Kramer 380, 480, 580 Operator's Manual

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Operator's Manual

Wheel loaders

Models 351-01 / 351-02 / 351-03

From serial nos. 351 01 0001 / 351 02 0001 / 351 03 0001

Edition 1.0

Order number 1000245584

Language EN

Documentation Language Order no.

Operator's Manual EN 1000245584

DE 1000159213

Service Booklet

Spare parts catalogue, model 351-01

Spare parts catalogue, model 351-02 1000249074

Spare parts catalogue, model 351-03 1000249075

Legend

Original Operator's Manual –

Translation of original Operator's Manual

Edition

Date

EN 1000159214

FR 1000159215

1000249073

DE/EN/FR

1.0

02/2010

Document

Copyright – 2010 Kramer-Werke GmbH Printed in Germany All rights reserved, in particular the copyright, the right of reproduction and the right of distribution applicable worldwide. No part of this publication may be reproduced, translated or used in any form or by any means – graphic, electronic or mechanical includ-

ing photocopying, recording, taping or information storage or retrieval systems – without prior permission in writing from the manufacturer. No reproduction or translation of this publication, in whole or part, without the written consent of KRAMER-WERKE GmbH. Any infringement of legal provisions, in particular of those regarding copyright protection, shall be subject to civil and criminal law prose-

cution. KRAMER-WERKE GmbH keep abreast of the latest technical developments and constantly improve their products. For this reason, we

may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which have already been delivered and which will not be implemented on these machines.

Technical data, dimensions and weights are given as an indication only. Responsibility for errors or omissions not accepted. The cover features the machine with possible optional equipment.

Kramer-Werke GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf

Tel. 0080090209020 E-mail info@kramer.de www.kramer.de

BA 35101/02/03 EN

Table of contents

Declaration of conformity EG

EC declaration of conformity (model 351-01) .........................................................EG-1

EC declaration of conformity (model 351-02) .........................................................EG-2

EC declaration of conformity (model 351-03) .........................................................EG-3

Introduction 1

General information on the Operator's Manual ........................................................ 1-1

Abbreviations/symbols ....................................................................................... 1-1

General information on machine safety ................................................................... 1-1

Machine outside view .............................................................................................. 1-2

Models and trade names: overview ......................................................................... 1-3

Brief description of the wheel loader ........................................................................ 1-3

General information on the machine ................................................................. 1-3

Main components of wheel loader ..................................................................... 1-3

Hydrostatic drive ................................................................................................ 1-4

Work hydraulics and 4 wheel steering ............................................................... 1-4

Cooling system .................................................................................................. 1-4

Wheel loader warranty ............................................................................................. 1-4

Fields of application and using a wheel loader with an attachment ......................... 1-5

Attachments with authorised material densities ................................................ 1-5

Legal regulations regarding wheel loader operation ................................................ 1-8

General safety instructions ................................................................................ 1-8

Driving licence ................................................................................................... 1-8

Licence/identification ......................................................................................... 1-8

Machine inspections .......................................................................................... 1-9

Documents ........................................................................................................ 1-9

On-board equipment .......................................................................................... 1-9

Machine warning identification (option) ............................................................. 1-9

Type labels and component numbers .................................................................... 1-10

Serial number .................................................................................................. 1-10

Cab number ..................................................................................................... 1-10

Engine number ................................................................................................ 1-10

Variable displacement pump number .............................................................. 1-11

Variable displacement motor number .............................................................. 1-11

Rear axle number ............................................................................................ 1-11

Front axle number ........................................................................................... 1-11

Description of labels and symbols ......................................................................... 1-12

Labels on the outside of the machine .............................................................. 1-12

Labels inside the cab ....................................................................................... 1-14

Labels in the engine compartment .................................................................. 1-17

Safety instructions 2

Identification of warnings and dangers .................................................................... 2-1

Designated use and exemption from liability ........................................................... 2-2

General conduct and safety instructions .................................................................. 2-3

Organisational measures ................................................................................... 2-3

Selection and qualification of staff, basic responsibilities .................................. 2-5

Safety instructions regarding operation ................................................................... 2-6

Normal operation ............................................................................................... 2-6

Applications with lifting gear .............................................................................. 2-8

Trailers and attachments ................................................................................... 2-9

Transporting, towing, loading ............................................................................ 2-9

Safety instructions for maintenance ....................................................................... 2-10

Maintenance work on protective ROPS and FOPS structures .............................. 2-12

Cab, roll-over bar, protective screen ............................................................... 2-12

BA 35101/02/ 03 EN - Ausgab e 1.0 * BA_35101_02_03_10_enIVZ.fm I-1

Table of contents

Warning of special hazards .................................................................................... 2-12

Electric energy ................................................................................................. 2-12

Gas, dust, steam, smoke ................................................................................. 2-12

Hydraulics ........................................................................................................ 2-13

Noise ................................................................................................................ 2-13

Oil, grease and other chemical substances ..................................................... 2-13

Battery ............................................................................................................. 2-13

Tyres ................................................................................................................ 2-13

Operation 3

Description of control elements ................................................................................ 3-1

Cab overview ........................................................................................................... 3-2

Instrument panel, multifunctional lever and drive lever (overview) .......................... 3-4

Functional description: telltales ................................................................................ 3-6

Telltale check ..................................................................................................... 3-6

Telltales and warning lights on the indicating instrument .................................. 3-6

Telltales and indicators on the instrument panel ............................................... 3-7

Putting the wheel loader into service ....................................................................... 3-9

Safety instructions regarding commissioning .................................................... 3-9

Important information for the operating staff ...................................................... 3-9

Running-in period of wheel loader ..................................................................... 3-9

Checklist ................................................................................................................ 3-10

Starting checklist .............................................................................................. 3-10

Operation checklist .......................................................................................... 3-11

Parking checklist .............................................................................................. 3-11

Cab ........................................................................................................................ 3-12

Safety instructions regarding cab entrance and exit ........................................ 3-12

Locking/unlocking the door .............................................................................. 3-12

Securing an open door in the arrester ............................................................. 3-13

Opening the right-hand side door to a gap ...................................................... 3-13

Engine cover lock ................................................................................................... 3-14

Opening/closing the engine cover ................................................................... 3-14

Protective screens for front window and/or main lights (option) ............................ 3-14

Removing the protective screens for driving on public roads .......................... 3-14

Fire extinguisher (option) ....................................................................................... 3-14

Fire extinguisher operation .............................................................................. 3-14

Putting the diesel engine into operation ................................................................. 3-15

Preparing to start the engine ........................................................................... 3-15

Starting the engine ........................................................................................... 3-16

Avoiding running the engine under low-load conditions .................................. 3-17

Stopping the engine ......................................................................................... 3-17

Battery master switch (option) ............................................................................... 3-18

Battery master switch operation ...................................................................... 3-18

Key-based drive interlock (option) ......................................................................... 3-18

Key-based drive interlock: scope of delivery ................................................... 3-18

Coding (“training”) new ignition keys ............................................................... 3-18

Enabling (locking) the drive interlock ............................................................... 3-19

Disabling (releasing) the drive interlock ........................................................... 3-19

Deleting coded keys ........................................................................................ 3-19

Safety functions ............................................................................................... 3-19

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Table of contents

Drive interlock with code input (option) .................................................................. 3-20

Keyboard for entering codes: overview ........................................................... 3-20

Entering/changing the personal code .............................................................. 3-21

Enabling the drive interlock ............................................................................. 3-21

Disabling the drive interlock ............................................................................. 3-22

Putting the drive interlock out of operation ...................................................... 3-22

Putting the drive interlock back into operation again ....................................... 3-23

Interruption of drive interlock power ................................................................ 3-23

Drive interlock maintenance ............................................................................ 3-23

Oil and fuel preheater (option) ............................................................................... 3-24

General information on the oil and fuel preheater ........................................... 3-24

Oil preheater operation .................................................................................... 3-24

Fuel preheater ................................................................................................. 3-24

Jump-starting the engine (external battery) ........................................................... 3-25

Safety instructions regarding external starting aids ......................................... 3-25

Providing external starting aid ......................................................................... 3-25

Before moving off ................................................................................................... 3-26

Special instructions for driving on public roads ............................................... 3-26

Preparing for driving on public roads ............................................................... 3-26

Bucket transport position ................................................................................. 3-27

Transport position of pallet forks ..................................................................... 3-28

Locking the control lever (joystick) and the 3rd control circuit (attachments) .. 3-29

Functional check of all control elements .......................................................... 3-29

Steering system ..................................................................................................... 3-30

Steering column height and angle adjustment (option) ................................... 3-30

Checking the steering system ......................................................................... 3-30

Wheel synchronisation (front/rear axles) ............................................................... 3-31

Synchronisation when starting the machine .................................................... 3-31

Synchronisation during work operation ........................................................... 3-31

Changing steering mode ........................................................................................ 3-32

General safety information on changing steering mode .................................. 3-32

Changing over to front axle steering (option) .................................................. 3-32

Changing over to 4 wheel steering .................................................................. 3-32

Changing over to diagonal steering (crab steering option) .............................. 3-33

Accelerator pedal ................................................................................................... 3-34

Speed control with the accelerator pedal ........................................................ 3-34

Accelerator pedal lock – manual throttle (option) .................................................. 3-34

Disabling/enabling the accelerator pedal lock ................................................. 3-34

Brake/inching pedal ............................................................................................... 3-35

Specific information on brake/inching pedal actuation .................................... 3-35

Braking with the brake/inching pedal ............................................................... 3-35

Inching with the brake/inching pedal ............................................................... 3-35

Parking brake ......................................................................................................... 3-36

General instructions regarding the parking brake ............................................ 3-36

Applying the parking brake .............................................................................. 3-36

Driving the machine ............................................................................................... 3-37

Selecting a speed range .................................................................................. 3-37

Changing direction (forwards/reverse) ............................................................ 3-38

Differential lock (self-locking differential) ............................................................... 3-38

Switching the differential lock ON and OFF ..................................................... 3-38

Low-speed control (option) .................................................................................... 3-39

Selecting the drive speed ................................................................................ 3-39

Load stabiliser (option) .......................................................................................... 3-40

General instructions regarding the load stabiliser function .............................. 3-40

Switching the load stabiliser ON and OFF ....................................................... 3-41

Backup warning system (option) ............................................................................ 3-42

Instructions regarding the backup warning system ......................................... 3-42

BA 35101/02/ 03 EN - Ausgab e 1.0 * BA_35101_02_03_10_enIVZ.fm I-3

Table of contents

Electric connection – front socket (option) ............................................................. 3-42

Putting the front socket into operation ............................................................. 3-42

Machine lights ........................................................................................................ 3-43

Machine lights operation .................................................................................. 3-43

Working lights operation ................................................................................. 3-44

Interior light operation ..................................................................................... 3-44

Signalling system ................................................................................................... 3-45

Turn indicator operation ................................................................................... 3-45

Hazard warning system operation .................................................................. 3-45

Rotating beacon (option) ........................................................................................ 3-45

Rotating beacon operation .............................................................................. 3-45

Cab heating and ventilation ................................................................................... 3-46

Heating and ventilation system operation ........................................................ 3-46

Auxiliary heating (option) ....................................................................................... 3-47

Operating and setting the auxiliary heating ..................................................... 3-47

Heating/air conditioning system (option) ................................................................ 3-48

Heating/air conditioning operation ................................................................... 3-48

Washer system ...................................................................................................... 3-49

Washer system operation ................................................................................ 3-49

Tank for washer system ................................................................................... 3-49

Seat ........................................................................................................................ 3-50

Seat adjustment: overview ............................................................................... 3-50

Weight adjustment ........................................................................................... 3-50

Height adjustment ............................................................................................ 3-51

Height adjustment (air-suspension seat, option) ............................................. 3-51

Backrest adjustment ........................................................................................ 3-51

Horizontal adjustment with control lever base ................................................. 3-52

Horizontal adjustment without control lever base ............................................ 3-52

Heated seat (option) .............................................................................................. 3-52

Heated seat operation ..................................................................................... 3-52

Seat belt (lap belt) .................................................................................................. 3-53

Specific instructions regarding the seat belt .................................................... 3-53

Fastening the seat belt .................................................................................... 3-53

Unfastening the seat belt ................................................................................. 3-54

Longer/shorter lap belt adjustment .................................................................. 3-54

Other controls ........................................................................................................ 3-55

Folding back the control lever base ................................................................. 3-55

Towing the machine ............................................................................................... 3-56

Safety instructions for towing away ................................................................. 3-56

Getting ready for towing ................................................................................... 3-56

Towing the machine ......................................................................................... 3-57

Once towing is over ......................................................................................... 3-57

Decommissioning the machine temporarily ........................................................... 3-58

Stopping/parking the machine ......................................................................... 3-58

Decommissioning the machine for a longer time ............................................. 3-58

Crane handling the machine .................................................................................. 3-59

Safety instructions regarding crane handling ................................................... 3-59

Crane handling the machine ............................................................................ 3-59

Loading and transporting the machine on a transport vehicle ............................... 3-60

Safety instructions regarding loading on a transport vehicle ........................... 3-60

Loading and tying down the machine .............................................................. 3-61

Loader unit control lever (overview) ....................................................................... 3-62

Control lever (joystick) for lift and tilt rams and 3rd control circuit ................... 3-62

Operating and securing the 3rd control circuit ....................................................... 3-63

Locking and unlocking an attachment from the quickhitch .............................. 3-63

Operation of hydraulic attachments ................................................................. 3-63

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Table of contents

Continuous operation of the 3rd control circuit (option) ......................................... 3-64

Continuous operation of the 3rd control circuit ................................................ 3-64

Emergency lowering of loader unit in case of diesel engine breakdown ............... 3-65

Lowering or raising .......................................................................................... 3-65

Pressure relief on the quickhitch couplers ............................................................. 3-65

Equipping the machine with a standard bucket ..................................................... 3-66

Fitting a standard bucket onto the quickhitch .................................................. 3-66

Removing a standard bucket from the quickhitch ............................................ 3-67

Driving on public roads with a standard bucket ..................................................... 3-68

Preparing road travel ....................................................................................... 3-68

Working with a bucket ............................................................................................ 3-69

Fields of application for bucket ........................................................................ 3-69

Safety instructions for working with the bucket ................................................ 3-69

Safety instructions for transporting material in a full bucket ............................ 3-70

Loading loose material .................................................................................... 3-71

Loading if the material is hard to penetrate ..................................................... 3-71

Removing material/digging in soft soil ............................................................. 3-72

Removing material/digging in hard soil ............................................................ 3-73

Loading heaped material (non-compacted material) ....................................... 3-73

Loading heaped material (compacted material) .............................................. 3-74

Grading ............................................................................................................ 3-74

Practical hints for loading vehicles .................................................................. 3-74

Freeing the machine ........................................................................................ 3-74

Fitting a multipurpose bucket ................................................................................. 3-75

Picking up a multipurpose bucket with the quickhitch ..................................... 3-75

Hydraulic connections on the multipurpose bucket (overview) ........................ 3-75

Connecting the hydraulic lines of a multipurpose bucket to the wheel loader . 3-76

Removing the multipurpose bucket from the quickhitch .................................. 3-77

Driving on public roads with the multipurpose bucket ............................................ 3-78

Preparing road travel ....................................................................................... 3-78

Working with the multipurpose bucket ................................................................... 3-79

Fields of application for multipurpose bucket .................................................. 3-79

Safety instructions for working with the multipurpose bucket .......................... 3-79

Safety instructions for transporting material in a full multipurpose bucket ....... 3-80

Grading and scraping ...................................................................................... 3-81

Removing and spreading material in thin layers .............................................. 3-81

Pulling out material from slopes ...................................................................... 3-82

Moving material with longer reach ................................................................... 3-82

Picking up remaining material completely ....................................................... 3-82

Grabbing bulky material ................................................................................... 3-83

Pulling out and setting posts ............................................................................ 3-83

Backfilling round gravel and precise unloading ............................................... 3-84

Unloading from the bottom of the bucket for increased dump heights ............ 3-84

Fitting pallet forks ................................................................................................... 3-85

Picking up pallet forks with the quickhitch ....................................................... 3-85

Removing the pallet forks from the quickhitch ................................................. 3-85

Driving on public roads with pallet forks ................................................................ 3-85

Working with the pallet forks .................................................................................. 3-86

General safety instructions regarding the pallet forks ..................................... 3-86

Brief instructions for fork arms ......................................................................... 3-88

Specific safety instructions for picking up loads with the pallet forks .............. 3-89

Load diagram for pallet forks ........................................................................... 3-89

Adjusting the fork arms of the pallet forks ....................................................... 3-90

Fields of application for pallet forks ................................................................. 3-91

Picking up loads with the pallet forks ............................................................... 3-91

Transporting loads with the pallet forks ........................................................... 3-92

BA 35101/02/ 03 EN - Ausgab e 1.0 * BA_35101_02_03_10_enIVZ.fm I-5

Table of contents

Load hook (option) ................................................................................................. 3-93

Safety instructions regarding work with a load hook ........................................ 3-93

Working with the automatic bucket repositioning (option) ...................................... 3-94

General information on automatic bucket repositioning ................................... 3-94

Front/rear hydraulic additional control circuit (option) ............................................ 3-95

Connections for additional control circuits (overview) ...................................... 3-95

Operation of front/rear additional control circuits ............................................. 3-96

Additional control circuit (4th control circuit proportional controls option) .............. 3-97

Operation of 4th control circuit ......................................................................... 3-97

Tilt ram lock (option) .............................................................................................. 3-98

Switching the tilt ram lock ON and OFF ........................................................... 3-98

“Hose burst valve” safety feature (option) .............................................................. 3-98

General information on the hose burst valve ................................................... 3-98

Hose burst valve function ................................................................................ 3-98

Automatic trailer coupling (option) ......................................................................... 3-99

General information on the trailer coupling ...................................................... 3-99

Trailer weights/drawbar loads on the trailer coupling ...................................... 3-99

Trailer coupling operation ................................................................................ 3-99

Final decommissioning of machine ...................................................................... 3-100

General information on decommissioning ..................................................... 3-100

Preparing disposal ......................................................................................... 3-100

Disposal ......................................................................................................... 3-100

Troubleshooting 4

Engine trouble .......................................................................................................... 4-1

Malfunctions in the air conditioning system (option) ................................................ 4-3

Maintenance 5

Important information on maintenance and service work ........................................ 5-1

Important information for maintenance personnel ............................................. 5-1

Fuel system .............................................................................................................. 5-2

Safety instructions for refuelling ......................................................................... 5-2

Diesel fuel specification ..................................................................................... 5-2

Stationary fuel pumps ........................................................................................ 5-2

Refuelling ........................................................................................................... 5-3

Checking/cleaning the additional fuel filter (water separator, option) ................ 5-3

Bleeding the fuel system .................................................................................... 5-4

Engine lubrication system ........................................................................................ 5-5

Safety instructions regarding inspections and maintenance

work on the engine ............................................................................................ 5-5

Checking the engine oil level ............................................................................. 5-5

Filling up engine oil ............................................................................................ 5-6

Engine and hydraulics cooling system ..................................................................... 5-7

General instructions regarding cooling system maintenance ............................ 5-7

