Operating Instructions
Load Haul Dumper LF - 9.3
Vehicle No: 3111-13/8
0-E
07.08
LF-9.3
1.6
Contents Introduction
How to use the operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Record of revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Conditions for Mining and Tunnelling Vehicles,
Airport Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tramming capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Travel drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions of vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound-pressure level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Concise description of vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proper use of LF-type loaders powered by diesel engines/electric motors . . .
1E
07.08
LF-9.3
1.1 - 1
1.1 - 3
1.2 - 1
1.3 - 1
1.4 - 1
1.4 - 1
1.5 - 1
1.5 - 1
1.5 - 1
1.5 - 1
1.5 - 1
1.5 - 2
1.5 - 2
1.5 - 3
1.5 - 3
1.5 - 3
1.5 - 3
1.5 - 3
1.5 - 3
1.5 - 4
1.5 - 4
1.5 - 5
1.5 - 6
1.6 - 1
1.6 - 2
1-1
1.1
Sections
The operating instructions comprise four sections.
1 = Introduction
2 = Operation
3 = Maintenance
4 = System drawings
Subsections
Sections 1 to 3 are divided into the necessary chapters.
A table of contents is provided at the beginning of every main section.
Pages
The pages of each subsection are numbered.
Example: 2. 4 -- 1
Page
Subsection
Section-Operation
030000E
07.08
LF-9.3
1.1 - 1
Caution
Warning
The word Warning draws attention to methods and procedures that must be adhered
to in order to avoid damage to the equipment.
Note
The word Note draws attention to particular technical matters which the driver must
observe and which also simplify the work.
Illustrations
The illustrations used in the operating instructions serve to explain the text. While they may vary from the
actual vehicle design, they will not basically change the factual information.
Patent, trademarks
The information included in these operating instructions is published regard less of any patent rights.
Trademarks are used without any warranty that they may be used freely.
Liability
The tets and illustrations were compiled with great care. Nevertheless, errors cannot be excluded completely. GHH Fahrzeuge GmbH and the authors cannot either assume any legal responsibility or any liability
for information and the consequences thereaf.
Please contact our Service Department if you have technical queries or if you notice any discrepancies.
The contents of these operating instructions are regularly revised to include technical innovations. We reserve the right of technical changes due to ongoing development without prior notice.
Copyright
Reproduction in any form or translation and storage on electronic media is not permitted without prior written consent by GHH Fahrzeuge GmbH. This also applies to extracts. All rights under copyright laws are
specifically reserved by GHH Fahrzeuge GmbH.
030011E
07.08
LF-9.3
1.1 - 2
Revision
Date
Date
Inserted
Name
Rev.
No.
Revision
Date
Date
Inserted
Name
032150E
07.08
LF-9.3
1.1 - 3
Preface
These operating instructions include important information on how to operate and keep your vehicle made
by
GHH Fahrzeuge GmbH
in working order.
One copy each of the instructions should at all times be available to both the driver and the maintenance
personnel. Each operation carried out on the vehicle presupposes that the contents of the operating instructions are known and strictly adhered to.
Therefore, please read these instructions carefully and familiarize yourself with the vehicle, in particular
before putting the vehicle into operation for the first time.
Proper operation and maintenance make for lasting operational reliability.
Any downtimes which are due to avoidable maintenance work can be minimized if special attention is paid
to the following:
-
Never alter without approval any parameters which are either permanently set or specified by the manufacturer, such as hydraulic pressures, tightening torques, etc.
Perform all specified maintenance and inspection work completely and in good time.
Use only oil brands and grease types which are in compliance with our recommendations.
Should you have any trouble or questions, or if you wish to order spare parts, please contact:
GHH Fahrzeuge GmbH
Abteilung S
Postfach 10 09 43
D-45809 Gelsenkirchen
Telephone: +49 (0) 209 389 07-300
Telefax: +49 (0) 209 389 07-349
or the representative responsible for your area.
Please state the vehicle type and serial number in all written queries or phone calls.
When making out spare parts orders, please adhere to the ordering instructions included in the spare parts
list.
Never have repairs or alterations carried out by third parties without our approval. You will appreciate that
we cannot be held responsible in any case of non-compliance with the above.
Note
030020E
07.08
Please note our Warranty Conditions for Mining and Tunnelling Vehicles, Airport
Equipment.
LF-9.3
1.2 - 1
S 0152
07.08
LF-9.3
1.3 - 1
Vehicle identification
For the specific data of your vehicle please see of the nameplates shown below.
Nameplates
The vehicle nameplate is located in the drivers compartment. All equipment such as engine, torque converter, transmission, axles, etc. have nameplates and may bear stamped equipment numbers.
Year of construction
Serial no
Rated power
kW
Payload
kg
Weight, empty
kg
The tire pressure plate indicates the tire type and the relevant pressure of the tires on the respective axles.
bar
bar
Type
bar
bar
of your vehicle.
030031E
07.08
LF-9.3
1.4 - 1
Technical Data
Length
Width, at the drivers cab
Width, at the bucket
Height, at the drive unit
(above drivers canopy)
Bucket capacity (SAE, heaped)
9 365 mm
2 740 mm
2 600 mm
1 790 mm
2 370 mm
4,5 m3
Weights
Deadweight
Payload
Front-axle load, unladen
Rear-axle load, unladen
Front-axle load, laden
Rear-axle load, laden
25 300 kg
9 500 kg
11 800 kg
13 500 kg
26 530 kg
8 270 kg
Tramming capacities
Maximum tramming speed
laden forward / reverse, on a level roadway
1st gear
2nd gear
3rd gear
4th gear
Maximum admissible gradient
Maximum allowed cross inclination
Maximum tractive force
4.5 km/h
9.2 km/h
15.4 km/h
25.0 km/h
25.0 %
15 %
217 kN
Engine
Manufacturer
Type
Design
DEUTZ
F10L413FW
air-cooled diesel engine two-stage
combustion
170 kW/2300 min-1
Dry air filter
Silencer, exhaust gas catalyst
6.6 kW/24 V
28 V/55 A
Max. power
Air intake system
Exhaust system
Starter power/voltage
Three-phase alternator/voltage
TechdatE
07.08
LF-9.3
1.5 - 1
Clark
series C8000
single-stage industrial type with auxiliary drives for steering and dump/hoist
hydraulic systems
Clark
series 32 000
power shift transmission with 4 forward
and 4 reverse gears each
Axles
Front axle
Manufacturer
Type
Design
Kessler
D102 PL341/528
rigid planetary axles with differential
gear
Rear axle
Manufacturer
Type
Design
Kessler
D102 PL341/528
rigid planetary axles with differential
gear
10
Swing angle
Wheels and tires
Front wheels
Rim
Size
13.00 - 25/2,5
Tires
Size
Tire filling pressure
18.00-25
6.0 0.1 bar
Rear wheels
Rim
Size
13.00 - 25/2,5
Tires
Size
Tire filling pressure
TechdatE
07.08
18.00-25
3.5 0.1 bar
LF-9.3
1.5 - 2
Service brake
Design
Parking brake
Design
Steering
Design
Steering angle
Outer clearance circle
Inner clearance circle
Hydraulic system
Dump/hoist hydraulic system
83,6+20,9 cm3/U
230 bar
2
1
5.9 sec.
5.5 sec.
83,6+20,9 cm3/U
175 bar
2
24V
2 x 12 V/180 Ah
Lighting system
Main/reversing headlights
Additional headlights
TechdatE
07.08
75/70W
70W
LF-9.3
1.5 - 3
TechdatE
07.08
390 l
320 l
appr. 31.5 l
appr. 36.0 l
28.0 l
2 x 6.0 l
26.0 l
2 x 6.0 l
LF-9.3
1.5 - 4
2950
3360
2050
1610
1790
2370
4615
4930
Dimensions of vehicle
3055
TechdatE
07.08
Spur 1905
2450
1515
9365
LF-9.3
1.5 - 5
4
6
8
1
Measuring distance
-
Measuring point 6
measuring point height = height of drivers head
Operating state
-
for 30 seconds, driving engine at full load and dump/hoist hydraulic against the stop.
Measurement result
Measuring point
db (A)
90
89
90
80
80
89
88
89
Schall
07.08
LF-9.3
1.5 - 6
The Load Haul Dumper is a vehicle with swivel-joint steering and hydrodynamic drive system, consisting
of the drive unit and payload unit.
The drive unit houses the drive system components, engine, converter, transmission, as well as the oil
cooler, tanks, hydraulic system components, brakes and the electrical equipment.
The driven axles are designed as rigid axles with differential gear and planetary gears in the axle ends.
The drivers cabin with its controls and instruments is arranged on the left-hand side of the vehicle, transverse to the tramming direction. The drivers seat is sprung and hydraulically cushioned.
The vehicle is steered by a hydraulic power steering system with one or two double-acting steering cylinders.
The service brake and the parking brake act on all four wheels. The service brake is executed as a dual
circuit braking system with a separate brake circuit for the front and rear axle. The parking brake is a
spring-actuated brake whose brake circuit works indepedently of the service brake.
The bucket and boom are linked to the payload unit. The bucket is tilted forward and backward by hydraulically operated dump/hoist cylinders. Control levers in the drivers cabin operate the boom and bucket.
The vehicle chassis is of welded construction, manufactured according to the applicable DIN standards
and the German Federal Railways DS 952 Code.
1_6-1E
07.08
LF-9.3
1.6 - 1
032140E
07.08
LF-9.3
1.6 - 2
Contents Operation
2.1
LF-9.3
2-1
2.1 - 1
Care for sufficient level of operating material, especially for engine, gears, axles, converters, brake
systems hydraulic and lubrication equipment, as
well as in cooling circuits.
2.1 - 2
030050E
07.08
LF-9.3
2.1 - 3
030060E
07.08
LF-9.3
2.1 - 4
Besides these safety instructions referring to a specific vehicle type, principally observe the general
safety instructions as well as the safety instructions
which correspond to operating mode of the engine.
For all work on the vehicle observe special safety
instructions for maintenance work.
Secure your parked vehicle especially at blind places with much traffic optically to avoid accidents
e.g. crashes.
030070E
07.08
LF-9.3
2.1 - 5
030080E
07.08
LF-9.3
2.1 - 6
Drivers seat
The drivers cab is equipped with a mechanically suspended drivers seat. To prevent health damage, the
drivers seat must be adjusted to the drivers body before starting the vehicle.
The restraint belt must be used at all times. The belt should be worn as tight as possible to the body. After
an accident the restraint belt must be replaced and the drivers seat and the fastening of the drivers seat
inspected by qualified personnel.
4
Adjustment
1
030090E
07.08
LF-9.3
2.2 - 1
All the instruments and control instruments necessary to operate the vehicle are arranged in the drivers
cab. The speed adjustment of the driving engine and therefore the adjustment of the driving speed is effected via the right-hand pedal and the operation of the service brake via the left-hand pedal. The built-in
steering wheel is tiltable. The control lever is located on the left side of the steering column. The boom
and the bucket are operated with the control switch (S84) and the gearshift mechanism with the lever that
is located on the left beside the instrument panel.
