Om MHPlus EN PDF

MH5.
6
MHPlus
Operation and Maintenance Instruction Manual

Operation and
Maintenance
Instruction
Manual
Print No. 604.35.232.00

English - Printed in Italy
MH5.6 - MHPlus
PROVEN PERFORMANCE PROVEN PERFORMANCE

OPERATING INSTRUCTIONS MH PLUS / MH 5.6
REPRODUCTION OF THESE OPERATING INSTRUCTIONS IN WHOLE OR IN

PART IS STRICTLY PROHIBITED EXCEPT WITH THE WRITTEN CONSENT OF
THE PUBLISHER
The data contained in these operating instructions were valid at the time of publication. As
we constantly endeavour to improve our products and to provide additional options, modifi-
cations or changes made in this context may have an impact on the procedures described in
these operating instructions. Please contact your local dealer if your find any discrepancies.
EACH MACHINE IS ACCOMPANIED BY ITS OWN SET OF

OPERATING INSTRUCTIONS.
2 - 01.02.2005 / For information only - 604.35.232.00-EN

PRODUCT MAINTENANCE
Many machine users and owners have all maintenance work except routine lubrica-
tion and minor servicing work performed by their dealer. This is advisable since all
our dealers are trained and equipped to render excellent maintenance services.
In the event of queries addressed to the dealer or the manufacturer, please always
state the serial number of your machine.
CNH Baumaschinen GmbH

Staakener Str. 53 – 63
D-13581 Berlin
SPARE PARTS
To maintain the efficiency of your machine, use original spares only
When ordering spare parts, please provide the following information:

- machine type
- serial number of machine and engine
- parts number (P/N) from the spare-parts catalogue
604.35.232.00-EN - 01.02.2005 / For information only - 3

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2245128-en

The operating instructions are divided into 5 sections,

the sections are designed for different target groups:
Operating instructions Target group

Part 1 INTRODUCTION Operating personnel
+
FUNDAMENTAL SAFETY Inspection and servicing personnel
INSTRUCTIONS +
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-how rele-
vant to the operation and the application of this or
comparable machines.
Part 3 INSPECTION AND Inspection and servicing personnel

The inspection and servicing personnel must have
SERVICING know-how relevant to the inspection and servicing
of this or comparable machines.
Part 4 REPAIR WORK Repair personnel

The repair personnel must have know-how and
experience relevant to the repair of this or compa-
rable machines.
Part 5 ANNEX Operating personnel

+
Inspection and servicing personnel
+
Repair personnel


Table of contents
PART 1 – INTRODUCTION ............................................................................23
Preface......................................................................................................................................... 25
Warranty .................................................................................................................................................25
Service Booklet ........................................................................................................................... 26
Fundamental saftey instructions ............................................................................................... 26

Warnings and symbols ............................................................................................................................26
Designated use ........................................................................................................................... 27
Organizational measures ........................................................................................................... 28

Selection and qualification of personnel, basic responsibilities .................................................................29
Saftey instructions governing specific operational phases ........................................................................29
Standard operation ..............................................................................................................................29
Special work in conjunction with utilisation of the machine and maintenance and repair work during
operation, disposal of parts and consumables..........................................................................................30
Warning of special dangers .....................................................................................................................31
Electric energy .....................................................................................................................................31
Gas, dust, steam and smoke................................................................................................................31
Hydraulic and pneumatic equipment ........................................................................................................32
Noise.......................................................................................................................................................32
Oil, grease and other chemical substances..............................................................................................32
Transporting and towing, recommissioning ..............................................................................................32

PART 2 – OPERATION...................................................................................35
Operation, safety instructions.................................................................................................... 37
Description of the machine (monoblock boom) ....................................................................... 40

Machine layout ........................................................................................................................................41
Undercarriage .........................................................................................................................................41
Superstructure.........................................................................................................................................41
Hydraulic system .....................................................................................................................................41
Steering ..................................................................................................................................................41
Service brake ..........................................................................................................................................41
Parking brake..........................................................................................................................................42
Floating axle............................................................................................................................................42
Electrical system .....................................................................................................................................42
Working equipment .................................................................................................................................42
Description of the machine (boom adjusting equipment)........................................................ 44

Machine layout ........................................................................................................................................45
Undercarriage .........................................................................................................................................45
Superstructure.........................................................................................................................................45
Hydraulic system .....................................................................................................................................45
Steering ..................................................................................................................................................45
Service brake ..........................................................................................................................................45
Parking brake..........................................................................................................................................46
Floating axle............................................................................................................................................46
Electrical system .....................................................................................................................................46
Working equipment .................................................................................................................................46
Machine parameters ................................................................................................................... 47

CE-mark..................................................................................................................................................47
Maschine number....................................................................................................................................47
Engine number........................................................................................................................................47
Numbers of components and assemblies ................................................................................................47
Noise emission........................................................................................................................................47
Outside the machine ............................................................................................................................47
Warning and instruction signs (mono-boom) ........................................................................... 48
Warning and instruction signs (boom adjusting equipment) .................................................. 52
Driver’s cab ................................................................................................................................. 56

Entering and Leaving ..............................................................................................................................56
Opening /closing the driver's cab door .....................................................................................................57
Adjustment of driver's seat, safety instructions.........................................................................................59
Driver’s seat – pneumatic suspension......................................................................................................60
1 – Adjusting the seat cushion angle ....................................................................................................60
2 – Adjusting the seat cushion height ...................................................................................................60
3 – Fore-and-aft adjustment of seat without consoles ...........................................................................60
4 – Adjusting the suspension/seat height..............................................................................................60
5 - Fore-and-aft adjustment of seat with consoles.................................................................................60
7 – Fold-back armrests ........................................................................................................................60
8 – Armrest angle ................................................................................................................................60
9 – Adjusting the longitudinal-horizontal suspension.............................................................................60
10 – Adjusting the backrest ..................................................................................................................60
11 – Adjusting the armrest height .........................................................................................................60
12 – Adjusting the lumbar support ........................................................................................................61

Seat heating ........................................................................................................................................61

Options ................................................................................................................................................61
Driver’s seat – mechanical suspension ....................................................................................................62
1 - Adjusting the seat cushion angle.....................................................................................................62
2 - Adjusting the seat cushion height ....................................................................................................62
3 - Fore-and-aft adjustment of seat without consoles............................................................................62
4 - Adjusting the suspension ................................................................................................................62
5 - Fore-and-aft adjustment of seat with consoles.................................................................................62
6 - Adjusting the seat height .................................................................................................................62
7 - Fold-back armrests .........................................................................................................................62
8 - Adjusting the armrests ....................................................................................................................62
9 - Adjusting the backrest.....................................................................................................................62
10 - Adjusting the armrest height..........................................................................................................62
Options ................................................................................................................................................62
Retaining belt ..........................................................................................................................................63
Backrest extension (headrest) .................................................................................................................64
Adjusting the mirrors................................................................................................................................65
Opening / closing the front window ..........................................................................................................65
Lower part of front window, ventilation / open ..........................................................................................66
Side window - opening / closing...............................................................................................................67
Emergency Exit .......................................................................................................................................67
First-aid kit, fire-extinguisher, warning triangle .........................................................................................68
Using the sunblind...................................................................................................................................69
Rolling out the sunblind........................................................................................................................69
Rolling in the sunblind ..........................................................................................................................69
Cab interior lighting - switching on and off................................................................................................70
Socket outlet in driver's cab .....................................................................................................................71
Monitoring, warning and control elements ............................................................................... 72

Multi-function display, general description and operating information .......................................................72
Operating mode ......................................................................................................................................72
Main menu ..............................................................................................................................................74
Control panels / rocker switches, general operating information ...............................................................76
Special equipment (options) ....................................................................................................................76
Arrangement of switches and keys ..........................................................................................................76
Conditions of use of the multifunction display...........................................................................................77
Switches / Keys.......................................................................................................................................78
Control elements / ISO ............................................................................................................................94
Multi-function display...............................................................................................................................98
Starting up the machine ........................................................................................................... 108

Refuelling..............................................................................................................................................109
Refuelling, safety instructions.............................................................................................................109
Filling in fuel.......................................................................................................................................110
Winter operation ................................................................................................................................110
Filter preheating (low-temperature package - optional) .......................................................................111
Switching the electrical system on and off..............................................................................................112
Immobilizer, re-entering / activating / deactivating the code....................................................................114
Immobilizer, re-entering / activating / deactivating the code....................................................................115
Re-entering the code .........................................................................................................................115
Activating the code.............................................................................................................................115
Deactivating the code.........................................................................................................................115
Further settings..................................................................................................................................115
Immobilizer, activating the code timer function.......................................................................................116
Starting and stopping the engine ...........................................................................................................118

Starting the engine ................................................................................................................................118
Warm-up phase .................................................................................................................................120
After engine start / warm-up ..................................................................................................................122
Engine does not start .........................................................................................................................123
Stopping the engine ...........................................................................................................................123
Ventilation and Heating .........................................................................................................................124
Ventilation (fresh air)..........................................................................................................................124
Heating ..............................................................................................................................................124
Adjusting the Heating Output .............................................................................................................125
Defrosting the front, side and rear windows ........................................................................................126
Switching the windscreen wiper/washer on and off ................................................................................127
Intermittent wiping..............................................................................................................................127
Permanent wiping ..............................................................................................................................127
Switching the wiper off .......................................................................................................................127
Activating the wipe / wash function.....................................................................................................127
Driving ....................................................................................................................................... 128

Travelling, safety instructions.................................................................................................................128
Braking system......................................................................................................................................132
Using the service brake......................................................................................................................132
Applying / releasing the parking brake................................................................................................134
Shifting the travel gearbox .....................................................................................................................136
Creep speed ......................................................................................................................................136
Gearshift response on mode-of-operation changes during driving:......................................................137
nd
Switching of "fixed 2 gear" (option) ..................................................................................................137
Travelling, multi-function display screens...............................................................................................138
Road travel, multi-function display screens.........................................................................................139
Switching on road travel: ....................................................................................................................139
Road travel ........................................................................................................................................139
Switching off road travel: ....................................................................................................................139
Steering column ....................................................................................................................................140
Steering column, safety instructions ...................................................................................................140
Adjusting the steering column................................................................................................................140
Blocking / unblocking the floating axle ...................................................................................................142
Blocking the floating axle ...................................................................................................................142
Unblocking the floating axle ...............................................................................................................142
Bringing the machine into its basic position .......................................................................... 144
Driving operation ...................................................................................................................... 146

Driving on roads ....................................................................................................................................147
Braking and stopping.............................................................................................................................148
Travelling uphill and downhill .................................................................................................................150
Driving with a suspended load ...............................................................................................................151
When driving on level ground with the superstructure in basic position: ..............................................151
Driving on public roads ..........................................................................................................................152
Machine recovery / towing ....................................................................................................... 153

Recovery and towing, safety instructions ...............................................................................................153
Recovering / towing the machine ...........................................................................................................154
Recovery / towing ..............................................................................................................................154
After the recovery / towing..................................................................................................................154
Parking brake, emergency release.........................................................................................................155

Transport of the machine ......................................................................................................... 156

Transport, safety instructions.................................................................................................................156
Tying down the machine........................................................................................................................158
Fastening point A...............................................................................................................................158
Fastening point B...............................................................................................................................159
Fastening point C...............................................................................................................................159
PCS failure while driving........................................................................................................................160
After travelling........................................................................................................................... 160
Working operation .................................................................................................................... 161

Working operation, safety instructions....................................................................................................161
Extreme position of working equipment, instructions ..............................................................................162
Before beginning work...........................................................................................................................162
Activating / deactivating the automatic speed reduction .........................................................................163
Activating the automatic speed reduction ...........................................................................................163
Deactivating the automatic speed reduction .......................................................................................163
Selecting the power level.......................................................................................................................164
Switching on the pilot control .................................................................................................................165
Switching off the pilot control .................................................................................................................165
Slewing and braking the superstructure ................................................................................. 166

Locking the superstructure ....................................................................................................................166
Unlocking the superstructure .................................................................................................................166
Slewing the superstructure ....................................................................................................................166
Slewing the superstructure to the right...................................................................................................166
Slewing the superstructure to the left .....................................................................................................166
Braking the superstructure.....................................................................................................................167
Slewing, setting the slewing power limitation..........................................................................................168
Setting the slewing power limitation .......................................................................................................169
Superstructure holding brake, function...................................................................................................170
Applying / releasing the superstructure holding brake ............................................................................172
Applying the superstructure holding brake..........................................................................................172
Releasing the superstructure holding brake........................................................................................172
Superstructure holding brake faults ....................................................................................................173
Superstructure holding brake, emergency release .................................................................................174
Machine in working position...................................................................................................................175
Stabilization of the machine..................................................................................................... 176

Control of stabilizers and levelling blade ................................................................................................176
"Independent stabilizer control (option)".................................................................................................176
Working with backhoe bucket or grab equipment (ISO control) ........................................... 180
Slewing the superstructure ....................................................................................................................181
Raising and lowering the boom..............................................................................................................181
Extending and retracting the stick ..........................................................................................................181
Filling and emptying the bucket .............................................................................................................181
Opening and closing the grab ................................................................................................................181
Adjusting the opening and closing speed of the grab (option).................................................................181
Turning the grab....................................................................................................................................181
Switching on the power boost ................................................................................................................181
Switching on the horn ............................................................................................................................181
Power-Assist function ............................................................................................................................182
Power-Boost function ............................................................................................................................184
Activating the Power-Boost function ...................................................................................................184
Power-Boost, automatic function ........................................................................................................184
Activating Auto-Power-Boost:.............................................................................................................184

Methods of working .................................................................................................................. 186

Switching to the "Setting Leveling" mode of operation ........................................................................190
Configuration of the " Setting Levelling " mode ............................................................................190
Working in the event of load limit regulator failure (PCS module) ........................................ 192
Setting the proportional valve to emergency operation...........................................................................192
After daily operation ................................................................................................................. 193

Parking the machine..............................................................................................................................193
Working equipment................................................................................................................... 194

Fitting of working equipment, safety instructions, faults ..........................................................................194
Securing the machine............................................................................................................... 196
Attaching and detaching the grab equipment......................................................................... 198

Attaching and detaching the grab equipment, safety instructions............................................................198
Attaching the grab .................................................................................................................................198
Detaching the grab ................................................................................................................................199
Selecting the backhoe / grab equipment ................................................................................................200
Backhoe bucket operations ................................................................................................................200
Grab operation...................................................................................................................................200
Volume flow switch-over for backhoe-grab equipment (option)...............................................................201
Switching scheme..............................................................................................................................201
Clamshell opening and closing speed, setting the parameters ...............................................................202
Detaching / attaching the backhoe bucket.............................................................................. 204
Corrosion protection for pins and bearings (Bushings and Hubs) ....................................... 205
Container size Voler A.C. ......................................................................................................................205
Application of Voler A.C.........................................................................................................................205
Boom-Adjusting Mechanism.................................................................................................... 207

Description of boom-adjusting mechanism.............................................................................................207
Working with the boom-adjusting mechanism ........................................................................................207
Transport of the machine with boom-adjusting mechanism.................................................................207
Speed limitation, adjusting (neck) cylinder .............................................................................................208
Hydraulic hammer..................................................................................................................... 211

Working with the Hydraulic Hammer, Safety Instructions........................................................................211
Working with the hydraulic hammer .......................................................................................................212
Before beginning work: ......................................................................................................................212
Switching on the hydraulic hammer....................................................................................................212
Hammer operation with fixed impact frequency ..................................................................................212
Hammer operation with variable impact frequency..............................................................................212
Switching off the hydraulic hammer....................................................................................................212
Hydraulic hammer, setting the parameters.............................................................................................214
Hydraulic hammer, setting the parameters .........................................................................................215
Setting the parameters for hydraulic hammers....................................................................................215
Hydraulic shears ....................................................................................................................... 217

Working with the hydraulic shears, safety instructions............................................................................217
Working with the hydraulic shears..........................................................................................................218
Before beginning work: ......................................................................................................................218
Switching on the hydraulic shears ......................................................................................................218
Slewing shears only: ..........................................................................................................................218

Switching off the hydraulic shears ......................................................................................................218

Operating the shears with the joystick (option) ...................................................................................218
Hydraulic shears, setting the parameters ...............................................................................................220
Hydraulic shears, setting the parameters............................................................................................221
Setting the parameters for hydraulic shears........................................................................................221
Hydraulic cutter......................................................................................................................... 223

Working with the Hydraulic cutter, Safety Instructions ............................................................................223
Working with the hydraulic rotary cutter .................................................................................................224
Before starting work: ..........................................................................................................................224
Switching on the hydraulic cutter........................................................................................................224
Switching off the hydraulic cutter........................................................................................................224
Hydraulic rotary cutter, setting the parameters.......................................................................................226
Hydraulic rotary cutter, setting the parameters...................................................................................227
Setting the parameters for hydraulic rotary cutters..............................................................................227
Smooth mode (hydraulic damping), setting the parameters....................................................................230
Smooth mode (damping of the working movements), setting the parameters......................................231
Setting the Smooth mode parameters ................................................................................................231
Resetting to default values .................................................................................................................231
Basic setting, setting the parameters .....................................................................................................232
Basic settings.....................................................................................................................................233
Factory setting ...................................................................................................................................233
Selecting the basic setting..................................................................................................................233
Lifting-gear operation ............................................................................................................... 235

Lifting-gear operation, safety instructions...............................................................................................235
Load hooks on bucket and linking element ............................................................................ 236

Load capacity of the load-carrying hook.................................................................................................236
Load capacity of the excavator ..............................................................................................................236
Overload warning system......................................................................................................... 237

Overload warning system, function ........................................................................................................237
Checking the overload warning system ..............................................................................................238
Putting the overload warning system into operation ............................................................................239
Malfunctioning of the overload warning system............................................................................239
Putting the overload warning system out of operation..........................................................................240
Pipe break protection, function ............................................................................................... 241
Electromagnet MOZELT (option) ............................................................................................. 242

Description of the electromagnet lifting system (MOZELT) .....................................................................244
Range of application ..........................................................................................................................244
Scope of supply .................................................................................................................................244
Electric generator drive ......................................................................................................................245
States-of-operation display.................................................................................................................245
Putting the electromagnet (MOZELT) into operation ..............................................................................246
Putting the electromagnet into operation ............................................................................................246
Activating the magnet ........................................................................................................................248
Deactivating the magnet ....................................................................................................................248
Multifunction display MFD I status indication..........................................................................................250

Rotary beacon (option)............................................................................................................. 253

Installing the rotary beacon....................................................................................................................253
Switching on the rotary beacons.........................................................................................................253
Switching off the rotary beacons.........................................................................................................253
Switching the floodlamps on and off....................................................................................... 254

Switching on the floodlamps...............................................................................................................254
Switching off the floodlamps...............................................................................................................254
Floodlamps at the rear of cab, switching on / off ....................................................................................255
Switching on the floodlamps...............................................................................................................255
Radio ....................................................................................................................................................256
Environmentally Compatible Hydraulic Fluid (biodegradable) ............................................. 258

Environmentally compatible hydraulic fluid, Operator's Manual ..............................................................258
PANOLIN HLP SYNTH 46.....................................................................................................................258
Environmentally compatible hydraulic fluid, conversion ..........................................................................258
Environmentally compatible hydraulic fluid, sampling.............................................................................259
Refuelling system ..................................................................................................................... 260

Refuelling with the refuelling system, safety instructions ........................................................................260
Refuelling with the refuelling station.......................................................................................................262
Air conditioner, switching on / off (option) ............................................................................. 264

Switching on the air conditioner .............................................................................................................264
Adjusting the air temperature.................................................................................................................264
Switching off the air conditioner .............................................................................................................265
Switching on recirculated air..................................................................................................................265
Switching off recirculated air..................................................................................................................265
Display settings ........................................................................................................................ 266

Display settings, main menu..................................................................................................................267
Display contrast .................................................................................................................................267
Display, setting the contrast ...............................................................................................................267
Display brightness .................................................................................................................................269
Display, setting the brightness............................................................................................................269
Display, time .........................................................................................................................................269
Display, setting the time .....................................................................................................................269
Setting the time, 12-hour display ........................................................................................................269
Setting the time, 24-hour display ........................................................................................................271
Setting the date..................................................................................................................................271
Display, setting the units of measurement..............................................................................................273
Display, setting the language.................................................................................................................274
Display, Information.................................................................................................................. 276

PART 3 – INSPECTION AND SERVICING ..................................................279
Inspection and Servicing, Safety Instructions ........................................................................ 281
Inspection and servicing plans, instructions.......................................................................... 288

Warranty ...............................................................................................................................................288
Intervals ................................................................................................................................................288
Inspection and servicing plans to be observed depending on operating hours........................................289
Regular oil analyses ..............................................................................................................................289
Engine oil change..................................................................................................................................289
Oils / greases ........................................................................................................................................289
Cleaning work .......................................................................................................................................289
Servicing materials ................................................................................................................................289
Further maintenance work .....................................................................................................................289
Plan V – Once before first commissioning.............................................................................. 290
Plan T - Every 10 OH or per working shift ............................................................................... 291
Plan W - Every 50 OH or weekly............................................................................................... 291
Plan N – Once after 250 OH...................................................................................................... 292
Plan A – First service at 750 OH .............................................................................................. 293
Plan B – First service at 500 OH .............................................................................................. 293
Plan C – First service at 1000 OH............................................................................................. 293
Plan D – First service at 3000 OH............................................................................................. 293
Lubricating chart – grease Working equipment ..................................................................... 296

Working equipment from other manufacturers:.......................................................................................297
Lubricating chart - grease Undercarriage ............................................................................... 298

Refilling quantities – Grease ..................................................................................................................299
Joints and hinges ..................................................................................................................... 299
Central lubrication system (LINCOLN) / option ...................................................................... 300

Safety instructions .................................................................................................................................300
Visual function check.............................................................................................................................301
Lubricants .............................................................................................................................................301
Reservoir pump.....................................................................................................................................302
Technical characteristics of the resevoir pump ...................................................................................302
Time settings.........................................................................................................................................302
Test run / Triggering a supplementary greasing interval .........................................................................303
Refilling the reservoir pump ...................................................................................................................304
Hand-operated refilling pump .............................................................................................................304
Other uses of the hand pump: ............................................................................................................304
Motor-driven refilling pump.................................................................................................................304
Central lubrication system, fault table ....................................................................................................306
Faults in the central lubrication pump .................................................................................................306
Faults in system connected to the pump.............................................................................................307

Oil inspection plan .................................................................................................................... 308

Oil change refilling quantities.................................................................................................................309
Refilling quantities - Other .....................................................................................................................309
Lubricants ................................................................................................................................. 310

I. Oils for internal combustion engines (change interval 500 OH) Standard..........................................310
I. Oils for internal combustion engines (change interval 250 OH) Option .............................................311
II. Oils for Hydraulic System, mineral ...................................................................................................312
II. Oils for Hydraulic System, synthetic (biodegradable)........................................................................313
III. Oils for Axles and Gearboxes (Selection).........................................................................................314
V. Greases for Bearing Points and Slewing Rings.................................................................................315
VI. Grease for the Slewing Ring Gearing ...............................................................................................316
Servicing.................................................................................................................................... 317
Draining hose for oil changes ................................................................................................................317
Engine........................................................................................................................................ 318
Engine and engine compartment, safety instructions for inspection and servicing ..................................318
Engine, checking the oil level / topping up oil .........................................................................................319
Changing the engine oil.........................................................................................................................320
Replacing the engine oil filter.................................................................................................................321
Checking the V-belt tensioner (automatic) .............................................................................................322
Drive belt, visual check..........................................................................................................................323
Replacing the drive belt .........................................................................................................................324
Cleaning the speed sensor ....................................................................................................................325
Checking the coolant level, topping up coolant ......................................................................................326
Risk of scalding..................................................................................................................................326
Topping up coolant ............................................................................................................................326
Coolant losses ...................................................................................................................................327
Replacing the coolant ............................................................................................................................328
Checking / adjusting the valve clearance ...............................................................................................330
Engine support, checking the screws for tight fit.....................................................................................332
Air intake system ...................................................................................................................... 333

Cleaning the dust removal valve............................................................................................................333
Removing, checking and cleaning of the main filter element ..................................................................334
Checking / replacing the safety filter element .........................................................................................336
Checking the air inlet lines.....................................................................................................................336
Fuel system ............................................................................................................................... 337

Fuel system, safety instructions.............................................................................................................337
Replacing the fuel filter ..........................................................................................................................338
Bleeding the fuel system .......................................................................................................................339
Fuel tank, draining off water and deposits..............................................................................................340
Cleaning the fuel tank............................................................................................................................341
Electrical system....................................................................................................................... 342

Electrical system, safety instructions......................................................................................................342
Alternator, instructions...........................................................................................................................342
Battery, checking the fluid level .............................................................................................................343
Battery – Checking the Charge ..........................................................................................................343
Winter Operation................................................................................................................................343
Charging the batteries ...........................................................................................................................344
Maintenance charge / Recharging......................................................................................................344
Rapid charging...................................................................................................................................344
Replacing of battery ..............................................................................................................................344
Removing and installing the battery .......................................................................................................345

Hydraulic system ...................................................................................................................... 346

Hydraulic system, safety instructions .....................................................................................................346
Checking the hydraulic oil level..............................................................................................................346
Depressurizing the hydraulic system......................................................................................................347
Topping up hydraulic oil.........................................................................................................................348
Replacing the hydraulic oil return-flow filter............................................................................................349
Replacing the breather valve .................................................................................................................350
Replacing the pilot-control filter..............................................................................................................351
Changing the hydraulic oil .....................................................................................................................352
Draining off hyraulic oil.......................................................................................................................352
To drain off hydraulic oil from the cooler: ............................................................................................352
Cleaning the hydraulic oil reservoir ........................................................................................................353
Filling in hydraulic oil .............................................................................................................................354
Bleeding the hydraulic system ...............................................................................................................355
Bleeding the floating-axle supporting cylinders.......................................................................................356
Combined radiator .................................................................................................................... 357

Cleaning the combined radiator .............................................................................................................357
Slewing gearbox ....................................................................................................................... 358

Slewing gearbox, checking the oil level..................................................................................................358
Slewing gearbox, changing the oil .........................................................................................................359
Superstructure holding brake, checking the operation............................................................................360
Slewing ring............................................................................................................................... 361

Slewing ring, instructions.......................................................................................................................361
Slewing ring, greasing the bearing.........................................................................................................361
Slewing ring, checking / changing the grease filling................................................................................362
Slewing ring, checking the screws for tight fit .........................................................................................363
Slewing gear, checking the screws for tight fit........................................................................................363
Counterweight, checking the screws for tight fit.................................................................... 364
Lubricating the greasing nipples ............................................................................................. 364
Floating-axle cylinder, greasing the bearing faces ................................................................ 365
Axles and travel gearboxes...................................................................................................... 366

Rigid axle and travel gearbox, checking the oil level ..............................................................................366
Before beginning the work..................................................................................................................366
Check the oil level in the wheel-hub gears..........................................................................................366
Checking the oil level in axle and travel gearbox ................................................................................366
Rigid axle and travel gearbox, changing the oil ......................................................................................368
Draining the oil...................................................................................................................................368
Filling in oil.........................................................................................................................................369
Steered axle gearbox, checking the oil level ..........................................................................................371
Planetary gearbox of steering axle, checking the oil level.......................................................................372
Planetary wheel-hub gears of steering axle, changing the oil .................................................................373
Wheel-hub gear of steering axle, changing the oil..................................................................................374
Draining off oil....................................................................................................................................374
Filling in oil.........................................................................................................................................375
Adjusting the wheel angle......................................................................................................................376
Brakes........................................................................................................................................ 377
Working on brakes, safety instructions...................................................................................................377
Service brake ............................................................................................................................ 378

Brake disks, checking the lining thickness..............................................................................................378

Bleeding the multiple-disk brake ............................................................................................. 379
Tyres and wheels ...................................................................................................................... 380

Tyres and wheels, safety instructions ....................................................................................................380
Tyre pressure, checking and topping up ................................................................................................382
Tyres – sizes / pressures / travelling speeds..........................................................................................384
For excavators with monoboom equipment ........................................................................................384
For excavators with boom adjusting equipment ..................................................................................384
Changing a wheel..................................................................................................................................386
Wheels, tread position........................................................................................................................387
Screenwasher ........................................................................................................................... 388

Topping up wash fluid............................................................................................................................388
Heating....................................................................................................................................... 389
Cleaning / replacing the air filter element ...............................................................................................389
Air conditioning system (option) ............................................................................................. 390

Safety instructions for inspection and servicing work..............................................................................390
Air conditioner, inspection and servicing work........................................................................................392
Location of conditioner components in the machine............................................................................392
In the cab:..........................................................................................................................................393
In the engine compartment.................................................................................................................394
In the battery compartment ................................................................................................................394
Work to be performed every month (machine operator) ......................................................................394
Work to be performed every 6 months (Approved special workshop) ..................................................395
Work to be performed every 2 years (Approved special workshop) .....................................................395
Air conditioner, checking / retensioning / replacing the compressor belt .................................................396
Air conditioner fault tables .....................................................................................................................398
Blower malfunctions...........................................................................................................................398
Insufficient cooling performance.........................................................................................................399
Insufficient heating performance ........................................................................................................400
Conditioner very noisy........................................................................................................................401
Machine care ............................................................................................................................. 402

Washing the machine by hand...............................................................................................................402
Washing the machine with a high-pressure cleaner ...............................................................................402
Conservation.........................................................................................................................................403
Polishing ...............................................................................................................................................403
Damaged paintwork ..............................................................................................................................403
Cab windows / mirrors ...........................................................................................................................403
Plastic parts and artificial leather ...........................................................................................................403
Upholstery and fabric coverings.............................................................................................................403
Cleaning the safety belt .........................................................................................................................403
Rims .....................................................................................................................................................403
Engine, pump and radiator assembly compartment, slewing gearbox, rotor, control block, connections..404
General Work ............................................................................................................................ 405

Putting the machine out of operation......................................................................................................405
Storing the battery / batteries.................................................................................................................405
Recommissioning ..................................................................................................................................405

PART 4 – REPAIR WORK ............................................................................407
Repair work, safety instructions .............................................................................................. 409
Accumulators, safety instructions........................................................................................... 410
Engine........................................................................................................................................ 411
Engine, repair instructions .....................................................................................................................411
Alternator, replacing the drive belt .........................................................................................................411
Assisted Starting (with jumper cables), Safety Instructions.................................................. 411
Assisted starting (with jumper cables).................................................................................... 412

Prior to assisted starting ........................................................................................................................412
Connecting the jumper cables ...............................................................................................................412
Starting up the engines..........................................................................................................................413
Fuses ......................................................................................................................................... 414

Checking / replacing the fuses...............................................................................................................414
Table of fuses........................................................................................................................................416
Bulbs.......................................................................................................................................... 418
Replacing the bulbs, instructions ...........................................................................................................418
Bulbs - Table.........................................................................................................................................418
Replacing the lamp bulb of the cab interior lamp....................................................................................418
Replacing the lamp bulb of the cab floodlamp........................................................................................419
Replacing the lamp bulb of the boom floodlamp.....................................................................................419
Replacing the headlamp bulb ................................................................................................................420
Replacing the lamp bulb in the front direction indicator lamp ..................................................................420
Replacing the lamp bulb of the tail-light .................................................................................................421
Working equipment, replacing the slip-on tooth .................................................................... 422
Trenching Grab, Wear Limits ................................................................................................... 423
Welding operations................................................................................................................... 424

Welding operations, safety instructions..................................................................................................424
General welding instructions..................................................................................................................425
Protecting electronic modules during welding operations .......................................................................426
Removing electronic modules and disconnecting plug and grounding connections .............................426
1st point (PCS) ..................................................................................................................................426
nd
2 point (CU).....................................................................................................................................427
rd
3 point (ESX) ...................................................................................................................................427
Effect of electromagnetic fields and electrostatic discharges ..................................................................429

PART 5 – ANNEX .........................................................................................431
Troubleshooting........................................................................................................................ 433
Instructions for troubleshooting..............................................................................................................433
Fault table layout ...................................................................................................................................433
Fault tables................................................................................................................................ 434

Combustion engine fault table ...............................................................................................................434
Steering system fault table ....................................................................................................................435
Service brake and parking brake fault table ...........................................................................................436
Working hydraulics (incl. boom-adjusting and grab cylinder) fault table ..................................................438
Transmission fault table.........................................................................................................................440
Slewing system fault table .....................................................................................................................441
Floating-axle blocking fault table............................................................................................................442
Stabilizing system (PLA - A 2) fault table ...............................................................................................443
Hammer operation (optional equipment) fault table ................................................................................444
Grab rotation circuit (optional equipment) fault table ..............................................................................445
Fault codes................................................................................................................................ 446

General information on fault codes ........................................................................................................446
Table of tightening torques ....................................................................................................................448
List of abbreviations ................................................................................................................. 450
Index .......................................................................................................................................... 453


2245128-en


2245128-en

PART 1 – INTRODUCTION 2261176-en
Operator's Manual Target group

FUNDAMENTAL +
SAFETY INSTRUCTIONS Inspection and servicing personnel
+
Repair personnel
The operating personnel must have know-how
relevant to the operation and the application
Part 3 INSPECTION Inspection and servicing personnel

The inspection and servicing personnel must
AND SERVICING have know-how relevant to the inspection and
servicing of this or comparable machines.

The repair personnel must have know-how
and experience relevant to the repair of this or

+
+
Repair personnel
o


2245128-en

Preface 10000270-en
This Operator's Manual is designed to familiarize Our service department will be pleased to deal
the operator with the machine and its designated with any queries you may have after reading
use. through the Operator's Manual.
The Operator's Manual contains important in- All Operator's Manuals are issued in German and
structions on how to operate the machine safely, then translated. Even a good translation may give
properly and with maximum efficiency. Observing rise to questions, which we will be pleased to an-
these instructions helps to prevent hazardous swer.
situations, to cut repair costs and downtimes, and
The Operator's Manual does not comprise work-
to increase the reliability and service life of the
ing instructions for carrying out major repairs.
machine.
Such work is willing done for you by our service
The Operator's Manual must be supplemented with department.
the respective national rules and regulations for
The documentation relating to the machine is listed
accident prevention and environmental pro-tection.
according to scope, quantity and language in the
shipping note of the machine or in the cov-ering
letter if supplied separately. The Operator's Manual
The Operator's Manual must always and spare-parts lists are marked with the serial
be available in the driver’s cab of number of the machine.
the machine.
On taking receipt of the consignment, please
check that the documentation is complete and in
the language requested by you.
The Operator's Manual must be read and applied
by any person authorized to carry out work with /
on the machine, e.g.
Warranty
- operation, including setting-up, troubleshooting
in the course of work, care, disposal of fuels and One of the preconditions for the granting of the
consumables, warranty by the manufacturer is that all inspection,
servicing and repair work is carried out properly in
- maintenance (inspection, servicing, repair) and / accordance with Part 3 of this Operator's Manual
or and that original spares are used.
- transport. The daily and weekly servicing can be carried out
In addition to the Operator's Manual and the man- by the machine operator.
datory rules and regulations for accident pre- Within the warranty period, all inspection, ser-
vention and environmental protection in the user’s vicing and repair work, with the exception of the
country and at the location where the machine is to daily and weekly inspection and servicing, is to be
be used, the generally recognized technical rules carried out by our service department or by work-
1)
for safe and proper working must be ob-served. shops authorized by us.
The Operator's Manual is directed to the con- The implementation of the inspection, servicing
struction machine specialist. They cannot provide and repair work must be documented in our
basic know-how. This can be acquired, for exam- "Service Booklet".
ple, in several days’ instruction by our qualified
mechanic or by attending our training course for o
operators or maintenance personnel.
1)
Complies with VDMA recommendation “Operator's Manual“

Service Booklet 10000119-en Fundamental saftey instruc-

tions 2261165-en
The Service Booklet is handed to you by our serv-

ice department on the initial commissioning of the Complies with VDMA recommendation 'Operator's Manual'
machine.
Warnings and symbols
The Service Booklet records/contains:
The following signs are used in the manual to
· the date on which the machine was initially designate instructions of particular importance:
commissioned (start of warranty period);
· transfer documents for the machine and for the
auxiliary and working equipment; Precautionary rules and measures
designed to protect the machine
· auxiliary and working equipment supplied by operator and other persons from
third parties (this is essential to subsequent pro- life-threatening danger or injuries
vision of the declaration of conformity); and to prevent extensive damage.
· the service department responsible for the custo-
mer;
Information and precautionary mea-
· the name and address of the owner and user of sures designed to prevent damage
the machine; to the machine or other property.
· the servicing performed on the item delivered ex o
works up to 6000 operating hours.
The transfer documents provided in the Service

Booklet for the machine and for the auxiliary and
working equipment have to be signed and stamped
by the customer after transfer of the machine to the
customer.
The copies for the manufacturer are returned to us
by our service department. Only when these
documents have been submitted can the validity of
the warranty for the respective construction ma-
chine be confirmed by us.
The respective service voucher is filled in by our
service department after execution of the work.
The Service Booklet must always be

kept with the machine so that the
machine operator and our service
department have an overview of the
service status of the machine at all
times.
o

Designated use 2732687.01-en
The machine has been built in accordance with Using the excavator or its attach-
state-of-the-art standard and recognized safety ments for purposes other than or
regulations. Nevertheless, its use may constitute a extending beyond those stated
risk to life and limb for the user or third parties or above, e.g.:
may cause damage to the machine and to other
material property. - for lifting or transporting persons,
The machine must be used only in technically - as a working platform,

perfect condition and in accordance with its desig- - for lifting crane loads without the
nated use and the instructions set out in the Op- equipment being approved for this
erator's Manual, and only by safety-conscious per- purpose,
sons who are fully aware of the risks involved in
operating the machine. Any functional disorders, - for pulling slung loads,
especially those affecting the safety of the ma- - for driving in posts, supports,
chine, should therefore be rectified immediately. sheet-piles etc. without the equip-
The excavator with backhoe, grab or loading ment being approved for this pur-
bucket attachment is designed solely for exca- pose,
vating and loading excavated soils, sand, gravel, is considered contrary to the desig-
blasted rock, ore, coal and other raw materials. nated use.
With other working equipment mounted, the exca- Improper use may involve a life-
vator can also be used as a special-purpose ma- threatening risk to operators or
chine, e.g. for drilling, for lifting loads, or with a other personnel or may cause injury
hydraulic hammer. Precise details are given in the or extensive damage.
Technical Data.
Operating the machine in accordance with the The manufacturer / supplier cannot be held res-
designated use also involves observing the in- ponsible for any damage resulting from other than
structions set out in the Operator's Manual and the designated use. The risk involved in such mis-
complying with the inspection and maintenance use lies solely with the user.
directives.
Noise emission specifications in accordance with
the 3rd Ordinance of the Machine Safety Act of
18.01.1991 and/or EC Machine Directive, Annex I,
The maximum temperature of use
section 1.7.4 f.
(air temperature) for the machine is
45°C. Using the machine beyond the If the earthmoving machine is operated in accord-
maximum ambient temperature limit ance with the designated use, the installation of
is not permitted. driver’ seats complying with ISO 7096 ensures that
the evaluated vibration accelerations azw (meas-
ured as per ISO 2631, Part 1) meet the require-
ments for protection from whole-body vibration.
o

Organizational measures 2261965-en
The Operator's Manual must always be at hand at Observe all safety instructions and warning at-
the place of use of the machine, e.g. by stowing tached to the machine.
them in the tool compartment or tool box provided
See to it that safety instructions and warnings
for such purposes.
attached to the machine are always complete and
In addition to the Operator's Manual, observe and perfectly legible.
instruct the user in all other generally applicable
In the event of safety-relevant modifications or
legal and other mandatory regulations relevant to
changes in the behaviour of the machine during
accident prevention and environmental protection.
operation, stop the machine immediately and re-
These compulsory regulations may also deal with port the malfunction to the competent autho-
the handling of hazardous substances, issuing rity/person.
and/or wearing of personal protective equipment
Never make any modifications, additions or con-
or traffic regulations.
versions which might affect safety without the
The Operator's Manual must be supplemented by supplier's approval. This also applies to the in-
instructions covering the duties involved in super- stallation and adjustment of safety devices and
vising and notifying special organizational fea- valves as well as to welding work on load-bearing
tures, such as job organization, working se- elements.
quences or the personnel entrusted with the work.
Spare parts must comply with the technical re-
Personnel entrusted with work on the machine quirements specified by the manufacturer. Spare
must have read the Operator's Manual and in parts from original equipment manufacturers can
particular the chapter on safety before beginning be relied on to do so.
work. Reading the instructions after work has
Replace hydraulic hoses within stipulated and
begun is too late. This applies especially to per-
appropriate intervals, even if no safety-relevant
sons working only occasionally on the machine,
defects have been detected.
e.g. during setting up or maintenance.
Adhere to prescribed intervals or those specified
Check - at least from time to time - whether the
in the Operator's Manual for routine checks and
personnel is carrying out the work in compliance
inspections.
with the Operator's Manual and paying attention to
risks and safety factors. For the execution of maintenance work, tools and
workshop equipment adapted to the task on hand
For reasons of security, long hair must be tied
are absolutely indispensable.
back or otherwise be secured, garments must be
close-fitting and no jewellery, incl. rings, may be The personnel must be familiar with the location
worn. Injury may result from being caught up in and operation of fire-extinguishers.
the machinery or from winding up
Observe all fire-warning and fire-fighting pro-
Use protective equipment wherever required by cedures.
the circumstances or by law.
è

Selection and qualification of personnel, Saftey instructions governing specific

basic responsibilities operational phases
Any work on and with the machine must be exe- Standard operation
cuted by reliable personnel only. Statutory mini-
mum age limits must be observed. Avoid any operational mode that might be pre-
judicial to safety.
Employ only trained or instructed staff and set out
clearly the individual responsibilites of the person- Before beginning work, familiarize yourself with
nel for operation, set-up, maintenance and repair. the surroundings and circumstances of the site,
such as obstacles in the working and travelling
Make sure that only authorized personnel works area, the soil bearing capacity and any barriers
on or with the machine. separating the construction site from public roads.
Define the machine operator's responsibilities - Take the necessary precautions to ensure that the
also with regard to observing traffic regulations - machine is used only when in a safe and reliable
giving the operator the authority to refuse in- state.
structions by third parties that are contrary to
safety. Operate the machine only if all protective and
safety-oriented devices, such as removable safety
Do not allow persons to be trained or instructed or devices, emergency shut-off equipment, sound-
persons taking part in a general training course to proofing elements and exhausters, are in place
work on or with the machine without being perma- and fully functional.
nently supervised by an experienced person.
Check the machine at least once per working shift
Work on the electrical system and equipment of for obvious damage and defects. Report any
the machine must be carried out only by a skilled changes (incl. changes in the machine's working
electrician or by instructed persons under the behaviour) to the competent organization/person
supervision and guidance of a skilled electrician immediately. If necessary, stop the machine im-
and in accordance with electrical engineering mediately and lock it.
rules and regulations.
In the event of malfunctions, stop the machine
Work on chassis, brake and steering systems immediately and lock it. Have any defects rectified
must be performed by skilled personnel only, immediately.
which has been specially trained for such work.
Start the machine from the driver's seat only.
Work on the hydraulic system must be carried out
only by personnel with special knowledge and During start-up and shut-down procedures always
experience of hydraulic equipment. watch the indicators in accordance with the Op-
erator's Manual.
Before setting the machine in motion, make sure
that nobody is at risk.
Before starting work or travelling with the ma-
chine, check that the braking, steering, signalling
and lighting systems are fully functional.
Before setting the machine in motion, always
check that the accessories have been safely
stored away.
When travelling on public roads, ways and places
always observe the valid traffic regulations and, if
necessary, make sure beforehand that the ma-
chine is in a condition compatible with these regu-
lations.
In conditions of poor visibility and after dark, al-
ways switch on the lighting system.
è

Persons accompanying the driver must be seated Special work in conjunction with utilisa-
on the passenger seats provided for this purpose. tion of the machine and maintenance and
When crossing underpasses, bridges and tunnels repair work during operation, disposal of
or when passing under overhead lines, always parts and consumables
make sure that there is sufficient clearance.
Observe the adjusting, maintenance and in-
Always keep at a distance from the edges of spection activities and intervals set out in the Op-
building pits and slopes. erator's Manual, including information on the re-
Avoid any operation that might be a risk to ma- placement of parts and equipment. These activi-
chine stability. ties may be executed by skilled personnel only.
Never travel across slopes; always keep the Brief operating personnel before beginning special
working equipment and the load close to the operations and maintenance work, and appoint a
ground, especially when travelling downhill. person to supervise the activities.
On sloping terrain always adapt your travelling In any work concerning the operation, conversion
speed to the prevailing ground conditions. Never or adjustment of the machine and its safety-
change to a lower gear on a slope but always be- oriented devices or any work related to main-
fore reaching it. tenance, inspection and repair, always observe
the start-up and shut-down procedures set out in
Before leaving the driver's seat, always secure the the Operator's Manual and the information on
machine against inadvertent movements and un- maintenance work.
authorised use. Shut off the engine.
Ensure that the maintenance area is adequately
secured.
If the machine is completely shut-down for main-
tenance and repair work, it must be secured
against inadvertent starting by:
- removing the ignition key and
- attaching a warning sign.
Carry out maintenance and repair work only if the
machine is positioned on stable and level ground
and has been secured against inadvertent move-
ment and buckling.
To avoid the risk of accidents, individual parts and
large assemblies being moved for replacement
purposes should be carefully attached to lifting
tackle and secured. Use only suitable and tech-
nically perfect lifting gear and suspension systems
with adequate lifting capacity. Never work or stand
under suspended loads.
The fastening of loads and the instruction of crane
operators should be entrusted to experienced
persons only. The marshaller giving the instruc-
tions must be within sight or sound of the oper-
ator.
For carrying out overhead assembly work, always
use specially designed or otherwise safety-ori-
ented ladders and working platforms. Never use
machine parts as a climbing aid.
è

Wear a safety harness when carrying out main- Warning of special dangers
tenance work at greater heights.
Electric energy
Keep all handles, steps, handrails, platforms, lan-
dings and ladders free from dirt, snow and ice. Use only original fuses with the specified current
rating. Switch off the machine immediately if trou-
Clean the machine, especially connections and
ble occurs in the electrical system.
threaded unions, of any traces of oil, fuel or pre-
servatives before carrying out maintenance or When working with the machine, maintain a safe
repair. Never use aggressive detergents. Use lint- distance from overhead electric lines. If work is to
free cleaning rags. be carried out close to overhead lines, the working
equipment must be kept well away from them.
Before cleaning the machine with water or steam CAUTION: DANGER. Check out the prescribed
jet (high-pressure cleaning) or detergents, cover
safety distances.
or tape up all openings which - for safety and
functional reasons - must be protected against If your machine comes into contact with a live
water, steam or detergent penetration. Special wire:
care must be taken with electric motors and
- Do not leave the machine
switchgear cabinets.
- Drive the machine out of the hazard zone; warn
Ensure during cleaning of the machine that the
others against approaching and touching the
temperature sensors of the fire-warning and fire-
machine
fighting systems do not come into contact with hot
cleaning agents, as this might activate the fire- - Have the live wire de-energized
fighting system.
- Do not leave the machine until the damaged line
After cleaning, remove all covers and tapes ap- has been safely de-energized.
plied for that purpose.
The electrical equipment of machines is to be
After cleaning, examine all fuel, lubricant and hy- inspected and checked at regular intervals. De-
draulic fluid lines for leaks, loose connections, fects, such as loose connections or scorched ca-
chafe marks and damage. Any defects found must bles, must be rectified immediately.
be rectified without delay.
Always tighten any screwed connections that
have been loosened during maintenance and Gas, dust, steam and smoke
repair. Operate internal combustion engines and fuel-
Any safety devices removed for set-up, main- operated heating systems only on adequately
tenance or repair purposes must be refitted and ventilated premises. Before starting the machine
checked immediately upon completion of the on enclosed premises, make sure that there is
maintenace and repair work. sufficient ventilation.
Ensure that all consumables and replaced parts Observe the regulations in force at the respective
are disposed of safely and with minimum en- site.
vironmental impact. Carry out welding, flame-cutting and grinding work
on the machine only if this has been expressly
authorised, as there may be a risk of explosion
and fire.
Before carrying out welding, flame-cutting and
grinding operations, clean the machine and its
surroundings from dust and other inflammable
substances and make sure that the premises are
adequately ventilated (risk of explosion).
è

Hydraulic and pneumatic equipment Transporting and towing, recommission-

Check all lines, hoses and screwed connections
ing
regularly for leaks and obvious damage. Repair The machine must be towed, loaded and trans-
damage immediately. Splashed oil may cause in- ported only in accordance with the Operator's
jury and fire. Manual.
Depressurize all system sections and pressure For towing the machine, observe the prescribed
pipes (hydraulic system, compressed-air system) transport position, admissible speed and itinerary.
to be removed in accordance with the specific
instructions for the unit concerned before carrying Use only appropriate means of transport and lift-
out any repair work. ing gear of adequate capacity.
Hydraulic and compressed-air lines must be laid The recommissioning procedure must be strictly in
and fitted properly. Ensure that no connections accordance with the Operator's Manual.
are interchanged. The fittings, lengths and quality o
of the hoses must comply with the technical re-
quirements.
Noise
During operation, all sound baffles of the machine
must be closed.
Always wear the prescribed ear protectors.
Oil, grease and other chemical substances

When handling oil grease and other chemical
substances, observe the product-related safety
regulations.
Be careful when handling hot consumables (risk
of burning and scalding).


2245128-en


2245128-en

PART 2 – OPERATION 2261177-en

FUNDAMENTAL SAFETY IN- +
STRUCTIONS Inspection and servicing personnel
+
Repair personnel
Part 3 INSPECTION AND SERVICING Inspection and servicing personnel

have know-how relevant to the inspection and


+
+
Repair personnel
o


2245128-en

Operation, safety instructions 2905697-en
Operator's Manual Safety belt

Never operate the machine before For machines with a safety belt for
having read and understood the operating personnel:
Operator's Manual.
Check safety belt attached to dri-
Pay special attention to: ver's seat. In the event of damage or
after an accident, have it replaced
"Fundamental safety instructions"
immediately.
and all warning and safety instruc-
tions attached to the machine. Apply safety belt before starting
work.
Familiarize yourself with the layout,
the functioning and the activating
devices of the control elements
prior to starting up the machine. State of the machine
Activate the control elements from Operate the machine only in a safe
the driver's seat only. state and only in accordance with
its designated use. Always observe
Keep the Operator's Manual with the the safety instructions.
machine (in driver's cab) at all
times. Always have inspection and mainte-
nance work carried out on schedule.
Operate the machine only with the
Operating personnel equipment and component combi-
nations approved by the manufac-
The operating personnel must be
turer. Clear-cut data are given in the
fully informed of the operation and
Technical Data.
application of this or comparable
machines. Never install and commission other
equipment and component combi-
The necessary know-how can be
nations without the manufacturer
acquired in several days' instruc-
having first inspected and approved
tion, e.g. by our mechanics or by
the project.
attending our operators' training
course. Before starting work or travelling
with the machine, check that the
braking, steering, signalling and
Personal protective gear and lighting systems are fully functional.
working clothing Poor visibility may result in acci-
Wear a safety helmet and working dents. Always clean the windows
footwear with non-slip soles. and the glass covers of all lights
before starting up the machine.
Smooth soles may slip from steps
and pedals resulting in injury or in- Check that all warnings and safety
correct operation. instructions attached to the ma-
chine are present and legible.
Wear closely fitting working cloth-
ing when operating the machine.
Loose, wide garments may result in
the control lever being inadvertently
activated.

Entering and leaving the ma- Marshallers

chine The marshaller must keep outside
Always face the machine when en- the hazard zone.
tering and leaving. Seek assistance from a marshaller:
Use only the steps, platforms and - when you have no clear overview
handrails provided when entering over the hazard zone of the ma-
and leaving the machine. chine,
Always keep steps and platforms, - when reversing,
handles and handrails in a non-slip,
safe state and remove any oil, - when shunting.
grease, soil, clay, snow, ice and Use only those communication sig-
other foreign matter immediately. nals which you and the marshaller
understand, or use aids for commu-
nication (e.g. walkie-talkie / camera).
Hazard range Calls cannot be understood by the
marshaller because of the noise by
The hazard zone is that zone around the machine during operation.
the machine in which persons are
within reach of falling load or falling Keep constant contact with the mar-
attachments due to operational shaller.
movements by the machine, to its Stop the machine immediately if you
equipment and attachments or to lose contact with the marshaller.
swinging loads.
Securing the machine

Persons within the hazard
zone Secure the machine as described in
the section "Securing the machine"
Always use the horn to warn per- before:
sons in the immediate vicinity of the
machine before starting up the ma- - mounting or dismantling the at-
chine. tachment,
- parking the machine after daily
Ensure that no one sets foot in the
operation,
hazard zone of the machine. Inter-
rupt work until such persons have - Carry out servicing or repair work.
left the hazard zone.


2245128-en

Description of the machine (monoblock boom) 10000480.00-en
Fig. 1 è

Machine layout Undercarriage

(Key to Fig. 1) The undercarriage of the hydraulic excavator is
used as a stable base and for travelling.
1 - Batteries
The undercarriage is moreover equipped with
2 - Combined radiator
components permitting stabilization of the machine
3 - Engine during working operations, such as the levelling
blade and the outriggers.
4 - Exhaust silencer
The machine is driven hydraulically by oil motors
5 - Hydraulic oil reservoir
and travel gearboxes acting on both axles.
6 - Hydraulic pumps Undercarriage and superstructure are connected
7 - Counterweight by a slewing ring.
8 - Fuel tank Superstructure

9 - Air intake system The superstructure accommodates the drive en-
gine and part of the hydraulic and electrical sys-
10 - Slewing gearbox tems.
11 - Rotor The superstructure carries also the working equip-
ment.
12 - Bucket
13 - Toggle link Hydraulic system
14 - Toggle lever All travelling and working movements are executed
hydraulically. The working commands are initiated
15 - Bucket cylinder manually and transmitted electronically. The oil
flow between superstructure and undercarriage is
14 - Stick
ensured by the rotor. The hydraulic system is pro-
15 - Stick cylinder tected against overloading by pressure relief
valves.
18 - Monoblock boom
19 - Boom cylinder Steering
20 - Stabilization / outriggers The machine is equipped with a hydrostatic power

steering system, i.e it can be steered by hand with
21 - Rigid axle increased force when the engine is not running or
when the hydraulic steering pump has failed.
22 - Slewing ring
23 - Tool box Service brake
The service brake is composed of four multiple-
24 - Access ladder
disk brakes integrated in the wheel-hubs. The
25 - Cardan shaft brake is operated hydraulically.
26 - Steered axle To ensure the braking function at all times, the

braking system is equipped with hydraulic pressure
27 Stabilization / levelling blade accumulators which are permanently monitored.
28 Driver's cab è

Parking brake Electrical system

The parking brake can be applied by blocking the The electrical system operates on 24 volts. An
brake disks with spring pressure. The parking electronic voltage regulator supplies also 12 volts.
brake is incorporated in the travel gearbox and Electronic modules (Power Control System) en-
acts therefore on all the wheels. sure that the available engine power is converted
in the best possible way into hydraulic perform-
Floating axle ance.
The steered axle is a floating axle that can be Working equipment

blocked hydraulically during the work with two cyl-
inders. The working equipment is composed of the
monoblock boom, stick, toggle link with toggle
lever and bucket. Other digging or working equip-
ment can also be attached to the machine..
o


2245128-en

Description of the machine (boom adjusting equipment) 10000004.01-en
Fig. 1 è

Machine layout
(Legend of Fig. 1) Undercarriage
1 - Batteries The undercarriage of the hydraulic excavator is
used as a stable base and for travelling.
2 - Combined radiator
The undercarriage is moreover equipped with
3 - Engine
components permitting stabilization of the machine
4 - Exhaust silencer during working operations, such as the levelling
blade and the supporting legs.
5 - Hydraulic pumps
The machine is driven hydraulically by oil motors
6 - Hydraulic oil reservoir and travel gearboxes acting on both axles.
7 - Counterweight Undercarriage and superstructure are connected
by a slewing ring.
8 - Fuel tank
9 - Air intake system Superstructure
10 - Slewing gearbox The superstructure accommodates the drive en-

gine and part of the hydraulic and electrical sys-
11 - Rotor tems.
12 - Toggle link The superstructure carries also the working equip-

ment.
13 - Bucket cylinder
14 - Stick Hydraulic system
15 - Stick cylinder All travelling and working movements are executed

hydraulically. The working commands are initiated
16 - Upper boom manually and transmitted electronically. The oil
flow between superstructure and undercarriage is
17 - Boom cylinder ensured by the rotor. The hydraulic system is pro-
18 - Boom adjusting cylinder tected against overloading by pressure relief
valves.
19 - Lower boom
Steering
20 - Driver's cab
The machine is equipped with a hydrostatic power
21 - Levelling blade
steering system, i.e it can be steered by hand with
22 - Rigid axle with travel gearbox increased force when the engine is not running or
when the hydraulic steering pump has failed.
23 - Tool box
24 - Slewing ring Service brake
25 - Cardan shaft The machine is braked by means of hydraulically
operated multiple-disk brakes on all four twin
26 - Steered floating axle wheels. The service brake can be blocked in
braked position.
27 - Stabilizers
è
28 - Backhoe
29 - Connecting rod

Parking brake Electrical system

The parking brake can be applied by blocking the The electrical system operates on 24 volts. An
brake disks with spring pressure. electronic voltage regulator supplies also 12 volts.
Electronic modules (Power Control System) en-
The parking brake is incorporated in the travel sure that the available engine power is converted
gearbox and therefore acts on all the wheels. in the best possible way into hydraulic perform-
ance.
Floating axle
The steered axle is a floating axle that can be Working equipment
blocked hydraulically with two cylinders during the The working equipment is composed of the boom
work. (lower and upper) or monoblock boom, stick, tog-
gle link with connecting rod and bucket. Other dig-
ging or working equipment can also be attached to
the machine.
o

Machine parameters 10000795.00-en
CE-mark Engine number

The CE-mark (Fig. 1) certifies that the machine has The nameplate (Fig. 3) with the engine number is
been built in conformity with EC directives 89/392, attached to the engine.
91/368, 93/44, 93/68 and 98/37.
Fig. 1 Fig. 3
CE means "Communauté Européenne" (European

Community).
Maschine number Numbers of components and assemblies

The nameplate with the machine number is at- Other larger components are also equipped with
tached on the right side of the undercarriage nameplates bearing in particular the corresponding
(Fig. 2). The maximum admissible axle loads are serial number.
also mentioned on this sign.
In case of steel parts, the spare-parts part number
(P/N) or the manufacturing number may be
stamped into the metal in an eye-catching position.
Noise emission
Outside the machine
The sound intensity level LWA during operation is:
MH plus 104 dB(A)

MH 5.6 104 dB(A)
Fig. 2 Evaluated on identical machines in conformity with

the standard 2000/14/EC.
o

Warning and instruction signs (mono-boom) (Page 1 of 2) 10000803.00-en
Fig. 1 è

Observe the warning and instruc- 9. Risk of injury from electric current. Keep
tion signs attached to the ma-chine. the following distances from live wires:
Keep the signs clean and legible.
up to 1000 V (1 kV) = 1 meter,
Replace the signs immediately if
they are no longer legible. from 1 kV to 110 kV = 3 meters,
New warning and instruction signs from 110 kV to 220 kV = 4 meters,
can be obtained from our spare-
parts service. The part no. For orde- from 220 kV to 380 kV = 5 meters,
ring is set out in the spare-parts list
of your machine. unknown voltage = 5 meters.
10. The steering works only when the engine
Legend of Fig. 1 is running.
1. Risk of injury from moving parts of the 11. Check the oil level in the engine before
working equipment. Move the working putting the machine into operation.
equipment only after all persons have left 12. This signs shows all control levers and
the hazard zone. pedals and the movements of the working
2. This sign indicates that the working equip- equipment and the travelling gear initiated
ment reaches far out over the machine and with these elements. Observe also the
that it can be moved without moving the information set out in the operating instruc-
machine. tions.
3. Risk of injury from falling loads or moving 13. Risk of injury from hot or rotating parts in
parts of the working equipment. Do not the engine compartment. Open the hood of
stand under suspended loads or under the the engine compartment only after the
working equipment. engine is stationary.
4. The CE mark indicates that this machine 14. Emergency operation for slewing drive and
has been built in compliance with the parking brake. For detailed information
European directives concerning the safety refer to the operating instructions.
of machines. 15. Risk of injury from falling loads or moving
parts of the working equipment. Do not
LWA indicates the level of noise emissions stand under suspended loads or under the
in dBA (acc. To standard 2000/14/EC). working equipment.
5. Lifting gear can be attached here when 16. Type rating plate of the machine.
parts of the machine are to be removed.
17. Load capacity table
6. This sign specifies the approved tyres and The load capacity table corresponding to
the prescribed inflating pressure. the type of the machine (which must be at
7. This signs states the admissible maximum hand in the cab) shows the maximum ad-
speed for travelling on public roads. missible loads, the working range and the
conditions under which these loads may be
8. Do not put the machine into operation un- lifted with the machine. The lifting loads
less you have read and understood the are indicated in tons (t).
operating instructions.
è

Warning and instruction signs (mono-boom) (Page 2 of 2)
Fig. 2 è

Legend of Fig. 2
Observe the warning and instruc- 1. Alternator, regulator and electronic mod-
tion signs attached to the ma-chine. ules may be damaged, if the batteries are
disconnected with the engine running. The
engine must therefore be shut off before
Replace the signs immediately if the batteries are disconnected and re-
they are no longer legible. moved.
New warning and instruction signs 2. Hydraulic oil reservoir.
can be obtained from our spare- 3. Hydraulic oil reservoir. Observe the oper-
parts service. The part no. for orde-
ating instructions. The reservoir is filled
ring is set out in the spare-parts list with a special hydraulic fluid (option).
of your machine.
4. Fuel tank.
5. This sign shows the layout of the machine
points to be regularly greased. The sign
states also the change intervals for con-
sumables and filters.
A detailed list of all regular servicing activi-

ties is contained in the inspection and
maintenance schedules (Part 3 of these
operating instructions). Always perform
servicing in compliance with the mainte-
nance schedules.
6. and 7. These signs indicate the numbers
and the ratings of the fuses in the driver's
cab.
8. Risk of injury from slewing superstructure
or moving machine. Slew the superstruc-
ture and drive the machine only after all
persons have left the hazard zone.
9. Fastening means must be attached here
when the machine is to be transported.
10. Control elements for the auxiliary heating
system (option).
11. and 12. Safety marking
This plate shows that the machine, when
equipped with either one or two yellow
rotary beacons, is entitled to special rights
in terms of § 35 (6) German road traffic act
(StVO).
The respective traffic regulations in

force in the country of use must be
observed.