General checks and cleaning work .................................................................... 5-7

Cleaning the radiator fins of the oil/water radiator ............................................. 5-8

Fan bearing – Visco clutch ................................................................................ 5-8

Checking the coolant level ................................................................................. 5-9

Filling up coolant .............................................................................................. 5-10

Air filter ................................................................................................................... 5-11

Checking the air filter for dirt ............................................................................ 5-11

Replacing the air filter cartridge ....................................................................... 5-12

V-belt ...................................................................................................................... 5-13

Checking V-belt tension ................................................................................... 5-13

Retightening the V-belt .................................................................................... 5-13

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Table of contents

Hydraulic system ................................................................................................... 5-14

Safety instructions regarding maintenance of the hydraulic system ................ 5-14

Monitoring the hydraulic oil and the reflux filter ............................................... 5-15

Checking the hydraulic oil level ....................................................................... 5-16

Filling up hydraulic oil ...................................................................................... 5-16

Important information for the use of biodegradable oil .................................... 5-17

Checking hydraulic pressure lines ......................................................................... 5-18

Safety instructions regarding pressure line checks ......................................... 5-18

Lubrication work ..................................................................................................... 5-19

General safety instructions regarding lubrication work .................................... 5-19

Lubricating the rear axle oscillation-type bearing ............................................ 5-19

Lubricating the front and rear axle planetary drive bearings ........................... 5-19

Lubricating the loader unit, lift, tilt and lock rams ............................................. 5-20

Lubricating with the central lubrication system (option) ......................................... 5-21

General functional description of the central lubrication system ..................... 5-21

Time control ..................................................................................................... 5-21

Repair work ..................................................................................................... 5-21

Setting the lubrication and break times ........................................................... 5-22

Filling the central lubrication system ................................................................ 5-22

Maintenance of the brake system .......................................................................... 5-23

Specific safety instructions regarding the brake system .................................. 5-23

Checking/filling up the brake fluid level ........................................................... 5-23

Tyres ...................................................................................................................... 5-24

Daily tyre checks ............................................................................................. 5-24

Wheel change .................................................................................................. 5-25

Heating and ventilation system maintenance ........................................................ 5-26

General instructions regarding the heating system ......................................... 5-26

Cleaning the dust filter of the heating system .................................................. 5-26

Heating/air conditioning system (option): maintenance ......................................... 5-27

General safety instructions regarding the air conditioning system .................. 5-27

Filling up the air conditioning system ............................................................... 5-27

Daily functional and visual checks of the heating and

air conditioning system .................................................................................... 5-28

Cleaning the heat exchanger (condenser) ...................................................... 5-29

Electrical system .................................................................................................... 5-30

General instructions ......................................................................................... 5-30

Safety instructions regarding the electrical system and the battery ................ 5-30

Checking/replacing the battery ........................................................................ 5-31

Inspection and maintenance work on the electrical system

at regular intervals ........................................................................................... 5-32

Checking the alternator ................................................................................... 5-32

Checking/replacing fuses and relays ............................................................... 5-33

Checking/replacing fuses of the main fuse box ............................................... 5-33

General cleaning and maintenance work .............................................................. 5-34

Safety instructions regarding general cleaning work ....................................... 5-34

Cleaning with washing solvents ....................................................................... 5-34

Cleaning with compressed air ......................................................................... 5-34

Cleaning with a high-pressure cleaner or steam jet ........................................ 5-34

Cleaning with volatile and flammable anticorrosion agents and sprays .......... 5-34

Cleaning inside the cab ................................................................................... 5-35

Cleaning the seat belt ...................................................................................... 5-35

Cleaning the exterior of the machine ............................................................... 5-35

Cleaning the engine compartment ................................................................... 5-36

Checking screw connections ........................................................................... 5-36

Checking pivots and hinges ............................................................................. 5-36

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Table of contents

Maintenance of attachments and of the work equipment ...................................... 5-36

Maintenance of the automatic trailer coupling (option) .......................................... 5-37

Cleaning and lubricating the trailer coupling .................................................... 5-37

Check the trailer coupling for wear .................................................................. 5-37

Maintenance: diesel particle filter (option) ............................................................. 5-38

Checking the electronic filter monitoring .......................................................... 5-38

Maintenance work “Aggressive Media” (option) ..................................................... 5-39

Anticorrosion protection applied in the factory ................................................. 5-39

Components coated with anticorrosive wax .................................................... 5-39

Measures for maintaining anticorrosive protection .......................................... 5-40

Applying the protective anticorrosion coating .................................................. 5-41

Treatment of oxidised surfaces ........................................................................ 5-41

Fluids and lubricants ............................................................................................. 5-43

Explanation of symbols on the maintenance label ................................................. 5-44

Maintenance label .................................................................................................. 5-45

Maintenance plan ................................................................................................... 5-47

Specifications 6

Models and trade names: overview ......................................................................... 6-1

Frame ....................................................................................................................... 6-1

Engine ...................................................................................................................... 6-1

Drive ......................................................................................................................... 6-2

Variable displacement pump/boost pump .......................................................... 6-2

Variable displacement motor ............................................................................. 6-2

Axles ........................................................................................................................ 6-3

Front axle ........................................................................................................... 6-3

Rear axle ........................................................................................................... 6-3

Brakes ...................................................................................................................... 6-4

Service brake ..................................................................................................... 6-4

Parking brake ..................................................................................................... 6-4

Steering system ....................................................................................................... 6-4

Work hydraulics ....................................................................................................... 6-5

Hydraulic pump .................................................................................................. 6-5

Hydraulic pilot control, pilot control unit ............................................................. 6-5

Hydraulic ram protection .................................................................................... 6-6

Lift and tilt ram speed ........................................................................................ 6-6

Usable consumer pressure at additional control circuit (option) ........................ 6-7

Electrical system ...................................................................................................... 6-8

Electric units ...................................................................................................... 6-8

Fuses ................................................................................................................. 6-8

Main fuse box with relays .................................................................................. 6-9

Relays .............................................................................................................. 6-10

Tyres ...................................................................................................................... 6-11

Tyres for wheel loader model 351-01 .............................................................. 6-11

Tyres for wheel loader models 351-02/351-03 ................................................ 6-11

Machine weights .................................................................................................... 6-12

Noise levels ............................................................................................................ 6-12

Vibrations, oscillation and acceleration value ........................................................ 6-12

Coolant compound table ........................................................................................ 6-13

Tightening torques, conversion tables ................................................................... 6-13

General tightening torques .............................................................................. 6-13

Specific tightening torques ............................................................................... 6-13

Conversion table: DIN standard – USA standard ............................................ 6-14

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Table of contents

Payloads ................................................................................................................ 6-15

Loader unit with bucket .................................................................................... 6-15

Loader unit with pallet forks ............................................................................. 6-15

Loader unit with pallet forks (foldable fork arms option) .................................. 6-16

Loader unit with load hook (option) ................................................................. 6-16

Trailer weight/drawbar load for automatic trailer coupling (option) .................. 6-16

Wheel loader dimensions with bucket (model 351-01) .......................................... 6-17

Wheel loader dimensions with bucket (model 351-02) .......................................... 6-18

Wheel loader dimensions with bucket (model 351-03) .......................................... 6-19

Wheel loader dimensions with pallet forks (models 351-01/351-02/351-03) ......... 6-20

BA 35101/02/ 03 EN - Ausgab e 1.0 * BA_35101_02_03_10_enIVZ.fm I-9

Index

Symbole

“Hose burst valve” safety feature (option) ...............................3-98

Abbreviations/symbols ...............................................................1-1

Accelerator pedal .....................................................................3-34

Accelerator pedal lock – manual throttle (option) ....................3-34

Additional control circuit (4th control circuit

proportional controls option) ....................................................3-97

Air conditioning (option) ...........................................................3-48

Air filter ....................................................................................5-11

Alternator .................................................................................5-32

Authorised attachments .............................................................1-5

Backup warning system (option) .............................................3-42

Battery master switch (option) .................................................3-18

Biodegradable oil ..................................................................... 5-17

Brake system ........................................................................... 5-23

Brake fluid .........................................................................5-23

Safety instructions .............................................................5-23

Brief instructions for fork arms .................................................3-88

Bucket repositioning (option) ...................................................3-94

Cab

Door ...................................................................................3-12

Opening the door to a gap .................................................3-13

Safety instructions regarding cab entrance and exit .........3-12

Cab overview .............................................................................3-2

Central lubrication system (option) ..........................................5-21

Changing direction (forwards/reverse) ....................................3-38

Changing wheels .....................................................................5-25

Checking/replacing the battery ................................................5-31

Cleaning the oil/water radiator ...................................................5-8

Continuous operation of the 3rd control circuit ........................3-64

Decommissioning of machine ................................................3-100

Description

Control elements .................................................................3-1

Disposal of machine ..............................................................3-100

Documents ................................................................................1-9

Drive ..........................................................................................6-1

Variable displacement motor ...............................................6-2

Variable displacement pump ...............................................6-2

Drive interlock with code ..........................................................3-20

Driving licence ...........................................................................1-8

Driving on public roads

Preparatory work ............................................................... 3-26

With a standard bucket ......................................................3-68

With the multipurpose bucket ............................................3-78

With the pallet forks ...........................................................3-85

Emergency lowering of the loader unit with the

engine stopped ........................................................................3-65

Engine

Avoiding running the engine under low-load conditions ....3-17

Check the engine oil ............................................................ 5-5

Filling up engine oil .............................................................. 5-6

Preparing to start the engine .............................................3-15

Start ...................................................................................3-16

Stopping ............................................................................3-17

Engine cover lock ....................................................................3-14

Equipment numbers

Cab number .......................................................................1-10

Engine number ..................................................................1-10

Front axle number .............................................................1-11

Rear axle number ..............................................................1-11

Serial number ....................................................................1-10

Variable displacement motor number ................................1-11

Variable displacement pump number ................................1-11

Fan bearing – Visco clutch ........................................................5-8

Fields of application

Bucket ...............................................................................3-69

Multipurpose bucket ..........................................................3-79

Pallet forks .........................................................................3-91

Wheel loaders .....................................................................1-5

Fire extinguisher (option) ......................................................... 3-14

Fluids and lubricants ................................................................5-43

Folding back the control lever base .........................................3-55

Front and rear additional control circuit (option) ......................3-95

Front socket (option) ................................................................3-42

Fuel preheater (option) ............................................................3-24

Fuel system

Refuelling ............................................................................ 5-3

Hazard warning system ...........................................................3-45

Heated seat (option) ................................................................3-52

Heating system dust filter ........................................................5-26

Hose burst valve (option) .........................................................3-98

Hydraulic connections

Multipurpose bucket ..........................................................3-76

Hydraulic connections on the multipurpose bucket

overview ............................................................................3-75

Important information on this Operator's Manual .......................1-1

Inching pedal ...........................................................................3-35

Instructions regarding the seat belt .........................................3-53

Instrument panel overview .........................................................3-4

Interior light ..............................................................................3-44

Key-based drive interlock ........................................................3-18

I-10 BA 35101/02 /03 EN - Ausg abe 1.0 * BA_35101_02_03_10 _enSIX.f m

Index

Legal regulations .......................................................................1-8

Licence, identification ................................................................1-8

Light system ............................................................................3-43

Load diagram ...........................................................................3-89

Load hook (option) ...................................................................3-93

Load on trailer coupling (option) ..............................................6-16

Load stabiliser (option) ............................................................ 3-40

Loader unit

Lubrication .........................................................................5-20

Releasing the pressure on the quick couplers ..................3-65

Locking the loader unit and 3rd control circuit control levers ...3-29

Lowering the loader unit with the engine stopped ................... 3-65

Lubrication work

With a grease gun .............................................................5-19

With the central lubrication system (option) ......................5-21

Machine

Brief description ...................................................................1-3

Crane handling ..................................................................3-59

Loading and transporting ...................................................3-60

Overview .............................................................................1-2

Towing ...............................................................................3-56

Machine inspections, regulations for accident prevention .........1-9

Machine lights ..........................................................................3-43

Maintenance

Additional fuel filter (option) .................................................5-3

Air filter cartridge ...............................................................5-12

Brake system ..................................................................... 5-23

Checking the engine oil level ...............................................5-5

Checking the hydraulic oil level .........................................5-16

Diesel particle filter (option) ...............................................5-38

Electrical system ...............................................................5-30

Engine and hydraulics cooling system ................................5-7

Engine lubrication system ...................................................5-5

Filling up coolant ...............................................................5-10

Filling up hydraulic oil ........................................................5-16

Fluids and lubricants ......................................................... 5-43

Fuel system .........................................................................5-2

General cleaning and maintenance work ..........................5-34

Heating and ventilation system .........................................5-26

Hydraulic pressure lines ....................................................5-18

Hydraulic system ...............................................................5-14

Maintenance of attachments ............................................. 5-36

Maintenance work if the machine is used in

a saline environment .........................................................5-39

Pivots and hinges ..............................................................5-36

Screw connections ............................................................5-36

Service and maintenance work at regular intervals ...........5-32

Trailer couplings ................................................................5-37

Tyre care ...........................................................................5-24

V-belt .................................................................................5-13

Maintenance of the air conditioning system ............................5-27

Maintenance plan ....................................................................5-47

Manual throttle (option) ............................................................3-34

Models and trade names ...........................................................1-3

Mounting

Multipurpose bucket ..........................................................3-75

Pallet forks .........................................................................3-85

Standard bucket ................................................................3-66

Move off the machine ..............................................................3-37

Oil preheater (option) ...............................................................3-24

On-board equipment .................................................................. 1-9

Operating staff ...........................................................................3-9

Operation

Parking the machine ..........................................................3-58

Operation of 3rd control circuit ................................................3-63

Overview of machine outside view ............................................1-2

Pallet forks ...............................................................................3-86

Adjusting the fork arms ......................................................3-90

Specific safety instructions ................................................3-89

Parking brake ..........................................................................3-36

Parking the machine ................................................................3-58

Payloads ..................................................................................6-15

Bucket ...............................................................................6-15

Loader unit with load hook ................................................6-16

Pallet forks .........................................................................6-15

Pallet forks with foldable fork arms ....................................6-16

Picking .....................................................................................3-75

Protective screen for front window (option) .............................3-14

Putting the machine into operation for the first time ..................3-9

Removing

Standard bucket from the quickhitch .................................3-67

The multipurpose bucket from the quickhitch ....................3-77

The pallet forks from the quickhitch ...................................3-85

Rotating beacon (option) .........................................................3-45

Running-in period ......................................................................3-9

BA 35101/02/ 03 EN - Ausgab e 1.0 * BA_35101_02_03_10_enSIX.fm I-11

Index

Safety instructions .....................................................................2-1

3rd control circuit on control lever (joystick) ......................3-63

Applications with lifting gear ................................................2-8

Battery ...............................................................................2-13

Electric energy ...................................................................2-12

Gas, dust, steam, smoke ...................................................2-12

General conduct ..................................................................2-3

Hydraulics ..........................................................................2-13

Identification of warnings and dangers ................................2-1

Maintenance ......................................................................2-10

Noise .................................................................................2-13

Oil, grease and other chemical substances .......................2-13

Operation .............................................................................2-6

Selection of staff and basic responsibilities .........................2-5

Service and maintenance work on the ROPS bar .............2-12

Trailers and attachments .....................................................2-9

Transporting with a full bucket ...........................................3-70

Transporting with a full multipurpose bucket .....................3-80

Transporting, towing, loading ..............................................2-9

Tyres ..................................................................................2-13

Use and exemption from liability ..........................................2-2

Working with a bucket .......................................................3-69

Working with the multipurpose bucket ...............................3-79

Working with the pallet forks ..............................................3-86

Seat .........................................................................................3-50

Backrest adjustment ..........................................................3-51

Height adjustment (air-suspension seat, option) ...............3-51

Seat adjustment .................................................................3-50

Seat belt ............................................................................3-53

Standard height setting ......................................................3-51

Weight adjustment .............................................................3-50

Seat belt ...................................................................................3-53

Selecting a speed range .......................................................... 3-37

Service brake ...........................................................................3-35

Signalling system .....................................................................3-45

Signs and symbols ...................................................................1-12

Specifications .............................................................................6-1

Additional control circuit (option) .........................................6-7

Axles ....................................................................................6-3

Brakes .................................................................................6-4

Coolant compound table ....................................................6-13

Dimensions with bucket model 351-01 ..............................6-17

Dimensions with bucket model 351-02 ..............................6-18

Dimensions with bucket model 351-03 ..............................6-19

Dimensions with pallet forks

(models 351-01/351-02/351-03) ........................................6-20

Electrical system ..................................................................6-8

Engine .................................................................................6-1

Frame ..................................................................................6-1

Hydraulic ram protection ......................................................6-6

Lift, tilt and push-out ram velocity ........................................6-6

Noise levels .......................................................................6-12

Pilot control ..........................................................................6-5

Steering system ...................................................................6-4

Tightening torques .............................................................6-13

Tyres for models 351-02/351-03 .......................................6-11

Tyres model 351-01 ........................................................... 6-11

Vibrations, oscillation and acceleration value ....................6-12

Weights ..............................................................................6-12

Work hydraulics ...................................................................6-5

Starting aid ...............................................................................3-25

Steering system

4 wheel steering ................................................................3-32

Checking ............................................................................3-30

Diagonal or crab steering (option) .....................................3-33

Front axle steering (option) ................................................3-32

Wheel alignment ................................................................3-31

I-12 BA 35101/02 /03 EN - Ausg abe 1.0 * BA_35101_02_03_10 _enSIX.f m

Telltales .....................................................................................3-6

Tilt ram lock (option) ................................................................3-98

Trailer coupling (option)

Operation ...........................................................................3-99

Transport position

Pallet forks .........................................................................3-28

Transporting loads with the pallet forks ...................................3-92

Type labels and component numbers ..................................... 1-10

Tyres ........................................................................................5-24

Warning identification ................................................................1-9

Washer system ........................................................................3-49

Tank ..................................................................................3-49

Wheel loader warranty ...............................................................1-4

Working

With a load hook (option) .................................................. 3-93

With a standard bucket ......................................................3-69

With the automatic bucket repositioning (option) .............. 3-94

With the multipurpose bucket ............................................3-79

With the pallet forks ...........................................................3-86

Working lights ..........................................................................3-44

Index

BA 35101/02/ 03 EN - Ausgab e 1.0 * BA_35101_02_03_10_enSIX.fm I-13

Index

I-14 BA 35101/02 /03 EN - Ausg abe 1.0 * BA_35101_02_03_10 _enSIX.f m

EC Dec laration of C onformity

EC Declaration of Conformity

Declaration of conformity

EC declaration of conformity (model 351-01)

Manufacturer

Kramer-Werke GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf

Product

Machine designation 351

Model/version 351-01 (380)

Serial number 351 01 _ _ _ _ _

Output kW 45

Measured sound power level dB(A) 100.3

Guaranteed sound power level dB(A) 101

Conformity assessment procedure

The following inspection body was involved in the procedure: Fachausschüsse Bau und Tiefbau (Notified body number (EU): 0515) Prüf- und Zertifizierungsstelle im BG-PRÜFZERT Landsberger Str. 309 D-80687 München

Directives and standards

We hereby declare that this product corresponds to the relevant regulations and requirements of the following EC Directives and standards: 2006/42/EC, 2004/108/EC, 2002/44/EC, 2003/10/EC, 2003/37/EC, DIN EN ISO 12100-1 and 2, DIN EN 474-1 and 3, DIN EN 14121, DIN EN 3471, DIN EN 13510, 2000/14 EC and EN ISO 3744: 1995, EN ISO 3746, DINENISO3449

Responsible for documentation

Dipl.-Ing. Manfred Mack KRAMER-WERKE GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf

Pfullendorf, (date)

i. A.