Changing steering direction
The steering direction of the vehicle thus corresponds to the sense of rotation of the steering wheel, independent of the tramming direction.
forward
reverse
9
gearshift
P2
P3
S87
release
S43
parking brake
apply
N 1
3
4
St+KonE
07.08
LF-9.3
2.3 - 1
S72
H2
H3
H1
H5
H6
H10
H17
H18
H19
H12
H7
H8
S80
S70
P2
St+KonE
07.08
S64
P3
LF-9.3
2.3 - 2
Note
Warning
Item
Description
P1
P2
AN speedometer
P3
AN revolutions counter
An engine speed of 2480+50 min-1 must never be exceeded.
H1
H2
ML preheating
Goes out when the engine is preheatet.
H3
H5
H6
H7
H8
St+KonE
07.08
LF-9.3
2.3 - 3
Description
H10
H12
H17
ML high beam
Lights up if the high beam is on.
H18
ML parking brake
Lights up if the parking brake is applied or is not fully released. It goes out as soon as
the parking brake is fully released.
H19
ML service brake
Lights up if the service brake is activated or when your foot rests lightly on the brake
pedal.
S43
S64
SL ignition-/starter switch
Turning position P:
Turning position 0:
Turning position 1:
Turning position 2:
Turning position 3:
not used
OFF
power ON
prehating
engine starting
S70
S72
SK lighting system
Turning position 0:
Turning position 1:
Turning position 2:
Turning position 3:
S80
DT headlight
S87
DT horn
St+KonE
07.08
OFF
parking light and material face lighting
low beam and material face lighting
high beam and material face lighting
LF-9.3
2.3 - 4
Checks
Before daily operation for reasons of safety and reliability of the vehicle perform the following checks:
-
Function of brake
Function of steering
Function of lighting
Note
All maintenance work on the vehicle frame, sub-assemblies and systems shall be carried out in accordance with the checklists in section 3.5.
Park vehicle on a level, dry surface, completely levelled. On gradients, park with the side of the vehicle
away from the drivers cab, swivelled towards the material face.
As a rule, the parking brake applies via the parking brake control lever (S43).
Clean vehicle.
2_4-1E
07.08
LF-9.3
2.4 - 1
Engine starting
Warning
If the engine is started using an external power supply through the external start socket,
it is essential to ensure that this power supply has the same voltage (24V) and that the
capacity is not greater than the batteries fitted. Do not isolate discharged batteries from
the electrical network.
Parking brake not released (goes out as soon as the parking brake is fully released).
battery switch
To preheat, set the ignition / starter switch to position Preheating and hold it in this position. Note that
the preheating signal lamp lights.
When the preheating signal lamp goes off, set speed adjustment pedal to approx. 1/4 speed and turn ignnition /starter switch to position Engine starting and hold it in this position.
Note
As soon as the engine is running, release the ignition-/starter switch and ease back the speed adjustment
pedal to such an extent that the engine runs smoothly at medium speed.
Warning
Do not start longer than 20 seconds; repeat the starting sequence if necessary.
Leave a one-minute pause between two starting sequences. If the engine has not
started after two starting sequences, inform maintenance and determine the cause. The
cold engine should not be operated at high speeds.
After the engine has fired and the various pressures have been built up, the indicators will go out.
Note
2_5-1E
07.08
In the event of faults see the engine operating instructions and the appertaining sections
of these operating instructions.
LF-9.3
2.5 - 1
Caution
The parking brake is not applied automatically when switching off the engine. It is therefore important to apply the parking brake manually via the control lever to secure the
vehicle against rolling away.
Place the gearshift lever in neutral position and switch off all consumers.
Switch-off the driving engine, turn the ignition/starter switch (S64) to position 0 and remove the key.
Note
Unless there is an emergency, do not switch off engine suddenly from full load. Allow
engine to cool down by running it at idling speed for a few minutes.
Warning
Switch off engine immediately if the engine oil pressure signal lamps light up in operation.
If the signal lamp alternator charge control lights up during operation, terminate the
operation as quickly as possible and switch off the engine.
Warning
If the Cylinder head temperature signal lamp lights up in operation, stop loader and
allow engine to cool down by running it at idling speed for appr. one minutes. Then
switch off engine.
2.5 - 2E
07.08
LF-9.3
2.5 - 2
Tramming operation
Caution
The vehicles steering system is inoperative when the engine has been stopped.
N=neutral position
N 1
2
Start-up
Start engine.
1st gear
reverse
Apply service brake to brake the loader to standstill. Keep service brake pedal depressed.
2_6-1_2E
07.08
LF-9.3
2.6 - 1
Warning
If the speeds in the individual gear steps fall below the minimum values specified for
the shifting point, this will cause excessive heating in the converter-transmission circuit
and consequently cause damage to the converter and the transmission.
In accordance with the shifting points for shifting down, the following gradient ranges can be travelled
in the individual gear steps:
(see annex, gradeability diagram 909-9-047220/106, page 3)
2nd gear
3rd gear
4th gear
1st gear
25 22%%
22% 11%
11% 5%
5% 0%
If the loader should be braked or stopped to standstill by changing to a lower gear, the point for changing
to a lower gear is at an engine speed of < 800 min-1.
2_6-1_2E
07.08
LF-9.3
2.6 - 2
Tramming on downhill slopes must never be done using the service brake. The brake will overheat !!
On all ranges of downhill slopes, for the same load (empty/laden), maximum the same gear and maximum the same driving speed as on uphill slopes shall be selected.
In the individual gears the maximum speed indicated in the technical data must not be exceeded.
When changing down to a lower gear, first brake to the switching gear using the service brake.
Warning
030162E
07.08
After changing to a lower gear, the rotational speed at the converter output/transmission
input is doubled (at least for a short time).
As a reference, the engine speed for changing to a lower gear is < 800 min-1.
LF-9.3
2.6 - 3
The brake power is converter into heat and the converter-transmission oil heated up.
The converter-transmission oil temperature indicator therefore has to be
watched.
Should the vehicles maximum converter oil temperature be exceeded, brake it by operating the service brake and allow engine to cool down at idling speed.
In pushing mode, the converter output/transmission input speed is substantially higher than the engine
speed, as indicated at the revolution counter.
Warning
In pushing mode, the speed at the converter output/transmission input is about twice
as high as the engine speed.
Therefore, the maximum admissible engine speed is 1500 min-1.
Note
For extensive driving on downhill slopes, sustained-action brakes (exhaust brakes, retarder brakes) should be used, or else a detrimental heat-up within the converter-transmission system may arise.
You must not exceed the speed at the several gears above the limits as listed below:
1st gear
4.5 km/h
2_6-4E
07.08
2nd gear
9.2 km/h
3rd gear
15.4 km/h
LF-9.3
4th gear
25.0 km/h
2.6 - 4
Note
Tow the vehicle only at walking speed and over short distances.
In the event of towing over a long distance or over a road gradient section proceed in compliance with the
indications on page 2.6 - 6.
Warning
Warning
To avoid chafing of the parking brake in case of too low a release pressure, a manometer
must be installed at test connectors B7.1 and B7.2. If the indicated pressure falls below
120 bar, this causes severe chafing, which may result in heating or even destruction
of the brake.
Towing in compliance with the indications on page 2.6 - 6.
Warning
During towing, monitor the brake pressure present for the service and parking brake on
the manometers in the drivers cab and on test connectors B7.1 and B7.2.
Caution
If the brake pressure for the srvice barke drops below 100 bar, a safe stop with the service brake is no longer guaranteed. The towing procedure must be immediately interrupted and if necessary executed in accordance with the indications on page 2.6 - 6.
A precondition for towing is an operational brake system and a sufficient available brake pressure in the
brake circuits of the service brake.
-
Check brake pressure on the manometers in the drivers cab and test connectors B7.1 and B7.2.
Warning
The available brake pressure for the service and parking brakes must be greater than
120 bar.
Place gearshift in neutral position. Switch on operating voltage and release parking brake.
Caution
Safe towing is not possible when the brake system is not operational, i.e. when the available brake pressure for the service brake is insufficient, when the towing vehicle has
a different brake system or as a result of removed component parts.
Warning
If the driving engine fails but the brake system is operational, the parking brake can be
released via the emergency release function (see 3.16 - 5) for towing and single stopping of the vehicle with the parking brake.
2_6-5E
07.08
LF-9.3
2.6 - 5
Provided both vehicles are fitted with the same brake system.
Oil is fillled in via the B4 test fittings. A DN 4 hose with suitable connecting couplers is required for this
purpose.
The following work operations are required:
-
Top up hydraulic oil on the hydraulic tank of the towing vehicle to maximum level.
Warning
With each braking operation hydraulic oil is pumped from the brake system of the towing
vehicle into that of the towed vehicle. It is therefore important to ensure that the hydraulic oil in the hydraulic reservoir of the towing vehicle does not fall below the minimum
level.
Decrease available brake pressure of brake system by pumping with the brake pedal. This has to be
done on both vehicles.
First connect filling hose to connection B4 of the vehicle being towed and vent hose by starting the
engine. (Hydraulic oil comes out bubble-free).
Restart engine of towing vehicle and charge brake system of both vehicles.
Turn on the electrical master and control switch of the vehicle to be towed. The service and parking
brakes are now ready for operation.
Remove the protections provided to secure the vehicle against rolling away.
Place gearshift in neutral position. Release parking brake and tow the vehicle.
Caution
At the end of the towing operation the hydraulic oil level on the hydraulic tank has to be
corrected on both vehicles.
Note
Before the filling hose is removed, the brake pressure in the brake system of both vehicles must be reduced simultaneously by pumping with the parking or service brake.
2_6-6E
07.08
LF-9.3
2.6 - 6
Dump/hoist operation
Fig. 1
Effect
boom/bucket
pull
push
left
right
spring-centered middle position
position 1
position 2
position 3
position 4
position 5
2_7-1E
07.08
LF-9.3
see
Fig. 1
2.7 - 1
Lower the boom to its stop, tip bucket forward until it is a few centimeters above the ground.
Drive evenly into the pile. Give full acceleration when the bucket penetrates the pile.
Warning
Avoid ramming the pile. The bucket should be introduced as far into the pile as is necessary to fill it.
Avoid spinning of wheels. Observe front wheels. If they start to spin, tip back bucket by inducing light
jerking movements on the control switch/operating lever. This will reduce penetration resistance and
increase the load on the wheels.
Before the front wheels enter the pile, the bucket should be fully tipped back and loaded.
Travel to the dumping point. Before reaching the dumping point use service brake to brake the loader
and raise the bucket to the necessary height for tipping it forward.
Tip back empty bucket and at the same time lower the boom to the stop.
030201E
07.08
LF-9.3
2.7 - 2
Winter operation
Low temperatures will aggravate the vehicles operating conditions. To ensure trouble-free operation in
winter, special maintenance and care are required. Preparing for the cold season in good time is of special
importance.
Engine
Engine oil
Too viscous engine oil will lead to starting problems and favour increased wear. Note the oil grades and
change intervals specified in the engine manufacturers operating instructions!
Injection nozzles
Have injection nozzles inspected regularly. Refer to engine manufacturers operating instructions.
Compression
Have compression checked before the winter begins. Insufficient compression will affect starting of the
engine, especially in cold weather.
Cold-starting equipment
Check existing cold-starting equipment regularly. Refer to the engine manufacturers operating instructions.
Cooling system
Coolant
Add a brand-name anti-freeze to the coolant of liquid-cooled engines in good time.
Refer to engine manufacturers operating instructions.
030210E
07.08
LF-9.3
2.8 - 1
Axle gear
Axle gear oil
Fill up axle gear oil according to the lubricant table.
