored.
6. Hoisting slings must be in excellent condition and robust enough to bear the
intended load.
7. Attach the slings through the lifting points.
100121643 1 - 1 EN 0918 ettekma 64 (76)

Operator’s Manual
4.5. Special Operating Conditions

4.5.1. Winter Operation
The following points should be observed at the start of the cold season:
Fuel
Danger!
Risk of fire
• Fuel is highly flammable. For this reason, avoid fire and naked
flames and refrain from smoking when handling fuel.
• Use cold-resistant diesel fuel.
Jump-starting
Danger!
Risk of explosion
• The use of liquid or gaseous starting aids can cause explosions.
This may result in severe injuries.
• Do not use liquid or gaseous starting aids, such as ether or
Startpilot to start the engine.
Engine oil
When changing the engine oil, select an engine oil that is compatible with the SAE
classification and the ambient temperatures expected during the period of use.
100121643 1 - 1 EN 0918 ettekma 65 (76)

Operator’s Manual
Coolant
Warning!
Risk of injury
The cooling system is pressurised. Hot coolant can escape under pressure when the
cooling system is opened and scald your skin and eyes.
– Only open the cooling system at coolant temperatures below 90 °C.
– Unscrew the cap slowly and release any excess pressure completely before
opening the cap fully.
– Wear suitable protective gloves, protective clothing and safety goggles when
handling coolant.
Warning!
Risk of poisoning
There is a risk of poisoning if coolant is swallowed.

– Never swallow coolant.
– Never store coolant in containers normally used for beverages.
– Store coolant out of the reach of children.
Check the antifreeze protection properties of the coolant in good time and increase
the antifreeze/corrosion inhibitor concentration if necessary.
100121643 1 - 1 EN 0918 ettekma 66 (76)

Operator’s Manual
Batteries
Have the batteries serviced and recharged more frequently during the cold months of
the year.
Warning!
Risk of injury
The acid contained in batteries burns skin and eyes on contact.

– Do not allow acid to come into contact with your skin, eyes or clothing.
– Wear suitable protective clothing, as battery acid can burn through normal
clothing. In addition, protective gloves and safety goggles should be worn.
– Rinse acid splashes off immediately with clean water and consult a doctor if
necessary.
Warning!
Risk of explosion
• Gases leaking from batteries may explode and therefore cause
injury.
• Fire, naked flames, smoking and sparks are therefore not
permitted in the vicinity of the batteries.
Careful maintenance and low power consumption will help to maintain the full battery
charge. Starting capacity is greatly reduced in cold weather; at -10 °C, for example, it
is only around 60% of normal capacity. If the engine is not used for a long period of
time, store the batteries in a heated place if possible. Ensure good ventilation when
recharging.
100121643 1 - 1 EN 0918 ettekma 67 (76)

Operator’s Manual
4.5.2. High Ambient Temperature, High Altitude
Power shift transmission operation in high ambient temperature, dusty atmos-

pheric conditions
– Normal drain periods and filter change intervals are for average environmental
and duty-cycle conditions.
– Severe or sustained high operating temperatures or very dusty atmospheric
conditions will cause accelerated deterioration and contamination.
– For extreme conditions judgment must be used to determine the required
intervals.
Effect of environmental conditions on carrier’s electrical equipment

– The rise of temperature reduces current-carrying capacity of cables and rated
output of electric motors.
– The rated output of electric motors reduces if the work site is above 1000 m of
sea level.
– The effect of humidity is condensation of water to housing of electrical equip-
ment. Therefore it is important to make sure that the water removal holes at
the bottom of housings are open.
– Sand and dust can change contact and creepresistance, impair movement of
moving parts and reduce cooling of electrical equipment. Clean the electric
equipment from sand and dust every time it’s needed.
100121643 1 - 1 EN 0918 ettekma 68 (76)

Operator’s Manual
4.5.3. Jump Start

If the battery is discharged, the engine can be started using jump leads and a donor
battery.
Warning!
Risk of injury
The acid contained in batteries burns skin and eyes on contact.
Do not allow acid to come into contact with your skin, eyes or clothing.
Wear suitable protective clothing, as battery acid can burn through normal clothing. In
addition, protective gloves and safety goggles should be worn.
Rinse acid splashes off immediately with clean water and consult a doctor if neces-
sary.
Caution!
Risk of explosion
Gases leaking from batteries may explode and therefore cause injury.
Fire, naked flames, smoking and sparks are therefore not permitted in the vicinity of
the batteries.
Caution!
Possible carrier damage

Make sure that the batteries have the same nominal voltage. A battery could other-
wise be irreparably damaged.
Do not place any metal objects on the batteries. There is a risk of short circuit.
Only use insulated jump leads (cable cross section approximately 70 mm2) and insu-
lated terminal clamps. There is a risk of short circuit.
A discharged battery can freeze at about -10 °C; it must have thawed out before jump
-starting.
When jump-starting the engine, the maximum on-board voltage of 28 V must not be
exceeded (as this would cause electronic damage to the control unit).
100121643 1 - 1 EN 0918 ettekma 69 (76)

Operator’s Manual
1. If a battery is dead or too low to crank the engine, you can jump start it using a
pair of jumper cables to connect the low/dead battery to a good battery in
another carrier.
2. Drive the other carrier as close as possible to the one with the dead/low battery,
but do not allow the carriers to touch.
3. Shut off the engine.
4. Jumper cables are colour coded, red for positive (+) and black for negative (—).
Do not mix up the cables or allow the metal ends to touch together because this
may damage the battery, charging system and/or electronics on a carrier.
5. Connect the positive terminals first and then the negative terminals of the bat-
tery.
6. Start the engine and run it for a short while.
7. Remove the jump leads in the reverse order.
8. If carrier is equipped with jump start terminal it is advisable to use it.
100121643 1 - 1 EN 0918 ettekma 70 (76)

Operator’s Manual
4.5.4. Engine Preservation
General
Engines are treated and equipped with the following corrosion protection:
– Interior corrosion protection
– Exterior corrosion protection
Note!
Your DEUTZ partner has the optimal corrosion protec-

tion agent for your.
The following corrosion protection measures ensure 12-month engine protection
during carrier storage.
The protection work may be carried out only by persons trained and experienced in
corrosion protection procedures and their potential dangers.
Deviation from these measures, e.g. by exposing corrosion protected engines or parts
to unfavourable conditions (installation outdoors or storage in damp, poorly ventilated
spaces) or through damage to the corrosion protection layer, will result in a shorter
corrosion protection period.
The engine corrosion protection should checked every 3 months or so by
opening the covers. If corrosion is detected, the corrosion protection should be
renewed.
Once the corrosion protection work has been completed, the crank drive may no
longer be turned. This ensures that the corrosion protection agent on the bearings,
bearing liners and cylinder liners remains undamaged.
Before operating a corrosion protected engine, the corrosion protection must be
removed.
100121643 1 - 1 EN 0918 ettekma 71 (76)

Operator’s Manual
Interior corrosion protection

– Interior corrosion protection is always provided by wetting the walls with cor-
rosion protection agent during a corrosion protection run of the engine.
– A single corrosion protection run is sufficient to protect all engine systems.
Fuel system
– Fill the fuel tank with a mixture of:
• 90 % distilled fuel
• 10 % corrosion protection oil SAE 20W-20
– Perform a corrosion protection run with no load for at least 5 minutes.
Lubricating oil system

– Drain the lubricating oil from the warm engine.
– Thoroughly clean the oil tray, cylinder head and rocker arms, valves, valve
springs with diesel fuel or cleaning agent.
– Fill the engine with corrosion protection oil SAE 20W-20 up to the MAX mark
and perform a corrosion protection run for at least 5 minutes so that all lubri-
cating oil system components and accessible parts are wetted with corrosion
protection oil. In addition, using a separate pump, pump corrosion protection
oil through the engine until all bearings and bearing liners are wetted.
Air compressor
If an air compressor is fitted, corrosion protection agent should be sprayed into the air
compressor intake system after switching off the engine until the agent visibly
emerges from the adapter.
100121643 1 - 1 EN 0918 ettekma 72 (76)

Operator’s Manual
Cooling System
– Depending on the series, the engines are equipped with a cooling air, cooling
oil or cooling fluid system (cooling water with cooling system protection agent).
– Refer to exterior corrosion protection of the cooling air system presented in the
exterior corrosion protection section below.
– In oil-cooled series engines, the circulating lubricating oil simultaneously
serves as cooling oil. The cooling chambers are automatically protected
against corrosion by the lubricating oil system.
– If a coolant with corrosion protection properties is poured into liquid- cooled
engines, no further action is necessary after draining.
– If not, the coolant must be drained and, to ensure the formation of a protective
layer on the inner surfaces of the cooling system, a corrosion protection run
performed with a mixture of:
• 95 % distilled water
• 5 % corrosion protection agent
– The duration of the corrosion protection run and the concentration of the cor-
rosion protection agent are specified by the manufacturer of the corrosion pro-
tection agent.
– Then, drain the coolant.
Air Intake Pipes

– After the corrosion protection run, remove the cylinder cover and reinstall the
injectors. The respective piston must be set to LDC.
– The accessible part of the cylinder liner should be coated with corrosion pro-
tection oil through the opening using a spray lance.
– Spray corrosion protection oil SAE 20W-20 into the air intake pipe.
– Oil drip lines are not permissible and must be suction-removed as necessary.
100121643 1 - 1 EN 0918 ettekma 73 (76)

Operator’s Manual
Exterior Corrosion Protection

The engine must be cleaned thoroughly with a cleaning agent before exterior corro-
sion protection. Any signs of corrosion and damage to the paintwork must be
removed.
Cooling air system in air-cooled engines

– The air duct space in V engines is unpainted and must be sprayed with corro-
sion protection agent.
Bare exterior surfaces and parts

– Coat or spray all bare exterior parts and surfaces (e.g. flywheel, flange faces)
with corrosion protection agent.
Rubber parts
– Rubber parts (e.g. muffs) which are not painted over must be rubbed down
with talcum powder.
Belt drives
– Remove V-belts and V-rib belts and store them in closed packages.
– Spray V-belt pulleys and tension pulleys with corrosion protection agent.
– Toothed belts of the engine control may not be removed.
Engine openings
– All engine openings must be fitted with airtight and water-tight covers to delay
the liquefication process of the corrosion protection agents.
– If an air compressor is installed, the suction and pressure connection must be
sealed with a cap.
– The air inlet (air supply pipe) should be sealed off to avoid ventilation of the
engine (chimney effect).
Storage and covering

– After being protected against corrosion, the engine must be stored in a dry,
ventilated hall and suitably covered.
– The cover must be placed loosely over the engine so that the air can circulate
around it to prevent condensation from forming. Use a dessicant if necessary.
100121643 1 - 1 EN 0918 ettekma 74 (76)

Operator’s Manual
Removal of corrosion protection

– The corrosion protection must be removed from the corrosion protected
engine before starting.
– The engine covering must be removed as well as all covers from the sealed
openings.
– Any signs of corrosion or paintwork damage must be removed/repaired.
Fuel system
– If the fuel tank was charged with a mixture of diesel fuel/corrosion protection
oil, drain it.
– Fill the fuel tank and fuel system with the proper fuel.
Coolant system
– If the implemented corrosion protection agent is compatible with the intended
coolant system protection agent, this can be filled directly into the coolant sys-
tem as specified.
– If it is uncertain whether the implemented corrosion protection agent is com-
patible with the coolant system protection agent, the cooling system should be
purged with fresh water for about 15 minutes before filling.
Removal of exterior corrosion protection

– Wash all surfaces and components coated with corrosion protection agent
with distilled fuel or a suitable cleaning agent.
– Wash out the grooves of V-belts if necessary.
– Mount V-belts or V-rib belts as specified.
– Pour in the coolant.
– Connect the fuel tank / supply line to the engine, observing strict cleanliness.
– Start up the engine.
100121643 1 - 1 EN 0918 ettekma 75 (76)

Operator’s Manual
NOTES
100121643 1 - 1 EN 0918 ettekma 76 (76)

Control System User Interface Manual
NORSMART ANFO NGE2
Version: . . . . . . . . . . . . . . . . . . v.1.03
Date: . . . . . . . . . . . . . . . . . . . . . 08.02.2018
Language: . . . . . . . . . . . . . . . . English
This manual is a guide to the proper and safe operation of the control system. The
information contained in this manual is current for this control system. In the interest of
continually improving its products, Normet reserves the right to update or modify information
contained in this manual. Illustrations shown in this manual were produced during the
development stages and may differ from the actual product.
Normet Oy Tel. +358 (0)17 83 241

Ahmolantie 6 email: info@normet.com
FINLAND
INDEX
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1. Purpose of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2. Warnigs and notifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3. Definitions, terms and abbreviations used . . . . . . . . . . . . . . . . . . . . . 8
2. General description of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1. Multi Information Display (MID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2. Can Hub Module (HUB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3. Controller Module HCM2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1. Navigation in the user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2. Adjusting values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3. Access rights of the user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4. Pop-up windows of the user interface . . . . . . . . . . . . . . . . . . . . . . . . 28
3.5. User interface alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.6. Drive display (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.7. Process display (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.8. Process control (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.9. Data Logging (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.9.1. Process log window (4.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.9.2. Alerts window (4.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.9.3. Platform operating hours (4.3) . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.9.4. File transfer settings (4.4) (Commercial option) . . . . . . . . . . . . . 56
3.10. Display settings window (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.11. Advanced settings window (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.11.1. Access level selection (6.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.11.2. Commercial options (6.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.11.3. Factory & default parameters (6.3) . . . . . . . . . . . . . . . . . . . . . 68
3.11.4. System versions and settings (6.4) . . . . . . . . . . . . . . . . . . . . . 71
3.11.5. System backup (6.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.12. Process maintenance (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.12.1. Calibrations (7.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.12.2. Process parameters (7.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.12.3. Feeder options & parameters (7.3) . . . . . . . . . . . . . . . . . . . . . 104
NORSMART ANFO NGE2 English v.1.03 08.02.2018

3.13. Vehicle maintenance window (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

3.13.1. Platform parameters (8.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.13.2. Engine and drivetrain (8.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.13.3. Drive speed calibration (8.4) . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.13.4. Inclinometer calibration (8.5) (Optional) . . . . . . . . . . . . . . . . . . 131
3.14. Boom maintenance window (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.14.1. Boom control parameters (9.1) . . . . . . . . . . . . . . . . . . . . . . . . 136
3.14.2. Joystick calibrations (9.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.15. Diagnostics window (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.15.1. Module I/O diagnostics (10.1) . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.15.2. Camera view (10.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3.15.3. Support leg diagnostics (10.3) . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.15.4. Measures (10.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.15.5. CAN diagnostics (10.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.15.6. Controller diagnostics (10.6) . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4. FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.1. Starting up the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.2. System update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.3. System backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.4. System backup restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
4.5. Changing the access level using a code or a login key . . . . . . . . . . . 166
4.5.1. Changing the access level using a code . . . . . . . . . . . . . . . . . . 167
4.5.2. Changing the access level using a login key . . . . . . . . . . . . . . . 169
5. Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
APPENDIX 1. System alert and info texts . . . . . . . . . . . . . . . . . . . . . . . . . 170
APPENDIX 2. I/O-errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
APPENDIX 3. ANFO system alert and info texts . . . . . . . . . . . . . . . . . . . . 180
APPENDIX 4. ANFO process start up enabling conditions . . . . . . . . . . . . 182
APPENDIX 5. Warning symbol explanations . . . . . . . . . . . . . . . . . . . . . . . 183
NORSMART ANFO NGE2 English v.1.03 08.02.2018

INTRODUCTION
This instruction manual contains instructions for the correct and safe use of the
system. The machine is equipped with a CAN bus based control system. The
properties of this system must be learned before using the machine.
Due to continuous development work by Normet, the machine may have new features
that are not included in these operating instructions. The latest version of the
operators’ manual is available via Normet's representatives.
This control system user interface manual contains information about the user
interface's structure and functions.
NORSMART ANFO NGE2 English v.1.03 08.02.2018 5 (183)

1. GENERAL
This instruction manual contains instructions for using the control system user
interface of the NorSmart devices manufactured by Normet.
The system description is followed by the user interface functions.
The purpose of this instruction manual is to familiarize the user with the functions of
the user interface windows and the effects of their settings on the system as a whole.
1.1. Purpose of the system

The purpose of the system is to ensure cost-effective operation by creating a
diversified and effective interface between the machine user and the machine
process.

1.2. Warnigs and notifications
Warning!
Parameters are to be adjusted by qualified persons only!
Warning!
The example images do not contain ready-made param-

eters. The values shown in the images must not to be
used.
Warning!
The emergency stop button must be pressed before

inserting a USB into the machine, e.g. when making a
backup, update or report copy on a USB memory stick.
Caution!
All version numbers and serial numbers shown in the

pictures are only examples and won’t necessarily match
with machines real numbers.

1.3. Definitions, terms and abbreviations used
CH Can Hub Module

HCM Hybrid Controller Module
CDC Compact Display Controller
CAN Controller Area Network
USB Universal Serial Bus
MID Multi Information Display

2. GENERAL DESCRIPTION OF THE SYSTEM

The machine control system is based on distributed, intelligent IO units that are
interconnected with each other and with the directive application controller via a CAN
bus (MID070S). The amount and type of IO units varies between different machine
types. Besides its own controllers, the system is also operated using the display
buttons, which are used primarily to control the machine user interface on the display.

2.1. Multi Information Display (MID)
The multi information display functions as the user interface of the machine. The multi
information display provides information on the machine status and enables various
machine adjustments and functions to be carried out.
Fig. 1. Multi Information Display

2.2. Can Hub Module (HUB)
The CH modules can be used to easily and effectively expand the CAN bus.
Fig. 2. Can Hub Module

2.3. Controller Module HCM2000
HCM2000 Controller Module is used for instance to control machines front and rear
end as well as boom and engine.
Fig. 3. Hybrid Controller Module HCM2000

HCM3100 Controller Module is used for instance to control the functions of buttons,
switches and control levers in the machines cabin.

HCM3200 Controller Module is used for instance to control the functions of buttons,
switches and control levers in the machines cabin.

3. USER INTERFACE
The system initialization window is the first thing that appears when the user interface
is launched.
Fig. 6. System initialization window.

System start-up takes about 30 seconds after the main power has been switched on.

After this, the user interface opens in the Drive display. If machine does not include
Drive display, the user interface opens in the Process view.
Fig. 7. Drive display.

The window's menu bar contains symbols for each of the user interface's main
windows. The main windows can be used to access the next level sub-views and sub-
lists.
The main windows are numbered 1, 2, 3 etc. The sub-views and sub-lists under the
main windows are numbered 1.1, 1.2, 1.3 etc. and 1.1.1, 1.1.2, 1.1.3 etc. where
applicable.

All 10 main windows are not in use in all machines types.All commercial options may
not be available at opened window.
Table 1: Symbols of on the user interface menu
Descriptions of the symbols on the user interface menu bar:
Drive display
Important information related to driving the machine
Process display
Information on the process carried out by the machine
Process settings
Process settings
Data logging
Warnings, process log information, condition monitoring
Display settings
Brightness, language, time, date
Advanced settings
System settings, alert settings, updates, file management
Process maintenance
Calibration, parameter settings, factory parameters
Vehicle maintenance
Vehicle maintenance related functions
Boom maintenance
Boom related adjustments
Diagnostics
Whole-system diagnostics

Table 2: Descriptions of menu button symbols
Descriptions of menu button symbols:
Sub-view icon
The icon opens a new view
Sub-list icon
The icon opens a new sub-list
Pop-up
Pop-up window for choosing yes/no

3.1. Navigation in the user interface
Menu pop-up
The Menu icon can be accessed by using the direction buttons on the display, and the
Menu screen can be opened by pressing Enter above the Menu icon. When the
navigation focus in on the Menu icon, the icon is shown in blue. Otherwise, the Menu
icon is gray.
When the user interface has opened in the window, the navigation focus is already on
the Menu icon.
Fig. 8. Menu icon. The icon is blue when it is active. It can then be used
to access the Menu screen by pressing the Enter button at the bottom
of display.
Fig. 9. Menu icon. The icon is gray when it is inactive
The user interface is navigated using display buttons and the accompanying Menu
and Enter button or using the four direction buttons and the accompanying Enter
button. All display’s do not have separate direction buttons.
Fig. 10. Buttons at the bottom of the display.
1. Menu button
2. Move left button
3. Move right button
4. Move up button
5. Move down button
6. Enter button

Fig. 11. Direction buttons, button functions.
Fig. 12. Button pad on the machine.

When Enter is pressed above the Menu icon, the user interface Menu screen is
displayed
Fig. 13. User interface Menu screen. The screen opens in a separate pop-up window
with the display's Menu button or Menu icon.

Selections in use are depending of commercial options. All commercial options may
not be available at opened window.
The Menu screen shows the icons of all main windows (10 pcs) of the user interface.
The user navigates through the Menu screen with the direction buttons on the display.
The selected icon turns blue. The desired menu can be opened by pressing the Enter
button.
Note!
The Menu pop up can be accessed by pressing and

holding the Menu button until the Menu pop up appears.

If the chosen window contains a sub-list, you can access the next level of windows in
the menu structure. The rows that can be used to access the next level windows have
one of the following symbols in their right-hand corner:
The next level window view can be accessed via the row by pressing the
Enter button.
The next level window sub-list can be accessed via the row by pressing the
Enter button to move forward to new window views.
To navigate back from the next level window sub-list or view, use the
direction buttons to navigate to the Back button and then press Enter.
Fig. 14. The Back button is located in the left-hand corner of the window.
If the window includes a sub-list and the list contains more rows than can fit in the
window at a time, a black arrow symbol is shown at the bottom of the window. To view
the rest of the sub-list, use the direction buttons to navigate to the next page of the
window.
Fig. 15. Arrow symbol.

3.2. Adjusting values
Some windows have fields with adjustable values. The values can be adjusted by
using the four direction buttons to navigate to the chosen value in the window, and
then choosing the value to be adjusted by pressing Enter. Up and down buttons are
then displayed above and below the value to be adjusted. The value can then be
raised or lowered using the up/down buttons. If the same field contains more than one
adjustable value (e.g. date), the value to be adjusted is chosen using the left and right
buttons. To accept the changed value and to exit the adjustment mode, press Enter.
Fig. 16. Example: Display brightness adjustment in window 5.
Fig. 17. Example: Date adjustment in window 5.

If the value to be adjusted can be either positive or negative, a + or - sign is shown in
front of the value.
Fig. 18. Positive and negative value.

In some windows there is a Save button in the right-hand corner for saving the
changed values. In these windows, the changed values can be saved in two different
ways.
1. If the changed value is accepted as described earlier by pressing the Enter but-
ton, the changed value is immediately taken into use for the duration of the ongo-
ing session, but it is not permanently saved in the system and the change is no
longer valid when the program is relaunched.
2. If the changed value is saved also by using the window's Save button, the
change is saved in the system and will apply also when the system is
relaunched.
Fig. 19. The Save button is located in the right-hand corner of the window.
To use the Save button, navigate to the button using the direction buttons and press
the Enter button to accept the save. After pressing Enter, the system requests
confirmation of the save in a separate window.
Fig. 20. Confirmation of the save in a separate popup window.

To accept the save, move to the Yes button in the window and accept it with Enter.

Virtual Keyboard
Some fields require entry of text and numbers. When Enter is pressed in these fields,
a virtual keyboard opens to enable letters, numbers and other characters to be typed
into the field.
Fig. 21. Virtual keyboard with numbers (left) and letters (right).
Use the direction buttons to select the desired character, and press Enter to accept it.
The chosen character can be deleted using the arrow key if necessary. Spaces are
entered using the Space key. Entered text is accepted with the OK key, which also
closes the keyboard automatically. To close the keyboard without saving, press
Cancel.
To switch the keyboard from number mode to letter mode, press the A key. To switch
back to number mode, press the 123 key.
The 19 most recently entered field texts are saved in the memory. When you move
from the writing field to the keyboard, the program suggests using the most recent text
entry. To access the list of saved texts, in the text writing field, press the Up direction
button and then the Enter button. The desired text can then be selected from the list
and accepted with the Enter button.

3.3. Access rights of the user interface
The user interface has four different access levels. The different levels correspond to
different user rights within the user interface, from basic use to more demanding
calibration and adjustment.
The access levels and their access rights are listed below:
1. Basic user
– The basic user has the right to drive the machine and browse the user interface.
The basic user can view all parameters but cannot adjust them.
2. Site supervisor
– The site supervisor has same rights as the basic user and also the right to
delete reports from the system
3. Maintenance
– Maintenance access rights cover all access rights to the user interface
excluding activating commercial options, setting machine serial number,
clearing platform operating hours and setting Neutral position switch on/off.
4. Factory
– Factory access rights cover all access rights to the user interface.

If a user tries to perform actions that exceed their user interface access rights, the
system gives the following notification:
Fig. 22. Popup window that appears when access level is too low.
The machine uses by default the access level 1 access rights, which do not require
log in. To perform functions that require access level 2, 3, or 4 access rights, the user
must log into the system using an access level code or a login key. Logging in is
presented in more detail in the Functions chapter.

3.4. Pop-up windows of the user interface
The user interface uses various pop-up windows, for example to provide information,
report errors and alerts, give warnings, or request confirmation.
Example pop-ups:
Fig. 23. Pop-up window: Inquiry.
Fig. 24. Pop-up window: Info.

Fig. 25. Pop-up window: Alert. Alert windows have a red margin.

3.5. User interface alerts
On the left-hand side of the user interface is a dedicated column for active system
alerts. The column is shown in red only when active alerts are present in the system.
At other times, the column is shown as a green bar at the edge of the window.
Fig. 26. Active system alerts on the left-hand side. Window 4.2.1. System Alerts.
A maximum of 7 different alerts can fit in the column. If more alerts than this are active,
a yellow icon appears at the bottom of the column, which can be used to access the
rest of the alert list (window 4.2.1).
In the Alerts window all active alerts are visible at the same time. The content of the
Alerts window is discussed in detail in Chapter “Data logging (4)” on page 51.
If the Alerts window has been entered using, for example, the alert bar on the left of
the Drive display, you can return to that window via the Back button. The navigation
focus then returns to the yellow alert list icon at the bottom of the alert column.
Alerts are displayed on the alert bar in order of occurrence, the most recent being
highest on the list. Alerts can be browsed with the four direction buttons, and the
desired alert can be selected by pressing the Enter button. After this, the alert mes-
sage window opens, showing the alert ID number and a description of the alert.

Fig. 27. Alert message window (pop-up).

For the most important alerts, a message window appears automatically when the
alert is activated in the system. Acknowledging the alert moves it to the Alert menu on
the display.

3.6. Drive display (1)
After the device has been started, the basic Drive display opens; this is
intended for the driving of the vehicle. The Drive display shows basic
information related to driving and the machine. The number of the Drive
display is 1.
Fig. 28. Drive display

The content of the Drive display is presented below:
Fig. 29. Meterboard
1. Speedometer. If the driving speed set is exceeded, the background of the

speedometer display turns red. (Note! All machines do not have a speedometer.)
2. Tachometer.
3. Glow indicator light. The indicator light is lit yellow when glowing is on. (Note!
All machine types do not have glow.)
4. Turn signal. The green indicator light of the symbol flashes when a turn signal is
on.
5. Figure shows which gear is active. If figure is blinking, selected gear is not yet
engaged (Optional).
Low gear
High gear.

Fig. 30. Gear information.
Gear information is available on the left side of the meter board.
The gear is indicated by a grey color.
Diesel exhaust fluid level. The exhaust system regeneration level is

indicated by a green bar beneath the symbol. (Note! All machine types do
not have a diesel exhaust regeneration system.)
Engine temperature. The temperature is also indicated by a green and red

color bar beneath the symbol.
Normal operating temperature.
Over temperature.
Transmission oil temperature.The temperature is also indicated by a

green and red color bar beneath the symbol.
Normal operating temperature.
Over temperature.
Fuel level. The fuel level is indicated by a green bar beneath the symbol.
If the ignition switch is in the wrong position, the bars of diesel exhaust fluid, hydraulic
fluid, engine temperature, and transmission oil temperature are no longer visible and
the values are replaced by - - -.

Fig. 31. When DM1 alerts are active, “1” blinks in red. The Left/Right button of the
display changes the view. If there is no connection to the engine or information is
unavailable for used engine type, the values are replaced by --.
tn 0.0 = Load tonnes, if weighting signal is set on.
1. DM1 SPN/FMI alert text from the diesel engine

2. Turbo boost pressure, (bar)
3. Engine oil temperature (C°)
4. Engine load (%)
5. Engine oil pressure (bar)
6. Consumption litres/hour (l/h)
7. Transmission oil pressure (bar)
8. Supply air temperature (C°)
9. System Voltage (V)
10. Engine hours (h)
11. Hydraulic fluid temperature (C°)
When the Up/Down buttons are pressed from the Drive display, the system cycles
among the following windows.
1. To move to the Camera view, press the Down button in the Drive display. If the
system has several cameras, the input data of the camera can be changed with
the Left/Right buttons.
2. The DM1 / J1939 message window can be accessed by pressing the Down
button in the Camera view.

Fig. 32. Camera view.
Fig. 33. DM1 / J1939 message window.

The number and order of the indicator lights on the bottom row of the Drive display
depend on the machine’s engine type. Additional information is available from the
manufacturer of the machine.
The Emergency stop indicator light is red when the function is active.
Check Engine indicator light is yellow when non-critical fault is active.

The diesel engine is in impermissible operating state and the vehicle
should be taken into service as soon as possible.
Stop Engine indicator light is red when serious fault is active. Stop
engine immediately. The engine might shut down automatically
depending on engine controller configuration.
The Safety/parking brake indicator light is red when the parking brake
pressure is below 10 bar.
The Service brake indicator light is red when the charging pressure of
the pressure-accumulators in the brake circuit falls below the limit set.

The Battery charging indicator light is red when the charging voltage
sinks below the limit set.
The Water in fuel indicator light is yellow if the fuel contains more
water than the settings allow.
The Transmission oil pressure indicator light turns red when the
pressure sinks below the limit set.
The Hydraulic fluid temperature indicator light is red when the

temperature of the hydraulic fluid is above the limit set.
The Hydraulic fluid level indicator light is red when the hydraulic fluid
level is low.

The Hydraulic fluid return filter indicator light is yellow if the return
filter is blocked.
The Engine air filter indicator light is yellow if the air filter is blocked.
The Axle temperature (front/back) indicator light is red when the

temperature exceeds the limit set.
The Engine oil temperature indicator light is red when the engine oil
temperature exceeds the limit set.
The Engine oil pressure indicator light is red when the engine oil
pressure is below the limit set.

The Exhaust system regeneration/SCR (Selective Catalytic

Reduction) system cleaning required indicator light is yellow when
the SCR system needs to be cleaned at the next opportunity.
This can be accoplished by:
1.Changing to a more challenging duty cycle, such as uphill driving,

for at least 20 minutes.
2.Performing a stationary SCR/exhaust system cleaning.
Note!
If Check engine indicator light is yellow or Stop engine

indicator light is red and the Exhaust system
regeneration required indicator light is yellow, it
indicates that the after treatment SCR needs to be
cleaned immediately. Engine power will be reduced
automatically if action is not taken.
The Exhaust system regeneration disabled indicator light is yellow

indicates that the inhibit switch is active and automatic or manual (non-
mission) SCR/exhaust system cleaning will not occur. This can be
corrected by switching the inhibit switch to permit mode.

The Diesel exhaust fluid low indicator light indicates, that the DEF
level has fallen below the initial warning level. This can be corrected by
filling the DEF tank with DEF.
Note!
It is recommended that the DEF tank be filled completely

full of DEF in order to correct any fault conditions.
The High exhaust system temperature indicator light, that exhaust

temperatures are high. The light could illuminate during normal engine
operation or during SCR/exhaust system cleaning.
When this light is illuminated, be sure the exhaust pipe outlet is not
directed at any surface or material that can melt, burn, or explode.
– Keep the exhaust outlet away from people and anything that can
burn, melt, or explode.
– Nothing within 0.6 m of the exhaust outlet.
– Nothing that can burn, melt, or explode within 1.5 m (such as
gasoline, wood, paper, plastics, fabric, compressed gas containers, or
hydraulic lines).
– In an emergency, turn the engine off to stop the flow of exhaust.
Warning!
When High exhaust system temperature indicator

light is yellow, the exhaust gas temperature could reach
extremely high temperature levels, which is hot enough
to ignite or melt common materials, and to burn people.

The Service brake indicator light is red when the service brake is on.
Support legs transport position indicator
Purpose
- To indicate that the support legs are not in the transport position.
MEWP transport position indicator
Purpose
- To indicate that the MEWP is not in the transport position.

3.7. Process display (2)
The second main window of the user interface is the Process display,
which shows the user information about the ongoing charging process.
The Process display window number is 2.
Fig. 34. Process display.
The content of the Process display is presented below:
Fig. 35. Small tank button is shown in the upper part of the window if option two
charger environment is available on the machine. In the middle part of the window
can be seen the tank figure which one is activated.
1. Two separate chargers and two separate tanks charging.

2. Two tanks charging one hole.

Fig. 36. A ja B shows the kilograms in the current tank.

ANFO charging process can be used either with two tanks charging one hole or two
separate chargers and two separate tanks charging two holes. Tank button in upper
row activates desired charging process and shows below which charging type is
active.
Fig. 37. Process display window, if option two charger environment is not available.
Fig. 38. Compressor ON and OFF button.
In the upper part of the window, a symbol describes the machine's two explosive
charge vessels A and B.
The vessel being used is highlighted in blue. A pressurized vessel is indicated by gray
coloration and arrows pointing at both sides of the vessel.

Fig. 39. Pressurized vessel A is used.
To the left and right of the vessels are the symbols for the vessel vibrators. The
symbols can be used to activate the vibra function of the desired vessel. Vibra stays
on as long as the button is pressed. When the vibrator is on, the vessel symbol on the
button is shown in green.
If automatic vibration of the vessel is set ON in window 7.1.4, the outermost symbol is
shown green always when the vibrator is on.
Fig. 40. Symbol for vessel vibra. On left the vibra is OFF. On right the vibra is ON and
the symbol is shown in green.
Fig. 41. If the automatic vibration is set ON in window 7.1.4, the outermost symbol is
shown in green when the vibra activates.
When automatic vibration is set ON, the vibra function always activates during
charging.

3.8. Process control (3)
Process control window is not in use in the ANFO charging unit.
Fig. 42. Process control display.

3.9. Data Logging (4)
The fourth main window of the user interface is the Data logging window
for observing the data gathered by the system. The Data logging window
has a sub-list for entering the next level windows and examining different
kinds of information.
Fig. 43. Data Logging window structure.

4.1 = Process log (not in use)
4.2 = Alerts
4.2.1 = System alerts
4.2.2 = Engine alerts
4.2.3 = Delete fault log
4.2.4 = Save system alerts to USB
4.3 = Platform operating hours
4.4 = File transfer settings
4.4.1 = Network settings
4.4.2 = Copy settings
4.4.3 = Email settings
4.4.4 = SCP settings

The Data logging window enables observing the system and engine alert lists and
platform related operating and maintenance times.
Fig. 44. Data Logging (4) main menu.
3.9.1. Process log window (4.1)
Function not in use.

3.9.2. Alerts window (4.2)
System alerts can be accessed via the second row of the Data logging window.
This opens the Alerts window, from which either system or engine alerts can be
chosen and viewed. The window number is 4.2.
Fig. 45. Alerts window 4.2.

System alerts (4.2.1)
System alerts can be accessed via the first row of the Alerts window. The window
number is 4.2.1.
Fig. 46. System alerts 4.2.1.

The System alerts window shows a list of all active system alerts. For each alert the
first and last occurrence time and the number of occurrences is shown. Alerts are
displayed in the list in order of occurrence, the most recent being highest on the list.
The following alert information is also given: alert ID number, status (active / not
active), and simplified name. IO-error indicates the signal and pin where the cause of
the alarm is located.

Engine alerts (4.2.2)
Engine alerts can be accessed via the second row of the Alerts window. The window
number is 4.2.2.
Fig. 47. Engine alerts message window.

At the bottom of the window are two buttons via which either DM1 alerts (active engine
alerts) or DM2 alerts (non-active engine alerts) can be viewed.

Delete fault log (4.2.3)
The system fault log can be deleted on the third row of the Alerts window.
Deletion is performed by pressing Enter on the row. A separate pop-up window opens
and deletion is confirmed by pressing the Yes button.
Fig. 48. Delete system alert from the memory by pressing Yes.
Fault log deletion removes all non-active alerts. If there are active alerts in the system
at the time of the deletion their occurrences are integrated as one and the time of
occurrence is the time of the latest alarm.
Saving system alerts to USB (4.2.4)

System alerts can be saved to USB-memory on the fourth row of the Alerts window.
Saving is performed by placing USB-memory into machine and pressing Enter on the
row.

3.9.3. Platform operating hours (4.3)
Platform operating hours can be accessed via the third row of the Data logging
window.
This opens the Platform operating hours window for viewing the operating hours
information. The window number is 4.3.
Fig. 49. Platform operating hours 4.3.

The content of the window is presented below:
Fig. 50. The content of Platform operating hours-window.
1. Power pack operating hours.

2. Power pack's last maintenance time in operating hours.
3. Power pack maintenance time save.
4. Compressor operating hours.
5. Compressor's last maintenance time in operating hours.
6. Compressor maintenance time save.
7. Engine operating hours.
8. Engine's last maintenance time in operating hours.
9. Engine maintenance time save.
10. Washer operating hours.
11. Washer's last maintenance time in operating hours.
12. Washer maintenance time save.
13. Additional power pack operating hours.
14. Additional power pack's last maintenance time in operating hours.
15. Additional power pack maintenance time save
16. Additional compressor operating hours.
17. Additional compressor's last maintenance time in operating hours.
18. Additional compressor maintenance time save
For saving the maintenance times, access level 3 (maintenance) access rights are
required.

Editing enabled (4.3.1)
Platform operating hours editing enabled window can be accessed via the Editing
enabled figure of the Platform operating hours window.
This opens the Platform operating hours editing enabled window for adjusting the
operating hours. The window number is 4.3.1.
Fig. 51. Platform operating hours editing enabled window 4.3.1
For editing the maintenance times, access level 4 (factory) access rights are required.

3.9.4. File transfer settings (4.4) (Commercial option)
File transfer settings can be accessed via the fourth row of the Data logging window.
This opens the File transfer settings window for adjusting the File transfer settings.
The window number is 4.4.
Fig. 52. File transfer settings 4.4.
For setting the file transfer settings, access level 2 (site supervisor) access rights are
required.

Network settings (4.4.1)
The Network settings can be accessed via the first row of the File transferring settings
window.
Via the Network settings window enables setting DHCP on/off, saving IP-address,
subnet mask and default gateway. The window number is 4.4.1
Fig. 53. File transfer settings 4.4.1.

For further information contact IT-department.
For adjusting the file transfer settings, access level 2 (site supervisor) access rights
are required.

Copy settings (4.4.2)
The Copy settings can be accessed via the first row of the File transferring settings
window.
Via the Copy settings window can be set an encryption key and encryption on/off.The
window number is 4.4.2
Fig. 54. Copy settings 4.4.2.

For adjusting the Copy settings, access level 2 (site supervisor) access rights are
required.

Email settings (4.4.3)
The Email settings can be accessed via the third row of the File transferring settings
window.
The Email settings window enables adjusting following sending time period, sender
email address and three receiver email addresses, port, domain, host, email topic and
user information. The window number is 4.4.3
Fig. 55. Email settings 4.4.3. window is on two pages.

For adjusting the Email settings, access level 2 (site supervisor) access rights are
required.
SCP settings (4.4.4)

The SCP settings can be accessed via the fourth row of the File transferring settings
window.
The SCP settings window enables installing private key to the system via USB
memory stick, setting the port number and server’s IP address, setting SHH user
name and server’s copy path. The window number is 4.4.4
Fig. 56. SCP settings 4.4.4.
For adjusting the SCP settings, access level 2 (site supervisor) access rights are
required.

3.10. Display settings window (5)
The fifth window of the user interface is the Display settings window for
adjusting display and user interface settings. Window number is 5.
Fig. 57. Display settings window 5.

The following settings can be adjusted via the window:
Display brightness - The first row is for adjusting display brightness from 0 to 9,
where 9 is the brightest value.
Display language - The second row opens the language selection window (5.2) for
choosing the user interface language.
Time - The third row is for setting the time shown in the upper right-hand corner of the
user interface windows.
Date - The fourth row is for setting the date for the user interface.

Fig. 58. Window 5.2 for choosing display language.
When changing the language, the change must be confirmed via a separate pop-up
window.
Fig. 59. Change language by pressing Yes.

3.11. Advanced settings window (6)
The sixth main window of the user interface is the Advanced settings win-
dow for performing functions related to system control.
Fig. 60. Advanced settings window structure.

6.1 = Access level selection
6.2 = Commercial options
6.3 = Factory & Default parameters
6.4 = System versions and settings
6.4.1 = Versions
6.4.2 = Machine serial number setting
6.4.4 = Enable / disable signals
6.4.5 = IoT
6.4.5.1 = CAN recorder

6.5 = System backup
6.5.1 = Module backup
6.5.2 = Full system backup
6.5.3 = Parameter system backup
6.5.4 = Application system backup
6.5.5 = Copy parameter lists to USB
The Advanced settings window enables, for example, the following functions: access
level selection, system backup on USB memory, system restore, and version viewing.
Most functions in the Advanced settings window require at least level 3 access rights.
Fig. 61. Advanced settings window 6.

3.11.1.Access level selection (6.1)
The access level can be changed via the first row of the Advanced settings window to
enable sufficient access rights for performing the restricted functions of the window.
The access level change is done by entering a code corresponding to the desired
access level or by entering a login key for the access level.
The code for the desired access level is entered in a separate window which opens
when Enter is pressed on the row.
Fig. 62. Log in window for different access levels.

Highest in the window is a challenge code corresponding to the desired access level.
Below that field, there is a field on the left for choosing the necessary access level (2-
4).
Fig. 63. Choosing access level.

The challenge code changes according to the access level chosen. The chosen
access level is confirmed with Enter and the response code matching the challenge
code is entered number by number in the field to the right of the access level field.

Fig. 64. Inserting response code.

The code is confirmed with the OK key. As a result, the chosen access level will
appear as the current access level.
Fig. 65. Current access level is shown in the text field and the open lock-symbol
shows that the access level is active.
The access level can be changed back to level 1 by pressing Enter on the row.
The response code for the challenge code is provided by the manufacturer.
The access level selection can also be done with a separate login key (USB). The
login key must be inserted into the machine when Enter is pressed on the access level
row. The program will automatically activate the access level corresponding to the
login key. This is discussed in detail in the chapter “FUNCTIONS” on page 163.

3.11.2.Commercial options (6.2)
Commercial options can be accessed via the second row of the Advanced settings
window.
In the opening window there is a list of commercial options.The window number is 6.2.
Fig. 66. Commercial options window 6.2.

Commercial option setting requires level 4 (factory) access rights.
Contact the machine manufacturer for further information.

3.11.3.Factory & default parameters (6.3)
Parameter backup and restoration can be accessed via the third row of the Advanced
settings window.
Parameter backup and restoration can be performed in the window that opens. The
window number is 6.3.
Fig. 67. Factory & Default parameters window 6.3.

Use of some functions in this window requires level 3 or 4 access rights.
The following functions can be carried out in the window:
– Save as default parameters (access level 3)
– Restore default parameters (access level 1)
– Save as factory parameters (access level 4)
– Restore factory parameters (access level 1)
– Save parameters to USB (access level 1)

The default and factory parameter rows show the date and time of the last save.
The Restore default parameters row and the Restore factory parameters row show
the date and time of the last restoration. If restoration has never been performed, the
text 'Not executed!' is shown on the row.
The desired function is performed by moving to the correct row and pressing Enter.
The parameters are saved in the system memory and are restored from the same
location.
When using a USB memory is for saving, insert the USB into the machine and press
Enter on the row of the function.
Save/restore parameters to USB 6.3.5

The Save/restore parameters to USB window is accessed via the fifth row of the
Factory and default parameters window.
Fig. 68. Save/restore parameters to USB window
Saving and restoring JSON parameter lists in Norsmart

Parameter list saving and restoring functionality handles all parameters in Norsmart
system. Parameters are handled in JSON format. Parameter functionality can be used
to save parameters to USB memory or to restore parameters from USB memory. To
restore parameters from USB memory access level 3 is required. Parameters can be
saved to USB memory without access level (access level 1).

Saving parameters
1. Go to Advanced settings > Factory & Default parameters > Save/restore param-
eters to USB
2. Ensure that USB memory is inserted
3. Press Save parameters to USB and confirm with Yes
4. Wait until a notification window pops up and tells that parameters are saved
5. Press OK and remove USB memory
If a warning notification pops up it means that there was an error saving parameters.
In this case some or all parameters may be missing or have wrong values. Following
situations can cause warning:
– There are more parameters in a parameter list than there should be
If an error notification pops up it means that there was a critical error saving parame-
ters. In this case parameters are not saved. Following situations can cause error:
– Parameter list has invalid name
– USB memory is not found
Restoring parameters
1. Go to Advanced settings
2. Insert USB memory
3. Log in with USB memory (access level 3 required for restoring parameters)
4. Go to Advanced settings > Factory & Default parameters > Save/restore param-
eters to USB
5. Press Restore parameters from USB and confirm with Yes
6. Wait until a notification window pops up and tells that parameters are restored
7. Press OK and remove USB memory
If a warning notification pops up it means that there was an error restoring parameters.
In this case some or all parameters may be missing or have wrong values. Following
situations can cause warning:
– Parameter list has invalid name
– Parameters array or its name is invalid in JSON
– Value of a parameter is outside limits
– Index of a parameter is outside limits
If an error notification pops up it means that there was a critical error restoring param-
eters. In this case parameters are not restored. Following situations can cause error:

– Invalid JSON syntax
– Lists array or its name is invalid in JSON
– Machine serial in JSON is different than the machine serial in Norsmart
JSON file
Name of the JSON file have to be parlist.json and it must be placed in root directory
of USB memory.
Name/value pair “serial” can be removed from the JSON file so that the JSON file
applies to all machine serials. Just remove the line where the “serial” is.
3.11.4.System versions and settings (6.4)

The System versions and settings window is accessed via the fourth row of the
Advanced settings window.
In the opened System versions and settings window you can proceed forward to
Versions window or set the machine serial number. The window number is 6.4.
Fig. 69. System versions and settings window 6.4.

Versions (6.4.1)
The Versions window can be accessed from the first row of the System versions and
settings window.
The window shows the machine number and the version numbers of the process (if
contained in the machine), platform, boom, feeder, and display. IP-address of the
display can be shown in the window and it can be renewed with the Renew Ip -button.
The image of the display can be generated by using the vnc-button. Custom iomux in
use (symbol is green) = Some signals are switched off and are not in use in this
machine type.
The window number is 6.4.1.
Fig. 70. Versions window 6.4.1.

Machine serial numbers (6.4.2)
The machine serial number can be set from the second row of the System versions
and settings window.
To set the machine serial number level 4 (maintenance) access rights are required.
Deliver to customer (6.4.3)

In the third row of the System versions and settings window is Deliver to customer
function. This function clears systems log information for customer delivery.
Customer delivery requires level 4 (factory) access rights.

Enable/Disable signals (6.4.4) (Option)
The enable/disable signals window can be accessed from the fourth row of the
System versions and settings window
The opened window enables viewing of signals related adjustments and adjustment
of their values as necessary. The window number is 6.4.4.
Fig. 71. Enable/Disable signals window 6.4.4.

Values in these pictures are not accurate and therefore must never be used as
example in adjusting.
To perform the functions at least level 4 access rights are required.

IoT (6.4.5)
The IoT window can be accessed from the fifth row of the System versions and
settings window
The opened window enables viewing of IoT related connections and tests. The
window number is 6.4.5.
Fig. 72. IoT window 6.4.5.

To perform the functions at least level 4 access rights are required.
Fig. 73. Testing result view.

Fig. 74. If the symbol is green, data transfer is allowed.
Fig. 75. Buttons in the middle of the window.
1. Test different connections to cloud services button

2. Renew IP address button
3. Restart data transfer from the beginning button
4. The image of the display can be generated by using the vnc-button.
Fig. 76. Symbols at the bottom part of the window
1. EMU reports sending, symbol is green if data is up to date at the server.

2. Nordoser reports sending, symbol is green if data is up to date at the server.

CAN recorder (6.4.5.1)
CAN recorder window can be accessed from the CAN recorder button of the IoT
window.
The opened window enables to start and stop CAN recording. The window number is
6.4.5.1.
Fig. 77. CAN recorder window 6.4.5.1.
CAN recording instructions are described below:
Start recorder:
1. Insert USB memory stick

2. Choose CANopen or J1939
3. Press Start
4. Select “Yes” in popup
5. Box in the middle of the window tells that recording is in progress. It also shows
seconds since start. CAN bus is recorded using circular buffer of 60 seconds. So
when the duration of 60 seconds have passed old recordings are removed from
the end of the buffer and new recordings are added to the beginning of the
buffer.

Stop recorder:
1. Press Stop
2. Select “Yes” in popup
3. Box shows that copying is in progress
4. Wait for info popup and press OK
5. Box shows time stamp of last recording
6. Remove USB memory stick
7. BREC file can be found in the root directory of USB memory stick

3.11.5.System backup (6.5)
The system backup is accessed via the fifth row of the Advanced settings window.
The window that opens enables a backup of an individual module or the entire system
to be performed. The window number is 6.5.
Fig. 78. System backup window 6.5.

Module backup (6.5.1)
Via the first row of the backup window, a new window can be opened to perform a
backup of an individual module.
The window number is 6.5.1.
Fig. 79. Module backup window 6.5.1.

Module backup involves saving the module parameters in the control system's
memory. The chosen module for backup is selected by moving the focus onto it.
Backup is started by pressing the Enter button. After this, the program requests, in a
separate window, confirmation to start the backup.

Fig. 80. Module backup is started by pressing Yes.

To perform the backup, the Yes button must be selected and then the Enter button
pressed.
The text field underneath the module's name shows the backup status of the module
in question. In addition, the date of the last backup is shown on the same row.
The color of the exclamation mark to the left of the module name represents the
module status.
yellow = temporarily off the bus
red = off the bus

Full system backup (6.5.2)
The second row of the backup window enables backing up of the entire system.
The date of the last backup is shown on the same row. The emergency stop button
must be pressed before starting the backup. A USB memory stick must be inserted
into the machine for saving the backup file. Pressing the Enter button commences the
backup. After this, the program requests, in a separate window, confirmation to start
the backup.
Fig. 81. Full system backup is started by pressing Yes.

Copying is started by pressing the Yes button. The backup time is then displayed on
the Full system backup row.
Full system backup takes about 2 minutes maximum. When the backup is ready, the
date and time of the last backup are updated.

Parameter system backup (6.5.3)
Parameter system backup can be performed from the third row of the System backup
window.
To perform backup press Enter on the row.
Application system backup (6.5.4)

Application system backup can be performed from the fourth row of the System
backup window.
To perform backup press Enter on the row.
Copying parameterlists to USB (6.5.5)

Parameterlists copying to USB memory can be performed from the fifth row of the
System backup window.
To perform copying connect USB memory to machine and press Enter on the row.

3.12. Process maintenance (7)
The seventh main window of the user interface is the Process maintenance
window for performing process-related maintenance functions.
Fig. 82. Process maintenance window structure.

7.1 = Calibrations
7.1.1 = Hose main feeder
7.1.2 = Hose middle feeder
7.1.3 = Hose feeder diagnostics
7.1.4 = ANFO vessel vibra
7.1.5 = ANFO vessel level
7.2 = Process parameters
7.3 = Feeder options & parameters
The Process maintenance window is for editing and saving values and parameters
related to hose feeding calibration. To perform the functions at least level 3 access
rights are required.
Fig. 83. Process maintenance window 7.

3.12.1.Calibrations (7.1)
The hose feeding calibrations can be accessed via the first row of the Process
maintenance window.
Via the opened Calibrations window various calibration functions can be carried out.
The window number is 7.1.
Fig. 84. Calibrations window 7.1.

Either hose feeder calibrations or feeder diagnostics window can be accessed from
the list.

Hose main feeder (7.1.1)
The Hose main feeder window opens via the first row of the Calibrations window.
The window is used for calibration functions related to the hose main feeder. The win-
dow number is 7.1.1.
Fig. 85. Hose main feeder calibration window 7.1.1.

Fig. 86. Diagnostic information and functions in the upper edge of the window.
1. Feeder rotation device pulse number from the feeder pulse sensor.
2. Pulse number after starting the feeder (always resets at start up).
3. Controls for hose feed in and out. Functions by moving over the desired control
and pressing Enter.
4. Feeder travel distance (mm)
5. Measured distance in millimeters per hundred pulses.

Fig. 87. The two curves in this window show the hose feed speed in different direc-
tions during calibration, the upper curve is for feed speed out of the hole and the
lower one into the hole. Beneath the curve, the hose feed minimum and maximum
current (mA) is shown.
In the right-hand corner of the window, hose feeder related values are given:
Fig. 88. Hose feeder related values and settings.
1. Feeder control value

2. Feeder real-time speed
3. Feeder speed demand
4. Hand use percentage
5. Speed demand (m/s)
6. P control adjustment value (%)
7. P control adjustment range (cm/s)
8. I control adjustment value (%)
9. I control adjustment range (cm/s)
10. I control reaction speed
11. Start button for automatic calibration
Calibration
The hose main feeder calibration can be performed manually or automatically. The
calibration is performed separately for each feed direction.
The calibration is performed as follows:
1. The feeder maximum and minimum speed are set according to the needed hose
maximum and minimum speed.
2. Calibration method selection: manual or automatic calibration.

Manual calibration is performed using a hand use percentage.
The minimum current is determined by setting the hand use percentage to 1%.
The minimum current is increased until the feeder starts to move in the desired
direction. The gained value is saved in the chart's Min mA field (left).
The maximum current is determined by setting the hand use percentage to
100%. The maximum current is increased until the maximum speed is reached.
The gained value is saved in the flow speed chart's Max mA field (right).
Intermediate points 25%, 50%, and 75% are determined by setting the hand
use percentage in question and saving the speed as the speed value (m/s) of
that control percentage. Note that the calibration curve is not linear, so it is not
possible to calculate the % control intermediate values directly. The intermedi-
ate value calibration is performed by augmenting each value by 1% of the con-
trol.
Automatic calibration automatically performs the manual calibration func-
tions. Automatic calibration is started with the Auto button. After pressing the
button, the green indicator light lights up next to the Auto button. After pressing
the button, the hose moving direction selected for calibration is selected via the
remote control. The remote control button is pressed until the calibration has
ended. During the calibration the green indicator light lights up and stays on
green next to already calibrated values. When all the values are calibrated and
the calibration is completed, the green indicator light next to the Auto button
switches off.
Fig. 89. The green indicator light shown next to Auto button and calibrated values.
3. The hand use percentage is changed back to zero.
4. The speed demand deviation is acquired by entering in the speed demand field
different values between the minimum and maximum demand. The value is com-
pared to the realized demand. After this, the deviation can be balanced with the
P and I controls. The gained deviation is entered as a value in the P and I control
adjustment ranges. The control adjustment values are acquired by experimental
testing.

P and I control functions
The purpose of the P control is to try to raise the speed demand to the demanded
level. The I control balances any possible adjustment deviation left by the P control.
The following images describe the P and I control functions:
Fig. 90. P control function. On the graph the red line indicates normal functioning of
the pump and the blue broken line indicates ideal pump functioning, i.e. where the
required output is reached in the shortest possible time. The P control helps the
pump to reach the demanded output faster. The remaining difference can be cor-
rected with the I control.
Fig. 91. I control function. On the graph the red line indicates normal functioning of
the pump and the blue broken line indicates ideal functioning. When the P control is
adjusted so that the output falls slightly short of the level required, it can be corrected
with the I control. The I control value is raised step-by-step by the time increments
set in the I interval until the output reaches the demanded level.

Hose middle feeder (7.1.2)
The Hose middle feeder window opens via the second row of the Calibrations window.
The window is used for calibration functions related to the hose middle feeder. The
Fig. 92. Hose middle feeder calibration window 7.1.2.

Fig. 93. Diagnostic information and functions in the upper edge of the window.
1. Actuator rotation device pulse number from the feeder pulse sensor.
2. Controls for hose feed in and out. Functions by moving over the desired control
and pressing Enter.
3. Measured distance in millimeters per hundred pulses.

Fig. 94. The two curves in the window show the hose feed speed in different direc-
tions during calibration, the upper curve is for feed speed out of the hole and the
lower one into the hole. Beneath the curve, the hose feed minimum and maximum
current (mA) is shown.
Fig. 95. Hose feeder related values and settings.
1. Feeder control value

2. Feeder real-time speed
3. Feeder speed demand
4. Hand use percentage
5. P control adjustment value (%)
6. P control adjustment range (cm/s)
7. Start button for automatic calibration
8. Feeder pulses
9. Middle feeder pulses

Calibration
The hose middle feeder calibration can be performed manually or automatically. The
calibration is performed separately for each feed direction.
The calibration is performed as follows:
1. The feeder maximum and minimum speed are set according to the required
hose maximum and minimum speed.
2. Calibration method selection: manual or automatic calibration.
Manual calibration is performed using a hand use percentage.
The minimum current is determined by adjusting the hand use percentage to
1%. The minimum current is increased until the feeder starts to move in the
desired direction. The gained value is saved in the chart's Min mA field (left).
The maximum current is determined by adjusting the hand use percentage to
100%. The maximum current is increased until the maximum speed is reached.
The gained value is saved in the flow speed chart's Max mA field (right).
Intermediate points 25%, 50%, and 75% are determined by setting the hand
use percentage in question and saving the speed as the speed value (m/s) of
that control percentage. Note that the calibration curve is not linear, so it is not
possible to calculate the % control intermediate values directly. The intermedi-
ate value calibration is performed by augmenting each value by 1% of the con-
trol.
Automatic calibration automatically performs the manual calibration func-
tions. Automatic calibration is started with the Auto button. After pressing the
button, the green indicator light lights up next to the Auto button. After pressing
the button, the hose moving direction selected for calibration is selected via the
remote control. The remote control button is pressed until the calibration has
ended. During the calibration the green indicator light lights up and stays on
green next to already calibrated values. When all the values are calibrated and
the calibration is completed, the green indicator light next to the Auto button
switches off.
Fig. 96. The green indicator light shown next to Auto button and calibrated values.
3. The hand use percentage is changed back to zero.

Hose feeder diagnostics (7.1.3)
The Hose feeder diagnostics window opens via the third row of the Calibrations win-
dow.
The window is used for viewing values related to the hose feeder. The window number
is 7.1.3.
Fig. 97. Hose feeder diagnostics window 7.1.3.

The content of the diagnostics window is presented below:
In the left-hand corner of the window, there is a section showing diagnostics related
to the controls and buttons of the cord remote control. The section shows the remote
control buttons and they are shown green when the button in question is pressed on
the remote control.
Fig. 98. Diagnostics of the cord remote con-
trol.
1. The top row of the remote control sec-

tion shows the control's potentiometer
and hose speed (m/s) reeling in (upper
value) and reeling out (lower value).
2. The second row contains the charging
and blowing on/off buttons and the ves-
sel switch button. They are shown green
in the window when the button is active.
3. The third row contains the control but-
tons for the main feeder. On the left is
the reel-in button, in the middle the reel-
out button. The button on the right is
used to reset the hose travel distance.
4. The fourth row contains the control but-
tons for the middle feeder. On the left is
the reel-in button, in the middle the reel-
out button.
5. The fifth row contains the reel buttons
for the main hose. On the left is the reel-out button, and next to it the reel-in but-
ton.
6. The sixth row contains the back-blowing buttons. The function activation button
is on the left, and vessel selection is performed via the middle button and the
button on the right.
7. Point 7 describes the status of vessels A and B. The symbols above the letters
are shown in red according to the vessel being used for charging. The symbols
below the letters are shown in green according to the vessel being pressurized.

In the right-hand section of the window, values related to the main and middle feeder
as well as reel control are shown.
Fig. 99. Main feeder diagnostics.
1. Main feeder control signal (value between -127 and 127, positive value into the
hole and negative value out of the hole).
2. Main feeder measured speed (m/s), measured frequency (hz), and measured
pulses.
3. Main feeder realized speed (m/s), realized frequency (hz), and realized pulses.
4. Hose travel distance (m) though the feeder, measured by the pulse wheel.
Fig. 100. Middle feeder diagnostics.
1. Middle feeder control signal (value between -127 and 127, positive value into the
2. Middle feeder realized speed (m/s), realized frequency (hz), and realized pulses.
3. Measured hose travel distance (m) though the feeder.

Fig. 101. P control values.
1. P control value (at top), shows the process pulses to the main feeder.
2. P control adjustment range (at bottom), shows the process pulses to the middle
feeder.
Fig. 102. Reel control signal (value between -127 and 127, positive value into the

ANFO vessel vibra (7.1.4) (Optional)
The ANFO vessel vibra window opens via the fourth row of the Calibrations window
and is used for adjusting values related to the vessel vibrator.
In this window, the automatic vibra function can be set for vessels A and B and the
vibrator on and off times can be adjusted.
Fig. 103. ANFO vessel vibra 7.1.4.

Fig. 104. The content of ANFO vessel vibra window.
1. Vessel automatic vibra on/off. When the automatic vibra is set on, the vibrator
functions automatically during charging according to the times set in points 2 and
3. When the vibrator is on a green indicator light is lit in the Process display.
2. Automatic vibra on time.
3. Automatic vibra off time.
4. Manual on/off button for vessel A vibrator. The vibrator can be switched on and
off by pressing this button.
5. Manual on/off button for vessel B vibrator. The vibrator can be switched on and
off by pressing this button.
Automatic vibra settings always apply to the vessel currently in use.

ANFO vessel level (7.1.5)
The ANFO vessel level window opens via the fifth row of the Calibrations window and
is used for adjusting values related to the vessel levels.
The window is used for viewing A and B tank level calibration parameters and
adjusting their values as necessary.
Fig. 105. ANFO vessel level 7.1.5.
Values in this picture are not necessarily accurate and therefore must never be used
as example in adjusting.

The content of the ANFO vessel level calibration window is more explained below:
Fig. 106. Minimum, maximum, RC filter and error range values.
1. Tank A values
2. Tank B values
3. Tank A: Minimum value is analog input adjustment. The input value is calibrated
and viewed as milliamperes (mA.)
4. Tank A: Maximum value is analog input adjustment. The input value is calibrated
5. Tank A: Value of RC filter. When adjusting the value, it filters signal. More bigger
value more peaks are removed from signal.
6. Tank A: Error range is analog input adjustment. The input value is calibrated and
viewed as milliamperes (mA).
7. Tank B: Minimum value is analog input adjustment. The input value is calibrated
8. Tank B: Maximum value is analog input adjustment. The input value is calibrated
9. Tank B: Value of RC filter. When adjusting the value, it filters signal. More bigger
value more peaks are removed from signal.
10. Tank B: Error range is analog input adjustment. The input value is calibrated and
viewed as milliamperes (mA).
11. Current measured value in the tank A (mA).
12. Current measured value in the tank B (mA).
13. Enable feature activates the feature On/Off
Fig. 107. Enable feature in the upper part of the window activates the feature.

Fig. 108. EMU Tank calibration. Five point conversion table is used to convert level
sensor readings to tank volume reading with the option to compensate irregular tank
shape.
1. Volume conversion point 1. Volume conversion points are used to define the
tank volume.
2. Volume conversion point 2.
6. Minimum value when tank is empty (mA).
7. Anfo density (kg/m³)
8. A tank weight in kilograms (kg)
9. A tank volume in liters (l)
10. B tank weight in kilograms (kg)
11. B tank volume in liters (l)

3.12.2.Process parameters (7.2)
Process parameters can be accessed via the second row of the Process maintenance
window.
The window is used to view the process parameters and adjust their values if
necessary. To adjust the values at least level 3 access rights are required. The
Fig. 109. ANFO parameters window 7.2.

3.12.3.Feeder options & parameters (7.3)
Feeder parameters can be accessed via the third row of the Process maintenance
window.
The window is used to view the feeder related parameters and to adjust their values
if necessary. The window number is 7.3.
Fig. 110. Feeder options & parameters window 7.3.

3.13. Vehicle maintenance window (8)
The eighth main window of the user interface is the Vehicle maintenance
window for performing vehicle-related maintenance functions.
Fig. 111. Vehicle maintenance window structure.
8.1 = Platform parameters

8.2 = Pedal calibrations
8.2.1 = Calibration window
8.2.2 = Calibration window
8.3 = Engine and drivetrain
8.3.1 = Engine settings
8.3.2 = Drivetrain settings
8.3.3 = Brake circuit calibration
8.3.4 = Transmission settings
8.3.5 = Hydraulic oil levels
8.4 = Drive speed calibration

8.5 = Inclinometer calibration
In the Vehicle maintenance window it is possible to adjust and save platform
parameters and perform throttle pedal calibrations.
Fig. 112. Vehicle maintenance window 8.

To perform the functions in the window at least level 3 access rights are required.
Note!
All windows are not in use in all machines types.

3.13.1.Platform parameters (8.1)
Platform parameters can be accessed via the first row of the Vehicle maintenance
window.
The opened window enables viewing of parameters related to platform functions and
adjustment of their values as necessary. The window number is 8.1.
Fig. 113. Platform parameters window 8.1.


3.13.2.Engine and drivetrain (8.3)
The engine and drivetrain settings can be accessed via the third row of the Vehicle
maintenance window.
The opened window enables viewing of settings related to the engine and drivetrain
and adjustment of their values as necessary. The window number is 8.3.
Fig. 114. Engine and drivetrain 8.3.

At least level 3 access rights are required to perform the functions in the window.

Engine settings (8.3.1)
The engine settings can be accessed via the first row of the Engine and drivetrain
window.
The opened window enables viewing and adjustment of engine related settings. The
Fig. 115. Engine settings 8.3.1.

Values in these pictures are not necessarily accurate and therefore must never be
used as example in adjusting.

Fig. 116. Engine settings.
1. Engine maximum revolutions (rpm)

2. Engine minimum revolutions (rpm)
3. Coefficient A
4. Coefficient B
Fig. 117. Engine settings.

5. Engine acceleration ramp (s)
6. Engine deceleration ramp (s)
7. Engine revolutions (rpm).
8. Pedal filtration (higher value increases filtration).
The S curve describes the reaction of engine revolution demand to throttle pedal
position. It prevents excessively fast revolution increases when pressing the throttle
pedal.
Fig. 118. Following pedal diagnostics are shown in the window:

Front pedal signal (A), Rear pedal signal (B) and filtered signal
to drivetrain control (C). The signal value range is 0 - 32 768.

Drivetrain settings (8.3.2)
The drivetrain settings can be accessed via the second row of the Engine and
drivetrain window.
The opened window enables viewing of settings related to the drivetrain and
adjustment of their values as necessary. The window number is 8.3.2.
Fig. 119. Drivetrain settings 8.3.2.


Transmission related settings are adjusted separately for slow (1) and fast (2) gear.
The machine must be stationary while changing gear.
Fig. 120. Gear related settings.
1. Slow gear acceleration ramp (s).

2. Fast gear acceleration ramp (s).
3. Slow gear deceleration ramp (s).
4. Fast gear deceleration ramp (s).
5. Slow gear travel distance in millimeters per 100 pulses.
6. Fast gear travel distance in millimeters per 100 pulses.
7. Power limitation ON for 1st gear
8. Power limitation ON for 2nd gear
9. Power limitation OFF for 1st gear
10. Power limitation OFF for 2nd gear
The power limitations set in points 7-10 are set as numerical values and by increasing
the value the reaction becomes slower.
Fig. 121. Following pedal diagnostics are shown in the window:

Front pedal signal (A), Rear pedal signal (B) and filtered signal
to drivetrain control. The signal value range is 0 - 32 768.

Fig. 122. Brake related settings.
1. Automatic braking start time (ms). When the throttle pedal is released, the
parking brake engages automatically after this time.
2. Automatic braking speed limit (km/h). When the speed falls below this limit, the
parking brake engages automatically.
Fig. 123. Drive pump and motor related values.
1. Drive pump maximum current backward (mA)

2. Drive pump minimum current backward (mA)
3. Drive pump maximum current forward (mA)
4. Drive pump minimum current forward (mA)
5. Engine maximum current (mA)
6. Engine minimum current (mA)
7. Minimum current locking.

Fig. 124. Engine revolutions related settings.
1. The allowed drop in revolutions before changing gear ratio and speed
deceleration.
2. The gear ratio is zeroed when the engine speed drops below this rpm value.
Fig. 125. Engine related settings.
1. Engine minimum cubic capacity (cm3)

2. Engine maximum cubic capacity (cm3)
3. Drivetrain pump and motor overlapping control. If the value is 0 %, the pump
must be on full power before the motor control starts.
4. Actual engine rpm
5. Desired engine rpm
6. Gear ratio (%)
7. Speed demand (%)

Brake circuit calibration (8.3.3) (Optional)
The brake circuit calibration can be accessed via the third row of the Engine and driv-
etrain window.
The opened window enables to view and calibrate of brake circuit values. The window
number is 8.3.3.
Fig. 126. Brake circuit calibration 8.3.3.


The content of the brake circuit calibration window is presented below:
The A and B columns at the top describe the A and B brake circuits.
Fig. 127. Adjustable values.

The following values are adjusted for both circuits:
1. Minimum current (mA)

2. Maximum current (mA)
3. Deceleration ramp (s)
4. Acceleration ramp (s)
5. Drive shaft frequency (8.) when maximum braking is applied (hz).
6. Maximum braking power percentage (%)
7. Drive shaft frequency (8.) when braking is started (hz)
8. Drive shaft frequency (hz)
9. Brake circuit relative control value (0/1-127)
10. Pedal position (0- ~32000)
11. Diesel RPM limit (rpm)
12. Current diesel RPM (rpm)
Caution!
Only factory personnel is allowed to adjust these values.

Transmission settings (8.3.4) (Optional)
The transmission settings can be accessed via the fourth row of the Engine and
drivetrain window.
The opened window enables to choose desired function related to transmission

settings. The window number is 8.3.4.
Fig. 128. Transmission settings 8.3.4.

At least level 3 access rights are required to perform the functions in the window.

Transmission parameters (8.3.4.1)
The transmission settings can be accessed via the first row of the transmission
settings window.
The opened window enables viewing of parameters related to transmission functions

and adjustment of their values as necessary The window number is 8.3.4.1.
Fig. 129. Transmission settings 8.3.4.1.

Unit of the adjustable value is shown in square brackets in current row.

Automatic gear settings (8.3.4.2)
The automatic gear settings can be accessed via the second row of the Transmission
settings..
The opened window enables viewing of values related to transmission functions and
adjustment of their values as necessary The window number is 8.3.4.2.
Fig. 130. Automatic gear settings 8.3.4.2.


The content of the Automatic gear settings is presented below.
Fig. 131. Upper corner of the Automatic gear settings window.
1. Engine load percentage (%)

2. Diesel engine RPM
3. Pedal position (%)
4. Measured drive speed (km/h)
Fig. 132. Automatic gear shifting map parameters

Fig. 133. Shift inhibit times
1. Shift down inhibit time (s)

2. Shift up inhibit time (s)
Fig. 134. Valve indicators

Active valve is indicated by green colour.
1. Drive direction forward

2. Drive direction backward
3. Gear 3
4. Gear 2
5. Gear 1
6. Lockup
In the right part of the window, inputs are described with the symbols:
Input, open in normal status.
Input, closed.

Fig. 135. Shifting sequence delays
1. Shifting up sequence delays (s)

2. Shifting down sequence delays (s)
Fig. 136. Automatic gear shifting enabled.

Lockup settings (8.3.4.3)
The automatic gear settings can be accessed via the third row of the Transmission
settings.
The opened window enables viewing of values related to lockup settings and
adjustment of their values as necessary The window number is 8.3.4.3.
Fig. 137. Lockup settings 8.3.4.3.


The content of the Lockup settings is presented below.
Fig. 138. Left side of the Lockup window.
1. Lockup engage/ disengage hysteresis (rpm)

2. Lockup minimum diesel engine (rpm)
3. Diesel engine (rpm)
4. Diesel engine load percentage (%)
5. Lockup valve indicator. The symbol is green when valve is active.
6. Turbine rotation (rpm)
7. Turbine pickup sensor pulse frequency (hz)

Fig. 139. Right side of the lock up window.
1. Lockup engage maximum rpm difference of diesel engine (rpm).

2. Lockup disabled below set speed limit (km/h)
3. Lockup on inhibit time (s)
4. Lockup off inhibit time (s)
5. Turbine pulse per 1 rotation
Fig. 140. Lockup map settings.
1. Lockup engage at zero engine load (rpm)

2. Lockup engage at hundred percentage engine load (rpm).
Fig. 141. Turbine lock is not in use.

Hydraulic oil levels (8.3.5) (Optional)
The hydraulic oil levels can be accessed via the fourth row of the Engine and drivetrain
window.
The opened window enables to view and calibrate of hydraulic oil levels. The window
number is 8.3.3.
Fig. 142. Hydraulic oil levels 8.3.5.


The content of the hydraulic oil levels window is more explained below:
Fig. 143. Drive hydraulics values A and B of the operating hydraulics.
1. The alarm limit of the sensor readings B53A

2. The alarm limit of the sensor readings B53B
3. Diesel engine shutdown limit B53A sensor
4. Diesel engine shutdown limit B53B sensor
5. Current measured value in the B53A as liters (l ) and milliamperes (mV).
6. Current measured value in the B53B as liters (l ) and milliamperes (mV).

Fig. 144. Hydraulic oil level tank calibration.
Five point conversion table is used to convert level sensor readings to tank volume
reading with the option to compensate irregular tank shape.
Volume conversion points are used to define the tank volume.
1. B53A: Volume conversion point 1. as measured value (mV) / litres

6. B53B: Volume conversion point 1. as measured value (mV) / litres

3.13.3.Drive speed calibration (8.4)
The drive speed calibration can be accessed via the third row of the vehicle
maintenance window.
The opened window enables viewing of calibrations related to drive speed and
Fig. 145. Drive speed calibration 8.4.


Fig. 146. The amount of pulses and drive speed km/h are shown in the window.
1. Drive speed (rpm)

2. Drive speed (km/h)
3. The amount of pulses
4. Pulse frequency (hz)
5. Channel A pulses
6. Channel B pulses
In the Drive speed window it is possible to adjust and save the amount of pulses and
required drive speed. The vehicle must be stopped during the adjustments
procedures.
Fig. 147. The settings related to drive speed.
1. The static rolling radius of the wheel (mm).

2. The amount of pulses per revolution.
3. Required speed limit (km/h).

3.13.4.Inclinometer calibration (8.5) (Optional)
The inclinometer calibration can be accessed via the last row of the vehicle
maintenance window.
The opened window enables viewing of calibrations related to inclinometer and

Fig. 148. Inclinometer calibration 8.5.

Note!
All windows may not be available for all machine types.

Fig. 149. .The content of the window
1. Inclinometer’s X direction inclination indicator (-100 - 0 +100 %) relative to

maximum setting (9.)
2. Inversion for X direction inclination indicator bar (on/off)
3. Green bar visualizes inclination sensor X direction relative value (1.).
4. Inclinometer’s Y direction inclination (-100 - 0 +100 %) relative to maximum
setting (11.)
5. Inversion for Y direction inclination indicator bar (on/off)
6. Green bar visualizes inclination sensor Y direction relative value (4.).
7. The node id which is equipped with inclination sensor.
8. X inclination Warning limit. Set value when warning about the inclination is given.
A value slightly lower than the field 9 is entered.
9. X inclination maximum limit. Set value when inclination is on its extreme
maximum limit.
10. Y inclination Warning limit. Set value when warning about the inclination is given.
11. Y inclination maximum limit. Set value when inclination is on its extreme
maximum limit.
12. When machine is levelled adjust X offset so that angle reading in field 15
indicates zero.
13. When machine is levelled adjust Y offset so that angle reading in field 16
indicates zero.

14. Swap X and Y indicator bars (on/off).
15. RC filter value for X angle
16. RC filter value for Y angle
17. X inclination maximum limit. Set value when inclination is on its maximum limit.
18. Y inclination maximum limit. Set value when inclination is on its maximum limit. A
value slightly lower than the field 11 is entered.

3.14. Boom maintenance window (9)
The ninth main window of the user interface is the boom maintenance
window, used for adjusting different parameters related to boom functions.
Fig. 150. Boom maintenance window structure 9.
9.1 = Boom control parameters

9.1.1 = Adjustment window
9.1.2 = Adjustment window
….9.1.x = Adjustment window
9.2 = Joystick calibrations
9.2.1 = Not available on this system

Boom related parameters can be adjusted and saved in the boom maintenance
window.
Fig. 151. Boom maintenance window 9.
At least level 3 (maintenance) access rights are required for performing the functions
available in this window.
If Boom maintenance is not in use, Normet for tough jobs window is opened. Back to
the Menu pop up can be accessed by pressing the Enter button of the display
Fig. 152. Normet for tough jobs window is opened if Boom maintenance window is
not in use.

3.14.1.Boom control parameters (9.1)
The boom control parameters can be accessed via the first row of the boom
maintenance window.
The window that opens enables viewing of parameters related to different boom
movements and adjustment of their values as necessary. The window number is 9.1.
Fig. 153. Boom control parameters window 9.1.
The window shows the different boom movements in separate rows. Boom
movements include lifting, turning, and zoom.

The values of a specific movement can be adjusted in a separate adjustment window
that opens by pressing the Enter button in each movement row.
Fig. 154. Adjustment window 9.1.1.

The content of the movement adjustment window is presented below:
The + and – columns at the top describe the direction of the movement being adjusted
e.g. boom lift (+) and lower (-), boom turn to the left (+) and right (-), and boom zoom
out (+) and in (-).
The values in the figures do not necessarily correspond to reality, and they should not
be taken as an example when one is adjusting the values.
Fig. 155. The following values are adjusted

for both movement directions:
1. Minimum current (mA)

2. Minimum current locking
3. Maximum current (mA)
4. Acceleration ramp (s)
5. Deceleration ramp (s)
6. Balance (%)
7. Progression
8. A yellow exclamation mark appears
above the right-hand column if the
adjusted movement functions only in
one direction. In this case, the column
values are zero and they cannot be
adjusted.
Fig. 156. The window shows dither and frequency

values.
1. A positive dither value as a percentage of the

signal
2. A negative dither value as a percentage of the
signal
3. PWM (pulse width modulation) frequency

Movement-specific balance adjustment (0–100%)
Balance adjustment enables setting specific speed ranges for different boom
movements.
When the boom potentiometer is in the minimum position, the movement speed is
determined by the balance adjustment, i.e. the adjustment determines the current
range within which the movement is limited when using the boom potentiometer. The
higher the balance adjustment value, the greater the reduction in movement speed.
In other words, by making the value bigger the movement becomes slower.
Fig. 157. The example shows in blue the range limitation within the minimum-to-max-
imum current range for two different movements at different balance percentages.
When the balance adjustment is 25 %, the movement speed is 75 % of the maximum
current value when the crane potentiometer is turned to the minimum position. For
the second movement, the minimum speed is adjusted to 50% of the maximum
value.

3.14.2.Joystick calibrations (9.2)
Joystick calibrations can be accessed via the second row of the boom maintenance
window.
The window is not in use in current system. The window number is 9.2.
Fig. 158. No configurable joysticks installed in current system.

3.15. Diagnostics window (10)
The tenth main window of the user interface is the Diagnostics window,
used for viewing diagnostics information.
Fig. 159. Diagnostics window structure

10.1 = Module I/O diagnostics
10.1.1 - 10.1.x = Module connector diagnostics
10.2 = Camera view
10.3 = Support leg and boom limit diagnostics
10.4 = Measures
10.5 = CAN diagnostic
10.6 = Controller diagnostics
The Diagnostics window gives access, for example, to Module I/O diagnostics,
Camera view, Support leg diagnostics, and CAN diagnostic.
Fig. 160. Diagnostics window 10 opens on two pages.

3.15.1.Module I/O diagnostics (10.1)
The first row of the Diagnostics window gives access to the Module I/O diagnostics
window.
The opened window shows a list of the different modules of the system according to
the connectors.
Fig. 161. Module I/O diagnostics window 10.1.

The module list shows the status of the module being diagnosed (operational / not
operational) beneath the module name and connector. An exclamation mark is also
shown to the left of the row to describe the connector status.
Not operational
Temporarily not operational

Information on the connectors and their status is available for the diagnosed module.
The connector diagnostics window opens by choosing the desired connector from the
list. The opened window enables viewing of modules' inputs and outputs and current
information as well as the amount of current (mA) directed to a certain pin. The module
inputs and outputs are also itemized in an illustrative form, depending on the
information to be diagnosed.
Fig. 162. Diagnostics information of the X1 connector.
Fig. 163. Diagnostics information of the X2 connector.

The module connector diagnostics windows show the different pins of the connector
and the status of the pins.
Fig. 164. The pin information field shows at the top the pin number and the output
control signal (value between -127-127) and underneath the input current informa-
tion. An arrow on the left-hand side of the field describes the pin input and the arrow
on the right describes the pin output. The output or input in question is active when
the arrow is black.
Fig. 165. An information field shown in red indicates pin error.
The following information can be viewed from the connector diagnostics window:
1. Module supply voltage

2. Is the input/output on
3. Is the input/output in error status (error popup)
4. Analog signal level
5. Output control level
6. Version numbers (firmware, boot, serial, product, vendor)
7. Bus errors (RX/TX error, bus off)
Note!
The HCM2000 and HCM3100 modules have both X1

and X2 connectors, but the HCM3200 modules have
only the X1 connector.

The list of pin spesific I/O information of the connector opens when Enter is pressed
on the i-button in the diagnostic window.
Fig. 166. I-button of the module diagnostics window.
Fig. 167. The pin spesific I/O information of the connector

3.15.2.Camera view (10.2)
The system's camera view opens via the second row of the Diagnostics window.
The opened camera window shows a camera image.
Fig. 168. Camera view

The camera window can also be accessed directly from the Drive display's camera
button.
Fig. 169. Drive display's camera button.
If the Camera view has been accessed directly from the Drive display,
the program returns to the Drive display by pressing the Enter button in the Camera
view.
If the Camera view has been accessed directly from the Diagnostics window, the
program returns to the Diagnostics window (10) by pressing the Enter button in the
Camera view.