Dipl.-Ing. Manfred Mack Head of Research & Development KRAMER-WERKE GmbH

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03_EG_Konformit ät.f m EG-1

EC Declaration of Conformity

EC declaration of conformity (model 351-02)

Manufacturer

Kramer-Werke GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf

Product

Machine designation 351

Model/version 351-02 (480)

Serial number 351 02 _ _ _ _ _

Output kW 45 (58 optional)

Measured sound power level dB(A) 100.3

Guaranteed sound power level dB(A) 101

Conformity assessment procedure

Directives and standards

Responsible for documentation

Dipl.-Ing. Manfred Mack KRAMER-WERKE GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf

Pfullendorf, (date)

i. A.

Dipl.-Ing. Manfred Mack Head of Research & Development KRAMER-WERKE GmbH

EG-2 BA 35101/02 /03 EN – Edition 1.0 * 35101_02_ 03_EG_ Konformit ät.fm

EC Declaration of Conformity

EC declaration of conformity (model 351-03)

Manufacturer

Kramer-Werke GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf

Product

Machine designation 351

Model/version 351-03 (580)

Serial number 351 03 _ _ _ _ _

Output kW 58

Measured sound power level dB(A) 100.3

Guaranteed sound power level dB(A) 101

Conformity assessment procedure

Directives and standards

Responsible for documentation

Dipl.-Ing. Manfred Mack KRAMER-WERKE GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf

Pfullendorf, (date)

i. A.

Dipl.-Ing. Manfred Mack Head of Research & Development KRAMER-WERKE GmbH

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03_EG_Konformit ät.f m EG-3

EC Declaration of Conformity

EG-4 BA 35101/02 /03 EN – Edition 1.0 * 35101_02_ 03_EG_ Konformit ät.fm

Introduc tion

1 Introduction

1.1 General information on the Operator's Manual

This Operator's Manual applies to the wheel loaders model 351-01/351-02 and contains important information on how to work safely, correctly and economically with the machine. Therefore, it aims not only at new operators, but it also serves as a reference for experienced ones. It helps to avoid dangerous situations and reduce repair costs and downtimes. Furthermore, the reliability and the service life of the machine will be increased by following the instructions in the Operator's Manual. This is why the Operator's Manual

must always be kept at hand in proper condition in the machine.

The Operator's Manual is stored in the storage compartment on the backrest of the seat. Please contact your dealer if you require more information on the machine or the Opera-

tor's Manual.

Abbreviations/symbols

☞ This symbol requires you to carry out the activity described

☞ Subdivision within lists or an activity. Follow the steps in the recommended sequence

• This symbol stands for a list

• Subdivision within lists or an activity.

➥ Description of the effects of an activity (result)

Introduction

“Option” = optional equipment Stated whenever controls or other components of the machine are installed as an option.

Driving direction in drawings or figures.

1.2 General information on machine safety

Your own safety, as well as the safety of others, depends to a great extent on how the machine is moved and operated. Therefore, carefully read and understand this Operator's Manual prior to the first drive. Also read chapter “Safety instructions” in order to be prepared for possible dangerous situations as it will be too late for it during operation. As a rule, keep the following in mind:

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

➥ – see chapter 2 “Selection and qualification of staff, basic responsibilities” on page 2-5

Operational safety and readiness of the machine do not only depend on your skill, but also on maintenance and servicing of the machine.

This is why regular maintenance and service work is absolutely necessary. Extensive maintenance and repair work must always be carried out by an expert with

appropriate training. Insist on using original spare parts when carrying out maintenance and repair work. This

ensures operational safety and readiness of your machine, and maintains its value. The machine's permits, certifications, registrations, etc., may be withdrawn if machine

parts/components with a prescribed condition or quality, or machine parts/components that can put persons at risk during operation, are subsequently modified or exchanged.

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b110.fm 1-1

Introduction

Fig. 1: Machine outside views

Pos. Description

1 Headlight with turn indicator

2 Rearview mirror

3 Front working light

4 Eye hook1 (for removing the cab)

5 Protective FOPS screen (option)

6 Rotating beacon (option)

7 Backup warning system (option)

8 Door arrester

9 Rear working light

Clearance lights with reflectors (to the rear) (option)

11 Numberplate light (option)

12 Engine cover lock

13 Brake, rear and turn indicator lights

14 Reflectors

Rear hooks for loading/tying down the machine (left/right)

16 Towing facility

17 Socket (oil and fuel preheater option)

18 Additional fuel tank filler inlet (option)

19 Handle

20 Wheel chock

21 Fuel tank filler inlet

Front hooks for loading/tying down the machine (left/ right)

23 Quickhitch for attachments

24 Front-edge protection

1. Eye hooks are fo r removing t he cab only, and may not be used for crane handling the machine

Pos. Description

3 5 94 4

1523 17

21 13162224 20

6 7 8

15 13

1010

14 14

1.3 Machine outside view

1-2 BA 35101/0 2/03 E N – Edition 1.0 * 35101_02 _03b110.f m

1.4 Models and trade names: overview

Wheel loader model Trade name

1.5 Brief description of the wheel loader

General information on the machine

According to German traffic regulations and the German agricultural and forestry tractors provision, the model 351-01/351-02/351-03 wheel loaders are self-propelled work machines, tractors or equipment carriers.

See also the wheel loader's “Data Confirmation” (Germany) and “Licence Certificate” (Germany).

Get informed on and follow the legal regulations of your country.

Due to a wide range of possible attachments, the machine is a versatile and powerful helper in the construction industry, in agriculture and in recycling operations.

Possible applications –seeFields of application and using a wheel loader with an attach- ment on page 1-5.

Retrofit the machine accordingly with specific safety equipment when using it as a lifting gear – see chapter 2 “Applications with lifting gear” on page 2-8 and “Load hook (option)”

on page 3-93.

Introduction

351-01 380

351-02 480

351-03 580

Main components of wheel loader

• ROPS/FOPS tested cab (closed version)

• Water-cooled Deutz four-cylinder in-line engine, exhaust emissions according to EC standard 2004/26 EC

• Sturdy steel sheet frame; rubber-mounted engine

• Automotive drive, infinitely variable hydrostatic axial-piston gearbox; maximum speed 20 kph (35 or 40 kph options)

• Hydraulic four-wheel power steering with emergency steering features

• Front and rear planetary steering axles, rear axle with oscillation

• Service brake (brake disc on front axle drive shaft, and also on rear axle drive shaft for 30 – 40 kph machines)

• Parking brake (brake disc on front axle drive shaft)

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b110.fm 1-3

Introduction

Hydrostatic drive

The diesel engine permanently drives a hydraulic pump (variable displacement pump), whose oil flow is sent to a hydraulic motor flanged on the gearbox. The force of the hydraulic motor is transmitted to the rear axle via the transfer gearbox. At the same time, the front axle is driven by the cardan shaft, ensuring permanent 4 wheel drive.

Work hydraulics and 4 wheel steering

The diesel engine also drives the joint gear pump for work hydraulics and hydrostatic 4 wheel steering. The oil flow of this pump depends on the diesel engine speed only.

When the machine is in operation, the entire diesel engine output can be transmitted to the gear pump for work hydraulics and steering. This is made possible by a so-called inching valve which responds as soon as the service brake is used, reducing or cutting off power input of the drive. Therefore, engine output is fully available for the loader unit by pressing the accelerator pedal and the brake pedal at the same time.

Cooling system

A combined oil/water radiator (for the diesel engine and the hydraulic oil) is located at the rear of the machine.

The gauges and the telltales on the instrument panel of the machine ensure constant monitoring of the coolant temperature and level, and of the hydraulic oil temperature.

1.6 Wheel loader warranty

Warranty claims can be made only if the conditions of warranty have been observed. They are included in the General Conditions of Sales and Delivery for new machines and

spare parts sold by the dealers. Furthermore, the instructions in this Operator's Manual must be observed.

1-4 BA 35101/0 2/03 E N – Edition 1.0 * 35101_02 _03b110.f m

1.7 Fields of application and using a wheel loader with an attachment

Caution!

The attachments will decide in the first place how the machine is used.

In order to avoid damage to the machine, only the attachments listed in the table have been authorised for installation on the machine. Mounting attachments other than Kramer is only allowed if they correspond to the description in chapter “Operation”, “Equipping the machine with a

standard bucket” on page 3-66, “Fitting a multipurpose bucket” on page 3-75

and “Fitting pallet forks” on page 3-85.

German road traffic regulations prohibit driving on public roads if the distance between the front edge of the bucket and the centre of the steering wheel is over 3500 mm in transport position.

The attachments complying with German road traffic regulations and the applicable provisions are listed in the General Certification for Vehicles (Germany) or the data confir- mation (Germany)!

Attachments listed neither in the General Certification for Vehicles (Germany) nor in

the Data confirmation (Germany) require a Separate Certification for Vehicles (Germany) made out by the competent authority!

Get informed on and follow the legal regulations of your country.

Attachments with authorised material densities

Introduction

Description of attachment

Standard bucket (normal material)

Standard bucket (lightweight material)

Standard bucket (superlightweight material)

Wheel loader

351-01

Part no.

(model)

1000102344 1000160648

1000096388

351-02

1000137538

1000110166 1000110167

351-03

1000154547

351-01 1000137538

351-02 1000096393

351-03 1000096394

351-01 1000096394

351-02 1000096397

351-03 1000187889

1, 2

Dimensions

mm (in)

1750 (68.90)

with teeth 1750 (68.90) without teeth

1850 (72.83)

with teeth

1850 (72.83) without teeth

1750 (68.90)

with teeth 1750 (68.90) without teeth

1950 (76.77)

with teeth

1950 (76.77) without teeth

1850 (72.83) without teeth

2050 (80.70) without teeth

2150 (84.64) without teeth

2300 (90.55) without teeth

ISO 7546 capacity

struck/heaped m³

0,55/0,65

0,65/0,75

0,55/0,65

0,75/0,851000245973

0,9/1,1

1,1/1,3

Use

Loosening, picking up, transporting and loading loose or solid material (material density ≤ p = 1.8 t/m³)

Picking up, transporting and loading very lightweight material (material density ≤ p = 1,3 t/m³)

Picking up, transporting and loading lightweight material (material density ≤ p = 0,9 t/m³)

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b110.fm 1-5

Introduction

Description of attachment

Multipurpose bucket

Side swing bucket

Verge grading bucket

High-tilt bucket

3, 4

Heavy duty bucket with hydraulic clamp

3, 4

Heavy duty forks with hydraulic clamp (silage

3, 4

fork)

Manure forks with grab

Pallet forks

3, 4

Pallet forks with foldable fork arms

3, 5

Pallet forks (hydraulic lateral displace-

3, 4

ment)

Pallet forks, floating fork arms3,

Wheel loader

Part no.

(model)

Dimensions

mm (in)

ISO 7546 capacity

struck/heaped m³

1750 (68.90)

351-01

1000187786 1000187787

with teeth

1750 (68.90)

0,55/0,65

without teeth

1850 (72.83)

351-02

1000187296 1000187297

with teeth

1850 (72.83)

0,65/0,75

without teeth

1950 (76.77)

351-03

1000236118 1000236120

with teeth

1950 (76.77)

0,75/0,85

without teeth

351-01 1000175757

351-02

1000176121

351-03

1744 (68.66) without teeth

1844 (72.60) without teeth

0,45/0,55

0,6/0,7

351-03 1000111078 Without teeth –

351-01

351-02

1000156433 1000154475

1850 (72.83) without teeth

–

351-03

351-01 1000111090 1850 (72.83) 0,6/0,7

351-02 1000111053 2050 (80.70)

–

351-03 1000100611 1850 (72.83)

351-01 351-02

1000128262 1800 (70.86) –

1000178474 1800 (70.86) –

351-01

351-02

1000237357 1000237358

1000 (39.37) 1200 (47.24)

–

351-03

351-01 351-02

1000237336 1200 (47.24) –

351-03

351-01 351-02 351-03

1000247565 1200 (47.24)

–

351-03 1000182585 1500 (60.00)

351-01 351-02

1000177240 1000 (39.37)

–

351-03 1000178334 1200 (47.24)

Use

Grading, removing and scraping vegetation, for example; picking up and evenly spreading material; grabbing bulky material; loading trucks (material density ≤ p = 1,8 t/m³)

Standard bucket, however with benefits for filling and backfilling material (material density ≤ p = 1,8 t/m³)

For stripping and picking up verge material

As standard bucket, however with a 80 – 100 cm higher dump height (material density ≤ p = 1,3 t/m³)

Picking up and transporting e.g. bulky recycling material (material density ≤ p = 1,3 t/m³)

Picking up and transporting e.g. bulky and fibrous r ecycling material (e.g. grass, manure, brushwood; material density ≤ p = 1,3 t/m³)

Picking up and transporting e.g. grass, manure, brushwood and straw

Picking up and transporting pallets

1-6 BA 35101/0 2/03 E N – Edition 1.0 * 35101_02 _03b110.f m

Introduction

Description of attachment

Wheel

loader

Part no.

(model)

Dimensions

mm (in)

ISO 7546 capacity

struck/heaped m³

Use

351-01

Material pusher

351-02 351-03

1000050660 3000 (118.11) –

For moving loose bulk material

351-03 1000100759 4000 (157.48) –

Tree replanter

351-02

1000100840 – –

351-03

351-01

Front scarifier

351-02

1000100841 – –

351-03

Round bale clamp

3, 4

351-02

1000177701

351-03

351-01

Rotary broom

Snow plough3, 6,

1. With screw ed-on blade

2. When dr iving on p ublic roads (F ederal R epublic of Ger many), a dditiona l cl earance l ights (or der no. 1000185392 ) with re flectors must be installed on the left and right of th e cab. Get informe d on and follow the legal regulations of your country.

3. See the Operator's Manual of the attachment for putting the attachment into operation and using it

4. Not auth orised for us e on public ro ads (Feder al Repu blic of G ermany)

5. Fork arms mus t be fold ed up whe n drivin g on publ ic roads (Federal Rep ublic of Germany)

6. Get informed on the l egal regulation s of you r countr y whi ch may r equire s pecific p ermits, c ertifications , registr ations etc. f or use on public roads!

7. Only in conne ction wi th rotati ng beacon orde r no. 10 00133985

For more inform ation on attachme nts, see:

Merkblatt für Anb augeräte (leafl et with spec ific inst ruct ions for atta chments) §30 Abs. 10/11/1 2 StVZO ( Federal Republic of Germany) Merkblatt für angeh ängte lan d- oder forstwi rtschaft liche Ar beitsgeräte (l eaflet wi th specific instructi ons for hi tching ag ricultura l or forestry equip ment onto the machine accor ding to German legislation)

3, 6

351-01 351-02

1000139717 – Sidewalk and street cleaning

1000142915 – Winter service

800 – 1800

(31.49 – 70.86)

–

Digging and transporting nursery trees

Scarifying dense soil, loosening humus soil

Picking up and transporting silage, straw and hay bales

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Introduction

Danger!

1.8 Legal regulations regarding wheel loader operation

General safety instructions

Transporting accompanying persons in the cab, on the wheel loader or in/on the attachments is not allowed!

Before leaving the seat, also apply the parking brake and stop the diesel engine!

Driving or operating the wheel loader outside the operator's compartment is not allowed!

☞ Put the wheel loader into service only when seated on the seat

Driving licence

Wheel loaders may be driven on public roads only if the driver has a driving licence for the machine, as defined by national traffic regulations.

German traffic regulations require one of the following driving licences for driving the wheel loader:

Driving licence category L (new, European Union)

• Self-propelled work machines up to 25 kph

• Tractors and agricultural or forestry machinery up to 32 kph (with trailer 25 kph)

Driving licence category C (new, European Union)

• Motor vehicles with over 3500 kg gross weight rating (with trailers up to 750 kg) Driving licence category C1 (new, European Union)

• Motor vehicles between 3500 and 7500 kg gross weight rating (with trailers up to 750 kg)

Driving licence category CE (new, European Union)

• Motor vehicles with over 3500 kg gross weight rating (with trailers over 750 kg)

Driving licence category T (new, European Union)

• Self-propelled work machines for agriculture and forestry up to 40 kph

• Tractors and agricultural or forestry machinery up to 60 kph

Get informed on and follow the legal regulations of your country.

Licence/identification

§ 3 FZV (German vehicle licensing ordinance) requires self-propelled work machines

with maximum speeds over 20 kph to be fitted with their own ein numberplates in accord- ance with §8 FZV (German vehicle licensing ordinance).

§ 4b of FZV (German vehicle licensing ordinance) requires owners of self-propelled

work machines with maximum speeds below 20 kph to affix their first name, surname and place of residence (company and registered office) in indelible print on the left-hand side of their machines.

Get informed on and follow the legal regulations of your country.

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Machine inspections

Fig. 1: Inspection tag

Introduction

When operating the machines, the national safety regulations must be followed as well, for instance in Germany, the regulations for accident prevention “Deutsche Prüfstelle für Land- und Forsttechnik” (DPLF German inspection and certification body for agriculture and forestry) and the accident prevention regulation “Fahrzeuge (vehicles)” (BGV D29 § 57 clause 1).

In Germany, legislation requires all machine operators to have all machines and equipment inspected regularly.

Inspections must be carried out as required, but at least once a year, by an expert and must be documented in written form. Subsequent inspections of detected defects must be carried out, too.

The competent inspection authority may require the inspection report to be available at the place where the machine is used.

☞ Fasten inspection tag A for evidence

➥ The inspection tag can be acquired from the inspection authorities

Bear in mind that all work equipment is inspected, i.e. not only the machine but also all technical auxiliary means, tools and attachments. (Work equipment is defined as all tools, attachments, machines or systems.)

This requirement is met, for instance, if the results are documented in a test logbook, a test log file or in a test report; see also policy of German employers' liability insurance association for construction engineering “Inspection of vehicles by experts” (BGG 916)

Get informed on and follow the legal regulations of your country.

Documents

German traffic regulations require to have the following documentation on board, e.g.:

• General Certification for Vehicles (Germany) or data confirmation (Germany)

• Driving licence

• Test report according to BGV D29 § 57 clause 2 (safety and health regulations of German employer's liability insurance association)

• Operator's Manual

Get informed on and follow the legal regulations of your country.

On-board equipment

§ 53 StVZO (German road traffic regulations) requires the following equipment to be sup-

plied by the operator and to be fitted on the machine, for instance:

• 1 warning triangle with design certification

• 1 warning light with design certification

• 1 first-aid kit in accordance with the legal regulations of your country

Get informed on and follow the legal regulations of your country.