Hydraulic system
Hydraulic oil
Fill up hydraulic oil according to the lubricant table.
Electrical system
Batteries
The starting capacity of the batteries depends on the charge state and the ambient temperature. Check
acid density regularly, charge batteries if necessary. Check for proper contact of terminals.
Alternator
The proper charging capacity of the alternator is especially important in winter. Check condition and tension of the V-belts regularly. Have alternator checked in good time (by specialist workshop).
Starter
Have starter checked if necessary by a specialist workshop. Grease flywheel gear rim if temperatures drop
below -20C.
Refer to engine manufacturers operating instructions.
030210E
07.08
LF-9.3
2.8 - 2
Shutdown of vehicle
Shut-off of vehicle
Caution
The parking brake is not applied automatically when switching off the engine. It is therefore important to apply the parking brake manually via the control lever to secure the
vehicle against rolling away.
Park vehicle on a level, dry surface, completely levelled. On gradients, park with the side of the vehicle
away from the drivers cab, swivelled towards the material face.
Shutdown of vehicle
If the vehicle is to be shut down for a longer period of time, the following work is to be carried out:
-
Jack up vehicle so that the tires do not touch the ground. Release parking brake.
Warning
2_9-1E
07.08
2.9 - 1
Warning
030230E
07.08
Generally, the usual preparations as for initial start-up of the vehicle must be made.
LF-9.3
2.9 - 2
Note
Caution
Transportation
To ensure maintenance of the loading dimensions, we recommend that a company experienced in this
field be consulted for transport.
Warning
030241E
07.08
Before transport the vehicle must be protected in a suitable way to prevent damage.
LF-9.3
2.10 - 1
Contents Maintenance
3.1
3.2
3E
07.08
LF-9.3
3.1 - 1
3.2 - 1
3.2 - 1
3.2 - 1
3.2 - 1
3.2 - 3
3.3 - 1
3.3 - 1
3.3 - 1
3.4 - 1
3.5 - 1
3.5 - 1
3.5 - 2
3.5 - 3
3.5 - 9
3.5 - 20
3.5 - 21
3.6 - 1
3.7 - 1
3.8 - 1
3.9 - 1
3.9 - 1
3.9 - 1
3.9 - 1
3.10 - 1
3.10 - 2
3.10 - 2
3.10 - 2
3.10 - 2
3.10 - 2
3.11 - 1
3.11 - 2
3.11 - 2
3.11 - 2
3.12 - 1
3.12 - 2
3.12 - 2
3.12 - 3
3.12 - 3
3.12 - 4
3-1
LF-9.3
3.13 - 1
3.13 - 1
3.13 - 1
3.13 - 2
3.14 - 1
3.14 - 2
3.14 - 2
3.14 - 2
3.14 - 2
3.14 - 2
3.15 - 1
3.15 - 1
3.15 - 1
3.15 - 2
3.15 - 3
3.15 - 4
3.15 - 5
3.15 - 6
3.15 - 7
3.15 - 8
3.15 - 9
3.15 - 10
3.15 - 11
3.15 - 11
3.15 - 12
3.16 - 1
3.16 - 1
3.16 - 2
3.16 - 2
3.16 - 2
3.16 - 2
3.16 - 2
3.16 - 3
3.16 - 3
3.16 - 4
3.16 - 4
3.16 - 5
3.17 - 1
3.17 - 1
3.17 - 1
3.17 - 2
3.17 - 2
3.17 - 2
3.17 - 2
3.17 - 3
3.17 - 3
3-2
3.18
3.19
3.20
3.21
3.22
3.23
3.24
3.25
3.26
3E
07.08
LF-9.3
3.17 - 3
3.17 - 4
3.17 - 5
3.18 - 1
3.18 - 1
3.18 - 2
3.18 - 2
3.18 - 2
3.18 - 3
3.18 - 3
3.18 - 3
3.18 - 3
3.18 - 3
3.18 - 3
3.19 - 1
3.19 - 1
3.19 - 1
3.19 - 1
3.19 - 1
3.19 - 1
3.20 - 1
3.20 - 2
3.21 - 1
3.22 - 1
3.22 - 1
3.22 - 1
3.22 - 2
3.22 - 2
3.22 - 2
3.22 - 2
3.22 - 2
3.22 - 2
3.23 - 1
3.24 - 1
3.25 - 1
3.25 - 1
3.25 - 2
3.25 - 3
3.26 - 1
3-3
Warning
3.1 - 1
Plug and socket connections should only be disconnected and reconnected with the voltage
switched off.
It is prohibited at any time to store any parts especially tools, installation material, clothes, etc. in the
dangerous vicinity of unsecured, uninsulated parts
which are connected to the power supply
In the event of damage it is possible the capacitor housing may crack, therefore proceed with
extreme care.
3.1 - 2
030253E
07.08
LF-9.3
3.1 - 3
Warning
Trouble-free operation and a long service life require regular and proper maintenance
and servicing.
Warning
The warranty is immediately void if any anti-tamper seals or paint seals attached to the
vehicle systems are detached or destroyed.
Maintenance and servicing of new vehicles, after a basic overhaul, after installation of replaced components, etc. up to the time at which regular work is to be carried out.
Maintenance and servicing of individual components which are particularly affected by varying operating conditions.
Maintenance and servicing work which cannot either be determined by the number of operating hours,
or whose intervals deviate from the usual apportioning into the number of operating hours.
Special measures for operation at low temperatures see 2.8 - 1 winter operation.
General remarks
The work specified in the check lists will be detailed in the various sections of the maintenance and servicing instructions.
Various items of the specified work may involve identical work steps. To avoid repetitions in the descriptions, these work steps are described below.
-
Safety at work
Note safety instructions for maintenance and servicing.
030260E
07.08
LF-9.3
3.2 - 1
Corrosion protection
Touch up damaged painted surfaces, grease bright spots regularly.
Oil change
Drain oil from warm components only. Clean surrounding of the filling port. Fill up oil from clean containers only. Do not remove strainers from filling ports.
Check oil level after a brief trial run.
Lubrication
Clean grease fittings before and after lubrication. Remove any excess grease from lubrication points.
030260E
07.08
LF-9.3
3.2 - 2
Safety notes
Liquid nitrogen has a temperature of -196C, which is why any contact with liquid nitrogen and undercooled
material must be avoided. To do so, protective clothing suiting the requirements (but at least protective
goggles and protective gloves) shall be worn.
Liquid nitrogen may be processed in well-ventilated rooms only, so as to avoid lack of oxygen caused by
the breathing air being enriched with too much nitrogen. Gaseous nitrogen is a colourless, tasteless and
odourless gas contained in the normal ambient atmosphere at a rate of 78%. Provided that sufficiently
large amounts of fresh air are supplied, the nitrogen, which upon heating of the frigorific mixture has changed to the gaseous phase, poses no special risk.
Inserting and withdrawing work pieces should preferably be done with the help of equipment made from
materials tough at subzero temperatures, such as hemp ropes, copper wire, tongs and hooks made of
suitable stainless steel grades (1.4541), as far as these are subjected to the influence of liquid nitrogen.
When exposed to subzero temperatures, ordinary structural steels lose their toughness and become coldbrittle.
Wall thickness/diameter in mm
50
100
200
10
20
Warning
The maximum admissible immersion time for sleeves made of polyester-resin fabrictype compound materials is 10 minutes.
After its removal from the bath, the work piece must be processed immediately, i.e., positioned as shown
in the fabrication documents and fixed in the specified position, if any. What must be observed especially
with smaller, thin-walled work pieces is that these may adjust to the ambient temperature and therefore
lose their joining tolerance already after a short time.
While joining undercooled materials, no impacts must be applied to the work piece, as this would increase
the materials sensibility to brittle fracture
033050E
07.08
LF-9.3
3.2 - 3
Warning
030270E
07.08
3.3 - 1
Warning
The use of operating agents not specified herein must, if necessary, be clarified with
the manufacturer of the component/unit.
The use of additives in combination with the operating agents specified (e.g. flow improving agents for
diesel fuels, oil additives etc.) shall, as a rule, be agreed on beforehand with the manufacturer of the component or assembly.
Note
For high reliability and minimal wear of your machine, always use high-viscosity lubricants suited to the season and the ambient temperature.
Lubricant
and operating agents
Spezification
Ambient
temperature
(C)
Classification/
Mixing ratio
Subassembly/ Remark
Component
Engine oil
API
CF-4 1)
CG-4; CH-4 2)
-25
+20
SAE 10 W-30
Lubrication of
drive engine
-25
+25
-20
+25
SAE-viscosity class
according toDIN 51511
-20
+>30
Lubricants
referred to
in comparable specifications, not
listed here,
may also be
used.
Frostproof
-22
65 % Water/
35 % additive
Cooling system
of drive engine
The mixing
ratio may vary
according to
the climatic
conditions.
60 % Water/
40 % additive
Frostproof
-35
55 % Water/
45 % additive
>0
Summer diesel
ACEA
E2-96 *
E3-96; E4-98 2)
Coolant
Fuel
BS 2869, A1 and A2
1)
2)
3)
-20
SAE 10 W-40
SAE 15 W-30
SAE 15 W-40
Warning:
Too high a
percentage
of protective
agent decreases the
cooling performance.
Fuel system of
drive engine
100%
Winter diesel
(four-star diesel)
Make sure to add
petroleum at temperatures below
-15C or -20C 3).
SchmierE
07.08
LF-9.3
3.4 - 1
Spezification
Ambient
temperature
(C)
Brake fluid
DOT 4/
SAE J 1703
all year
Hydraulic oil
HVLP
DIN 51524 T3
-35
+15
ISO VG 15
-28
+25
ISO VG 22
-22
+33
ISO VG 32
-15
+45
ISO VG 46
-5
+50
ISO VG 68
+60
ISO VG 100
HLP
DIN 51524 T2
ATF
Subassembly/
Component
Remark
Speed
adjustment
-22
+20
ISO VG 22
-15
+30
ISO VG 32
-10
+40
ISO VG 46
Transmission oil
Classification/
Mixing ratio
+50
Steering and
dump/hoist
hydraulic system
ISO VG 68
+7
+57
ISO VG 100
-20
+10
+ 35
Note
For transmissions that are executed with a clutch modulation, the suffix with modulation is added to the type desgination in the technical data.
Note
On some transmissions and torque converters with a throughshift clutch no ATF oils
Dextron II D may be used. The oils based on this specification are not compatible with
graphitic friction linings. That is why these oils shall only be used after prior consultation
with our Service department or the manufacturer of the component.
Dextron is a registered trademark of the General Motors Corporation.
API GL5, Dexron III and multiviscosity oils with a temperature range of more than 10
points, e.g. 10W30, shall, as a rule, not be used.
SchmierE
07.08
LF-9.3
3.4 - 2
Spezification
Ambient
temperature
(C)
Classification/
Mixing ratio
Subassembly/
Component
Transmission oil
Hypoid-gear oil
MIL-L - 2105 B
API GL5
API GL5 LS
> +30
SAE 140
Axle
planetary gear
Hypoid multigrade
oil
MIL-L - 2105 C / D
API GL5
-10
+30
SAE 90
-35
+38
SAE 75W-90
-26
+38
SAE 80W-90
-35
>+60
SAE 75W-140
-26
>+60
SAE 80W-140
-12
>+60
SAE 85W-140
differential gear
Lubricating
grease:
Lithium grease of
NLGI class 2 4)
-30
+130
K2K-30
DIN 51502
grease fittings
bearings
drivelines
Lubricating
grease:
Graphite
K2K DIN 51502
-30
+130
sliding surface
metal / metal
4)
Remark
Note
SchmierE
07.08
For axles with a multi-disc self-locking differential (limited slip differential) (see type
designation in the technical data sheet), lubricant API GL5 LS shall, as a rule, be used.