Warning and instruction signs (boom adjusting equipment) (Page 1 of 2) 10000804.00-en
Fig. 1 è

Observe the warning and instruction 9. Risk of injury from electric current. Keep
signs attached to the machine. the following distances from live wires:
up to 1000 V (1 kV) = 1 meter,
Replace the signs immediately if
they are no longer legible. from 1 kV to 110 kV = 3 meters,
New warning and instruction signs from 110 kV to 220 kV = 4 meters,
can be obtained from our spare-
parts service. The part no. for orde- from 220 kV to 380 kV = 5 meters,
ring is set out in the spare-parts list
of your machine. unknown voltage = 5 meters.
10. The steering works only when the engine
Legend of Fig. 1 is running.
1. Risk of injury from moving parts of the 11. Check the oil level in the engine before
working equipment. Move the working putting the machine into operation.
equipment only after all persons have left 12. This signs shows all control levers and
the hazard zone. pedals and the movements of the working
2. This sign indicates that the working equip- equipment and the travelling gear initiated
ment reaches far out over the machine and with these elements. Observe also the
that it can be moved without moving the information set out in the operating instruc-
machine. tions.
3. Risk of injury from falling loads or moving 13. Risk of injury from hot or rotating parts in
parts of the working equipment. Do not the engine compartment. Open the hood of
stand under suspended loads or under the the engine compartment only after the
working equipment. engine is stationary.
4. The CE mark indicates that this machine 14. Emergency operation for slewing drive and
has been built in compliance with the parking brake. For detailed information
European directives concerning the safety refer to the operating instructions.
of machines. 15. Risk of injury from falling loads or moving
parts of the working equipment. Do not
LWA indicates the level of noise emissions stand under suspended loads or under the
in dBA (acc. to standard 2000/14/EC). working equipment.
5. Lifting gear can be attached here when 16. Type rating plate of the machine.
parts of the machine are to be removed.
17. Load capacity table
6. This sign specifies the approved tyres and The load capacity table corresponding to
the prescribed inflating pressure. the type of the machine (which must be at
7. This signs states the admissible maximum hand in the cab) shows the maximum ad-
speed for travelling on public roads. missible loads, the working range and the
conditions under which these loads may be
8. Do not put the machine into operation un- lifted with the machine. The lifting loads
less you have read and understood the are indicated in tons (t).
operating instructions.
è

Warning and instruction signs (boom adjusting equipment) (Page 2 of 2)
Fig. 2 è

Legend of Fig. 2
Observe the warning and instruction 1. Alternator, regulator and electronic mod-
signs attached to the machine. ules may be damaged, if the batteries are
disconnected with the engine running. The
engine must therefore be shut off before
Replace the signs immediately if the batteries are disconnected and re-
they are no longer legible. moved.
New warning and instruction signs 2. Hydraulic oil reservoir.
can be obtained from our spare- 3. Hydraulic oil reservoir. Observe the oper-
parts service. The part no. for orde-
ating instructions. The reservoir is filled
ring is set out in the spare-parts list with a special hydraulic fluid (option).
of your machine.
4. Fuel tank.
5. This sign shows the layout of the machine
points to be regularly greased. The sign
states also the change intervals for con-
sumables and filters.
A detailed list of all regular servicing activi-

ties is contained in the inspection and
maintenance schedules (Part 3 of these
operating instructions). Always perform
servicing in compliance with the mainte-
nance schedules.
6. and 7. These signs indicate the numbers
and the ratings of the fuses in the driver's
cab.
8. Risk of injury from slewing superstructure
or moving machine. Slew the superstruc-
ture and drive the machine only after all
persons have left the hazard zone.
9. Fastening means must be attached here
when the machine is to be transported.
10. Control elements for the auxiliary heating
system (option).
11. and 12. Safety marking
This plate shows that the machine, when
equipped with either one or two yellow
rotary beacons, is entitled to special rights
in terms of § 35 (6) German road traffic act
(StVO).

observed.

Driver’s cab 10000050-en
Entering and Leaving
Risk of injury
Soiled or damaged grab handles
and steps may not offer sufficient
grip.
Clean oil, grease, earth, mud, snow,
ice and other contaminants from
grab handles, steps and your foot-
wear.
Ensure that steps and platforms as
well as handles offer a good grip.
Fig. 1
Always face the machine when entering or leaving
it.
Use only the steps, platforms and grab handles
provided for entering and leaving (see figures).
When leaving the cab, never use operating or
control levers as grab handles. They are not de-
signed to take such strain.
Fig. 2

Opening /closing the driver's cab door 10000051-en
Opening the door from outside

· Unlock the door (Fig. 1).
· Withdraw the flap on the door lock (arrow,
Fig. 1).
· The door can now be opened.
· Fully opened, the door can be locked into place.
Opening the door from inside

To open the driver's cab from inside, shift lever
forwards (Fig. 2).
Fig. 1
Closing the door

Unlock the opened, locked-in door by pushing
down the lever (Fig. 3). Grab the handle on the
upper side of the door frame and close the door.
Fig. 2
Fig. 3


2245128-en

Adjustment of driver's seat,

safety instructions 10000092-en
The driver's seat permits adjustment of backrest

inclination, height and position. The suspension of
the seat can be adjusted to suit the driver's
weight.
Risk of accidents
Never adjust the seat while driving,
because you must concentrate on
the road. Before adjusting the seat:
- Stop the machine.
- Select pushbutton "travelling di-
rection" neutral.
- Apply parking brake.
- The locking levers of the fore-and-
aft position and of the backrest ad-
justment must engage in the de-
sired position.
- After locking, the driver's seat and
the backrest can no longer be
moved into other positions.
Suspension of driver's seat

To avoid health risks for the driver's
back, the weight adjustment of the
seat should be adapted before op-
erator changes to the individual
weight of the new driver.

Driver’s seat – pneumatic suspension 10000091.01-en
An electrically operated compressor installed in the 5 - Fore-and-aft adjustment of seat with

seat supplies the suspension of the seat cushion consoles
and the air chambers of the backrest with com-
pressed air. Corresponding valves are installed in Pull bracket (5, Fig. 1) upwards, shift seat and
the seat. engage bracket.
1 – Adjusting the seat cushion angle 7 – Fold-back armrests

Pull handle (1, Fig. 1) at front edge of seat up- The armrests (7, Fig. 1) can be folded upwards for
wards, adjust seat cushion, engage handle entering and leaving the seat.
(1, Fig. 1).
· Adjustment range 3°-11°, in 4 steps
8 – Armrest angle
The angle of the slope can be changed in the low-
2 – Adjusting the seat cushion height est position irrespective of the backrest angle, us-
ing the integrated handwheel (8, Fig. 2).
Pull handle (2, Fig. 1) at front edge of seat up-
wards, adjust seat cushion, engage handle · Adjustment range +10° to –30°
(1, Fig. 1).
9 – Adjusting the longitudinal-horizontal

3 – Fore-and-aft adjustment of seat without suspension
consoles Open Move lever (9, Fig. 2) forward
Pull locking lever (3, Fig. 1) upwards, shift seat to Blocked Move lever (9, Fig. 2) back
required position and release locking lever.
4 – Adjusting the suspension/seat height 10 – Adjusting the backrest
Suspension Sit down on seat and lean lightly against the back-
rest. Pull locking lever (10, Fig. 2) upwards, bring
The driver’s weight should be adjusted upwards backrest to required position by pressing back or
with the machine stationary and the driver’s seat leaning forward, release locking lever.
loaded by brief actuation of the handle (4, Fig. 1).
The suspension is adapted automatically to the
driver’s body weight. 11 – Adjusting the armrest height
Seat height Remove plastic cap (11, Fig. 2), slacken nut (size
Pull handle (4, Fig. 1) upwards or downwards until 13 mm), adjust to required height, tighten nut, fit
the seat (6, Fig. 1) has reached the required plastic cap.
height. Release handle (4, Fig. 1). è

12 – Adjusting the lumbar support

An upper and a lower air chamber are integrated
into the backrest. They can be inflated or deflated
independently of each other. The backrest convex-
ity can be adapted to the shape of the operator’s
spine with the two pushbuttons (12, Fig. 2).
For both pushbuttons:
+ press – air chambers are inflated
- press – air chambers are deflated
Seat heating
Fig. 1
Two electric heating elements (seat and backrest)
are installed in the driver’s seat.
The maximum heating capacity is preset. The tem-
perature is thermostat-controlled.
Switching on and off
This is done with a rocker switch (1, Fig. 3) on the
left side of the backrest.
0 Heating OFF
I Heating ON
The seat heating can be switched on only when

the key switch Electrical System is switched to Fig. 2
position I (Ignition ON).
Options
· Backrest extension (head support)
· Safety belt
(see: "Options").
Fig. 3

Driver’s seat – mechanical suspension 10000052-en
1 - Adjusting the seat cushion angle 9 - Adjusting the backrest

Pull handle (1, Fig. 1) at front edge of seat up- Sit down on seat and lean lightly against the back-
wards, adjust seat cushion, engage handle rest. Pull locking lever (9, Fig. 2) upwards, bring
(1, Fig. 1). backrest to required position by pressing back or
leaning forward, release locking lever.
2 - Adjusting the seat cushion height
10 - Adjusting the armrest height
Pull handle (2, Fig. 1) upwards, adjust seat cush-
ion, engage handle (2, Fig. 1). Remove plastic cap (10, Fig. 2), slacken nut (size
13 mm), adjust to required height, tighten nut, fit
3 - Fore-and-aft adjustment of seat without plastic cap.
consoles
Options
Pull locking lever (3, Fig. 1) upwards, shift seat to
required position and release locking lever. · Backrest extension (head support)
4 - Adjusting the suspension · Safety belt
The respective operator’s weight should be set (see: "Options").
with the operator’s seat unloaded by turning the
handwheel (4, Fig. 1).
5 - Fore-and-aft adjustment of seat with
consoles
Pull bracket (5, Fig. 1) upwards, shift seat and
engage bracket.
6 - Adjusting the seat height
Lifting the upper part of the seat (6, Fig. 1) permits
engagement into four different positions at 80 mm
intervals.
If the operator’s seat is lifted beyond the last stage,
the seat is lowered again to the lowest position.
7 - Fold-back armrests
Fig. 1
The armrests (7, Fig. 1) can be folded upwards for
entering and leaving the seat.
8 - Adjusting the armrests
The angle of the slope can be changed in the low-
est position irrespective of the backrest angle ,
using the integrated handwheel (8, Fig. 2).
· Adjustment range +10° to –30°
Fig. 2

Retaining belt (option) 10000094-en
Check the retaining belt and its fas-

tening elements regularly. If the belt
or its fastening elements are found
to be damaged or if parts are miss-
ing, the belt must be repaired imme-
diately or replaced by a new one.
Damaged retaining belts or belts
overstrained in an accident must be
replaced.
The opening of the belt buckle must
not be blocked, for instance, by pa-
per since the belt tongue can then
not engage in the buckle.
Fig. 1
Do not run the retaining belt over
firm or fragile objects as, for in-
stance, keys or spectacles. Risk of
injury in the event of an accident.
The driver's seat is equipped with a lap retaining

belt with retractor (1, Fig. 1). The automatic re-
tractor/belt-tightener is installed on the left side of
the seat.
Put on the retaining belt before driving.
Putting on the retaining belt

Fig. 2
Slide the tongue (2, Fig. 1) into the belt buckle
(1, Fig. 2). Check by pulling on the belt that the o
tongue has properly engaged.
The retaining belt must not be blocked or twisted.
Opening the retaining belt

Depress the buckle lock (2, Fig. 2) and pull out the
belt tongue.
The retaining belt is retracted automatically.

Backrest extension (headrest) 10000093-en
The backrest can be extended in height by pulling

out the headrest (Fig. 1) and by letting it engage in
the suitable notch.
Height adjusting range: 100 mm in 7 positions
To remove the headrest completely pull out over
the limit stop.
Fig. 1

Adjusting the mirrors 10000063-en Opening / closing the front

window 10000054-en
Before using the machine, the outside mirrors

(Fig. 1) must be adjusted so that as wide a part of The front window can be pushed under the roof of
the working area as possible can be overlooked. the driver's cab.
· Sit down on the driver's seat. · Roll up the sunblind.
· Have the outside mirrors adjusted by an assis- · Windscreen wiper in basic position (fully to the
tant. left).
· Grab both handles (2, Fig. 1) at the front window
(left and right side) and push lock levers
(1, Fig. 1) forwards.
· Tilt front window inwards and slide back upwards
to the stop.
· Release the locks (1, Fig. 1), they will engage.
· Make sure that both locks are properly engaged.
If the locks are not properly en-

gaged, the front window may move
forward under high vibration.
Fig. 1
Fig. 1
Make sure the wiper blade does not

protrude into the cab when closing
the front window.
o

Lower part of front window, ventilation / open 10000055-en
The lower segment of the front window can be

moved from the closed position into the "venting"
or "open" position.
Venting
· Loosen the lock of the lower front window seg-
ment on the left and right by pressing the lever
(1, Fig. 1) downwards against the handle
(2, Fig. 1) and by keeping it pressed.
· Slide lower front window segment downwards to
the stop, creating a 3.5 cm wide slot for venting.
· Release lever (1, Fig. 1) on the left and right.
Open Fig. 1
· Roll in the sunblind.
· Loosen the lock of the lower front window seg-
ment on the left and right by pressing the lever
(1, Fig. 1) downwards against the handle
(2, Fig. 1) and by keeping it pressed.
· Slide lower front window segment by means of
handles (2, Fig. 1) upwards in front of the upper
segment of the front window and let lever
(1, Fig. 1) engage in the notches (Fig. 2).
In the open position, the lower segment together
with the upper segment of the front window can be
pushed under the cab roof (see "Opening/ closing
the front window“)
Fig. 2

Side window - opening / closing 10000056-en Emergency Exit 10000057-en
· Release locking device (Fig. 1), then push pane Use the front window as an emergency exit if the
backwards. cab door cannot be opened after it has been dam-
aged (e.g. in case of an accident).
To close, push pane forwards until the locking
To break the glass panes in the event of danger, a
device engages.
hammer is provided on the rear wall behind the
driver's seat on the left (Fig. 1).
Fig. 1 Fig. 1
o o

First-aid kit, fire-extinguisher, warning triangle 10000337.01-en
First-aid kit
The first-aid kit can be stowed away in the com-
partment behind the driver's seat (Fig. 1).
Check the contents of the first-aid

kit and replace removed or unusable
material regularly.
Fire-extinguisher
The fire-extinguisher is located behind the driver's
seat.
Fig. 1
Have the fire-extinguisher checked at

the prescribed intervals by au-
thorized testing institutions.
Warning triangle
The warning triangle can be stowed away in the
compartment behind the driver's seat (Fig. 1) or in
the tool box.
Fig. 2

Using the sunblind 10000059.01-en
The sunblind is fitted in a holder above the front

window.
It can be pulled out in front of the front window
(Fig. 1) or the roof window (Fig. 2).
Rolling out the sunblind
· Grab the end of the sunblind, roll out against
spring action and engage in the holders on the
right and left of the screen (arrows, Figs. 2
and 1).
Rolling in the sunblind
· Take the end of the blind, detach from holders
and let it be pulled in slowly by the spring. Do not Fig. 1
let go the unrolled sunblind; it might get dam-
aged.
Fig. 2

Cab interior lighting - switch-

ing on and off 10000080-en
The interior lighting is switched on and off with the

switch (Fig. 1).
Important:
The interior lighting can be switched on and off in
positions I and P of the ignition-key (ignition lock).
If the machine is left alone for a longer period with
the key in position P and the interior lighting on,
the batteries may be unnecessarily discharged.
Therefore always check that the interior lighting is
switched off before leaving the machine.
Fig. 1

Socket outlet in driver's cab 10000060-en
A socket outlet is installed in the panelling on the

right behind the operator's seat (Fig. 1).
This provides the output voltage of the voltage
transformer (12 V) for connection of the cool-box
(option). Other electrical consumers can also be
connected as long as the maximum output of the
voltage transformer is not exceeded.
Important:
The voltage transformer installed at the factory is
designed so as to supply not only a cassette radio
but also the cool-box (option); the maximum output
is 90 W.
So check the power input of the equipment you Fig. 1
wish to connect. When the voltage transformer is
overloaded, its temperature rises so that the over- o
load protection switches off and leaves the con-
nected unit without current. In this case, pull the
plug out of the socket (Fig. 1). After 5 - 10 minutes,
the overload protection has cooled down and reac-
tivates the voltage transformer. If the overload
condition persists, the thermal shutdown does not
work anymore and fuse F B6 in the fuse box
blows. To replace the fuse, the panelling below the
radio must be removed.
The socket is live when the ignition-key is either in
position I or in position P.

Monitoring, warning and control elements 10000813.00-en
The tables on the following pages provide an over- Operating mode

view over the functions of
In the operating mode, the machine operator is
- the multi-function display provided with information on machine perform-
- the control panels / switches and ance, machine operating modes etc. In this mode,
the display screen is divided into five segments
- all control elements. (Fig. 2).
More detailed information can be found in the other
chapters of the operating instructions.
A table of contents and an index are provided as
help to retrieve information.
Multi-function display, general description

and operating information
The multi-function display (Fig. 1) handles all im-
portant settings, controls and functions of the ma-
chine.
Fig. 2
The fuel bargraph (1, Fig. 2) shows the fuel re-

serve presently available in the fuel tank. The gen-
eral information segment (2) displays the following
information depending on the mode of operation,
e.g.:
- Time of day
- Operating hours
- Engine speed
Fig. 1
- Travelling speed
The display can be operated in three different
modes. è
1 operating mode
2 main menu
3 set mode
The arrow keys are basically used for scrolling
through the menus, whereas the SET key is used
for activating the menus.
Each press on a key is accompanied by a tactile
touch sensation. The wedges in the main menu on
the right and left margin of the display indicate that
further menus can be accessed in the respective
direction with the arrow keys. In the submenus,
these wedges are arranged on the right side of the
display at the upper and lower margins.

The temporary options selected for special modes of operation are shown in the lower left segment (3). Ob-
serve the priority of the temporary symbols as per table 1.
Priority Temporary options Symbol

1 Raise stabilizers
(option "Independent stabilizer operation")
1 Lower stabilizers
(option "Independent stabilizer operation")
2 Stabilizers
3 Auto Power Boost
4 Grab adjusting speed (option)
5 Slewing power
6 Neck cylinder adjusting speed
7 Damping
Table 1
The preselected mode of operation is displayed in the lower central field (4), e.g.:
Preselected mode Symbol

Gear selection
Power level
Table 2

The right lower field (5) displays information about the selected working mode in the form of sysmbols, e.g.:
Preselected mode Symbol

Excavating
Levelling
Hammer
Shears
Rotary cutter
Road travel
Creep speed
Load hook (crane operation)
Magnetic liefting system
Wood handling
Table 3
Main menu
Pressing an arrow key in the operating mode calls In this mode, the display is divided into two seg-
up the main menu. The arrow keys equally permit ments, with symbols displayed in the upper seg-
access to the various sub-menus (Fig. 4), e.g.: ment and the corresponding menu text appearing
in the lower one (Fig. 3).
- Machine parameters
The SET key gives access to the submenus for
- Operating hours recalling information or for changing machine set-
- Immobilizer tings.
- Display settings Wedges under the pictograms indicate that further

menus are available in the respective direction
- Fault analysis (Fig. 3).
- Tester function Detailled information on the handling of individual
- Information mode functions is provided in the corresponding sections
of the operating instructions.
- Service
The tester and service functions menus are
reserved for our Service Dept. and disabled in
normal machine operation.
è

Fig. 3
Fig. 4 è

Control panels / rocker switches, general

operating information
The different functions are activated with 3 keypad
modules comprising 4 keys each, a multifunction
lever on the steering column and a large number of
rocker switches.
The keys of the keypad modules and the rocker
switches are equipped with symbols describing the
function of the key or switch on which they are
printed.
The smbols are illuminated automatically when the
key-switch is turned to position I (ignition ON).
Fig. 5
The key surface can be damaged by

pointed objects. The LED above the symbol on the left (1, Fig. 5) is
Press the keys with your fingers referred to in the following chapters as LED1 and
only. the LED above the symbol on the right (2, Fig. 5)
as LED2. The 4 keys (Fig. 5) form a keypad mod-
Never use ball-point pens, pencils, ule.
nails or similar pointed objects.
Rocker switches:
The function is activated when the switch face with
The keys are pressed with the fingers. The keys the light strip is depressed.
are short-stroke keys with a tactile touch confirma-
tion informing the user that the keys has been
pressed. Special equipment (options)
Light-emitting diodes (LEDs) indicating the actual Some rocker switches are reserved for optional
switching state of the keys are arranged above the equipment. They are installed only if the machine
keys. The symbols of activated keys are illumi-
is equipped with the corresponding option.
nated automatically when key-switch is turne to
position I (ignition ON).
The keys can be used to activate different switch- Arrangement of switches and keys
ing states if they are pressed successively.
The switch arrangement is variable. Unused switch
openings in the panelling are covered up.
The figures show the maximum number of swit-
ches installed.
è

Conditions of use of the multifunction dis- Some functions of the navigation menu are op-
play tional. They can only be activated and used if the
machine is equipped with the corresponding option
Please observe the specified ambient conditions and if the function has been enabled in the elec-
and limits of use: tronics, e.g.:
- Temperature between -20 and 70 C - Hydraulic hammer
- Relative air humidity < 95 % - Overload warning system
If these conditions are not fulfilled, malfunctions The display is illuminated automatically as soon as
cannot be excluded. In the event of malfunctions or the key-switch is turned to position I (ignition ON).
in case of doubt, please contact our Service Dept. The symbols in the upper row are assigned only to
At low winter temperatures (below ca. -20 °C) the one function.
function menus / displays are hardly or not at all o
readable. This is not a defect, but a typical effect of
liquid-crystal displays.
After a short time in operation, the display is again
clearly readable with a good contrast

Switches / Keys 10000814.00-en
Fig. 1 è

Switches / Keys (Fig. 1)

Page 1 of 8
No. Designation Function Symbol
1 Multi-function dis- Control and monitoring of ma-
play chine functions (detailed desc-
ription, see "Multi-function dis-
play")
2 Rocker switch Shifted boom shifted boom operation
operation - to activate -
(hinged joint upper depress switch face without symbol T452
boom section op-
tion) - to deactivate -
depress symbol face of switch
(see: "Upper boom section, shifted opera-
tion")
3 Rocker switch Hydraulic shears Hydraulic shears
(option) - to activate -
depress switch face without symbol T436
- to deactivate -
4 Rocker switch Hydraulic rotary Hydraulic rotary cutter
cutter - to activate -
(option) depress switch face without symbol T451
- to deactivate -
5 Rocker switch Hydraulic hammer Hydraulic hammer
(Option) - to activate -
- to deactivate -
6 Rocker switch Rotary beacon Rotary beacon
depress switch face without symbol
T444
- to deactivate -
7 Key-switch Electrical system Activation / deactivation of e-
lectrical system, starting / stop-
ping the engine
Activation / deactivation of part
of the electrical system (P)
(Radio, cab interior lighting)
8 Rocker switch Floodlamp at the Floodlamp
rear - to activate -
(option) depress switch face without symbol T450
- to deactivate -
9 Rocker switch Floodlamp on cab / Floodlamp
equipment - to activate -
- to deactivate -
è

Switches / Keys
Fig. 2 è


Page 2 of 8
10 Rocker switch Screen-wiper Activates the screen-washer pump and the
automatic wipe / wiper as long as the switch face without
wash function symbol is kept depressed
T25
11 Rocker switch Screen-wiper Screen-wiper with multistage switch

stage 0 = screen-wiper OFF
stage I = intermittent wiping
stage II = continuous wiping T26
To deactivate the screen-wiper -

depress the symbol face of the switch until
the pilot lamp in the switch is off
12 Key Engine speed con- Engine speed reduction in 7 steps (power
trol stages see No. 13)
T400
13 Key Engine speed con- Engine speed increase up to max. speed

trol in 7 steps (7 power stages with fixed speed
levels)
T401
Power stage 1
Power stage 2
Power stage 3
Power stage 4
Power stage 5
Power stage 5
Power stage 7
14 Key Auto-Idle Activation / deactivation of automatic
speed reduction.
After activation, the speed of the diesel
T433
engine is automatically reduced to a lower
speed during no-work phases lasting
longer than 4 seconds. (see "Activating /
deactivating the automatic speed reduc-
tion")
15 Key Low-Idle Sets engine to idling speed. If Auto-Idle
and Low-Idle are on at the same time,
Low-Idle has higher priority.
T434
12-15 Keypad module C5.1

16 Key Gearshift LED1 on = 1st gear fixed (off-road travel)
LED1 off = automatic gearshift (depending
on travel speed and travel re- T430
sistance, the machine shifts
automatically into off-road
st nd
gear (1 gear) or into 2 gear)
(see: "Shifting the travel gear-
box")
è

Switches / Keys
Fig. 3 è


Page 3 of 8
17 Key Superstructure The key is equipped with 2 LEDs
holding brake
LED1 and LED2 = off
holding brake released, super- T431
structure free to turn
LED1 = on
holding brake applied, super-
structure braked
LED2 = on
automatic mode, holding brake is
applied and released automatically,
exact braking in difficult working
conditions, see: "Applying / releas-
ing the superstructure holding
brake")
18 Key Overload warning LED = off overload warning system off
system
LED1 = on overload warning system on
(option) (machine not additionally stabi- T405
lized)
LED2 = on overload warning system on
(machine additionally stabilized,
option)
19 Key Slewing movent The key is equipped with 2 LEDs
braking action
LED = off soft braking of superstructure
slewing movement T432
LED1 = on standard braking of super-

structure slewing movement
LED1 and 2 = on
harsh braking of superstructure
slewing movement see: "Slewing
and braking the superstructure")
20 Rocker switch Quick tool coupler Quick tool coupler
- to deactivate -
(see: "Quick tool coupler, hydraulic")
è

Switches / Keys
Fig. 4 è


Page 4 of 8
21 Rocker switch Electromagnet Electromagnet
depress switch face without symbol
T466
- to deactivate -
(see: "Working with the electromagnet"
22 Socket outlet 12 V
24 Rotary switch Blower Switches the blower into stages:
0 = off,1, 2, 3
25 Pushbutton/white Air conditioner / Recirculated air on / off
heating
(option)
T454
26 Pushbutton /blue Air conditioner / Air conditionder on / off

heating (See "Air conditioner, switching
(option) on / off")
T453
27 Control knob Heating Heating performance control:

fully left - min. heating perfor-
mance (blue)
fully right - max. heating per-
formance (red)
28 Rocker switch Independent con- Rear stabilizer, right
trol of stabilizer
Activates/deactivates the stabilizer to be
(option) moved T445
29 Rocker switch Independent con- Rear stabilizer, right

trol of stabilizer
(option) moved T446
30 Rocker switch Independent con- Front stabilizer , left

trol of stabilizers / or
levelling blade front levelling blade T446
(option) Depending on the option, the stabilizer /

levelling blade is activated or deactivated.
T443
31 Rocker switch Independent con- Front stabilizer , left

tol of stabilizer
(option) moved T445

Switches / Keys
Fig. 5 è


Page 5 of 8
32 Rocker switch Parking brake To apply the parking brake:
(activate only when the machine is station-
ary)
T447
press switch face (the rocker switch is
latched at the same time; the symbol on
the switch lights up red; at the same, the
floating axle is being blocked)
To release the parking brake:
unlock switch and press switch face beside
the light strip (red symbol backlighting is
off.
The floating axle is free to move if not
blocked with key (33) see: "Blocking the
floating axle").
Attention:
When the ignition is off (key-switch No. 7),
the parking brake is applied independent of
the position of switch (32).
If switch (32) is in the
"Release parking brake“,
position when the ignition is switched on
(key-switch No. 7), the parking brake re-
mains nevertheless applied (background of
symbol lit up red and floating axle is
blocked) until switch (32) has first been set
to the
"Apply parking brake“
and then to the
"Release parking brake“
position.
33 Key Floating axle - To block the floating axle -
blocking depress symbol face of switch; LED2
lights up
T409
- To unblock the floating axle -
depress symbol face of switch; LED2 is
off
34 Key - not used -
T406

Switches / Keys
Fig. 6 è


Page 6 of 8
35 Key Road travel Attention:
Safety lever (72, Fig. 2 in “Control ele-
ments“) must be at 0 position
T411
(see Fig. 1 “Starting the engine”)/
(electro-hydraulic pilot control = OFF)
To activate road travel:
- depress symbol face of key;
LED2 lights up.
To deactivate road travel:
- depress symbol face of key;
LED2 is off.
36 Key Creep speed To activate creep speed:
depress symbol face of key;
LED 1 and the symbol light up
T412
To deactivate creep speed:

depress symbol face of key;
LED 1 and the symbol are off
37 Multifunction lever Lighting Lighting OFF
(steering column)
T413
38 Multifunction lever Lighting Sidemarker lights ON

(steering column)
T414
39 Multifunction lever Lighting Dipped beam ON

(steering column)
T415
40 Multifunction lever Signal horn Acoustic war- Old

(steering column) ning signal symbol
T507 T416
41 Multifunction lever Turn signal Turn signal "to the left" on/off
(steering column)
T417
42 Multifunction lever Turn signal Turn signal "to the right" on/off
(steering column)
T418
43 Multifunction lever Lighting Switches over between:

(steering column)
(option) Headlamp flasher - lever upwards (mo-
mentary contact),
Dipped beam - lever in center posi-
tion and
High beam - lever downwards
T43-neu

Switches / Keys
Fig. 7 è

Switches / Keys (Fig. 7) Page 7 of 8

44 Key Hazard warning Hazard warning system on/off
system
T34
Buzzer Individual acoustic warning signals when:

- after "ignition ON"
- 1) the self-test routine of the electronic con-
trol is started
- 2) the pilot control is ready for operation and
the machine can be moved
- the return-flow filters of the hydraulic system
are contaminated
- the machine has been switched over from stick
function to levelling blade / stabilizer function
- during hydraulic hammer or cutter operation
the machine has been switched over by means
of pedal (77) temporarily to neck cylinder for
repositioning movements
- faults in the electronic control unit have oc-
curred that do not constitute a severe threat to
the safety of the operator and of the machine.
Further short acoustic warning signals:
- triple tone in the event of operating errors
- single tone on switching over to forward
travel
- double tone on switching over to reverse
travel
- prolonged single tone when travel direction is
shifted to neutral
- single tone when key (33, Fig. 7) is pressed
while the parking or the service brake is ap-
plied.
Periodic acoustic warning signals when:
- the brake pressure too low
- the engine oil pressure insufficient
- the coolant temperature too high
- the admissible load moment is exceeded (with
verload warning option)
- no voltage is supplied by the alternator
- the temperature of the hydraulic oil too high
- the "Stabilizers / levelling blade" raising and
lowering function is on
- severe faults have occurred in the electronic
control module
- emergency operation has been activated
è

Switches / Keys
Fig. 8 è


Page 8 of 8
nd
50 Rocker switch Fixed 2 gear After installation of the option, key (16, Fig. 2 )
(option) has a different function (see "Switching of fixed
2nd gear" (option)“
T428
51 Rocker switch Independent sta- - Independent raising / lowering of the stabilizers

bilizer operation
(option)
T429
52 Rocker switch Grab opening Speed of opening and closing movements in

and closing accordance with preset parameters
speed (option)

Control elements / ISO 10000173.03-en
Fig. 1 è

Control elements / ISO (Fig. 1)

Page 1 of 2
No. Designation Function
60 Steering column Transfer of steering movement to steered axle
and steering wheel
61 Pedal Travelling Control of machine travel
62 Pedal Service brake Braking of travelling movements. The locking lever

blocks the service brake in braked position and, at the
same time, the floating axle. Unblocking the brake
pedal automatically unblocks the floating axle.
63 Pushbutton Grab rotation / Selects sense of grab rotation: right
adjustable boom (with option "Upper boom section shift operation":
upper section (op- slew to the right
tional)
64 Pushbutton Signal horn Acoustic warning signal
65 Pushbutton Travel direction Selects forward travel
(No. 101 lit up)
66 Pushbutton Travel direction Selects reverse travel
(No. 107 lit up)
67 Pushbutton Travel direction Selects neutral travel
68 Locking bolt Superstructure Locks up the superstructure and the undercarriage

lock
69 Control lever Boom forward - lowering the boom
backward - raising the boom
Bucket to the right - emptying the bucket

to the left - filling the bucket
Grab With grab option:
to the right - opening the grab
to the left - closing the grab
70 Control lever Slewing to the right -
superstructure slewing to the right
to the left-
superstructure slewing to the left
Stick forward -
stretching out stick -
Levelling blade /
lowering the levelling blade / the stabilizers
stabilizers
backwards -
retracting the stick -
raising the levelling blade / the stabilizers.
(see also Nos. 22 - 25)
71 Pushbutton Levelling Supplementary activation of the "levelling" mode
(see: "Switching over to "levelling")
è

Control elements
Fig. 2 è

Control elements (Fig. 2)

Page 2 of 2
No. Designation Function
72 Safety lever Electro-hydraulic Pull up –
pilot control
Electro-hydraulic pilot control OFF
Push down –
Electro-hydraulic pilot control ON
(see: "Switching on the pilot control")
73 Pushbutton Power-Boost Brief working with increased engine speed and higher
pressure.
(see: "Power-Boost, function")
Independent stabi- Raising the stabilizers
lizer actuation
In conjunction with rocker switch (51) "Independent sta-
(option)
bilization" (See "Independent stabilization")
74 Pushbutton Switch-over from Switches over between "Stick" and "Stabilizers / level-
stick to stabilizers ling blade".
/levelling blade
(The buzzer sounds when the "Stabilizers / levelling
blade" function is activated).
Independent stabi- Lowering the stabilizers
lizer actuation
In conjunction with rocker switch (51) "Independent sta-
(option)
bilization" (See "Independent stabilization"
75 Pushbutton Hydraulic hammer Activation of hydraulic hammer
(option)
76 Pushbutton Grab rotation / Selects sense of grab rotation: to the left
adjustable upper (with option "Upper boom section shift operation":
boom section (op- slew to the left
tion)
77 Pedal Examples:
(for options) - with upper boom section shifting equipment
in / out of shifting cylinder
- with hydraulic hammers:
hammer operation
- with hydraulic rotary cutters
rotary cutter operation
- for hydraulic shears
control of hydraulic shears
78 Foot-rest
79 Lever Steering column Locks up the steering column in the desired inclination:
lock push down - steering column can be adjusted.
release lever - steering column locked
o

Multi-function display 10000801.00-en
Fig. 1 è

Multi-function display (Fig. 1)

Page 1 of 5
101 Pilot lamp Travel direction Lights up when forward travel is
indicator active
(see No. 65 in "Control elements") T420
102 Pilot lamp Travel direction Lights up when turn signal left (No.
indicator 41 in "Switches/Keys") is activated
T421
103 Pilot lamp Preheating Lit up during the preheating cycle

(preheating timer active)
T422
104 Pilot lamp Main beam Lit up blue when the headlamps
are on main beam (No. 43 in
"Switches/Keys" is on) T440
105 Pilot lamp Superstructure Lit up when the superstructure

holding brake holding brake (No. 17) is activated
T404
106 Pilot lamp Travel direction Lights up when turn signal right
indicator (No. 42 in "Switches/Keys") is acti-
vated T423
107 Pilot lamp Travel direction Lights up when reverse travel is

indicator active
(see No. 66 in "Control elements") T424
108a Multi-function Time/ operating Time of day in hours and minutes /

display hours / fuel re- display of machine operating hours
serve / fuel reserve.
Fuel level above horizontal line =
OK
Fuel level below horizontal line = fill
up fuel tank mfa01k-de_fr_it_es
108b Multi-function Time / engine Time of day in hours and minutes /

display power level graphic display of respective en-
gine power level.
mfa02k-de_fr_it_es
108c Multifunction Coolant tem- Displays the coolant temperature

display perature / hy- and the hydraulic oil temperature
draulic oil tem-
perature
mfa03k-de_fr_it_es

Multi-function display
Fig. 2 è


Page 2 of 5
Pos. Benennung Funktion Symbol
108d Multi-function Code Input of secret code number for
display electronic immobilizer.
(See: "Immobilizer, entering the
code")
mfa04k.01-de_en_fr
108e Multi-function Operating hours Display of operating hours as:

display
- total of operating hours
- partial count
- day count
mfa05k.01-en
108f Multi-function Machine Setting of hydraulic oil pressure

display and of volumetric flow for the fol-
lowing attachments:
- 4 different hydraulic hammers
- 4 different rotary cutters
- 4 different hydraulic shears mfa06k.01-en
Further options can be activated by

the dealer for use by the operator:
- degree of damping for equipment
movements and travel function
- slewing power limiting
- activation of the "Auto Power-
Boost" function
- setting of the levelling function
- basic setting
- grab rotation
neck adjusting cylinder speed
For further explanations refer to

working settings of the machine.
108g Multi-function Display Setting of display contrast and
display brightness, clock, language and
measuring units.
(See: "Display, settings")
mfa07k.01-de_en_it

Fig. 3 è


Page 3 of 5
108h Multi-function Information Displays operating data of the ma-
display chine and the control system.
See operating information.
mfa08k.01-de_en
108i Multi-function Tester Monitoring and display of process

display data and settings / operating
status.
This menu is reserved for our
Service Dept. and not accessible in
normal machine operation.
mfa10k.01-de_en_es_fr_it
108j Multi-function Service - Display of operating hours by

display function groups of the machine
(disabled in normal machine op-
eration).
- Display and setting of servicing
intervals (disabled in normal ma-
chine operation). mfa11k.01-de_en_fr_it
- Calibration of machine functions

(reserved for Service Dept.).
- Activation of optional machine
functions (disabled in normal
machine operation).
- Resetting of faults (reserved for
Service Dept. – password pro-
tected).
108k Multi-function Fault retrieval Faults occurred are stored in detail
display by electronic control unit.
This menu is reserved for our
Service and disabled in normal
machine operation (password pro-
tected).
mfa09k.01-en

Fig. 4 è


Page 4 of 5
109 Key SET key Key for selection and confirmation
of items in function and navigation
menus T425
110 Key Arrow key Key for selection and scroll-down in

function and navigation menus
T426
111 Key Arrow key Key for selection and scroll-up or

escape key in function and naviga-
tion menus T427
112 Warning lamp Fault message Lights up yellow in the event of

faults which are not safety- or func-
tion-relevant.
When a yellow fault occurs:
- yellow warning lamp lights up
- buzzer warning is sounded.
Faults can be recalled by pressing
the SET key.
If several yellow faults have oc-
curred, they are displayed one after
another at certain intervals.
Recalling of faults can be aborted
by pressing the SET key once
again.
Not all yellow faults are displayed
on the screen.
Only such yellow faults are dis-
played as are important for ma-
chine maintenance or of help to the
service personnel in the event of
technical problems.
A detailed list of yellow faults is
accessible via the FAULT RECALL
menu item. This item can only be
activated with a code and is re-
served for our Service Dept.
The cause of the fault should be
rectified as soon as possible. In
most cases, the machine can con-
tinue to be used with all its func-
tions.
(See: "Fault codes")
è

Fig. 5 è


Page 5 of 5
113 Warning lamp Fault message Lights up red, when the safety of
persons (e.g. safety lever defec-
tive, overload warning) and the
functioning of main assemblies of
the machine is endangered.
This is the case, for instance, when
there is no engine oil pressure or
when the admissible load moment
is being exceeded (with overload
warning option) and when pres-
sure-relief valves open.
When a red fault occurs, a fault
number is displayed and an inter-
mittent buzzer warning is sounded
in addition to the red warning lamp
lighting up.
In some fault cases, certain ma-
chine functions are deactivated or
can be switched over to emergency
operation.
There is also the possibility of sev-
eral faults being indicated at the
same time. If 2 red faults occur,
both are indicated. If a yellow and
red fault occur at the same time,
only the red fault will be indicated.
After removal of the cause of the
red fault, the yellow fault is indi-
cated.
(See: "Fault codes")
o

Starting up the machine 2413786.en
Prior to starting up the machine each day, carry

out the works listed in maintenance schedule T
(see Section 3 of these Operator's Manual "In-
spection and Servicing").
o

Refuelling 2747295-en
Refuelling, safety instructions
Explosion hazard Securing the machine

Fuels and fuel vapours are readily Secure the machine against unau-
flammable and may explode into thorized starting during the re
flame. Therefore avoid any sparking fuelling operation:
and never use a naked flame, e.g.
- set the working equipment down
lighter or matches, for lighting.
on the ground,
- switch off fuel-driven auxiliary
Potential health hazard heating systems and air condition-
ing systems,
Diesel fuel and fuel vapours are a
potential health hazard. Fuels must - shut off the engine,
never be swallowed. Also avoid pro- - withdraw the key from the Elec
tracted contact with the skin. trical System key switch.
Avoid inhaling the vapours.
Wear protective gloves or apply a o
barrier cream.
Do not eat, drink or smoke while
refuelling.
Avoid environmental impact

Prevent fuel from overflowing. Pre-
vent fuel from penetrating into the
soil; this constitutes an environ-
mental hazard.
Soak up spilt fuel immediately with
rags or binding agent. Then discard
in accordance with local environ-
mental regulations.
Report accidents involving fuels
without delay to the machine owner
or his agent.

Filling in fuel 10000177-en
Read and observe "Refuelling, safety

instructions" before filling in fuel.
Refuelling from cans

If the machine is refuelled frequently
or regularly with fuel from cans or
barrels, there is an increased risk of
dirt particles and water getting into
the fuel system.
In this case:
- Always fill in fuel through a fine-
Fig. 1
meshed strainer;
- Use only suction hoses equipped
with a fine filter; Winter operation
- Drain off water and deposits from When "summer diesel" is used, there is a risk of
the fuel tank in shorter intervals; operating problems at temperatures of below 0 °C
- Replace all fuel filter in shorter in- as the fuel becomes too viscous due to paraffin
tervals. separation. For this reason, cold-resistant "winter
diesel" is available in Germany during the cold
season. Depending on the brand, this fuel is safe
for operation even at temperatures of about –15 °C
Never use "biodiesel" for refu- to –22 °C.
elling In countries with other climatic conditions, the fuels
Possible damage to injection system available often have a different temperature be-
and engine caused by "biodiesel". haviour. Our Service Dept. and the fuel stations of
the respective countries will be pleased to inform
Fill up only with diesel fuel made you about the diesel fuel situation in the country in
from mineral oils to standard EN 590. question.
1)
The cetane number CZ of the fuel è
should not be lower than 49.
For more information, contact your
dealer service.
· Unlock the cap of the filler neck (1, Fig. 1), then
screw off cap.
· Fill in fuel through the strainer (2) in the filler
neck. Do NOT remove the strainer.
1
The cetane number is a measure of the ignition performance
of diese fuel

Filter preheating
(low-temperature package - optional)
The machine can optionally be equipped with a
filter preheating system. The fuel system is then
safe for operation down to about –25 °C when
"winter diesel" resisting the cold down to –15 °C is
used.
Should the fuel nevertheless have become so vis-
cous at temperatures below –25 °C that the engine
cannot be started anymore, it is sufficient to place
the machine for a short time into a heated room.
It is forbidden to mix fuel additives

(pour point depressants) and similar
agents into the diesel fuel.

Switching the electrical system on and off 10000815.00-en
The key-switch is used to switch the following - Time of day in hours and minutes / display
functions (7, Fig. 1): of machine operating hours (Fig. 2)
0= All electrical consumers without power, en- - Time of day in hours and minutes / display
gine off. of performance level (Fig. 3)
A main relay disconnects all current circuits - Temperature of coolant and temperature of
from the battery set. hydraulic oil (Fig. 4)
P= Cab interior lighting and socket outlet in cab On all screens, the fuel reserve is displayed
and the radio are connected to the power as a graph.
supply. All other consumers without power
supply. The electronic unit now activates the func-
tions in acc. with table 1
I= Electrical system on.
When the immobilizer is activated, the code "State after ignition ON"
must now be entered (see "Immobilizer, en-
tering the code").
II = Engine start. All monitoring and warning
If the immobilizer is not activated, the central elec- lamps must go out when the engine is run-
tronic unit performs a self-test. ning.
All monitoring and warning lamps are switched on Exception:
for a few seconds and the buzzer sounds briefly When the superstructure holding brake is
two times. applied, the respective indicator lamp is on.
The display contents is visible. è
The following information can be displayed with the
arrow keys:

Fig. 1 Fig. 3
Fig. 2 Fig. 4

Immobilizer, re-entering / activating / deactivating the code 10000185.02-en
Fig. 1
Fig. 2 è

Immobilizer, re-entering / activating / deac- Activating the code

tivating the code · In the operating mode, press an arrow key until
This machine is equipped with an electronic immo- “CODE“ in the main menu is highlighted grey
bilizer as a standard feature. When activated, the (Fig. 1).
immobilizer prevents unauthorized starting of the
· Select the "closed-lock" symbol with the arrow
machine. keys and confirm with the SET key.
The immobilizer is not active on delivery from the
factory. It can be activated by the customer when
the machine is handed over. Before activation, the Deactivating the code
customer has to enter a four-digit code chosen by
him. · In the operating mode, press an arrow key until
“CODE“ in the main menu is highlighted grey and
confirm with the SET key (Fig. 1).
Re-entering the code
· Select the "open-lock" symbol with the arrow
· In the operating mode, press an arrow key until keys and confirm with the SET key.
the lock symbol is highlighted grey (text “CODE“
appears Fig. 1). Confirm the selection with the
SET key. Further settings
· Activate the key symbol with arrow DN [ß] and Similar to the above procedure, the code can also
confirm the selection with the SET key. be changed and deactivated in this submenu and a
time set after which the code is to become active.
· Enter the presently valid four-digit code with the
The machine can thus be put back into operation
arrow keys and the SET key. Attention when
after a pause without the need to re-enter the
making the change for the first time: the code
code, if this is done within the preset time.
preset at the factory is 1111. After confirming the
fourth digit, you are requested to enter the new o
code.
Note the code and keep it in a safe

place.
· Confirming with the SET key saves the entered

code, whereas arrow UP [Ý] rejects the change
and takes you back to main menu.

Immobilizer, activating the code timer function 10000209.02-en
Fig. 1
Fig. 2 è

Immobilizer, activating the code timer function · Select the clock symbol with the arrow keys and
confirm with the SET key.
This menu can be used for setting a time after
which the code is to be activated. The machine can · Enter the activation time with the arrow keys and
thus be used again without entering the code a the SET key. The activation time can be between
second time, if this is done within the preset time. 1 minute and 12 hours. After confirming the last
number you are requested to confirm once again
· In the operating mode, depress an arrow key
(Fig. 2).
repeatedly until “CODE“ is highlighted grey in the
main menu on the screen and depress the SET · Confirming with the SET key saves the selected
key (Fig. 1). time of activation, whereas the arrow UP key re-
jects the change and takes you back to the main
· Select the closed-lock symbol with the arrow
menu.
keys and confirm the selection with the SET.
o

Starting and stopping the engine 10000802.00-en
Starting the engine
The following text describes starting of the ma-

Engine exhaust gases are a health
chine without entering a number code.
risk.
· Deactivate the pilot control by pulling up lever
Start the engine only in the open air
(72, Fig. 1) into position 0.
or in rooms with an exhaust evacua-
tion system. · Set the travel direction with pushbutton
(67, Fig. 2) to neutral.
· Insert the key into the key-switch (ignition lock)
The machine is factory-equipped with an immobi- (7, Fig. 2) and turn into position I.
lizer as standard equipment. After 2 seconds, the key can be turned to posi-
The machine can be secured against unauthorized tion II and the engine starts up.
starting of the engine with a four-digit number No display on the screen. A brief warning is
code. sounded. The machine performs a system check
The immobilizer function is deactivated when the of the electronics.
machine is dispatched from the factory. · Quick start:
To activate the immobilizer function or to change 6 seconds after ignition switch-on, a second brief
the code, see: “Immobilizer, activating the code“. tone signal is heard. The safety lever can now be
set to position I and the machine can be oper-
To start the machine when the immobilizer is acti- ated (72, Fig. 4).
vated, see: "Immobilizer, entering the code".
· The screen displays the operating hours sepa-
rately as:
- total number of operating hours
- partial count
- day count
· The logo appears. 2 seconds later, the main
screen is displayed (Fig. 5).
Key position I gives access to the

extensive onboard electronics menu.
Access to the menu is possible be-
fore starting of the engine and when
the engine is running.
· Turn key to position II, the engine starts up.

· Release the key, it goes back to position I
è

Fig. 1 Fig. 4
Fig. 2 Fig. 5
Fig. 3

Cold starting Warm-up phase
At temperatures (engine coolant) The engine will now run for 3 seconds at idling.
within the range of – 1,5 °C to – 28°C, When the engine is cold (< 40 °C), an information
the wam-up phase begins ca. that warming up is still in progress is displayed on
1-2 seconds after switching on the the screen every 3 seconds for abt. 1 second
ignition (key 7, Fig. 2) in position I). (Fig. 3). The degree of engine warming is dis-
The indicator lamp (103, Fig. 2) in the played by a horizontal bargraph.
multi-function display is on for about During warmup, the power level can be preset with
10 to 15 seconds. When the indicator the arrow keys (12 and 13, Fig. 2). Up to level 5,
lamp goes out, turn the key to posi- the setting becomes active during warm-up. When
tion II and start the engine. When power levels 6 and 7 are preselected, they will be
preheating is accomplished (indica- activated only after the diesel engine has reached
tor lamp (103) is extinguished), there its operating temperature.
are still 30 seconds left in the
standby cycle during which the en- After the warm-up phase, the engines runs with the
gine must have started to activate speed of the preset power level.
the after-heating phase. Otherwise,
there will only be between 0 and
15 seconds left for starting and The engine can be only be started if
warming up of the intake air. the pilot control is deactivated
(Pos. 0, Fig. 1).
Within 40 to 45 seconds after
switch-on of the ignition, the en-
gine must already be running in
· After starting of the machine, the pilot control
order to activate the after-heating must be activated. To do so, push lever
phase. (72, Fig. 4) down into position I.
The after-heating phase begins when è
the alternator charging voltage is
present. The duration is temperature-
dependent and lies between 60 and
120 seconds.
For optimal timing of the cold-start-
ing procedure, the engine should be
started immediately after extinction
of indicator lamp (103) (by turning
the key to position II).

When a warning signal is sounded

and when the red warning lamp is lit
up, there is a risk of severe damage
to the engine. Shut off the engine
immediately. Locate the cause of the
fault by interpreting the fault mes-
sages in accordance with the fault
code table and rectify the fault before
restarting the engine. In the event of
faults, contact our Service Dept.
Fig. 6 o

After engine start / warm-up 10000573.01-en
The oil in the hydraulic system of the machine Subjecting one or several functions
serves the purpose of driving the hydraulic cylin- of the machine for a prolonged pe-
ders and the various hydraulic motors. Cold oil is riod to heavy loading in limit stop
viscous. Certain machine functions as, for in- conditions may cause malfunctions
stance, driving and slewing movements are there- resulting in accidents with injuries
fore executed more slowly than when the oil is to persons.
warm.
It is important that the oil in the machine's hydraulic

It is forbidden to warm up the oil by system is warmed up properly. For this reason, the
force, as forced warming may cause following instructions must be observed during
damage to the machine. warm-up:
· Start the engine and let it run at low idle for five
At very low temperatures, the hy- minutes.
draulic system of the machine may · Then execute a number of boom, stick, slewing
be sluggish. It is therefore advisable and travelling movements to distribute the warm
to use caution as long as the ma- hydraulic oil to all hydraulic cylinders and the hy-
chine has not reached its operating draulic motor.
temperature. This is important to
avoid accidents. Execute these movements until the hydraulic sys-
tem of the machine has reached the operating
temperature.
o

Engine does not start 10000182-en Stopping the engine 10000183-en
Do not use starting-aid fluid such as Do not shut off the engine from full
ether. The use of starting fluid leads load, but rather let it run for further 3
to high pressures in the cylinders to 5 minutes at idling to allow for
and may cause overspeeding of the cooling.
engine: Risk of engine damage
As an option, the engine can be
equipped with automatic preheating · Stand the working equipment on the ground.
of the combustion air. This option
· Switch the engine back to idling speed by de-
permits engine starting at tempera-
pressing the Low Idle key (15, Fig. 1).
tures below –15 °C (5 °F).
· Turn key-switch (7) to 0. The engine is shut off
If the engine cannot be started even
and stops.
with external batteries (jump start-
ing), please contact our Service · Withdraw the key from key-switch (0). The key
Dept. can only be withdrawn in position (0).
Important:
If the engine does not start, turn the key-switch Key-switch (7) has a switch position P. In this posi-
(igniton lock) back to 0 (mechanical start repeat tion, some electrical consumers remain connected
preventer), then start again. to the power supply even when the engine is off
(see: "Switching the electrical system on and off").
Do not start longer than 30 seconds without inter-
ruption. Leave a pause of two minutes between the If these consumers remain on for a prolonged pe-
starting attempts. riod, the batteries may be discharged to such an
extent that starting of the engine is no longer pos-
If the engine does not start after three attempts , sible.
check the fuel supply. Missing blue or white smoke
from the exhaust is a sign of the engine not getting Therefore always make sure the key-switch is in
fuel. position 0 before parking the machine for pro-
longed periods (e.g. after a workshift).
Check the fault messages.
It is is possible that there is water in the fuel.
Drain off water and try to restart the engine. If it
does not start, contact our Service Dept.
o
Fig. 1

Ventilation and Heating 10000272.01-en
Ventilation (fresh air) Heating
The engine coolant flows through the heat ex-

changer of the heating system. The heating output
is therefore also dependent on the engine tem-
perature. The full heating output is not achieved
until the engine has run up to operating tempera-
ture.
Even if the heating is not required for an extended
period, switch heating systsem on at full output
once a week for ca. 5 minutes in order to mix the
coolant in the engine and that in the heating sys-
tem.
· When working in dusty, severely contaminated
air, the heating system can be operated tempo-
Fig. 1 rarily in the circulating air mode (only with op-
tional air conditioner).
With the engine running:
Turn rotary switch (27, Fig. 1) for heating control to
"min" (heating output = 0). (If the engine is not Optional equipment: Auxiliary heating
running, switch the key switch (7, Fig. 2) to position If an auxiliary heating system is installed, refer also
I. Only then can the blower be switched on). to: "Putting the auxiliary heating system into op-
Switch blower to required air output (stage 1 – 3) eration".
with rotary switch (24, Fig. 1). Optional equipment: Air conditioner
If an air conditioning system is installed, refer also
to: "Switching the air conditioner on / off").
· After cooling of the air in the cab by the air con-
ditioner, the cab air can be cooled further by run-
ning the system in the recirculating mode.
· The air conditioner can also be activated during
the cold season to remove moisture from the cab
air.
è
Fig. 2

Adjusting the Heating Output
Fig. 3
· Turn rotary switch (27, Fig. 1) clockwise accord-

ing to required heating output.
· Depending on the quantity of hot air required,
switch blower to stage 1 – 3 with rotary switch
(24).
The slats of the air outflow system (arrow, Fig. 3)
are adjustable. The air flow can thus be deflected
laterally and upwards.
¨

Defrosting the front, side and rear windows 10000195-en
Windows that are steamed or iced

up obstruct the operator's view of
the hazard zone.
Never move the machine until the
windows are defrosted and the haz-
ard zone can be clearly seen.
· Start up the engine. Full heating output is at-

tained only when the engine is at operating tem-
perature.
· Close the air-flow vents under the operator's seat
(Fig. 1).
Fig. 1
· Open the two air-flow vents for the front windows
(Fig. 2) as wide as possible and direct onto the
front windows.
· Open the air-flow vents for the side window
side window.
· Open the air-flow vents of the rear window
rear window.
· Set heating output to max.
· Switch blower to stage 3.
Fig. 2
Fig. 3

Switching the windscreen wiper/washer on and off 10000196.01-en
Intermittent wiping
- Depress rocker switch (11, Fig. 1) once. (The
switch face without symbol is depressed and the
pilot lamp in the rocker is lit up.)
Permanent wiping
- Depress rocker switch (11) twice. (The switch
face without symbol is depressed and the pilot
lamp in the rocker is lit up.)
Switching the wiper off
- Switch off rocker switch (11). (Depress symbol
face of switch, the pilot lamp goes out.)
Fig. 1
Activating the wipe / wash function
- Depress rocker button (10) (the pilot lamp inside
the rocker button lights up). The screenwasher
pump is switched on with the wiper being acti-
vated at the same time.
After releasing the button, the wiper continues to
perform wiping movements for a short time.
If the front screen is pushed back

under the cab roof as described un-
der "Opening /closing the window",
the screen wiping /washing func-
tions are automatically deactivated
Fig. 2
by a contact switch (arrow, Fig. 2).
o

Driving 10000084.01-en
Travelling, safety instructions
Before setting off Selecting the direction of

travel
Remove any soil, mud, snow, ice,
grease and oil from your working The specifications "Forward" and
footwear before operating the ma- "Reverse" as well as "Right" and
chine. You might otherwise slip "Left" apply only when the machine
from steps and pedals and thus ini- is in basic position and the machine
tiate inadvertent movements. operator is looking through the front
window towards the working equip-
Adjust the driver’s seat and the mir- ment.
ror before setting off.
Bear in mind that the required and
Close the front window and the cab the actual directions of travel "For-
door.
ward" and "Reverse" as well as the
If the machine is equipped with a required and actual directions of
restraining belt for the operator, fas- cornering "Right" and "Left" are
ten the belt. identical only when the machine is
in basic position (see: "Bringing the
Before setting off, sound the horn to machine to basic position").
warn any persons in the immediate
vicinity. If the superstructure of the machine
is turned more than 90° from the
Never allow other persons to travel basic position, the machine moves
with you on the machine. in the opposite direction from the
viewing direction of the machine
operator.
Therefore check the position of the
superstructure in relation to the un-
dercarriage before setting off.
è

Note the position of the work- Travelling on slopes

ing equipment Never drive across slopes or turn
the machine on a slope. The ma-
Never drive with the working equip-
chine may slip or overturn.
ment extended, as that may impair
the stability of the machine. Bring Take special care on slippery soils.
the working equipment as close as
possible to the machine. Ensure that the tyres offer adequate
grip. Only then are the steering and
This applies especially when the braking properties maintained (see:
bucket is filled or when a load is to "Travelling uphill and downhill").
be transported on the load hook.
Therefore bring the working equip-
ment as close as possible to the Travelling uphill and downhill
machine and slew the super-
Travel uphill and downhill at crawl-
structure into the direction of travel
before setting off. ing speed only.
This provides for adequate power
Lift the working equipment only so
reserves when travelling uphill and
high as to avoid obstacles on or
above the ground. prevents excessively high speeds
when travelling downhill (see:
"Travelling uphill and downhill").
Contact with overhead power Always control your travelling
lines speed using the accelerator pedal
(61). Releasing the pedal for long
Lift the working equipment only so periods when driving down slopes
high as to permit risk-free travel is forbidden as it may lead to strong
below overhead power lines. overheating and damage to the en-
If an overhead line has been gine due to lack of cooling and hy-
touched, drive the machine out of draulic oil lubrication.
the hazard zone or lower the work-
ing equipment.
If that is impossible: Reverse travel
- Do NOT leave the driver’s cab During reverse travel the view of the
hazard zone is restricted. Therefore
- Instruct other persons to keep enlist the help of experienced mar-
away and to have the power shallers. Come to an agreement with
switched off the marshaller to ensure that you
interpret his signals correctly.