Machine warning identification (option)

From 01.10.1998 onwards, § 52 clause 4.1 of StVZO German road traffic regulations require wheel loaders that are used on public roads for the construction and maintenance of roads, and for the cleaning of roads or facilities, to be fitted with the red and white warning identification as per DIN 30 710 in connection with a yellow rotating beacon (option).

Get informed on and follow the legal regulations of your country.

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b110.fm 1-9

Introduction

Fig. 2: S erial nu mber, type label

6 7 8 9

1 2 3 4 5

Fig. 3: C ab type lab el

Fig. 4: Diesel engine type label

1.9 Type labels and component numbers

Serial number

The serial number is stamped on the machine frame A (next to the axle attachment, on the right in driving direction). It is also located on type label B on the machine frame at the front right (on the side of the loader unit bulkhead).

The CE mark C on the type label means that the machine meets the requirements of the Machine Directive (2006/42 EC) and that the conformity procedure has been carried out.

Type label indications (example)

Machine model

Version

Serial no.

Year of construction

Output (kW)

Front gross axle weight rating (kg)

Rear gross axle weight rating (kg)

Gross weight rating (kg)

Dead weight (kg)

Maximum payload (kg)

351

351-01

351 01 0055

2010

4000

6500

–

Cab number

Engine number

Other information – see chapter 6 “Specifications” on page 6-1

The type label (arrow) is located in the cab, at the top right in driving direction.

The type label (arrow) is located on the cylinder-head cover (engine).

Example: Deutz D 2011 L04 W

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Variable displacement pump number

Fig. 5: H ydraulic pump type label Fig. 6: H ydraulic moto r type label

Fig. 7: R ear axle and gearbo x type lab el Fig. 8: Front axle type label

The type label (arrow) is located on the hydraulic pump housing (next to where the pump is installed on the diesel engine)

Variable displacement motor number

The type label (arrow) is located on the hydraulic motor, on the right in driving direction.

Introduction

Rear axle number

Front axle number

The type label (arrow) is located on the upper side of the differential housing, at the rear.

The type label (arrow) is located on the upper side of the differential housing, at the front.

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b110.fm 1-11

Introduction

Fig. 9: Cab eye hook label

Fig. 10: Lab el for loading a nd tyin g down the machine

A B

Fig. 11: Noi se level label

Fig. 12: Spe ed label

4030

Fig. 13: Dang er label

1.10 Description of labels and symbols

Labels on the outside of the machine

Cab eye hook label

The eye hooks on the cab are for removing the cab only and may not be used for crane handling the machine – see chapter 3 “Crane handling the machine” on page 3-59 for further details.

Location

Cab roof (4x).

Label for loading and tying down the machine

Eye hooks for tying down the machine B during transport, and eye hooks A for lo ading the machine.

➥ – see chapter 3 “Crane handling the machine” on page 3-59 ➥ – see chapter 3 “Loading and transporting the machine on a transport vehicle” on

page 3-60

Location

On left and right of machine frame above the front axle attachment and at the rear under the machine.

Noise level label

Noise levels produced by the machine.

➥ L

= sound power level – see chapter 6 “Noise levels” on page 6-12

Location

On the rear window.

Label: maximum design-specific speed

Design-specific max. machine speed 20 kph (30/40 kph option)

Location

At the rear of the machine and on the left/right of the counterweight.

Label: general indication of danger

This label warns persons standing or working near the machine of an existing danger within the area of increased danger around the machine.

Location

Front left and right of loader unit, and at rear of machine.

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Introduction

Fig. 14: Explanation of “Book” symbol

Fig. 15: Proh ibitive label: turning pa rts Fig. 16: Label: fuel filler opening

Explanation of “Book” symbol The “Book” symbol on a label means that the indications are explained in further detail in

the Operator's Manual.

Location

On labels.

Label: Danger of shearing!

Caution! Do not touch any moving or turning parts! Carry out inspections and maintenance work only at engine standstill!

Location

In the area of the engine cooling (V-belt guard)

Label: fuel filler opening.

Use only the diesel fuels indicated.

• DIN EN 590 (EU)/ASTM D975-94 (USA)/EN 14214 (biodiesel)

• Do not use diesel fuel with additives

If other fuels are used, warranty rights shall not apply in case of diesel engine damage (guarantee)!

Location

Near the filler inlet of the fuel tank (left-hand side of machine)

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b110.fm 1-13

Introduction

Important!

Fig. 17: Loa d diagram

Fig. 18: Con trol lever la bel

Labels inside the cab

Label: load diagram (A) for pallet forks and tyre pressure table

The framed weight indications state the maximum authorised load on the fork arms for industrial and offroad applications.

The maximum load varies according to the distance between the load centre and the rear end of the pallet forks.

Example on how to read the load diagram – see chapter 3 “Load diagram for pallet forks” on page 3-89

The load diagram is valid only for applications with pallet forks!

• –seeAttachments with authorised material densities on page 1-5.

Observe the specific loads of other attachments used, e.g. rotary crane jib.

Label (B): tyre pressure table

List of authorised types of tyres with prescribed tyre inflation pressures.

➥– see chapter 6 “Tyres” on page 6-11

Location

Inside the cab, on left side of front window

Label: control lever (joystick) operation

• A = driving direction: (F) forwards (R) reverse and (N) neutral position

• B = additional control circuit with additional functions (option)

• C = automatic bucket repositioning (option) or front socket power supply

• D = locking/unlocking an attachment fitted on the quickhitch

• E = differential lock

• F = 4th control circuit (option)

• G = loader unit control pattern: raise/lower and dump in/out (optional float position)

Location

On the right-hand side window next to the control lever (joystick)

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Introduction

Fig. 19: Brake fluid label

Fig. 20: Operator 's Manual label Fig. 21: Lab el: seat , fasteni ng the se at belt

Fig. 22: Lab el: read and underst and the s ervice manual

Brake fluid label A = Caution! Do not fill in any water! B = Use only LHM brake fluids!

• – see chapter 5 “Maintenance of the brake system” on page 5-23

• – see chapter 5 “Fluids and lubricants” on page 5-43

Location

On the trim next to the brake-fluid tank (left-hand side cab access)

Operator's Manual label Caution! Read and understand this Operator's Manual before putting the machine into

operation, and before servicing or repairing it.

Location

On the right-hand side member inside the cab

Label: seat belt and machine stability

• Operate the machine only from the seat.

• Fasten the seat before operating the machine.

• Ensure machine stability.

• Read and understand the Operator's Manual

Location

On the right-hand side member inside the cab

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b110.fm 1-15

Label: Remove the ignition key! Caution! Remove the ignition key before working on the machine.

• Read and understand the service manual

Location

On the right-hand side member inside the cab

Introduction

Fig. 23: Proh ibitive label: no transp ort of pe rson s

Fig. 24: Proh ibitive label: no other perso ns allowed

Fig. 25: Labe l: load hoo k diagram (option)

N = 1900kgN = 1400kg

1000149082

346-01

Fig. 26: Lab el for air con ditioning system refi ll (option)

Label: No transport of persons! Warning! Lifting or transporting persons on the wheel loader, in the bucket or on the pallet

forks is prohibited.

Location

Inside the cab, on right side of front window.

. Label: No other persons allowed in the cab!

Warning! Carrying or transporting accompanying persons in the cab or on the wheel loader is not allowed!

Location

In the cab (near the tool kit)

Label: load hook diagram (option) Example: Maximum load capacity

• A Extended loader unit and quickhitch tilted in

➥Max N => 2200 kg

• B Extended loader unit and quickhitch

➥Max N => 1700 kg

Location

Inside the cab, on left side of front window

Label for air conditioning system refill (option)

Use only the refrigerants R 134a indicated on the label (see arrow) for refilling the air conditioning system.

Location

Inside the cab

1-16 BA 35101/0 2/03 E N – Edition 1.0 * 35101_02 _03b110.f m

Labels in the engine compartment

Fig. 27: Lab el: hot fluid ( coolant)

Fig. 28: Lab el: hot s urface

Fig. 29: L abel: fil ler opening for hyd raulic oil

A B

Introduction

Label: Container under pressure, danger of burns!

The container is hot and under pressure. Do not open the container as long as it is still hot. Open the container only after the coolant has cooled down Open the cover carefully and slowly to allow the pressure to escape.

Location

In the engine compartment next to the expansion tank (coolant)

Label: Danger of burns! Caution! Do not touch.

Location

On the rear wall of the engine compartment, on the left next to the exhaust silencer and the filler inlet (hydraulic oil tank).

Label: filler opening for hydraulic oil A = hydraulic oil or B = biodegradable hydraulic oil

➥ – see chapter 5 “Important information for the use of biodegradable oil” on

page 5-17

Location

On the rear wall of the engine compartment, on the left next to the filler inlet (hydraulic oil tank)

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b110.fm 1-17

Introduction

Notes:

1-18 BA 35101/0 2/03 E N – Edition 1.0 * 35101_02 _03b110.f m

Danger!

Caution! Important!

Environment!

Safe ty inst ructions

2 Safety instructions

2.1 Identification of warnings and dangers

Important indications regarding the safety of the staff and the machine are identified in this Operator's Manual with the following terms and symbols:

Failure to observe the instructions identified by this symbol can result in personal injury or death for the operator or other persons.

☞ Measures for avoiding danger to life and limb of the

operator or other people

Failure to observe the instructions identified by this symbol can result in damage to the machine.

☞ Measures for avoiding danger for the machine

Safety instructions

This symbol identifies instructions for a more efficient and economical use of the machine.

Failure to observe the instructions identified by this symbol can result in damage to the environment. The environment is in danger if environmentally hazardous material (e.g. waste oil) is not subject to proper use or disposal.

BA 35101/02/ 03 EN – Edition 1.0 * Sic herhei t_Radlader.fm 2-1

Safety instructions

2.2 Designated use and exemption from liability

• Carrying or transporting accompanying persons in the cab or on the wheel loader is not allowed! Carrying or transporting persons in the attachments (e.g. bucket, pallet forks) is not allowed either!

• The machine may not be used for transport jobs on public roads!

• Fire hazard due to hot engine silencer – the machine may not be used in areas posing a fire hazard (hay or straw storage facilities, etc.) !

• The machine is intended for:

• moving earth, gravel, coarse gravel or ballast and rubble, and for applications with

the attachments listed in chapter Introduction “Fields of application and using a wheel

loader with an attachment” on page 1-5!

• Every other application is regarded as not designated for the use of the machine. The manufacturer will not be liable for damage resulting from use other than mentioned above. The user alone will bear the risk. Designated use also includes observing the instructions in the Operator's Manual and observing the conditions of maintenance and service!

• Observe the pertinent regulations relevant to accident prevention, other generally acknowledged regulations regarding safety and occupational medicine, as well as the regulations and standards relevant to motor vehicles and traffic which are valid in your country. Get informed on and follow the legal regulations of your country. The manufacturer shall not be liable for damage resulting from the failure to observe these regulations!

• The safety of the machine can be negatively affected by carrying out machine modifications without proper authority and by using spare parts, equipment, attachments and optional equipment which have not been checked and released by the manufacturer. The manufacturer will not be liable for damage resulting from this!

• The manufacturer shall not be liable for personal injury and/or damage to property caused by failure to observe the safety instructions and the Operator's Manual, and by the negligence of the duty to exercise due care when:

• handling

• operating

• servicing and carrying out maintenance work and

• repairing the machine. This is also applicable in those cases in which special

attention has not been drawn to the duty to exercise due care, in the safety instructions as well as in the operation and maintenance manuals (machine/engine).

• Read and understand the Operator's Manual before starting up, servicing or repairing the machine. Observe the safety instructions!

• In applications with lifting gear, the machine is used according to its designated use only if the prescribed devices are installed and functional!

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2.3 General conduct and safety instructions

Organisational measures

• The machine has been designed and built in accordance with state-of-the-art standards and the recognised safety regulations. Nevertheless, its use can constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material property!

• The machine must only be used in technically perfect condition in accordance with its designated use and the instructions set forth in the Operator's Manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine. Immediately rectify any functional disorders, especially those affecting the safety of the attachment!

Basic rule:

Before starting up the machine, inspect the machine for safety in work and road operation!

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

• The Operator's Manual must always be at hand at the place of use of the machine, and must therefore be kept in the storage compartment provided for in the cab. Immediately complete or replace an incomplete or illegible Operator's Manual!

• In addition to the Operator's Manual, observe and instruct the operator in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection. These compulsory regulations may also deal with handling hazardous substances, issuing and/or wearing personal protective equipment, or traffic regulations!

• With regard to specific operational features, e.g. those relevant to job organisation, work sequences or the persons entrusted with the work, supplement the Operator's Manual by corresponding instructions, including those relevant to supervising and reporting duties!

• Persons entrusted with work on the machine must have read and understood the Operator's Manual and in particular, chapter “Safety Instructions” before beginning work. This applies especially to persons working only occasionally on the machine, e.g. set-up or maintenance!

• The user/owner must check – at least from time to time – whether the persons entrusted with operation or maintenance of the machine are working in compliance with the Operator's Manual and are aware of risks and safety factors!

• The user/owner commits himself to operate and keep the machine in a perfect condition, and, if necessary or required by law, to require the operating or servicing persons to wear protective clothing etc.

• In the event of safety-relevant modifications or changes on the machine or of its behaviour, stop the machine immediately and report the malfunction to the competent authority/person. Safety-relevant damage or malfunctions of the machine must be rectified immediately!

Safety instructions

BA 35101/02/ 03 EN – Edition 1.0 * Sic herhei t_Radlader.fm 2-3

Safety instructions

• Never make any modifications, additions or conversions to the machine and its superstructures (e.g. cab, loader unit etc.), as well as to the attachments, which might affect safety without the approval of the manufacturer! This also applies to the installation and the adjustment of safety devices and valves, as well as to welding work on load-bearing elements!

• Spare parts must comply with the technical requirements specified by the manufacturer. Original spare parts can be relied to do so!

• Replace hydraulic hoses within stipulated and appropriate intervals even if no safetyrelevant defects have been detected!

• Before working on or with the machine, remove jewellery, such as rings, wristwatches, bracelets etc., and tie back long hair and do not wear loose-fitting garments, such as unbuttoned or unzipped jackets, ties or scarves. Injury can result from being caught up in the machinery or from rings catching on moving parts!

• Keep the machine clean. This reduces

• Fire hazard, e.g. due to oil-soaked rags lying around

• Danger of injury, e.g. due to dirt or debris on the footholds, and

• Danger of accident e.g. due to dirt or debris on the brake or accelerator pedal!

• Observe all safety, warning and information signs and labels on the machine!

• Adhere to prescribed intervals or those specified in the Operator's Manual for routine checks/inspections and maintenance work!

• Tools and workshop equipment adapted to the task on hand are absolutely indispensable for carrying out service, inspection, maintenance or repair work!

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Selection and qualification of staff, basic responsibilities

• Any work on or with the machine must be carried out by reliable staff only. Do not let unauthorised persons drive or work with the machine! Observe statutory minimum age limits!

• Employ only trained or instructed staff on the machine, and clearly and unequivocally define the individual responsibilities of the staff for operation, set-up, maintenance and repair!

• Define the machine operator's responsibilities – also with regard to observing traffic regulations. Give the operator the authority to refuse instructions by third parties that are contrary to safety!

• Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person!

• Work on the electrical system and equipment, on the chassis and the steering and brake systems must be carried out only by technical staff which has been specially trained for such work. Work on the hydraulic system of the machine must be carried out only by staff with special knowledge and experience in hydraulic systems!

• Seal off the danger area should it not be possible to keep a safe distance.

• Stop work if persons do not leave the danger area in spite of warning! Keep out of the danger area!

Danger area:

The danger area is the area in which persons are in danger due to the movements of the

• Machine

• work equipment

• other equipment or load!

• This also includes the area affected by falling material, equipment or by parts which

are thrown out.

• The danger area must be extended accordingly in the immediate vicinity of buildings,

scaffolds or other elements of construction!

Safety instructions

BA 35101/02/ 03 EN – Edition 1.0 * Sic herhei t_Radlader.fm 2-5

Safety instructions

2.4 Safety instructions regarding operation

Normal operation

• Avoid any operational mode that might be prejudicial to safety!

• Before beginning work, familiarise yourself with the surroundings and circumstances of the work site. These are e.g. obstacles in the working and travelling area, the loadbearing capacity of the ground and any necessary barriers separating the work site from public roads!

• Take the necessary precautions to make sure the machine is used only when in a safe and reliable state! Operate the machine only if all protective and safety-oriented devices, e.g. removable safety-devices, soundproofing elements and exhausters etc., are in place and fully functional!

• Check the machine at least once a day/per work shift for visible damage and defects. Report any changes (incl. changes in the machine's working behaviour) to the competent organisation/person immediately! If necessary, stop the machine immediately and lock it!

• In the event of malfunctions, stop the machine immediately and lock it! Have any defects rectified immediately!

• Start and operate the machine from the seat only!

• Before leaving the seat, apply the parking brake and stop the diesel engine!

• Carry out start-up and shut-down procedures in accordance with the Operator's Manual, and observe the telltales!

• Before putting the machine/attachment into operation (start-up/moving), make sure nobody is at risk by putting the machine/attachment into operation!

• Before driving with the machine, and also after interrupting work, check whether the brakes, the steering, signalling and light systems are functional!

• Before moving the machine always check whether the supplementary equipment and the attachments have been safely stowed away or attached!

• When driving on public roads, ways and places, observe the valid traffic regulations and, if necessary, make sure beforehand that the machine is in a condition perfectly compatible with these regulations!

• Always switch on the lights in conditions of poor visibility and after dark!

• No raising, lowering or carrying persons in the work equipment/attachments!

• Installing a man basket or a working platform is prohibited! (Always contact Kramer-Werke GmbH for installation!)

• When crossing underpasses, bridges and tunnels, or when passing under overhead lines always make sure there is enough clearance!

• Always keep at a safe distance from the edges of building pits and slopes!

• When working in buildings or in enclosed areas, look out for:

• Height of the ceiling/clearances

• Width of entrances

• Maximum load of ceilings and floors

• Sufficient room ventilation – danger of poisoning!

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Safety instructions

• Avoid any operation that might be a risk to machine stability!

• During operation on slopes, drive or work uphill or downhill. If driving across a slope cannot be avoided, bear in mind the tilting limit of the machine! Always keep the attachments/work equipment close to the ground. This also applies to driving downhill! When driving or working across a slope, the load must be on the uphill side of the machine!

• On sloping terrain always adapt your drive speed to the prevailing ground conditions! Never change to lower gear on a slope but always before reaching it!

• Before leaving the seat always secure the machine against unintentional movement and unauthorised use! Lower the work equipment/attachments to the ground

• Before starting work check whether:

• all safety devices are properly installed and functional

• and an approved warning triangle, hazard warning light and first aid kit are at hand!

• Before moving the machine or before taking up work:

• Make sure visibility is sufficient (do not forget rearview mirrors!)

• Adjust correct seat position (you must be able to press the brake pedal as far as it will

go). Never adjust the seat when driving or working!

• Fasten your seat belt

• Inspect the immediate area (children!)

In the work area the operator is responsible for third parties!