3.15.3.Support leg diagnostics (10.3)
The Support leg diagnostics window can be accessed via the third row of the
Diagnostics window.
The opened window enables viewing of the status of both the front and rear end
support leg keys and the status of all leg valves and switches. The window also shows
the turn and lift limits of the boom when the support legs are on the ground. Window
number is 10.3.
Fig. 170. Support leg diagnostics window 10.3.
Note!
Window is not available for all machine types.

The content of the window is detailed in the following:
Left front support leg:
Fig. 171. Left front support leg diagnostics.
1. Lower position limit switch. When the support leg is in the lower position the
upper symbol is open and the lower one is closed.
2. Support leg up/down movement. When the support leg raises, the upper sym-
bol is shown green. When the support leg lowers, the lower symbol is shown
green.
3. Upper position limit switch. When the support leg is in the upper position the
symbol is closed.
4. Extension extreme position limit switch. When the support leg extension is in
the extreme position the upper symbol is open and the lower one is closed.
5. Extension inner position limit switch. When the support leg extension is in the
inner position the symbol is open.
6. Extension movement. When the support leg moves outwards, the left-hand
symbol is shown in green. When the support leg moves inwards the right-hand
symbol is shown in green.

Right front support leg:
Fig. 172. Right front support leg diagnostics.
1. Lower position limit switch. When the support leg is in the lower position, the
green.
symbol is closed.
4. Extension extreme position limit switch. When the support leg extension is in
the extreme position the upper symbol is open and the lower one is closed.
5. Extension inner position limit switch. When the support leg extension is in the
inner position the symbol is open.
6. Extension movement. When the support leg moves inwards the left-hand sym-
bol is shown in green. When the support leg moves outwards the right-hand
symbol is shown in green.

Front support leg movements:
Fig. 173. Front support leg movement diagnostics.
1. The extension of the left front support leg moves outwards

2. The left front support leg moves up
3. The extension of the left front support leg moves inwards
4. The left front support leg moves down
5. The extension of the right front support leg moves inwards
6. The right front support leg moves up
7. The extension of the right front support leg moves outwards
8. The right front support leg moves down
The arrow is shown in black when the movement representing the arrow in question
is active.
Boom lift limit while the support legs are on the ground:
Fig. 174. Boom lift limit diagnostics.
1. Boom drive position lift limitation limit switch. When the boom is raised the
2. Boom lift. When the boom is raised the symbol is shown green.

Boom drive position turn limit while the support legs are on the ground:
Fig. 175. Boom drive position turn limit diagnostics.
1. Boom turn limitation limit switch to the left. When the boom is turned to the left
the upper symbol is open and the lower one is closed.
2. Boom turn limitation limit switch to the right. When the boom is turned to the
right the upper symbol is open and the lower one is closed.
3. Boom turn to the left. When the boom is turned to the left the symbol is shown
green.
4. Boom turn to the right. When the boom is turned to the right the symbol is
shown green.
Left rear support leg:
Fig. 176. Left rear support leg diagnostics.
green.
symbol is closed.

Right rear support leg:
Fig. 177. Right rear support leg diagnostics.
green.
symbol is closed.
Rear support leg movements:
Fig. 178. Rear support leg movement diagnostics.
1. The rear support legs move up

2. The rear support legs move down
The arrow is shown in black when the movement representing the arrow in question
is active.

3.15.4.Measures (10.4)
The Measures window can be accessed via the fourth row of the Diagnostics window.
The opened window shows the status of certain switches and functions and some of
the system temperatures and use times. Window number is 10.4.
Fig. 179. Measures window 10.4.

In the upper part of the window, inputs are described with the symbols:
Input, open in normal status.
Input, closed.
Note!
Window is not available for all machine types.

Fig. 180. Input status representations in Measures window.
1. Hydraulic fluid return filter blocked

2. Drive hydraulic fluid filter
3. Drive hydraulic fluid level
4. Power pack failure
5. Rear axle temperature
6. Front axle temperature
7. Axle temperature
8. Hydraulic fluid high temperature
9. Low hydraulic fluid level
10. Water in fuel filter
11. Cable 1 cable reel limit switch
12. Cable 2 cable reel limit switch
13. Brake pressure low
14. Rear wheels straight
15. Front wheels straight
16. Safety belt
17. Seat switch
18. Door switch
19. Engine coolant level low
20. Safety brake

In addition, the following information is shown in the window:
Fig. 181. General information about the system in Measures window.
1. Engine operating hours (h).

2. Engine temperature (°C).
3. Engine revolutions (rpm).
4. Engine oil pressure (bar).
5. Diesel engine load percentage (%).
6. System operating voltage (V).
7. Transmission temperature (°C).
8. Transmission oil pressure (bar).
9. Hydraulic fluid temperature (°C).
10. Compressor operating hours (h).
11. Symbol indicates from which bus information is received. Active engine bus indi-
cator symbol is green.
12. Fuel level (% of maximum).

Fig. 182. Safety brake diagnostics.
1. Safety brake on
2. Safety brake off
Fig. 183. Gear and drive direction diagnostics.
1. Gear selector is indicated at the left column

2. Gear box is controlled with outputs indicated on the right side column
3. Gear 3
4. Gear 2
5. Gear 1
6. Neutral gear
7. Forward
8. Reverse
9. Odometer (m)

3.15.5.CAN diagnostics (10.5)
The CAN diagnostic window can be accessed via the fifth row of the Diagnostics
window.
The opened window shows information related to CAN bus. Window number is 10.5.
Fig. 184. CAN diagnostic window 10.5.

3.15.6.Controller diagnostics (10.6)
The first row of the second page of Diagnostics window gives access to the Controller
diagnostics window.
The opened window shows diagnostics information of the two charger environment
and radio controller. The window is useful when diagnosing a system fault. The
Fig. 185. Controller diagnostics window 10.6.
The content of the window is described below:
Fig. 186. Requested feeder pull and feed speed.
1. Hose feeder out (m/s)

2. Hose feeder in (m/s)

The basket electrical box diagnostics information shows the status of the bow
switches. Switch activity is indicated by a green color.
Fig. 187. Two charger environment diagnostics information.
1. Back blowing on vessel B

2. Hose feeder out
3. Reset hose length
4. Hose feeder in
5. Charging on
6. Hose middle feeder out
7. Hose middle feeder in
8. Blowing on
9. Hose reel out
10. Hose reel in
11. A/B vessel selected
12. Back blowing on
13. Back blowing on vessel A
14. Charging from vessel A
15. Charging from vessel B
16. Vessel A pressurized
17. Vessel B pressurized

The radio controller diagnostics information show the status of the controllers
switches. Switch activity is indicated by a green color.
Fig. 188. Radio controller A diagnostics information.
1. Remote A
2. Charging on
3. Blowing on
4. Winding the hose onto the reel
5. Charging off
6. Blowing off
7. Unwinding the hose from the reel
8. Remote on (Length reset, if the power is on)
9. Lamp indicates the status of the remote controller.

Fig. 189. Radio controller B diagnostics information.
1. Remote B
2. Charging on
3. Blowing on
4. Charging off
5. Blowing on
6. Power on (or Length reset, if the power is on)
7. Lamp indicates the status of the remote controller.

4. FUNCTIONS
4.1. Starting up the system

The machine control system starts up automatically when the machine's main power
is switched on. During start up, the system checks the modules on the bus, sends
parameters to the modules, and the modules switch to OPERATIONAL status. The
system only starts up the modules that are specified in the system configuration.
System start up takes about 30 seconds.
4.2. System update

System updates are carried out from a USB memory stick containing the update
package. Emergency stop must be engaged before starting the update. After inserting
the USB into the USB port in the cabin, wait about 10 seconds for the update program
to start.
After the update program has started, you have 30 seconds to remove the memory
stick to cancel the update. If the memory stick is removed, the main power must be
switched off and on again for the system to be restored.
If the memory stick is not removed, the update starts after 30 seconds. Completion of
the update is notified by a separate info window. The machine must be fully restarted
after the update.
Fig. 190. The update starts 30 seconds after the update program has started.

Fig. 191. If the USB memory stick is removed during the 30 second waiting period,
the update is interrupted and the main power must be switched off.
Fig. 192. The update has been completed successfully. The machine must now be
fully restarted.

4.3. System backup
Module backup
After adjustment, the module parameters can be backed up on the application
controller (MID070S). The backup is performed in window 6.5.1.
The latest parameters are always sent to the modules during start up. The files are
checked with a check sum to avoid erroneous parameters. If the system tries to load
an erroneous parameter file on a module, the system makes a report of the error and
the module will not be started.
System backup
Full system backup creates an identical copy of the machine's settings on a USB
memory stick. Emergency stop must be engaged before starting the backup. A
backup directory must be created in the USB memory for saving the backup. The
backup can be made on any USB memory, but not on the same update memory stick.
The backup is performed in window 6.5.
The backup file format is .tar. The file can be opened with standard compression
programs (e.g. winzip). In addition to the tar file, the following directories and files are
created:
– Chk; contains the check sums of the parameter files
– Parameters; contains the system parameters
– Backup; contains the parameter files of the modules
– Temp; directory for storing temporary files
– Usagemonitoring; contains operating monitoring files (if in use)
– Log; contains the process log
– Config.gui; user interface file
– Config_language1.gui; language file (usually English)
– Config_language2.gui; language file (Finnish)
– Config_language3.gui; language file (other language)
– Maini; Norsmart application file
– text_presets; memory file for the entered texts

4.4. System backup restoration
Backup restoration can be performed for the whole system or a part of it. Backup
restoration takes about 2 minutes maximum. The USB memory containing the backup
should be kept separate from other USB memories used.
If necessary, the backup can be transferred to the backup directory of the update
memory stick. It is recommended to remove all other similar files, if any, from the
directory before transferring the file. The update program automatically searches for
the latest .tar file from the directory and updates it in the system.
Emergency stop must be engaged before starting the backup restoration. When the
USB memory stick is inserted into the USB port located in the cabin, the update
program starts automatically in 10 seconds. After this, the procedure is the same as
for a system update.
4.5. Changing the access level using a code or a login key

Carrying out certain functions (e.g. maintenance and calibration) requires a higher
access level and the corresponding access rights. The access right levels are
explained in Chapter 3.3. Access rights of the user interface.
The machine uses access level 1 access rights by default, which do not require log in.
The access right level can be changed in the Advanced settings window (6). A
separate login key (USB) or a code is needed to change the access level.

4.5.1. Changing the access level using a code
Sufficient access rights to perform more demanding system functions (e.g.
calibrations) can be gained by entering the required higher level access code via the
first row of the Advanced settings window (6).
The access code for the desired access level is entered in a separate window. To
open this window, press Enter when in the row.
Fig. 193. Log in window for different access levels.

Highest in the window is a challenge code corresponding to the desired access level.
Below that field, there is a field on the left for choosing the necessary access level (2-
4).

Fig. 194. Choosing access level 3.

The challenge code changes according to the access level chosen. The chosen
access level is confirmed with Enter and the response code matching the challenge
code is entered number-by-number in the field to the right of the access level field.
Fig. 195. Inserting response code one number at a time.

The code is confirmed with the OK key. As a result, the chosen access level will
appear as the current access level.
Fig. 196. Current access level 3 is shown in the text field and the open lock-symbol
tells that the access level is active.
The access level can be changed back to level 1 by pressing Enter on the row.
The response code for the challenge code is provided by the manufacturer.

4.5.2. Changing the access level using a login key
The access level can also be changed with a login key (USB) that contains the
required access rights.
The login key must be inserted into the machine when the Advanced settings window
is accessed.
When the login key is in the machine and the Enter button is pressed on the first row
of the Advanced settings window, the program will automatically apply the access
level corresponding to the login key. The program gives successful login notification
in a separate window.
Fig. 197. The program gives successful login notification in a separate popup win-
dow.
Fig. 198. The access level row shows the number of chosen access level and the
name of the person to whom the login key is registered.
The access level can be changed back to level 1 by pressing Enter on the access level
row.

Appendices
5. APPENDICES
APPENDIX 1. System alert and info texts
Table 1:
Platform alerts
No. Alert text
1023 Low hydraulic oil level
1024 Coolant level critically low
1025 Engine air filter clogged
1026 Boom turn lift limitswitch failure
1027 Right supportleg limit switch failure
1028 Left supportleg limit switch failure
1035 Engine red stop alarm
1036 Engine amber warning
1037 Compressor overheat
1039 Compressor airfilter clogged
1040 Compressor hydraulics return filter clogged
1041 Platform hydraulics return filter clogged
1044 Fire suppression activated
1046 H2KN18 24V system
1053 H3K1N48 24V system
1065 Low fuel level
1066 Alternator failure
1067 Battery voltage low
1068 Battery voltage critical low
1069 Battery voltage high
1070 Transmission high temperature
1071 Transmission low pressure
1072 Critical low fuel level
1073 Water in fuel prefilter

Appendices
Table 1:
Platform alerts
1074 Engine end axle high temperature
1075 Load end axle high temperature
1076 Hydraulic oil high temperature
1077 Hydraulic oil critical high temperature
1080 Basket overload
1082 J1939 connection to diesel engine lost
1084 Compressor motor overheat
1088 Boom turn left limitation output short circuit to supply voltage
1089 Boom turn right limitation output short circuit to supply voltage
1090 Boom lift limitation output short circuit to supply voltage
1091 Hydrostat oil level low
1092 Hydrostat oil filter clogged
1093 Compressor critical temperature
1095 Powerpack motor protector
1096 Compressor motor protector
1097 Too many hydraulic oil contamination particles
1098 Brake accumulator pressure low
1099 Hydraulic oil temperature high switch closed
1102 Powerpack motor overtemp
1103 Wrong powerpack phase sequence
1104 Drive hydraulics return filter clogged
1105 Safety brake pressure exist while should not
1106 Safety brake pressure missing
1107 Emergency stop test failed
1108 Engine protect alarm
1109 Engine malfunction alarm
1118 Platform parameters corrupted
1118 Platform parameters corrupted
1124 Platform parameters missing
1130 Out of RAM
1134 Engine oil temp switch alarm
1135 Engine temperature high
1136 Engine oil pressure switch alarm
1144 Hydraulic oil high temperature
1147 Axle high temperature
1151 M1K1N97 24V SYSTEM
1152 Boom down limit switch failure
1153 Boom extensions in limit switch failure
1155 Load end axle high temperature
1156 Engine end axle high temperature

Appendices
Table 1:
Platform alerts
No. Alert text
1460 Engine oil pressure alarm
1461 Emergency stop test failed
1462 Drive speed sensor failure too much difference in readings
1463 No pulses from drive speed sensor
1464 No pulses from drive speed sensor
1465 Analog boom turn sensor channel readings deviate
1466 Analog boom turn sensor test failed
1467 Analog boom turn sensor calibration not correct
1475 CAN RX errors cumulating
1476 CAN TX errors cumulating
1477 Boom transport position limit switch failure
1478 Speed limit brake control valve error
1479 Speed limit brake control valve error
1480 Speed above limit for too long
1481 Transmission low pressure
1482 Steer valve error
1483 Compressor overheat
1486 Compressor airfilter clogged
1487 Compressor critical temperature
1488 Compressor motor overheat
1489 Compressor motor protector
1490 Lift sensor signal sum does not match
1491 MEWP pressure sensor difference too high
1492 MEWP load sensor test failed
Table 2:
Boom alerts
No. Alert text
1045 Joystick toggle information not detected
1083 Control place selection error

Appendices
Table 3:
Platform info texts

No. Info text
2002 Parking brakes inactive
2003 Parking brakes active
2005 Boom usage limited
2005 Boom usage limited
2007 Gear select not neutral
2008 Emergency stop is active
2009 Engine already running
2010 Supply cable reel limit 3m
2011 Compressor can not start because charging process is active
2012 Support legs not driving position
2013 Release park brake button before reset
2014 Engine not started
2015 Boom outside limits
2022 Supply cable reel limit 1m
2027 Fasten your seat belt
2028 No water pressure
2029 Delayed diesel shutdown active!
2033 Cabin door open
2034 Rev up the engine first
2035 Rev down the engine first
2036 Safety brake released
2045 Immediate new start is not allowed
2048 Release emengency stop if pressed
2049 Emstop line 1 set when not expected
2052 Emstop line 2 set when not expected
2053 Emstop input 1 and 2 set when expected input 1
2054 Emstop input 2 set when expected input 1
2055 Emstop input1 line broken
2056 Emstop input 1 and 2 set when expected input 2
2057 Emstop input 1 set when expected input 2
2058 Emstop input 2 line broken
2059 Emstop relay did not interrupt line 2
2060 J1939 connection to diesel engine lost
2061 Hydraulic oil condition poor
2062 Diesel RPM not recognised

Appendices
Table 3:
Platform info texts

2063 Low fuel level
2064 Compressor restart possible after 2min delay
2065 Wall wash on
2066 Ignition switch off
2070 Gear select not neutral
2071 Battery voltage low
2074 Problem reading platform parameters but recovery was possible
2077 Parameter save failed please try again
2078 Boom slide limited when boom note in middle
2079 Boom turn limited when boom slide in
2080 Fire suppression activated
2082 EMS 24V output defective
2084 Boom turn limited cable reel in transport position
2085 Parking brakes active
2087 Concrete pump position
2088 Recodrive not enabled
2089 High reach boom position
2090 Man lift boom position
2091 Support legs not driving position
2092 Waiting for joystick neutral positions to activate
2093 Different control place selected
2098 Root tube not in spraying position
2099 Boom not in safety sector
2302 No USB stick found, please insert USB stick
2303 Machine Serial Does Not Match With MIC
2304 Machine serial file corrupted
2311 Parameter save failed please try again
2315 Level four access opened
2705 High reach boom extension
2706 Support legs not down
2711 Man lift boom extension

Appendices
Table 3:
Platform info texts

2714 Man lift boom extension
2715 Boom not in work sector
2717 Machine must be stopped first
2718 Gear not engaged
2719 Ems engaged input not set with ems outputs
2719 Release emengency stop if pressed
2720 Ems engaged input set with ems relay only
2721 Ems engaged input set with ems supply only
2722 Ems engaged input not set with ems outputs
2725 Emstop input1 line broken
2726 SUPPORTLEGS NOT DRIVING POSITION
2727 Boom not in transport position
2728 Not all controlling switches are at neutral position
2731 Speed sensor errors prevent driving
2733 Drive permission granted
2737 PARKING BRAKES ACTIVE
2737 PARKING BRAKES INACTIVE
2738 ENGINE NOT STARTED
2744 Function not in use!
2745 Idling engine will stop
2746 Idling engine will stop
2747 Rear wheels are not straight
2748 Rev up the engine first
2749 PARKING BRAKES INACTIVE
2752 Too much inclination
2753 Speed sensor errors prevent driving
2754 Boom control selected
2756 Steer valve test not ready
2757 Steer valve error
2758 Operator present switch stuck
2761 MEWP drive active
2762 Drive direction selected

Appendices
Table 3:
Platform info texts

2764 Gear selector at neutral
2765 PARKING BRAKES ACTIVE
2767 Work platform not in middle
2769 Safety brake released
2770 Compressor restart possible after 2min delay
2771 Compressor can not start because charging process is active
2772 FIRE SUPPRESSION ACTIVATED
2778 Work platform height limit
2792 Boom sledge position
2793 Concrete pump position
2795 Erector boom left extension position
2796 Erector boom right extension position
2797 Basket boom left extension position
2798 Basket boom right extension position
2799 Main boom extension position
2803 Collision avoidance active
2805 Operator present switch stuck
2806 Work platform not in driving pos
2807 Support legs must be lowered first

Appendices
Table 3:
Platform info texts

2810 Boom slide limited when boom note in middle
2811 Xlifter not in driving pos
2812 Work Oscillation lock was not released
2815 Crane not in home position
2820 Controller not at work platform

Appendices
Table 4:
Boom info texts

No. Info text
2024 Boom turn right limitation output short circuit to supply voltage
2025 Boom turn left limitation output short circuit to supply voltage
2026 Boom lift limitation output short circuit to supply voltage
2043 Remote control on switch must be switched off on first
2044 Remote control on switch must be switched on first
2046 Radio Remote lost RF connection
2047 Radio Remote not on bus
2095 Recodrive selected
2096 Manlifting boom selected
2734 Boom disabled MEWP transport active
Table 5:
System info texts

Nro Infotext
1114 Two or more nodes found with the same node number
1115 File operation failed: file could not be written
1120 Commercial options parameters corrupted
1121 LTC parameters corrupted
1126 Commercial options parameters missing
1130 Out of RAM

Appendices
APPENDIX 2. I/O-errors
System I/O errors are always in form:
Error in signal AAA located in BBB!
AAA refers to signal and BBB to location (module, connector, pin)
Example: Error in signal app_safety_brake_on_DO located in N48 X2/26!

Appendices
APPENDIX 3. ANFO system alert and info texts
Table 6:
ANFO alerts
No. Alert text
1042 Tank A over pressure
1043 Tank B over pressure
1122 ANFO parameters corrupted
1128 ANFO parameters missing
1130 Out of RAM

Appendices
Table 7:
ANFO info texts

No. Text
2018 Not all controlling switches are at neutral position
2019 Not all necessary control modules are present on bus
2103 Weighing release must be waited
2104 Please select different control place
2104 Radio remote not active/connected
2105 No round active at the moment
2107 Weighing delay must be waited
2108 Remote control not switched on
2109 Process not enabled
2111 Process not enabled
2113 Process enable switch at neutral
2115 Problems reading process parameters but recovery was possible
2116 Process parameters were automatically recovered from backup
2118 Parameter save failed, please try again
2119 Please select different control place
2120 Two charger process not selected
2121 Tank B not installed
2122 Charging prevented Anfo tank low level
2302 No USB stick found, please insert USB stick

Appendices
APPENDIX 4. ANFO process start up enabling conditions
Table 8:
ANFO system start up enabling conditions
Enabling condition System alert / info
Ignition switch key must be turned to

Ignition switch off
the first position
None of the emergency stop switches

Emergency stop is active
should be engaged
Process control modules must be on Not all necessary control modules are
the bus present on bus
All process controlling switches must

be in neutral before enabling the
process
Process enabling switch (and

accompanying green light is lit or
blinking if the switch is set)

Appendices
APPENDIX 5. Warning symbol explanations
Danger!
Warning!
Risk of injury.
Caution!
Note!

Service Schedule
Once per shift (10h)

Weekly (50 hours)
Every 1 Years
Every 2 Years
As required
12000 h
1000 h
1500 h
2000 h
3000 h
6000 h
125 h
250 h
500 h
● = Maintenance interval (which comes first)
○ = First maintenance for a new carrier Note!
Engine
1 Check the air cleaner. ●
2 Check the engine oil level. ●
3 Check the coolant level. ●
4 Check the engine for leaks. ●
5 Check the fuel pre-filter. ●
6 Check the fuel level. ●
7 Replace the engine oil filter. ○ ●
8 Check the ribbed V-belt. ●
9 Change the engine oil. ○ ●
10 Check the coolant additive concentration. ●
11 Check the battery and clean battery terminals. ●
12 Clean the catalytic exhaust gas purifier ●
13 Replace the fuel filters. ●
14 Replace the fuel pre-filter insert. ●
15 Clean the radiator. ●
16 Replace the air cleaner filter. ●
17 Check the glow plugs. ●
18 Check the engine monitoring system. ●
19 Check the wear limit of V-rib belt. ●
20 Check the engine suspension. ●
21 Check the fastenings and hose connections. ●
22 Adjust the valve clearance. ●
23 Replace the V-rib belt. ●
24 Replace the injection valves. ●
25 Carry out a basic engine overhaul. ●
26 Change the coolant. ●
Powershift Transmission
1 Check transmission oil level ●
2 Replace the transmission oil filter. ○ ●
3 Change transmission oil ○ ●
Mechanical Transmission
1 Check the tyres visually. ●
2 Check drive line bolts. ●
3 Lubricate the propeller shaft greasing fittings. ●
4 Check tyre pressure and condition. ●
5 Check the oil level in axle differential. ●
6 Check the wheel nuts. ●
7 Check the axle planetary gear oil level. ●
8 Check the brake plate wear. ●
9 Change the axle differential oil. ○ ●
10 Change the axle planetary gear oil. ○ ●
11 Air bleed the service brakes. ●
12 Air bleed the safety/parking brakes. ●
Hydraulic System
1 Check the hydraulic fluid level. ●
2 Check there are no leaking or hanging hoses. ●
3 Check the pressure accumulators ●
4 Replace the hydraulic return fluid filter. ○ ●
5 Change the hydraulic fluid. ●
6 Accumulator gas pressure test. ●
7 Check the steering hydraulic pressure. ●
8 Check and adjust the charging pressure. ●
3 1 - 1 EN 0918 ettekma 1(3)

Service Schedule

Weekly (50 hours)
Every 1 Years
Every 2 Years
As required
12000 h
1000 h
1500 h
2000 h
3000 h
6000 h
125 h
250 h
500 h
9 Check the service brake pressure. ●
10 Check and adjust the safety/parking brake pressure. ●
Frame
1 Lubricate the carrier greasing fittings. ●
2 Check the oscillation axle bushings. ●
3 Check the frame joint bearings. ●
4 Check the steering cylinder joint pin, pin locking and bearing. ●
Portable Fire Extinguisher

1 Ensure that the powder flows freely. ●
2 Check the pressure. ●
3 Check the valve system. ●
4 Check the hoses. ●
5 Check the tank. ●
MEWP
1 Make a visual inspection. ●
2 Check the tilting cylinder pin and work platform joint pin. ●
3 Keep the working area clean. ●
4 Lubricate the grease fittings. ●
5 Check the boom mounting attachment. ●
6 Inspect the hydraulic cylinder, cylinder joint pin, pin locking and bearing. ●
7 Check the boom extension clearance. ●
8 Check the hydraulic pressures. ●
9 Inspect the turning joint lug welding. ●
10 Inspect the tilting cylinder fixing lug welding. ●
11 Inspect the condition of the boom beams. ●
12 Inspect the function of the load-lowering valve. ●
13 Inspect the boom mounting bolt connections. ●
14 Change the tilting cylinder joint pin and bearing. ●
15 Change the tilting cylinder. ●
16 Adjust the boom lowering speed. ●
17 Adjust the boom slewing speed. ●
18 Adjust the load sensing system. ●
ANFO Charging Module

1 Drain water from the modular type air filter. ●
2 Drain water from the water separator ●
3 Check the lubricator drippage amount and oil level. ●
4 Keep the pressure vessel and charging unit clean. ●
5 Check the interior and exterior condition of the vessel. ●
6 Check the charging hose wear. ●
7 Check total resistance of the carrier. ●
8 Check the resistance between earthing straps and anfo charger quick acting
●
coupling
9 Check the vacuum pump oil level. ●
10 Clean the modular type air filter filter-element. ●
11 Clean the vacuum pump oil reservoir. ●
12 Clean the filter in the water line. ●
13 Check the resistance of the earthing straps. ●
14 Change the water separator filter-element. ●
15 Clean the cyclone separator filter-element. ●
16 Fix the earthing strap and earthing point connections. ●
17 Replace the earthing strap. ●
Compressor
3 1 - 1 EN 0918 ettekma 2(3)

Service Schedule

Weekly (50 hours)
Every 1 Years
Every 2 Years
As required
12000 h
1000 h
1500 h
2000 h
3000 h
6000 h
125 h
250 h
500 h
1 Check the condition of electric motor and clean it if necessary. ●
2 Check oil level and the condition of oil hoses. ●
3 Check the condition of prefilter mat and clean it if necessary. ●
4 Check the oil cooler and clean it if necessary. ●
5 Check bolts and clamps and retighten if necessary. ●
6 Clean the oil cooler ● ●
7 Check oil level ●
8 Change oil filter ○
9 Change oils ●
10 Check the condition of oil hoses and replace with new ones if necessary. ●
11 Change air filter. Air filter sensor lights up a signal light if the filter is clogged and
● ●
needs to be replaced.
12 Change oil filter ●
13 Clean oil return filter. ●
14 Change prefilter mat. ●
15 Change oil separator elements. ●
16 Change oil return filter. ●
17 Change air inlet valve maintenance kit. ●
18 Change minimum pressure valve maintenance kit. ●
19 Change control valves. ●
20 Change air inlet valve repair kit ●
21 Change minimum pressure valve repair kit. ●
Note!
The intervals given are for normal usage. For tougher working conditions, consult
the responsible service person for information on the appropriate intervals.
3 1 - 1 EN 0918 ettekma 3(3)

Maintenance Manual
CARRIER
Code: . . . . . . . . . . . . . . . . . . . . 100121643
Carrier No: . . . . . . . . . . . . . . . . DJ305
This manual is a guide to the proper and safe maintenance of the carrier. The information
contained in this manual is current for this carrier. In the interest of continually improving its
products, Normet reserves the right to update or modify information contained in this
manual. Illustrations shown in this manual were produced during the development stages
and may differ from the actual product.
Normet Oy Tel. +358 (0)17 83 241

FINLAND
Maintenance Manual
About this manual

Read this manual carefully before operating the carrier. Follow the instructions
Danger!
Warning!
Risk of injury.
Caution!
Note!

Maintenance Manual
CONTENTS
1. Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2. Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3. Other precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2. Oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance Manual
3. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1. Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.1. Quality grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.2. Lubricating oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2.3. Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.4. Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.5. Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3. Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3.1. Daily or once per shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Check the air cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Check the engine oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Check the coolant level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Check the engine for leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Check the fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check the fuel level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.3.2. Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Replace the engine oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Change the engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Check the ribbed V-belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check the coolant additive concentration. . . . . . . . . . . . . . . . . . . . . . . . . . 41
Check the battery and clean battery terminals. . . . . . . . . . . . . . . . . . . . . . 43
Clean catalytic exhaust gas purifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3.3. Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Replace fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Replace the fuel pre-filter insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Clean the radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Replace the intake air cleaner filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Check the glow plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Check the engine monitoring system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Check the wear limit of the ribbed V-belt. . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Check the engine suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Check the fastenings and hose connections. . . . . . . . . . . . . . . . . . . . . . . . 60
3.3.4. Every 1500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Adjust the valve clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.3.5. Every 3000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Replace the ribbed V- belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3.6. Every 6000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Replace the injection valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.3.7. Every 12000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Carry out a basic engine overhaul. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.3.8. Every 2 Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Change the coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Maintenance Manual
4. Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.1. Lubricant recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2. Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2.1. Daily or once per shift (10 hours) . . . . . . . . . . . . . . . . . . . . . . . . 78
Check the transmission oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2.2. Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Replace the transmission oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.2.3. Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Change the transmission oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.3.2. Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.3.3. Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5. Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.1. Lubricant Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.2. Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Check the tyres visually. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.2.2. Weekly (50 hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Lubricate the propeller shaft greasing fittings. . . . . . . . . . . . . . . . . . . . . . . 93
Check tyre pressure and condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Check the drive line bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.2.3. Every 125 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Check the axle differential oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.2.4. Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Check the wheel nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Check the axle planetary gear oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.2.5. Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Check the brake plate wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Change the axle differential oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.2.6. Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Change the axle planetary gear oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.2.7. As required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Air bleed the service brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Air bleed the safety/parking brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Maintenance Manual
6. Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

6.2. Pressure accumulator safety precautions . . . . . . . . . . . . . . . . . . . . . 107
6.3. Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Check the hydraulic fluid level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Check there are no leaking or hanging hoses. . . . . . . . . . . . . . . . . . . . . . . 110
6.3.2. Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Check the pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Replace the hydraulic return fluid filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Change the hydraulic fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.3.3. Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Accumulator gas pressure test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.3.4. As required maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Check the steering hydraulic pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Check and adjust the charging pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Check the service brake pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Check and adjust the safety/parking brake pressure. . . . . . . . . . . . . . . . . 121
6.4.1. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.4.2. Service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.4.3. Safety/parking brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7. Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.2. Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.2.1. Weekly (50 hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Lubricate the carrier greasing fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.2.2. Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Check the oscillation axle bushings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Check the frame joint bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Check the steering cylinder joint pin, pin locking and bearing. . . . . . . . . . . 133
8. Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

8.1. Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.2. Screws with locking washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
8.2.1. Wedge lock washers (e.g. Wurth®, HEICO®) . . . . . . . . . . . . . . 136
8.2.2. Nord-lock® Steel washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Maintenance Manual
1. SAFETY PRECAUTIONS
1.1. Service
1. When servicing or repairing the carrier, shut down the engine unless it is
required to be running for adjustment purposes.
2. Keep your head, hands, feet and loose clothing away from power-driven
parts.
3. Lock the frame joint by the safety bar when working near the frame joint.
Stop the engine before inserting and removing the safety bar.
4. Do not grab the steering wheel when mounting the carrier.
5. Ensure that all tyre and rim parts are undamaged and correctly assembled
before inflating the tyre.
6. Always inflate the tyres with the correctly designed inflation device. Do not
exceed the tyre manufacturer’s recommended maximum pressure.
7. Use caution when draining hot fluids from the carrier, splashing hot fluid
can cause serious burns.
8. Accumulated grease or oil on the carrier is a fire hazard. Remove debris
whenever a significant quantity of oil is spilled on the carrier.
9. Do not arc weld on the carrier without first disconnecting the alternator.
10. Before performing maintenance or repair work on any equipment, consult
the manufacturer’s instruction manual and follow the recommended proce-
dures.
11. Inspect equipment daily for signs of failure.
12. Perform all recommended checks.
13. Before you start cleaning the carrier with water, high-pressure washer,
steam jet or other washing methods cover all such openings, places and
components which may cause danger or break.
Do not use the high pressure washer to clean components such as:
• Service brake valve
• Electric motors, switch cabinets, electric components and boxes.
• Rubber parts.
14. Report all defects.
15. Use the proper tools for servicing.
16. Never attempt to clean, lubricate or adjust the carrier while it is in motion.
17. Always comply with your company’s regulations and practices for the safe
servicing of this carrier.
2001 1-1 EN MSO 7 (141)

Maintenance Manual
1.2. Hydraulics
1. When troubleshooting a hydraulic system for leaks, use a piece of card-

board or other material to detect the leak rather than your bare hand. Pres-
surized hydraulic fluid escaping from a fault component can penetrate the
skin and cause serious injury.
2. Never attempt the do work on the hydraulic system before you are sure
that there is no pressure. Before disconnecting lines:
– Release pressure from the system.
– Release pressure from the accumulators.
3. Use caution when draining hot fluids – splashing hot fluids can cause seri-
ous burns.
4. Do not use corrosive agents when washing parts.
5. Do not change the pressure setting of any hydraulic valves unless author-
ized instruction has been obtained.
6. Clean the area around the component to be repaired before starting work.
If possible, change the complete component.
7. Hydraulic components and hoses should be stored with all connections
firmly plugged. Do not remove the plugs until the components are
mounted on the rig.
8. Hydraulic pumps and motors are heavy. Use appropriate lifting equipment
to ensure safe removal and lifting of these components.
2001 1-1 EN MSO 8 (141)

Maintenance Manual
1.3. Other precautions
1. Avoid mixing lubricants. Use recommended oils or oils with corresponding

properties!
2. Ensure the carrier is level before filling reservoirs.
3. Perform oil changes only when the engine is hot.
4. Carefully clean all lubricating fittings, breathers and oil check windows.
5. When the engine is drained, place a clear notice on the vehicle to prevent
others form operating it before it is refilled. In the event of prolonged shut-
down with engine or circuits drained, use a device to prevent accidental
start-up prior to refill.
6. Analyse the drained lubricant if appropriate.
7. Ensure regular lubrication.
8. The intervals given are for normal usage. For tougher working conditions,
consult the responsible service person for information on the appropriate
intervals.
9. Ensure daily reading of the hour meter to help determine when lubrication
is due.
2001 1-1 EN MSO 9 (141)

Maintenance Manual
2. OIL SAMPLES
Take an oil sample and check the oil quality.
Take oil samples and send part out for analysis. These oil samples should include a
simple, quick ”patch test” and a more complete lab analysis. A patch test considers
only oil color and the presence of particles visible with a low power microscope or
hand-held magnifying glass. The patch test gives an indication of the general condi-
tion of the oil. An interpretation of the color and the nature of the foreign material might
indicate pending component failure. A chart is available to aid in this interpretation.
Do not overlook the importance of an oil analysis as a regular part of every mainte-
nance program and the direction the results lead. A complete oil analysis confirms
information already found in addition to providing other data needed to establish the
total condition of the oil and machinery.
An analysis of the lubricants will supply you with a multitude of data and findings and
it is an important source of information in proactive servicing. Early detection of
damage cannot be done without a lubricant analysis. This will not prevent break-
downs, but is an accurate guide to the actual condition of the carrier and provide infor-
mation that can be used for decisions what action is to be taken.
2001 1-1 EN MSO 10 (141)

Maintenance Manual
3. ENGINE
3.1. Safety precautions
Regulations for working on the fuel system

A) General
Danger!
Engine must be switched off!

Smoking and naked lights prohibited!
No injection/high pressure pipes may ever be disconnected when the engine is
running.
Caution when handling hot fuel!
Pay attention to absolute cleanliness when refueling and working on the fuel system!
Clean the vicinity of components concerned carefully.
Blow damp areas dry with compressed air.
Observe safety regulations and national regulations for handling fuels.
Dispose of leaked fuel and filter elements according to regulations.
Do not allow fuel to seep into the ground.
After working on the fuel system, bleed it, conduct a test run and check for leaks.
It will be necessary to vent the fuel system when commissioning for the first time, after
maintenance work or if the tank has been run dry.
Note!
The filters must always meet the requirements of the manufacturer. This can be
ensured by using original spare parts.
3003 2-2 EN 0116 MSO 11 (141)

Maintenance Manual
B) Cleanliness tips and measures for handling the fuel system
Caution!
Additional venting of the fuel system by a 5-minute trial run at idle speed or on low load
is absolutely essential.
Because of the high production accuracy of the system, utmost cleanliness must be
observed.
The fuel system must be tight and closed.
Make a visual inspection for leaks and damage to the system.
Clean and dry the engine and the engine compartment thoroughly before starting
work.
Cover parts of the engine compartment from which dirt could be loosened with a new,
clean foil.
Work on the fuel system may only be carried out in an absolutely clean environment.
Air contamination such as dirt, dust, moisture etc. must be avoided.
C) Additional regulations for the fuel system
Danger!
Never work on the fuel system while the engine is running.

The fuel system is under high pressure!
Do not stand near to leaks in the high pressure system. Fuel jets can cause severe
injury!
After switching off the engine, wait 30 seconds before working on the fuel system.
In the event of leaks in the fuel system contact your Normet Service immediately!
3003 2-2 EN 0116 MSO 12 (141)

Maintenance Manual
Regulations for working on the lubricating oil system
Danger!
Do not work when the engine is running.

Smoking and naked flames prohibited!
Danger of scalding with hot lubricating oil!
Note!
Pay attention to utmost cleanliness when working on the lubricating oil system.
Carefully clean the area around the affected parts.
Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling oils.
Dispose of leaking lubricating oil and filter elements properly.
Do not allow used oil to seep into floor.
Perform a trial run after all work.
Pay attention to tightness and oil pressure and then check the engine oil level.
For fuels with a sulfur content higher than 1 % ask your responsible service represent-
ative.
3003 2-2 EN 0116 MSO 13 (141)

Maintenance Manual
Regulations for working on the cooling system
Danger!
Danger of scalding with hot coolant!

Cooling system is under pressure!
Only open the filler cap in cooled state!
Coolant must have a prescribed cooling system corrosion protection concentration!
Observe safety regulations and national specifications for handling cooling media.
In case of an external cooler, proceed according to the manufacturer’s specifications.
Dispose of leaking coolant properly and prevent seepage into the ground.
Order cooling system corrosion protection agents from your DEUTZ partner.
Never operate the engine without coolant, not even briefly.
3003 2-2 EN 0116 MSO 14 (141)

Maintenance Manual
Regulations for working on the electrical system
Danger!
Do not touch live parts!

Replace defective pilot lamps immediately!
Caution!
Pay attention to correct polarity of the connections.

Cover electrical/electronic parts and connections before cleaning the engine (e.g.
control units, generator, solenoid valves etc.) Do not aim the water/steam jet directly
at them.
Run the engine warm afterwards to evaporate moisture residues.
Do not check for voltage by tapping against the ground.
For electrical welding work, the ground terminal of the welding gear must be clamped
directly to the part being welded.
Three-phase current generator:
Do not interrupt the connections between the battery, generator and governor when
the engine is running.
3003 2-2 EN 0116 MSO 15 (141)

Maintenance Manual
Regulations for working on the intake system
Danger!
Do not work when the engine is running.
Caution!
Pay attention to utmost cleanliness when working on the intake system, close intake
openings if necessary.
Dispose of old filter elements properly.
3003 2-2 EN 0116 MSO 16 (141)

Maintenance Manual
3.2. General
Modern diesel engines place very high demands on the lube oil used. Engine perfor-
mances are increasing constantly, leading to an increased thermal load on the oil and
increased exposure of the oil to contamination due to reduced oil consumption and
longer oil change intervals. For these reasons, the requirements and recommenda-
tions described in this instruction manual should be followed in order to maximize the
life of the engine.
Lube oils always consist of a basic oil and an additive package. The most important
tasks of a lube oil (e.g. wear protection, corrosion protection, neutralization of acids
from combustion products, prevention of coke and soot deposits on engine parts) are
assumed by the additives. The properties of the basic oil are also decisive for the
quality of the product, e.g., with regard to thermal load.
In principle, all engine oils can be mixed. However, mixing of engine oils should be
avoided because the worst properties of the mixture are always dominant.
The lube oil quality has a considerable influence on the life, performance and thus also
on the cost-effectiveness of the engine. The better the lube oil quality, the better these
properties.
The lube oil viscosity describes the flow behaviour of the lube oil relative to its temper-
ature. Lube oil viscosity has no effect on the lube oil quality.
Synthetic lube oils are increasing in use, and do offer some advantages. These oils
have better temperature and oxidation stability as well as relatively low cold viscosity.
Some process factors that determine the lube oil change intervals are not directly
dependent on the quality of the lube oil (such as soot and other contamination). For
this reason, when using synthetic lube oils the lube oil change interval given in the
lubrication schedule may not be changed.
Biodegradable lube oils may be used in DEUTZ engines if they meet the requirements
of this operating manual.
3003 2-2 EN 0116 MSO 17 (141)

Maintenance Manual
3.2.1. Quality grade

Lube oils are classified by DEUTZ according to their performance and quality class
(DQC : Deutz Quality Class). The efficiency or quality of the lube oil increases the
higher the quality class (DQC I, II, III, IV).
Other lube oils of similar specifications can be used as long as they meet the DEUTZ
requirements. In regions where none of these qualities are available, please contact
the DEUTZ Service representative.
The best results are achieved with DEUTZ lube oils. These can be ordered from
DEUTZ Service using the designated order number.
The following lubricating oils are specified for the engines described in this manual.
Recommended quality class
Deutz Others
DQC II ACEA E3-96; E4-07; E5-02API CH-4/CG-4; CI-4; CJ-4; DHD-1

DQC III Please contact your DEUTZ partner or see www.deutz.com
DQC IV SERVICE\Operating Media and Diagnosis\Deutz Quality
Class\DQC Release List
Initial oil filling Quantity
Initial oil filling quantity without filter Litres approximately

Minimum/maximum 12,5/15,0
Initial oil filling quantity with filter Litres approximately
Minimum/maximum 13.0/15.5
Note!
The lubricating oil dipstick mark is always decisive.
3003 2-2 EN 0116 MSO 18 (141)

Maintenance Manual
3.2.2. Lubricating oil change intervals

The intervals depend on:
– Oil quality
– Fuel sulphur content
– Type of engine application
The lubricating oil change interval must be halved if at least one of the
following conditions apply:
– Ambient temperatures permanently below -10 °C or oil
temperature below 60 °C.
– Sulphur content of the diesel fuel 0.5 – 1 weight %.
– Operation with bio-diesel fuel.
An oil change should be carried out at least once per year, even if the oil change
interval limits are not exceeded within the year.
3003 2-2 EN 0116 MSO 19 (141)

Maintenance Manual
3.2.3. Viscosity
The ambient temperature at the installation site or area of application of the engine is
decisive for the choice of the right viscosity class. Too high a viscosity can lead to
starting difficulties, too low a viscosity can endanger the lubrication effect and cause
high lube oil consumption. At ambient temperatures below -40 °C the lube oil must be
pre-heated (e.g. by storing the carrier in a heated shed). The viscosity is classified
according to SAE. Multipurpose oils should be used as standard. Single purpose oils
can also be used in closed, heated rooms at temperatures >5 °C. The specified lube
oil qualities must, naturally, also be single purpose oils.
We recommend the following common viscosity classes depending on the ambient
temperature.
3003 2-2 EN 0116 MSO 20 (141)

Maintenance Manual
3.2.4. Fuel
Permissible fuels
The following fuel specifications are permitted:
– Diesel fuels according to DIN EN 590
– US diesel fuel according to ASTM D 975 Grade No. 1-D and 2-D
– Japanese diesel fuel JIS K 2204 Grade 1 Fuel and Grade 2 Fuel with lubricat-
ing properties according to diesel fuel EN590 (HFFR max. 460 micrometer
according to EN ISO 12156)
Use commercially available diesel fuels with a sulphur content below 0.5 %. If the
sulphur content is higher, the lube oil change intervals must be reduced.
If other fuels are used which do not meet the requirements of this manual, the
warranty will be voided.
The certification measurements to satisfy the legal emission limits are performed with
the test fuels defined by law. These correspond to the diesel fuels according to EN
590 and ASTM D 975 described in this operating manual. No emission values are
guaranteed for the other fuels described in this manual.
Carrier Capacity Classification
S / NT60 series 120 l CEN EN 590

M / NT100 series 112 l CEN EN 590
L / NT100HD / Scamec 2000 series 160 l CEN EN 590
3003 2-2 EN 0116 MSO 21 (141)

Maintenance Manual
Winter operation with diesel fuel
Caution!
Only carry out mixing in the tank! First pour in the neces-
sary amount of kerosine, then the diesel fuel. Addition of
normal and super petrol is not permitted.
At low ambient temperatures fuel discharges can lead to blockages in the fuel system
and cause operating faults. Begin using winter fuel, as available from standard petrol
stations, in outside temperatures below 0 °C (to -20 °C) in good time before the cold
season begins.
– Kerosine should be added at temperatures below -20 °C. The mixing ratios
required are as per the diagram.
– Special diesel fuels can be used for arctic climates to -44 °C.
If it is necessary to use summer diesel fuel below 0 °C, kerosine can also be added
up to 30 % as per the diagram.
Usually a sufficient cold resistance can be achieved by adding a flow improver. For
questions regarding this please contact your DEUTZ partner.
I - Summer diesel fuel

II - Winter diesel fuel
A - Outside temperature
B - Kerosine mixing proportion
3003 2-2 EN 0116 MSO 22 (141)

Maintenance Manual
3.2.5. Coolant
General
Engine type Capacity (approx.)
TCD 2012/2013 L04 17 l
Caution!
Never operate the engine without coolant, not even

briefly.
In liquid-cooled engines, the coolant must be conditioned and monitored otherwise the
engine may incur damage due to:
– corrosion
– cavitation
– freezing
Water quality
The correct water quality is important for conditioning the coolant. Clear, clean water
with the following properties must be used:
Water quality min. max

pH-value at 20° 6.5 8.5
Chloride ion content (mg/dm3) - 100
Sulfate ion content (mg/dm3) - 100
Total hardness (°dGH) 3 12
Carbonate hardness proportion of total hardness min. 3 °dGH.

Water quality data are obtainable from the local waterworks.
A water testing kit can be requested from DEUTZ Service to test your water quality.
3003 2-2 EN 0116 MSO 23 (141)

Maintenance Manual
The water must be treated if it deviates from the analysis values.

pH value too low
– Addition of diluted caustic soda or caustic potash solution.
– Small sample mixtures are advisable.
Total hardness too high
– Mix with softened water.
– Softened water can be distilled water, pH neutral condensate or water treated
with ion exchangers.
Total hardness or carbon hardness too low
– Mix with harder water.
– Harder water is available in most cases in the form of drinking water (city
water).
Chloride and / or sulfate too high
– Mix with softened water.
– Softened water can be distilled water, pH neutral condensate or water treated
with ion exchangers.
3003 2-2 EN 0116 MSO 24 (141)

Maintenance Manual
Cooling system corrosion protection agent
Warning!
The mixing of nitrite based cooling system preservatives

with amine -based agents forms nitrosamines which are
hazardous to the health!
Note!
Cooling system preservatives must be disposed of in an

environmentally friendly manner.
The coolant for liquid-cooled DEUTZ compact engines is conditioned by mixing an
antifreeze with ethylene-glycol-based corrosion protection inhibitors into the water.
The best results are achieved with DEUTZ cooling system preservatives.
This cooling system protection agent is free from nitrites, amines and phosphates and
adapted to the materials in our engines. Order from your DEUTZ partner.
If the DEUTZ cooling system protection agent is not available, please contact your
DEUTZ partner.
3003 2-2 EN 0116 MSO 25 (141)

Maintenance Manual
The cooling system must be monitored regularly. This includes checking the concen-
tration of the cooling system preservative, as well as inspecting the coolant level.
The inspection of the concentration of cooling system preservative can be carried out
with standard testing devices (e.g. refractometer).
At temperatures below -35 °C, please consult your responsible DEUTZ Service. It is
possible to use other cooling system preservatives (e.g. chemical corrosion preserv-
atives) in exceptional cases.
3003 2-2 EN 0116 MSO 26 (141)

Maintenance Manual
3.3. Procedures
Daily or once per shift

1. Check the air cleaner
2. Check the engine oil level.
3. Check the coolant level.
4. Check the engine for leaks
5. Check the fuel pre-filter.
6. Check the fuel level
Every 500 hours

7. Replace the engine oil filter
8. Check the ribbed V-belt
9. Change the engine oil
10. Check the coolant additive concentration
11. Check the battery and clean battery terminals.
12. Clean the catalytic exhaust gas purifier
Every 1000 hours

13. Replace the fuel filters
14. Replace the fuel pre-filter insert.
15. Clean the radiator.
16. Replace the air cleaner filter.
17. Check the glow plugs.
18. Check the engine monitoring system.
19. Check the wear limit of V-rib belt.
20. Check the engine suspension.
21. Check the fastenings and hose connections.
Every 1500 hours

22. Adjust the valve clearance.
Every 3000 hours

23. Replace the V-rib belt.
Every 6000 hours

24. Replace the injection valves.
3003 2-2 EN 0116 MSO 27 (141)

Maintenance Manual
Every 12000 hours

25. Carry out a basic engine overhaul.
Every 2 years
26. Change the coolant
Danger!
When lubricating the carrier, shut down the engine.
Note!
Change oil and oil filter after first 50 hours
3003 2-2 EN 0116 MSO 28 (141)

Maintenance Manual
3.3.1. Daily or once per shift

ITEM 1
Check the air cleaner.
A) Cleaning intervals
Filter servicing is required if the indicator lamp for the air filter goes on when the
engine is running.
– It is not advisable to service the cartridge more frequently, as this may affect
the seal between the cartridge and housing.
– Replace the cartridge not later than at the end of 12 months.
– Replace the cartridge when soiled by soot.
Fig. 1. Air cleaner
3003 2-2 EN 0116 MSO 29 (141)

Maintenance Manual
B) Dust vacuator valve

The air filter is equipped with a vacuator valve which automatically expels most of the
accumulated dirt and water, thereby preventing the build-up of dust or mud, and
reduces the need for servicing the cleaner.
1. The vacuator valve should be removed and cleaned periodically.
– The lips of the vacuator should always be on the outside and pointing down.
– As the engine idles, the vacuator expels any foreign material in that area.
– As the rpm increases the lips are pulled together, preventing dust from
being sucked into the air cleaner.
2. Check the vacuator lips to insure they are on the outside of the vacuator.
3. Valve lips must be kept free of debris.
– Mud and chaff can lodge in the lips and hold them open during operation.
Fig. 2. Dust discharge valve
3003 2-2 EN 0116 MSO 30 (141)

Maintenance Manual
ITEM 2
Check the engine oil level.
Caution!
Low oil level or overfilling lead to engine damage!

The oil level may only be checked with the engine in a horizontal position and switched
off.
If the engine is warm, switch off the engine and check the oil level after 5 minutes.
If the engine is cold the oil can be checked immediately.
Danger!
Beware of hot oil. Danger of scalding!
3003 2-2 EN 0116 MSO 31 (141)

Maintenance Manual
1. Park the carrier to level position.

3. If engine is warm, wait for 5 minutes and check the oil level. If engine is cold,
check the oil level immediately.
4. Extract the oil dipstick.
5. Wipe with a clean, lint-free cloth.
6. Insert the oil dipstick until it stops and extract again.
7. Check oil level and refill to ”MAX” if necessary.
8. If the oil level lies just above the ”MIN” line marking, refilling is necessary. The oil
level may not fall below the ”MIN’’ line marking.
Fig. 3. Dipstick
3003 2-2 EN 0116 MSO 32 (141)

Maintenance Manual
ITEM 3
Check the coolant level.
Danger!
Never remove the cap when the coolant is hot.

Always use caution when removing the cap to avoid severe burns from pressurized,
scalding coolant.
1. Check coolant level when engine is cold, and top up if necessary.
2. If adding coolant to the circuit during service, first allow the engine to cool before
adding.
3. Remove the filler cap slowly as dangerous coolant can discharge if the coolant is
still hot and the system under pressure.
Fig. 4. Coolant level
3003 2-2 EN 0116 MSO 33 (141)

Maintenance Manual
ITEM 4
Check the engine for leaks.
Carry out a visual inspection. Inspect the engine for loose fasteners, oil leaks and
general wear and damage. This inspection should be performed in conjunction with
each one of the maintenance procedures rather than treated as a separate procedure.
Each time a maintenance procedure is carried out, spend a couple of minutes to check
for damaged or deteriorating hoses and electrical wiring. Check also for loose hard-
ware, fluid leaks and structural damage.
Preventive maintenance of this type often enables an operator to spot potential
trouble and thereby prevent many hours of engine downtime.
Fig. 5. Engine lay-out
3003 2-2 EN 0116 MSO 34 (141)

Maintenance Manual
ITEM 5
Check the fuel pre-filter
1. Position a collecting receptacle beneath the filter.
2. Drain the water out.
3. Bleed the fuel system.
Fig. 6. Filter
1. Drain plug
3003 2-2 EN 0116 MSO 35 (141)

Maintenance Manual
ITEM 6
Check the fuel level.
1. Check the engine fuel level.
2. Clean the area around the fuel filler cap before removing it.
3. Remove the fuel filler cap.
4. Fill the reservoir with the proper grade diesel fuel each day.
– At the end of the work shift.
– To prevent condensation in the reservoir during shutdown.
Fig. 7. Fuel reservoir
3003 2-2 EN 0116 MSO 36 (141)

Maintenance Manual
3.3.2. Every 500 hours

ITEM 7
Replace the engine oil filter.
Note!
The filter cartridge may never be prefilled. There is a

danger of soiling.
1. Loosen and unscrew the filter cartridge with the appropriate tool.
2. Collect the draining oil.
3. Clean the sealing surface of the filter support with a lint-free, clean cloth.
4. Oil the gasket of the new filter cartridge lightly.
5. Screw on the new filter to 15 to 17 Nm, i.e. firm hand tightness.
Fig. 8. Engine oil filter
3003 2-2 EN 0116 MSO 37 (141)

Maintenance Manual
ITEM 8
Change the engine oil.
Danger!
Observe caution when draining hot oil! Danger of scald-

ing! Collect the used oil; prevent seepage into the
ground! Dispose of according to instructions!
1. Carry out oil changes on a warm engine when the engine is not running.
2. Lube oil temperature approximately 80 °C.
3. Position the carrier so it is level.
5. Position an oil drip cup under the engine.
6. Unscrew the oil drain plug. Drain off the oil.
7. Screw in the oil drain plug with a new sealing ring and tighten to 50 - 60 Nm.
8. Fill the lube oil.
9. Check the oil level.
Fig. 9. Drain plug
3003 2-2 EN 0116 MSO 38 (141)

Maintenance Manual
ITEM 9
Check the ribbed V-belt.
Danger!
Only carry out work on the belt drive when the engine is
not running!
Only test / tighten / replace ribbed V-belt when the engine is not running.
If necessary, remount ribbed V-belt guard.
Re -tension ribbed V-belt after it has run for 15 minutes.
1. Visually inspect entire V-belt for damage.
2. Replace damaged V-belts.
3. Remount protective devices if necessary.
4. Pay attention to correct fit of new belts and check the tension after running for 15
minutes.
Fig. 10. Belt drive
3003 2-2 EN 0116 MSO 39 (141)

Maintenance Manual
5. To check the tension of the V-belt, use a tension gauge.

– Place the indicator arm into the gauge.
– Position the guide on the V-belt, midway between the pulleys, with flange on
the bottom of gauge against the edge of the belt.
– Push slowly on the black pad at right angles to the V-belt until the spring is
heard or felt to trigger.
– Carefully raise the gauge without changing the position of the indicator arm.
– Read the value where the indicator arm intersects the scale (arrow) and read
the indicator arm.
– If necessary, re-tension the belt and measure again.
3
2
Fig. 11. V-belt tension gauge
1. Indicator arm
2. V -belt
3. Guide
4. Pad
5. Scale
3003 2-2 EN 0116 MSO 40 (141)

Maintenance Manual
ITEM 10
Check the coolant additive concentration.
1. Ensure that the carrier is on level ground.
2. Operate the engine until it is warm enough to open the filler cap. Continue to run
the engine until the coolant has circulated the cooling system.
3. Stop the engine.
4. Allow the engine to cool until the temperature of the coolant is below 60 °C.
5. Remove the filler cap of the cooling system.
Danger!
Danger of hot coolant discharge – do not remove the

filler cap while the engine is still hot and the system is
under pressure.
Fig. 12. Coolant hydrometer
3003 2-2 EN 0116 MSO 41 (141)

Maintenance Manual
6. Use a special coolant hydrometer that will check the temperature and the spe-
cific gravity of the coolant, follow the manufacturer’s instructions.
7. Adjust the strength of the mixture as necessary.
Note!
If it is necessary to fill or replenish the coolant system in

service, mix the coolant to the correct strength before
adding to the coolant system. Antifreeze at 50 % con-
centration will provide frost protection to a temperature
of -35 °C. It will also protect against corrosion. This is es-
pecially important if the coolant circuit contains alumini-
um components.
3003 2-2 EN 0116 MSO 42 (141)

Maintenance Manual
ITEM 11
Check the battery and clean battery terminals.
A.) Safety precautions
B.) Checking the acid level
C.) Checking the voltage
D.) Removing the battery
E.) Charging the battery
F.) Installing the battery
G.) Checking acid density
Note!
The carriers have been delivered from the factory with

maintenance-free batteries. No servicing of the battery
need therefore be carried out during the battery’s normal
service life.
The following maintenance tips are only for standard-duty batteries.
3003 2-2 EN 0116 MSO 43 (141)

Maintenance Manual
A.) Safety precautions
Danger!
Danger of explosion!
• Explosive gases released by battery!
• Fire, sparks, smoking and naked lights are prohibited!
• Danger of acid burns!
• Wear protective gloves and glasses!
• Avoid contact with skin and clothing.
• Danger of short circuit!
• Do not place tools on the battery!
Caution!
Risk of loss of electronically saved data when the battery

is disconnected.
• Keep the battery clean and dry.
• Ensure the battery is correctly and firmly in place.
• Dispose of old batteries in an environmentally responsible
manner.
B.) Checking the acid level

1. Unscrew caps.
2. Note the manufacturer’s specifications on the liquid level.
3. The liquid should normally be 10–15 mm above the top edge of the plates.
– Reach up to any available control device.
4. Only use distilled water to top up the battery.
5. Screw in caps.
3003 2-2 EN 0116 MSO 44 (141)

Maintenance Manual
C.) Checking the voltage

Check the battery voltage with a conventional voltmeter.
– The voltage indicates the charging state.
– It should be between 24 and 28 V.
D.) Removing the battery

1. Always disconnect the minus pole first when removing the battery.
– To avoid danger of short-circuiting.
2. Remove the fastenings and take out the battery.
E.) Charging the battery

1. Unscrew caps.
2. Charge the battery with a conventional battery charger.
– Observe the manufacturer’s instructions.
3. Screw in caps.
F.) Installing the battery

1. Insert new or charged battery and attach the fastenings.
2. Clean the terminals and battery poles with fine-grained sandpaper.
3. Connect the positive pole first and then the negative pole.
– To avoid danger of short-circuiting.
– Make sure the terminals have good contact.
– Tighten the clamping screws by hand.
4. Grease the assembled terminals with an acid-free, acid-resistant grease.
3003 2-2 EN 0116 MSO 45 (141)

Maintenance Manual
G.) Checking acid density

1. Unscrew caps.
2. Measure the acid density of individual cells with a standard acid testing device.
– The measured values indicate the charging state of the battery.
– The acid temperature when measuring should be 20 °C if possible.
3. Check the acid level before recharging.
4. Screw in caps.
Electrolyte density
in [kg/l] in [°Bé (Baumé scale)*] Charge status

Normal Tropical Normal Tropical
1.28 1.23 32 27 well charged
1.20 1.12 24 16 semi-charged, re-charge
1.12 1.08 16 11 discharged, immediately charge
Fig. 13. Commercial hydrometer
3003 2-2 EN 0116 MSO 46 (141)

Maintenance Manual
ITEM 12
Clean catalytic exhaust gas purifier.
Caution!
Use cleaning solution in accordance with manufacturers

recommendations and in a properly ventilated area.
Fig. 14. Catalytic exhaust gas purifier

The condition of exhaust, amount of wet or heavy particulate, determines the cleaning
cycle.
1. Remove the purifier from the exhaust system.
– Remove the center body only if quick-release clamp design is installed.
2. Immerse the purifier in diesel fuel.
– Allow soak for 1 hour.
3. Wash the purifier using steam or high pressure water through both the inlet and
outlet ends.
– Keep the tip of the nozzle at least 50mm away from the purifier face.
– Pressure not greater than 5 bar.
– Do not use detergents.
4. Dry the purifier thoroughly with compressed air.
– Keep the tip of the nozzle at least 50mm away from the purifier face.
– Pressure not greater than 5 bar.
5. Place the purifier back into the exhaust system.
– Tighten all clamps and fittings and replace gaskets where necessary.
3003 2-2 EN 0116 MSO 47 (141)

Maintenance Manual
Caution!
Risk of fire. Check that there are no leaks in exhaust sys-

tem.
Caution!
Check that the heat insulators are in good condition and

properly installed.
Danger!
Ensure sufficient ventilation in the work area. Diesel

engine exhaust emissions are harmful to health. Car-
cinogenic substances increase the risk of cancer.
3003 2-2 EN 0116 MSO 48 (141)

Maintenance Manual

ITEM 13
Replace fuel filters
Note!
The filter cartridge may never be prefilled. There is a

danger of soiling.
1. Loosen and unscrew the filter cartridge with the appropriate tool.
2. Collect the fuel as it drains off.
3. Clean the sealing surface of the filter support with a lint-free, clean cloth.
4. Oil the gasket of the new filter cartridge lightly.
5. Screw on the new filter to 15 to 17 Nm, i.e. firm hand tightness.
6. Vent the fuel system.
Fig. 15. Fuel filter
3003 2-2 EN 0116 MSO 49 (141)

Maintenance Manual
ITEM 14
Replace the fuel pre-filter insert.
1. Position a fuel collecting vessel beneath filter.
2. Loosen the drain plug and drain the water/fuel completely.
3. Unscrew the filter cartridge together with water collecting vessel in anti-clock-
wise direction and remove.
4. Loosen water collecting vessel from old filter cartridge in anti-clockwise direction
and remove.
5. Empty remaining fuel into the fuel collecting vessel and clean water collecting
vessel.
– Dispose of collected fuel and old filter cartridge properly.
6. Screw water collecting vessel onto the new filter cartridge in clockwise direction.
7. Clean any dirt from the sealing surface of the new filter cartridge and the reverse
side of the filter head.
8. Fill the filter with clean fuel.
9. Wet the sealing surfaces of the filter cartridge slightly with fuel and screw back
onto the filter head in clockwise direction (17-18 Nm).
2
4
Fig. 16. Filter and air bleeding pump
1. Drain plug
2. FIlter cartridge
3. Mechanical pump
4. Electric pump switch
3003 2-2 EN 0116 MSO 50 (141)

Maintenance Manual
Bleeding the fuel system

Mechanical pump
1. Open the air bleeding screws from fuel filters.
Fig. 17. Air bleeding screws
2. Pump fuel with hand pump until fuel without air bubbles starts to come out of the
filter.
3. Close the air bleeding screws.
4. Continue pumping until pressure raises up in fuel line.
5. Carry on pumping for 2 more minutes.
6. Start the engine and run for about 5 minutes at idling or low load.
– Check the fuel system for leaks
Electric pump
1. Actuate the fuel pump for 2 minutes.
2. Start the engine and run for about 5 minutes at idling or low load.
– Check the fuel system for leaks.
Note!
When bleeding the fuel system ensure that current is ON

and fuel valve in fuel line is open.
3003 2-2 EN 0116 MSO 51 (141)

Maintenance Manual
ITEM 15
Clean the radiator.
Caution!
For all cleaning work, make sure that no parts are dam-
aged (e.g. bent cooler mesh).
Cover electrical/electronic parts and connections to clean the engine (e.g. control
units, generator, solenoid valves etc.)
Do not aim water/steam directly at electrical parts.
Run the engine warm afterwards.
Danger!
Do not carry out cleaning work on the engine when it is

running!
Remove the engine cover and cooling air cover if available and remount after
cleaning.
General
The following causes of soiling require cleaning of the engine:
– High dust content in the air.
– Debris in and around the engine.
– Coolant leakage
– Lubricating oil leakage
– Fuel leakage
Due to differences in application conditions, cleaning depends on the degree of
soiling.
Cleaning with compressed air

Blow dirt off or out. Always blow out the cooler and cooling fins from the exhaust air
side to the fresh air side.
3003 2-2 EN 0116 MSO 52 (141)

Maintenance Manual
Cleaning with cold cleaner

1. Spray the engine with cold cleaner.
– Leave for about 10 minutes to take effect.
2. Spray the engine clean with a high pressure water jet.
3. Warm up the engine to evaporate water residues.
Cleaning with a high pressure cleaner

1. Clean the engine with a steam jet.
– Maximum spray pressure 60 bar.
– Maximum steam temperature 90 °C.
– Distance at least 1 m.
2. Warm up the engine to evaporate water residues.
Fig. 18. Radiator
1. Engine intercooler
2. Engine coolant
3. Transmission oil cooler
3003 2-2 EN 0116 MSO 53 (141)

Maintenance Manual
ITEM 16
Replace the intake air cleaner filter.
1. Release the filter seal gently.
The filter fits tightly over the outlet tube, creating the critical seal on the inside diameter
of the filter end cap.
– The filter should be removed gently to reduce the amount of dust dislodged.
– There will be some initial resistance, similar to breaking the seal on a jar.
– Gently twist the end of the filter to disengage the seal.
2. Avoid dislodging dust from the filter.
Gently pull the filter off the outlet and out of the housIng, straight and not at an angle.
– Take care not to remove the safety element with the main element.
– Avoid knocking the element against the housing.
– Remove and change the safety element at every third replacement of the main
element.
Fig. 19. Filter
3003 2-2 EN 0116 MSO 54 (141)

Maintenance Manual
3. Always clean the sealing surface of the outlet tube.

Make sure that all contaminant is removed before the new filter is inserted.
4. Always clean the inside of the outlet tube carefully.
Dirt accidentally transferred to the inside of the outlet tube will reach the engine and
cause wear.
– Be careful not to damage the filter sealing area on the tube.
5. Check your old filter.
Your old filter could help you detect foreign material on the sealing surface that is
causing leakage.
– A streak of dust on the clean air side of the element is the telltale sign. If it
exists, be sure the cause is removed before installing a new element.
– Take care not to knock or drop the new element. This might cause physical
damage which could affect its efficiency.
Fig. 20. Sealing surfaces
3003 2-2 EN 0116 MSO 55 (141)

Maintenance Manual
6. Inspect the new filter for damage.

Always look for possible shipping or handling damage.
– Pay particular attention to the inside of the open end (the sealing area).
– Check for cuts, etc.
– Do not install a damaged filter.
7. Insert the new filter properly.
Before installing a new element, apply a thin film of motor oil or, preferably, silicone oil
to the sealing surface, on the inside for the main element and on the outside for the
safety element.
– This critical sealing area will stretch slightly, adjust itself and distribute the
sealing pressure evenly on the outlet tube as the element is installed.
– To complete a tight seal, apply firm pressure to the outer rim of the element,
not the flexible centre.
– Due to its unique design, cover pressure is not necessary to compress the ele-
ment seal.
A certain care is needed to ensure the end cover is properly installed.
– Before pushing the end cover in place, make small rotating movements to
ease the cover into the body slots.
– Close the latches without forcing.
8. Check connections for air tight fit.
Fig. 21. Air cleaner
3003 2-2 EN 0116 MSO 56 (141)

Maintenance Manual
ITEM 17
Check the glow plugs.
In low temperatures, factors such as cold intake air and cold cylinder walls hinder the
attainment of the necessary starting temperature. In these situations, glow plugs func-
tion as an additional heat source to bring the intake air up to the temperature neces-
sary to initiate the combustion cycle.
It is recommended to replace all the glow plugs at the same time if one glow plug fails.
The following signs are the clearest indicators that the glow plugs should be replaced.
If any of these conditions exist, be sure to check the carrier’s glow plugs and if neces-
sary, replace them with a new set of glow plugs.
– Carrier won’t start.
– Carrier starts only after excessive cranking. Excessive cranking can cause the
engine oil to be diluted with fuel, which could adversely affect the life of the
engine.
– Carrier idles roughly during initial start-up
– Excessive exhaust emissions during initial set-up.
3003 2-2 EN 0116 MSO 57 (141)

Maintenance Manual
ITEM 18
Check the engine monitoring system.
The instruments and controls to monitor and operate all of the systems are located in
the operator’s area. A brief description of each is described in the Operator Manual.
Gauges provide indications of engine performance. Ensure that the gauges are in
good working order. Determine the normal operating range by observing the gauges
over a period of time.
Noticeable changes in gauge readings indicate potential gauge or engine problems.
Problems may also be indicated by gauge readings that change even if the readings
are within specifications. Determine and correct the cause of any significant change
in the readings.
If any of the readings do not read within the normal operating ranges, stop the engine
and investigate the problem.
Once all the gauges have been checked and found to be reading within the normal
operating ranges, the carrier is ready to operate.
The engine will reach normal operating values after a few minutes operation at
moderate load and varying speed.
• Engine oil pressure . . . . . . . . . . . . . . . . . . min. 0.8 bar
• Engine coolant temperature . . . . . . . . . . . max. 100 °C
• Transmission feed pressure . . . . . . . . . . . min. 16.5 bar
• Transmission oil temperature . . . . . . . . . . max. 90 °C
• Voltmeter. . . . . . . . . . . . . . . . . . . . . . . . . . 24...28 V
3003 2-2 EN 0116 MSO 58 (141)

Maintenance Manual
ITEM 19
Check the wear limit of the ribbed V-belt.
The wear limit of the ribbed V-belt is checked as follows:
1. Check the distance between the projection of the moving tension arm and the
contact with the fixed tensioner housing.
2. If the distance ”a” is less than 3 mm, the ribbed V-belt should be replaced.
Fig. 22. Wear limit of ribbed V-belt
3003 2-2 EN 0116 MSO 59 (141)

Maintenance Manual
ITEM 20
Check the engine suspension.
1. Visually inspect the engine suspensions for damage.
2. Replace damaged suspensions.
Fig. 23. Engine suspension
ITEM 21
Check the fastenings and hose connections.
The connections of the intake manifolds to the cylinder heads should be checked for
tightness, and retightened where necessary. The connections of the fuel piping should
be checked also.
Installation Total Comments
Cylinder head cover 9 ± 1 Nm M6

Lock nut valves 20 ± 2 Nm Nut with inner aquare
Front face mounting foot 280 Nm M16
Oli drain screw 55 Nm M18 x 1.5 with Cu ring
3003 2-2 EN 0116 MSO 60 (141)

Maintenance Manual

ITEM 22
Adjust the valve clearance.
1. Let the engine cool down for at least 30 minutes before setting the valve clear-
ance. Oil temperature below 80 °C.
2. Place the turning gear over the fastening screws of the belt pulleys.
3. Turn over the engine until valve overlap is achieved.
– Exhaust valve is not yet closed
– Inlet valve begins to open
– The cylinders to be set are specified in the setting schematic.
Fig. 24. Turning gear
3003 2-2 EN 0116 MSO 61 (141)

Maintenance Manual
Setting schematic for the valve clearance

The cylinders are counted consecutively, starting from the flywheel.
Engine TCD 2012/2013, L04 2V
Valve overlap set
1 4
3 2
4 1
2 3
Engine TCD 2012/2013, L06 2V
Valve overlap set
1 6
5 2
3 4
6 1
2 5
4 3
Note!
This engine is equipped with an internal exhaust gas re-

turn system.
4-cylinder: inlet valve opens briefly on the discharge stroke.
6-cylinder: exhaust valve opens briefly on the discharge stroke.
Do not confuse this with valve overlap!
3003 2-2 EN 0116 MSO 62 (141)

Maintenance Manual
Setting the valve clearance

1. Loosen the lock nut (1).
2. Set the protractor (3) with the socket insert (4) on the adjusting screw (2).
3. Fix the magnet (5) of the protractor (3) on the cylinder head.
4. Turn the protractor (3) clockwise to the stop (rocker arm without clearance) and
set the scale to zero.
5. Turn the protractor (3) anti-clockwise until you reach the specified rotation angle
size.
Valve clearance on a cold engine
Engine TCD 2012 Engine TCD 2013
IN = Inlet valve 75° IN = Inlet valve 90°

EX = Outlet valve 120° EX = Outlet valve 150°
6. Hold the protractor (3) tight to prevent twisting.

7. Tighten the lock nut (1).
8. Set the second valve on the rocker arm as described above.
9. Repeat the setting procedure for each cylinder.
2 1
4
3003 2-2 EN 0116 MSO 63 (141)

Maintenance Manual

ITEM 23
Replace the ribbed V- belt.
1. Push the tension roller with the ratchet in the arrow direction.
– Until the locking pin fits into the mounting hole.
– The ribbed V-belt is now tension-free.
2. Pull the ribbed V-belt off the smallest roller or off the tension roller.
3. Fit a new ribbed V-belt.
4. Hold the ratchet in the opposite direction to the arrow and remove the pin.
5. Loosen the tension pulley in the opposite direction to the arrow until the ribbed V-
belt is tight.
– Check at the same time that the ribbed V-belt is positioned correctly in its
guides.
1. Tension roller
2. Ribbed V-belt
3. Ratchet
4. Locking pin
3003 2-2 EN 0116 MSO 64 (141)

Maintenance Manual

ITEM 24
Replace the injection valves.
Fuel injection nozzles are subject to tip wear. Tip wear is a result of fuel contamination.
Tip wear can cause the following problems:
– Increased fuel consumption
– Black smoke
– Misfire
– Rough running
Fuel injection nozzles should be cleaned, inspected, tested, and replaced, as neces-
sary.
The following items are symptoms of a malfunctioning fuel injection nozzle:
– Abnormal engine operation
– Smoke emission
– Engine knock
Each fuel injection nozzle must be isolated one at a time in order to identify the
malfunctioning fuel injection nozzle.
Maintenance must only be carried out by authorized service personnel.
3003 2-2 EN 0116 MSO 65 (141)

Maintenance Manual

ITEM 25
Carry out a basic engine overhaul.
To minimize downtime, it is recommended to make a scheduled engine overhaul
before the engine fails. This will provide you with the best cost-value relationship.
Reduced hours of operation at full load will result in lower average power demand. A
decreased average power demand should increase both the engine service life and
the overhaul interval.
The need for an overhaul is generally indicated by increased fuel consumption and
reduced power.
The following factors are important when considering scheduling an engine overhaul:
– The need for preventive maintenance
– The quality of the fuel used
– The operating conditions
Maintenance must only be carried out by authorized service personnel.
3003 2-2 EN 0116 MSO 66 (141)

Maintenance Manual
3.3.8. Every 2 Years

ITEM 26
Change the coolant.
Danger!
Do not drain the coolant while the engine is still hot and
the system is under pressure – danger of hazardous
coolant discharge.
1. Ensure that the carrier is on level ground.
2. Remove the filler cap of the radiator.
3. Remove the drain plug from the side of the radiator in order to drain the radiator.
If the radiator does not have a drain plug, disconnect the hose at the side of the
radiator. Drain the coolant.
4. If necessary, flush the system with clean water.
5. Fit the drain plug or connect the radiator hose.
6. Fill up with coolant.
7. Fit the radiator filler cap.
8. The cooling system is bled automatically after filling.
9. After the first engine run, check coolant level on cold engine.
Fig. 27. Radiator
3003 2-2 EN 0116 MSO 67 (141)

Maintenance Manual
3.4. Troubleshooting
Faults are often the result of incorrect engine operation or maintenance.
For all faults, check whether all operation and maintenance instructions have been
followed.
If you cannot identify the cause of the fault or fix it yourself, contact your authorised
service representative.
Danger!
Before starting, make sure that nobody is standing in the

immediate vicinity of the engine or driven machine.
Note!
When performing repairs:

• The engine must not be started if the speed regulator has been
removed.
• Disconnect battery!
3003 2-2 EN 0116 MSO 68 (141)

Maintenance Manual
Engine does not start or turns over slowly

– Not disengaged (if possible)
• Check clutch
– Engine start/stop lever still in stop position / faulty stop solenoid (for a mechan-
ical injection system)
• Check/change
– Starting limit temperature not reached
• Check
– Lubricating oil level too high
• Check lubricating oil level and drain if necessary
– Exhaust back pressure too high
• Check
– V-belt / ribbed V-belt (fuel pump in belt drive)
• Check whether torn or loose
– Engine lubricating oil has the wrong SAE viscosity grade
• Change the lubricating oil
– Fuel quality does not comply with the operating manual
• Change the fuel
– Air in fuel system
• Air bleed the fuel system
– Battery faulty or not charged
• Check battery
– Cable connections to starting motor loose or oxidized
• Check cable connections
– Faulty starting motor or gear does not engage
• Check starting motor
– Base load too high
• Decrease load
Engine does not start and diagnostic light flashes

– Engine electronics prevent the engine from starting
• Check fault according to error code and repair if necessary
3003 2-2 EN 0116 MSO 69 (141)

Maintenance Manual
Motor starts but runs erratically or cuts out

– V-belt / ribbed V-belt (fuel pump in belt drive)
– Wrong valve clearance
• Adjust
– Faulty injector
• Replace
– Faulty fuel injector
• Replace
– Faulty sheathed-element glow plug
• Replace
– Air in fuel system
• Air-bleed
– Fuel prefilter dirty
• Clean
• Change the fuel
– Leaky injection pipe
• Check injection pipe
• Check/change fuel injector
RPM can be changed and diagnostic light illuminates

– Engine electronics have identified a system fault and have activated a replace-
ment RPM
3003 2-2 EN 0116 MSO 70 (141)

Maintenance Manual
Engine becomes too hot. Temperature warning system activates.