Travelling over long distances Cornering

Before travelling over long distan- Reduce speed when cornering. If the
ces: speed is too high and the steering
wheel is wrenched round, there is a
Bring the machine to basic position risk of the machine overturning (due
and to a wheel of the rigid axle being
Switch the superstructure retaining lifted off the ground). Extremely hard
brake to automatic mode braking while cornering may also
cause the machine to overturn.
The machine is then in basic posi-
tion.
Before driving on the public high- Parking the machine
way, familiarize yourself with the Machines that are parked on slopes
laws and regulations in force in your may be inadvertently set in motion.
country.
Therefore always park the machine
Read and observe: on flat, horizontal surfaces.
"Driving on public roads".
Do NOT tow a trailer

The machine is not suitable for
towing trailers or other vehicles
over long distances; this would re-
sult in damage to the axles and
gearbox.
Information on the engine
The towing fixture is provided solely
At low temperatures the engine first
for towing or recovery from hazard
undergoes the "WARMUP" phase.
zones or for fastening on transport
Only then may the engine be fully
vehicles; see "Recovery and towing,
loaded.
safety instructions".
o


2245128-en

Braking system 10000197.02-en
Using the service brake · To brake the machine, depress pedal

(62, Fig. 2).
· The service brake can be blocked in operation
The service brake consists of four multiple-disk
while in actived state. To do so, depress pedal
brakes in the wheel-hubs. The brake is actuated
(62). The brake is locked in depressed position
hydraulically.
with the locking lever (arrow, Fig. 3)
The hydraulic pressure accumulators of the service The floating axle is blocked at the same time
brake are permanently monitored. (irrespective of the switching position of key
(33, Fig. 4) which controls blocking of the floating
If the pressure drops below a predefined minimum, axle.
the red warning lamp (113, Fig. 1) in the display
lights up and the buzzer sounds intermittently. · The machine cannot be be set in motion when
the service brake is blocked.
At the same, a fault code and the symbol for insuf-
ficient braking pressure are displayed on the · When the travel pedal is pressed with the travel
screen accompanied by the request to shut off the direction selected and the service brake blocked,
engine immediately (see: "Fault code table"). an instruction to release the service brake is dis-
played once on the the screen for a short time.
· When the parking brake is applied in addition to
the service brake being blocked and when the
travel pedal is pressed with the travel direction
selected, an instruction to release the parking
brake is displayed.
Fig. 1
When warning lamp (113) lights up

during operation:
- stop the machine immediately,
Fig. 2
- apply the parking brake, and è
- secure the machine.
Do not put the machine back into
operation unless the fault has been
rectified.

Fig. 3
· To unblock the service brake, depress the lever

on the left of the pedal (62, Fig. 2). The pedal is
unlocked and the brake is released. The floating
axle is unblocked at the same time if it was not
blocked with key (33, Fig. 4) (see: "Blocking the
floating axle").
Fig. 4
The automatic unblocking of the

floating axle during unlocking of the
service brake can, under certain cir-
cumstances, compromise the sta-
bility of the machine. This is the
case, for instance, when the opera-
tor intends to travel with a load on
the hook, the superstructure being
slewed out of basic position.
For these cases, observe the chap-
ter:
"Travelling with a load on the hook".

Applying / releasing the parking brake 10000198.02-en
Do NOT apply the parking brake Under certain circumstances, this

unless the machine is stationary. action can compromise the stability
When the machine is moving, the of the machine, for instance, when
parking brake must not be applied the operator intends to travel with a
except in an emergency, e.g. when load on the hook, the superstructure
the service brake has failed. being slewed out of basic position.
The braking action sets in abruptly In these cases, see:
and the wheels will block up.
" Driving with a load on the hook ".
See also "Switches/pushbuttons;
The travel gearbox is equipped with two sets of No. 32“
braking disks which are blocked by spring pressure
when the parking brake is applied.
Applying the parking brake If switch (32) is in the
"Parkig brake release"
The parking brake is actuated with rocker switch
(32, Fig. 1) by depressing the switch face with the position when the ignition is switched
locking wedge. The rocker switch is now locked on, the parking brake remains none-
against inadvertent actuation. The light slot on the theless applied (light slot on rocker
rocker switch lights up red. At the same time, the switch illuminated red and floating
floating axle is being blocked irrespective of the axle being blocked) until switch (32)
switching position of key (33) which controls is being brought first to the
blocking of the floating axle.
"Apply parkingbrake" position
· Though it is still possible to select the travel di-
and then to the
rection with pushbuttons (65 and 66, Fig. 1), the
machine cannot be set in motion against the "Release parking brake " position
blocked parking brake.
See also "Switches / pushbuttons
· When the travel pedal is pressed with the travel No.32".
direction selected and the parking brake applied,
an instruction to release the parking brake is dis-
played once on the screen for a short time.
Releasing the parking brake
· Unlock switch (32) and depress the switch face
under the light slot (the light slot goes out; die
floating axle is unblocked if it was not blocked
with key (33). (see: "Blocking the floating axle").
Fig. 1


2245128-en

Shifting the travel gearbox 10000816.00-en
Fig. 1 è
Shifting the travel gearbox Creep speed

Depending on the type of work for which the ma- Shifting into and out of creep gear is possible only
chine is used, the following gearshift operating at driving speeds below 15 km/h. The creep speed
modes can be preselected: gear can be activated and deactivated with key
(36, Fig. 2) (LED2 is lit up when the creep speed
- Fixed 1st gear for slow driving, e.g. off the road. reduction is active). At the same time, the snail
(LED1 above key (16, Fig. 2) is on) symbol shows up in the display at the lower right
- Automatic operation. (Fig. 1). The travelling speed is reduced in the
(LED1 above key (16) is off) respective gear by about 80 %.
The screen (Fig. 1) displays in the middle of the
lower half the symbol for the selected gear (turtle
st nd
= 1 gear or rabbit = 2 gear) when pedal When the creeep speed is addition-
(61, Fig. 2) is being depressed. ally activated, the actual speed is
fixed..

Switching of "fixed 2nd gear" (option)

After installation of the option, key (16, Fig. 2 ) has
a different function:
- LED1 above the key not illuminated:
Automatic operation
This setting corresponds to the standard scope
of functions of the machine.
- LED1 above the key illuminated:
In conjunction with additional rocker switch
st nd
(50, Fig. 2), the 1 and also the 2 gear can be
fixed:
- Switch face without symbol depressed:
st
1 gear
Fig. 2 - Switch face with symbol depressed:
nd
2 gear
When switching over from the automatic mode to
Gearshift response on mode-of-operation fixed gears and vice versa, delayed shifting opera-
changes during driving: tions similar to those described under "Gearshift
1. The driver shifts from automatic operation into response on mode-of-operation changes during
the fixed 1st gear. LED1 above key (16, Fig. 2) driving" must be expected depending on travelling
lights up. The gearbox shifts as follows: speed and machine loading.
For installation and activation of the option, please
- At travelling speeds < 1 km/h: immediate shift contact our Service Dept.
st
into 1 gear. o
- At travelling speeds < 5 km/h: shift into the 1st
gear at heavy loading of the travel drive. At low
loading, shifting into 1st gear takes place only
when the travel drive loading increases or
when the machine travels at less than 1 km/h.
st
2. The driver shifts from the fixed 1 gear into the
automatic mode. LED1 above key (16, Fig. 2 )
goes out. The gearbox shifts as follows:
- At travelling speeds < 3 km/h and low loading
of the travel drive: immediate shift into auto-
matic.
- At heavy loading of the travel drive or at a trav-
elling speed greater than 3 km/h, the change
takes place only when the above conditions
are fulfilled.

Travelling, multi-function display screens 10000808.00-en
Fig. 1
Fig. 2 è

Road travel, multi-function display screens
If the safety lever is brought by acci-

dent into lower position I during road
travel, the working equipment is free
to move. In this case, a perodic
warning is sounded and warning mes-
sage displayed on the screen.
The slewing movement continues to
be blocked. The superstructure
holding brake remains applied and
cannot be released with key
(17, Fig. 3).
Fig. 3
Switching on road travel: Switching off road travel:

- Set safety lever (72, Fig. 3) to position 0 (see: · Safety lever (72, Fig. 3) must be in position 0.
"Switching off the pilot control").
- Depress the "Road travel" key (35, Fig. 3): LED2
- Depress "Road travel" key (35, Fig. 3). LED2 above key 35 goes out. The road travel symbol is
above key 35 lights up and the road travel sym- no longer displayed on the screen.
bol is displayed on the screen (Fig. 1).
If key (35) is pressed without the

Road travel safety lever being in position 0, a
When road travel is activated: warning is sounded and a text mes-
sage is displayed. This is the case
1. the DRIVE power mode is activated in addi- when road travel is switched on and
tion; also when it is switched off. For rea-
2. all machine functions except travelling are off sons of safety, the road travel func-
(this applies also to the levelling blade and tion can only be activated and deac-
stabilizer functions. In this case, the safety tivated when the safety lever is in
lever must be in position 0 throughout the position 0.
driving operations);
3. the superstructure holding brake is applied.
The last switching status of the
When the travel pedal (61) is pressed, one of the "Road travel" key / function is saved
screens shown in Fig. 2 is displayed depending on at "Ignition off" and is reactivated
the temporary option selected. again after the machine is started.
o

Steering column 10000297.01-en
Steering column, safety instructions
Risk of accidents
Do not adjust the steering column
while driving, because you must
concentrate on the road to avoid
accidents.
Before adjusting the steering col-
umn:
- stop the machine
- press pushbutton (67, Fig. 1) "trav-
elling direction" (neutral)
- apply parking brake.
Fig. 1
Adjusting the steering column
Read and observe:

"Steering column, safety instruc-
tions".
The angle of the steering column can be adjusted

to suit the height and posture of the operator:
- Press lever (79, Fig. 1) with toe cap down and
keep in position to unlock the steering column.
Fig. 2
- Tilt steering column into required position.
o
- Release lever (79) to lock steering column.
- Check that steering column is locked.


2245128-en

Blocking / unblocking the floating axle 10000837.00-en
The steered axle is suspended from the undercar- The floating axle is unblocked automatically when
riage in such a way that it can float about the logi- the parking brake (32) and the service brake (62)
tudinal axis of the machine (floating axle). This are released.
feature is an advantage when driving on uneven
Important:
terrain. During working it is, however, necessary to
avoid axle floating. To achieve this, the oil ex- After blocking of the floating axle by one of the
change between two hydraulic cylinders taking brakes, the 'brake applied' condition can be acti-
support on the axle is prevented. The floating axle vated in permanence by pressing key (33, Fig. 1).
is then blocked and the stability of the machine The switching action is confirmed by an acoustic
considerably increased. Before using the machine signal. After releasing of the brakes, the floating
for driving, the floating axle must be unblocked axle is now not being released at the same time. It
(exception: see "Driving with a load on the hook"). remains in blocked condition until key (33, Fig. 1)
is pressed again.
When the floating axle is blocked with key
Blocking the floating axle (33, Fig. 1) and the machine shut off (ignition
Depress key (33, Fig. 1), pilot lamp LED2 lights up. OFF), the "blocked" condition will be restored when
the machine is started next time.
Unblocking the floating axle
- Depress key (33, Fig. 1), pilot lamp LED2 goes
out. When the 'Road travel' function has
been activated by means of key
(35, Fig. 1), blocking of the service
Important: brake does NOT result in blocking
of the floating axle.
A freely moving floating axle is blocked automati-
cally when the parking brake (32, Fig. 2) or the
service brake are being applied. When switch (32) is in the
'Parking brake released'
After application of the parking brake position at the time the ignition (7)
with rocker switch (32, Fig. 2), the is switched on, the parking brake
floating axle is blocked with a brief will nevertheless remain applied
delay. (light strip on rocker switch lit up
During this delay, do not "release" red and floating axle blocked) until
the floating axle with key (33, Fig. 1). switch (32) has first been brought to
There is otherwise the risk of the the
floating axle being unlocked for a 'Parking brake applied'
short moment before locking via the
parking brake becomes active. and then thereafter to the
'Parking brake released'
position.
See also 'Switches/keys', pos. 32“

Fig. 1
Fig. 2

Bringing the machine into its basic position 10000086-en
Example (Fig. 2):

Read and observe the chapter:
The superstructure is turned by more than 90° out
"Driving, safety instuctions". of its basic position.
The operator looks through the front window and
wants to travel in this direction.
All indications concerning the travelling direction
are always referred to the machine in its basic He depresses the travel pedal. The machine, how-
position (Fig. 1 and Fig. 2). ever, does not travel in direction B but in direction
A.
The machine is in its basic position when the
driver's cab (1, Fig. 1) is over the left pair of wheels Although the operator wants to drive "forwards" he
of the steering axle (2). is actually driving 'backwards".
A = travelling forwards: the wheels of the steered Therefore:

axle are in front If the position of the superstructure in relation to
B = travelling backwards: the wheels of the rigid the undercarriage is not exactly known, look out of
axle are in front the windows to check the direction of the super-
structure with respect to the undercarriage.
Only in the basic position are the travel direction
selected and the true travel direction the same. If this is not possible, the travel pedal must be de-
pressed only slightly.
You can now find out in which direction the ma-
Risk of accident chine is actually travelling.
If the superstructure is slewed more Depress the travelling pedal fully only after the
than 90° out of basic position actual travelling direction is perfectly clear.
(Fig. 2), the machine travels in the è
direction opposite the selected trav-
elling direction.

Fig. 1
Fig. 2

Driving operation 10000189.01-en
Fig. 1 è

Driving on roads
Read and observe: When the "Road travel" function

(key 35, Fig. 1) is active, blocking of
"Driving, safety instructions".
the brake does not cause blocking of
the floating axle.
All reference positions are shown in the picture · Unblock the service brake by depressing the
opposite. locking pin on the left of pedal (62) releasing the
pedal slowly.
· Raise the levelling blade and the stabilizer legs
completely. The stabilizers must be vertical. Be- · Depress travel pedal (61). The machine sets off.
fore setting off, make a visual inspection of the The selected gear and the travelling speed are
machine. displayed on the screen. The selected travel di-
rection is indicated by pilot lamps (1). Control the
· Lock the superstructure with pin (68) (see: "Su-
travelling speed with travel pedal (61).
perstructure slewing / braking / locking").
· Apply the superstructure holding brake by de-
pressing key (17, Fig. 1) until LED1 lights up.
· Set safety lever (72, Fig. 2) to its uppermost po-
suítion "0".
· Selet the the "Road Travel" function (see: "Trav-
elling, multifunction display screens").
· Select the gearshift operating mode (see: "Shift-
ing the travel gearbox").
· Release the parking brake by unlocking rocker
switch (32) and by depressing the switch face
beside the light slot. At the same time, the float-
ing-axle blocking is released and the selected
travel direction is enabled (see: "Unblocking the
floating axle"). Fig. 2
· Select the travel direction with pushbutton (65) or o

(66):
- Depress button (65) =
- selects forward travel; the travel direction is
indicated by pilot lamp (101) on the display
screen.
An acoustic warning is sounded once.
- Depress button (66) =
- Selects reverse travel; the travel direction is
indicated by pilot lamp (107) on the display
screen (see: "Multi-function display").
(If a very low travelling speed is necessary,
select the 1st gear with key (16) (off-road
travel) and the creep speed with key (36).
An acoustic warning is sounded twice.

Braking and stopping 10000190.01-en
Fig. 1 è

Braking and stopping
· Release travel pedal (61, Fig. 1). If travelling is not continued after stopping,
secure the machine against inadvertent move-
· Depress service brake pedal (62): the machine ments:
stops.
· Park the machine only on level surfaces and
· Depress key (15): the engine is reduced to idling stand the working equipment and the stabilizers
speed (Low Idle). on the ground.
· Depress pushbutton (67): the travel direction · Apply the parking brake with rocker switch (32)
selector is in neutral position by depressing the switch face with the locking
· A prolonged tone is heard. slide. The switch is now protected against inad-
vertent actuation.
· Depress the "Road travel" key (35, Fig. 3): LED2
above key 35 goes out. The road travel symbol
on the display screen is switched off. Safety
lever (72, Fig. 1) must in this case be in position
0 (see: "Driving, enlarged functions").
· Block the service brake by depressing pedal (62)
until it engages in the low position.
· The floating axle is blocked at the same time.
· Shut off the engine.
o

Travelling uphill and downhill 10000191-en
If driven for a longer time at high

speed down excessively steep
slopes, the machine might get out of
control and therefore not respond to
braking. Therefore:
- Never drive down slopes with a
gradient of more than 30 ° (57,7 %)
(Fig. 2). Take an alternative route
with a lower gradient.
- Never drive on extensive downhill
slopes with the service brake pe-
dal constantly applied. That may
lead to extreme wear on the brake
disks and, in the worse-case sce- Fig. 1
nario, to service brake failure.
- To prevent the travel speed from
getting too high, switch with key
st
(16, Fig. 1) into 1 gear.
- On steep gradients, switch addi-
tionally into creep speed with key
(36, Fig. 1).
Read and observe "Travelling, safe-
ty instructions".
· Drive in basic position and forwards only; the

steering wheel is then above the steering axle.
Fig. 2
· Never drive across slopes and never turn on
slopes: risk of the machine overturning.
The engine must not be run when
· Always change to 1st gear (off-the-road travel; the slope has a gradient of more
see “Changing Gear“) before the downhill / uphill than 35 degrees, as interrupted oil
slope, using key (16, Fig. 1). and lubrication effects lead to se-
This increases the braking action of the travel vere wear on the components with
motor, preventing inadmissibly high travel consequent damage.
speeds.
o
· Control the travel speed with the Travel pedal
(61, Fig. 1). 10000695.01-en
Always control your travelling speed

using the accelerator pedal (61). Re-
leasing the pedal for long periods
when driving down slopes is forbid-
den as it may lead to strong over-
heating and damage to the engine
due to lack of cooling and hydraulic
oil lubrication.
o

Driving with a suspended load 10000192-en
Read and observe the section on

· Slew load into direction of travel. The steering

wheel is then above the steered axle.
· Keep load as close as possible to the ground
and to the machine.
· Lock superstructure with bolt (68, Fig. 2).
· Apply superstructure holding brake with rocker
switch (17, Fig. 2). LED1 above the symbol lights
up. At the same time, the pilot lamp (105, Fig. 2) Fig. 1
above the display is also lit up.
· Release swing axle blocking with rocker switch
(33, Fig. 1). (LED2 extinguishes).
· Drive slowly and carefully.
When driving on level ground with the su-

perstructure in basic position:
Avoid this situation whenever pos-

sible. The stability of the machine is
otherwise endangered.
Fig. 2
¨
· Block swing axle with rocker switch (33, Fig. 1)
(Switch face and LED2 light up).
· After completing the journey and setting down
the load, release blocking of swing axle.

Driving on public roads 10000179.03-en
Read and observe:

· Bring the working equipment into such a position

that the maximum admissble dimensions of the
machine are not exceeded (Fig. 1 and 2).
· Set the backhoe / grab switching valve to "grab
equipment". The bucket cylinder is then hydrauli-
cally blocked (See: “Switching between backhoe
and grab equipment“).
· Attach the sidemarker light (2, Fig. 1 und 2) to
the stick. Fig.1
· Connect the sidemarker light to the external

socket on the frame.
· Raise the levelling blade completely.
· Attach the retro-reflector to the levelling blade.
· Raise the stabilizer legs completely (option).
They must be vertical.
· Switch off the floodlamps.
· Lock the superstructure.
· Activate the "Road travel" function (35, Fig. 3)
see: “Driving, Multi-function display messages“.
For machines with grab equipment observe Fig. 2
also:
- Install safety locking pin for toggle link and con-
necting rod (1, Fig. 2).
- Place grab on the grab support on the undercar-
riage.

observed.
Fig. 3

Machine recovery / towing 2904037.01-en
Recovery and towing, safety instructions
Tow the machine only with a tow- Tow only if the brakes and the
rod. steering of the machine are func-
tioning properly and if the machine
The tow-rod must be free from dam-
cannot be transported otherwise.
age. It must be dimensioned in such
a way that the calculated breaking Tow defective machines only as far
load is equal to three times the trac- as necessary to recover the ma-
tive power of the towing machine. chine from hazardous areas.
The towing vehicle must have ade- After the recovery, the machine
quate tractive and braking power. must be secured against inadvertent
movements and unauthorized
Drive slowly, carefully and smooth-
starting.
ly.
Have the machine repaired before
All persons must keep clear of the
transporting it over greater distan-
tow-rod.
ces, or load it onto a transport vehi-
cle.
The machine is not suitable for
towing trailers or other vehicles;
this would result in damage to axles
and gearboxes. The tow coupling
(see chapter: "Machine, recovery /
towing") is designed solely for
towing or recovering vehicles from
hazardous areas or for lashing pur-
poses on transport vehicles..

Recovering / towing the machine 10000798.01-en
Observe the current accident pre- After the recovery / towing

vention regulations. · Secure the machine against inadvertent move-
Read and observe: ments,
"Recovery and towing, safety in- - Stand the working equipment on the ground.
structions". - Press the bucket into the soil.
- Place chocks under the wheels.
Towing with the tow-bar · Secure the machine against unauthorized start-
Attach the tow-bar to the upper hole of the rigging ing.
and towing lug of the excavator and to the tractor · Re-engage the drive in the travel gearbox by
vehicle (Fig. 1). turning the hex-head bolt (Fig. 2) ca. 180° to the
right or the left until the index ball is felt to en-
gage. The connection between travel gearbox
Towing with chains and the axles is now re-established.
Attach a chain of Æ 13 mm with an admissible
tensile load of 10 000 daN (10 t) / EN 12195-3 to
one of the lateral holes of the rigging and towing
lug of the excavator (arrow, Fig. 1) using a heavy-
duty shackle type A / DIN 82101 (load capacity 8,5
... 12,5 t) or the chain-hook, and to the tractor vehi-
cle (Fig. 1).
Disengage the travel gearbox

Disengage the drive in the travel gearbox by turn-
ing the hex-head bolt (Fig. 2) ca. 180° to the right
or the left until the index ball is felt to engage.
The connection between travel gearbox and the
axles is now interrupted. Fig. 1
Recovery / towing
· Block off the hazard zone generously.
· Drive carefully and slowly.
· When the engine is running:
the service brake is operational.
· When the engine is not running:
the service brake is operational within certain
limits.
The legal requirements are fulfilled:
· Even with the engine stationary, a filled brake
pressure accumulator permits ca. 6 to 8 braking Fig. 2
cycles until standstill of the machine.
o

Parking brake, emergency release 10000188.01-en
Secure the machine against inadver-

tent movements before working un-
der the machine to release the
parking brake:
- press the bucket into the soil and
shut off the engine;
- withdraw the key from the key-
switch;
- lock up the cab and attach a sign
with the following warning to the
cab door: "Do not put into opera-
tion, machine without brake";
Fig. 1
- block the wheels with chocks.
o
To avoid dangerous situations, the
emergency release function should
be used only in exceptional cases
when it is necessary to release an
applied parking brake.
Have the defective parking brake re-
paired immediately.
The pilot pressure required for releasing of the

brake is controlled by a solenoid valve. In the
event of solenoid malfunction or power supply fail-
ure, the parking brake can be released manually
with the emergency release device.
The solenoid is located in the frame above the
travel gearbox near the rotor dome (Fig. 1).
· Screw the setscrew (1) down to the limit stop
using an Allen key SW 3. The parking brake is
released.
· After rectification of the fault, screw out the
setscrew completely.

Transport of the machine 10000186.02-en
Transport, safety instructions
For transport on public roads apply to the compe-

The machine must only be loaded tent traffic authority for a transport permit.
and transported if all safety regula-
tions are complied with. In case of rail transport, arrange for loading and
transport of the excavator with the competent rail-
Entrust loading and transporting of way authority to obtain a corresponding approval.
the machine only to a company ex-
perienced in the transport of heavy Depending on the size of the low-bed trailer or
equipment. railway waggon, the working equipment must be
partially or completely detached. Dimensions and
The responsibility for loading and weights for loading are set out in the "Technical
transporting lies with the transport data".
company or their representative.
Remove oil, grease soil, mud, snow,
ice and other materials from the ma- Drive the machine carefully onto the transport ve-
chine's wheels and from ramps and hicle.
loading platforms of the transport Have a marshaller assist you in this operation.
vehicle to minimize slipping.
Secure the machine against unintentional move-
Secure transport vehicle against in- ments (Fig. 1).
advertent movements.
Use only tying equipment of suf-
ficient strength (the weights of the
machine are set out in the "Technical
data").
Fig. 1

· Apply parking brake with rocker switch

(32, Fig. 2)
· Block service brake (62)
· Lock superstructure with bolt (68)
· Stand working equipment on the loading platform
of the transport vehicle
· Switch off pilot control with lever (72)
· Shut off engine
· The superstructure holding brake is now auto-
matically applied
· Withdraw key from key-switch Fig. 2
· Close doors and windows

· Put chocks under the wheels
· Tie down the machine safely by attaching tying
chains at the marked positions (Fig. 3) (see:
"Tying down the machine").
Never place tying chains over

steering cylinder and braking or hy-
draulic lines.
Fig. 3

Tying down the machine 10000799.00-en
For transport purposes, the machine must be tied

down in front and at the rear with two tying chains
each.
Depending on the existing working equipment or
stabilization variant, the following prescriptions/
spacings are applicable for tying down of the ma-
chine.
The fastening points for the tie-down chains for
fastening of the machine are identified by the sym-
bol shown in Fig. 1.
Fig. 1
Fastening point A
Lower the levelling blade for trans-
port and for fastening onto the
loading platform.
Tie down the machine at the left-hand and at the

right-hand fastening point to the respective side
(do not tie crosswise) using heavy-duty shackles
(Fig. 2).
Shackle
Form A / DIN 82101, load capacity 9500 kg or
12 000 kg.
Tying chains Fig. 2
Æ13 mm and an admissible tensile load of von
10 000 daN (10 t) / EN 12195-3.

Fastening point B
Tie down the machine crosswise at the fastening
points of the undercarriage using the hooks of the
tying chain (Fig. 3).
Tying chains
Æ13 mm with an admissble tensile load of 10 000 daN
(10 t) / EN 12195-3.
The fastening points on the loading platform must
be at least 2 m apart (Fig. 3)
Fig. 3
Fastening point C
Tie down the machine at the lateral holes of the The fastening points on the loading platform must
rigging and towing lug to the respective side (do be at least 2 m apart (Fig. 3).
not tie crosswise) using heavy-duty shackles
(Fig. 4).
Shackles
Form A / DIN 82101, load capacity 8500 kg.
Tying chains
Æ13 mm with an admissible tensile load of
10 000 daN (10 t) / EN 12195-3.
Total weight of the Fastening distance

machine [t] a
< 20 t > 750 mm
> 20 t > 1300 mm
Fig. 4

PCS failure while driving 2904048.01-en After travelling 2486236-en
Read and observe: If the machine is no longer needed for working,

perform the operations described under "Parking
"Operation, safety instructions". the machine".
o
If the engine speed suddenly drops during working

operation or while the machine is being driven
(engine throttling) or if the engine even stalls, there
may be a malfunction in the load-limit regulator
(PCS module).
In the event of malfunction in the PCS module, a
fault code appears in the display (see: "Fault
codes").
Measures to be taken in the event of failure in the
load-limit regulator (PCS module) are detailed un-
der "Working in the event of load-limit regulator
(PCS module) failure".
o

Working operation 10000087-en
Working operation, safety instructions
Before starting work Contact with overhead power

Read and observe the sections lines
"Fundamental safety instructions" Make sure the clearance between
and "Operation, safety instruc- working equipment and overhead
tions". power lines and other structures is
Inspect the site for underground sufficient.
gas, power and water lines before If a power line has been contacted,
starting work. drive the machine out of the hazard
Any damage to such lines is a risk zone or lower the working equip-
to life. ment.
Clean off any earth, mud, snow, ice, If this is not possible:
grease and oil adhering to your - do not leave the driver's cab
working footwear before operating
the machine. - inform persons outside the hazard
zone to keep away from the ma-
There is otherwise a risk of slipping chine and to take the necessary
off the pedals and steps and initiat- steps to have the power line shut
ing inadvertent movements. off.
Warn persons in the immediate vici-
nity by sounding the horn before
starting work. Notes on engine operation
Work with the machine only in its At low temperatures, the engine per-
basic position and when it is forms the "warming-up" phase.
standing on level and - if possible Then activate all hydraulic functions
horizontal ground. for abt. 10 minutes (bring to service
There is otherwise a risk of affecting temperature). For further instructi-
the machine's working stability (see: ons, see section "Lubricants".
"Machine in working position". As soon as the warning lamps for
Bear the load capacity of the ma- engine operation or filter monitoring
chine in mind (cf. load-capacity ta- (hydraulic oil at service tempera-
ble on the machine). ture) light up: lower the working
equipment and shut off the engine.
o
Persons in the machine's
hazard range
Stop work if anyone is in the hazard
range of the machine.
Make sure such persons have left
the hazard range before resuming
work.
Trenches and building pits

Trenches and building pits may give
way. Keep well clear of them.

Extreme position of working Before beginning work 10000818.00-en

equipment, instructions 2411342.01-en
Parts of the working equipment may

Read and observe:
damage the machine if moved into
extreme positions (Fig. 1). "Working operation, safety instruc-
tions".
If moved into extreme positions, parts
of the boom adjusting equipment
may hit the driver's cab and cause
damage and injuries. Before starting work every day, perform all checks
and activities in acc. with servicing plan T (see
Slewing is possible only to a limited part 3 of these operating instructions: "Inspection
extent, for instance, when the equip- and servicing").
ment is in low position and/or when
the stabilizers and the levelling
blade are up
Work with due care and attention
avoiding such extreme positions.
Fig. 1
· Sit down on the driver's seat.

· Start up the engine.
Fig. 1
· Set the required speed of the engine with key
o (13, Fig. 1). Depending on the mode of opera-
tion, up to 7 engine speed levels / power levels)
can be preset.
Mode of operation Power levels

Crane operation 1-3
Digging 4-7
Levelling 4-7
Road travel DRIVE
Hammer 4-7
Shears 1-7
Rotary cutter 4-7
Lifting magnet 4-7
Wood handling 4-7
¨

Activating / deactivating the automatic speed reduction 10000212.01-en
Activating the automatic speed reduction

Do not activate the speed reduction
function (performance reduction) in - Depress key (14, Fig. 1); LED2 is lit up.
the following cases: lifting gear,
Deactivating the automatic speed reduc-
hammer, rotary cutter or driving op-
erations.
tion
- Depress key (14), LED2 goes out.
Risk of unexpected changes in ma-
chine power. (The Auto-Idle speeds and the time to activation
are preprogrammed at the factory. These pa-
rameters can be modified depending on the condi-
The speed reduction function (Auto Idle) automati- tions of use of the machine. Contact our Service
cally reduces the engine speed in no-load working Dept. if a modification of the programmed values is
conditions. required).
The drive engine is throttled down to idling speed if

work with the working equipment is interrupted for
longer than 4 seconds.
Fuel consumption and noise and exhaust emis-
sions are reduced.
When the operator activates a hydraulic function,
the drive engine speed is again increased to the
previously set speed of the respective power level.
The switching state of the Auto Idle function
(ON / OFF) is saved after engine shut-off.
Fig. 1

Selecting the power level 10000239.02-en
The power level is selected with keys

(12 and 13, Fig. 1). If the arrow keys are de-
pressed longer, the values keep changing automa-
tically.
The engine speed can be varied in 7 stages up to
maximum engine speed and pump performance.
Power levels 6 and 7 are used for working with
high pump output (see: "Before beginning work").
Power levels 4 and 5 are used for working in the
economy power range of the engine. Engine speed
and pump output are reduced and the working
speed is slightly lower.
In power levels 1 thru 3, the machine works with Fig. 1
further reduced engine speed and pump output.
These power levels are particularly useful for pre-
cision work, e.g. lifting operations, and for further
reduction of the fuel consumption.
The selected power level is indicated on the dis-
play screen by dark bars representing the power
stages (1, Fig. 2).
When the road travel mode is active (see: "Travel-
ling, multi-function display screens"), the DRIVE
mode is activated additionally.
After starting of the engine, the machine is set to
power level 2 which was in use before engine shut-
off (exception: warming up phase / WARMUP).
Fig. 2

Switching on the pilot control 10000210.01-en Switching off the pilot control 10000211.01-en
Set the safety lever (72, Fig. 1) to position I.

Before leaving the driver's seat, set
The electrical pilot control is then activated; the safety lever (72, Fig. 1) to position 0.
control levers (69 and 70, Fig. 2) and the pedal Triggering a working function, e.g.
(77, optional equipment) are operational. superstructure slewing, by inadver-
tent actuation of one of the control
levers is thus prevented.
Set safety lever (72, Fig. 1) to position 0. The pilot

control is then deactivated.
Before switching into the "Road travel" mode
(key 35, Fig. 2) the pilot control must be switched
off (see: "Travelling, multi-function display symbols
and indicators “).
Fig. 1
Fig. 1
Fig. 2
Fig. 2

Slewing and braking the superstructure 10000819.00-en
Locking the superstructure Slewing the superstructure

· Bring the machine into its basic position. · Switch the superstructure holding brake into the
automatic mode by depressing key (17, Fig. 2)
Locking lever (68, Fig. 1) is then right above an
until LED2 is lit up (this mode is selected auto-
opening in the undercarriage.
matically on engine start-up, see also: "Apply-
· Pull up lever (68), turn it away from the seat and ing/releasing the superstructure holding brake").
push downwards.
· Swith on the pilot control with lever (72, Fig. 2)
The locking pin engages in the opening in the by shifting the safety lever forwards (see:
undercarriage. "Switching on the pilot control").
If the locking lever cannot be turned at all or only
· Unlock the superstructure (68, Fig. 1).
with difficulty, slew the superstructure slowly to
the left or to the right, pushing the lever down-
wards at the same time.
Slewing the superstructure to the right
Unlocking the superstructure
- Push control lever (70, Fig. 2) to the right.
· Pull up locking lever (68, Fig. 1), turn towards the
seat and engage.
· If the locking lever cannot be turned at all or only Slewing the superstructure to the left
with difficulty, slew the superstructure slowly to - Push control lever (70) to the left.
the left or to the right, pulling the lever upwards
at the same time.
Fig. 2
Fig. 1 è

The slewing speed increases the further the control

lever is moved to the right or left.
Braking the superstructure

The slewing movement of the superstructure is
braked when the slewing control lever (70, Fig. 2)
returns to position 0.
Key (19, Fig. 2) can be used to adjust the braking
effect of the superstructure holding brake. The time
between control lever release and standstill of the
superstructure can thus be adapted in three steps
to the actual requirements.
LED - soft braking of superstruc-

= OFF ture slewing movement
LED1 - standard braking action
= ON
LED1 and 2 - hard braking of superstruc-
= ON ture slewing movement
Countering (i.e. shifting the slewing control lever in

the opposite direction) enhances the braking action
even further.
Both LEDs flash at intervals if a fault

occurs in the system. Key (19) has
lost its function. The switching func-
tions are blocked. In neutral posi-
tion of slewing control lever
(70, Fig. 2), the slewing braking ac-
tion is weaker. If necessary, in-
crease the slewing braking action
by moving the lever to the opposite
direction (countering).
Attention
There is now a greater risk in the
slewing range.
o

Slewing, setting the slewing power limitation 10000821.00-en
Fig. 1 è

Setting the slewing power limitation DEFAULT = resets the settings

The hydraulic slewing power of the superstructure Depending on the type of machine, the pa-
can be individually adapted to the working needs rameters are reset to the factory-defined
and to the conditions of use of the machine. standard values (1, Fig. 1).
To set the slewing power of the superstructure The standard values may vary with the type of
· In the working mode, depress an arrow key until machine.
MACHINE in the main menu is highligted grey When the slewing power limitation is on and active,
and depress the SET key (Fig. 1). the slewing power symbol (1, Fig. 2) is displayed in
the lower left corner of the screen.
· Depress the arrow keys to move the bar to
“SWING POWER” and depress the SET key. Observe the priority of the temporary symbols dis-
played (Section "Multifunction display operating
Arrows in the lower right corner of the display indi-
mode").
cate that further submenus can be called up
ON = slewing power limitation active, the

slewing power preset is indicated as a
percentage, e.g. 40 %.
OFF = slewing power limitation inactive
ADJUST = values can be set
The values are increased or decreased with the

arrow keys in 5 % steps.
A long press of the arrow keys starts automatic
scrolling of the values.
Fig. 2
The desired hydraulic slewing power of the super-
structure can be set with the UP and DOWN arrow o
keys. Higher values mean more power available
for slewing with a simultaneous reduction of the
hydraulic power available to other working move-
ments such as "Raising the boom" and vice versa.
The settings are shown as a bargraph display be-

tween 30 % and 100 %. Depressing the SET key
twice saves the settings whereas depressing SET
only once and then the arrow key UP rejects all
changes made and returns to the main menu.

Superstructure holding brake, function 10000205.01-en
The slewing gearbox is equipped with a multiple-

disk brake which is applied by spring pressure and
released by hydraulic pilot pressure.
The superstructure holding brake

can be applied at any time with key
(17, Fig. 1, LED1 on) (see "Applying
the superstructure holding brake").
The holding becomes active only
after slewing control lever (70) is in
neutral position and the superstruc-
ture slewing moving has come to a
halt. About 3 seconds later, the
"Holding brake" indicator (105; Fig. 2) Fig. 2
lights up on the display screen.
The superstructure holding brake is applied when
the key-switch is off, when the engine is stationary
or in the event of system voltage failure. The su-
perstructure is then braked.
o
Fig. 1


2245128-en

Applying / releasing the superstructure holding brake 10000822.00-en
Applying the superstructure holding brake When the pilot control is switched
The superstructure holding brake can be operated off, the holding brake is switched si-
in the following three modes: multaneously from "released" to "au-
tomatic". When the pilot control is off
· Key (17, Fig. 1) not pressed, LED1, LED2 off: with safety lever (72, Fig. 2) in posi-
superstructure holding brake released; super- tion 0, the holding brake can only be
structure free to turn. switched from "automatic" to "applied".
· Key (17, Fig. 1) depressed once, LED2 lit up: In this situation, the safety level of
Indicator lamp (105, Fig. 3) lights up when the the holding brake can only be in-
superstucture is not slewed for more more 3 se- creased. Releasing of the brake in
conds. this state is not possible.
This mode is automatically activated if safety
lever (72, Fig. 2) is set to 0 out of the "Released"
switching position. Releasing the superstructure holding
Automatic operation; holding brake is automati- brake
cally applied when the superstructure is station-
ary and released when a slewing movement is · Depress key (17, Fig. 1) repeatedly until the two
initiated. LEDs above the key are extinguished. The hold-
ing brake is released and the superstructure is
· If the superstructure holding brake is set to "Ap- free to turn (not possible when pilot control is off,
plied" during a slewing movement, LED1 lights see info box).
up.
For safety reasons, the brake is applied, how- In the automatic mode with LED2 lit up, the holding
ever, only after the slewing movement has brake is released when the slewing control lever is
ended. moved out of neutral position.
· Technical problems can lead to a change of the è
functions of key (17). See "Malfunctions of the
superstructure holding brake".
The following switching states of the superstructure

holding brake that are active when the ignition is
switched off, are active again when the ignition is
switched on.
Ignition off Ignition on

released automatic
automatic automatic
applied applied

Superstructure holding brake faults

· Fault condition 1
- all 3 switching states continue to be available;
in the "Automatic" or "Applied" states, the re-
spective LED flashes (automatic LED2, ap-
plied LED1)
The braking action of the superstruc-

ture holding brake is no longer en-
sured under all conditions of use.
Higher risk of accident!
Fig. 1
· Fault condition 2
- only the "Released" and the "Applied" states
are available; in switching state "Applied",
LED1 flashes.
When switching over from "Released"

to "Applied" in fault condition 2, the
holding brake is activated immediate-
ly. This may result in damage to the
holding brake. Switch over from
"Released" to "Applied" only when the
superstructure is stationary and
when LED1 flashes.
Fig. 2
Switch over from "Released" to "Ap-
plied" only in cases of emergency
when the superstructure is still
moving.
o
Fig. 3

Superstructure holding brake, emergency release 10000339-en
In the event of solenoid failure, the superstructure

The superstructure is free to turn holding brake can be released with the emergency
when the superstructure holding release device.
brake is released with the emer-
gency release device. The solenoid valve is installed in the frame behind
the driver's cab (Fig. 1).
In such case, the superstructure
does not stop automatically after
the end of the slewing movement.
When working on slopes or in an
inclined position of the excavator,
the superstructure can continue to
slew uncontrolled if the slewing
movement is not stopped by coun-
tering.
To avoid dangerous situations, the
emergency release function should
be used only in exceptional cases.
Rectify any faults of the superstruc-
ture holding brake immediately (or
have them repaired).
Fig. 1
· Remove the base-plate of the maintenance

The pilot pressure needed for releasing the super- opening below the valve stack.
structure holding brake is controlled by means of a
· Screw the setscrew (arrow, Fig. 1) down to the
solenoid valve.
limit stop using an Allen key SW 3. The super-
structure holding brake is released and the su-
perstructure can turn freely.
· After removal of the fault, screw the setscrew
back out to the upper stop.
o

Machine in working position 10000206.01-en
Bring the machine into ist basic position. Whenever

possible, use this position for working since it of-
fers a maximum of stabilty.
· Stop the machine

· Block the service brake by depressing pedal
(62). The pedal is locked in depressed position.
· Apply the parking brake with rocker switch
(32, Fig. 1) by depressing the switch face with
the locking slide.
· Extend the stabilizers. The machine can be
equipped with different stabilization variants (op- Fig. 1
tional equipment). Operating instructions see:
"Stabilization of the machine".
Important:
Before travelling with the machine: A freely moving floating axle is blocked automati-
cally when the parking brake (32, Fig. 2) or the
· Raise all stabilizers. service brake (62) are being applied.
· Release the parking brake with rocker switch The floating axle is unblocked automatically when
(32) by sliding the lock in the direction of the ar- the parking brake (32) or the service brake (62) are
row and depress the symbol face of the switch. released.
· Unblock the service brake by depressing the
locking lever on the left of pedal (62). The pedal
is unlocked and the brake released. Release the When the "Road travel" function
pedal slowly. (key 35, Fig. 1) is active, blocking of
the brake does not cause blocking of
the floating axle.

Stabilization of the machine 10000823.00-en
The standard version of the machine does not The stabilizing cylinders move only as long as the
permit independent control of the stabilizers. This pushbutton is pressed. The speed of the up and
means that the stabilizer legs are lifted and low- down movement is fixed.
ered in common. An independent control of the
stabilizers is available as an option in stabilization
variants A2, PLA2 and A4.
Attention:
Depending on the equipment option, the openings
for switches not needed are covered up. 1. As long as the function is active, it is not pos-
sible to activate the "Power-Boost" function by
means of pushbutton (73, Fig. 1 ). Automatic
addition of the power-assist function in power
Control of stabilizers and levelling blade levels 1 - 3 and during travelling as well as as
Set control lever (70, Fig. 1) to position 0. Press of the Power-Boost for some movements of
pushbutton (74) to switch over to the "Stabilizers/ the equipment remains available.
Levelling" function. The buzzer sounds intermit- 2. As long as the function is active, the propor-
tently as long as this function is on. tional control of a levelling blade, if any, is not
When the "Stabilizers/Levelling" function is active, available.
the stick movement is not operational.
"Independent stabilizer control (option)"

After installing the option, the stabilizers can be
moved up and down by depressing pushbuttons
(73 and 74, Fig. 1) in the left joystick without mak-
ing use of the stick proportional control.
To activate this operating mode, the switch face

without symbol of rocker switch (51, Fig. 2), must
be pressed.
A symbol as shown in table 1 is displayed and

pushbuttons (73 and 74 , Fig. 1) now have the
following altered functtions: Fig. 1
Pushbutton Temporary options Symbol

51 independent stabilizer
control ON
control Raising
control Lowering
Table 1
Fig. 2

Standard stabilizer Independent stabilizer

Stabilizer options Levelling blade
control control
Lowering at the rear:

push control (70) for-
wards
(without switches 28, 29,
30 and 31)
Raising at the rear:

pull control lever (70)
backwards
(without switches 28, 29,
PLH 30 and 31)
Lowering at the rear: Lowering at the rear:

push control (70) for- right stabilizer at the rear,
wards switch on
(without switches 28, - switch (28, Fig. 1)
29, 30 and 31) and / or
left stabilizer at the rear
- switch (29)
and push control lever (70)
forwards
Raising at the rear: Raising at the rear:

pull control lever (70) right stabilizer at the rear,
backwards switch on
(without switches 28, - switch (28, Fig. 1)
29, 30 and 31) and / or
left stabilizer at the rear
- switch (29)
and pull control lever (70)
A2 backwards
Table 2

Standard stabilizer Independent stabilizer

Stabilizer options Levelling blade
control control
Lowering in front and Lowering in front and at the

at the rear: rear:
push control lever (70) switch on right front stabilizer
forwards – switch (31)
(without switches 28, and / or
29, 30 and 31, all stabi- left front stabilizer
lizers lowered in com- – switch (30)
mon) and / or
right rear stabilizer
- switch (28, Fig. 1)
and / or
left rear stabilizer
- switch (29)
forwards
Lowering in front and Raising in front and at the

at the rear: rear:
pull control lever (70) switch on right front stabilizer
backwards – switch (31)
(without switches 28, and / or
29, 30 and 31, all stabi- left front stabilizer
lizers raised in com- – switch (30)
mon) and / or
right rear stabilizer
- switch (28, Fig. 1)
and / or
left rear stabilizer
- switch (29)
A4 backwards
Lowering at the rear: Lowering at the rear: Lowering in front:

switch on the right and switch on the right rear stabi- switch on
left rear stabilizer in lizer - switch (30)
common - switch (28) and push control lever
- switch (29) and / or (70) forwards
and push control lever the left rear stabilizer
(70) forwards - switch (29)
forwards
Raising at the rear: Lowering at the rear: Raising in front:
switch on right and left switch on the right rear stabi- switch on
rear stabilizer in com- lizer - switch (30)
mon - switch (28) and pull control lever
- switch (29) and / or backwards (70)
and pull control lever the left rear stabilizer
(70) backwards – switch (29)
PL/A2 backwards
Table 3


2245128-en

Working with backhoe bucket or grab equipment (ISO control) 10000824.00-en
Fig. 1 è

Before starting work Extending and retracting the stick

Read and observe: First switch over to "Stick" function with pushbutton
(74).
"Working Operation, safety instruc-
tions". · To extend the stick:
Persons in the hazard zone - Press control lever (70) forward.
Stop work if persons enter the haz- · To retract the stick:

ard zone and warn them by sound- - Press control lever (70) back.
ing the horn.
Filling and emptying the bucket
Wait until the persons have left the
hazard zone before starting work · To fill the bucket:
again.
- Press control lever (69) to left.
· To empty the bucket:
When levelling ground, the equip- - Press control lever (69) to right.
ment must be moved in trenching
direction only. Never "sweep or Opening and closing the grab
beat" with the trenching attachment (option)
(as in demolition work).
· To open the grab:
The working equipment is not de-
signed for high, laterally acting for- - Press control lever (69) to right.
ces; it would be damaged. · To close the grab:
· Press control lever (69) to left.
All control levers and pedals for the working func- Adjusting the opening and closing speed
tions return automatically to 0 - position on being
released.
of the grab (option)
Before starting work: Press rocker switch (52, Fig. 1). The grab opening
and closing speeds now correspond to the values
- Block service brake by depressing the service preset on the display.
brake pedal (62) until it locks.
For presetting of the speeds see "Grab opening
- Switch on servo-control with safety lever and closing speeds".
(72, Fig. 1).
Turning the grab
- Activate superstructure slewing brake (19).
(option)
Slewing the superstructure
· To turn grab to right:
· To slew superstructure to right:
- Press pushbutton (63) in control lever (69) to the
- Press control lever (70) to right. right.
· To slew superstructure to left: · To turn grab to the left:
- Press control lever (78) to left. - Press pushbutton (76) in control lever (70).
Raising and lowering the boom Switching on the power boost

· To raise the boom: · Press pushbutton (73) in control lever (70) (cf.:
"Power boost, function").
- Pull control lever (69) back.
· To lower the boom: Switching on the horn
· Press control lever (69) forward. · Press pushbutton (64) in control lever (69); the
horn sounds.
o

Power-Assist function 10000674.01-en
The Power-Assist function is always automatically

active in power levels - 3 and in the travelling
function (travel pedal depressed). In the event of
heavier loading, the hydraulic pressure for the
working functions and for travelling is increased.
This means:
- higher lifting forces,
- higher extraction forces,
- higher breaking forces
- higher traction forces and
- improved precision control
at reduced working speeds.
(see: "Technical Data").
When button (73) is depressed, the activation of

the power-assist function is displayed on the
screen (1, Fig. 1).
Exception:
In power levels 1 - 3 and during travelling, the
automatic activation of the function is not displayed
in order to have more free space on the screen for
other symbols during the work.
Fig. 1


2245128-en

Power-Boost function 10000825.00-en
Activating Auto-Power-Boost:
Do not switch on the "Power-Boost"
function during lifting and travelling · In the working mode, depress an arrow key until
operations. main menu MACHINE is highlighted grey and
depress the SET key (Fig. 3).
Risk of unexpected changes in ma-
chine power. · Depress the arrow keys until the "Auto Power-
Boost" bar is active and depress the SET key.
· Use the arrow keys to select the working equip-
When the "Power-Boost" function is on, the hy- ment for which you want to activate or deactivate
draulic pressure increases for a short time. This the "Auto-Power-Boost", for instance, the stick
function can be activated automatically or manu- and depress the SET key.
ally, if maximum force is needed for a short time for
a given working movement (e.g increased breaking · Use the arrow keys to select "on" or "off" and
force). The on-time is limited to approximately ten depress the SET key.
seconds. · Confirm the change with the SET key or keep the
The function is only active if: old setting by depressing an arrow key.
- performance levels 4 - 7 have been preselected
and Activation of the standard Power-Boost function
- if the on-time has not been exceeded. with button (73, Fig. 1) is always possible, even
when Auto-Power-Boost is on
Activating the Power-Boost function
è
· Depress button (73, Fig. 1) in control lever 70.
The increased hydraulic pressure is available for
a time span of about 10 seconds. After about
10 seconds, the increased hydraulic pressure is
shut off again. The state of activation of the
Power-Boost function is simultaneously dis-
played on the screen (1, Fig. 2). To activate the
function once again release button (73) and
press again.
Power-Boost, automatic function

The Auto Power-Boost function can be activated
and deactivated with the help of the multi-function
display's movements menu "Fill bucket" and/or
"Retract stick".
On delivery from the factory, "Auto Power-Boost" is
on.
With Auto-Power-Boost on, the Power-Boost func-
tion is activated automatically in performance lev-
els 4 - 7, if maximum system pressure is prevailing
for prolonged periods for the "Fill bucket" and/or
"Retract stick" movements and if the corresponding
control lever is at maximum deflection.
In the industrial version (option), Auto-Power-Boost
is configured for the "Extend stick" function.

Fig. 1 Fig. 2
Fig. 3

Methods of working 10000090.01-en
Read and observe: · Hold the teeth of the bucket in the direction of
digging. This reduces the digging resistance and
"Working operation, safety instruc-
possible damage of the teeth (Fig. 3).
tions".
· If possible, working operations should always be

carried out by pulling the stick. When digging,
use the retracting forces of the stick and work
with shallow cutting angles of the backhoe
(Fig. 1). Steep backhoe angles during digging
reduce the performance. See: “Switching over to
levelling").
Fig. 3
· The maximum digging forces are produced at

angles ß ~166° (Fig. 4).
· If the machine is to develop maximum digging
forces, digging must be done slowly. The stick
cylinder must have the longest possible lever
arm.
Fig. 1
· Make smooth and regular movements with the

boom. Raising and lowering of the boom must
always be initiated slowly and smoothly. When
the boom is stopped abruptly, the machine is
subjected to heavy shock loads. This results in
excessive wear and damage (Fig. 2).
Fig. 4
Fig. 2 è

· To remove sand and soil adhering to the back- · Levelling of terrain. For filling and levelling the
hoe, the stick must be stretched out to nearly ground after excavation work, the bucket must
horizontal position and the bucket be brought in- be moved horizontally forwards and backwards
to dumping position. If sand and soil do not drop (Fig. 7).
out of the bucket by gravity alone, the corre-
sponding control lever must be moved several
times forwards and backwards. Do not move the Never "sweep" or "beat" with the
bucket cylinder against block if strong shaking of digging tool (e.g. during demolition
the bucket is needed to remove adhering soil work). The working equipment is not
(Fig. 5). designed to cope with forces acting
laterally on it. In such case, the
equipment will be damaged.
Fig. 5
Stop the slewing movement gently. To stop the

slewing movement, release the slewing control Fig. 7
lever before reaching the place where work is to
be done or material to be dumped (Fig. 6). When levelling the ground, do not use the bucket
to shove or rake soil material as with a bulldozer.
(See also: "Slewing and braking the superstruc- Use the levelling blade instead.
ture ").
When levelling towards yourself, retract the stick
slowly, raise the boom slightly and then, when the
stick crosses the vertical position, lower the boom
again slowly and drive the machine so that the
bucket is held horizontal.
è
Fig. 6

For ground levelling in the opposite direction, the

above steps must be applied in reverse order.
For the working operations described above, sev-
eral movements can be combined. By corres-
ponding actuation of the boom control lever it is
possible to cut a slope and to grade it at the same
time.
Never move the machine when the

working equipment is in contact
with the ground. Risk of severe
structural damage to the machine.


2245128-en

Switching to the "Setting Leveling" mode of operation 10000826.00-en
The "Levelling" mode of operation can be switched 2. Fine levelling

on in power stages 4 - 7. The "Precision levelling" mode permits even mor
sensitive working. In this case, the maximum
equipment speed is no longer available for boom
· Press button (71, Fig. 1). The „levelling” symbol and stick movements.
appears on the display (Fig. 2). The joysticks This working mode must have been configured
now have a softer characteristic. beforehand on the display.
· If both joysticks are brought to position 0, an
automatic return to the "Trenching" mode is exe- · In the working mode, press an arrow key until the
cuted after 4 seconds. main menu MACHINE is highlighted grey on the
· If the "Levelling" mode is to be switched off out of display and confirm with the SET key (Fig. 3).
joystick movement (with no waiting time), press · Press the arrow keys until the bar is on SET-
button (71) again. TING LEVELLING and confirm with the SET key.
· Select the FINE LEVELLING function with the
Configuration of the " Setting Levelling " mode arrow keys and press SET.
1. Save "Levelling" · Select the options "on" or "off" with the arrow
keys and press the SET key.
The "Levelling" mode remains activated in perma-
nence after having been switched in with push- · Confirm the changes with the SET key or leave
button (71, Fig. 1) if this mode has been pre- the existing setting by depressing the arow keys.
configured on the display.
è
If the machine is shut off while in the "Levelling"
mode, the "Levelling" mode is active again after
new starting.
· In the working mode, press an arrow key until the

main menu MACHINE is highlighted grey on the
display and confirm with the SET key (Fig. 3).
· Press the arrow keys until the bar is on SET-
TING LEVELLING and confirm with the SET key.
· Select the MEMORY LEVELLING function and
depress the SET key.
· Select the options "on" or "off" with the arrow
keys and press the SET key.
· Confirm the changes with the SET key or leave
the existing setting by depressing the arow keys.