• Caution when handling fuel – increased danger of fire! Make sure fuel does not come into contact with hot parts! Do not smoke during refuelling, and avoid fire and sparks! Stop the engine during refuelling and do not smoke!

• Never get on or off a moving machine! Never jump off the machine!

• Should the lights of the machine not be sufficient for carrying out work safely, provide additional lighting of the work area!

• Installed work lights must not be switched on for travel on public roads. They can be switched on in work operation if users of public roads are not dazzled!

• Hydrostatic 4 wheel steering takes time getting used to it. Therefore, adjust the drive speed to your abilities and the circumstances. Selection and change of steering mode at machine standstill only!

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Safety instructions

Applications with lifting gear

Definition:

Applications with lifting gear are understood as procedures involving raising, transporting and lowering loads with the help of slings and load-securing devices (e.g. ropes, chains). In doing so, the help of persons is necessary for securing and detaching the load. This applies for example to raising and lowering pipes, shaft rings or containers!

• The machine may be used for applications with lifting gear only if the prescribed safety devices are in place and functional. These are e.g.:

• Safe possibilities of slinging and securing lifting gear (load hook)

• Load diagram!

• The load must be secured so as to prevent it from falling or slipping!

• Persons guiding the load or securing it must stay in visual contact with the machine operator!

• The machine operator must guide the load the nearest possible to the ground and avoid any oscillating or swinging movements!

• The machine may be moved with a raised load only if the path of the machine is as level as possible!

• The persons attaching or securing loads may approach the boom from the side only, and only after the machine operator has given his permission. The machine operator may give his permission only after the machine is at a standstill and the work attachment no longer moves!

• Do not use any lifting gear (ropes, chains) which is damaged or not sufficiently dimensioned. Always wear protective gloves when working with lifting gear!

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Trailers and attachments

Safety instructions

• Prior to driving on public roads remove all attachments which cannot be secured in compliance with the legal regulations of your country!

• Get informed on the legal regulations of your country which deal with the use and applications of trailers towed by the machine!

• Trailer operation with the towing device of the machine is not permitted!

• Attachments and counterweights affect handling, as well as the steering and brake capability of the machine!

• Fit the attachments with the specially required devices only!

• Before uncoupling or coupling hydraulic lines (hydraulic quick couplers):

• Stop the engine

• Release the pressure in the hydraulic system. In order to do so, move the control

levers of the hydraulic control units back and forth a couple of times!

• Coupling attachments requires special care!

• Secure the attachments against unintentional movement!

• Operate the machine only if all protective facilities have been installed and are functional, and if all brake, light and hydraulic connections have been connected!

• If optional equipment is installed, all additionally required light installations, telltales etc., must be provided for and functional!

• Mount the attachments only if the engine and the drive have been switched off!

• Especially when driving or working with machines equipped with a quickhitch for the attachments, make sure the attachment is safely locked in the quickhitch. The lock pin must be visible on either side of the bores on the attachment. Check before starting work!

• Prior to fitting attachments to the loader unit, secure the control lever of the hydraulic control unit against unintentional movement!

• Be careful when coupling attachments to the loader unit: danger of personal injury due to crushing and shearing. Make sure nobody is between the machine and the attachment without securing the machine and the attachment against movement!

Transporting, towing, loading

• The machine must be towed, loaded and transported only in accordance with the Operator's Manual!

• For towing the machine observe the prescribed transport position, admissible speed and itinerary!

• Use only suitable means of transport and lifting gear of adequate capacity/payload!

• Safely secure the machine on means of transport! Use suitable slinging points and load-securing devices!

• The recommissioning procedure must be strictly in accordance with the Operator's Manual!

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Safety instructions

2.5 Safety instructions for maintenance

• Avoid any operational mode that might be prejudicial to safety!

• Observe the adjustment, maintenance and inspection activities and intervals set forth in the Operator's Manual, including information on the replacement of parts/partial equipment! These activities may be carried out by technical staff only!

• The machine may not be serviced, repaired or test-driven by unauthorised staff!

• Brief operating staff before beginning special operations and maintenance work! Appoint a person to supervise the activities!

• In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices, or any work related to maintenance, inspection and repair, observe the start-up and shut-down procedures set forth in the Operator's Manual, and the information on maintenance work

• If required, secure the maintenance area appropriately!

• Prior to carrying out service, maintenance and repair work, attach a warning label, such as “Repair work – do not start machine!”, to the ignition lock/steering wheel or to the control elements. Remove the ignition key!

• Carry out service, maintenance and repair work only if the

• machine is positioned on firm and level ground

• lever for selecting the driving direction is in neutral

• parking brake is applied

• all hydraulically movable attachments and working equipment have been lowered to

the ground

• engine is stopped

• ignition key is removed and the

• machine has been secured against unintentional movement!

• Should maintenance or repair be inevitable with the engine running:

• Only work in groups of two

• Both persons must be authorised for the operation of the machine

• One person must be seated on the seat and maintain visual contact with the other

person

• Observe the specific safety instructions in the work manual

• Keep a safe distance from all rotating and moving parts, e.g. fan blades, V-belt

drives, PTO shaft drives, fans etc.!

• Prior to carrying out assembly work on the machine, make sure no movable parts will roll away or start moving!

• To avoid the risk of accidents, parts and large assemblies being moved for replacement purposes must be carefully attached and secured to lifting gear. Use only suitable lifting gear and suspension systems in a technically perfect state with adequate load-bearing capacity! Stay clear of suspended loads!

• The brake and steering systems are crucial to safety. Maintenance work must be carried out by trained staff and an authorised workshop only!

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Safety instructions

• Have loads fastened and crane operators instructed by experienced persons only! The person giving the instructions to the operator must be within sight or sound of him!

• Always use specially designed or otherwise safety-oriented ladders and working platforms to carry out overhead assembly work. Never use machine parts or attachments/superstructures as a climbing aid! Wear a safety harness when carrying out maintenance work at greater heights! Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice!

• Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair work! Do not use aggressive detergents! Use lint-free cleaning rags!

• Before cleaning the machine with water, steam jet (high-pressure cleaner) or detergents, cover or tape up all openings which – for safety and functional reasons – must be protected against water, steam or detergent penetration. Special care must be taken with the electrical system!

• After cleaning, remove all covers and tapes applied for that purpose!

• After cleaning, examine all fuel, lubricant and hydraulic oil lines for leaks, chafe marks and damage! Rectify all defects without delay!

• Always tighten any screwed connections that have been loosened during maintenance and repair!

• Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work!

• Make sure all consumables and replaced parts are disposed of safely and with minimum environmental impact!

• Do not use the work equipment as lifting platforms for persons!

• Before taking up work on machine parts dangerous for life and limb (bruising, cutting), always ensure safe blocking/support of these areas!

• Carry out maintenance and repair work beneath a raised machine, work equipment/ attachments or additional equipment only if a safe and secure support has been provided for (the sole use of hydraulic rams, jacks etc. does not sufficiently secure raised machines or equipment/attachments)!

• Avoid contact with hot parts, such as the engine block or the exhaust system during the operation of the machine and for some time afterwards – danger of burns!

• Retainer pins can fly out or splinter when struck with force – danger of personal injury!

• Do not use starting fuel! This especially applies to those cases in which a heater plug (intake-air preheating) is used at the same time – danger of explosions!

• Apply special care when working on the fuel system – increased danger of fire!

BA 35101/02/ 03 EN – Edition 1.0 * Sic herhei t_Radlader.fm 2-11

Safety instructions

2.6 Maintenance work on protective ROPS and FOPS structures

Cab, roll-over bar, protective screen

• Straightening and welding work on cabs, roll-over bars and protective screens are prohibited. These structures must be replaced by original spare parts from the manufacturer!

• Drilling holes or modifying protective ROPS/FOPS structures is prohibited!

• Driving or working with the wheel loader without installing the protective ROPS/FOPS structures correctly is prohibited!

2.7 Warning of special hazards

Electric energy

• Use only original fuses with the specified current rating! Switch off the machine immediately and rectify the malfunction if trouble occurs in the electrical system!

• When working with the machine, maintain a safe distance from overhead electric lines! If work must be carried out close to overhead lines, the equipment/attachments must be kept well away from them. Caution, danger! Get informed on the prescribed safety distances!

• If your machine comes into contact with a live wire

• Do not leave the machine

• Drive the machine out of the danger area

• Warn others against approaching and touching the machine

• Have the live wire de-energised

• Do not leave the machine until the line that has been touched or damaged has been

safely de-energised!

• Work on the electrical system may only be carried out by a technician with appropriate training, in accordance with the applicable electrical engineering rules!

• Inspect and check the electric equipment of the machine at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately!

• Observe the operating voltage of the machine/attachments!

• Always remove the earthing strap from the battery when working on the electrical system or when carrying out welding work!

• Starting with a battery jump cable can be dangerous if carried out improperly. Observe the safety instructions regarding the battery!

Gas, dust, steam, smoke

• Operate the machine only on adequately ventilated premises! Before starting internal combustion engines or operating fuel-operated heating systems on enclosed premises, make sure there is sufficient ventilation! Observe the regulations in force at the respective site!

• Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorised. There can be a risk of explosion and fire, for example!

• Before carrying out welding, flame-cutting and grinding work, clean the machine and its surroundings from dust and other inflammable substances, and make sure the premises are adequately ventilated – danger of explosions!

2-12 BA 35101/0 2/03 EN – Edition 1.0 * Sich erheit_Radlader .fm

Hydraulics

• Work on the hydraulic equipment of the machine must be carried out only by persons having special knowledge and experience in hydraulic systems!

• Check all lines, hoses and screwed connections regularly for leaks and obvious damage! Repair any damage and leaks immediately! Splashed oil can cause injury and fire!

• In accordance with the Operator's Manual/instructions for the respective assembly, release the pressure in all system sections and pressure lines (hydraulic system) to be opened before carrying out any implementing/repair work!

• Hydraulic and compressed-air lines must be laid and fitted properly. Make sure no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements!

Noise

• During operation all sound baffles must be closed!

• Wear ear protectors if necessary!

Oil, grease and other chemical substances

• When handling oil, grease and other chemical substances (e.g. battery electrolyte – sulphuric acid), observe the product-related safety regulations (safety data sheet)!

• Be careful when handling hot consumables – risk of burning or scalding!

Safety instructions

Battery

Tyres

• When handling the battery observe the specific safety instructions and regulations relevant to accident prevention. Batteries contain sulphuric acid – caustic!

• Especially when charging batteries, as well as during normal operation of batteries, an oxyhydrogen mixture is formed in the battery cells – danger of explosion!

• In the case of a frozen battery or of an insufficient electrolyte level, do not try start-up with a battery jump cable. The battery can burst or explode!

• Repair work on tyres and rims must be carried out by technical staff or by an authorised workshop only!

• Damaged tyres and/or wrong tyre pressure reduce the operational safety of the machine. Therefore carry out regular checks of the tyres for

• Prescribed tyre pressure and

• Damage!

• Do not inflate tyres with inflammable gas – danger of explosion! Check the wheel nuts once a day for tightness. After changing wheels, retighten the wheel nuts after 10 service hours!

BA 35101/02/ 03 EN – Edition 1.0 * Sic herhei t_Radlader.fm 2-13

Safety instructions

Notes:

2-14 BA 35101/0 2/03 EN – Edition 1.0 * Sich erheit_Radlader .fm

Operation

3 Operation

3.1 Description of control elements

This chapter describes the controls, and contains information on the function and the handling of the telltales and controls in the cab.

The pages stated in the table refer to the description of the controls. A combination of digits, or a combination of digits and letters (e.g. 40/18 or 40/A) used for identifying the control elements, means:

fig. no. 40/control element no. 18 or position A in fig. no. 40 Figures carry no numbers if they are placed to the left of the text.

You can unfold pages (3-2 and/or 3-4) for a better overview.

The symbols used in the description have the following meanings:

• This symbol stands for a list

• Subdivision within lists or an activity. Follow the steps in the recommended sequence

☞ This symbol requires you to carry out the activity described

➥ Description of the effects or results of an activity

n. s. = not shown “Option” = optional equipment Stated whenever controls or other components of the machine are installed as an option.

Cab overview: see overleaf

BA 35101/02 /03 EN – Edition 1.0 * * 35201_02b310.fm 3-1

Operation

3.2 Cab overview

Inside of cab (overview) For more information see page

1 3 4 5238 39 5

4 A

192021222425 1823

1 Sun visor

2 Board – relays and fuses (left) ............................................................................................... ...................................................

3 Front window wiper motor ................................................................................................................................................. 3-49

4 Interior light ....................................................................................................................................................................... 3-44

5 Front working light............................................................................................................................................................. 3-43

6 Board – relays and fuses (right) ................................................................................................................................................

7 Steering column adjustment lever..................................................................................................................................... 3-30

8 Steering electronics

9 Front window air vents (left/right) ..................................................................................................................................... 3-46

10 Lights................................................................................................................................................................................. 3-43

11 Fresh air filter for heating.................................................................................................................................................. 3-46

12 Instrument panel – fresh air, heating (air conditioning option) .......................................................................................... 3-46

13 12 V socket 14 Proportional electronics control valve

15 Control lever (joystick)....................................................................................................................................................... 3-62

16 Accelerator pedal .............................................................................................................................................................. 3-34

17 Fire extinguisher (option) .................................................................................................................................................. 3-14

18 Parking brake lever........................................................................................................................................................... 3-36

19 Preheating start switch...................................................................................................................................................... 3-16

20 Prepared installation for radio (option)

21 Joystick lock (stop cock) for road travel ............................................................................................................................ 3-26

22 Seat belt............................................................................................................................................................................ 3-53

23 Loudspeakers (option)

24 Brake/inching pedal........................................................................................................................................................... 3-35

25 Storage net for Operator's Manual

26 Rear window wiper motor.................................................................................................................................................. 3-49

27 Fixture – first-aid kit

28 Tank – washer system ...................................................................................................................................................... 3-49

29 Storage compartment 30 Tool kit

31 Left/right-hand side door arrester...................................................................................................................................... 3-13

32 Seat................................................................................................................................................................................... 3-50

33 Coolant level sensor amplifier

34 Rear working light ............................................................................................................................................................. 3-43

35 Hook 36 Aerial (option)

37 Rotating beacon (option)................................................................................................................................................... 3-45

38 Brake fluid tank

39 Multifunctional lever – turn indicators, wipers, horn .......................................................................................................... 3-45

Fig. 30: Cab overview

3-2 BA 35101/02 /03 EN – Edition 1.0 * 35201_02b3 10.fm

Operation

Instrument panel overview: see overleaf Instrument panel overview: see overleaf

BA 35101/02 /03 EN – Edition 1.0 * * 35201_02b310.fm 3-3

AIR

bar

DPF

Operation

45 4746

Fig. 33: Indicating instrument overview

Fig. 35: M ultifunctiona l lever

103 104

105

48 49

106

Fig. 31: Rig ht-hand side switch panel

Fig. 34: Swi tch panel for heating

94 95 96 97 98

60 61

70 71

Fig. 32: Left -hand side swi tch pane l

87 88 89

3.3 Instrument panel, multifunctional lever and drive lever (overview)

Indicating instrument console For more information see page

40 Not assigned

41 Hydraulic oil temperature gauge ........................................................................................................................................5-16

42 Telltale (red/yellow/green) – diesel particle filter (option)...................................................................................................5-36

43 Telltale (green) – front socket (option) ...............................................................................................................................3-42

44 Telltale (yellow) – accelerator pedal lock (option)..............................................................................................................3-34

45 Hose burst valve, load stabiliser (option) telltale (yellow) ........................................................................................ 3-40, 3-98

46 Diesel engine temperature telltale (red) ...............................................................................................................................5-5

47 Telltale (green) – not assigned

48 Steering synchronisation telltale (red)................................................................................................................................3-31

49 Telltale (green) – diagonal steering (crab steering option).................................................................................................3-33

50 Telltale (green) – front axle steering ..................................................................................................................................3-32

51 Forwards driving direction telltale (green) ..........................................................................................................................3-38

52 4 wheel steering telltale (green) .........................................................................................................................................3-32

53 Reverse driving direction telltale (green)............................................................................................................................3-38

54 Diesel engine temperature gauge (115 °C ON with acoustic warning/110 °C OFF) ...........................................................5-9

55 Speedometer (high speed option)

Switch console on the right For more information see page

56 Not assigned 57 Switch (grey) – heated rear window, mirror heating (option) 58 Not assigned (reversing fan option) 59 Not assigned

60 Tip switch (blue) – steering synchronisation ......................................................................................................................3-31

61 Switch (grey) – diagonal steering (crab steering option) ....................................................................................................3-33

62 Switch with lock (blue) – 4 wheel/front axle steering..........................................................................................................3-32

63 Speed range selection switch (blue) ..................................................................................................................................3-37

64 Switch (grey) – rear wiper ..................................................................................................................................................3-49

Switch console on the left For more information see page

65 Not assigned – quickhitch lock (option only for telescopic boom)

66 Switch (green) – load stabiliser (option) .............................................................................................................................3-40

67 Switch (grey) – rear working light.......................................................................................................................................3-43

68 Lights switch (grey) ............................................................................................................................................................3-44

69 Hazard warning system switch (red) ..................................................................................................................................3-45

70 Switch (grey) – front working light...................................................................................................................................... 3-44

71 Front socket (option) tip switch (grey)................................................................................................................................3-42

72 Switch (grey) – rotating beacon (option) ............................................................................................................................3-45

73 Not assigned – overload cutoff and emergency lowering (option only for telescopic boom)

107

102

101

100

Fig. 36: Control lever (joystick)

Fig. 37: Rig ht-hand side console (overview)

3-4 B A 35101/02/03 EN – Edition 1.0 * 352 01_02b31 0.fm

Operation

Indicating instrument For more information see page

74 Hour meter

75 Right/left turn indicators telltale (green) for rear attachments ............................................................................................3-45

76 Right/left turn indicators telltale (green) .............................................................................................................................3-45

77 Coolant level telltale (red) ....................................................................................................................................................5-9

78 Hydraulic oil filter telltale (red)............................................................................................................................................5-16

79 Air filter telltale (yellow) ......................................................................................................................................................5-11

80 Alternator charge function telltale (red)..............................................................................................................................5-32

81 Parking brake telltale (red) .................................................................................................................................................3-35

82 Engine oil pressure telltale (red) ..........................................................................................................................................5-5

83 Telltale (red) – 3rd control circuit, continuous operation ....................................................................................................3-64

84 High beam telltale (blue) ....................................................................................................................................................3-44

85 Cold starter telltale (yellow)................................................................................................................................................3-16

86 Tank gauge (fuel)

Heating switch console (optional air conditioning) For more information see page

87 Rotary switch – heater fan .................................................................................................................................................3-46

88 Rotary switch – heating temperature .................................................................................................................................3-46

89 Air conditioning (option) switch (grey) ................................................................................................................................3-48

Multifunctional lever turn indicators, wipers, horn For more information see page

90 Horn tip switch....................................................................................................................................................................3-45

91 Rotary switch and tip switch – front wiper, washer pump ..................................................................................................3-45

Switch console (armrest) For more information see page

92 Tip switch – accelerator pedal lock (option) .......................................................................................................................3-34

93 Crawler gear potentiometer/low-speed control (option) .....................................................................................................3-39

94 Switch with lock (green) – 3rd control circuit lock ..............................................................................................................3-63

95 Switch with lock (green) – continuous operation of 3rd control circuit (option) ..................................................................3-64

96 Switch (green) – front additional control circuit (option) .....................................................................................................3-95

97 Switch (green) – rear additional control circuit (option) ......................................................................................................3-95

98 Tip switch (green) – raise/lower hydraulic tipper (option only for trailer operation) 99 Switch – tilt ram lock (option)

Control lever (joystick) For more information see page

100 Not assigned

101 Switch – unlock/lock 3rd control circuit ..............................................................................................................................3-63

102 Tip switch – driving direction in neutral ..............................................................................................................................3-37

103 Switch – forwards/reverse driving direction........................................................................................................................3-38

104 Tip switch – additional control circuit with additional functions (option) .............................................................................3-95

105 Tip switch – additional control circuit with additional functions (option) .............................................................................3-95

106 Front socket tip switch (option) or bucket repositioning (option) ..............................................................................3-42, 3-94

107 Switch (scroll wheel) – additional control circuit (4th control circuit proportional controls option)......................................3-97

BA 35101/02/ 03 EN – Edition 1.0 * 35201_02b320.fm 3-5

Operation

Caution!