Optionally, the lubricant can also be used for axles with no multi-disc self-locking differential.
LF-9.3
3.4 - 3
Maintenance work
Measures/
Remarks/
Cross references
Operat. agents/
Quantity/
Dimensions
Note of
performance
1. Lubricating points
1.1 Lubricating bearing positions
with hand pump
Remarks:
Remarks:
Remarks:
Remarks:
Remarks:
Remarks:
Warning
3.5-1E
07.08
Lubricants with solid additives (e.g. molybdenum bisulphide) shall never be applied to
bearing positions where polyester resin fabric composite materials are used.
LF-9.3
3.5 - 1
Maintenance work
check
change
clean
Operat. agents/
Quantity/
Dimensions
Note of
performance
1. Drive engine
All engine maintenance work according to engine
manufacturers maintenance plan.
Remarks:
Remarks:
Remarks:
Remarks:
Remarks:
3.5-2E
07.08
LF-9.3
3.5 - 2
The position of the measuring points for the individual pressure measurements shall be
taken from the relevant system drawing and the measuring points plan, see page
3.5 - 22. As a rule, only calibrated measurement instruments shall be used.
Maintenance intervals
150 Bh
300 Bh
450 Bh
750 Bh
900 Bh
Maintenance work
check
change
clean
Operat. agents/
Quantity/
Dimensions
Note of
performance
1. Axles
1.1 Visual check for leaks
o
1.2 Breather
Remarks:
2. Wheels
2.1 Wheel nuts for completeness and firm
seating
Tighten, if necessary
front
right/left
( 445 Nm )
rear
( 445 Nm )
Replace, if necessary
front
right/left
right/left
Note
In case of wheel change
and when replacing/retightening wheel nuts observe
the tightening torques.
2.2 Condition of tyres
rear
2.3 Tyre filling pressure
o
right/left
Correct, if necessary
front
right/left
rear
right/left
Remarks:
3_5-3_8E
07.08
LF-9.3
3.5 - 3
Maintenance work
check
change
clean
Operat. agents/
Quantity/
Dimensions
Note of
performance
Vehicle in general
right/left
dump cylinder
bucket-connecting link
boom-stabilizer link
swivel joint
payload unitboom
right/left
boombucket
right/left
top/bottom
Remarks:
( 295 Nm )
transmission fastening
M10- ( 48 Nm )
3/4- ( 525 Nm )
M16- ( 90Nm )
flexible supporting
torque converter fastening
( 48 Nm)
axle fastening
M24x1,5
( 1160 Nm )
M30x2
( 2206 Nm )
Connecting of drivelines
o
intermediate driveline
M12- ( 120 Nm )
M14- ( 195 Nm )
M16- ( 210 Nm )
Remarks:
3_5-3_8E
07.08
LF-9.3
3.5 - 4
Maintenance work
check
change
clean
Operat. agents/
Quantity/
Dimensions
Note of
performance
On the level indicator with driving engine running and retracted cylinders.
Top up oil, if necessary
see 3.17 - 1 and 3.17 - 2
Remarks:
Check oil level at service temperature and with driving engine running. Oil level between
MIN and MAX marks on dipstick.
Top up oil, if necessary.
see 3.12 - 2
o
o
see 3.12 - 4
Check for damage, if necessary, change component.
see 3.12 - 1
Remarks:
3_5-3_8E
07.08
LF-9.3
3.5 - 5
Maintenance work
check
change
clean
Operat. agents/
Quantity/
Dimensions
Note of
performance
6. Service brake
6.1 Connections, lines and
hoses for leaks.
o
70+3 bar
70+3 bar
Residual pressure
max. 0,5 bar, at
high idling speed.
Residual pressure
max. 0,5 bar, at
high idling speed.
15 5 bar, at high
idling speed.
Remarks:
3_5-3_8E
07.08
LF-9.3
3.5 - 6
Maintenance work
check
change
clean
Measures/
Remarks/
Cross references
Operat. agents/
Quantity/
Dimensions
Warning lamp
available braking
pressure in drivers cab lights up
when pressure
drops below
1003 bar
1173.5 bar- ON
1453.5 bar-OFF
Residual pressure
min. 75 bar
After one-hour
immobilization
time:
min. 100 bar
Note of
performance
Remarks:
3_5-3_8E
07.08
LF-9.3
3.5 - 7
Maintenance work
check
change
clean
Operat. agents/
Quantity/
Dimensions
Note of
performance
7. Electrical system
7.1 Function of instruments
and signal lamps in the
drivers cab.
o
7.2 Function of the lighting
system
o
Remarks:
8. Lubricating points
8.1 Lubrication of drivelines
converter-transmission
2 grease fitting
Note
see 3.13
transmissionintermediate driveline
2 grease fitting
2 grease fitting
transmission-rear axle
2 grease fitting
2x
Remarks:
Warning
3_5-3_8E
07.08
Lubricants with solid additives (e.g. molybdenum bisulphide) shall never be applied to
bearing positions where polyester resin fabric composite materials are used.
LF-9.3
3.5 - 8
The position of the measuring points for the individual pressure measurements shall be
taken from the relevant system drawing and the measuring points plan, see page
3.5 - 22. As a rule, only calibrated measurement instruments shall be used.
Maintenance intervals:
600 Bh
Maintenance work
check
change
clean
Operat. agents/
Quantity/
Dimensions
Note of
performance
1. Axles
1.1 Visual check for leaks
o
1.2 Oil level
differential gear
front axle
front axle
right
left
rear axle
rear axle
right
left
1.4 Breather
front axle
filling volume 28.0 l
rear axle
filling volume 26.0 l
Bemerkungen:
3_5-9_19E
07.08
LF-9.3
3.5 - 9
Measures/
Remarks/
Cross references
Operat. agents/
Quantity/
Dimensions
Tighten, if necessary
front
right/left
( 445 Nm )
rear
( 445 Nm )
Replace, if necessary
front
right/left
check
change
clean
Maintenance work
Note of
performance
2. Wheels
2.1 Wheel nuts for completeness and firm
seating
right/left
Hinweis
In case of wheel change
and when replacing/retightening wheel nuts observe
the tightening torques.
2.2 Condition of tyres
rear
2.3 Tyre filling pressure
o
right/left
Correct, if necessary
front
right/left
rear
right/left
Remarks
Vehicle in general
hoist cylinder
dump cylinder
bucket-connecting link
boom-stabilizer link
swivel joint
payload unitboom
right/left
boombucket
right/left
right/left
top/bottom
Remarks
3_5-9_19E
07.08
LF-9.3
3.5 - 10
Maintenance work
check
change
clean
Measures/
Remarks/
Cross references
Operat. agents/
Quantity/
Dimensions
( 295 Nm )
transmission fastening
M10- ( 48 Nm )
3/4- ( 525 Nm )
M16- ( 90Nm )
flexible supporting
Note
When replacing/retightening o
connecting screws observe
o
the tightening torques.
( 48 Nm)
axle fastening
M24x1,5
( 1160 Nm )
Note of
performance
M30x2
( 2206 Nm )
Connecting of drivelines
o
intermediate driveline
3.3 Speed adjustment
M12- ( 120 Nm )
M14- ( 195 Nm )
M16- ( 210 Nm )
engine speed
2480 50 min-1
see 3.10 - 1
Remarks
Remarks
3_5-9_19E
07.08
LF-9.3
3.5 - 11
Maintenance work
check
change
clean
Operat. agents/
Quantity/
Dimensions
Note of
performance
see 3.17 - 1
Clean the magnet
o see 3.17 - 5
Measures/
Remarks/
Cross references
filling volume
390 l
Remarks
Remarks
3_5-9_19E
07.08
LF-9.3
3.5 - 12
Maintenance work
check
change
clean
Operat. agents/
Quantity/
Dimensions
Note of
performance
see 3.12 - 4
filling volume
circuit 36.0 l
o on transmission sump
see 3.12 - 1 and 3.12 - 3
Remarks
6. Betriebsbremse
6.1 Connections, lines and
hoses for leaks.
o
Remarks
3_5-9_19E
07.08
LF-9.3
3.5 - 13
Maintenance work
check
change
clean
Measures/
Remarks/
Cross references
Operat. agents/
Quantity/
Dimensions
70+3 bar
70+3 bar
Note of
performance
Residual pressure
max. 0,5 bar, at
high idling speed.
Residual pressure
max. 0,5 bar, at
high idling speed.
15 5 bar, at high
idling speed.
6.5 Pressure switch S53
o
Warning lamp
available braking
pressure in drivers cab lights up
when pressure
drops below
1003 bar
Remarks
3_5-9_19E
07.08
LF-9.3
3.5 - 14
Maintenance work
check
change
clean
3_5-9_19E
07.08
Measures/
Remarks/
Cross references
Operat. agents/
Quantity/
Dimensions
1173.5 bar- ON
1453.5 bar-OFF
After one-hour
immobilization
time:
min. 100 bar
Measuring point
pressure
B24 > B28
B25 > B29
B26 > B30
B27 > B31
at high idling
speed.
LF-9.3
Note of
performance
Change-over of
driving direction
at a brake pressure > 51 bar
3.5 - 15
Switch activating
point at 180+5
bar rising.
Remarks
3_5-9_19E
07.08
LF-9.3
3.5 - 16
Maintenance work
check
change
clean
only at Bh
2400 / 4800 / 7200 .....
Measures/
Remarks/
Cross references
Operat. agents/
Quantity/
Dimensions
Switch activating
point at 140+10
bar rising.
Actual dimension
= 2.0 mm greater
than control dimension. Inspect
brake.
rear wheel
right/left
front wheel
right/left
if necessary, change component. see 3.15 - 10
6.14 Braking deceleration
o
min. 40%
1 sec. after
actuating the
brake the retardation must have
reached 35%
Note of
performance
Remarks
7. Parking brake
3_5-9_19E
07.08
LF-9.3
3.5 - 17
Warning lamp
parking brake in
drivers cab goes
out when pressure rises above
115-3 bar.
Warning lamp
lights up when
pressure drops
below 1043 bar
Remarks
3_5-9_19E
07.08
LF-9.3
3.5 - 18
Maintenance work
check
change
clean
Measures/
Remarks/
Cross references
Operat. agents/
Quantity/
Dimensions
released
min. 115 bar
min. 53%
1 sec. after
actuating the
brake the retardation must have
reached 35%
Note of
performance
applied
max. 0,5 bar
Remarks
8. Electrical system
8.1 Battery
o
o
Remarks
3_5-9_19E
07.08
LF-9.3
3.5 - 19
Operat. agents/
Quantity/
Dimensions
converter-transmission
2 grease fitting
Note
see 3.13
transmissionintermediate driveline
3 grease fitting
2 grease fitting
transmission-rear axle
2 grease fitting
check
change
clean
Maintenance work
Note of
performance
9. Lubricating points
Radiator grill
2 grease fitting
2x
Remarks
Warning
3_5-9_19E
07.08
Lubricants with solid additives (e.g. molybdenum bisulphide) shall never be applied to
bearing positions where polyester resin fabric composite materials are used.