Fig. 1 Fig. 2

Working in the event of load limit regulator failure (PCS module) 10000340.02- en
When the speed of the engine suddenly drops Setting the proportional valve to emer-
sharply during working or driving (engine throttling) gency operation
or when the engine even stalls, the cause may be
a fault in the load limit regulator electronics (PCS The proportional valve (1, Fig. 1) is installed in the
module). In the event of a failure of the PCS mod- superstructure frame behind the driver's cab.
ule, a fault code is displayed on the screen. · Loosen the screws to remove the cover plate
If it is not possible to rectify the fault in situ, the below the frame.
proportional valve can be set to emergency opera- · Proportional valve:
tion.
- Remove the retaining screw of the electrical
With this setting, working or driving can continue at connector.
reduced speed.
- Unplug the connector.
- Remove the protective cap over the setscrew.
- Slacken the lock-nut (2).
- Start the engine and run up to maximum
speed.
- Turn the setscrew (3) so far down that slewing
is still possible without the engine being throt-
tled (engine speed reduction).
- Retract the stick cylinder to the limit stop and
check engine throttling.
- Have the PCS
o
Fig. 1

After daily operation 10000203.02-en
Parking the machine · Close the cab window.

· Park the machine on firm and level ground. · Lock up the cab door and all flaps and covers
· Bring the machine into its basic position. equipped with a lock.
· Lock the superstructure. · Place chocks under the wheels.
· Stand the working equipment on the ground. · Clean off gross dirt adhering to the machine.
· Activate the parking brake. · Fill up the fuel tank.

· Check the hydraulic system, the axles and the
gearboxes visually for leaks.
Do not shut off the engine from full
load, but rather let it run for further
three to five minutes at idling to al- Escaping oil pollutes the environ-
low for cooling. ment.
Repair leaks immediately (or have
them repaired).
· Shut off the engine Report oil accidents to the owner of
(turn electrical system key-switch (7, Fig. 1) to the machine.
position 0).
· Shift both control levers in all directions and de-
press pedal (77) with optional equipment to de- · Check the superstructure, the undercarriage and
pressurize all hydraulic cylinders. the working equipment for damage and all steel
· Shut off the pilot control. components for cracking or fracturing.
· Turn electrical system key-switch to position 0 · Report any damage immediately to the owner of
and withdraw the key. the machine.
Important:
Key-switch (7) has a switch position P. In this posi-
tion, some electrical consumers remain connected
to the power supply even when the engine is off
(see: "Switching the electrical system on and off").
If these consumers remain on for a prolonged pe-
riod, the batteries may be discharged to such an
extent that starting of the engine is no longer pos-
sible.
Therefore always make sure the key-switch is in
position 0 before parking the machine for pro-
longed periods (e.g. after a workshift).
Fig. 1 o

Working equipment 10000081.01-en
Fitting of working equipment, safety instructions, faults
Personnel Tools and auxiliaries

Fitting work may only be performed Tools, hoists, slings, trestles and
by personnel having the required other auxiliary devices must be in a
technical knowledge. reliable and safe state of operation.
If such knowledge is lacking, thor- When chasing out or driving in
ough instruction must be given to equipment bolts, there is always a
such personnel by experienced spe- riks of injury from metal splinters.
cialists, e.g. by our Service Dept. For this reason, use a brass or cop-
per mandrel and always wear gog-
The personnel must have read and
gles.
understood the Operator's Manual
and in particular the "Fundamental For climbing onto or down from the
safety instructions" chapter. machine, use only the steps, plat-
forms and handles provided for this
Only persons fulfilling these re-
purpose.
quirements are entitled to put the
machine into operation during the Keep steps, platforms and handles in
assembly work in order to make the a non-slip state. Remove oil, grease,
necessary corrections of the working soil, clay, snow, ice and other for-
equipment. eign materials immediately.
Wrong operation of the machine or
of the working equipment may lead
to situations involving life-threaten- Securing the working equip-
ing risks. ment
Stand the working equipment on the
ground so that no movements can
Personal protective gear and occur when mechanical or hydraulic
working clothing connections are being detached.
Wear closely fitting working clothing When working in jointed areas, block
when working on the machine. the articulated joint. Remove the
Loose, wide garments may catch on blocking at the end of the work.
machine parts and thus cause injury.
Equipment or components to be at-
Wear a safety helmet, working foot- tached or detached or whose posi-
wear and gloves. tion is to be changed must be se-
cured with hoists or appropriate
slinging / supporting devices against
inadvertent movements, slipping or
falling.

Securing the machine Protective roof against falling

Do not carry out work on the working
objects
equipment unless the machine has If the machine is used in areas where
been secured as described in the there is a risk of heavy objects fal-
"Securing the machine" section. ling on the machine, as in:
Selection of attachments - work on earth or rock faces,
The machine can be equipped with - demolition or forestry work
various attachments. The compo-
the machine must be equipped with
nents of the working equipment are
a protective roof (FOPS) and a front
assembled with hydraulic cylinders
guard. Contact our Service Dept. for
and linking parts. Components can
details.
be combined in various ways for op-
timum adaptation of the attachments
to the specific application.
Operate the machine only with
equipment and component combina-
tions expressly approved by us.
See "Technical Data". Faults in a working equipment
Attachments from other manufactur- control system
ers for which the EC Machine Direc- When a fault occurs in the system
tive 89/392 EC applies, may only be during a movement of the equip-
installed and put into operation after ment, the movement concerned is
the manufacturer's declaration of stopped and the mechanical slewing
conformity and our declaration of brake activated. All controls elements
compatibility have been provided. (control levers, pedals) must be brought
to neutral position. Movements of the
equipment may thereafter be possi-
ble only to a limited extent. The dis-
play shows the corresponding fault
message. Some machine functions
may then no longer be fully avail-
able. Contact the Service Dept. im-
mediately.

Securing the machine 2904441.03-en
Risk of injury Never shut off the engine direct

from full load but idle for another
The machine must not be started up
by unauthorized persons. three to five minutes to adjust the
temperature.
Therefore secure the machine.
· Shut off engine

Secure the machine as described below (Switch Electrical System key switch (7, Fig. 1) to
position 0).
- before carrying out any fitting and modification
work on the working equipment · Switch both control levers in all directions, actu-
- before carrying out any servicing and repair work ate pedal 77, Fig. 2 (with adjusting equipment
on the machine extensionretraction of adjusting cylinder resp.
other optionalö equipment) to depressurize the
· Park machine on level and stable ground hydraulic cylinders.
· Lock superstructure · Switch off servo control.
· Set working equipment down on the ground · Switch Electrical System key switch to position 0
and withdraw the key.
· Activate the parking brake
· Chock the wheels.
· Prior to working on the electrical system of the
machine, disconnect batteries and connecting
terminals.
Fig. 1
Fig. 2
Before carrying out any welding

work on the machine:
Read and observe the chapter
"Welding work".


2245128-en

Attaching and detaching the grab equipment (optional equipment) 10000220.01-en
Attaching and detaching the grab equip- Attaching the grab

ment, safety instructions
Movements of working or grab Read and observe:

equipment involve a risk of injury. "Attaching and detaching the grab
So never attempt to change position equipment, safety instructions".
of grab or grab suspension by hand.
Keep away from grab when working · Detach backhoe bucket as described in section
equipment is being moved. "Detaching and attaching the backhoe bucket".
This description applies to ma- · Retract bucket cylinder and mount locking pin for
chines with SAE control (see sec- linking element and toggle lever (1, Fig. 1).
tion "Control elements").
After fitting of the safety pin, the
If the machine is equipped with a bucket cylinder must no longer be
different control, control commands extended as the safety pin and the
such as "depressurize hydraulic toggle lever and link may otherwise
lines to grab" must be adapted to be damaged.
the control.
The linking element must not be · Shut off engine, turn electrical system key-switch
used for lifting loads when in a se- to position I.
cured state. · Depressurize hydraulic lines to grab:
The locking pin might bend or
- push control lever (69, Fig. 2) to the left and
break.
hold in place,
Use the load hooks/lugs on the grab
or remove the locking pin as long as - depress "rotate grab" button (63) and button
loads have to be lifted. (76),
Read and observe: - push control lever (69) to the right,
'Fitting of working equipment, safety - release buttons (63) and (76) and control lever
instructions'. (69).
· Turn Electrical System key-switch to position 0,
shut off pilot control (72).
Before fitting, check that grab and
machine are filled with identical or
mixable hydraulic oil.
If this is not the case, drain oil out of
hydraulic system of grab.
Conventional hydraulic oil and bio-
degradable hydraulic fluid should
not be mixed, as this affects bio-
degradability.
Fig. 1 è

Fig. 2 Fig. 4
· The marker grooves on the valves' squares (ar-

rows, Fig. 3) must be in vertical position
Detaching the grab
· Open grab shells completely and set grab down
on level surface
· Shut off engine, turn Electrical System key-
switch to position I
· Depressurize hydraulic lines to grab:
- push control lever (69, Fig. 2) to the left and
hold in place
- depress "rotate grab" button (63) to the right
and button (76) to the left
- push control lever (69) to the right
- release buttons (63) and (76) and control lever
(69)
Fig. 3
· Turn Electrical System key-switch to position 0,
· Clean and grease bearing pins and bushes shut off pilot control (72)
· Drive machine towards grab · Disconnect hydraulic hoses (1 and 2, Fig. 4) from
· Insert stick into grab bearing, push bearing pin express couplings
home and secure (2, Fig. 1) · Protect express couplings at grab and stick from
· Shut off engine and depressurize hydraulic lines soiling by fitting dust caps
to grab as described · Unscrew safety device of bearing pin (2, Fig. 1)
· Clean express couplings on grab and stick and withdraw pin
· Connect hydraulic hoses to grab cylinder · Start up engine

(1, Fig. 4) and grab rotation motor (2). Check that · Lift working equipment carefully to release grab
the express couplings are perfectly engaged
o
· Grease all nipples on grab and gearing of grab
rotating mechanism
· Start up engine and lift grab clear of ground
· Bleed grab hydraulic system by opening and
closing grab repeatedly and turning clockwise
and counter-clockwise

Selecting the backhoe / grab equipment (optional equipment) 2905642-en
To switch the working equipment over from back-

hoe bucket to grab operation, two valves (Figs. 5
and Fig. 6) must be switched over at the stick cyl-
inder.
Switch the valves only when the hydraulic system
is depressurized to avoid damaging seals.
Backhoe bucket operations

row, Fig. 5) must be in horizontal position.
Grab operation Fig. 5

row, Fig. 6) must be in vertical position.
Fig. 6

Volume flow switch-over for backhoe-grab equipment (option) 10000834.00-en
After installing the option, the machine can be

switched over with rocker switch (52, Fig. 1) from
backhoe operation with unlimited volume flow in
the working pumps to grab operation with preset-
table independent volume flow rates for opening
and closing of the grab.
Switching scheme
Backhoe Rocker switch (52, Fig. 1)
operation switch face without symbol de-
pressed.
Grab Rocker switch (52, Fig. 1)
operation switch face with symbol de- Fig. 1
pressed.
The grab symbol is displayed on
the screen (1, Fig. 2).
The volume flow rates/speeds for opening and

closing of the grab can be set via the display inde-
pendently of one another (see "Grab opening and
closing speed, setting the parameters").
Fig. 2

Clamshell opening and closing speed, setting the parameters 10000835.00-en
Fig. 1
Fig. 2 è

· In the working mode, depress an arrow key until First digt (tens)
“MACHINE” appears in the lower half of the Depressing the SET key highlights the first digit
screen, i.e. until the machine symbol is high- (tens) for the "OPEN" movement. The number can
lighted by a frame and depress the SET key be changed with the arrow keys and then con-
(Fig. 1). firmed with the SET key.
· Depress the arrow keys until the bar is on After confirmation the bar moves on to the next
“CLAMSHELL”. and confirm with the SET key. digit.
· To get back into the “MACHINE” menu, depress Second digit (units)
the arrow key UP [Ý] or the arrow key DOWN [ß] The number can be changed with the arrow keys
until reaching the beginning or the end of the as described and confirmed with the SET key.
display selection list. If scrolling in the respective After confirmation of the units digit, the first number
direction is continued after reaching the begin- (tens digit) for the "CLOSE" movement is high-
ning or the end of the list, the program jumps lighted and the setting is repeated as above.
back into the next higher menu. If the keys are After confirming both entered digits for the
not pressed for a prolonged time, this return is "CLOSE" movement, the program returns to the
automatic. higher menu level.
· Depressing the SET key calls up the “CLAM- o
SHELL” menu (Fig. 2). The opening and closing
movements of the grab are displayed as a per-
centage designating a relative speed. The ma-
chine is delivered with a factory setting of 50 %
respectively.

Detaching / attaching the backhoe bucket 2411343-en
Danger of injury
Risk of crushing when working
equipment or backhoe is moved.
Therefore, do not attempt to alter
the position of the backhoe manu-
ally.
Stand back from the backhoe when
the working equipment is moved.
Read and observe:
"Fitting of working equipment, safe-
ty instructions"
Fig. 1
· Stand working equipment on the ground
· Place safety wedges under the backhoe (arrow,
Fig. 1)
· The bucket may otherwise overturn as soon as
the linkage pins have been driven out.
· Remove screws (2 und 4)
· Drive out pins (1 and 3)
· Raise working equipment cautiously (Fig. 2)
· The bucket stands now freely on the ground
· Clean linkage pins and bearing bushes before
refitting and protect them against corrosion as Fig. 2
described in the section "Corrosion protection for
pins and bearings (bushings and hubs)" o
Attach the other backhoe bucket by proceeding in
reverse order.

Corrosion protection for pins and bearings (Bushings and Hubs) 10000103.01-en
Application of Voler A.C.

Use Voler A.C. anti-corrosive agent
only. · Clean off grease, oil, dirt and corrosion protec-
Other agents are not approved. tion agents from pins and bearings using white
spirit or diesel fuel.
Rust patches must be thoroughly removed, if

All pins and bearings (bushings and hubs) of the any.
working equipment or in equipment components
must be treated with Voler A.C. anti-corrosive All parts must present a dry, bright metal surface.
agent before fitting.
· Apply a thin layer of Voler A.C. on pins and all
Voler A.C.: bearings using a brush or a spray can. Pin shafts
· permits easy fitting and dismantling and bearings must be completely covered by the
protective layer.
· protects against rust, oxidation and similar wear
If the protection layer of a pin already treated
· prevents seizing and fretting corrosion in non-
with Voler A.C. is damaged, these areas must
moving parts of bearings
be touched up before fitting the part.
This is achieved by aluminium and copper particles
forming a protective layer on the metal. This layer · Fitting and securing of pins.
removes surface irregularities and does not sweat,
seize or harden. IIf the pin is too heavy to be fitted manually, ap-
ply Voler A.C. at first only on abt. a quarter of
Container size Voler A.C. the pin's length.
- 0,5 l spray can (CFC-free) Then position pin by means of a lifting gear
- 0,5 kg tin ready for fitting.
- 4,5 kg bucket Apply Voler A.C. on the remaining length of pin

Available from our spare-parts service. shaft, fit pin and secure.
o


2245128-en

Boom-Adjusting Mechanism (Option) 10000827.00-en
Description of boom-adjusting mechanism Transport of the machine with boom-ad-

If the excavator is equipped with a boom-adjusting
justing mechanism
mechanism, the lower boom section (3, Fig. 1) and The optimal transport height for loading on a low-
the upper boom section (1) are linked by means of bed trailer can be achieved if
an additional articulated joint (2),
· the adjusting (neck) cylinder is fully retracted,
The upper section of the boom can be adjusted
with an additional hydraulic cylinder (neck cylin- · the stick cylinder is fully extended,
der, 4). · the bucket cylinder is fully extended.
The boom-adjusting mechanism has the following The boom cylinder must be retracted so that the
advantages for travelling and working: boom-adjusting mechanism rests as flat as possi-
· enlarged working range, ble on the loading platform.
· greater mobility of the working equipment,

· easier transport of machine on low-bed trailers,
· the size restrictions prescribed for travelling on
public roads are respected.
Working with the boom-adjusting mecha-

nism
· Depress upper end of pedal (77, Fig. 2) to retract
the adjusting (neck) cylinder.
· Depress lower end of pedal (77) to extend the
adjusting (neck) cylinder.
The working speed of the adjusting (neck) cylinder
can be adapted to individual and job-specific re- Fig. 1
quirements by means of a special menu. The con-
trol range of pedal (77) is adjusted in the process.
See "Speed limitation, adjusting (neck) cylinder"
Fig. 2

Speed limitation, adjusting (neck) cylinder 10000829.00-en
Fig. 1
Fig. 2 è

In this menu, the working speed of the adjusting · Move the frame with the arrow keys to the de-
cylinder can be adapted to individual and job- sired selection and depress the SET key.
specific requirements. The control range of pedal The following items can be selected:
(77) is adjusted in the process.
- ON
The settings described below have an influence on
- OFF
retraction and extension of the adjusting (neck)
cylinder. - DEFAULT
- ADJUST
Setting the adjusting cylinder speed parame- · With ADJUST, the working speed of the adjust-
ters ing cylinder can now be set with the arrow keys
in steps of 10% between 0 % and 100 % and
· In the working mode, depress an arrow key until
MACHINE appears in the lower half of the confirmed with the SET key.
screen, i.e. until the machine symbol is high- · You are now requested to save or to reject the
lighted by a frame and depress the SET key setting. Depressing the SET key saves the new
(Fig. 1). setting and the change is active. Depressing the
· To get back into the MACHINE menu, depress arrow UP key [Ý] rejects the setting and the
change is NOT active.
the arrow key UP [Ý] or the arrow key DOWN [ß]
until reaching the beginning or the end of the · The program returns to the next higher level. The
display selection list. If scrolling in the respective user can now repeat the adjustment or use the
direction is continued after reaching the begin- arrow keys to go back to the main menu MA-
ning or the end of the list, the program jumps CHINE.
back into the next higher menu. If the keys are
not pressed for a prolonged time, this return is o
automatic.
· Depress the arrow keys until the bar is on
POS. SPEED LIMIT. and confirm with the SET
key.
· In the POS. SPEED LIMIT. menu, the bar mark-
ing the actual setting is highlighted grey.


2245128-en

Hydraulic hammer (optional equipment) 2905686-en
Working with the Hydraulic Hammer, Safety Instructions
Keep hazard zone clear Alternating operation with

All persons must be kept clear of the other attachments
hazard zone of the hydraulic ham- If the machine is designed for alter-
mer: nating operation with other hydrau-
Risk of flying rock fragments. lically operated attachments (e.g.
hydraulic hammer, hydraulic shears
Therefore stop work as soon as any or concrete cruncher), observe the
persons enter the hazard zone of the instructions in the corresponding
hammer or the machine. sections of this Operator's Manual:
Wait until all persons have left the
"Working with the hydraulic shears,
hazard zone before starting work
safety instructions" or
again.
Close the front window of the ma- "Working with the concrete crun-
chine before starting up the hammer. cher, safety instructions"
Mount a protective grating as a Before mounting the attachment,

guard against rock fragments. check that hydraulic hammer and
machine are filled with identical or
Wear ear protectors compatible hydraulic oil.
Operate the hammer from the dri- If this is not the case, drain the oil
ver’s seat only. out of the attachment.
Read the Operator's Manual Mineral hydraulic oil and biode-
Read and observe also the safety in- gradable hydraulic fluid should not
structions and the instructions on be mixed, as this destroys the bio-
designated use in the Operator's compatibility.
Manual issued with the hammer. In the event of damage
Stop work immediately on detecting
Power rating coordination any damage or loss of oil.
The power rating of the machine Soak up escaping oil and discard in
must be coordinated with that of the accordance with local environmental
hammer This prevents the hydraulic regulations.
hammer from being overloaded. Report accidents involving oil with-
If in doubt, contact our after-sales out delay to the machine owner or to
service department. his agent.
Never adjust pressure reducing Ensure that any damage and leaks
valves without authorization, never are rectified immediately.
remove lead seals.

Working with the hydraulic hammer 10000806.00-en
Read and observe: When several hydraulic attachments

"Working with the hydraulic hammer, are activated at the same time, the
safety instructions". rocker switch setting (5, Fig. 1) has
priority.
Before beginning work: Hammer operation with fixed impact fre-

quency
· Check that the hydraulic hammer is safely locked
on the working equipment and that the hydraulic · Place tip of chisel on material, then switch on
lines are connected in the right way (see the op- hammer with pushbutton (75). The hammer
erating instructions of the hammer manufac- works with the maximum preset hydraulic power
turer). and is on as long as the button is depressed.
Switching on the hydraulic hammer Hammer operation with variable impact

frequency
· Preselect the "Hydraulic hammer" function by de-
pressing rocker switch face without symbol · Place tip of chisel on material, depress pedal
(5, Fig. 1). (77) backwards. The impact frequency in-
creases with the press on the pedal.
- The electronic control unit switches into power
level 4, 5, 6 or 7, depending on which level was
active before ignition shut-off.
Switching off the hydraulic hammer
- Pedal (77) – if the machine is so equipped –
now controls the hydraulic hammer". · Release pushbutton (75) or pedal (77).
- The selection menu for 4 hammer types is dis- · Depress symbol face of rocker switch (5, Fig. 1);
played for 10 seconds as shown in Fig. 2. An- the illumination behind the switch is off.
other hammer can now be selected, e.g. 3 in- · Pedal (77) now controls the boom adjusting cyl-
stead of 2 and/or the pertaining pressure and inder.
volume flow settings can be changed. To quit
the menu before the 10-second interval has è
elapsed, depress one of the arrow keys used
for setting the machine power levels.
- After returning to the main screen, the ham-
mer symbol is displayed.
- The hammer symbol for the selected working
mode is displayed.
- The number of the selected hammer is shown
above the symbol (Fig. 3).
- If the machine is to work alternately with the
hydraulic hammer and with other hydraulic at-
tachments (e.g. hydraulic shears), an electri-
cally operated shuttle valve automatically con-
nects the return-flow line of the hydraulic
hammer with the hydraulic reservoir.

Fig. 1
Fig. 2
Fig. 2

Hydraulic hammer, setting the parameters 10000807.00-en
Fig. 1
Fig. 2 è

Fig. 3
Hydraulic hammer, setting the parameters Setting the parameters for hydraulic ham-
mers
Depending on the working needs and conditions of
use, up to four hydraulic oil pressure and volume · In the working mode, depress an arrow key until
flow configurations can be set for hydraulic ham- "MACHINE" appears in the lower part of the dis-
mers. play (until the machine symbol is marked by a
For the first configuration – hammer 1 - the ma- frame) and depress the SET key (Fig. 1).
chine is delivered ex factory with the following pa- · Depress the arrow keys until the bar is on
rameter settings: "HAMMER", then depress SET.
- Volume flow 80 l/min; pressure 160 bars. · To get back to the "MACHINE" menu, depress
For hammers 2 thru 4, the preset values for pres- the arrow UP [Ý] or arrow DOWN [ß] keys until
sure and flow are in both cases 0. the beginning resp. the end of the display selec-
tion is reached. When scrolling is continued on
reaching the beginning or the end of the list, the
program returns to the next higher menu. The
To use the hammer functions, the
return to the next higher menu is automatic if the
values specified by the hammer
keys are pressed for a prolonged period.
manufacturers must be adjusted as
described below. è

· Depressing SET activates the "HAMMER" sub- · If the settings for hammer 3 are to be changed,
menu (Fig. 2). The grey number field indicates depress the arrow DOWN key [ß]. Enter the four-
actually active hammer 2 with the selected pa- digit code and change the settings with the arrow
rameters for volume flow and pressure. keys (Fig. 3). Depressing the UP key [Ý] incre-
ments the number by one, whereas depressing
· Four different hammer settings can now be pre- the DOWN key [ß] decrements the number by
selected with the arrow keys. The selection is is one. The SET key confirms the desired setting
marked by a frame around the number. In the and the cursor moves on to the next digit. When
example shown, (Fig. 2) hammer 3 is prese- the cursor is on the last digit of a set value, a
lected. Depress SET to confirm the selection of press on the SET key moves it on to the first digit
hammer 3. of the next set value.
· To activate the settings for hammer 3 without After changing the set values, depress the SET
any changes, depress SET. The following op- key. The following options are available:
tions are available: - to reject selected hammer 3 with the newly
selected values and to retain the settings of
- to reject selected hammer 3 and to retain the
settings for hammer 2: depress arrow UP key. hammer 2: depress the arrow UP key [Ý].
- to activate selected hammer 3 with unchanged - to activate hammer 3 with the changed set-
settings: depress SET. The settings are saved. tings: depress SET. The settings are saved.
· Use the arrow keys to go back to higher menu
level. The return is automatic when the keys are
not depressed for a prolonged period.
For queries concerning the hydraulic oil volume
flow and oil pressure settings or the specified set-
ting range please contact our Service Dept.
o

Hydraulic shears (option) 10000238-en
Working with the hydraulic shears, safety instructions

All persons must be kept clear of other attachments
the hazard zone of the hydraulic If the machine is designed for alter-
shears: nating operation with other hydrau-
Risk of flying or falling scrap frag- lically operated attachments (e.g.
ments. hydraulic shears with hydraulic
hammer or concrete cruncher), ob-
Therefore stop work as soon as any serve the instructions in the corre-
persons enter the hazard zone of sponding sections of this Operator's
the hydraulic shears or the machine. Manual:
Wait until all persons have left the "Working with the hydraulic ham-
hazard zone before starting work mer, safety instructions" or
again.
"Working with the concrete crun-
Close the front window of the ma- cher, safety instructions"
chine before starting up the hydrau-
lic shears. Before mounting the attachment,
check that attachment and machine
Mount a protective grating. are filled with identical or com-
Operate the hydraulic shears from patible hydraulic oil.
the driver’s seat only If this is not the case, drain the oil
out of the attachment.
Mineral hydraulic oil and biode-
Read the Operator's Manual gradable hydraulic fluid should not
Read and observe also the safety be mixed, as this destroys the bio-
instructions and the instructions on compatibility.
designated use in the Operator's
Manual issued with the hydraulic In the event of damage
shears. Stop work immediately on detecting
any damage or loss of oil.
Soak up escaping oil and discard in
Power rating coordination accordance with local environmen-
The power ratings of the machine tal regulations.
and of the hydraulic shears must be Report accidents involving oil with-
coordinated. out delay to the machine owner or
This prevents: to his agent.
- the machine from being overload- Ensure that any damage and leaks
ed or are rectified immediately.
- the stability from being jeopardized

If in doubt, contact our service de-
partment.
Never adjust pressure reducing val-
ves without authorization, never re-
move lead seals.

Working with the hydraulic shears 10000809.00-en

are activated at the same time, the
"Working with hydraulic shears,
rocker switch first activated (3, Fig. 1)
has priority.
Before beginning work:

· Check that the hydraulic shears are safely locked The hydraulic shears are now ready for operation
on the working equipment and that the hydraulic (Fig. 1):
lines are connected in the right way (see the op- - to close the shears = press pedal (77) for-
erating instructions of the manufacturer of the wards;
shears).
- to open the shears = press pedal (77) back-
Switching on the hydraulic shears wards.
· Preselect "Hydaulic shears" with rocker switch - pushbutton (75) can be used to switch pedal
(3, Fig. 1) (Depress the switch face without sym- (77) during the work temporarily over to control
bol, switch backlighting is on). the adjusting cylinder. The buzzer sounds a
· The selection menu for 4 types of shears is dis- warning as long as the pushbutton is kept de-
played for 10 seconds (Fig. 2). Another type of pressed.
shears can now be selected, e.g. 3 instead of 2
and/or the pertaining pressure and volume flow
settings can be changed. To quit the menu be- Slewing shears only:
fore the 10-second interval has elapsed, depress - to slew the shears to the right = depress push-
one of the arrow keys used for setting the ma- button (63) in control lever (69);
chine power levels.
- to slew the shears to the left = depress pushbut-
· If the machine is to work alternately with hydrau- ton (76) in control lever (70).
lic shears and, for instance, hydraulic hammers,
an electrically operated shuttle valve automati-
cally connects the return-flow line of the hydrau- Switching off the hydraulic shears
lic shears to the hydraulic reservoir.
· Release pedal (77, Fig. 1).
- The hydraulic shears can be operated in
power levels 1 - 7. The electronic control unit · Set rocker switch (3) to "off" position (depress
switches into the power level that was active the symbol face of switch; switch backlighting is
before ignition shut-off. off).
- When several hydraulic attachments are acti-
vated at the same time, the rocker switch first
activated (3, Fig. 1) has priority. Operating the shears with the joystick (op-
tion)
1. Grab operation on quick tool coupler
Switch "Joy" on - shears over to bucket
- bucket inactive
Active only when shears are on!
2. Sorter grab
Switch "Joy" on - shears over to bucket
- bucket over to shears pedal
è

Fig. 1
Fig. 2
Fig. 3

Hydraulic shears, setting the parameters 10000810.00-en
Fig. 1
Fig. 2 è

Fig. 3
Hydraulic shears, setting the parameters Setting the parameters for hydraulic
shears
Depending on the working needs and conditions of
use, up to four hydraulic oil pressure and volume · In the working mode, depress an arrow key until
flow configurations can be set for hydraulic shears. MACHINE appears in the lower part of the dis-
For the first configuration – shears 1 - the machine play (until the machine symbol is marked by a
is delivered ex factory with the following parameter frame) and depress the SET key (Fig. 1).
settings: · Depress the arrow keys until the bar is on
- Volume flow unlimited (9999) SHEARS, then depress SET.
- Pressure unlimited (9999). · To get back to the MACHINE menu, depress the
arrow UP [Ý] or arrow DOWN [ß] keys until the
For shears 2 thru 4, the preset values are: beginning resp. the end of the display selection
- Volume flow unlimited (9999) is reached. When scrolling is continued on
- Pressure 0 bar. program returns to the next higher menu. The
return to the next higher menu is automatic if the
keys are pressed for a prolonged period.
To use the shears functions, the val- è
ues specified by the manufacturer of
the shears must be adjusted as de-
scribed below.

· Depressing SET activates the SHEARS sub- · If the settings for hammer 3 are to be changed,
menu (Fig. 2). The grey number field indicates depress the arrow DOWN key [ß]. Enter the four-
actually active shears 2 with the selected pa- digit code and change the settings with the arrow
rameters for volume flow and pressure. keys (Fig. 3). Depressing the UP key [Ý] incre-
ments the number by one, whereas depressing
· Four different shears settings can now be pre-
selected with the arrow keys. The selection is is the DOWN key [ß] decrements the number by
marked by a frame around the number. In the one. The SET key confirms the desired setting
example shown, (Fig. 2) shears 3 is preselected. and the cursor moves on to the next digit on the
Depress SET to confirm the selection of right. When the cursor is on the last digit of a set
shears 3. value, a press on the SET key moves it on to the
first digit of the next set value.
· To activate the settings for shears 3 without any
changes, depress SET. The following options are Pressure and volume flow are restricted by limit
available: values in the system. If these limits are ex-
ceeded during the adjustment, the display goes
- to reject selected shears 3 and to retain the to 9999 (pressure or volume flow unlimited).
settings for shears 2: depress arrow UP key. Pressing the arrow DOWN key restores the pre-
vious value below the limit value.
- to activate selected shears 3 with unchanged
settings: depress SET. The settings are saved.
After changing the set values, depress the SET
key. The following options are available:
- to reject the selected shears no. 3 with the
newly set values and to retain the settings of
shears no. 2: depress the arrow UP key [Ý].
- to activate shears no. 3 with the changed set-
tings: depress SET. The settings are saved.
o

Hydraulic cutter (optional equipment) 10000235-en
Working with the Hydraulic cutter, Safety Instructions

All persons must be kept clear of other attachments
the hazard zone of the hydraulic cut- If the machine is designed for alter-
ter: nating operation with other hydrau-
Risk of flying rock fragments. lically operated attachments (e.g.
hydraulic cutter with hydraulic ham-
Therefore stop work as soon as any mer or concrete cruncher), observe
persons enter the hazard zone of the instructions in the correspond-
the hydraulic cutter or the machine. ing sections of this Operator's Man-
Wait until all persons have left the ual:
hazard zone before starting work "Working with the hydraulic ham-
again. mer, safety instructions" or
Close the front window of the ma- "Working with the hydraulic shears,
chine before starting up the hydrau- safety instructions"
lic cutter.
Before mounting the attachment,
Mount a protective grating. check that attachment and machine
Operate the hydraulic cutter from are filled with identical or com-
the driver’s seat only. patible hydraulic oil.
If this is not the case, drain the oil
out of the attachment.
Read the Operator's Manual Mineral hydraulic oil and biode-
Read and observe also the safety in- gradable hydraulic fluid should not
structions and the instructions on be mixed, as this destroys the bio-
designated use in the Operator's compatibility.
Manual issued with the hydraulic
cutter.
In the event of damage
Stop work immediately on detecting
Power rating coordination any damage or loss of oil.
The power ratings of the machine Soak up escaping oil and discard in
and of the hydraulic cutter must be accordance with local environmen-
coordinated. tal regulations.
This prevents: Report accidents involving oil with-
out delay to the machine owner or
- the machine from being overload- to his agent.
ed or
Ensure that any damage and leaks
- the stability from being jeopardized are rectified immediately.
If in doubt, contact our service de-
partment.
Never adjust pressure reducing val-
ves without authorization, never re-
move lead seals.

Working with the hydraulic rotary cutter 10000811.00-en

"Working with the hydraulic rotary are activated at the same time, the
cutter, safety instructions". rocker switch first activated (4, Fig. 1)
has priority.
Before starting work:

Work can then be started with the hydraulic cutter
· Check that the hydraulic cutter is securely locked (Fig. 1):
with the working equipment and that the hydrau-
lic lines are correctly connected (see instructions - The pedal (77) is switched over to the “Hydraulic
issued by the manufacturer of the hydraulic cut- Cutter“ function.
ter).
- Bring hydraulic cutter to working position, push
Switching on the hydraulic cutter pedal (77) forward. The further the pedal is de-
pressed, the higher the speed of the hydraulic
· Select "Hydraulic Cutter" function with rocker cutter.
switch (4, Fig. 1) (Depress switch face without
symbol, the switch background lights up). - During work with the hydraulic cutter, the pedal
(77) can be temporarily switched over to the
· The selection menu for 4 types of cutters is dis- “Adjusting Cylinder“ function with pushbutton
played for 10 seconds (Fig. 2). Another type of (75). A warning signal sounds as long as the
cutter can now be selected, e.g. 3 instead of 2 pushbutton remains depressed.
and/or the pertaining pressure and volume flow
settings can be changed. To quit the menu be-
fore the 10-second interval has elapsed, depress Switching off the hydraulic cutter
one of the arrow keys used for setting the ma-
chine power levels. · Release pedal (77, Fig. 1).
· If the machine is designed for alternating oper- · Switch off rocker switch (4) (Depress switch face
ating with hydraulic cutter and e.g. hydraulic with symbol, the switch background is no longer
hammer the return line of the hydraulic cutter is illuminated).
connected automatically with the control block by
è
means of an electric switchover valve.
- The hydraulic cutter can be operated in
power levels 4 - 7. The electronic control unit
activates the power level that was active before
turning off the ignition switch.
- After return to the main screen, the cutter sym-
bol is displayed. The number of the selected
cutter is displayed in the upper right corner
(Fig. 3).

Fig. 1
Fig. 2
Fig. 3

Hydraulic rotary cutter, setting the parameters 10000830.00-en
Fig. 1
Fig. 2 è

Fig. 3
Hydraulic rotary cutter, setting the Setting the parameters for hydraulic rotary
parameters cutters
Depending on the working needs and conditions of · In the working mode, depress an arrow key until
use, up to four hydraulic oil pressure and volume MACHINE appears in the lower part of the dis-
flow configurations can be set for hydraulic rotary play (until the machine symbol is marked by a
cutters. frame) and depress the SET key (Fig. 1)
For the first configuration – ROTARY CUTTER 1 - · Depress the arrow keys until the bar is on RO-
the machine is delivered ex factory with the fol- TARY CUTTER , then depress SET.
lowing parameter settings:
· Arrows in the lower right corner of the screen
- volume flow 80 l/min indicate the presence of submenus.
- pressure 160 bars · To get back to the machine menu, depress the
For cutters 2 thru 4, the preset values are in both arrow UP [Ý] or arrow DOWN [ß] keys until the
cases 0. beginning resp. the end of the display selection
is reached. When scrolling is continued on
program returns to the next higher menu. The
To use the rotary cutter functions, return to the next higher menu is automatic if the
the values specified by the cutter keys are pressed for a prolonged period.
manufacturers must be set as de-
scribed below. è

· Depressing SET activates the RO- · If the settings for cutter 3 are to be changed,
TARY CUTTER submenu (Fig. 2). The grey field depress the arrow DOWN key [ß]. Enter the four-
indicates the actually active cutter 2 with the se- digit code and change the settings with the arrow
lected parameters volume flow and pressure. keys(Fig. 3).
· Four different cutter settings can now be prese- · Depressing the UP key [Ý] increases the number
lected with the arrow keys. The selection is by one, whereas depressing the DOWN key [ß]
marked by a frame around the number. decreases the number by one. The SET key
confirms the desired setting and the cursor
· In the example shown, (Fig. 2) cutter 3 is prese-
lected. Depress SET to confirm the selection of moves on to the next digit. When the cursor is on
the last digit of a set value, a press on the SET
cutter 3.
key moves it on to the first digit of the next set
· To activate the settings for cutter 3 without any value.
changes, depress SET. The following options are
available: · After changing the set values, depress the SET
key. The following options are available:
- to reject selected cutter 3 and to retain the set-
tings for cutter 2: - to reject selected cutter 3 with the newly se-
lected values and to retain the settings of cut-
depress the arrow UP key.
ter 2:
- to activate selected cutter 3 with unchanged depress the arrow UP key [Ý].
settings:
- to activate cutter 3 with the changed settings:
- depress SET. The settings are saved. depress SET. The settings are saved.
o


2245128-en

Smooth mode (hydraulic damping), setting the parameters 10000831.00-en
Fig. 1
Fig. 2 è

Smooth mode (damping of the working · With arrow UP [Ý] and / or arrow DOWN [ß] the
movements), setting the parameters following assemblies and functions can be se-
lected (Fig. 2):
The working movements damping function smoo-
thens the control movements initiated by the op- - BOOM
erator. Abrupt movements of the joystick and the - STICK
travel pedal are transformed into soft and flowing - BUCKET
machine movements. -TRAVEL
The control of boom, stick, bucket and travel - DEFAULT
movements can thus be adapted in an optimal way · The selected function is confirmed with SET.
to the capabilities of the driver and to the condi-
tions of use of the machine. · Four different damping degrees per function
ranging from hard to soft can now be selected
with the arrow keys and then confirmed with SET
Examples: (Fig. 2). When the standard value is or will be set
for the selected function, "Default" is displayed
- Low degree of Smooth mode: under the text of the respective assembly, e.g.
precision response without delay to joystick BOOM. If a setting deviating from the standard
movements during pile-sheeting work and for value is chosen, "Default" is not displayed.
lifting operations
· Depressing SET returns the program to the main
- High degree of Smooth mode:
menu MACHINE after a request to save the set-
Soft starting and stopping of movements in han-
tings or not. When the arrow UP key [Ý] is
dling operations.
pressed, the setting is NOT saved. When SET is
pressed, the settings are saved and the changes
are effective.
Setting the Smooth mode parameters
· The TRAVEL submenu permits setting the
· In the working mode, depress an arrow key until damping of the travel valve control piston. De-
MACHINE is marked by a frame in the main pending on the setting, the travelling movement
menu and depress the SET key (Fig. 1). initiated with pedal (61) is either 'hard' or 'soft'.
· Depress the arrow keys until the bar is on · For queries in conjunction with damping of the
SMOOTH MODE and press SET. machine's working movements and the optimiza-
· Arrows in the lower right corner of the screen tion of the movement of individual assemblies,
indicate the presence of submenus. please contact our Service Dept.
· With arrow UP [Ý] the program returns to the

main menu. Resetting to default values
· Depressing the SET key calls up the · If the DEFAULT bar in the SMOOTH MODE
SMOOTH MODE menu. menu is selected and confirmed with SET, all
damping settings for assemblies and functions
are reset to standard factory settings.
o

Basic setting, setting the parameters 10000832.00-en
Fig. 1
Fig. 2 è

Basic settings Factory setting

Depending on the requirements and conditons of The machine is delivered with setting type
use, up to four different basic settings concerning C - COMFORT.
the response of pedals and control levers for travel
This setting can be modified by the Service Dept.
and working movements can be selected.
The following settings can be selected:
Selecting the basic setting
· A – SPORTIVE
- vigorous response · In the working mode, press an arrow key until
· B – CLASSIC MACHINE is displayed or until the machine sym-
bol is highlighted by a frame and press the SET
- balanced response key (Fig. 1).
· C – COMFORT · Press the arrow keys until the BASIC SETTINGS
- soft and smooth response bar is selected and confirm with the SET key.
· D – EVOLUTION · To return to the MACHINE menu, press the ar-
- leisurely response with specific slewing row UP [Ý] or the arrow DOWN [ß] key until
charasteristics reaching the start or the end of the display selec-
The letter representing the selected basic setting tion. If scrolling is continued on reaching the start
A to D (1, Fig. 3) is always displayed in the center or the end, the program goes back to next higher
of the screen. menu. Return is automatic, if the keys are not
pressed for a longer period.
è
Fig. 3

· Pressing the SET key calls up the BA- · After confirmation with the SET key, you are
SIC SETTINGS menu (Fig. 2). asked whether you want to save the change of
the basic setting or not. Pressing the arrow UP
· The display shows four basic settings for selec- [Ý] key does not save the new setting so that
tion (SPORTIVE, CLASSIC, COMFORT and there is no change at all. Pressing the SET key
EVOLUTION). The currently selected basic set- saves the new setting and the change of the old
ting is highlighted. basic setting is valid. Thereafter, the program
· Press the arrow keys until the desired basic set- returns to the next higher menu. Setting can now
ting is highlighted by a frame and confirm your be repeated or one of the other items (e.g. ham-
selection with the SET key (Fig. 2). mer) be selected for setting (Fig. 1). Pressing the
arrow UP [Ý] key quits the "MACHINE" menu and
causes the program to return to the main menu.
In case of queries concerning changes of the basic

settings, please contact our Service dept.
o

Lifting-gear operation 2413662-en
Lifting-gear operation, safety instructions
Never use the machine for lifting- Sling only those loads not exceeding
gear operation unless it is equipped the load capacity of the lifting gear
and approved for this purpose. and of the machine (cf. "Technical
data").
The machine must be equipped with
an overload warning system and Sling the load in such a way as to
pipe-fracture safety devices. prevent it from slipping or falling
Read the sections "Fundamental while being lifted or transported.
safety instructions" and "Operation,
safety instructions" with care and
observe the instructions contained Transporting the load
in them. Never move the load above persons.
Switch the overload safety device Keep the load as close as possible
on before starting work. to the ground.
Prevent the load from swinging.
The machine must never be driven
Room for slingers with a slung load unless the road
Slingers must approach the working surface is even and the roadway is
gear from the side when the load is clearly visible. Roadway visibility
slung. can be improved by adjusting the
During the lifting and transporting boom and slewing the superstruc-
of loads, slingers or other assistant ture to the right. If the super-
personnel must stand in a safe posi- structure is slewed, the floating axle
tion or go beside the machine to must be blocked.
ensure that they are outside the ha- The built-in overload warning device
zard zone. cannot totally exclude accidents
Ensure that slingers and other as- due to incorrect operation. This ap-
sistant personnel are always in plies in particular to:
sight. - inadequate hooking of the load or
the load-carrying device
Slinging loads - excessive deceleration or acce-

leration forces (hard braking or
Use only tested and efficient lifting strong slewing with the load to be
gear with an adequate load capacity. moved)
Hoist the load only from the hooks - loads dropping into the cable
provided for that purpose.
- oblique pull
Never use the teeth of backhoe dip-
pers, buckets or grippers. - driving the excavator into an area
Cable lugs, thimbles or U-bolts may with steeply sloping ground
slip from the teeth putting the load - exposure to strong wind
out of control.
Avoid these risks by handling the
Register the weight of the load. machine carefully and with discre-
tion.

Load hooks on bucket and linking element (optional equipment) 2732886-en
To enable hydraulic excavators with bucket

Before slinging loads: equipment to be used in lifting gear operation too,
Read and observe: "Lifting-gear op- buckets and linking elements with welded load
eration, safety instructions". hooks (Figs. 1 und 2) are available (option).
Before starting work, switch on the
overload warning system.
Load capacity of the load-carrying hook
Sling the load only from the hooks
provided. The maximum load capacity of the load-carrying
Special instructions for load hooks hook is specified on the hook (Figs. 1 and 2).
on the linking element:
If another attachment (e.g. a grab) is
mounted instead of the bucket, the Load capacity of the excavator
linking element and toggle lever
The maximum load capacity depending on working
must be joined with a securing bolt.
equipment and boom length can be taken from the
In this case the load hook must NOT "Load capacity values" table; see "Technical Data".
be used for lifting loads.
The securing bolt is not designed
for such loading and may bend or
suddenly break. In this case the
linking element and the slung load
suddenly start to swing.
That may result in the swinging load
getting out of control and persons
being injured or property damaged.
In an extreme case the stability of
the machine may be jeopardized.
Therefore:
Never sling loads from the load
hook of a secured linking element. Fig. 1
Always use the load hooks/lugs on

the attachment (e.g. grab). If the at-
tachment is not equipped with a
load hook but a load has none-
theless to be moved, the securing
bolt can be removed from the link-
ing element and toggle lever as long
as the load hook on the linking ele-
ment has to be used.
Fig. 2

Overload warning system (optional equipment) 10000224-en
Overload warning system, function
The overload warning system gives

only optical and acoustic warning
signals. It cannot eliminate the risk
of toppling over.
When the warning signal sounds:
- put down the load immediately,
- reduce the working radius or the
load.
Hydraulic excavators used for lifting operations or

for transporting loads must be equipped with an
Fig. 1
overload warning system and pipe break protec-
tions in the lifting cylinders of the working equip-
ment.
The admissible load moment is exceeded if too
The overload warning system must be activated heavy a load is to be lifted with the working radius
when such work is being carried out. of the equipment being too great (lifting capacity
When the admissible load moment is exceeded, see "Technical Data / lifting loads table").
the red warning lamp (113, Fig. 1) lights up and the o
buzzer sounds at the same time. The overload
symbol and the text message OVERLOAD appear
on the display screen.

Checking the overload warning

system 10000226-en
Check the overload warning system for operation:

- every day before beginning the work, and
- every time before using the machine for lifting.
Fig. 1
· Raise the boom to the highest position and move

against block.
· Warning lamp (113, Fig. 1) lights up and an
acoustic warning is sounded (continuous tone).
The overload symbol is displayed together with a
text message.
If a fault occurs, have the overload warning system
checked and repaired immediately by our Service
Dept.
The new setting and the inspection are docu-
mented in a certificate.
Never perform unauthorized setting

or repair work on the overload
warning system on your own.
The overload warning system might
be impaired in its correct functioning
or even fail completely.

Putting the overload warning system into operation 10000225.01-en
The overload warning system can be used option-

ally in two modes of operation:
· Depress key (18, Fig. 1) once,
LED1 (1) is lit up
= when the machine is used for lifting operations
without additional stabilization.
· Depress key (18) twice, LED2 (2) is lit up
= when the machine is used for lifting operations
with additional stabilization (levelling blade / sta-
bilizer legs).
Before using the machine for lifting operations, the
overload warning system must be put into opera-
tion:
Fig. 1
· Select the desired mode of operation for the o
overload system with key (18). The LED above
the key lights up.
· Check the overload warning system (see:
"Checking the overload warning system").
The overload warning system is then ready for
operation.
Malfunctioning of the overload warning system
If a fault occurs in the overload warning system,
LED1 and LED 2 above key (18, Fig. 1) are both
flashing.
In this case, too, the red warning lamp lights up
and the "Overload" message is displayed on the
screen.
Have the overload warning system

repaired immediately by our Service
Dept.

Putting the overload warning

system out of operation 10000227-en
If the machine is used exclusively as an excavator,

the overload warning system can be put out of
operation.
Fig. 1
Depress key (18, Fig. 1) until the LEDs (1 and 2)

are no longer lit up.
The overload warning system is now out of opera-
tion.
o

Pipe break protection, function (option) 2413657.01-en
The pipe break protection prevents the working When a hydraulic line is broken:
equipment from lowering inadvertently when a
hydraulic line feeding the piston side of the boom · set the control lever for the "boom lowering"
cylinders breaks. function or the the pedal for the "upper boom
section lowering" function to position "0";
The hydraulic connection on the piston side of the
boom cylinder is blocked so that hydraulic oil can · warn bystanders with the horn;
flow out only if the "boom lowering" function is acti- · secure the range of the working equipment with
vated. a load on the hook to prevent persons from
In machines with boom adjusting equipment, not standing under the equipment or close to the
only the boom cylinders but also the rod side of the broken hydraulic line.
adjusting cylinder of the upper boom section is
equipped with a pipe break protection valve. When the working equipment and the load are
deposited on the ground, oil emerges from the
As an option, also the stick can be equipped with a broken part of the hydraulic line.
pipe break protection.
· Set working equipment and load carefully on the
ground.
· Replace the broken hydraulic line (or have it
replaced) before continuing the work.
· Absorb spilled hydraulic oil and discard oil-
soaked cleaning rags, binding agents, etc. with-
out polluting the environment.
o

Electromagnet MOZELT (option) 10000410.00-en
General information Keep the hazard range clear

The operation of a load-lifting mag- During work with the load-lifting mag-
net attached to the machine consti- net it is forbidden to stay
tutes a special mode of operation - in the extended hazard range -
with increased safety risks. Unlike
the work with an hydraulic grab, the of the machine.
magnet will attract all ferromagnetic Risk of falling objects
materials within its reach immedi-
ately after activation. The amount of Stop the work immediately if persons
material often exceeds the lifting ca- are within the extended hazard range
pacity of the machine. In the same of the electromagnet or of the ma-
way, the magnet abruptly releases chine.
the material after its deactivation and Do not continue the work unless all
in the event of a broken cable or a persons have left the extended haz-
short-circuit in the magnet power ard range.
feed line. This may result in danger-
Close the machine's front window be-
ous situations within its extended
fore putting the electromagnet into
working range, when the falling ma-
operation.
terials toss up other objects in the
air. There is moreover the possibility Install a grid as a protection against
of scrap pieces detaching from the falling objects. Wear ear protectors.
magnet during slewing, if these pie-
ces are at the bottom the material
cluster hanging under the magnet.
Machine capacity Read the operating instruc-

The capacity of the machine must be tions
compatible with the power of the
Read and observe also the safety in-
electromagnet. The maximum load
structions and the information con-
capacity of the machine must not be
cerning the designated use in the
exceeded. (See: "Load capacity tables"
operating instructions issued by the
section)
manufacturer of the electromagnet.
In case of doubt, contact our Service Operate the electromagnet only when
Dept. sitting on the driver's seat.
Do not readjust the pressure-limiting
valves and remove lead seals at your
own discretion.

Warning: Protection
- The power supply system T 4002 The power cables must be protected
works with an operating voltage of by effective means.
230 V DC.
Use only appropriate supply equip-
- Contact with live parts can cause ment and accessories approved by
injuries and fatal electric shocks. the manufacturer of the electromag-
- In the event of system faults, this net. Check the heavy-duty suspen-
voltage may also be present when sion chains of the magnet perma-
the system is off. nently for signs of wear and damage.
- Connect only load-lifting magnets After discharging the load, the mag-
to this system. Connecting other net may swing heavily. Safe me-
electrical consumers to the system chanical fastening of the magnet in
is dangerous and not permitted. form of a special magnet suspension
- Before working on the 230 V lines, on the stick of the machine is there-
the engine of the machine must be fore urgently recommended.
shut off. Persons with heart pacemakers must
- Repairs of the line system may only not stay within the active range of
be performed by authorized and the electromagnet.
qualified personnel. Risk of burns
- Never open terminal compartments The electromagnet reaches operating
and unplug 230 V connectors on temperatures of more than 200 °C. Do
the supply unit and the electro- not touch the electromagnet after the
magnet when the engine is run- operation with bare hands.
ning.
- Never disconnect the load-lifting mag-
net from the system when the en- In the event of damage
gine is running.
Stop the work at once if you detect
- Do not slew the working equipment faults. Contact our Service Dept. im-
or change the machine's position mediately if you cannot find or elimi-
when the load-lifting magnet is ac- nate the fault yourself.
tivated without a payload being at-
tached to it.
- Materials inadvertently lifted by the
magnet can injure persons and cause
the machine to topple over. Use
only ORIGINAL spare parts when
repairing defective or irreparably
damaged control lines.

Description of the electromagnet lifting system (MOZELT) 10000584.02-en
Range of application
The power supply units T 4002 (DBP) have a rated
power of 13,0 kW at a regulated output voltage of
220 V DC. The duty factor of the T 4002 system is
100 % for continuous 24-hour operation.
The systems are designed for mobile machines
primarily used for the handling of ferromagnetic
materials such as heavy scrap, pigs, gray pig-iron,
cast-iron, shears scrap and metal chips and scale.
The electrical power rating of the magnets con-
nected to the T 4002 system may be up to 10 %
higher than the rated power of the system. The
T 4002 system permits connection of all types of
load-lifting magnets.
Fig. 1
Main components of the electromagnet lifting sys-

tem (Fig. 1): Scope of supply
The electric generator is driven by an hydraulic
motor. The unit is supported by a common base
1 Generator T 4002
frame installed by means of welded fastening
2 Multifunction display MFA / MFD I strips on the right side above the tanks (ar-
row, Fig. 2).
3 Control button (see "Commissioning of the
electromagnet lifting system (MOZELT)
4 Control button cable
5 Control line
6 Magnet line 230 V
7 Connector 7 terminal box
8 Magnet supply line
9 Load-lifting magnet from 900 mm Ø – 1500
mm Ø
Fig. 2

Electric generator drive

The electric generator T 4002 needs a constant
drive speed of 3000 rpm. Its working speed range
extends to +/- 10 % of this value, i.e. to between
2700 rpm and 3300 rpm. During shut-off of the
magnet, the hydraulic drive motors can tolerate
peak speeds of up to 4000 rpm if they do not last
longer than 0.5 s. At speeds above 3400 rpm and
below 2700 rpm no magnet operation or only lim-
ited operation is possible.
States-of-operation display
The most important operating and switching states
are displayed on a multifunction display (MFD)
inside the cab. The multifunction display is installed
in a holder besides the machine multifunction dis-
play (Fig. 3). The following values are displayed:
- ready for operation (a)
- magnet attracts material (b)
- magnet releases material (c)
- 220 V line interrupted (d)
- generator speed fault (e)
- duty factor from 50 to 100 % (f) Fig. 3
Any work inside the electromagnet

lifting system during and after the
warranty period is forbidden. Inter-
vention in the unit will automatically
entail irreparable damage to the
electromagnet lifting system. At the
same time, the right to replacement
free of charge during the warranty
period and also the right to re-
placement of the electric generator
by a low-cost spare unit will expire
in this case.
o

Putting the electromagnet (MOZELT) into operation 10000585.01-en
Putting the electromagnet into operation After activation, the system is set to power level 4
(see: "Selecting the power level"). A higher level
selected earlier remains preset. When all compo-
During the work with the load-lifting nents are ready for operation, the magnet system
magnet, the applicable safety and symbol (Fig. 2) is displayed on multifunction dis-
accident prevention regulations must play MFD I. Moreover, the yellow "Ready-for-
be observed. No work with the load- operation" LED lights up on multifunction display
lifting magnet must be started un- MFD I in the cab (a, Fig. 3).
less the instructions and warnings
set out in the "Work with the elec-
tromagnet, safety instructions" chap-
ter are known to the operator.
Before putting the power supply unit T 4002 into

operation, the operator must check the 230 V line
system visually for perfect condition. Plugs and
connectors must be firmly in place and the magnet
supply cable suspension must be checked for
proper functioning.
The magnet system is activated with rocker switch
(21, Fig. 1) on the right of the switch console.
Fig. 2
Fig. 1
Fig. 3

The electric generator speeds up until it reaches When the switch-on command is given, electric
the working speed range. The signal light remains generator T 4002 switches the DC voltage through
on during the operation and goes out only if a fault to the load-lifting magnet. When the shut-off com-
is signalled. mand is given, the generator automatically initiates
the demagnetizing cycle. During the demagnetiz-
ing cycle (ca. 1.5 s) when the magnet releases its
The electromagnet system can only load, no new switch-on command can be given.
be switched on when a load-lifting After more than a 10-minute operation of the load-
magnet is connected to the system. lifting magnet, the multifunction displays additionally
If the unit is switched on neverthe- indicates the duty factor reached by the load-lifting
less, system T 4002 will cut out the magnet.
supply voltage immediately. The
multifunction display signals a fault
by means of a red LED: "230 V line With a duty factor of more than
interrupted" (see "Multifunction dis- 80 %, inadmissible warming of the
play status indication"). magnet must be expected. In this
case, it is advisable to interrupt work-
ing for a certain time or to change
the working mode. Risk of burns
from the hot electromagnet.
The power supply, i.e. the load-lifting magnet is è
switched on by means of pushbutton (75, Fig. 1) in
control lever (70).