3.4 Functional description: telltales

Telltale check

All telltales come on briefly for a check when the ignition is switched on.

For your own safety and in order to avoid consequential damage to the machine, have defective telltales immediately checked or replaced by an authorised workshop!

Telltales and warning lights on the indicating instrument

Engine oil pressure telltale (red)

Comes on if the engine oil pressure is too low. In this case:

☞ Stop the machine ☞ Stop the engine immediately and check the oil level – see chapter 5 “Checking the

engine oil level” on page 5-5

Coolant level telltale (red)

Danger of engine breakdown if the telltale comes on with the engine running!

☞ Stop engine immediately ☞ Check the coolant level – see chapter 5 “Checking the coolant level” on

page 5-9

Alternator charge function telltale (red)

The telltale comes on when the ignition is turned on and goes out as soon as the engine runs.

The V-belt or the charging circuit of the alternator is faulty if the telltale comes on with the engine running. The battery is no longer charged.

Right/left turn indicators telltale (green)

Flashes intermittently when the turn indicators are used

Right/left turn indicators telltale (green) on rear attachment

Flashes intermittently when the turn indicators are used and a front or rear attachment is connected electrically.

High beam telltale (blue)

Comes on if high beam is switched on, or during headlight flashing.

3-6 BA 35101/ 02/03 EN – Edition 1.0 * 35201_02b320.f m

Operation

41 42 43

Parking brake telltale (red)

Comes on when the parking brake is applied. The electric driving interlock prevents starting the engine with the parking brake applied.

Hydraulic oil filter telltale (red)

Indicates inadmissibly high pressure in the hydraulic reflux line to the tank. In this case:

☞ Have the hydraulic oil reflux filter checked and, if necessary, replaced by an authorised

workshop

Air filter telltale (yellow)

☞ Indicates air filter contamination.

Telltale (red) – continuous operation of 3rd control circuit (hydraulics)

Comes on during operation of an attachment with its own hydraulic circuit (e.g. rotary broom with hydraulic motor).

Telltale (yellow) – preheating time lag relay

Comes on when the key in preheating start switch is in position 1.

➥ A glow plug preheats the intake air of the diesel engine during this time.

Telltales and indicators on the instrument panel

Temperature gauge with acoustic warning – engine (coolant)

Indicates the engine temperature detected by a sensor. Engine temperature should be between 80 and 105 °C.

• Max. admissible temperature is 110 °C.

• The acoustic warning sounds from 115 °C

• – see chapter 5 “General instructions regarding cooling system maintenance” on page 5-7

Hydraulic oil temperature gauge

Indicates the hydraulic oil temperature detected by a sensor.

• – see chapter 5 “Monitoring the hydraulic oil and the reflux filter” on page 5-15

Telltale (red/yellow/green) – diesel particle filter (option)

The LED indicates the status in the exhaust gas particulate filter system.

➥ – see chapter 5 “Checking the electronic filter monitoring” on page 5-38

Telltale (green) – front socket (option)

The LED indicates whether electrically operated attachments are connected.

Telltale (yellow) – accelerator pedal lock (option)

Indicates that the accelerator pedal lock is switched on (manual throttle).

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Operation

46 47

53 51

Telltale (yellow) – hose burst valve/load stabiliser (option)

Indicates that the load stabiliser is switched on, and that the hose burst valve is disabled.

➥ –seeLoad stabiliser (option) on page 3-40 and “Hose burst valve” safety feature

(option) on page 3-98

Telltale (red) – hydraulic oil temperature

Indicates that the temperature in the hydraulic system is too high.

➥ – see chapter 5 “Monitoring the hydraulic oil and the reflux filter” on page 5-15

Telltale (green) – differential lock

Indicates that the differential lock is switched on

Telltale (red) – steering synchronisation

Indicates that the wheels on both axles are aligned.

Telltale (green) – diagonal steering (crab steering option)

Indicates that diagonal steering is switched on

Telltale (green) – front axle steering (option)

Indicates that front axle steering is switched on

4 wheel steering telltale (green)

Indicates that 4 wheel steering is switched on

Telltale (green) – driving direction

Indicates forwards or reverse driving direction

3-8 BA 35101/ 02/03 EN – Edition 1.0 * 35201_02b320.f m

3.5 Putting the wheel loader into service

Safety instructions regarding commissioning

• Only use the steps and handles when entering and leaving the cab

• Face the machine as you enter and leave it

• Never use the controls or movable lines and cables as handles

• Keep the footholds and the handles clean to ensure a safe hold at all times

• Immediately remove dirt, such as oil, grease, earth, snow or ice

• Never get on or off a moving machine! Never jump off the machine

• Stop the diesel engine and apply the parking brake before leaving the wheel loader

• Always observe the warning and information labels, and the load diagrams (e.g. pallet forks) of the loader unit

Important information for the operating staff

• The operating staff (driver) must have read and understood this Operator's Manual before putting the machine into operation

• The machine may be put into operation by authorised staff only

➥ – see chapter 1 “Driving licence” on page 1-8 and – see chapter 2 “Selection and

qualification of staff, basic responsibilities” on page 2-5 of this Operator's Manual.

• The machine may only be put into operation when the driver is seated

• Carrying or transporting accompanying persons in the cab or on the wheel loader is not allowed

• The machine may only be used in technically perfect condition in accordance with its designated use and the instructions set forth in the General Certification for Vehicles (Germany), the data confirmation (Germany) and in the Operator's Manual, and only by persons who are fully aware of the risks involved in operating the machine

• Run through the checklists in the following tables

Operation

Running-in period of wheel loader

Handle the machine carefully during its first 100 operating hours. Observe the following recommendations during the running-in period.

• Do not overload the machine, but at the same time do not drive too cautiously either, as the machine will never reach its proper operating temperature

• Do not run the engine at high speed for extended periods

• Increase the load gradually while varying the engine speed

• Never let the engine run at idling speed for longer time –seeStarting the engine on page 3-16

• Strictly observe maintenance schedules and carry out (or have carried out) the specified maintenance work – see chapter 5 “Maintenance plan” on page 5-47

BA 35101/02/ 03 EN – Edition 1.0 * 35201_02b320.fm 3-9

Operation

3.6 Checklist

Starting checklist

These checklists cannot claim to be exhaustive; they are merely intended as an aid for you in fulfilling your duties as a conscientious operator.

The checking and monitoring jobs listed below are described in greater detail in subsequent chapters of the Operator's Manual.

If the answer to one of the following questions is NO, first rectify the cause of the fault before starting or continuing work.

Check the following points before putting the machine into service or starting the engine:

No. Starting checklist ✔

1 Enough fuel in the tank? (➠ 5-3)

2 Engine oil level OK? (➠ 5-5)

3 Oil level in hydraulic tank OK? (➠ 5-16)

4 Water level in washer tank OK? (➠ 3-2)

5 V-belt condition and tension checked? (➠ 5-13)

6 Loader unit lubricated? (➠ 5-20)

7 Brake system (including parking brake) OK? (➠ 3-35)

8 Tyre condition and inflation pressure OK? (➠ 5-24, 6-11)

Wheel nuts safely tightened (especially after a wheel change)?

(➠ 6-13)

Lights, signals, indicators, warning lights and telltales OK?

(➠ 3-43, 3-45, 3-6)

11 Windows, mirrors, lights and steps clean?

12 Attachment on the loader unit safely locked? (➠ 3-63)

13 Engine cover safely locked? (➠ 3-14)

Especially after cleaning, maintenance or repair work:

Rags, tools and other loose objects removed?

Approved warning triangle, hazard warning light and first aid kit in the

machine?

16 Seat position and rearview mirrors correctly adjusted? (➠ 3-50)

17 Seat belt fastened? (➠ 3-53)

3-10 BA 35101/ 02/03 EN – Edition 1.0 * 35201_02b320.f m

Operation checklist

Operation

After starting the engine and during operation, check and observe the following points:

No. Operation checklist ✔

Telltales for engine oil pressure and alternator gone out?

(➠ 3-16)

2 Braking effect sufficient? (➠ 3-35)

3 Temperature gauge for engine coolant in normal range? (➠ 3-6)

4 Steering system working properly? (➠ 3-26)

5 Anyone dangerously close to the machine? (➠ 2-6)

6 3rd control circuit locked? (➠ 3-63)

When driving on public roads, particular attention should be paid to the following points:

7 Bucket and attachments in transport position? (➠ 3-26)

Parking checklist

8 Transport locks installed? (➠ 3-26)

Control lever for lift and tilt hydraulics of the loader unit locked with the stop

cock? (➠ 3-26)

10 Front-edge protection fitted to bucket?

Check and observe the following points when parking the machine:

No. Parking checklist ✔

1 Attachments on the loader unit lowered to the ground? (➠ 3-67)

2 Parking brake applied? (➠ 3-36)

3 Diesel engine stopped? (➠ 3-17)

4 Cab locked, especially if the machine cannot be supervised? (➠ 3-12)

When parking on public roads:

5 Machine adequately secured? (➠ 3-58)

When parking on slopes:

Machine additionally secured with chocks under the wheels to prevent it from

rolling away? (➠ 3-58)

BA 35101/02/ 03 EN – Edition 1.0 * 35201_02b320.fm 3-11

Danger!

Important!

Fig. 38: Outside d oor ope ner and lo ck

Fig. 39: Ins ide doo r opener

Operation

3.7 Cab

Safety instructions regarding cab entrance and exit

• Remove dirt (oil, grease, earth, snow and ice) from handles, footholds and shoes before entering the cab

• Use only the machine footholds, platforms and handles for entering the cab

• Face the machine as you enter and leave it

In order to avoid crushing and injury, close the doors and windows when driving the machine!

☞ Lock the door or secure it in the door arrester before moving the machine

•See Locking/unlocking the door on page 3-12 or Securing an open door

in the arrester on page 3-13

Locking/unlocking the door

☞ Opening the door from the outside:

• Press door button A

☞ Locking the door:

• Lock the door with the ignition key (turn to the right)

☞ Unlocking the door:

• Unlock the door with the ignition key (turn to the left)

Opening the door from the inside:

☞ Pull handle B up

Enter and leave the cab only by the left door as a rule.

Secure the control lever (joystick) and fold back the control lever base when leaving the cab by the right-hand side door

• –seeFolding back the control lever base on page 3-55!

3-12 BA 35101/0 2/03 EN – Edition 1.0 * 35101_02_03b33 0.fm

Securing an open door in the arrester

Important!

Fig. 40: Securing an open d oor

Fig. 41: Unl ocking th e door a rre ster

Fig. 42: Door arre ster

☞ Press the door against bracket 31 of the arrester until it engages with an audible click

☞ Release the door out of the arrester:

Operation

Lubricate arrester 31 regularly!

• The door arrester is located on the left in the cab

• Press lever B of the arrester forwards

➥ The door is released from the lock by spring action

• Close the door

Opening the right-hand side door to a gap

The right-hand side door can be opened to a gap and secured with the arrester to improve cab ventilation.

☞ Safely engage lever C in door lock D

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-13

Operation

Danger!

Caution!

Fig. 43: Engine cover lock

3.8 Engine cover lock

Opening/closing the engine cover

Caution, turning parts!

☞ Stop the diesel engine before opening the engine cover

☞ Open the engine cover:

• Stop the diesel engine and remove the ignition key

• Press lock A

• Pull the engine cover upwards

☞ Close the engine cover:

• Firmly press down the engine cover until lock A engages with an audible click

☞ Lock and unlock the engine cover:

• Close the engine cover with the ignition key of the preheating start switch.

3.9 Protective screens for front window and/or main lights (option)

Removing the protective screens for driving on public roads

The wheel loader can be fitted with protective screens on the front window and/or the main headlights as a protection against falling material.

The protective screens may be used only for work operation and must be removed when driving on public roads!

☞ See also the machine documentation and the data confirmation (Germany)

3.10 Fire extinguisher (option)

Fire extinguisher operation

The fire extinguisher is not included in the machine's standard equipment (option).

• If a fire extinguisher is retrofitted according to DIN-EN 3, then this must be carried out by an authorised workshop

• Located on the cab column, to the right of the seat (see fig.)

• Fire extinguisher operation is described with the symbols on the fire extinguisher

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The fire extinguisher must be refilled and sealed by authorised staff after it has been used.

3.11 Putting the diesel engine into operation

Danger!

Important!

Preparing to start the engine

The wheel loader may be put into service only if the operator is seated on the seat!

☞ Operate the machine from the seat only

☞ Prepare to start the engine as follows:

• Run through the “Start-up” checklist 3-10

• Switch on the battery master switch

–seeBattery master switch (option) on page 3-18

• Adjust seat position and rearview mirrors –seeSeat on page 3-50

• All controls must be within easy reach

• You must be able to move the brake and accelerator pedals to their limit positions

• Fasten your seat belt –seeSeat belt (lap belt) on page 3-53

• Make sure the parking brake is applied –seeParking brake on page 3-36

• Make sure the control lever for the loader unit is in neutral position –seeChanging

direction (forwards/reverse) on page 3-38

Operation

The engine will not start unless:

• the parking brake is applied to the last notch

–seeParking brake on page 3-36

• the drive interlock is disabled (option)

–seeDrive interlock with code input (option) on page 3-20 –seeKey-based drive interlock (option) on page 3-18

• The starter cannot be actuated if the engine is already running (start repeat interlock)

• Do not run the starter for more than 10 seconds

• Wait about 1 minute so the battery can recover before trying again

• The engine cannot be started by tow starting the machine, as there is no driving connection between the engine and the gearbox (e.g. cardan shaft) when the engine is stopped –seeTowing the machine on page 3-56

When working at outside temperatures of less than -10 °C for extended periods, we recommend retrofitting the machine with an oil and fuel preheater (option).

• –seeOil and fuel preheater (option) on page 3-24

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-15

Operation

Caution!

Fig. 44: Preh eating s tart switch

Fig. 45: Indi cating instrume nt tellta les

81 8280

Starting the engine

The ignition lock is located on the right-hand side control lever console.

☞ Apply the parking brake to the last notch ☞ Turn the ignition key (preheating start switch 19) to position “1” ☞ The following telltales must come on

• Engine oil pressure telltale 82

• Telltale 81 if the parking brake is applied

• Alternator charge function telltale 80

• Automatic preheating telltale 85, comes on for about 30 – 60 seconds at normal temperatures (up to 0°), and for about 60 – 90 seconds at low temperatures (below 0°)

➥The intake air is preheated via a temperature-dependent time lag relay, and telltale

85 goes out once the temperature is reached

After telltale 85 (automatic preheating) has gone out:

☞ Start the engine as follows:

• Press the accelerator pedal through about 1/4 of its travel

• Turn the ignition key to position “3” and hold it in this position until the engine starts

• Release the ignition key

• Check that the following telltales have gone out:

➥Engine oil pressure telltale 82 ➥Alternator charge function telltale 80 ➥Cold starter telltale 85

In order to avoid damage to the engine and the exhaust turbocharger due to insufficient lube oil supply:

☞ Do not run the cold engine at full throttle when starting ☞ Let the engine warm up at low idling speed (for about 30 seconds) ☞ Replace defective telltales immediately

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Avoiding running the engine under low-load conditions

Caution!

Fig. 46: Sto p the engi ne

The running performance of the engine can be negatively affected if it runs at high speed and at less than 20 % of the load. Operating temperature is not reached!

• Effects: Increased lube oil consumption

• Lube oil in exhaust system

• Engine contamination

• Blue smoke in exhaust

We recommend running the engine at loads of over 20 % during regular operation

Stopping the engine

Operation

In order to avoid heat accumulation and damage to the exhaust gas turbocharger, do not stop the engine from full throttle!

☞ Let the engine run at idling speed for about 2 minutes and then switch it off

☞ Apply the parking brake to the last notch ☞ Turn the ignition key in the preheating start switch to “0” and remove it

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-17

Operation

Caution!

Fig. 47: Battery master switch

3.12 Battery master switch (option)

Battery master switch operation

Battery master switch A is located in the engine compartment at the upper left above the variable displacement pump (drive)

☞ Interrupting power supply

• Turn and remove the key of the battery master switch (notched position)

☞ Switching on power supply

• Insert the key in the battery master switch

• Turn the key to the notched position

3.13 Key-based drive interlock (option)

Key-based drive interlock: scope of delivery

The drive interlock is integrated in the ignition lock and can be enabled only with the blue ignition keys!

Scope of delivery:

• Drive interlock installed in the machine

• 2 x blue keys (coded)

• 1 x red master key (for training the blue keys)

Coding (“training”) new ignition keys

New personal keys are coded with the master key (red). This is why it must be carefully stored outside the machine.

• The master key is only used for coding new keys, and cannot be used for disabling the

• Coding is carried out by inserting the master key in the ignition lock and by turning it to

• Coding is automatically stopped if no key requiring coding is detected within 15

• Several keys requiring coding can be inserted one after another in the ignition lock

• Each key must remain at least 1 second in position '1'.

• Coding can be carried out for a maximum 10 keys

Each drive interlock has only one master key!

☞ The drive interlock must be replaced if the master key is lost

drive interlock

position '1' for a maximum 5 seconds. After the master key has been returned to position '0' and removed, you have 15 seconds for inserting a key that requires coding. It must be inserted in the ignition lock and turned to position '1' in order to be registered as a valid key.

seconds.

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Enabling (locking) the drive interlock

Caution!

☞ Apply the parking brake

➥ –seeParking brake on page 3-36 ☞ Stop the engine ☞ Remove the ignition key (blue)

➥ The drive interlock is enabled in 30 seconds

Disabling (releasing) the drive interlock

Start and stop the engine exactly as described on page 3-16 “Starting the engine”.

☞ The system is enabled 5 seconds after the ignition key is inserted in the ignition lock ☞ Start the engine –seeStarting the engine on page 3-16

➥ The drive interlock is disabled as long as the engine runs

Operation

The drive interlock remains disabled if the ignition key (blue) is not removed from the ignition lock!