– Insufficient amount of coolant
• Refill
– Air extraction duct blocked
• Clean
– Faulty injector
• Replace
– Coolant in the heat-exchanging device dirty
• Clean
– Faulty coolant pump (V-ribbed belt torn or loose)
– Lubricating oil level too low
• Fill up with lubricating oil
– Faulty fan/V-belts torn or loose
• Check fan/V-belts and change if necessary
– Heat leakage in the cooling system
• Check cooling system
– Resistance in cooling system too high / flow rate too low
• Check cooling system
3003 2-2 EN 0116 MSO 71 (141)

Maintenance Manual
Engine lacks power

– Lubricating oil filter (air or lubricating oil side) contaminated
• Replace
– Engine start/stop lever still in stop position / faulty stop solenoid (for a mechan-
ical injection system)
• Check/change
• Change the fuel
– Air filter contaminated/faulty exhaust gas turbocharger
• Check/change
– Faulty air filter maintenance switch/service indicator
• Check/change
– Leaky charge air pipe
• Check charge air pipe
– Dirty charge air cooler
• Clean
– Faulty injector
• Replace
• Check fuel injector
Engine lacks power and diagnostic lamp illuminates

– Engine electronics reduce power
3003 2-2 EN 0116 MSO 72 (141)

Maintenance Manual
Engine not running on all cylinders

– Faulty injector
• Replace
Engine has little or no lubricating oil pressure

– Lubricating oil level too low
• Fill up with lubricating oil
– Engine position too inclined
• Check engine position / reduce incline
– Engine lubricating oil has the wrong SAE viscosity grade
• Change the lubricating oil
Engine consumption of lubricating oil too high

– No load or too-light load operation for too long
• Change load
3003 2-2 EN 0116 MSO 73 (141)

Maintenance Manual
Engine produces blue smoke

– No load or too-light load operation for too long
• Change load
Engine produces white smoke

– Starting limit temperature not reached
• Check
• Change the fuel
Engine produces black smoke

– Air filter dirty / faulty exhaust gas turbocharger
• Check/change
– Faulty air filter maintenance switch/service indicator
• Check/change
– Leaky charge air pipe
• Check charge air pipe
– Faulty injector
• Replace
3003 2-2 EN 0116 MSO 74 (141)

Maintenance Manual
4. POWERSHIFT TRANSMISSION
4.1. Lubricant recommendations

Oil capacity without cooler and hydraulic lines.
Transmission Oil capacity Pressure (bar)
20000 18,9 l 16,5 / 19,3

24000 30,0 l 16,5 / 20,7
32000 30,0 l 16,5 / 20,7
Requirements:
Transmission lubricant must be qualified by one of the following specifications in order
of preference.
– Caterpillar TO-4
– John Deere J20 C,D
– MIL-PRF-2104G
– Dexron® IID or Dexron III quality level*
GL-5 and engine oils are not approved. The lubricant must be designed for transmis-
sions.
Multi-viscosity lubricants are approved.
Preferred oil viscosity:
– Select a lubricant with a viscosity grade that fully covers the prevailed ambient
temperature on the Oil Application Chart.
For example
Ambient temperature from 14 to 68ºF / -10 to 20ºC.
Select 10W30.
– When multiple viscosity grades are suitable, select the grade where the ambi-
ent temperature is closest to the middle of the viscosity range.
For example
Ambient temperature from 68ºF / 20ºC.
SAE30 is preferred over SAE40 or SAE50.
4001 1-2 EN 0515 MSO 75 (141)

Maintenance Manual
Sump pre-heaters – Before operating, the transmission fluid must be preheated to a

minimum temperature, according to the viscosity grade, to assure sufficient pumping
viscosity.
Warm up – For full load transmission functionality, a minimum sump temperature of
68ºF / 20ºC is required. Before reaching the minimum sump temperature, only neutral
gear or unloaded driving is allowed. Engine is not to exceed 1500 RPM or more than
half-throttle.
Extended oil change interval – Extended oil service life may result when using
synthetic fluids. Appropriate change intervals should be determined for each transmis-
sion by measuring oil oxidation and wear metals over time to determine the baseline.
Wear metal analysis can provide useful information but a transmission should not be
removed from service based solely on this analysis.
Any deviation from the above requirements must have written approval from the Appli-
cation Engineering Department of Dana Off-Highway.
Fig. 28. Oil application chart
4001 1-2 EN 0515 MSO 76 (141)

Maintenance Manual
4.2. Procedures
Daily or once per shift (10 hours)

1. Check the transmission oil level.
Every 500 hours

2. Replace the transmission oil filter.
Every 1000 hours

3. Change the transmission oil.
Note!
Change oil and oil filter after first 50 hours
4001 1-2 EN 0515 MSO 77 (141)

Maintenance Manual
4.2.1. Daily or once per shift (10 hours)

ITEM 1
Check the transmission oil level.
1. To check the oil level the engine should be running idle.
2. Shift the direction change-over to neutral.
3. Check the oil level on the dipstick. The oil temperature should be 80...90 °C.
4. The level should be between the min. and max. marks, preferably at the top limit.
Fig. 29. Checking transmission oil level
4001 1-2 EN 0515 MSO 78 (141)

Maintenance Manual

ITEM 2
Replace the transmission oil filter.
DANA 20000 and 24000 series

1. Remove and discard the filter element.
2. Clean the filter shell and install a new element.
3. Lubricate the seal before installing the new filter.
4. Tighten the filter to 28...33 Nm.
Fig. 30. Transmission filter (example location)
4001 1-2 EN 0515 MSO 79 (141)

Maintenance Manual
DANA 32000 series

1. Unscrew the bowl using the hex wrench provided.
2. Remove the bowl carefully, as it will be full of fluid, to reveal the dirty element.
3. Grasp the element handle and pull upwards with a slight twisting movement to
remove.
4. Discard the used element and check the head and bowl for damage.
5. Clean inside the bowl with a cleaning agent, do not use a cloth or paper towels.
6. Check the seals are fitted to the new element and replace the element in the
bowl.
7. Replace the head-to-bowl seal included with the new element, and refit the bowl
to the filter head. Lubricate the seal before installing.
8. Tighten the filter bowl to 40 Nm.
9. Check for leaks on repressurising the system.
Fig. 31. Transmission filter (example location)
Note!
Element must be replaced on visual indication at operat-

ing temperature, or at specified intervals 500 hours max-
imum. Failure to replace the element will cause filter to
go bypass.
4001 1-2 EN 0515 MSO 80 (141)

Maintenance Manual

ITEM 3
Change the transmission oil.
The oil should be changed shortly after the carrier has been in operation while the oil
is warm and any foreign particles are still suspended in the fluid.
1. Drain the transmission.
2. Refill the transmission to the low mark. Pour fresh oil into the transmission
through the dipstick opening. Refer to the oil recommendation table for appropri-
ate oil type and quantity.
3. Run engine at 500...600 RPM to prime converter and lines.
4. Re-check oil level with engine running at 500...600 RPM and add oil to bring oil
level to low mark. When the oil temperature is hot (82...93 °C) make a final oil
level check. Bring the oil level up to the full mark.
Fig. 32. Drain plugs
4001 1-2 EN 0515 MSO 81 (141)

Maintenance Manual
4.3.1. General
The following information serves as an aid in isolating and determining the specific
cause of a possible transmission malfunction.
When troubleshooting a “transmission” problem, it should be kept in mind that the
transmission is only the central unit of a group of related powertrain components.
Proper operation of the transmission depends on the condition and correct functioning
of all components in this group. Therefore, to properly diagnose a suspected trans-
mission problem, the transmission fluid, charging pump, torque converter, transmis-
sion assembly, oil cooler, filter, connecting lines, and controls, and also the engine,
must be considered as a complete system.
By analysing the transmission operation principles together with the information
presented in this section, it should be possible to identify and correct any malfunction
which may occur in the system.
Power shift torque converter transmission troubles fall into three general categories:
1. Mechanical problems.
2. Hydraulic problems.
3. Electrical problems.
In addition to mechanical and electrical components, all of which must be in proper
condition and functioning correctly, the correct functioning of the hydraulic circuit is
also vital. Transmission fluid is the “life blood” of the transmission. It must be supplied
in an adequate quantity and delivered to the system at the correct pressures to ensure
converter operation, to engage and hold the clutches from slipping, and to cool and
lubricate the working components.
4001 1-2 EN 0515 MSO 82 (141)

Maintenance Manual
4.3.2. Procedures
Stall Test
A stall test to identify transmission, converter, or engine problems. Use the following
procedure:
1. Position the carrier against a solid barrier, such as a wall, and/or apply the park-
ing brake and block the wheels.
2. Put the gear selector in forward or reverse, as applicable.
3. Select the highest speed. With the engine running, slowly increase the engine
speed to approximately one-half throttle and hold until the transmission (con-
verter outlet) oil temperature reaches the operating range.
Caution!
Do not operate the converter in the stall state for longer

than 30 seconds at a time, shift to neutral for 15 seconds
and repeat the procedure until the desired temperature
is reached.
Exceeding a temperature of 120 °C will damage the trans-
mission clutches, fluid, converter, and seals.
Transmission pressure checks

Transmission problems can be isolated by means of pressure tests. If the stall test
indicates a slipping clutch, measure the clutch-pack pressure to determine if the slip-
page is due to low pressure or clutch plate material failure.
In addition, converter charging pressure and transmission lubrication pressure can
also be measured.
4001 1-2 EN 0515 MSO 83 (141)

Maintenance Manual
Mechanical and electrical checks

Prior to checking any part of the system for hydraulic function (pressure testing), the
following mechanical and electrical checks should be made:
– Check the safety/parking brake for correct adjustment.
– Ensure all lever linkages are properly connected and adjusted in each seg-
ment and at all connecting points.
– The controls are actuated electrically. Check the wiring and electrical compo-
nents.
– Check that all components of the cooling system are in good condition and
operating correctly. The radiator must be clean to maintain the proper cooling
and operating temperatures for the engine and transmission. Air clean the
radiator if necessary.
– The engine must be operating correctly. Check that it is correctly tuned and
adjusted to the correct idle and maximum no-load speed specifications.
Hydraulic checks
Also, before checking the transmission clutches, torque converter, charging pump,
and hydraulic circuit for pressure and oil flow rate, it is important to make the following
transmission fluid check:
1. Check the oil level in the transmission. The transmission fluid must be at the cor-
rect, full level.
2. All clutches and the converter and its fluid circuit lines must be fully filled at all
times.
Note!
The transmission fluid must be at an operating

temperature of 82 - 93 °C to obtain correct fluid level and
pressure readings. Do not attempt to make these checks
with cold oil.
To raise the oil temperature to this specification it is neces-
sary to either operate the carrier or run the engine with the
converter on ”stall”.
Caution!
Beware of unexpected carrier movement when operat-

ing the engine and converter at stall RPM.
4001 1-2 EN 0515 MSO 84 (141)

Maintenance Manual
4.3.3. Troubleshooting guide

Refer to the following troubleshooting guide for diagnosis of typical transmission trou-
bles.
Low clutch pressure

– Low oil level.
• Fill to proper level.
– Clutch pressure regulating valve stuck open.
• Clean valve spool and housing.
– Faulty charging pump.
• Replace pump.
– Broken or worn clutch shaft or piston sealing rings.
• Replace sealing rings.
– Clutch piston bleed valve stuck open.
• Clean bleed valves thoroughly.
Low charging pump output

– Low oil level.
– Suction screen plugged.
• Clean suction pump.
– Defective charging pump.
• Replace pump.
4001 1-2 EN 0515 MSO 85 (141)

Maintenance Manual
Overheating
– Worn oil sealing rings.
• Remove, disassemble, and rebuild converter assembly.
– Worn charging pump.
• Replace charging pump.
– Low oil level.
– Dirty oil cooler.
• Clean cooler.
– Restriction in cooler lines.
• Change cooler lines.
Noisy converter
– Worn charging pump.
• Replace charging pump.
– Worn or damaged bearings.
• Complete disassembly will be necessary to determine which bearing is
faulty.
Lack of power
– Low engine RPM at converter stall speed.
• Tune engine check governor.
– See ”Overheating” and perform the same checks.
• Make corrections as explained in ”Overheating”.
4001 1-2 EN 0515 MSO 86 (141)

Maintenance Manual
5. MECHANICAL TRANSMISSION
5.1. Lubricant Recommendations
Axle Axle differential capacity Planetary reduction capacity
123 11,6 l 1,90 l

113 16,3 l 2,00 l
Axle lubricant must be qualified by one of the following specifications in order of pref-
erence*:
– API GL-5/MT-1/
– SAE J2360
– Axles with wet disc brakes or limited-slip (LS) differentials must have “LS”
additives
LS = Additive
– Limited Slip
– Additive for oil-bath brakes, for units presenting hypoid crown wheel and pin-
ion and /or self-locking differential gear.
API Category MT-1
– Designates lubricants intended for non-synchronized manual transmissions
used in heavy-duty trucks.
– Lubricants meeting API MT-1 provide protection against the combination of
thermal degradation, component wear, and oil seal deterioration which is
not provided by lubricants meeting only the requirements of API GL-4 and
API GL-5.
5001 1-4 EN 0117 MSO 87 (141)

Maintenance Manual
Extreme pressure gear lubricant is recommended for use in all drive-steer and rigid
drive axles except where explicitly stated differently by Dana Off-Highway Application
Engineering.
Preferred oil viscosity – Select highest oil viscosity compatible with the prevailing
ambient temperature on the Oil Application Chart.
Severe applications* – 85W140 or 80W140 lubricants that meet the requirements of

API GL-5 or MIL-PRF-2105E. Before using a synthetic lubricant in severe applica-
tions, the customer must check with the lubricant supplier on the issue of high-pres-
sure lubricant applications.
Steep grade applications – Grades of 15% or more for extended distances of 0.3 miles
[0.5km] must consult the Dana Off-Highway Application Engineering.
Vehicle warm-up procedure should be utilized when machine is at temperatures lower

than oil operating range
Friction modifiers for Posi-torq (limited slip) differentials can be used to minimize oper-
ational noise or in liquid-cooled brakes to reduce brake noise. 2% to 5% by
weight is recommended.
Danger!
After the additives are placed into the oil, verify service
brake and safety/parking brake performance after a few
hours of work. Also verify brake noise has been elimi-
nated. If brake performance is insufficient or noise is still
occurring, flush with washing oil, refill with new oil and
check again.
It is important to consult the applicable axle Service Manual as it may have unique
lubrication requirements not outlined in this manual.
Any deviation from the above requirements must have written approval from the
Dana Off-Highway Application Engineering.
5001 1-4 EN 0117 MSO 88 (141)

Maintenance Manual
Fig. 33. Oil Application Chart
*Axles with Hypoid Gears must use API GL5 and no Universal Tractor Transmission
Oil [UTTO]
Axles with Non-Hypoid Gears can use API GL4 or API GL5
Axles with USA serial numbers must use gear oil (no UTTO)
Axles with wet disc brakes or limited-slip (LS) differentials must have “LS” additives (If
UTTO is being used, the “LS” additive is not necessary).
5001 1-4 EN 0117 MSO 89 (141)

Maintenance Manual
5.2. Procedures

1. Check the tyres visually.
Weekly (50 hours)

2. Lubricate the propeller shaft greasing fittings.
3. Check tyre pressure and condition.
4. Check the drive line bolts.
Every 125 hours

5. Check the axle differential oil level.
Every 250 hours

6. Check the wheel nuts.
7. Check the axle planetary gear oil level.
Every 500 hours

8. Check the brake plate wear.
9. Change the axle differential oil.
Every 1000 hours

10. Change the axle planetary gear oil.
As required
11. Air bleed the service brakes.
12. Air bleed the safety/parking brakes.
Note!
Change oils after first 50 hours
5001 1-4 EN 0117 MSO 90 (141)

Maintenance Manual

ITEM 1
Check the tyres visually.
Examine the tyres on a regular basis for cuts, nicks, and uneven wear. Checking the
tyres visually can indicate whether or not the tyre is under or over inflated.
Main causes of deterioration in tyres:
– incorrect inflation pressure
– overload
– excessive speed
– severe impacts
– a combination of the above factors
Separations between components of the tyre results from:
A.) Overheating due to
– travelling speeds higher than those recommended for the loads and pressures
given.
– under inflation or overload for the application in question.
– heat generated by parts of the axle; brakes, hub-reduction gears, etc.
B.) Mechanical force
– lateral forces occurring in very tight radius curves.
– impacts on badly maintained surfaces.
– hammering due to condition of the road.
5001 1-4 EN 0117 MSO 91 (141)

Maintenance Manual
1. Check for uneven and rapid wear

– Caused by mechanical faults.
– Defects must be repaired immediately.
2. Remove stuck objects.
– Rushed glass, pieces of wood, metal filings, etc.
3. Replace damaged tyres.
4. Inspect the rim wheel while lubricating the propeller shaft greasing fittings.
– Inspect the tyre side ring to see if it has been damaged.
– Check that the tyre lock ring is set correctly.
Fig. 34. Tyre
5001 1-4 EN 0117 MSO 92 (141)

Maintenance Manual
5.2.2. Weekly (50 hours)

ITEM 2
Lubricate the propeller shaft greasing fittings.
Use a grease gun with grease as specified in the grease recommendation and lube
fittings as shown in the figure.
All drive line sections are furnished with grease nipples on universal joints and tele-
scopic sections. Lubrication must be done carefully to avoid damaging the seals.
Fig. 35. Greasing fittings
5001 1-4 EN 0117 MSO 93 (141)

Maintenance Manual
ITEM 3
Check tyre pressure and condition.
Tyres use high pressures (8 - 10 bar). Make sure that there is clearly higher pressure
in the filling line (12 - 15 bar) than required in tyres for appropriate inflation pressures.
Air pressure gauge shall be calibrated at least once a year. The gauge can be
damaged and show wrong values, if:
– the gauge drops to ground.
– exceeding the upper limit of the gauge.
Take off the gauge and check again the pressure when the needed inflation pressure
has been reached.
Interval for inflation pressure measurements is at least 2 weeks. Normal drop is 0.3 -
0.5 bars during service period. Cross-ply tyres will grow a bit after first filling and use,
so the first drop is greater than next to follow.
Note!
There can be some escaping air from small white spots

on sidewalls during the implementation of the tyre. The
trapped air between the outer ply -cords is guided out on
purpose. No effect to the inside inflation pressure.
Inflation pressure must be measured when the tyre is cold.
If the tyre is warm, increased pressure shall not be low-
ered.
Pressure versus inside temperature of the tyre body:
– 10.0 bar vs. 20 °C
– 11.5 bar vs. 64 °C
– 12.0 bar vs. 79 °C
Outdoor temperature lowering must be notified. Decrease of temperature by 10 °C
lowers pressure by 0.35 bar. The basic pressures must be increased when using tyres
at temperatures below 5 °C.
5001 1-4 EN 0117 MSO 94 (141)

Maintenance Manual
Low inflation pressure effects to the tyre life:

– Tyre wears quickly on shoulders.
– Tubeless inner liner can break and cause a serious pressure drop.
Too much pressure wears the centre of the tyre more.
Regular air leakage checking:

Valve . . . . . . . . . . . . . . . Damages, leakages.
Tyre . . . . . . . . . . . . . . . . Punctures, impacts, damages etc.
Rim . . . . . . . . . . . . . . . . Damages, O-ring, wearing.
Danger!
Do not stand directly in front of the wheel while inflating

the tyre. Stand to the side of the wheel.
Make sure that the tyres and rims are undamaged and cor-
rectly assembled. Use safety cables or other safety devic-
es when inflating the tyres. Failure to observe appropriate
safety precautions can result in serious personal injury.
Fig. 36. Safety precaution
5001 1-4 EN 0117 MSO 95 (141)

Maintenance Manual
ITEM 4
Check the drive line bolts.
The drive line connects the transmission and differential through universal joints,
turning the axles which turn the wheels. It’s important to have the universal joints and
flanges inspected to ensure there are no cracks that can damage the carrier.
Check all drive line and flange bolts to ensure:
1. No bolts are missing.
2. All bolts are tight
3. Use a torque wrench to torque the bolts to the recommended specification.
– Refer to section “Tightening Torques”
Warning!
If the brakes and drive line are not operating properly,

carrier should be shut down until proper repairs can be
made. Inspect the drive line while lubricating the propel-
ler shaft greasing fittings.
5001 1-4 EN 0117 MSO 96 (141)

Maintenance Manual

ITEM 5
Check the axle differential oil level.
1. Ensure that the carrier is parked on level ground when performing the oil check.
2. Check the oil level immediately after driving when the oil is warm.
3. Allow a few minutes for the oil level to settle.
4. Clean the breathers.
5. If required, replenish with recommended oil.
6. Oil is filled via the filler plug situated in the axle casing cover.
7. Top up the oil level after every 125 hours of running.
Fig. 37. Filler plugs
5001 1-4 EN 0117 MSO 97 (141)

Maintenance Manual

ITEM 6
Check the wheel nuts.
The wheel nuts must be tightened to a torque of 630 Nm. If the carrier is new, or a
wheel change has been recently carried out, this torque must be checked after the first
5 or 10 operating hours and then after every 250 operating hours.
Whenever changing a wheel, the contact surface between the hub and the wheel rim
must always be cleaned at the same time. This is important for ensuring that the
correct torque is maintained.
Fig. 38. Wheel nuts
5001 1-4 EN 0117 MSO 98 (141)

Maintenance Manual
ITEM 7
Check the axle planetary gear oil level.
1. Ensure that the carrier is parked on level ground when performing the oil check.
2. Check the oil immediately after driving when the oil is warm.
3. Allow a few minutes for the oil level to settle.
4. Turn the wheel hubs until the word ”OIL LEVEL” can be read in the horizontal
position.
5. Remove the oil plug and fill until the correct level is reached as shown by the
”OIL LEVEL” line on the planet carrier.
6. Reinstall the oil plugs when the filling is completed.
Fig. 39. Oil plug
5001 1-4 EN 0117 MSO 99 (141)

Maintenance Manual

ITEM 8
Check the brake plate wear.
Danger!
Never work under the carrier supported by jacks only.

Always use stands. Brake system failure on roadways or
ramps can have disastrous consequences.
2. Carry out the check when the oil in the axle differential is to be changed.
3. Remove the oil level plug.
4. The brake discs can be seen through the oil level plug hole.
5. Check the clearance between the intermediate brake discs.
6. Replace the brake discs if the clearance between the intermediate brake discs is
less than 5,2 mm.
– A new brake disc is 6,1 mm thick.
7. The same operations must be carried out on both arms.
Fig. 40. Oil level plug hole
5001 1-4 EN 0117 MSO 100 (141)

Maintenance Manual
ITEM 9
Change the axle differential oil.
1. Ensure that the carrier is parked on level ground when performing the oil
change.
2. Change the oil immediately after driving when the oil is warm and flows easily.
3. Clean the area around the filler plugs, and remove them.
4. Remove the axle differential drain plugs, and drain the oil into a container.
5. When the differentials are empty, reinstall the drain plugs.
6. Fill the differential with fresh oil through the filler plug openings until the level in
each axle reaches the bottom of the filler plug opening.
7. Use a recommended oil type.
8. Reinstall the filler plugs.
Fig. 41. Oil plug
5001 1-4 EN 0117 MSO 101 (141)

Maintenance Manual

ITEM 10
Change the axle planetary gear oil.
1. Ensure that the carrier is parked on level ground when performing the oil
change.
2. Change the oil immediately after driving when the oil is warm and flows easily.
3. Turn each wheel so that the oil plugs are positioned downwards.
4. Drain the oils.
5. Turn the wheel again until the word ”OIL LEVEL” on the planet carrier is in the
horizontal position.
6. Refill with fresh oil of the correct grade.
7. Fill until the correct level is indicated by the ”OIL LEVEL” line on the planet car-
rier.
8. Reinstall the oil plugs when the filling is completed.
Fig. 42. Oil plug
5001 1-4 EN 0117 MSO 102 (141)

Maintenance Manual
5.2.7. As required
ITEM 11
Air bleed the service brakes.
The brakes must be bled if air has entered the system and the braking effect has
diminished.
Make sure the carrier is levelled, and that the wheels are blocked against movement
before venting.
1. Push a clear plastic hose over the bleeding screw.
– To catch the oil and to help detect air bubbles.
2. Start up the diesel engine.
3. Loosen the bleeding screws by about a 1/2 turn.
4. Press the foot brake to the floor in one movement, do not pump.
5. Close the bleeding screws as soon as the oil emerges fee of air bubbles.
Danger!
Always check the braking action after air bleeding! If the

braking action is inadequate, check the brake discs for
wear.
Fig. 43. Venting the brakes
5001 1-4 EN 0117 MSO 103 (141)

Maintenance Manual
ITEM 12
Air bleed the safety/parking brakes.
For trouble-free operation of the safety/parking brake, it is important that the hydraulic
system is entirely free of air. Air can enter the system, for example, in connection with
component replacements or repairs and as a result of possible leaks. The brake is
released by hydraulic pressure. If the system contains air, this causes the pressure to
decrease and the brake to not release properly, or to engage after a delay. For this
reason, the brake circuit must be bled after each repair operation or whenever
malfunctions occur.
Danger!
Park on level ground if possible.

Turn the wheels into a bank or berm, or block the wheels when air bleeding the
brakes.
1. With the engine running and the safety/parking brake released.
2. Push a clear plastic hose over the bleeding screw.
– To catch the oil and to help detect air bubbles.
3. Loosen the bleeding screws by about a 1/2 turn.
4. Close the bleeding screws as soon as the oil emerges fee of air bubbles.
5. Repeat the above measures several times if necessary.
Fig. 44. Venting the brakes
5001 1-4 EN 0117 MSO 104 (141)

Maintenance Manual
Malfunctions are often due to improper operation or maintenance of the axle.
In the event of a malfunction, always check whether the operating instructions have
been strictly followed.
Insufficient braking.
– Brake discs worn out.
• Inspect disc thickness and replace if necessary.
Soft brake pedal.

– Air in the brake circuit.
• Bleed the brakes.
5001 1-4 EN 0117 MSO 105 (141)

Maintenance Manual
6. HYDRAULIC SYSTEM

Selection of an fluid with the correct viscosity grade for the operating temperature
range is essential. Other factors affecting the fluid selection are:
– High lubrication value
– High oxidation stability
– Resistance to foaming
– Shear stability
– Demulsification characteristics
– Corrosion prevention
ISO VG Industrial fluids are commonly used in the hydraulics.
Selection of viscosity grade is made on the basis of starting viscosity at ambient
temperature and optimum operating viscosity according to system and operating data.
High viscosity is permissible for a short period while starting.
vstart ≤ 1000 mm2/sec
Marginal lubrication limits the lower permissible viscosity to:
vmin ≥10 mm2/sec
Temperature:
tF = Fahrenheit
tC = Celsius
tF = 9/5 tC + 32
tC = 5/9 (tF - 32)
Ambient Classification
Carrier/Capacity
temperature ISO 3448
M / NT100 series...........115 l -25...+60 °C ISO-VG 22

L / NT100HD series......160 l -18...+70 °C ISO-VG 32
S series.........................110 l -10...+80 °C ISO-VG 46
-03...+90 °C ISO-VG 68
+03..+100 °C ISO-VG 100
6003 2-2 EN 0515 MSO 106 (141)

Maintenance Manual
6.2. Pressure accumulator safety precautions

1. Release hydraulic pressure from the accumulator before unfastening any
hydraulic parts from brake circuit:
2. Connect pressure gauges (0-200 bar) to the brake charge valve check points M7
and M8.
4. Apply and release the service brake foot pedal continually until both accumula-
tors are depressurized.
5. Check the pressure gauges.
– Both gauges should read 0 bar.
M8
M7
Fig. 45. Depressurization of hydraulic accumulators
6003 2-2 EN 0515 MSO 107 (141)

Maintenance Manual
6.3. Procedures

1. Check the hydraulic fluid level.
2. Check there are no leaking or hanging hoses.
Every 500 hours

3. Check the pressure accumulators.
4. Replace the hydraulic return fluid filter.
5. Change the hydraulic fluid.
Every 1000 hours

6. Accumulator gas pressure test.
As required
7. Check and adjust the steering hydraulic pressure.
8. Check and adjust the charging pressure.
9. Check the service brake pressure.
10. Check and adjust the safety/parking brake pressure.
Note!
Change fluid and filter after first 50 hours
6003 2-2 EN 0515 MSO 108 (141)

Maintenance Manual

ITEM 1
Check the hydraulic fluid level.
1. Use only the same type of fluid as already contained in the system.
– Use the filling device.
– Avoid mixing fluids of different makes.
2. Fill to the correct level.
– View through the sight gauges.
– Do not overfill the reservoir.
– Observe strict cleanliness when replenishing fluid.
– Contaminated fluid is a major cause of premature component failure.
1
2
Fig. 46. Check the hydraulic fluid level.
1. Quick acting coupling

2. Breather
3. Sight gauges
6003 2-2 EN 0515 MSO 109 (141)

Maintenance Manual
ITEM 2
Check there are no leaking or hanging hoses.
1. Visually inspect the exterior of the carrier for loose, leaking, hanging, or broken
hoses.
– This inspection should be performed in conjunction with each one of the main-
tenance procedures rather than treated as a separate procedure.
2. Check lines, tubes and hoses carefully.
– Do not use your bare hand to check for leaks.
– Use a board or cardboard to check for leaks.
– Leaks can cause fires.
– Tighten all connections to the recommended torque.
3. Each time a maintenance procedure is carried out, spend a couple of minutes to
check for damaged or deteriorating hoses and electrical wiring.
– Check also for loose hardware and structural damage.
– Preventive maintenance of this type often enables an operator to spot poten-
tial trouble and thereby prevent many hours of engine downtime.
4. Repair any lines that are loose or damaged.
– Do not install any lines that are bent or damaged.
5. Inspect the carrier for loose fasteners, oil leaks and general wear and damage.
6. Make sure that all clamps, guards, and heat shields are installed correctly.
– During engine operation, this will help to prevent vibration, rubbing against
other parts, and excessive heat.
7. Check for loose electrical wires and check all wires for wear.
6003 2-2 EN 0515 MSO 110 (141)

Maintenance Manual

ITEM 3
Check the pressure accumulators
1. Connect pressure gauges (0-200 bar) to the brake charge valve.
– To pressure check points M7 and M8 or remote test point S13/BR3.
2. Start and run the engine for 1 minute to charge the accumulators.
– Accumulator pressure should be 150 bar.
– Adjust the charging pressure if not within specification.
3. Switch OFF the engine.
4. Turn the current on with the current key switch.
5. Check the pressure gauges.
– Accumulator pressure should be 130 - 150 bar.
– If not:
• Check the accumulator Nitrogen gas pressure.
• Check that there is no leaks.
6. Apply and hold the service brake foot pedal for 10 seconds and release.
7. Repeat pressing and releasing.
– Service brake warning lamp lights up at 100 bar
– Replace the brake pressure switch if not within specification.
8. The accumulator pressure should be above 50 bar with 10 brake
pedal applications.
– If not:
• Check there is no air in service brake circuit.
• Check that there is no leaks.
• Check the accumulator Nitrogen gas pressure
Warning!
Special equipment and training is required to service Ni-

trogen accumulators. Do not service these items unless
qualified and competent to do so. Contact Normet Ser-
vice.
6003 2-2 EN 0515 MSO 111 (141)

Maintenance Manual
ITEM 4
Replace the hydraulic return fluid filter.
1. Unscrew the filter assembly lid.
2. Slowly remove the element assembly from the hydraulic fluid tank.
3. Remove the filter element from the hydraulic fluid return tube.
– No tools are needed.
– The element is installed hand-tight only.
4. Replace the old filter element with a new one.
5. Reinstall in reverse order.
Note!
Observe absolute cleanliness. Before changing the

filter, thoroughly clean the outside of the tank to prevent
dirt and foreign matter from entering the system.
Fig. 47. Hydraulic fluid filter assembly
1. Lid
2. Filer element
6003 2-2 EN 0515 MSO 112 (141)

Maintenance Manual
Replace the breather filter element.

1. Unscrew the cover.
2. Remove the filter element from the cover.
3. Replace the old filter element with a new one.
– Alternatively wash with solvent or diesel fuel.
– Blow out with compressed air.
4. Check that the filler sieve is clean.
– Release the setscrews and remove the filler sieve if it is not clean.
– Wash the filler sieve with diesel fuel and dry it with compressed air.
5. Reinstall in reverse order.
3
4
Fig. 48. Reservoir breather
1. Cover
2. Filer element
3. Setscrews
4. Filler sieve
6003 2-2 EN 0515 MSO 113 (141)

Maintenance Manual
ITEM 5
Change the hydraulic fluid.
Note!
Cleanliness is of extreme importance. Before changing

the fluid, the exterior of the reservoir must be thoroughly
cleaned to prevent dirt and foreign matter from entering
the system.
1. Remove the reservoir filler cap.
2. Empty the hydraulic fluid reservoir by opening the drain plug.
3. Change the fluid while it is warm.
4. Fill the reservoir with fresh fluid.
5. Use fluids as specified in the fluid recommendation.
6. Check the hydraulic reservoir sight gauges and add fluid as needed.
– The fluid level should not be above the top sight gauge or below the bottom
sight gauge.
Fig. 49. Drain plug
6003 2-2 EN 0515 MSO 114 (141)

Maintenance Manual
Use a filling device for the hydraulic fluid reservoir filling.

Filling the fluid by using the filling device removes all dirt particles larger than 10
micron from the hydraulic fluid because the fluid goes through the hydraulic fluid reser-
voir filtration during filling.
The device has a reservoir containing hydraulic fluid, a pump and a connection hose
so that the device is connectable to the carrier’s quick acting coupling.
1. Remove the dust plug from the quick acting coupling.
2. Clean the quick acting coupling thoroughly.
3. Connect the hose from the filling device to the quick acting coupling.
– Make sure no dirt or lint gets into the system.
4. Switch the filling pump on.
5. Fill up to the correct level.
– Check the level from the sight gauge on the side of the reservoir.
6. Stop filling when the hydraulic fluid level nears the top of the reservoir.
– Fluid level should not be above the top sight gauge or below the bottom sight
gauge.
Fig. 50. Quick acting coupling
6003 2-2 EN 0515 MSO 115 (141)

Maintenance Manual

ITEM 6
Accumulator gas pressure test.
Accumulator gas pressure should be checked every 1000 hrs. Pre-charge pressure is
40 bar.
Warning!
Special equipment and training is required to service Ni-

trogen accumulators. Do not service these items unless
qualified and competent to do so. Contact Normet Ser-
vice.
6003 2-2 EN 0515 MSO 116 (141)

Maintenance Manual
6.3.4. As required maintenance

ITEM 7
Check the steering hydraulic pressure.
Conditions
– Hydraulic fluid is at normal working temperature.
– Pressure gauge connected to the pressure check point.
Check
Fig. 51. Steering pressure check point.

A) Check the pressure.
1. Press continually the LS-valve (Y19) push button.
2. Check the pressure gauge.
– The pressure should be 175 bar max.
Push
Fig. 52. LS-valve push button.
6003 2-2 EN 0515 MSO 117 (141)

Maintenance Manual
B) Adjust the pressure

1. Remove the cover and slacken the jam nut.
2. Adjust the pressure by turning the adjustment screw.
3. Lock the adjustment screw in place with its jam nut when the pressure gauge
reads 175 bar.
Adjust
Fig. 53. Steering pressure adjust.
6003 2-2 EN 0515 MSO 118 (141)

Maintenance Manual
ITEM 8
Check and adjust the charging pressure.
Conditions
– Pressure gauge connected to the pressure check point M7.
– The pressure should rise rapidly to max. 150 bar.
3. Adjust the pressure if it is too low or high.
B) Adjust the pressure.
Adjust the pressure by turning the adjustment screw.
– Adjustment screw at the charging valve.
– Pressure differs from the given value.
– Turn the adjustment screw in the desired direction.
Adjust
M7
Fig. 54. Pressure check point and valve adjustment screw.
6003 2-2 EN 0515 MSO 119 (141)

Maintenance Manual
ITEM 9
Check the service brake pressure.
Conditions
– Pressure gauges connected to the pressure check points
3. Press the service brake pedal down fully.
– The pressure should be 80 bar max.
Fig. 55. Service brake pressure check points

B) Adjust the pressure.
Pressure is too low.
– Change the service brake valve to a new one.
– Send the old one to the valve manufacturer to be repaired.
6003 2-2 EN 0515 MSO 120 (141)

Maintenance Manual
ITEM 10
Check and adjust the safety/parking brake pressure.
Conditions
– Pressure gauge connected to the pressure check point M1.
A) Check the reducing valve pressure.
– The pressure should be 21....25 bar.
3. Adjust the pressure if it is too low or high.
1
4
2
Fig. 56. Safety/parking brake valve (V167)
1. Adjustment screw
2. Jam nut
3. Check point M1
4. Check point M2
6003 2-2 EN 0515 MSO 121 (141)

Maintenance Manual
B) Adjust the reducing valve pressure.

1. Slacken the jam nut.
2. Adjust the pressure by turning the adjustment screw.
– If pressure is not 21...25 bar.
– With 5 mm hex wrench.
– In the closing direction to increase the pressure.
– In the opening direction to reduce the pressure.
3. Lock the adjustment nut in place with its jam nut.
– Pressure gauge reads 25 bar max.
C) Check the releasing pressure.
1. Safety/parking brake pressure gauge is connected to the pressure check point
M2.
3. Release the safety/parking brake.
– The release pressure should be 21....25 bar.
If the measured pressure differs from the given value.
– Brake cylinder sealings are leaking
– Brake hoses are leaking etc.
6003 2-2 EN 0515 MSO 122 (141)

Maintenance Manual
Trouble
Location
– Probable cause
• Remedy
6.4.1. Steering
Steering is very stiff

Steering hydraulics
– Steering pressure relief valve damaged or pressure setting changed.
• Check and adjust the pressure.
• Replace the relief valve if necessary.
Pump side
– Steering hydraulic pump damaged.
• Replace the steering pump.
Steering cylinder
– Steering cylinder seals are leaking.
• Cylinder leakage can be ascertained by operating the steering a number of
times to see whether the cylinder heats up abnormally. Change the cylinder
seals.
Steering valve
– Steering valve damaged.
• Replace the steering valve.
Steering is sticking and unsteady

Steering hydraulics
– Air in the steering hydraulics.
• Carry out bleeding by turning the steering to its extreme positions a number
of times. Check the inlet side of the steering pump.
Steering valve
– Steering valve worn.
• Replace the steering valve.
– Steering column bearing worn.
• Replace the bearing.
6003 2-2 EN 0515 MSO 123 (141)

Maintenance Manual
6.4.2. Service brakes
Service brake does not hold

Service brake system
– Internal leak in the brake valve.
• Change the brake valve.
– Brake pressure too low.
• Check and adjust the brake hydraulic pressure.
– Air in the brake hydraulics.
– Brake discs are worn out.
• Check the brake discs and replace if necessary.
Soft brake pedal.

Brake circuit
6.4.3. Safety/parking brakes
Safety/parking brake does not hold

Safety/parking brake system
– Brake discs are worn out.
• Replace the brake discs.
– Incorrect pressure adjustment.
Safety/parking brake does not release (open)

Safety/parking brake system
– Releasing pressure too low.
6003 2-2 EN 0515 MSO 124 (141)

Maintenance Manual
7. FRAME

Lithium based greases:
– NLGI class . . . . . . . .2
– penetration . . . . . . .265/295
– dropping point . . . . .180 °C
– base oil viscosity . . .150 - 250 mm2/s @ 40 °C
7002 1-2 EN 0515 MSO 125 (141)

Maintenance Manual
7.2. Procedures
Weekly (50 hours)

1. Lubricate the carrier greasing fittings.
Every 1000 hours

2. Check the oscillation axle bushings.
3. Check the frame joint bearings.
4. Check the steering cylinders.
Note!
Check the steering cylinder expander bolt tightening

torque after first week.
7002 1-2 EN 0515 MSO 126 (141)

Maintenance Manual

ITEM 1
Lubricate the carrier greasing fittings.
Warning!
Accumulated grease or oil on the carrier is a fire hazard.

Remove debris any time a significant quantity oil is
spilled on the carrier.
Use a grease gun with grease as specified in the grease recommendation and lube
fittings as shown in the figure.
Ensure that all of the carrier’s greasing fittings are lubricated.
7002 1-2 EN 0515 MSO 127 (141)

Maintenance Manual
Central lubrication (Optional)

Lubricate all greasing fittings that are not covered by central lubrication. Use a grease
gun with grease as specified in the grease recommendation.
Ensure that all of the carrier’s greasing fittings are lubricated.
Additional lube cycle.

Press the button for an additional lubrication cycle if extra lubrication is needed.
– Is initiated via the button.
– Press the button for 2 seconds.
– Can be initiated at any time, provided that the power supply is applied.
Fig. 58. Central lubrication
Warning!
Accumulated grease or oil on the carrier is a fire hazard.

Remove debris any time a significant quantity oil is
spilled on the carrier.
7002 1-2 EN 0515 MSO 128 (141)

Maintenance Manual

ITEM 2
Check the oscillation axle bushings.
1. Check the oscillation by lifting up the engine end frame.
2. Check for possible play by moving the axle slightly.
– Replace the bushings if any play is found.
Fig. 59. Oscillation axle
7002 1-2 EN 0515 MSO 129 (141)

Maintenance Manual
ITEM 3
Check the frame joint bearings.
Danger!
Keep clear of the hinge area while the engine is running!

1. Check the frame joint by turning the steering.
– To and fro with small movements.
2. Check for possible play.
– Adjust the frame joint if any play appears.
Fig. 60. Checking the frame joint bearings
7002 1-2 EN 0515 MSO 130 (141)

Maintenance Manual
Adjusting the frame joint play (If adjustable model).

Upper joint play adjusting
1. Unscrew the locking plate (1) fixing bolts (2).
2. Loosen the upper and lower tenons (3).
3. Turn the adjuster sleeve (4) clockwise until it sticks.
4. Mark to the adjuster sleeve a zero point (5) if the adjusting nut (6) has markings
0, 0.1 and 0.2.
5. Unthread the adjuster sleeve:
– 12-24 degrees, or
– until the zero point is between the adjusting nut markings 0.1 and 0.2.
6. Install the locking plate to the suitable adjuster sleeve groove.
– The locking plate can also be turned around to find out the best match.
7. Tighten the locking plate fixing bolts to 114 Nm.
8. Tighten the tenons to 600 Nm.
2 4
3
1
6
Fig. 61. Upper joint
7002 1-2 EN 0515 MSO 131 (141)

Maintenance Manual
Lower joint play adjusting

1. Tighten the tenon (1) to 600 Nm.
2. Tighten the fixing bolts (2) to 125 Nm.
Fig. 62. Lower joint
7002 1-2 EN 0515 MSO 132 (141)

Maintenance Manual
ITEM 4
Check the steering cylinder joint pin, pin locking and bearing.
The following points regarding inspections are:
– proper installation
– excessive wear
– cracks or distortion appear
– bruises or corrosion damages appear
– permanent deformations
– bad wear
– there should not be any visible fractures or cracks in the welding seams.
7002 1-2 EN 0515 MSO 133 (141)

Maintenance Manual
Check the expander bolt tightening torque

1. Apply appropriate torque according to table.
2. Tighten until the torque wrench ”clicks out” on setting.
Nuts
Unit M12 M14 M16 M20 M24 M30 M36 M42
Nm 65 115 175 250 350 500 600 700
Bolts
Unit M12 M14 M16 M20 M24 M30 M36 M42
Nm 70 115 175 350 500 600 700 900
Fig. 63. Steering cylinder joint
7002 1-2 EN 0515 MSO 134 (141)

Maintenance Manual
8. TIGHTENING TORQUES
8.1. Screws
Tightening torques Nm
Size Class 8.8 Class 10.9 Class 12.9

M4 3 4 5,1
M5 5,9 8,7 10
M6 10 15 18
M8 25 36 43
M10 49 72 84
M12 85 125 145
M16 210 310 365
M20 425 610 710
M24 730 1050 1220
M27 1100 1550 1800
M30 1450 2100 2450
M33 2000 2800 3400
M36 2600 3700 4300
M39 3400 4800 5600
7900 1-1 EN 0117 MSO 135 (141)

Maintenance Manual
8.2. Screws with locking washers

8.2.1. Wedge lock washers (e.g. Wurth®, HEICO®)
Torque guidelines according to the wedge lock washer manufacturers.
Tightening torques Nm
Bolt size Class 8.8 Class 8.8 Class 10.9 Class 12.9
Galvanized Galvanized Non-plated Non-plated
or zinc plated or zinc plated screws screws
Oiled Dry Oiled Oiled
M3 1,3 1,3 1,8 2
M4 3,1 3,1 4,1 4,6
M5 6 6 8,1 9,1
M6 10,5 10,5 14,1 15,8
M8 25 25 34 38
M10 49 50 67 75
M12 85 85 115 128
M14 135 136 183 204
M16 205 208 279 311
M18 288 291 391 437
M20 402 408 547 610
M22 548 557 745 831
M24 693 703 942 1052
M27 1010 1028 1375 1533
M30 1379 1401 1875 2091
M33 1855 1889 2526 2815
M36 2394 2436 3259 3633
M39 3087 3145 4203 4683
M42 3820 3890 5202 5799
7900 1-1 EN 0117 MSO 136 (141)

Maintenance Manual
8.2.2. Nord-lock® Steel washers

Torque guidelines according to the Nord-lock® manufacturer.
These values are to be considered as recommended nominal values to maximize the
preload achieved in joints secured with Nord-lock® washers.
Nord-lock® Steel washers Metric grade 8.8
Wash Bolt Pitch Oil, GF=71% Cu/C paste*, Cu/C paste*,

er size size [mm] µth=0,15, GF=75% GF=75%
µh=0,13 µth=0,13, µh=0,14 µth=0,13, µh=0,14
Torqu Clam Torqu Clamp Torque Clamp
e [Nm] p load e [Nm] load [Nm] load
[kN] [kN] [kN]
NL3 M3 0,5 1,7 2,4 1,5 2,4 1,5 2,0
NL4 M4 0,7 3,8 4,2 3,6 4,2 3,5 3,5
NL5 M5 0,8 7,5 6,8 6,9 6,8 6,8 5,6
NL6 M6 1,0 13,1 9,7 12,1 9,7 11,9 8,0
NL8 M8 1,25 32 18 29 18 29 15
NL10 M10 1,5 62 28 57 28 56 23
NL12 M12 1,75 107 40 98 40 97 33
NL14 M14 2,0 170 55 157 55 155 46
NL16 M16 2,0 260 75 240 75 237 62
NL18 M18 2,5 364 92 336 92 331 76
NL20 M20 2,5 510 118 470 118 464 97
NL22 M22 2,5 696 146 642 146 635 120
NL24 M24 3,0 878 169 809 169 800 140
NL27 M27 3,0 1284 221 1183 221 1171 182
NL30 M30 3,5 1750 269 1613 269 1596 222
NL33 M33 3,5 2360 333 2173 333 2155 275
NL36 M36 4,0 3043 392 2803 392 2776 324
NL39 M39 4,0 3931 468 3619 468 3589 387
NL42 M42 4,5 4860 538 4476 538 4436 445
7900 1-1 EN 0117 MSO 137 (141)

Maintenance Manual
Washer Bolt Pitch Oil, GF=71% Cu/C paste*, GF=75%

size size [mm] µth=0,15, µh=0,13 µth=0,13, µh=0,14
Torque Clamp load Torque Clamp load
[Nm] [kN] [Nm] [kN]
NL3 M3 0,5 2,0 3,2 2,0 3,4
NL4 M4 0,7 4,5 5,6 4,5 5,9
NL5 M5 0,8 8,9 9,1 8,9 9,6
NL6 M6 1,0 15,5 12,9 15,5 13,6
NL8 M8 1,25 37 23 37 25
NL10 M10 1,5 73 37 73 39
NL12 M12 1,75 126 54 126 57
NL14 M14 2,0 201 74 201 78
NL16 M16 2,0 307 100 306 106
NL18 M18 2,5 430 123 429 130
NL20 M20 2,5 602 156 600 165
NL22 M22 2,5 821 194 818 205
NL24 M24 3,0 1036 225 1034 238
NL27 M27 3,0 1514 294 1509 310
NL30 M30 3,5 2064 358 2058 378
NL33 M33 3,5 2783 443 2772 468
NL36 M36 4,0 3589 522 3576 551
NL39 M39 4,0 4632 624 4614 659
NL42 M42 4,5 5731 716 5709 757
7900 1-1 EN 0117 MSO 138 (141)

Maintenance Manual
Washer Bolt Pitch Oil, GF=71% Cu/C paste*, GF=75%

size size [mm] µth=0,15, µh=0,13 µth=0,13, µh=0,14
Torque Clamp load Torque Clamp load
[Nm] [kN] [Nm] [kN]
NL3 M3 0,5 2,2 3,9 2,3 4,1
NL4 M4 0,7 5,1 6,7 5,3 7,1
NL5 M5 0,8 10 10,9 10,3 11,5
NL6 M6 1,0 17,4 15,4 18 16,3
NL8 M8 1,25 42 28 43 30
NL10 M10 1,5 82 44 85 47
NL12 M12 1,75 142 65 146 68
NL14 M14 2,0 226 89 233 94
NL16 M16 2,0 345 120 355 127
NL18 M18 2,5 483 148 498 156
NL20 M20 2,5 676 188 696 198
NL22 M22 2,5 921 233 948 246
NL24 M24 3,0 1165 270 1199 286
NL27 M27 3,0 1700 352 1749 372
NL30 M30 3,5 2318 430 2385 454
NL33 M33 3,5 3124 532 3213 562
NL36 M36 4,0 4029 626 4145 662
NL39 M39 4,0 5199 748 5346 790
NL42 M42 4,5 6434 860 6617 908
7900 1-1 EN 0117 MSO 139 (141)

Maintenance Manual
Cu/C paste* = Copper/graphite paste (Molykote® 1000)

GF = ratio of yield point
µth = thread friction
µb = washer friction
1 N = 0,225 lb
1 Nm = 0,738 ft-lb
7900 1-1 EN 0117 MSO 140 (141)

Maintenance Manual
NOTES
0100 1-1 EN MSO 141 (141)

NBB 3XS Operator’s Manual
MOBILE ELEVATING WORK PLATFORM

.
Code: . . . . . . . . . . . . . . . . . . . . 100087044
This manual is a guide to the proper and safe operation, maintenance, minor repair and
adjustment of the MEWP. The information contained in this manual is current for this unit. In
the interest of continually improving its products, Normet reserves the right to update or
modify information contained in this manual. Illustrations shown in this manual were
produced during the development stages and may differ from the actual product.
Normet Oy Tel. +358 (0)17 83 241

FINLAND
About this manual

Read this manual carefully before operating the MEWP. Follow the instructions
Danger!
Warning!
Risk of injury.
Caution!
Note!

CONTENTS
1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2. Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3. Work platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4. Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5. In Case Of Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6. Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4. Instructions for the owner and operator . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1. Operator Suitability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2. Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5. Operator's controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1. Work platform controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2. Lower controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.3. Terminal box TB3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4. Work platform terminal box TB4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.5. Alarm unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6. Safety canopy locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.1. Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2. Use of the MEWP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.3. Daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.4. Operation definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.5. Safety harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.6. Extreme conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7. Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.1. Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.2. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.3. Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.4. Commissioning on delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.2. Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.3. Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.4. Maintenance items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.4.1. Daily or once in shift (10 hours) . . . . . . . . . . . . . . . . . . . . . . . . . 44
Visually check the hydraulic hoses, couplings and the structure. . . . . . . . . 44
Check the tilting cylinder pin and work platform joint pin. . . . . . . . . . . . . . . 45
Keep the working area of the work platform clean. . . . . . . . . . . . . . . . . . . . 45
8.4.2. Weekly (50 hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Lubricate the grease fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Check the boom mounting attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Inspect the hydraulic cylinder, cylinder joint pin, pin locking and bearing. . 47
8.4.3. Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Check the boom extension clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.4.4. Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Check the hydraulic pressures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Inspect the tilt cylinder fixing lug welding. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspect the condition of the boom beams. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspect the function of the load-lowering valve. . . . . . . . . . . . . . . . . . . . . . 54
Inspect the boom mounting bolt connections. . . . . . . . . . . . . . . . . . . . . . . . 56
8.4.5. Every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Change the tilting cylinder joint pin and bearing. . . . . . . . . . . . . . . . . . . . . . 57
8.4.6. Every 6000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Change the tilting cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.4.7. When necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Adjust the boom lowering speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Adjust the boom slewing speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Adjust the load sensing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9. Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.1. Speed values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.2. Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.2.1. General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.2.2. Daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1. FOREWORD
These instructions are intended for both the MEWP owner and persons who operate,
service and repair the MEWP.
The instructions help you to:

– familiarize yourself with the safe operation of the MEWP.
– operate the MEWP safely in order to avoid damage.
– use the MEWP appropriately and productively.
– notice, avoid and prevent possible dangerous situations.
These instructions provided by the manufacturer must be kept in a safe, easily acces-
sible place at the work site.
All operators are obliged to familiarize themselves with the safety and operating
nstructions of the MEWP and apply them in practice.
The MEWP is fully compliant with current technical standards and safety regulations.
Despite this, faulty operation, service and repair may cause danger.
The precondition for all operation is that the operator is familiar with the operating
instructions and follows them. It is therefore recommended that the instructions are
read through several times and that the operator familiarises him/herself thoroughly
with the MEWP before taking it into use.
In addition to the operating instructions, the operator must follow the regulations of the
local labour protection authorities as well as the laws and statutes of the country in
which the MEWP is in use.
Using the MEWP for any other task than that for which it has been designed, or
exceeding its operating capacity is considered inappropriate usage. The manufac-
turer/supplier does not assume liability for damage resulting from such usage.
100087044 1 - 1 EN 0918 ettekma 5 (70)

2. INTRODUCTION
2.1. General
The MEWP is intended for mining and tunnelling lifting purposes including, e.g.,
manual charging and scaling and other mounting tasks performed at height.
The MEWP can be fitted as an accessory onto a carrier that is specially designed for
MEWP use.
The MEWP is a so-called telescopic construction boom, consisting of a basic boom
and one hydraulically operated extension telescope in addition.
The MEWP also contains a work platform which automatically remains parallel during
raising and lowering of the MEWP. This is performed hydraulically with assistance of
the stabilization cylinder and work platform tilting cylinder.
Lifting capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 kg

Max. lifting height (basket floor) . . . . . . . . . . . . . . . . 6500 mm
2.2. Boom
The MEWP is a so-called telescopic construction boom, consisting of a basic boom
and a hydraulically operated extension.
The extension cylinder incorporates pressure-opened non-return valves that prevent
uncontrolled boom movements in the event of possible hose breakage.
Lifting of the boom is affected hydraulically by means of a cylinder. The boom lift
cylinder incorporates a load-lowering valve for both directions of motion. The valves
ensure that the boom does not drop in an uncontrolled maner in the event of possible
hose breakage. Additionally, they protect the boom from overloading in either direc-
tion. The basket tilt cylinder is also fitted with a similar load-lowering valve.
100087044 1 - 1 EN 0918 ettekma 6 (70)

2.3. Work platform

The MEWP contains a work platform which automatically remains parallel during
raising and lowering of the MEWP. This is performed hydraulically with assistance of
the stabilization cylinder and work platform tilting cylinder.
The work platform is fixed with link pins to the extension piece of the boom. The bot-
tom of the work platform is made of mesh plate to prevent slipping. For safety reasons,
the railing gates only open inwards. The work platform is equipped with control devic-
es to operate the MEWP. The work platform can be tilted to achieve a comfortable
working position in uneven terrain.
Fig. 1. Dimensioned drawing
100087044 1 - 1 EN 0918 ettekma 7 (70)

3. SAFETY INSTRUCTIONS
3.1. General
1. Read and understand all instructions before operating.
2. Make sure that personnel are familiar with the contents of this manual.
3. Ensure the safety of all personnel.
4. Use the MEWP correctly and appropriately.
5. It is forbidden to operate a faulty MEWP.
6. All safety and warning plates on the MEWP must be legible and intact.
7. Personal safety equipment must be worn inside the entire operating area of the
MEWP.
8. Pressure hoses must never be bent when while the pump is in operation.
– Obstruction caused by hose bending increases the risk of accident.
9. Connect different circuits, such as pressure and water lines, carefully and safe-
guard them as necessary.
10. The operator must always have an unobstructed overview of the working area.
– If this is not possible, an assistant must be appointed.
11. Stop the MEWP movement immediately if any risk of causing a safety hazard is
identified or suspected.
12. Always protect the MEWP against unauthorized use and unintentional operation
when left unmanned.
13. It is prohibited to increase the working height of the MEWP by using additional
equipment, such as ladders.
14. It is prohibited to increase wind load of the work platform, e.g. by attaching sign-
boards to the railings.
15. Never exceed maximum inclination values.
100087044 1 - 1 EN 0918 ettekma 8 (70)

3.2. Operation
1. Only use the MEWP for the purpose informed by the manufacturer.
2. While operating the MEWP always follow the operating instructions, safety regu-
lations and warning plates and pay attention to generally accepted regulations to
prevent damage.
3. Safety measures and precautions before lifting the MEWP:
– Turn the gear selector to the neutral position.
– Engage the safety/parking brake.
– Lower the support legs (option) and ensure that the MEWP is positioned in
accordance with the permitted inclination values.
– Ensure that the support legs (option) are lowered onto firm ground.
– The carrier must be positioned straight and level.
– Lower the work platform as low as possible in order to enter the platform.
• Do not enter the work platform by climbing the MEWP.
– Close the work platform gate carefully, and make sure it is thoroughly locked.
– Make sure there are no obstacles in the working area.
– Exercise special caution when working in tight places or close proximity to
power cables, pipelines etc.
– Do not swing the MEWP before it is clear of the ground.
4. Make sure that everybody at the working place knows where emergency stop
switch is.
– Daily check function of the emergency stop switch.
5. Use the emergency stop button to quickly stop the motion of the MEWP.
– Brings all hydraulic operations to a halt.
– After being used, the button must be returned to its original position.
6. Unauthorized persons must be prevented from entering the working area.
7. Being under the raised MEWP prohibited.
8. Do not exceed the maximum load permitted.
9. Clean the work platform daily.
10. Move the MEWP to the transport position when driving the carrier.
– Before moving the carrier, make sure that the support legs (option) are fully
raised.
11. When in operation, the position of the MEWP must be in accordance with the
inclination values given.
– longitudinal 3°
– lateral 3°
100087044 1 - 1 EN 0918 ettekma 9 (70)

12. The work platform must be free of load and personnel while the carrier is being
driven.
13. The MEWP is equipped with various safety equipment.
– These must not be changed or removed.
14. The work platform must not be used for transporting materials.
– The MEWP must not be used as a lifting device.
– When lifting personnel however, tools and equipment can also be lifted in the
work platform.
– It is forbidden to lift materials that extend beyond the edges of the work plat-
form.
15. Do not direct water- or steam jets towards electric cables.
16. After using the MEWP, lower the MEWP as low as possible.
17. Make sure that regular safety tests and corresponding inspections are carried
out.
18. Operation and use of a faulty or damaged MEWP is forbidden.
19. Constantly keep an eye on
– mounting bolts
– balance of the carrier
– oil leakages
– function of controls
100087044 1 - 1 EN 0918 ettekma 10 (70)

3.3. Maintenance
1. Only qualified and specially trained persons are allowed to use, service or repair
the MEWP.
2. Service the MEWP regularly at the prescribed intervals, and observe all sched-
uled safety inspections.
3. Support the boom correctly or use a hoist when carrying out the service.
– Turn off the engine and the powerpack.
• Engine running only for adjustment purposes.
– Empty the work platform.
4. Do not repair or change the structures without the manufacturer's permission.
Structural changes may affect the MEWP durability.
5. Clean all explosive material from the work platform before the repair work.
6. Lubricate the bearings regularly.
7. Replace clogged or damaged grease nipples.
8. Pay special attention to the condition of the entire MEWP.
– The tightness of the bolt joints.
– The condition and tightness of the hydraulic hoses and connectors.
– The locking of the joint pins.
9. Air bleed the system if the hoses or other components are changed.
– Air in the hydraulic system can cause malfunction and safety hazard.
10. Spare parts must meet the requirements of the manufacturer.
– Always use genuine spare parts.
11. Do not make changes without the manufacturer's permission.
– Extension of pressurized pipes and hoses.
– Factory settings such as pressures, speeds and capacities.
– Replacements with a material of different specs to the original.
– Pressure limits.
12. The pipe joints must not be opened when there is operating pressure in the
pipes.
– The pressure must be released before opening the pipe system.
13. Only authorized persons are permitted to repair damaged electrics and hydrau-
lics.
100087044 1 - 1 EN 0918 ettekma 11 (70)

3.4. Emergency stop
Purpose
To engage
To reset
100087044 1 - 1 EN 0918 ettekma 12 (70)

3.5. In Case Of Danger

1. If the carrier begins to fall, bring the MEWP to the ground immediately.
2. If the carrier comes into contact with an electric line, you can avoid damage or
death by following the instructions below:
– Do not touch any part of the carrier or attempt to climb into it if you are outside
the carrier.
– Warn others to keep away from the carrier.
– Leave the carrier no later than when the tyres start to smoke.
– Do not make yourself into a conductive bridge between the carrier and the
ground.
– Once on the ground, move away from the carrier by jumping with both feet
together, or by leaping so that only one foot at a time touches the ground.
– The electric field on the ground can generate a dangerous voltage between
your feet.
– You are not safe until you are at a distance of at least 20 meters from the car-
rier.
– Call for help immediately.
100087044 1 - 1 EN 0918 ettekma 13 (70)

3.6. Environment
Special care must be taken to ensure that the equipment, carriers, lifting equipment,
stock, tools, safety equipment, galleries, passages and mine areas remain in an
appropriate condition.
1. Explain the meaning of the warning plates, signs etc of the MEWP to all person-
nel working on the site.
2. The working area must be kept clear of waste and other unnecessary material.
Tools, such as belts, chains, hoses , etc., must be checked regularly for wear,
looseness, breakage, rubbing or chafing, and damaged items must be replaced
or repaired immediately.
3. The surroundings of the operator's panel must be kept clean so that the emer-
gency stop button can be reached unobstructed.
4. Working may become dangerous due to operating conditions. It is always dan-
gerous to work on a slope. If necessary, the working area must be levelled. The
inclination values informed must not be exceeded.
5. If the work is carried out near to an underground drain, power cable, gas-, oil-, or
water pipe, always contact the owner / responsible for the installation in question
before starting work. Necessary safety measures can be decided in co-operation
with the owner / responsible. The operator and the designated site representa-
tives are responsible for implementing the necessary safety precautions.
6. The working environment must be arranged so as to promote safety taking into
consideration the quarrying methods, quarrying work and equipment, blasting
technique and preparatory work, loading and transportation, concrete spraying,
crushing of blasted rock, lifting methods, supporting and enforcing methods, pos-
sible construction work, electric, water and air equipment, ventilation, labor, fire
safety and other possible safety measures.
7. Always follow the local environmental norms and laws.
100087044 1 - 1 EN 0918 ettekma 14 (70)

4. INSTRUCTIONS FOR THE OWNER AND OPERATOR
4.1. Operator Suitability

1. The MEWP can only be operated and serviced by a person who
– is at least 18 years old.
– is mentally and physically suitable for the job.
– has proven to be skilful, conscientious and thorough in their work.
– is responsible and reliable.
2. The operator must be provided with training in operating and servicing the
MEWP. The operator must familiarize himself with the manual provided by the
manufacturer, and be familiar with the performance values and characteristics of
the MEWP he operates.
– Prove that by documentary evidence
• applies only for a country in where this is required by the authorities.
– The operating personnel must familiarize themselves once changes are made
to the MEWP. There must always be updated operating instructions for the
specific MEWP available.
4.2. Responsibility
1. Only use the MEWP for the purpose informed by the manufacturer.
2. It is to be noted that the manufacturer of the MEWP is not liable for damages and
accidents caused by:
– incorrect, careless, and inappropriate use.
– changes made without the manufacturer's permission.
– spares that are not original.
– normal wear.
– bringing the MEWP into a country, without taking the manual's limitations and
instructions into account when considering the regulations of the country in
question.
– operating errors caused by personnel.
100087044 1 - 1 EN 0918 ettekma 15 (70)

5. OPERATOR'S CONTROLS
5.1. Work platform controls
1 2 3 4
Fig. 3. Controls
1. Work platform tilting

2. Boom slewing
3. Boom extension in/out.
4. Boom raising/lowering
5. Claw coupling and pressure air shut off valve
100087044 1 - 1 EN 0918 ettekma 16 (70)

1. Workplatform tilt
Lever operation
– Push the lever forward to tilt the workplatform upward.
– Pull the lever backward to tilt the workplatform downward.
– Use the lever to adjust the work platfrom horizontally level.
2. Boom slew
Lever operation
– Push the lever forward to slew the boom counterclockwise.
– Pull the lever backward to slew the boom clockwise.
3. Boom extension in / out
Lever operation
– Push the lever forward to drive the telescope extension in.
– Pull the lever backward to drive the telescope extension out.
4. Boom raising / lowering
Lever operation
– Push the lever forward to lower the boom.
– Pull the lever backward to raise the boom.
5. Claw coupling and shut-off valve
Purpose
– Compressed air outlet.
100087044 1 - 1 EN 0918 ettekma 17 (70)

5.2. Lower controls
1 2 3
Fig. 4. Controls
1. Boom slew
2. Boom extension in / out.
100087044 1 - 1 EN 0918 ettekma 18 (70)

1. Boom slew
Lever operation
– Push the lever forward to slew the boom counterclockwise.
– Pull the lever backward to slew the boom clockwise.
2. Boom extension in / out
Lever operation
– Push the lever forward to drive the telescope extension in.
– Pull the lever backward to drive the telescope extension out.
Lever operation
– Push the lever forward to lower the boom.
– Pull the lever backward to raise the boom.
100087044 1 - 1 EN 0918 ettekma 19 (70)

5.3. Terminal box TB3
1 2 3
4 5
6
7 8 9 10
11 12
13
Fig. 5. Terminal box
1. Control position selector 10. Emergency pump

2. Carrier inclined (optional) 11. Load end left support leg exten-
3. Emergency stop sion
4. Support leg transport position indi- 12. Load end right support leg exten-
cator sion
5. MEWP transport position indicator 13. Compressor start/stop (optional)
6. Emergency pump test
7. Load end left support leg
8. Load end right support leg
9. Engine end support legs
100087044 1 - 1 EN 0918 ettekma 20 (70)

1. Control position selector switch
Purpose
– Frame side control - 0 - work platform control
Use
– Frame side control and cabin control when the handle turned left.
– Turn the handle to "0" position when driving.
– Work platform control when the handle turned right.
2. Carrier inclined (optional)
Lights up
– Indicates if carrier is exceeding inclination limits.
• longitudinal 8°
• lateral 3°
At same time
– Control system user interface gives alert message.
– Alarm unit warns user.
This feature is not active when MEWP is in trasport position.
Purpose
To engage
To reset
100087044 1 - 1 EN 0918 ettekma 21 (70)

4. Support legs transport position indicator
Purpose
– To indicate that the support legs are not in the transport position.
Lights up
– Support leg extensions are out.
– Support legs are lowered.
– Boom has slewed.
5. MEWP transport position indicator
Purpose
– To indicate that the work platform is not in the transport position.
Lights up
– Work platform has raised.
6. Emergency pump test
Purpose
– Only for testing the emergency pump. Not for continuous use.
– Use only to lower down the work platform.
Definition
– Main switch must be closed.
– Current key switch must be on.
– Emergency stop is not actuated.
– Load sensing system is not active.
Use
– Actuate the switch.
– At the same time actuate the work platform lowering function.
7. Load end left support leg
– Support leg raising / lowering

Switch operation
– Up or down.
8. Load end right support leg
– Support leg raising / lowering

Switch operation
– Up or down.
100087044 1 - 1 EN 0918 ettekma 22 (70)

9. Engine end support legs (optional)
– Support legs raising / lowering

Switch operation
– Up or down.
10.Emergency pump
Purpose
– To use in a situation which poses an immediate risk to health, life,
property or environment.
– Use only to lower down the work platform if the:
• hydraulic pressure is lost.
• emergency stop is actuated.
• load sensing system stops the movement of the work platform.
Definition
– Pump can be used until the carrier's battery is discharged.
– Overrides the emergency stop function.
– Overrides the control place selector switch.
Use
– Actuate the switch.
11. Load end left support leg - extension in and out.
Switch operation
Remote display
– Indicator light lights up on the screen when the support legs are
not in the transport position.
12. Load end right support leg - extension in and out.
Switch operation
Remote display
– Indicator light lights up on the screen when the support legs are
not in the transport position.
100087044 1 - 1 EN 0918 ettekma 23 (70)

13. Compressor start/stop (optional)
Indicator lamp
– Indicates compressor is on/off.
Switch
– To start and stop compressor.
100087044 1 - 1 EN 0918 ettekma 24 (70)

5.4. Work platform terminal box TB4
1 2 3 4 5
8
6 7
Fig. 6. Terminal box
1. Engine Start / Stop

2. Hand throttle activation
3. Hand throttle adjustment
4. Horn
5. Emergency pump
6. Work platform safety roof lifting / lowering (optional)
7. Work platform safety roof front / back (optional)
8. Emergency stop
100087044 1 - 1 EN 0918 ettekma 25 (70)

1. Engine Start / Stop
In the driver’s cab

– turn current key switch clockwise.
Use
– Move the lever up to start the engine.
– Move the lever down to stop the engine.
Engine stopping
– Reduce the engine revs to idling for a few minutes.
– Allow the engine temperature to equalize before stopping.
–
2. Hand throttle On / Off
Purpose
– Used to set the engine speed during stationary operations.
– Use the “hand throttle + / -” switch to get the desired rpm.
Switch operation
– On / Off
3. Hand throttle + / -
Purpose
– Engine speed can be adjusted after switching the hand throttle ON.
Switch operation
– Right – increase the engine speed.
– Left – decrease the engine speed.
4. Horn
Purpose
– A warning device
100087044 1 - 1 EN 0918 ettekma 26 (70)

5. Emergency pump
Purpose
– To use in a situation which poses an immediate risk to health, life,
property or environment.
• hydraulic pressure is lost.
• emergency stop is actuated.
• load sensing system stops the movement of the work platform.
Definition
– Pump can be used until the carrier's battery is discharged.
Use
– Actuate the switch. Max 20 s.
– Let she pump cool down. Wait 30 s.
6. Safety roof lifting/lowering
Switch operation
– Move the lever up or down..
Use
– Move the lever up to lift the safety roof.
– Move the lever down to lower the safety roof.
7. Safety roof front/back
Switch operation
– Move the left or right.
Use
– Move the lever to move the safety roof.
100087044 1 - 1 EN 0918 ettekma 27 (70)

Purpose
To engage
To reset
Indicator lamp
– Indicates compressor is on/off.
Switch
– To start and stop compressor.
100087044 1 - 1 EN 0918 ettekma 28 (70)

5.5. Alarm unit
Fig. 7. Alarm unit
– Audible and visual alarms can be controlled simultaneously or individually.

– Lens colour red.
– Warns persons of excessive external loading of the work platform.
100087044 1 - 1 EN 0918 ettekma 29 (70)

5.6. Safety canopy locking

Locking mechanism ensures that the safety canopy stays at working position in all
situations.
Fig. 8. Lock the protective safety equipment to operating position before use.
– Safety canopy must be lifted at its working position and locked properly before
using the MEWP.
– Sliding safety canopy must be slided above the user before using the MEWP
100087044 1 - 1 EN 0918 ettekma 30 (70)

6. OPERATION
6.1. Preparations
1. Turn the carrier's gear selector to the neutral position.
3. Check whether the ground is slippery.
– Place blocks in front of the wheels if necessary.
4. Use the MEWP when the carrier is well-supported and as level as possible.
– Position the carrier as straight and level as possible.
5. Check the carrying capacity of the ground.
– Lower the support legs (option).
– Use extra plates underneath the support legs (option).
• E.g. an asphalt surface can give way if water has eroded the soil beneath
the asphalt.
6. Close and lock the gates of the work platform.
7. Make sure that its operating area is unobstructed.
– Exercise caution when working near power cables, pipelines etc.
– Do not turn the MEWP until the work platform is clear of the ground.
8. There is an emergency stop button in the work platform.
– To quickly stop the motion of the MEWP e.g. in an emergency situation.
9. The work platform must not be used for transporting materials.
– The MEWP must not be used as a crane.
– When lifting personnel, tools and equipment can be lifted in the work platform.
– It is forbidden to lift materials that extend beyond the edges of the work plat-
form.
100087044 1 - 1 EN 0918 ettekma 31 (70)

6.2. Use of the MEWP

The MEWP is operated through the carrier hydraulics.
Carry out the normal daily checks before starting the engine up when operating the
MEWP with the carrier's hydraulic system, referring to the operating and maintenance
manual for the carrier.
The MEWP is designed to facilitate the execution of a wide range of tasks, particularly
there versatile lifting is required.
The load sensing system stops the work platform movements in the event of exces-
sive external loading of the work platform until the overload is removed. This reduces
possible structural damage and prevents loss of stability.
Caution!
When the MEWP is in use, at least one other person,

who is not onboard the MEWP, must be present.
This person is required to provide assistance, e.g. in the

event of a power cut (applies only to countries where this
is required by the authorities).
The support legs (option) must be lowered to take the

load completely off the carrier's wheels.
Do not operate the MEWP without a protective roof

when-ever there's a risk of falling objects at a worksite.
Fig. 9. Lock the protective safety equipment to operating position before use
100087044 1 - 1 EN 0918 ettekma 32 (70)

6.3. Daily checks
1. Carrying strength of the ground

2. MEWP mounting bolts
3. Balance of the carrier
4. Emergency stop
5. Lights
6. Controls
7. Travel paths
8. Work platform
9. Limit switches
10. Oil leakage
11. Working area
100087044 1 - 1 EN 0918 ettekma 33 (70)

6.4. Operation definitions

Control via the key selector switch
– -Down Control
• Turn the key left.
– Remote Control
• Turn the key middle.
– Up Control
• Turn the key right.
Lifting
– The MEWP cannot be lifted over 3m.
• Lower the support legs down to bypass the limit switch.
Work platform tilting
– Use when the work platform is lifted.
– Do not use when the work platform is down.
Support legs
– Support leg actuation down.
• Use the cabin switches.
– The support legs are not operative.
• The MEWP has been lifted over 3 m.
Driving
– The transport position indicators must be off.
Safety/parking brake
– The safety/parking brakes is automatically engaged.
• The MEWP is lifted over 3 m.
– The safety/parking brake cannot be disengaged.
• Support legs are not fully raised and retracted.
Emergency stop
– Release the emergency stop mushroom head buttons up to reset.
• Operation is impossible unless all of them are in the upper position.
• Only emergency pump is available.
100087044 1 - 1 EN 0918 ettekma 34 (70)

Work platform overload

– Work platform movement ceases.
– Audible alarm and red visual light.
– Operation only via the emergency pump.
Emergency pump
– Pump can be used until the carrier’s battery is discharged.
100087044 1 - 1 EN 0918 ettekma 35 (70)

6.5. Safety harness

All personnel on the work platform must follow the regulations on personal protective
equipment, as determined by the employer, for the working area, and from the local
authorities, and comply with national legislation. All personal protective equipment
must meet the requirements of the applicable regulations. The manufacturer's instruc-
tions must be followed in inspection and use of the equipment.
Always wear a safety harness on the work platform. Fasten the harness rope to the
fastening point on the work platform. The safety harness worn by personnel working
on the platform must be attached to the platform with a rope and prevent falling if the
platform lurches. Use of personal equipment for protection against falling while one is
working on the platform is essential. This equipment includes safety ropes,
harnesses, and belts.
– Put on the safety harness and move to the work platform.
– Attach the harness to the fastening point immediately after reaching the work
platform.
– Do not fasten the harness to any other location.
– The rope length of equipment for protection against falling should be easily
adjustable such that it prevents the user from slipping over the edge of the
work platform.
Fig. 10. Safety harness fastening points
100087044 1 - 1 EN 0918 ettekma 36 (70)

6.6. Extreme conditions

Cold conditions
1. Working in low temperatures
– accelerates hydraulic seal wear.
– increases hydraulic hose exposure to damage.
– exposes steel constructions to brittle fracture.
2. The lowest allowed working temperature is -20 °C.
3. The fluid in the boom must be warmed at the same time as the carrier's hydrau-
lics are warmed to prevent thermal shock.
– Thermal shock can damage the hydraulics.
4. Thermal shock can also occur if the fluid in the boom hydraulic system has
cooled.
– Driving long distances between work sites, and hot fluid from the carrier
hydraulics is fed to the boom.
5. Let the fluid circulate freely through the system for a few minutes.
6. Drive each function slowly and several times until the boom movements normal-
ise.
– To increase the pliability of the seals before they receive any full pressure.
Warm conditions
Beware of the hydraulic fluid overheating in exceptionally warm conditions.
– Too high > 80 °C fluid temperature
• degrades the fluid.
• damages the seals.
Hard wind
Fig. 11. Max wind load
100087044 1 - 1 EN 0918 ettekma 37 (70)

7. TRANSPORT AND STORAGE
7.1. Driving
1. Read the driving instructions of each carrier carefully.
– Owing to the carrier, driving requires special measures.
2. Do not disengage the safety/parking brake before you have checked that:
– the steering functions correctly.
– the MEWP is in a correct position for moving.
– all equipment and operations are in order.
– operating the carrier does not cause any danger to people or property.
3. The carrier must never be driven or operated until it has been ensured that doing
so entails no danger to personnel.
4. Never attempt to drive the carrier from any place other than the operator's cabin.
5. Only trained personnel are allowed to drive the carrier.
6. It is forbidden to enter or leave the carrier while it is moving.
8. Always position the MEWP in its driving position.
– This brings the centre of gravity as low as possible and makes the carrier more
stable to drive.
9. When transporting the carrier, adjust the driving speed according to the terrain.
– This prevents the MEWP from swaying and wobbling, which causes strain on
the pins, bushings and the mechanical structure.
10. The support legs (option) must be fully raised and retracted.
11. No personnel are permitted on the work platform while driving.
100087044 1 - 1 EN 0918 ettekma 38 (70)

7.2. Storage
If the MEWP is to be stored for extended period, it is necessary to take protective
measures to prevent rust formation. The protective measures described here will
protect the MEWP for a period of up to 6 months. Before reusing the MEWP, the
protection must be removed. Use anti-corrosive agent for external protection only.
1. Clean the MEWP with a high-pressure steam jet.

2. Use a cold cleansing agent as necessary.
3. Clean and dry the hoses.
4. Spray the MEWP with anti-corrosive agent.
5. Lubricate the MEWP pins, bushings etc.
6. Release the pressure from the hydraulic cylinders.
7. Cover the hydraulic cylinders' piston rods and exposed parts of the control valve
with wax or grease.
8. Store the MEWP in a shed or under a canvas on wooden blocks, away from
direct contact with ground.
9. Before use, remove the anti-corrosive agent from the MEWP.
10. Before use, thoroughly remove all protective wax or grease from cylinder piston
rods and control valve stems.
7.3. Lifting
Only a correct type of carrier with a sufficient lifting capacity can be used for lifting.
Fasten two hoists to the lifting points. Ensure that the MEWP is properly fastened and
balanced by first lifting it a few centimeters from the ground. Continue the lifting only
after you are convinced that the MEWP is in balance and safely fastened.
100087044 1 - 1 EN 0918 ettekma 39 (70)

7.4. Commissioning on delivery

The following inspections of the MEWP must be performed during the delivery check-
up and before test operation.
Note!
The person performing the delivery check-up and test

operation must be qualified to use the equipment
1. Make a walk-around inspection of the MEWP.
2. Check that the MEWP is mounted properly and the hydraulics are properly con-
nected.
3. Check the hydraulic circuit for possible leaks and repair if needed.
4. Check the hydraulic oil level.
5. Check that the hoses can move freely.
6. Remove the transport bracings.
7. Check the safety symbols and warnings.
8. Adjust the settings if necessary.
9. Perform test operations of the MEWP functions.
100087044 1 - 1 EN 0918 ettekma 40 (70)

8. MAINTENANCE
8.1. General
The boom contains both slide and ball bearings whose lubrication should be carried
out regularly at intervals of about 50 operating hours. Blocked or damaged grease
nipples must always be replaced immediately. If the holes in the joint pins get blocked,
the pin must be removed and the hole opened to ensure proper lubrication.
Because the MEWP is used for lifting people, special attention should be paid to the
condition of the equipment as a whole. The things to be checked weekly are the tight-
ness of the bolt connections, the condition and tightness of the hydraulic hoses and
fittings, and the joint pin locking.
Hydraulic pressures should be checked if malfunctions occur in the operation. The
specified pressure values must not be exceeded without the manufacturer's permis-
sion. If hoses or other components are changed, the involved movement needs air
bleeding by driving the relevant a few times to the extreme position. Air in the hydraulic
system can cause malfunctions and dangerous situations.
The rest of the inspections are regular checking of joints, pins and bearings etc, and
changing the worn/damaged parts if necessary. The worn components must be
replaced with new ones as soon as possible, to avoid further damage to other compo-
nents.
Warning!
Air in the hydraulic system can cause malfunctions and

dangerous situations.
100087044 1 - 1 EN 0918 ettekma 41 (70)

8.2. Greasing
Lithium based greases:
– NLGI grade . . . . . . .2
– Penetration . . . . . . .265/295
– Dropping point . . . . .180 °C
– Base oil viscosity . . .150 - 250 mm2/s @ 40°C
Warning!
Accumulated grease or oil on the MEWP is a fire hazard.

Remove debris whenever a significant quantity of oil is
spilled on the MEWP.
100087044 1 - 1 EN 0918 ettekma 42 (70)

8.3. Schedule
In addition to these instructions, always follow the local regulations, laws and stand-
ards concerning periodical inspections.

1. Visually check the hydraulic hoses, cables, couplings, and the structure.
2. Check the tilting cylinder pin and work platform joint pin.
3. Keep the working area of the work platform clean.
Weekly (50 hours)

4. Lubricate the grease fittings.
5. Check the boom mounting attachment.
6. Inspect the hydraulic cylinder, cylinder joint pin, pin locking and bearing.
Every 250 hours

7. Check the boom extension clearance.
Every 500 hours

8. Check the hydraulic pressures.
9. Inspect the tilt cylinder fixing lug welding.
10. Inspect the condition of the boom beams.
11. Inspect the function of the load-lowering valve.
12. Inspect the boom mounting bolt connections.
Every 2000 hours

13. Change the tilting cylinder joint pin and bearing
Every 6000 hours

14. Change the tilting cylinder.
When necessary
15. Adjust the boom lowering speed.
16. Adjust the boom slewing speed.
17. Adjust the load sensing system.
100087044 1 - 1 EN 0918 ettekma 43 (70)

8.4. Maintenance items

8.4.1. Daily or once in shift (10 hours)
ITEM 1
Visually check the hydraulic hoses, couplings and the structure.
Because the MEWP is used for lifting people, special attention should be paid to the
condition of the MEWP as a whole. The checks to be made are:
1. The bolt connections.
2. The condition and tightness of the hydraulic hoses and fittings.
3. Joint pin locks and parts used directly for lifting operations must not be damaged.
4. The steel construction of the boom has not been damaged.
5. Corrosion, cracking and abrasion.
By checking the equipment at regular intervals you will discover any defects in good
time, and in that way the repair work will be easier.
100087044 1 - 1 EN 0918 ettekma 44 (70)

ITEM 2
Check the tilting cylinder pin and work platform joint pin.
1. If the work platform has hit an obstacle;
– detach the tilting cylinder pins.
– detach the work platform joint pin.
2. Check the bearing.
3. Check the joint pin.
4. Check the locking of the pin.
5. Check that the work platform does not start to descend when positioned horizon-
tally.
Fig. 12. Joint pin and tilting cylinder
ITEM 3
Keep the working area of the work platform clean.
Keep the working area of the work platform clean and free of oil, ice, mud and loose
objects.
– Use a high pressure washer.
100087044 1 - 1 EN 0918 ettekma 45 (70)


ITEM 4
Lubricate the grease fittings.
Use a grease gun with grease as specified in grease recommendation and lube fittings
as shown in the figure.
Warning!
Accumulated grease or oil on the MEWP is a fire hazard.