Activating the magnet

Important note for magnet op-
- Press pushbutton (75, Fig. 1) in control lever (70) eration
once. In the multifunction display, a green LED
"Magnet attracting material" lights up in addition Place the magnet on the material to
to the yellow "Ready-for-operation" LED. be lifted before switching it on.
Switch off the magnet before slew-
ing it back.
Deactivating the magnet
- Press pushbutton (75) in control lever (70) only
once. The green LED "Magnet attracting mate- Malfunctions and faults are indicated by permane-
rial" goes out and a red LED "Magnet releasing netly lit red LEDs. The cause of such faults and
material" lights up. After release of the material, their rectification are explained in detail in the sec-
this LED goes out automatically. The continu- tion: "Multifunction display MFD I status indica-
ously lit "Ready-foroperation" LED indicates that tion").
the magnet can be switched on again. o
(See the section "Multifunction display MFD I
status indication")


2245128-en

Multifunction display MFD I status indication 10000586.00-en
The electric generator T 4002 is ready for operation only after the generator is running
within its working speed range. This is the case when hydraulic drives are running with a
minumum speed of 2700 rpm and a maximum speed of 3400 rpm. The switch-on command
which can then be given, will however, only be executed if the 230 V line system between
generator T 4002 and the load-lifting magnet is uninterrupted and not defective.
Electric generator T 4002 running within its

working speed range:
Indication (a): yellow LED, "System ready for
operation"
Fig. 1
After switch-on command by means of

pushbutton (75):
operation"
Indication (b): green LED, "Magnet attracting
material"
Indication (f): green LED, "Duty factor 70%"
Fig. 2
After switch-off command by means of

pushbutton (75):
operation"
Indication (c): red LED, "Magnet releasing mate-
rial “
Note: The switch-off command auto-
matically initiates the demag-
netization of the magnet. Dur-
ing demagnetization, the mag-
net cannot be switched on
again.
Fig. 3


pushbutton (75):
operation"
Indication red LED "Speed problem"

(b, e): green LED, "Magnet attracting
material"
Fault: Generator running with insufficient
speed below nominal speed
range. Only limited operation of
magnet possible. (low perform-
ance)
Fig. 4
Remedy: 1) Bring machine engine to full
speed (increase output
power stage)
2) Readjust speed of hydraulic
drive

pushbutton (75):
Indication (a): yellow LED active, no further LED
on
Fault: Broken cable in switching line,
pushbutton defective
Remedy: Replace switching line
check / replace pushbutton (75)
Fig. 5

pushbutton (75):
Indication (d): red LED "230 V line open circuit"
Fault: Broken cable in 230 V circuit;
no load connected; magnet de-
fective; fault in connector
Remedy: 1) Stop engine of the machine
2) Repair broken cable
3) Have load-lifting magnet
checked
4) Check connectors and plugs
for firm contact
Fig. 6


pushbutton (75):
Indication All LEDs flashing at intervals!
(a, b, c, d, e):
Fault: Short-circuit in 230 V lline system;
magnet fully shorted to ground
Remedy: 1) Stop the engine of the machine
2) Repair short-circuit, replace line
3) Check line; check connector
4) Replace load-lifting magnet

Fig. 7
Generator running within working speed

range:
Indication: No LED indication visible
Fault: Broken cable / interruption in con-
trol line
Remedy: Replace control line
Fig. 8

Rotary beacon (option) 10000440.00-en
Installing the rotary beacon

Variant 1:
Rotary beacons are fitted on a mounting stud
(1, Fig. 1) and secured with a retaining screw. The
electrical connection is incorporated in the base.
Connecting cables are not required.
In some countries, two rotary bea-

cons are mandatory.
Fig. 1
Variant 2 (country-specific version):
1st rotary beacon
Fitting is the same as for variant 1.
nd
2 rotary beacon
The second rotary beacon (2, Fig. 1) is attached
either by means of a magnetic base (electrical
connection via coupling) or as in variant 1.
Switching on the rotary beacons
Switch on rocker switch (6, Fig. 2).
(Depress switch face without symbol, the indicator
lamp inside the switch lights up.)
Important: Fig. 2
The rotary beacons can only be switched on when o
the electrical system key-switch (7, Fig. 2) is in
position I (ignition ON).
Switching off the rotary beacons
Switch off rocker switch (6, Fig. 2).
(Depress switch face with symbol, the indicator
lamp inside the switch is off.)

Switching the floodlamps

on and off 10000213.01-en
Switching on the floodlamps

· Depress the blank face of rocker switch (9, Fig. 1).
The working floodlamps on top of the driver's cab
and on the working equipment (optional equip-
ment) are on.
Switching off the floodlamps
· Depress the symbol face of the switch.
The working floodlamps on top of the driver's cab
and on the working equipment (optional equip-
ment) are off.
Fig. 1

Floodlamps at the rear of cab, switching on / off 10000229.01-en
The floodlamps (Fig. 1) can be only be switched on

when the electrical system key-switch is in posi-
tion I (ignition ON).
Switching on the floodlamps
· Set rocker switch (8, Fig. 2) to "on". (Depress
switch face without symbol, the pilot lamp inside
the switch lights up.)
Switching off the floodlamps
Set rocker switch (8) to "off". (Depress switch face
with symbol, the pilot lamp goes out.)
Fig. 1
Fig. 2

Radio 10000230-en
The radio is installed by the machine manufacturer

to the right of the driver’s seat (Fig. 1).
Various types of radio may be installed. Instruc-
tions are given in the handbook provided with the
radio.
The on-board voltage (24 V) is reduced to the
service voltage of the radio (12 V) by a voltage
transformer.
When the motor is switched off (key switch Electri-
cal System in position 0), no power is supplied to
the radio.
Therefore switch the key-switch to position P be-
fore switching on the radio.
Important:
Programmed settings in the radio (e.g. safety
codes) may be lost, as the entire on-board electri-
cal system is without power when the key switch is
in position 0. This depends, however, on the spe-
cific features of the installed radio. Therefore check
in your radio manual whether the entered codes
can be secured by programming (e.g.: "Save
safety codes permanently").
Fig. 1


2245128-en

Environmentally Compatible Hydraulic Fluid (optional equipment)

(biodegradable) 2913022-en
Environmentally compatible hydraulic Environmentally compatible hydraulic

fluid, Operator's Manual fluid, conversion
The hydraulic system of this machine can be filled

ex factory with environmentally compatible, syn- Read and note: 'Inspection and
thetic hydraulic fluid (non-standard). Stickers with servicing, Safety instructions'.
corresponding instructions are then attached to the
machine.
For the initial filling, we use only: - Bring hydraulic system to operating temperature.
PANOLIN HLP SYNTH 46 - Retract all hydraulic cylinders.
This synthetic hydraulic fluid has been tested by us - Drain off hydraulic oil (see Operator's Manual,
and approved for application in our machines. section 3 'Inspection and servicing').
A change from mineral hydraulic oil to this syn- - Fill hydraulic oil tank with HLP SYNTH 46 up to
thetic hydraulic oil can, however, be made at a halfway mark.
later date.
- Activate all hydraulic functions including travel-
Environmentally compatible hydraulic fluid, too, ling for about 30 minutes. The hydraulic system
must not be simply poured away but disposed of in is flushed.
the same way as used oil.
- Then drain off the hydraulic fluid.
If hydraulic oil seeps into the ground, the machine It can be used repeatedly for flushing. Otherwise
owner and the competent authorities must be in- it must be properly disposed of. A disposal ex-
formed. pert must be consulted in this case, as this is a
HLP SYNTH 46 is suitable only for hydraulic sys- mixture of synthetic hydraulic fluid and mineral
tems. hydraulic fluid.
As HLP SYNTH 46 is not soluble in water, con- - Change all filters in the hydraulic system.
densate may be deposited in the hydraulic oil tank. - Fill the hydraulic oil tank with new
It must therefore be drained off at regular intervals HLP SYNTH 46.
and after lengthy downtimes, then disposed of in è
the same way as used oil.
Use only HLP SYNTH 46 for changing or topping
up the hydraulic fluid.
The hydraulic fluid must not be mixed with hydrau-
lic oils or hydraulic fluids from other manufacturers,
as this affects its biodegradability.
Operating equipment and attachments driven with
mineral hydraulic oil must not be mounted until
thoroughly emptied, cleaned and flushed.
Analysis will show whether the hydraulic fluid can
be used beyond the standard changing intervals.
See section: "Environmentally compatible hydraulic
fluid, sampling".

Environmentally compatible hydraulic

fluid, sampling
Complete sets are compiled for hydraulic fluid
analysis. They contain all necessary parts.
- Sets are available from our spare-parts service.
- After 30 - 50 operating hours with environmen-
tally compatible hydraulic fluid, take a sample of
the hydraulic fluid.
Send this sample in for analysis.
- After this, we recommend sending in a sample
for analysis every 1000 operating hours or once
a year.
Fig. 1
- It is essential that the hydraulic fluid should be
Fix an instruction sticker (Fig. 1): analysed not later than after 3000 operating
- in the cab, hours.
The results of the analysis show whether the hy-
- on the hydraulic oil tank and draulic fluid is still serviceable and the changing
intervals can be extended.
- on the equipment.
In case of questions ask our service department.
- Start up the machine. check level in hydraulic
¨
tank according to servicing plan.
- The hydraulic fluid may dissolve deposits in the
hydraulic system.
Therefore change all filters 30 - 50 operating
hours after making the change.
Make further filter changes according to servicing
plan.
- Sample the hydraulic fluid after 30 - 50 operating
hours and send in for analysis (see section 'Envi-
ronmentally compatible hydraulic fluid, sam-
pling').

Refuelling system 2747294.01-en
Refuelling with the refuelling system, safety instructions
Before refuelling Avoid environmental impact

Before refuelling with the refuelling Prevent fuel from overflowing. Pre-
system, the tank cap must be vent fuel from penetrating into the
opened and laid aside to prevent soil; this constitutes an environ-
overpressure in the tank. mental hazard.
Risk of leaks in tank and pump. Soak up spilt fuel immediately with
rags or binding agent. Then discard
See also "Refuelling with the refuel-
without polluting the environment.
ling station".
Report accidents involving fuels
without delay to the machine owner
or his agent.
Explosion hazard Securing the machine

Fuels and fuel vapours are readily Secure the machine against unau-
flammable and may explode into thorized starting during the refuel-
flame. Therefore avoid any sparking ling operation:
and never use a naked flame, e.g.
lighter or matches, for lighting. - set the working equipment down
on the ground,
- switch off fuel-driven auxiliary
Potential health hazard heating systems and air condition-
ing systems,
Diesel fuel and fuel vapours are a
potential health hazard. - shut off the engine,
Fuels must never be swallowed.
Also avoid protracted contact with - withdraw the key from the Elec-
the skin. trical System key switch.
Wear protective gloves or apply a
barrier cream.
Do not eat, drink or smoke while
refuelling.

Refuelling from cans

If the machine is refuelled often or
regularly with fuel from cans or bar-
rels, there is an increased risk of
foreign matter and water getting into
the fuel system.
In this case:
- Always fill in fuel through a fine
mesh;
- Use only intake hoses with a mi-
crofilter;
- Drain off water from the fuel filter
more often than specified in the
maintenance schedule;
- Drain off water and deposits from
the fuel tank at shorter intervals;
- Replace all fuel filters at shorter
intervals.
Never use "biodiesel"

"Biodiesel" may damage the injec-
tion system and the engine.
Use only diesel fuel produced from
mineral oil complying with standard
specification EN 590.
Further information can be obtained
from your after-sales service.
o

Refuelling with the refuelling station 10000231.02-en
Read and observe:
"Refuelling with the refuelling sta-

tion, safety instructions".
With the help of the refuelling station, fuel can be

pumped from a large storage tank into the fuel tank
of the machine.
The refuelling station is installed on the left side of
the machine beside the fuel tank (Fig. 1).
The refulling station includes an intake hose, an
electrically operated fuel pump and the filling hose
Fig. 1
to the fuel tank.
The intake hose is stored rolled up in the tool-box.
The filling hose (3, Fig. 3) is firmly attached to the
pump and the fuel tank.
Refuelling with the refuelling station:
- Open the tank cap (sign, Fig. 3).
Before refuelling, the tank cap must be opened
to avoid overpressure in the tank. Risk of leaks in
tank and pump.
- Protect the tank opening from soiling.
- Connect the intake hose to the pump and the
large storage tank (Fig. 2).
- Insert the key into the key-switch (ignition lock) Fig. 2
and turn to position I
- Switch on the pump with the green pushbutton
(1, Fig. 3) on the pump.
- Switch off the pump with the red pushbutton
(2, Fig. 3) on the pump.
The pump shuts off automatically when the

fuel tank is full.
The pump can be deteriorated or ir-

reparably damaged by prolonged dry
running.
Therefore, switch on the pump only Fig. 3
when needed for refuelling. o


2245128-en

Air conditioner, switching on / off (option) 10000233.01-en
Switching on the air conditioner Instructions for proper use

· Start up the engine (see Operator's Manual). - Remove heat build-up in the cab first,
then ventilate the cab before cooling (windows
· Depress pushbutton (26, Fig. 1). The pilot lamp
and door closed), then
inside the button lights up blue.
- select maximum cooling
· The blower is switched automatically to stage 1.
by setting the system to recirculated air, maxi-
· Turn rotary switch (24) to select the desired mum blower performance, lowest temperature
blower performance (stages 1 - 3). and air distribution in the middle. When the cab
interior is cool enough,
Adjusting the air temperature
- switch over to normal cooling
· The temperature of the air blown into the cab can by setting the blower to stage 1 or 2, the tem-
be adjusted with heater control knob (27). Posi- perature to the desired value, and by selecting
tions: fresh air instead of recirculated air.
- left stop (min) = cooled air blown into cab, - Demisting the windows:
Air conditioner on at highest temperature and
- right stop (max) = heated air blown into cab.
maximum blower performance with air directed
The temperature between these two positions can towards the windows
be adjusted continuously.
- Preventing the windows from misting up:
For higher cooling or heating performance, the In damp and cool weather use air conditioner
blower can be switched to stages 2 and 3. with the air directed towards the windows, tem-
perature and blower settings as necessary.
Prerequisites for good cooling performance:
- Protection against exhaust gases and dust:
- The fresh air intake opening at the rear of the In dusty and heavily contaminated environments
cab must not be covered up or clogged up by switch on air conditioner and set temporarily to
dirt. recirculated air.
- The air filter element for fresh air and the ribs of - Temperature ranges:
the evaporator must be clean. Optimal range is 20-23 degrees, minimum is 18
- The door and the windows of the cab must be degrees. For leaving and entering the cab very
closed. often on hot days, the temperature should be set
to 25 degrees.
The air conditioner not only cools,

but also dries the air in the cab. Win- For further details (e.g. adjusting the air outlets)
dow misting is thus prevented and see "Ventilation and heating" in the Operator's
driver comfort and safety are enhan- Manual.
ced. è

Switching off the air conditioner

· Depress pushbutton (26). The pilot lamp inside
the pushbutton goes out.
Switching on recirculated air

the pushbutton lights up.
Switching off recirculated air

the pushbutton goes out.
Air recirculation can also be used when the air
conditioner is off.
Fig. 1

Display settings 10000243.01-en
Fig. 1
Fig. 2 è

Display settings, main menu Display contrast

The liquid-crystals are directly under the display Under unfavourable lighting conditions, in strong
glass cover. Strong shadows impairing the sunlight or extreme cold, it may be necessary to
readibility of the display are thus avoided. change the contrast setting for the display to en-
sure perfect readibilty of the information dis-
· In operating mode, press an arrow key repeat- played.
edly until DISPLAY appears with a grey back-
ground in the main menu and confirm by press- Display, setting the contrast
ing the SET key (Fig. 1).
· In operating mode, press an arrow key repeat-
· With the upward [Ý] arrow key the program re- edly until DISPLAY appears with a grey back-
turns to the main menu. ground in the main menu and confirm by press-
· With the downward [ß] arrow key, the following
submenus can be activated: · Press the downward [ß] arrow key until the con-
trast symbol is active on a grey background
- CONTRAST
(1, Fig. 1) and confirm the selection with SET.
- BRIGHTNESS
· Pressing the upward [Ý] arrow key increases the
- CLOCK contrast, whereas the downward [ß] arrow key
- UNITS reduces the contrast in small steps. The con-
trast setting is shown by a bargraph (Fig. 2).
- LANGUAGE
· The SET key exits the CONTRAST submenu
and the program returns to main menu DIS-
PLAY. The contrast settings are saved at the
same time.
è

Display settings
Fig. 3
Fig. 4 è

Display brightness Setting the time, 12-hour display

Under unfavourable lighting conditions, in strong · Press the arrow keys repeatedly until "12 h" is
sunlight or extreme cold, it may be necessary to active on a grey background and confirm your
change the brightness setting for the display to selection with SET (Fig. 4).
ensure perfect readibilty of the information dis- · The actual time is now displayed with AM (ante
played. meridiem) meaning before noon and PM (post
Display, setting the brightness meridiem) meaning after noon.
· In operating mode, press an arrow key repeat- · The cursor is now on the first digit of the hour
edly until DISPLAY appears with a grey back- display. With the upward [Ý] arrow key, the
ground in the main menu and confirm by press- number is incremented by one unit. With the
ing the SET key (Fig. 1). downward [ß] arrow key, the number is decre-
mented by one unit. The SET key confirms the
· Press the downward [ß] arrow key repeatedly setting and the cursor moves one place to the
until the brightness symbol is active on a grey right onto the second digit of the hour display.
background (2, Fig. 1) and confirm your selec- Select the second number as described above.
tion with SET. The cursor is now on the first digit of the min-
· Pressing the upward [Ý] arrow key increases the utes display. The minutes are set in the same
brightness, whereas the downward [ß] arrow way as the hour.
key reduces the brightness in small steps. The · After confirming the minutes setting with the
brightness setting is displayed by a bargraph SET key, PM or AM are now active. The arrow
(Fig. 3). keys can be used to change between these two
· The SET key exits the BRIGHTNESS submenu settings which are confirmed with the SET key.
and the program returns to main menu DIS- The changes made are then displayed as the
PLAY. The brightness settings are saved at the active settings and confirmed with the SET key.
same time. · You are then asked whether you want to save
the settings or not. When the upward [Ý] arrow
Display, time key is pressed, the settings are not saved and
For different reasons it may be necessary to set the changes remain ineffective. Pressing the
the time stored in the central electronic unit and SET key confirms the new time setting and the
displayed on the screen (e.g. changing from changes are effective. The program returns to
summer to winter time). the main menu. The setting can now be re-
peated or another setting selected (24-hour dis-
Display, setting the time play or date display) (Fig. 4). PM or AM is now
displayed beside the time on the right (1, Fig. 6).
edly until DISPLAY appears with a grey back- è
ground in the main menu and confirm by press-
· Press the downward [ß] arrow key repeatedly
until the clock symbol is active on a grey back-
ground (3, Fig. 1) and confirm your selection
with SET.
· A clock symbol is displayed on the left and a
selection on the right for:
- a 12-hour display
- a 24-hour display, and
- a date setting field
· Any of these three fields can now be selected
with the arrow keys and confirmed with SET.

Display settings
Fig. 5
Fig. 6

Setting the time, 24-hour display Setting the date

· Press the arrow keys repeatedly until "24 h" is · Press the arrow keys repeatedly until "DATE" is
active on a grey background and confirm the active on a grey background and confirm the
selection with SET (Fig. 5). selection with SET (Fig. 5).
· The actual time is now displayed. · The actual date is now displayed.
· The cursor is now on the first digit of the hour · The cursor is on the first digit of the day display.
display. With the upward [Ý] arrow key, the With the upward [Ý] arrow key, the number is in-
number is incremented by one unit. With the cremented by one unit. With the downward [ß]
downward [ß] arrow key, the number is decre- arrow key, the number is decremented by one
mented by one unit. The SET key confirms the unit. The SET key confirms the setting and the
setting and the cursor moves one place to the cursor moves one place to the right onto the
right onto the second digit of the hour display. second digit of the day display. Select the sec-
Select the second number as described above. ond number of the day display as described
The cursor is now on the first digit of the min- above. The cursor is now on the month display.
utes display. The minutes are set in the same With the upward [Ý] arrow key, the month dis-
way as the hour. play is incremented by one month. With the
downward [ß] arrow key, the month display is
· The hours and minutes set are now displayed
decremented by one month. The SET key con-
as the active setting and are confirmed with the
firms the month setting and the cursor moves on
SET key.
to the first digit of the year display. With the up-
· You are then asked whether you want to save ward [Ý] arrow key, the number is incremented
the settings or not. When the upward [Ý] arrow by one unit. With the downward [ß] arrow key,
key is pressed, the settings are not saved and the number is decremented by one unit. The
the changes remain ineffective. Pressing the SET key confirms the setting and the cursor
SET key confirms the new time setting and the moves one place to the right onto the second
changes are effective. The program returns to digit of the year display. Set the second, third
the main menu. The setting can now be re- and fourth digit of the year display as described
peated or another setting selected (12-hour dis- above.
play or date display) (Fig. 5).
· The date setting is now displayed as the active
setting and confirmed with the SET key.
You are then asked whether you want to save the
date settings or not. When the upward [Ý] arrow
key is pressed, the new setting is not saved and
the changes remain ineffective. Pressing the SET
key confirms the new date setting and the
changes are effective. The program returns to the
main menu. The setting can now be repeated or
another setting selected (12-hour or 24-hour dis-
play) (Fig. 5).
è

Display settings
Fig. 7
Fig. 8 è

Display, setting the units of measurement · The cursor is now on the actually set unit of
measurement for pressure. Either "bar" (unit of
· In the working mode, press an arrow key until pressure) or “psi“ (pounds per square inch) is
DISPLAY in the main menu is marked with a active on a grey background. Select one of these
grey bar and confirm by pressing the SET key units with the arrow keys and confirm with SET.
(Fig. 1).
· The cursor is now on the actually set unit of
· Press the downward [ß] arrow key until the units measurement for volume flow. Either "L/min" (li-
of measurement symbol is active on a grey ters per minute) or "gpm" (gallons per minute) is
background (4, Fig. 1) and confirm the selection active and on a grey background. Select one of
with SET. these units with the arrow keys and confirm with
· The display shows two different units of meas- SET.
urement for temperature, speed, pressure and · You are then asked whether you want to save
volume flow and the corresponding symbols the units of measurement settings or not. When
(Fig. 7). Small triangles on the right and left sides the upward [Ý] arrow key is pressed, the new
of the display indicate that further settings are setting is not saved and the changes remain in-
available in both directions and can be called up effective. Pressing the SET key confirms the new
with the SET key. units of measurement setting and the changes
· The cursor is now on the actually set unit of are effective. The program returns to the main
measurement for temperature. Either "°C" (de- menu. The setting can now be repeated or an-
grees Celsius) or "°F (degrees Fahrenheit) is ac- other setting selected (contrast, brightness; time
tive on a grey background. Select one of these or language) (Fig. 1). Pressing the upward [Ý] ar-
units with the arrow keys and confirm with SET. row key exits the display menu and returns to the
main menu.
· The cursor is now on the actually set unit of
è
measurement for speed. Either "km/h" (kilome-
ters per hour) or "mph" (miles per hour) is active
on a grey background. Select one of these units
with the arrow keys and confirm with SET.

Display, setting the language · Press the arrow keys until the desired language
is marked by a frame and confirm your selection
· In operating mode, press an arrow key repeat- with SET (Fig. 8).
edly until DISPLAY appears with a grey back-
ground in the main menu and confirm by press- · The selected language setting appears on a grey
ing the SET key (Fig. 1). background within a frame and must be con-
firmed once again with the downward [ß] key.
· Press the downward [ß] arrow key until the lan-
guage symbol is active on a grey background · After confirming with the downward [ß] arrow
(5, Fig. 1) and confirm the selection with SET. key, you are asked whether you want to save the
language settings or not. When the upward [Ý]
· The display now offers a choice of five lan- arrow key is pressed, the new setting is not
guages (German, English, French, Italian and saved and the changes remain ineffective.
Spanish). The actually set language is marked Pressing the SET key confirms the new lan-
as the active setting. guage setting and the changes are effective. The
· The actual language setting appears on a grey program returns to the main menu. The setting
background. can now be repeated or another setting selected
(contrast, brightness; time or units of measure-
ment) (Fig. 1). Pressing the upward [Ý] arrow key
exits the display menu and returns to the main
menu.
For queries concerning the display settings, please

contact our Service Dept.
o


2245128-en

Display, Information 10000246.01-en
Fig. 1 è

Display, information
Operating information for the machine and the The required lettering bar is then selected with the
control system (central electronic unit (CU), load arrow keys and confirmed with the SET key.
limit regulator (PCS), electrohydraulic controller
(ESX), display (C4) and keyboard modules The corresponding information then appears in the
(C5.1, C5.2, C5.3)) is displayed with this menu. display, e.g.:
- Soft. Version 1.01
edly until the frame around “INFORMATION” ap- - Soft. Date 02/02/03
pears in the display of the main menu and con- o
firm by pressing the SET key (Fig. 1). - Hard n 161238
o
- Soft n 783903
· Two options now appear in the display:
“INFORMATION“ and “CONTROLLERS“. Select
the required lettering bar with the downward ar-
row key [ß] and confirm the selection with the · Wedges at the righthand upper and lower mar-
gins of the display show that a move can be
SET key.
made to the next or to the previous page with the
· You can return to the main menu “INFORMA- arrow keys. The respective page x of y is shown
TION“ by actuating the upward arrow key [Ý]. at the right in the display.
· When the active lettering bar “CONTROLLERS“ · After confirmation with the SET key, a return is
has been confirmed with the SET key, the fol- made to the submenu „INFORMATION“, where
lowing selection options appear in the submenu: all further possible information can be called up
analogously.
- Central electronic unit (CU)
· You can return to the main menu by actuating
- Load limit regulator (PCS)
the upward arrow key [Ý].
- Electrohydraulic controller (ESX)
- Display (C4)
Please consult our Service Department if you have
- Keyboard module 1 (C5.1) any questions on calling up information.
- Keyboard module 2 (C5.2) o
- Keyboard module 3 (C5.3)
· Wedges at the righthand upper and lower mar-
gins of the display show that further selection
options are available in the respective direction.


2245128-en

PART 3 – INSPECTION AND SERVICING 2261178-en

+
FUNDAMENTAL SAFETY IN- Inspection and servicing personnel
STRUCTIONS +
Repair personnel



+
+
Repair personnel
o


2245128-en

Inspection and Servicing, Safety Instructions 10000121-en
Operating manual Personal protective equipment

No inspection and servicing work and working clothing
may be carried out until the Opera- Wear closely fitting working cloth-
tor's Manual have been read and ing when working on the machine.
understood. Loose, wide garments may catch on
Pay special attention to the: machine parts and result in injury.
"Fundamental safety instructions" Wear a safety helmet, safety foot-

and all warning and safety instruc- wear, gloves and, in the event of
tions attached to the machine. high noise levels, ear protectors.
The Operator's Manual lists all jobs

to be done. The descriptions of job Securing working equipment
sequences, however, provide only
experienced personnel with the Stand working equipment on the
necessary instructions. ground in such a way that no move-
ments can be made if mechanical or
The Operator's Manual must be kept hydraulic connections become de-
with the machine at all times. tached.
When working in jointed areas,
Inspection- and servicing per- block off the joints. Remove the
blocks on finishing work.
sonnel
Secure any equipment or compo-
nent which is to be mounted or dis-
must have the necessary know-how
mantled, or whose position is to be
on the inspection and servicing of
changed, with hoists or appropriate
this or comparable machines.
slinging/supporting devices to pre-
The necessary know-how can be vent them from moving, slipping or
acquired in several days' instruc- falling inadvertently.
tion, e.g. by our service department
or by attending a training course of
the manufacturer. Securing the machine
"SE" Jobs marked with this symbol Carry out servicing work only if the
should be carried out by our service machine is secured as described in
department. the section "Securing the machine".

Climbing onto and off the ma- Cleaning jobs

chine Clean the units within the working
Use only the steps, platforms and range before starting work.
handrails provided when climbing Select the cleaning agent according
onto or off the machine. to the material constituting the parts
Always keep steps, platforms, han- to be cleaned.
dles and handrails in a non-slip, Example: Never clean rubber or
safe state and remove any oil, electrical parts with solvents or
grease, soil, clay, snow, ice and steam jets.
other foreign matter immediately.
Use lint-free cleaning rags when
Always face the machine when working on the hydraulic system or
climbing on and off. the engine.
Cleaning agents and solvents may
Check state of tools give off harmful, readily flammable
vapours.
Use only fully functional, reliable
tools. Never work with such agents except
on well ventilated premises; never
Select the right tool for the job. inhale the vapours and never
Wrenches of the wrong size, for ex- smoke.
ample, may slip and cause injury. Prevent solvents and cleaning
agents from coming into contact
with the skin.
Wear solvent-proof gloves.
Observe the instructions on the
packaging.

Handling flammable liquids Handling oils and greases

When handling flammable liquids: Hot lubricant or hydraulic oil emer-
ging uncontrolled from the system
- never smoke,
may result in severe burns.
- keep away from unshielded light
Cool burns immediately with run-
sources and naked flames.
ning water. Apply a dry dressing to
Fuel and other consumables often the burn.
have low flash points and are read-
Never set foot within reach of the
ily ignited. Never attempt to extin-
emerging oil jet.
guish burning liquids with water.
Use: Avoid contact with the skin. Wear
gloves and firm protective clothing.
- dry powder,
Used oil may be harmful to the skin.
- carbon dioxide or
Clean soiled skin thoroughly with
- foam extinguishers.
warn soapy water and apply a bar-
Water used for extinguishing pur- rier cream. Never use fuels or sol-
poses would vapourize instantane- vents for cleaning the skin.
ously on contact with burning sub-
If you have swallowed any oil, avoid
stances and spread burning oil, for
vomiting but consult a doctor imme-
example, over a wide area. Water
diately.
generates short circuits in the elec-
trical system, possibly producing
new hazards.
Visible loss of oil
Notify the fire brigade.
Have any visible leakage repaired
immediately.
Fastening and securing ele- Escaping oil is an environmental
ments hazard.
Check fastening sand securing ele- Soak up any oil that has escaped
ments, e.g. bolts, nuts, washers, be- with a binding agent.
fore using them again. Sweep up binding agent and dis-
Replace any damaged parts. pose of it separately from other
waste

Relieving residual pressure in Environmentally compatible

the hydraulic system disposal
Only unpressurized hydraulic sys- Oils, greases, brake fluids, cleaning
tems may be opened. Even when a agents, solvents and oily compo-
machine is parked on a horizontal nents, e.g. filters, cleaning rags, re-
surface with its attachments sup- placed wear parts and unser-
ported on the ground and its driving viceable machine parts, must be
motor switched off, there may still disposed of separately in the in-
be substantial residual pressure in terest of environmental protection.
parts of the hydraulic system, e.g.
Never dispose of such substances
primary pressure from the last hy-
with standard household refuse.
draulic movements prior to stopping
the machine. Empty substances into the con-
tainers provided for this purposes.
Residual pressure is reduced only
gradually. If an intervention into the Even biodegradable "environment-
hydraulic system is to be under- ally friendly" hydraulic oil has to be
taken immediately after stopping, disposed of separately like any
depressurize the system as de- other oil.
scribed in the section "Depressur-
izing the hydraulic system". Never allow oils and oily waste to
get into the soil or into water: envi-
ronmental hazard.
Screwd connections, piping,
hydraulic hoses Sealing faces
Repair any leakages in the piping Individual spares may contain as-
and hose system immediately. bestos. Such spares or their pak-
A fine, highly pressurized jet of hy- kaging are marked with: A.
draulic oil can penetrate the skin. Never process spares containing
Never search for leakages with the asbestos mechanically. Inhaling as-
fingers, but use a piece of card- bestos dust is a health hazard.
board and always wear goggles. Clean sealing faces prior to assem-
If oil has penetrated into the skin, bly.
consult a doctor immediately.
Never repair damaged piping; al-
ways replace it.
Exhaust gases
Replace hydraulic hoses immedi- Exhaust gases are a health hazard:
ately on detecting any damage or never inhale them.
moist areas. When working on enclosed pre-
Tighten leaking screw plugs only mises, draw off exhaust gases with
when the system is depressurized. a suction plant and ventilate the
premises well.
Escaping oil is an environmental
hazard.
è

Handling batteries Prior to work on the electrical

Batteries give off explosive gases. system
Never handle batteries close to na- Prior to any work on the electrical
ked flames and unshielded light system involving tools, spares, etc.
sources, never smoke. coming into contact with electric
cables or contacts, disconnect the
Battery acid is toxic and corrosive. battery. Disconnect first the nega-
Avoid any contact with the skin, tive pole, then the positive pole.
mouth, eyes and clothing. Avoid After work:
spilling battery acid or inhaling the
vapours. Connect first the positive pole, then
the negative pole.
Wear acid-proof gloves, firm protec-
tive clothing and goggles when When changing lamps, it is suffi-
handling batteries. cient to switch off the correspond-
ing lamp.
If the skin is splashed with acid,
rinse thoroughly with water and
consult a doctor.
If the eyes are splashed with acid,
rinse thoroughly with running water Selecting oils / greases
and consult a doctor immediately.
Use the recommended qualitites
Never set tools down on the battery. only, matching viscosities with the
They may induce a short circuit, temperature level.
causing irreparable damage to the
battery and injuring persons.
Never wear metal necklaces, brace- Filters
lets or watch-straps when working Replace all filter elements or filter
on the battery. The metal parts may cartridges within the specified peri-
induce a short ciruit resulting in ods.
burns.
All filters are coordinated carefully
Dispose of used batteries separately with the equipment.
from other waste in the interests of
environmental protection. Original spare-parts from the manu-
facturer must be used to ensure
smooth running and a long service
life of the engine and the hydraulic
units.

Sealing elements
When dismantling parts, watch for
sealing elements.
Check sealing elements prior to in-
stallation and replace any that are
even slightly damaged.
When assembling, ensure a perfect
fit.
Oil-level check and oil change
Position the machine horizontally.
Change the oil when the machine is
at operating temperature.
Warm oil flows better and carries
suspended particles (carbon or ab-
raded matter) better.
Lubricating
Clean the lubricating nipple, then
lubricate as scheduled.
After servicing
To prevent corrosion, coat all bright
metal parts with a grease film. On
completing work, reinstall all protec-
tive devices.
Never start the drive motor while
work is being done on the machine.
Carry out a performance test with
the machine.


2245128-en

Inspection and servicing plans, instructions 10000013.01-en
Warranty
One of the preconditions for the granting of the
warranty by the manufacturer is that all inspection,
servicing and repair work is carried out properly in
accordance with the present Operator's Manual
and that original spares are used.
Within the period of warranty, all inspection, serv-
icing and repair works, except the daily and weekly
inspection and servicing activities, have to be per-
formed by our Service Dept. or by workshops duly
authorized by us.
The performance of the inspection, servicing and
repair works must be documented in our Service
Booklet. Fig. 1
Intervals
Information on plans:
The intervals specified are valid for normal condi-
tions of use. In severe working conditions, the V once prior to initial commissioning
intervals must be shortened accordingly. For clari- T every 10 OH or every workshift 1) 2)
fication, contact our Service Dept.
W every 50 OH or weekly 1)
The inspection and servicing plans list all works to
be performed on the machine in regular intervals. N once after 250 OH 3)
The individual inspection and servicing plans are A first after 750 OH, then every 500 OH
identified by different letters. The works of subordi- B first after 500 OH, then every 1000 OH
nate servicing plans are included in the primary
first after 1000 OH, then every 1000 OH
plans (e.g.: T and W in A; T, W, A and B in C, etc.). C
(except for 3000, 6000, ... etc.)
Tables 1 and 2 show the relationship between D first after 3000 OH, then every 3000 OH
servicing plan (V-D), operating hours interval and
advancing operating hours count of the machine. Table 1
The daily maintenance (Plan T) and the weekly For reasons of clarity, table 2 does not show the
maintenance (Plan W) can be performed by the daily (T) and the weekly (W) plan. The work in acc.
machine operator. with plans T and W must nevertheless be per-
formed in any case.
è
Important:
After starting the machine, the multi-function dis-
play (Fig. 1) informs the operator about the oper-
ating hours left until the next maintenance is to be
performed and about the servicing plan.
1)
whichever occurs first
2)
check engine oil level during the run-in phase (up to 200 OH)
every 4-5 operating hours
3)
OH = operating hours

Inspection and servicing plans to be ob- In the event of higher sulphur contents and/or
served depending on operating hours permanent ambient temperatures of less than mi-
nus 10 °C, it is necessary to observe shorter inter-
Plan vals (see engine Operator's Manual).
Bh V N A B C D If the engine oil change intervals are not reached
0 l within one year, the engine oil must be changed at
least once every year.
250 l
500 l Oils / greases
750 l The specifications of the oils and greases to be
1000 l used are set out in the "LUBRICANTS" section.
1250 l Oil and grease designations:
1500 l I Oils for combustion engines
1750 l II Oils for hydraulic systems
2000 l III Oils for axles and gearboxes
2250 l V Greases for bearings and slewing rings
2500 l VI Grease for slewing ring toothings
2750 l Table 3
3000 l
3250 l The following sections:
3500 l
„Lubricating chart grease – working equip-
3750 l ment“
4000 l „Lubricating chart grease – undercarriage“
4250 l „Oil checking plan“
4500 l
list the servicing points, refilling quantities and the
4750 l maintenance intervals in the form of comprehen-
5000 l sive tables.
5250 l Cleaning work
5500 l Cleaning jobs, especially on cooling systems, must
5750 l be done at shorter intervals if the machine is ex-
6000 l posed to severe dust build-up.
usw. Servicing materials

Table 2 The materials required for servicing are set out in
the spare-parts list under Assembly 92.020.
Regular oil analyses
Oil change intervals can be prolonged and wear of Further maintenance work
components be detected in good time, if regular Optional equipment may require further inspection
oil analyses are performed. Please contact our and servicing work as prescribed by the equipment
Service Dept. manufacturer.
Engine oil change These works are then described under the corre-
sponding key-word in the table of contents, e.g.
The intervals specified for engine oil changes are "Air conditioner, inspection and servicing" or in a
valid for fuels with a sulphur content <= 0,5% and separate brochure.
permanent ambient temperatures of not less than
–10 °C. o

Plan V – Once before first commissioning 10000166.02-en
Page 1 of 1
Quantity /
Component designation Servicing activity
Number
Engine
Check oil level in acc. with oil inspection plan
Oil-sump retaining screw Check for tightness
Engine support retaining screws Check for tightness
Cooling system Check coolant level
Electrical system
Battery Check acid level 1)/ charge condition 2
Lighting Check for proper operation
Monitoring, warning and control elements Check for proper operation
Hydraulic system Check for proper operation
Oil reservoir Check oil level in acc. with oil inspection plan
Brake
Service brake Check for proper operation
Parking brake Check for proper operation
Wheel
Tyres Check pressure
Wheel-nuts Check tightening torque
Steered axle Check oil level in acc. with oil inspection plan 1
Wheel-hub gears Check oil level in acc. with oil inspection plan 2
Rigid axle Check oil level in acc. with oil inspection plan 1
Travel gearbox Check oil level in acc. with oil inspection plan 1
Wheel-hub gears Check oil level in acc. with oil inspection plan 2
Retaining screws Check for tightness
Slewing gearbox
Expansion tank Check oil level in acc. with oil inspection plan 1
Superstructure holding brake Check for proper operation
Slewing ring
Ballast
Retaining screws Check oil level in acc. with oil inspection plan
Driver's cab
Retaining screws
All lines, fittings and connections Check visually for leaks
Check lubricating points, if necessary grease /
All articulated joints and hinges
lubricate
Working equipment 31
lubricate
Undercarriage 39
lubricate
è
1)
not applicable with mantainenance-free batteries.

1)
Plan T - Every 10 OH or per working shift
1)
Plan W - Every 50 OH or weekly
Page 1 of 1
Quantity / Plan Plan
Number T W
Machine Visual inspection of the machine and all its l l
components, lines and connections for defects
and leaks
Engine Check oil level in acc. with oil inspection plan l 2) l
Cooling system Check and clean combined radiator, if needed l
Check liquid level l l
Air intake system
Electronic vaccum sensor on air filter Check for proper operation
housing 1 l
Dust discharge valve Clean 1 l l
Intake air, clean-air and charging air Check for tightness and leaks l l
line
Electrical system
Battery Check liquid level 3) 2 l
Lighting Check for proper operation l l
Monitoring, warning and control Check for proper operation l l
elements
Hydraulic system Check visually for leaks l l
Oil reservoir Check oil level in acc. with oil inspection plan l
Brake
Service brake Check for proper operation l l
Parking brake Check for proper operation l l
Wheel Check visually for condition l l
Slewing gearbox
Expansion tank Check oil level in acc. with oil inspection plan 1 l
Superstructure holding brake Check for proper operation l l
4)
Machine Overall cleaning l
Undercarriage Grease in acc. with lubricating chart 'Grease' 4 l
Working equipment Grease in acc. with lubricating chart 'Grease' 30 l
Heating
Air filter element (fresh air) Check, clean 1 l
è
1)
whichever occurs first
2)
during run-in period (up to 250 OH) at least twice every day
3)
not applicable with maintenance-free batteries.
4)
After wet-cleaning the machine must be regreased.

Plan N – Once after 250 OH
Page 1 of 1
Quantity /
Number
Engine Check visually for leaks
Engine oil Change oil in acc. with oil inspection plan
Oil filter Replace 1
Drive belt (alternator) Check voltage
Oil-sump retaining screws Check for tightness
Intake and exhaust piping Check for condition
Engine support retaining screws Check tightening torque
Lubricationg oil line Check for condition
Speeds Calibrate with engine in no-load condition
Cooling system Check visually for leaks
Combined radiator Check / clean
Coolant Check liquid level
Coolant lines Check for tightness and condition
Fuel system
Filter Replace 2
Air intake system
Electronic vaccum sensor on air filter housing Check for proper operation 1
Dust discharge valve Clean 1
Hydraulic system
Return-flow filter (reservoir) Replace 1
Breather filter (reservoir) Replace 1
Operating pressure Check (by our Service Dept.)
Wheel
Wheel-nuts Check tightening torque
Steered axle and wheel-hub gears Change oil in acc. with oil inspection plan 3
Rigid axle and wheel-hub gears Change oil in acc. with oil inspection plan 3
Retaining screws Check tightening torque
Travel gearbox Change oil in acc. with oil inspection plan 1
Slewing gearbox Change oil in acc. with oil inspection plan 1
Drive pinion Check for condition
Slewing ring
Ballast
Driver's cab
All lines, fittings and connections Check visually for leaks
Grease / lubricate in acc. with lubricating chart
All articulated joints and hinges
'Grease'
Working equipment Grease in acc. with lubricating chart 'Grease' 31
Undercarriage Grease in acc. with lubricating chart 'Grease' 39
è

Plan A – First service at 750 OH Plan B – First service at 500 OH

(at 750, 1250, 1750 ... OH) (at 500, 1500, 2500 ... OH)
Plan C – First service at 1000 OH Plan D – First service at 3000 OH

(at 1000, 2000, 4000 ... OH) (at 3000, 6000, 9000 ... OH)
Page 1 of 3
Quantity / Plan Plan Plan Plan
Designation Servicing activity
Number A B C D
Servicing in acc. with W or T l l l l
Engine
Drive belt (alternator) Check 1 l l l
V-belt (compressor) Check 1 l l l
1)
Oil filters Replace 1 l l l l
Engine oil Change l1) l l l
Valve clearance Check / adjust 12 l
Engine support retaining screws Check for tightness l l l
Speed sensor (pick-up) Check, clean l l l
Speeds Calibrate with engine in no-load l l l l
condition
Cooling system
Coolant Check additive concentration 2) l l l
Coolant lines Check for tightness and condition l l l
Air intake system
Main filter element Clean or replace in the event of 1 l l l l
corresponding fault message on
3)
multifunction display
Safety filter element Replace 3) 1 l l
Fuel system
Filter Replace 2 l l l
Tank Clean 1 l
è
1)
First change after 250 OH in PLAN N, then every 500 OH in PLAN A. (The use of engine oil to specification ACEA – E2 reduces the
the interval from 500 OH to 250 OH).
2)
Check additive concentration additionally before each cold season.
3)
Replace filter element after 3 cleaning cycles, but after 1 year at the latest.


(at 750, 1250, 1750 ... OH) (at 500, 1500, 2500 ... OH)

(at 1000, 2000, 4000 ... OH) (at 3000, 6000, 9000 ... OH)
Page 2 of 3
Number A B C D
Electrical system
Battery and cable connections Check for tightness l l l
Battery terminals Grease with terminal grease l l l
Hydraulic system
Return-flow filter (reservoir) Replace 1 l l l
Breather filter (reservoir) Replace 1 l l l
Operating pressure Check (by our Service Dept.) l l
1)
Oil reservoir Change oil in acc. with oil inspec- l
tion plan and clean reservoir
Pilot-control filter (stacking unit) Replace 1 l l l
Tyres Check pressure l l l l
Steered axle
Axle gearbox Check oil level in acc. with oil in- l l l
spection plan l l
Change oil in acc. with oil inspection
plan
Wheel-hub gears Check oil level in acc. with oil in- l l l
spection plan l l
plan
Brake disks Check lining thickness l l
Floating-axle blocking cylinder
Seat of piston rod Clean / grease 2 l l l l
Rigid axle
Axle gearbox Check oil level in acc. with oil in- l l l
spection plan
Change oil in acc. with oil inspection l l
plan
Travel gearbox Check oil level in acc. with oil in- l l l
spection plan
plan
Wheel-hub gears Check oil level in acc. with oil in- l l l
spection plan
Change oil in acc. with oil inspection l l
plan
Retaining screws Check for tightness l l l
Brake disks Check lining thickness l l
è
1)
Change hydraulic oil after 3 years at the latest.


(at 750, 1250, 1750 ... OH) (at 500, 1500, 2500 ... OH)

(at 1000, 2000, 4000 ... OH) (at 3000, 6000, 9000 ... OH)
Page 3 of 3
Number A B C D
Slewing gearbox Change oil in acc. with oil inspection l
plan
Slewing ring
Grease fill Check in acc. With lubricating chart l l l
'Grease'
Drive pinion Check for condition l l l
Grease fill Change l
Driver's cab
Superstructure
Ballast retaining screws Check for tightness l l l
Superstructure locking pin Grease 1 l l l l
Heating Check visually for leaks l l l
Filter mat (recirculated air) Replace l l
Air filter element (fresh air) Replace l l
Undercarriage Grease in acc. with lubricating chart 34 l l l l
'Grease'
All joints and hinges Grease / lubricate 1) l l l
o
1)
After wet-cleaning, the machine must be regreased.

Lubricating chart – grease Working equipment = Operating hours 10000009-en
Fig. 1 è

Lubricating Chart - Grease - working equipment (Legend of Fig. 1)
Lubricant Greasing every....

Pos. Greasing point Number
properties operating hours
1 Stick cylinder bearing (rod-side) 1) 1 10
1)
Bucket cylinder bearing (base) 1 10
1)
2 Boom cylinder bearing 2 x1 10
1)
3 Stick bearing 2x1 10
4 Two-shell grab (optional equipment) 10
- joints 10 10
- grab rotation toothing 1 10
- grab / stick bearing 2x1 10
1)
Greasing nipple array
5
V 3)
- stick cylinder bearing (base)

- boom cylinder bearing (rod-side)
2)
- adjusting cylinder bearing (rod-side)
2x1 10
- adjusting cylinder bearing (base) 2)
- boom cylinder bearing (rod-side)
- lower/upper boom bearing
2)
- monoblock boom/lower boom bearing
6 Connecting rod joints 4 10
Toggle link bearing on stick 2 10
Bucket cylinder bearing (rod-side) 1 10
Bucket / stick bearing 2x1 10
7 Superstructure 1
- superstructure locking pin 250
Working equipment from other manufacturers:

Perform inspection and servicing in compliance with the instructions issued by the manufacturer.
o
1)
not required with central greasing system
2)
only for boom adjusting equipment
3)
see "LUBRICANTS" section

Lubricating chart - grease Undercarriage = Operating hours 10000011.01-en
Fig. 2 è

Lubricating Chart - Grease Undercarriage (Legend of Fig. 2)
Lubricant Greasing every....

Pos. Greasing point Number
properties operating hours
1)
1 Slewing ring - Bearing 2 V 50
1)
2 Grease filling of toothing 1 VI check every 500
3 Levelling blade bearing and levelling blade cylinder 12 250
2)
4 Cardan joint of articulated shaft 2 250
1)
5 Steering knuckle pin 4 V 250
6 Stub axle joint 2 250
7 Tie-rods 4 250
Floating-axle blocking
8 2 250
- bearing faces of piston rods
9 Floating-axle pin 2 50
10 Stabilizers 2x4 250
Refilling quantities – Grease
Lubricant MH plus MH 5.6

Lubricants, component
properties [kg] [kg]
Slewing ring toothing (lifetime grease filling) VI 1) ca. 5,0 ca. 13,5
Joints and hinges 2411970-en
Grease or oil all joints and hinges, e.g. on covers and flaps, in accordance with the inspection and servicing
plan.
o
1)
2)
not applicable with maintenance-free cardan shaft

Central lubrication system (LINCOLN) / option 10000341.00-en
Safety instructions
Designated use Dangers in the event of non-

Use the reservoir pump and the
observance of the safety in-
grease distributors only for the structions
purpose of pumping lubricants in Any non-observance of the safety
central lubrication systems. instructions may result in danger
General safety instructions to persons as well as to the envi-
ronment and to the machine.
Make sure the machine cannot be
started while you are working on it. Non-observance of the safety in-
structions may lead to the forfei-
Pay special attention to blockages ture of all claims for damages.
in all parts as, for instance, in ar-
ticulated joints and in the equip- Non-observance of the safety in-
ment. structions may involve the fol-
lowing risks:
The central lubrication system con-
- failure of vital machine func-
nected to the reservoir pump is
tions;
protected by a pressure-limiting
valve (arrow, Fig. 1). Operation of - failure of specified servicing and
the overall system can be visually maintenance procedures;
checked at the pressure-limiting
valve. If grease emerges from the - danger to persons from electri-
pressure-limiting valve during lu- cal, mechanical and chemical
brication, the system is blocked. action;
Risk of injury from grease ejected - danger to the environment due

under high pressure. to leakage of dangerous sub-
stances.
Inapproriate operation of the sys-
tem can cause damage to the ma-
chine due to excessive or insuffi-
cient greasing of bearings or
bearing points.
Avoid damage to lines and hoses.
Reconversions or modifications of
the installed system by the user
may only be performed after con-
sultation with the manufacturer or
his contractors.
Use only original spare parts.
Fig. 1

Visual function check

Operation, servicing
and repair The distributors may be equipped with a check pin
(1, Fig. 2). The pin is connected inside the dis-
Repair and servicing may only be tributor with the piston and moves to and fro during
performed by: pumping. If the system is blocked, the control pin
- commissioned, does not move anymore.
- authorized and
- instructed
persons who are familiar with cen-
tral lubrication systems.
Always wear goggles during re-
pairs.
In the event of a blockage in the
system, the high-pressure plastic
hoses are under pressure. In this
case, it is diffcult to open the
plugged connections of the high-
pressure hoses. The system must
then be depressurized by removing
the pressure-limiting valve car- Fig. 2
tridge or by removing the filling
nipple, if any, of the plug-in limiting
valve. Lubricants
For checking of the individual out- The reservoir pump can convey commercial-grade
lets, leave each outlet open for greases up to NLGI class 2 (see: "Greases for
some time, as the pump performs bearings and slewing rings")
only one stroke per revolution of
the motor. A complete cycle in- The NLGI class only indicates the static density,
cluding all distributors requires, but not the dynamic pumpability of the grease.
however, several pump strokes (cf: Greases of the same NLGI class may have differ-
"Central lubrication system", fault ent flow properties.
table").
Keep the place of work clean and No liability is assumed for damage
tidy.
to the central lubrication system
Use only main and greasing-point caused by chemical or biological
connecting lines specified by the alterations of the lubricant used or
manufacturer and observe the rated by the use of greases that cannot
system pressures. be pumped or pumped only with re-
strictions in central lubrication sys-
tems.

Technical characteristics of the resevoir

When handling greases, clean
pump
working conditions are of great im-
portance. Impurities contained in - operating temperature : - 40° C ... 70° C
greases remain suspended and will
- max. operating pressure : 350 bars
not settle. This causes damage in
the system resulting in damage to - capacity :2l
the bearings.
- filling : via nipple
Lubricants with solid-matter addi-
- operating voltage : 24 V DC
tives of more than 3 % must not be
used in the central lubrication sys- - max. current consumption .3A
tem.
- revolutions . approx. 17 rpm
3
- delivery rate : 2.8 cm /min
Reservoir pump - preset greasing interval : 6 min
The reservoir pump (Fig. 1) is installed behind the - preset pause interval : 3 hrs.
cab and accessible through the left-hand side
door. The greasing cycles are activated depending
on machine operating hours. When the key is Time settings
turned in the key-switch (ignition lock) to position I For checking of the pause or greasing interval set-
the central lubrication system is activated, LED 1 tings, remove the cover (Fig. 3) at the front of the
on the left (Fig. 5) is lit up. reservoir pump housing.
A full lubrication cycle comprises a pause and a
greasing interval. The lubrication cycle is perma-
nently repeated after the machine has been put
into operation. During the greasing interval, the
reservoir pump conveys lubricant to the greasing
points via the distributors.
The duration of the pauses determines the total
number of lubrication cycles performed within the
working time. The amount of lubricant pumped is
determined by the length of the greasing intervals.
Longer greasing intervals require more lubricant
whereas shorter ones mean lower consumption.
Pauses and greasing intervals are permanently
stored and added up in the control unit when the
machine is shut off. After switching on (ignition
lock), the control cycle is resumed where it was Fig. 3
stopped on shut-off.
è

The pause interval is preset with the blue rotary Test run / Triggering a supplementary
switch (1, Fig. 4) whereas the greasing interval greasing interval
may be preset with the red rotary switch (2) in
15 steps respectively. For function checking, a test run with the reservoir
pump can be performed.
Test run
- Turn key in key-switch (ignition lock) to position I.
- The left LED (1, Fig. 5) lights up when the re-
sevoir control panel is activated.
- Keep the pushbutton (3) on the control panel
depressed until the right LED (2) lights up for
more than 2 seconds.
- In this case, the pause interval is shortened and
followed by a normal greasing interval.
- Supplementary greasing is always possible.
Collect any grease escaping from the bearings
Fig. 4 and discard without polluting the environment.
The times are factory-adjusted to 3

hours for the pause interval (switch
in position 3) and 6 minutes (switch
position 3) for the greasing inter-
val.
Pauses and greasing intervals may
only be modified and adjusted by
our Service Dept. or by authorised
workshops. Setting of the time in-
tervals requires procedures that
cannot be described in full in the
present Operator's Manual. De-
tailed descriptions concerning the
setting of time intervals and fault
message handling are contained in Fig. 5
the Technical Handbook for this è
machine.
After checking / adjusting the pauses or greasing

intervals, the cover must be put back in place and
retightened.

Refilling the reservoir pump Motor-driven refilling pump

The reservoir pump is refilled through ports (1 or 2, - Press grease with the refilling hose into the res-
Fig. 6). ervoir pump via port (1 or 2, Fig. 6). Stop refilling
when the grease has reached maximum level.
Overfilling is indicated by grease emerging from
the overflow opening of the reservoir.
- After filling of the reservoir pump, refit plug
(2, Fig. 8) and cap (4).
Fig. 6
Hand-operated refilling pump

Fitting:
Fig. 7
- Remove both covers from the cartridge
(1, Fig. 7)
- Before reassembling the refilling pump, make
sure seal (3) is in place.
- Pump grease with the rod through port (1 or 2,
Fig. 6) into the reservoir pump. Repeat the pro-
cedure until the grease has reached maximum
level. Overfilling is indicated by grease emerging
from the overflow opening of the resevoir.
- After filling of the reservoir pump, refit plug
(2, Fig. 8) and cap (4).
Other uses of the hand pump:
- The refilling pump can also be filled from a Fig. 8
grease drum. The sealing sleeve (4, Fig. 7) must o
not be reverted.


2245128-en

Central lubrication system, fault table 10000342.00-en
Information:
Functioning of the reservoir pump can be seen from outside by the rotation of the agitator blades (e.g. by
starting a supplementary greasing cycle or by observing the LED on the control panel).
Fig. 1 Fig. 2
Faults in the central lubrication pump

Page 1 of 2
Fault Cause Remedial action
Motor of reservoir Power supply failure Check power supply lines to reservoir pump and rectify
pump not running fault, if any.
Power supply to control Check cable between connector at reservoir pump and
board interrupted control board. If the power supply is OK, the left LED (5,
Fig. 1) is lit up (see also: "Central lubrication, test run /
triggering a supplementary greasing cyle").
Power supply from Trigger a supplementary greasing cycle; if the power
control board to motor supply is OK, the right LED (3) is on during the greasing
interrupted interval.
Control board defective Replace the control board. Before installing the board,
the jumpers for pauses and greasing intervals must be
preset in the same way as on the old control bord. Have
the work performed by our Service Dept.
Right LED flashing (3) One of the two rotary Set both rotary switches to position 3.
switches (1, 2) is in
position "0"
Signalling: LED flashing
4 times
Short circuit in push- Check whether there is a short circuit on control board. If
button (4) necessary replace the control board.
Signalling: LED flashing
3 times
è

Faults in system connected to the pump

Page 2 of 2
Faults Cause Remedial action
Blockage in system Bearing, lines or dis- Locate cause of the fault as described below and rectify:
connected to the pump tributors blocked
- Run the reservoir pump (see: "Central lubrication sys-
Fault is characterized tem, test run / triggering a supplementary greasing cy-
by the following signs: cle").
- grease escaping from - Detach all plastic high-pressure hoses (G) to the sub-
pressure-limiting distributors one by one from the main distributor (B,
valve Fig. 2). If, for instance, grease under pressure
emerges from outlet 1 of main distributor (B), the
- check pins of dis-
blockage must be localized in the lubrication circuit of
tributor pistons (if
subdistributor (D).
any) not moving
- Continue to run the reservoir pump.
- Detach all plastic pressure pipes (E) one by one from
subdistributor (D). If grease under pressure emerges,
for instance, at outlet 3 of subdistributor (D), the block-
age is located somewhere in the line at outlet 3 or in
the bearing connected to this line.
- Blocked lines or bearings must be cleared with pres-
sure from a hand pump.
Distributor blocked - Replace distributor or have distributor cleaned by our

Service Dept.
Different amounts of Incorrect dosage - Check whether the dosage complies with the lubricat-
lubricant at greasing ing chart specification.
Valve body concerned
points
installed without - Remove valve body and insert clamping ring.
clamping ring
- Check timing preset.
Incorrect preset of
greasing and pause
intervals
Over-greasing or un- Incorrect preset of Check time settings in control units, on control boards or
der-greasing of greas- greasing and pause at controls.
ing point intervals
o

Oil inspection plan = Operating hours 10000014.01-en
Fig. 3 è

Oil inspection plan (Legend of Fig. 3)

Num- Lubricant Check oil level Change oil level
Pos. Component
ber properties1) every … OH every … OH
1 Engine 1 I 10 2) 500 3) 4) 5)
2 Slewing gearbox 1 III 50 3000 3)

3 Hydraulic system 1 II 50 3000 6)
3) 7)
4 Rigid axle gearbox 1 1000
3) 7)
Travel gearbox 1 III 500 1000
Wheel-hub gears 2 1000 3) 7)
3) 7)
5 Steered axle gearbox 1 1000
III 500
Wheel-hub gears 2 1000 3) 7)
Oil change refilling quantities

Refilling quantity (liters) 8)
Component
MH plus MH 5.6
Drive engine (with oil filter) 16 16
9)
Hydraulic system – tank capacity ca. 260 / 140
Slewing gearbox ca. 3.5 ca. 3.5
10)
Rigid axle travel gearbox ca. 2.4 ca. 2.4
10)
Rigid axle body ca. 7.8 ca. 12
10)
Wheel-hub gears of rigid axle 2 x ca. 2 2 x ca. 1
3)
Steered axle body ca. 11 ca. 11.5
3)
Steered axle wheel-hub gears 2 x ca. 2.5 2 x ca. 1.5
Refilling quantities - Other

Refilling quantity (liters) 8)
Component
MH plus MH 5.6
Coolant engine/radiator ca. 25 ca. 30
Fuel tank ca. 270 ca. 340
Windscreen washer ca. 5 ca. 5
1)
2)
check engine oil level during the run-in phase (up to 200 OH) every 4-5 operating hours.
3)
first after 250 OH
4)
when engine oil acc. to specification ACEA – E2 is used, the interval is shortened from 500 OH to 250 OH.
5)
change engine oil after 1 year at the latest (see engine operating instructions)
6)
change hydraulic oil after 3 years at the latest
7)
change oil after 1 year at the latest
8)
the refilling quantities of consumables indicated are approximate and intended as a planning help. Each unit has appropriate checking
devices, e.g. dipstick or checking plugs where correct filling can be checked.
9)
depending on indicated filling level, see Checking the hydraulic oil level
10)
fill in separately

Lubricants 10000328-en
I. Oils for internal combustion engines (change interval 500 OH) Standard
API: American Petroleum Institute

ACEA: Association des Constructeurs Européen d'Automobiles g.i.e.
Engine preheating necessary.Cold-starting aid may be sufficient in upper

range. Follow with a warming-up phase. When warming up, increase engine
speed and loading gradually.
When using single-range or other multi-range motor oils and at temperatures lower than those stat-
ed, the oil recommendations of the engine manufacturer are to be observed. For directions, see en-
gine Operator's Manual.
o

I. Oils for internal combustion engines (change interval 250 OH) Option 10000329-en

ACEA: Association des Constructeurs Européen d'Automobiles g.i.e.
Engine preheating necessary.Cold-starting aid may be sufficient in upper

range. Follow with a warming-up phase. When warming up, increase engine
speed and loading gradually.
When using single-range or other multi-range motor oils and at temperatures lower than those stat-
ed, the oil recommendations of the engine manufacturer are to be observed. For directions, see en-
gine Operator's Manual.
o

II. Oils for Hydraulic System, mineral 2801009-en
Warming-up phase necessary before commencing operation. Warming up

hydraulic system for approx. 10 minutes, running at half speed and with
repeated actuation of all control valves.
o

II. Oils for Hydraulic System, synthetic (biodegradable) 2905625-en
Warming-up phase necessary before commencing operation. Warming up

hydraulic system for approx. 10 minutes, running at half speed and with
repeated actuation of all control valves.
o

III. Oils for Axles and Gearboxes (Selection) 10000343-en
Axles and gearboxes may be damaged by low-grade oils. Use only high-grade oils with
additives in the prescribed quantity (see "Specification").