Deleting coded keys

Safety functions

Deleting coded keys is necessary whenever a coded key is lost

• All coded keys are deleted during deletion

• After deletion has been carried out, all existing keys can be recoded

• Deletion is carried out by inserting the master key in the ignition lock and by turning it to

position '1' for a minimum 20 seconds.

• All coded keys are then deleted, and all existing keys can be recoded

• The master key code is not deleted during deletion

The drive interlock remains enabled for 15 minutes and does not accept any valid keys if more than 5 keys with different invalid codes are inserted and turned in the ignition lock within 1 minute.

This function avoids 'finding' the correct key by chance by trying different keys. It is only available if the control valve relay is connected in addition with terminal 30.

The drive interlock remains enabled for 15 minutes and does not accept any valid keys if several invalid keys have been detected without having set the ignition lock to position '0'.

Valid keys are accepted only after 15 minutes and after the position '0' of the ignition lock has been detected. This avoids testing keys without actuating the mechanical ignition lock, e.g. by moving the ignition lock to position '1' by force.

Interruptions of the supply line or other control lines do not disable the drive interlock or delete data (e.g. data codes). All important data is saved in a non-volatile memory.

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-19

Operation

Caution!

Fig. 48: Dr ive inte rlock (code in put option)

LED

3.14 Drive interlock with code input (option)

Keyboard for entering codes: overview

The drive interlock is enabled or disabled with “personal” codes entered via the keypad. Two codes are available:

• The existing unchangeable six-digit main code for disabling the drive interlock, for entering a personal code or for changing the personal code

• The four, five or six-digit personal code is used for disabling the drive interlock and is entered by the driver

We recommend using the personal code for disabling the system.

☞ Keep the main code in a safe place.

The keypad consists of:

• 10 numeric keys for entering the codes

• A (*) key for confirming the code that has been entered

• An LED (red telltale)

• An internal acoustic signal for signalling specific procedures

➥Example: a signal sounds to confirm a key has been pressed

The keypad comes on:

• When pressing any key

• The keypad flashes to indicate specific system statuses

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Entering/changing the personal code

Caution!

In order to enter or modify the personal code, disable the drive interlock by entering the main code (6 digits) and pressing the (*) key

☞ Turn the ignition key to 1

☞ Enter the 4, 5 or 6-digit new personal code and confirm with the (*) key within 20 sec-

☞ Enter the new personal code again and confirm it with the (*) key after a short flashing

☞ Turn the ignition key to the ZERO position and remove it as soon as the LED goes out

Operation

➥ The LED comes on for 2 seconds

onds after the LED has gone out

of the LED

➥ Confirmation: LED flashes twice briefly, then comes on for 2 seconds

➥ The new personal code is now set and can be used for disabling the drive interlock.

The personal code must be entered correctly twice consecutively otherwise an error is indicated by means of a single flashing of the LED:

☞ Codes consisting of 3 and less, or of more than 6 digits are ignored by the

system

☞ Simple codes (with identical or consecutive digits, e.g. 1, 2, 3, 4) are

rejected by the system with four short acoustic signals

☞ Entering a new personal codes replaces the previous code. A code can be

changed any time if the main code is known

Enabling the drive interlock

☞ Stop the engine and remove the ignition key

➥ The drive interlock is automatically enabled ➥ Flashing LED (on the keypad)

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-21

Operation

Caution!

Disabling the drive interlock

☞ Enter the personal code or main code (6 digits). ☞ Press the (*) key.

➥Confirmation: 2 long acoustic signals and long LED flashing ➥LED OFF = drive interlock is disabled ➥Diesel engine can be started

The diesel engine will not start if a wrong code has been entered

➥Confirmation: 4 short acoustic signals, flashing LED = wrong code ➥Re-enter the code

☞ Turn the ignition key and switch on the engine before the LED flashes again (30 sec-

onds)

The keypad is blocked for 5 minutes and no codes can be entered if the wrong code is entered four times consecutively.

☞ Enter the code after 5 minutes

• The keypad does not come on as long as it is blocked. It comes on briefly every 4 seconds and an acoustic signal sounds

☞ Press the (*) key after every code ☞ The LED comes on briefly when turning the ignition key to the engine start

position

Putting the drive interlock out of operation

We recommend putting the drive interlock out of operation if the machine has to stay in a workshop, for instance, or if the machine does not require any protection. This avoids having to communicate the code.

1 Disable the system by entering the personal or main code and by confirming with the

(*) key

2 Turn the ignition key to the ON position

➥The LED comes on for 2 seconds

3 As soon as the LED goes out, press the (*) tip switch for about 2 seconds until a short

acoustic signal, followed by two further signals, sounds

➥The LED now flashes very slowly, and the keypad is disabled

4 Turn the ignition key to the ZERO position and remove it 5 The engine can be started without entering the code. The system is out of service

even if electric power is interrupted.

If the system is out of operation, the LED flashes slowly even if the ignition key is in position 1

☞ Entering the personal or main code does not have the effect of putting the

system back into operation again (the acoustic signals for confirmation are still given). See the following procedure (“Putting the drive interlock back into operation again”) to leave the out-of-operation status again.

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Putting the drive interlock back into operation again

☞ Press the (*) key for 2 seconds (ignition key in position OFF) until two short acoustic

signals are given for confirmation

➥ The system is enabled again. The code must be entered to start the engine.

Interruption of drive interlock power

If the drive interlock was enabled before electric power was interrupted, short acoustic signals are given upon switching on the keypad (similar to those that are given when entering the wrong code four times). In this case, wait until the acoustic signals are no longer given. Then disable the drive interlock with the personal or main code.

The LED still does not come on if the drive interlock was disabled. The engine can be started before the LED starts flashing again.

If the drive interlock was out of operation, this status remains unchanged and the LED flashes slowly.

Drive interlock maintenance

The drive interlock does not require any maintenance. Protect the keypad and the control unit from heat and humidity

Operation

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-23

Operation

Important!

Fig. 49: Socket

3.15 Oil and fuel preheater (option)

General information on the oil and fuel preheater

• Connect the oil and fuel preheater only to an earthed socket

• Check the connecting cable regularly for damage

• Replace a damaged cable by a new one immediately

• The heating element can be damaged:

• if the oil and fuel preheater is connected to intermittent or pulsating voltage

• if dirty or not enough coolant is used

• if the cooling system is not bled

• if a radiator repair compound is used

Oil preheater operation

The engine and hydraulic oil is heated by means of heating elements with a capacity of 750 W in the engine oil pan and in the hydraulic oil tank, according to the gravity principle (warm oil rises and is replaced by cold oil). The oil can only be thoroughly warmed up to operating temperature if the oil preheater is connected over a longer period of time – preferably over night.

The machine socket is located at the rear right in the cover plate of the counterweight.

☞ Put the oil preheater into operation

• Park the machine near a 220 V socket

• First connect the special cable with the machine socket, then insert the plug into the 220 V (110 V) socket

☞ Before starting the engine:

• Remove the plug from the 220 V (110 V) socket

• Unplug the special cable from the machine socket

• Close the machine socket with a protective cap

The oil preheater (option) reduces pollutant emissions during the warm-up phase by up to 60 %, saving fuel at the same time.

Fuel preheater

The fuel preheater prevents paraffin crystals forming, which otherwise clog the fuel filter at low temperatures.

A temperature switch automatically switches on a heating element in the fuel line between the tank and the fuel prefilter when ignition is switched on at temperatures below + 10 °C.

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3.16 Jump-starting the engine (external battery)

Caution!

12 V

34001b710_05.eps

Fig. 50: Sta rting aid with jump l eads

Flat battery

Starting battery

Safety instructions regarding external starting aids

The jump lead connected to the positive (+) terminal of the starting battery must never be brought into connection with electrically conductive vehicle parts – danger of short circuit!

☞ The external power source must deliver 12 V; higher supply voltages will

damage the electrical system of the vehicles!

☞ Use only authorised jump leads which conform to the safety requirements

and which are in perfect condition!

☞ Route the jump leads so they cannot catch on rotating components in the

engine compartment!

Providing external starting aid

☞ Proceed as follows:

• Drive the jump-starting vehicle close enough to the wheel loader so that the jump leads can reach to connect the two batteries

• Let the engine of the jump-starting vehicle run

• First connect one end of the red jump lead (+) to the + terminal of the flat battery, then connect the other end to the + terminal of the starting battery

• Connect one end of the black jump lead (-) to the – terminal of the starting battery

• Connect the other end of the black jump lead (-) onto a solid metal component fimly mounted on the engine block or onto the engine block itself. Do not connect it to the negative terminal of the flat battery, as otherwise explosive gas emerging from the battery can ignite if sparks are formed!

• Start the engine of the machine with the flat battery

Once the engine has started:

• With the engine running, disconnect both jump leads in exactly the reverse order (first remove the – terminal, then the + terminal) – this prevents sparking in the vicinity of

the battery!

Operation

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-25

Operation

3.17 Before moving off

Special instructions for driving on public roads

• Carrying or transporting accompanying ersons in the cab or on the wheel loader is

not allowed

• The machine is subject to the applicable national legal regulations (e.g. StVZO German road traffic regulations) and to the provisions laid down in the General Certification for Vehicles (Germany) or the data confirmation (Germany).

• Only the attachments are authorised for use on public roads that are described in the General Certification for Vehicles (Germany), in the data confirmation (Germany) or in this Operator's Manual – see chapter 1 “Fields of application and using a wheel loader with an attachment” on page 1-5 (the footnotes must be taken into account).

• Bear in mind the mandatory regulations for accident prevention

• For operation on public roads, bear in mind the provisions laid down in the machine documentation and in the data confirmation (Germany)

Preparing for driving on public roads

German road traffic regulations prohibit driving on public roads if the distance between the front edge of the bucket and the centre of the steering wheel is over 3500 mm in transport position! – see chapter 1 “Fields of application and using a wheel loader with an attach- ment” on page 1-5. See also the provisions laid down in the machine documentation and in the data confirmation (Germany)

☞ Prepare to start the engine as follows:

• Empty and dump in the bucket as far as it will go

➥–seeWorking with a bucket on page 3-69

• Raise the loader unit to transport position (ground clearance about 250 mm)

➥–seeBucket transport position on page 3-27

• Mount the front-edge protection onto the leading edge of the bucket or onto the fork

arms of the pallet forks

• If the machine is equipped with pallet forks with foldable fork arms (option), fold them

up and secure them

• Switch off the working lights when driving on public roads

• High speed version (30/40 kph): switch the steering system to front axle steering

–seeChanging over to front axle steering (option) on page 3-32

• Switch on the load stabiliser –seeLoad stabiliser (option) on page 3-40

• Secure the control lever (joystick) and the 3rd control circuit of the loader unit

–seeLocking the control lever (joystick) and the 3rd control circuit (attachments) on

page 3-29

• Remove the protective screens for the front window and/or the main lights (options)

–seeProtective screens for front window and/or main lights (option) on page 3-14

• Adjust the seat position and the rearview mirrors

• Fasten your seat belt –seeSeat belt (lap belt) on page 3-53

Get informed on and follow the legal regulations of your country.

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Bucket transport position

Important!

308b0350.eps

Fig. 51: Tran sport pos ition

Operation

Loader unit operation

–seeLoader unit control lever (overview) on page 3-62

☞ Set the bucket to transport position as follows:

• Empty and tilt back the bucket B

• Raise the loader unit so that both red marks D on the lift frame and the bulkhead are

aligned

➥ Ground clearance C about 250 mm

• Cover the blade or teeth of the bucket across their entire width with the tooth guard A

provided

Remove buckets/attachments that are not authorised for transport on public roads and use a suitable means of transport to move or transport them.

• – see chapter 1 “Attachments with authorised material densities” on page 1-5

• Secure the control lever (joystick)

➥ –seeLocking the control lever (joystick) and the 3rd control circuit (attachments) on

page 3-29

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-27

Operation

Important!

Fig. 52: Tran sport pos ition of pallet fo rks

Transport position of pallet forks

Only pallet forks with foldable fork arms are authorised for travel on public roads!

Remove pallet forks that are not authorised for transport on public roads and use a suitable means of transport to move or transport them.

• – see chapter 1 “Attachments with authorised material densities” on page 1-5

Pallet forks operation –seeFitting pallet forks on page 3-85

☞ Set the pallet forks to transport position as follows:

• Remove the load off the pallet forks

• Fold back and secure the fork arms

• Raise the loader unit so that both red marks D on the lift frame and the bulkhead are

aligned

➥Ground clearance C about 250 mm

• Cover the fork arms across their entire width with the protection A provided

• Secure the control lever (joystick)

• –seeLocking the control lever (joystick) and the 3rd control circuit (attachments) on page 3-29

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Locking the control lever (joystick) and the 3rd control circuit (attachments)

Fig. 53: Cont rol leve r and 3rd control circui t lock

Secure the control lever (joystick) and the 3rd control circuit (quickhitch) against unintentional actuation when driving on public roads.

➥ –seeOperating and securing the 3rd control circuit on page 3-63

The stop cock for locking the control lever is located on the console of the control lever base (on the right in driving direction).

☞ Lock the control lever:

• Push stop cock 21 lever to the rig ht A

➥ The hydraulic oil circuit to the control valve (joystick 15) is interrupted

☞ Unlock the control lever:

• Push stop cock 21 lever to the left B

➥ The control valve (joystick 15) is connected with the hydraulic oil circuit

☞ Locking the 3rd control circuit:

• Slide lock C on switch 94 in the direction of the arrow and press the switch to pos ition B at the same time

• Release lock C

➥ The 3rd control circuit is completely secured against unlocking

Operation

Functional check of all control elements

• –seeSteering system on page 3-30

• –seeBrake/inching pedal on page 3-35

• –seeMachine lights on page 3-43

• –seeSignalling system on page 3-45

• –seeWasher system on page 3-49

• –seeSeat on page 3-50

• –seeOther controls on page 3-55

• –seeOperating and securing the 3rd control circuit on page 3-63

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-29

Operation

Danger!

Important!

Fig. 54: Steering column adjustment

3.18 Steering system

Steering column height and angle adjustment (option)

In order to avoid danger of accidents, do not adjust the steering column when driving!

☞ Adjust the steering column at machine standstill as follows:

• Stop the wheel loader and the engine

• Apply the parking brake

• Sit down on the seat and adjust the height and the inclination of the steering column to your size (see table)

Function Operation

Height adjustment

Angle adjustment

Pull lever 7 upwards to position A, pull or push the steering column to the correct position, and release the lever

• The steering column is locked at the required height

Push lever 7 downwards to position B, adjust the correct inclination of the steering column, and release the lever

• The steering column is locked at the required inclination

Checking the steering system

☞ Functional check of steering system

• With the engine running, turn the steering wheel to the left and right

The machine can still be steered if the diesel engine or the pump drive breaks down – emergency steering feature.

Turning the steering wheel requires greater effort! Take this into account especially when towing the machine!

➥Adapt towing speed to the altered steering behaviour! ➥–seeTowing the machine on page 3-56

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3.19 Wheel synchronisation (front/rear axles)

Danger!

Important!

Fig. 55: Tip s witch f or steering synchroni sation

Do not synchronise the wheels when driving on public roads!

☞ Synchronise the steering system before driving on public roads

Synchronisation when starting the machine

Wheel synchronisation is automatically set by turning the steering wheel to the left and right when the engine is running.

Only the speed range is active during synchronisation – telltale 48 on the instru- ment panel flashes.

The hare speed range (switch 63/B) can be selected but is not active until syn- chronisation is over.

Operation

Synchronisation during work operation

The steering system must be synchronised if the wheels of the machine no longer follow the same track when driving straight-ahead on level ground.

The steering system is synchronised with tip switch 60 on the switch console on the right on the instrument panel.

☞ Proceed as follows:

• Press switch 62 to position A

➥ –seeChanging over to 4 wheel steering on page 3-32

• Select the “Turtle“ speed range by pressing switch 63 to position A

• At walking speed, press tip switch 60 (synchronisation) to position B and turn the steering wheel to the left and right until telltale 48 goes out

➥ Steering synchronisation is over

• Carry out a functional check of the steering system

Synchronisation is over as soon as both steering rams have passed through the straight-ahead position from both directions and telltale 48 on the instrument panel goes out.

If the machine is equipped with the front axle steering option, switch over to 4 wheel steering before synchronising the steering system!

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-31

Operation

Danger!

Important!

Fig. 56: Se lecting front ax le steering

5052 49

Fig. 57: Selecting 4 wheel steering

5052 49

3.20 Changing steering mode

General safety information on changing steering mode

In order to avoid danger of accidents, do not change steering mode when driving the machine on public roads!

Furthermore, do not change steering mode when driving at high speed!

☞ Change steering mode before driving on roads and only a walking speed

Changing over to front axle steering (option)

☞ Proceed as follows:

• Slide lock S in switch 62 in the direction of the arrow and press the switch to position A at the same time

• Release lock S

• Turn the steering wheel to the left and/or right until the wheels of the front and rear axles have passed through the straight-ahead position from both directions

Changing over to 4 wheel steering

➥Telltale 50 comes on and front axle steering is enabled

➥Telltales 52 and 49 go out

If the machine is equipped with the “High speed” option, changing over to 4 wheel steering automatically reduces speed to 20 kph!

☞ Proceed as follows:

• Slide lock S in switch 62 in the direction of the arrow and press the switch to position B at the same time

• Release lock S

• Turn the steering wheel to the left and/or right until the wheels of the front axle have passed through the straight-ahead position from both directions

➥Telltale 52 comes on and 4 wheel steering is enabled

➥Telltales 50 and 49 go out

3-32 BA 35101/0 2/03 EN – Edition 1.0 * 35101_02_03b33 0.fm

Changing over to diagonal steering (crab steering option)

Danger!

Important!

Fig. 58: Se lecting di agonal steeri ng

5052 49

S61

Use diagonal steering (crab steering) only for moving away laterally from a wall or for repositioning the wheel loader laterally.

In order to avoid danger of accidents, do not drive over longer distances. Furthermore, driving on public roads with diagonal steering (crab steering) is not allowed!

☞ Change over to 4 wheel steering, or to front axle steering in the case of high

speed mode!

➥ –seeChanging over to 4 wheel steering on page 3-32 ➥ –seeChanging over to front axle steering (option) on page 3-32

☞ Change steering mode before driving on roads and only a walking speed

Changing to diagonal steering is only possible by enabling “4 wheel steering”!

Operation

☞ Proceed as follows:

• Slide lock S in switch 62 in the direction of the arrow and press the switch to position A at the same time

• Release lock S

➥ 4 wheel steering is switched on

• Slide lock S in switch 61 in the direction of the arrow and press the switch to position B at the same time

• Release lock S

• Turn the steering wheel to the left and/or right until the wheels of the front and rear axles have passed through the straight-ahead position from both directions

➥ Telltale 49 comes on and diagonal steering is enabled

➥ Telltales 50 and 52 go out

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-33

Operation

Important!

Danger!

