Page 1 Operator’s Manual Telescopic wheel loader 4080T Basic Line Vehicle model RL60T-00 Material number 1000408123 Version Date 05/2019 1000408123 Language [en]...
Page 2 Violations of legal regulations, in particular of the copyright protection, will be subject to civil and criminal prosecu- tion. Weidemann GmbH keeps abreast of the latest technical developments and constantly improve their products. For this reason, we may from time to time need to make changes to figures and descriptions in this documentation that do not reflect products that have already been delivered and that will not be implemented on these machines.
Page 3: Table Of Contents
Table of Content Table of Content Declaration of Conformity Preface Operator’s manual .......................... 9 Warranty and liability ........................ 13 Usage Use of the vehicle ........................... 14 Limits of the vehicle ........................ 16 Safety Safety symbols and signal words .................... 20 Qualification of operating personnel ....................
Page 4 Table of Content Operating the front hydraulic connections .................. 136 7.10 Operating the rear hydraulic connections .................. 142 7.11 Operating electrical functions ....................... 146 7.12 Working with attachments...................... 148 Transportation Towing the vehicle ........................ 162 Loading the vehicle ........................ 167 Transporting the vehicle .......................
Page 5 Table of Content Index ................................. 244 [en] | 05/2019 | 1000408123 | 4080T Basic Line | Operator’s Manual...
Page 6 Table of Content Operator’s Manual | 4080T Basic Line | 1000408123 | 05/2019 | [en]...
Page 7: Declaration Of Conformity
EC Declaration of Conformity Manufacturer Weidemann GmbH, Mühlhäuser Weg 45-49, 34519 Diemelsee, Germany Product Wheel Loader Vehicle designation Type/Version Trade name Chassis number Power kW at rated speed min Measured sound power level dB(A) Guaranteed sound power level dB(A) Conformity assessment procedure...
Page 9: Preface
Preface Operator’s manual 2.1 Preface Operator’s manual 2.1.1 Information on this operator’s manual • This operator's manual is only valid for the vehicles listed on the title page. • The operator's manual provides information on the use, settings, op- eration and maintenance of the vehicle, including different attach- ments approved for the vehicle.
Page 10 Preface 2.1 Operator’s manual 2.1.2 Storing the operator’s manual The operator’s manual and any supplements are part of the vehicle and must be available to the operator at all times. The vehicle is equipped with a storage location for the operator’s manual. The storage location is a position A in the cab.
Page 11 Preface Operator’s manual 2.1 2.1.3.1 Explanation of symbols Symbol for warning notices This symbol is a warning symbol. It is used to alert you to potential hazards. The safety symbol is always followed by a signal word, which indicates the hazard. These warnings are to be observed in particular.
Page 12 Preface 2.1 Operator’s manual 2.1.4 Information for the buyer and operating company • The buyer or operating company is responsible for the user’s/operat- ors’ training in safe working on and with the vehicle. – We recommend repeating training at regular intervals. •...
Page 13: Warranty And Liability 2.2
Preface Warranty and liability 2.2 Warranty and liability 2.2.1 Warranty Warranty claims can be made only if the conditions of warranty have been observed. They are included in the General Conditions of Sales and Delivery for new vehicles and spare parts sold by the dealers. Further- more, the instructions of this operator's manual are to be observed.
Page 14: Usage
Usage 3.1 Use of the vehicle Usage Use of the vehicle 3.1.1 Designated use The following chapter describes the range of application of the vehicle. The listed works were classified by the manufacturer as intended and thus as safe. Read this operator’s manual carefully prior to the first drive. Always work carefully and cautiously with the vehicle.
Page 15 Usage Use of the vehicle 3.1 3.1.3 Reasonably foreseeable misuse Not using the vehicle according to its designated use means that it is used for an application that is not specified by the manufacturer. There- fore, this is misuse in the terms of the Machinery Directive. The operator is solely liable for any resulting damage.