Remove debris whenever a significant quantity of oil is
spilled on the MEWP.
100087044 1 - 1 EN 0918 ettekma 46 (70)

ITEM 5
Check the boom mounting attachment.
Slackened or stretched bolts must be replaced with new ones.
ITEM 6
Inspect the hydraulic cylinder, cylinder joint pin, pin locking and bearing.
1. Check all cylinders, nuts, pins, pin lockings and bearings for proper installation.
2. Check for excessive wear, cracks or distortion.
3. Check closely for permanent deformation, extreme wear, dents or corrosion
damage.
4. Welding seams should be visibly free of fractures or cracks.
100087044 1 - 1 EN 0918 ettekma 47 (70)


ITEM 7
Check the boom extension clearance.
The clearance gap of the telescopic extension is limited by means of wear plates.
Wear plates allow the clearance gap to be reduced creating better tolerance boom
assemblies.
Wear plates allow the inner boom to slide linearly inside the intermediate boom. Wear
plates reduce the friction between the sliding telescoping parts.
This allows for guideability and wear resistance both vertical and lateral when the
boomsections are extended.
You will notice large clearance gap by observing that the boom has an increasing
tendency to bend downwards. As this clearance gap is increased, excessive partial tilt
of the boom will result.
Large clearance gap allows dirt and other debris to gather between the telescoping
parts and cause friction and premature wear of the parts. The wear plates will be worn
depending on the service condition and environment.
Side clearance
1. Loosen the fixing bolts.
2. Position the inner boom in the middle of the intermediate boom.
– The intermediate boom in the middle of the outer boom.
3. Tighten the covers fully and firmly.
4. Loosen the covers 1/4 turn.
5. Tighten the fixing bolts.
Fig. 14. Cover and bolts
100087044 1 - 1 EN 0918 ettekma 48 (70)

Base clearance
1. Check the clearance gap.
– Clearance gap between the steel plate and the inner/intermediate boom.
– Check the clearance gap using a feeler gauge.
– Maximum 2,0 mm clearance gap.
2. Change the worn base wear plates.
3. Fasten a hoist to lift the boom end.
– In order to get space for the change.
5. Remove the cover.
6. Install new wear plates.
Fig. 15. Boom extension clearance
1. Clearance gap
2. Hoist
3. Fixing bolt
4. Cover
5. Wear plate
100087044 1 - 1 EN 0918 ettekma 49 (70)

Intermediate boom end

1. Drive the boom extensions fully out.
2. Drive the intermediate boom in.
– Leave 20 cm in order to get space for the change.
1. Fixing bolt
2. Cover
3. Wear plate
100087044 1 - 1 EN 0918 ettekma 50 (70)

Inner boom end

1. Drive the boom extensions fully out.
2. Drive the intermediate boom in.
3. Drive the inner boom in.
– Leave 20 cm in order to get space for the change.
1. Fixing bolt
2. Cover
3. Wear plate
100087044 1 - 1 EN 0918 ettekma 51 (70)


ITEM 8
Check the hydraulic pressures.
Conditions
– Pressure gauge connected to the pressure check point.
1. Check the pressure when the hydraulic oil is at normal operating temperature.
2. Connect the pressure gauge (0 - 200 bar) to the measurement point.
3. Drive the desired function of the boom to its extreme position by the control lever.
4. The pressure should be 200 bar max.
5. Pressure values shown in the hydraulic scheme are absolute top limits, which
must not be altered without manufacturer's permission.
Fig. 18. Pressure check points
100087044 1 - 1 EN 0918 ettekma 52 (70)

ITEM 9
Inspect the tilt cylinder fixing lug welding.
There should not be any visible fractures or cracks in the welding seams.
Fig. 19. Tilt cylinder
ITEM 10
Inspect the condition of the boom beams.
Check boom structure, boom members and their connections for absence of frac-
tures, cracks, permanent deformations, bad wear, bruises or corrosion damages.
Inspect paint and overall appearance.
100087044 1 - 1 EN 0918 ettekma 53 (70)

ITEM 11
Inspect the function of the load-lowering valve.
1. Perform valve readjustment as follows if it is necessary.

2. Loosen the lock nut.
– Use a 17 mm ring wrench.
3. Turn the hexagonal socket head screw fully closed.
– Use 5 mm hexagon socket spanner.
4. Drive the boom to its most extended position.
5. Place a 10 % overload in the work platform.
6. Raise the boom to the horizontal position.
7. Turn the hexagonal socket head screw in the opening direction.
– The work platform starts to slowly descend.
8. Check that the boom / work platform function normally.
– At the maximum load.
9. Tighten the lock nut.
Fig. 20. Load lowering valve
100087044 1 - 1 EN 0918 ettekma 54 (70)

Use of the load-lowering valve in an emergency

The boom lift cylinder is equipped with a load-lowering valve, which enables lowering
of the boom if hydraulic pressure is not available.
1. If pressure is not available and the boom is up, follow these steps:
– The diesel engine is not functioning.
– The emergency pump is not functioning.
2. Unscrew the load-lowering valve lock nut.
– Use a ring wrench.
3. Loosen the hexagon socket head screw until the boom starts to lower.
– Use a hexagon socket spanner.
4. Pay attention to the number of turns the screw is loosened.
– You can then restore the original position of the screw by tightening it the nec-
essary number of turns.
Fig. 21. Load lowering valve
100087044 1 - 1 EN 0918 ettekma 55 (70)

ITEM 12
Inspect the boom mounting bolt connections.
1. Check the bolt connections.
– Use a torque wrench.
2. Replace all bolts if any of the bolts has slackened or stretched.
– Size M 12
– DIN 912 Grad 12.9
– Tightening torque 78 Nm with grease on the threads.
Fig. 22. Check the bolt connections
100087044 1 - 1 EN 0918 ettekma 56 (70)


ITEM 13
Change the tilting cylinder joint pin and bearing.
Joint pins and bearings must be replaced at latest every 2000 operating hours.
1. Lower the work platform on ground or proper on proper supports.
2. Clean the parts before opening any hydraulic connections.
3. Turn the tilt mechanism so that the tilt cylinder joint pins are not under load.
4. Remove the joint pins.
– Detach joint pin locking and use sliding hammer or hydraulic pin puller/ pusher
to remove the pins.
5. Remove the cylinder.
6. Replace cylinder bearings.
– Remove circlips and press the bearing out
– Install new bearing and circlips.
7. Install cylinder with new joint pins.
Fig. 23. Tilting cylinder
100087044 1 - 1 EN 0918 ettekma 57 (70)


ITEM 14
Change the tilting cylinder.
Tilting cylinder must be replaced at latest every 6000 operating hours.
2 3
Fig. 24. Tilting cylinder
1. Tilt cylinder
2. Protective structure
3. Joint pin
Danger!
Risk of crushing! Be extra careful when using the

hydraulics during the maintenance operation.
100087044 1 - 1 EN 0918 ettekma 58 (70)

Removal
1. Lower the work platform on ground or proper on proper supports.
– Remove the protective structure.
2. Clean the parts before opening any hydraulic connections.
3. Turn the tilt mechanism so that the tilt cylinder joint pins are not under load.
4. Mark hoses and make notes about locations and routing of the hydraulics.
5. Position collecting vessel beneath cylinder
– Dispose oil in accordance with local environmental regulations.
6. Ensure that system is unpressurised.
7. Disconnect hydraulic hoses
8. Remove the joint pins.
– Detach joint pin locking and use sliding hammer or hydraulic pin puller/ pusher
to remove the pins.
9. Remove the tilt cylinder.
Installing
10. Connect hoses to new cylinder.
11. Drive the cylinder in and out several times to get air out from cylinder.
12. Drive the cylinder to same length as the old one was.
13. Install the cylinder with new joint pins an pin locking mechanisms.
– Install the protective structure.
Danger!
Perform a test drive before use.
100087044 1 - 1 EN 0918 ettekma 59 (70)

8.4.7. When necessary

ITEM 15
Adjust the boom lowering speed.
The boom lowering speed is set to a certain value at the factory. This speed is based
n the boom lifting speed, which is determined by a valve on the main block.
The lowering speed depends also on the actual weight of the boom, necessitating the
use of a one-way flow control valve to make the lowering speed equal to the lifting
speed. In certain conditions and applications, it may be necessary to adjust the
lowering speed.
Caution!
The lowering speed must be adjusted in accordance

with the pump output. If the one-way flow control valve is
opened too far, the boom may be lowered in a rocking
movement, since not enough hydraulic fluid reaches the
other side of the piston.
Fig. 25. One-way restrictor
1. One-way flow control valve

2. Adjustment knob
100087044 1 - 1 EN 0918 ettekma 60 (70)

1. Adjust the valve if necessary.

– Make the adjustment while the hydraulic fluid is warm.
– Adjustment may be necessary on account of the conditions and the applica-
tion.
– Perform the adjustment with the load that is normally used.
– Note that the load affects the lowering speed.
– Raise the boom from horizontal orientation.
2. Open the locking of the one-way flow control valve adjustment knob.
– Use a 2 mm hexagon socket spanner.
3. Lower the boom while turning the adjustment knob in the desired direction.
– Turn the knob clockwise to decrease the lowering speed.
– Turn the knob counterclockwise to increase the lowering speed.
4. Lock the valve adjustment knob after making the adjustment.
100087044 1 - 1 EN 0918 ettekma 61 (70)

ITEM 16
Adjust the boom slewing speed.
The boom slewing speed is set to a certain value at the factory. This speed is based
on the main block valve setting.
To stabilize the slew movement, the slew cylinder is fitted with a one-way flow control
valve.
1. Adjust the valve if necessary.
– Make the adjustment while the hydraulic fluid is warm.
– Adjustment may be necessary on account of the conditions and the applica-
tion.
2. Open the locking of the one-way flow control valve adjustment knob.
– Use a hexagon socket spanner.
3. Adjust the boom slew speed to the desired value with the valve adjustment knob.
– Turn the knob clockwise to decrease the slew speed.
– Turn the knob counterclockwise to increase the slew speed.
4. Lock the valve adjustment knob after making the adjustment.
Fig. 26. One-way flow control valves
100087044 1 - 1 EN 0918 ettekma 62 (70)

ITEM 17
Adjust the load sensing system
The load sensing system is a safety device which prevents any normal movement of
the work platform from a stationary working position after the rated load is reached
and before 120 % of the rated load is exceeded.
A flashing red warning light together with an acoustic alarm signal is activated when
normal movement is prevented at the pre-selected control position. Normal movement
can only be resumed once the overload is removed.
Adjust the load sensing system to activate no later than 10% overload.
Fig. 27. Load sensing system
1. Lock nut
2. Adjustment screw
100087044 1 - 1 EN 0918 ettekma 63 (70)

Perform a 10 % overload adjustment as follows.

1. Add 10 % overload to the basket.
2. Loosen the lock nut.
3. Loosen the adjustment screw until the buzzer gives no signal.
4. Tighten the adjustment screw until the buzzer just gives a signal.
5. Remove the load from the basket.
6. Place again a maximum permitted load in the work platform.
– Check that the buzzer gives no signal.
7. Add 10 % overload to the basket.
– Check that the buzzer gives a signal.
8. Tighten the lock nut.
9. Conduct sealing painting.
– Enables later determination of whether the adjustment has changed.
100087044 1 - 1 EN 0918 ettekma 64 (70)

9. SPECIFICATION
9.1. Speed values
Function Speed / output System
Boom swing 0,7 m/s Adjustable

Boom lowering 0,4 m/s Adjustable
Boom telescope 0,4 m/s Does not exceed pump output
Pump output 40 l/min
To check the speed values, measure the work platform movement distances and time
values. Check the table below in order to determine the correct boom movement
speeds.
Operate the boom until the oil reaches normal operating temperature.
1. Drive the boom to its most extended position.
2. Measure the distance using the work platform centre point movement while
checking the boom slewing speed.
3. Measure the distance using the work platform bottom movement while checking
the boom lowering speed.
Speed 0,4 m/s 0,7 m/s Speed 0,4 m/s 0,7 m/s
Distance / m Time / s Time / s Distance / m Time / s Time / s

3 7,5 4,3 11 27,5 15,7
4 10,0 5,7 12 30,0 17,1
5 12,5 7,1 13 32,5 18,6
6 15,0 8,6 14 35,0 20,0
7 17,5 10,0 15 37,5 21,4
8 20,0 11,4 16 40,0 22,9
9 22,5 12,9 17 42,5 24,3
10 25,0 14,3 18 45,0 25,7
100087044 1 - 1 EN 0918 ettekma 65 (70)

9.2. Sticker
9.2.1. General instructions
The operator must be at least 18 years old.

Familiarize yourself with the operating manuals.
Follow all the safety regulations.
Check the carrying capacity of the ground.
Place the support legs to the support position.
Use plates underneath the support legs when needed.
Adjust the boom as straight as possible.
Do not exceed the maximum load permitted.
Do not cause to the boom side draw.
Do not use the boom in hard wind.
Note the allowed temperature.
Avoid quick lifting and lowering movements
Be aware of electric wires.
Be aware of obstacles in the operating area.
Never use a faulty or damaged boom.
Report all defects and faults detected.
Carry out all the daily inspections.
Take care of the working site order.
Protect the boom against unauthorized use.
100087044 1 - 1 EN 0918 ettekma 66 (70)

9.2.2. Daily checks
Bearing strength of the ground Travel ways

Boom supports Basket
Balance of the carrier Limit switches
Emergency stop Oil leakage
Emergency rope Working area
Controls Lights
100087044 1 - 1 EN 0918 ettekma 67 (70)

10. TROUBLESHOOTING
Trouble
– Possible cause
• Remedy
Boom working movements slow

– Pump running too slowly
• Check pumps rotating speed
– Not enough oil
• Add oil (air-bleeding)
– Faulty pump
• Change or get the pump fixed
– Leaks or obstructions in oil lines
• Inspect oil lines
– Oil too thick
• Change to a thinner (correct) oil grade
Boom descending movements slow

– Obstructions in the oil lines
• Check the lines and the chokes
– Clogged-up (return) filter
• Clean or renew filter
– Oil too thick
• Change to a thinner (correct) oil grade
100087044 1 - 1 EN 0918 ettekma 68 (70)

Boom movements too fast

– Rotation speed too high or pump too big
• Choose a correct speed of rotation and correct pump size
– Incorrect operation Learn to open the control valve to a suitable degree
• Boom working movements powerless
– Not enough oil
• Add oil (air bleeding)
– Faulty pump
• Change or get the pump fixed
– Faulty relief valve or shock valves
• Change the relief valve or shock valves
– Faulty control valve
• Change or get the valve fixed
– Faulty cylinders or seals
• Check the cylinders and change the seals
Boom movements are jerky

– Air in hydraulic system
• Check oil level, bleed air from system
– Check that there are no obstructions or leaks on the inlet side
• Faulty pump Inspect the pump and get it fixed
Boom descend by it self

– Faulty control valve
• Inspect the control valve and get it fixed
– Faulty cylinders or hoses
• Fix the leakage point
• Check cylinder seals
100087044 1 - 1 EN 0918 ettekma 69 (70)

NOTES
100087044 1 - 1 EN 0918 ettekma 70 (70)

OPERATION AND MAINTENANCE
Code: . . . . . . . . . . . . . . . . . . . . 100121643
Carrier No: . . . . . . . . . . . . . . . . DJ305
The information contained in this manual is current for this unit. In the interest of continually
improving its products, Normet reserves the right to update or modify information contained
in this manual. Illustrations shown in this manual were produced during the development
stages and may differ from the actual product.
Normet Oy Tel. +358 (0)17 83 241

FINLAND
About this manual

Read this manual carefully before operating. Follow the instructions presented in the
manual to ensure the safety of operators and others.
Danger!
Warning!
Risk of injury.
Caution!
Note!

CONTENTS
1. Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2. Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3. ANFO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Charging Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1. Pneumatic Loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2. Charging Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3. Mobile Elevating Work Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4. Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5. Charging The Round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6. Smooth Wall Blasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3. Safety Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1. Static Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2. Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3. Chemical Reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4. Operational Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1. General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2. Work Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5. Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1. Charging Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2. Charging Hand Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3. Charging Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4. Selecting the Pressure Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5. Terminal Box TB5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6. Connector Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.7. Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.8. Pressure Release Valves For Charging Hose . . . . . . . . . . . . . . . . . . 32
5.9. Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6. Filling The Vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6.1. Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.2. Blockage during tank filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7. Preparatory Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.1. Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2. Charging Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8. Blowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1. Borehole Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.2. Charging The Borehole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.3. Charging Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9. Lubricant Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.1. Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10. Maintenance Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

10.1. Hot Work During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10.2. Fire Prevention Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10.3. General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10.4. Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11.2. Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11.2.1. Daily or once per shift (10 hours) . . . . . . . . . . . . . . . . . . . . . . . 60
Drain water from the modular type air filter. . . . . . . . . . . . . . . . . . . . . . . . . 60
Drain water from the water separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Check the lubricator drippage amount and oil level. . . . . . . . . . . . . . . . . . . 62
Keep the pressure vessel and charging unit clean. . . . . . . . . . . . . . . . . . . . 63
Check the interior and exterior condition of the vessel. . . . . . . . . . . . . . . . . 63
Check the wear of the charging hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Check the total resistance between earthing strap and free end of the charging
hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Check the resistance between earthing strap and ANFO charger quick acting
coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check the vacuum pump oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.2.2. Every 500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Clean the modular type air filter element. . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Measure the earthing strap resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Clean the vacuum pump oil reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
11.2.3. As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Change the water separator filter element . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fix the connections of the earthing straps and earthing points. . . . . . . . . . 72
Replace the earthing straps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Clean the cyclone separator filter element. . . . . . . . . . . . . . . . . . . . . . . . . . 74
1. TECHNICAL INFORMATION
1.1. Foreword
The charging unit can be used for drift as well as up-hole and down-hole stope
charging.
Normet mining carriers equipped with either a lifting platform or basket boom are
designed for easy site-to-site transfer. The carrier referred to in this manual is
equipped with a basket boom. The lifting platform or basket boom is hereafter referred
to as a mobile elevating work platform, or MEWP.
Pneumatic charging of bulk ANFO provides an economical and time-saving method
of blasting in relatively dry borehole conditions. For such applications,
Normet manufactures complete units with ANFO chargers and other accessories
installed.
As an option, the carriers are available with fire resistant hydraulic fluid and a fixed fire
suppression system.
The basic requirements for successful blasting are:
– Safe working method.
– Desired fragmentation and throw of the rock.
– Blasting economy.
– Smooth tunnel profile and minimum disturbance of surrounding rock in order
to reduce support costs and assist ventilation.
– Rapid charging of boreholes
100121643 1 - 1 EN 0918 ettekma 5 (77)

1.2. Technical Specification

Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For drift and stope charging
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pneumatic controls
Vessel size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 l
Borehole diameter, max. . . . . . . . . . . . . . . . . . . . . 150 mm
Up-hole diameter, max . . . . . . . . . . . . . . . . . . . . . . 100 mm
Charging density . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 - 1.2 kg/dm3
Charging capacity. . . . . . . . . . . . . . . . . . . . . . . . . . over 100 kg per minute
Air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 - 6.0 m3/min
All parts directly connected to explosive . . . . . . . . . Stainless steel
ANFO
Prilled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 – 1.0 kg/dm3
50/50 crystalline/prilled. . . . . . . . . . . . . . . . . . . . . . 1.1 – 1.15 kg/dm3
Crystalline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 – 1.2* kg/dm3
* maximum value for ANFO
100121643 1 - 1 EN 0918 ettekma 6 (77)

1.3. ANFO
Pneumatic loaders are intended for charging of boreholes with ready-made ammo-
nium nitrate/fuel oil (NH4NO3/oil). The use of ammonium nitrate/fuel oil explosive has
become widespread due to its economical price per kilogram and its suitability for
labour--saving pneumatic charging, instead of the conventional method of tamping
cartridges into the boreholes.
– Is the most widely used civil explosive in the world.
– Is classed as a blasting agent and requires initiation by a primer.
– Consists of a mix of ammonium nitrate and fuel oil.
– Special ANFOs include various additives.
– Explosives are used mainly in large open-cast blasting in non-urban areas and
in underground mines.
The limitation of the method is the low water resistance of bulk ANFO. The risk of
ammonia emissions should be considered if the likelihood of exposure to fresh
concrete exists.
Special ANFO products have been developed for specific applications:
– enhanced moisture tolerance ANFOs.
– “sticky” ANFOs for better up-hole adherance.
– lighter density ANFOs.
Fig. 1. Sacks containing ANFO
100121643 1 - 1 EN 0918 ettekma 7 (77)

Two kinds of ammonium nitrates and oil are used.

Prills
– The term ANFO describes a mixture of solid ammonium nitrate prills and No.
2 fuel oil (normal road diesel).
– In this form, it has a bulk density of approximately 840 kg/m3.
– The density of individual prills is about 1 300 kg/m3.
– Small, porous pellets with a particle size range of 0.3 - 2.5 mm.
– Prills are less likely to cake, ensuring unrestricted flow from the charging ves-
sel.
Crystalline
– Density of pure crystalline ammonium nitrate is 1 700 kg/m3.

– A 50/50 mixture of prills and crystalline can give good results in up-holes.
– The charging units can also be used for upward oriented holes, and mixing the
prills with chrystalline ammonium nitrate, e.g. to a 1:1 ratio, eliminates the
need for ejector charging.
Oil
– The amount of fuel oil mixed varies between 5.5 - 6.0 % depending on the
quality of the ammonium nitrate.
– Too much oil results in high carbon monoxide production.
– Too little oil increases nitrous oxides.
– The optimum is 5.7 % of the mixture by weight.
Fig. 2. Prills
100121643 1 - 1 EN 0918 ettekma 8 (77)

2. CHARGING TECHNIQUE
2.1. Pneumatic Loaders

The ANFO feed is controlled by a transmitter/remote control unit.
Pressure type charging unit
These heavy duty, rapid-charging transportable units can effectively charge up to 25
meters of vertical up-holes.
A plug of ANFO mixture is ejected under pressure into the borehole in a continuous
column. The prills crack under the pressure, and the ANFO breaks into small frag-
ments as soon as it exits the charging hose and hits to the bottom of the bore hole.
The charging rate is directly dependent upon the charging pessure. High pressure
charging will eject the ANFO at high speed, whereas too low a pressure can cause
the ANFO to clog inside the charging hose.
– The correct balance is determined through experience, based on key param-
eters such as: hole length and direction, moistness/dryness of the ANFO mix,
prill size uniformity, and the powderiness of the ANFO used.
Ejector type charging unit
Ejector feeding ejects the ANFO particles at such high velocity that the prill granules
are crushed upon impact and adhere to the borehole wall without dropping.
– particles are blown by a continuous air flow.
– particles bombard the loaded surface and disintegrate upon impact, resulting
in compaction.
Combined charging unit
When charging with NH4NO3/oil in prill form, there is a risk that the charge can spill
out from the boreholes. In such cases, charging units which operate on a combined
pressure vessel and ejector principle must be used.
By combining both application methods, the charging unit can achieve double the
charging rate compared to pressure type charging, and can effectively handle up
borehole lengths of up to 30 m.
100121643 1 - 1 EN 0918 ettekma 9 (77)

2.2. Charging Carrier

Successful drill & blast excavation is dependent on professional and safe charging
and blasting procedures. The rock and groundwater conditions dictate the drilling
parameters, types of explosives, charging patterns and initiating systems. Inadequate
drilling cycles cannot be improved by charging, and good quality drilling can be ruined
by inadequate blast design and poor charging quality.
The charging carrier with its robust support legs provides uncompromising driving
safety and lifting stability. The charging carrier is a safe, reliable and cost-effective
solution for high quality explosive charging of bulk ANFO.
Different types and sizes of ANFO charging unit are available for installation on the
carrier. The pressure vessel type of charger is especially suitable for drifting and long
production holes. The charging density when using prills is normally 0.95 kg/dm3,
poured ANFO is about 0.85 kg/dm3. These chargers produce less oil vapour than
ejector type units, which have a higher flow speed.
When charging up-holes with the pressure vessel unit, it may be difficult to ensure that
the prills stay in the holes. In this case, an ejector is required to increase the particle
speed so that they partially disintegrate and remain in the hole.
Fig. 3. ANFO charging carrier
100121643 1 - 1 EN 0918 ettekma 10 (77)

2.3. Mobile Elevating Work Platform

The mobile elevating work platform was designed within specific pre-set operating
parameters. The desired performance was achieved by combining the lifting platform
with the highly flexible movement of the telescopic boom.
The range of operational tasks carried out with the mobile elevating work platform is
extensive, and includes charging of boreholes with ANFO or cartridges in large cross-
section galleries without needing to move the carrier.
The charging carrier equipped with mobile elevating work platform offers an easy
solution for ANFO charging of boreholes.
Fig. 4. Mobile elevating work platform
100121643 1 - 1 EN 0918 ettekma 11 (77)

2.4. Compressed Air

For work sites that do not have a compressed air network, Normet offers a safe way
of generating pneumatics for charging.
Where the working environment cannot provide a direct supply of compressed air, a
safe solution can be found by utilizing either electric or diesel power to operate a
compressor. As the drive time is relatively short compared to the total operating time,
and the worklights are in constant use, a pneumatic or hydraulic alternator (optional)
should be seriously considered.
The air feed required for cleaning the boreholes prior to charging is about 4 m3/min.
The feed required for charging is lower, at 0.7 - 1.4 m3/min depending on the charger
type. The rate of flow is adjusted by changing the working pressure of the vessel.
Ensure that sufficient compressed air pressure is available for the charging hose for
up-hole charging with ANFO. This may require checking of the pressure regulators.
Fig. 5. Charged ANFO
1. Packed charge column

2. Normal charge column
100121643 1 - 1 EN 0918 ettekma 12 (77)

2.5. Charging The Round

The telescopic movement of the mobile elevating work platform makes it easy to main-
tain the right distance from the boreholes across the entire face.
As ANFO is a relatively insensitive explosive, a standard detonator alone is not a suffi-
ciently reliable primer, and a booster charge is needed. Use of a cartridge for this
purpose is usually recommended, as the cartridge also provides mechanical protec-
tion for the sensitive detonator when it is inserted in the borehole.
If possible, the primer should be located at the bottom of the hole with the detonator
pointing toward the explosive, so as to reduce borehole cut offs. In conditions where
the rock is ”tight”, such as advancing rounds, this method gives better displacement
because the gases expand for a longer period of time. In addition, the possibility of
”cut offs” is reduced.
2.6. Smooth Wall Blasting

The change from hand-held drills to heavy drill jumbos has led to the use of larger
diameter holes and higher charges per hole. This has resulted in increased rock fall
incidences due to blast disturbance and, consequently, attention has turned towards
creating smoother and stronger roofs and walls.
Ideal profile of the tunnel can not be achieved without using a lighter charge in the
perimeter holes. Smooth wall is achieved by using a lighter charge in the perimeter
and buffer holes than the production holes. This method is effective even in hard
homogeneous rocks.
It should be noted that when charging with ANFO not only the perimeter holes but also
holes in close proximity can damage the surrounding rock. For this reason, it has been
claimed that smooth wall blasting may result in more severe rockfall problems than
conventional blasting. This can certainly be true in cases where strongly charged
holes damage the roof and the lightly charged perimeter holes are unable to bring the
fractured zone down.
100121643 1 - 1 EN 0918 ettekma 13 (77)

3. SAFETY ASPECTS
3.1. Static Electricity

Static electricity can build up when ANFO is pneumatically conveyed through the
charging unit. If the charges are allowed to accumulate and then discharge suddenly,
the energy released can be enough to detonate the explosive.
The amount of electrical charge depends on three factors:
1. Absolute humidity of the conveying air.
– Dry air generates higher electrical charges than moist air.
2. Charging rate kg/min.
– Higher charging rate results in higher currents.
3. Capacitance of places where electrical energy may accumulate.
– For instance, between the detonator wires and the ANFO.
– Longer holes have higher capacitance.
– For these reasons, the charging system must be made sufficiently conductive.
1. Use only a proper semiconductive charging hose.
– The hose supplied by Normet is semiconductive.
2. Provide an electrical path between the charging vessel and the ground.
– An earthing cable is needed if the vessel is installed on a rubber-tyred carrier.
3. Do not disrupt the electrical path between the ANFO and the borehole walls.
– Non-conductive borehole liners should not be used.
– Non-electric detonators have higher resistance against static but cannot be
considered completely safe. Use of a semiconductive charging system is
therefore recommended.
– The abovementioned measures are sufficient in most mines, where the rock
resistance and mine humidity provide adequate conductivity.
– Conductivity may also be insufficient in the vicinity of extremely non-conduc-
tive materials such as salt, or in dry mine conditions.
100121643 1 - 1 EN 0918 ettekma 14 (77)

Preventing electrostatic charge

A) Charging hose
1. The resistance of the charging hose must be minimum 1 kΩ/m and maximum 30
kΩ/m.
2. The charging hose must be clearly marked to make it easily distinguishable from
other hose types.
3. The charging hose supplied by Normet meets the resistance requirements.
– The inside diameter, stiffness class, and length are clearly marked on each
meter of hose.
– The charging hose is also marked with a continuous orange stripe to distin-
guish it from non-conductive hoses.
4. The length of the charging hose should not exceed 60 meters.
B) Charging carrier
1. The charging carrier must be earthed to the ground during operation.
2. The support legs of the charging carrier must be directly against the ground or
mine sole, or must have some other metallic contact with it.
3. A stainless steel chain must be fixed to the charging carrier frame if the carrier is
on rubber tyres.
– At least 10 cm of the total chain length should drag along the bottom of the drift
or along the ground.
4. A corresponding contact between the carrier and the earth must be installed, and
likewise between the charging unit and the carrier if the charging unit is mounted
on a fork lift or other carrier.
C) Borehole
1. The resistance of the casing pipe should not exceed 30 kΩ/m if the borehole
must be lined with casing pipe.
– E.g. if the rock is cracked.
100121643 1 - 1 EN 0918 ettekma 15 (77)

3.2. Electrical Hazards

In underground mines the risk of lightning, radio frequency energy, and induced
currents from high-voltage power lines are negligible.
A stray current from poorly insulated or improperly earthed electrical equipment is,
however, possible.
– It is important to keep the electric blasting circuit away from continuous metal
objects that may carry a current.
– Do not earth the charging unit to metal structures, such as pipelines or rails.
– Non-electrical detonating methods are completely safe from stray currents.
Fig. 6. Safety sticker
100121643 1 - 1 EN 0918 ettekma 16 (77)

3.3. Chemical Reaction

Certain materials
Galvanised steels, zinc, copper and alloys of these materials can form impact-sensi-
tive explosive compounds with ammonium nitrate, which may be hazardous.
For this reason, their use is prohibited for vessels, internal linings or where the mate-
rial is likely to came into contact with ammonium nitrate, ANFO or similar mixtures.
They should not be used in locations where contact with ANFO cannot be avoided.
This also precludes their use as corrosion-resistant treatments of internal lining
fastenings, such as screws.
Steel, stainless steel, aluminium and some anti-static plastics are generally suitable.
Plain steel screws may be used, although they are highly susceptible to accelerated
corrosion in the presence of ammonium nitrate.
Tetra-amine copper nitrate (TACN)
Tetra-amine copper nitrate is an impact-sensitive explosive compound that can
present a hazard during the operation of ammonium nitrate handling equipment and
during ammonium nitrate storage.
According to the explosive manufacturers, TACN is formed by the action of ammo-
nium nitrate on copper or it’s alloys (i.e. brass/bronze) in the presence of moisture.
TACN can be recognised as a dark blue/purple coloration generally found on the
surface of copper-based components. The compound has been found to be highly
sensitive under certain conditions to impact detonation.
TACN contamination is removed by painting with a mixture of 1 part spirit of salts (35
% Hydrochloric acid) and 10 parts water. Once completed, flush with water.
– TACN can be formed by the action of ANFO on copper in the presence of
moisture.
– TACN formation can be avoided by eliminating copper and brass parts.
– TACN is a potentially explosive compound.
– TACN is a highly impact-sensitive explosive.
– TACN’s impact-sensitivity increases with dryness.
– TACN is dark blue/purple in color.
100121643 1 - 1 EN 0918 ettekma 17 (77)

4. OPERATIONAL SAFETY RULES
4.1. General Instructions

A) General
1. Do not smoke or allow open flames near to the charging carrier.
2. Ensure that there are no fire hazards or combustible materials in the vicinity.
– Hot work is not allowed on the maintenance site while the charging carrier is
present, unless the charging unit’s tanks have been emptied and all explosives
have been removed from the carrier.
3. Do not store the charging carrier near to where blasting work is in progress.
4. Only essential personnel must be present during the transport and handling of
explosives.
5. The person using the charging carrier must
– have sufficient training.
– be familiar with the work instructions.
– have been approved by the supervisor in charge.
6. Before starting charging work, check
– the condition of the charging hose.
– the connections for leaks.
– the charging hose for longitudinal splits.
– the charging hose for bends/kinks.
100121643 1 - 1 EN 0918 ettekma 18 (77)

B) Instructions
1. The information contained in this operator’s manual is intended for charging unit
operators.
– The charging unit may be handled and operated only by persons with the
appropriate technical skills, training and operating permission.
2. The operator must obtain detailed work instructions from the responsible work
supervisor, and must be fully familiarised with the contents of this operator’s
manual before operating the unit.
3. The instructions contained in the operator’s manual must be followed in detail.
4. The operator must be familiar with the carrier and mobile elevating work platform
functions in order to operate the charging unit.
5. Each user is responsible for being aware of the details contained in the opera-
tor’s manual and of the proper scope of application of the charging unit with
respect to its specific intended use.
6. While Normet makes every effort to ensure that the details contained in the oper-
ator’s instructions are as accurate as possible, the conditions under which the
charging unit is used are not within its control.
7. Contact Normet for assistance if technical advice is required within the specified
scope of application of the charging unit.
8. Always comply with the instructions in this operator’s manual and with your com-
pany’s regulations and practices when operating the charging unit.
100121643 1 - 1 EN 0918 ettekma 19 (77)

C) Explosives
1. The explosives used with this charging unit are classified as dangerous goods
and can cause severe personal injury and damage to property if used incorrectly.
2. Explosives must be handled, transported and stored in accordance with all rele-
vant regulations.
3. Ensure that the explosive is loaded through a semi-conductive hose or tube with
a minimum resistance of 15 kΩ and a maximum resistance of 2 mΩ along its
entire length.
4. Handle explosives carefully and be aware of their specific hazards.
5. Use only approved explosives.
6. Rotate the stock so that older explosive is used first.
7. Protect the detonator against damage during the charging operation.
– Use protected type detonators when pneumatic loading and electrically firing.
8. Charge only after the entire face has been fully drilled
– to avoid accidental detonation by drilling into explosives
9. Keep away from the blast area.
– Switch off the ventilation completely before blasting.
– Switch on the ventilation at full capacity after blasting.
– The entire work crew must withdraw to a protective shelter during blasting.
– In small tunnels, the protective shelter can be installed in a niche.
– Keep at a safe distance from flying debris and toxic fumes resulting from blast-
ing.
100121643 1 - 1 EN 0918 ettekma 20 (77)

4.2. Work Instructions

A) Safety equipment
1. Use the recommended safety equipment and personal protective equipment
required by law.
– A hard hat, ear protection, eye protection, protective coveralls, gloves, safety
shoes and other necessary protective equipment.
2. Wear protective clothing when and where required.
– Wear protective equipment and keep them clean and in good condition.
B) Instructions
1. Follow the work instructions and remember which tasks require a work permit.
2. Ask your supervisor for further instructions if anything is unclear.
3. In addition to work-site-specific instructions, familiarize yourself with the operat-
ing, lubrication, maintenance, and safety instructions provided by the equipment
and component manufacturers.
4. Ask your supervisor for detailed work instructions.
– Read and make sure you fully understand these operating instructions.
5. When operating the charging unit, always follow the instructions in this manual
and the instructions and policies of your company.
– Follow the operating instructions in every detail.
6. Study the material safety data sheet for each substance before use.
C) Earthing
1. Before handling and connecting electric detonators, remove your gloves and
ensure that you are properly earthed to discharge any electrostatic charge.
2. Do not use water lines, compressed air lines, wire covered hoses, rail or perma-
nent electrical earthing systems as a means of earthing.
100121643 1 - 1 EN 0918 ettekma 21 (77)

D) Work routines
1. Ensure that you know the location and proper use of safety devices and fire-
extinguishing equipment, alarm systems, and emergency exits.
2. Report any deficiencies in the safety arrangements to your supervisor.
3. Keep the work site clean and in good order.
4. Work in a deliberate, systematic manner.
5. Collect rubbish and explosive waste in the appropriate locations.
6. Familiarize yourself with the basic operation of the carrier and the mobile elevat-
ing work platform
– to ensure safe operation of the charging unit.
7. Follow these rules if you are going to drive the charging carrier on public roads.
– Remove all explosives from the charging carrier.
– Obtain a transport permit.
8. Do not make any modifications or perform any trials without your supervisor’s
permission.
9. Use the charging carrier only for the purposes stated in the instructions.
10. Always put the lid on the grid while driving.
– Not required if equipped with ANFO filling system (fixed lid).
Fig. 6. Lid on the grid.
100121643 1 - 1 EN 0918 ettekma 22 (77)

E) Charging
1. Do not operate unless the charging unit, charging hose and earthing arrange-
ments are safe and effective and in accordance with the manufacturer’s recom-
mendations.
2. Carry out charging work only under the supervision of an authorised and quali-
fied blasting specialist.
3. Keep unauthorized persons out of the working area during operation.
4. Protect the detonator/primer against damage during charging.
5. Stand to the side of the borehole, not directly in front of it when charging.
6. Supervise the charging process and monitor the condition of the charging unit.
7. In the event of a fault or malfunction, shut down the charging unit.
– Do not operate a faulty charging unit.
8. Perform maintenance and inspections of the charging carrier in accordance with
the maintenance plan.
9. Report any unusual observations or occurrences to your supervisor.
10. Keep a record of the inspections and procedures performed.
– Store the records carefully.
11. When filling the vessel, make sure no loose, hard objects, such as rocks or tools,
can fall into it.
12. Normet bears no risk, responsibility or liability arising from incorrect use of the
charging unit.
100121643 1 - 1 EN 0918 ettekma 23 (77)

5. OPERATOR CONTROLS
5.1. Charging Controls
2 3
Fig. 7. Terminal Box TB4
1. Process activation
2. Vessel “B” pressurised
3. Vessel “A” pressurised
4. Compressor
5. Emergency stop
100121643 1 - 1 EN 0918 ettekma 24 (77)

1. Process activation
Use
– Move the lever up to use the charging unit.
Action
– Process activation indicator light lights up.
2. Indicator light - vessel selection ’’B’’
Green light
– Indicates that the vessel is selected.
3. Indicator light - vessel selection ’’A’’
Green light
– Indicates that the vessel is selected.
4. Compressor
Use
– Start the compressor.
– Stop the compressor.
Action
– Compressor ON indicator light lights up.
Purpose
To engage
To reset
100121643 1 - 1 EN 0918 ettekma 25 (77)

5.2. Charging Hand Valve
1 2
Fig. 8. Hand valve for charging
1. Blow
Use
– If necessary, blow the boreholes clean with pressurized air.
• Spring returned
2. Charge
Use
– Press the button to start feeding explosive to the borehole.
• Manually returned
– Press slightly the blow button to stop charging.
100121643 1 - 1 EN 0918 ettekma 26 (77)

5.3. Charging Pedal
2 1
Fig. 9. Pedals for charging
1. Blow
Use
– If necessary, blow the boreholes clean with pressurized air.
• Spring returned
2. Charge
Use
– Press the pedal to start feeding explosive to the borehole.
• Spring returned
100121643 1 - 1 EN 0918 ettekma 27 (77)

5.4. Selecting the Pressure Vessel

Select pressure vessel (1) or (2) by using the three-way valve lever.
Three-way valve and quick acting coupling
100121643 1 - 1 EN 0918 ettekma 28 (77)

5.5. Terminal Box TB5
1 2
Fig. 10. Terminal Box
1. Back blowing
2. Vessel selector
1. Back blowing
Use
– To open a blockage.
Warning!
Back blowing is allowed only when pressure in the ves-

sel is below 3 bar.
Read the detailed instructions on section “Blockage dur-
ing tank filling”
2. Back blowing vessel selector
Use
– Select vessel “A”
– Select vessel “B”
100121643 1 - 1 EN 0918 ettekma 29 (77)

5.6. Connector Sets

A) At the mobile elevating work platform.
Note!
Connectors must not be connected or disconnected

while the supply voltage is on. Removing the cord plug
of the remote control unit or the hood from the housing
turns the emergency stop feature on. Put the hood into
the housing when the remote control unit is not in use.
1
2
Fig. 11. Connector
1. Housing
2. Hood
100121643 1 - 1 EN 0918 ettekma 30 (77)

5.7. Hose Connections
2
1
Fig. 12. Air lines
1. Pressure air shut off valves and claw couplings for air take-out.
2. Pressure air shut off valves and claw couplings for air in.
Fig. 13. Quick acting coupling

3. 1. Couple the charging hose to the nozzle of the quick acting coupling.
100121643 1 - 1 EN 0918 ettekma 31 (77)

5.8. Pressure Release Valves For Charging Hose
Fig. 14. Vessel actuator pressure air release valve

Release pressure from the charging hose before opening any connections.
100121643 1 - 1 EN 0918 ettekma 32 (77)

5.9. Emergency stop
Purpose
To engage
To reset
100121643 1 - 1 EN 0918 ettekma 33 (77)

6. FILLING THE VESSELS
6.1. Procedure
1. Turn the gear selector switch in the drive cabin to the N (neutral) position
2. Engage the safety/parking brake before starting to operate.
3. Release the pressure from the explosive tank by pushing the tank control valve
lever. Check that the hydraulic oil pressure gauge shows 70 bar.
Fig. 16. Tank control valve lever
100121643 1 - 1 EN 0918 ettekma 34 (77)

4. Place the Anfo bulk bag onto the hopper unit.

– Let the contents drop into the hopper.
Fig. 17. Bulk bag
100121643 1 - 1 EN 0918 ettekma 35 (77)

5. Fill the explosive tank with the explosive substance by pushing the vacuum
pump control valve lever. The tank air pressure gauge pointer gradually drops to
- 0,5...-1 bar when actuating the valve lever.
Fig. 18. Vacuum pump control valve lever
100121643 1 - 1 EN 0918 ettekma 36 (77)

6. The explosive tank is full when the gauge pointer shows close to -1 bar. Release
the vacuum pump control valve lever when the vessel is full.
Fig. 19. Vacuum pump control valve lever
100121643 1 - 1 EN 0918 ettekma 37 (77)

7. Start the compressor.

8. Pull the tank control valve lever so that the explosive tank gets pressurized.
Fig. 20. Tank control valve lever

9. Explosive tank is now ready for charging.
100121643 1 - 1 EN 0918 ettekma 38 (77)

6.2. Blockage during tank filling

The procedure is as follows if there occurs a blockage during filling the explosive tank.
Danger!
Make sure before starting up this operation that there is

no one behind the danger area of the filling hopper.
Pressurized explosive substance escaping from the sys-
tem can penetrate the skin and cause serious injury. Use
safety glasses!
1. The explosive tank is filled with the explosive substance by pulling the vacuum
pump control valve lever but the tank filling is not successful because of a block-
age.
100121643 1 - 1 EN 0918 ettekma 39 (77)

2. Pressurize explosive tank a certain extent by pushing the tank control lever.
Warning!
Back blowing is allowed only when pressure in the ves-

sel is below 3 bar. Make sure that there is no camlock
plugs attached to the hoses.
3. Release the pressure from the explosive tank by pulling the tank control valve
lever forward.
4. Turn the vessel selector switch and at the sametime press the back blowing
switch.
– The remaining air pressure from the explosive tank pushes the blockage back
to the hopper.
1 2
Fig. 21. Terminal Box
1. Back blowing
2. Vessel selector
100121643 1 - 1 EN 0918 ettekma 40 (77)

7. PREPARATORY TASKS
7.1. Adjustments
1. Adjust the vessel air pressure by turning the pressure regulator knob
– To a pressure of 3.5 bar (0,35 MPa) when using NH4NO3/oil.
– Lock the knob.
2. Adjust the extra air flow as required by turning the flow control valve hand wheel.
Drift charging
– Open the hand wheel 1/2 - 1 turns or more if needed.
Stope charging
– Open the hand wheel 2 - 5 turns(@ 6 m3) or more if needed.
3 4
Fig. 22. Valves
1. Pressure regulator valve

2. Flow control valve
3. Vessel air pressure gauge
4. Extra air pressure gauge
100121643 1 - 1 EN 0918 ettekma 41 (77)

ANFO tank pressure regulator
To increase pressure turn rotary knob to clockwise.
To decrease pressure turn rotary knob to anticlock-

wise.
One rotation of the knob changes the pressure

approximately 0,04 MPa. (0,1 MPa = 1 Bar)
Extra air flow control

To increase flow turn rotary knob to anticlockwise.
To decrease flow turn rotary knob to clockwise.
Flow @ 0.5 MPa (0.1 MPa = 1 Bar)

r open l/min
1 1800
2 2900
3 3500
4 4200
5 6000
6 9000
7 12500
8 15000
9 16200
10 16900
100121643 1 - 1 EN 0918 ettekma 42 (77)

7.2. Charging Start-up

A) Driving
1. Before driving into a tunnel, check the following:
– That entry into the tunnel is safe.
– That there is no risk of damage to the charging unit.
2. Apply the safety/parking brake.
3. Set the carrier body straight.
– Extend and lower the support legs.
4. Walk to the tunnel drift and check that the charging site is in the appropriate con-
dition.
– Are there any rocks in the tunnel roof or walls that could come loose?
– Are there any other factors affecting safety and charging?
5. Perform scaling in accordance with the work instructions if necessary.
6. Put up a works warning sign.
B) Charging from the work platform

1. Extend the MEWP telescope.
– The work platform should be as close to the ground as possible.
– This enables the work platform to be accessed easily and safely.
2. Close the work platform gates carefully.
3. Continue working in accordance with the charging instructions.
Danger!
Transport of electric detonators on this carrier is

prohibited.
100121643 1 - 1 EN 0918 ettekma 43 (77)

8. BLOWING
8.1. Borehole Cleaning

1. Feed the charging hose into the borehole and to the bottom of the hole.
2. Connect the charging unit to the compressed air net by means of claw coupling
or use compressor.
3. Blow the borehole clean.
Fig. 23. Blow control
100121643 1 - 1 EN 0918 ettekma 44 (77)

8.2. Charging The Borehole

1. Blow the borehole clean.
Detonator/primer
– Interrupt the charging cycle to the desired detonator/primer site.
– Feed the primer cartridge with a detonator or other approved ignition sub-
stance to the borehole.
– A sufficient quantity of primer is needed to properly ignite the loaded borehole.
– The detonator conductors, whether cord or Nonel type, must follow the bore-
hole during charging hose feeding.
Note!
The primer must be hard cored.

2. Feed the charging hose to the bottom of the borehole.
3. Withdraw the charging hose approximately 30 cm.
4. Keep in the charging hose with a firm grip as near the drill hole as possible in
order to avoid recoil.
5. Start feeding explosive.
6. Withdraw the charging hose using proper speed.
7. Stop charging at the desired position according the charging schema.
– the bottom valve is closed by pressing the black button of the hand valve.
8. The remaining explosive substance is charged with the help of pressure still
remaining in the charging hose.
– Put a mark on the hose, e.g. with white tape, from where this charging is suc-
ceeding best.
9. The charging speed is changed by changing the pressure in the vessel with the
help of the pressure reduction valve.
10. Move to the next borehole.
100121643 1 - 1 EN 0918 ettekma 45 (77)

The speed is selected on the basis of:

• the quality of the explosive
• the diameter of the borehole
• the length of the charging hose
• the capacity and type of charging unit
Note!
Too slow a charging hose speed will increase spillage and dust formation.
Too high a speed can result in an inconsistent charge in the borehole.
Keep the speed a just above the speed at which spillage occurs.
The speed of charging is affected negatively if the loading hose is permitted to lie with
sharp bends. This also increases the wear of the hose.
It is important to keep the correct distance between the charge column in the borehole
and the mouth of the hose. If this distance is increased or reduced, the charge density
is negatively affected.
The detonator must be protected against damage during the charging operation. The
detonator can be inserted in an explosives cartridge or protection shell.
When using cartridges, so-called tube loads, a single cartridge may be sufficient. This
is used as the primer cartridge, with the detonator placed away from the bottom of the
borehole.
All remaining explosive must be charged from the hose when charging the final bore-
hole, or prior to a lengthy break in charging work.
Caution!
Check that there always is enough explosive in the charging unit during charging. If
the hose runs empty, it can be ejected from the borehole, causing potential injury to
the operator.
100121643 1 - 1 EN 0918 ettekma 46 (77)

8.3. Charging Faults
Initial Data
Drift charging
– Vessel air pressure 2.0 – 3.5 bar.
Stope charging
– Vessel air pressure 2.0 - 5.0 bar.
Definition
Increased extra air
– Increases ANFO speed in the charging hose.
– Decreases ANFO volume in the charging hose.
– Decreases the charging capacity.
Increased vessel pressure
– Increases ANFO speed in the charging hose.
– Increases the charging capacity.
100121643 1 - 1 EN 0918 ettekma 47 (77)

No ANFO flow from the charging hose

A) ANFO clogging in the vessel’s base cone.
Remedy alternatives
– Release the pressure by opening the pressure air release valve.
Fig. 24. Pressure air release valve and cam lock
100121643 1 - 1 EN 0918 ettekma 48 (77)

a. Open the vessel lid and clear the blockage with a rod.
Fig. 25. Pressure air release valve and cam lock
b. Open the bottom valve by pressing the charging button.

c. Open the cam lock beneath the vessel and clear the blockage with a rod.
– Increase the vessel pressure to 5.0 bar.
B) The charging hose has sharp bends.

Remedy alternative
– Straighten the charging hose.
C) The charging hose is blocked.
Remedy alternatives
– Physically remove the blockage.
– Shake the hose.
– Pulse air down the hose to clear the blockage.
100121643 1 - 1 EN 0918 ettekma 49 (77)

Poor ANFO flow

– Poor flow during charging.
– No ANFO backflow from the borehole.
– Optional charging; ANFO backflows continually from the borehole in powder
form.
Remedy alternatives
– Increase extra air.
– Increase vessel pressure.
ANFO pressure too high

A) ANFO exits the charging hose at too high pressure.
– Difficult to handle the charging hose.
Remedy alternatives
– Decrease the vessel pressure.
– Decrease the extra air.
B) Too much ANFO backflows from the borehole.
Remedy alternatives
– Draw back the charging hose a little faster.
100121643 1 - 1 EN 0918 ettekma 50 (77)

Too much ANFO packed into the borehole

A) ANFO consumption too high.
Remedy alternatives
B) The charging hose is drawn back too slowly.
– Charge will not be homogeneous.
– ANFO backflows from the borehole.
Remedy alternative
– Draw the charging hose back a little faster.
C) Wrong distance between the charge column and the mouth of the charging hose
in the borehole.
– The charge density is negatively affected if this distance is increased or
reduced.
– The charge density is too small if the distance is too big.
– No ANFO backflow if the distance is too big.
– ANFO backflows continually from the borehole if the distance is too small.
Remedy alternative
– Keep the correct distance.
100121643 1 - 1 EN 0918 ettekma 51 (77)

Too little ANFO from the charging hose

A) ANFO vessel is almost empty
– The charging hose can be ejected from the borehole, potentially injuring the
operator.
Remedy alternatives
– Make sure that there always is enough ANFO in the vessel during charging.
– Hold the charging hose firmly.
B) Vessel pressure and extra air pressure are in the wrong ratio.
Remedy alternative
– Adjust the initial data adjustments.
ANFO doesn’t stick in the borehole

Remedy alternatives
– Increase the extra air.
– Increase the vessel pressure.
– Finish the up-hole charging using the blowing function.
Note!
Blow the charging hose clean after charging is complet-

ed. Residual explosive can become encrusted on the
charging hose, making subsequent charging difficult or
impossible.
100121643 1 - 1 EN 0918 ettekma 52 (77)

9. LUBRICANT RECOMMENDATIONS
9.1. Vacuum Pump
Lubrication oil consumption
Pump type Oil consumption l/h Reservoir capacity in litres

SLS34 0,07 2,6
Oil recommendation
It is recommended to use the following lubrication oils.
– Do not use multigrade oils.
Fig. 26. Oil recommendation plate
100121643 1 - 1 EN 0918 ettekma 53 (77)

10. MAINTENANCE SAFETY RULES
10.1. Hot Work During Maintenance

Do not perform hot work until you have checked that there are no detonators or explo-
sives on the carrier.
Hot work fulfills two different conditions.
Hot work involves an ignition source.

– The scope of hot work includes all gas and arc welding that causes sparking,
flame and arc cutting, disc cutting, and grinding of metals. Hot work is also
considered to include work utilizing a gas burner, other types of open flame, a
hot-air blower, or similar tools that produce strong heat emissions.
The work causes a fire hazard within the work environment.

– Hot work constitutes a high safety risk and is subject to several legislative
restrictions and regulations. Hot work legislation requires careful planning,
prevention of accidents, and preparation for accidents, to ensure the safety of
people, the environment, and property.
Hot work must be performed in compliance with a specific standard.

– SFS 5900: Hot work safety in assembly, maintenance, and repair work.
100121643 1 - 1 EN 0918 ettekma 54 (77)

10.2. Fire Prevention Measures

1. Do not smoke or allow open flames near to the charging carrier.
2. Ensure that there are no fire hazards in the vicinity of the charging carrier.
3. Do not store the charging carrier near to where blasting work is being conducted.
4. Carefully clean the charging unit before driving the charging carrier to the work-
shop.
– Remove all ANFO from the charging vessels.
– Remove all remaining explosive.
– Remove all detonators and explosive cartridges from the work platform.
– Carefully clean the carrier and charging unit.
– Remove any flammable material, such as greasy cloths.
Caution!
Ensure that you know the location and proper use of

safety devices and fire-extinguishing equipment, alarm
systems, and emergency exits.
100121643 1 - 1 EN 0918 ettekma 55 (77)

10.3. General Instructions

1. Carefully clean the charging unit, removing all explosives, before making any
repairs to the charging carrier.
2. These instructions cover the most important maintenance-related issues.
3. Use these instructions in combination with the separate maintenance instruc-
tions delivered with the carrier instructions.
4. When servicing the charging unit, it is important to protect the unit against inap-
propriate use and unnecessary wear.
5. Persons performing installation, connection, start-up, maintenance, and repair
work must take into account the following:
– These instructions.
– Other instructions concerning the unit and its installation.
– Warnings and other signs displayed on the charging unit.
– All regulations and requirements set for the system in which the charging unit
is used.
– Currently applicable national and local regulations.
Caution!
The charging unit must not be altered or modified with-

out approval from the appropriate entities. The charging
unit may be modified with the manufacturer’s permission
only.
100121643 1 - 1 EN 0918 ettekma 56 (77)

10.4. Maintenance Instructions

1. Only the following repairs may be made without the supervisor’s permission:
– Repairs that are necessary to avoid danger.
– Standard repairs related to the normal charging process, such as tightening of
loosened hoses.
2. Remember that the charging carrier has
– pressurized hoses.
– toxic and oxidizing substances.
3. Do not perform any electrical work yourself.
– Electrical work must be performed by skilled professionals only.
4. Before making any repairs, remember to clean the carrier and charging unit.
5. When repairs are to be made by a third party, follow these steps:
– Remove all explosive from the carrier and charging unit.
– Clean the carrier and charging unit.
– Remove all detonators and explosive cartridges from the carrier.
6. Repairs must be made outside the mine area or quarrying site.
– Remove all explosives from the charging carrier.
– Lower the mobile elevating work platform onto its transport support.
– Lock all doors and latches that need not be open to enable repairs.
– Fasten the transport plates to the carrier.
7. Supervise the repairs if necessary.
– Machining or welding of parts whose cleanness cannot be ensured before dis-
assembly.
8. After maintenance and repair work, check that:
– the pumps are intact.
– the hydraulic and pneumatic motors rotate in the correct direction.
– there are no foreign objects in the vessel.
– the vessels are clean, clean them if necessary.
– all hoses are connected correctly.
– there are no flammable substances on the carrier, such as greasy cloths.
9. Keep a record of the repairs made, and show it to your supervisor as soon as
possible.
100121643 1 - 1 EN 0918 ettekma 57 (77)

11. MAINTENANCE
11.1. General
1. Empty all remaining ANFO in the vessel into the storage container after charging
work is finished for the day.
– Put the charging hose into the storage container.
– Charge the remaining ANFO into the storage container.
2. Blow the charging hose clean.
– Keep the charging hose end in the storage container to prevent the explosive
from being blown around.
– It is important that the charging hose is blown clean, as any remaining explo-
sive can become encrusted on the hose, rendering subsequent charging diffi-
cult or impossible.
– Clean the hose using the same method used to clear charging hose block-
ages.
3. Always clean the charging unit carefully to remove any remains of explosive after
finishing charging work and before carrying out repair work on the unit.
– Clean the unit also when it is not in daily use.
– Clean at minimum by wiping down.
– Oil all valves and couplings.
– Flush clean with water.
4. Valves may not function initially if the charging unit has been out of use for some
time.
Note!
No changes or modification of the unit are permitted

without the consent of the stated authorities. The charg-
ing unit must only be used in the operating conditions in-
dicated in this manual.
Warning!
Before opening any connections ensure that all compo-

nents, pipes, hoses and pressure vessels are unpres-
surized.
100121643 1 - 1 EN 0918 ettekma 58 (77)

11.2. Maintenance Schedule

1. Drain water from the modular type air filter.
2. Drain water from the water separator.
3. Check the lubricator drippage amount and oil level.
4. Keep the pressure vessel and charging unit clean.
5. Check the interior and exterior condition of the vessel.
6. Check the wear of the charging hose.
7. Check the total resistance between earthing strap and free end of the charging
hose.
8. Check the resistance between earthing strap and ANFO charger quick acting cou-
pling.
9. Check the vacuum pump oil level.
Every 500 Hours

10. Clean the modular type air filter element.
11. Measure the earthing strap resistance.
12. Clean the vacuum pump oil reservoir.
As Required
13. Change the water separator filter element
14. Fix the connections of the earthing straps and earthing points.
15. Replace the earthing straps.
16. Clean the cyclone separator filter element.
100121643 1 - 1 EN 0918 ettekma 59 (77)

11.2.1.Daily or once per shift (10 hours)

ITEM 1
Drain water from the modular type air filter.
1. Drain water from the modular type air filter in the air intake line.
– The condensate level must never rise sufficiently high for the air to become
recontaminated.
– The level must therefore be checked and condensate drained regularly.
2. Depressurize the unit before removing the bowl.
3. Clean the bowl with neutral detergent.
Warning!
Prevent the unit from soiling with synthetic oils, organic

solvents, chemicals, cutting oils, screw tightening agent,
etc. Protect from ultraviolet light.
Max drain level
Fig. 27. Modular type air filter
100121643 1 - 1 EN 0918 ettekma 60 (77)

ITEM 2
Drain water from the water separator.
Discharge the drain before the drain fluid surface reaches the center of the sight glass.
– Use the drain valve.
Fig. 24. Water separator
100121643 1 - 1 EN 0918 ettekma 61 (77)

ITEM 3
Check the lubricator drippage amount and oil level.
1. Check the drippage daily.
– Drip failure can cause damage to components requiring lubrication.
2. Adjust the amount of lubricant using the needle on the front face.
– Turning the needle clockwise increases the amount of lubricant.
– Turning the needle counter-clockwise until fully opened shuts off the lubricant.
3. Depressurize the unit before removing the bowl.
4. Clean the bowl with neutral detergent.
5. Fill the bowl with ISO VG 32 Industrial fluids.
– Filling amount 1,35 dl.
Warning!
Do not introduce air from the outlet side as this can dam-
age the damper. Prevent the unit from soiling with syn-
thetic oils, organic solvents, chemicals, cutting oils,
screw tightening agent, etc. Protect from ultraviolet light.
Needle
Max. oil level
Min. oil level

Min. oil level
Fig. 28. Lubricator
100121643 1 - 1 EN 0918 ettekma 62 (77)

ITEM 4
Keep the pressure vessel and charging unit clean.
1. Thoroughly clean all explosive from the unit.
– Explosives have a corroding effect on machinery.
2. Lubricate the O-rings of all valves with moving parts.
– Once or several times each month.
– In addition to cleaning the valves, lubrication will prevent the valves from jam-
ming.
– Cleaning is recommended by the explosive suppliers.
ITEM 5
Check the interior and exterior condition of the vessel.
1. Check the pressure vessel periodically as part of normal maintenance opera-
tions
– To observe fouling, which interferes with the explosive flow.
– To ensure safe operation prior to vessel inspection, repairs and charging.
2. Inspect especially for rust, dirt and other debris formed or entered into the unit
during fabrication, shipment, or erection that are likely to cause damage after
start-up.
– There should be no visible fractures or cracks in the vessel.
100121643 1 - 1 EN 0918 ettekma 63 (77)

ITEM 6
Check the wear of the charging hose.
A) Check the wear
1. Check the charging hose at each workshift.
– In addition to outer mechanical wear, the lifetime of the charging hose is also
limited by internal wear.
– Internal wear cannot be visually inspected.
2. Replace the charging hose before unforeseeable failures occur, e.g. due to
cracking or hose rupture:
– Inspect visually.
– Bulges are a sign of a failing hose.
– If in doubt, replace the hose.
3. Hose conductivity is known to vary with age and usage.
– Periodic replacement or testing is necessary to ensure safe values are main-
tained.
Danger!
The resistance of the charging hose must be minimum 1

KΩ/m and maximum 30 KΩ/m. The hose must be
marked to make it easily discernible from hoses of other
types.
B) Replacing the charging hose.

1. Connect the charging hose to the cam lock coupler nozzle.
– Heat a 15–20 cm section of the free end of the hose in hot water.
– Expand the end using a rounded, oiled rod.
– Do not use a longer hose than necessary.
– The charging capacity reduces in proportion to the hose length.
2. Connect the cam lock coupler to the Y branch female cam lock adapter.
3. Attach a piece of tape near the free end of the hose to indicate the point at which
hole charging should be discontinued.
100121643 1 - 1 EN 0918 ettekma 64 (77)

ITEM 7
Check the total resistance between earthing strap and free end of the charging hose.
– Measure the resistance of the earthing straps (engine end/load end/support
legs) separately.
• Between points 1-4, 2-4 and 3-4.
– Use classified measurement device.
– Use MΩ scale in the measurement device.
– Measured value must be under 5 MΩ.
– Fix the earthing connections if measured resistace is over 5 MΩ.
1
2
Fig. 29. Resistance measurement
1. Support leg earthing straps

2. Load end earthing strap
3. Engine end earthing strap
4. Charging hose
Note!
Measured resistance value must be under 5 MΩ.
100121643 1 - 1 EN 0918 ettekma 65 (77)

ITEM 8
Check the resistance between earthing strap and ANFO charger quick acting
coupling.
– Measure the resistance of the earthing straps (engine end/load end/support
legs) separately.
• Between points 1-4, 2-4 and 3-4.
– Use classified measurement device.
– Use MΩ scale in the measurement device.
– Measured value must be under 1 MΩ.
– Fix the earthing connections if measured resistance is over 1 MΩ.
1
2
Fig. 30. Resistance measurement
1. Support leg earthing straps

4. ANFO charger quick acting coupling
Note!
Measured resistance value must be under 1 MΩ.
100121643 1 - 1 EN 0918 ettekma 66 (77)

ITEM 9
Check the vacuum pump oil level.
1. Check the oil level in the oil reservoir daily via the dipstick.
– The oil must be topped up immediately whenever the oil level drops to the
lower notch.
– Never allow the oil level to drop below the minimum level.
2. Remove the oil filler cap and top up the oil reservoir.
3. Close the oil filler cap firmly after filling the reservoir.
Fig. 31. Vacuum pump
100121643 1 - 1 EN 0918 ettekma 67 (77)

11.2.2.Every 500 Hours

ITEM 10
Clean the modular type air filter element.
1. Clean the filter element with standard solvents.
– The filter element can be easily replaced without using tools and without
removing the filter body from the piping system.
2. Avoid contact of solvent with the bowl.
Fig. 32. Modular type air filter
100121643 1 - 1 EN 0918 ettekma 68 (77)

ITEM 11
Measure the earthing strap resistance.
– Measure each earthing strap separately.
– Use only classified measurement device.
– Use Ω scale in the measurement device.
1. Connect a measurement wire to one end of the earthing strap.
2. Connect the second measurement wire to the another end of the earthing strap.
– Measured value must be under 0.5 Ω.
– Replace the earthing strap if measured resistance is over 0.5 Ω.
Fig. 33. Resistance measurement points
Note!
Measured resistance must be under 0.5 Ω.
100121643 1 - 1 EN 0918 ettekma 69 (77)

ITEM 12
Clean the vacuum pump oil reservoir.
1. Clean the oil reservoir every 500 hours.
2. Drain off the lube oil with the pump on standstill.
– Open the hexagonal plug and drain the oil.
3. Flush the oil tank with flushing oil.
4. To prelubricate, inject about a ¼ litre of oil into the intake socket.
– Repeat every 15 minutes during the initial 1-2 operating hours.
Note!
Do not rinse the oil reservoir with solvent or degreasant!

Do not forget to pre-lubricate before renewed use!
1 2
Fig. 34. Vacuum pump
1. Hexagonal plug
2. Sealing ring
100121643 1 - 1 EN 0918 ettekma 70 (77)

11.2.3.As Required
ITEM 13
Change the water separator filter element
1. Replace the element every 2 years or when the pressure drop reaches 0.1MPa,
whichever comes first, to prevent damage to the element.
2. Replace the old element with a brand new element.
– Replace also the O-ring and gasket.
Fig. 35. Dimensioned drawing
100121643 1 - 1 EN 0918 ettekma 71 (77)

ITEM 14
Fix the connections of the earthing straps and earthing points.
Check the earthing links if the measured resistances are too high.
Make sure that:
– there is no corrosion on the earthing straps or cables.
– contact between earthing straps, cables and carrier frame are in good condi-
tion.
– earthing straps and cables are secured.
1 2 3
4 5 6
Fig. 36. Earthing straps and cables

3. Earthing cable under the cabin
4. ANFO vessel earthing cable
5. Middle joint earthing cable
6. Support leg earthing cable
100121643 1 - 1 EN 0918 ettekma 72 (77)

ITEM 15
Replace the earthing straps.
Replace the earthing strap if the measured resistance is too high (>0.5 Ω).
Procedure:
1. Open the earthing strap mounting nut or bolt.
2. Replace the earthing strap with a new one.
– Remove dirt and corrosion from the connection point.
3. Tighten the earthing strap mounting nut or bolt.
– Tightening torque 47 Nm.
100121643 1 - 1 EN 0918 ettekma 73 (77)

ITEM 16
Clean the cyclone separator filter element.
The condition of the ANFO used (moisteness, powderiness etc.) determines the filter
cleaning cycle. Clean the filter element when:
– Vacuum pump output reduces.
– Vacuum pump sound changes.
Maintenance sequence
– Clean the filter element using a high pressure washer.
– Replace the filter element.
4
2
1
3
Fig. 37. Cyclone separator
1. Quick -release clamp

2. Filter housing
3. Wing nut
4. Filter element assembly
100121643 1 - 1 EN 0918 ettekma 74 (77)

Clean the filter element using a high pressure washer.

1. Open the housing by releasing the quick-release clamp.
2. Unscrew the wing nut.
3. Remove the filter element assembly from the housing.
4. Wash the filter element assembly using a high pressure washer.
– Use steam or high pressure water, max. 100 bar.
5. Dry the filter element assembly with compressed air.
6. Place the filter element assembly back into the housing.
7. Replace the wing nut and tighten.
8. Install the quick-release clamp.
– Make sure that the housing is sealed completely.
Fig. 38. Using a high pressure washer
100121643 1 - 1 EN 0918 ettekma 75 (77)

Replace the filter element.

Replace the filter element if the filter element is heavily clogged.
– Cannot be cleaned using a high pressure washer.
1. Remove the lock ring and the inner screen frame.
2. Insert a new filter element in the outer screen frame.
3. Insert the inner screen frame and the lock ring.
– Attach the lock ring to the top part of the filter element.
– See the arrow in the figure below.
1 2
Fig. 39. Filter element assembly.
1. Outer screen frame

2. Inner screen frame
3. Filter element
4. Lock ring
100121643 1 - 1 EN 0918 ettekma 76 (77)

NOTES
100121643 1 - 1 EN 0918 ettekma 77 (77)

1 --- 1 GB 0996 US
Safety Instructions
Normet Vehicles and Equipment
SAFETY INSTRUCTIONS
Code: . . . . . . . .
Carrier No. . . .
Equipment: . . .
This manual is a guide to the safety instructions of the vehicle. In respect of opera-
tion the equipment outfit over the vehicle causes changes and additions which must
be considered separately. The information contained in this manual is current for the
standard vehicle. Continued product improvement, and different versions of the
equipment may result in changes to the vehicle which are not covered.
Normet Oy Tel. . . . . +358 (0)17 83 241

Ahmolantie 6 Fax. . . . +358 (0)17 8324 308
FI--74510 IISALMI e--mail: info@normet.com
.
FINLAND www. .normet.com
.
1 --- 1 GB 0996 US
Safety Instructions
CONTENTS
1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page . . . 3
2. Terms and symbols used in the operating instructions . . . . . . . . . . . . . . . 4
3. General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Safety instructions in manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1. Safety instructions of the operating instructions . . . . . . . . . . . . . . . . . . . . 6
4.2. Safety instructions of the workshop manual . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Instructions and warnings in the equipment . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. Instructions for the owner and operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1. Working environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.2. Operation of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3. Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.4. Distribution of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.5. Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7. Operator suitability and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.1. Operator suitability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.2. Operator responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.3. Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8. Summary of the most important instructions
to prevent damage and maintain safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9. Operation of the machine or equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.1. Safety instructions prior to operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.2. Starting up the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9.3. Safety instructions for the operation of the equipment . . . . . . . . . . . . . . . 19
9.3.1. Safety instructions for boom operation . . . . . . . . . . . . . . . . . . . . . . 20
9.3.2. Safety instructions for lifting platform operation . . . . . . . . . . . . . . . 21
9.4. Operation in cold conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.5. Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.5.2. Correct operation of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.5.3. Incorrect operation of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.6. Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.7. Working methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.8. Stopping the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.9. Ending of shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.10. Dowage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.11. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Page 1 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

10. Lifting cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page . . . 29
10.1. Taking the lifter into use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.2. Instructions for safe lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.3. Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11. Lifting people . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.1. General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.2. Preparing the lifting equipment for operation . . . . . . . . . . . . . . . . . . . . 35
11.3. Instructions for the operation of the lifter . . . . . . . . . . . . . . . . . . . . . . . . 36
12. Maintenance and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
12.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
12.2. General safety instructions for maintenance . . . . . . . . . . . . . . . . . . . . . 39
12.2.1. Safety instructions for servicing the booms . . . . . . . . . . . . . . 40
12.2.2. Safety instructions for servicing the lifting platform . . . . . . . . 41
12.3. Oils, greases and fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
12.4. Adding fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
12.5. Engine service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
13. Safety instructions for repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
14. Safety instructions for electric circuits and equipment . . . . . . . . . . . . . . 46
14.1. Electric system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
14.2. Electric equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
14.3. Electric lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
14.4. Contact with electric line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
14.5. Measures to be taken in case of bodily injury . . . . . . . . . . . . . . . . . . . 49
14.6. Service of electric equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
14.7. Service of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15. Safety instructions for the hydraulic circuits . . . . . . . . . . . . . . . . . . . . . . . 52
16. Safety instructions for compressed air hoses and water pipes . . . . . . 55
Page 2 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
1. FOREWORD
These safety instructions are intended for both the owner of a Normet
machine and the persons who operate, service and repair the machine or
equipment.
The instructions help you to:

D familiarize yourself with the safe operation of the machine.
D operate the machine safely in order to avoid any damage.
D use the machine appropriately and productively.
D notice, avoid and prevent possible dangerous situations.
These instructions have been provided by the manufacturer. The instructions
must be kept in a special place reserved for them in the machine and they
must always be available at the work site.
All operators are obliged to familiarize themselves with the safety and
operating instructions of the equipment and apply them in practice.
Operation of the equipment

--- In preparatory work, fault finding, handling of raw materials and auxiliaries
Service of the equipment
--- In inspections and repair work
Transportation of the equipment
The machine is in accordance with the technical requirements and the existing
and necessary safety regulations. Despite this, faulty operation, service and
repair may cause danger.
The requirement for all operation is that the operator is familiar with the
operating instructions and follows them. It is therefore recommended that the
instructions are read through several times and that the operator becomes
familiar with the machine before it is taken into use.
In addition to the operating instructions, the operator must remember to act in
accordance with the regulations of the local labour protection authorities, and
the laws and statutes of the user country.
Using the equipment for any other task than for which it has been designed or
to exceed its operating capacity is considered inappropriate usage. Any other
kind of use of the equipment or machine is not acceptable. The manufacturer/
supplier does not assume liability for a damage resulting from such usage.
Page 3 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
2. TERMS AND SYMBOLS USED IN THE OPERATING

INSTRUCTIONS
The following terms and symbols are used in the operating instruction when
giving important instructions. Pay attention to the warnings indicated with the
following terms and symbols and follow them.
! DANGER
When there is an immediate danger, which
may cause a dangerous bodily injury or
death.
! WARNING
When there is a danger, which may cause a
bodily injury.
! CAUTION
When there is a danger or misuse, which may
damage property.
To remind you of the things related to service or repair

work, which you should remember, check or do.
Page 4 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
3. GENERAL SAFETY INSTRUCTIONS

1. Combine the work safety instructions related to the equipment and all oth-
er work safety instructions of your company so that the operation of the
equipment meets both regulations.
2. Make sure that everyone who uses the machine is familiar with the manu-
al, the contents of the safety instructions applying to each case and that
he has been trained appropriately before taking the machine into use.
3. Familiarize yourself with the capacity and limitations of the machine and
equipment and the most effective operating technique.
4. Familiarize yourself with the use and operation of the machine in detail be-
fore taking it into use.
5. Familiarize yourself with the danger areas of the machine and prevent
people from entering these areas.
6. Do not walk or stand in the immediate vicinity of the machine, when it is in
operation. During operation, prevent all unauthorized people from enter-
ing the working area.
7. Make sure that all operators are provided with the necessary safety equip-
ment such as a helmet, safety glasses, boots and the necessary safety
clothing. Make sure that the equipment is operated in accordance with the
regulations of the Labour Protection Law.
8. Keep the working platforms clean and free from any extra materials to pre-
vent slipping and tripping.
9. Do not stand up or try to leave the machine, when it is in operation.
10. Always keep a first aid kit in the machine.
11. Transporting passengers anywhere other than in a place provided for this
purpose is strictly forbidden.
12. It is forbidden to use a machine which is out of order or faulty.
13. Never operate the machine, when under the influence of alcohol or other
intoxicating substance.
14. Depending on its type, the machine has different kinds of safety equip-
ment and safety guards. The purpose of these is to protect the equipment
and its operator and, under no circumstances, should they be changed or
removed.
Page 5 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
4. SAFETY INSTRUCTIONS IN MANUALS
4.1. SAFETY INSTRUCTIONS OF THE OPERATING INSTRUCTIONS

Safety instructions, legal provisions and actions classified as follows are used
and followed in the operating instructions depending on the machine,
conditions and requirements.
1. General safety instructions
2. Safety instructions related to operation including e.g.
--- A description of the safety equipment installed and of their operation.
The safety equipment must not be removed from the machine without the
consent of the manufacturer and the machine must not be used when the
safety equipment is broken.
--- Statutory instructions when requested and when necessary
Labour protection law, statutory regulations, national standards and regu-
lations, international standards and regulations, safety instructions related
to pneumatic equipment
--- Danger to the machine caused by the environment
Electric wires, pressure lines, weather conditions, pits, falling objects, soil
--- Danger to the environment caused by the machine
Bordering the working area, Road Traffic Law
--- In the event of an accident
Measures, emergency exit, extinction
--- Due to the machine structure
Permitted load, cleaning, extra materials, dangerous movements and their
restriction, legal requirements, testing what could go wrong when using
the machine, controls, starting the machine, operating the machine, ulti-
mate operation, unwanted operators
3. Safety instructions for service
4. Specified safety instructions
5. Safety instructions related to the equipment
--- Statutory instructions, labour protection law, statutory regulations, national
standards and regulations, international standards and regulations
4.2. SAFETY INSTRUCTIONS OF THE WORKSHOP MANUAL
General safety, and detailed safety instructions in the text itself.
Page 6 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
5. INSTRUCTIONS AND WARNINGS IN THE

EQUIPMENT
Warning and instruction plates classified as follows are used in the machines
depending on the equipment and requirements.
OPERATOR’S SAFETY
D Diagram of places of risk
D Warning of the frame joint
D Symbols of gauges, warning lights and control levers
CONDITIONS AND THE ENVIRONMENT
D Unobstructed starting
D Parking
D Transporting personnel
D Emergency stop
D Warning equipment, beacon, warning plates
OF THE EQUIPMENT
D Type plate
D Operating plate of the main switch
D Tyre pressure plate
D Operating instruction plate of the gearing
D Starting
D Inspection of the brakes
D Operating instruction plate of the parking brake
D Daily and weekly service instruction
D Symbols of the signal lights
D Instruction for the extinction equipment
D Instruction for extras as necessary
D Symbols of the safety equipment
The warning and safety equipment installed in the machine must neither be
changed nor removed, and they must be used correctly.
All safety and warning plates in the machine must be legible and undamaged.
A damaged plate must be replaced.
Page 7 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
6. INSTRUCTIONS FOR THE OWNER AND OPERATOR

These safety instructions must be complemented with instructions required by
the laws of the country, other minor statutory provisions and the regulations
provided by the authorities so as not to endanger the safety of the workers
and other people or of property.
6.1. WORKING ENVIRONMENT

Special care should be taken so that the equipment, machines, lifting
equipment, stock, tools, safety equipment, galleries, passages and mine
areas remain in an appropriate condition.
1. Explain to those working on the site the meaning of the warning plates
and lights of the equipment.
2. The working area must be kept clear of waste material and other extra
material. The tools such as belts, chains, hoses and others must be
checked regularly in case of wearing, looseness, braking or rubbing, and
damaged equipment must be removed immediately.
3. The surroundings of the equipment must be kept clean so that the emer-
gency stop button can be reached unobstructed. The location of the
emergency stop button must be shown to all those working on the site.
4. When the equipment is in operation, all unauthorized persons must stay
away from the working area.
5. All persons must keep away from the boom operating area.
6. Working may become dangerous due to operating conditions. It is always
dangerous to work on a slope. If necessary, the working area must be lev-
elled. The inclination values informed must not be exceeded.
7. If the work is done in the vicinity of an underground drain, electric wire,
gas, oil, or water pipe, always contact the owner of the pipe before you
start working. It can be decided in co---operation with the owner, which
measures should be taken in order to ensure complete safety. It is the re-
sponsibility of the operator and the proper representatives to take care of
the necessary safety precautions.
8. The working environment must be arranged so as to promote safety tak-
ing into consideration the quarrying methods, quarrying work and equip-
ment, blasting technique and preparatory work, loading and transporta-
tion, crushing of blasted rock, lifting methods, supporting and enforcing
methods, possible construction work, electric, water and air equipment,
ventilation, labour and fire safety and other possible safety measures.
9. Always follow the local environmental norms.
Page 8 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

6.2. OPERATION OF THE MACHINE
1. Only use the equipment for the purpose informed by the manufacturer.
2. Allow only qualified and trained personnel use and service the machine.
Make sure that the new operators have received guidance and training.
3. There must always be an updated operating instruction for the specific
machine available. Ask for a written confirmation from the personnel that
they have understood the operating, maintenance, repair and safety in-
structions of the equipment. The operator must sign a confirmation which
proves that he is familiar with the instructions.
4. Due to the design criteria, the noise level of the machine may exceed 85
dB(A). Use ear mufflers. Oblige the personnel to use additional safety
equipment (helmet, safety boots, safety glasses, gloves) as necessary.
5. Make sure that:
--- the use of faulty equipment is forbidden.
--- the warning and safety equipment installed in the machine have not been
removed or changed and that they are used correctly.
--- the safety equipment are installed back in their place immediately after
servicing has terminated.
--- regular safety tests and corresponding inspections are carried out.
6. It is to be noted that the manufacturer of the machine is not liable for dam-
ages caused by
--- faulty, careless and inappropriate use.
--- changes made without the manufacturer’s consent.
--- spare parts, which are not original.
--- natural wearing.
--- bringing the machine into a country without making amendments to the
regulations of the manual so that the provisions of the user country are
not taken into consideration.
--- operating errors caused by erroneous performances by an unqualified
person.
Page 9 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

6.3. PERSONNEL
1. When hiring new employees, the operators must undergo a medical ex-
amination and it is to be recommended that these examinations be per-
formed regularly also in future.
2. The safety requirements of the employer presuppose that each job has a
responsible person in charge of the safety issues. The employees must
know who this person is and be familiar with the safety regulations of the
job.
3. The employees must work in co---operation with the person responsible
and follow his instructions.
4. The employer/principal must clearly define the equipment user responsi-
bilities and forbid the employees to follow any instructions contrary to the
safety regulations.
5. New employees or persons being trained are only allowed to use, service
or repair the equipment under constant supervision of an experienced
person.
6. The operator must familiarize himself with the manuals provided by the
manufacturer and with the characteristics of the equipment.
7. In addition, the operator must have a permit granted by the authorities if
so required by law.
8. The employer must clearly define the qualifications required for the use,
installation, service and repair of the equipment.
6.4. DISTRIBUTION OF LIABILITY

Agree on the distribution of liability in writing.
D Organization
D Sub---contractors
D Casual labour
D Other possible cases
Agreements in which the manufacturer and representative limit the right of a
third person to compensation for bodily or material damage are not valid.
Instead, the parties may agree to divide the responsibility among themselves
or to limit it.
Page 10 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

6.5. TRAINING
1. The operator must be provided with training in operating and servicing the
equipment. The operator must familiarize himself with the manual pro-
vided by the manufacturer and be familiar with the performance values
and characteristics of the equipment he uses.
2. All persons using the equipment must receive appropriate training.
3. Make sure that new operating personnel is provided with training and
document this.
4. Do not use the machine before you have thoroughly familiarized yourself
with the location and operation of the steering and control equipment.
5. Practise the work phases dealt with in the operating instructions under the
supervision of an experienced expert till you master them yourself.
6. The operating personnel must familiarize themselves with the changes
made to the equipment.
7. The operating instructions of the extinguishing equipment are included in
the instruction glued on the side of the equipment.
Page 11 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
7. OPERATOR SUITABILITY AND RESPONSIBILITY
7.1. OPERATOR SUITABILITY

The machine can only be operated and serviced by a person who
D is at least 18 years old.
D is mentally and physically suitable for the job.
D has been trained for operating and maintaining the machine and who has
proved to the company to be qualified for this job.
D has proved to be skilful and conscientious and thorough in his work.
D is responsible and reliable.
D follows the instructions provided.
Page 12 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

7.2. OPERATOR RESPONSIBILITY
Occupational accidents often occur under unusual circumstances. It is
therefore important to take all possibilities into consideration, even the most
unlikely situations, which may occur in each job.
1. When using the equipment, the operator is responsible for the safety and
danger zone of the entire operating area of the equipment.
2. The operating safety of the equipment must be inspected every time be-
fore taking the equipment into use. If there are faults or defects to be de-
tected, they must be repaired immediately.
3. If it is impossible to abolish factors that endanger the operating safety, the
work must be terminated.
4. The operator is responsible for accidents caused by negligence and care-
lessness. If the operator has not been sufficiently trained, and he cannot
be made liable, the liability is transferred to his superior. It should also be
remembered to act in accordance with both the instructions given by local
labour protection authorities and the laws and statutes of the country.
5. All safety regulations must be followed.
6. All operating and service instructions must be followed.
7. Do not use any piece of equipment unless you have thoroughly familiar-
ized yourself with its operation.
8. The operator must be familiar with the operation of the equipment and all
its control devices.
9. The safety systems must never be bypassed or removed to facilitate the
job. The equipment must never be started up or used if any of the safety
protective devices has been removed.
10. Make sure before starting up or using the equipment that it will not cause
any danger to people or property.
11. The equipment must not be used for any other purpose than which it has
been designed for.
12. It is forbidden to exceed the performance values given.
13. It is forbidden to use the equipment when sick or under the influence of
alcohol or other intoxicating substance.
Page 13 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