LF-9.3
3.5 - 20
Maintenance work
check
change
clean
Operat. agents/
Quantity/
Dimensions
Note of
performance
see 3.15 - 8
see 3.15 - 9
Remarks
Service brake
Remarks
Remarks
Remarks
Remarks
Remarks
3_5-9_19E
07.08
LF-9.3
3.5 - 21
B5, B7.1
B27, B31
B26, B30
11
14
H1 (4)
13
H2
B6, B7.2
B25, B29
H10-H13
H20-H23
(3)
B24, B28
Measuring-points
Steering- dump/hoist hydraulic system
Brake system
B4
B5
B6
Brake system
10
11
12
13
14
15
3_5-20E
07.08
LF-9.3
3.5 - 22
16,17 21
1,2
1
5,6
10
14,15
22 18,19,20
23
24
7,8
13
14
15
16
Bucket bearing
17
Bucket bearing
18
19
20
21
10
Boom bearing
22
23
24
11
12
12,13
3,4
7,8
right and left
3_5-22E
07.08
LF-9.3
3.5 - 23
150
300
450
750
900
1050
1350
1500
1650
1950
2100
2250
2550
2700
2850
3150
3300
3450
3750
3900
4050
4350
4500
4650
4950
5100
5250
5550
5700
5850
6150
6300
6450
6750
6900
7050
7350
7500
7650
030381E
07.08
Data
Signature
Hours in
service
Data
Signature
7950
8100
8250
8550
8700
8850
9150
9300
9450
9750
9900
10050
10350
10500
10650
10950
11100
11250
11550
11700
11850
12150
12300
12450
12750
12900
13050
13350
13500
13650
13950
14100
14250
14550
14700
14850
15150
15300
15450
Hours in
service
Data
Signature
15750
15900
16050
16350
16500
16650
16950
17100
17250
17550
17700
17850
18150
18300
18450
18750
18900
19050
19350
19500
19650
19950
20100
20250
20550
20700
20850
21150
21300
21450
21750
21900
22050
22350
22500
22650
22950
23100
23250
LF-9.3
3.6 - 1
600
1200
1800
2400
3000
3600
4200
4800
5400
6000
6600
7200
7800
030381E
07.08
Data
Signature
Hours in
service
Data
Signature
8400
9000
9600
10200
10800
11400
12000
12600
13200
13800
14400
15000
15600
Hours in
service
Data
Signature
16200
16800
17400
18000
18600
19200
19800
20400
21000
21600
22200
22800
23400
LF-9.3
3.6 - 2
Before carrying out any maintenance and servicing work on the diesel engine, please carefully read the
attached engine manufacturers operating instructions.
Satisfactory operation of the diesel engine in the long term can only be ensured by investing a certain
amount of work in maintenance.
This work is a prerequisite for long engine service life and for maintaining the performance, consumption
level and exhaust gas quality.
Warning
030390E
07.08
LF-9.3
3.7 - 1
Note
The vehicle is equipped with a dry-air filter. Whenever the filter is serviced, the connecting points of the intake pipes have to be checked for leaks.
The dry air filter is equipped with an integrated pre-separator, a 6-stage vacuum indicator and, depending
on the type, a main and safety element. The main element respectively main element and safety element
must also be replaced outside the maintenance intervals as soon as the display of the underpressure indicator changes to the red area.
Note
The maximum service life of the main element must not exceed one year.
Damaged filter elements and seals must be in any case be replaced forthwith.
Note
With every third maintenance of the main element, the safety element, if present, must
be replaced as well. The number of maintenances must be marked on the safety element, e.g. by means of a bar drawn with a felt-tip pen.
Depending on the filter type, either a dust collecting vessel or a dust discharge valve is fitted.
-
To protect the paper cartridge from overloading, the dust collecting vessel should be emptied when half
full, however, at least once a day. For emptying, remove the lid of the dust collector (see fig. 3). On this
filter type, however, the discharge slot of the dust discharge valve should be cleaned periodically. Any
baked dust that may be present must be removed by compressing the valve.
Fig. 2
Fig. 1
9
Fig. 3
Fig. 4
3_8-1_2E
07.08
LF-9.3
3.8 - 1
Note
All maintenance work on the air intake system must be carried out with the engine
turned off. Do not start the engine when the main element has been removed.
Loosen clamp ring (9) and remove the dust collector (1) or loosen the wing nuts on the lid (4) and remove the main element (2). The safety element (3) remains in the filter housing.
Dispose of the main element in accordance with the applicable regulations. Clean the filter housing,
especially the sealing area for the main element, using a damp cloth.
Note
With every third replacement of the main element (2) the safety element (3) must be removed and replaced as well.
Note
The main element (2) may be cleaned up to 6 times. Cleaned elements are, however,
no longer covered by the warranty. To protect the engine, we recommend the use of new
main elements.
Warning
Never wash or brush out the main element. When blowing out, make sure that no dust
gets on the inside of the main element.
Prior to fitting, the cleaned main element should be checked for any damage.
Fit dust collector and secure with clamp ring or screw on lid with the wing nuts.
Reset vacuum indicator (6) to its initial position by pressing the reset button (7). The indicator in the
display window (8) changes to green.
See operating instructions issued by the engine manufacturer for further information.
3_8-1_2E
07.08
LF-9.3
3.8 - 2
Note
Check exhaust manifold and pipe regularly for firm seating and leaks.
MAN engine
MWM engine
DB engine
F6 L 413 F/FW
max. 650 mm WC
F8 L 413 F/FW
max. 750 mm WC
max. 750 mm WC
max. 750 mm WC
BF 4 L 1011
max. 750 mm WC
BF 12 L 413 FW
max. 750 mm WC
F6 L 912 W
max. 750 mm WC
F6 L 914
max. 750 mm WC
D 0826 LF
max. 600 mm WC
D 2865 LF
max. 600 mm WC
D 2866 LF
max. 600 mm WC
D 2866 LUH
max. 600 mm WC
D 916-6
max. 980 mm WC
D 932-V8
max. 980 mm WC
D 932-V12
max. 980 mm WC
OM 421 A
max. 610 mm WC
max. 860 mm WC
The exhaust back-pressure limit values also apply to the use of catalytic converters. Check exhaust back
pressure at regular intervals.
Silencer, exhaust gas catalyst
The silencer and catalytic converter require no special maintenance and have to be replaced if defective.
Check regularly for proper condition and firm seating.
CO-measurement
The maximum admissible CO level depends on the official regulations applicable at the jobsite.
030420E
07.08
LF-9.3
3.9 - 1
Fuel system
1
2
4
Screw cap
Intake nozzle
Drain plug
Tank lid
Intake filter
Ventilation filter
030430E
07.08
LF-9.3
3.10 - 1
Caution
Shut off engine before working on the fuel system, including filling up fuel and checking
the fuel line.
Do not smoke or use open flame.
Do not spill fuel on hot engine parts (exhaust pipe, etc.).
Note
Never let the fuel tank run completely dry. If, for example, the tank is emptied for cleaning, the fuel system has to be vented.
Filling up fuel
Never remove the strainer when filling up fuel and do not extract fuel from the bottom of a barrel as this
will stir up the slurry at the bottom of the barrel. Provide a fine-mesh filter in the filling hose, if possible.
Note
To prevent inflammation due to static charges, the intake nozzle and the mouth of the
filling nose must be in contact with each other.
Draining fuel
Use the drain plug on the tank underside to drain fuel or slurry. Make sure that the plug seals well.
Cleaning the intake filter
-
Release tank lid and lift off filler nozzle. Wash out intake filter with diesel fuel.
Mount nozzle and, while doing so, make sure that the gasket is properly seated. Replace gasket, if required.
Warning
LF-9.3
3.10 - 2
Speed adjustment
Speed adjustment of the diesel engine between idling and full load speed is accomplished with the footoperated treadle on the drivers place floor, via a hydraulic system
Note
71
Control cylinder
adjusting screw
working pressure (G2) (IS)
51
P = inlet
A = outlet
T = drain
P
A
T
13
adjusting screw
working pressure (G2) (HI)
connection lever
injection pump
49
swivel head
rod
29
HI = High
idling speed
Check points
IS = idling speed
Operating pressure
G1
Working pressure
G2
Return pressure
G3
17.0 -- 20.0
at IS+HI
IS max. 2.7
HI min. 141
max. 0.7
G1
G3
return line transmission sump
G2
3_11-1_2E
07.08
LF-9.3
3.11 - 1
Fit rod on the threaded rod leading to the lever of the injection pump.
Align the length of the rod so that the hole in the lever of the setting cylinder and the hole in the swivel
head register perfectly as shown on the drawing.
Mount the pin. It must be possible to insert the pin without applying any force.
Pull rod by hand until the lever of the injection pump is positioned at the mechanical stop.
At the selected hole in the lever of the setting cylinder there must be an overtravel of min. 3 mm with
respect to the rod.
Note
If the overtravel is less than 3 mm, the basic setting of the rod length must be adjusted
to another hole in the lever of the setting cylinder and the overtravel checked again.
Release accelerator pedal and refit and fasten rod on lever of the setting cylinder, using the hole to
which the rod length has been adjusted.
Final check
Start engine and check speeds.
Idling speed = 650 50 min-1
High idling speed = 2480 50 min-1
Diaphragm accumulator
Checking the diaphragm accumulators see page 3.15 - 3 and 3.15 - 6.
3_11-1_2E
07.08
LF-9.3
3.11 - 2
3
6
Oil dipstick
Tightening torques
Oil drain
Fastening screws
Transmission vent
Torque converter 48 Nm
Intake strainer
Drive-plate / engine 70 Nm
Oil cooler
033420E
07.08
LF-9.3
3.12 - 1
Warning
Ensure absolute cleanliness when working on the converter and transmission system.
No foreign matter is allowed to penetrate the system.
Park the vehicle on a level surface and run engine at idling speed for two minutes.
Pull out the oil dipstick and wipe it off with a lint-free cloth.
Insert the oil dipstick up to the stop, pull it out and check the oil level between the markings on the
stick.
The oil fill is to reach up to the bottom edge of the control screw.
If required, top up oil as per lubricant table through the filling port.
030461E
07.08
LF-9.3
3.12 - 2
Note
The converter-transmission hydraulic oil is to be drained with the oil at operating temperature.
Fill up oil through the filling port until the oil level is at the lower dipstick mark.
Start engine and run at idling speed for two minutes to fill the torque converter and hydraulic lines with
oil.
Check oil level with engine runnig (idling speed) and top up oil to lower dipstick mark.
On reaching the operating temperature (82-93 C), recheck oil level and top up oil to the upper dipstick
mark.
Remove oil level control screws and fill up oil through the filling port until oil comes out of the lower
control bore.
Start engine and run at idling speed for two minutes to fill the torque converter and hydraulic lines with
oil.
Screw in lower oil level control screw, start engine and as the operating temperature (82-93 C) is reached, top up oil until it comes out of the upper control bore.
Warning
030461E
07.08
LF-9.3
3.12 - 3
Stop the system and relieve the filter on the pressure side.
Screw off cover (1), remove spring (3) and the complete filter insert consisting of (4 - 7, 9 and 10).
Screw off drain plug (12) on filter housing (8) and drain the oil.