P+S: Phosphor and sulphur alloy corresponding to delivery specification: 22 93 219
* e.g.: Titan Hydra ZF 20 W-40
o

V. Greases for Bearing Points and Slewing Rings 2732723-en
for centralized lubricating systems and tensioning systems,

e.g. driving chain
Minimum requirement:
Grease base : Lithium
Solid lubricant content : max. 3%
(MoS2 or graphite)
NLGI - class : see above
Corrosion protection acc. ASTMD 17 43 (CRC) : code no. 1
o

VI. Grease for the Slewing Ring Gearing 10000257-en
Minimum requirements:
Grease base : lithium soap
NLGI class : 2
Solid lubricant content : max. 3 %
(molybdenum disulphide or graphite) Dripping point: > 180 °C / 356 °F
o

Servicing 10000016-en
Draining hose for oil changes
Collect escaping oil and evacuate it

Carry out oil changes when the en-

gine is at operating temperature;
warm oil drains away more easily.
The engine, hydraulic oil reservoir and gearboxes

may be equipped with special oil drain valves
(1, Fig. 1).
These plugs permit to perform oil changes in a Fig. 1
clean and non-polluting way. o
Carry out oil changes as follows:
· Place a recipient for waste oil under the drain
opening (for the capacity see under "Filling
quantities").
· Choose the proper drain hose from the tool kit.
· Unscrew protective cap from oil drain valve.
· Screw on drain hose (2); the valve opens and the
oil drains away.
· After the oil has drained away, unscrew drain
hose; the valve closes automatically.
· Screw protective cap back in place.

Engine 2747814.01-en
Engine and engine compartment, safety instructions for inspection and servicing
Risk of injury Before carrying out work in the en-

gine compartment, secure the ma-
through rotating fan blades and chine as described in "Securing the
moving fan belts. Machine".
Shut off the engine before opening Read and observe:
the engine compartment.
"Inspection and servicing, safety
Risk of burns through hot engine, instructions" and the engine in-
exhaust and radiator components. struction manual.
Risk of scalding through hot engine o
oil or coolant.
Wait until the engine, exhaust and
radiator have cooled down before
starting servicing and repair work.
Used engine oil is classified as a
potential carcinogen and genetic
risk factor. It is therefore absolutely
essential not to swallow any oil or
inhale oil vapours and to avoid
prolonged contact with the skin.
Wear protective gloves.
When carrying out work in the en-
gine compartment outdoors during
windy weather, the hood may be
slammed down by a gust of wind,
especially if the gas-filled springs
are defective.
Therefore:
- Use rods to give the bonnet additi-
onal support in the described situ-
ation.
- Check at regular intervals that the
gas-filled springs are in good
working order. Have defective
springs replaced immediately.
If gas-filled springs with mechanial

blocking in open position are in-
stalled, additional supporting by
means of rods is not needed. See:
"Engine hood support")

Engine, checking the oil level / topping up oil 10000026.01-de
· Park the machine on a horizontal surface and

secure against inadvertent travelling movements.
· After shutting off the engine, wait about five min-
utes before checking the oil level. This delay is
sufficient for the oil to flow back into the oil sump.
· Open the engine hood from above.
· Draw out the oil dipstick (Fig. 1) and wipe off oil
with a clean and lint-free cleaning rag before re-
inserting the dipstick.
· Draw out the dipstick a second time.
· Check the oil level and fill in oil through the filler
neck (Fig. 2) up to the "max" mark (Fig. 1). (oil Fig. 1
quality: see "LUBRICANTS").
If the oil level is only just above the "min" mark
(Fig. 1) top up oil..
The oil level must not drop below

the "min" mark and not exceed the
"max" mark.
Fig. 2

Changing the engine oil 10000027.01-en
Risk of scalding caused by hot en-

gine oil.
Collect escaping oil and discard
Read and observe:
instructions".
· Run the engine until the engine oil has reached

operating temperature.
· Park the machine on a horizontal surface and Fig. 1
secure against inadvertent travelling movements.
· Remove the cover of the maintance opening
under the engine compartment. The oil drain
valve is then accessible (Fig. 1).
· Drain off the engine oil through the drain valve,
using the oil draining hose. See "Draining hose
for oil changes".
After the engine oil has drained away:

· Screw the draining hose off the valve.
· Refit the cover of the maintenance opening un- Fig. 2
der the engine compartment.
· Replace the engine oil filter.
· Fill in engine oil through the filler neck (Fig. 2)
until the oil level reaches the "max" mark on the
dipstick (Fig. 3). (oil quality and refilling quantity
see: "LUBRICANTS" and "Refilling quantities for
oil changes").
Check the oil level (see: "Engine, checking the oil
level / topping up oil").
Fig. 3

Replacing the engine oil filter 10000028.01-en
Risk of scalding caused by hot en-

gine oil.
Wear appropriate protecting equip-
ment (googles, protective gloves).
Read and observe:
instructions".
· Screw off the filter cartridge (Fig. 1) and pour Fig. 1

used oil into a collecting recipient.
· Dispose of filter separately from other wastes.
· Clean the sealing surface on the engine, remov-
ing all residues of the old seal completely.
· Fill new filter cartridge with fresh engine oil.
· Oil the rubber seal of the new filter cartridge
lightly.
· Screw down the filter cartridge until the seal fits
tightly and tighten cartridge by hand.
· Fill in engine oil through the filler neck (Fig. 2)
until the oil level reaches the "max" mark on the
dipstick (Fig. 3). Fig. 2
· Start the engine and check that no oil leaks out
between the filter cartridge and the engine.
· Check the oil level (see: "Engine, checking the oil
level / topping up oil").
Fig. 3

Checking the V-belt tensioner (automatic) 10000501.01-en
· Check that the spring box, tensioning arm and

Risk of injury from rotating fan
housing are close to one another. If these parts
blades and running V-belts.
are spaced too far apart or out of alignment, the
Shut off the engine before opening tensioner must be replaced.
· Check for signs of the tensioning arm touching
Risk of burning from hot parts of the the spring box. If these parts are in contact, the
engine, exhaust and the radiators. bearing bush of the tensioning arm is defective
and the tensioner must be replaced.
Begin servicing and repair work only
after engine, exhaust and radiator
have cooled down. A worn-out tensioner with too much clearance or a
belt slipping off the pulley are a sign of possible
misalignment of the pulleys (pulleys not properly
The automatic V-belt tensioner must aligned with respect to each other).
be checked after every 1000 hours
of operation or once a year, which-
ever occurs first. Important:
The maximum admissible alignment error for the
pulleys is 3 degrees.
The alignment can be checked with a straightedge
· Make sure the tensioning arm does not come and a protractor.
into contact with either the upper or the lower
stop at the housing (1, Fig. 1).
If one of these stops is touched, the belt (2) of
the alternator must be replaced.
Make sure during the replacement that only belts
of the correct length are installed (see spare-
parts list).
· Check the tensioning roller and the housing for
cracks (3).
In the event of cracks, the tensioner must be re-
placed. Have such work carried out by an
authorized workshop.
Check the tensioner for deposits of dirt. If there
are any, the tensioner must be removed from the
machine and cleaned with a steam-jet appliance.
Fig. 1

Drive belt, visual check 10000035-en

Shut off the engine before opening
Risk of burning from hot parts of the
engine, exhaust and the radiators.
Begin servicing and repair work only
after engine, exhaust and radiator
have cooled down.
· Open the hood of the engine compartment.

Fig. 1
· Check all drive belts visually. To do so, open the
side door on the right viewed in the sense of o
driving.
· Check the drive belts for intersecting cracks.
Transverse cracks (1, Fig. 1) parallel to the width
of the belt are admissible. Longitudinal cracks
parallel to the length of the belt intersecting with
transverse cracks are not admissible (2, Fig. 1).
· In this case, the belt must be replaced. The belt
must also be replaced when it is frayed at the
edges or when parts of the belt material are
missing.
· Check the drive belts for shining or worn-out
areas. These areas are a sign of the belt being
too slack and sliding on the pulleys.
· Have the belt tension checked and adjusted by
our Service Dept.

Replacing the drive belt 10000032.01-en

Risk of burning from hot parts of the
engine, exhaust and the radiators.
Begin servicing and repair work
only after engine, exhaust and radia-
tor have cooled down.
The drive belt can be replaced through the side

door in the engine compartment. Fig. 1
Replace the damaged / worn-out drive belt in acc.
with the servicing plan.
· Push the automatic belt tensioner (1, Fig. 1)
backwards using a special square socket wrench
(arrow, Fig. 2) and withdraw the used drive belt
(2, Fig. 1) from the alternator, the pumps and the
belt pulley.
· Place new drive belt in correct position over the
belt pulley, pumps, alternator and the deflection
rollers.
· Bring automatic belt tensioner back into tension-
ing position.
· Further adjustments are not necessary Fig. 2
(See also: "Checking the automatic V-belt ten- o

sioner").

Cleaning the speed sensor 10000040-en

blades, running V-belts and from hot
parts of the engine and the exhaust
system.
the engine compartment and let it
cool down.
Read and observe: "Inspection and
servicing, safety instructions".

· Open the hood over the engine compartment. Fig. 1
The speed sensor is screwed into the flywheel
housing and accessible from below (Fig. 1) after o
removal of the sheets under the pump and the
engine compartment.
· Undo the connector in the speed sensor supply
cable.
· Slacken the lock-nut and screw out the speed
sensor.
· Clean front of the speed sensor.
· Check the electrical contacts of the speed sen-
sor. Clean, if necessary, and remove corrosion.
· Refit the speed sensor. To do so:
- Screw the sensor down into the flywheel
housing by hand until resistance is felt. The
front face of the sensor is then in contact with
the gearing of the flywheel.
- Turn out the sensor by 1/2 turn. The sensor is
now at the correct distance from the flywheel.
- Tighten the lock-nut without changing the posi-
tion of the sensor.
- Redo the connector in the sensor supply cable.

Checking the coolant level, topping up coolant 10000033.01-en
· To top up, loosen the screw cap of the expansion

Risk of scalding reservoir carefully by a half turn. The overpres-
from hot coolant and hot steam. sure escapes from the cooling system. Screw off
the cap completely and fill in coolant (see: "Top-
Do not screw off the cap of the ping up coolant").
cooling system before the engine is
stationary and has cooled down. · Screw cap back in place.
Never fill cold coolant into a hot en- · Close the hood of the engine compartment.
gine. Parts of the engine may be
damaged by the sudden change of
temperature. Let the engine cool
down to below 50 °C before topping
up coolant.
Never mix sealing additives into the
coolant when leaks are detected in
the cooling system. Additives can
clog up the cooling system. In this
case, the insufficient flow of coolant
can cause overheating of the en-
gine.
Have the cooling system repaired
immediately.
Fig. 1
The coolant level must be checked daily in order to

detect coolant losses in time and to avoid damage. Topping up coolant
· Shut off the engine and wait until the engine and
· The coolant must be a mix of 50 % distilled water
the cooling system have cooled down to about
and of 50 % antifreeze compound (ethylene gly-
50 °C.
col). (Refilling quantity see: "Refilling quantities -
· Open the hood over the engine compartment. other").
· The coolant level must be visible between the · This mixture offers not only the necessary frost
MIN and MAX marks on the expansion reservoir protection down to ca. –30 or –35 °C, but it also
(Fig. 1). If necessary, top up coolant. protects the cooling and heating system against
corrosion. It moreover prevents lime deposits
and increases the boiling point of the coolant.
For this reason, the concentration of the coolant
must not be reduced by adding water, even in
hot weather and in countries with a tropical cli-
mate.
The proportion of antifreeze added

must be at least 50 %.

· If higher frost protection is necessary for climatic Coolant losses

reasons (e.g. Sweden, Norway, Finland), the
proportion of antifreeze can be increased, but Coolant losses are primarily due to leaks. In this
case, the cooling system should be inspected by
only up to 60 % (frost protection down to about –
our Service Dept. Topping up coolant is not
40 °C), as beyond this point the frost protection
enough!
decreases again and the cooling performance is
In a tight system, losses can only occur when the
reduced (less heat carried away).
coolant reaches the boiling point as a result of
· Before adding or replacing coolant additives, overheating and is thereby ejected from the cool-
contact our Service Dept. with regard to the ad- ing system.
missible additive specifications required for your
machine.
· Mix the parts in a clean recipient before filling If you cannot locate and rectify the
them into the cooling system. If the parts are cause of overheating by your own
filled into the system one after another, there is means, contact our Service Dept.
no proper control over the correct mixing propor- immediately to prevent severe dam-
tion. It is also possible that the parts are not age to the engine.
properly mixed.
o
Coolant additives other than those

approved by us can considerably
affect the corrosion protection effi-
ciency.
Corrosion damage caused by re-
duced protection may lead to losses
of coolant and to severe consequen-
tial engine damage

Replacing the coolant 10000037-en
Risk of scalding An antifreeze concentration of less

than 50 % affects, the corrosion pro-
from hot coolant and hot steam. tection efficiency, whereas a con-
Risk of injury from hot parts of en- centration of more than 50 % re-
gine and radiator. duces the cooling performance.
Drain off the coolant only after it has Check the antifreeze content of the
cooled down sufficiently. coolant before the cold season be-
gins. Replace the coolant every
Secure the machine before carrying 2 years.
out work in the engine compartment
and on the cooling system (see:
"Securing the machine").
Discard used coolant without pol-
luting the environment.
Read and observe:
instructions".
Coolant specification
The quality of the coolant has a de-
cisive influence on the efficiency
and the service life of the cooling
system. Observe the following in- Fig. 1
structions carefully in order to en- In accordance with the servicing plan, the coolant
sure high cooling performance and must be replaced every two years. Apart from this
protection of the cooling system regular replacement, changing or draining of the
against frost damage and / or corro- coolant is otherwise only necessary after repairs of
sion. the cooling system.
The protection against corrosion is · Open the hood over the engine compartment
of special importance when the and then the flap in front of the combined radia-
cooling system contains compo- tor.
nents made of aluminium. For this
reason, only an antifreeze com- · Prepare a collecting recipient for coolant (capac-
pound on an ethylene glycol base ity see: "Refilling quantities, other").
must be used. Mix this compound, if · Unscrew the cap of the expansion reservoir
possible, with clean and soft water. (Fig. 1).
The mixture must consist of 50 % · Open the cap (Fig. 2) carefully only so far that
water and 50 % antifreeze. The the overpressure can escape from the cooling
cooling system is then protected system. Open the cap completely only after the
down to temperatures of –30 °C to – system is depressurised. Collect escaping cool-
35 °C against frost. ant in the recipient prepared.
è

When the coolant has drained off completely,

screw the plug back in place. Fill in fresh coolant
through the expansion reservoir until the level is
visible between the "MIN" and the "MAX" mark.
Useful information about mixing can be found un-
der: "Topping up coolant".
Recheck the coolant level after a short trial run and
top up, if necessary.
Fig. 2

Checking / adjusting the valve clearance 10000104.01-en
· Now, check and adjust the valves marked in

Read and observe: table 1 with an asterisk:
"Engine, safety instructions for in-
spection and servicing" before
working on the engine. Cylinder no. 1 2 3 4 5 6
Intake - - -
Prescribed valve clearance: Exhaust - - -

Table 1
Intake valves: 0.30 ± 0.05 mm
Exhaust valves: 0.55 ± 0.05 mm Check the clearance between rocker and valve
bridge with a feeler gauge (2, Fig. 3); adjust with
the help of an Allen key (1) and a ring spanner (3).
Tightening torques:
Thereafter, turn the crankshaft through 360° until
Lock-nut of setscrews: 24 ± 4 Nm the valves of the sixth cylinder overlap.
Valve cover screws: 24 ± 4 Nm
Now, check and adjust the valves marked in ta-
Special tool for crankshaft turning: P/N 6901526 ble 2 with an asterisk:
· Shut off the engine and open the engine com-
partment hood. Cylinder no. 1 2 3 4 5 6
· Wait until the engine has cooled down. Intake - - -
· Detach all lines / hoses from the valve cover. Exhaust - - -
· Remove the valve cover. Table 2
· Remove the sheet covering the opening for in-

sertion of the crankshaft turning tool.
Refit the valve cover with a new gasket.
· Introduce the crankshaft turning tool above the
starter into the flywheel casing (Fig. 1). Reconnect all lines / hoses to the valve cover.
Important:
Counting sequence of cylinders see Fig. 2.
To adjust the valve clearance quickly and precise- The clearance is properly adjusted if the feeler
ly, proceed as follows: gauge can just be moved to and fro between valve
shaft and rocker.
· Turn the crankshaft until the valves of the first
Recheck the valve clearance after tightnening of
cylinder overlap.
the rocker lock-nuts to make sure the clearance
has not changed.
è

Fig. 1
Fig. 2
Fig. 3

Engine support, checking the screws for tight fit 10000036-en
Read and observe:

"Engine, safety instructions for in-
spection and servicing" before
working on the engine.
· Check the rubber cushions and screws of the

engine bearings for damage or loss. If they are
damaged or affected by cracking or brittleness,
the cushions must be replaced. Replace also
damaged or lost screws.
· Check tightening of the screws with a torque
wrench in acc. with the table below and the illus- Fig. 1
tration opposite (Fig. 1). o
Screw Tightening torque MA

Pos.
size/quality Nm lbft
1 M 16x70-10.9 250 199
2 M 12x70-10.9 105 77
3 M 10x40-10.9 60 44

Air intake system 2472228-en Cleaning the dust removal valve 10000039-en
Risk of injury The dust removal valve (Fig. 1) collects all dirt
particles that have entered the air filter housing.
From hot or rotating parts of the en-
gine. To remove dirt, squeeze the flexible mouthpiece of
the valve together several times.
Shut off the engine before working
on the air intake system. Loose dirt falls out of the valve.
Wear goggles before working with

compressed air.
Read and observe:
"Engine, safety instructions".
Never start the engine when parts of

the air intake system are dismantled.
The engine can be damaged if it is
allowed to draw in unfiltered air.
o
Fig. 1

Removing, checking and cleaning of the main filter element 10000041-en
An electronic vaccum detector on the air filter

housing (1, Fig. 2) triggers a corresponding fault
message on the multi-function display informing
the operator that the main filter element needs
servicing (see: “Fault code table“).
In such case, the main filter element is contami-
nated to such an extent that the flow of air passing
through the filter is insufficient.
· Open the flap on the left side of the superstruc-
ture.
· Unsnap the clamps on the air filter housing
(3, Fig. 2) and remove the cover (4).
· Withdraw the main filter element (2) carefully Fig. 1
from the air filter housing.
· The safety filter (1) remains in place.
· Clean the main filter element with dry and oil-free
compressed air of less than 6 bars (87 psi)
(Fig. 3).
· Hold the air nozzle about 3 cm (1.18") away from
the filter paper.
· Do not clean the filter element by knocking it
against other objects: risk of damage.
· Replace the main filter element after 3 cleaning
cycles or, at the latest, after 1 year of operation.
Fig. 2
Fig. 3

Perform a visual inspection:

- Introduce a lamp into the filter element. Dam-
aged areas are indicated by light shining
through the filter (Fig. 4).
- The filter element must show no deformations.
- The rubber seals of the filter element must
show no damage.
· In the event of damage, the filter must be re-
placed.
· Clean the inside of the air filter housing.
· Install an inspected and cleaned or a new filter
element. Fig. 4
· Clean the dust removal valve and refit the cover. o

Checking / replacing the safety Checking the air inlet lines 10000042-en
filter element 2800865-en
Damaged or leaking pipes and hoses of the air

Never start up the engine when the ducting circuit have a decisive influence on the
safety filter element has been re- performance and on the lifetime of the engine:
moved. · Dirt or detached parts of the air inlet lines may
The unfiltered air then drawn in may get into and cause damage to the engine.
damage the engine. · The charging pressure delivered by the turbo-
charger can escape. In this case, the engine
cannot supply its full power.
· Remove main filter element to gain access to the It is important that no unfiltered air reaches the
safety filter element (1, Fig. 1). engine. For this reason:
· All hosepipes and pipelines for clean air must be
checked for leaks (Fig. 1).
· All clamps must be in place and fit tightly.
· All pipe connections must be checked to ensure
that no corrosion has occurred under the clamps
or hoses. Rust might come loose and then get
into the engine.
Rectify such damage immediately and have dam-
aged parts replaced immediately.
Fig. 1
· Check safety filter element for contamination.

Do NOT clean the safety filter element; it must
always be replaced when contaminated.
The safety filter element must be replaced after 3
cleaning cycles of the main filter element or no
later than after one year of operation.
· Clean inside of air filter housing and cover thor-
oughly, removing all deposits with a vacuum
cleaner.
Fig. 1
· If necessary, install a new safety filter element. o
· Install main filter element again.
· Mount cover of air filter housing.
o

Fuel system
Fuel system, safety instructions 2747273-en
Explosion hazard due to va- Never use "biodiesel"

pours "Biodiesel" may damage the injec-
Fuel vapours are readily flammable tion system and the engine.
and may explode into flame. There- Use only diesel fuel produced from
fore avoid any sparking and never mineral oil complying with standard
use a naked flame, e.g. lighter or specification EN 590.
matches, for lighting.
Further information can be obtained
If you have to work on the fuel sys- from your after-sales service.
tem:
- switch off the engine and auxiliary
heating, Refuelling from cans
- secure the machine, If the machine is refuelled often or
regularly with fuel from cans or bar-
- avoid naked flames,
rels, there is an increased risk of
- do not eat, drink or smoke while foreign matter and water getting into
working. the fuel system.
In this case:
Potential health hazard - always refuel through a fine mesh;
Diesel fuel and any water/fuel mix- - drain off water from the fuel filter
ture drained off are a potential more often than specified in the
health hazard. maintenance schedule;
These fluids must never be swallow- - drain off water and deposits from
ed. the fuel tank at shorter intervals;
Protracted contact with the skin - replace all fuel filters at shorter
must also be avoided. intervals.
Wear protective gloves or apply a
barrier cream.
Avoid environmental impact

Collect escaping fuel and discard in
accordance with local environmen-
tal regulations.
Discard fuel filters and fuel-soaked
rags separately from other waste.

Replacing the fuel filter 10000031.01-en
Read and observe:

"Fuel system, safety instructions".
The double fuel filter is located beside the engine

in the engine compartment and accessible via the
lateral engine hood (Fig. 1).
Fig. 1
These filters cannot be cleaned. They must be

replaced in acc. with the servicing plan.
· Screw off the fuel filter cartridge. Do not spill the
fuel, but pour into a collecting recipient.
· Dispose of old filter cartridges.
· Clean the sealing faces on the filter head.
· Fill the new filter with fuel.
· Oil the seals of the new filter cartridges lightly.
· Screw down the new filters until the seal fits
tightly, then tighten by hand.
· Check after some time that no oil leaks out be-
tween filter head and fuel filter.
o

Bleeding the fuel system 10000551.00-en
The fuel system bleeds itself when components in An injection nozzle blocked in open position may
the fuel supply line have been replaced. also be responsible if combustion gases are blown
back into the pump with the result of too much air
During removal or replacement of the high-pres-
getting into the system. Start the engine and watch
sure fuel line, no external bleeding is necessary for
the lines. If it looks like combustion gases being
starting of the engine. During the starting proce-
blown back through the line, the injection nozzle is
dure, the fuel pump generates high pressure forc-
blocked.
ing the air out of the injection nozzles on the high-
pressure side.
Important:
If an excessive amount of air should have got into
the system, the fuel system must be bled.
Detach the fuel supply line at the injection pump
(arrow, Fig. 1). Reconnect the line when the air has
completely escaped (Fig. 2). The fuel pump is
driven from the camshaft and is located on the
engine block on the cab side. The fuel pump is
accessible from above when the hood is open.
If air bubbles continue to be visible for a few min-
utes, the cause is air entering the system. A cause
often neglected for the penetration of air into the Fig. 1
fuel system, is the segment between the filter inlet
and the suction pipe in the fuel tank. Fuel tanks
with the outlet on top have a suction pipe reaching
down to the underside of the tank. Through cracks
or pores in the weld joining the pipe to the con-
necting piece in the tank, the air can get into the
fuel system.
Check all lines and connections and the fuel filter
assembly as a whole for leaks.
Fig. 2

Fuel tank, draining off water and deposits 10000022-en
Risk of explosion
Diesel fuel may give off easily flam-
mable and explosive gases, too.
Therefore, when working on the fuel
system:
- shut off the engine and the auxil-
iary heating,
- secure the machine, keep away
open flames,
- do not smoke.
Collect the contaminated fuel and Fig. 1
discard without polluting the envi-
ronment.
Diesel fuel may cause skin injury. · Remove the cover of the maintenance opening
Wear protective gloves or use a bar- under the fuel tank. The drain valve is then ac-
rier cream. cessible.
· Place a collecting recipient under the drain plug
of the tank.
The fuel tank is made of plastic. · Turn out the drain plug under the fuel tank cau-
Avoid excessive heat and mechani- tiously (Fig. 1) and drain off water and deposits.
cal stress. Screw drain plug back in place.
· Refit the cover of the maintenance opening.
Impurities and water settle on the bottom of the o
fuel tank. This is the case if the machine is refu-
elled frequently or regularly with fuel from cans or
barrels or if the machine is used in places with
strong fluctuations between daytime and nighttime
temperatures. This leads to the formation of con-
densed water, especially if the tank is not com-
pletely filled. Condensed water freezes at tem-
peratures below 0 °C and can therefore not be
removed from the tank through the drain plug.
Therefore, drain off water and deposits at the end
of the workshift and fill up the fuel tank.

Cleaning the fuel tank 10000021-en
Risk of explosion
Do not use white spirit, paraffin oil
or other solvents for cleaning of the
tank.
These substances give off easily
flammable and explosive gases.
Therefore use only diesel fuel or a
special cleaning oil for cleaning of
the tank.
Observe the instructions for use of
the cleaning oil manufacturer.
Fig. 1
· Unscrew the cap of the filler neck (1, Fig. 1).

Do no let fuel or cleaning oil seep
into the ground. · Remove the filter sieve (2, Fig. 1).
Keep for re-use or discard without · Clean the tank with the cleaning appliance and
polluting the environment. flush.
· Refit the drain plug.
· Refit the cover of the maintenance opening.
· Empty the tank by using up as much fuel as pos-
sible. · Insert the filter sieve into the filler neck.
· Check how much fuel is still left in the tank and · Fill in fuel through the filter sieve in the filler
place a recipient of sufficient capacity under the neck.
tank drain plug.
o
· Remove the cover of the maintenance opening
under the fuel tank. The drain plug is then ac-
cessible.
· Loosen the drain plug under the fuel tank
(3, Fig. 1) and drain off fuel.
· Place a recipient under the tank to collect the
cleaning fluid.

Electrical system 10000267-en
Electrical system, safety instructions Alternator, instructions
Risk of injury from battery acid Never disconnect cables from the
and gases. alternator, regulator and battery
when the engine is running.
Wear goggles, working gloves and
firm working clothing. This would damage the alternator
and regulator.
Repair work on the electrical system
must be carried out by a qualified Take care not to interchange the
electrician only. cables when connecting the batter-
ies (observe polarity).
Carry out voltage and continuity
Prior to working on the electri- checks with a measuring instrument
cal system only.
Shut off the engine. Do NOT use a check lamp.
Prior to any work on the electrical Do NOT check by "touching
system where tools, spare parts etc. ground" with a bare wire.
might come into contact with elec-
tric cables or contacts, switch key The resulting short-circuit would
switch Electrical system (7) to 0, damage the alternator or the elec-
withdraw key and disconnect bat- tronic control units.
teries. To start up the engine, the alternator
Disconnect first negative pole ter- is controlled (pre-excited) by an
minal, then positive pole terminal. electronic circuit. This ensures that
the alternator can deliver power.
On completion of work:
The circuit is an integral part of the
Connect first positive pole terminal, central electronic system in the con-
then negative pole terminal. trol console.
Read and observe "Inspection and A LED in the control console (load-
Servicing, safety instructions". ing control) indicates that the alter-
nator is functioning correctly.
This LED must light up when the
Carry out voltage and continuity key switch is switched on; it is ex-
checks with a measuring instrument tinguished when the engine is run-
only. ning.
Do NOT use a check lamp. If this is not the case, there is a fault
in the alternator circuit or in the
Do NOT check by "touching
ground" with a bare wire. control console.
To prevent further damage, the
The resulting short-circuit would
cause of the fault must be traced
damage the alternator or the elec-
tronic control units. and eliminated as quickly as possi-
ble.
Our service department will be
pleased to advise you.

Battery, checking the fluid level 10000260-en
(Not applicable to maintenance-free batteries)

· Unscrew caps.
· If checking inserts are provided, the battery fluid
must reach up to their bases.
· If no checking inserts are installed, insert a clean
wooden rod into the battery until it contacts the
upper edge of the cell plates. The rod must be
moistened over a length of at least 10 mm
(0.39").
· If the fluid level is too low, top up with distilled
water only.
Fig.1
Battery – Checking the Charge
The acid temperature should be 20 °C (68 °F). Winter Operation
· Unscrew the battery caps (Fig. 1).
In winter the batteries are subject to exceptionally
· Measure the acid density of the battery with a high demands. At low temperatures, they more-
commercially available acid tester (Fig. 1). over have only part of the starting capacity that
they have at normal temperatures.
The acid density is in direct correlation with the
battery charge. A discharged battery may freeze at just a few de-
grees below zero.
We therefore recommend that you should have
Acid density your batteries checked and recharged if necessary
in kg / dm3 Charge by our service department before the cold time of
year sets in.
Normal Tropical
cond. cond. o
1.28 1.23 fully charged

1.2 1.12 half charged, recharge
1.12 1.08 discharged, recharge im-
mediately

Charging the batteries 10000261-en Replacing of battery 10000262-en
Maintenance charge / Recharging Used batteries must be replaced by batteries of the

same capacity, voltage (12 volts) and type. Our
For charging with low current intensities (main- service department or spare-parts service offers a
tenance charge with small-scale charging unit) the
great range of suitable batteries.
connecting cables of the on-board system need
not be disconnected. However, the instructions
issued by the manufacturer of the charging unit
must be observed in all events. If batteries are not Because of disposal difficulties, the
removed, use a charging unit with a charging volt- batteries should be replaced by our
age of 24 V (batteries are connected in series). service department. Among other
substances, batteries contain sul-
phuric acid and lead and must
therefore by no means be disposed
For the recharging of the battery,
of together with ordinary waste.
the maximum charging current must
not exceed 10 % of the nominal ca- o
pacity of the battery. Loading time:
not more than 30 hours when the
battery is completely discharged.
Rapid charging
· Observe the instructions issued by the manufac-
turer of the charging unit.
· Prior to rapid charging, i.e. charging with high
current intensities, disconnect both connecting
cables and remove the batteries (see: “In-
spection and servicing, safety instructions“ and
“Removing and installing the battery“).
· Prior to charging, release the plug far enough to
allow gas to escape from all battery cells.
· A discharged battery can freeze even at –10 °C.
It is absolutely essential to thaw out a frozen
battery prior to rapid charging; there is otherwise
a risk of explosion.
· Do not insert the mains cable of the charging unit
into the socket until the clips of the charging unit
have been connected to the battery terminals as
prescribed.
- red = positive
- black = negative
· On completion of charging, install battery again
and connect correctly (first positive, then nega-
tive cable).
o

Removing and installing the battery 10000043-en
· Open the flap in front at the right over the bat-

Switch off the engine before re- teries.
moving the batteries to prevent
damage to the alternator and regu- · Unscrew the batteriy holders and remove the
lator or to electronic components. cover over the batteries (Fig. 2).
Set key-switch for electrical system · Detach the negative battery terminal.
to 0 and withdraw key.
· Remove the bridging cables between the batter-
Detach and mount to pole terminals ies.
in the specified sequence.
· Detach the positive battery terminal.
The incorrect sequence may result
in short-circuiting. · Insulate the pole terminals.
· Lift the battery out of the battery box.
Prior to installing the new battery, make the con-
tact surfaces of the battery poles and the terminals
bright.
· Install the new battery.
· Connect the pole terminal to the positive pole of
the battery.
· Refit the bridging cables between the batteries.
Tighten the clamping screws of the terminals.
Never use force when tightening the clamping
screws, however, as this might result in damage.
· Connect the terminal to the negative pole of the
battery.
Fig. 2 Then coat battery poles and terminals with pole
Both 12 V batteries are connected in series; the grease or non-acid Vaseline.
system voltage is therefore 24 volts. Loose or corroded terminals overload the alter-
nator and the regulator.
o

Hydraulic system 2747810-en Checking the hydraulic oil level 10000044.01-en
Hydraulic system, safety instructions · Before starting the machine check that the oil
level is above the "min" mark on the inspection
glass of the hydraulic reservoir (Fig. 1). If this is
not the case, top up hydraulic oil to the "min"
Risk of injury mark.
caused by hydraulic fluid under
· Bring the hydraulic oil to operating temperature
high pressure.
(approx. 50 °C / 122 °F).
Before working on the hydraulic
· Park the machine on a horizontal surface
system, make sure that the whole
system is depressurized and that · Retract all hydraulic cylinders. Retract boom cy-
there is no residual pressure re- linder until the working equipment rests on the
maining in the system (cf. "Depres- ground.
surizing the hydraulic system".
Shut off engine.
· Open the engine hood.
Secure the machine as described in
the "Securing the machine" section. The oil level must be at the "max" mark of the in-
spection glass (Fig. 1).
Avoid contact of hydraulic oil with
the skin. Contact of hydraulic oils When the oil level has dropped below the "max"
with the skin is a health hazard. mark, top up hydraulic oil.
Wear gloves and protective cloth-

ing. In all working equipment positions, the oil level
Read and observe "Inspection and must be visible between the "min" and "max"
servicing, safety instructions". marks.
Fig. 1

Depressurizing the hydraulic system 10000045-en
Before beginning the work, the hydraulic system

must be depressurized:
· Set the working equipment on the ground.
· Turn the electrical system key-switch to position I
(ignition ON).
· Switch on the pilot control (lever 72).
· Move the control lever or the pedal of the cylin-
der on which work is to be performed into both
directions.
Important:
Fig. 1
Special caution is required when working on cylin-
ders equipped with pipe break systems. After ac-
tuation of the control levers and pedals, the cylin-
ders may still contain residual pressure.
- In boom cylinders with pipe break systems on
the piston side, this residual pressure can be re-
moved by lifting the undercarriage about 10 cm.
In this case, the machine is pressure-supported
by the rod side of the cylinder. The piston side to
be opened is without pressure.
- In adjusting cylinders or in stick cylinders with a
pipe break system on the rod side, the residual
pressure can be removed by retracting the re-
spective cylinder almost completely, with the un-
dercarriage being raised about 10 cm with the Fig. 2
extended working equipment. In this case, the o
machine is pressure-supported by the piston side
of the respective cylinder. The rod side to be
opened is without pressure.
· Turn the electrical system key-switch to position
0 (ignition OFF).
· Switch off the pilot control (lever 72).
· Remove the precharging pressure in the hydrau-
lic oil reservoir by inserting the locking pin into
the side of the breather valve (Fig. 2). Unscrew
the valve (Fig. 1) carefully until the breather bore
is open (audible hiss).
The residual pressures in the working equipment
and in the hydraulic pilot control are now removed.
· Retighten the valve by hand and withdraw the
locking pin.

Topping up hydraulic oil 10000046-en
The hydraulic oil reservoir is under a precharging

pressure of approx. 0,3 bars (4.36 psi). This pres-
sure must be removed before the reservoir is
opened.
· Remove the reservoir precharging pressure, see
"Depressurizing the hydraulic system".
· Loosen the screws (1, Fig. 1 and 2). The cover
(2) is spring-loaded.
· Remove the cover (2, Fig. 2) with spring (4) and
sealing ring (3). Do not loose the spring and the
sealing ring.
· The return-flow filter in filter chamber (5) is now
visible. Fig. 1
Pour hydraulic oil into the filter chamber until the oil
level is visible between the "min" and "max" mark
of the inspection glass. (oil quality: see "LUBRI-
CANTS").
Check the sealing ring (3) before refitting the cover
(2) and replace, if damaged.
Refit the cover with sealing ring and spring.
Fig. 2

Replacing the hydraulic oil
return-flow filter 10000047-en
The return-flow filter must be replaced:

- during maintenance work in acc. with the serv-
icing plan.
- when a fault message is displayed. In this case,
the filter is heavily contaminated. (See "Fault
code table").
- after repairs on the hydraulic system.
· Remove the reservoir precharging pressure.
See "Depressurizing the hydraulic system".
· Remove the cover (2, Fig. 1), as described un-
der "Topping up hydraulic oil".
Fig. 6
· Withdraw the return-flow filter (5) from the filter

chamber.
· Discard the filter without polluting the environ-
ment and separately from other wastes.
· Refit the cover (2) with a new sealing ring (3)
and the spring (4).
o

Replacing the breather valve 10000048-en
The breather valve (Fig. 1) ensures venting and

aerating of the hydraulic reservoir when the hy-
draulic oil level varies.
The valve also ensures a reservoir precharging
pressure of approx. 0,3 bars (4.36 psi).
The valve is equipped with a filter element. This
filter cannot be replaced or cleaned. For this rea-
son, the valve must be replaced as a whole in acc.
with the servicing plan.
The filter head turns freely on the base. The valve
can therefore not be removed by unauthorized
persons.
- For unscrewing of the valve it is necessary to Fig. 1
insert the locking pin (supplied with each valve)
into the side of the valve (Fig. 2). The old valve
can then be screwed off carefully (precharging
pressure escaping from the hydraulic reservoir).
- Insert the locking pin into the new valve and
tighten by hand.
- Withdraw the locking pin and keep for future use
(e.g. on your key ring).
Fig. 2

Replacing the pilot-control filter 10000049-en
The pilot-control circuit filter is integrated in a valve

assembly. The valve assembly is installed in the
frame between driver's cab and engine com-
partment (Fig. 1).
· Remove the residual pressure in the hydraulic
system. See "Depressurizing the hydraulic sys-
tem".
· Unscrew the housing (2, Fig. 2) and lower as far
as possible. Do no spill the hydraulic oil.
· Withdraw the filter element (1) from the socket
with a slight turn.
· Clean the filter housing and the sealing faces on
the filter head. Fig. 1
· Slide a new filter element on the socket with a

slight turn.
· Screw the filter housing into the filter head.
· Check the filter housing for leaks after putting the
hydraulic system into operation.
· Discard used filter without polluting the envi-
ronment and separately from other wastes.
Fig. 2

Changing the hydraulic oil 10000150-en
· Drain the hydraulic oil from the reservoir using

Risk of scalding from hot hy- the draining hose for oil changes.
draulic oil · The use of the oil draining hose is described
Avoid skin contact with hydraulic under "Draining hose for oil changes".
oil.
· The oil drain valve (arrow, Fig. 1) of the reservoir
Wear working gloves. is accessible from below through an opening in
the counterweight.
without polluting the environment. To drain off hydraulic oil from the cooler:
Secure the machine against inadver- · Unscrew the drain plug (Fig. 2) carefully to let the
tent starting as described under overpressure still existing in the system escape.
"Securing the machine". Remove the plug completely only thereafter and
Read and observe: "Inspection and collect the escaping hydraulic oil in the recipient
servicing, safety instructions". prepared.
· Clean the hydraulic oil reservoir.
Do not start up the drive engine

when the hydraulic oil has been
drained.
Dry runing may affect or even cause
irreparable damage to the hydraulic
pumps.
Draining off hyraulic oil

· Bring the hydraulic oil to operating temperature
(approx. 50 °C / 122 °F).
· Park the machine on a horizontal surface.
· Retract the hydraulic cylinders as far as possible Fig. 1
and stand working equipment on the ground.
· Remove the reservoir precharging pressure, see
"Depressurizing the hydraulic system".
· Place a collecting recipient under the hydraulic
reservoir (Fig. 1) and the combined radiator
(Fig. 2).
· Recipient capacity: see "Refilling quantities for oil
changes".
Fig. 2

Cleaning the hydraulic oil reservoir 10000151-en
Risk of explosion
Therefore, do not use white spirit,
paraffin oil or other solvents for
cleaning of the reservoir.
These substances give off easily
flammable and explosive gases.
Use only hydraulic oil or a special
cleaning oil for cleaning and flush-
ing of the reservoir.
Observe the instructions for use
issued by the manufacturer of the
cleaning oil.
Fig. 1
o
Do not let hydraulic oil and cleaning
oil get into the soil.
Keep for future use or discard with-
out polluting the environment
· Drain off the hydraulic oil, see: "Draining off hy-

draulic oil".
· Slacken all nuts (1, Fig. 1) and remove the cover
(2).
· Place a collecting recipient for flushing oil under
the hydraulic oil reservoir.
· Clean the inside of the reservoir with hydraulic oil
or with flushing oil.
· Remove all deposits and also the residues of the
flushing oil thoroughly.
· Replace the O-ring seal under the cover (2).
· Refit the cover.
· Fill in hydraulic oil.

Filling in hydraulic oil 10000158-en
· Remove the cover of the return-flow filter as de-

scribed under "Topping up hydraulic oil".
· Slacken the bleeding plug of the hydraulic oil
cooler (Fig. 1).
· Fill hydraulic oil into the filter chamber until oil
emerges from the bleeding plug bore (Fig. 1).
Tighten the bleeding plug.
· Continue to fill in hydraulic oil up to the "max"
mark of the inspection glass (refilling quantities
and oil qualities, see: "Refilling quantities for oil
changes" and "LUBRICANTS").
· Bleed the hydraulic system as described under
“Bleeding the hydraulic system".
· Check the oil level in the hydraulic oil reservoir. If
necessary, top up oil.
Fig. 1

Bleeding the hydraulic system 10000152-en
The bleeding procedure to be applied after repair

Collect escaping oil and discard work on other components of the hydraulic system
without polluting the environment. (e.g. on other pumps or on valve blocks) are more
complicated and require special knowledge that
cannot be provided in full in the present Operator's
Manual.
Hydraulic pumps, hydraulic motors and hydraulic
cylinders must be carefully bled after oil changes to In case of doubt or for queries please contact our
prevent them from being severly affected in their Service Dept.
intake and operating behaviour.
· Unscrew the bleeding plugs (1, Fig. 1) of the
working pump and the bleeding plug of the
slewing pump (2, Fig. 1) on the control unit side
in front on the flange.
· Hydraulic oil flows from the reservoir into the
pumps, displacing the air.
· Screw the bleeding plugs back into the bores
when the emerging hydraulic oil is free from
bubbles.
· Start the engine and let it run ca. 2 minutes at
medium speed.
· Extend and retract all hydraulic cylinders several
times until all movements are jerk-free. Fig. 1
· Slew the superstructure several times in both o

directions.

Bleeding the floating-axle supporting cylinders 10000157-en

· Stand the working eqipment on the ground.

· Block the wheels with chocks.
· Unscrew the plugs (2, Fig. 1) on both supporting
cylinders.
The check valve can protrude into Fig. 1

the open oil filling bore. Make sure
not to damage the valve when driv-
ing down the piston rod.
· Drive down the piston rod until it rests on the

contact plate on the axle.
· Fill both cylinders with hydraulic oil and screw
plugs back in place.
· Unscrew both bleeding plugs (1) and fill hydraulic
oil into the bores.
· Screw the bleeding plugs back into the bore, but
do not tighten them.
Fig. 2
· Start up the engine, release the brakes.
o
· Release the floating-axle blocking by depressing
key (33, Fig. 2) – LED2 and the symbol are ex-
tinguished.
· Tighten the bleeding plugs (1, Fig. 1) when the
oil flowing out of the bore is free from bubbles.

Combined radiator 10000153.01-en
Cleaning the combined radiator
The combined radiator (Fig. 1) is equipped with

Risk of injury cooling elements for engine coolant (3), hydraulic
oil (2) and engine charging air (1).
from rotating fan blades and V-belts.
Shut off the engine before opening · Open the lateral flap on the right side of the su-
the engine compartment. perstructure. The cooler is then accessible.
Risk of burns caused by hot parts of · Remove the cover sheet above and below the
the engine, the exhaust and the ra- radiator.
diators. · Brush dirt off the cooling fins and evacuate with a
Begin cleaning work only after all vacuum cleaner.
moving parts and components have · Remove any firmly adhering dirt using com-
come to a standstill and when en- pressed air or water pressure.
gine, exhaust and radiators have
cooled down. Wear working gloves. · Clean the radiator proceeding from top to bot-
tom. Remove detached dirt.
Put on goggles before working with
compressed air. · When dirt has accumulated, clean also the cas-
ing and the drain openings.
If the machine is used on sites with

heavily contaminated ambient air,
the combined radiator must be
cleaned more often than prescribed
in the servicing plan.
Do not use pointed or hard tools as,
for instance, wire brushes or screw-
drivers for cleaning of the radiator.
They may damage the radiator fins.
The charging air cooler is housed in
a casing with drain openings for en-
closed humidity. When the openings
are clogged up, the enclosed humid-
ity is captured inside the casing. If it Fig. 1
freezes in, the cooler will be dam-
aged. o
Check before and during the cold

season that the drain openings are
free.

Slewing gearbox 10000154-en
Slewing gearbox, checking the oil level
Read and observe:

instructions".
· Secure the machine. See "Securing the machi-

ne".
· Open the cover over the engine compartment.
· Unscrew the cap of the expansion reservoir
(Fig. 1)
Fig. 1
· The reservoir must be filled with at least 1 – 2 cm

of oil. If necessary, top up oil. (oil quality see
"LUBRICANTS").
o

Slewing gearbox, changing the oil 10000155-en
Risk of scalding from hot oil. Wear

working gloves and goggles.
· Prepare a collecting recipient for used oil. Re-

quired capacity, see "Refilling quantities for oil
changes". The drain valve is accessible from
below in an opening of the superstructure
(Fig. 2).
· Unscrew the cap of the expansion tank (Fig. 1).
Fig. 1
· Unscrew the cap of the drain valve (Fig. 2).
· Drain off oil with a 1-m long draining hose.
· Use of the oil draining hose is described under
"Draining hose for oil changes".
· Raise oil draining hose alongside the slewing
gearbox.
· Fill in fresh oil through the oil draining hose until
the expansion tank is filled ca. 1 - 2 cm with oil.
(Refilling quantity and oil quality, see: "Refilling
quantities for oil changes" and "LUBRICANTS").
· Unscrew the oil draining hose.
· Screw cap back in place on the expansion tank. Fig. 2

Superstructure holding brake, checking the operation 10000156-en
Read and observe:
Inspection and servicing, safety in-

structions".
· Start the engine. The superstructure holding

brake is switched by the central electronic unit
into the AUTOMATIC mode. LED2 above key
(17, Fig. 1) lights up. In this mode, the super-
structure is braked when the slewing control
lever (70, Fig. 1) is not actuated and when the
slewing movement has ended.
Fig. 1
· Switch on the pilot control with safety lever (72).
o
· Moving the slewing control lever (70) out of its
neutral position releases the superstructure
holding brake and the superstructure begins to
turn.
· Depress key (17) until all LEDs are off. The su-
perstructure holding brake is released. The su-
perstructure can now turn freely even without the
slewing control lever (70) being actuated
· Depress key (17) once. LED1 lights up. The su-
perstructure holding brake is applied and no
slewing movement is possible.
· Depress key (17) once more. LED2 lights up.
The superstructure holding brake is now working
again in the automatic mode. This mode permits
precise stopping of the superstructure during
slewing even in difficult working conditions.
In the event of malfunctions contact our Service
Dept.

Slewing ring Slewing ring, greasing the

bearing 10000025-en
Slewing ring, instructions 1946746-en
Risk of injury
Gearing and bearings of the slewing
ring must be inspected and re- Slew the superstructure only when
greased at shorter intervals than nobody is standing inside the
specified in the servicing plan in the slewing range.
event of:
- great heat, The slewing ring is equipped with greasing nipples
- high moisture levels, around the ring (Fig. 1).
- exposure to dust and dirt,

- marked temperature fluctuations,
- continuous slewing.
The grease packing of the gearing
must be replaced when repairs have
been carried out on the:
- slewing ring,
- sealing system or
- housing of the slewing ring,
- or if greater quantities of water
have penetrated into the ring.
Remove the used grease completely Fig.1
before replacing.
· The bearing is greased through these nipples:
If major grease losses are noted,
find the cause immediately to pre- · Attach the filling hose of the grease gun to the
vent damage to the slewing ring. greasing nipple.
Grease the slewing ring additionally · Inject grease repeatedly into each nipple.
before and after extended down-
· Slew the superstructure three times through 45°
times.
and repeat the greasing procedure.
Dispose of grease and greasy cloths
o
separately from other waste in the
interest of environmental protection.

Slewing ring, checking / changing the grease filling 10000259.01-en
Risk of injury
Never slew the superstructure with-
out having ensured that no persons
are in the slewing range.
The gearing of the slewing ring and the pinion of

the slewing gearbox are enclosed in a grease-filled
housing.
· Remove cover at A-frame (Fig 1).
· Check gearing and pinion for damage.
· Check grease filling:
Fig. 1
- The grease level in the trough should be ca.
13 mm for the MH plus ca. 20 mm for the
MH 5.6. If this is not the case, grease must be
added.
- Check whether water has penetrated the
housing. This is the case if the grease has a
light discolouring. Large quantities of water
form pools, which have to be drained or suc-
tioned off.
- Check the gearing housing and the rotor seal-
ing on the superstructure. Leakages or dam-
age may allow water to penetrate and cause
damage, or grease may be lost. Have any
damage repaired immediately.
Fig. 2
· Replace seal (2, Fig. 2) and fit cover (1) back in

place.
If the grease filling is to be replaced

(see: “Inspection and servicing
plans“), the housing must be re-
moved and the old grease must be
completely removed. Then replace
the seal and install the housing
again. Fill in new grease uniformly
distributed (for quality and required
quantity see: LUBRICANTS" and
"Refilling quantities, grease").
o

Slewing ring, checking the Slewing gear, checking the

screws for tight fit 1946584-en screws for tight fit 10000038-en
Risk of injury Risk of injury

Never slew the superstructure with- Do not start the engine when work
out having ensured that no persons on the slewing gearbox is in prog-
are in the slewing range. ress and when persons are standing
in the hazard zone.
The fastening screws of the slewing ring at the The fastening screws of the slewing gearbox on
superstructure (1, Fig. 1) and undercarriage (2) are the superstructure (Fig. 1) are tightened with a
tightened with torque (see: "Tightening torques, prescribed torque (see: "Tightening torques, ta-
table"). ble").
Fig. 1 Fig. 1
First slacken loose screws, then tighten with a Detach loose screws first before retightening them
torque spanner or an electric / hydraulic tightening with a torque wrench to the prescribed torque (see:
device to the prescribed tightening torque (see: "Tightening torques, table").
"Tightening torques, table"). o
o

Counterweight, checking the Lubricating the greasing

screws for tight fit 10000029-en nipples 2411349.01-en
Risk of injury Read and observe "Inspection and

servicing, safety instructions".
Do not start the engine unless all
work on the counterweight has fin- Before starting lubrication:
ished and all persons have left the - Set extended working equipment
hazard zone of the machine. down on the ground.
- Secure machine as described in
’Securing the machine’.
The retaining screws of the counterweight (Fig. 1)
are tightened with a torque wrench (see: "Tighten- Never discard greasy cleaning
ing torques, table"). cloths but arrange for separate dis-
posal.
Grease nipples on working equipment and under-

carriage with a grease gun.
· The loaded area of the bearing must be relieved
from loading.
· Remove cap from greasing nipple.
· Clean greasing nipple.
· Press grease-gun filler onto greasing nipple.
· Now force in grease until the fresh grease forces
the used grease out of the joints of the bearing.
· Wipe off used grease with cleaning cloths.
Fig. 1
· After greasing, fit the cap on the greasing nipple
Slacken detached screws first before tightening again.
them with a torque wrench or an electrical / hy-
draulic tightener to the prescribed tightening torque o
(see: "Tightening torques, table").
o

Floating-axle cylinder, greasing the bearing faces 10000023-en
Read and observe:

instructions".
The bearing faces of the floating-axle cylinders on

the steered axle must be greased.
When these surfaces are dry, the axle is noisy
during floating movements.
The rounded ends of the piston rods cannot slide
on the bearing surface. Jerky and rubbing move-
ments are the result.
The bearing faces begin to grip. Fig. 1
· Clean the piston rod end and the surface of the o

slide bearing.
· Spray grease between the piston rod end and
the slide bearing (Fig. 1). For selection of the lu-
bricant see "Corrosion protection for bolts and
bearings".
· Repeat this procedure on the other floating-axle
cylinder.

Axles and travel gearboxes 10000546.00-en
Rigid axle and travel gearbox, checking the Before beginning the work
oil level
· Park the machine on a level and horizontal sur-
face.
Risk of scalding caused by hot · Block the wheels of the steered axle with chocks.
oil Check the oil level in the wheel-hub gears
After long drives, the axle and the Raise the machine with the levelling blade or the
gearbox housing may be hot, too. working equipment so that the wheels of the rigid
axle are clear of the ground an can turn freely.
Let axle and gearbox housing cool Shut off the engine.
down and wear working gloves.
· Bring the plugs (Fig. 1 resp. Fig. 2) into the posi-
The axle and the gearbox may be
tion shown depending on the wheel-hub gear in-
under slight overpressure. There-
stalled.
fore, unscrew the checking plug
The marker line above the words "REAR" resp.
cautiously by a small amount to let
"OIL" must be in horizontal position.
the overpressure escape (audible
hiss). · Clean the surroundings of the plugs
(Fig. 1 and Fig. 2).
without polluting the environment. · Loosen the screw plug (1) cautiously to let the
Read and observe: overpressure escape. Screw out the plug com-
pletely. The oil level must reach up to the open-
"Inspection and servicing, safety ing. If necessary, add oil through the opening.
instructions". (oil quality see: "LUBRICANTS").
· Screw the plug (1) back in place.
· Repeat the check on the wheel-hub gear at the
opposite end of the axle.
· Lower the machine to the ground.
Checking the oil level in axle and travel

gearbox
· Check the surroundings of the screw plugs on
the axle (arrow, Fig. 3) and the travel gearbox
(arrow, Fig. 4).
· Loosen the screw plugs cautiously by a small
amount to let the overpressure escape. Screw
out the plug completely. The oil level must reach
up to each opening. If necessary, add oil through
the opening. oil quality see: "LUBRICANTS").
· Screw the plugs back in place.
è

Fig. 1 Fig. 3
Fig. 2 Fig. 4

Rigid axle and travel gearbox, changing the oil 10000544.00-en
Risk of scalding caused by hot

oil
After long drives, the axle and the
gearbox housing may be hot, too.
Let axle and gearbox housing cool
down and wear working gloves.
The axle and the gearbox may be
under slight overpressure. There-
fore, unscrew the checking plug cau-
tiously by a small amount to let the
overpressure escape (audible hiss).
Fig. 1
Read and observe:
"Inspection and servicing, safety in-
structions".
Information on refilling quantities and oil quality

can be found under: "Refilling quantities for oil
changes" and "LUBRICANTS".
Draining the oil
face (see: "Securing the machine").
· Bring the screw plugs (oil drain plugs Fig. 2
2, Fig. 1 or 2, Fig. 2) into the position shown de-
pending on the existing wheel-hub gear.
· Clean the surroundings of the screw plugs (Fig. 1
thru Fig. 3).
· Place a recipient for used oil under the travel
gearbox (Fig. 3) and the wheel-hub gears
(Fig. 1 or Fig. 2).
· Remove the oil drain plugs of the travel gearbox
and of the rigid axle (1 thru 3, Fig. 3) and the
drain plugs of the wheel-hub gears
(2, Fig. 1 or 2, Fig. 2) The oil drains off now.
· Screw the drain plugs (Fig. 1 thru Fig. 3) back in
place.
Fig. 3

Filling in oil
Important:
The refilling quantities indicated in the "Refilling
quantities for oil changes" table are approximate.
The gearbox and the axle are correctly filled when
the oil level reaches up to the lower edge of the
screw plugs mentioned in the text.
Fill first the wheel-hub gears. To do so:
· Block the wheels of the steered axle with chocks.
· Raise the machine with the levelling blade or the
working equipment so that the wheels of the rigid
axle are clear of the ground an can turn freely.
Shut off the engine.
· Bring the drain plugs (1 and 2, Fig. 4 resp. Fig. 5)
into the position shown depending on the exist- Fig. 4
ing wheel-hub gear.
The marker line above the words "REAR" resp.
"OIL" must be in horizontal position.
· Clean the surroundings of the plug
(1, Fig. 4 resp. 1, Fig. 5).
· Screw out the plug (1, Fig. 4 resp. 1, Fig. 5) cau-
tiously to let the overpressure escape before re-
moving the screw completely.
· Fill in the prescribed amount of oil through the
drain plug bore (1, Fig. 4 resp. 1, Fig. 5).
· Screw drain plug (1, Fig. 4 resp. 1, Fig. 5) back
in place.
· Fill oil into the wheel-hub gear at the opposite Fig. 5
end of the axle. è
· Lower the machine.