7.3. SAFETY EQUIPMENT
The operator must always use the safety equipment required for the job or by
law such as a helmet, mufflers, safety glasses, overalls, safety boots or other
necessary safety equipment.
Fig. 1. Symbols of the safety equipment
Page 14 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
8. SUMMARY OF THE MOST IMPORTANT

INSTRUCTIONS TO PREVENT DAMAGE AND TO
MAINTAIN SAFETY
1. Only qualified and specially trained persons are allowed to use, service
and repair the machine. Remember to stress the liability of the personnel.
2. Work in accordance with the operating instructions, safety regulations and
warning plates when operating the machine and also pay attention to the
generally accepted regulations to prevent damage.
3. Use the machine correctly and appropriately. It is forbidden to work with
faulty equipment.
4. The warning and safety equipment installed in the machine must neither
be changed nor removed and they must be used correctly.
5. All the safety and warning plates in the machine must be legible and
whole.
6. Personal safety equipment must be worn inside the entire operating area
of the machine.
7. When in operation, the position of the machine must be in accordance
with the inclination values given.
8. Place the machine sufficiently far from pits, banks, electric wires hanging
above and from other obstacles.
9. It is forbidden to make any of the changes mentioned below without the
manufacturer’s consent
--- Extension of pressurized pipes and hoses.
--- The values set at the factory such as pressures, speed, capacity and the
adjustment of the safety valves.
--- Replacing the pipe and hose lines with one with a larger diameter or with
a heavier pipe or hose.
--- Structural changes affecting durability.
10. The pressure hoses must never be bent when the pump is in operation.
The danger of an obstruction caused by bending adds to the risk of an
accident.
11. Connect the different lines such as the pressure and water lines carefully
and safeguard them as necessary. Also remember the safety of the work-
ers.
Page 15 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

12. Do not place the remote control equipment on the ground. Carry the re-
mote control equipment so as to prevent any unintentional operation of
the machine i.e. so that the operating levers are not moved by mistake.
13. It is forbidden to haulage the machine when the extension boom is in an
outer position.
14. The operator must always have an unobstructed view over the working
area. If this is not possible, an assistant must be appointed.
15. When faults occur that decrease the operation safety, stop the machine.
16. The piping joints must not be opened when there is operating pressure in
the pipes. The pressure must be released before opening the pipe sys-
tem.
17. Never try to touch moving parts when the engine is running or the pres-
sure accumulator is pressurized.
18. Only authorized professionals are allowed to repair electric and hydraulic
damages.
19. Only persons authorized by the manufacturer are allowed to weld load
carrying structures. Ask an expert to check all welding.
20. Do not direct a water or steam jet at the electric cables.
21. Service the machine regularly at prescribed intervals and remember the
annual safety inspections.
22. When the shift ends, place the equipment installed on the machine e.g.
the boom, on supports.
23. Always protect the machine against unauthorized use and unintentional
operations when leaving it.
24. The spare parts and equipment must always meet the requirements of the
manufacturer. This can be ensured by using original spare parts.
Page 16 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
9. OPERATION OF THE MACHINE OR EQUIPMENT
9.1. SAFETY INSTRUCTIONS PRIOR TO OPERATION

1. Always make sure before entering the operator’s cabin that there are no
unauthorized persons near the machine.
2. Go into the machine and climb down from it with caution by using the
support handles provided. Beware of slippery surfaces.
3. Check the interior, surroundings, and underneath the machine before
starting it up or before it begins to operate.
4. Make sure that the safety brake has been engaged and that the gears are
disengaged before starting up the machine.
5. Make sure that all the controls are in the correct position before starting
up the engine.
6. If there is a warning sign on the starting switch or levers, the control
equipment in question must not be touched before the person who has
placed the sign or some other person familiar with the situation has re-
moved the sign.
7. Start up the engine only with the ignition switch.
8. Make sure that the machine is only used when it is safe and in operating
condition.
9. Use the machine only when all the necessary protective and safety equip-
ment, e.g. detachable protectors, emergency stop equipment, sound in-
sulation, dust collector and other safety equipment are in a safe and oper-
ating condition.
10. Follow the starting and stopping instructions given by the control equip-
ment and signalling devices as well as other instructions.
11. Make sure that there is enough space for the movements of the equip-
ment.
12. Keep the equipment clean, especially the controls, windows, glasses and
lights. Remove possible oil and grease stains and ice. Wash the equip-
ment regularly.
Page 17 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

9.2. STARTING UP THE EQUIPMENT
1. Make sure before starting up the equipment that this operation does not
endanger anyone and that there is no one inside the danger area of the
work machine.
2. It is forbidden to start up any automatic equipment if there are people in
the operating area. Do not start up the power units when the machine is in
automatic mode.
3. A number of machines have been equipped with an alarm and control
system to prevent serious damage caused by erroneous operation.
4. The safety systems should never be bypassed or removed to facilitate the
work.
5. Check the safety equipment.
6. Test the operation of all control equipment.
7. Check all gauge readings and signal lights and replace all faulty equip-
ment.
8. Check at least once during the shift if there are faults or defects to be ob-
served. Report all possible faults, also faulty operation of the machine, im-
mediately to the department or person responsible. The equipment must
be stopped immediately if necessary, and all necessary safety measures
should be taken.
9. Never leave the immediate vicinity of the machine, if the engine is running.
10. When working near the machine, mufflers, helmet and safety glasses
should be used.
11. Never use an excessive amount of starting fuel (Startpilot). Excessive
amounts of fuel before starting up the engine may damage the engine.
Starting syringe must never be used with flame plug glow.
Page 18 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

9.3. SAFETY INSTRUCTIONS FOR THE OPERATION OF THE EQUIPMENT
1. Only people who have been trained and are familiar with the contents of
the manual are allowed to use the equipment.
2. Before taking the equipment into use, the operator must also be familiar
with the operation of the extras.
3. Always make sure before starting to drive the machine that all the equip-
ment and operations are in order.
4. In addition to the operator, other personnel can only be transported inside
the machine in a place specially designed for this purpose.
5. Prevent people from standing near the frame joint, when the machine is in
operation.
6. Keep a safe and sufficient distance between other people and the operat-
ing area of the machine.
7. When operating the machine, the safety instructions that apply to the job
in question must also be followed.
8. Repair or immediately report the faults or irregular operation of the equip-
ment.
9. Do not use the safety brake to stop the machine, except in an emergency
situation.
10. Drive downhill slowly. It is forbidden to drive downhill in neutral.
11. Disengage the gears while the engine is running at idle.
12. A hot engine must not be stopped directly from high revolution speeds.
13. Do not open the main switch, when the engine is running.
14. When charging, the engine must be switched off or the main switch
opened.
15. It is forbidden to charge and do other operations at the same time.
16. Stop the engine while refuelling, servicing or repairing the machine.
17. Park the vehicle preferable on a flat surface. If you park it on a slope,
jack---knife the vehicle.
Page 19 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

9.3.1. SAFETY INSTRUCTIONS FOR BOOM OPERATION
1. Make sure that all those using the equipment are familiar with the contents of
the manual before starting the work.
2. Safety measures and precautions before lifting the boom:
--- The reversing lever of the vehicle is turned to center position.
--- The safety brake is engaged.
--- The support legs are lowered and it is ensured that the equipment is in a posi-
tion required by the inclination values. Make sure that the support legs are on
firm ground and not, for example, on a piece of rock. When using the boom,
the vehicle must be as straight as possible and on a flat surface.
--- Climb into the cage by using the steps, not by walking on the boom.
--- Close the gates of the cage carefully.
--- Make sure before the boom is operated that there are no obstacles in the oper-
ating area.
--- Exercise special caution when working in the vicinity of electric wires and pipe-
lines.
--- Do not make a turn before the boom is up.
3. There is a valve in the cage to quickly stop the motion of the boom and the
cage e.g. in an emergency situation, which brings all hydraulic operations to a
hault. After being used, the operating lever or push button of the valve must be
returned to the original position. The emergency stop only functions when the
boom is operated with the control valves inside the cage.
4. When the boom is operated, all unauthorized persons must be prevented from
entering the working area.
5. Do not work underneath a boom that has been lifted up.
6. Make sure that the boom can be lifted unobstructed. Take every precaution
when lifting near electric wires or underneath them.
8. Clean daily the working platform of the cage.
9. When the vehicle is being driven, the boom must be drawn completely in and
lowered on its supports. Make sure, before moving the vehicle, that the support
legs are raised completely.
10. When the vehicle is being driven, there must be neither people nor load in the
cage.
11. The boom is equipped with different kinds of safety equipment. These protect
the operator and the equipment and therefore, they must not be changed.
12. A man cage must not be used for transporting materials. When lifting men,
however, tools and equipment can also be lifted in the cage. It is forbidden to
lift materials which extend outside the edges of the cage.
Page 20 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

9.3.2. SAFETY INSTRUCTIONS FOR LIFTING PLATFORM OPERATION
1. Familiarize yourself with operating instructions before driving the machine.
2. The safety and preventive measures before lifting the platform:
---Park the vehicle as level as possible.
---The reversing lever of the vehicle is turned to center position.
---The safety brake is engaged.
---The support legs are lowered and they are used to balance the vehicle.
---Make sure that the support legs stand on firm ground and not e.g. on a
piece of rock.
3. Familiarize yourself with the equipment and learn the correct operating
technique.
4. Make sure that the platform can be lifted and lowered unobstructed. Be-
ware of electric cables, air and water pipes, when lifting the platform.
5. Make sure that the guard---rail posts and chains of the platform are in
place and undamaged.
6. Keep the platform surface clean to prevent slipping and clear of extra ma-
terial.
7. Do not exceed the permitted lifting loads. When lifting a maximum load
ensure that the load is placed evenly on the platform.
8. When moving the vehicle, lower the platform completely to down position.
9. It is to be noted that when two people are working, the platform can only
be used when the persons are in each other’s sight.
10. Tilting the lifting platform:
--- Make sure that the load does not begin to move when the lifting platform
is tilted.
--- Tilting is possible (not all models) only when the platform is lifted a little,
not when it is down.
--- Before the lifting platform is lowered down, it must be parallel to the ve-
hicle (not tilted).
Page 21 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

9.4. OPERATION IN COLD CONDITIONS
1. Read the manufacturer’s instructions on cold start procedure.
2. Operate the control equipment with caution until the hydraulic oil has
reached the correct operating temperature. Warm up the hydraulic oils
according to the instructions provided by the manufacturer.
3. Especially quick stroke---like loads require special caution.
4. In cold conditions, only recommended oils must be used.
5. Always empty the air and water pipes and valves after use, if the tempera-
ture goes below freezing point.
6. Use anti---freeze agent in the cooling system of a liquid cooled engine.
Check the cold tolerance of the cooling system.
Page 22 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

9.5. SAFE OPERATION
9.5.1. GENERAL
1. Familiarize yourself with the manuals provided by the manufacturer and
act accordingly. Plan your work beforehand to avoid accidents and inju-
ries.
2. If an accident occurs or a fire breaks out, act quickly by using the equip-
ment available. Familiarize yourself with the use of first aid equipment and
fire extinguishers. Also find out where you can get help in emergency situ-
ations. Do not take anything for granted. You must not assume that every-
thing is in order, when the day begins only because everything seemed to
be in order yesterday.
3. Work clothing must not be too loose. A wide jacket, long hair, rings and
other jewellery may get stuck to the moving parts. Clean you shoes of
mud and grease before climbing into the machine and beginning the
work. Always use personal safety equipment such as a helmet, safety
glasses, mufflers, safety overalls and boots. Always follow the safety regu-
lations provided.
4. Before commencing the work, inspect the machine carefully in case of
possible wearing and check all the functions. When beginning your shift,
ask the previous shift about the working conditions and the operation of
the equipment.
5. Before operating the equipment, you must know the height, width, length
and weight limits of the working area and make sure that the equipment
does not exceed these limits. Before commencing the work, the operating
area must be known. All gas, water and sewer pipes and the places of
electric wires hanging above or dug underground as well as other ob-
stacles and objects that may cause a danger situation must be known.
The person responsible should mark these clearly in order to avoid acci-
dents.
6. Cave---ins and depressions are dangerous. Use supports to avoid cave---
ins as necessary.
7. Keep the tools and other equipment in the tool box.
8. Always keep the working environment clean. Thus you will avoid acci-
dents.
9. The boom is operated with the hydraulics of the basic machine or with an
aggregate. It is to be remembered that the boom and the man cage must
be in their original condition when operated. They must not be repaired or
changed in a way that could affect the operating safety without the con-
sent of the manufacturer.
Page 23 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

9.5.2. CORRECT OPERATION OF THE MACHINE
1. The correct use of the machine or equipment requires that the operating
and service instructions prepared by the manufacturer are followed.
2. Using the equipment for other purpose than for which it has been de-
signed or exceeding its operating capacity is not considered to be ap-
propriate use. Any other kind of use of the equipment is not acceptable.
The manufacturer/ supplier shall not assume liability for damage caused
by this kind of use.
3. Choosing the most appropriate machine or equipment for a specific job
depends on the type of work e.g. concreting, transport of crushed stone
etc.
4. Only a person who has been trained and authorized for the job is allowed
to operate, service and repair the machine or equipment.
5. It is forbidden to make any changes in the machine without the consent of
the manufacturer. The maximum operating values permitted are men-
tioned on the machine plate and in the technical specifications.
6. Only original spare parts must be used.
7. The operator is responsible for accidents caused by negligence and care-
lessness. The work must be carried out in accordance with the instruc-
tions provided by local labour protection authorities and the laws and stat-
utes of the country. In order to avoid damages, the operators and their su-
periors must be informed of the existing regulations and statutes and ex-
treme caution must be exercised.
9.5.3. INCORRECT OPERATION OF THE MACHINE
The manufacturer of the machine does not assume liability for damages
caused by inappropriate use of the machine, incorrect or insufficient
operation, service or repair.
Page 24 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

9.6. DRIVING
Owing to the equipment, driving requires special measures. Read the driving
instructions of each machine carefully.
1. Do not disengage the parking brake before you have checked that:
--- steering functions correctly.
--- the equipment such as the boom are in a correct position for moving.
--- the driving speed area has been correctly chosen.
--- the driving direction has been chosen.
--- all equipment and operations are in order.
--- operating the machine does not cause any danger to people or property.
2. In narrow places, in addition to the actual control devices of the base
used in driving, the control levers of the boom must also be used. If a
cable or hose reel has been connected to the machine, special attention
must be paid to the use of the reels when driving.
3. The machine must never be driven or operated unless it has been en-
sured that it causes no danger to anyone.
4. Never try to drive the equipment from any other place than the actual op-
erator’s cabin.
5. Only trained personnel are allowed to drive the machine.
6. It is forbidden to enter or leave the machine while it is moving.
7. It is forbidden to transport passengers inside the machine if the machine
has not been bought for that purpose.
9. Familiarize yourself with the driving instructions in detail before moving or
driving the machines.
10. Always place the boom in the driving position. Thus you get the centre of
gravity as low as possible and the machine is more firm to drive. Also the
stress on the boom decreases considerably.
11. In difficult places in the terrain, the boom may have to be moved due to
obstacles. However, keep the boom short. Always move the boom with
great care so that the machine can also maintain its balance on slopes
and in difficult parts of the terrain.
12. If the machine has been equipped with oscillation, familiarize yourself with
the use of oscillation. If the operating instructions are not followed, this
may cause the machine to fall over and cause serious damage.
Page 25 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

9.7. WORKING METHODS
Due to the equipment and working methods, there are special safety
instructions and legal provisions related to the work e.g. charging and
concreting. Read these instructions carefully before commencing the work.
The most important safety instructions are included in the operating
instructions of the machines.
9.8. STOPPING THE MACHINE

1. Check at least once a week during your shift, if there are any faults or de-
fects to be detected in the machine. Report all possible faults, also faulty
operation of the machine, immediately to the department or person re-
sponsible. The machine must be stopped immediately if necessary and
the necessary safety measures must be taken.
2. Stop the machine immediately and take the necessary safety measures in
case there is any fault in operation. Repair the fault or get it repaired im-
mediately.
3. The emergency stop push button or lever bring all operations to a hault
and the warning light lights up. Before restarting the machine, the push
button must be turned to the direction indicated with an arrow in order to
return the push button to the upper position or the lever to be returned to
its original position.
9.9. ENDING OF SHIFT

1. Choose carefully the place where you can stop the machine. Do not leave
the machine in a place where cave---ins can occur or in a ditch which can
be filled with water from heavy rain.
2. Do not leave the machine on a slope or ramp if you are not absolutely
sure that it will stay in its place.
3. Make sure that the machine will stay in its place by following the instruc-
tions in the manual.
4. Stop the machine and carry out all necessary procedures when ending
your shift, in accordance with the operating instruction.
5. Turn all the control levers to centre or parking position.
6. Engage the brake or lock it in order to prevent the machine from moving.
7. Make sure that the pressure systems are in the operating mode described
in the operating instruction.
8. Lock the ignition switch or starting circuit and take off the key, if it is pos-
sible to lock the machine. In this way you can prevent unauthorized use of
the machine.
9. Lock the operator’s cabin and install all possible safety equipment.
Page 26 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

9.10. TOWAGE
1. Always exercise extreme caution and follow the operating instructions
when you tow the machine. If the operating instructions are not followed,
this may cause serious damage to the machine and after the machine has
broken, there is a danger of an accident.
2. Do not start the engine by towing.
3. If the engine is running, the machine can be towed at the machine’s nor-
mal driving speed.
4. If it is impossible to start up the engine, towing requires special measures
depending on the machine. See the towing instructions in the proper
manuals.
5. A machine without brakes must not be towed except with a fixed bar. If the
engine is not running, the machine can be steered, but steering is heavy
and slow.
6. Always make sure that the brakes of the towing equipment are in good
condition and sufficient to stop both machines in all conditions.
Page 27 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

9.11. TRANSPORT
1. Always plan the transport of a machine beforehand so that it can be done
safely. Always choose the safest way of transporting and make sure that
the transport equipment has sufficient load bearing capacity.
2. Use ramps when moving the machine on or off a trailer. This should al-
ways be done on a flat surface.
3. Always use slow speed and exercise extreme caution, when driving the
machine from the ramps on to the trailer.
4. When driving on to the ramps, the machine must be balanced with the
movements of the boom and oscillation (if the machine is equipped with
oscillation).
5. When planning the route, the measurements of the machine must be tak-
en into consideration. Always measure the maximum height and width of
the cargo.
6. The lifting points of each machine have been marked with hook symbols.
When lifting the machine, make sure that the lifting equipment is in prime
condition.
7. The weight of the machine to be lifted must be known before lifting.
8. The lifting points of the machines have been marked with a sticker shown
below. Lift the machine only from the marked points.
Fig. 2. Symbol of a lifting point.
Page 28 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
10. LIFTING CARGO
10.1. TAKING THE LIFTER INTO USE

1. Clean the ends of the hydraulic hoses of the lifter before connecting them
to the base.
2. All hoses between the base and the lifter must be connected.
3. The hydraulic tank has been filled to the gauge glass and the possible
shut---off cock of the hydraulic circuit is open.
4. Service the lifter in accordance with the service instruction. Check the fas-
tening screws.
5. The base frame of the lifter must be level.
6. Make sure that there are no unauthorized persons or obstacles in the op-
erating area.
Page 29 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

10.2. INSTRUCTIONS FOR SAFE LIFTING
1. Always engage the parking brake when loading. Place blocks in front of the
wheels if necessary.
2. Make sure when lifting that the soil underneath the support points is firm
enough.
3. Make sure that there are no people in the operating area of the lifter.
4. Familiarize yourself with the characteristics of the lifter by first lifting small loads.
5. Fasten the load carefully and always as close as possible to the centre of gravi-
ty.
6. Loads must not be lifted, if there are people below.
7. Make sure that you can see the entire operating area clearly.
8. The load should not be lifted with the maximum reach of the telescope boom,
but it should first be drawn closer and then lifted.
9. The lifter must neither be towed by a vehicle nor pulled sideways.
10. Avoid quick lifting and lowering movements with the maximum reach of the
boom and turns before the load is in the air.
11. Do not drive the boom linkage at a great speed against extreme positions.
12. Avoid obstacles when getting out the extensions.
13. Exercise extreme caution, when working near electric wires. Keep a safe dis-
tance from the wires and follow the instructions (Electric safety regulations).
14. The lifter must not be used for lifting people.
15. Do not try to exceed the values given in the load table.
16. It is forbidden to install extra extensions in the lifter without the consent of the
manufacturer.
17. Do not leave the boom linkage of the lifter in the upper position without supervi-
sion.
18. If the boom linkage begins to fall, bring the load to the ground immediately.
19. Loading on a slope should be avoided. However, if this cannot be avoided, ex-
treme caution should be exercised. In this case, it is forbidden to lift a maxi-
mum load. When loading from uphill, it is to be remembered that turning may
cause the outward relief valves to overload and the load may move downwards
thus causing a danger of the lifter falling over.
20. If the lifter has not been equipped with support legs, the balance of the lifter
must be guaranteed e.g. with a sufficient weight of the base frame. If you some-
times are uncertain of the balance of the loading combination, check the bal-
ance by first lifting the load a little from the ground and, if necessary, lift the
load at a shorter distance.
Page 30 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

10.3. LIFTING
Many countries have special laws and statutes related to lifting, hoisting
cables and lifting equipment. Always follow the safety regulations required by
local laws.
1. Only a correct type of machine with a sufficient lifting capacity can be
used for lifting. It is forbidden to lift equipment and parts of equipment
with other equipment than lifters designed for this purpose.
2. The weight of the load to be lifted must be known and the operating ca-
pacity of the lifter informed by the manufacturer must not be exceeded.
3. The course of the lift must be chosen so that loads are not moved above
people or object which may have people inside.
4. Check that the lifting equipment is in order.
5. The hoisting cables and chains must be checked regularly. Discarded
cables must be marked and removed from use immediately.
6. If the lifting points have been marked, lift only from the marked points.
Fig. 3. Mark of a lifting point.
7. Ensure that the load is properly fastened and balanced by first lifting it a
few centimeters from the ground. Continue the lifting only after you are
convinced that the load is in balance and safely fastened.
8. Hoisting cables, which consist of several parts must not be wound. The
hoisting cables must be fastened in accordance with the instructions pro-
vided by the manufacturer.
NO YES
Fig. 4. Use of hoisting cables
Page 31 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

9. The lifting wire must not make a loop round the load in place of a lifting
strap or chain.
NO YES
Fig. 5. Use of hoisting cables.
10. The load must never be lowered so much that there are less than two
rounds of cable on the reel. In this way, we ensure that the weight of the
load to be lifted is evenly distributed on the cable and on the fastening
point.
11. Check the capacity and length of the cable, if the length of the cable or
mast is changed.
12. Never stand or work underneath a load hanging from the lifter.
13. Never use the machine balance as a measurement for capacity.
14. Never lift a load above people.
15. Make sure that lifting can be carried out unobstracted.
16. Never use any other machine for lifting people than a special passenger
hoist.
17. Lifting people on top of the load is strictly forbidden.
Page 32 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
11. LIFTING PEOPLE
11.1. GENERAL SAFETY INSTRUCTIONS

1. Familiarize yourself with the operating instructions of the machine before
operating it.
2. Keep the instructions in a special place reserved for them in the lifter.
3. When lending the machine, make sure that the lender reads the instruc-
tions before using the machine.
4. The lifter has been equipped with different kinds of safety equipment.
These protect the operator and the machine and must not be changed in
any way.
5. The safety equipment must not be put out of order.
6. All safety equipment which are found to be faulty must be repaired before
the machine can be taken into use.
7. Exercise caution when working near electric wires. Stay at a safe distance
from the wires and follow the instructions (Electric safety regulations).
8. If the lifter is used in the traffic:
--- Note the signal lights.
--- Bordering of the area.
--- Requirements of the Road Traffic Law
9. Special attention should be paid to the weather conditions e.g. wind force,
temperature and rain.
10. If the balance of the lifter is endangered e.g. due to the foundation giving
way:
--- Stay within the edges of the cage.
--- Press the emergency---stop push button to turn off the engine.
12. Remove all extra material and tools from the cage after the shift.
13. Clear the lifter from all dirt, snow and ice.
14. Do not use the lifter for transporting people or materials.
Page 33 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

15. Never use a faulty lifter. Report all defects and faults detected.
16. Do not take any risks, when using the lifter.
17. Use the lifter with caution and care.
18. Do not use any elevations on the working platform.
19. Do not climb on the rail of the working platform.
20. Do not throw anything down from the platform.
21. When you have stopped working, drive the lifter to a safe place, preferably
in the driving position. Stop the engine and prevent any unauthorized use
of the lifter.
Page 34 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

11.2. PREPARING THE LIFTING EQUIPMENT FOR OPERATION
1. The safety measures and precautions before lifting the boom:
--- The reversing lever of the vehicle is turned to centre position.
--- Always engage the parking brake when lifting. See if the ground is slip-
pery. Place blocks in front of the wheels if necessary.
--- The support legs are lowered and it is ensured that the vehicle is level.
Check the carrying capacity of the ground and use extra plates under-
neath the support legs if necessary. An asphalt surface can also give way
if water has eroded soil underneath the asphalt. When using the lifter, the
vehicle must be as straight as possible and on a flat surface.
--- The gates of the cage are closed carefully.
--- Make sure before moving the boom that its operating area is unob-
structed.
--- Exercise special caution when working near electric wires and pipelines.
--- Do not make a turn before the cage is in the air.
2. If the lifter has not been equipped with support legs, the balance of the
lifter must be guaranteed e.g. with a sufficient weight of the base frame. If
you are uncertain of the balance of the loading combination, check the
balance by first lifting the load a little from the ground and, if necessary, lift
the load at a shorter distance.
3. The lifter can only be used when it is well supported and as level as pos-
sible.
4. Loading on a slope should be avoided. However, if this cannot be
avoided, extreme caution should be exercised. In this case, it is forbidden
to lift a maximum load. When loading from uphill, it is to be remembered
that there is always a danger of the lifter falling over.
5. There is a valve in the cage to stop the motion of the boom and the cage
quickly e.g. in an emergency situation, which brings all hydraulic opera-
tions to a hault. After being used, the operating lever or push button of the
valve must be returned to the original position. The emergency stop only
functions when the boom is operated with the control valves inside the
cage.
6. A man cage must not be used for transporting materials. When lifting
people, however, tools and materials can also be lifted in the cage. It is
forbidden to lift materials which extend outside the edges of the cage.
Page 35 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

11.3. INSTRUCTIONS FOR THE OPERATION OF THE LIFTER
1. The operator must be familiar with the contents of the manual before lift-
ing.
2. The operator must be familiar with the safety instructions before lifting.
3. The operator must be at least 18 years old.
4. The operator must be adequately trained for the use of the lifter.
5. All instructions provided by the manufacturer must be followed.
6. If possible, the lifter should be taken into use for the first time under the
supervision of the seller or leaseholder.
7. Prevent any unauthorized persons from entering the working area.
8. Plan the lifting of people beforehand.
9. Ensure the most advantageous position of the lifter with respect to the
work object.
10. Check before lowering the cage that the base frame is free from ob-
stacles.
11. Make sure that the side load of the working platform does not exceed the
permitted value.
12. When using the lifter in cold conditions, note the following:
--- The minimum operating temperature permitted.
--- Let the engine/power unit run idle a while before operating the equipment.
--- First make slow movements to warm up the system.
--- Note the operation of the limit switches, emergency lowering and move-
ments
13. Read the instructions on the operation and the use of the emergency low-
ering system carefully.
14. When your shift is over:
--- Lower the lifter on the driving supports.
--- Remove the ignition key of the base to prevent any unauthorized use of
the lifter.
--- Report all operating trouble and defects.
Page 36 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
12. MAINTENANCE AND SERVICE
12.1. GENERAL
Keep a record of the service of the equipment and its wearing parts. Regular
maintenance carried out at prescribed intervals and at the correct time adds
to the operating reliability, economy and safety of the equipment.
Maintenance work can be dangerous if not carried out by executing special
caution. Everyone should understand the possible danger factors involved
and use safe working methods. Before commencing the service or
maintenance work, familiarize yourself with the instructions provided by the
manufacturer, and follow them.
Clearly define the responsible person for the service and maintenance work.
1. Do nothing you are not entitled to do.
2. Inform the operators about the timetable of special service and mainte-
nance work.
3. Reserve a sufficient service area around the machine.
4. If the machine or its part has been stopped for service or repair, make
sure that it will not restart or that it is impossible to start it up by mistake.
--- Turn off the main switch.
--- Remove the ignition key.
--- Place a warning sign on the main switch. The sign can only be removed
by a person who is aware of the situation and knows when the sign can
be removed without danger.
5. Clean and wash the equipment regularly and always before service and
maintenance work.
6. Before you start cleaning the equipment with water, high---pressure wash-
er, steam jet or other washing methods cover all such openings and
places which may cause danger or break. Special attention should be
paid to the protection of electric motors, switch cabinets and boxes.
7. If required, use suitable and safe ladders or working platforms for repair
and maintenance work
8. Do not use any parts of the machine as stepping stones. If the service
must be carried out in a high or dangerous place, use safety equipment
that prevents you from falling.
9. All working platforms, steps, handles, rails, ladders and other places
where you can slip or meet with an accident must be kept clear of oil, dirt,
snow and ice.
Page 37 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

10. Always use appropriate working equipment.
11. If you service underneath the machine, engage the safety and parking
brake. Make sure that the equipment cannot be started or moved.
12. When changing the tyres make sure that the machine is in balance and
well supported. Check the maximum pressure of the tyres. See the values
on the tyre pressure plate on the machine. Do not exceed the pressure
values.
13. Do not stand in front of the tyre when filling it with air.
14. When filling loose tyres with air. DANGER! If the rim is what is called a
locking rim, the tyres must always be filled within a safety cage. Never
stand directly in front of the rim, when the tyre is being filled.
15. Special care must be taken of the exhaust pipes and exhaust gas cleaning
systems. Ensure sufficient ventilation.
16. Over---heating means that something is wrong. Stop the engine and get
the fault repaired before more serious damage is caused. Check that the
radiator has not been covered or become blocked.
17. When checking the amount of the engine radiator fluid, stop the engine
and first let the engine and the radiator cool. If you must stop an over---
heated engine, first let the radiator cool. If you cannot wait for the cooling,
use thick safety gloves and clothes when opening the radiator cap. Stand
aside, turn your face away and open the cap carefully. Wait until there is
no more pressure and no more fluid comes out and then open the plug
carefully.
18. When changing parts or aggregates, fasten them carefully to the lifter and
make sure that the transfer does not cause any danger. Use only ap-
propriate lifters, which technically are in prime condition, and lower the
parts on a surface with a sufficient load carrying capacity.
19. Use original spare parts.
20. It is forbidden to make any structural changes in the equipment without
the consent of the manufacturer.
Page 38 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

12.2. GENERAL SAFETY INSTRUCTIONS FOR MAINTENANCE
1. Before service and maintenance operations, the operator must familiarize
himself with the operating and service instructions of the main compo-
nents and follow these instructions.
2. Do not service the machine while the engine is running if not absolutely
necessary, e.g. when discharging air from the brake circuit.
3. Keep your hands and clothes away from rotating parts.
4. Check the vehicle daily and get even the minor faults repaired immediate-
ly.
5. The ground cable of electric welding must always be connected directly to
the piece to be welded, the excitation current conductor of the charger is
disconnected and the main switch is opened.
6. Carry out all the inspections mentioned in the service manual.
7. Report all faults.
8. Use only appropriate tools for maintenance.
9. Adjusting, servicing and cleaning of the machine is forbidden, when the
machine is in operation.
10. It is forbidden to touch the steering wheel while the machine is being re-
paired.
11. Make sure before filling a tyre with air that the wheel disc and tyre are in
good condition and correctly installed.
12. Add air into the tyres with a compressed air system designed for this pur-
pose. Do not exceed the maximum pressure recommended by the tyre
manufacturer.
13. When changing oils extreme caution must be exercise d, because the oil
may be hot and cause burns.
14. The grease and oil spilled on the machine parts may cause a danger of a
fire. Remove the grease and oil as necessary.
15. Combine the safety instructions related to the service of the machine and
the other service and maintenance operations of your company so that
the maintenance operation of the machine meets both regulations.
Page 39 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

12.2.1.SAFETY INSTRUCTIONS FOR SERVICING THE BOOMS
1. Before servicing the boom:
--- Empty the cage.
--- Support the boom correctly or use the lifter.
--- Turn off the engine before commencing the service and maintenance op-
erations unless the engine must be running, when adjusting the pressure.
2. It is forbidden to repair or change the structures of the supporting booms
without the consent of the manufacturer.
3. It is forbidden to change the pressure values of any of the operations.
4. Do not repair the hydraulic system without first ensuring that there is no
pressure in the system.
5. If the cage has been used for charging, it is absolutely necessary that the
cage be cleared of all charging material before commencing the repair
work.
6. The boom has both sliding and ball bearings, which must be lubricated
regularly.
7. An obstructed or damaged grease nipple must be replaced. If the holes in
the joint pins become obstructed, the pin must be removed and the hole
properly opened to ensure sufficient lubrication.
8. Because people are also lifted with the boom, special attention must be
paid to the condition of the entire equipment. The tightness of the bolt
joints, the condition and tightness of the hydraulic hoses and connectors
and the locking of the joint pins must be checked weekly.
9. The pressure of the hydraulics must be checked in case of malfunction.
The pressure values informed must not be exceeded without the consent
of the manufacturer. If hoses or other components are changed, the sys-
tem must be vented by running the operations a few times to extreme
position. Air in the hydraulic system may cause malfunction and danger-
ous situations.
Page 40 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

12.2.2.SAFETY INSTRUCTIONS FOR SERVICING THE LIFTING PLATFORM
1. Familiarize yourself with the operating and maintenance instructions of the
equipment before any maintenance operations.
2. Turn off the engine before commencing the service and repair work unless
the engine must be running, when adjusting the pressure.
3. Never go underneath a lifted platform unless the mechanical supports on
the front and back edge of the platform are in place.
4. Change all bad and leaking hydraulic hoses immediately.
5. It is forbidden to change the pressure values of any operation without
consent. It is forbidden to repair or change the supporting structures of
the lifting platform without the consent of the manufacturer.
6. Check daily and always after a damage, the important parts of the lifting
platform. Repair all damaged parts immediately. Never use a damaged
lifting platform.
7. When repairing hydraulic leaks, use gloves to prevent compressed hy-
draulic oil from penetrating your skin.
8. Exercise caution when emptying the hydraulic tank. Hot oil may cause
injuries.
9. Do not repair the hydraulic system without first ensuring that there is no
10. Clean the surface of the components to be repaired. Do not use dissol-
vents when cleaning the parts.
11. To ensure troublefree and safe operation of the lifting platform, it is impor-
tant that the equipment is kept in good condition. There are not many
parts in the lifting platform that require special maintenance. Cleanliness
of the platform and repairing or immediately changing all faulty parts are
important safety factors.
12. Unnecessary idle hours can be avoided and the safety risks caused by
possible faults can be minimized, when the machine is serviced and in-
spected regularly.
Page 41 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

12.3. OILS, GREASES AND FUELS
1. Always use only the types of oils recommended by the manufacturer. If
these recommendations are not followed, it may damage the machine or
cause the machine not to operate properly, which again may cause seri-
ous bodily injury or material damage.
2. Make sure that the fuel, lubrication oil, radiator fluid and hydraulic fluid
tanks have been filled to the correct level.
3. Do not mix different kinds of fluids or oils together.
4. Remember that not all bearings are alike. Each bearing has its own char-
acteristics and lubrication requirements. Follow the instructions provided
by the manufacturer.
5. Cold starting fluid or other inflammable substances must not be kept in
the cabin.
6. Inflammable substances must be stored protected from heat, sparks and
open fire.
7. The vessels containing inflammable substances must not be punctured or
disposed off by burning, because this may cause a danger of an explo-
sion.
8. Smoking is strictly forbidden when handling fuel.
12.4. ADDING FUEL

When adding fuel, the following precautions must be taken into consideration:
1. Do not fill up the fuel tanks, when the engine is running.
2. Make sure not to spill fuel on hot surfaces.
3. Fill up the tanks in a well ventilated place.
4. Smoking, open fire and sparks are always dangerous when adding fuel.
5. Wipe off all spilled fuel before starting the engine.
6. Keep the fuel inlet pipe attached to the tank or earth it to prevent sparkling
due to static electricity.
7. Switch off the cabin heater.
Page 42 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

12.5. ENGINE SERVICE
1. The filter cartridge must be cleaned with hot liquid or petrol.
2. The oil coming out of the engine is hot and may cause burns.
3. Always turn off the engine before cleaning.
4. Always turn off the engine before inspecting the safety device of the en-
gine, because there is great danger of an accident.
5. The engine must be stopped when the engine belts are retightened. Do
not forget the V belt safety cover.
6. Remember that when disconnecting the fuel oil filter cartridge and taking
out the side flow filter cartridge, a little oil comes out and it may be hot.
7. Never service the fuel equipment near open fire or when smoking.
8. Keep away from rotating parts when the engine is running.
9. When checking the temperature control device of the cylinder cap, warm
the oil vessel on a heating plate and not with a welding burner.
10. The fuel spray jet must not touch the skin. It may cause an injury.
Page 43 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
13. SAFETY INSTRUCTIONS FOR REPAIRS

Before welding is commenced, find out about the material to be welded as
well as the welding method and additives. If necessary, contact the Normet
Service.
1. Check the plates and weldings of the equipment for possible damages,
e.g. fractures, bends or transformations. Cracks in the coat of paint or
peeling may be a sign of a dangerous fracture underneath the painting.
The equipment must not be used before the necessary repairs have been
carried out.
2. Do not repair the steering gear by welding.
3. Only professionals are allowed to carry out welding work. Only persons
authorized by the manufacturer are allowed to weld load carrying struc-
tures. Ask an expert to inspect the welding.
4. Disconnect both cables from the battery and disconnect all possible cir-
cuit cards before welding the machine. The welding voltage may damage
the electric equipment.
5. Use safety mask when welding.
6. Ensure sufficient ventilation.
7. Look after fire safety.
8. When repairing hydraulic leaks, use safety gloves to prevent compressed
hydraulic oil from penetrating your skin. Compressed oil is inflammable
and may cause bodily injuries.
9. It is forbidden to change the pressure values of any operation without the
consent of the manufacturer.
10. Exercise extreme caution when emptying the hydraulic tank. Hot oil may
cause injuries.
11. Release the hydraulic pressure before unfastening the hydraulic parts.
--- Release the pressure in the system.
--- Release the pressure in the pressure accumulator.
Page 44 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

12. Before commencing the repair work, check that the component and its
environment are clean. If possible, replace the component.
13. Use clean plastic plugs to block the hoses and other holes when storing
the components or when disconnecting hoses, cylinders and other equip-
ment.
14. The hydraulic pumps and control valves are heavy. Before disconnecting
them, reserve a firm device such as a block or a lifter to unfasten the part
safely.
15. When washing the parts, do not use corroding detergents.
16. Do not remove the cylinders unless the equipment is lying on the ground.
If the equipment must be held up while being serviced do as follows:
--- Empty the boom.
--- Place a proper support under the equipment.
--- Turn off the engine.
Page 45 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
14. SAFETY INSTRUCTIONS FOR ELECTRIC

CIRCUITS AND EQUIPMENT
14.1. ELECTRIC SYSTEM

1. Check the operation of the safety devices. Test the warning lights of the
meter board by pressing the test button. See the manual for the location
of the button. This test does not show the condition of the detectors of the
safety devices and therefore also the detectors must be inspected regular-
ly. Test also the correct operation of the quenching solenoid.
2. Inspect the cables visually and make sure that the switch boxes and cabi-
nets are closed.
3. An excessive deflection in the supply voltage damages the equipment.
Overvoltage damages the components and undervoltage in starting dam-
ages the components of the engines’ starting circuits.
Page 46 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

14.2. ELECTRIC EQUIPMENT
1. Only professional electricians or persons who have been trained for the
job are allowed, under the supervision and guidance of a professional
electrician, to install, repair or service electric equipment and materials in
accordance with the electric safety regulations.
2. In order to prevent any bodily injuries or material damage in connection
with the use of electricity, there are a number of regulations related to the
structure, installation and use of electric equipment. These regulations are
always based on local laws and electric safety regulations, which must be
followed.
3. Only use original electric parts.
4. It must be assumed, in all situations, that an electric wire has a voltage
and can be dangerous. Damaged wires and cables may cause a danger
of a fire or endanger your life.
5. All parts to be inspected, serviced and repaired must be made dead.
6. If the part worked on must have a voltage, an extra persons is appointed
for the job who, in the event of an emergency, turns off the voltage with
the emergency or main switch.
7. When a fault is detected in the electric equipment, e.g. the door of the
electric switch gear cabinet is open, damaged cables, a broken compo-
nent etc. the equipment must be made dead. The equipment can only be
used after the fault has been repaired and the equipment tested by mea-
suring and testing it in practice.
8. The voltage must not be switched on until it is absolutely certain that it will
not cause any danger and that the local instructions and legal regulations
have been read and followed.
9. When repairing or servicing the electric system, make sure that the volt-
age has been switched off and that no one can switch it on by mistake.
Remember that the cable reel system may have a voltage even though the
main switch has been turned off. When repairing the cable reel system,
disconnect the connecting plug of the cable.
10. The rotation direction of the electric motors should be correct. If the direc-
tion is not right, a warning light lights up. In this case, change two phases
with each other.
Page 47 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

14.3. ELECTRIC LINES
In order to prevent any bodily injuries or material damage in connection with
the use of electricity, there are a number of regulations related to the structure,
installation and use of electric equipment. Make sure that you follow the valid
regulations when working near electric lines.
Electricity always flows to the ground if possible.
1. Contact the local electricity plant if you intend to work in the vicinity of
overhead cables. If necessary, ask the electricity plant to send their expert
to the work site.
2. Remember! You do not have to come into direct contact with electricity.
With a high voltage, electricity can ’jump’ long distances, even as long as
five meters.
3. Do not go near wires! No part of the equipment must go closer to the
overhead cables than the safety distance. Find out, from the local electric
safety regulations, what the safety distance is.
4. If it is difficult to follow the safety regulations in your work, contact the pos-
sessor of the electric wire.
5. You can make working safer by earthing the equipment with a thick cop-
per cable which is connected e.g. from the top of the boom to an earth
bar. However, this does not provide complete protection.
14.4. CONTACT WITH AN ELECTRIC LINE

If the machine comes into contact with an electric line, you can avoid damage
or death by following the instructions below:
1. If you are outside the machine, avoid touching any part of the machine or
trying to climb into it. Keep everyone away from the machine.
2. If you are inside the machine, do not try to leave. A machine which is in
contact with a wire can catch fire. If the machine base has rubber tyres,
leave the machine not later than when the tyres start to smoke. JUMP! Do
not make yourself a wire, which conducts electricity. Leave the machine
by jumping up and down with both feet together or by jumping so that
only one foot at a time touches the ground. The electric field in the ground
may cause a dangerous voltage between your feet. You are not safe until
you are at a distance of at least 20 meters from the machine.
3. If the lifting equipment or some other component comes into contact with
an electric line, the whole machine gets a voltage. Although the situation
may seem safe due to the insulating rubber tyres, a person who is stand-
ing on the ground may get a lethal electric shock when touching the ma-
chine.
4. Ask for help immediately.
Page 48 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

14.5. MEASURES TO BE TAKEN IN CASE OF BODILY INJURY
1. If you come to a scene of an electrical accident, do not endanger your
own life by careless action!
2. First find out if it is a question of a high or low voltage.
3. If it is a question of a high voltage, do not commence any saving opera-
tions before the electricity plant has switched off the current. Approaching
the victim who is inside the machine, which is in contact with an electric
wire or cable, can be dangerous. Remember that, in a high voltage wire,
there is no fuse which blows, but the wire is always dangerous until an ex-
pert has made it dead.
4. The victim can be saved from low voltage wires or from a machine, which
is in contact with a low voltage wire, by using a dry, clean rope or a dry
and unpainted wooden stick or board. Remember to stay as far away
from the wires or the machine as possible. The victim must not be
touched before he has been completely detached from the parts with a
voltage.
5. If the victim is unconscious, resuscitation and artificial respiration should
be commenced immediately.
Page 49 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

14.6. SERVICE OF ELECTRIC EQUIPMENT
1. Only professional electricians or their subordinates are allowed, under the
supervision and guidance of a professional electrician, to install, repair or
service electrical equipment and materials in accordance with the regula-
tions related to electrotechnology.
2. Always follow the regulations of the law related to electricity and electric
safety regulations of the user country.
3. Always use original electric parts.
4. If there is trouble in the electric supply, stop the machine immediately.
5. The machine parts to be inspected, serviced and repaired must be made
dead if the regulations so require. First check that there is no voltage in
the parts disconnected, lock the main switch or earth the part if necessary.
6. Inspect the electric equipment of the machine regularly. All faults e.g.
loose wires or damaged insulation must be repaired immediately.
7. Before making any changes in the electric equipment, contact the electric
design department of the manufacturer to get a written permit for the
changes so as not to affect the machine operation.
8. Do not direct a water or steam jet at the electric cables.
If the part has a voltage

1. If the part worked on must have a voltage, an extra persons is required for
the job who, in the event of an emergency, turns off the voltage with the
emergency or main switch. Follow the electric safety regulations.
2. Isolate the working area with the help of a red and white safety chain and
a warning sign.
3. Use only voltage limited tools.
4. Exercise extreme caution.
Page 50 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

14.7. SERVICE OF BATTERIES
Always use safety glasses, overalls and gloves when servicing batteries.
1. When disconnecting the batteries, always disconnect first the --- pole and
then the + pole. Connect first the + pole and then the --- pole.
2. In order to prevent sparkling when connecting the charging device of the
battery, disconnect the charging device from the current supply or always
turn it off before connecting the charging wires to the poles. The plugs of
the battery cells must be opened a little in order to release the gases from
the battery.
3. The battery acid burns the skin, makes holes in clothes and may cause
blindness if you get it in your eyes. If you get battery acid on you, rinse
the skin immediately with an abundant amount of water. Use sodium car-
bonate to neutralize the acid if you have got acid in your eyes. In addition,
rinse your eyes with an abundant amount water and call a doctor.
4. When servicing the batteries, it is to be remembered that when charging
or discharging them, a lead accumulator develops hydrogen and oxygen,
which combine to form an extremely inflammable gas mixture. A sparkle
or flame may cause an explosion. Ventilate the space if necessary before
disconnecting or connecting the cable.
5. In order to prevent an explosion, the fluid level must be correct and it
should be checked regularly. Add distilled water as necessary only before
starting but never after the machine has been in operation. When the fluid
level is high enough, there is less space for gas in the cells.
6. Always use a torch when checking the fluid level, never use an open fire.
7. The battery poles must never be short---circuited because the sparkling
may explode the battery.
8. Do not test the electric equipment by connecting a wire to the battery
pole.
Page 51 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
15. SAFETY INSTRUCTIONS FOR THE HYDRAULIC

CIRCUITS
Only experienced professionals are allowed to service, repair and install the
hydraulic equipment.
1. Only trained and experienced technicians are allowed to install, repair or
service hydraulic equipment.
2. Check the equipment for possible leaking. All leaks in the hydraulic sys-
tem must be repaired before the equipment is taken into operation. Check
all hydraulic hoses, especially those which have to bend in use and re-
place the hoses as necessary. Check that all the safety caps and filling
plugs have been closed tightly.
3. Check that all the safety equipment such as pressure control valves, pres-
sure gauges etc. are in place and in operating condition. You must know
how to use them. The safety systems must never be bypassed.
4. All hydraulic hoses, which are in bad condition or leaking must be re-
placed.
5. It is forbidden to change the pressure values of any operation.
6. Check daily and always after damage the most important parts of the hy-
draulic system. Repair the damaged parts immediately.
7. Exercise caution when emptying the hydraulic tank. Hot oil may cause
injuries.
8. Clean the surface of the components to be repaired. Do not use dissol-
vents when cleaning the parts.
9. Do not try to do repairs which you do not master.
10. Never try to do repairs in the hydraulic circuit, when the system is pressur-
ized.
11. Do not use the equipment if the system has a leaking hose.
12. Never try to tighten a leaking hose if the system is pressurized but,
instead, the boom must be lowered and the pump stopped. A com-
pressed oil jet may penetrate your skin and be lethal.
13. Make sure that all joints are tight and that the lines have not been dam-
aged.
14. Never try to locate a leakage in the hoses or connectors with your hand. A
high---pressurized oil jet from the leakage may penetrate your skin and be
lethal. The oil jet may also cause a danger of a fire.
Page 52 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions

15. When repairing hydraulic leaks use safety gloves to prevent compressed
oil from penetrating your skin.
16. Compressed oil is inflammable and may cause bodily injuries.
17. Avoid direct contact with oil. Use safety glasses to prevent oil from getting
into your eyes.
18. Do not work underneath a machine or component, which is only held up
hydraulically. Use separate supports when servicing or repairing.
19. Do not disconnect the cylinders of the boom or the machine or their
counter valves before the boom or machine has been supported well.
20. The length and quality of the pipe connectors and hoses must correspond
to the set requirements. When replacing or repairing the hoses, use origi-
nal spare parts or hoses and connectors, which are in accordance with
the manufacturer’s recommendations. It is to made sure, in particular, that
the pressure classes of the hoses and connectors correspond to the oper-
ating pressures.
21. All changes in the equipment require a written permit from the manufac-
turer.
22. The pressure hoses must never be bent when the pump is in operation. A
danger of an obstruction caused by bending adds to the risk of an acci-
dent.
23. Use the control equipment with special care until the hydraulic oil has
reached the correct temperature. Warm up the hydraulic oils in accor-
dance with the instructions provided by the manufacturer.
24. Do not service the machine when the engine is running unless absolutely
necessary e.g. when discharging air from the system.
25. Before you disconnect lines:
--- Release the pressure in the system.
--- Release the pressure in the pressure accumulator.
26. The hydraulic pumps and control valves are heavy. Before you disconnect
them, reserve a firm device such as a block, a lifter or a bench to unfasten
the equipment safely.
27. Keep the hydraulics correctly adjusted to ensure control of the machine.
28. Hydraulic oils do not normally evaporate easily. However, hot oil, splashes
and oil fog (under pressure) are danger factors. Small amounts do not
normally cause intoxication when inhaled or swallowed. Old, dirty oil is
more dangerous than new oil.
29. If you get oil in your eyes, rinse them with abundant water and see a doc-
tor.
Page 53 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions

30. Occasional skin contact is not normally harmful if the skin is healthy and
there are no open wounds. You can wipe or wash the oil from the skin.
The problem is repeated skin contact, which results in dry and chapping
skin of the hands. The oil dissolves the natural protective grease layer off
the skin and the skin gets small cuts and scratches easily. Hydraulic oil
that penetrate the scratches can cause an inflammation and a rash.
31. If you cannot avoid splashes or skin contact, use safety gloves, glasses
and clothing as necessary. Do not use oily clothes .
32. Hydraulic oil must not get into the environment, because it may pollute the
water system and groundwater. However, if it is necessary to work in eco-
logically sensitive areas, mineral oil should be replaced by vegetable oil
(rape---seed oil).
33. Store the oil in a closed vessels provided by the factory. Try to get the oil
directly from the vessel into the tank.
34. If you must pour oil into other containers, it is important that they are
clean. Also the caps, funnels, filters and filling holes must be clean.
35. Do not store oil out---of---doors to prevent water from condensing in the
oil.
36. Always drain waste oils into a vessel and not into the environment.
37. Although no outside damage can be inspected in the hydraulic hoses, re-
place them at six months intervals (the maximum storing time of two years
included).
Page 54 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
16. SAFETY INSTRUCTIONS FOR COMPRESSED AIR

HOSES AND WATER PIPES
There must be no pressure in the pneumatic circuit, when it is being repaired.
1. Check the pipes, valves, draining cocks and other components of the
pneumatic and water system. Make sure that both the air and water pres-
sure are correct and that there are no leaks.
2. When servicing and repairing the compressor make sure that there is no
3. Never adjust the pressure of the system higher than the manufacturer has
recommended. Exceeding the given values does not increase the operat-
ing capacity of the equipment.
4. The pressure accumulators of the vehicle have been pressurized with Ni-
trogen N2. Before disconnecting the pressure accumulators from the ma-
chine, release the pressure from the accumulators by opening the filling
valve. Do not overfill the pressure accumulators. Service and repair the
accumulators in accordance with the operating instruction.
5. Only specially trained persons are allowed to install, repair or service hy-
draulic equipment.
6. Empty the air and water pipes and valves if the temperature falls below
the freezing point.
7. Drain the condensed water from the system in accordance with the in-
structions provided by the manufacturer.
Page 55 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
Technical Bulletin
0199 - 99 - 3005/9 EN
This Circular supersedes: TR 0199-99-3005/8
Date: 09.08.2010 DEUTZ AG

Author: Winkler/Knuth, VE-TK1; Fischer, VE-FI Ottostraße 1
51149 Köln
Phone: +49 (0) 221 822-4590 www.deutz.com

Fax: +49 (0) 221 822-15 4590
DEUTZ engines
● All above-mentioned DEUTZ engines
● Product number(s) EKZ:
All product code numbers
● Assemblies:
99
Fuels
The 9th replacement was introduced due to more detailed specifications of:
● introduction of engines with new emission stages Tier 4 interim and stage IIIB.
● Extension of biodiesel releases
● Revision of fuel standards
General
This bulletin defines for which compact engines of the DEUTZ brand the following fuels are
approved:
● Diesel fuels
● MDF distillate fuels
● Light heating oils
● Jet fuels
● Biofuels
For general data on fuels, see section:
● Biological contamination in fuels

● Fuel additives
Note:
The part numbers indicated in this document are not subject to updating.
Binding for the identification of spare parts is exclusively the spare parts documentation.
OBJ_DOKU-22583-001.fm 1 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Distillate fuels with residue oil percentages or mixed fuels may not be used in DEUTZ com-
pact engines.
The DEUTZ vehicle engines are designed for diesel fuels in accordance with EN 590 with
a cetane number of at least 51. DEUTZ engines for mobile work machinery are designed
for a cetane number of at least 45. When using fuels with a low cetane number, a disturbing
formation of white smoke and ignition stutter is to be expected under some circumstances.
This Technical Bulletin applies for all air-cooled and liquid-cooled compact engines of the
DEUTZ brand. For engines which are no longer in production, this TB applies accordingly.
This TB only applies up to year of production 2000 for engines of the 226 series.
A cetane number of at least 40 is approved for the US market, therefore special engine ver-
sions were developed to avoid starting difficulties, extreme white smoke or increased hy-
drocarbon emissions. If the use of fuels with a very low cetane number is also known in
advance in other countries, we recommend ordering the engines in EPA versions. It is gen-
erally recommened to use fuels with a higher cetane number than the minimum require-
ment of 40 in winter.
Fuels must be used which are regulated in the respective national regulations (e.g. in Ger-
many by the 10th BimSchV). No fuels which deviate from these national regulations may
be used (e.g. no fuel may be used in Europe if it only meets the limit values of the US stand-
ard purely by chance).
The certification measurements for compliance with the legal emission limit values are car-
ried out with the test fuels specified in the laws. These correspond with the diesel fuels ac-
cording to EN 590 and ASTM D 975 described in the following section. No emission values
are guaranteed with the other fuels described in this bulletin. The owner is obliged to check
the permission for the use of fuels according to the regional regulations.
Engines which are equipped with exhaust gas after-treatment by particle filters (DPF), die-
sel oxidation catalytic converters (DOC), particle oxidation catalytic converters or an SCR
system (Selective Catalytic Reduction) may only be operated with sulphur-free diesel fuels
(EN 590, DIN 51628, ASTM D975 Grade 2-D S15, ASTM D975 Grade 1-D S15 or heating
oil in EN 590 quality). Otherwise compliance with the emission requirements and durability
is not guaranteed.
In a warranty case the customer must prove by a certificate from the fuel supplier that a re-
leased fuel was used.
The following list specifies the released fuels for the different series and emission stages,
the following text contains further data about these releases:
OBJ_DOKU-22583-001.fm 2 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
List of released fuels
2009/ TCD 2.9 1011/ 1012/ 2012/ TCD 4.1 DEUTZ

226/909/ L4 2011 1013/ 2013/2V/ L4 Natural
910 2012/ 4V Fuel En-
TDC 3.6 TCD 6.1
2013 gine ®
L4 L6
TCD 7.8
L6
up to from up to up to from
Tier 3 Tier 4 in- Tier 3 Tier 2 Tier 3 Tier 4 in-

terim terim
Stage Stage Stage Stage Stage Stage

IIIA IIIB IIIA II IIIA IIIB
EN 590, DIN 51628,  5    5 

ASTM D975
Distillate fuels for marine engines - - - - - - -

1
Non-road fuels (light heating oils)  2   1 2
-
Jet fuels - -   - - -
Biodiesel (up to 100 % EN14214,    

up to 20 % ASTM D7467) - - -
Vegetable oil (DIN V 51605) 

- - - - - -
TCD TCD 1015 2015 TCD 12.0 413/513/ 912/913/

2013 4V 2013 4V V6 912/913/ 1013M/
914 1015M/
Commer- Commer- TCD 16.0
2015M/
cial vehi- cial vehi- V8
914M
cles cles
Marine
engines
up to from up to from
Euro III Euro IV Tier 2 Tier 3 Tier 4 in-

terim
Stage II Stage Stage

IIIA IIIB
EN 590, DIN 51628,     5  

ASTM D975
Distillate fuels for marine engines - - - - -  

1 2
Non-road fuels (light heating oils)     
- -
Jet fuels   
- - - -
3 4
Biodiesel (up to 100 % EN14214,    
up to 20 % ASTM D7467) - -
OBJ_DOKU-22583-001.fm 3 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Restrictions
 1 Release only for heating oils with EN 590 quality but less strict limit values for density, viscosity
and sulphur content, see chapter Non-road fuels and light heating oils.
2 Release only for heating oils with EN 590 quality, see chapter Non-road fuels and light heating oils.
3 Release up to 30 %(V/V) EN14214 at replacement interval of the SCR catalytic converter of
200,000 km, see chapter Biofuels.
4 Release for engines as of 01.07.2010, retrofitting possible in earlier engines.
US biodiesel release up to 50 % (V/V) for MSHA engines
5 Release for US diesel fuel according to ASTM D975 S15 only
6 Does not apply for the 1015M series
Diesel fuels
Diesel fuels are released and can be used according to the following specifications:
Fuel Specifications
DIN EN 590 (biodiesel content max. 7 %(V/V)) Appendix 2
DIN 51628 (biodiesel content max. 7 %(V/V)) Appendix 3
ASTM D 975-09b Grade 1-D S15 Appendix 4
JIS K 2204 No. 1, No. 2, No. 3 Appendix 5
NATO F-54, equivalent to diesel fuel in accordance with EN 590 Appendix 2
US fuels in accordance with ASTM D 975 1-D S500 and ASTM D 975 2-D S500 are not
released for engines from Tier 4 interim or Stage IIIB.
Japanese diesel fuels according to JIS K 2204 Grade 1 Fuel und Grade 2 Fuel are only re-
leased if the lubricating properties correspond with diesel fuel EN 590 (HFRR max. 460 mi-
crometer according to EN ISO 12156-1).
The EN 590 standard has the status of a national standard in the countries of the EU, e.g.
DIN EN 590. The NATO fuel F-54 is equivalent to diesel fuel in accordance with EN 590.
Diesel fuels in other countries

The table in appendix 15 contains the requirements for diesel fuels for the countries in
which none of the released fuels named in this bulletin exist.
OBJ_DOKU-22583-001.fm 4 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Lubricating capacity for low-sulphur and sulphur-free fuels

Insufficient lubricating capacity can lead to serious wear problems above all in common rail
injection systems. Too low a lubricating capacity is particularly a problem in fuels with a low
sulphur content (and in this respect sulphur contents <500 mg/kg can already be consid-
ered low). An adequate lubricating capacity is guaranteed by the appropriate additives in
low-sulphur (<50 mg/kg) or sulphur-free (<10 mg/kg or <15 mg/kg) diesel fuels according
to EN 590, DIN 51628 and ASTM D 975. In low-sulphur and sulphur-free diesel fuels which
do not comply with this standard, the lubricating capacity may have to be guaranteed by
additives. The parameter for sufficient lubricating capacity is a maximum wear spot of 460
micrometers in the HFRR test (EN ISO 12156-1).
High sulphur content in the fuel

Fuels with a sulphur content >0.5 %(m/m) (5000 mg/kg) demand a shorter lubricating oil
change interval (see Technical Bulletin 0199-99-3002). These fuels with a high sulphur con-
tent may not be used in engines with exhaust gas after-treatment as already explained (Tier
4 interim or Stage IIIB). Fuels with a sulphur content >1.0 %(m/m) are not permissible due
to high corrosion and considerable shortening of the engine life. Low-ash engine oils (low
SAPS oils, sulphate ashes 1.0 %(m/m) may not be used with fuels with a sulphur content
>50 mg/kg.
Winter operation with diesel fuel

Special demands are placed on the cold behaviour (temperature limit value of the filtrability)
for winter operation. Suitable fuels are available at filling stations in winter.
Mixing with petrol is not permissible for safety and technical reasons (cavitation in the in-
jection system).
Diesel fuels up to -44 °C are available for an Arctic climate. Mixing flow improvers with the
diesel fuel is possible. The choice of a suitable additive and the necessary dosing and mix-
ing procedure must be discussed with the fuel supplier.
If only summer diesel fuel is available, petroleum can be added to the diesel fuel up to 30
% (V/V) at low temperatures as shown in the diagram below.
A1 Mixing petroleum with summer diesel fuel
OBJ_DOKU-22583-001.fm 5 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
The mixing should take place in the engine tank: First fill in the necessary amount of petro-
leum and then add the diesel fuel.
For engines with common rail injection, the mixing of petroleum and adding of extra low ad-
ditives is not permissible. Fuels in accordance with ASTM D 975 Grade 1-D or DIN EN 590
- Arctic-Diesel may have no petroleum added.
Marine distillate fuels

This includes distillate fuels which are used in shipping. Only marine distillate fuels which
contain no residue oils (residue from the distillation process) may be used. The releases
apply exclusively for DEUTZ marine engines of the 413/513/912/913/914M/1013M/1015M/
2015M series.
The following marine fuels may be used:
Fuel Specifications
DIN ISO 8217 DMX Appendix 6
DIN ISO 8217 DMA (restriction: sulphur content max. 1,0 %(m/m) Appendix 6
NATO F-75 Appendix 7
NATO F-76 Appendix 8
● The cetane number must be at least 40, otherwise starting difficulties, extreme white
smoke or increased hydrocarbon emission may occur.
● At a density of > 0.860 g/cm3 a return blocking on the injection pump is necessary (may
only be done by personnel authorised by DEUTZ).
● The possible high sulphur content  0.5 %(m/m) requires a shorter lubricating oil
change interval. Fuels with a sulphur content > 1.0 %(m/m) are not permissible due to
higher corrosion and considerable shortening of the engine life. It must also be pointed
out that fuels in accordance with ISO 8217 DMA are only permissible when the maxi-
mum sulphur content is 1.0 %(m/m).
● Low-ash oils (low SAPS) are not permissible already at sulphur contents >50 mg/kg,
i.e. are not usually suitable for marine fuels.
● Because of the possible heavy contamination, great emphasis must be placed on fuel
cleaning and possibly the installation of an additional fuel filter with a water trap to avoid
biological contamination especially.
OBJ_DOKU-22583-001.fm 6 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Non-road fuels and light heating oils

In some European countries, non-road fuels are defined with the same properties as heat-
ing oil but are taxed differently to diesel fuels. Systems which allow the use of heating oils
and are subject to tax relief in Germany are described in the Energy Taxation Act (§3). The
user must always abide by the pertient tax regulations. These are not part of this bulletin.
With regard to use in the engine (warranty rights), no differences are to be made between
the appropriate non-road fuels and light heating oils.
● For engines up to Tier 2 / Stage II and engines up to Tier 3 / Stage IIIA with mechanical
injection, the following light heating oil may be used:
Fuel Specifications
DIN 51603-1 Appendix 9
● For all engines up to Tier 3 / Stage IIIA, other light heating oils and non-road fuels may
be used if they comply with all the limit values of EN 590 except for the fuel density, the
cetane number, and the sulphur content. The following limit values apply for these pa-
rameters:
Fuel parameter Unit Limit value Test method

Cetane number min. 49 EN ISO 5165 or EN
15195 or DIN 51773
with national appen-
dix DIN EN 590 NB.4
Fuel density at 15 °C kg/m3 820 - 860 EN ISO 3675
or
EN ISO 12185
Sulphur content mg/kg max. 1000 EN ISO 14596 or EN
ISO 8754 or EN
24260
● For engines from Tier 4 interim / Stage IIIB, light heating oils may only be used if they
comply with all the limit values of EN 590.
● The cetane number must be at least 40 otherwise starting difficulties, extreme white
● Light heating oils and non-road fuels are not generally released for commercial vehicle
engines.
OBJ_DOKU-22583-001.fm 7 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Jet fuels
The following jet fuels can be used:
Fuel Specifications
F 34/F 35 (kerosene, NATO designation) Appendix 10
F 44 (kerosene, NATO designation)
F-63 (kerosene, NATO designation, equivalent to F-34/F-35 with additives)
F-65 (kerosene, NATO designation, 1:1 mixture of F-54 and F-34/F-35) Specifications
available on re-
JP-8 (kerosene, US military designation)
quest
JP-5 (kerosene, US military designation)
Jet A (kerosene for civil aviation)
Jet A1 (kerosene for civil aviation)
● Released for engine series 912/913/914/1011/1012/1013/2011/2012/2013/1015 up to

Tier 2 / Stage II and Euro III. These series are also released for Tier 3 / Stage IIIA where
engines with mechanical injection are concerned. The TCD 2012/2013 series with so-
lenoid valve injection (MV-system) Tier 3 / Stage IIIA are also released.
● Individual series which already have Common Rail injection systems in Tier 2 / Stage
II and all other engines with electronic injection are not released for jet fuels. All en-
gines with exhaust gas after-treatment are not released for jet fuels either.
● The cetane number must be at least 40, otherwise starting difficulties, extreme white
● Because of the lower density and the greater leak fuel volume due to lower viscosity,
depending on the engine speed and torque, a power loss up to 10 % is possible.
Blocking up of the injection pump is not allowed!
● There are some problematical fuel properties amongst the listed jet fuels (viscosity, lu-
bricating capacities and low boiling point). A slight increase in wear in the injection sys-
tem is to be expected which can lead to a statistically shorter life of these components.
The engine guarantee is maintained when these fuels are used.
● Jet fuels can be mixed with each other. Mixing of kerosene with diesel fuel in accord-
ance with EN 590 in order to improve the flow properties in winter operation is permit-
ted.
OBJ_DOKU-22583-001.fm 8 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Bio fuels
The generic term biofuels includes biodiesel and pure vegetable oils.
Bio-diesel
Biodiesel is Fatty Acid Methyl Ester (FAM) of the vegetable oil. It is produced on a large
scale by re-estering of vegetable oil and methanol to glycerine and fatty acid methly ester.
It is possible to use different vegetable oils such as soya oil, palm oil, rape seed oil or sun-
flower seed oil.
In Europe biodiesel must comply with the EN 14214 standard. Because the biodiesel qual-
ities available on the market do not always meet the requirements, DEUTZ customers in
Germany are recommended to ensure the quality by buying biodiesel with an AGQM cer-
tificate (Association for Biodiesel Quality Management). The customers should also have
compliance with the quality demands confirmed by the supplier by submission of a current
analysis certificate of an ISO 17025 certified laboratory.
The use of US biodiesel, based on soya oil methly ester, is only permissible in mixtures with
diesel fuel with a maximum biodiesel content of 20 %(V/V). The US biodiesel used for the
mixture must comply with the ASTM D6751-09a (B100) standard. Users are recommended
to use biodiesel qualities with a quality certified in accordance with BQ 9000.
Fuel Specifications
Biodiesel according to EN 14214 Appendix 11
US biodiesel blends according to ASTM D7467 - 09a (B100) Appendix 12
(only for biodiesel mixtures with diesel fuel of 6-20 %(V/V))
US biodiesel according to ASTM D6751 - 09a (B100) Appendix 13
(only permissible for mixtures with diesel fuel of 20-50 %(V/V))
Released engines
● The series 413/513/912/913/914/1011/1012/1013/2011/2012 and 2013 are released if

compliant with the basic conditions specified in the text below as of year of manufac-
ture 1993 for biodiesel according to EN 14214 as well as mixtures up to 20 %(V/V) US
biodiesel according to ASTM D7467-09a (B100).
● The TCD 2012 2V/4V and TCD 2013 2V/4V series for mobile work machinery up to
Stage IIIA/Tier 3 are released for 100 %(V/V) biodiesel according to EN 14214 as well
as mixing of up to 20 %(V/V) US biodiesel according to ASTM D7467-09a. For TCD
2013 EURO III/IV/V commercial vehicles the mixing in of up to 30 %(V/V) biodiesel in
accordance with EN 14214 is released as of October 2009 on condition that the SCR
catalytic converters are replaced every 200,000 km. Before this date not all the engines
are fitted with biodiesel-resistant hoses.
Further information is available from head office. Regular replacement of the SCR cat-
alytic converter is necessary because biodiesel in accordance with EN 14214 can con-
tain up to 5 mg/kg sodium+potassium and these elements are damaging to SCR
catalytic converters. Engines in which an additional diesel particle filter (DPF) is in-
stalled are excepted from the release.
● Engines of the 2015 series with MV injection systems are released for operation with
biodiesel as of production date 01.07.2010.
The release applies for biodiesel in accordance with EN 14214 as well as as an addi-
OBJ_DOKU-22583-001.fm 9 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
tive mixture for up to 20 %(V/V) US biodiesel in accordance with the ASTM D7467-09a
standard. For engines operated within the jurisdiction of the Mine Safety and Health
Administration (MSHA), additive mixtures of up to 50 %(V/V) US biodiesel in accord-
ance with ASTM D6751-09a are permissible.
Mixtures of US-biodiesel with diesel fuel are not very suitable for cold conditions so that
their use in winter is not recommended.
Engines with an earlier production date can be retrofitted. Head office can provide in-
formation about the scope of the retrofit.
● Turbocharged engines are excepted from the release for applications which are nor-
mally operated with a high load above 80% nominal power; these are, for example, en-
gines in block type heating power stations.
● Engines for Tier 4 interim / Stage IIIB are not released for biodiesel at present. Howev-
er, suitable tests are being planned.
Basic conditions to be observed
● Because of the low heating value, a power loss of 5-9 % and an extra fuel consumption
of 7-8 % in comparison with diesel fuel according to EN 590 is possible. Increasing of
injection fuel quantity to compensate the lack of power is not allowed.
● The lubricating oil change interval must be halved in comparison with operation with
diesel fuel according to EN 590.
● Standstill times of longer than 4 weeks must be avoided with biodiesel. Otherwise the
engine must be started and shut down with diesel fuel.
● Engines with a low annual running time, e.g. emergency generators, are excluded from
operation with bio-diesel.
● In series engines, the fuel pipes, the fuel manual supply pumps, and the LDA dia-
phragms (series 1012/1013/2012/2013/TCD 2012 2V mechanical and TCD 2013 2V
mechanical) are not resistant to biodiesel and must be changed annually.
● To avoid the annual replacement, a piston with an LDA diaphragm resistant to biodie-
sel fuel was introduced. This piston can be ordered from DEUTZ Service with part
number 02113543 if required. Since the fuel pipes can dissolve prematurely at increas-
ing fuel temperature and high running performance, they may have to be replaced be-
fore one year is up. The fuel pipes must be checked for damage (swelling) in the course
of daily maintenance E 20. The use of biodiesel-resistant fuel pipes (Viton) is recom-
mended; in this case the annual replacement can be dispensed with.
● Biodiesel can be mixed with normal diesel fuel but the basic conditions described in
this section apply for mixtures. Mixtures containing up to 7 %(V/V) biodiesel (B7) as
they are permitted in EU countries according to national laws are excepted. However,
the biodiesel mixtures must comply with EN 14214 in any case.
● Approx. 30-50 oh after changing over from diesel fuel to bio-diesel, the fuel filter should
be changed as a precaution to avoid a drop in performance due to clogged fuel filters.
Deposited fuel ageing products are dissolved by bio-diesel and transported into the
fuel filter. They should not be changed immediately, but after approx. 30 to 50 hours,
because the dissolving of dirt takes a certain amount of time.
● All parts carrying fuel which are installed later (by OEM or end customers, e.g. fuel pre-
filter and fuel pipes) must be suitable for operation with biodiesel.
● To increase the oxidation stability of the used biodiesel and to improve the storability
OBJ_DOKU-22583-001.fm 10 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
and reduce deposits and clogging in the injection system, it is recommended to use the
DEUTZ additive "DEUTZ Clean-Diesel InSyPro" in the recommended concentration
(see Technical Bulletin 0199-99-1210).
Plant oil
Pure plant oils (e.g. rape seed oil, soy oil, palm oil) are not classified as bio-diesel and ex-
hibit problematic properties for engines which were not designed for operation with plant
oils (strong tendency to coke, risk of piston seizure, extremely high viscosity, poor evapo-
ration behaviour).
DEUTZ NATURAL FUEL ENGINE®

DEUTZ has developed the first series engine based on the TCD 2012 2V/4V series with the
DEUTZ Common Rail System ® (DCR) for use with rape seed oil.
These engines are released for use of 100 %(V/V) rape seed oil (refined or cold pressed)
according to DIN V 51605 (appendix 14) and biodiesel according to EN 14214 (appendix
11).
Basic conditions to be observed
● Because of the lower heating value, a power loss of 5-10 % and an extra fuel consump-
tion of 4-5 % in comparison with diesel fuel according to EN 590 is possible. Blocking
up of the injection pump is not allowed.
● The engine is a two-tank system with switching between diesel fuel and rape seed oil.
Alternatively biodiesel can be used instead of rape seed oil or diesel fuel.
● At temperatures below 5 °C, rape seed oil should be replaced by diesel fuel or biodie-
sel.
● Shutdown periods of longer than 4 to 6 weeks must be avoided with bio-diesel and rape
seed oil. Otherwise the engine must be started and stopped with diesel fuel.
● The lubricating oil change interval must be halved in comparison with operation with
diesel fuel according to EN 590.
● Important fuel properties such as water content, oxidation stability, calcium, magnesi-
um and phosphorus content and the total contamination are influenced especially by
the harvest time, the pressing process in the oil mill, the storage of the rape seed oil
and the further logistics chain. Because of the frequent exceeding of the limit values at
distributed oil mills, the user is recommended to have the quality of the rape seed fuel
delivery confirmed by an analysis certificate. In cases of doubt, the quality can be cer-
tified by an analysis carried out by a laboratory accredited according to ISO 17025,
(e.g. ASG Analytik GmbH, D-86356 Neusäß, Tel. ++49 (0)821-450-423-0).
● Mixtures with other plant oils such as sunflower seed oil, soya oil or palm oil are not
permissible. Pure vegetable oils (e.g. rape seed oil, soya oil, palm oil) are not classified
as biodiesel and have problematical properties in engines which were not developed
for vegetable oil operation (great tendency for coking, danger of piston seizure, ex-
tremely high viscosity, poor evaporation behaviour.
● To increase the oxidation stability of the used biodiesel and to improve the storability
and reduce deposits and clogging in the injection system, it is recommended to use the
DEUTZ additive "DEUTZ Clean-Diesel InSyPro" in the recommended concentration
(see Technical Bulletin 0199-99-1210).
OBJ_DOKU-22583-001.fm 11 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Notes for the storage of rape seed oil in fuel stations for own use:
● To be stored in dark places at constant low temperatures (maximum 20 °C, optimal in

ground tanks at 5 – 10 °C). Storage temperatures below freezing point should be avoid-
ed, ground tanks are also optimal in this respect. The tanks may not be permeable to
light (no polythene tanks).
● The storage time for rape seed oil should be limited to a maximum of 6 months at stor-
age temperatures up to 20 °C, for ground tanks <10 °C maximum 12 months).
● Due to the hygrosopic (attracting water) properties of rape seed oil, works fuel stations
should if possible be fitted with dehumidification on the air exchange system.
● Minimise contact with air with the use of thick locks.
● Contact with metals with a catalytic effect, above all copper or brass, must absolutely
be avoided. These materials must not be used at all in the storage system (e.g. pipes,
screws, pumps, etc).
● Avoidance of gathering of sediments by removal approx. 10cm above the tank floor.
● The tanks should be regularly cleaned, if a bacterial infestation occurs the bactericide
Grotamar 71 should be used by a specialised firm.
Series diesel engines
The conversion of other DEUTZ engines to operation with pure plant oil with conversion kits
and modified tanks systems of various manufacturers is not allowed and leads to loss of the
guarantee rights.
Only engines of the 912W/913W/413FW/413W series with the 2-tank system from Henkel-
hausen, D-47809 Krefeld, Fax no. ++49 (0)2151 574 112, can be operated with rape seed
oil fuel according to the DIN pre-standard DIN V 51605, see appendix 15.
OBJ_DOKU-22583-001.fm 12 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Synthetic fuels (GTL, CTL, BTL and HVO)

These fuels are produced synthetically from natural gas (Gas-to-Liquid), coal (Coal-to-Liq-
uid) or biomass (Biomass-to-Liquid). At BTL one also refers to so-called biogenic fuels of
the 2nd generation.
They differ from diesel fuel as follows:
● Chemical composition: pure paraffins, no aromates

● High centane number
● Positive influences on emissions (nitric oxides and particles)
● Lower density, this results in a lower engine performance
Deutz has tested such fuels and confirmed the positive influences on the emissions. How-
ever, it is a well known fact that engines which are operated for longer periods with conven-
tional diesel fuel and then converted to synthetic fuels suffer shrinkage of polymer seals in
the injection system and thus from fuel leaks. The reason for this behaviour is that the aro-
mate-free synthetic fuels can lead to a change in the selling behaviour of polymer seals.
Therefore conversion from diesel fuel to synthetic fuel may only be done after changing the
critical seals. The problem of swelling does not occur when an engine was operated with
synthetic fuel from the start.
Hydrogenated or hydrotreated vegetable oils (HVO) defines vegetable oils which are con-
verted into hydrocarbons by a catalytic hydrogenation. Paraffins produced from vegetable
oils by this process consisting of mixtures of saturated hydrocarbon chains of different
lengths.
The density of these hydrated vegetable oils is about 700 kg/m3 and is therefore much low-
er than mineral diesel fuel, the cetane value is much higher than that of diesel fuel with val-
ues of 80-90. This fuel is also free from sulphur and aromatic compounds.
Because of their very positive influences with regard to the cetane number and emission
behaviour, these synthetic fuels are blended partly in small percentages in the so-called
premium diesel fuels and in this case have no negative influences on the polymer compat-
ibility.
OBJ_DOKU-22583-001.fm 13 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Biological contamination in fuels
Symptoms
The following symptoms may indicate that a fuel tank is contaminated by micro-organisms:
● Corrosion of inside of tank

● Filter blockage and associated loss of power due to gel-like deposits on the fuel filter
(especially after longer standstill times)
Cause
Micro-organisms (bacteria, yeast, fungus) can multiply into biosludge under favourable
conditions (especially favoured by heat and water).
The water entry is usually caused by condensation of the water contained in the air. Water
dissolves poorly in fuel so that the water which enters sinks to the bottom of the tank. The
bacteria and fungi grow in the watery phase at the boundary with the fuel phase from which
they draw their nutrition. There is an increased risk especially with biodiesel (FAME).
In suspicious cases biological contamination according to DIN 51441 (determination of the
number of colonies in mineral oil products in the boiling range below 400 °C) can be ana-
lysed by laboratories certified according to ISO 17025 (e.g. Petrolab GmbH, D-67346 Sp-
eyer, Tel.: ++49 (0) 6232-33011).
Remedial measures
● Keep storage tanks clean, regular tank cleaning by specialist companies.