Clean filter housing with suitable medium and screw on drain plug (12); use new gasket (11) if
necessary.
Disassemble filter insert by unscrewing the fixing nut (10) and pulling off the filter element (7).
Dispose of the filter element in an environmentally-friendly manner. Clean the remaining parts of the
filter insert.
Assemble filter insert using new filter element (7) and new gaskets (6, 9).
Install filter insert in the filter housing (8) with new gasket (5). Make sure that the gasket sits correctly.
Install spring (3), screw on cover (1) with new gasket (2) and tighten up.
1
Maintenace indicator
green area
red area
3
4
5
marking
6
7
8
9
10
11
12
033710E
07.08
LF-9.3
3.12 - 4
Drivelines
Grease fitting
Grease fitting of
individual joint
Lubrication
Drivelines and intermediate bearing points have to be greased at regular intervals according to the manufacturers maintenance instructions. As the lubrication path extending within the spider and through the
spaces between the rolling elements is long and narrow, the grease takes time to expand. Only slow greasing at low pressure will ensure a uniform distribution of the grease.
Warning
030473E
07.08
LF-9.3
3.13 - 1
Lubricants
For lubrication use only lithium-saponified greases with a penetration of 265/295 and a thawpoint of approx. 180C. The lubricants must not contain any MoS2 additives.
drive unit
converter
030473E
07.08
rear axle
payload unit
transmission
LF-9.3
front axle
3.13 - 2
Axles
Differential
Fig. 1
1+2
1+2
Planetary gear
1+2
3
Abb. 2
LF-9.3
3.14 - 1
Note
To check the oil level and change the differential and planetary gear oil, park the vehicle
on a level surface.
Note
Whenver oil has been changed: Check differential and planetary gear oil level again after waiting for a few minutes.
Whenver oil has been topped up: Check differential and planetary gear oil level again
after waiting for a few minutes.
031730E
07.08
LF-9.3
3.14 - 2
Brake system
All four wheels of the vehicle are equipped with combined brakes. Each combined brake consists of a service and a parking brake component that act on the oil-cooled brake disks. When operated, hydraulic pressure is admitted into the service brake, whereas the parking brake is spring-actuated and released hydraulically.
Brake system :
Parking brake:
General notes
Caution
Prior to works on the brake system, release pressure on the diaphragm accumulator
on the fluid side and check that the system is pressure-free.
Always bear in mind that the pressure-free condition indicated on the manometer (P12)
in the drivers cab does not mean that the entire system is pressure-free.
Note
For setting data, check points and notes see Brake system drawing.
All instructions relating to the maintenance, disassembly and re-assembly of brakes and brake components are issued on the condition that the relevant work is carried out by trained personnel.
-
Brake disks that have reached the wear limit must be replaced.
Pressure and tension springs as well as sealing rings, protective caps and bellows must be replaced
after a service life of no more than two years.
Where mineral oil is used as brake fluid, mineral-oil resistant rubber parts must be used in the brakes
and wheel cylinders.
Bleed complete brake system and check for leaks after maintenance work has been carried out.
Warning
3_15-1E
07.08
Mounting and dismounting the brakes must be carried out in accordance with the
Kessler+CO installation instructions (see page 3.15 - 11).
LF-9.3
3.15 - 1
Caution
Secure vehicle against movement by placing chocks etc. in front of the wheels. Check
that system is pressure-free.
Warning
Before starting the unit for the first time and after repair work has been carried out on
the hydraulic pump or on the intake line, oil has to be filled up at the filling connector
of the intake line.
Bleed brake at all bleed valves of the four wheel brakes using a portable hose and on all four existing test
fittings using a Minime hose.
Bleeding of service brake
Note
When bleeding the individual wheel brakes, make sure to bleed any stub lines that may
be present, as well.
Use a pedal arrestor or a suitable object to block the brake pedal in fully depressed position.
Mount hose to the appropriate bleed or test connections. (Several bleed points may be operated at
a time.)
Start engine and shut off immediately when the pressure gauge indicates an available pressure of
50 to 60 bar.
Open bleeder valve, drain prestressed oil and close valve again when the pressure reading on the manometer indicates zero bar. Repeat operation at all vent points until the oil comes out bubble-free.
Note
All four parking brakes must be vented at the corresponding vent nipples of each wheel.
Switch on operating voltage and release parking brake. The 3/2 way valve is then opened to the spring
brakes on the front and rear wheels.
Connect the transparent hose to the appropriate bleed port. (Note that several points can be bled simultaneously).
Start the motor and continue bleeding the system as described under Bleeding of service brake.
Checks
Check the bleeder valves for leakage.
Check oil level on the hydraulic tank.
With the engine running, charge brake system up to the shut-off pressure of the shut-off valve and with
depressed service brake and released parking brake check tightness of bleed points.
Operate service brake and parking brake for 2 to 3 times. Repeat bleeding operation if there is a creaky
noise in the treadle or hand brake valve.
Checkfunction ot the service brake and parking brake.
3_15-2E
07.08
LF-9.3
3.15 - 2
Warning
The diaphram accumulators are preloaded with nitrogen to a predefined pressure. As certain gas losses
occur during operation, it is necessary to check and, when appropriate, correct the preload pressure at
regular intervals. The periods for the periodic tests must be determined by the operator in accordance with
the legal provisions.
Because of its safety-critical function and taking into account the service conditions, the diaphragm accumulator shall not be used for more than three years. Experience may, however, show that it needs to be
replaced at shorter intervals.
Caution
Prior to working on equipment fitted with diaphram accumulators, it is essential to reduce the pressure in the appropriate system.
Caution
Note
The diaphram accumulator filling device for checking or correcting the preload pressure
is obtainable from our after-sales service department.
Diaphragm accumulator in
steering-dump/hoist hydraulic
3_15-3_4E
07.08
LF-9.3
3.15 - 3
Checking the gas preload pressure of the diaphragm accumulators on the analog indicator in the drivers
cab.
-
Start the driving motor and switch off again when the analog indicator displays a available braking pressure of at least 100 bar.
Repeatedly actuate the brake pedal to decrease the available braking pressure. Actuate the brake
pedal so that the pressure decreases slowly.
The indicator on the manometer abruptly drops to zero when the available braking pressure falls below
a gas preload pressure of 555 bar.
Note
If the indicator on the manometer abruptly drops to zero outside the specified tolerance
range, the gas precompression must be corrected (see page 3.15 - 7).
Reduce stored pressure by operating the dump/hoist device. The available pressure can be read off
on the pressure gauge.
The indicator on the manometer abruptly drops to zero when the available braking pressure falls below
a gas preload pressure of 101 bar.
Note
If the indicator on the manometer abruptly drops to zero outside the specified tolerance
range, the gas precompression must be corrected (see page 3.15 - 7).
Repeatedly actuate the travel pedal to decrease the available pressure. Actuate the travel pedal so
that the pressure decreases slowly.
The indicator on the manometer abruptly drops to zero when the available braking pressure falls below
a gas preload pressure of 61 bar.
Note
3_15-3_4E
07.08
If the indicator on the manometer abruptly drops to zero outside the specified tolerance
range, the gas precompression must be corrected (see page 3.15 - 7).
LF-9.3
3.15 - 4
15
3_15-5_7E
07.08
LF-9.3
3.15 - 5
Note
The gas preload pressure must be checked with the driving motor switched off.
Relieve the diaphragm accumulator to zero bar on the fluid side and check the unpressurized condition.
Remove the protective cap (2) from the diaphragm accumulator and loosen the gas filling screw (4)
max. one-quarter turn using a hexagon socket wrench.
Lock up the drain screw (5) on the filling device (6) by screwing it in as far as the stop.
Screw the filling device (6) without hose (7) onto the diaphragm accumulator, making sure that the Oring (8) is located in the groove.
Warning
The non-return valve (9) mounted on the hose connection is only active if the hose (7)
is not screwed on.
Move the toggle (11) to and fro until the screwdriver (10) clicks into hexagon socket of the gas filling
screw (4).
Loosen the gas filling screw (4) as far as necessary to allow the gas to flow into the filling device (6).
Note
When the filling device is screwed on completely the gas filling screw (4) cannot be
turned out of the threaded hole.
On the manometer (12) read off the gas preload pressure present in the diaphragm accumulator.
Note
If the gas preload pressure outside the specified tolerance range, the gas preload pressure must be corrected (see section Correcting the gas preload pressure).
Gas preload pressure of the individual diaphragm accumulators (see page 3.15 - 3).
Screw down the gas filling screw (4) using the screwdriver (10). Open the drain screw (5) and let nitrogen escape from the filling device (6).
Retighten the gas filling screw (4) with a hexagon socket wrench and press on the protective cap (2).
Warning
3_15-5_7E
07.08
If the measured gas preload pressure lies more than 25% below the set pressure, it
must be assumed that the diaphragm accumulator is defective. Replace the diaphragm
accumulator.
LF-9.3
3.15 - 6
To drain the nitrogen, slowly open the drain screw (5) until the nitrogen escapes.
If the manometer (12) indicates the correct gas preload pressure, lock up the drain screw (5) until no
more nitrogen escapes.
After about one minute check the gas preload pressure again and correct if necessary.
Screw down the gas filling screw (4) using the screwdriver (10). Open the drain screw (5) and let the
nitrogen escape from the filling device (6).
Retighten the gas filling screw (4) with a hexagon socket wrench and press on the protective cap (2).
Pressure increase
-
Screw the pressure reduction armature (15) onto the nitrogen bottle valve (16). Make sure that the
shut-off valve (17) and the adjusting screw (18) are locked up.
Screw down the gas filling screw (4) using the screwdriver (10), so that the gas valve is closed.
Connect the pressure reduction armature (15) and the filling device (6) with the hose (7).
Open the nitrogen bottle valve (16) and set the required gas preload pressure of the diaphragm accumulator with the aid of the adjusting screw (18) and under control of the manometer (19).
Loosen the gas filling screw (4) as far as necessary to allow the gas in the diaphraghm accumulator
to overflow.
Let the gas overflow until the manometer (12) indicates the required gas preload pressure.
Close the shut-off valve (17), unscrew hose (7) from the filling device (6) and wait for temperature
equalization in the diaphragm accumulator.
In case of pressure decrease, repeat the filling sequence; in case of pressure increase, reduce the too
high gas precompression to the required value via the drain screw (5).
Screw down the gas filling screw (4) using the screwdriver (10). Open the drain screw (5) and let nitrogen escape from the filling device (6).
Retighten the gas filling screw (4) with a hexagon socket wrench and press on the protective cap (2).
3_15-5_7E
07.08
LF-9.3
3.15 - 7
Stop the system and relieve the filter on the pressure side.
Pull out filter element (3) and clean filter cup (2) with suitable fluid.
Check the O-ring (2) for damage. If necessary, replace these parts.
Re-install filter element and filter cup. Pay special attention to proper position.
Warning
After works on the brake system, bleed the entire brake system and check for leaks and
operation.
plug
5
3_15-8E
07.08
LF-9.3
3.15 - 8
Stop the system and relieve the filter on the pressure side.
Screw off cover (1), remove spring (3) and the complete filter insert consisting of (4 - 7 and 10).
Screw off drain plug (12) on filter housing (8) and drain the oil.
Clean filter housing with suitable medium and screw on drain plug (12); use new gasket (11) if
necessary.