Now, fill the axle and travel gearbox. To do so:

· Turn out the screw plugs of axle (arrow, Fig. 6)
and travel gearbox (arrow, Fig. 7).
· Fill in the prescribed amount of oil through the
drain plug bores
· The amount of oil filled into the travel and axle
gearbox is sufficient when the oil flows out of the
drain plug bores.
· Screw the drain plugs back in place.
· Put the machine into operation. Check after
some time that the oil levels are o.k. and that the
drain plugs do not leak. Fig. 6
Fig. 7

Steered axle gearbox, checking the oil level 10000548.00-en
· Park machine as described in "Securing the ma-

Risk of scalding through hot chine".
oil
· Clean area around screw plug (Fig. 1).
The axle and the gearbox housing
may also be hot after a long jour- · Remove screw plug. The oil level must reach up
ney. to the drilled hole.
Leave the axle and gearbox hous-

ing to cool down and wear working
gloves.
The axle and gearbox may be
slightly overpressurized, so turn
the control screw carefully just far
enough to release the excess pres-
sure (audible hissing sound).
Intercept escaping oil and discard
in accordance with local environ-
mental regulations.
Servicing, Safety Instructions".
Fig. 1
· If necessary, top up oil to level of drilled hole.

(For oil quality, see: "LUBRICANTS").
· Fit screw plug in place again.
o

Planetary gearbox of steering axle, checking the oil level 10000547.00-en
Risk of scalding through hot

oil
may also be hot after a long journey.
Leave the axle and gearbox housing
to cool down and wear working
gloves.
The axle and gearbox may be slight-
ly overpressurized, so turn the con-
trol screw carefully just far enough
to release the excess pressure
(audible hissing sound).
Fig. 1
Intercept escaping oil and discard in
accordance with local environ-men-
tal regulations.
Servicing, Safety Instructions".
· Park machine on a level surface (see: "Securing

the machine").
· Block the wheels of the rigid axle by placing
chocks under the wheels.
· Raise the machine with the levelling blade or the
working equipment until the wheels of the steer- Fig. 2
ing axle are clear of the ground and turn freely. o
Stopping the engine.
· Bring the screw plugs (1 and 2, Fig. 1
resp. Fig. 2) into the position shown depending
on the gearbox installed.
- Screw plug (1, Fig. 1) must be above the cen-
terline.
- The line under the word "Front" (Fig. 2) must
be in horizontal position.
· Clean the area around screw plug (1).
· Unscrew screw plug (1) carefully just far enough
to release the excess pressure. Only then may it
be completely removed.
· The oil level must reach up to the drilled hole. If
necessary, top up oil to level of drilled hole (For
oil quality, see: "LUBRICANTS").
· Fit screw plug in place again.
· Repeat check on other wheel-hub gear.

Planetary wheel-hub gears of steering axle, changing the oil 10000550.00-en
Important:
oil The refilling quantities specified in the table "Re-
filling quantities, oil change" are reference quanti-
The axle and the gearbox housing ties. The gearbox and axle are correctly filled when
may also be hot after a long journey. the oil level reaches up to the lower edge of the
screw plug mentioned in the text.
to cool down and wear working · Park machine as described in "Securing the ma-
gloves. chine".
The axle and gearbox may be · Clean area around screw plugs (1 and 2, Fig. 1).
slightly overpressurized, so turn the
control screw carefully just far · Place a recipient for used oil below the screw
enough to release the excess pres- plug (2). For necessary capacity, see: "Refilling
sure (audible hissing sound). quantities, oil change".
Intercept escaping oil and discard in · Unscrew screw plugs (1 and 2) to allow the oil to
accordance with local environ- drain off.
mental regulations. · Fit screw plug (2) in again.
Read and observe:
· Fill in fresh oil through the screw plug hole (1).
"Inspection and Servicing, Safety The oil level must reach up to the drilled hole.
Instructions". (For refilling quantity and oil quality, see: "Refill-
ing quantities, oil change" and "LUBRICANTS").
· Fit screw plug (1) in place again.
o
Fig. 1

Wheel-hub gear of steering axle, changing the oil 10000549.00-en

oil
may also be hot after a long journey.
to cool down and wear working
gloves.
The axle and gearbox may be
slightly overpressurized, so turn the
control screw carefully just far
enough to release the excess pres-
sure (audible hissing sound).
Fig. 1
Intercept escaping oil and discard in
accordance with local environ-
mental regulations.
Read and observe:
"Inspection and Servicing, Safety
Instructions".
Draining off oil

face (see: "Securing the machine").
· Block the wheels of the rigid axle by placing
chocks under the wheels. Fig. 2
· Raise the machine with the levelling blade or the è

working equipment until the wheels of the steer-
ing axle are clear of the ground and turn freely.
Stopping the engine.
· Bring the screw plugs (oil drain plugs 2, Fig. 1
resp. 2, Fig. 2) into the position shown depend-
ing on the gearbox installed.
· Clean area around the screw plugs (1 and
2, Fig. 1 resp. Fig. 2).
· Place a recipient for used oil below the screw
plug (2). For necessary capacity, see: "Refilling
quantities, oil change".
· Unscrew the screw plugs (1 and 2) to allow the
oil to drain off.
· Screw plug (2) back in place.
· Drain off the oil in the other wheel-hub gear.

Filling in oil
Important:
The refilling quantities specified in the table "Re-
filling quantities, oil change" are reference quanti-
ties. The wheel-hub gear is correctly filled when
the oil level reaches up to the lower edge of the
screw plug mentioned in the text.
· Bring the screw plugs (1 and 2, Fig. 3
resp. Fig. 4) into the position shown depending
on the gearbox installed.
- Screw plug (1, Fig. 1) must be above the cen-
terline.
- The line below the word "Front" (Fig. 2) must
be in horizontal position.
· Fill in fresh oil through the bore of screw plug (1). Fig. 3
The oil level must reach the bore. (Refilling
quantities and oil quality see: "Refilling quantities
for oil changes" and "LUBRICANTS").
· Screw plug (1) back in place.
· Fill oil also into the other wheel-hub gear.
Fig. 4

Adjusting the wheel angle 10000553.00-en
Fig. 1
The pivoting steering knuckle (arrow, Fig. 1), trans-

fers the steering forces to the wheel which is
turned by the steering knuckle. The wheel angle is
limited by a spacer (1) fastened to the steering
knuckle with a screw (2, Fig. 1) and by a stop on
the axle body (3) to ensure contact-free turning of
the steered wheels at full wheel angle and maxi-
mum floating of the axle.
To ensure perfect driving and

steering properties of the machine,
the wheel angle must be limited in
consideration of existing machine
conditions. The wheel angle varies
depending on the axle and the tyres.
After each replacement of the axle
or change of tyres, the wheel angle
must be properly readjusted and
permanently checked. The necessa-
ry spacers and screws can be ob-
tained from our spare-parts service.
The part numbers for ordering are
set out in the spare-parts list of your
machine. If in doubt, please contact
our service department.
o

Brakes 10000258-en
Working on brakes, safety instructions
Personnel
Never do repair work on brakes un-
less you are qualified to work on
brake systems.
If in doubt, have the work done by
our service department.
Read and observe the section:
"Repair work, safety instructions".
Securing the machine

Never do repair work on brakes un-
less the machine is secured as de-
scribed in the section "Securing the
machine".

Service brake 10000244.01-en
Brake disks, checking the lining thickness
The brake disks must be checked in compliance · The reference limit value (release clearance) is
with the servicing plans. max. 3.8 mm with the MH plus and max. 4.5 mm
with the MH 5.6. Compare the measured value to
The required measuring equipment can be ordered
from our spare-parts service under the respective the reference limit.
parts number. · Measurment of the brake wear must be per-
formed every 1000 OH. If the value found is
greater or equal to the reference limit value, the
MH plus 2 809 278 max. release clearance brake disks must be replaced. Contact our Serv-
3.8 mm ice Dept.
MH 5.6 2 494 916 max. release clearance · Screw out the measuring spindle (2) and screw
4.5 mm the plug (1, Fig. 1) back in place.
The checking procedure must be performed on all

wheels. For checking, proceed as follows:
· Position the machine so that the screw plugs in
the wheel hub are in the position shown (Fig. 1).
· Secure the machine (see: "Securing the ma-
chine".
· Screw out the plug (1, Fig. 1).
· Block the service brake (see: "Using the service
brake").
· Screw the measuring device (2, Fig. 2) into the
open bore of the screw plug (fork wrench
SW 22). Fig. 1
· Slacken the lock-nut (4) of the measuring device.
· Screw down the measuring spindle (5) to the
limit stop by turning the knurled knob.
· Set the graduated drum (3) to mark "0" and lock
in this position with lock-nut (4).
· Release the service brake blocking.
· Turn the spindle (5) with the knurled knob down
to the limit stop.
Note the number of full turns (see mark "0") and
the number of the partial turn. A full turn corre-
sponds to a tspindle travel of 1 mm. A turn by
one graduation mark corresponds to 0.1 mm.
Fig. 2

Bleeding the multiple-disk brake 10000019-en
· Start the engine.

Carry out work on brake systems
only if you have been trained for · Depress the brake pedal (62) until the hydraulic
such work. fluid flowing out of the minimess hose is bubble-
free (see "Control elements")
Read also:
· Repeat the bleeding procedure on the second
"Work on brake systems, safety in- multiple-disk brake of this axle. Bleeding of one
structions". braking circuit is then terminated.
If you do not have the necessary
qualifications, have the works per-
formed by our Service Dept.
The brake system of this machine consists of two

braking circuits. One circuit for the wheel pairs of
the steered axle and the other circuit for the wheel
pairs of the rigid axle.
If work has been performed on the brake system
during which air might have got into the system
(e.g. replacement of a line), the braking circuit con-
cerned must be bled after the work.
· Secure the machine against inadvertent move-
ments.
Fig. 1
· Connect a hose to the minimess port of the mul-
o
tiple-disk brake (Fig. 1).
· Hold the other end of the hose into a recipient
filled with the same hydraulic oil or fluid as that
used in the machine.

Tyres and wheels 1946551-en
Tyres and wheels, safety instructions
Risk of injury - If in doubt as to the safety of tyres,

rims or rim components, have the
Heat-induced gas combustion in the
complete wheel removed from the
tyre may lead to explosions in air-
machine at a professional work-
filled tyres. This heat may result, for
shop.
example, from frequent braking or
when welding is being carried out on Special tools and special methods
the machine. A tyre explosion in- are needed to change tyres, rims
duced in this way is far stronger than or rim components. Therefore al-
normal bursting of tyres and may ways have such work carried out at
hurl tyre and rim parts several hun- a specially equipped professional
dred meters. Exploding or bursting workshop.
tyres and breaking-away tyre or rim
parts may cause very serious, poten- Never carry out on tyres and rims
tially fatal injury. any work for which you are not quali-
fied.
Therefore:
- If a tyre is suspected to have over-
heated, secure the machine and
wait at a safe distance until the tyre
has cooled down again.
- Before inflating tyres, check rims
and rim components for damage,
penetrated foreign matter and a
firm fit.
- Always have any damage repaired
at a professional workshop.

Tyre pressure Twin fitment

- Check the tyre pressure only when - In the case of twin fitment, pay
the tyre is cold; higher pressures special attention to the inner
are recorded when tyres heat up. sidewalls, where damage may re-
sult from unnoticed foreign bod-
- Use inflating equipment with a long
ies if the tyres have been mounted
inflating hose, self-locking nozzle
without spacing rings.
and pressure gauge (Fig. 1).
- If the inside wheel of a twin fit-
- Inflate tyres only with compressed
ment has been driven without or
ambient air. Never use combustible
with excessively low pressure,
gases: risk of explosion.
there is a risk of parts of a multi-
- While the tyre is being inflated, part rim (e.g. the lock ring) be-
stand at some distance from the coming unseated without being
tyre, facing the tread. noticed.
- Keep an eye on the tyre and the
In this case, check the state of the
pressure gauge of the inflating
wheel and rim with special care
equipment throughout the inflating
before inflating the tyre. If in
time. Never exceed the prescribed doubt, consult an expert.
tyre pressures.
- If the tyre has been removed from
the vehicle, enclose it in a safety Wheel nuts
cage.
Always tighten wheel nuts with a
- Ensure that no persons are within torque spanner. After some operat-
reach of the tyre while it is being ing hours, check with a torque
inflated. spanner for a firm fit.
Always inflate tyres to the pre-

scribed pressure:
- Excessive pressure means poor
handling properties on terrain and
a risk of bursting tyres.
- Inadequate pressure means in-
creased wear on the tyres and poor
machine stability.
Fig. 1

Driving on the highway Tyre pressure, checking and

topping up 10000661.00-en
When driving on the highway, en-
sure that the tyres have the pre-
scribed minimum tread depth and
the correct pressure. Read and observe:
Always ensure that both axles are "Tyre pressure, safety instructions".
fitted with tyres of the same size and
the same state of wear.
· Park machine on level, firm ground. Set working
Non-uniform tyre diameters may
equipment down on the ground.
cause damage to the differentials.
· Apply parking brake and superstructure retaining
Therefore prevent excessive wear on
brake.
the tyres by:
- inflating to the correct pressure, · Shut off engine.
- avoiding abrupt starting or brak- · Fit self-locking nozzle of inflating equipment onto
ing, tyre valve (Fig. 1).
- avoiding rapid cornering. · Inflate all tyres to prescribed pressure

(see : "Tyres – sizes / pressures / travelling
Clean tyres and spaces between speeds")
tyres before driving on the highway.
This will prevent other drivers from
being put at risk through soiled
roadways or through clumps of earth
or stones being thrown up from the
tyres.
Spacing rings
If your machine has radial tyres for
twin fitment, never install spacing
rings. Radial tyres are not designed
for spacing rings to be used and
would very soon be irreparably dam-
aged.
Radial tyres can be identified by the Fig. 1
"R" in the marking, e.g. "18-R19.5".
o
If you have any queries, consult the
Service Department or a profes-
sional workshop.


2245128-en

Tyres – sizes / pressures / travelling speeds 10000344.04-en
For excavators with monoboom equipment
Air MH plus MH 5.6

Manufac- pres- vmax [km/h] vmax [km/h]
Tyres Tyre dimensions
turer sure PL/ PL/
[bars] PLH A2 A2
A4 PLH A2
A2
A4
Mitas 10.00-20 PR16 NB38 7,50 30 30

Mitas 11.00-20 PR16 NB38 7,25 30 30
Bridgestone 10.00-20 PR16 FGF 7,50 30 30
Twin
Bridgestone 10.00-20 PR14 FG 6,50 30 30
Banden- Excavator 8,00 30 30 1)
markt PR18 315/80 R 22,5
2)
Banden- Grader 8,50 30 30
markt PR18 315/80 R 22,5
Michelin 18 R 19,5 XF 8,00 30 30
Single Michelin 18 R 22,5 XF 7,80 --- 30
Alliance 600/40 - 22,5 I-331 6,00 30 30
For excavators with boom adjusting equipment
Air MH plus MH 5.6

Manufac- pres- vmax [km/h] vmax [km/h]
Tyres Tyre dimensions
turer sure PL/ PL/
[bars] PLH A2 A2
A4 PLH A2
A2
A4
Mitas 10.00-20 PR16 NB38 7,50 30 30

Mitas 11.00-20 PR16 NB38 7,25 30 30
Twin
Bridgestone 10.00-20 PR14 FG 6,50 30 £ 25 3)
Banden- Excavator 30 30 1)
8,00
markt PR18 315/80 R 22,5
2)
Banden- Grader 30 30
8,50
markt PR18 315/80 R 22,5
Michelin 18 R 19,5 XF 8,00 30 ---
Single Alliance 600/40 - 22,5 I-331 6,00 30 30
Alliance 600/50 - 22,5 I-331 6,00 --- 30
è
1)
max. 19.5 t total weight. For retrofitting of these tyres please contact our Service Dept.
2)
max. 19.0 t total weight. For retrofitting of these tyres please contact our Service Dept.
3)
if these tyres are retrofitted on the machine, the speed of the travel motor is to be reduced to the specified values. Contact our Service
Dept. for further information.

Permissible tyre pressures for the following stabilization variants:

PLH - rear levelling blade
A2 - rear stabilizers
A4 - front and rear stabilizers
PL/A2 - front levelling blade and rear stabilizers
Wheel nut tightening torque: 450 Nm
The tyre pressures are valid for the specified tyre dimensions and attachment configurations on the
following conditions:
- working equipment attached,
- bucket emptied,
- tyres at ambient temperature (approx. 20 °C / 68 F),
- fuel tank full.
Check the weight of the machine after changes of the working equipment!
For queries please contact our Service Dept. or authorized special workshops.

Changing a wheel 10000160-en
Observe the fitting sequence:

Read and observe:
- Inner wheel (rim with high-offset dish)
"Tyres and wheels, safety instruc- - Intermediate ring (optional equipment)
tions".
- Outer wheel (rim with low-offset dish). Observe
the fitting sequence. Incorrect mounting of the
wheels may result in the total admissible width
· Park the machine on firm and level ground. of the machine being exceeded.
· Apply the parking brake. - Observe the information set out in "Wheels,
· Slacken the wheel-nuts by about 1 full turn. tread position".
· Raise the axle with the defective wheel until the - Do not damage the threads of the wheel-studs.
tyres lose contact with the ground by jacking up - Center the intermediate ring.
the machine with the help of the working equip-
ment or the stabilizers on the respective side of - Make sure there are no foreign objects be-
the machine. tween tyre and intermediate ring.
· Support the raised axle with squared timber to · Tighten the wheel-nuts by hand.
prevent it from lowering. · Remove the timber from under the raised axle
· Secure the machine as described under "Secur- and lower the axle.
ing the machine". · Tighten the wheel-nuts with the prescribed
· Deflate the tyres. torque.
· Slacken the wheel-nuts and remove the dam- · Inflate the tyres with the correct pressure.
aged wheel and the intermediate ring (optional · Recheck the wheel-nuts after several hours in
equipment. operation with a torque wrench for tight fit.
Mark inner and outer wheel. Do not lose center-
ing rings, spring washers and wheel-nuts. Reuse è
these parts when refitting the wheel.
· Fit new wheels:
- Inflate both tyres with approx. 1 bar.

Wheels, tread position

Observe the tread position when fitting the wheels
(Fig. 1 and 2).
Fig. 1
Fig. 2
Fig. 1 shows the tread position recommended for

all-wheel driven machines which must have the
same traction power for both driving directions.
Fig. 2 shows the tread position of the tyres when
the all-wheel-driven machine needs especially
good traction in one direction, e.g. during work with
the levelling blade.
In some cases, tread positions other than those
above may be of advantage. In these cases,
please contact our Service Dept.
o

Screenwasher 10000163-en
Topping up wash fluid

For space-saving and for functional reasons, the
reservoir has been incorporated in the panelling
behind the driver's seat.
The panelling serves at the same time as a tray for
the driver's private belongings.
The reservoir (Fig. 1) can be filled from the outside
of the cab.
Fill only clear and clean water into the reservoir to
prevent the spray nozzles of the screenwasher
from being clogged up.
For better cleaning of the windscreen, a commer-
cially available cleaning agent can be added to the Fig. 1
water.
In the cold season, add also antifreeze for screen- Important:
washing systems. As to the mixing ratio, observe
the recommendations of the manufacturer. Undamaged wiper blades are indispensable for a
long service life of the front screen and for perfect
· Remove the screw cap at the rear wall of the viewing conditions and functioning. To prevent
cab. streaks on the windscreen, the wiper blades must
· Top up wash fluid until the level reaches the be cleaned regularly with a window cleaner. In the
lower edge of the filler neck. event of heavy soiling, the wiper blades can be
cleaned with a sponge or a cleaning rag.
· Screw the cap back onto the filler neck and
check that it closes tightly.
Refilling quantity, see "Refilling quantities – other" When switching on the wiper for the
in the "Oil inspection plan" chapter. first time at freezing temperatures,
make sure the blades have not fro-
zen to the windscreen.
For reasons of safety, wiper blades should be re-

placed every year by new ones. The blades are
available from our spare-parts service.
o

Heating 10000164.01-en
Cleaning / replacing the air filter element
Always wear goggles when carrying

out cleaning work with compressed
air.
Fig. 1
The heating blower sucks in fresh air from the cab

rear wall.
The filter element is accessible after opening the
flap in the rear wall of the cab with a square socket
wrench (Fig. 1)
· Open the flap over the suction opening.
· Remove the filter element (arrow, Fig. 1) and
clean by beating or with oil-free compressed air
of less than 6 bars (87 psi). Hold the com-
pressed-air nozzle about 3 cm (1.18“) away from
the paper. Replace the filter element when heav-
ily contaminated or after 3 cleaning cycles.
· Do not clean the filter element by beating or
knocking it against hard objects. Risk of damage.
· Insert a new or a cleaned element into the holder
and reclose the flap. (see also: “Inspection and
servicing plans“).
o

Air conditioning system (option) 2904630-en
Safety instructions for inspection and servicing work
Inspection and servicing work that - Avoid any contact with liquid re-
can be carried out by the machine frigerant. Treat skin areas that
operator is described in this sec- have come into contact with refrig-
tion. erants in the same way as chil-
blains.
More detailed work on the air con-
ditioning system requires special - Wear goggles to protect your eyes.
know-how and special tools; it If refrigerant nevertheless gets into
must therefore be carried out only your eyes, seek medical advice
by trained specialists. In such immediately.
cases, apply to a workshop spe-
- Before any repairs are carried out
cializing in air conditioning sys-
on the air conditioning system, it
tems.
must be emptied. Be sure not to let
In the interests of your own safety, the refrigerant dissipate into the
observe the following instructions: environment. Use only purpose-
approved suction units to collect it.
Never reach into the system or in-
sert any objects into it. - Welding is not permissible on
parts of the closed system or in
Shut off the engine and wait until it
close proximity to them. Irrespec-
has cooled down before carrying
tive of whether or not the system is
out any servicing work.
filled with refrigerant, the resulting
Disconnect the blower from the heat build-up results in very strong
power supply to ensure that the excess pressure that may result in
blower cannot inadvertently start damage to the system or even in
up, resulting in injury. an explosion.
Some air conditioning system - Refrigerant cylinders must not be
components (e.g. heat exchanger thrown and, when full, not be ex-
and resistor at blower) may still be posed to sustained sunshine or
hot after being switched off. There other sources of heat. The maxi-
is thus a risk of burns. Wait for mum admissible temperature of a
these components to cool down filled refrigerant cylinder is 45 °C.
before working on them with the
- It is crucial that the cooling system
system opened.
should be kept free of chlorine and
chlorine-containing substances as
well as of oils and greases.
When working on the refriger- Evacuation systems and filling
ant circuit (specialists): systems should be used only for
R 134a.
The used refrigerant R 134a is
known as a safety refrigerant, i.e. it
is non-combustible, non-explosive,
non-toxic, non-irritating, and free of
smell and taste. The following
points must nonetheless be ob-
served:


2245128-en

Air conditioner, inspection and servicing work 10000439.01-en
Read and observe:

instructions".
Location of conditioner components in the

machine
The heating / air-conditioning (Fig. 1) unit is in-
stalled in the driver's cab under the driver's seat.
The conditioner is composed of the following com-
ponents:
- blower (1), Fig. 1
- heat exchanger (2),
- evaporator (3),
- filter mat (4),
- heating valve (5),
- hose for condensed water drainage (6),
- servomotor for recirculated/fresh air operation
(7).
- thermostat, electronics (8),
- air outlets in lower part of cab (9),
- air outlets on front screen and rear window (10),
Fig. 2
- cooling water inlet (11),
- cooling water outle (12),
- conditioner hose connections (13),
- fresh air inlet (14).
They are accessible after removal of the top cover.
Except for cleaning, the heat exchanger, the
evaporator and the blower do not require any
servicing.
The compressor is installed in the engine com-
partment in front of the engine.
The condenser is installed (1; Fig. 2) in front of the
combined radiator and can be seen from the cab.
Fig. 3
The refrigerant reservoir with drier (1, Fig. 3) is
located in the battery compartment. è

In the cab:
· Evaporator (3, Fig. 1) contaminated or ribs de-
formed?
Blow out dirt and suck off, straighten the ribs.
· Antifreeze protection sensor on evaporator kin-
ked or leaking?
Have sensor repaired.
· Can condensed water (6) run off freely?
Remove obstructions in hose or replace.
· Filter mat (4) contaminated?
Depending on the conditions of use, the filter mat
must also be checked more often and cleaned by
blowing out or beating.
· Is heater valve (5) completely closed when the Fig. 4
heater control knob is in the "min" position?
This can be checked when the cover at the back
wall of the cab is removed. The heater valve (1,
Fig. 4) is attached to the right side of the heat-
ing/air conditioning unit. The adjusting lever of
the heater valve must be in the "closed" position
at the bottom (see also: "Heater valve, adjusting
the Bowden cable").
· Filter element (Fig. 5) contaminated?
· Clean or replace filter element (see "Heating,
cleaning / replacing the air filter element")
· Temperature control knob (1, Fig. 6) moving
easily?
If sluggish, check the Bowden cable for kinking Fig. 5
or corrosion and replace, if necessary.
Fig. 6

In the engine compartment · Chafing marks on hoses and lines?

Have damaged hoses and lines replaced. Lay /
· V-belt of compressor (2, Fig. 7) in good condi- fasten new ones in a safer place. (This work
tion? must be carried out by a specialized workshop).
Replace defective V-belt.
· Condenser contaminated?
· V-belt properly tensioned? Contaminated condensers have a bad conden-
Readjust, if necessary. sing performance. Clean by blowing out or by
· Compressor safely fastened? flushing with water (do not use high-pressure
Tighten loosened screws (1, Fig. 7) (see also: cleaners). Deformed ribs can be restraightened.
“Air conditioner, checking / retensioning / re-
placing the compressor belt“).
In the battery compartment
· Amount of refrigerant in the system sufficient
(1, Fig. 3)?
Insufficient amounts of refrigerant are indicated
in the cab by a warning message. The system
must be checked for leaks and refilled by a spe-
cialized workshop for air conditioning systems.
Work to be performed every month

(machine operator)
The visual checks should be carried even in those
cases where the air conditioner is not used. The air
conditioner should moreover be activated once
every month for 10 - 15 minutes to prevent drying
Fig. 7 out and embrittlement of the shaft seal in the com-
pressor with the risk of refrigerant leaking out of
the unit. This measure also ensures regular lubri-
cation of the compressor components.
Check the filter element (Fig. 5) for contamination.
See also: "Heating, cleaning / replacing the filter
element".
è

Work to be performed every 6 months

(Approved special workshop)
Check refrigerant circuit and refrigerant level. (Re-
place contaminated refrigerant).
Check hoses and screwed connections for faste-
ning, tightness and proper laying.
Check compressor and magnetic clutch for proper
operation (noise-free running, oil level, safe fas-
tening of compressor).
Check electrical lines and connectors for perfect
condition and tight fit.
Check the complete system.

The refrigerant container should be replaced
whenever work has been carried out on the refrig-
erant circuit.
Work to be performed every 2 years

(Approved special workshop)
All works described in "Work to be performed
every 6 months" must be performed.
Check of the complete system.
Replacement of refrigerant reservoir with drier.
o

Air conditioner, checking / retensioning / replacing the compressor belt 10000034-en
Risk of injury · Check the V-belt. Replace the belt if it is dam-

aged or in acc. with the servicing plan.
from rotating or hot parts of the en-
gine. · Depress the V-belt with your thumb in the middle
between the pulleys. The belt should give in by
Shut off the engine before opening about 10 mm. If the belt tension does not corre-
the engine compartment. spond to this value, the belt must be retensioned
Even the compressor may be hot or slackened. To do so:
after operation. Let the compressor - Loosen retaining screw and nut (1, Fig. 1).
cool down before working on it.
- Swing the compressor towards the engine to
Read and observe: slacken the belt.
"Inspection and servicing, safety in- - Replace damaged or used belt (2) in acc. with
structions". the servicing plan by a new one.
- Tension the belt by swinging the compressor to
the right.
An improperly tensioned V-belt af-
fects the performance of the com- - Retighten retaining screw and nut (1).
pressor. - Check the belt tension.
There is also the possibility of dam- · Check that the screws fixing the compressor to
age to the V-belt and/or the com- the bracket and the bracket to the engine block
pressor. are properly tightened and retighten, if neces-
sary.
The compressor (Fig. 1) is flange-mounted on the · Check the belt tension again after the belt has
been in operation for some hours.
engine block.
The V-belt tension can be checked through the
lateral door of the engine compartment.
The belt can be retensioned from the side.
Fig. 1


2245128-en

Air conditioner fault tables 10000165-en
Blower malfunctions
Page 1 of 4
Malfunction Cause Remedial action
Blower not working Fuse defective or loose Check fuse contact, if necessary, plug in correctly. Re-
place defective fuse. Reappearance of the defect after a
short time indicates a short-circuit.
Check blower for blocking or other defects and rectify.
Loose connector Check that connector at the side of the unit is firmly in
place. Plug in properly, if necessary.
Check connections at blower switch.
Open the unit and check electrical connections inside.
Connecting cable dam- Replace cable, observing correct cable run and connec-
aged or ripped off tion.
Wrong electrical con- Check connecting cables and, if necessary, reconnect
nections properly.
Blower switch defective Replace by new OEM part.
Blower assembly Eliminate cause of blockage, e.g. by removing foreign
blocked object from rotor. If necessary, install new blower.
Blower motor defective Replace blower.
Blower cannot be Blower switch defective Replace blower switch.
stopped
Blower performance Wrong nominal supply Nominal voltage of conditioner and of vehicle system
reduced voltage must be identical. Replace blower.
Contacts dirty Clean connector contacts. Work carefully to avoid short-
circuits.
Heat exchanger heavily Clean carefully to avoid any damage resulting in conse-
contaminated quential leaks.
Blower ducts ob- Check air ducts and outlets for obstructions and remove
structed any foreign objects.
è

Insufficient cooling performance

Page 2 of 4
Compressor not work- Open circuit in com- Check power supply to the clutch.
ing pressor solenoid
Thermostat defective Replace thermostat.
V-belt loose or broken Adjust belt tension, replace belt.
Belt pulley not turning Check compressor and replace, if necessary.
although magnetic
clutch is engaged
Compressor clutch Repair clutch or replace compressor.
slipping
Evaporator flooded Expansion valve Replace expansion valve (block valve).
jammed or stuck in
open position
Evaporator frozen up Thermostat sensor in Install sensor in another place.
wrong position
Evaporator clogged up Cooling fins dirty Clean evaporator.
Loss of refrigerant Refrigerant line defec- Check all lines for discontinuities caused by external
tive influences or chafing.
Leaks in the system Evacuate the system, refill, check for leaks and repair.
Filter mat (recirculated Filter mat clogged up Clean or replace filter mat.
air)
Air filter element (fresh Air filter element Clean or replace air filter element. See also: “Heating,
air) clogged up cleaning the fiilter element“.
Heating is on Bowden cable wrongly Adjust Bowden cable (see: "Heater valve, adjusting the
centered or defective Bowden cable") or replace.
è

Insufficient heating performance

Page 3 of 4
Heating not working Cooling agent still cold Wait until the engine has reached its operating tem-
perature.
Water valve closed Open the heater valve (see Operator's Manual: "Ventila-
tion and heating").
Water lines kinked or Eliminate cause of the fault.
crushed
Heating working with Heat exchanger, filter Clean carefully to avoid any damage resulting in conse-
reduced performance mat or air filter element quential leaks. When too heavily soiled, replace filter
(heating) heavily soiled mat or air filter element.
Amount of water flow- Water lines crushed or kinked. Change position of
ing through heat ex- hoses. Insufficient pressure of water pump (remedial
changer insufficient action see above).
Air in heat exchanger The radiator is self-venting when the pump pressure is
high enough. Install an auxiliary or more powerful water
pump.
Conditioning unit under- If necessary, install an additional heating or a more
dimensioned powerful conditioning unit.
Heating cannot be Bowden cable control- Readjust the Bowden cable.
stopped ling the water valve
wrongly adjusted
Heater valve not in- Check valve mounting position with respect to flow and
stalled correctly in flow reflow direction and correct if necessary. See also: "Air
and/or reflow line conditioner, inspection and servicing work“.
Betätigung bzw. Bow- Check control / Bowden cable and replace if necessary.
denzug defekt
Air distribution flaps Flap hinges sluggish Check flap and lubricate, if necessary.
uncontrollable
Flap deformed Check flap.
Flap blocked by foreign Check flap and remove foreign object if necessary.
object
è

Conditioner very noisy

Page 4 of 4
Conditioner very noisy V-belt loose or exces- Retension V-belt or replace.
sively worn
Clutch noisy Repair clutch.
Compressor supporting Repair bracket, replace compressor.
bracket loose or worn-
out parts inside the
compressor
Blower motor exces- Replace blower.
sively worn
System overfilled Evacuate refrigerant until the high pressure reading is
normal again (approved workshop).
Not enough refrigerant Check for leaks, refill the system.
in the system
o

Machine care 10000263-en
Regular, expert servicing helps maintain the value

of the machine. In the interests of the environment,
the machine should be washed only
It may also be one of the preconditions for upon designated washing areas, pref-
holding claims under warranty in the event of cor- erably equipped with oil and grease
rosion damage. separators. Washing the machine
outside such facilities may even be
The necessary servicing agents can be obtained
prohibited in certain regions and
through our Service Department or Spare-Parts
countries.
Service. The instructions on the packaging must be
observed.
Washing the machine by hand

If incorrectly used, servicing agents
· First soften the dirt with plenty of water and rinse
may constitute a health hazard.
off as thoroughly as possible.
They must always be kept in a se-
cure place. · Then clean the machine with a sponge or wash-
ing brush.
Servicing agent residues must be
disposed of as problem waste, not · Clean wheels, undercarriage and stabilizers last,
as normal waste. using a second sponge or washing brush if pos-
sible.
· Use cleaning shampoo only for the removal of
The best means of protecting the machine from stubborn spots.
detrimental environmental influences is frequent
washing and preservation. The recommended · If the machine is washed down with a hose, the
treatment frequency depends on various factors jet should not be aimed directly at locking cylin-
including deployment conditions, seasonal factors, ders, door and cover joints and other openings,
weather and environmental influences. as they might freeze up in winter.
The longer bird droppings, resin, roadway, con- Washing the machine with a high-pressure
struction-site and industrial dust, tar spots, soot cleaner
particles, de-icing salt and other aggressive de-
posits and fluids remain adhering to the paint sur- · It is essential to observe the instructions for op-
faces, the more sustained is their destructive ac- erating the high-pressure cleaner, especially with
tion. High temperatures, e.g. due to intensive sun- respect to pressure and distances to be kept.
shine, reinforce the corrosive action. This means
· Never use omnidirectional nozzles or so-called
that daily washing may be necessary in some
“dirt cutters“.
cases, but that monthly washing with correspond-
ing preservation measures may well be sufficient. · The water temperature must not exceed 60° C.
Machine washing should include thorough washing
of the underside. è

Conservation Plastic parts and artificial leather

Good conservation protects the paint largely from External plastic parts are cleaned by normal
the environmental influences described in the pre- washing, and internal parts with a damp cloth. If
vious section and even from minor mechanical this is not adequate, plastic parts and artificial
effects. The paint surfaces, especially of the leather must be treated only with special solvent-
driver’s cab, should be given a new hard wax free plastic cleaning and preserving agents.
coating no later than when water no longer runs off
the clean paint. Upholstery and fabric coverings
Polishing Upholstery and fabric coverings on the operator’s

seat and cab roof are treated with special cleaning
Polishing is necessary only when the paintwork agents or dry foam and a soft brush.
has become unsightly and a shine can no longer
be achieved with preserving agents. Cleaning the safety belt
Important Keep the safety belt clean. Clean soiled belts only
with mild soapy water without dismantling the belt.
Matt-painted parts and plastic surfaces must not be
treated with polishing agents or hard waxes. Rims
Damaged paintwork The wheel rims should be thoroughly cleaned dur-
ing the regular machine wash. This will prevent dirt
Minor damage to paintwork, e.g. scratches or and aggressive substances from forming deposits.
stone-induced damage, must be touched up im- Stubborn deposits can be removed with an indus-
mediately with a touching-up applicator, paint trial dirt remover. Damaged paint must be touched
spray or repair paint before corrosion starts. Any up before corrosion sets in.
rust that has once formed must be thoroughly re-
moved. The defect must then be given an anti- è
corrosion base coat before a paint coating is ap-
plied. Our Service Department will be pleased to
carry out such work for you.
Cab windows / mirrors

Remove snow and ice from windows and mirrors
with a plastic scraper only. To prevent dirt
scratches, the scraper should not be moved to and
fro but only pushed.
Rubber, oil, wax, grease or silicone residues can
be removed with a glass cleaner or silicone re-
mover. The windows should also be cleaned from
inside at regular intervals.

Engine, pump and radiator assembly com-

partment, slewing gearbox, rotor, control
block, connections
Before starting cleaning operations

in the engine compartment and at
other locations, it is absolutely es-
sential to read and observe: “In-
spection and servicing - safety in-
structions“.
The ignition must be switched off if
the engine is to be washed.
As fuel, grease and oil residues float

off when the engine is washed, the
contaminated water must be
cleaned with an oil separator.
When washing the engine, never direct the water

jet at electrical or electronic components and mod-
ules or at openings. Splashed or sprayed water
may lead to malfunctions or to a failure of the en-
tire electronic system.
o

General Work 10000268-en
Putting the machine out of operation Storing the battery / batteries

Carry out the following measures if the machine is For extended outage periods (longer than two
to be put out of operation for a longer period of weeks), remove battery / batteries and store on
time: dry, well ventilated premises at ca. 20 °C (68 °F).
Observe the following maintenance points:
· Park the machine on firm and level ground.
· Clean battery ( batteries.
· Set the attachment on the ground and retract the
piston rods as far as possible. · Check acid density and battery fluid level once a
fortnight.
· Set all control elements to the 0 position.
· Charge battery / batteries when acid density has
· Clean the machine. fallen to 1.23 kg/dm3 or earlier.
· Carry out a visual check for leaks and damage · Keep battery / batteries clean and dry externally.
and have these repaired, if any.
· Protect all bright metal parts (e.g. piston rods)
against rust and dirt by applying a thin layer of Recommissioning
grease.
Prior to recommissioning after an extended outage
· Preserve the engine acc. to the recommen- period, observe the following points:
dations of the engine manufacturer.
· Put the engine into operation acc. to the recom-
· Remove the battery / batteries; cf. also "Storing mendations of the engine manufacturer.
the Battery".
· Check oil level in hydraulic tank.
· Protect the machine against unauthorized start-
up: · Check acid density and level of battery fluid.
- Withdraw key from key-switch. · Install and connect battery / batteries.

- Lock all windows. · Degrease piston rods of hydraulic cylinders.
- Close cab door. · Switch on battery main switch (option).
- Secure all lockable trap doors. · Start up engine.
- Cover up openings. · Bring machine to travelling position and apply
parking brake.
· Bleed hydraulic system.
o


2245128-en

PART 4 – REPAIR WORK 2261179-en

+
STRUCTIONS +
Repair personnel



+
+
Repair personnel
o


2245128-en

Repair work, safety instructions 1946462-en
Operator's Manual Prestressed units

Never carry out repair and servicing Never open defective prestressed
work without having read and un- units but replace them as an en-
derstood the Operator's Manual. tirety.
Pay special attention to: In exceptional cases, open only
when the system and the operating
"Fundamental safety instructions"
sequence are precisely known and
and all warnings and safety in-
any special tools required are avail-
structions attached to the machine.
able.
All working procedures to be carried
The operating manual contains no
out are listed in the Operator's Man-
information on this point.
ual. The descriptions of job se-
quences provide only experienced
personnel with the necessary in-
structions. Dismantling components
The operating manual must be kept Never dismantle while the machine
with the machine (in driver's cab) at is at operating temperature.
all times. Oils, greases, brake fluid or cool-
ants may have a high temperature
and result in burning or scalding.
Repair personnel
Leave time for the machine to cool
Repair personnel must have know- down.
how and experience relevant to re-
Before starting work, depressurize
pairing this or comparable ma-
piping and hoses, cylinders, radi-
chines.
ator, hydraulic tank, compressed-air
In the absence of such know-how, reservoir and other systems or
meticulous training must be given units.
by experienced repair personnel.
Replace defective components in
"SERVICE" Have jobs marked in good time to prevent major damage.
this way done by our service depart-
Clean the defective component
ment.
carefully before dismantling it.
Mark the dismantled parts in the
Working at greater heights correct sequence to facilitate as-
sembly.
Always wear safety harnesses when
working at greater heights. When dismantling the component,
close off exposed hose and piping
Wear an approved safety harness; it connections, exposed drill holes
must be equipped with stabilizers and housings carefully to prevent
and safety cables. any dust from penetrating.

Accumulators, safety
instructions 1946463-en
Accumulators are installed in the

Never remove lead seals hydraulic system. These accumu-
Never change rated pressure of lators contain nitrogen under high
pressure relief valves without our initial pressure.
explicit authorization. Even when the hydraulic pressure in
Never remove lead seals from pres- the system is reduced, the nitrogen
sure relief valves and accumulators. remains in the accumulator.
The accumulators are completely
safe in operation. If incorrectly han-
After the repair work dled, however, there is a risk of ex-
plosion.
To prevent corrosion, coat all bright
metal machine parts with a grease The accumulators installed in this
film. machine can not be repaired. Defec-
tive accumulators have to be
On completing the work, reas-
changed.
semble all protective devices, cov-
ers and sound-proofing and anti- Never handle accumulators mecha-
vibration material. nically, never weld or solder them.
Never start up the driving motor Prior to change the accumulator,
while work is being done on the ma- always wear goggles and working
chine. gloves. Depressurize the hydraulic
system.
Check the repaired components for
operation and all machine functions Use only original spare-parts. In
in a trial run. case of questions, ask our spare-
parts service or our service depart-
Never release the machine for re-
ment.
commissioning until all functions
work perfectly. Never remove warning and in-
struction signs, the identification
o
plate or engraved type markings. Do
not paint them over when re-
touching the paint coat. Replace ille-
gible or damaged plates immedi-
ately.
o

Engine 10000072-en Assisted Starting

(with jumper cables),
Engine, repair instructions
Safety Instructions 2904638-en
Read and observe: "Repair, safety

instructions" and the Operator's Explosion hazard
Manual of the engine before begin- Keep potential ignition sources
ning any work on the engine. such as unshielded lights or burn-
Risk of injury from rotating or hot ing cigarettes away from the batter-
parts of the engine. ies. Battery gases are highly flam-
mable.
Shut off the engine and let it cool
down. Wear goggles.
Do not carry out repair work unless Never lean over the batteries when
the machine has been secured as starting the machine from another
described in the "Securing the ma- vehicle: Risk of injury from acid
chine" section of the present Opera- splashes and battery gases.
tor's Manual. Never use assisted starting if the
Check and replace V-belts only when batteries are defective or frozen.
the engine is stationary. Never connect batteries (battery as-
Qualified repair work on the engine semblies) unless they have the
requires extensive knowledge and same voltage.
special tools. Use only tested jumper cables with
In case of doubt, have repair work insulated terminal clips and an ade-
performed by our Service Dept. or by quate lead diameter.
a specialized workshop recommen- Ensure that the bodies of the sup-
ded by our Service Dept. plying and receiving machines are
not in contact. Otherwise a current
flow could result from connecting
Alternator, replacing the drive belt the positive poles. Risk of short-
circuiting.
See "Replacing the drive belt" and the engine Op-
erator's Manual. Never use assisted starting in-
volving overvoltage, e.g. three or
o four batteries connected in series or
auxiliary devices generating higher
voltages than 24V.
Never use welding generators or
welding transformers as a source of
current.
Position the jumper cables in such a
way that they cannot be caught by
rotating engine components.
servicing, safety instructions", pay-
ing special attention to the section
"Handling batteries".

Assisted starting (with jumper cables) 10000264-en
Prior to assisted starting
Read and observe the section: Explosion hazard

"Assisted starting, safety instruc- When the negative terminal is con-
tions". nected to ground, a strong current
flows through the jumper cables.
Sparks produced in the contact area
may ignite gases escaping from the
· Switch off all consumers at the receiving ma-
discharged battery.
chine (empty batteries) and switch the key-switch
to 0. The negative terminal must there-
fore be connected to ground as far
· Switch off all consumers at the supplying ma-
away from the discharged batteries
chine (charged batteries) and switch off the en-
as possible.
gine.
The non-insulated parts of the ter-
· The capacity of the supplying batteries must not minal clamps must not get into con-
be essentially smaller than that of the discharged tact with each other. The jumper ca-
battery. ble attached to the positive pole of
the battery must moreover not get
into contact with conducting parts
A discharged battery can freeze in of the machine:
already at –10 °C. Before connecting
the jumper cable, it is absolutely
Risk of short-circuit.
necessary to defreeze the battery.
There is otherwise a risk of explo- Do not lean over the batteries:
sion.
Risk of injury from caustic
agents.
Connecting the jumper cables
· Connect the red jumper cable to the positive pole
of the empty battery (1, Fig. 1), then to the posi-
tive pole of the charged battery (2).
· Connect the black jumper cable first to the nega-
tive pole of the charged battery (3), then to a
bare-metal part of the machine (4).
Fig. 1

Starting up the engines

· Start up engine of supplying machine and run at
high speed.
· Start up engine of receiving machine. If the en-
gine fails to start up after 15 seconds, wait for
one minute, then start up again.
· When engine has started up, proceed as follows:
- switch on several consumers with high current
demand, e.g. the complete lighting system, the
blower at stage 3 and possibly also the air
conditioner. This prevents voltage peaks being
produced when detaching the jumper cable.
Voltage peaks may cause damage to elec-
tronic components.
- Disconnect the jumper cables in the following
order:
- negative pole at receiving machine (4)
- negative pole at supplying machine (3)
- positive pole at supplying machine (2)
- positive pole at receiving machine (1)
- Switch the high-current consumers off again.
- Run engine for about half an hour at low
speed. The batteries are partially charged.
Have the electrical system of the machine checked
to determine why the batteries were discharged.
o

Fuses 10000073-en
Checking / replacing the fuses
Shut off the engine and turn key-

switch to 0 before removing a fuse.
Replace defective fuses only by
fuses of the same rating.
The fuses are housed in a fuse-box in the right-

hand cover panel (Fig. 1).
· Remove the transparent cover of the fuse-box
by unsnapping the clips on both sides. The
fuses are now accessible (Fig. 2). Fuse assign-
ment and rating see: "Table of fuses".
Fig. 1
If an electrical circuit fails, check first the corres-

ponding fuse:
· Withdraw the fuse from the holder. For this pur-
pose, the fuse-box contains a special fuse re-
moval tool. (Fig. 2).
· Check the fuse. In most cases, a blown fuse
wire can be seen with the naked eye (Fig. 3). In
case of doubt, check the fuse with an ohmmeter
or replace right away by a new one.
· If the fuse is defective, insert a new one of the
same rating into the fuse holder.
· If the fuse is not defective, check the electrical Fig. 2
components, the connectors and the cables (or
have them checked).
Fig. 3

Fig. 4
Location of fuses and modules in the cab and in the engine compartment, Legend of Fig. 4:
1 Driver's cab 8 Grid-Heater fuse

2 Driver's seat 9 Hydraulic oil reservoir
3 Fuse-box 1, driver's cab 10 Starter
4 Fuse-box 2, driver's cab 11 Engine
5 Hydraulic pump 12 Combined radiator
6 Fuel tank 13 Battery
7 Counterweight
o

Table of fuses 10000071.01-en
Pedestal (Fuse box 2 on the right behind the driver's seat, Fig. 1)
FA.1 5A Power relay (main switch function), central electronics,
Restraining coil engine stop magnet
FA.2 5A Start relay, option: Grid-Heater-Controller
FA.3 5A - not used -
FA.4 2A ESX 1) ground for sensors
FA.5 15 A Option: refuelling system
FA.6 5A Safety switch electro-hydraulic pilot control,
Relay for power supply of central unit,
Pilot control working system pressure switch, pilot control travelling pressure switch
FA.7 5A Power supply PCS 2) - Box,
FA.8 5A Parking brake switch, brake pressure switch (stop-light),
Alternator (exciter voltage)
FA.9 10 A Option: driver's seat compressor, auxiliary heating timer
FA.10 5A Option: stabilizers / levelling blade
FA.11 10 A Main beam via relay
FA.12 1A Power supply for joystick left and right
FA.13 2A Power supply (ESX)
FA.14 30 A Power supply (ESX)
FA.15 1A Power supply for travel pedal and keyboard module on steering wheel
FA.16 5A Option: Power supply for greasing pump
FA.17 - Option: auxiliary heating - 15 A
FA.18 - Option: auxiliary heating - 5 A
FA.19 - Option: blower stage 1 for auxiliary heating - 7,5 A
FA.20 - Option: quick-change device - 5 A
FA.21 5A Option: heating filter relay, Grid-Heater-Controller
FA.22 30 A Option: heating filter
FA.23 25 A Stop magnet energizing coil
FA.24 5A Diagnosis socket CAN1 and CAN2 3)
FA.25 10 A 24 V/12 V voltage converter supply
Radio and socket, Option: conditioner actuator (electrically operated flap for switch-
ing between recirculated and fresh air)
FA.26 2A Relay for cab interior lighting
FA.27 2A Power relay (main switch function)
FA.28 15 A to ignition/starter switch
è
1)
ESX : Electro-hydraulic Controller
2)
PCS: Power Contol System
3)
CAN: Acronym for Control Area Network (2-wire bus)

Pedestal (Fuse box 2 on the right behind the driver's seat, Fig. 1)
FA.29 5A Hazard warning signal switch
FA.30 15 A Blower / air conditioner compressor
FA.31 - - not used -
FA.32 - - not used -
Driver's cab (fuse-box 1 on the right beside the driver's seat, Fig. 2)
FB.1 10 A Option: rotary beacon
FB.2 10 A Option: floodlamp at the rear of driver's cab
FB.3 10 A Floodlamp in front of driver's cab
FB.4 10 A Wiper motor and wash pump
FB.5 5A Cab interior lighting
FB.6 7,5 A 24 V/12 V voltage converter supply for radio and socket
FB.7 2A Power supply for display and keyboard modules in cab
FB.8 5A Option: frequency switching solenoid
FB.9 5A Illumination of switches
FB.10 - - not used -
Engine compartment
F 20 125 A Grid-Heater
Fig. 1 Fig. 2

Bulbs 10000335-en
Replacing the bulbs, instructions Replacing the lamp bulb of the cab interior
lamp
Replace defective bulbs only by-

bulbs with the same rating.
Before installing a new bulb:
Remove all traces of corrosion from
lamp holder and electrical contacts.
Contact problems and high contact
resistance can thus be avoided.
Do not touch new bulbs with bare
fingers. Sweat and dirt evaporating
and burning in when the lamp is hot
may reduce the service life of the
bulb and of the reflector.
Fig. 1
Hold the bulb therefore with a clean
rag or a piece of packing paper and
insert it into the lamp holder.
· Unsnap the cover of the lamp and remove
(Fig. 1)
Bulbs - Table · The lamp bulb is now accessible and can be

replaced.
· Place the cover back on the lamp.
Headlamps 75/70W/24V
è
Sidemarker lamps 4W/24V
Working floodlamps 70W/24V
Turn signal lamps 21W/24V
Stop lamps 21W/24V
Tail lamps 10W/24V
Cab interior lighting 10W/24V

Replacing the lamp bulb of the cab flood- Replacing the lamp bulb of the boom
lamp floodlamp
(optional equipment)
Fig. 2 Fig. 4
Fig. 2 Fig. 5
· Remove the lamp body from the floodlamp on · Unscrew the fastening screws of the lamp glass
the cab roof (Fig. 2). (Fig. 4)
· Swing lamp retaining clip aside (Fig. 3). · Remove the lamp glass.
· Replace the lamp bulb. · Swing lamp retaining clip aside (Fig. 5).
· Re-install the floodlamp. - Replace the lamp bulb.
Screw the lamp glass back in place.
è

Replacing the headlamp bulb Replacing the lamp bulb in the front direc-
tion indicator lamp
Fig. 6 Fig. 8
Fig. 7 Fig. 9
· Remove the headlamp from the superstructure Remove the screws of the lamp glass (Fig. 8).
frame (Fig. 6).
Remove the lamp glass.
· Withdraw the big rubber cap from the back of the · The lamp bulb is installed in a socket (Fig. 9):
headlamp body.
- Press down the lamp bulb and turn counter-
· Withdraw the electrical connector (Fig. 7). clockwise.
· Remove the protective cap from the lamp holder. - Withdraw the lamp bulb.
· Swing the lamp retaining clip aside. - Engage the new lamp bulb safely in the holder.
· Replace the lamp bulb. · Screw the lamp glass back in place.
· Refit the headlamp. è

Replacing the lamp bulb of the tail-light
Fig. 10
Fig. 11
· Unscrew the fastening screws of the lamp glass

(Fig. 10).
· Remove the lamp glass.
· The lamp bulbs (Fig. 11) are installed in plug-in
holders.
- Press down lamp bulb and turn counterclock-
wise.
- Withdraw the lamp bulb.
- Engage the new lamp bulb safely in the holder.
Screw the lamp glass back in place.
o

Working equipment, replacing the slip-on tooth 2413674-en
Read and observe "Repair work,

Secure the machine (see: "Securing
the machine").
The area facing the driven-out tooth-
securing device and the driven-out
tooth must be free of all persons.
The tooth-securing device or the
tooth may suddenly be released
while being driven out and hit per-
sons.
Knocked-off metal fragments may
result in injury. Fig. 2
Wear your personal protective

equipment and goggles.
Fig. 3
Fig. 1
· Strike tooth-securing device (1, Fig. 1) with an

appropriate flat object made of soft metal or
hardwood (2).
· Drive tooth (3, Fig. 2) out of socket (4) with an
appropriate flat object made of soft metal or
hardwood.
· Clean inside of socket, removing any dirt and
corrosion.
· Insert new tooth (3) into socket (4, Fig. 3). The Fig. 4
tooth must fit at the point marked with an arrow o
(Fig. 4).
· Knock new tooth-securing device (1, Fig. 4) into
opening (5) of socket (4).
The securing device can be mounted from either
side.

Trenching Grab, Wear Limits 1946466-en
Trenching grab components subject

to wear are made of alloyed, high-
grade steels.
When repairs are carried out by
welding on new parts, special in-
structions have to be observed.
Repairs should therefore be carried
out only by specially trained staff
using corresponding equipment.
Contact our service department for
advice.
Fig. 5
If the natural wear on grab edges and stops ex- The trenching grab must be repaired before the
ceeds an admissible degree, this may result in marking on the cylinder guide (2) is at the same
damage to the grab cylinder. The admissible stroke level as one of the markings on the guide rail (1).
of the grab cylinder is then exceeded, with piston
and cylindrical pipe impacting in their limit posi- The lower marking (1) provides information on the
tions. wear at the grab edges, and the upper marking on
the wear at the stops on the clamshells.
o
To enable the wear status to be checked, factory-
new trenching grabs are marked (Fig. 5):
- by prick-punching at the guide rail (1),
- with a notch at the cylinder guide (2).

Welding operations 10000250-en
Welding operations, safety instructions
Never perform welding operations Prior to any welding opera-

unless you are qualified to do so. tions on the machine:
Observe the accident prevention re- - Disconnect battery by disconnect-
gulations. ing first negative pole terminal,
Any work on receptacles that con- then positive pole terminal
tain or have contained substances - Disconnect positive pole terminal
- that are combustible or encourage at three-phase alternator (genera-
combustion, tor)
- that are susceptible to explosion or - Detach corresponding terminals

and plugs from the electronic con-
- that may develop health-hazardous trol units (read and observe: “Pro-
gases, vapours, mist or dust dur- tecting electronic control units
ing welding operations during welding operations“).
must be carried out only under ex- - Protect disconnected terminals
pert supervision and only by ex- and plugs from short-circuiting
perienced persons authorized to do and soiling by covering them with
such work. foil or adhesive tape.
Systems and units (e.g. piping, radi- Attach the welding-current pincers
ator, hydraulic tank, compressed-air in the immediate vicinity of the
reservoir) must be depressurized welding zone.
prior to being opened.
Never connect the grounding ter-
Detailed information on the correct minal of the welding equipment with
execution of welding operations is electronic components or with the
given in the Technical Manual attachment points of these compo-
"Welding for maintenance and re- nents.
pair".
It is not advisable to carry out weld-
Should you have any problems or ing operations on the engine or on
queries, apply to our service depart- components mounted on the en-
ment. gine, as this may damage the com-
If parts of the machine have to be ponents.
dismantled, read and observe the
following sections:
The welding current must not flow
"Installing attachments, safety in- via the ball-bearing slewing ring
structions", or via pin couplings, articulated
"Inspection and servicing, safety in- joints or hydraulic cylinders.
structions", On completion of the welding oper-
"Repair, safety instructions". ation, restore all electrical connec-
tions.
When reconnecting the battery, con-
nect first the positive pole terminal,
then the negative pole terminal.