● Installation of fuel pre-filters with water traps, especially in countries with frequently
fluctuating fuel qualities and high percentage of water (e.g. Separ-filter or RACOR fil-
ter).
● Use of biocide GrotaMar 71 from
Schülke & Mayr GmbH,
D-22840 Norderstedt,
Tel.: +49 (0)4052 100-0,
e-mail: info@schuelke.com
if fuel system and storage tank are already contaminated by micro-organisms. The bio-
cide must be dosed according to the manufacturer's specifications.
● Avoid direct radiation of sunlight on the storage tank.
● Use of smaller storage tanks with correspondingly short dwell times of the stored fuel.
OBJ_DOKU-22583-001.fm 14 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Fuel additives
The DEUTZ Clean-Diesel InSyPro additive is released exclusively for use in DEUTZ en-
gines. See Technical Bulletin 0199-99-1210 for notes on use and dosing.
The previously mentioned flow improvers (not for DEUTZ Common Rail engines) are an-
other exception. The use of other fuel additives is prohibited. Voiding of the warranty is to
be expected when unsuitable, unapproved additives are used.
Fuel filters
Modern diesel engines, especially with high-pressure injection and common rail injection
system make very high demands on the fuel quality. The Deutz original fuel filters are
adapted and tested for these demands. Continuous, trouble-free operation of the engines
is only guaranteed when the original filters are used. In case of damage to the injection sys-
tem within the warranty period and proof that no original filters were used, the warranty will
be voided.
Please contact the following persons if you have any questions about the listed topics.
Contact:
DEUTZ Engines
E-mail: lubricants.de@deutz.com
or
E-mail: service-kompaktmotoren.de@deutz.com
Service Information
This document has been created digitally and is valid without a signature.
OBJ_DOKU-22583-001.fm 15 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 1
General information on fuel properties, exhaust gas after-treatment systems and emission regulations
Density
The density is usually specified in g/cm3 or kg/m3 at 15 °C and is important for converting
the fuel consumption from volume to weight unit. The higher the density, the greater the
weight of the injected fuel. At the same control linkage setting, the engine output increases
with higher density.
Boiling curve
The boiling curve indicates how many volume% of the fuel is overdistilled at a certain tem-
perature. The greater the boiling residue (amount remaining after evaporation), the more
combustion residue may occur in the engine, especially in partial load operation.
Viscosity
The kinematic viscosity in mm2/s at a certain temperature (1 mm2/s = 1 cSt [centistoke]) is
specified. The viscosity must be within certain limits for engine operation. Too high viscosity
requires pre-heating.
Flashpoint
The flashpoint has no significance for the engine operation. It applies as a value for the fire
hazard and is important for classification in one of the hazard classes (decisive for storage,
transport and insurance).
Sulfur content
High sulfur content and low component temperature can cause increased wear due to cor-
rosion. The sulfur content influences the lubricating oil change intervals. Too low a sulfur
content may impair the lubricity of the fuel if this has not had lubricity improvers added.
Coke residue
The coke residue serves as a reference value for the tendency for residue to form in the
combustion chamber.
Water
Too high a water content leads to corrosion and, in connection with corrosion products and
sediments, to sludge. Disturbances in the fuel and injection system are the result.
Ash
Ash is carbon-free combustion residue which can lead to wear due to deposits in the engine
and turbocharger.
Sediments/total contamination
Sediments are solids (dust, rust, scale) which can cause wear in the injection system and
combustion chamber as well as leaks in the valves.
OBJ_DOKU-22583-001.fm 16 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Behaviour in cold
The following parameters indicate the suitability of the fuel for low temperatures:
● The solidification point indicates at what temperature the fuel no longer flows under its
own weight.
● The pour point is approx. 3 °C above the solidification point.
● The cloud point indicates at what temperature solid emissions (paraffin) are visible.
● The limit of filtrability (CFPP) indicates at what temperature filters and pipes may be
blocked.
Cetane number/cetane index

The cetane number indicates the fuel's willingness to ignite. Too low a cetane number may
lead to starting difficulties, formation of white smoke, increased carbon emission and ther-
mal and mechanical overloading of the engine. The cetane number is determined on a test
engine. The cetane index can be used alternatively as a calculated value of density and
boiling behaviour and usually correlates well with the cetane number.
Heating value
The lower heating value (Hl) indicates the amount of heat which is released when burning
1 kg of fuel.
Neutralisation number
The neutralisation number is a measure of the content of free acids in the diesel fuel or bio-
diesel fuel. It describes the amount of potassium lye required for neutralising the acids. Acid
compounds in the fuel lead to corrosion, wear and formation of residue in the engine.
Copper corrosion
Diesel fuel can act corrosively especially during prolonged storage with fluctuating temper-
ature and formation of condensation on the tank walls. To test the limit values specified in
DIN EN 590 and DIN 51628, a polished copper strip is brought into contact with diesel fuel
at 50 °C for 3 hours. Appropriate additives ensure protection of the metals which come into
contact with the fuel even under difficult conditions.
Oxidation resistance
Fuels may oxidise and polymerise partly during long storage. This can lead to the formation
of insoluble (varnish like) ingredients and the associated filter blockage.
OBJ_DOKU-22583-001.fm 17 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Lubricity
The lubricity decreases with the degree of desulphurisation and can drop to a level that
leads to considerable wear in the distributor injection pumps and common rail systems. Ex-
tremely desulphurised fuels contain special lubricity additives. The HFRR test (High Fre-
quency Reciprocating Wear Rig) was developed for evaluating the fuels (EN ISO 12156-1).
This test simulates the sliding wear in the injection pump by rubbing a ball on a polished
steel plate with constant contact force. The flattening of the ball after 75 minutes is meas-
ured as an average wear diameter (limit value 460 µm).
Zinc/copper in the fuel

Even small traces of zinc can lead to deposits in the injection nozzles, especially in the mod-
ern common rail injection systems. Therefore, zinc coatings are not permitted in tanks and
fuel pipes. Materials containing copper (copper pipes, brass parts) must also be avoided.
Bio-diesel
Biodiesel is made by re-estering of greases or oils (triglyceride) with methanol. The correct
chemical name is fatty acid methyl ester, often abbreviated to FAME. In Europe it is usually
produced by re-estering of rape seed oil (rape seed oil methyl ester = RME). In the USA,
biodiesel comes almost exclusively from soya oil (soya methyl ester = SME). Other vege-
table oils (sunflower seed oil, palm oil, jatropha oil) or animal fats are also possible.
Due to national and EU regulations biodiesel (FAME) percentages are now possible or pre-
scribed in most diesel fuels. In the new EN 590 max. 7 %(V/V) are permissible for example,
in the US-ASTM D975 max. 5 %(V/V). According to the biofuel quota law, at least 5 %(V/
V) FAME must be mixed with the normal, commercially available diesel in Germany.
Exhaust gas after-treatment systems

The introduction of new, stricter exhaust emission regulations demands the use of exhaust
gas after-treatment systems such as the SCR technique (selective catalytic eduction), the
diesel oxidation catalytic converter (DOC), the particle oxidation catalytic converter and the
diesel particle filter (DPF). For trouble-free use of fuels, as great as possible a reduction of
ash and deposit forming elements and elements which damage the catalytic converter,
such as sulphur, is necessary. Therefore these engines may only be operated with sulphur-
free diesel fuels (EN 590, ASTM D975 Grade 2-D S15, ASTM D975 Grade 1-D S15 or heat-
ing oil in EN590 quality (sulphur content max. 10 mg/kg)). Other elements such as phos-
phorus, calcium, magnesium, sodium and potassium, which especially biogenic fuels may
contain, should also be avoided as far as possible. Otherwise compliance with the emission
requirements and durability of the exhaust gas after-treatment systems is not guaranteed.
Conversion ppm
The term parts per million (ppm) is often used in fuel analyses.
The term ppm alone is not a unit of measure. It usually describes the weight concentration
(1 ppm (m/m) = 1 mg/kg). 1 ppm = 10-6 = parts per million = 0,0001 %
OBJ_DOKU-22583-001.fm 18 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Fuel quality and exhaust gas legislation

The fuel qualities to be used are closely related to the used engine and exhaust gas after-
treatment technologies and these are selected in turn with regard to the emission limits of
the exhaust laws of the countries in which the engines are used. Since the bulletin frequent-
ly refers to the exhaust gas law stages, these are explained below.
Emission laws for mobile work machinery (including building machinery, tractors, compressors, mobile elec-
tricity units)
Europe and the USA have largely similar emission legislations so that the stages specified
for EU and the USA in one line in the following table are both satisfied by an engine devel-
oped for this. The dates for introduction and limit values differ for different performance cat-
egories. The dates for the category >130 kW are the first respectively for a certain stage.
Designation of the emission stage Introduction date for engines

130 - 560 kW
EU USA EU USA
Stage I Tier 1 01.01.1999 01.01.1996
Stage II Tier 2 01.01.2001 01.01.2001
up to
01.01.2003
Stage IIIA Tier 3 01.01.2006
Stage IIIB Tier 4 interim 01.01.2011
Stage IV Tier 4 final 01.01.2014
Emission laws for commercial vehicles in the EU

The emission stages EURO I to Euro V were introduced on the following dates:
Designation of the emission stage Introduction date for engines

EURO I 01.01.1993
EURO II 01.01.1996
EURO III 01.01.2001
EURO IV 01.01.2006
EURO V 01.01.2009
EURO VI 01.01.2014
Fuel laws have also been introduced appropriate to the emission laws. For the work ma-
chinery, the limit values from stage IIIB or Tier 4 interim are so low that exhaust gas after-
treatment systems such as particle filters or SCR have to be introduced in most cases. Sul-
phur-free fuels are largely required for this and these are legally prescribed for the specified
dates. Exhaust gas after-treatment has been introduced for commercial vehicle engines as
of EURO IV.
OBJ_DOKU-22583-001.fm 19 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 2
Fuel specification (requirements and test methods):

Diesel fuel according to DIN EN 590 **
Edition October 2009
Properties Units Limit values Test method

EN 590
Cetane number min. 51 EN ISO 5165 or EN 15195 or
DIN 51773 with national ap-
pendix DIN EN 590 NB.4
Cetane index min. 46 EN ISO 4264
3
Density at 15 °C kg/m 820 - 845 EN ISO 3675/EN ISO 12185
Polycyclic aromatic hydrocarbons %(m/m) max. 11 EN 12916
Sulphur content mg/kg max. 10 EN ISO 20846 or EN ISO
20847
Flashpoint °C min. 55 EN ISO 2719
Coke residue %(m/m) max. 0.30 EN ISO 10370
(from 10 % distillation residue)
Ash content %(m/m) max. 0.01 EN ISO 6245
Water content mg/kg max. 200 EN ISO 12937
Total contamination mg/kg max. 24 EN 12662
Corrosion effect on copper Degree of Class 1 EN ISO 2160
corrosion
(3 h at 50 ℃ )
Oxidation stability g/m3 max. 25 EN ISO 12205
Oxidation stability h min. 20 EN ISO 15751
Lubricity, corrected "wear scar diameter" (wsd 1.4) m max. 460 EN ISO 12156-1
at 60 °C
Viscosity at 40 °C mm2/s 2.00 - 4.50 EN ISO 3104
Distillation EN ISO 3405
– collected at 250 ℃ %(V/V) max. 65
– collected at 350 ℃ %(V/V) min. 85
– 95 vol.% starting at °C 360
Fatty acid methyl ester (FAME) %(V/V) 7 EN 14078
Limit of filtrability * EN 116
– 15.04. - 30.09. °C max. 0
– 01.10. - 15.11. °C max. - 10
– 16.11. - 28.02. °C max. -20
– 01.03. - 14.04. °C max. -10
* Specifications apply for Germany. National regulations may deviate.
** Specification also applies for NATO fuel F-54
OBJ_DOKU-22583-001.fm 20 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 3
Fuel specification (requirements and test methods):

Diesel fuel according to DIN 51628 Edition
August 2008

DIN 51628
Appearance Clear and non-cloudy at tem- Visual assessment
peratures above the cloud
point
Cetane number min. 51 EN ISO 5165 or DIN 51773
(see chap. 5.6.)
Cetane index min. 46 EN ISO 4264
Density at 15 °C kg/m3 820 - 845 EN ISO 3675
EN ISO 12185/C1
Polycyclic aromatic hydrocarbons %(m/m) max. 8 EN 12916
20884
Flashpoint °C min. 55 EN ISO 2719
Corrosion effect on copper Degree of Class 1 EN ISO 2160
corrosion
(3 h at 50 ℃ )
Oxidation stability g/m3 max. 25 EN ISO 12205
Oxidation stability h min. 20.0 DIN 51627-2
Lubricity, corrected "wear scar diameter" (wsd 1.4) m max. 460 EN ISO 12156-1
at 60 °C
Distillation EN ISO 3405
– collected at 250 ℃ %(V/V) max. 65
– collected at 350 ℃ %(V/V) min. 85
– 95 vol.% starting at °C 360
Fatty acid methyl ester (FAME) %(V/V) 7 DIN 51627-1
Limit of filtrability * EN 116
– 15.04. - 30.09. °C max. 0
– 01.10. - 15.11. °C max. -10
– 16.11. - 28.02. °C max. -20
– 01.03. - 14.04. °C max. -10
OBJ_DOKU-22583-001.fm 21 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 4
Fuel specification (minimum requirement)

US diesel fuel according to ASTM Designation D 975-09b

Grade No. 1-D Grade No. 2-D
S500 S500
Grade No. 1-D Grade No. 2-D
S15 S15
Density at 15 °C kg/m3 max. 860 * max. 860 *
Flashpoint °C min. 38 min. 52 ASTM D 93
Water and sediments %(V/V) max. 0.05 max. 0.05 ASTM D 2709
Boiling curve at 90 vol. % °C – min. 282 ASTM D 86
°C max. 288 max. 338
Kinematic viscosity at 40 ℃ mm2/s 1.3 - 2.4 ASTM D 445
Ash content %(m/m) max. 0.01 max. 0.01 ASTM D 482

Sulphur content
– Grade No. 1/2-D S500 %(m/m) max. 0.05 max. 0.05 ASTM D 2622
– Grade Low Sulfur No. 1/2-D %(m/m) max. 0.0015 max. 0.0015 ASTM 5453
S15
Corrosion effect on copper Degree of cor- No. 3 No. 3 ASTM D 130
rosion
(3 h at 50 ℃ )
Cetane number min. 40 min. 40 ASTM D 613
Coke residue %(m/m) 0.15 0.35 ASTM D 524
according to Ramsbottom
Limit of filtrability °C ** **
* minimum requirement DEUTZ
** depending on the season and region
OBJ_DOKU-22583-001.fm 22 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 5

Diesel fuel according to JIS K 2204:2007

Special No. 1 No. 2 No. 3 Special
No. 1 No. 3
Flashpoint °C min. 50 min. 50 JIS K 2266-3
Boiling curve at 90 vol. % °C max. 360 max. max. max. JIS K 2254
350 330 330
Pour point °C max.+5 max. - max. - max. - max. - JIS K 2269
2.5 7.5 20 30
Limit of filtrability °C - max. -1 max. -5 max. - max. - JIS K 2288
12 19
Coke residue %(m/m) max. 0.1 JIS K 2270
(from 10 % distillation resi-
due)
Cetane index min. 50 min. 45 JIS K 2280
Kinematic viscosity at 30 %(V/V) min. 2.7 min. 2.5 min. 2.0 min. 1.7 JIS K 2283
℃
Sulphur content mg/kg max. 10 * JIS K 2254-1, -
2, -6, -7
Density at 15 °C kg/m3 max. 860 JIS K 2249
OBJ_DOKU-22583-001.fm 23 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 6

Distillate fuel according to DIN ISO 8217 Edition
August 2009

Category ISO-F
DMX DMA
Density at 15 °C kg/m3 / max. 890 ISO 3675 / ISO

12185
Viscosity at 40 °C mm2/s 1.4 - 5.5 1.5 - 6.0 ISO 3104
Flashpoint °C min. 43 min. 60 ISO 2719
Pour point
– Winter °C – max. -6 ISO 3016
– Summer °C – max. 0 ISO 3106
Cloud point °C max. -16 – ISO 3015
Sulphur content %(m/m) max. 1.0 ** max. 1.0 * ISO 8754
Cetane number min. 45 min. 40 ISO 5165
Coke residue %(m/m) max. 0.30 max. 0.30 ISO 10370
Ash content %(m/m) max. 0.01 max. 0.01 ISO 6245
Visual inspection clear and glossy (for DMX and DMA)
* minimum requirement DEUTZ
** observe shorter lubricating oil maintenance interval
OBJ_DOKU-22583-001.fm 24 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 7

Diesel fuel according to NATO specification

F-75 *
Density at 15 °C kg/m3 815 - 860 DIN 51757
Kinematic viscosity at 40 ℃ mm2/s 1.8 - 4.3 DIN 51562 Part 1
Flashpoint °C min. 61 DIN EN 22719
Cloud point °C max. -13 DIN EN 23015
Pour point °C max. -18 DIN ISO 3016
Ash content %(m/m) max. 0.01 DIN EN ISO 6245
Neutralisation number mg KOH/g max. 0.5 DIN 51558 Part 1
(acid)
Neutralisation number mg KOH/g 0.0 DIN 51558 Part 1
(water soluble acids)
Sulphur content %(m/m) max. 0.05 DIN 51400 Part 1 and 6
Corrosion effect on copper Degree of cor- max. 1 DIN EN ISO 2160
rosion
(3 h at 100 ℃ )
Coking tendency %(m/m) max. 0.16 DIN 51551 Part 1
Boiling curve at 90 vol. % °C max. 357 DIN 51751
Boiling curve at 90 vol. % °C max. 385
Cetane number min. 45 DIN 51773
Water content mg/kg max. 200 DIN 51777 Part 1
Sediments mg/l max. 10 ASTM D 2276 App. A 2
Demulgation capacity minutes max. 10 ISO 6614
* national specifications
DE = TL 914-0003
FR = STM 7120 B
IT = MM C 1002/E
OBJ_DOKU-22583-001.fm 25 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 8

Diesel fuel according to NATO specification

F-76 *
Density at 15 °C kg/m3 820 - 880 IP 160
Distillation %(V/V) min. 85 IP 123
– collected at 350 ℃
Kinematic viscosity at 40 ℃ mm2/s 1.7 - 4.3 IP 71
Flashpoint °C min. 61 IP 34
Cloud point °C max. -1 IP 219
Pour point °C max. -6 IP 15
Ash content %(m/m) max. 0.01 IP 4
Neutralisation number mg KOH/g max. 0.3 IP 139
Neutralisation number mg KOH/g 0.0 IP 182
(water soluble acids)
Sulphur content %(m/m) max. 1.0 ** IP 336
Corrosion effect on copper Degree of cor- max. 1 IP 154
rosion
(3 h at 100 ℃ )
Coke residue %(m/m) max. 0.2 IP 14
Cetane number min. 45 ASTM D 613
Sediments mg/l max. 10
EN = DEF. STAN 91-4
US = MIL-F-16884 J
FR = STM 7120 B
NL = KN 10323
** Observe national requirements, max. 1.0 %(m/m)
OBJ_DOKU-22583-001.fm 26 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 9

Light heating oil EL according to DIN 51603-1 Edition
August 2008

DIN 51603-1
3
Density at 15 °C kg/m max. 860 DIN 51757 or
EN ISO 12185
Combustion point MJ/kg min. 45.4 DIN 51900-1 and
DIN 51900-2 or
DIN 51900-3 or
Calculation
Flashpoint in closed pot according to Pen- °C more than 55 EN 22719
sky-Martens
Kinematic viscosity at 20 ℃ mm2/s max. 6.0 DIN 51562-1
Distillation curve EN ISO 3405
total evaporated volume parts
– up to 250 ℃ %(V/V) max. 65
– up to 350 ℃ %(V/V) min. 85
Cloud point °C max. 3 EN 23015
Temperature limit of filtrability (CFPP) de- EN 116
pending on the cloud point
– at cloud point = 3 ℃ °C max. -12
– at cloud point = 2 ℃ °C max. -11
– at cloud point <1 °C °C max. -10
Coke residue %(m/m) max. 0.3 EN ISO 10370 or
(from 10 % distillation residue) DIN 51551-1
according to Conradson
Sulphur content %(m/m) max. 0.10 EN 24260 or EN ISO 8754 or
EN ISO 14596
– for heating oil EL-1 standard
20846
– for heating oil EL-1 low sulphur
Water content mg/kg max. 200 DIN 51777-1 or
EN ISO 12937
Thermal stability (sediment) mg/kg to be specified EN DIN 51371
Storage and thermal stability It is not possible to specify a limit value until a suitable method has been
developed.
OBJ_DOKU-22583-001.fm 27 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 10

Jet fuels
NATO code F-34/F-35

NATO code **
F-34/F-35 *
Density at 15 °C kg/m3 775-840 DIN 51757
Boiling curve
– at 10 vol. % distillate amount °C max. 205 DIN 51751
– Boiling end point °C max. 300
– Distillation residue %(V/V) max. 1.5
– Distillation loss %(V/V) max. 1.5
Kinematic viscosity mm2/s max. 8.0 at -20 °C DIN 51562-1
Flashpoint °C min. 38 EN ISO 2719/IP 170
Sulphur content %(m/m) max. 0.2 DIN 51400-1 and 6
Ash content %(V/V) – EN ISO 6245
Water content mg/kg – DIN 51777-1
Sediments mg/dm3 – ASTM D 2276 App. A2
Heating value Hu MJ/kg min. 42.8 DIN 51900-1 and -2
Cloud point °C – EN 23015
Pour point °C – DIN ISO 3016
Cetane number min. 40 *** DIN 51773
Corrosion effect on copper Degree of cor- 1 EN ISO 2160
rosion
(2 h at 100 ℃ )
D = TL 9130-0012, D. STAN 91-91
USA = MIL-DTL-83133 E
F = DCSEA 134/A
GB = D. STAN 91-87/91
NL = D. STAN 91-87/91
** also applies for Germany
*** minimum requirement DEUTZ
OBJ_DOKU-22583-001.fm 28 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
NATO code F-44/F-63

NATO code
F-44 * F-63 **
Density at 15 °C kg/m3 788-845 797 ASTM-D 1298
Boiling curve
– at 10 vol. % distillate °C max. 205 max. 205 ASTM-D 86
amount
– Boiling end point °C max. 290 max. 300
– Distillation residue %(V/V) max. 1.5 max. 1.5
– Distillation loss %(V/V) max. 1.5 max. 1.5
2
Kinematic viscosity mm /s max. 8.5 at -20 °C max. 8.0 at -20 °C ASTM-D 445
Flashpoint °C min. 61 min. 38 ASTM-D 93
Sulphur content %(m/m) max. 0.30 max. 0.20 ASTM-D 1266/
2622
Ash content %(m/m) – –
Water content mg/kg – –
Sediments mg/l – –
Heating value Hu MJ/kg min. 42.6 min. 42.8 ASTM-D 240/
2382
Cloud point °C – –
Pour point °C – –
Cetane number min. 40 *** min. 48
Corrosion effect on copper Degree of 1 1 ASTM-D 130
corrosion
(3 h at 100 ℃ )
DE = D. STAN 91-86
USA = MIL-DTL-5624 T Grade JP-5
F = DCSEA 144/A
GB = D. STAN 91-86
** national specifications
*** minimum requirement DEUTZ
OBJ_DOKU-22583-001.fm 29 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 11

Fatty acid methyl ester (FAME) for diesel engines (biodiesel) according to EN 14214
Edition February 2009

DIN EN 14214
Fatty acid methyl ester (FAME) %(m/m) min. 96.5 EN 14103
Density at 15 °C kg/m3 860 - 900 EN ISO 3675
EN ISO 12185
Flashpoint °C min. 101 EN ISO 2719/EN ISO 3679
Sulphur content mg/kg max. 10 EN ISO 20846/EN ISO 20884
Cetane number min. 51 EN ISO 5165
Ash content %(m/m) max. 0.02 ISO 3987
(Sulphate ash)
Corrosion effect on copper Degree of cor- Class 1 EN ISO 2160
rosion
(3 h at 50 ℃ )
Oxidation stability hours min. 8 EN 15751 EN 14112
110 ℃
Acid number mg KOH/g max. 0.5 EN 14104
Iodine number g Iodine/100g max. 120 EN 14111
content of linolenic acid methylester %(m/m) max. 12.0 EN 14103
Content of multiple unsaturated fatty %(m/m) max. 1 EN 15779
acid methyl esters with 4 double
bondings
methanol content %(m/m) max. 0.20 EN 14110
Monoglyceride content %(m/m) max. 0.80 EN 14105
Diglyceride content %(m/m) max. 0.20 EN 14105
triglyceride content %(m/m) max. 0.20 EN 14105
content of free glycerine %(m/m) max. 0.020 EN 14105
EN 14106
content of total glycerine %(m/m) max. 0.25 EN 14105
OBJ_DOKU-22583-001.fm 30 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN

DIN EN 14214
Content of alkaline-metals (Na + K) mg/kg max. 5.0 EN 14108
EN 14109
EN 14538
Content of earth alkaline-metals (Ca + mg/kg max. 5.0 EN 14538
Mg)
phosphor content mg/kg max. 4.0 EN 14107
Limit of filtrability EN 116
– 15.04. - 30.09. °C max. 0
– 01.10. - 15.11. °C max. -10
– 16.11. - 28.02. °C max. -20
– 01.03. - 14.04. °C max. -10
* Specifications apply for Germany. National regulations may deviate.
OBJ_DOKU-22583-001.fm 31 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 12

US biodiesel blends according to ASTM D 7467-09a (B6-B20)

ASTM D 7467-09a
Biodiesel content %(V/V) 6-20 ASTM D 7371
Flashpoint °C min. 52 ASTM D 93
Water and sediments %(V/V) max. 0.05 ASTM D 2709
Ash content %(m/m) max. 0.01 ASTM D 482
(oxide ash)
Sulphur content %(m/m) max. 0.0015 * ASTM D 5453
max. 0.05 **
Corrosion effect on copper Degree of cor- No. 3 ASTM D 130
rosion
Cloud point °C Report ASTM D 2500
Coke residue %(m/m) max. 0.35 ASTM D 524
Acid number mg KOH/g max. 0.30 ASTM D 664
Boiling curve at 90 vol. % °C max. 343 ASTM D 86
Lubricity, HFRR at 60 °C m max. 520 ASTM D 6079
Oxidation stability hours min. 6 EN 14112
110 ℃
* ASTM D 7467-09a Grade S 15
** ASTM D 7467-09a Grade S 500
OBJ_DOKU-22583-001.fm 32 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 13

US biodiesel according to ASTM D 6751-09a (B100)

ASTM D 6751-09a
Calcium and Magnesium (together) mg/kg max. 5 EN 14538
Flashpoint °C min. 93 ASTM D 93
Water and sediments %(V/V) max. 0.05 ASTM D 2709
Ash content %(m/m) max. 0.02 ASTM D 874
(oxide ash)
Sulphur content %(m/m) max. 0.0015 * ASTM D 5453
max. 0.05 **
Corrosion effect on copper Degree of cor- No. 3 ASTM D 130
rosion
Cloud point °C Report ASTM D 2500
Coke residue %(m/m) max. 0.050 ASTM D 4530
Acid number mg KOH/g max. 0.50 ASTM D 664
content of free glycerine %(m/m) 0,020 ASTM D 6584
content of total glycerine %(m/m) 0.240 ASTM D 6584
phosphor content %(m/m) max. 0.001 ASTM D 4951
Boiling curve at 90 vol. % °C max. 360 ASTM D 1160
Sodium and potassium (together) mg/kg max. 5 EN 14538
110 ℃
* ASTM D 6751-09a Grade S 15
** ASTM D 6751-09a Grade S 500
OBJ_DOKU-22583-001.fm 33 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 14
Fuel specification (requirements, test methods and limit values)

Rape seed oil fuel according to pre-standard DIN V 51605 Edition
July 2007

DIN V 51605
Visual assessment Free from visible
contamination and
sediments and
free water
Density at 15 °C kg/m3 min. 900.0 EN ISO 3675
max. 930.0 EN ISO 12185/C1
Flashpoint according to Pensky- °C min. 220 EN ISO 2719
Martens
Kinematic viscosity at 40 ℃ mm2/s max. 36.0 EN ISO 3104/C2
Heating value kJ/kg min. 36,000 DIN 51900-1, -2, -3
Willingness to ignite min. 39 Experience value
Iodine number g Iodine/100g min. 95 EN 14111
max. 125
Sulphur content mg/kg max. 10 EN ISO 20884
EN ISO 20846
Acid number mg KOH/g max. 2.0 EN 14104
110 ℃
phosphor content mg/kg max. 12 EN 14107
Calcium and Magnesium (togeth- mg/kg max. 20 EN 14538
er)
(oxide ash)
Water content %(m/m) max. 0.075 EN ISO 12937
OBJ_DOKU-22583-001.fm 34 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Appendix 15
Limit values for countries in which none of the named diesel fuels released by DEUTZ exist
Parameter Basic condition Test method Units DEUTZ re-

quirement
min. max.
Density at 15 °C - ISO 3675 / ISO 12185 kg/m3 8201 8762
Cetane number Ambient temperatures ISO 5156 / ISO 15195 - 40.0 -
> 0 °C / ASTM D613 / ASTM
D6890
Ambient temperatures 45.0 -
< 0 °C
Kinematic viscosity at 40 ℃ Ambient temperatures ISO 3104 / ASTM D44 mm2/s 1.8 5.0
> 0 °C
Ambient temperatures 1.2 4.0
< 0 °C
Cloud point - - - Not higher
than the
ambient
temperature
Pour point - ISO 3016 / ASTM D97 - At least 6 °C
lower than
the ambient
temperature
Sulphur content Engines without ex- ISO 20846 / ISO %(m/m) - 1.0
haust gas after-treat- 20847 / ASTM D 3605
ment / ASTM D1552
Engines with exhaust mg/kg - 15
gas after-treatment
Lubricity, corr. Wsd 1.4 at 60 °C ISO 12156-1 /ASTM m - 460
D6079
10 %V/V boiling temperature ISO 3405 /ASTM D86 °C - 282
90 %V/V boiling temperature - 360
Coke residue ASTM D524 %(m/m) - 0.35
Ash content Engines without ex- ISO 6245 / ASTM %(m/m) - 0.01
haust gas after-treat- D482
ment
Inorganic elements Engines with exhaust EN 14108 / EN 14109 mg/kg - 5
(Ca+Mg+Na+K) gas after-treatment / EN 14538
Water content ISO 12937 mg/kg - 2004
Total contamination EN 12662 mg/kg - 245
OBJ_DOKU-22583-001.fm 35 / 36 © 2010
Technical Bulletin
0199 - 99 - 3005/9 EN
Parameter Basic condition Test method Units DEUTZ re-

quirement
min. max.
Alternative to water content and ASTM D473 %(V/V) - 0.05
total contamination: Water and
sediment
Corrosion effect on copper ISO 2160 / ASTM Degree - 1
D130 of cor-
(3 h at 50 ℃ )
rosion
1 For Arctic diesel fuels the lower density limit is 800 kg/m3 at 15 °C.
2At densities >860 kg/m3 at 15 °C return blocking of the engine power by authorised DEUTZ dealers is
necessary.
3 At sulphur contents >5000 mg/kg the oil change intervals must be halved.
4
Water contents up to 1000 mg/kg are permissible when water trapping fuel filters are used.
5
At dirt contents >24 mg/kg fuel filters with a higher dirt capacity and very high efficiency must be used.
OBJ_DOKU-22583-001.fm 36 / 36 © 2010
Technical Bulletin
0199-99-1210/0 EN
This Circular supersedes:
Date: 01.06.2010 DEUTZ AG

Author: Rudolf Fischer, TE-FI Ottostraße 1
51149 Köln
Phone: +49 (0) 221 822-3008 www.deutz.com

Fax: +49 (0) 221 822-15 3008
DEUTZ engines
 All current DEUTZ engines
 Product number(s) EKZ:
All product codes of the DEUTZ engines named above
 Assemblies:
99
Engine problems due to stuck/resinated fuel injectors introduction DEUTZ diesel

additive "DEUTZ Clean-Diesel InSyPro"
General
Greater percentages of biodiesel (FAME) are now contained in diesel fuels in accordance
with EU directives and many other national regulations. The current diesel fuel standards
in Germany (DIN 51628 / DIN EN 590) and in Europe enable biodiesel percentages up to
7 %(V/V).
There are also special diesel/biofuel blends of up to 30 %(V/V) (B30, B20) which national
regulations in France or Italy allow for example.
Outside Europe (USA, Soth America, Asia) fuel blends based on soya oil methyl ester
(SME) are often produced. SME is of a much poorer quality in its chemical properties, es-
pecially the oxidation stability, than biodiesel in accordance with EN 14214 which is normal-
ly produced based on rape seed methly ester.
These bio components in the fuel behave differently to fuels without bio components added,
especially during storage.
The biodiesel components in the fuel can decompose under the influence of temper-
ature, air oxygen and time. This produces deposits in the injection system during op-
eration which can lead to sticking of the injectors and pumps especially in the
current Common Rail injection systems. The results are ignition failure, black
smoke, starting problems and increased fuel consumption.
Note:
The part numbers indicated in this document are not subject to updating.
Binding for the identification of spare parts is exclusively the spare parts documentation.
OBJ_DOKU-21535-001.fm 1/6 © 2010

Technical Bulletin
0199-99-1210/0 EN
Change in pure biodiesel in storage at 50°C

Oxidised fuel parts give it a dark colour.
A1 Change in pure biodiesel in storage at 50°C.
Deposits from a pump plunger after longer standstill with a diesel fuel containing bi-
odiesel.
A2 Deposits from a pump plunger
To avoid these negative influences, DEUTZ AG has now developed a fuel additive specially
adapted to the DEUTZ engines which prevents premature ageing of the biodiesel parts and
can effectively eliminate deposits which have already been left.
The fuel additive is released for all current engine series up to EPA TIER 3 / EU Stage IIIA.
OBJ_DOKU-21535-001.fm 2/6 © 2010

Technical Bulletin
0199-99-1210/0 EN
"DEUTZ Clean-Diesel InSyPro"
Main properties
"Keep Clean"
 Increase in the oxidation stability of the used fuel when using biogenic fuels (biodiesel
(FAME) or plant oils).
 Protects against deposits and sticking.
 Therefore prolongs the storage time of these fuels.
 Reduces incidences of filters becoming contaminated and clogged.
Recommended area of application
 For preservation of engines which are out of operation for a long time.
 Devices with longer storage periods without operation (e.g. new devices in the deliv-
ery).
 Operation with biodiesel (FAME).
 Operation with pure vegetable oil (only applies for DEUTZ Natural Fuel Engine ®).
“Clean-Up”
 Dissolves deposits in injectors, injection pumps and lines and makes them as good as
new provided there is no mechanical damage.
 Increased smoke values are normalised.
 Reduces fuel consumption with improved engine performance.
 Protects against corrosion.
 Improves poor lubricating properties.
Recommended area of application
 For start problems and increased smoke values.

 First "application alternative" with injector problems.
 In regions with poor quality fuel.
The above properties were proven both in laboratory tests and in practical use.
Only "DEUTZ Clean Diesel InSyPro" has the release for use in DEUTZ engines, other prod-
ucts available on the market do not have this release!
OBJ_DOKU-21535-001.fm 3/6 © 2010

Technical Bulletin
0199-99-1210/0 EN
The additive is suitable for all internationally approved diesel and biodiesel fuels as well as
diesel/biodiesel blends.
In addition, tests on injection components in use in the field have revealed that these can
be returned to a functioning state in case of problems by treating with "DEUTZ Clean Diesel
InSyPro" and therefore save cost-intensive exchange.
Machine downtimes are also avoided in addition to saving costs.
For the above reasons we urgently recommend the use of "DEUTZ Clean Diesel InSyPro"
when the following conditions are satisfied:
1 Devices which are not put into operation at the OEM or for more than 3 months after
production.
"Keep Clean"
2 Devices which are operated in regions with poor quality fuel.
“Clean-Up”
3 If problems in the injection system (start problems and increased smoke values) are
reported, at least one or better still two tank fillings should be operated with the additive
in the fuel before exchanging expensive components.
“Clean-Up”
4 Operation with biodiesel (FAME) or with vegetable oil (only applies for DEUTZ Natural
Fuel Engine ®), see Technical Bulletin 0199-99-3005 for fuels.
"Keep Clean"
5 Preservation of engines. (See Technical Bulletin 0199-99-1170).
"Keep Clean"
6 Engines which are shut down at the end customers for more than 3 months (e.g. har-
vesting machinery).
"Keep Clean"
OBJ_DOKU-21535-001.fm 4/6 © 2010

Technical Bulletin
0199-99-1210/0 EN
The "DEUTZ Clean Diesel InSyPro" additive
A3 "DEUTZ Clean Diesel InSyPro"
Available under:
- Part no.:
01017967
- Container size:
1 litre
OBJ_DOKU-21535-001.fm 5/6 © 2010

Technical Bulletin
0199-99-1210/0 EN
Application instructions
See the safety instructions in the safety data sheet!
 For good mixing first put in the additive and then top up with diesel fuel.
Avoid overdosing!
 Dosing
- 1:400 for "Keep Clean"
As preventive protection and diesel stabiliser

- 1:200 for "Clean-Up"
 Repeated application is recommended in connection with lubricating oil changes (usu-
ally every 500 oh).
Please contact the following persons if you have any questions about the listed topics.
Contact:
DEUTZ Engines
E-mail: service-kompaktmotoren.de@deutz.com
Service Information
This document has been created digitally and is valid without a signature.
OBJ_DOKU-21535-001.fm 6/6 © 2010

BE-970WM vehicle CCTV monitor
User & fitting guide
User Guide & montage
User & Einbau Anleitung
Utente di montaggio e guida
Guía de usuario y montaje
User & montage handleiding
Stock code #3431

1 Contents/Contenu/Inhalt/Contenuti/Contenidos/inhoud
2
2 Monitor installation/Surveiller l’installation/
Monitor-Installation/L’installazione del monitor/
Vigilar la instalación/Monitor installatie
3
3 Connections/Connexions/Verbindungen/
Connessioni/Conexiones/Aansluitingen
Red: Rouge Green: Vert Black: Noir White: Blanc

Rot Grün Schwarz Weiß
Rosso Verde Nero Bianco
Rojo Verde Negro Blanco
Rood Groen Zwart Wit
Fuse: Fusible Ground: Terre Trigger: Déclencher
Sicherung Grund Auslösen
Fusibile Terreno Attivare
Fusible Terreno Desencadenar
Zekering Grond Trekker
4
4 Controls/Contrôles/Kontrollen/Controlli/Controles/
Controles/
1
2
3
4
5
1 2
1 2
3 MENU 4 UP 5 DOWN
Automatic low light sensor - automatically adjusts monitor brightness.

6 Capteur optique automatique de basse luminosité - Réglage automatique de
luminosité du moniteur
Automatischer Low-Light Sensor -passt Monitorhelligkeit automatisch an
Sensore automatico di bassa luminosità – varia automaticamente la luminosità
dello schermo
Sensor automático de baja luminosidad – adapta automáticamente la
luminosidad del monitor
Automatische low-light sensor – past de helderheid van de monitor
automatisch aan
5
1 Controls/Contrôles/Kontrollen/Controlli/Controles/
Controles
x1=
3 MENU
3 MENU x 0.5sec =
5 DOWN = UP =
6
2 Operation/Opération/Betrieb/Operazione/Operación/
Werking
Auto Power
4 MENU x 20sec =
4 MENU x 20sec =
7
3 Set up menu/Menu setup/Setup Menü/Menu setup/Menú
setup/Setup menu
4 MENU x 0.5sec =
1. CAMERA SETTING
2. TRIGGER SETTING
3. AUTO SCAN SETTING
4. DAY/NIGHT SETTING
5. ADVANCED MENU
1. LANGUAGE: [ENGLISH;DEUTCH;
FRANCAIS;ITALIANO;ESPANOL]
2. AUTO POWER: [ON]
3. FACTORY RESET
MENU =
8
4 Specifications/Spécifications/ Spezifikationen/
Specifiche/Especificaciones/Specificaties
ENGLISH FRANCAIS
Specifications Specifications
Monitor BE-970WM Moniteur BE-970WM
TV system NTSC/PAL Système TV NTSC/PAL
Picture 7" TFT LCD colour monitor with Image 7" TFT LCD moniteur couleur avec
on-screen display function affichage de fonction (OSD)
Display size 7" diagonal Dimension de l’ecran 7" diagonal
Field of view Top: 50°, Bottom: 60°, Left: 65°, Champ de vision Haut: 50°, Bas: 60°, Gauche: 65°,
Right: 65° Droite: 65°
Resolution (800x3(RGB)x480) Résolution (800x3(RGB)x480)
Picture image Factory set to reverse image Image vidéo Réglage d’usine sur image inverse
Power 12~24Vdc input Alimentation 12~24Vdc input
Inputs 2 x camera Entrées 2 x caméra
Dimensions 194(w) x 124(h) x 48(d)mm Dimensions 194(w) x 124(h) x 48(d)mm
7.6(w) x 4.9(h) x 1.9(d) inches 7,6(w) x 4,9(h) x 1.9(d) inches
Operating -40°C ~ +70°C Température -40°C ~ +70°C
temperature -40°F ~ +158°F d'utilisation -40°F ~ +158°F
ITALIANO DEUTSCH
Specifiche Spezifikationen
Schermo BE-970WM Monitor BE-970WM
Sistema TV NTSC/PAL TV-System NTSC/PAL
Immagine 7" TFT LCD colour monitor with Bild 7" TFT LCD Farbmonitor mit Funk-
on-screen display function tionsanzeige (OSD)
Formato display 7" diagonale Bildschirmgröße 7" diagonal
Campo visivo Top: 50°, Bottom: 60°, Left: 65°, Sichtfeld Oben: 50°, Unten: 60°, Links: 65°,
Right: 65° Rechts: 65°
Risoluzione (800x3(RGB)x480) Auflösung (800x3(RGB)x480)
Immagine a video Immagine reversibile program- Videobild Werkseinstellung Reversebild
mabile Stromversorgung 12~24Vdc input
Alimentazione 12~24Vdc input Eingänge 2 x kamera
Prese 2 x telecamera Abmessungen 194(w) x 124(h) x 48(d)mm
Dimensioni 194(w) x 124(h) x 48(d)mm 7.6(w) x 4.9(h) x 1.9(d) inches
7.6(w) x 4.9(h) x 1.9(d) inches Betriebstemperatur -40°C ~ +70°C
Temperatura di -40°C ~ +70°C -40°F ~ +158°F
servizio -40°F ~ +158°F
9
7 Specifications/Spécifications/Spezifikationen/
Specifiche/Especificaciones/Specificaties
ESPANOL NEDERLANDS
Especificaciones Specificaties
Monitor BE-970WM Monitor BE-970WM
Sistema de TV NTSC/PAL TV-systeem NTSC/PAL
Imagen Monitor a color de 7" TFT LCD Beeld 7" TFT LCD colour monitor with
con visualización de las funciones on-screen display function
(OSD) Displayformaat 7" diagonaal
Tamaño de pantalla 7" diagonal Gezichtsveld Boven: 50°, Onder: 60°, Links:
Campo visual arriba: 50°, abajo: 60°, a la izqui- 65°, Rechts: 65°
erda: 65°, a la derecha: 65° Resolutie (800x3(RGB)x480)
Resolución (800x3(RGB)x480) Videobeeld Fabrieksinstelling reversebeeld
Imagen de vídeo Ajuste de fábrica de la imagen Stroomvoorziening 12~24Vdc Ingang
inversa
Ingangen 2 x camera
Suministro de 12~24Vdc entrada
corriente Afmetingen 194(w) x 124(h) x 48(d)mm
7.6(w) x 4.9(h) x 1.2(d) inches
Entradas 2 x cámara
Bedrijfstemperatuur -40°C ~ +70°C
Dimensiones 194(w) x 124(h) x 48(d)mm -40°F ~ +158°F
7.6(w) x 4.9(h) x 1.2(d) inches
Temperatura de -40°C ~ +70°C
servicio -40°F ~ +158°F
Specifications subject to change. Sous réserve de modifications techniques. Vorbehaltlich technischer

Änderungen. Con riserva di modifiche tecniche. Reservadas las modificaciones técnicas. Technische
10 wijzigingen voorbehouden.
Disclaimer
Camera monitor systems are an invaluable driver aid but do not exempt the driver from taking
every normal precaution when conducting a manoeuvre. No liability arising out of the use or
failure of the product can in any way be attached to Brigade or to the distributor.
Dénégation
Les systèmes de moniteurs des caméras sont une aide précieuse pour le conducteur, mais
celui-ci doit toutefois prendre toutes les précautions nécessaires pendant les manœuvres.
Brigade ou ses distributeurs n’assument aucune responsabilité résultant de l’utilisation ou d’un
défaut du produit.
Verzichterklärung
Die Kamerabildschirmsysteme sind eine wertvolle Hilfe für den Fahrer, entbinden ihn jedoch
nicht von der notwendigen Sorgfalt beim Manövrieren des Fahrzeuges. Brigade und seine Ver-
triebshändler haften nicht für Schäden aus der Nutzung oder einer Fehlfunktion des Produktes.
Disconoscimento
I sistemi di monitor della telecamera sono un aiuto prezioso per il conduttore, ma non lo eson-
erano dall’obbligo di prendere le precauzioni necessarie durante le manovre del veicolo. Brid-
age e i suoi distributori non si assumono nessuna responsabilità per danni risultanti dall’utilizzo
o da un malfunzionamento del prodotto.
Negante
Los sistemas de pantalla de cámara son una valiosa ayuda destinada a los conductores; en
todo caso no les resta la responsabilidad de proceder con precaución a la hora de maniobrar
con el vehículo. Brigade y sus distribuidores comerciales no se responsabilizan de los daños
derivados de un mal funcionamiento del producto.
Verwerping
De camera-monitorsystemen zijn een waardevolle hulp voor de bestuurder, ontheffen hem
echter niet van de nodige zorgvuldigheid bij het manoeuvreren van het voertuig. Brigade en zijn
distributeurs zijn niet aansprakelijk voor schade door gebruik of een gebrek van het product.
Serial No: Stock code:
11
OPERATION AND
MAINTENANCE
MANUAL
SCREW COMPRESSOR
PTR-40-HV
Version 1.1 (10/2017)

PTR-40-HV JBPTR40HV03082 1.1
INTRODUCTION
This operation and maintenance manual for PTR-40-HV informs you about all details required
to install, start, operate and maintain the compressor unit. In addition to operation manual, fully
illustrated manuals concerning lubrication, manual, parts as well as workshop manual are also
included.
This operating manual describes how the machine must be handled and operated in order to achieve
safe operation, maximum efficiency and long service live.
Read the operating manual before starting the machine, so that appropriate handling, operation and
maintenance is ensured from the very beginning. The maintenance plan contains all measures required
to keep the machine in good condition. Maintenance must be executed regularly.
Keep the operating manual available for the operators and take care that operation and maintenance is
performed according to the instructions. Enter all operating data, executed maintenance measures in
an operating log book. Repair and maintenance work should be performed by qualified personnel only.
When ordering spare parts it is very important to mention complete compressor name and mode, serial
number as well as order number of the spare part needed.
If you do not observe this operating instruction and/or arbitrarily change the unit or components
supplied by Paineteho, you forfeit any claim under warranty. Please contact customer service
department if initial troubles or breakdowns occur.
The manufacturer assumes no responsibility for any damage or injury caused by ignoring these safety
provisions or the usual carefulness and precaution during handling, operation, maintenance and repair,
even if they are not expressly mentioned in this operating manual.
The manufacturer reserves the right to make technical changes without prior notice.
© Copyright 2008 Paineteho Oy
3
TABLE OF CONTENTS
INTRODUCTION ................................................................................... 3
1 COMPRESSOR NAME INTERPRETATION ...................................... 6
2 WARRANTY TERMS ......................................................................... 6

2.1 General ........................................................................................................... 6
2.2 Warranty period .............................................................................................7
2.3 Disclaimer ...................................................................................................... 7
3 TECHNICAL SPECIFICATIONS ........................................................ 9

3.1 Compressor’s technical specifications ...................................................... 9
3.2 Angles of tilt and lifting points .................................................................... 10
4 GENERAL SAFETY INSTRUCTIONS AND REGULATIONS ........... 11

4.1 General safety instructions ......................................................................... 11
4.2 Safety regulations ......................................................................................... 11
4.2.1 Installation .......................................................................................................... 11
4.2.2 Operation ........................................................................................................... 12
4.2.3 Maintenance ....................................................................................................... 12
4.3 Warning signs ............................................................................................... 14
5 OPERATING MANUAL ...................................................................... 15

5.1 Compressor details ...................................................................................... 15
5.1.1 Working principle of screw compressor ......................................................... 15
5.1.2 Main components .............................................................................................. 16
5.1.3 Electric components ......................................................................................... 17
5.1.4 Pneumatic components .................................................................................... 18
5.1.5 Hydraulic components ...................................................................................... 19
5.1.6 Type plates ......................................................................................................... 20
5.1.7 Component locations ........................................................................................ 21
5.1.8 Hoses .................................................................................................................. 24
5.2 Schemes and symbols used ........................................................................ 28
5.2.1 Symbols used in electric scheme .................................................................... 28
5.2.2 Electric scheme ................................................................................................. 28
5.2.3 Symbols and drawings used in pneumatic scheme ...................................... 30
5.2.4 Pneumatic scheme ............................................................................................ 30
5.3 Compressor installation, start-up and shut down ..................................... 32
5.3.1 Safety instructions to installation and start-up .............................................. 32
5.3.2 Installation instructions .................................................................................... 32
5.3.3 Start up ............................................................................................................... 33
5.3.4 Compressor shut down .................................................................................... 33
5.4 Daily procedures ........................................................................................... 34
5.4.1 Safety issues in daily operations ..................................................................... 34
5.4.2 Checks performed prior to operation .............................................................. 34
5.4.3 Checks performed while operating .................................................................. 34
5.4.4 Special conditions of use ................................................................................. 34
5.5 Preservation and storage ............................................................................. 34
4
6 LUBRICATION MANUAL .................................................................. 35

6.1 Oil recommendations ................................................................................... 35
6.2 Oil circulation ................................................................................................ 36
6.3 Lubricating the compressor unit before initial start-up ............................ 37
6.4 Lubrication chart ........................................................................................... 38
6.5 Lubrication safety and other precautions .................................................. 38
7 MAINTENANCE MANUAL ................................................................ 39

7.1 General safety instructions concerning maintenance .............................. 39
7.2 Procedures before and after maintenance ................................................. 40
7.3 Locations of maintenance points ................................................................ 41
7.4 Maintenance procedures .............................................................................. 43
7.4.1 Condensate drain .............................................................................................. 43
7.4.2 Adding oil and oil change ................................................................................. 44
7.4.3 Changing oil hoses ........................................................................................... 45
7.4.4 Changing oil filter .............................................................................................. 46
7.4.5 Cleaning oil cooler ............................................................................................ 47
7.4.6 Changing oil separator elements ..................................................................... 48
7.4.7 Cleaning and changing oil return filter ............................................................ 50
7.4.8 Changing air inlet valve maintenance and repair kits .................................... 52
7.4.9 Cleaning and changing prefilter mat ............................................................... 55
7.4.10 Changing control valves ................................................................................. 55
7.4.11 Changing minimum pressure valve maintenance and repair kits .............. 56
7.3.12 Cleaning and changing air cleaner ................................................................ 59
7.3.13 Cleaning cyclone.............................................................................................. 60
7.4.14 Testing safety valve... ..................................................................................... 61
7.5 Maintenance intervals .................................................................................. 62
7.6 Wear parts and maintenance intervals ....................................................... 63
7.7 Trouble shooting ........................................................................................... 63
8 SPARE PARTS MANUAL .................................................................. 65

8.1 General ........................................................................................................... 65
8.2 Compressor part list ..................................................................................... 65
8.3 Part lists and explosion diagrams .............................................................. 66
8.3.1 Tempest 12 ......................................................................................................... 66
8.3.2 Compressor unit Enduro 12 TS ........................................................................ 68
8.3.3 Minimum pressure valve ................................................................................... 70
8.3.4 Air inlet valve ..................................................................................................... 72
8.3.5 Hydraulic motor ................................................................................................. 74
8.3.6 Hoses .................................................................................................................. 75
ANNEXES
Annex A Maintenance intervals
Annex B Procedures done prior to, during and after operation
5
1 COMPRESSOR NAME INTERPRETATION
The compressor model name can be interpreted as follows:
First letters in the name = Type of compressor

Numbers after the first letters = Compressors capacity m³/min
Letters after the numbers = Drive or Type indicator
PTR = Paineteho Screw compressor

40 = Compressors calculated capacity is 4,00 m³/min
HV = Type model
Compressor type plates are found in the frame outside and inside.
2 WARRANTY TERMS
2.1 General
PTR -compressors are thoroughly tested at the production plant. Correctly operated and installed,
they are fail-safe. The PTR- warranty includes all components (as long as the term of warranty
applies). Claims that fall under this warranty are ones where delivered product does not comply with
specifications defined in order agreement.
Concerning our warranty, please note:

Paineteho exclusively produces complete screw compressor installations ready for work. Therefore,
Paineteho (hereafter “Company”) is merely accountable for those shortcomings that may occur with
the above mentioned individual compressor(s) and which fall into Company’s liability according to
the warranty conditions.
Warranty cannot be granted in case of:

- Inadequate application
- Incorrect handling of the installation
- Inappropriate oil
- Modifications of the original state
- Use of inadequate tools
- Using other than original spare parts
- Modification of the installation or the components
- Use of inappropriate add-on pieces
- Natural wear and tear
Respecting the indicated working temperatures avoids the formation of condensate in the screw
compressor. Warranty does not apply in case of damages caused by condensation.
Compressor oils
Only those types of oil may be filled in, which have been classified by the oil producer as appropriate
for screw compressors. In case of doubt, please consult Paineteho prior to filling in the oil in order
to determine the appropriate type of oil. In case defects occur having used inappropriate types of oil
results in the loss of the warranty.
Compressor components are designed for ambient temperatures of +0°C to + 35°C / 28°F to 104°F.
Operation at other ambient temperatures is only permitted after having consulted Paineteho.
6
2.2 Warranty period
The company‘s obligation under this warranty is limited to repairing or, at its option, replacing,
during normal business hours at an authorized service facility of the company, any part which in its
judgement proved not to be as warranted within the applicable warranty period as follows.
Compressor units
Compressor unit, consisting of all parts within and including the compressor cylinder and gear
housing, are warranted for 24 months from the date of initial use or 27 months from the date of
shipment to the purchaser, whichever occurs first.
Any disassembly or partial disassembly of the air end, or failure to return the „unopened“ air end per
Company instructions, will be cause for denial of warranty.
Compressor package
All other components in the compressor package are warranted for 12 months from the date of initial
use or 15 months from the date of shipment to the purchaser, whichever occurs first.
Spare parts
The genuine spare parts delivered by the Company are warranted for 6 months from the date of
shipment to the purchaser.
Costs
All costs of transportation, freight, importation or insurance or local taxes or customs clearances
of product or parts claimed not to be as warranted and, of repaired or replacement parts to or from
such service facility shall be borne by the Purchaser. The Company may require the return of any
part claimed not to be as warranted to one of its facilities as designated by Company, transportation
prepaid by Purchaser, to establish a claim under this warranty.
Replacement parts provided under the terms of this warranty, are warranted for the remainder of the
Warranty Period of the Product upon which installed to the same extent as if such parts were original
components.
2.3 Disclaimer
The foregoing warranty is exclusive and it is expressly agreed that, except as so title, the Company
makes no other warranties, expressed, implied or statutory, including and implied warranty of
merchantability.
The remedy provided under this warranty shall be the sole, exclusive and only remedy available to the
Purchaser and in no case shall the Company be subject to any other obligations or liabilities. Under
no circumstances shall the Company be liable for any special, indirect, incidental or consequential
damages, expenses, losses or delays howsoever caused.
Under no circumstances and in no conditions, the Company’s liability, whether in respect of one claim
or in the aggregate, arising out of any contract shall not exceed the purchase price payable under the
contract for such part in which Company’s liability shall arise.
No statement, representation, agreement or understanding, oral or written, made by any agent,

distributor, representative, or employee of the Company which is not contained in this Warranty will
be binding upon the Company unless made in writing and executed by an officer of the Company.
This warranty shall not be effective as to any claim which is not presented within 30 days after the
date upon which the Product is claimed or should have been claimed not to have been as warranted.
Any action for breach of this warranty must be commenced within one year after the date upon which
the cause of action occurred.
7
No claim will be considered, and the warranty will be considered null and void, if other than genuine
parts are used in the Product.
The obligations under this warranty are limited at Company’s option, to:
- replace the part, free of charge, Ex Works Kuopio (Incoterms 1990) or
- repair the part free of charge, Ex Works Kuopio (Incoterms 1990) or
- refund the part at Company’s order price.
The Purchaser shall retain the claimed part or Product for six (6) months for Company’s inspection
and on request the alleged defective part shall be sent to a destination designated by the Company at
the Purchaser’s costs. After warranty handling, the title to the defective parts shall be transferred to the
Company.
Any adjustment made pursuant to this warranty shall not be construed as an admission by the
Company that any Product was not as warranted.
The warranty shall not be suspended on the grounds of non-use, intermittent use or for any other
reason.
Contact information regarding warranty is found in the end of the manual.
8
3 TECHNICAL SPECIFICATIONS
3.1 Compressor’s technical specifications
COMPRESSOR MODEL PTR-40-HV
Compressor unit
Model..…………………………………............. TEMPEST 12
Speed of rotation………………………….......... Max. 6500 rpm and min: 1000 rpm
Working pressure..……………………............... 7.0 bar
Calculated capacity............…………………...... 4.00 m³/min
Weight..……………………………………….... 180 kg
Direction of rotation……………………............. Check the arrow on top of the compressor unit
Hydraulic motor
Rated power…………………………………..... 19 cm³
Rated rotation speed.......……………………...... 3600 rpm
Pressure...……………………………………..... 250 bar
Oil flow...........………………………….............. 68 l/min
Safety valve
Activating pressure……………………….......... 14.5 bar
Operating requirements
Minimum ambient temperature……………….... + 0 °C
Maximum ambient temperature………………... + 35 °C
Maximum angle of tilt......................................... See chapter 3.2 Angles of tilt, page 10
Oil capacity
Total oil capacity………..........……………........ 20 Liters.
9
3.2 Angles of tilt and lifting points
Compressor can be tilted as indicated in the angle of tilt -sign that is located on top of the compressor.
It is forbidden to exceed those values. If the compressor is tilted more than advised, oil can flare
up and mix with the exhaust air. When the amount of oil in the compressor is reduced, compressor
overheats and is shut down.
PTR-40-HV compressor can be tilted 7 degrees maximum towards the oil separator unit and 25
degrees to other directions.
Sign indicating tilt angles is to be found on top of the compressor.
Figure 1. Angles of tilt -sign
There are links on the corners of the compressor top to esure safe lifting. These lifting points are
pointed with signs (see figure below).
Figure 2. Lifting point -sign
10
4 GENERAL SAFETY INSTRUCTIONS AND REGULATIONS
This chapter deals with safety issues in general. It is suggested to study safety instructions introduced
in other chapters as well. All the safety instructions must be studied before starting to work with the
compressor. In addition to these instructions and regulations, local regulations must be taken into
consideration.
4.1 General safety instructions
ATTENTION - IMPORTANT!
1. Operating Instructions must be carefully read before operating machine.

2. Limits such as pressure values, temperature values, time settings, must be permanently marked.
3. Fill in oil and/or check oil level.
4. When connecting the machine to electric power, pay attention to the direction of rotation.
5. The machine will function properly when regularly maintained (cleaning - lubrication).
6. Continuous overloading of the machine should be avoided.
7. In case of malfunction check main fuses and machine fuses first.
8. The operator is responsible for the machine to be kept in safe operating condition. If any part is
considered not to be reliable for safe operation, it must be replaced immediately.
9. The unit must only be installed, operated, maintained and repaired by authorized, trained and
qualified personnel.
10. The operating personnel must employ safe techniques and observe all local safety regulations for
operation.
11. Observe the local/company regulations on the use of hearing and other protectors.
12. Compressor should not be used with its doors open.
13. Observe the tension and condition of the belts. Tighten or change belts always when necessary.
4.2 Safety regulations
These provisions shall apply for screw-type compressor components of the PAINETEHO company.
The relevant manufacturers’ provisions shall apply for components of other manufacturers or
suppliers, respectively. Please read them carefully and act accordingly when you install, start or repair
the machine or its components.
If any of the provisions contained in this list (especially concerning safety) does not comply with local
provisions of law, the safer provision must be applied.
4.2.1 Installation
In addition to the general technical operation according to the regulations of the local authorities, the
following guide lines must be strictly observed:
1. Use an appropriate hoist complying with the local safety regulations to lift a screw-type compressor.
Secure all loose and swinging parts such that they cannot be moved before lifting the machine. It
is strictly forbidden to be in the danger area of a lifted load. The acceleration and deceleration of
transportation must stay within permissible limits.
2. Remove all blind flanges, plugs, caps and bags containing drying agents before assembling the
tubes. Unions and tube connections must have the right size and be fit for the relevant operating
pressure. Screw connections must be torqued to the indicated values, unless otherwise indicated.
11
3. The unit must be installed in a place where the ambient air is as cool and clean as possible. Never
obstruct admission of air. Make sure that moisture in the intake air is kept to a minimum.
4. The intake air must not contain any inflammable vapors, such as paint solvents, which may cause an
internal fire.
5. Air cooled machines must be installed such that an adequate flow of cooling air is provided and that
the outlet air does not recirculate into the inlet.
6. Use pneumatic hoses that are rated to withstand the working pressure. Pay special attention to the
hose mountings. A whipping hose may cause unpredictable damage.
7. There might be some oil in the water condensate. Notice the regulations concerning the oil remove!
8. Prevent the exhausted air from recirculating to the intake. Make sure that foreign objects cannot get
into the compressor with the intake air. Arrange the air intake such that loose clothes cannot be drawn
in.
9. Make sure that the pressure pipe from the compressor to the after cooler or air delivery main can
expand due to the heat and does not come into contact with inflammable material.
10. If a remote control is provided, the unit must be equipped with a clearly visible plate with the
following lettering: Warning: This unit is operated by remote control and could start without any
warning. As an additional protective measure, persons who start a unit by remote control must make
sure that no person is checking or operating the unit. For this purpose, a corresponding plate must be
provided at the remote control unit.
11. Screw-type compressors must in principle be set up on a level surface and levelled with a spirit
level as necessary. In exceptional cases, for example in the case of portable systems, the latter must be
operated within maximum angle of tilt limits. See chapter 3.2 Angles of tilt, page 10.
4.2.2 Operation
1. Do not blow pressured air to bare skin.

2. Do not use the compressor with its doors open.
3. Use only recommended oil types. Do not mix oils.
4. Remotely started compressors should be equipped with proper warning sights.
5. Do not use compressor in an explosive environment.
6. Do not exceed values given in technical details.
7. Do not detach hoses untill the unit is completely discharged.
4.2.3 Maintenance
Maintenance and repair work may only be executed under the supervision of a person qualified for
this work.
1. Use only the right tools designed for maintenance and repair work.
2. Use only original spare parts. When ordering spare parts it is necessary to indicate model, machine
number and spare part number.
3. Execute any repair or maintenance work other than current repair work only when the unit is
switched off and the mains supply is disconnected. Make sure that the unit cannot be switched on
unintentionally. The shut-off valve to the pressurized air network should also be closed.
12
4. Shut off the unit from all pressure sources and discharge the entire unit from pressure before
removing a part under pressure. It may take 1 to 2 minutes to depressurize the whole compressor.
Make sure that the air/oil receiver is pressureless before you start maintenance.
5. Do not use inflammable solvents or carbon tetrachloride to clean parts. Take precautions against
toxic vapors of cleaning solvents.
6. Take care that extreme cleanliness is observed during maintenance or repair work. Keep away dust.
Cover parts or bare openings with a clean cloth, paper or adhesive tape.
7. Do not repair the container by welding. Do not weld or perform any other work requiring heat near
the oil system.
8. Make sure that no tools, loose parts or cleaning rags are left in or on the unit.
9. Before releasing the unit for operation after it has been maintained or overhauled, check whether
the operating pressure temperatures and time adjustments are correct and the control and switch-off
devices in perfect working order.
10. Protect the motor, the air filter, electrical components, control system against moisture, when
cleaning them by means of steam jet.
11. Do not remove or change the noise-insulating material.
12. Do not use corrosive solvents, which could affect the materials of the air delivery main, such as
poly carbonate bowls.
13. All alterations must conform to the regulations concerning pressure vessels.
14. Starting of compressors with remote control must be prevented while maintenance work is in
progress.
15. Do not neglect the regular check-ups and maintenance of the compressor.
13
4.3 Warning signs
Cooling air holes, do not cover Watch out of rotating parts
Hot surfaces Compressor is Lift point Use hearing protectors

remote controlled

Read manual before Electric voltage Compressor oil type
operating
Pressure Oil separator test Temperature Direction of rotation
Air exhaust
Figure 3. Warning signs
14
5 OPERATING MANUAL
5.1 Compressor details
5.1.1 Working principle of screw compressor
PTR-compressors are used to produce compressed air. The air in compressed in compressor unit,
which is powered by electric motor. PTR-compressors can also be powered by hydraulic motors.
Meshed rotors suck air between rotor cogs while at the inlet opening. When rotors rotate, the
connection to the inlet opening closes and the space between cogs gets smaller. In the end of
compression the desired pressure is achieved and connection to the oil separator unit opens.
Oil is injected to the screw unit to cool the unit and the compressed air. It also lubricates bearings and
seals clearances of rotors and housing.
Figure 4. Compressing air in the screw unit (Fig. © Gardner Denver)
Main parts of the screw unit are the frame of the unit (1), two rising rotors (2, 3), pressure flange (4)
and bearing shield (6). Rotors are connected to the frame (1) and to the pressure flange (4) through
bearings. Drive shaft and the fan axel (7). In cases where there is separate air module, the screw unit
comes without fan axel.
Figure 5. Compressor screw unit (Fig. © Gardner Denver)
15
5.1.2 Main components
1. Tempest 12 and Enduro 12 TS compressor unit
The frame (1), in which the oil separator unit is located. Main
part of the oil is separated in the oil separator unit and the rest in
the oil separator cartridge (3). The meshed rotors that produce
compressed air are located in the screw unit (2).
Figure 6. Tempest 12 and Enduro 12 TS
2. Air inlet valve
Air inlet valve controls the compressor’s output by opening and

closing.
Figure 7. Air inlet valve
3. Oil cooler
Oil cooler cools the circulating oil in the compressor.
Figure 8. Oil cooler
4. Prefilter mats
PTR-40-HV has two prefilter mats. The other is located in the

motor end and the other on the long side opposite to meterboard.
Prefilter mat filters larger particles from the compressor’s intake
air.
Figure 9. Prefilter mat
5. Fans
Fan takes air through the prefilter mat and cools the oil cooler.
Fan is attached to the shaft of the ait end.
Figure 10. Fan
16
6. Air filter and cyclone
Air filter is located in the filter housing (1). Air filter and
cyclone (2) are located on top of the compressor. Air filter filters
the intake air of the compressor.
Figure 11. Air filter
7. Coupling housing
Coupling housing supports the motor.
Figure 12. Coupling housing and hydraulic motor
8. Coupling
Coupling is used to transfer the power from the motor to the

compressor.
Figure 13. Coupling Bowex 38
5.1.3 Electric components
1. Electric connection housing
Line connections are located in the housing.
Figure 14. Electric connection housing
2. Air filter service indicator
Air filter service indicator activates an indicator light (meter

board) when air filter is clogged.
Figure 15. Air filter service indicator
17
3. Thermometer and hour meter
Thermometer is found in the meter board. It shows the

temperature inside the compressor. (Left meter in the picture.)
Hour meter shows compressors working hours.
Figure 16. Thermometer and hour meter
4. Warning lights and compressor on light
Green light on the meter board indicates that the compressor is

on (left in the picture). Both of the warning / indicator lights are
also located on the meter board. The other indicates compressor
overheating (middle red light) and the other the air filter
clogging (right red light).
Figure 17. Warning lights and compressor on -light
5.1.4 Pneumatic components
1. Pressure gauge
Pressure gauge (bar) is located in the meter board and shows the
pressure of the compressor.
Figure 18. Pressure gauge
2. Pressure difference button
When pressure difference button (1) is pushed, the pressure

difference, which is measured before and after oil separator, is
shown in the pressure gauge.
Figure 19. Pressure difference button
3. Maximum pressure valve
Maximum pressure valve controls compressors maximum

pressure. maximum pressure is set acoordingly at the factory.
Figure 20. Maximum pressure valve
18
4. 3/2 direction valves
3/2 Direction valve empties compressors minimum pressure and

adjusts the compressor to run unloaded. The other 3/2 direction
valve controls air inlet valve.
Figure 21. 3/2 direction valves
5. Safety valve
Safety valve prevents the pressure rising on a dangerous level by

opening at certain pressure. The opening pressure value of the
safety valve is informed in a chapter 3.1 Compressor technical
specifications, page 9.
Figure 22. Safety valve
6. Minimum pressure valve
Minimum pressure valve makes sure the pressure will not drop
under minimum pressure.
Figure 23. Minimum pressure valve
5.1.5 Hydraulic components
1. Hydraulic motor
Hydraulic motor powers the compressor.
Figure 24. Hydraulic motor
2. 3/2 Direction valve
3/2 Direction valve makes sure that the motor cannot be rotated
to the wrong direction.
Figure 25. 3/2 Direction valve
19
5.1.6 Type plates
1. Frame serial number
Serial number of the frame is running number of Paineteho

starting from 050001.
Figure 26. Frame serial number
2. Compressor type plate
Compressor type plate includes following information: the size

of the electric motor, manufacturing month and year as well as
Paineteho’s running number starting from 050001.
Figure 27. Compressor type plate
3. Enduro 12 TS type plate (compressor unit)
Enduro 12 TS type plate include information such as code, serial

number, type and weight.
Figure 28. Enduro 12 TS type plate
4. Tempest 12 type plate
Tempest 12 type plate states code, serial number, type, weight,

maximum and minimum temperature and volume.
Figure 29. Tempest 12 type plate
5. Hydraulic motor type plate
Hydraulic motor type plate states following information: motor

serialnumber, part number and type.
Figure 30. Hydraulic motor type plate
20
5.1.7 Component locations
Ref. number Component Page(s)

1 Tempest 12 22
2 Enduro 12 TS compressor unit 22
3 Air inlet valve 22
4 Prefilter mats 23
5 Hydraulic motor, coupling and coupling 23
housing
6 Meter board 23
7 Electric connection housing 23
8 Air filter service indicator 22
9 3/2 direction valves 22
10 Maximum pressure valve 22
11 Minimum pressure valve 22
12 3/2 direction valve 23
13 Safety valve 22
14 Compressor type plate 23
15 Frame serial number 22
16 Enduro 12 TS compressor unit type plate On top of compressor unit
17 Tempest 12 type plate 22
18 Hydraulic motor type plate On the side of the motor
19 Oil cooler 22
20 Fan and fan housing 22
21 Air filter and cyclone 23
22 Intake hose 23
Table 1. Components’ locations in the compressor
See Figures from next spread!
21
Figure 31. Components’ locations in the compressor 1
22
23
5.1.8 Hoses
Reference number Description Page(s)

L1 Hydraulic motor pressure 25, 26
L2 Hydraulic motor return 26
L3 Hydraulic motor leak 25, 26
L4 Compressor drain
L5 Cooler drain
L6 Cooler in 25, 26, 27
L7 Cooler out 25, 26, 27
L8 Air out 25
L9 Hydr. 3/2 tank 26
L10 Hydr. 3/2 pressure A 26
L11 Hydr. 3/2 B 26
L12 Hydraulic cell in 26
L13 Block - cell 2Bar 25, 26
L14 Hydraulic cell out 26
L15 Air out lead-through 24, 25
L16 3/2 valve lead-through 24, 25
L17 3/2 valve lead-through 24, 25
L18 Cooler lead-through 24, 25
L19 Cooler lead-through 24, 25
L20 Motor lead-through 24, 25
L21 Motor lead-through 24, 25
L22 Fluid level gauge bottom 26, 27
L23 Fluid level gauge top 26, 27
L24 Block - cell 26
Table 2. Hoses
Figure 35.Hoses 1
24
Figure 36.Hoses 2
Figure 37. Hoses 3
25
Figure 38. Hoses 4
Figure 39. Hoses 5
26
Figure 40. Hoses 4
27
5.2 Schemes and symbols used
5.2.1 Symbols used in electric scheme
Pressure controlled Motor Hour meter 3/2 direction valve

make contact
Temperature controlled Temperature controlled Signal light Fuse

connector connector
Coil
Fig. 41. Symbols used in electric scheme
5.2.2 Electric scheme
1. Whether compressor temperature rises to 100 °C, signal light H38 light up indicating danger of
compressor overheating
2. Whether compressor temperature rises up to 115 °C, is compressor overheated and shuts down.
3. Signal light H5 lights up when air filter is clogged.
28
Fig. 42. Electric scheme
29
5.2.3 Symbols and drawings used in pneumatic scheme
Maximum pressure valve 3/2 Direction valve Non-return valve
3/2 Direction valve Minimum pressure valve Air inlet valve
Fig. 43. Symbols and drawings used in pneumatic scheme
5.2.4 Pneumatic scheme
1. Start:
Air inlet valve (1) is closed. After starting compressor intakes air from non-return valve (2).
Compressor achieves adjusted minimum pressure (4 to 4.5 bar) using minimum pressure valve (3).
.
2. Output
Shut-off valve is open. Maximum pressure valve (6) closes 3/2 direction valve (5). Adjusting air
directs air inlet valve (1) according to air consumption/pressure.
3. Maximum pressure
No air intake, shut-off valve closed. Maximum pressure valve (6) closes air inlet valve and opens 3/2
direction valve (5). Compressor runs idle at maximum pressure. Maximum pressure is controlled with
maximum pressure valve (6).
4. Shut down
When compressor is shut down, air inlet valve (1) and minimum pressure valve (3) are closed. 3/2
direction valve (5.1) opens and compressor minimum pressure is exhausted.
5. Pressure difference
Pressure difference is seen in pressure gauge by pressing pressure difference button (5.2). Pressure
difference is measured before and after oil separator and shown by pressure gauge. If the pressure
difference is 0.5 to 1 bar, oil separator elements must be replaced. Pressure difference with new
separator elements is 0.2 bar.
30
Fig. 44. Pneumatic scheme
31
5.3 Compressor installation, start-up and shut down
5.3.1 Safety instructions to installation and start-up
In addition to the general technical operation according to the regulations of the local authorities, the
following guide lines must be strictly observed:
1. Use an appropriate hoist complying with the local safety regulations to lift a screw-type compressor.
Secure all loose and swinging parts such that they cannot be moved before lifting the machine. It
is strictly forbidden to be in the danger area of a lifted load. The acceleration and deceleration of
transportation must stay within permissible limits.
2. Remove all blind flanges, plugs, caps and bags containing drying agents before assembling the
tubes. Unions and tube connections must have the right size and be fit for the relevant operating
pressure. Screw connections must be torqued to the indicated values, unless otherwise indicated.
3. The unit must be installed in a place where the ambient air is as cool and clean as possible. Never
obstruct admission of air. Make sure that moisture in the intake air is kept to a minimum.
4. The intake air must not contain any inflammable vapors, such as paint solvents, which may cause an
internal fire.
5. Air cooled machines must be installed such that an adequate flow of cooling air is provided and that
the outlet air does not recirculate into the inlet.
6. Use pneumatic hoses that are rated to withstand the working pressure. Pay special attention to the
hose mountings. A whipping hose may cause unpredictable damage.
7. There might be some oil in the water condensate. Notice the regulations concerning the oil remove!
8. Prevent the exhausted air from recirculating to the intake. Make sure that foreign objects cannot get
into the compressor with the intake air. Arrange the air intake such that loose clothes cannot be drawn
in.
9. Make sure that the pressure pipe from the compressor to the after cooler or air delivery main can
expand due to the heat and does not come into contact with inflammable material.
10. If a remote control is provided, the unit must be equipped with a clearly visible plate with the
following lettering: Warning: This unit is operated by remote control and could start without any
warning. As an additional protective measure, persons who start a unit by remote control must make
sure that no person is checking or operating the unit. For this purpose, a corresponding plate must be
provided at the remote control unit.
11. Screw-type compressors must in principle be set up on a level surface and levelled with a spirit
level as necessary. In exceptional cases, for example in the case of portable systems, the latter must be
operated within maximum angle of tilt limits. See chapter 3.2 Angles of tilt, page 10.
5.3.2 Installation instructions
Following instructions apply to PTR-compressors in general. One must always study each compressor
and its manual thoroughly before installation and operations.
32
ATTENTION!
Oil tank is to be filled with recommended coolant. Before initial start-up 0,5 liter oil is poured
to into compressor screw unit (intake opening). This procedure is repeated every time the
compressor has been unused more than a months period of time. See instructions chapter 6.3
Compressor lubrication before initial start-up on page 37.
ATTENTION! DO NOT EXCEED OIL MAXIMUM!
1. Air conditioning must me adequate around the compressor and the cooling air must be of
temperature between +0°C and +35°C.
2. Around the compressor there must be enough space to perform maintenance duties.
3. Compressor is installed always on level position. Compressor can be tilted, but only according to
given values. See chapter 3.2 Angles of tilt, on page 10.
4. Between compressor and compressed-air network must be flexible connector and shut-off valve.
5. The direction of rotation must be checked and corrected before initial start-up as well as every time
the compressor is reconnected to electric network.
5.3.3 Start up
Every PTR-compressor is thoroughly tested at the factory before delivery. Testing ensures that
compressor meets the technical needs set for it and that it functions properly. It is however
advised to keep an eye on the compressor during initial operating hours to discover any possible
disfunctionalities.
ATTENTION! See chapter 5.3.2 Installation instructions!
When the compressor is running, let it run idle about one (1) minute unloaded or as long as it
needs the pressure to reach normal level. See reading from pressure gauge. If the compressor is
loaded right away, it is possible for oil to foam.
Avoid repeatedly opening and closing the shut-off valve. If however it is opened and closed in
small intervals, it may cause oil to foam and leak to the air filter and output air.
Following points must be taken into account before initial start-up:
1. Compressor must be connected only to appropriate voltage. See type plates of the electric motor.
Make sure that the direction of rotation is correct.
2. Compressor must not be loaded over maximum pressure. See compressor type plate.
3. Compressor is to be installed so that the ambient temperature is between 0° and 35°C.
4. One must never shut compressor down by using the main electric switch.
5. Check oil level.
6. The direction of rotation must be checked before initial start-up and every time it is reconnected to
electrical network. Direction of rotation is checked by starting the motor up for a moment.
!! WRONG DIRECTION OF ROTATION FOR MORE THAN TWO (2) SECONDS

DAMAGES THE COMPRESSOR SEVERELY !!
Reoperation right after shut down

Compressor can be restarted right after shut down when the pressure has gone down to 0 bar. For the
compressor to depressurize it takes about one to two (1-2) minutes.
5.3.4 Compressor shut down
1. Close shut-off valve.

2. Before shut down let the compressor run unloaded for two (2) minutes.
3. Stop the compressor.
33
5.4 Daily procedures
5.4.1 Safety issues in daily operations
See chapter 4. General safety instructions and regulations on page 11.
5.4.2 Checks performed prior to operation
1. Check oil level and drain or refill accordingly.

2. Check the condition of the prefilter mat and clean if necessary.
3. Check the condition of the overall compressor and act accordingly.
4. Whether operating in a very damp atmosphere, check oil tank for condensate water and drain water
if necessary.
5. Check the ambient temperature. It is recommended not to operate the compressor in an ambient
temperature below 0 °C.
6. Check the condition of the motor.
7. Check the condition of the oil cooler and clean it if necessary.
8. Check the direction of rotation. It is to be done at least every time the compressor is reconnected to
the electric network.
5.4.3 Checks performed while operating
1. Check the reading of the pressure gauge.

2. Check whether any of the signal light are on and act accordingly.
3. Avoid repeatedly opening and closing the shut-off valve. If however it is opened and closed in small
intervals, it may cause oil to foam and leak to the air filter and output air.
5.4.4 Special conditions of use
Precautions to be taken when operating in very hot atmosphere

1. Make sure that compressor gets as fresh intake air as possible.
Precautions to be taken when operating in very dusty atmosphere

1. Keep an eye on the condition of prefilter mat and air filter. Clean and replace them when necessary.
Precautions to be taken when operating in very damp atmosphere

1. Check the amount of condensate water before start-up and drain if necessary. See instructions on
page 42, chapter 7.4.1 Condensate drain.
Precautions to be taken when operating in very cold atmosphere

1. Compressor is advised not to operate in temperatures below 0 °C.
2. Make sure that the oil cooler is frost protected.
5.5 Preservation and storage
1. Protect the compressor against corrosion.