Disassemble filter insert by unscrewing the fixing nut (10) and pulling off the sleeve (7) together with
the filter element (6). Make sure that the sleeve (7) is not damaged.
Remove filter element (6) from the sleeve (7) and dispose of the filter element in an environmentallyfriendly manner. Clean the remaining parts of the filter insert.
Fit new filter element (6) in the sleeve (7). Make sure that the filter element stands upright on the bottom
of the sleeve and comes flush with the upper side of the sleeve.
Assemble filter insert (4, 6, 7 and 10) and fit in the filter housing (8) with new gasket (5). Make sure
that the gasket sits correctly.
Install spring (3), screw on cover (1) with new gasket (2) and tighten up.
1
2
3
4
5
6
7
8
10
11
3_15-9E
07.08
12
LF-9.3
3.15 - 9
Warning
Checking for disk wear is to be performed with the brake pedal depressed.
The reference dimension for the disk wear check is stamped on the axle housing below the measuring
hole.
The reference dimension X is measured on the piston through the measuring hole.
-
Remove dirt, paint or any burrs in the vicinity of the measuring hole.
Using an appropriate measuring instrument, measure the distance from the housing surface to the piston.
If the distance measured exceeds the reference dimension X by more than 2.0 mm, check the brake
and replace, if necessary.
housing
surface
Measuring hole
Warning
031821E
LF-9.3
07.08
3.15 - 10
Warning
Preloading or unloading of the springs shall not be carried out via the brake screwing
(12). Opening of the brakes should preferably be carried out at Kessler+Co.
The complete brake can be removed from the axle trumpet by loosening the screwing
(13).
12
11
10
13
3
5
2
1
Mounting brakes
1.
2.
3.
Insert internal and external discs (2,3) into the brake housing (1) according to the lateral wheel drawing.
4.
Fit piston seals and guide rings (7) in intermediate piece (6).
5.
6.
Fit intermediate piece (6) taking into account the hole spacing on the brake housing (1).
7.
Fit piston (5) taking into account the hole pattern of the springs and the screw holes of the intermediate part (6). Caution: do not tilt the piston!
8.
Insert springs (8) into the piston. The number of springs is indicated on the installation drawing.
(When using fewer springs than the number of holes provided, make sure that they are distributed
symmetrically!)
9.
10.
Put brake support (10) on the springs (8). Pay attention to the location of the cooling oil inlet or oil
outlet hole! Screw in partially 4 screws (12) for accurate positoning of the brake support.
11.
Using an appropriate press and die (11), press together the brake support (10) and the brake housing (1). For the required preloading force, see installation drawing.
12.
Put all screws under the press (11) and screw down at the specified tightening torque. Slowly raise
the press die.
13.
Fix the warning plate to the brake and imprint the preloading force as indicated on the installation
drawing.
3_15-11_12E
07.08
LF-9.3
3.15 - 11
Caution
3_15-11_12E
07.08
The brake is preloaded. Preloading force see warning plate. Before loosening the
screwing (12) of the brake, the brake must be held together using a press and die (11)
suitable for the preloading force specfiied. After all screws have been removed, the
press die (11) can be slowly raised until the springs are unloaded.
LF-9.3
3.15 - 12
Qty.
Description
gear pump
high-pressure filter
relay valve
pressure gauge
10
11
12
non-return valve
13
non-return valve
18
hand pump
19
23
nozzle
26
pressure filter
27
30
pressure switch
31
pressure switch
32
pressure switch
33
pressure switch
720
hydraulic block
722
distributor block
723
hydraulic block
LebremsE
07.08
LF-9.3
3.16 - 1
Service brake
To operate the service brake, the brake pedal (5) is depressed. The hydraulic pressure controlled by the
force exerted by the foot flows via circuits I+II to the front-axle brakes and rear-axle brakes. As the brakes
are released, the brake pressure is decreased towards the hydraulic tank.
A mechanical stop on the running plate limits the brake pressure and a further stop ensures the pressureless condition of the service brake.
Residual brake pressure monitoring
Connection 24 of the pedal-type brake valve has a built-in pressure switch (31) (S52). At a hydraulic
brake pressure of 3-6 bar, this switch causes the indicator light service brake to be displayed in the drivers field of vision.
This device is intended to remind the driver to take his foot off the brake pedal after each braking operation.
Caution
In case the foot remains slightly leaned against the brake pedal after braking, a residual
brake pressure will remain. This pressure causes severe dragging which will heat up
the brakes and may lead to their destruction.
3_16-2_5E
07.08
LF-9.3
3.16 - 2
Caution
The pump flow is distributed via the shut-off valve (3) for charging of the diaphragm accumulator and cooling of the disk brakes. With filled diaphragm accumulators of the pressure supply system, the entire pump
flow is routed via the shut-off valve (3) to the distributor block (722) where the hydraulic pressure is built
up and evenly distributed over the multidisk brakes via 4 nozzles (23).
The cooling flow is introduced at the centre of the multi-disk brake and flows through the disks. Through
the outlet arranged on top the cooling flow is returned to the transmission oil sump. A sufficient oil flow
is a precondition for cooling of the disk brakes.
Fouling of the nozzles or any restriction in the cooling pipes causes the built-up pressure in the distributor
block to rise.
Warning
In case the nozzles should be clogged completely, the pump flow returns to the hydraulic tank via the pressure relief valve (10) and the brakes are uncooled.
This is indicated to the driver by the pressure as indicated by the pressure gauge (9) rising to 180 bar.
To avoid damage to the seals of the disk brake, the cooling pressure within the brake housing shall not
exceed 1.0 bar at high idling speed.
Warning
3_16-2_5E
07.08
If further contamination causes the differential pressure to increases beyond the max.
permissible value, the built-in safety valve will open to allow the medium to flow unfiltered into the brake system circuit. This may cause damage to the components of this
system and lead to failure of the service brake.
LF-9.3
3.16 - 3
Parking brake
Warning
When exiting the drivers cab the parking brake should, as a rule, be applied manually
via the control lever.
To release the parking brake, pull the control lever out of the detent and move forward. From connection
2 of the hand brake valve (19) the hydraulic release pressure flows to the spring accumulator cylinder
and neutralises the spring force acting on the parking brake.
When applying the parking brake the pressure towards the hydraulic reservoir is reduced via the hand
brake valve (19). To apply the parking brake, move the control lever backward until it locks into place.
The vehicle may only be moved when the parking brake is completely released.
Caution
If the parking brake is not released completely there will remain a residual brake pressure. This pressure causes significant scuffing, which may heat up and even destroy
the brakes.
The pressure switch (30 (S51) activates the indicator light parking brake in the drivers cab to indicate
that the parking brake is not released completely.
3_16-2_5E
07.08
LF-9.3
3.16 - 4
Caution
Emergency release of the parking brake may only be performed on an operational parking brake system. After the emergency release only restricted operation without cooling
of the brakes will be possible.
In case of a driving engine failure, the parking brake can be released by means of the hand pump fitted
on the right side and after checking the release pressure indicated on the manometer.
Warning
Prior to the emergency release, check the oil level in the hydraulic reservoir and top up
to the Max. mark, if necessary.
Place gearshift in neutral, switch on operating voltage and put lever for the parking brake in the release
position.
Plug the lever on the fitting of the hand pump and manually build up the pressure in the parking brake
circuit until the manometer indicates a pressure of > 120 bar.
Warning
After releasing the parking brake, the vehicle can be stopped once by applying the parking brake. To release the parking brake again, the pressure must again be built up to
> 115 bar.
fitting
hand pump
3_16-2_5E
07.08
manometer
LF-9.3
lever
3.16 - 5
Hydraulic system
Aeration/ventilation filter
1
max
min.
Level indicator
Screw
Bar
Cover
Return filter
Drain plug
3_17-1E
07.08
LF-9.3
3.17 - 1
To check the oil level, park the vehicle on a level surface. Check the oil level with the
engine running and with retracted cylinders.
The oil level check must be carried out on the level gauge of the hydraulic reservoir. The oil level must
lie between the top and bottom level marks. If the oil has dropped below the bottom level, the hydraulic
system must be checked for leaks and the oil topped up to the top level mark on the level gauge.
Level monitoring
The oil level in the hydraulic tank is continuously monitored by a level switch. If the oil drops below the
min. level, this is indicated by signal lamp (H10) Hydraulic oil level. Check the hydraulic system for leaks
and top up oil to the max. mark on the oil level indicator.
Top up hydraulic oil to maximum mark with engine stopped and retracted cylinders.
The oil may only be topped up at the special filling screw plug on the hydraulic tank. Only here is it ensured
that impurities are filtered out by the return filter before the oil flows into the hydraulic tank.
Return filter
To protect the hydraulic system against fouling damage a return filter with magnetic element has been
fitted in the hydraulic reservoir. An electric service signal monitors the filter plugging. As the plugging of
the filter element increases the filter flow resistance also increases. At a flow resistance in excess of 1.3
bar, the indicator light (H8) return pressure/brake filter lights up brightly to indicate that the filter element
must be replaced. To prevent the filter inset from bursting it releases itself under excessive overpressure
and allows the oil to flow unfiltered in the reservoir chamber. This may cause the hydraulic components
to be damaged.
3_17-2_3E
07.08
LF-9.3
3.17 - 2
Change hydraulic oil with stopped engine and the hydraulic cylinders retracted.
The drain plug is arranged on the underside of the hydraulic tank. After the tank has been completely emptied and cleaned, fill up to the maximum mark.
Warning
If there is an intake pipe leak, the vacuum in the pipes will draw in air. Air in the hydraulic system causes
cavitation damage to pumps, valves and cylinder seals.
A restricted suction cross-section, caused for example by a restricted hose, causes an increased intake vacuum and hydraulic pump failure.
Note
Carry out pressure measurements while the hydraulic oil is at operating temperature.
To measure the steering pressure, a pressure gauge with a measuring range between 0 and 250 bar has
to be connected to the measuring points provided. The pressure indicated is the currently used steering
pressure. With the steering mechanism fully locked, the maximum pressure is measured.
To measure the working pressure, a pressure gauge with a measuring range between 0 and 250 bar has
to be connected to the measuring points provided. The pressure indicated is the currently used working
pressure. The maximum pressure is measured when the respective cylinder is operated against its stop.
3_17-2_3E
07.08
LF-9.3
3.17 - 3
Remove spring (3) and the complete filter insert consisting of (2 -5, 7 and 8).
Disassemble filter insert by unscrewing the fixing nut (8) and pulling off the filter element (5).
Dispose of the filter element (5) in an environmentally-friendly manner. Clean the remaining parts of
the filter insert.
Assemble filter insert using new filter element (5) and new gaskets (4, 7).
Install filter insert in the hydraulic oil tank with new gasket (3). Make sure that the gasket sits correctly.
Install spring (1) and assemble the cover on the hydraulic oil tank by using the screw and the catch.
1
2
3
4
6
Gasket for
hydraulic oil tank
8
9
3_17-4E
07.08
LF-9.3
3.17 - 4
In case of major contaminations, clean the radiator net against the air flow direction, using compressed
air or a steam-jet cleaner (a cold-cleaning compound can be added).
If necessary, dismount the cooling system and remove fan and drive.
Warning
If necessary, complete the cooling system, i.e. fit fan and drive.
If necessary, reinstall the cooling system. Check fan for direction of rotation (see identification) and
smooth operation.
Warning
033650E
07.08
After replacing parts and topping up, the system must be vented. Air in the system may
lead to reduced performance and vapour locks.