General welding instructions 10000253-en
Observe accident prevention regula- · The frames of our machines are made of high-
tions, in particular: strength fine-grain steels. The frame material is
suitable for all tested and recognized arc welding
- Avoid inhaling gases/vapours con- procedures, including the inert-gas-shielded arc
stituting a health hazard, e.g. en- process. Any type of heat treatment is inadmissi-
gine exhaust vapours, hazardous ble
substances released in the welding
process, vapours from cleaning · Only at the following steel components of at-
agents and solvents. Draw them off tachments and modules may welding be done,
with appropriate suction equip- with cross sections not being changed in any
ment. way in shape or area:
- Secure machine against inadver- - trenching attachments (e.g. buckets; clam-
tent movement. shells)
- Secure units when dismantling. - toggle lever and linking elements
- Observe handling instructions for - sticks
machines and attachments (see - top boom section / bottom boom section / mono-
also: "Welding, safety instruc- block boom
tions").
- superstructure frame
- undercarriage frame
Thorough preparation of the weld area is essential
to the production of a high-grade weld. Sensitive - stabilizers (claws) and dozer blade
components must be protected or dismantled. The
weldment connecting points to the machine and Any other welding work is inadmissible.
ground terminal at the welding unit must be bright; o
therefore remove any paint, rust, oil, grease, dirt
etc. The welding work must be done with direct
current only; the polarity of the electrodes must be
checked. Welders must be sufficiently qualified to
carry out welding work on vehicles. Therefore spe-
cialized training is a precondition for such work. In
Germany this is subject to a verification of suitabil-
ity in accordance with DIN 18800, part 7. Welding
must NOT be done when the ambient temperature
falls to below +5°C.
· Prior to disconnecting the batteries, ventilate the
battery case thoroughly (detonating gas), e.g. by
blowing out with compressed air
· Attach grounding pliers of welding unit with good
conductivity directly to the area to be welded
· If two components are to be welded together,
they must be connected to each other with good
conductivity (e.g. connect the two components
with the grounding pliers)

Protecting electronic modules during welding operations 10000254.02-en
Zur Vermeidung von Schäden an e-

lektronischen Baugruppen (z. B. CU,
PCS, ESX, Display, Tastaturmodule)
beim Schweißen ist nachstehende
Vorgehensweise einzuhalten.
· Disconnect negative and positive cables of bat-

teries (see: “Battery removal and installation“)
and join loose cable ends (- with +).
Removing electronic modules and discon-

necting plug and grounding connections Fig. 1
Electronic components and further plug connec-

tions to electronic modules and grounding connec-
tions must then be disconnected at 2 points.
1st point (PCS)
- Remove rear wall of driver’s cab (Fig. 1).
- In some cases, a cover to the rear of the driver’s
cab must also be removed.
- Push arresting lever (1, Fig. 2) away from plug
and withdraw plug (2) of PCS unit upwards. At
the front of the plug is an extension (nose) that
has to be disengaged in this process.
- Loosen 4 hex nuts (3) and remove the PCS. Fig. 2
Fig. 3

2nd point (CU)

- The CU is located below the plate on which the
PCS is mounted. The plate is fixed to the rear
wall of the driver’s cab with 3 screws (Fig. 3).
- Withdraw plugs (1 - 5, Fig. 4) from CU, pressing
laterally on the plug arresting device. Mark plug
connections correspondingly in advance to avoid
mix-ups when plugging together.
- Disconnect three further plugs located on a
separate p.c. board to the right beside the CU
(Fig. 5).
3rd point (ESX) Fig. 4
The ESX is located to the right below the cab, be-

side the slewing ring. The grounding cable
(3, Fig. 7) is located to the right beside the ESX.
- Unscrew base plate.
- Disconnect grounding connection between frame
and cab/platform plate (Fig. 6), insulating the
grounding cable in such a way that no ground
connection can be inadvertently restored.
- Withdraw arresting lever (1, Fig. 7) at plug for-
ward, and withdraw plug (2) parallel from the
control unit.
Fig. 5

Removed electronic modules (PCS,

ESX) must be stored at least 10 to
15 m away from the welding point.
The greater the distance to the
welding point, the lower the adverse
effects of electromagnet fields.
Never store the components on the
machine or in the cab.
Once all working steps have been executed,

welding operations can be carried out on the ma-
chine (read and observe: “Welding operations –
safety instructions“ and “Welding instructions“).
Fig. 6
On completion of the welding operation, reinstall all
removed electronic components and reconnect all
plug and grounding connections by performing the
steps listed above in the reverse sequence.
Failure to observe this procedure

will rule out any liability and war-
ranty coverage for resulting dam-
age.
Fig. 7

Effect of electromagnetic
fields and electrostatic dis-
charges 10000255.01-en
Strong electromagnetic fields resulting from high-

voltage cables, lightning stroke current, transmitter
systems or other sources of interference can influ-
ence electronic modules in the machine and may
lead to malfunctions.
Mobile phones or radio equipment

with no separate external aerial may
constitute a health hazard due to
excessive electromagnetic fields if
operated inside the driver’s cab.
Attention must be paid to the Opera-
tor's Manual issued for the mobile
phones and radio equipment.
Electrostatic discharges may also cause irrepara-

ble damage to electronic components.
If inexplicable malfunctions occur in the machine,
stop the machine and secure it. If lightning strikes
close to the machine, wait in the driver’s cab until
the thunderstorm is over.
For safety reasons, work must not

be continued in the event of inexpli-
cable malfunctions in the machine.
In such cases, the Service Depart-
ment should be contacted immedi-
ately.
o


2245128-en

PART 5 – ANNEX 2261969-en

+
STRUCTIONS +
Repair personnel



+
+
Repair personnel
o


2245128-en

Troubleshooting 10000099-en
Instructions for troubleshooting Fault table layout

Fault
Faults are often due to the machine not having The fault is described as a result of an observation
been operated or serviced properly. or of a preceding activity.
When dealing with faults, it is therefore necessary Observe the machine carefully.
to read the corresponding chapter of the Opera-
Examine the problem thoroughly. First think, then
tor's Manual once again.
act.
If you cannot find the cause of a fault or rectify it,
Ask yourself the following questions:
contact our Service Dept.
- Which warning signs preceded the fault?
Describe the fault and the accompanying circum-
stances as precisely as possible when contacting - Which repair and servicing work had been per-
our Service Dept. formed beforehand?
Exact information helps to locate and to rectifiy - Has this defect already been noticed in the past?
faults as fast as possible.
- Are we faced with one or with several defects
Never do work for which you are not qualified. occurring at the same time?
The present fault table lists the faults reported to Causes
date, their possible causes and the remedial ac-
tion. This column describes the possible causes of the
fault observed. The causes are listed in the order
In exceptional cases, a described fault may also of their probability of occurrence, i.e. the possible
have another cause. cause applying in most of the cases is mentioned
in first place.
Chapter reference
The chapter reference informs the reader where to
find the pertaining troubleshooting instructions in
this Operator's Manual. In the event of missing
reference, please contact our Service Dept.
Remedial action
This column informs about how to detect the
causes of faults and how to remedy them.
o

Fault tables 10000100-en
Combustion engine fault table
Remedial
Fault
action
Engine fails to start or starts only with difficulty
Engine cannot be turned over Check P
Engine starts, but runs unevenly or intermittently Adjust E
Engine gets too hot, temperature warning is activated Replace W
Engine power insufficient Top up A
Engine not working on full cylinder capacity Reduce S
Engine without oil pressure or oil pressure too low Clean R
Engine oil consumption too high
Engine emits blue smoke Contact our
Engine emits white smoke Service Dept. SE
Engine emits black smoke
Engine cannot be shut off, pilot lamps extinguished
Engine speed strongly reduced
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 Cause Chapter
reference
Temperature below limit starting temperature/cold starting Starting the
l l l P
system defective engine
l Oil level too low Engine oil level A
l ll Oil level too high Engine oil level S
lll Inclination of engine too great Op. instruct. P
1)
l l l l l Fuel quality not complying with specification Op. instruct. W
l l l l l l Air filter contaminated/ turbocharger defective Air-intake sys. P
l l l l Fuel filter contaminated Fuel filter P/W
l l l Charge-air line leaks P
2)
l Combined radiator / cooling fins dirty Clean radiator R
l Cooler fan defective Op. instruct. P/W
l Insufficient coolant level P
l Battery defective or not charged Battery P
l Loose or corroded cable connectors in starter circuit P
l Starter defective or pinion not in engagement P
l l Shut-off solenoid jamming SE
l Fuse FA.2 / starter relay defective W
l llll l Incorrect valve clearance setting SE
l l ll l Leaks in injection line P
l llll ll l Injection valve defective SE
l Engine internally blocked SE
l Combustion engine blocked at power output side SE
l PCS system malfunction SE
ll Cylinder head gasket leaking / defective SE
1)
observe fuel quality
2)
engine temperature too high

Steering system fault table 10000101-en
Remedial
Fault
action
Steering not operational
Steering wheel hard to turn, grab rotation not operational Check P
Steering wheel hard to turn when driving on level ground Adjust E
Steering inexact, permanent correction required Replace W
Steering easy to turn at limit stop Top up A
Steering wheel turns fast for a short moment during steering action (steering discontinuous) Reduce S
Clean R
Contact our
Service Dept. SE
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 Cause Chapter
reference
l Double pump without frictional connection SE
Topping up
l Hydraulic oil level too low P
hydraulic oil
l Malfunction of primary/secondary pressure limiting valves SE
Tyres and
l Tyre pressure too low P/A
wheels
l l l Air in hydraulic system SE
lll Internal leaks in steering valve / cylinder SE
l Oil delivery insufficient SE

Service brake and parking brake fault table 10000102-en
Remedial
Fault
action
No braking or insufficient braking action of machine
Machine braking action too strong Check P
Parking brake blocked Adjust E
Parking brake cannot be applied Replace W
Top up A
Reduce S
Clean R
Contact our
Service Dept. SE
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 Cause Chapter
reference
l Malfunction or defect of brake pedal valve SE
l Leaks in diaphragm brake cylinder SE
l Hydraulic oil loss / external leaks Service brake P
l Brake disks worn out SE
l Air in hydraulic brake system SE
ll Malfunction of service brake valve SE
ll Malfunction of parking-brake solenoid SE
l Brake release pressure not reached SE
l Toggle switch defective SE
l Gearbox blocked (check gearshift) SE


2245128-en

Working hydraulics (incl. boom-adjusting and grab cylinder) fault table 10000105-en
Remedial
Fault
action
Working and slewing movements not operational
Working movements too slow Check P
Power losses in working hydraulics Adjust E
Inadvertent working movements, after actuation of control lever Replace W
Boom without function Top up A
Boom raising function not operational Reduce S
Boom lowering function not operational Clean R
Backhoe not operational
Backhoe closing function not operational (extension of backhoe cylinder) Contact our
Backhoe opening function not operational (retraction of backhoe cylinder) Service Dept. SE
Stick not operational
Stick extension not operational (retraction of stick cylinder)
Stick retraction not operational (extension of stick cylinder)
Adjusting cylinder not operational
Retraction of adjusting cylinder not operational
Extension of adjusting cylinder not operational
Backhoe cylinder extends inadvertently during grab operation
Grab opens and closes too slowly
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 Cause Chapter refer-
ence
l Pilot control lever not in working position/defective Working oper. P
l Hydraulic oil level too low Hydraulic oil P/A
l l l ll lll ll lll l l Malfunction in pressure limiting valve (stacking) SE
l l Pilot control pump defective SE
l Main pump drive coupling defective SE
l l ll lll ll lll l l Malfunction in primary/secondary pressure limiting valve SE
l l LOW IDLE too low Working oper. P
l l PCS level CRANE selected Working oper. P
l Fuel filter contaminated Fuel filter P/W
Engine malfunc-
l l Engine lacks power SE
tion
Hydraulic oil temperature too high (warning lamp lit up) oil Hydraulic oil
l P/R
cooler contaminated cooler cleaning
l Coolant temperature too high (warning lamp lit up) SE
Malfunction of pilot control valve (fault occurring after
l SE
actuation of a control lever)
l l l Malfunction of control spool SE
l Express coupling not completely open P
Switch-over valve backhoe/grab operation not completely
l Grab operation P
closed, internal leaks
Equipment safety valve Y113 or pressure switch S113.4
l SE
defective, cable broken
l ESX failure (Electro-hydraulic Controller) SE
l CAN2 communication error SE
l Load-sensing pressure valves Y290 / Y291 defective SE

Working hydraulics (incl. boom-adjusting and grab cylinder) fault table
Remedial
Fault
action
Working and slewing movements not operational
Working movements too slow Check P
Power losses in working hydraulics Adjust E
Inadvertent working movements, after actuation of control lever Replace W
Boom without function Top up A
Boom raising function not op Reduce S
Boom lowering function not operational Clean R
Backhoe not operational
Backhoe closing function not operational (extension of backhoe cylinder) Contact our
Backhoe opening function not operational (retraction of backhoe cylinder)) Service Dept. SE
Stick not operational
Stick extension not operational (retraction of stick cylinder)
Stick retraction not operational (extension of stick cylinder)
Adjusting cylinder not operational
Retraction of adjusting cylinder not operational
Extension of adjusting cylinder not operational
Backhoe cylinder extends inadvertently during grab operation
Grab opens and closes too slowly
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 Cause Chapter refer-
ence
l Pilot valve 203b defective (or ESX output Pin...) SE
l Pilot valve 203a defective SE
l Pilot valve 204b defective SE
l l l Control lever left defective SE
l ll l l l Control lever right defective SE
l l l Aux pedal or travel pedal defective SE

Transmission fault table 10000106-en
Remedial
Fault
action
No forward travel, no reversing
No forward travel or no reversing Check P
Max. travelling speed not reached Adjust E
Insufficient traction power Replace W
Top up A
Reduce S
Clean R
Contact our
Service Dept. SE
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 Cause Chapter
reference
l ll Pilot control pump defective SE
l Main-pump drive coupling defective SE
l Fuse F7 defective Fuses P
l Parking brake blocking, required storage pressure too low SE
ll Travel direction solenoid valve defective SE
l ll Malfunction in travelling valve (pedal) SE
l Engine nominal speed too low SE
l ll Malfunction of control spool SE
l PCS switched to LIFT Driving P
Engine mal-
l Insufficient engine power SE
function
Hydraulic oil temperature too high (warning lamp lit up, fault Hydraulic oil
l P/R
code indicated), oil cooler contaminated cooler cleaning
Cooling-agent temperature too high, warning lamp lit up,
l SE
fault code indicated
ll Incorrect wheel brake setting Service brake P/E
ll Malfunction of travel motor regulator SE
Tyres and
l Tyre inflation too low or not the same P/A
wheels
ll Travel direction selector switch defective P

Slewing system fault table 10000107-en
Remedial
Fault
action
Slewing not operational
Slewing left or right not operational Check P
Slewing power insufficient Adjust E
Inadvertent slewing movements Replace W
Superstructure holding brake not operational Top up A
Reduce S
Clean R
Contact our
Service Dept. SE
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 Cause Chapter
reference
Pilot control lever not in working position / defective / pilot-
l Working oper. P
control pump
Pilot control pressure limiting valve (stacking) threshold set
l l l SE
too low / defective
l Pilot control circuit pump defective SE
l Main pump drive coupling defective SE
l l Malfunction of slewing pump feeding circuit SE
l Malfunction of slewing system high-pressure circuit SE
Malfunction of slewing-pump displacement variation (slew-
l l SE
ing cylinder)
l Leakage losses in slewing motor too high SE
Air included in the system after pump replacement or hy-
l P
draulic oil changes, change of hoses
Superstructure
l Superstructure holding brake blocked P
holding brake
Unlocking the
l Superstructure locking pin engaged P
superstructure
l Brake disks worn out P/W
l Fuse F2 defective Fuses P/W
l Solenoid valve defective SE
l Control lever failure
l ESX (Electro-hydraulic Controller) failure
l Safety switch / safety valve
l CAN2 defective
l Error 4209/212
l ESX (Electro-hydraulic Controller) failure
l Display setting incorrect
l Current in prop. valves too high / prop. valves defective

Floating-axle blocking fault table 10000108-en
Remedial
Fault
action
Floating-axle support not blocking
Floating-axle support not releasing Check P
Floating-axle support not stable in blocked condition Adjust E
Noises during floating of axle Replace W
Top up A
Reduce S
Clean R
Contact our
Service Dept. SE
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 Cause Chapter
reference
lll Malfunction of floating-axle blocking valve SE
ll Malfunction of control valve SE
Blocking the
l Rocker switch 52 in blocked position P
floating axle
Venting the
floating-axle
l Floating-axle blocking valve not vented P
supporting
cylinder
Floating-axle
cylinder,
l Contact faces of blocking cylinder not lubricated P
greasing the
contact faces

Stabilizing system (PLA - A 2) fault table 10000109-en
Remedial
Fault
action
Levelling blade not operational
Stabilizer legs not operational Check P
Selection of individual stabilizer leg cylinders not possible Adjust E
lnadvertent extension of a stabilizer leg cylinder Replace W
Inadvertent retraction of stabilizer leg cylinders Top up A
lnadvertent extension or retraction of the levelling blade cylinders Reduce S
Levelling blade support working only on one side Clean R
Stabilizer leg support working only on one side
Contact our
Service Dept. SE
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 Cause Chapter
reference
ll Pilot control lever not in working position / defective Working oper. P
ll Hydraulic oil level too low Hydraulic oil P/A
ll Malfunction of pilot control pressure limiting valve (stacking) SE
ll Main pump drive coupling defective SE
ll Malfunction of primary pressure limiting valve SE
ll Malfunction of pilot control valve SE
ll Internal leaks in rotor SE
llllllll Malfunction of double check valves in the cylinders SE
ll Braking system storage pressure too low P
l Rocker switch defective SE
Switch-over valve in stabilizer leg cylinders defective
l SE
(in undercarriage)
Internal leaks in cylinders
lllll SE
(piston seal or double check valve)

Hammer operation (optional equipment) fault table 10000110-en
Remedial
Fault
action
Hammer equipment not operational
Hammer performance insufficient Check P
Adjust E
Replace W
Top up A
Reduce S
Clean R
Contact our
Service Dept. SE
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 Cause Chapter
reference
ll Malfunction of hammer equipment pressure limiting valve SE
Hydraulic
l Engine speed too low P
hammer
Hydraulic oil temperature too high (warning lamp lit up (fault Hydraulic oil
l P/R
code indicated), oil cooler contaminated cooler
Engine coolant temperature too high, warning lamp lit up,
l SE
fault code indicated
l Pilot control lever not in working position / defective Working oper. P
l Malfunction of pilot control pressure limiting valve (stacking) SE
ll Malfunction of primary control spool pressure limiting valve SE
Pump delivery rate insufficient or PCS not programmed for
l SE
attached type of hammer

Grab rotation circuit (optional equipment) fault table 10000111-en
Remedial
Fault
action
Grab rotation circuit not operational
Grab rotates too slowly Check P
Grab does not rotate at cylinder limit stops Adjust E
Replace W
Top up A
Reduce S
Clean R
Contact our
Service Dept. SE
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 Cause Chapter
reference
l Grab rotation pump defective SE
l Hydraulic oil level too low Hydraulic oil P
lll Malfunction of grab-rotation pressure-limiting valve SE
l Grab rotation valve defective Fuses P
l Pushbutton in control lever defective SE
ll Grab rotation solenoid valve defective SE
l Express couplings not completely open P
l Express couplings not opened P
ll Grab rotation motor defective SE
l Grab blades or limit stops show excessive wear P
l Pinion or slewing ring defective P
l ESX failure (Electro-hydraulic controller)

Fault codes 10000112.01-en
General information on fault codes

The following units of the machine are permanently
monitored:
- Central Unit (CU)
- Power-Control-System (PCS)
- Electro-Hydraulic Controller (ESX)
In the event of a fault, a fault code (e.g. N°7004)

is diplayed in the upper half of the multi-function
display (108, Fig. 1) in combination with two col-
oured warning lights (112 yellow and 113 red,
Fig. 1) which will light up individually or together,
depending on the type of fault. Depending on the Fig. 1
severity of the fault, a special tone signal will be
In addition to the fault code, the lower half of the
heard in addition.
multi-function display (108, Fig. 1) gives an expla-
Meaning of signals: nation of the fault code (error text).
In individual cases there is the possibility of several
RED Severe fault faults occurring at the same time.
+ The safety of persons and/or the The corresponding error codes are then displayed
CONTINUOUS functioning of essential units of one after another in alternation with the normal
TONE the machine is at risk. display contents.
è
Severe faults must be rectified

immediately.
Shut off the machine at once.
The fault signalled is not relevant

to the safety of persons or to the
YELLOW functioning of the machine.
+ These faults must be rectified as
SINGLE BEEP fast as possible. In most of the
cases, however, the machine re-
mains fully functional.
(see also "Multi-function display")

The following groups of error codes can be dis-

played:
Group Unit
7000 Central unit and engine
8000 Power-Control-System
9000 Hydraulics
These faults can, as a rule, not be rectified by your

own means as they require special tools and spe-
cial knowledge.
Therefore, note the fault code and inform our
Service Dept. accordingly if you cannot rectify the
fault yourself.
Apart from the fault code, the Service Dept. needs
the following information:
- machine type, machine no., possibly also the
engine no.
- part number P/N of the PCS, ESX
- what work was being done when the fault oc-
curred?
- did the machine behave differently from normal
situations?
- which pilot and warning lamps were lit up?
- what else was displayed on the screen?
- what external influences was the machine ex-
posed to (great heat/cold, dust, continuous
loading over a long time)?
o

Table of tightening torques 10000367.01-en
The screws and nuts used in this machine have a For tightening of screws and nuts, only tools for
metric ISO thread. New screws and nuts must metric sizes must be used. The wrench sizes of
have the same dimensions and quality as those the screws to be checked in acc. with the servicing
replaced. plans are set out in the table below.
The quality is stated on the bolt head or on the nut A table for all other wrench sizes is contained in
(e.g. 8.8; 10.9 or 12.9). the Service Manual.
Screw size Tightening torque

Wrench size
Thread Quality MA [Nm]
[mm]
1)
Wheel nuts M 22 x 1.5 8.8 30 (34) 450
1)
Slewing ring M 16 x 1.5 10.9 24 280
Engine bearing M 10 10.9 17 (16) 60
M 12 10.9 19 (18) 105
M 16 10.9 24 250
Slewing gearbox M 16 1) 10.9 24 250
1)
Counterweight M 30 12.9 46 2250
1)
Rigid axle M 20 8.8 30 (34) 520
o
1)
slightly oiled


2245128-en

List of abbreviations 10000245.02-en
< Less than Fig. Figure, picture number

> Greater than FOPS Falling objects protective structures
°C Degree Celsius (temperature) FS Rock shovel (equipment)
°kW Degree of crankshaft angle GLR Load-limit regulator (electronic module
A Ampere (unit of electric current) of PCS)
A All-wheel drive HD Heavy duty
A2 Two-point stabilization (legs) HDS Heavy duty small = reinforced undercar-
riage, small version
A4 Four-point stabilization (legs)
i Transmission ratio
ABE General type approval
IFN ISO useful power, blocked
Ah Ampere-hours (unit of electric charge)
ISO International Standardisation Organisa-
AOT Upper boom section tion
API American Petroleum Institute kg Kilogram (unit of mass)
AUT Lower boom section kg/dm 3
Kilogramm per cubic decimeter ( = unit
BA Operator's Manual of specific weight)
Bh Operating hour km/h Kilometer per hour
C4 Display kNm Kilonewtonmeter (1 kNm = 1000 Nm) =
C51 Switch Pad 1 unit of torque
Kw Kilowatt (1 kW = 1.36 PS)
C52 Switch Pad 2
C53 Switch Pad 3 l Liter
ca. circa (= approximately) l/min Liters per minute

CE Communaute Européenne = European LC Long crawler
Community LDA Load-pressure dependent full-load limit
CECE Commitee for European Construction LED Light-emitting diode
Equipment (definition of measure for LpA Sound pressure at place of work
bucket, shovel and grab filling)
LPS Load-sensing power system
CEN European Committee of Standardization
LS Limited slip, additive in gearbox oils
cm Centimeter
LS Load-sensing
cm3/U Cubic centimeter per revolution
LwA Sound power level of machine running,
CU Central Unit stationary
dB (A) Decibel (sound power in acc. with è
measuring procedure A)
DIN German Institute for Standardization
EDC Electronic travel drive control (standard
excavators)
EDCV Electronic Drive Control / -volumetric
flow control (graders)
EDS Electronic Diagnosis System
ESX Electro-hydraulic Controller

m Meter t Ton (= 1000 kg)

MA Tightening torque TBG Tiefbau-Berufs-Genossenschaft
mA Milliampere (= 1/1000 A) [German civil engineering employers'
liability insurance association]
max Maximum
THB Technical Handbook
min Minimum
-1 TL Backhoe bucket equipment
min Revolutions per minute
tm Ton by meter (old unit of slewing mo-
mm Millimeter ment)
Mono Single section boom UW undercarriage
N Standard undercarriage V Volt
(= normal version) (unit of electric potential)
N, kN Newton, kiloNewton (unit of force) VDMA Verband Deutscher Maschinen- und An-
NLGI National Lubricating Grease Institute lagenbau e.V.
(USA) W Watt (unit of electric power)
NLGI- Consistency - grease classification in o
Klasse acc. with DIN 51 818
Nm Newtonmeter (unit of torque)
OLS load stabilization system
OW Superstructure
PCS Power Control System
PLA Levelling blade
PS Horsepower (1 PS = 0.74 kW)
PSI Pounds per square inch
R, r Radius
ROPS Roll-over protective structure
rpm Revolutions per minute (= min-1)
SAE Society of Automotive Engineers (USA)
SN Part Number
StVO German Highway Code
StVZO German Motor Vehicle Safety Standards
SW Spanner opening
Sw. Switch pad
Pad


2245128-en

Index 10000122-en
A
accessories ........................................................................................................................................................ 29, 243
Accumulators, safety instructions ........................................................................................................................ 19, 410
Activating / deactivating the automatic speed reduction.................................................................................. 11, 81, 163
Activating the automatic speed reduction............................................................................................................. 11, 163
Activating the Power-Boost function .................................................................................................................... 11, 184
Adjusting the armrests ............................................................................................................................................9, 62
Adjusting the backrest .................................................................................................................................. 8, 9, 60, 62
Adjusting the mirrors...............................................................................................................................................9, 65
Adjusting the seat cushion ............................................................................................................................ 8, 9, 60, 62
Adjusting the steering column ............................................................................................................................. 10, 140
Adjusting the suspension .............................................................................................................................. 8, 9, 60, 62
After daily operation............................................................................................................................................ 12, 193
After travelling .................................................................................................................................................... 11, 160
Air conditioner, checking / retensioning / replacing the compressor belt ........................................................ 18, 394, 396
Air conditioner, inspection and servicing work.............................................................................................. 18, 392, 400
Air conditioner, switching on / off ................................................................................................................... 14, 85, 264
Alternator ...........................................................................................................................16, 19, 51, 55, 342, 411, 416
Alternator, instructions ........................................................................................................................................ 16, 342
Applying the parking brake........................................................................................................................................134
Applying the superstructure holding brake ................................................................................................... 11, 170, 172
Assisted starting (with jumper cables).................................................................................................................. 19, 412
Attaching and detaching the grab equipment ....................................................................................................... 12, 198
Attaching and detaching the grab equipment, safety instructions .......................................................................... 12, 198
Attaching the grab .............................................................................................................................................. 12, 198
attachment .............................................................................................. 27, 38, 181, 211, 217, 223, 236, 385, 405, 424
Axles and travel gearboxes ................................................................................................................................. 17, 366
B
Backhoe bucket operations ................................................................................................................................. 12, 200
Backrest extension (headrest).................................................................................................................................9, 64
Battery ...........................................................................................16, 285, 290, 291, 294, 343, 405, 411, 415, 426, 434
Battery, checking the fluid level ........................................................................................................................... 16, 343
Before beginning work ......................................................................................................11, 12, 29, 162, 164, 212, 218
Bleeding the floating-axle supporting cylinders .................................................................................................... 17, 356
Bleeding the fuel system ..................................................................................................................................... 16, 339
Bleeding the hydraulic system..................................................................................................................... 17, 354, 355
Bleeding the multiple-disk brake.......................................................................................................................... 18, 379
Blocking the floating axle ....................................................................................................... 10, 87, 133, 134, 142, 442
Brake disks, checking the lining thickness ........................................................................................................... 17, 378
Braking and stopping .................................................................................................................................. 10, 148, 149
Braking system........................................................................................................................................... 10, 132, 443
Braking the superstructure .................................................................................................................................. 11, 167
bucket11, 12, 27, 42, 46, 95, 129, 152, 154, 155, 180, 181, 184, 186, 187, 198, 200, 204, 205, 207, 218, 231, 236, 385,
450, 451
bushings .......................................................................................................................................................... 204, 205
C
cab8, 14, 18, 25, 37, 41, 45, 49, 51, 53, 55, 56, 57, 65, 66, 67, 79, 112, 124, 127, 128, 129, 144, 155, 161, 162, 174,
192, 193, 245, 246, 254, 255, 259, 264, 290, 292, 295, 302, 339, 351, 388, 389, 392, 393, 394, 403, 405, 409, 415,
416, 417, 419, 426, 427, 428, 429
Cab windows...................................................................................................................................................... 18, 403
Central greasing system blocking........................................................................................... 10, 87, 133, 134, 142, 442
Central greasing time setting............................................................................................................................... 15, 302
Changing a wheel............................................................................................................................................... 18, 386
Changing the engine oil ...................................................................................................................................... 16, 320
Changing the hydraulic oil................................................................................................................................... 17, 352
Checking / replacing the fuses ............................................................................................................................ 19, 414
Checking / replacing the safety filter element ....................................................................................................... 16, 336
Checking the coolant level .................................................................................................................................. 16, 326
Checking the hydraulic oil level ................................................................................................................... 17, 309, 346

Checking the overload warning system ....................................................................................................... 13, 238, 239
Checking the V-belt tension ................................................................................................................................ 16, 322
class ........................................................................................................................................................ 301, 315, 316
Cleaning the fuel tank ......................................................................................................................................... 16, 341
Cleaning the hydraulic oil reservoir...................................................................................................................... 17, 353
Cleaning the speed sensor ................................................................................................................................. 16, 325
Cleaning work .................................................................................................................................................... 15, 289
climate .....................................................................................................................................................................326
Closing the door .........................................................................................................................................................57
Combustion engine fault table ............................................................................................................................. 20, 434
components8, 18, 41, 45, 47, 150, 193, 194, 195, 205, 244, 246, 284, 289, 291, 318, 328, 339, 345, 355, 357, 380, 390,
392, 394, 404, 409, 410, 411, 413, 414, 423, 424, 425, 426, 428, 429
Connecting the jumper cables ............................................................................................................................. 19, 412
Contrast ...................................................................................................................................................................267
control9, 11, 18, 37, 49, 53, 56, 72, 81, 85, 89, 91, 97, 103, 118, 120, 124, 129, 150, 157, 165, 166, 167, 170, 172, 176,
177, 178, 180, 181, 182, 184, 187, 188, 193, 195, 196, 198, 199, 207, 209, 212, 218, 224, 231, 233, 235, 236, 241,
243, 247, 248, 252, 264, 277, 290, 291, 301, 302, 303, 306, 307, 312, 313, 327, 342, 347, 355, 360, 371, 372, 373,
374, 393, 400, 404, 405, 416, 424, 427, 438, 439, 440, 441, 442, 443, 444, 445, 450
control lever37, 49, 53, 56, 165, 166, 167, 170, 172, 176, 177, 178, 181, 184, 187, 188, 193, 195, 196, 198, 199, 218,
233, 241, 247, 248, 347, 360, 438, 439, 441, 443, 444, 445
Control panel..........................................................................................................................................................9, 76
controls ................................................................................................................................72, 132, 134, 195, 212, 307
Coolant losses.................................................................................................................................................... 16, 327
Corrosion .............................................................................................................................12, 204, 205, 315, 327, 365
Counterweight ......................................................................................................................... 17, 41, 45, 364, 415, 448
Cutter................................................................................................................................................................. 13, 223
D
damage26, 27, 29, 31, 32, 37, 110, 121, 122, 123, 129, 130, 150, 153, 161, 162, 173, 186, 188, 193, 211, 217, 223, 243,
245, 261, 284, 285, 300, 301, 302, 326, 327, 328, 332, 334, 335, 336, 337, 342, 345, 352, 356, 357, 361, 362, 380,
381, 382, 386, 389, 390, 396, 398, 400, 402, 403, 405, 409, 413, 423, 424, 428, 429
Damaged paintwork............................................................................................................................................ 18, 403
Damping ....................................................................................................................................................................73
Deactivating the automatic speed reduction......................................................................................................... 11, 163
Depressurizing the hydraulic system ............................................................................. 17, 284, 346, 347, 348, 349, 352
Detaching the grab ............................................................................................................................................. 12, 199
diameter...................................................................................................................................................................411
dirt ...........................................................31, 110, 193, 205, 264, 322, 333, 357, 361, 393, 402, 403, 405, 418, 422, 425
Display settings .............................................................................................................. 14, 74, 266, 267, 268, 270, 272
Display, setting the contrast ................................................................................................................................ 14, 267
Draining hose for oil changes ....................................................................................................... 16, 317, 320, 352, 359
Draining off hydraulic oil............................................................................................................................................353
Drive belt.............................................................................................................................................16, 292, 293, 323
Driving on public roads ............................................................................................................................... 10, 130, 152
Driving with a suspended load............................................................................................................................. 10, 151
dust.................................................................................. 16, 31, 199, 264, 284, 289, 333, 335, 361, 402, 409, 424, 447
dust caps .................................................................................................................................................................199
E
earthmoving ...............................................................................................................................................................27
Electric energy........................................................................................................................................................7, 31
Electrical system, safety instructions ................................................................................................................... 16, 342
Electronic modules ...............................................................................................................................................42, 46
Electrostatic discharge..............................................................................................................................................429
Engine does not start.......................................................................................................................................... 10, 123
Engine number .......................................................................................................................................................8, 47
Engine oil change ............................................................................................................................................... 15, 289
Engine, checking the oil level / topping up oil ........................................................................................16, 319, 320, 321
Engine, repair instructions................................................................................................................................... 19, 411
Entering and Leaving..............................................................................................................................................8, 56
Environmentally compatible hydraulic fluid................................................................................................... 14, 258, 259
Environmentally compatible hydraulic fluid, conversion ........................................................................................ 14, 258
Environmentally compatible hydraulic fluid, sampling ................................................................................... 14, 258, 259
equipment8, 9, 11, 12, 18, 20, 26, 27, 28, 29, 30, 31, 37, 38, 41, 42, 44, 45, 46, 49, 52, 53, 54, 71, 76, 79, 97, 101, 109,
118, 123, 124, 128, 129, 139, 149, 152, 154, 156, 157, 158, 161, 162, 163, 165, 175, 176, 180, 181, 184, 187, 188,
190, 193, 194, 195, 196, 198, 199, 200, 201, 204, 205, 207, 211, 212, 218, 223, 224, 236, 237, 241, 243, 254, 258,

259, 260, 281, 285, 289, 297, 300, 321, 346, 347, 352, 364, 366, 369, 372, 374, 378, 381, 382, 384, 385, 386, 419,
422, 423, 424, 425, 429, 444, 445, 450, 451
Extending and retracting the stick........................................................................................................................ 11, 181
Extreme position of working equipment, instructions ............................................................................................ 11, 162
F
fault15, 18, 20, 105, 107, 121, 123, 132, 155, 160, 167, 173, 174, 192, 195, 238, 239, 243, 245, 247, 251, 293, 301, 303,
306, 307, 334, 342, 349, 398, 400, 433, 438, 439, 440, 444, 445, 446, 447
Fault code ............................................................................................................ 20, 105, 107, 132, 160, 334, 349, 446
Fault codes ................................................................................................................................. 20, 105, 107, 160, 446
Fault table layout ................................................................................................................................................ 20, 433
Filling and emptying the bucket ........................................................................................................................... 11, 181
Filling in fuel .........................................................................................................................................................9, 110
Filling in hydraulic oil........................................................................................................................................... 17, 354
Filter preheating ...................................................................................................................................................9, 111
Fire-extinguisher.........................................................................................................................................................68
First-aid kit .............................................................................................................................................................9, 68
Fitting of working equipment, safety instructions ...................................................................................12, 194, 198, 204
Floating-axle.......................................................................................................................... 17, 20, 294, 299, 365, 442
Floating-axle blocking fault table ......................................................................................................................... 20, 442
Floating-axle cylinder, greasing the bearing faces................................................................................................ 17, 365
floodlamps................................................................................................................................... 14, 152, 254, 255, 418
foreign matter .............................................................................................................................. 38, 261, 282, 337, 380
Fuel system, safety instructions .................................................................................................................. 16, 337, 338
FUNDAMENTAL SAFETY INSTRUCTIONS............................................................................... 5, 23, 35, 279, 407, 431
G
Gas, dust, steam and smoke...................................................................................................................................7, 31
Grab operation ............................................................................................................................ 12, 200, 201, 218, 438
Grab rotation ...........................................................................................................................................20, 95, 97, 445
greases .........................................................................................................15, 283, 284, 285, 289, 301, 302, 390, 409
greasing points ................................................................................................................................................. 302, 307
ground10, 30, 109, 123, 129, 130, 149, 151, 154, 161, 181, 187, 188, 193, 194, 196, 199, 204, 235, 241, 252, 258, 260,
281, 284, 341, 342, 346, 347, 352, 356, 364, 366, 369, 372, 374, 382, 386, 405, 412, 416, 425, 427, 435
H
Hammer operation (optional equipment) fault table .............................................................................................. 20, 444
Heating ................................................................................ 10, 18, 61, 85, 124, 125, 291, 295, 389, 393, 394, 399, 400
hook............................................................................................................................. 74, 129, 133, 134, 142, 236, 241
Hydraulic and pneumatic equipment........................................................................................................................7, 32
hydraulic fluid .................................................................................... 31, 51, 55, 198, 211, 217, 223, 258, 259, 346, 379
hydraulic hose ............................................................................................................................................ 28, 199, 284
hydraulic pressure ....................................................................................................................... 41, 132, 182, 184, 410
Hydraulic system ...........................................................................................8, 17, 41, 45, 290, 291, 292, 294, 309, 346
Hydraulic system, safety instructions ................................................................................................................... 17, 346
I
Immobilizer, entering the code .................................................................................................................. 101, 112, 118
inspection5, 16, 23, 25, 27, 30, 35, 37, 51, 55, 147, 238, 279, 281, 288, 289, 290, 291, 292, 294, 295, 297, 299, 308,
309, 318, 330, 332, 335, 346, 348, 354, 388, 407, 431
Inspection and servicing plans, instructions ......................................................................................................... 15, 288
Inspection and servicing, safety instructions318, 320, 321, 325, 328, 344, 346, 352, 358, 360, 364, 365, 366, 368, 392,
396, 411, 424
Intervals ............................................................................................................................................................. 15, 288
J
Joints and hinges................................................................................................................................................ 15, 299
L
Language.................................................................................................................................................................267
Levelling............................................................................... 12, 45, 74, 95, 162, 176, 177, 178, 187, 190, 299, 443, 451
lifting capacity............................................................................................................................................. 30, 237, 242

Lifting-gear operation, safety instructions..................................................................................................... 13, 235, 236
linkage pin................................................................................................................................................................204
load12, 30, 38, 49, 53, 91, 107, 123, 129, 133, 134, 142, 151, 153, 154, 158, 159, 161, 192, 193, 196, 198, 235, 236,
237, 241, 242, 243, 247, 251, 277, 451
Load capacity of the excavator............................................................................................................................ 13, 236
Load capacity of the load-carrying hook............................................................................................................... 13, 236
Load hooks on bucket and linking element .......................................................................................................... 13, 236
locking .............................. 59, 60, 62, 67, 95, 132, 134, 142, 147, 149, 152, 166, 175, 198, 295, 297, 347, 350, 402, 441
locking pin ................................................................................................... 147, 152, 166, 198, 295, 297, 347, 350, 441
Locking the superstructure.................................................................................................................................. 11, 166
LUBRICANTS ........................................ 289, 297, 299, 309, 319, 320, 348, 354, 358, 359, 362, 366, 368, 371, 372, 373
lubricating nipple ......................................................................................................................................................286
Lubricating the greasing nipples .......................................................................................................................... 17, 364
lubrication ............................................................................................. 15, 129, 150, 300, 301, 302, 306, 307, 364, 394
lugs.......................................................................................................................................................... 198, 235, 236
M
Machine care...................................................................................................................................................... 18, 402
Machine in working position ........................................................................................................................ 11, 161, 175
machine type............................................................................................................................................................447
Main filter element ....................................................................................................................................................293
maintenance7, 15, 25, 27, 28, 29, 30, 31, 37, 51, 55, 105, 108, 174, 261, 288, 289, 300, 320, 337, 340, 341, 344, 349,
405, 424
malfunction...........................................................................................................................28, 155, 160, 434, 438, 440
Malfunction....................................................................398, 399, 400, 401, 435, 436, 438, 440, 441, 442, 443, 444, 445
manual........................................................................................................................................ 26, 256, 281, 318, 409
maximum25, 27, 47, 49, 53, 61, 71, 76, 152, 164, 175, 184, 186, 190, 192, 212, 236, 242, 250, 264, 304, 322, 344, 376,
390
measurement ............................................................................................................................................. 14, 273, 274
Methods of working ............................................................................................................................................ 12, 186
Multifunction display ....................................................................................................... 13, 99, 169, 244, 247, 248, 250
N
Noise ......................................................................................................................................................7, 8, 27, 32, 47
Noise emission ................................................................................................................................................. 8, 27, 47
O
Oil, grease and other chemical substances..............................................................................................................7, 32
Oils for internal combustion engines ............................................................................................................ 16, 310, 311
Opening / closing the front window..........................................................................................................................9, 65
Opening /closing the driver's cab door .....................................................................................................................8, 57
Opening and closing the grab ............................................................................................................................. 11, 181
Opening the door from inside ......................................................................................................................................57
Opening the door from outside ....................................................................................................................................57
operation5, 7, 10, 11, 12, 13, 23, 25, 28, 29, 30, 32, 35, 37, 38, 47, 49, 53, 72, 73, 74, 77, 79, 91, 93, 95, 97, 103, 107,
109, 110, 111, 115, 124, 132, 136, 137, 146, 155, 156, 160, 161, 162, 172, 186, 190, 192, 194, 195, 200, 201, 211,
212, 217, 218, 223, 235, 236, 238, 239, 240, 242, 243, 244, 245, 246, 247, 248, 250, 251, 260, 279, 290, 291, 292,
300, 302, 312, 313, 322, 334, 336, 351, 370, 386, 392, 395, 396, 405, 407, 410, 424, 428, 431, 438, 439
Operation, safety instructions................................................................................................... 8, 37, 160, 161, 181, 235
Options ............................................................................................................................................................ 9, 61, 62
Outside the machine...............................................................................................................................................8, 47
Overload warning system.........................................................................................................................13, 77, 83, 237
Overload warning system, function...................................................................................................................... 13, 237
P
Parking brake ...................................................................................8, 10, 42, 46, 87, 142, 155, 290, 291, 416, 436, 440
Parking brake, emergency release ...................................................................................................................... 10, 155
Parking the machine ............................................................................................................................12, 130, 160, 193
PART 5 – ANNEX............................................................................................................................................... 20, 431
part number................................................................................................................................................ 47, 376, 447
PCS failure while driving ..................................................................................................................................... 11, 160
Pilot-control filter.......................................................................................................................................................294
pins............................................................................................................................................. 12, 199, 204, 205, 307
piston rod .................................................................................................................................. 294, 299, 356, 365, 405
Plan T - Every 10 OH or per working shift ............................................................................................................ 15, 291

Plan W - Every 50 OH or weekly ......................................................................................................................... 15, 291
Planetary gearbox of steering axle, checking the oil level ..................................................................................... 17, 372
Plastic parts ....................................................................................................................................................... 18, 403
Polishing ............................................................................................................................................................ 18, 403
Power-Assist function ......................................................................................................................................... 11, 182
Power-Boost function.......................................................................................................................................... 11, 184
Power-Control-System...................................................................................................................................... 446, 447
pressure setting........................................................................................................................................ 216, 222, 228
Protecting electronic modules during welding operations ..................................................................................... 19, 426
Putting the machine out of operation ................................................................................................................... 18, 405
Putting the overload warning system into operation ............................................................................................. 13, 239
Putting the overload warning system out of operation .......................................................................................... 13, 240
R
Radio ....................................................................................................................................................14, 79, 256, 416
Raising and lowering the boom ........................................................................................................................... 11, 181
rapid charging ..........................................................................................................................................................344
Recharging the battery........................................................................................................................................ 16, 344
Recommissioning ............................................................................................................................................... 18, 405
Recovering / towing the machine......................................................................................................................... 10, 154
Recovery and towing, safety instructions ..............................................................................................10, 130, 153, 154
Refilling quantities - Other................................................................................................................................... 16, 309
Refilling quantities for oil changes ............................................................................... 320, 352, 354, 359, 368, 369, 375
Refuelling................................................................................................................. 9, 14, 109, 110, 260, 261, 262, 337
Refuelling system ............................................................................................................................................... 14, 260
Refuelling with the refuelling station ............................................................................................................ 14, 260, 262
Refuelling with the refuelling system, safety instructions ...................................................................................... 14, 260
Regular oil analyses ........................................................................................................................................... 15, 289
Releasing the parking brake......................................................................................................................................134
Releasing the superstructure holding brake ......................................................................................................... 11, 172
Removing and installing the battery............................................................................................................. 16, 344, 345
Repair work, safety instructions............................................................................................................19, 377, 409, 422
Replacing the breather valve............................................................................................................................... 17, 350
Replacing the engine oil filter .............................................................................................................................. 16, 321
Replacing the fuel filter ....................................................................................................................................... 16, 338
Replacing the headlamp bulb.............................................................................................................................. 19, 420
Replacing the hydraulic oil return-flow filter.......................................................................................................... 17, 349
Replacing the lamp bulb in the front direction indicator lamp ................................................................................ 19, 420
Replacing the lamp bulb of the boom floodlamp................................................................................................... 19, 419
Replacing the lamp bulb of the cab floodlamp...................................................................................................... 19, 419
Replacing the lamp bulb of the cab interior lamp.................................................................................................. 19, 418
Replacing the lamp bulb of the tail-light ............................................................................................................... 19, 421
Reservoir pump .................................................................................................................................................. 15, 302
Rigid axle and travel gearbox, changing the oil .................................................................................................... 17, 368
Rigid axle and travel gearbox, checking the oil level............................................................................................. 17, 366
Risk of explosion ...................................................................................................................................... 340, 341, 353
Road travel........................................................................................ 10, 74, 89, 139, 142, 147, 149, 152, 162, 165, 175
Rolling in the sunblind.............................................................................................................................................9, 69
Rolling out the sunblind...........................................................................................................................................9, 69
S
Safety belt ...................................................................................................................................................... 37, 61, 62
safety device ................................................................................................................................... 28, 29, 31, 199, 235
safety instructions8, 9, 11, 16, 28, 37, 59, 109, 110, 147, 151, 152, 161, 162, 186, 194, 211, 217, 218, 223, 224, 235,
242, 246, 262, 281, 300, 318, 330, 332, 333, 342, 379, 382, 404, 409, 411, 412, 424, 425, 428
Safety instructions ......................................................................................................................... 15, 18, 258, 300, 390
Safety instructions for inspection and servicing work............................................................................................ 18, 390
Securing the machine12, 38, 109, 195, 196, 260, 281, 328, 346, 352, 358, 364, 368, 371, 372, 373, 374, 377, 378, 386,
411, 422
Selecting the backhoe / grab equipment .............................................................................................................. 12, 200
serial number .......................................................................................................................................................25, 47
Service brake ............................................................................................ 8, 17, 20, 41, 45, 95, 290, 291, 378, 436, 440
Service brake and parking brake fault table ......................................................................................................... 20, 436
SERVICING .........................................................................................................................5, 15, 23, 35, 279, 407, 431
Servicing materials ............................................................................................................................................. 15, 289

setting11, 12, 13, 14, 28, 29, 101, 103, 117, 120, 128, 129, 137, 147, 151, 168, 184, 190, 192, 201, 202, 203, 209, 212,
214, 215, 216, 218, 220, 221, 222, 224, 226, 227, 228, 230, 231, 232, 233, 234, 238, 264, 267, 269, 271, 273, 274,
303, 434, 440, 441
Setting the proportional valve to emergency operation ......................................................................................... 12, 192
Shifting the travel gearbox .....................................................................................................................10, 81, 136, 147
Slewing and braking the superstructure ..................................................................................................11, 83, 166, 187
Slewing gearbox, changing the oil ....................................................................................................................... 17, 359
Slewing gearbox, checking the oil level................................................................................................................ 17, 358
Slewing power .................................................................................................................................................... 73, 441
slewing range ....................................................................................................................................167, 361, 362, 363
Slewing ring, checking the screws for tight fit ....................................................................................................... 17, 363
Slewing ring, greasing the bearing ...................................................................................................................... 17, 361
Slewing ring, instructions .................................................................................................................................... 17, 361
Slewing system fault table................................................................................................................................... 20, 441
Slewing the superstructure.......................................................................................................................... 11, 166, 181
Slewing the superstructure to the left................................................................................................................... 11, 166
Slewing the superstructure to the right................................................................................................................. 11, 166
Socket outlet in driver's cab ....................................................................................................................................9, 71
stability...........................................................................................30, 129, 133, 134, 142, 151, 161, 217, 223, 236, 381
Stabilization of the machine ........................................................................................................................ 11, 175, 176
Stabilizing system (PLA - A 2) fault table ............................................................................................................. 20, 443
standard....................................27, 47, 49, 53, 83, 110, 115, 118, 137, 167, 169, 176, 184, 231, 258, 261, 284, 337, 450
starting13, 19, 29, 30, 31, 37, 38, 79, 108, 109, 115, 118, 120, 123, 153, 154, 161, 162, 164, 181, 190, 193, 211, 217,
223, 224, 231, 235, 236, 260, 282, 288, 306, 318, 339, 343, 346, 352, 364, 382, 404, 409, 411, 412, 434
Starting and stopping the engine ...........................................................................................................................9, 118
Starting the engine ................................................................................................................................10, 89, 118, 434
Steered axle gearbox, checking the oil level ........................................................................................................ 17, 371
Steering ..............................................................................................................8, 10, 20, 41, 45, 95, 97, 140, 299, 435
Steering column, safety instructions .................................................................................................................... 10, 140
Steering system fault table.................................................................................................................................. 20, 435
Stopping the engine.............................................................................................................................10, 123, 372, 374
Storing the battery / batteries .............................................................................................................................. 18, 405
superstructure10, 11, 41, 45, 51, 55, 83, 95, 99, 112, 128, 129, 130, 133, 134, 139, 144, 147, 151, 152, 157, 165, 166,
167, 169, 170, 172, 173, 174, 181, 192, 193, 196, 235, 297, 334, 355, 357, 359, 360, 361, 362, 363, 382, 420, 425
Superstructure holding brake, checking the operation .......................................................................................... 17, 360
Superstructure holding brake, function ................................................................................................................ 11, 170
supply line ................................................................................................................................................ 244, 306, 339
switch29, 61, 70, 76, 79, 81, 83, 85, 87, 93, 97, 109, 112, 123, 124, 125, 127, 134, 137, 142, 147, 149, 150, 151, 157,
175, 176, 177, 178, 181, 184, 193, 196, 200, 201, 212, 218, 224, 236, 246, 253, 254, 255, 256, 260, 262, 264, 285,
303, 337, 342, 398, 405, 412, 413, 416, 417, 436, 438, 440, 441, 442, 443
Switching off the floodlamps........................................................................................................................ 14, 254, 255
Switching off the hydraulic hammer ..................................................................................................................... 12, 212
Switching off the pilot control....................................................................................................................... 11, 139, 165
Switching off the rotary beacon ........................................................................................................................... 14, 253
Switching on the floodlamps........................................................................................................................ 14, 254, 255
Switching on the horn ......................................................................................................................................... 11, 181
Switching on the hydraulic hammer ..................................................................................................................... 12, 212
Switching on the pilot control..................................................................................................................11, 97, 165, 166
Switching on the rotary beacon ........................................................................................................................... 14, 253
Switching the electrical system on and off ..............................................................................................9, 112, 123, 193
Switching the windscreen wiper/washer on and off .............................................................................................. 10, 127
symbols ..................................................................................................................... 73, 74, 76, 77, 165, 169, 182, 273
T
Table of fuses............................................................................................................................................. 19, 414, 416
Test run ............................................................................................................................................................. 15, 303
Tightening torques, table................................................................................................................................... 363, 364
time14, 28, 77, 81, 87, 95, 107, 111, 115, 117, 127, 132, 133, 134, 136, 142, 147, 149, 150, 151, 163, 166, 167, 170,
184, 188, 190, 203, 209, 212, 218, 224, 237, 238, 245, 247, 267, 269, 271, 273, 274, 289, 301, 302, 303, 307, 319,
326, 338, 343, 344, 370, 381, 388, 398, 405, 409, 433, 446, 447
Time ............................................................................................................................................... 15, 72, 99, 112, 302
tool....................................................................................................................28, 68, 83, 187, 218, 282, 317, 330, 414
Topping up coolant ..............................................................................................................................16, 326, 327, 329
Topping up hydraulic oil ............................................................................................................... 17, 348, 349, 354, 435
Topping up wash fluid......................................................................................................................................... 18, 388
Transmission fault table ...................................................................................................................................... 20, 440
Transport of the machine .......................................................................................................................11, 12, 156, 207
Transport of the machine with boom-adjusting mechanism .................................................................................. 12, 207
Transport, safety instructions .............................................................................................................................. 11, 156

Travelling, safety instructions ...................................................................................................................... 10, 128, 150
Turning the grab ................................................................................................................................................. 11, 181
Tyre pressure, checking and topping up .............................................................................................................. 18, 382
Tyres.............................................................................................................18, 290, 294, 380, 382, 384, 386, 435, 440
Tyres and wheels, safety instructions .......................................................................................................... 18, 380, 386
U
Unblocking the floating axle ........................................................................................................................ 10, 142, 147
Undercarriage ...............................................................................................8, 15, 41, 45, 290, 291, 292, 295, 298, 299
unlocking.......................................................................................................................................................... 133, 147
Unlocking the superstructure....................................................................................................................... 11, 166, 441
Upholstery.......................................................................................................................................................... 18, 403
Using the service brake .............................................................................................................................. 10, 132, 378
Using the sunblind ..................................................................................................................................................9, 69
V
Valve clearance........................................................................................................................................................293
Ventilation ...........................................................................................................................................10, 124, 264, 400
Ventilation and heating ..................................................................................................................................... 264, 400
Visual inspection ......................................................................................................................................................291
W
WARMUP......................................................................................................................................................... 130, 164
Warning and instruction signs ................................................................................................................8, 48, 50, 52, 54
Warning of special dangers.....................................................................................................................................7, 31
Warning triangle .........................................................................................................................................................68
Warnings and symbols............................................................................................................................................7, 26
Warranty .................................................................................................................................................. 7, 15, 25, 288
washers ........................................................................................................................................................... 283, 386
Washing............................................................................................................................................................. 18, 402
Washing the machine ......................................................................................................................................... 18, 402
Washing the machine by hand ............................................................................................................................ 18, 402
wear32, 150, 186, 194, 205, 243, 284, 285, 289, 301, 366, 368, 371, 372, 373, 374, 378, 381, 382, 389, 409, 410, 423,
445
weight ...................................................................................................................... 59, 60, 62, 159, 235, 384, 385, 450
Welding operations, safety instructions................................................................................................................ 19, 424
Wheels, tread position ................................................................................................................................ 18, 386, 387
Winter operation ...................................................................................................................................................9, 110
Work to be performed every 2 years.................................................................................................................... 18, 395
Work to be performed every 6 months................................................................................................................. 18, 395
Working equipment..................................................................... 8, 12, 15, 19, 42, 46, 194, 290, 291, 292, 296, 297, 422
Working equipment, replacing the slip-on tooth.................................................................................................... 19, 422
Working on brakes, safety instructions ................................................................................................................ 17, 377
Working with the hydraulic hammer......................................................................................................12, 212, 217, 223
Working with the hydraulic hammer, safety instructions.............................................................................. 212, 217, 223
Working with the hydraulic shears ................................................................................................ 12, 211, 217, 218, 223
Working with the hydraulic shears, safety instructions ...........................................................................12, 211, 217, 223

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MH5.

Operation and Maintenance Instruction Manual

Print No. 604.35.232.00

PROVEN PERFORMANCE PROVEN PERFORMANCE

REPRODUCTION OF THESE OPERATING INSTRUCTIONS IN WHOLE OR IN

EACH MACHINE IS ACCOMPANIED BY ITS OWN SET OF

2 - 01.02.2005 / For information only - 604.35.232.00-EN

CNH Baumaschinen GmbH

To maintain the efficiency of your machine, use original spares only

When ordering spare parts, please provide the following information:

604.35.232.00-EN - 01.02.2005 / For information only - 3

This page left blank intentionally

4 - 01.02.2005 / For information only - 604.35.232.00-EN

The operating instructions are divided into 5 sections,

Operating instructions Target group

Part 3 INSPECTION AND Inspection and servicing personnel

Part 4 REPAIR WORK Repair personnel

Part 5 ANNEX Operating personnel

604.35.232.00-EN - 01.02.2005 / For information only - 5

This page left blank intentionally

6 - 01.02.2005 / For information only - 604.35.232.00-EN

PART 1 – INTRODUCTION ............................................................................23

Service Booklet ........................................................................................................................... 26

Fundamental saftey instructions ............................................................................................... 26

Designated use ........................................................................................................................... 27

Organizational measures ........................................................................................................... 28

604.35.232.00-EN - 01.02.2005 / For information only - 7

Operation, safety instructions.................................................................................................... 37

Description of the machine (monoblock boom) ....................................................................... 40

Description of the machine (boom adjusting equipment)........................................................ 44

Machine parameters ................................................................................................................... 47

Warning and instruction signs (mono-boom) ........................................................................... 48

Warning and instruction signs (boom adjusting equipment) .................................................. 52

Driver’s cab ................................................................................................................................. 56

8 - 01.02.2005 / For information only - 604.35.232.00-EN

Seat heating ........................................................................................................................................61

Monitoring, warning and control elements ............................................................................... 72

Starting up the machine ........................................................................................................... 108

604.35.232.00-EN - 01.02.2005 / For information only - 9

Driving ....................................................................................................................................... 128

Bringing the machine into its basic position .......................................................................... 144

Driving operation ...................................................................................................................... 146

Machine recovery / towing ....................................................................................................... 153

10 - 01.02.2005 / For information only - 604.35.232.00-EN

Transport of the machine ......................................................................................................... 156

After travelling........................................................................................................................... 160

Working operation .................................................................................................................... 161

Slewing and braking the superstructure ................................................................................. 166

Stabilization of the machine..................................................................................................... 176

604.35.232.00-EN - 01.02.2005 / For information only - 11

Methods of working .................................................................................................................. 186

After daily operation ................................................................................................................. 193

Working equipment................................................................................................................... 194

Securing the machine............................................................................................................... 196

Attaching and detaching the grab equipment......................................................................... 198

Detaching / attaching the backhoe bucket.............................................................................. 204

Boom-Adjusting Mechanism.................................................................................................... 207

Hydraulic hammer..................................................................................................................... 211

Hydraulic shears ....................................................................................................................... 217

12 - 01.02.2005 / For information only - 604.35.232.00-EN

Switching off the hydraulic shears ......................................................................................................218

Hydraulic cutter......................................................................................................................... 223

Lifting-gear operation ............................................................................................................... 235