2. Before storing, remove all the liquids that may have been deteriorated in use.
3. Make sure that the temperature in the storage is above 0 degrees Celsius.
4. Make sure that the storage is not subject to flooding.
5. Whether the compressor is stored for a longer periods of time, should the storage be dry and warm.
6. Drain the condensate water, when the compressor is cooled down. See instructions on page 42,
chapter 7.4.1 Condensate drain.
34
6 LUBRICATION MANUAL
6.1 Oil recommendations
Only the suitable oils can be used in operating PTR- compressors. Oil must be approved by the
manufacturer. The oil must also be suitable for use in unfavorable conditions such as contamination
of the intake air by gases, solvent vapors, exhaust gases as well as in conditions with high ambient
temperature.
Suitable types and brands of oil can be specified on request. Suitable oils can be mineral oils, synthetic
oils as well as biological degradable oils. The substances and materials used in compressors such as
seals must be taken into account when selecting the oil type. Corrosion or other material degradation
must not occur.
In case of low ambient temperature, compressor must be protected against freezing.
Oil refill:
Use the same product and the same oil type. Different types of oil must no be mixed.
Pipeline materials:
The oil used in compressor may attack compressed-air pipeline networks made of plastic.
The coolant used in screw compressor must fulfill these requirements:

- High ageing stability
- Minimum foaming
- High dispersive capacity
- High corrosion protection
- Low emulsification tendency
- Hydraulic or turbine oil
- Flash point above 200°C / 400°F
- Basic oil: Solvate
- Pour-point: minimum 5 degrees below the lowest ambient temperature.
- Viscosity at 40° C /1014°F: ca. 42-50 mm²/s (cST)
- ISO VG class 46
Caution:
Absolutely observe the oil viscosity, otherwise the life of the bearings is at risk.
Damages caused by condensate:

It is of great importance to take the relative humidity, ultimate working pressures for the working
temperatures of the thermostat component and the compressor into the account in order to prevent
damage caused by condensate water
Cold starts:
When effecting compressor cold starts, it is equally important that upon the start the viscosity of the
oil, taking into account that the pressure drop is higher when the oil circuit is still cold, facilitates a
sufficient and immediate lubrication of the compressor. The higher demand for energy of cold starts
may not overload the compressor machinery.
Oil separation:
In the upper range, the fine separation of oil decreases as the compressor outlet temperature increases.
Multigrade oils:
The problem with some multigrade oils is that after a certain period of time the molecular chains of
their viscosity improvers can get what you could call “cut into small pieces” (sheared off). When this
happens, the upper viscosity grade is endangered and therefore the oil does no longer offer complete
temperature stability. For this reason multigrade oils are not to be used for PTR-compressors.
35
6.2 Oil circulation
From the screw compressor unit pressured air/oil mist is goes to the oil separator unit in which they
are separated. There are two phases in oil separating process. The most of the oil is separated in the
cyclone of the separator unit employing centrifugal force. Remaining oil is separated in oil separator
cartridge (1).
From the oil separator cartridge the separated oil is lead back to the oil circulation through oil return
lead (2). In the return lead there is an orifice plate (3) to prevent excessive air flow back to the unit.
From the oil separator unit the hot oil is lead through the cooler (7) and oil filter (4) back to cool the
screw unit. There is a thermostat (5) in the container, which leads the oil pass the cooler if the oil
is already cold. Oil circulation is forced and is maintained by the pressure difference between the
container and the screw unit.
To ensure oil circulation all times while air is produced is the compressor equipped with an minimum
pressure valve (6). Minimum pressure valve controls the pressure in the container and ensures that it
does not drop under minimum value (3 bar).
Safety valve (8) protects the oil separator cartridge from excessive pressure. Valve prevents the
pressure rising to dangerous levels by opening at certain pressure.
Figure 45. Oil circulation (Figure © Gardner Denver)
36
6.3 Lubricating the compressor unit before initial start-up
It is of great importance to lubricate the compressor unit before initial start-up and every time the
compressor has not been used for a months period of time or longer. Pour 0,5 liter oil into the intake
opening.
ATTENTION! DO NOT EXCEED OIL MAXIMUM!
1. Remove air hoses coming to the valve

2. Remove bolts (1) 4 pieces. Figure 46.
3. Detach air inlet valve.
4. Pour 0,5 liter oil into the intake opening. Figure 47.
5. Assemble in reverse order.
Figure 46. Bolts to be removed
Figure 47. Air inlet opening
37
6.4 Lubrication chart
Lubrication interval Procedure
Daily before start-up - Check oils

After 100 operating hours - Check oils and add if necessary
After 500 operating hours - Change oils and carry out other duties to be
done while the compressor is drained.
Table 3. Lubrication chart
6.5 Lubrication safety and other precautions
1. Keep an eye on the hour meter and follow instructions concerning lubrication intervals.
2. Before oil change, drain or refill the compressor must be fully shut down, depressurized and in level
position. After shut down compressor should be depressurized after one to two minutes.
Confirm zero pressure from the pressure gauge!
3. In case of oil refill right after operation, one must wait at least 15 minutes to make sure that oil
foam has vanished to indicate correct oil level.
4. Do not mix different types of oil, flush before refilling.
5. Clean/change all filters if necessary
6. Check the condition of the sealing gaskets (do not forget to put them back)
7. When an engine is drained, clearly mark it so that it is not operated before it is refilled.
8. Analyze drained lubricant if necessary
38
7 MAINTENANCE MANUAL
7.1 General safety instructions concerning maintenance
Maintenance and repair work may only be executed under the supervision of a person qualified for
this work.
1. Switch off all the operations of the compressor from the main switch before starting any
maintenance work and make sure it is not switched on unintentionally.
2. Execute maintenance and repair work only when the unit is completely discharged.
3. Use only original spare parts and the right tools designed for maintenance and repair work.
4. Execute any repair or maintenance work only when the unit is switched off and the mains supply is
disconnected. Make sure that the unit cannot be switched on unintentionally. The shut-off valve to the
pressurized air network should also be closed.
5. Shut off the unit from all pressure sources and discharge the entire unit from pressure before
removing a part under pressure. Make sure that the air/oil receiver is pressureless before you start
maintenance.
6. Do not use inflammable solvents or carbon tetrachloride to clean parts. Take precautions against
toxic vapors of cleaning solvents.
7. Take care that extreme cleanliness is observed during maintenance or repair work. Keep away dust.
Cover parts or bare openings with a clean cloth, paper or adhesive tape.
8. Make sure that no tools, loose parts or cleaning rags are left in or on the unit.
9. Before releasing the unit for operation after it has been maintained or overhauled, check whether
the operating pressure temperatures and time adjustments are correct and the control and switch-off
devices in perfect working order.
10. Protect the motor, the air filter, electrical components, control system against moisture, for
instance when cleaning them by means of steam jet.
11. Do not remove or change the noise-insulating material.
12. Do not use corrosive solvents, which could affect the materials of the air delivery main, such as
poly carbonate bowls.
13. All alterations must conform to the regulations concerning pressure vessels.
14. Starting of compressors with remote control must be prevented while maintenance work is in
progress.
15. Do not neglect the regular check-ups and maintenance of the compressor.
16. When switching the unit back on again, make sure there is no person working on the machine.
Make sure that all connections are properly tightened and all safety installations are in perfect working
order.
39
7.2 Procedures before and after maintenance
DANGER! - Surfaces inside the compressor cabinet are hot immediately after shutting
down the compressor!
Procedures before maintenance

1. Stop the compressor and make sure that the receiver is pressureless. The blow-out function empties
the receiver after shut-down. Compressor is pressureless within 1 to 2 minutes. However, always
check the pressure from pressure gauge before starting mainetenance!
2. Turn power off at the main switch and make sure that the compressor cannot be accidentally started.
3. Close the shut-off valve between the network and the compressor.
4. Open pressure relief valve cap 4-5 turns.
5. The space between the minimum pressure valve and the systems shut-off valve stays under pressure
when the compressor is stopped and the shut-off valve is closed.
Procedures after maintenance

1. Close the pressure relief valve
2. Open the shut-off valve between compressor and the network
3. Start the compressor
40
7.3 Locations of maintenance points
Reference Description Maintenance Page(s)

number procedure
1 Oil separator elements Change 41
2 Air inlet valve maintenance Change 41
and repair kits
3 Prefilter mats Cleaning and change 42
4 Oil return filter Cleaning and change 41
5 Oil checking hose Check oil level 41, 42
6 Oil filter Change 41
7 3/2 direction valves Change 41
8 Maximum pressure valve Change 41
9 Minimum pressure valve Change 41
maintenance and repair kits
10 3/2 direction valve Change 42
11 Safety valve Testing 41
12 Oil drain points Oil drain when necessary 42
and oil change
13 Oil adding point Oil refill when necessary 41
and oil change
14 Condensate Drain 42
15 Oil cooler Cleaning 42
16 Oil hoses Change 41, 42
17 Air filter and cyclone Clean and change 42
Table 4. Locations of maintenance points
Figure 48. Locations of maintenance points 1
41
Figure 49. Locations of maintenance points 2
Figure 50. Locations of maintenance points
42
7.4 Maintenance procedures
7.4.1 Condensate drain
See pages 39 and 40 for safety instructions and procedures prior to operation.
ATTENTION! Drain the condensate regularly when the screw compressor unit is cold, for
instance before start-up. It is of advantage if the unit has been standing still for a
longer time.
The condensate content in the oil affects operating safety and life of the screw compressor unit. If
you operate the screw compressor unit for a short period of time and consequently at low operating
temperature, for instance below the switch temperature of the thermal oil bypass valve, condensate
will possibly accumulate in the oil separator receiver. The relative humidity in the intake air
determines the quantity of condensate.
Possible Malfunctions:
-Insufficient lubrication of the screw unit.
-Insufficient air/oil separation and high differential pressure in the purifier cartridge.
-Corrosion and rust formation due to condensate in the oil.
Drain the condensate regularly when the screw compressor unit is cold, for instance before start-up. It
is of advantage if the unit has been standing still for a longer time.
Maintenance Procedure:
1. Switch off unit with main switch and position switch (prevent it from being switched on
unintentionally).
2. Slowly unscrew cover screw of oil filling pipe. Figure 51.
3. Oil drain points are located underneath the compressor. After placing a container underneath the
drain hoses, open drain valves.
4. Drain the condensate unti oil comes out, than close drain valves.
5. Fill receiver with oil up to maximum, then close oil filling pipe manually with the cover screw.
6. Switch on compressor unit and let it run for approximately three (3) minutes.
7. Stop the compressor and let it cool down approximately two (2) minutes.
8. Check oil level: if oil is missing, fill up to maximum.
9. Dispose of condensate in accordance with regulations.
Figure 51. Oil filling pipe Figure 52. Oil sckecking glass
43
7.4.2 Adding oil and oil change
DANGER! - Use recommended oil types only; do not mix different oils!
- Oil is hot when the compressor has just been stopped!
- Do not open the oil filling plug if the receiver is pressurized!
- Dispose of used oil according to current local regulations on handling of waste oil!
Adding oil
1. Open the plug of oil filling pipe (Fig. 53) and the hose connection (Fig. 54) and add oil up to top
mark of the measuring glass. Fig. 55.
2. Close the plug and hose connection. Figs. 53-54.
4. Close the safety valve and open shut-off valve.
Oil change
1. Run the compressor until the oil temperature is +40...50 °C.
2. Open the oil filling plug and place a contaner underneath the oil drain valves. Open the drain valves
and plugs and let the oil drain.
3. Close the drain valves and add oil up to the maximum of the oil measuring rod. Figure 55.
4. Close the oil filling pipe plug. Figure 53.
5. Close the safety valve and open the net work shut-off valve.
Check also the condition of oil hoses and if necessary change defected ones. Oil filter is also usually
changed while the compressor is drained. See chapters 7.4.3 Changing oil hoses, on page 45 and 7.4.4
Changing oil filter, on page 46.
Figure 53. Oil filling pipe Figure 54. Hose connection Figure 55. Oil measuring glass
44
7.4.3 Changing oil hoses
Checking and/or changing the oil hoses are done at the same time as oil change.
1. Check the hoses by eye and bending them.

2. The hose needs changing whether oil or cracks are discovered
3. Detach hose clamps and replace the hose with a new one. Make sure the connections are properly
tightened.
Reference number Description

L1 Hydraulic motor pressure
L2 Hydraulic motor return
L3 Hydraulic motor leak
L4 Compressor drain
L5 Cooler drain
L6 Cooler in
L7 Cooler out
L8 Air out
L9 Hydr. 3/2 tank
L10 Hydr. 3/2 pressure A
L11 Hydr. 3/2 B
L12 Hydraulic cell in
L13 Block - cell 2Bar
L14 Hydraulic cell out
L15 Air out lead-through
L16 3/2 valve lead-through
L18 Cooler lead-through
L20 Motor lead-through
L22 Fluid level gauge bottom
L23 Fluid level gauge top
L24 Block - cell
Table 5. Oil hoses
45
7.4.4 Changing oil filter
ATTENTION! - Allow the compressor to cool down before starting the work.
- Dispose the used filter according to regulations on toxic waste.
- Use only the original oil filters.
1. The oil filter (1) is located in the compressor unit. Use protective cloth, as some oil will drain out
when the filter is being removed.
2. To remove the filter, turn it counterclockwise with a oil filter wrench.
3. Lubricate the oil filter sealing ring of the new filter with clean oil.
4. Screw the new oil filter cartridge on the fitting by hand, without using any tool.
5. Check whether the oil filter is tight when the unit is running.
Figure 56. Changing oil filter (Figure © Gardner Denver)
46
7.4.5 Cleaning oil cooler
For the operational safety of the screw compressor unit, clean the cooler weekly and more often if it
is necessary. Keep the cooling ribs of the cooler clean. This is a prerequisite for achieving optimum
cooling power. Adequate cooling means low oil temperature and thus longer service life.
We recommend cleaning with compressed air, steam jet or cleansing agent. Should the intake
air (cooling air) be strongly contaminated, clean the cooler in shorter intervals, especially if the
compressor outlet temperature is above the normal value.
In case a prefilter mat is fitted before the screw compressor, shake out the dust or replace mat daily.
Maintenance procedure:
1. Switch off system and protect it against unauthorized re-starting.
2. Remove the bolts and other fasteners and remove the covering metal shield of the cooaler end.
3. Clean the oil cooler.
4. After cleaning, put back the prefilter mat and close the stand.
Figure 57. Oil cooler
47
7.4.6 Changing oil separator elements
DANGER! - Allow the compressor to cool down before starting the maintenance work!
- Dispose used separator element according to regulations on handling toxic
waste!
1. Detach air hoses and remove bolts (4 pieces) of the cover of the recceiver (1).
2. Remove the body of the minimum pressure valve/the cover of the receiver (1).
3. Remove the oil separator elements (2). Use tool to assist. See figure 67.
4. Clean the sealing surfaces on the receiver and the minimum pressure valve body (1).
5. Clean the orifices (3) inside the pipe.
6. Clean the oil return filter and assemble in reverse order. See chapter 7.4.9 Cleaning and changing
oil return filter on page 50.
7. Grease the O-rings of the separator elements and install new separator elements (2) into place.
8. Change the O-ring (5) between the receiver and the minimum pressure valve.
9. Place the cover of the receiver/body of the minimum pressure valve back on. Make sure that the
plugs of the receiver cover match with the holes in the separator elements.
10. Tighten the screws alternately to even tightness.
Fig. 58. Changing oil separator elements (Fig. © Gardner Denver)
48
Fig. 59. Bolts 4 pieces. Fig. 60. Tool used to remove elements
Fig. 61. Cover and O-ring removed Fig. 62. Removing separator elements
Fig. 63. Oil separator element removed Fig. 64. Elements replaced. Installling the cover.
49
7.4.7 Cleaning and changing oil return filter
ATTENTION! - Oil return filter is cleaned or changed when it is clogged or in connection

with oil change!
Changing oil return filter

Pay attention to direction of assembly. Make sure that all the parts are assembled the same way they
were before starting maintenance!
1. Detach hoses coming to the oil return filter.

2. Open the oil return filter frame by uncrewing parts 1 and 2 and change the filter (3). See figs. 66-70.
3. Assemble filter in reverce order. Use sealing substance on threads.
4. Attach hoses.
5. Make sure everything is assembled properly.
Cleaning oil return filter

Pay attention to direction of assembly. Make sure that all the parts are assembled the same way they
were before starting maintenance!
1. Detach hoses coming to the oil return filter.

2. Open the oil return filter frame by uncrewing parts 1 and 2 and clean the filter (3). Clean also the
nozzle (4) which is attached to the hose. See figs. 66-70.
3. Assemble the cleaned filter and nozzle in reverce order. Use sealing substance on threads.
4. Attach hoses.
5. Make sure everything is assembled properly.
Fig. 65. Oil return filter location
50
Fig. 66. Detachable parts Fig. 67. Opening part 2
Fig. 68. Opening part 1 Fig. 69.
Fig. 70. Filter Fig. 71. Nozzle
51
7.4.8 Changing air inlet valve maintenance and repair kits
DANGER! Notice the tension of the spring!
Changing air inlet valve maintenance kit

1. Detach hoses and hose clamps coming to the valve.
2. Remove bolts 4 pcs and detach air inlet valve. Remember to cover the air inlet opening carefully.
Figure 72.
3. Remove hexagonal socket screws 2 pcs and put thread bars (M 10x150 mm) instead, tighten the
nuts.
4. Remove remaining two hexagonal socket screws.
5. Open the nuts evenly so that the flange releases.
6. Remove bolts and detach flange. Make sure that piston stays in placce.
7. Change parts.
8. Reassemble in reverce order.
Changing air inlet valve repair kit

1. Detach hoses and hose clamps coming to the valve.
2. Remove bolts 4 pcs and detach air inlet valve. Remember to cover the air inlet opening carefully.
Figure 72.
3. Remove hexagonal socket screws 2 pcs and put thread bars (M 10x150 mm) instead, tighten the
nuts.
4. Remove remaining two hexagonal socket screws.
5. Open the nuts evenly so that the flange releases.
6. Remove bolts and detach flange. Make sure that piston stays in placce.
7. Change parts.
8. Reassemble in reverce order.
Figure 72. Air inlet valve bolts Figure 73. Removable hex. socket screws
Figure 74. Thread bars, nuts and screws Figure 75. Spring and piston
52
Reference Order number Quantity Description

number
Air inlet valve
Seal kit assy (Incl. parts 16-20)
Repair kit assy (Incl. parts 3, 7, 8, 10, 11
and 13-20)
1 1 Frame
2 1 Piston
3 1 Cover
4 1 Plate
5 1 Bushing
6 1 Piston rod
7 1 Spring
8 1 Spring
9 1 Screw
10 1 Bearing bushing
12 1 Retaining ring
13 1 Retaining ring
14 1 Slide ring
15 1 Piston gasket
16 1 O-ring
17 1 O-ring
18 1 Gasket
19 2 O-ring
20 1 O-ring
21 1 Flange
22 4 Screw
23 1 Supporting ring
Table 6. Part list, air inlet valve
Reference numbers in the table correspond with numbers in the air inlet valve explosion diagram!
See the diagram on the next page!
53
Figure 76. Explosion diagram, Air inlet valve (fig © Gardner Denver)
54
7.4.9 Cleaning and changing prefilter mat
PTR-40-HV has two prefilter mats. Both mats are located

in the motor end of the compressor the other on the short side
and the other on the long side.
Cleaning prefilter mat

1. Open the stand of the prefilter mat.
2. If the mat is in good condition, it needs only to be cleaned.
Clean prefilter mat carefully with compressed air.
3. Put the mat back and make sure the stand is closed
properly.
Changing prefilter mat

1. Open the stand of prefilter mat.
2. Change the mat.
3. Close the stand properly Figure 77. Prefilter mat
7.4.10 Changing control valves
Control valves include 3/2 direction valves and maximum pressure valve. The following instructions
apply to all the valves listed.
1. Detach hoses coming to maximum pressure valve.

2. Detach clamps and replace valve.
Figure 78. 3/2 direction valves Figure 79. Maximum pressure valve Figure 80. 3/2 direction valve
55
7.4.11 Changing minimum pressure valve maintenance and repair kits
DANGER! Notice the tension of the spring!
Changing the maintenance kit (See pictures from the next spread)
1. Detach minimum pressure valve hoses.
2. Tighten the nut and release the spring.
3. Remove the retaining ring.
4. Lift the cover up.
5. Change parts 3, 4, 8, 9, 13, 14.
Changing the repair kit (See pictures from the next spread)
1. Detach minimum pressure valve hoses.
2. Tighten the nut and release the spring.
3. Remove the retaining ring.
4. Lift the cover up.
5. Change parts 3-5, 7-17, 19.
6. Assemble in reverse order
Reference Quantity Description

number
1 Part kit assy (Incl. items 2-20)
Seal kit assy (Incl. items 3, 4, 8, 9, 13, 14)
Repair kit assy (Incl. items 3-5, 7-17, 19)
1 1 Frame
2 1 Cover
3 1 O-ring
4 1 O-ring
5 1 Spring
6 1 Pipe
7 1 Piston
8 1 Piston gasket
9 1 Slide ring
11 1 Plate
12 1 Plate
13 1 Plate gasket
14 1 Spring
15 1 Gasket
16 1 Thrustring
17 1 Retaining ring
18 1 Washer
19 1 Nut
20 1 Nut
Table 7. Part list, minimum pressure valve
56
Fig. 81. Explosion diagram, minimum pressure valve (Fig. © Gardner Denver)
57
Fig. 82. Minimum pressure valve Fig. 83. Tightening the nut
Fig. 84. Removin lock ring Fig. 85. Removing minimum pressure valve
Fig. 86. Minimum pressure valve detached Fig. 87. Minimum pressure valve
58
7.4.12 Cleaning and changing air filter
ATTENTION! Make sure that no dust get into the compressor’s intake air!
DANGER! Never clean the filter with gasoline or any fluids!
Main element of the air cleaner (2) is cleaned when service indicator light is on.
Main element is changed after four times of cleaning and if necessary. However, at least once a year.
If the intake air is very dusty are the cleaning and changing intervals shorter that in normal conditions.
Underneath the main element (2) there is a safety cartridge (3) (secondary element), which is replaced
after the main element has been changed four times or after 500 operating hours, or when necessary
for instance in case of main element failure. Safety cartridge is to be changed after two years of use at
the latest.
Maintenance operations:
1. Switch off system and protect it against unauthorized re-starting.
2. Clean the dust discharge valve by compressing it sideways to remove the dust. Dust discharge valve
is located on the bottom of the filter lid. See picture 108.
3. Open filter lid (1) and carefully remove dust.
4. Remove the main element (2), clean or change it. Underneath the main element there is a secondary
element (3) (Safety cartridge).
a) Cleaning by knocking out: Knock the face of the cartridge several times against the ball of your
thumb so that dust falls off. Do not use force, avoid damaging the cartridge. Clean seating of
gaskets.
b) Cleaning by blowing: Blow cartridge surface with dry compressed air of no more than 5 bar at
an angle from the outside and the inside.
5. Close filter lid, observe correct positioning during assembly.

6. Disposal of the used oil filter cartridge must be carried out in accordance with regulations.
Figure 88. Air filter Figure 89. Main elenent Figure 90. Safety cartridge
(secondary element)
59
7.4.13 Cleaning cyclone
ATTENTION! Make sure that no dust get into the compressor’s intake air!
Cyclone is located on the top of air filter housing (1).
1. Open the bracket of cyclone cover (2).

2. Remove cyclone cover (3).
3. Lift the cyclone container (4) up and clean it.
4. Put the cleaned container and cover back and attach the bracket.
Figure 91. Cyclone parts and air filter Figure 92. Cyclone bracket removed
Figure 93. Cyclone opened Figure 94. Cyclone container removed
60
7.4.14 Testing safety valve
DANGER! - All the maintenance and adjustment procedures regarding safety valve are to
be done by professionals only!
The safety valve is spring-weighed. The blow-off pressure is 1 - 2 bar (14-28 psig) above the relevant
operating pressure (final pressure) of the unit. The valve is type-tested.
Safety valve is equipped with a testing device. The opening pressure of the pressure relief valve must
be tested in a separate pressurized air line.
The functional test can be executed while the compressor is running:
! LOOK OUT FOR THE PRESSURE UNLOADING FROM THE SAFETY VALVE!
1. Turn the knurled screw (cap) (1) on the top 1-2 turns counterclockwise.
2. Reset the valve again by turning it clockwise until it stops.
3. Always tighten up the pressure relief valve cap properly to avoid damage caused by vibration.
Figure 95. Safety valve Figure 96. Testing safety valve

(Figure © Gardner Denver)
61
7.5 Maintenance intervals
Interval/operating hours(oh) Maintenance procedure

When air cleaner indicator Change air filter.
light is on
Daily prior to operation Check the condition of motor and clean it if necessary.
Check oils and the condition of oil hoses.
Check the condition of prefilter mat and clean it if
necessary.
Check oil cooler and clean it if necessary.
Check bolts and clamps and retighten if necessary.
Weekly and when necessary Clean oil cooler
After two operating hours Check oils.
After 24 operating hours Check oils.
After 100 operating hours Change oil filter.
After 500 operating hours Change oils.
Check the condition of oil hoses and replace if damaged.
Change oil filter
Clean oil return filter.
Change prefilter mat.
In every 1 000 operating hours Change oil separator elements
In every 2 000 operating hours Change oil return filter
Change air inlet valve maintenance kit.
Change minimum pressure valve maintenance kit.
Change control valves. (maximum pressure valve and 3/2
direction valves).
In every 3 000 operating hours Change air inlet valve repair kit.
Change minimum pressure valve repair kit.
Table 8. Maintenance intervals
62
7.6 Wear parts and maintenance intervals
Procedure Set interval Change when necessary

Changing air inlet 2 000-3 000 h If malfunctions occur.
valve maintenance and
repair kits
Changing and cleaning 2 000 h If oil reaches the compressed air
oil return filter network, the oil return filter is clogged
and should be cleaned or changed.
Changing oil hoses Replaced in accordance Check hoses by bending and if leaks or
with oil change when cracks are discovered, the hose is to be
necessary. changed.
Changing oil separator 1 000 h Pressure difference is shown in pressure
elements gauge when pressure difference button
is pushed. When the pressure difference
is from 0,5 to 1 bar should the oil
separator elements be changed. With
new elements the pressure difference is
0,2 bar.
Changing oil filter 500h Oil filter is changed in connection with
oil change.
Cleaning and changing 500 h Check if the mat is dirty and clean or
prefilter mat change if necessary. Changing interval
is shorter when working atmosphere is
very dusty.
Changing air filter When indicator light Air filter is always changed when
is on clogged. Change intervals determined
according to the service indicator.
Changing control 2 000 h If any malfunctions occur.
valves
- 3/2 direction valves
- Maximum pressure valve
Table 9. Wear parts and maintenance intervals
7.7 Trouble shooting
Problem Propable cause(s) Procedure

Compressor Low oil level. Add oil.
overheats Dirty oil cooler. Clean the cooler (from both sides).
Wrong oil type. Change oils.
Inadequate air circulation. Add more fresh air into circulation. Check
ventilation and clean if necessary.
Too high ambient temperature. Add fresh cooling air.
Clogged oil filter. Change oil filter.
Faulty thermostat Change thermostat.
63
Motor shuts Faulty motor Check wheter the shaft rotates, if not
down motor is broken and needs to be repaired
or replaced.
Faulty compressor unit Check the whether the screw unit
functions properly, if not must the unit be
repaired or replaced.
Inadequate oil flow to the motor Check the pressure and liters coming to
the motor. See technical information on
page 9.
Faulty coupling Check coupling, whether broken, replace
or repair.
Faulty or worn-out coupling Replace coupling element.
element
Too high working pressure Lower working pressure. See technical
details on page 9.
Low air output Dirty or clogged air filter Change air filter.
Faulty or clogged air inlet valve Repair valve, change seal kit.
Faulty or clogged 3/2 direction Check valve and replace if faulty.
valve
Clogged oil filter Change oil separator elements.
High air consumption Check hoses and fasteners for leakage,
repair if leaks found.
Incorrectly adjusted minimum Check pressure adjustments and readjust if
and maximum pressures necessary.
No air output Shut-off valve is closed Open shut-off valve.
Faulty or clogged 3/2 direction Check valve and replace if faulty.
valve
Faulty or clogged air inlet valve Repair valve, change seal kit.
High air consumption Check hoses and fasteners for leakage,
repair if leaks found.
Compressor is Too high angle of tilt Check angles of tilt and follow
leaking oil instructions.
Seal, connection or oil hose Check seals, hoses and connections and
leaks change or retighten if necessary.
Shut-off valve has been Do not open and close the valve in short
repeatedly opened and closed. intervals.
Oil hose leaks Check hoses and change if necessary.
When problem is located, add oil to meet the correct oil level.
High oil Clogged oil separator Change oil separator elements.

consumption Clogged oil return filter Clean or change oil return filter.
Wrong oil type Change oils.
Too much oil Check oil level and drain if necessary.
Too high frequency Check pressure adjustments. Widen
pressure range.
Table 10. Trouble shooting
64
8 SPARE PARTS MANUAL
8.1 General
This manual includes clear identification of all spare parts, components through explosion diagrams,
photographs and drawings. Also part lists of major components are included. When ordering spare
parts, it is important to mention compressor model, type, serial number and order number of the part
in question. Locations of the serial numbers are found on the type plates.
8.2 Compressor part list
Quantity Description
0,14 Prefilter mat
0,23 Prefilter mat
1 Thermometer
1 Pressure gauge
2 3/2 Direction valve
1 Oil cooler
1 Hydraulic motor
1 Coupling
1 Coupling
1 Coupling
1 3/2 Direction valve (hydraulic)
1 Fan impeller
1 Coupling housing Tempest 12
1 Hour meter
1 Oil filter
1 Safety valve
1 Compressor unit
1 Air inlet valve
1 Minimum pressure valve
1 Air filter service indicator
1 Maximum pressure valve
2 Oil separator element
1 Air filter housing bracket
1 Air filter Europiclon 400
1 Cyclone
1 Intake hose
1 Intake hose
1 Non return valve
Table 11. Compressor part list
65
8.3 Part lists and explosion diagrams of the compressors main components
8.3.1 Tempest 12
Fig. 97. Explosion diagram, Tempest 12 (Fig. © Gardner Denver)
Ref. number Quantity Description

Tempest 12
1 Part kit (items 11, 32)
1 1 Frame
2 1 Cyclone
3 1 Filter frame
4 1 Cover
5 1 Manifold
66
7 1 Suction pipe
8 1 Measuring rod
9 1 Fitting
10 3 Filling plug
11 1 Oil checking glass
12 2 Bushing
13 1 Cyclone pipe
15 2 Oil separator
16 1 Oil thermostat element (Incl. spring)
17 1 Oil filter
18 1 Safety valve
19 1 Plug
21 1 Plug
22 1 Seal
23 4 Plug
24 1 Screw
25 1 O-ring
26 1 O-ring
27 1 O-ring
28 2 O-ring
29 1 O-ring
30 1 O-ring
31 1 O-ring
32 1 Seal
33 8 Screw
34 4 Screw
35 2 Screw
36 2 Screw
37 3 Screw
38 2 Spring washer
39 6 Screw
40 4 Screw
42 1 Part kit for discharge valve
43 See discharge valve
44 2 Screw
48 1 Fitting
50 2 Fitting
51 Orifice
52 1 Tube
52_1 3 Support bushing
55 1 Check valve
56 4 Seal
57 1 Oil pipe
58 1 O-ring
99 1 Spring
Table 12. Part list, Tempest 12
67
8.3.2 Compressor unit Enduro 12 TS
Fig. 98. Explosion diagram, compressor unit Enduro 12 TS (Fig. © Gardner Denver)
68
Ref. number Order number Quantity Description

Enduro 12 TS Compressor air end
Seal kit (items 1-7)
1 1 Inner ring
2 1 Gasket
3 1 Inner ring
4 2 Shaft seal
6 1 Dust seal
7 1 Shaft seal
8 1 Compressor air end
9 1 Sealing cover
10 6 Hexagonal socket screw
11 1 Discharge cover
12 9 Hexagonal socket screw
Table 13. Part list, compressor unit Enduro 12 TS
69
8.3.3 Minimum pressure valve
Figure 99. Explosion diagram, minimum pressure valve (Figure © Gardner Denver)
70

number
1 Part kit assy (Incl. items 2-20)
Seal kit assy (Incl. items 3, 4, 8, 9, 13, 14)
Repair kit assy (Incl. items 3-5, 7-17, 19)
1 1 Frame
2 1 Cover
3 1 O-ring
4 1 O-ring
5 1 Spring
6 1 Pipe
7 1 Piston
8 1 Piston gasket
9 1 Slide ring
11 1 Plate
12 1 Plate
13 1 Plate gasket
14 1 Spring
15 1 Gasket
16 1 Thrustring
17 1 Retaining ring
18 1 Washer
19 1 Nut
20 1 Nut
Table 14. Part list, minimum pressure valve
71
8.3.4 Air inlet valve
Figure 100. Explosion diagram, air inlet valve (Figure © Gardner Denver)
72

number
Air inlet valve
Seal kit assy (Incl. parts 16-20)
Repair kit assy (Incl. parts 3, 7, 8, 10, 11
and 13-20)
1 1 Frame
2 1 Piston
3 1 Cover
4 1 Plate
5 1 Bushing
6 1 Piston rod
7 1 Spring
8 1 Spring
9 1 Screw
12 1 Retaining ring
13 1 Retaining ring
14 1 Slide ring
15 1 Piston gasket
16 1 O-ring
17 1 O-ring
18 1 Gasket
19 2 O-ring
20 1 O-ring
21 1 Flange
22 4 Screw
23 1 Supporting ring
Table 15. Part list, air inlet valve
73
8.3.5 Hydraulic motor
Figure 101. Explosion diagram, hydraulic motor (Figure © Parker)
Ref. number Description

Hydraulic motor 3788103 F11-019-QB-CV-K-000-MVL-0
1 Barrel housing
2 Valve plate
3 Cylinder barrel
4 Guide spacer with O-rings
5 Timing gear
6 Roller bearing
7 Bearing housing
8 Shaft seal
9 Output/input shaft
10 Piston with laminatedpiston ring
Table 16. Part list, hydraulic motor
74
8.3.6 Hoses
No. Description
L1 Hydraulic motor pressure
L2 Hydraulic motor return
L3 Hydraulic motor leak
L4 Compressor drain
L5 Cooler drain
L6 Cooler in
L7 Cooler out
L8 Air out
L9 Hydr. 3/2 tank
L10 Hydr. 3/2 pressure A
L11 Hydr. 3/2 B
L12 Hydraulic cell in
L13 Block - cell 2Bar
L14 Hydraulic cell out
L15 Air out lead-through
L22 Fluid level gauge bottom
L23 Fluid level gauge top
L24 Block - cell
Table 17. Hoses
75
ANNEXES
Annex A Maintenance intervals
Interval/operating hours(oh) Maintenance procedure

When air cleaner indicator Change air filter.
light is on
Daily prior to operation Check the condition of motor and clean it if necessary.
Check oils and the condition of oil hoses.
Check the condition of prefilter mat and clean it if
necessary.
Check oil cooler and clean it if necessary.
Weekly and when necessary Clean oil cooler
After two operating hours Check oils.
After 24 operating hours Check oils.
After 100 operating hours Change oil filter.
After 500 operating hours Change oils.
Check the condition of oil hoses and replace if damaged.
Change oil filter
Clean oil return filter.
Change prefilter mat.
In every 1 000 operating hours Change oil separator elements
In every 2 000 operating hours Change oil return filter
Change air inlet valve maintenance kit.
Change minimum pressure valve maintenance kit.
Change control valves. (maximum pressure valve and 3/2
direction valves).
In every 3 000 operating hours Change air inlet valve repair kit.
Change minimum pressure valve repair kit.
76
Annex B Procedures done prior to, during and after operation
Timing Procedure
Prior to operation Check the condition of electric motor and clean it if necessary.
Check oil level and the condition of oil hoses.
Check the condition of prefilter mat and clean it if necessary.
Check the oil cooler and clean it if necessary.
Make sure that the direction of rotation is correct. This is to be
done at least when the compressor is reconnected to electric
network.
Whether ambient atmosphere is very damp, check the amount of
condensate and drain if necessary.
Check the ambients temperature and make sure it is between + 0
to +35 degrees Celsius.
Check the condition of the belts.
Check the overall condition of the compressor and act
accordingly.
During operation Monitor meter readings.
Make sure that intake air is fresh.
Check whether any of the signal light are on and act accordingly.
Listen to the compressor, if any unusual noises are discovered,
locate the sound origin and act accordingly.
Monitor the compressor, whether any malfunctioning is
discovered, locate the problem and act accordingly.
Avoid situations in which the shut-off valve is repeatedly
opened and closed. If however, it is opened and closed in small
intervals, it may cause oil to foam and leak to the air filter and
output air.
After operation Let the compressor run unloaded for two (2) minutes before
shutting down.
The compressor should cool down for fifteen (15) minutes
before starting any maintenance or repair work.
Compressor can be restarted after shut down when the pressure
has gone down to zero. This will take about one to two minutes
time. Monitor the pressure gauge reading.
Remember that compressor surfaces are hot after shut down.
77
Using the portable fire extinguisher
A dry powder fire extinguisher is suitable for extinguishing most types of fires (not suitable
for grease fires; risk of injury when sprayed at close distances). A fire extinguisher of this
type is not optimal for extinguishing fires affecting computers and other electronic
equipment, though.
Familiarize yourself with the fire extinguisher and its operating instructions before a fire
occurs.
• REMOVE the extinguisher from its mounting bracket.

• PULL out the safety pin. Pull it quickly and strongly in the direction of the pull ring.
• APPROACH the fire from the upwind side. If the fire is indoors, approach it
crouched. When you are on the upwind side, the smoke and most of the heat from
the flames flow away from you, so visibility is better and you do not breathe in any
toxic gases.
• AIM the extinguisher nozzle at the base of the fire. Hold the hose or nozzle firmly.
DISCHARGE the extinguisher.
• START extinguishing by aiming the extinguishant stream at the fire.
• BEGIN at the front of the fire, and continue to the back. WORK from bottom to top
to prevent reignition of an extinguished area.
• EXTINGUISH a liquid fire by sweeping back and forth across the liquid surface back
and forth with a horizontal powder stream. If you aim the stream at the liquid at too
steep an angle, the burning liquid may splash, causing the fire to spread.
• When the flames are out, STOP spraying extinguishant. Do not turn your back on
the area; it might reignite.
• If the area reignites, REPEAT the above steps. The operating time of a portable fire
extinguisher is limited (10–20 s). Try to save extinguishant in case the fire reignites.
• USE several fire extinguishers at a time to extinguish a larger fire.
• DELIVER the fire extinguisher for maintenance immediately after use, regardless of
how much it has been used.
Every two weeks

1. Ensure that the powder flows freely.
Every year
1. Check the pressure.
2. Check the valve system.
3. Check the hoses.
4. Check the tank.

$
$
.LUMDLQPHUNLQQlW(NRPSRQHQWWHMDYDUWHQ /HWWHUVIRU(FRPSRQHQWV

/HWNXOOHNLUMDLQWXQQXV+6 $LGOHWWHUIRUKRVHW\SHV+6
$SXNLUMDLQOHWNXW\\SHLOOH $LGOHWWHUIRUKRVHW\SHV
352-(&7,'
%
5(/$7(72
$NXGRVSHUXVOHWNX $VWHHOEUDLGKRVH
%
%NXGRVSHUXVOHWNX %VWHHOEUDLGKRVH
&LPXOHWNX &6XFWLRQKRVH
''.2SllWWHLQHQNXGRVOHWNX ''.2W\SHVWHHOEUDLGKRVH
('.2SllWWHLQHQNXGRVOHWNX ('.2W\SHVWHHOEUDLGKRVH
)06+$K\YlNV\WW\SROWWRDLQHOHWNX )06+$DSSURYHGIXHOKRVH
*7HUPRSODVWLVHWOHWNXW *7KHUPRSODVWLFKRVH
+6OLPOLQHOHWNXW +6OLPOLQH+26(
,MlWHWW\SRLVHSlVHOY\\NVLHQYlOWWlPLVHNVL ,/HIWRXWWRDYRLGPLVXQGHUVWDQGLQJ
&
-NXGRVDLVLOHWNX -VWDLQOHVVVWHHOEUDLGKRVH
&
.NXGRVDLVLOHWNX .VWDLQOHVVVWHHOEUDLGKRVH
/6DPPXWXVMlUMHVWHOPlQOHWNXW /)LUHVXSSUHVVLRQKRVH
0,OPDVWRLQQLQOHWNXW 0$LUFRQGLWLRQKRVH
1.DQJDVSXQRVOHWNXW 17H[WLOHEUDLGKRVH
2PXRYLOHWNXW 23ODVWLFKRVH
3,62K\YlNV\WW\SROWWRDLQHOHWNX 3,62DSSURYHGIXHOKRVH
4.RUNHDQOlPS|WLODQOHWNXW 4+RVHZLWKKLJKWHPSHUDWXHUHVLVWDQFH

5HSURGXFWLRQXVHRUGLVFORVXUHWRWKLUGSDUWLHVZLWKRXWH[SUHVVDXWKRULW\LVVWULFWO\IRUELGGHQ
3XWNLOOHNLUMDLQWXQQXV7% /HWWHUIRUSLSHW\SHV7%
' '
$SXNLUMDLQSXWNLW\\SHLOOH $LGOHWWHUIRUSLSHW\SHV
$7HUlVSXWNL $6WHHOSLSH
%5XRVWXPDWRQWHUlVSXWNL %6WDLQOHVVVWHHOSLSH
:HUHVHUYHDOOULJKWVLQWKLVGRFXPHQWDQGLQWKHLQIRUPDWLRQFRQWDLQHGWKHUHLQ
&0XRYLSXWNL &3ODVWLFSLSH

1LSDW- )LWWLQJV-
1LSRWXNVLHQRVDNRRQQDW-$ )LWWLQJVDVVHPEOLHV-$
/LGHW-& -XQFWLRQV-&
(
9HQWWLLOLW9 9DOYHV9 (
9HQWWLLOLQSRKMDODDWWD93 9DOYHVXESODWH93
9HQWWLLOLQRVDNRRQQDW9$ 9DOYHDVVHPEOLHV9$
/LGHMHQRVDNRRQQDW-&$ -XQFWLRQDVVHPEOLHV-&$
) )
1(: (77(118 '$7(

'(6,*1

+<'5$8/,&6
$33 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' &+$50(&0)'$'- 6K

$ 237,21$/$,572*5281' $
/(9(/&+$5*,1*23(5$725

9$ 9$
$,5287 $,5287
-
+6 $

% %
+6 $ &-

&&

& &
9$
$,5,1
352-(&7,'
5(/$7(72
' '
$
237,21$/$,5/,1()520$,5+26(5((/

+6
&
-
+6 $ +6+6 $$
(
&' (
72%220 &-
9
,1 287 +6 $

&'
$,5/,1(72&+$5*,1*&21752/81,7 &-
'5$,1
=$
) )
+6 $


&)
$,5/,1(72&+$5*,1*&21752/81,7 &-
9
* 530 *
PPLQ $
+ +
$''('&52665()(5(1&( +-8 '$7( &+$50(&0)'$'-

$+ '(6,*1 DK

&2035(66('$,56&+(0(
$33 & 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' &2035(66('$,5,1&+$50(& 6K

$ $
% %
9D -
+6 $
PP

&'

9 -
9D 9D +6 $

&&

PP
5 %
3 &

& $D - - +6 1PP &
& 5 $
&'
&- +6 $ &$D$
9D %/2:
&&
& 72$&78$7252)7+(&+$5*,1*%$//9$/9(

[ -$
72$,5287 $D - - +6 1PP
; 99D &'
- &$D$

3 9E
- &

$E - - +6
352-(&7,'
5 % 1PP
3
&+
- &$E$
& $
5
+6 $ & 72$&78$7252)7+(&+$5*,1*%$//9$/9(

&) $E - - +6

1PP
5(/$7(72
' &- '

&+
)520:$7(56(3$5$725 &$E$

[ ; -
9E +6 $
9D (;75$$,5

&&

PP
:$ 237,21$/

3,/2735(6685(:$7(572$1)26<67(0

%$
( 237,21$/ &' (
&-
:$7(572$1)2 -
3
- = =
,1 287
-
& =D =D
+6 $
&)
9D $1)27$1.35(6685( (;75$$,535(6685( &
&- -
)520:$7(56(3$5$725 +6 1

&$
- &9D
3 - +6 1 - - -

-
) 5HJEDU & )
0D[EDU -
+6 1

&(
- &9E
&211(&7,2132,176
)52179,(:
3 3
* *
%$
%%
$D $E
$E 9D
$D
:$ :% 9E
+ +
%$ %%
9D 9E
9D 9E
$''('960&(;3257723'0 (77(.18 '$7( &+$50(&0)'$'-

'(6,*1 HWWHMNR

&2035(66('$,56&+(0(
$33 & 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' &+$5*,1*!0(&+$1,&$/60&&+$50(& 6K

$ $
% %
& &
9$
&
=E -&
- - -
+6+6 $$ +6 $ +6 $ +6 $
352-(&7,'
&(
&-
,1 287 $,5287,1%$6.(7
5(/$7(72
' '

&)
&-
$,572&+$5*,1*&21752/
( (
) )
* *
+ +
83'$7,1*6&+(0$,7& $+ '$7( &+$50(&0)'$'-

'(6,*1 $0\

&2035(66('$,56&+(0(
$33 & 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' $,5/,1(72%$6.(71%%;6 6K

$ 9
$
-
$ $
+6 1PP
%D
&- +6 1 99
&)
9D

35(6685(72$1)29(66(/ -
- +6 1

- -
+6 1

EDU &
9D 9
$

$D - 287 ,1
237,21$/:$7(572$1)2 =D

% FFPñU %
/ 9D
35(6685(9(66(/ 9D
%
9 9D
- =D
$,5,1
1
-

,1 287
287
+6
,1 $D 287
& &
$D
$ $
- -

-
'
&- +6 1PP

&&
352-(&7,'

&- +6 1PP
&&

5(/$7(72
' '
- -
&9%$ +6 1
&(
-
(;75$$,5
-
+6 1

-

( 9
(
-
( (
+6 1PP
%E
&- +6 1 99
&)
9E
35(6685(72$1)29(66(/ -
- +6 1

- -
+6 1

EDU )
9E 9
$
$E
237,21$/:$7(572$1)2
=E
- 287 ,1
FFPñU
) )
/ 9E
35(6685(9(66(/ 9E
%
9 9E
- =E &211(&7,2132,176
$,5,1
5($59,(:
+6 1
-

,1 287
287
3 3
,1 $E 287
* $E *
$ $
- - %$
%%
*
- $E $D
9D $E $D
&- +6 1PP
&'
9E
:% :$
&- +6 1PP
+
&'
%% %$ +

9E 9D
9E 9D
1(: (77(-.2 '$7( &+$50(&0)'$'-

'(6,*1 HWWHMNR

+<'5$8/,&6&+(0(
$33 & 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' $,5/,1(72(-(&7256!9$&880),//,1*60&&+$50(& 6K

$D$ +6 $

$

=D
=D287
$ $ $

+6 $ +6 $ +6 $

9D
9D
9D % $ 3 9
$
<D
$
$
$D 9

FFPñU
+6 $
+6
% / %
%

+6 $

9
99
67 3 3
5(*
; 5
=D,1

& % &
$

$
$D 9
+6
$1)2+233(5
FFPñU =
/
352-(&7,'
%

RXW RXW
+6 &
=D 7 7
+6 $
<E
$D% +6 $ 9 9

5(/$7(72
' '
&
9E

+6 $

+6 $

+6 $

9E 9E
$E$ +6 $
(
% $ 3

$
$
$
=E287
(
$
$

$

( (
&
&
+6
+6
+6

+6
+6
+6
$
9
+6
+6
$E
$
FFPñU

/ % +6 $

+6
67
99 3
;
%
9$
) )
+6 &

+6 $

=E,1
)

$
=
99
+6 $ +6 $

$E $ 9 $ FFPñU

99
+6
FFPñU $ $ +6 $

7 7
* 0$; *
/
530 % /
% +6 $

+6 $

+6+6
$E% $$ +6 &
*

*
97
+-

+6 $

+-
3

3
+&
+-&
+ 7 +

7
+*
/ /
+'
1(: (77(-.2 '$7( &+$50(&0)'$'-
'(6,*1 HWWHMNR

+<'5$8/,&6&+(0(
$33 & 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' $,5/,1(72(-(&7256!9$&880),//,1*60&&+$50(& 6K

$ $
- +6 $

$

- +6 $

% )
%

& &
% $ 3
9

352-(&7,'
5(/$7(72
' '
9
67 3

OPLQ

( (

7
7
) )
- +6 $

+

* *
+ +
1(: (77(-.2 '$7( &+$50(&0)'$'-

'(6,*1 HWWHMNR

+<'5$8/,&6&+(0(
$33 & 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' $,5/,1(72(-(&7256!9$&880),//,1*60&&+$50(& 6K

$ $
% %
9$ 9$
9$ 9D

-&E
- -
- - - -
+6 $ +6 $ +6 $ +6 $ +6 $ +6 $
&&

& 9 &

99
- -
- - - -
+6 $ +6 $ +6 $ +6 $ +6 $ +6 $
&'
-
99
- -
352-(&7,'
- - - -

+6 $ +6 $ +6 $ +6 $ +6 $ +6 $
&&

5(/$7(72
' - '
1PP
1PP
9$
9E

+6
+6
- -
+6 1PP

( (
- -
-
+6 1PP

) - )

&'
&-&
* *
+ +
83'$7,1*6&+(0$7,& $+ '$7( &+$50(&0)'$'-

'(6,*1 DK

&2035(66('$,56&+(0(
$33 & 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 0(&+$1,&$/&+$5*,1*&21752/!1%%;6 6K

-&$ +- +6 $ 0,''/(-2,17
:,1&+ (1*,1((1' *(1(5$725 +$
+-
+&
-& -
237,21$/(0(5*(1&<72:,1* 3 +- +6 $
+9 +6 $ +$
+&
+*
- +-
$
6833257/(*6 372
3 $
+6 $

+-
+&
-
&$%/(5((/ &2035(6625 +6 $
/

+'
26&,//$7,21$%625'(5 - +-

+6 $
7

+)
0$*1(7,&%5$.( - +-
-& +-
:,1&+ / +)
+6 $

+(
+6 $
- +-&

+6 $ +6 $ +-&
+(
%
- %

+- %5$.(6 +6 $ &$%/(5((/ +6 $
++

&$%,1/2$'(1'&21752/0,;(5 7+5277/(
:,1&+

6833257/(*6
7 -&
+6 $

+- 67((5,1* +6 $ &2035(6625
++

26&,//$7,21/2&.$%625'(5 *(1(5$725
9
& &
&$%/(5((/7
3
+- +6 $ 0
+*
0 <
)52067((5,1*
EDU
$
6
9$ 3 6
$

3

9
352-(&7,'
)520237,21$/'(9,&( 6
$
+6
9$
< $ +6 $
,)237,216$5(12786('! EDU

32576$5(&211(&7('72/($. /6 3 <

-
5(/$7(72
' ¡PP '
+6

+ 7
+99 +6 $ +6 $ 0 7
+)
-
EDU
372/6 ¡
)520/2$'(1'
$

/6 $

(1*,1((1'$;/(
<
6(59,&(%5$.(6 %5($7+(5 3$5.,1*%5$.(
+6
9
( % (
237,21$/:(/',1**(1(5$725
0 +6 $

237,21$/5'6

+6
EDU EDU

237,21$/(0(5*(1&<72:,1*

$

7267((5,1*%5$.(6 3 %5 7 6D W
+93 +6 $
+)
&

237,21$/32:(53$&. +6 $
)
)

237,21$/&2035(6625 -
+6 $

+)
237,21$/32:(53$&. +-
237,21$/32:(53$&.


+6 $ +6 $

9D
+%
237,21$/+<'5$8/,&3803 +-
;
3-$96(77,1*9$/8( 3
63$5<0(& 27+(59(+,&/(6 530 0 3 &2035(6625
* 237,21$/32:(53$&. *
$ EDU $ EDU
% EDU % EDU FFPñU 6 / 0$*1(7,&%5$.(
+6 $
OPLQ -

$EDU 237,21$/+<'5$8/,&3803 372-81&7,217

EDU
+6 $

6863(16,21
6
&
=

EDU
237,21$/$,5&2035(6625 372-81&7,21/
+6
= 6 P

(0(5*(1&<3803
/ 6 W %<3$66 EDU +*
/ EDU +-
+ 6 & +
= -
6 / 6 / 65 7 / 6
6&+(0(83'$7(' 6,+ '$7( &+$50(&0)'$'-

'(6,*1 +-X

+<'5$8/,&6&+(0(
$33 + 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' (1*,1((1'0)&$55,(5 6K

$ $
% %

$
0,''/(-2,17 -
-
-
+- +6 $
+$

+6 $

& &
+6 $

+- +6 $

+$

-
-
352-(&7,'
-
$
5(/$7(72
' '
:,7+75$160,66,21
+6 $

:,7+75$160,66,21
+- +6 $
+%

( /2$'(1'$;/( (
9$
6(59,&(%5$.(6 %5($7+(5 3$5.,1*%5$.(
:,7+75$160,66,21
+- +6 $
+%

+6 $
EDU EDU
:,7+75$160,66,21
6E W
+6 $

& -&
) )
* *
+ +
83'$7(+26(/(1*7+6 +-8 '$7( &+$50(&0)'$'-

'(6,*1 DK

+<'5$8/,&6&+(0(
$33 + 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' /2$'(1'0)&$55,(5 6K

-
+6 $ +6 $

+$
$ +- $
&$%,1+2/(12
-
+6 $ +6 $

+$
+-
&$%,1+2/(12
-
+6 $
/ 5

+*
+-
&$%,1+2/(12
% %
9
9
&&05

+6 $
7
+6 $
3 3
&$87,21
& 3UHVVXULVHG &
0) 0)
YHVVHO
'LVFKDUJHSULRU ) )
6 WRGLVDVVHPEO\ +6 $
3
EDU
3 /6 7 9
6
3
EDU
352-(&7,'
6 %5 0 6 7
+6 $
$
$ %5 +6 $

3 3

3 ¡
5(/$7(72
' 0) 0) '

+6
+6
9 ) )
¡
$ EDU %5 +6 $

99D
$
+6 $
+6

/6 7 0 6 SD EDU
S EDU
EDU
( 3 6 (
+6
S EDU
9 OLW
1LWURJHQ1
7HPS &
99E
+6 $

+6 $

5(* -
+6 $
9

+)
+-
$
&$%,1+2/(12

$
) )

3 5 -
$
+6 $
+6

+%
+6
+-

+)
&$%,1+2/(12
+-
+6
-
+- +6 $
+&
99

&$%,1+2/(12
* *
-
+6 $

-
- - &$%,1+2/(12

&$%,1+2/(12
+-
3 3

7 +- 7

+&
+ / +
/
+%
83'$7('+26(6 (77(258 '$7( &+$50(&0)'$'-

'(6,*1 +-X

+<'5$8/,&6&+(0(
$33 + 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 67((5,1*$1'%5$.(6)5217&$%,167' 6K

)
(
%
'
$
+
&
*
:HUHVHUYHDOOULJKWVLQWKLVGRFXPHQWDQGLQWKHLQIRUPDWLRQFRQWDLQHGWKHUHLQ 5(/$7(72
352-(&7,'

$

/
7
3
9(5 &+$1*(

$
$
9
3
7
<

+6 $

+6 $

3
$
7
%
%
+6 $

+6 $

/()7-$&.

<
'$7(

$
<
$+

$
+6 $

1$0(
$
3
$
7
%

%
+6 $

(;7(16,21
$33
'$7(
$
67$1'
'(6,*1

<
DK
$

<

$
+6 $

$
3
$

7
%
%
+6 $

(;7(16,21
$

<
<

+6 $

+6 $

3
$
7
%
%
+6 $

+6 $

5,*+7-$&.
<

3
7
$
$
9$

+<'5$8/,&6&+(0(
+6 $

+&
+-&
6833257/(*6/2$'(1'
&+$50(&0)'$'-
+-& +6 $

+)

$
/
3

+

6+((7
6K
)
(
%
'
$
+
&
*

$
$
,16758&7,216)25,'(17,)<,1*'(9,&(6,16&+(0$7,&6
352-(&7,'
+,*+(5/(9(/$66,*10(17+/$ '(9,&('(6,*1$7,21/(77(5&2'(6
000272502'8/( $&21752/81,7(;7(51$/'(9,&(
%
5(/$7(72
&0&$%,102'8/( %6(1625
30352&(6602'8/( &&$3$&,725 %
%0%22002'8/( '',2'(
505($502'8/( (/,*+7:25./,*+7
)0)5217(1'02'8/( ))86(&,5&8,7%5($.(5
+0+,*+92/7$*(02'8/( *$/7(51$725*(1(5$725
%$%$6.(702'8/( +6,*1$//,*+7+251%8==(5
.5(/$<&217$&725
002725
3*$8*(
& 4&,5&8,7%5($.(5
/2&$7,21 55(6,6725 &
66:,7&+
7%0$,1(/(&75,&%2; 6+,//80,1$7('6:,7&+
7%&%/2$'(1' (*%220(1' 775$16)250(5&219(57(5
7%&%/2$'(1'6(&21'$5< 8&21'8,7+26(3527(&7,21
7%&%%$6.(73/$7)250 ::,5(&$%/(
7%&%%$6.(73/$7)2506(&21'$5< ;7(50,1$/%/2&.&211(&7253,1
7%&%352&(6625$33/,&$7,2102'8/(%2; (*(0802'8/($1)202'8/( <9$/9(
7%&%352&(6602'8/(6(&21'$5<
7%&%&$%,1'$6+%2$5'
' 7%&2035(6625&21752/%2; '
7%&%5(027(&21752/ 12560$5702'8/(,'(17,),&$7,216<67(0
(0+(1*,1(02'8/(+286,1*
1&$%,1 102725 1&$%,1
+9%+,*+92/7$*(%2;
1%$6.(7 1%220 1%$6.(7
7)0%75$16)250(5%2;
15($5 15($5 10,'
5&5$',2&21752/
15(027( 1)5217 10,&
656/,35,1*
:+:,5,1*+$51(66
$/62(9(5<&21&5(7,&$/3/$&(2876,'(2)%2;&$1%(86('$6
( /2&$7,21(*&$55,(5 (
'(9,&(1$0,1*&219(17,216(3$5$725&+$5$&7(56
12560$576<67(0,'(17,),&$7,21
+/$
/2&$7,21
'(6,*1$7,21
$1)2&+$50(&B)&B7,(5
(;$03/(6:,7&+6+,1+,*+92/7$*(&$%,1(7
+9+9%6+
) )
237,21683'$7(' (77(152 '$7( '-

'(6,*1 (77(++$

(/(&75,&6&+(0$
$33 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' &+$50(&0)'$'- 6K

$ $
&200216<0%2/6,16&+(0$7,&6
% )86( &211(&7,21 &217$&7 %
&,5&8,7%5($.(5 )86( 7(50,1$/%/2&. )5$0( 62/'(5 7(50,1$/%/2&. )(0$/(3,1&217$&7 0$/(3,1&217$&7 81&211(&7(' &217$&7 &217$&7 &+$1*(29(5&217$&7
)86( *5281',1* &211(&7,21 :,5( 1250$//<23(1 1250$//<&/26('
& &
$&6&+(0$
6(16256:,7&+ : 9 8 9 :
,1&/,1$7,21
9 8
0 0 0
5' 97 %. 5' *1 5' 8 :
a a
W S S W 3( 3(
:,) )
352-(&7,'
6/,35,1* 3+$6( &217$&725 3+$6( 3+$6(

%. <( %8 :+ %. 5'
81,7 0$,16:,7&+ (/(&75,&02725 (/(&75,&02725
7(03(5$785( 35(6685( /(9(/ 35(6685( 7(03(5$785( /(9(/ 352;,0,7< :$7(5,1)8(/ )/2: /(9(/ ,1&/,1$7,21 0(&+$1,&$/
6:,7&+ 6:,7&+ 6:,7&+ 6(1625 6(1625 6(1625 6:,7&+ 6(1625 6(1625 6:,7&+ 6:,7&+ 326,7,216:,7&+
5(/$7(72
' ,1'8&7,9( &$3$6,7,9( '

,! ,! ,!
*(1(5$/'(9,&(
&,5&8,7%5($.(5 7+(50$/ ($57+/($.$*(3527(&725 &,5&8,7%5($.(5

:,7+ 5(/$<
) 5
7+(50$/
0 $1'
5 ) 0$*1(7,&

( 75,33,1* (
D
*($56(/(&725 ,*1,7,216:,7&+ 3803 %8==(525 &2,/ 9$/9( %($&21 :25./,*+7

+251 &2,/
/ / /
8H
9 $
)DXOW
92/7$*(*$8*( $03(5*$8*( 7+(50,67255(/$< 3+$6(6(48(1&(

5(/$<
/ $ D
$ D
) )
5(6,6725 &$3$&,725 ',2'( /(' /$03 5(/$< 32:(55(/$< 0$,16:,7&+ 5(/$<
&217$&725 &217$&7 % E
&2,/ 1 % E
& F
$&'& 3+$6(
&219(57(5 75$16)250(5 Q
3+$6(
0 * 75$16)250(5
* *
%$77(5< 67$5702725 $/7(51$725 */2:3/8* &$1%8602'8/(
$&&808/$725 ,1387
287387
+ +
237,21683'$7(' (77(152 '$7( '-

'(6,*1 (77(++$

(/(&75,&6&+(0$
$33 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' &+$50(&0)'$'- 6K

5($',1*,16758&7,216)25&52665()(5(1&(6%(7:((1'5$:,1*6
$
$
352-(&7,'
%
5(/$7(72
&
&
' '
( (
) )
(;3/$1$7,216)25 +/$$1'/2&$7,21$%%5(9,$7,216$5(35(6(17(',1,1)26+((7
237,21683'$7(' (77(152 '$7( '-

'(6,*1 (77(++$

(/(&75,&6&+(0$
$33 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' &+$50(&0)'$'- 6K

1RUPHW&RGH 5HYLVLRQ 1DPH 'HVFULSWLRQ

$ &2035(6625 12560$57$1'1*(&203$7,%/(
$
:,5,1*+$51(66 06(5,(623(1&$%,1
(/(&75,&6&+(0$ 5(9(56(&$0(5$60/6(5,(6
(/(&75,&6&+(0$ &203.,708/7,0(&6)0)
352-(&7,'
(/(&75,&6&+(0$ (0(5*(1&<3803

% (/(&75,&6&+(0$ 7%$1'7%60/6(5,(6
5(/$7(72
%
(/(&75,&%2; 7%;;00&+$50(&60/)
(/(&75,&6&+(0$ '(87=(1*,1(02'8/(60/6(5,(6
(/(&75,&6 7%%7%7%&+$50(&60/)
(/(&75,&6&+(0$ &2035(66('$,5&22/(5.,760/6(5,(6
&
&
' '
( (
) )
237,21683'$7(' (77(152 '$7( '-

'(6,*1 (77(++$

(/(&75,&6&+(0$
$33 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' &+$50(&0)'$'- 6K

$ $
&29(5,16,'(
5,*+76,'( 0272502'8/(3$576$66(0%/('833(5'2253/$7(
% %
;)0
;)0
;)0
;)0
;09
;09
;%
;%
;(
;(
;(
;(
;(
;(
;(
;(
;(
;(
;(
;(
;(&
;(&
D D D D

& . . &

N N N N
;&)
352-(&7,'
5(/$7(72
' '

(05,6,167$//(':,7+:,%5$7,21'$03(56
)25,168/$7,21
.
(0581,7
( ;$ (

(0+

) )
00:5
* *
127(
7+,67<3(&,5&8,7&$//6)25$&7,21:+(1
,03257(',172(352-(&76((3$*(
5(029(7+,67(;7,17+(),1$/352-(&7'2&80(17$7,21
+ +
1,5 '$7( '-

'(6,*1 1,5

(/(&75,&6&+(0$
$33 00 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' '(87=(1*,1(02'8/(60/6(5,(6 6K

,16,'( '225,16,'(
$
+&0
;.$ $
+.1
+&0
$ $ ;
$ $ $ $ $ $ $ $ $ $ $ $
$ ;

. . . . .% .

.$ .
352-(&7,'
;
5(/$7(72
;

;
;

;

;

< $
;

;

;

;

;

;

;
0272502'8/(02817,1*3/$7(

;

;

% ;

;

;

; %

;

;

;

;

;

;

;

;

;

;

;

;

;

;

;

;

;

;
;

;

;

;

;

;

;

;

& ;9

;9
;9
;9
;9 &
;9

;9

;9 )%

;9

;9

;9

;9

;9

D )< )< )< )< )< )<
)< )< )< )<

;) 63$&(5(6(59(')25'(87=(05&211(&7256
;)
;)
;)
;)
)<
)<
;)
;) N 7
;) 9'&$
D
N
;) 9%$7
D
N
9'&&219(57(5&20(6 .$
;)
D
N
:,7+$&&(6625<6758&785(
;)
D
N
;)
D
N
;)
D
N
;)
D
N
' ;5 '

D
D
N
N
;5
D
D
N
N

;5
D
D
N
N

;5
$ $ $ $ $ D
$ $ $ $ $ D
. . . . . N
. . . . . N
;'
;'
;'
;'
;'
;)
;
;
;
;
;
;
;
;

.$ .% . . .$ .% . .

( (
. . . . . .D .E
;.% ;.D
V'(/$<2))
D
5(/$<6.$$1'.%$5(3/$&(':+(10$&+,1(
,6(48,33(':,7+),5(68335(66,216<67(0
) 5(/$<.,63/$&(':+(175$163257326,7,21
)
3$5.,1*%5$.(,17(5/2&.,686('
6&+$1*(' (77(152 '$7( '-

'(6,*1 -3H

(/(&75,&6&+(0$
$33 00 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%$1'7%60/6(5,(6 7% 6K

5,*+76,'( '2252876,'( /()6,'(

$
$
352-(&7,'
5(/$7(72
%
%
;$

&

&
;$

:*1'

:)
;$

%/$1. %/$1.

:7%
;$
' '

)52179,(:)25)86(3$1(/

:*

;$

:&+$5*

)

)
)
)
)
)
$

$
$
$
$

$

;$

:0

&29(55(&(37$&/( ) ) ) ) ) )

)
)
)
)
)
)

)

;$
( (

$
$
$
$

) ) ) ) ) ) )

) ) ) ) ) ) )

)
)
)
)
)
)

)

;$

$
$
$
$
$
$
$

) )
&29(5/,'$66(0%/<
'2&
6&+$1*(' (77(152 '$7( '-

'(6,*1 -3H

(/(&75,&6&+(0$
$33 00 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%$1'7%60/6(5,(6 7% 6K

%27720
$
$
72**/(6:,7&+
$66(0%/<',5(&7,21
352-(&7,'
5(/$7(72
9(57,&$/+25,=217$/
;$$
%/$1.
;' ;'

&29(55(&(37$&/( &29(55(&(37$&/( &29(55(&(37$&/(

%
;$$
%

%/$1.
&
&
6$ 6%
3
6
3
6 6 6 6D 6E
/$ 237,21$/ 6 6+
7(67
6
6 6
' '
237,21$/ 0.1 6723

237,21$/

237,21$/
%.
6

6 6
6723
XVE;
6 6

$
;
6 6
6+'
6
237,21$/
+%
( 6
%.
5' (
2,//(9(/
75$160,66,21&+$5*(35(6685(
7%
$&&808/$725&+$5*(35(6685(

0,'602817,1*
02817,1*3/$7(
;6&5(:0; ;:3
;:3
3/$&(':+(1$8720$7,& $ 3/$&(':+(175$160,66,21
75$160,66,2186(' 0 6 :,7+29(5'5,9(86('
)
)
5,*+76,'( 6
)5217 /()76,'(
6&+$1*(' (77(152 '$7( '-

'(6,*1 -3H

(/(&75,&6&+(0$
$33 &0 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%$1'7%60/6(5,(6 7% 6K

',$*1267,&&211(&725&20(6
:,7+',(6(/(1*,1(5(/$7('3$576
$
$
;',$*
352-(&7,'
5(/$7(72

;
;
;
;
;
;
;
;
;
;
;
;
;
;9
;9
;9
;9
%
;)
;)
;)
;)
;)
;)
;)
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%

;'
;'
;'
;'
;'
;'
;5

;&7
;
;
D D D D D D D

. . . . . . .
. . . . . . .

$ $ $ $ $ $ $
&
$ $ $ $ $ $ $
&
N N N N N N E
' '
( (
.
;.
) &3D )
.$1'.$66(0%/('72)5217,1&/,1('/(9(/2)7+(%2;
6&+$1*(' (77(152 '$7( '-

'(6,*1 -3H

(/(&75,&6&+(0$
$33 &0 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%$1'7%60/6(5,(6 7% 6K

%27720
$
$
352-(&7,'
%/$1.
;$ ;$ +3

%

5(/$7(72

%

%/$1.
&
&
6% 6% 6%
6
' '
6% 6%
6B6
6
( (

) )
)5217
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 &0 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 7%E 6K

)
(
%
$
'
&
352-(&7,'

9(5 &+$1*(
,283'$7('

(&

;9

;9

;9

;9

;9

;9
(&

;%

;%

;%
+.1

;%

;%

;%
(&

;%

;%

;%

;%
(&
'$7(
.
$
;)
.
$
;)
(&

1$0(
(77(7(+
$33
'$7(
67$1'
'(6,*1

(77(152

1$0(

(/(&75,&6
+
.
1

&
+&

+ 0

7%%7%7%&+$50(&60/)
0
&0
7%E

6+((7
6K
)
(
%
$
'
&
)
(
%
$
'
&
352-(&7,'

9(5 &+$1*(

'$7(

1$0(
$33
6:(&26( '$7(
67$1'
'(6,*1

6:(&26(
372
*1

6D
+D

'-

(/(&75,&6&+(0$

&203.,708/7,0(&6)0)

6+((7
6K
)
(
%
$
'
&

127(+.1
$ ,1&/,120(7(5,1&/8'('
$
,167$//+25,6217$/
. .
+&0
+.1
352-(&7,'
+&0
PD[ PD[

:+
%
5(/$7(72
:( 5'
%
127(6(73/8*728186('+2/(6
;)
;)
;)
;)
;)
;)
6
(3
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;5
;'
;'
;'
;'
;'
+
6
(3
(3
(3
(&
(&
$ $ $ $ $ .
;'
+.1
;$

;$
$ $ $ $ $ $
7(67
8 $ $ $ $ $ $
%/$1.

5' 5'

+ +
6

%/$1.

. . . . . .

. . . . . .
;$
;$
)/,3&29(5
6($/('
&
. . . . . $
+&0
+&0
&3
&3
6$ 6$ 6$ &
&29(55(&(37$&/(
&29(55(&(37$&/(

6

;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;9
;9
;9
;9
;9
;9
;9
;9
;9
;9
;9
;9
;9
;9
;9
;9
;9
;9
6$ 6$
(3
(3
(&
(&

*1

+

'
'
6

( (
3(5)25$7,21

) )
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 30 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 7% 6K

$
$
&3 &3
;' ; ;

; ;
: . : .
- -
+ % / + % /
9 9

$ $
&29(55(&(37$&/( &29(55(&(37$&/(
* & * &
8 0 8 0
) ' ) '
( 1 ( 1
7 7
2 2
6 5 6 5
3 3
352-(&7,'
4 4
%/$1.
%/$1.

%
5(/$7(72
;%$ ;%%
<$<% (( +<

<$<% (( 6
%27720
&
&

)/,3&29(5
6($/('

6 6 6 6

6
/
6
;
6$
6%
' + 6
'
*1 *1
372
6 6
+ +
+ +
<( <(
*1 *1
+% +$
*1 *1
*
( 6% 6% 6 6 6 (

) )5217 )
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 30 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 7% 6K

)
(
%
$
'
&
352-(&7,'

9(5 &+$1*(
,283'$7('

'$7(

1$0(
(77(7(+
+&0 +.1
+&0
$33
'$7(
67$1'
'(6,*1

(77(152

;)
;)
;)
;)
;)
;)
;)
;9
;9
;9
;9
;9
;9
;9
;9
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;5
;5
;
;
;
;
;
;
;
;
$ $ $ $ $ $ $
(&
(&
(&
D D
D D
N N
,16,'(

N N
. . . . . . .
1$0(

(/(&75,&6

3(5)25$7,21

7%%7%7%&+$50(&60/)
30
7%

6+((7
6K
)
(
%
$
'
&

$
$
;' ;$

,167$//(',16,'(72'225

&29(53/8*

352-(&7,'

5(/$7(72

%
%
+.1
&
&
' '
$ %
6 6
;9
;9
;9
;9
;9
;9
;9
;9
;9
;
;
;
;
;
;
;
;
;
;
;

( (

) )
3(5)25$7,21

&211(&7256)25+$1'+ 0,6, '$7( '-

'(6,*1 1,5

(/(&75,&%2;
$33 30 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%;;00&+$50(&60/) 7% 6K

$
$
:$7(5'5$,13/8*,1727+(/2:(6732,17
352-(&7,'
5(/$7(72
9('(132,67278/33$$/,03$$1.2+7$$1
%
%
:+ :6
;&2
;&2
;&2
;&2
;&2
;&2
;&2
;&2
;&2
;&2
:< :3
;9
;9
&
:&2 :6+ :6 &

63$&()25)/,3)/23
' '


( (

) )
237,216'(),1(' -3( '$7( '-

5(/$<&211(&7,21&255(&7(' -3( '(6,*1 -3H

&2035(6625
:,5(/(1*+76$''(' $33 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 12560$57$1'1*(&203$7,%/( &2035 6K

)
(
%
'
$
+
&
*
352-(&7,'
5

$
).
5 <( ;0%
*/2:3/8*6
VWDWXVSUHKHDW %
;0B
5
.
;5 %. %. ;)
7%

*

5
35(+($7
'
5

35(+($7
5
'
.
*1' ;. ;. <( ;
0)
3UHKHDWUHOD\
;

%. ;*QG
* ;
<(
3UHKHDWUHOD\

;*QG
0
0
0; %. ;)

'

0;

(1*,1(%/2&.*1'
$
;0 ;0 <( ;% ;$
;**1'

'
.
;)0
$
$
)
)(

%. <(<( <( ;% ;$ <( 5'
7%
*

N D (0+
9(5 &+$1*(
*
;*%
*%
;*' ;*% %.
*
7%
%
;*:
*
'

(1*,1(67$57
:
;(
;% ;$ <(

<( ;% ;$ <( <( ;0%
$/7(51$725

%
;0B
'
.
/%8 <( ;0%

*

;0B

'
(05 ' <(
9

'
.
9%$7
$
'
'$7(
)(
;%
' <( 5' 5' %.
9
7%
+

'

' <(
9

127(
1,5
*29(5125
(05
<(
'
1$0(

' <(

(/(&75,&(1*,1(
'
'
&2167$1732:(5
' <(

9HPV 9HPV

'
$33
'$7(
' <(
FRRODQWOHYHOORZ FRRODQWOHYHOORZ

67$1'
'(6,*1
1,5
6
;09
/%8 ;$ ;% ;6 ;6 ;% ;$

6

$
)
;)0
;(
;6 ;% ;$ <( ;0%

9HPV )

N D ;0B

(05
&22/$17/(9(/6(1625
6
3
' ;6 ;6

;(
' ;$ ;% ;% ;$

6DLUILOWHU

*29(5125
$,5),/7(5
(/(&75,&(1*,1(

'
;(
' <(

$B9

'-
'
' <(
$B287

'
' <(
$B9

'
' <(
$B9

'
' <(
$B287

(/(&75,&6&+(0$
'
' <(
$B9

127(
&211(&7,217%
*
'
9
' /%8

&2167$17*5281'
9%$7
'
'(87=(1*,1(02'8/(60/6(5,(6
;%
' /%8 %.

7%
;0%

'
' /%8

;09

6
/%8
;6 ;6 /%8 ;% ;$

<( 6
$
;)0
)
;6 <( ;% ;$ <(

:,)
:$7(5,1)8(/
N D

%. 5'
00
$
)
;)0
(0+
<( ;% ;$ <( <( ;0%

N D
%
;0B

/%8 /%8 ;0%

9 *
;0B

6+((7
6K
)
(
%
'
$
+
&
*

$
$
&0
7%
0.1
352-(&7,'
5(/$7(72
$GGUHVV 5HI3DJH 3/&&RPPHQW 3/&&RPPHQW $GGUHVV 5HI3DJH 3/&&RPPHQW 3/&&RPPHQW

9B;B $ 9)25(/(&75 86%B;B $ 5;86%'
*1'B;B $ 9 86%B;B $ 7;86%'
% 9B5()B;B $ 5()(5(1&(92/7$*()256(16256 86%B;B $ &765;86%9
&$1B;B $ &$123(1+,*+ 86%B;B $ 5767;86%B*1' %
&$1B;B $ &$123(1/2:
',B;B $ ',B;B $
',B;B & 675$160,66,21&21752/12', DSSBDXWRPDWLFBWUDQVPLVVLRQBFRQWUROBRQB12B', &$1B;B $ -/2:
',B;B $ &$1B;B $ -+,*+
& ',B;B $

&
',B;B $
',B;B $
' '
$,B;B $ $$7+5277/(3('$/$9$, DSSBHOBWKURWWOHSHGDOB$B$,
$,B;B $ $%7+5277/(3('$/%9$, DSSBHOBWKURWWOHSHGDOB%B$,
$,B;B $ 758&.%('/2$'6(1625$, DSSBEXFNHWBORDGBSUHVVXUHB$,
$,B;B $
',B;B $
( (
',B;B $
',B;B $
',B;B &
) )
6&+$1*(' (77(152 '$7( '-

'(6,*1 -3H

(/(&75,&6&+(0$
$33 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%$1'7%60/6(5,(6 6K

$
$
&0
7%
0.1
352-(&7,'
5(/$7(72

9B;B $ 9)252873876
9B;B $ 9)252873876
% *1'B;B $ 9
%
'2B;B $ +:$51,1*+251'2 DSSBZDUQLQJBKRUQB'2 ',B;B & 6*($56(/(&7,21*($5', DSSBJHDUBVHOHFWBBJHDUB12B',
'2B;B $ 6(16256833/<'2 DSSBVHQVRUBVXSSO\BFDELQBSRVB'2 ',B;B & 6*($56(/(&7,21*($5', DSSBJHDUBVHOHFWBBJHDUB12B',
',B;B $ (1*,1(%5$.((1$%/(''2 DSSBHQJLQHBEUDNHB'2 ',B;B & 6*($56(/(&7,21):', DSSBJHDUBVHOHFWBIRUZDUGB12B',
& ',B;B & 66$)(7<%5$.(1&', DSSBVDIHW\BEUDNHBRQB1&B', ',B;B & 6*($56(/(&7,215(9', DSSBJHDUBVHOHFWBUHZHUVHB12B',
&
',B;B & ',B;B & 6*($56(/(&7,21*($5', DSSBJHDUBVHOHFWBBJHDUB12B',
',B;B & ',B;B $ (0(5*(1&<6723(1*$*('', DSSBHBVWRSBFLUFXLWBLQSXWB',
',B;B & ',B;B $ 78516,*1$/ DSSBWXUQBOLJKWB12B',
',B;B & ',B;B % ,*1,7,21216:,7&+ DSSBLJQBVZLWFKBSZUBRQB12B',

' '
',B;B % 6',(6(/672329(55,'(', DSSBGLHVHOBVWRSBRYHUULGHB12B',
',B;B & 6(1*,1(%5$.(', DSSBHQJLQHBEUDNHB12B',
',B;B &
',B;B &
',B;B & 6+$1'7+5277/(530', DSSBKDQGBWKURWWOHBUSPSOXVBSRVB12B',

( (
',B;B & 6+$1'7+5277/(530', DSSBKDQGBWKURWWOHBUSPBPLQXVBSRVB12B',
',B;B & 6+$1'7+5277/(212))', DSSBKDQGBWKURWWOHBVHOHFWLRQBSRVB12B',
) )
6&+$1*(' (77(152 '$7( '-

'(6,*1 -3H

(/(&75,&6&+(0$
$33 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%$1'7%60/6(5,(6 6K

$
$
00 &$1%862YHUYLHZ
7%
+.1 &21752/81,7(;(5786+&06$03683(56($/3,1&211(&7259
0$
352-(&7,'
5(/$7(72

9B;B + 9 ;B ( &$1B/B-
*1'B;B + *1' &$1B;B ) &$1B/&$123(1
% *1'B;B + *1' ;B ( &$1B+B-
*1'B;B + *1' &$1B;B ) &$1B+&$123(1 %
',B;B & *'$/7(51$725'', DSSBDOWHUQDWRUB'BSOXVB', ;B ' 5()92/7$*(72%$1'%9
',B;B & *:$/7(51$725(1*,1(5(9 DSSBGLHVHOBUSPB', ;B ) 5()92/7$*(9
',B;B ) 6%5$.(/,*+735(666:', DSSBEUDNHBOLJKWVB12B',
& ',B;B + %785%,1(63(('6(1625', DSSBWXUELQHBVSHHGB',

&
',B;B + %&$55,(563(('6(1625', DSSBVSHHGBVHQVRUB',
',B;B & 35(+($7(521 DSSBSUHKHDWHUBRQBQSQB',
',B;B *
',B;B *
' '
$,B;B + %$$;/(7(03$, DSSBD[OHBWHPSBHQJLQHBHQGB$,
$,B;B + %)8(/6(1625 DSSBIXHOBVHQVRUB$,
',B;B & %(1*,1(7(03(5$785(6(1625 DSSBHQJLQHBWHPSB$,
$,B;B + %+<'2,/7(03(5$785(6(1625$, DSSBK\GBRLOBWHPSB$,
$,B;B + %*($5%2;2,/7(03(5$785(6(1625$, DSSBJHDUER[BWHPSB$,

( (
$,B;B + %*($5%2;2,/35(6685(6(1625$, DSSBJHDUER[BSUHVVXUHBVWGB$,
;B + %%$;/(7(03$, DSSBD[OHBWHPSBORDGBHQGB$,
;B + *1'02'8/(5(*2&1,7,21
) )
6&+$1*(' (77(152 '$7( '-

'(6,*1 -3H

(/(&75,&6&+(0$
$33 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%$1'7%60/6(5,(6 6K

$
$
00 &$1%862YHUYLHZ
7%
+.1 &21752/81,7(;(5786+&06$03683(56($/3,1&211(&7259
0$
352-(&7,'
5(/$7(72
9B;B + 9 9

% 9B;B + 9 9
%
'2B;B ) '2B;B ( <*($59$/9('2 DSSBBJHDUB'2
'2B;B ) '2B;B ' ',6$%/(:,5('&21752/6'2 DSSBGLVDEOHBZLUHGBFRQWUROVB'2
'2B;B ) '2B;B ' 5'6%5$.(5(/($6('2 DSSBUGVBEUDNHBUHOHDVHB'2
& '2B;B ) ',B;B + 6%5$.(35(6685(6:,7&+12', DSSBEUDNHBSUHVVXUHB12B',

&
'2B;B ) ',B;B & 6:$7(5,1)8(/:,)12', DSSBZDWHUBLQBIXHOB:,)B12B',
'2B;B * ',B;B + 6$+<'52,/5(7851),/7(512', DSSBK\GBRLOBUHWXUQBILOWHUB12B',
'2B;B ' 6(16256833/<0272502'8/('2 DSSBVHQVRUBVXSSO\BPRWRUPRGXOHB'2 ',B;B & 6$,5),/7(56:,7&+1&', DSSBDLUBILOWHUB1&B',
'2B;B ' %5$.(5(/($6(5(48(67', DSSBEUDNHBUHOHDVHBUHTXHVWB12B', ',B;B * (06$1'29(5/2$'021,725,1*', DSSBHPVBHQJDJHGB1&B',
' '
'2B;B ' </2&.785%,1('2 DSSBORFNBXSB'2 $2B;B ( 5(7$5'(5',6$%/(''2 DSSBUHWDUGHUBGLVDEOHGB'2
'2B;B ' ((%5$.(/,*+76'2 DSSBEUDNHBOLJKWVB'2 $2B;B ( 0$18$/5(7$5',1*$&7,9$7('', DSSBUHWDUGHUBDFWLYDWHGB12B',
',B;B ) .5'6%5$.(&21752/5(/$<'2 DSSBUGVBEUDNHBFRQWUROB'2 '2B;B *
'2B;B * 66$)(7<%5$.(35(666:'2 DSSBVDIHW\BEUDNHB1&B', '2B;B *
'2B;B ' <*($59$/9('2 DSSBBJHDUB'2 ',B;B * 6$$;/(7(0312', DSSBD[OHBWHPSB12B',
( (
'2B;B ' <*($59$/9('2 DSSBBJHDUB'2 '2B;B + 66($76:,7&+,1387 DSSBVHDWBSRVLWLRQBVZLWFKB',
'2B;B ' <)):'',5(&7,219$/9('2 DSSBGLUHFWLRQB):'B'2 ',B;B ( ',(6(/5811,1*'2 DSSBGLHVHOBUXQQLQJB'2
'2B;B ' <55(9',5(&7,219$/9('2 DSSBGLUHFWLRQB5HZB'2 ',B;B & 6$+<'5$8/,&2,//(9(/6:,7&+12', DSSBK\GBRLOBOHYHOB12B',
) )
6&+$1*(' (77(152 '$7( '-

'(6,*1 -3H

(/(&75,&6&+(0$
$33 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%$1'7%60/6(5,(6 6K

)
(
%
'
$
+
&
*
352-(&7,'
0$,16:,7&+
0)
9%$7B 9%$7B
00
*
*
6

:* :6 7(/0$

;* ;* ;* ;* %. ;)0 ;)0 %. ;6

(0+(

0
)0
%.
:*
$
9(&0 &$7-803
%$77(5<
%$77(5<
0$,1)86(
96<67(0
*1'
(0+(
0*1'
;*QG
)
:6 ;6
;)6 %. ;6
&$7-803

&+$5*
$
)6
7(/0$
)5217)5$0(*1'
0$,1)86(
;*QG
67$5702725
7%
:)
;
;) %. %.
9%$7
:7%
9%$7B %.