LF-9.3
3.17 - 5
Qty.
Description
steering cylinder
hoist cylinder
dump cylinder
gear pump
hydraulic motor
13
15
16
Orbitrol
17
18
20
filter
21
22
24
28
29
36
non-return valve
39
non-return valve
40
filter
42
66
hydraulic block
LehydrE
07.08
LF-9.3
3.18 - 1
Filter
Filter mesh
Soiling indicator
10 m
electrical type
or
analog indicator
see Section 2.3
Return filter
032020E
07.08
LF-9.3
3.18 - 2
Caution
Even with the engine shut off, the control manifolds may be activated because of the
accumulator installed in the control oil supply system. Of course, only movements due
to bucket and boom deadweight can be performed. Before starting maintenance work
on the control system the accumulator has to be discharged by operating the control
lever several times.
Float position
If the control lever is operated in Lower bucket direction beyond the pressure point, outlet five of the
servo valve is pressurized and the directional control valve activated. This will set the bucket to floating
position. Through the directional control valve the secondary valves are depressurized towards the dump
cylinder.
033240E
07.08
LF-9.3
3.18 - 3
Pressure filter
The pressure oil is cleaned by the pressure filter. If the filter is soiled, the overflow valve allows the oil to
pass unfiltered.
Torque converter
The torque converter is bolted to the drive engine to form a unit.
The rotating parts are coupled to the engine flywheel via an elastic coupling. At the rear end of the torque
converter, flanging points for the connection of hydraulic pumps are provided in addition to the output
flange for the drive unit.
The oil flow from the converter charging pump is preloaded to 16.8 to 19.6 bar by a valve mounted to the
converter. This pressure is admitted to the multi-disc clutches in the power shift transmission.
The surplus oil flows to the torque converter for filling and cooling it. A safety valve protects the internal
parts of the torque converter against excessive pressure. The spur gears in the converter housing are
lubricated by spray nozzles. The oil flowing off is collected in the converter oil sump from where it flows
unpressurized to the transmission.
The second stage of the converter pump is used to drain the converter. The pump conveys oil from the
converter sump to the transmission sump.
Oil cooler
The oil flowing out of the torque converter has the highest temperature and is directed straight to the oil
cooler. The cooled oil flows to the lubricant distributor of the power shift transmission. The maximum temperature of the converter/transmission hydraulic system must not exceed 120
LF-9.3
3.19 - 1
2
3
6
5
Turbine wheel
Hydraulic pump
To transmission
030580E
07.08
LF-9.3
3.20 - 1
LF-9.3
3.20 - 2
3_21E
07.08
LF-9.3
3.21 - 1
Electrical equipment
Caution
The alternator, which is driven directly by the engine, supplies 24V for the vehicles electrical equipment.
Two series-connected batteries will assist in starting the engine.
Electrical equipment components
Battery
The two series-connected 12 V batteries of the electrical system are arranged in the battery compartment.
For maintenance and servicing of batteries observe the following:
-
Loose clamps or sulphatized battery poles (green-white coating) will affect current transmission.
There must be an approx. 10 mm liquid level on top of the battery lead plates.
Maximum charging current: 10 % of battery capacity (e.g. charge 165 Ah battery with a maximum charging current of 16.5 A).
Caution
3_22-1_2E
07.08
Explosive gases are developed during charging. Do not smoke, use open flame and
make sure there are no sparks.
LF-9.3
3.22 - 1
Operate the alternator only with appertaining controller and connected battery.
When testing the engine without batteries, disconnect V-belt and cables from alternator.
Before carrying out electric arc welding on the vehicle disconnect all cables from the alternator.
The resistor connected in parallel to the LED of the alternator charging control lamp serves for pre-excitation of the alternator.
Battery switch
The battery switch installed in the battery box insolates the two series-connected batteries from the onboard elecrical system. The battery switch should only be switched on or off when the engine is standing
still.
External-starting socket
If the battery is discharged, the engine of the vehicle can be started using an external power supply and
jump-start cable at the external starter socket.
Lighting system
The vehicle is equipped at the front and rear with respectively two and four headlamps with parking light,
low beam and high beam. Three headlamps for material face lighting are fitted on the roof of the drivers
cab.
The lighting system is switched on and off with the three-position rotary switch (S72) in the drivers cab.
In the first position, the parking light in the front and rear headlamps and the material face lighting are
switched on. In the second and third positions, the low beam and the high beam in the front and rear headlamps are switched on.
Warning equipment
An audible warning device is installed in the form of a horn, which sounds when the horn push-button (S86)
is pressed.
3_22-1_2E
07.08
LF-9.3
3.22 - 2
3_23E
07.08
LF-9.3
3.23 - 1
6
9
2
1
3
4
10
5
8
2
Fig. 2
Hand fire extinguisher
1
Quick-release lock
2
3
7
8
Safety valve
Handle
4
5
Dunlop-valve
Riser pipe
9
10
031981E
07.08
LF-9.3
3.24 - 1
Caution
It is absolutely necessary to follow, in the g iven order, the notes on the extinguisher for
operating the device.
For an extinguishing service open the quick-release lock of the protective cap, fold up the cap and clear
the hose with the extinguishing pistol. Then press down with force the nickel-plated button of the striking
valve or strike it down by hand. This will cause piercing of the seal foil of the CO2 bottle inside the outer
container of the extinguisher. The carbon dioxide (CO2) will then flow into the holding chamber of the CO2
bottle and is discharged, via the Dunlop valve attached to the chamber, into the extinguishing-substance
vessel, where it fluidizes the extinguishing powder and pressurizes at the same time the vessel to the necessary service pressure. Only then, i.e. after pressing down the striking valve, must the extinguishing
pistol be operated and the fire be fought with the emerging powder cloud.
The extinguishing pistol can be stopped, allowing for repeated interruption of the extinguishing procedure
for short times.
Warning
As a matter of principle, the extinguisher must be refilled after each use, even if the fill
has not been completely used up. Only this will ensure complete readiness for service
at any time.
Note
The easily destructible green control foil under the striking head serves for checking
whether the valve has been actuated.
031981E
07.08
LF-9.3
3.24 - 2
Release the extinguishing-substance vessel and hose from pressure after each extinguishing service,
by operating the extinguishing pistol
First loosen lightly the closing cap with striking valve, using a suitable spanner, by 1 - 2 turns, to let
escape any pressure still present through the pressure release holes provided at the side of the closing
cap.
Open the closing cap, completely and remove the striking valve together with the CO2 bottle and the
holding chamber from the extinguisher vessel. Take off the rubber guide sleeve loosely placed on the
neck of the CO2 bottle and put it aside for placing it on the new, filled bottle.
Unscrew the pressure hose from the vessel and remove powder remainders still present in the hose
and in the riser pipe and also the pierced control foil.
Fit riser pipe and new control foil and screw the hose tightly on the nipple of the vessel top. Check extinguishing pistol for proper functioning, i.e. for free movement.
Fill 10 kg of well fluidized dry extinguishing powder, preferably by using a strainer funnel, into the vessel
(dont tamp it).
Warning
Only the TOTALIT-G-type extinguishing powder from TOTAL Foerstner & Co. must be
used.
Fit new CO2 bottle (original charge from manufacturers works) into the holding chamber, after placing
the rubber guide sleeve onto the bottle neck, i.e. with the metal plate facing upwards.
Note
Ensure, by weighing, that the CO2 bottle (without sleeve) contains the specified charge
weight. The charge weight is stamped on the bottle.
Fit the holding chamber with the CO2 bottle into the extinguishing-substance vessel. Make sure that
the flange edge of the chamber is properly and flatly supported and that the sealing face is free from
any powder residues.
Screw on tightly closing cap with striking valve and seal it together with the screwed cap of the spraying
hose.
Place the green control foil around the striking valve between striking head and cap, and seal it likewise.
Place the hose without kinks on the top part. When doing so, take care that the striking head remains
clear and avoid its actuation. Finally, close the protective cap and seal the quick-release lock tightly.
Note
031981E
07.08
Always heed the safety guidelines for inspection and maintening the fire extinguisher.
Refer to the inspection service of TOTAL for any further questions arising.
LF-9.3
3.24 - 3
Fault-finding table
031050E
07.08
Reason
Remedy
Brakes overheated
LF-9.3
3.25 - 1
No oil pressure
Reason
Remedy
Oil foaming
Tighten clip
Air in system
Check activation
Check activation
Replace pipe
Adjust pressure
Pump defective
Replace pump
Check activation
Check activation
Replace valve
Replace pipe
Adjust pressure
Check activation
Pump defective
Replace pump
Pump defective
Replace pump
Replace clutch
030630E
07.08
LF-9.3
3.25 - 2
Insufficient power
Reason
Remedy
Clutch defective
Repair clutch
Tighten connections
Check intake pipe
Repair converter
Tighten connections
Check intake pipe
Repair converter
Adjust engine
Converter overheated
Clutch defective
Repair clutch
030640E
07.08
LF-9.3
3.25 - 3
3_26E
07.08
Appendix
LF-9.3
3.26 - 1
System drawings
Service brake
Translation sheet pertaining to drwg. 909-1-055564
909-1-055564 D
909-1-055423 E
909-1-060145
Electrical equipment
4E
07.08
LF-9.3
4-1
Messpunkt
Measuring point
Druck (bar)
Pressure
Ttigkeit
Activity
Abschaltventil
Shut-off valve
B4
Ein
on
kontrollieren
check
Trittplattenbremsventil
Treadle brake valve
B5+B6
Restdr. Bremse
Residual brake pressure
B5+B6
max. 0.5
kontrollieren
bei hohem Leerlauf check
at high idling speed
Drucksch. S51
Pressure switch
B7.1 / B7.2
steigend / fallend
rising / falling
Drucksch. S53
Pressure switch
B4
fallend
falling
steigend
rising
Drucksch. S47.2
Pressure switch
Aus
off
einstellen
set
Druckbegrenz. Pos. 11
pressure relief valve
B5
Manometer
Druckbegrvent. Pos. 27
pressure relief valve
B5
Vorratsdruck
Available pressure
Manom. Pos.9
gauge item 9
Pumpe Saugdruck
Pump intake pressure
B9
max. 0.3
kontrollieren
bei hohem Leerlauf check
at high idling speed
Kuehldruck
Cooling pressure
BB24-B27
max. 1.0 / 5
kontrollieren
bei hohem Leerlauf check
und Feststellbremse aufgelegt.
at high idling speed and applied parking brake
Druckgeflle
Pressure gradient
B24 + B28
B25 + B29
Druckgeflle
Pressure gradient
B26 + B30
B27 + B31
Staudruck
Dynamic pressure
B11
hoh. Leerl.
kontrollieren
at high idling speed check
Speichertest
Test of diaphragm
accumulator
B4
145 nach
kontrollieren
5 Bremsungen min. check
95 bei Motor aus
after 5 brakes min. 95 engie switched off
Dichtigkeit
For leakage
B4
Feststellbremse
Parking brake
B7.1 + 7.2
gelst min.115
kontrollieren
aufgelegt max.0,5 check
released min.115 / applied max.0.5
4E
07.08
einstellen
set
(Umschaltung)
(switching)
LF-9.3
4-2
4E
07.08
LF-9.3
4-3
4E
07.08
LF-9.3
4-4
4E
07.08
LF-9.3
4-5