Fig. 59: Disabling/enabling the accelerator

pedal lock

103

3.21 Accelerator pedal

Speed control with the accelerator pedal

☞ Accelerator pedal Fig. 30/16 controls the drive speed as follows:

• Press the accelerator pedal down

➥Drive speed is increased

• Release the accelerator pedal slowly

➥Drive speed is reduced

• Release the accelerator pedal fully

➥Hydrostatic braking

Maximum speed depends on the speed range selected.

• –seeSelecting a speed range on page 3-37

3.22 Accelerator pedal lock – manual throttle (option)

Disabling/enabling the accelerator pedal lock

This option is especially useful for operation of hydraulic attachments in order to ensure a continuous hydraulic oil supply and/or drive speed.

The accelerator pedal lock is set by means of the accelerator pedal and tip switch 92 on the switch panel on the right on th control lever base.

Use the accelerator pedal lock only during work operation.

Driving on public roads with the accelerator pedal lock (manual throttle) is not allowed!

☞ See also the machine documentation and the data confirmation (Germany)

☞ Enabling the accelerator pedal lock:

• Select and hold the required engine or drive speed with the accelerator pedal

• Press tip switch 92 in the switch panel (1 x) and telltale 44 comes on

➥The required engine or drive speed is set

☞ Disabling the accelerator pedal lock:

• Press tip switch 92 in the switch panel (1 x), or switch 103 on the joystick (change of direction)

➥The accelerator pedal lock is disabled and telltale 44 goes out

3-34 BA 35101/0 2/03 EN – Edition 1.0 * 35101_02_03b33 0.fm

3.23 Brake/inching pedal

Danger!

Caution!

Specific information on brake/inching pedal actuation

• The brake/inching pedal is located on the left in the machine.

• Dirt accumulation and objects in the area of the brake/inching pedal can result in brake malfunctions.

• Keep the brake/inching pedal clean and remove all objects in the area of the pedal

The brake lights at the rear of the machine neither come on when applying the parking brake, nor during inching.

☞ Press the brake/inching pedal down with force in order to brake the

machine

Braking with the brake/inching pedal

☞ Before braking, check in the rearview mirror that no-one will be hindered ☞ Release the accelerator pedal fully and press the brake/inching pedal down with force

beyond the inching range

➥ The machine is braked to a standstill regardless of the position of the forwards-

reverse control on the joystick

Caution when stopping on slopes:

☞ Press brake/inching pedal Fig. 30/24 down with force until the braking effect is felt

Operation

Inching with the brake/inching pedal

☞ Press brake/inching pedal Fig. 30/24 down slightly (inching range)

When driving downhill, use the brake pedal to support the braking effect of the drive. This avoids damage (excessive speed) to the drive and/or the diesel engine! During trailer operation (option), also select the “Turtle” speed range before driving downhill!

☞ Reduce engine speed ☞ Reduce the speed to less than 11 kph with the service brake ☞ Select the “Turtle” speed range

• The brakes are supported by the hydraulic braking effect of the drive

➥ In the inching range (pedal pressed lightly), the pedal can be used like a car's clutch ➥ The drive's output is reduced, making the engine power available to the work

hydraulics

➥ This makes it possible to raise the loader unit more quickly

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-35

Operation

Important!

Danger!

Fig. 60: App lyi ng and releasi ng the parking b rake

3.24 Parking brake

General instructions regarding the parking brake

The parking brake is located to the right of the control lever base. A starting interlock prevents the machine from starting even with the parking brake slightly

applied.

The driving direction can only be selected if the parking brake is completely released.

Applying the parking brake automatically cancels the selection of the forwards/ reverse driving direction (drive) and switches the drive to neutral.

Applying the parking brake

When driving the machine, apply the parking brake only in an emergency. The brake lights do not come on in this case!

☞ In normal operation use only the brake/inching pedal as a service brake

☞ Apply the parking brake

• Pull lever 18 up to the last notch

➥Telltale 81 on the indicating instrument comes on ➥The engine can be started ➥Selection of forwards/reverse driving direction (drive) is automatically cancelled and

neutral activated

• Secure the machine with wheel chocks –seeStopping/parking the machine on page 3-58

☞ Release the parking brake

• Pull lever 18 up slightly

• Press button A

• Move lever 18 down as far as it will go

➥Telltale 81 on the indicating instrument goes out

3-36 BA 35101/0 2/03 EN – Edition 1.0 * 35101_02_03b33 0.fm

3.25 Driving the machine

Fig. 61: S peed range sel ection swi tch

103

102

Selecting a speed range

Operation

The machine has two speed ranges. The switch for selecting the speed range is located on the switch console on the right-hand

side of the instrument panel.

☞ Select the 1st speed range

• Set driving direction to neutral with tip switch 102 on the joystick

• Press switch 63 to position A

• Select the driving direction (F or R) with switch (scroll wheel) 103

☞ Select the 2nd speed range

• Press switch 63 to position B

• Select the driving direction (F or R) with switch (scroll wheel) 103

• Gradually press down the accelerator pedal

➥ Machine moves off

• Test the brakes at low speed

Speed range symbol

Speed range Recommended

Used for work involving short loading cycles, i.e. a rapid succession of loading

1st speed range

0– 7 kph

2nd speed range

0 – 20 kph

0 – 30/40 kph (option)

and unloading operations, e.g. onto a truck, and for work requiring precise speed adjustment, e.g. rotary broom applications.

For long-haul travel

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-37

Operation

Important!

51 53

Fig. 62: Chan ging di rec tion

103

102

Changing direction (forwards/reverse)

☞ Select the driving direction

• Reduce engine speed: remove your foot from the accelerator pedal

• Slow down your drive speed to less than 15 kph

• Select the driving direction with switch 103, or stop the machine with tip switch 102

• Apply the parking brake at machine standstill

Driving direction Operation Telltale on instrument panel

Forwards

Reverse

Neutral

For reasons of safety, changing direction (forwards/reverse) during machine travel is only possible if drive speed is reduced to less than 15 kph!

Press switch 103 on the control lever (joystick) forwards F

Press switch 103 on the control lever (joystick) backwards R

Press tip switch 102 on the con- trol lever (joystick)

Telltale 51 comes on

Telltale 53 comes on

Telltale 51/53 goes out

3.26 Differential lock (self-locking differential)

Switching the differential lock ON and OFF

The differential lock neutralises the compensating effect of the differential, i.e. traction is distributed evenly to the front and rear wheels.

• Both the front and the rear axle of the machine are fitted with a

self-locking differential

• The lock value is 45 % for each axle.

The differential is locked automatically and cannot be switched on or off!

3-38 BA 35101/0 2/03 EN – Edition 1.0 * 35101_02_03b33 0.fm

3.27 Low-speed control (option)

Important!

Fig. 63: Low- speed contr ol

Selecting the drive speed

This function is especially useful for operation of hydraulically driven attachments (e.g. rotary broom, rotary hoe) in order to ensure continuous drive speed.

Unregulated low-speed control

Drive speed is set with potentiometer 93 and maintained by means of the manual diesel engine speed setting (accelerator pedal).

Regulated low-speed control (CSD – Constant Speed Drive printed on symbol)

Drive speed is set with potentiometer 93 and maintained by means of the automatic die- sel engine speed setting.

☞ Select the drive speed as follows:

Operation

Regulating drive speed with potentiometer (regulator) 93 is not possible unless the “Turtle” speed range has been selected!

• Press switch 63 to position A

• Set the drive speed with potentiometer 93 (see table)

Speed range symbol

Drive speed Recommended

Used for work involving short loading cycles, i.e. a rapid succession of loading

0– 7 kph

Once the low-speed control is no longer needed: set potentiometer 93 to “Hare” so you can reach maximum speed in normal operation!

and unloading operations, e.g. onto a truck, and for work requiring precise speed adjustment.

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-39

Operation

Important!

Caution!

3.28 Load stabiliser (option)

General instructions regarding the load stabiliser function

The load stabiliser cushions and dampens the movements of the loader unit. It avoids unstable oscillating movements of the loader and increases drive comfort and safety!

Always switch on the load stabiliser when driving on public roads!

In order not to impair the load stabiliser function in transport position of the loader unit, do not retract the tilt ram to the limit (pressure)!

• After setting the loader unit to transport position, dump in the bucket as far as it will go, then dump it out slightly again

• Switch off the load stabiliser during pallet forks operation

• –seeSwitching the load stabiliser ON and OFF on page 3-41

If the machine is equipped with the “Hose burst valve” option, switching on the load stabiliser automatically disables the hose burst valve, and the hydraulic lines and pipes are no longer protected against possible damage!

☞ –see“Hose burst valve” safety feature (option) on page 3-98 ☞ Switch off the load stabiliser during pallet forks operation

3-40 BA 35101/0 2/03 EN – Edition 1.0 * 35101_02_03b33 0.fm

Switching the load stabiliser ON and OFF

Important!

Fig. 64: Swi tch f or load s tabiliser (option)

The switch is located on the left on the switch console of the instrument panel

Function Work operation

Auto

(A)

Operation

Switch on the load stabiliser only in transport position!

In order not to impair the load stabiliser function in transport position of the loader unit, do not retract the tilt ram to the limit (pressure)!

• After setting the loader unit to transport position, dump in the bucket as far as it will go, then dump it out slightly again

The loader unit yields easily with the load stabiliser switched on, making it difficult to carry out any precise lifting movements.

• Switch off the load stabiliser during pallet forks operation

Switches the load stabiliser on automatically

☞ Press switch 66 to position A

➥The load stabiliser is automatically switched

on when driving faster than 15 kph

➥Telltale 45 on the instrument

panel comes on

➥The hose burst valve (option) is disabled

For driving on public roads, for lighter work with the loader unit and for light offroad transport

Switches off the load stabiliser

OFF

☞ Press switch 66 to centre position B

(B)

➥Telltale 45 on the instrument panel goes out ➥The hose burst valve (option) is enabled

Load stabiliser in continuous operation

☞ Press switch 66 to position C

(C)

➥Telltale 45 on the instrument

panel comes on

➥The hose burst valve (option) is disabled

For heavy-duty work, e.g. picking up excavated material

For driving on public roads, for lighter work with the loader unit and for light offroad transport

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-41

Operation

Danger!

Fig. 65: Backup wa rning sy stem (opti on)

Fig. 66: Fro nt socket (option )

3.29 Backup warning system (option)

Instructions regarding the backup warning system

The backup warning system consists of a signal transmitter fitted on the rear of the cab. The signal transmitter generates an acoustic signal when shifting into reverse. The acoustic level is about 103 dB (A) at a distance of 1 m and at a frequency of 2800 Hz.

Do not rely exclusively on the backup warning system when reversing with the machine!

☞ Make sure nobody is within the danger area of the machine when changing

the driving direction!

3.30 Electric connection – front socket (option)

Putting the front socket into operation

The machine can be equipped with a 4 pole socket (at the front left on the loader unit). Tip switch 71 at the left on the switch console of the instrument panel switches the electric

power supply on or off for electrically operated attachments such as a spray water pump for a rotary broom.

Power supply for front attachments (option) Function

ON Press tip switch 71 briefly (1 x)

OFF Press tip switch 71 briefly (1 x) Power supply is switched OFF

Power supply at the socket is switched on

3-42 BA 35101/0 2/03 EN – Edition 1.0 * 35101_02_03b33 0.fm

3.31 Machine lights

Important!

Fig. 67: Light system

Machine lights operation

Operation

The switch for the machine lights is located on the switch panel on the left-hand side of the instrument panel.

Side marker light operation Function

ON Press switch 68 to the 1st position B Te lltale in switch co mes on

OFF Press switch 68 down to position A Tellta le in switch goe s out

Low beam operation Function

Press switch 68 to the

2nd position B and pull lever 28 to

position II

OFF Press switch 68 down to position A Tellta le in switch goe s out

Tellta le in switch comes on

Only the side marker lights stay lit if ignition is switched off while low beam is still switched on!

High beam operation Function

Press switch 68 to the

2nd position B and push lever 39 to

position I

Tellta le (blue) 84 on the indicating instrument comes on

Tellta le (blue) 84 on the indicating instru-

OFF Pull lever 39 to position II

ment goes out Low beam comes on

Headlight flasher operation Function

Briefly pull lever 39 fully up (beyond

position II)

Tellta le (blue) 84 on the indicating instrument comes on

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-43

Operation

Danger!

Fig. 68: Work ing light switc hes

Fig. 69: Swi tch f or interi or light

Working lights operation

Switch off the working lights to avoid dazzling motorists on public roads!

☞ Do not switch on the working lights when driving on public roads ☞ When operating the machine, only switch on the working lights when no-

one can be dazzled by them

Function Telltale

Press switch 70 (front) and/or switch

67 (rear) to position B

Press switch 70 (front) and/or switch

OFF

67 (rear) to position A

Telltale in switch comes on

Telltale in switch goes out

Interior light operation

Function

ON Press switch 4 to the left or right

OFF Move switch 4 to centre position

3-44 BA 35101/0 2/03 EN – Edition 1.0 * 35101_02_03b33 0.fm

3.32 Signalling system

Caution!

Important!

Fig. 70: Turn indicators

Fig. 71: Switch for hazard warning system

Fig. 72: Swi tch f or rotatin g beaco n

Turn indicator operation

Operation

Function Telltale

RIGHT Push lever 39 forwards R Telltale 76 flashes

LEFT Pull lever 39 to the rear L Telltale 76 flashes

➥ Telltale 75 flashes during trailer operation.

The turn indicator system is not in order if telltale 76 flashes about twice as fast as normally!

• Check the front and rear turn indicators, have the turn indicator system

repaired if necessary

Hazard warning system operation

3.33 Rotating beacon (option)

Rotating beacon operation

Function Telltale

Press hazard warning switch 69 to

position B

Press hazard warning switch 69 to

OFF

position A

The telltale in the switch and telltale 76 both flash

The telltale in the switch and telltale 76 both go out

☞ Fold up and lock the rotating beacon

Function Telltale

ON Press switch 72 to position B Telltale in switch comes on

OFF Press switch 72 to position A Telltale in switch goes out

Legal regulations of your country may require you not to switch on the rotating beacon on public roads unless the road is within the machine's working range and the machine represents an obstruction to the normal flow of traffic when the machine is in work operation. Furthermore, legal regulations may require your machine to have some type of warning identification (e.g. red and white warning stripes)!

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-45

Operation

Fig. 73: Heat ing adju stment

III

8887

3.34 Cab heating and ventilation

Heating and ventilation system operation

The air is guided to the front window by the air vents on the left and right, to two leg room vents and to the rear window by two air vents.

➥ –seeCab overview on page 3-2

Each nozzle can be closed and directed separately. The machine heater can be set to 2 operating modes:

• Ventilation in fresh-air mode and heating The rotary switches (heating/ventilation) are located on the switch console on the right

(near the door)

☞ Ventilation, fresh air

• Turn fan switch 87 to positions 1 – 3

• Temperature switch 88 in position C (cold)

☞ Heati ng

• Turn fan switch 87 to positions 1 – 3

• Set the required temperature with temperature switch 88

➥C = cold (blue) ➥W = warm (red)

3-46 BA 35101/0 2/03 EN – Edition 1.0 * 35101_02_03b33 0.fm

3.35 Auxiliary heating (option)

Important!

Danger!

III

8887

Fig. 74: Auxiliary heating timer

Operating and setting the auxiliary heating

At engine standstill, the auxiliary heating warms up the coolant and the cab.

☞ Adjust the vehicle heater as follows before setting (programming) the timer:

• Turn fan switch 87 of the vehicle heater to positions 1 – 3

• Set temperature switch 88 to the required temperature

➥ W = warm (red )

• Set the auxiliary heating timer

Refer to the Operator's Manual of the auxiliary heating supplied with the machine for operating and setting (programming) the timer.

Operation

Double advantage: warm cab and preheated engine!

Danger of explosion near filling and service stations and places where inflammable vapours or dust may arise!

Danger of poisoning and suffocation when operating the auxiliary heating in enclosed areas!

☞ Switch off the auxiliary heating when refuelling the machine ☞ Switch off the auxiliary heating in enclosed areas

BA 35101/02/ 03 EN – Edition 1.0 * 35101_02_03b330.fm 3-47

Operation

Important!

Caution!

Important!

Fig. 75: Air condi tioning switch

3.36 Heating/air conditioning system (option)

Heating/air conditioning operation

The heating/air conditioning system heats or cools the air in the cab. The control elements for the heating/air conditioning system are located on the switch con-

sole on the right (near the door)

Close the door and the windows to achieve best air conditioning results.

The air conditioning system allows you to select the same operating modes as for normal heating and ventilation!

• See Heating and Ventilation, fresh air on page 3-46

☞ Press switch 89 to position B

➥Telltale in switch comes on ➥Heating/air conditioning system in operation

Carry out the following checks to avoid malfunctions and possible loss of refrigerant!

☞ Run the air conditioning system once a month. This prevents the seals in

the compressor from drying

☞ Check the V-belt tension at the compressor – see chapter 5 “Heating/air

conditioning system (option): maintenance” on page 5-27

Only trained staff and an authorised workshop may clean the heat exchanger and the evaporator, and repair, service and fill the air conditioning system with refrigerant!

3-48 BA 35101/0 2/03 EN – Edition 1.0 * 35101_02_03b33 0.fm

Kramer 380, 480, 580 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

Index

1 Introduction

1.1 General information on the Operator's Manual

1.2 General information on machine safety

1.3 Machine outside view

1.4 Models and trade names: overview

1.5 Brief description of the wheel loader

1.6 Wheel loader warranty

1.7 Fields of application and using a wheel loader with an attachment

1.8 Legal regulations regarding wheel loader operation

1.9 Type labels and component numbers

1.10 Description of labels and symbols

2 Safety instructions

2.1 Identification of warnings and dangers

2.2 Designated use and exemption from liability

2.3 General conduct and safety instructions

2.4 Safety instructions regarding operation

2.5 Safety instructions for maintenance

2.6 Maintenance work on protective ROPS and FOPS structures

2.7 Warning of special hazards

3 Operation

3.1 Description of control elements

3.2 Cab overview

3.3 Instrument panel, multifunctional lever and drive lever (overview)

3.4 Functional description: telltales

3.5 Putting the wheel loader into service

3.6 Checklist

3.7 Cab

3.8 Engine cover lock

3.9 Protective screens for front window and/or main lights (option)

3.10 Fire extinguisher (option)

3.11 Putting the diesel engine into operation

3.12 Battery master switch (option)

3.13 Key-based drive interlock (option)

3.14 Drive interlock with code input (option)

3.15 Oil and fuel preheater (option)

3.16 Jump-starting the engine (external battery)

3.17 Before moving off

3.18 Steering system

3.19 Wheel synchronisation (front/rear axles)

3.20 Changing steering mode

3.21 Accelerator pedal

3.22 Accelerator pedal lock – manual throttle (option)

3.23 Brake/inching pedal

3.24 Parking brake

3.25 Driving the machine

3.26 Differential lock (self-locking differential)

3.27 Low-speed control (option)

3.28 Load stabiliser (option)

3.29 Backup warning system (option)

3.30 Electric connection – front socket (option)

3.31 Machine lights

3.32 Signalling system

3.33 Rotating beacon (option)

3.34 Cab heating and ventilation

3.35 Auxiliary heating (option)

3.36 Heating/air conditioning system (option)