;
(0+%
35
9%$7B)*
9HPV)
.%

. '
&0
;)
7%

;
;

<( ;$ ;% ;& ;' 9HPV)
$

6
&+$5*
/HQJWKPP PP
)
$
;

%. <( ;$
5(/$<
+9%

9(5 &+$1*(
;$B
+9%
5(7$5'(5
<( ;$
$
;)B7/0

)
;$B
9) <(<( 9)
(0(5*(1&<6723

' $
6&+$1*('
. 6[;
*%
;
;
;

%. <( ;$ ;% ;& ;'
(0+(
(0+

0$,1)86(6&211(&7('
3$5(//(/:,7+&233(5%$5
0$,1)86(237,216 0$,1)86(
<( 9)
%$77(5<&+$5*(5 $/7(51$725
)
$
+
$
; D N 9)
$
)
;
;% $

35
35
D N 9)
$
;'$ &
%.
%.
:*1'
<( ;$ D N
$
) ) )
$
;)

30

/,1()86(6&211(&7('
;$B )
3$5(//(/:,7+&233(5%$5
/HQJWKPP PP
/HQJWKPP PP
;

<( ;$ ;% ;& ;'
'$7(

;7%
0 ;%B
;
;%

7%E

%.
30
)
$
%

<( 9)
;$ +
0$,1)86(
$
;

<( 9)
)
;$ '
'
1$0(

%. %. <( 9)
$
)
%

$

; ;5D
;
(0(5*(1&<3803 7%
(77(152
0$,1)86(
5'
$
;
<(<( 9)
.$
)
9B;B

2873876
9)25
0.1
;.;0$ ' D N
;)D %.
$
)
' %
$33
;)
9) ;
'$7(
;
)
$
67$1'
5'
'(6,*1
;$ ;% ;& ;' ;&$%
&0
9B;B
35(+($7
2873876
0.1
9)25
&$%,1%

;&$%B
(0+% %
(0+
;
-3H

(0+ ;
35(+($7
&$%,1$
&211(&7,21

0$,1)86(
;&$%B 5'
(0+%
$
&$%,1&$123<
$
)
)
)
9B;B
(/(&75
9)25
0.1
$

%.
;
;

%. <( ;$ ;% ;& ;' D N

; 9)
7%
;'$ &
0$,1)86(
<( 9)

)
$
'
$
;))< D N
$
)
)
$
%
;)
)
; )
9 5' %.
N D ;
9B;B
+.1
;

%
<(
$
)
;)
6
;
.$
*
$1'
32:(55(/$<
9 5'

&/26('326
23(1326
N D ;9 /%8 <( ;$ ;% ;& ;' <(
9B;B
+.1
;
*

9

'
%
;
,*1,7,216:,7&+

*<
9 5' ;)D ;

' 9)
9B;B

+.1
;
',B;B
0.1
35
%

,*1,7,2121
6:,7&+
;
326
*<

&/26('
*1'
;0$ <( ;$ ;% ;& ;' HQJLQHVWDUW
*1'B;B
+.1

$ ;%
;

'-
;0B
'
%
(0+
;
%.
*1' %8

/HQJWKPP PP
6
<(
*1'B;B
+.1

/,1()86(6&211(&7('
;
<( ;$

%
35(+($7%87721
3$5(//(/:,7+&233(5%$5
%
30
237,21$/
; ;$B
*1' %8
;
<( ;$ ;% ;& ;'

+.1
*1'B;B
&

;
)
(/(&75,&6&+(0$
;%B
7%E
;%
)
$
; <( ;$

;9

%
*<
30
;$B
;B

$RSWLRQDO
<( 9)

+.1
6 $
;
<( 9)

7%$1'7%60/6(5,(6
. (
9%$7B
;
;
<( ;$ ;% ;& ;' <( 9)
*1'02'8/(5(*2&1,7,21
6$[ $

9%$7B)* <( 9)
)
;*
$
; '
;*
;*QG /%8 ;.$ <( 9)

9 ( ;. &

;9
/%8 ;$ <( 9)

;$ '
;$B
+9%
/%8 ;$ <( ;$

;
;$B

;$B %
+9%
<( ;$ ;

;9
;9
/%8 ;$ ;$B ;$ ;% ;& ;' /%8 %8 9
$
%
)

30
*1'B;B
;$B

0.1
/%8 ;$ <( 9)

72;97(50,1$/675,3
% & %

;
;.

;
;$B
;9

7%*1'%2/7&211(&7('
<( 9) ;$ ;% ;& ;' /%8 %8 9
;0$ ;.$ '
/%8
:,7+7:2%5$1&+,1*+$51(66
*1'B;B

$

0.1
97%
)

<( 9)

;0B
;9
&
(0+
;
;.$

/%8 ;0$

<( 9)
;0B
;9
' '
97%
;.%

/%8 ;0$ ;$ ;% ;& ;' /%8

;%B
$
(0+%
)
7%E

;0B '

<( 9)

& ;%B
7 ;%
;
;$ ;% ;& ;' ;&$%

&0
;9
;$ ;% ;& ;' ;&$%
&$%,1$
&0
;&$%B

&$%,1)
;&$%B
$
97%
)
&211(&7,21
;&$%B

&$%,1)
&$%,1&$123<
;&$%B

;
<( 9)

&$%,1) ;.% &
&211(&7,21
;&$%B
&$%,1&$123<

$
)
6+((7
6K
)
(
%
'
$
+
&
*
)
(
%
'
$
+
&
*
352-(&7,'
00
&0
7%
7%

(0+
;0$

$
(05
;)N
9)
*29(5125

<( ;'$ ;'% <( $
(/(&75,&(1*,1(
;',$*
'
' <( ;0% ;0$ 9) <(
\HOORZZDUQLQJOLJKW \HOORZZDUQLQJOLJKW ;)( $
;)N
'
' <( ;0% ;0$
UHGHQJLQHVWRSOLJKW UHGHQJLQHVWRSOLJKW ;)(
;9 /%8 ;'% /%8 %
% 9 ;',$*
<( ;$ ;% ;& ;' <(

'
' <( ;0% ;0$ <( ;$ ;% ;& ;' <( ;'% <( .
.',$* ./,1(
;',$*

;0$ <( ;$ ;% ;& ;' <(

%1 ;'% %1 )

;',$*
9(5 &+$1*(
:+ ;'% :+ 0
;',$*

6&+$1*('
-B+
&
(0+
;
;
;

(05
;0% ;0$ :+ ;$ ;% ;& ;' :+
-+

&$1B;B
0.1
-+,*+

'
*29(5125
;(
' :+
-+

'
(/(&75,&(1*,1(
' %1
UP
-/ -B/
5-

2+0
&
'$7(
7(50,1$7,215(6,6725
;
;(
5-
;

;0$ %1 ;$ ;% ;& ;' *<
-/
;0%
&$1B;B
0.1

-/2:

(1'5(6,6725
;0$ ;$ ;% ;&
1$0(

(77(152

;9
&
$33
'$7(

;%B
7%E

67$1'
;%
'(6,*1
97%
&
-3H

;%B
;%
-B6+
;$ ;$ ;% ;&
30
%

;$B
;
;
;
;$ :+ :+ ;$ ;% ;& ;' :+ :+

+,*+

;$B
&$1B;B
0.1

&$123(1
;&7

5&2
5&2
UP
2KP
2KP
%
;&7
;
;
;$ %1 %1 ;$ ;% ;& ;' %1 %1

/2:

;$B
&$1B;B
0.1
&$123(1

%
$

;
*<
'
92/7$*(
0.1
9B5()B;B

)256(16256
&$1%86%$&.%21(
3/$&('(1'2)7+(
(
;$
'-
7(50,1$7,215(6,6725

'
;$B
+9%
;
&
;$& :+ ;$% ;$$

;$ :+ & %. ;
;
<( *<

;$B
$ %8
$,B;B
9$,
7+5277/(3('$/6(1625

0.1
*1
% :+

(/(&75,&6&+(0$
5()(5(1&( $$7+5277/(3('$/$
;9
;'$
;$ 9 &
%1
97%

;$B
'
7%$1'7%60/6(5,(6
%
;$& *1 ;$$ ;$$

% % :+
; ;
;
&$1B+&$123(1 :+ <( *<

$ %8
$,B;B
9$,
&$1B;B
+.1

0.1
&
;
:+
& %.

%
(
;
$%7+5277/(3('$/%
&$1B/&$123(1 %1

'
&$1B;B
+.1
;
7+5277/(3('$/6(1625
)
;$

30
;$B
$
$
<
)<
;)
;< ;<
;
;$ ;% ;% ;$ <( ;$ ;% ;& ;'

;%B

7%E
;%
26&,//$7,21/2&.9$/9(
;9
$

<
)<
97%
;)
;< ;<
;
;$ ;% ;% ;$ <( ;$ ;% ;& ;'
%

;%B
;%
/69$/9(
;$

30
;$B

;$

;$B
+9%

6+((7
6K
)
(
%
'
$
+
&
*
)
(
%
'
$
+
&
*
352-(&7,'
00
7%

&
'
(
63(('6(1625
; ; ;
;
(0+
*< ;$ ;% %. ;% ;% %1 ;% ;$ *< ;0$
',B;B

V

'2B;B
',B;B
+.1
+.1
+.1
6(1625
;0B
;
;
6(1625',
;
;%
02'8/('2

%
%&$55,(563(('
6(16256833/<02725
%(1*,1(7(03(5$785(
;9 /%8 ;$ ;% %8
+ 9
&
&
EDU
P ;

3
*< ;0$
6$
;
',B;B
*1 ;$ ;% ;& ;' ;' ;& ;% ;$
+.1
;0B

;

',B;B
(1*,1(5(9
+.1
5(7851),/7(5
;
),/7(512',
*:$/7(51$725
;
6$+<'52,/5(7851
(
&

%
; ;
*< ;$ ;% :+ ;% ;% %1 ;% ;$ *< ;0$

(0+%

',B;B

$,B;B
S
+.1
+.1
;0B
;
6(1625$,
;
&+$5*(35(6685(6(1625
%*($5%2;
2,/35(6685(
35(+($7(521

&
&
%
; ;

*< ;$ ;% ;% ;% ;% ;$ *1 ;0$

(0+%
',B;B

',B;B
12',
+.1
+.1
;0B
;
;
6:$7(5
,1)8(/:,)
%785%,1(
63(('6(1625',

;5
;5
9(5 &+$1*(
<(
(
5
N D
W
5:
&
6%
;
;

38//835(6,6725
*< ;$ ;% ;6% ;6% ;% ;$

6&+$1*('
;B

+.1
(

;
$;/(7(03(5$785(6:,7&+
;
%%$;/(7(03$,
;5
;5
;
<(
5

N D
',B;B
'
+.1

97%
5:
6$$;/(
&+$1*(&211(&7,21
7(0312',
'
W
38//835(6,6725
6$
&
;
;;
021,725,1*.,7,167$//('
;$ ;% ;6$ ;6$ ;% ;$

:+(1$;/(7(03(5$785(
*< ;

$,B;B
*1 ;0$
%$%
+.1
;

(0+

',B;B
$;/(7(03(5$785(6:,7&+
+.1
;0B
;
%$$;/(7(03$,
W
6$,5),/7(5
6:,7&+1&',

'
%
%
'$7(
%
; ; ;
;
*< ;$ ;% <( ;% ;% <( ;% ;$ *< ;0$

(0+%

;B

',B;B
'',
$,B;B
*'
+.1
+.1
+.1
;0B
;
)8(/6(1625
;
;
$/7(51$725
%$1'%9
%)8(/6(1625
5()92/7$*(72
(
1$0(
; %
(77(152
;5
;5
*< ;$ ;% <( ;% ;% <( ;% ;$ ;

(

9)
5
N D
$,B;B
W

+.1
6(1625$,
;
%*($5%2;
75$160,66,217(03(5$785(6(1625
5:
$33
'$7(
2,/7(03(5$785(
38//835(6,6725
67$1'
(
'(6,*1
)
%
;
;
-3H
*< ;$ ;% ;& ;& ;% ;$ ;
;5
;5
;
;
*1 <(
$,B;B
W
+.1
%+<'
N D
6(1625$,
;
',B;B
+<'5$8/,&2,/7(03(5$785(6(1625
+.1
;

2,/7(03(5$785(
6:,7&+12',
'
<
6$+<'5$8/,&2,//(9(/
5
;< ;< ;

/%8 ;$ ;% ;% ;$

5:
/2$'5(6,6725
;$;$

'2B;B
+.1
' 69B1
</2&.
;
785%,1('2
/2&.785%,1(
;'
;$ ;
9 + . $ RSWLRQDOHQJLQHVWRS '
$ '
;
<( ;' ;& <( ;% ;$ <( ;$

;$B
+9%
+<'5$8/,&2,//(9(/
;9

;6 <( ;' ;& <( ;% ;$ ;
97%
9) (

;6 ;6 <( ;' ;& /%8
'-

6
;$ ;%
<(
/%8

&0
7%
5'
+%
;'
;$ ;% ;& ;'

'

. $

EDU
;
;
6
(/(&75,&6&+(0$
$
;6 ;% ;$ ;$ ;% ;& ;'

'
<(
;
/%8 ;$ ;% <( ;6 . $

$

35(6685(6:,7&+&+$5*(35(6685(
7%$1'7%60/6(5,(6
2,//(9(/
237$/$50%8==(5
;
<( ;$ ;% ;& ;' <(

(
;

;
;$ ;% ;& ;' %. ;% ;% ;' ;& ;% ;$ ;
69B1 $
V

'2B;B
+.1
66($7
;
;%
6:,7&+,1387

&0
$&&808/$725&+$5*(35(6685(
75$160,66,21&+$5*(35(6685(
%
6:,7&+6($77851,1*
/%8 ;$ ;% ;& ;' %8

;9

/%8 ;$ ;% ;& ;' /%8
97%

&

3
EDU
;6
6
;
;

;$ ;% ;& ;' ;6 ;' ;& ;% ;$

',B;B
+.1
;
%5$.(35(6685(6(1625
6:,7&+12',
6%5$.(35(6685(
;'
;$ ;% ;& ;'

'
<(
. $
$
.

+9%
*
;)
$
)
.B
;

;$ 9) <( <( ;$ ;% ;& ;'
( ;

;$B D E

)
<(
7(/0$

70
6+((7
6K
)
(
%
'
$
+
&
*

00 &0
;' ' $
7% 7%
&
<( <(
%
9HPV) 9HPV)
$
<(
; ; 6 $ .
;9

/%8 /%8
;$
;$
$ $

;6

7%E 7%E *($56(/(&725
6
<(
<(
29(5'5,9( 75$160,66,21
(1$%/(' $8720$1
6 ;
;%

;%

%/ 5 )
6 6+ 97%
6
&
$ $ $ $ $ 6+
21
21
) 5
%/
,
;
3$5.,1*%5$.(

;&
;&
5(6(7%87721
;

3$5.,1*%5$.(
;%B
;%B

&0

$ $ $ $ <(
<(

<(
%87721
;'

;'

;%
;%
*<
*<
% %

<( <(
;

9)

<(
<(
<(
<(
<(
;

;'$

<(
;
;
<(

<(
*<
*<
*<
;6
<(
<(
<(
<(
;

$
6($7%(/76:,7&+
*<
0.1 0.1

D

;'
;'
;'
;'
;'
.D ',B;B ',B;B
6 & &
;
;
;
;

6*($56(/(&7,21 675$160,66,21
+ *($5', &21752/12',
75$163257 0.1 0.1 0.1 0.1
;6
;&
;&
;&
;&
;&

326,7,21
& ; &

;'
;'
;'
;'
',B;B ',B;B ',B;B ',B;B

% & & &

6*($56(/(&7,21 6*($56(/(&7,21 6*($56(/(&7,21 6*($56(/(&7,21
;6
&+$5*(35(6685(
*($5', *($5', 5(9', ):',

$&&808/$725

;%
;%
;%
;%
;%
;&
;&
;&
;&

6
3
.
'
EDU
;$
;$
;$
;$
;$

5'6%5$.( %5$.(5(/($6(
352-(&7,'
*
5(/$7(72

;6

5(/($6('2 5(48(67',
;%
;%
;%
;%
(1*,1(5811,1*

'2B;B '2B;B
;
9HPV
<(
)
+.1 +.1 ;

& '
;$
;$
;$
;$

' ',6$%/(:,5(' < < <55(9 <)):' '
;'
; ;
;' &21752/6'2 *($59$/9('2 *($59$/9('2 ',5(&7,219$/9('2 ',5(&7,219$/9('2
;
;
.
$

<(

' $ $ '2B;B '2B;B '2B;B '2B;B '2B;B
. .
SDUNEUDNHRQ
;'$

;&

+.1 +.1 +.1 +.1 +.1

<(
<(
<(
<(
<(
& ( ( ) (
; D (

<( ; ; ; ; ;
$ <
;
;
;
;
;
;%
+

*($59$/9('2

(
; ;

'2B;B
. *($51(875$/ *1 *1 *1 *1
;$

127(5(029(-803(5 +.1
. .
<(
<(
,)75$163257326,7,21 $ %
021,725,1*6($7%(/7 . .
;
( ; . (
;
6:,7&+2535(6685( * * '

021,725,1*$5(86('

;$
;$
;$
(

$

;

3$5.,1*%5$.(
,1 ( *($5
.5'6%5$.( '(/$<5(/$< &21752/ $
;) ;)
%5B72:
;%

;%

;%

&21752/5(/$<'2
;$
V'(/$<2)) D 5(/$<
UHYHUVH
' $
/%8
)< )<
*1
<(
<(
<(
',B;B
30 $ $ .
;0$

+.1
(
3$5.,1*%5$.( ( <(
;6
;6
35(6685(6:,7&+
;$
;

;$
;$
;$
;$
;$
;$
;$

;
(0+

;0B
6

) 6 )
3 3
/6(5,(6

;%

;%

;%

;%

;%

;%
;%

;%

*1

EDU EDU
;6
;6

;$B
75$160,66,219$/9(65)
(1*,1(02'8/(6&+(0$
;&
75$160,66,21&+$5*(
35(6685(6:,7&+
;&5
;&)
;&
;&
;&

;<

6$)(7<%5$.(9$/9(

;<
3$5.,1*%5$.(9$/9(
3/$&(%/2&.)520
< <
;%
;%

;$

<&/$5.
5 )
$
;&$% ;'

.
EORFNB
<(
;$
;$

*

$
;<
;<

;&
;&
;&)
;&
;&5

* ; ; *

;

; 127(,17(51$/3527(&7,9(
.
;&$%B
',2'(,686('21/<606(5,(6
* 75$160,66,21,1/6(5,(6
+.1 <(
3527(&7,9(',2'(,6,17+(
;%
;%
;%
;%
;%
;%
;%
9$/9(&211(&725

(

'2B;B
&$%,1$
(

9)
66$)(7< . .D (

;'.
%5$.(35(66
<(
;$
;$
;$
;$
;$
;$
;$

6:'2
( &
&0
(
&$%,1&$123<
;9 ;9 ;9

9) /%8 /%8 /%8 &211(&7,21 /%8
+ ( ;
+
237 75$163257 97% 97% 97%

3$5.,1*%5$.( 326,7,21
6&+$1*(' (77(152 '$7( '-

'(6,*1 -3H

(/(&75,&6&+(0$
$33 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%$1'7%60/6(5,(6 6K

)
(
%
'
$
+
&
*
352-(&7,'
&
00
&0
7%

%
.
'
;
;9 *<
% 9

',B;B
+5B ;

0.1
;
*1
7% (1$%/(''2
(1*,1(%5$.(

&
$2B;B
&21752/
+.1
;
5(7$5'(5
',6$%/(''2
;
;
(;+$867%5$.(
6[ <( *<
$
'2B;B

6(1625
0.1
6833/<'2
'
;

+5B
;
*1

&
$2B;B
+.1
%
;
$&7,9$7('',
;
6
0$18$/5(7$5',1*
*<

',B;B

0.1
66$)(7<
(0+
%5$.(1&',
<(
'
21
; 21
6
*<

$
$
',B;B

0.1
%5$.(',

(05
6(1*,1(
*29(5125
;$
$
$

30
;$B

6
(/(&75,&(1*,1(
'
;
;0$ <( <( ;$ ;% ;& ;' <(
KDQGWKURWWOH

$
$
'
;0$ <( <( ;$ ;% ;& ;' <(
KDQGWKURWWOH

9(5 &+$1*(
$
$
<(
;$ ;& ;' <(

30

;$B
6&+$1*('
;$

(
;$B
;
;
;0$ <( <( ;$ ;% *<

+$1'7+5277/(
',B;B
530',
0.1
7+5277/(

6+$1'
%
%
(
9 /%8 ;0% ;0$ <(

;
(0++ ;09
%
%
;
*<
*
.
',B;B

'
530',
0.1
7+5277/(

6+$1'
' <( ;0% ;0$ <(

(QJLQH

VKXWGRZQ
'$7(
RYHUULGH

;$ ;% ;& ;' <(

6
)$8/729(55,'(
;
;0$ <( ;$ ;% ;& ;' <(
(05
*29(5125
1$0(

(77(152
(/(&75,&(1*,1(
*
.E
D
<(
<(

'
;0$ <(
KDQGWKURWWOHRQ
$33

'$7(

<(
67$1'
'(6,*1
.
%
D
+$1'7+5277/(
;0$ <( ;$ ;% ;& ;' <(
-3H

&21752/

<(

6
(;+$867%5$.(

;0$ <( ;$ ;% ;& ;' <(

$
$
;0$ <( ;$ ;% ;& ;' <(

$
$
5(*(1(5$7,21
(

,
.D
6
;
<( ;$ ;% ;

*<
/%8/%8
$
$ $
',B;B
0.1
212))',

;$
30
212))
6+$1'7+5277/(
;$B
$
;$B
+$1'7+5277/(
;& ;' <(
'-
/%8
6
+$1'7+5277/(
%
% %
;$B

,1$*,7$725
9HPV)
$33/,&$7,21
/%8
.E
(
.D
D
6
5(029(-803(5
;
;
<( <( ;$ ;% ;& ;' <( <(

;%
9) &
127(
*
.
&

;)D %
(/(&75,&6&+(0$
;%B

7%E
/%8 <( .% ;%

9HPV) '

%

,1
6
;$
<(
7%$1'7%60/6(5,(6
HQJLQHVWDUW
5(029(:,5(.B;9

;$B
(48,33(':,7+32:(53$&.
.
+9%
:+(175$160,;(50$&+,1(,6
6
(
.
*
.
;$ ;% ;& ;' <(

67$57'(/$<5(/$<
;

;0$ <(

(0+%

;0B ;%B ;%

(0+

D

%
%
7%E
;$
' HQJLQHVWDUW
(1*,1(5811,1*
;
*($51(875$/
'
;'
;'

V'(/$<21
<( ;$ ;% ;& ;' *<

$ .
'2B;B

0.1
$
(
(
'
'

(

6
.
+:$51,1*+251'2
+251
,
(

%<3$66
.
*
;
;9
/%8 *1

',B;B
$
$ $
$
$
+.1
97%
$
;

',(6(/5811,1*'2
%.
6
+251
;
+
(1*,1(5811,1*
;$ ;% ;+B ;+B ;% ;$ <( ;$ ;% ;& ;' <(
9)

;%
+251

7%E
;%B
;%

6+((7
6K
)
(
%
'
$
+
&
*

&0
;

7% %
9) <( 9)
$
<(
$
9) <( <(
;; 6D; ;)N (0(5*(1&<6723
7%E ; (1*$*('', 7%E

/%8 <(
$ 6',(6(/6723 $
',B;B
; 29(55,'(',

0.1
;%
;%
;%
;%
',B;B &
%
6
;
0.1 $ $
' 6 ,
;%B
;%B
;%B
;%B
$ $ $
(06B
(06B
(06B
(06B

6 ,
6 ,
(0(5*(1&<6723
;
;%B
;%B
$ %87721

%
$
%
$
$ $ $ 237(1*,1(6723
&
$168/)2*0$.(5
7(676:,7&+
;%
;%
*<

% ; %
*<

;.
9
7%E $&& 237,21$/ $&& 237,21$/ 7%E
<(
<(
<(
<(
<(
<(
;9

/%8 /%8
;'
;'
;'
;'
;'
;'

97%
30 30
;&
;&
;&
;&
;&
;&

6[ 6[
& &
;%
;%
;%
;%
;%
;%

( (;$03/(
00

<( ;$
;$
;$
;$
;$
;$

7% (
9) 9)
' '
.$
; ; 9HPV
352-(&7,'
5(/$7(72
; 30

<(

.
;
9)
$
.
;

*
' * '
$
$
%
$
;$ <(
;)

;$B
;$B

)< .% . .
.

$
$
RSWLRQDOHQJLQHVWRS
;'$
<(<(
D D *
$ ' ' (
$ $

+ (
;$
;$
;%

.
. (0(5*(1&<6723
$)))B

; 5(/$<6$)(7<
<(

<
<( $ ; ;
(1*,1(6723
9)
(
DODUPEHDFRQ
;)66
;.
)8(/9$/9(
;$
$87$168/
. .
<(
(1*,1(
$)))),5(68335(66,216<67(0
( (

.
. 32:(55(/$< .

. . .

. .
D &283/,1*
),5(68335(66,216<67(0
$1'
.
V . 021,725,1* . . .
+
&,5&8,7
.
'
. .
35(6685(6:,7&+

( ;)
(
$8720$7,&$168/
6 ,1
)
)
(

)< $
6723&217$&7
<(
<(
<(
D ; ;

3 <(
$
/%8
<(
<(
/%8
/%8
;.$
;.$
;.$
*1
<(
<(

;0$
;0$
;

<(
;$
;$
) )

;)66
$)))B.%

;0B

;0B
&211(&772*1'
;%

;%

$ <
;
;%
,)0%(1*,1(

;
(0+%
( ( &+$1*(<6833/<)520;
<(

.$ +.1 72;:+(10$&+,1(,6
(0(5*(1&<67239$/9(
.$ (48,33(':,7+/2$'6(16,1*6<67(0
;<
;<

;$

* ',B;B
< < '
(06$1'29(5/2$'
<(
. * 021,725,1*', $

' $ .%

)8(/9$/9(

* ; ' *
;<
;<

(0+
(1*,1(67235(/$< ; $

( ),5(68335(66,216<67(0

(
;%
;%
;.$

9)
5(/$<6(77,1*6

/%8
( &5(/($6,1*'(/$<
;
.% 7,0(6(77,1*V
;$
;$

$8720$7,&$168/ !V
(
0$18$/6<67(0 !V
(

.$$1'.%,63/$&(':+(1
;9 ;9

+
/%8 7+(0$&+,1(,6(48,33(':,7+ /%8 /%8
+
),5(68335(66,216<67(0
),5(68335(66,216<67(0
021,725,1*5(/$< 97%
&211(&7,)),5(68355(66,21
6<67(0127,167$//(' 97%
6&+$1*(' (77(152 '$7( '-

'(6,*1 -3H

(/(&75,&6&+(0$
$33 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%$1'7%60/6(5,(6 6K

)
(
%
'
$
+
&
*
352-(&7,'
&0
7%
00
7%

$
5($5
6D
6[

9)
:25./,*+7
.$
'
,
/%8 <( ;$ ;% ;& ;'

$
$
$
$
:25./,*+75($5

<(
6E
/%8
5($5
21
'
.%
)
/(
:25./,*+7
21
<( ;$ ;% ;& ;'

$
$
UHYHUVH
;
$
$
:25./,*+75($5
+
;9
;$ ;% ;+ ;+ ;% ;$ <(

<(
6
)5217

/%8
97%

:25./,*+7
'
.
5(9(56($/$50 ,

<( ;$ ;% ;& ;'

$
$
$
$
:25./,*+7)5217
5($5
9(5 &+$1*(
<(
6
/%8

+($'/,*+7
/%8
'
.
,

(
6&+$1*('
<( ;$ ;% ;& ;'

;$ ;% ;( ;( ;% ;$ <(

$
$

$
$
237:25./,*+7 +($'/,*+75($5
<(
(
'
.%
D
;
;$ ;% ;( ;( ;% ;$ <( <( ;

(

9)

237:25./,*+7
9)
6[
<(
(
<( ;$

;9
;$ ;% ;( ;( ;% ;$
$
30
;$B

'$7(
97%
$
5(9(56(/,*+75,*+7
(

;'
;$ ;% ;( ;( ;% ;$ <(<(

.
5(9(56(/,*+7/()7 $ '
1$0(
(77(152
$
(

$33
;
'$7(
<(
(
7%
'
&0
D
.
9)
67$1'
'(6,*1
;
;$ ;% ;& ;' ;( ;( ;' ;& ;% ;$

9)
;
-3H
:25./,*+76,'(
(
<(
/%8

;( ;(
(
/%8

%
:25./,*+76,'(
;

.$
(
'
D
9)
;9
;$ ;% ;& ;' /%8 ;( ;( ;' ;& ;% ;$ <(

97%
:25./,*+75($5
(
<(
/%8
;( ;(

:25./,*+75($5
(
;( ;(
(

:25./,*+7)5217
;
<(
/%8
'
.
(
D
9)
;$ ;% ;& ;' ;( ;( ;' ;& ;% ;$ <(
'-

:25./,*+7)5217
(
$
;$ ;% ;& ;' ;( ;( ;( ;( ;' ;& ;% ;$ <( ;

(

9)
6,'(/,*+7
;

(/(&75,&6&+(0$
<(
9)
(
/%8
;( ;( ;( ;(

6$
6,'(/,*+7

:$51,1*%($&21
<(
7%$1'7%60/6(5,(6
+$
,
+$ +$ ;' ;& ;% ;$ <( ;$ ;% ;& ;'

$
$
:$51,1*%($&21
$
$

/%8
6%
<(

/%8
+%
,
237:$51,1*%($&21
+% +% ;' ;& ;% ;$ <( ;$ ;% ;& ;'

$
$
127((%$1'(%&$1%(&211(&7('
:$51,1*%($&21
$
$
3$5(//(/:,7+($1'(+$51(66
+&
;9
;$ ;% ;& ;' +% +% ;' ;& ;% ;$ ;.%D

(

DODUPEHDFRQ
97%
:$51,1*%($&21
;&$% <( ;' ;& ;% ;$ 7 ;

&$%,1% 9'& 9) (
;&$%B
<( 9'&

;&$%B 9'&$

<(
/%8
;&$%B

&211(&7,21
<(
&$%,1&$123<
;&$%B

/%8
92/7$*(5('8&(5

6+((7
6K
)
(
%
'
$
+
&
*
)
(
%
'
$
+
&
*
352-(&7,'
00
&0
7%
7%

$
6

$
+($'/,*+7)5217
6;
$ %
.$
'
9)
/%8 <( ;$ ;% ;& ;' <(
$

$
;$ ;% ;& ;' <(

%
$ $ % %

%
/2:%($0
/%8
<(
'
.%

&0
($
+,*+%($0

;($ ;($

(
+($'/,*+7/2:

<(
/%8
($
.$
'
D
;
;$ ;% ;& ;' ;($ ;($ ;' ;& ;% ;$ <( 9)

9(5 &+$1*(
+($'/,*+7/2:
(%

;9
6&+$1*('
;(% ;(%

97%
<(
(
+($'/,*+7+,*+
<(
/%8
'
(%
.%
D
;
;$ ;% ;& ;' ;(% ;(% ;' ;& ;% ;$ <(
9)

+($'/,*+7+,*+
<
;< ;<

<( ;' ;& ;% ;$ <( ;
HQJLQHVWDUW *
$
$

'$7(
5(/,()9$/9(
/%8
/%8

(
;( ;( ;( ;( ;' ;& ;% ;$

3$5./,*+7
1$0(
<(
(
(77(152
;$ ;% ;& ;' ;( ;( ;( ;(

3$5./,*+7
$33
'$7(
<(
67$1'
'(6,*1
'

+

-3H
;+ ;+ ;+ ;+ ;' ;& ;% ;$ <( ;
&3

',B;B
%/,1.(5
0.1

78516,*1$/
D
/%8
.
+
D
/%8
;$ ;% ;& ;' ;+ ;+ ;+ ;+ ;' ;& ;% ;$ <(
%/,1.5(/$<

%/,1.(5
;9
<(

(
97%
EDU
6
3
;
;
9)
;$ ;% ;& ;' <( ;6 ;6 <( ;' ;& ;% ;$
6
/%8

,
%/,1.(5
%5$.(/,*+735(6685(6:,7&+
,2
5:
5
;5
<(

. $
$
$
$
$
<(
&
;
<( ;$ ;% ;& ;' <(
'-

%
%
;
;
;
*< <( ;$ ;% ;& ;' <(
',B;B

%
%
6:',
+.1
;
/%8
$
6%5$.(/,*+735(66
;'

' $
(/(&75,&6&+(0$
.
/(

XVE;
(

;( ;% ;$ <(

5'
86%&211(&725
'
'
9
7%$1'7%60/6(5,(6
6+'
*1'
;( ;% ;$ <( %

<(
;
5($5/,*+7/()7
:XVE
XVE;
;9
;
;$ ;% ;( ;( ;% ;$ 5'

/%8 <(
86%B;B
0.1

%.
:+
97%
&765;86%9
+5B

%
:XVE ;
XVE;
:+
86%B;B
0.1

7;86%'
%
(
:XVE ;
/%8 ;$ ;% ;( ;( ;% ;$ <( XVE;
*1
%.
:+
86%B;B
0.1

;( ;% ;$ <(

'

%

<(
; :XVE ;

;
;( ;% ;$ <( *1 XVE;

%.
5'
'2B;B
+.1
86%B;B
0.1
5($5/,*+75,*+7

;
/,*+76'2
((%5$.(
5;86%' 5767;86%B*1'
XVE;
<(
6+'
$ '
$)))B*1' SDUNEUDNHRQ $ .

' ;
;'
;'
$)))),5(68335(66,21
6<67(0
97%

6+((7
6K
)
(
%
'
$
+
&
*
)
(
%
$
'
&
352-(&7,'

00
&0
7%
7%

'
9(5 &+$1*(
.
9)
6&+$1*('
9B3803
D
%
)
;)

&
.
;
<( ;$
$
N

$

30
;$B
)

5(/$<
&872))
5(/$<
&872))
D
.
9B3803B&75/
'$7(
;

)
;)
N D ;
9) )
)
/%8
1$0(
.%

(77(152
N D $

)
)
(0(5*(1&<6723
5(/$<
$33
'$7(
N D
67$1'
'(6,*1
)

N D ;)D
-3H
9) *
)
N D

7%$
)
&2035(
;&2B
&2035(
;&2B
;&2B ;%
&211(&7,216)25237,216
;
<( ;$ ;% ;& ;'

7%E

;237B ;%B

;$

$
30
;$B
;%
;
<( ;$ ;% ;& ;'

;237B ;%B
;$

$
30
;9B ;$B
;9
'-

&2035$
;&2B
;%
;
<( ;$ ;% ;& ;'

&2035%
%

;&2B ;%B
(/(&75,&6&+(0$
;$

$
30
;$B
<(
;$

;$B
+9%
7%$1'7%60/6(5,(6
;%
;
&2035& <( ;$ ;% ;& ;'

%

7%$ ;&2B ;%B

;$

$
30
;$B
<(
;$

;$B
+9%
;%
&211(&7,216)25237,216
;
<( ;$ ;% ;& ;'

&2035'

;&2B ;%B
&2035) ;$
;&2B

$
30
7%$ ;$B
;&2B

;&2B

6+((7
6K
)
(
%
$
'
&
)
(
%
'
$
+
&
*
352-(&7,'
00
&0
7%
7%

;$
;$
<( ;$ ;% ;& ;' <(

<( ;$ ;% ;& ;' <(

<( ;$ ;% ;& ;' <(

<( ;$ ;% ;& ;' <(

<( ;$ ;% ;& ;' <(

9(5 &+$1*(

6&+$1*('
<( ;$ ;% ;& ;' <(

<( ;$ ;% ;& ;' <(

3 9,'(2

3 9,'(2
'$7(

;
0.1
0.1

;
3 9,'(2

(7+(51(7

9,'(2
3 9,'(2

*1'
1$0(

(77(152
&

$33
'$7(
;
67$1'
*<
'(6,*1

;)(

',B;B

0.1
-3H
%

;
*<

;)(

',B;B
0.1

;$ ;% ;& ;' <(

%
;)( ;)(

;
;$ ;% ;& ;' <( *<

;)( ;)( ;)(

',B;B

0.1
;% ;&

&
%
;
*< &$1B/B- ;% ;& ;
;)(
;B
*<

+.1
;)(

;
',B;B

0.1
;% ;&

&
)
&
;% ;&
'-
;
*< ; ;
;)(
;B
*< *<

+.1
;)( ;)(

;
;% ;&
',B;B
',B;B

0.1
0.1

5()92/7$*(9
;% ;&
&
&
%

;

*< &$1B+B- ; ;

(/(&75,&6&+(0$
8186(',2$1':,5,1*
;)(
;B
;% ;& *< *<

+.1
;)( ;)(

;
',B;B
',B;B

0.1
0.1
;% ;&
&
%

'
(
7%$1'7%60/6(5,(6
; ;
*1 *1 ;% ;& ; ;
;)( ;)(

'2B;B
*< *<

'2B;B

+.1
+.1
$,
;)(
;
;
;)(
',B;B
$,B;B

0.1
0.1

;% ;&

(
&

'
(
758&.%('/2$'6(1625
; ; ;% ;&

*1 *1 ; ;
;)( ;)(

'2B;B
*< *<

'2B;B

+.1
+.1
;)( ;)(
;

;
;% ;&
',B;B
$,B;B
0.1
0.1

(
&
;% ;&
(
(
; ;

*1 *1 ; ;
;)( ;)(
;% ;&
'2B;B
*< *<

'2B;B

+.1
+.1
;)( ;)(
;

;
',B;B
',B;B

0.1
0.1

;% ;&
'
&

(
(
; ;
*< *1 ; ;
;)( ;)(
',B;B

'2B;B
*< *<

+.1
+.1
;)( ;)(
;
;

',B;B
',B;B
0.1
0.1

'
&
&
(
; ;
*< *1 ; ;

;)( ;)(
',B;B

'2B;B
*< *<

+.1
+.1
;)( ;)(
;
;

',B;B
',B;B

0.1
0.1

6+((7
6K
)
(
%
'
$
+
&
*
)
(
%
$
'
&
352-(&7,'

9(5 &+$1*(

'$7(

-3(
1$0(
$33
'$7(
67$1'
'(6,*1

-3H
7%

0
0*1'
:0
:0
0
;0B*1' %. ;0 ;0 %.
0
* *
9B3803
;06 ;06 <(

)
/%8

97%
'-

(/(&75,&6&+(0$
(0(5*(1&<3803

00

6+((7
6K
)
(
%
$
'
&
)
(
%
'
$
+
&
*
352-(&7,'
0

$
)&
/%8 ;6($7 ;6($7 ;6($7 ;6($7 <( )&; )&;
0

$
6($7&2035(662502725

;&$%

6
,
5$
* ;9
;9 ;5$ ;5$ ;5$ ;5$ ;6 ;6 ;&$%B

+($7('0,5525
'

* ;9
5%
;5% ;5% ;5% ;5%

+($7('0,5525
(/
$
)&
* ;9 <( )&; )&;

;9 /%8
%

%.
5'

E D

'
'
)
*
%8
&$%,1
:+
5'
/,*+7,1*'(9,&(
;&$%B
;&$%B
;&$%B
;&$%B
* ;9
;9 /%8 ;&$%

)
;&$%B
/%8
/%8

(5
* ;9

;9 /%8 ;&$%

;&$%
;&$%
;&$%
;&$%

)

%.
5'
;&$%B
E D
* ;9
;9 /%8 ;&$%

)
%8
;&$%B &$%,1
:+
5'
/,*+7,1*'(9,&(
9(5 &+$1*(

* ;9
<(
<(
<(
<(

$
)&
;9
;9 ;9 237,21$/9 ;9 )&; )&;
&
83'$7('0($685(0(176
62&.(76833/<
$
)&
;9
;9 ;9 237,21$/9 ;9 )&; )&;
;9 *
;9 62&.(76833/< '

$
)&
;9
;9 ;%& 237,21$/%$77(5< ;%& )&; )&;
&+$5*(56833/< )
'$7(

<(
<(
-(
-(
;9 5&$0B
1$0(
;9 /%8 ;5&$0 ;5&$0

' &
5&$0B
237,21$/5(9(56(

* ;9 ;9

;9 /%8 ;9 &$0(5$
$33

'$7(
67$1'
;5&$0
'(6,*1
'
5&$0B
-(
* ;9
;9 /%8 ;/8%( ;/8%( ;/8%( ;7%

<(

[$
$
Y

7%
$
9

/8%5,&$7,21.,7
6+
237,21$/&$55,(5
[$
$
5HVHW

/,1&2/1
;
;
$
$
)&
)
$ ;) ;) ;7% ;/8%( ;/8%( ;/8%( )&; )&;

(UURU
(
'-
)&;
:,5,1*+$51(66

)&;

06(5,(623(1&$%,1
)&;

)&;

237,21$/)86(6
$
)&
)&;
&0
)&
&$%,1
$
)&

)&;
)&

6+((7
6K
)
(
%
'
$
+
&
*

$
&$1%862YHUYLHZ $
7%E
+.1 &21752/81,7(;(5786+&06+<%5,'&21752//(502'8/($03683(56($/
3,1&211(&72590$
352-(&7,'

9B;B 30+ 9
;B 30% 95() &$1B;B 30( &$12SHQ/
*1'B;B 30+ *1'
% *1'B;B 30+ *1' &$1B;B 30( &$12SHQ+
5(/$7(72

%
',B;B 30' %220/,)7,1*', DSSB&$%BERRPBOLIWLQJBXSB12B', $,B;B 30%
',B;B 30' %220/2:(5,1*', DSSB&$%BERRPBOLIWLQJBGRZQB12B', ',B;B 30%
',B;B 30' %2207851/()7', DSSB&$%BERRPBWXUQLQJBOHIWB12B', $,B;B 30%
',B;B 30' %22078515,*+7', DSSB&$%BERRPBWXUQLQJBULJKWB12B', $,B;B 30%

&
',B;B 30' 6&$%/(5((/,1*287,1387 DSSBFDEOHBUHHOLQJBRXWBSRVB12B', &
',B;B 30' 6&$%/(5((/,1*,1,1387 DSSBFDEOHBUHHOLQJBLQBSRVB12B',
',B;B 30&
',B;B 30&
' *1'B;B 30+ *1' '
',B;B 30&
',B;B 30&
',B;B 30' '06%220&21752/', DSSB%B&$%B5-6B',
',B;B 30%
( ',B;B 30% (
',B;B 30%
$,B;B 30%
) 8186(',2:,5('72&211(&725 )
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 &0 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 6K

$
&$1%862YHUYLHZ $
7%E
+.1 &21752/81,7(;(5786+&06+<%5,'&21752//(502'8/($03683(56($/
3,1&211(&72590$
352-(&7,'
9B;B 30+ 9

9B;B 30+ 9 9
%
5(/$7(72
'2B;B 30$ 6(1625683//<1'2 DSSBVHQVRUBVXSSO\BFDELQB'2 $2B;B 30%
',B;B 30& 6/()76833/(*(;7,112', DSSBVZBOHIWBVXSSBOHJBH[WBLQB12B', $2B;B 30&
',B;B 30' 6/()76833/(*(;728712', DSSBVZBOHIWBVXSSBOHJBH[WBRXWB12B', '2B;B 30$ &$55,(5,175$163257326,7,21'2 DSSBFDUULHUBLQBGULYLQJBSRVB'2
',B;B 30& 65,*+76833/(*(;7,112', DSSBVZBULJKWBVXSSBOHJBH[WBLQB12B', ',B;B 30%

&
',B;B 30' 65,*+76833/(*(;728712', DSSBVZBULJKWBVXSSBOHJBH[WBRXWB12B', ',B;B 30+ 6$/()7(1*,1((1'6833257/(*8312', DSSBOHIWBUHDUBVXSSBOHJBXSB12B', &
',B;B 30& 6/()7/2$'(1'6833257/(*8312', DSSBVZBOHIWBVXSSBOHJBXSB12B', ',B;B 30+ 6%/()7(1*,1((1'6833257/(*'2:11&', DSSBOHIWBUHDUBVXSSBOHJBGRZQB1&B',
',B;B 30' 6/()7/2$'(1'6833257/(*'2:112', DSSBVZBOHIWBVXSSBOHJBGRZQB12B', ',B;B 30+ 6%/()7(1*,1((1'6833257/(*'2:112', DSSBOHIWBUHDUBVXSSBOHJBGRZQB12B',
',B;B 30& 65,*+7/2$'(1'6833257/(*8312', DSSBVZBULJKWBVXSSBOHJBXSB12B', ',B;B 30%

' ',B;B 30' 65,*+7/2$'(1'6833257/(*'2:112', DSSBVZBULJKWBVXSSBOHJBGRZQB12B', '2B;B 30& '
',B;B 30& 6(1*,1((1'6833257/(*68312', DSSBVZBUHDUBVXSSBOHJVBXSB12B', '2B;B 30$ </69$/9('2 DSSBOVBYDOYHB'2
',B;B 30' 6(1*,1((1'6833257/(*6'2:112', DSSBVZBUHDUBVXSSBOHJVBGRZQB12B', $2B;B 30%
'2B;B 30$ 6833257/(*6(16256833/<(1*,1((1''2 DSSBVXSSRUWOHJBVHQVRUBVXSSO\BHQJLQH(QGB'2 '2B;B 30&
',B;B 30' 66$)(7<%5$.(21', DSSBVDIHW\BEUDNHBRQB12B', ',B;B 30+ 6$5,*+7(1*,1((1'6833257/(*8312', DSSBULJKWBUHDUBVXSSBOHJBXSB12B',
( ',B;B 30% ',B;B 30+ 6%5,*+7(1*,1((1'6833257/(*'2:11&', DSSBULJKWBUHDUBVXSSBOHJBGRZQB1&B', (
'2B;B 30% <(1*,1((1'6833257/(*6839$/9('2 DSSBULJKWBUHDUBVXSSBOHJBXSB'2 ',B;B 30+ 6%5,*+7(1*,1((1'6833257/(*'2:112', DSSBULJKWBUHDUBVXSSBOHJBGRZQB12B',
'2B;B 30% <(1*,1((1'6833257/(*6'2:19$/9('2 DSSBULJKWBUHDUBVXSSBOHJBGRZQB'2 ',B;B 30&
) 8186(',2:,5('72&211(&725 )
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 &0 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 6K

$
&$1%862YHUYLHZ $
7%
+.1 &21752/81,7(;(5786+&06$03683(56($/3,1&211(&7259
0$
352-(&7,'

9B;B + 9 ;B ) &$1B/-
*1'B;B + *1' &$1B;B + &$1B/&$123(1
*1'B;B + *1' ;B ) &$1B+-
% *1'B;B + *1' &$1B;B + &$1B+&$123(1
5(/$7(72

%
',B;B + 6%2200/,0,7/,)71&', DSSBERRPBPBOLPLWBOLIWB1&B', ;B ) 5()92/7$*(9
',B;B + 6%2200/,0,7/,)712', DSSBERRPBPBOLPLWBOLIWB12B', ;B ) 5()92/7$*(9
',B;B + 6%%22078515,*+7/,0,71&', DSSBERRPBWXUQBULJKWBOLPLWB1&B',
',B;B + 6%%22078515,*+7/,0,712', DSSBERRPBWXUQBULJKWBOLPLWB12B',

&
',B;B + 6$%2207851/()7/,0,71&', DSSBERRPBWXUQBOHIWBOLPLWB1&B', &
',B;B * 6$%2207851/()7/,0,712', DSSBERRPBWXUQBOHIWBOLPLWB12B',
',B;B )
',B;B + 6%%2206863(16,21/,0,71&', DSSBERRPBVXVSHQVLRQBOLPLWBOLIWB1&B',

' ',B;B ) '
',B;B )
',B;B )
',B;B ) %%22078516(1625&+$, DSSBERRPBWXUQLQJBVHQVRUB&+B$,
',B;B ) %%22078516(1625&+$, DSSBERRPBWXUQLQJBVHQVRUB&+B$,
( ',B;B ) 63$5($, (
;B ) 63$5($,
;B + 02'8/(5(&2*1,7,219
) 8186(',2:,5('72&211(&725 )
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 30 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 6K

$
&$1%862YHUYLHZ $
7%
+.1 &21752/81,7(;(5786+&06$03683(56($/3,1&211(&7259
0$
352-(&7,'
9B;B + 9

9B;B + 9 9
%
5(/$7(72
'2B;B ( 6(16256833/<1'2 DSSBVHQVRUBVXSSO\BIURQWB'2 $2B;B ( <$%220/,)7,1*83$2 DSSB%BOLIWLQJB8'B$2
'2B;B ' 237,21', DSSBRSWLRQBIIB', $2B;B ( <%%220/,)7,1*'2:1$2 DSSB%BOLIWLQJB8'B$2
'2B;B ' 237,21'2 DSSBRSWLRQBHPSBIIB'2 ',B;B ' <%2206863(16,21'2 DSSBERRPBVXVSHQVLRQB'2
'2B;B ' 237,21/,*+7'2 DSSBRSWLRQBRQBOLJKWB'2 ',B;B ( %2206$)(7<:$51,1*'2 DSSBERRPBXVHBVDIHW\BZDUQLQJB'2

&
'2B;B ' 237,21', DSSBRSWLRQBIIB', ',B;B + 6/()76833/(*(;7,112', DSSBVZBOHIWBVXSSBOHJBH[WBLQBSRVB12B', &
'2B;B ' 237,21', DSSBRSWLRQBHPSBIIB'2 '2B;B + 6/()76833/(*(;728712', DSSBVZBOHIWBVXSSBOHJBH[WBRXWBSRVB12B',
'2B;B ) 237,21/,*+7'2 DSSBRSWLRQBRQBOLJKWB'2 '2B;B + 65,*+76833/(*(;7,112', DSSBVZBULJKWBVXSSBOHJBH[WBLQBSRVB12B',
'2B;B ) ',B;B + 65,*+76833/(*(;728712', DSSBVZBULJKWBVXSSBOHJBH[WBRXWBSRVB12B',

' '2B;B ( <5,*+76833/(*(;7,1'2 DSSBULJKWBVXSSBOHJBH[WBLQB'2 $2B;B '
'2B;B ( <5,*+76833/(*(;7287'2 DSSBULJKWBVXSSBOHJBH[WBRXWB'2 $2B;B

'2B;B ( </()76833/(*(;7,1'2 DSSBOHIWBVXSSBOHJBH[WBLQB'2 '2B;B + 6%22075$163257326,7,216(16251&', DSSBERRPBWUDQVSRUWBSRVB1&B',
'2B;B ( </()76833/(*(;7287'2 DSSBOHIWBVXSSBOHJBH[WBRXWB'2 '2B;B + 6%22075$163257326,7,216(162512', DSSBERRPBWUDQVSRUWBSRVB12B',
$2B;B ( <$%2207851/()7$2 DSSB%BWXUQLQJB/5B$2 '2B;B ' <%%220/2:(5,1*/,0,7'2 DSSBERRPBORZHULQJBOLPLWB'2
( $2B;B ( <%%22078515,*+7$2 DSSB%BWXUQLQJB/5B$2 '2B;B ( (
$2B;B ( <$%220=220,1$2 DSSB%B]RRPB,2B$2 ',B;B )
$2B;B ( <%%220=220287$2 DSSB%B]RRPB,2B$2 ',B;B ' %2206(16256833/<'2 DSSBERRPBVHQVRUBVXSSO\B'2
) 8186(',2:,5('72&211(&725 )
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 30 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 6K

$
&$1%862YHUYLHZ $
7%
+.1 &21752/81,7(;(5786+&06:,7+,1&/,120(7(5$03683(56($/3,1
&211(&72590$
352-(&7,'

9B;B + 9 ;B ' &$1B/-
*1'B;B + *1' &$1B;B + &$1B/&$123(1
*1'B;B + *1' ;B ' &$1B+-
% *1'B;B + *1' &$1B;B + &$1B+&$123(1
5(/$7(72

%
',B;B ' 6$/()7/2$'(1'6833/(*8312', DSSBOHIWBIURQWBVXSSBOHJBXSB12B', ;B ' 5()92/7$*(9
',B;B ' 6$5,*+7/2$'(1'6833/(*8312', DSSBULJKWBIURQWBVXSSBOHJBXSB12B', ;B ' 5()92/7$*(9
',B;B ' 6$5,*+76833/(*(;7,112', DSSBULJKWBVXSSBOHJBH[WBLQB12B',
',B;B ' 6$/()76833/(*(;7,112', DSSBOHIWBVXSSBOHJBH[WBLQB12B',

&
',B;B ' &
',B;B '
',B;B '
',B;B ' 6(0(5*(1&<380321/2:(5&21752/3/$&(',DSSBHPBSXPSBSRVB12B',

' $,B;B ' '
',B;B ) 65(027(6(/(&7,21', DSSBUHPRWHBVHOHFWLRQB12B',

',B;B ) 6/2:(56(/(&7,21', DSSBORZHUBVHOHFWLRQB12B',
',B;B '
$,B;B '
( $,B;B ) 6833(56(/(&7,21', DSSBXSSHUBVHOHFWLRQB12B', (
$,B;B ' 63$5($,
;B + 02'8/(5(&2*1,7,21NRKP!*1'
) 8186(',2:,5('72&211(&725 )
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 30 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 6K

$
&$1%862YHUYLHZ $
7%
+.1 &21752/81,7(;(5786+&06:,7+,1&/,120(7(5$03683(56($/3,1
&211(&72590$
352-(&7,'
9B;B + 9 9

9B;B + 9 9
%
5(/$7(72
'2B;B ( 6(16256833/<1'2 DSSBVHQVRUBVXSSO\BIURQWBSRVB'2 ',B;B + 65($56833257/(*68312', DSSBVZBUHDUBVXSSBOHJVBXSBSRVB12B',
'2B;B ( </()7/2$'(1'6833257/(*839$/9('2 DSSBOHIWBIURQWBVXSSBOHJBXSB'2 ',B;B + 65($56833257/(*6'2:112', DSSBVZBUHDUBVXSSBOHJVBGRZQBSRVB12B',
'2B;B ( </()7/2$'(1'6833257/(*'2:19$/9('2 DSSBOHIWBIURQWBVXSSBOHJBGRZQB'2 '2B;B % (0(5*(1&<6723$1'29(5/2$'2.'2 DSSBHPVBFLUFXLWBUHOD\B'2
'2B;B ( <5,*+7/2$'(1'6833257/(*839$/9('2 DSSBULJKWBIURQWBVXSSBOHJBXSB'2 ',B;B '

&
'2B;B ( <5,*+7/2$'(1'6833257/(*'2:19$/9('2 DSSBULJKWBIURQWBVXSSBOHJBGRZQB'2 ',B;B ' 6%/()7/2$'(1'6833/(*'2:11&', DSSBOHIWBIURQWBVXSSBOHJBGRZQB1&B', &
'2B;B ( </2:(5&21752/'2 DSSBORZHUBFRQWUROB'2 ',B;B ' 6%/()7/2$'(1'6833/(*'2:112', DSSBOHIWBIURQWBVXSSBOHJBGRZQB12B',
'2B;B ( <833(5&21752/'2 DSSBXSSHUBFRQWUROB'2 '2B;B $ +&$55,(5,1&/,1(''2 DSSBLQFOLQDWLRQBRYHUBOLPLWB'2
'2B;B ( <%220/,)7,1*/,0,7'2 DSSBERRPBOLIWLQJBOLPLWB'2 ',B;B $ 6833257/(*6(16256833/</2$'(1''2 DSSBVXSSRUWOHJBVHQVRUBVXSSO\BORDG(QGB'2
' '2B;B $ +%220127'5,9,1*326'2 DSSBERRPBQRWBGULZLQJBSRVB'2 '2B;B ( %%2207851,1*6(16256833/<'2 DSSBWXUQLQJBVHQVRUBVXSSO\B'2 '
'2B;B $ +6833/(*6127'5,9,1*326'2 DSSBVXSSBOHJVBQRWBGULZLQJBSRVB'2 $2B;B ' 6%5,*+7/2$'(1'6833/(*'2:11&', DSSBULJKWBIURQWBVXSSBOHJBGRZQB1&B',
'2B;B ( <$%2207851/,0,75,*+7'2 DSSBERRPBWXUQBULJKWBOLPLWB'2 $2B;B ' 6%5,*+7/2$'(1'833/(*'2:112', DSSBULJKWBIURQWBVXSSBOHJBGRZQB12B',
'2B;B ( <%%2207851/,0,7/()7'2 DSSBERRPBWXUQBOHIWBOLPLWB'2 $2B;B '
',B;B + 6/()76833257/(*8312', DSSBVZBOHIWBVXSSBOHJBXSBSRVB12B', '2B;B ' 6%/()76833/(*(;728712', DSSBOHIWBVXSSBOHJBH[WBRXWB12B',
( ',B;B + 6/()76833257/(*'2:112', DSSBVZBOHIWBVXSSBOHJBGRZQBSRVB12B', ',B;B ' 6%5,*+76833/(*(;728712', DSSBULJKWBVXSSBOHJBH[WBRXWB12B', (
',B;B + 65,*+76833257/(*8312', DSSBVZBULJKWBVXSSBOHJBXSBSRVB12B', ',B;B ' 6%/()76833/(*(;72871&', DSSBOHIWBVXSSBOHJBH[WBRXWB1&B',
',B;B + 65,*+76833257/(*'2:112', DSSBVZBULJKWBVXSSBOHJBGRZQBSRVB12B', ',B;B ' 6%5,*+76833/(*(;72871&', DSSBULJKWBVXSSBOHJBH[WBRXWB1&B',
) 8186(',2:,5('72&211(&725 )
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 30 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 6K

$ &$1%862YHUYLHZ
7% $
+.1 &21752/81,7(;(5786+&06+<%5,'&21752//(502'8/($03683(56($/
3,1&211(&72590$

352-(&7,'
9B;B ( 9

;B + &$1B;B ( &$123(1/
*1'B;B ( *1'
*1'B;B ( *1' &$1B;B ( &$123(1+
%
5(/$7(72
%
',B;B + $,B;B ) 6%0$18$/&+$5*,1* DSSBFKDUJLQJBRQBSRVB12B',
',B;B & 5(027(&21752/&211(&7(' DSSBUHPRWHBFRQWUROBFRQQHFWHGBSRVB', ',B;B ) $1)25$',25(027($&7,9$7(' DSSB$1)2BUDGLRBUHPRWHBDFWLYDWHGB',
',B;B ) 56$1)25&&+$5*,1*21 DSSB$1)2B5&BFKDUJLQJBRQB6:B12B', $,B;B ) 6%0$18$/%/2:,1* DSSBEORZLQJBRQBSRVB12B',
',B;B * 56$1)25&&+$5*,1*2)) DSSB$1)2B5&BFKDUJLQJBRIIB6:B12B', $,B;B * 56$1)25&%%/2:,1*2)) DSSB$1)2B5&B%BEORZLQJBRIIB6:B12B',
& ',B;B ) 56$1)25&%/2:,1*21 DSSB$1)2B5&BEORZLQJBRQB6:B12B',

&
',B;B + %&+26(0,''/()(('(56(1625', DSSBKRVHBPLGGOHIHHGHUBSXOVHB',
',B;B % %%+26()(('(56(1625', DSSBKRVHBPHDVXULQJBSXOVHB',
',B;B % %%+26()(('(56(1625', DSSBKRVHBIHHGHUBSXOVHB',
*1'B;B ( 902'8/5(&2*1,7,21 YBPRGXOB5(&2*1,7,21

' '
$,B;B ) 56$1)25&%&+$5*,1*21 DSSB$1)2B5&B%BFKDUJLQJBRQB6:B12B',
$,B;B * 56$1)25&%&+$5*,1*2)) DSSB$1)2B5&B%BFKDUJLQJBRIIB6:B12B',
$,B;B ) 56$1)25&%%/2:,1*21 DSSB$1)2B5&B%BEORZLQJBRQB6:B12B',
$,B;B * $1)25$',25(027(%$&7,9$7(' DSSB$1)2BUDGLRBUHPRWHB%BDFWLYDWHGB',
',B;B * 56$1)25&%/2:,1*2)) 56$1)25&%/2:,1*2))

( (
',B;B & /69$/9($&7,9$7,21 DSSBOVBYDOYHB',
',B;B ) 6352&(66(1$%/('6:,7&+ DSSBSURFHVVBHQDEOHBUHTB',
) )
8186(',2:,5('72&211(&725
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 30 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 6K

$
&$1%862YHUYLHZ $
7%
+.1 &21752/81,7(;(5786+&06+<%5,'&21752//(502'8/($03683(56($/
3,1&211(&72590$
352-(&7,'
9B;B ( 9

9B;B ( 9
%
5(/$7(72
'2B;B & 6(16256833/<%$6.(7'2 DSSBVHQVRUBVXSSO\BEDVNHWB'2 ',B;B ) $1)25&5(6(7/(1*+76:', DSSB$1)2B5&B%BUHVHWBOHQJWKB6:B12B',
',B;B + $2B;B & 237,21'2 DSSBRSWLRQBHPSBIIB'2
'2B;B % +%%9(66(/35(6685,=(''2 DSSB%BYHVVHOBSUHVVXUL]HGBSRVB'2 $2B;B & 237,21', DSSBRSWLRQBIIBSRVB',
'2B;B & +$$9(66(/35(6685,=(''2 DSSB$BYHVVHOBSUHVVXUL]HGBSRVB'2 $2B;B & 237,21/,*+7'2 DSSBRSWLRQBRQBOLJKWBSRVB'2
&
',B;B ) $1)25&5(6(7/(1*+76:', DSSB$1)2B5&BUHVHWBOHQJWKB6:B12B', ',B;B + 629(5/2$'/,0,71&', DSSBRYHUORDGBOLPLWB1&B', &
'2B;B % +352&(66(1$%/(5(48(6721'2 DSSBSURFHVVBHQDEOHBUHTB'2 ',B;B + 629(5/2$'/,0,712', DSSBRYHUORDGBOLPLWB12B',
'2B;B & +%22029(5/2$'$/$50'2 DSSBRYHUORDGBDODUPB'2 ',B;B + 6$/$50+251'2 DSSBDODUPBKRUQBSRVB12B',
'2B;B & 29(5/2$'6(16256833/<'2 DSSBRYHUORDGBVHQVRUBVXSSO\B'2 ',B;B ' 6(03803', DSSBHPBSXPSBSRVB12B',
' ',B;B ) 6%9(66(/$%', DSSBDBEBYHVVHOBSRVB12B', $2B;B $ (06$1'29(5/2$'2.'2 DSSBHPVBFLUFXLWBVXSSO\B'2 '
',B;B * 6+$1'7+5277/(212))', DSSBKDQGBWKURWWOHBVHOHFWLRQBSRVB12B', $2B;B *

'2B;B & +&+$5*,1*$9(66(/'2 DSSBFKDUJLQJB$BYHVVHOB'2 $2B;B *
'2B;B % +&+$5*,1*%9(66(/'2 DSSBFKDUJLQJB%BYHVVHOB'2 $2B;B *
',B;B ) 56$1)25&+26(2876: DSSB$1)2B5&BKRVHBRXWB6:B12B', ',B;B + 6+$1'7+5277/(530', DSSBKDQGBWKURWWOHBUSPSOXVBSRVB12B',
( ',B;B * 56$1)25&+26(,16: DSSB$1)2B5&BKRVHBLQB6:B12B', ',B;B * 6+$1'7+5277/(530', DSSBKDQGBWKURWWOHBUSPBPLQXVBSRVB12B', (
$2B;B ) 60$18$/&+$5*,1*%9(66(/ DSSBFKDUJLQJBRQB%BYHVVHOB12B', ',B;B +
$2B;B ) 60$18$/%/2:,1*%9(66(/ DSSBEORZLQJBRQB%BYHVVHOB12B', ',B;B +
) )
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 30 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 6K

00 7% 7%
;

7% ' ;$B
;% <( ;& ;' <( <(<( ;$ ;% ;& ;' <( <(
<( <( <(
' ;$B

<( <(
$ ' ;$B $

<( <( <(<( <(
' ;$B

<( <( <(
' ;$B

;
<( <( <(<( <(<(

' ;$B

;
<( <( <(<( <(<( 6 6 + +

' ;$B
, $ $ , $ $

;9

* ;$B
/%8 /%8 + 6 *1 *1
$ $
/%8 /%8 ,

$ $
* ;$B

<( <(

' ;$B
% ' ;$B
<( <( *1 $ %

<( /%8
<(
&0
.
7%E
.
$&&(6625,(6
/%8 ;)

/%8

;)
$
/%8
7%
$

6[
(
;
;% ;$ ;% ;& ;' <(
; ;
<( <( <( <(

& ;%B
<(
*1
& &
; :+ 9 9
% ;%B
6[
' 6[
&
; ; ;

-03 -03 -03
; %1 <(<( <(

% ;%B
;
; <( ; 9 9
% ;%B ) *
$
$
$
$
+.1 ;$ ;)$
9
5&2 ;)
',B;B ;$
)
352-(&7,'
<(
(
66$)(7<%5$.(21', ) ) ) )
2KP ;9

$ $ $ $
%
%
;% ;
.
.
.
.
:+ :+ :+

5(/$7(72
' ;% ; ; ; '

%1 %1 %1

:D6+ :G6+ ; :%6+

%

:+
5'
5'
5'
*<
%1
<(
<(
:+

;%B
;%B
%1
%8
%8

;D
;D
;D
;D
;D
;D

;
;
&$1B+
&$1B/

;
;
;
;
; ; ; ; ; ;

; ;
+.1 +.1 +.1 +.1 +.1 +.1
;D
;D
(
(
+.1 +.1
&$1B;B &$1B;B 9B;B 9B;B 9B;B *1'B;B ; ;
'
&$1B;B &$1B;B
/%8
/%8
902'8/ +.1 +.1
%
%
%
%
%
9
9
9
( (
5(&2*1,7,21
&$12SHQ+
%
%
&$12SHQ/
&$123(1/ &$123(1+ *1'B;B *1'B;B

;9 ;9

%
*1'
%
*1'

97% 97%
) )
$
$
$
$
$
$
$
;) ;) ;) ;) ;) ;) ;)
) ) ) ) ) ) )

$ $ $ $ $ $ $
.
.
.
.
.
.
.
;9 5

<(
<(
; N:

<(
<(
;5
.
$
;$
;$
'
;9 ;% ;%
&$1B+
&$1B/

;9 ; ; ;9 ; ;

:+
%1

* *
:+
5'
5'
5'
5'
5'
5'
5'
5'
5'
*<
*<
*<
*<
*<
%8
%8
%8
%8
%1
%8
%8
)
)

;D
;D
;D
;D
;D
;D
;D
;
;
;
;
;
;
;
;
; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;
+.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1 +.1
*1'B;B *1'B;B *1'B;B 9B;B 9B;B 9B;B &$1B;B &$1B;B *1'B;B *1'B;B *1'B;B 9B;B ;B 9B;B 9B;B &$1B;B &$1B;B *1'B;B *1'B;B *1'B;B ;B 9B;B 9B;B 9B;B
(
&$1B+&$123(1
&$1B/&$123(1
&$1B/&$123(1
&$1B+&$123(1
*1' 02'8/( 02'8/(
%
*1'
%
*1'
'
%
%
%
%
%
%
*1'
%
*1'
%
*1'
%
%
%
%
%
%
*1'
%
*1'
%
*1'
%
%
%
9
9
9
9
9
9
9
9
9
5(&2*1,7,21 5(&2*1,7,21
+ 9 NRKP!*1' +
97%% 97%
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 30 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 6K

00 7%
7% ' ;$B
;% ;& ;' <(

$ &0 </69$/9('2 $

;

7%E
7% ; <( ;$ ;% ;& ;' <(
;
<(

'2B;B
% ;%B

+.1
;
;
<( <( <(

'
% ;%B
;
<(<(
; (
;
; <( <( <(

% ;%B 237,21

; /,*+7
; <( <( <(

% ;%B

; <( <( 6
*1
% ;%B

% %
; ; <( <(

;%B % % ;%B

;9

97%
;$

;%

& &
;&

7%
;'

/69$/9($&7,9$7,21 29(5/2$'6(16256833/<'2 +%22029(5/2$'$/$50'2
( ' &
',B;B '2B;B '2B;B
<(
<(
<(
<(
<(<(
+.1 +.1 +.1
352-(&7,'
; ; ;

;D
;D
;D

*1

6
;

5(/$7(72
' '
*1
<(
<(
<( <( <( <( <( ;
$ 6B9 6B9 ' ;

;

6$ 6%
$ $ % % $ $ % %
&

;
;
;
;

$ $ % % $ $ % %
*<
<(

(
(
(
(
;

%8
%1
<(
( ; ; (

<(
<(
<(
<(
<( <(
;6$
;6$
6

;

6 6 6

$ $ $ $ $ $ % %
21 21 ,
6$

$ $ $ $ $ $ $ $ % %

;6$ (1*,1(
;6$

:+
:(
:(
%.
%.
%.
67$576723
%1
%1
%1
%1
)

) )
;<$
;<%
;(
;(
;(
;(
;<$
;<%


<$ <% <$ <%
:+
+$
%.
( ( ( (

*1
*1
*1
*1
/%8

;<%
;<%
;<$
;<$
;(

;(
;(
;(

;D
;D

; ;
; ;

%8
%8
%8
%8
+.1 +.1
:+
:(
:(
%.
%.
%.
*1
*1
* *

',B;B ',B;B
' (

6+$1' 6+$1'
;D
;D

7+5277/(212)) 7+5277/(530
;D
;D
', ; ', ;

; ;
+.1 +.1
+.1 +.1
',B;B ',B;B
( &
',B;B ',B;B
6+$1' 6$/$50+251'2 & &
7+5277/(530 629(5/2$'/,0,7 629(5/2$'/,0,7
', 1&', 12',
;9 ;9 ;9

+ +
97%
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 30 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 6K

&0 6(1625683//< 00 30 7% 7% (06$1'

;

7%E 1'2 7% ' ;$B
;% <( ;& ;' <( <( ;$ ;% ;& ;' 29(5/2$'2.
'2B;B $2B;B

<( <(
$ +.1 ' ;$B
+.1 $
% '
;' ' $ ; ;
.
$

; <( ;
;
;D

;' ' $ ;
*1
.
$

<(

<(1*,1((1' <(1*,1((1'
;' ' $
.
$
6833257/(*6 6833257/(*6 (0(5*(1&<6723
839$/9('2 '2:19$/9('2 $1'29(5/2$'2.'2
*1
*1
<(
;%
VHQVRUVXSSO\1 D D
*<
<(
<(
<(
<(

'2B;B '2B;B '2B;B

6B6[
$ . .
+.1 +.1 +.1
<(
( ( &

& &
<( <( <( <( VHQVRUVXSSO\1 ; ; ;
% $ %

;
;
;D
6[
$ $ $ $ $ $

6 ,
6 ,
6 ,

6% 6% 6% 6% 6%
'2:1
'2:1
'2:1
$ $ $ $ $ $ $ $ $ $
83
83
83
$ $ $

;$
;$

<(
<(
$ $ $ $ $ $ $ $ $ $
;
<(

;%

;%

9
*1
*1
*1
*1
*1
*1
*1
*1
*1
*1
;<
;<

&
< <
. .

& &

;
;
;
;
;

;D
;D
% %
; ; ; ; ;
; ;
+.1 +.1 +.1 +.1 +.1
;<
;<
+.1 +.1
',B;B ',B;B ',B;B ',B;B ',B;B

& '
;9

',B;B ',B;B
;%
;%
6/()7/2$'(1' 65,*+7/2$'(1' 6(1*,1((1' 6/()76833 65,*+76833 /%8 /%8 ' '

6833257/(* 6833257/(* 6833257/(*6 /(*(;7,112 /(*(;7,112 6(0(5*(1&<380321 6(03803',
8312', 8312', 8312', ', ',
;
;
;
;
;
352-(&7,'
/2:(5&21752/3/$&(',
;' ;'
$
$
; ; ; ; ;
97%
;$
;$

+.1 +.1 +.1 +.1 +.1
;9 ' '

',B;B ',B;B ',B;B ',B;B ',B;B $ $
& ' ' & & 9
5(/$7(72
' & ;' ;' '
.
.
6/()7/2$'(1' 65,*+7/2$'(1' 6(1*,1((1' 6/()76833 65,*+76833 ;
6833257/(* 6833257/(* 6833257/(*6 /(*(;728712 /(*(;728712 97%%
'2:112', '2:112', '2:112', ', ',
</()7/2$'(1' <5,*+7/2$'(1' </()7 <5,*+7 <%220 <%%220

6(16256833/<1'2 <( <( <( 6(16256833/< 6833257/(*83 6833257/(*83 6833/(* 6833/(*(;7 /,)7,1*/,0,7'2 7851/,0,7/()7'2
/2:(5
833(5
1'2 9$/9('2 9$/9('2 (;7287'2 287'2 %2206$)(7<
<5,*+7 '2B;B '2B;B
6833/(* </2:(5 <833(5 :$51,1*'2
'2B;B '2B;B '2B;B </()7/2$'(1' '2B;B <5,*+7/2$'(1' '2B;B </()7 '2B;B
6 6833257/(*'2:1 6833257/(*'2:1 6833/(* (;7,1'2 &21752/'2 &21752/'2 &
',B;B '
+.1
(
+.1
+.1 +.1 +.1 9$/9('2 +.1 9$/9('2 +.1 (;7,1'2 +.1
; ;
<(
<(
% 6 '2B;B '2B;B '2B;B <$%220

% +.1
;D
;D
; ; ; '2B;B ; '2B;B ; '2B;B ; 7851/,0,75,*+7'2
+.1 +.1 +.1
;D
;
;D
;D
;
;

& ; '2B;B
( +.1 +.1 +.1 (
*1

;
& ; ; ;
+.1
;
;D
;D

; ; ;
*<
*<
'

;D
;D
;

;
*1

;D

*1
*1
*1
;D
;D
;D
;
*1
*1
*1
*1
*1
*1
*1
*1
*1
*1
*1

; ; ; ;

; ;

+.1 +.1 +.1
;

<(
;$
;$
;$
;$
;$
;$
;$
;$
;$
;$
;$
;$
;$
',B;B ',B;B $,B;B

' ' (

<(
6/2:(5 65(027( 6833(5

6(/(&7,21', 6(/(&7,21', 6(/(&7,21',
) )
;%

;%

;%

;%

;%

;%

;%

;%

;%

;%

;%

;%

;%

<( <(
<(
<(
<(
<(
<(
<(
<(
<(
<(
<(
<(
<(
<(
<(
:+

6$ 6$ 6$ 6$ 6$

'2:1
'2:1
'2:1
$ $ $ $ $ $ $ $ $ $
83
83
83

;<$
;<%

;<
;<
;<
;<
;<
;<
;<
;<
;<
;<
;<

$ $ $ $ $ $ $ $ $ $ < < < < < < < < <
< <$ <%
< +

*1
*1
*1
*1
*1
*1
*1
*1
*1
*1

;<
;<
;<
;<
;<
;<
;<
;<
;<
;<
;<
;<%
;<$
* *

;D
;D
;D
;
;
; ; ; ; ;

/%8
/%8
/%8
/%8
/%8
/%8
/%8
/%8
/%8
/%8
/%8
/%8
/%8
:+

+.1 +.1 +.1 +.1 +.1
',B;B ',B;B ',B;B ',B;B '2B;B

;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
;%
(

6/()76833257 65,*+76833257 65($56833257 6/()76833 65,*+76833

/(*8312', /(*8312', /(*68312', /(*(;7,112 /(*(;7,112

;D
;D
;D
;
;
', ',
;$
;$
;$
;$
;$
;$
;$
;$
;$
;$
;$
;$
;$

; ; ; ; ;

+.1 +.1 +.1 +.1 +.1 /%8 /%8 /%8 /%8 /%8 %./%8 /%8
+ +
;9 ;9 ;9 ;9
',B;B ',B;B ',B;B '2B;B ',B;B
(
6/()76833257 65,*+76833257 65($56833257 6/()76833/(* 65,*+76833/(* 97%
/(*'2:112', /(*'2:112', /(*6'2:112', (;728712', (;728712',
,283'$7(' (77(7(+ '$7( 1$0(

'(6,*1 (77(152

(/(&75,&6
$33 30 6+((7
9(5 &+$1*( '$7( 1$0( 67$1' 7%%7%7%&+$50(&60/) 6K

&0 7%
7%E ;9 ;9

&$55,(5,175$163257 6833257/(*6(1625 /%8 /%8 /%8 /%8 +&$55,(5 +%220127 +6833/(*6127
6833257/(* ;

326,7,21'2 6833/<(1*,1((1''2 <( <( <( ,1&/,1(''2 '5,9,1*326'2 '5,9,1*326'2
6(1625
'2B;B '2B;B 6833/</2$' '2B;B '2B;B '2B;B
;$
$ $
(1''2

+.1 +.1 +.1 +.1 +.1
& ( ',B;B & ' '
; ; ; ; ;
;%

+.1
;
;
;D
;D
;D
*1

; 6$ 6$ 6% 6% 6% 6$ 6% 6$
;D

*1
*1
*1
313
313
313
313
313
313
313
313
%1
%8
%1
%8
%1
%8
%1
%8
%1
%8
%1
%8
%1
%8
%1
%8
+[
+[
*1
*1
% %

; ;
+ +

+

:+
%.

:+
%.

:+
%.

:+
%.

5' 5'
%.
%.
%.
%.
5'
;

+[
+[

;
;%

;%B
7%
/%8 /%8
;$

/%8
& &

%
6;;;
*<
*<
;D
;D
;D
;D
;9

*1
*1
*1
*1
*<
*<
; ; ; ;

+.1 +.1 +.1 +.1
;D

97%
;D
; ',B;B ',B;B $2B;B ',B;B
( ' &
313
6%5,*+7/2$'(1' ;
+.1 6%/()7 6%5,*+7 6%/()7/2$'(1'

6833/(*'2:11&',

352-(&7,'

6833/(* 6833/(*(;7 +.1 6833/(*'2:112', <%220 <%%220/2:(5,1*
;D
;D
;D
;D
;D
;D
',B;B (;72871& 2871&', 6863(16,21'2 /,0,7'2
&
*
', ',B;B &
6$5,*+7
; ; ; ;
%
; ;
',B;B '2B;B
6833/(*(;7,1

+.1 +.1 +.1 +.1 6$5,*+7/2$'(1' +.1 +.1

12', 6833/(*8312', +.1 +.1

(
5(/$7(72
' ',B;B '2B;B ',B;B $2B;B ',B;B ',B;B '

&211(&7,21:,7+ & ' & % ; ;
;
;
,17(*5$7('6(1625
;).
6$/()76833/(* 6%/()76833/(* 6%5,*+7 6%5,*+7/2$'(1' 6%/()7/2$'(1' 6$/()7/2$'(1'

&</,1'(5,1,1)250$7,21 (;7,112', (;728712', 6833/(*(;7 833/(*'2:112', 6833/(*'2:11&', 6833/(*8312',
%2206(1625 28712', -03
*1
*1
6833/<'2
*1
;% ;

<( <( <( <(

',B;B
; ;

<(

;$
;$
;$
;$
+.1
/%8
/%8
/%8

<(
<(
;$ <(
;$ <(

;
;
;$
;$
;$
;%

;%

;%

;%

( (
6% 6$ 6% 6$
;%

;%

;%

Instruction Manual Charmec MF 605 DA

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Instruction Manual Charmec MF 605 DA

Uploaded by

Copyright:

Available Formats

Contents

1. Technical Data Sheet

Pictured machine may include options and additional equipment.

CHARGING SYSTEM BRAKES

AXLES Open 2-man cabin FOPS/ROPS approved

STEERING 12 kg hand held fire extinguisher (2 pcs)

Optional equipment Additional equipment

CHARGING SYSTEM CHARGING SYSTEM

- Charging equipment (e.g. charging hoses) Audit services to improve:

ELECTRONIC MANUALS ON THE WEB

Start-up training Commissioning

2. Maintenance and repair training

DIMENSIONS TURNING RADIUS

DEUTZ TCD 2013 L4 120 kW

MERCEDES-BENZ OM 904 LA 110 kW

DEUTZ D914 L6 86,5 kW

– is in conformity with following (parts/clauses of) technical standards and spec-

– the following (parts/clauses of) national technical standards and specifications

Place and date: Iisalmi 06.09.2018

Signature: Timo Rask

Normet Oy Tel. +358 (0)17 83 241

About this manual

The following warnings are found in the text:

Immediate risk of serious injury or death.

Risk of damage to property.

Important information related to servicing or repair work.

4. Operation and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

100121643 1 - 1 EN 0918 ettekma 5 (76)

1.2. Carrier identification

Fig. 1. Plate locations

100121643 1 - 1 EN 0918 ettekma 6 (76)

1.3. Frame Structure

1.3.1. Engine end Frame

1.3.2. Load end Frame

100121643 1 - 1 EN 0918 ettekma 7 (76)

Fig. 2. Axle oscillation

100121643 1 - 1 EN 0918 ettekma 8 (76)

1.4.2. Fuel Injection

100121643 1 - 1 EN 0918 ettekma 9 (76)

Fig. 3. Engine layout

100121643 1 - 1 EN 0918 ettekma 10 (76)

1.4.5. Exhaust system

The Catalytic Exhaust Gas Purifier

Fig. 4. Exhaust pipe

100121643 1 - 1 EN 0918 ettekma 11 (76)

1.5. Hydrodynamic Transmission

Fig. 5. Basic design of the transmission

100121643 1 - 1 EN 0918 ettekma 12 (76)

1.5.2. Torque Converter

Fig. 6. Basic design of the torque converter

100121643 1 - 1 EN 0918 ettekma 13 (76)

100121643 1 - 1 EN 0918 ettekma 14 (76)

1.5.4. Transmission Controls

100121643 1 - 1 EN 0918 ettekma 15 (76)

1.6. Mechanical Transmission

1.6.3. Axle Assemblies

Fig. 7. Axle assemblies

100121643 1 - 1 EN 0918 ettekma 16 (76)

100121643 1 - 1 EN 0918 ettekma 17 (76)

Function of the dual-circuit brake valve

Function of the accumulator loading valve

Safety/parking brake valve

100121643 1 - 1 EN 0918 ettekma 18 (76)

100121643 1 - 1 EN 0918 ettekma 19 (76)