Page 16: Limits Of The Vehicle
Usage 3.2 Limits of the vehicle 3.1.4 Driving license Vehicles may only be driven on public roads if the operator is in posses- sion of a driving license as defined by national traffic laws. In the Federal Republic of Germany, one of the following driving licenses is required to drive a vehicle in accordance with §...
Page 17 Usage Limits of the vehicle 3.2 3.2.2 Climatic limits of the vehicle The operating and storage temperature range for the vehicle is between -15 °C and +40 °C. Operating temperatures below -15 °C or above +40 °C require special equipment or vehicle fluids (fuel, engine oil and hydraulic oil). The service partner is available at any time to answer any further ques- tions regarding use in extreme temperature ranges.
Page 18 Usage 3.2 Limits of the vehicle Measures to be taken at low outside temperatures Avoid damage to the vehicle and facilitate vehicle start up by taking the following measures. • Use the correct mixing ratio of coolant. • Use engine oil of the correct viscosity class. •...
Page 19 Usage Limits of the vehicle 3.2 Temperature °C Operating time in hours (h) -20° -10° -5° 0° +10° Requirements for connecting the engine and hydraulic oil preheating ü 230 volt mains supply ü Maximum 16 ampere fuse protection ü Fault current protective switch ü...
Page 20: Safety
Safety 4.1 Safety symbols and signal words Safety Safety symbols and signal words The following symbol identifies safety instructions. It is used for warning against potential personal risk or danger. DANGER DANGER identifies a situation causing death or serious injury if it is not avoided.
Page 21: Qualification Of Operating Personnel 4.2
Safety Qualification of operating personnel 4.2 Qualification of operating personnel 4.2.1 Owner’s duties • Only allow specifically authorized, trained and experienced persons to operate, drive and perform maintenance on the vehicle. • Do not allow persons to be trained or instructed by anyone other than an authorized and experienced person.
Page 22: Conduct
Safety 4.3 Conduct Conduct Prerequisites for operation • The vehicle has been designed and built in accordance with state-of- the-art standards and the recognized safety regulations. Nevertheless its use can cause danger to the operator or third parties, or damage to the vehicle.
Page 23: Operating 4.4
Safety Operating 4.4 Operating 4.4.1 Preparative measures • Operation is only allowed with correctly installed and intact protective structures. • Keep the vehicle clean. This reduces injury, accident and fire haz- ards. • Safely store objects you carry with you in the places provided for this (for example in the storage compartment, drinks holder).
Page 24 Safety 4.4 Operating 4.4.2 Job site • The operator is responsible for third parties. • Before starting work, familiarize yourself with the job site. This applies to, for example: – Obstacles in the work area and vehicle travel area. – Any barriers separating the job site from public roads. –...
Page 25 Safety Operating 4.4 4.4.5 Mechanical integrity • The operator and owner are obligated to operate the vehicle only in a safe and working condition. • Only operate the vehicle if all protective and safety-related equipment (e.g. protective structures such as cab or roll bar, detachable protect- ive devices) are installed and functional.
Page 26: Lifting Gear Applications
Safety 4.5 Lifting gear applications 4.4.8 Vehicle travel on public roads and sites • The specific national driving license is required. • When driving on public roads or sites, observe the national regula- tions (e.g. road traffic regulations). • Ensure that the vehicle is in compliance with the national regulations. •...
Page 27 Safety Lifting gear applications 4.5 4.5.2 Fastening, guiding and removing loads • Follow the applicable specific regulations for fastening, guiding and removing a load. • Wear protective equipment when fastening, guiding and removing loads (e.g. a hard hat, safety glasses, protective gloves, safety shoes).
Page 28: Trailer Operation
Safety 4.6 Trailer operation Trailer operation • The vehicle must be certified for trailer operation. • Observe the national regulations for trailer operation. • The specific national driving license is required. • Transporting persons on and in trailers is not permitted. •...
Page 29 Safety Operation of attachments 4.7 4.7.2 Operating • Transporting persons on/in an attachment is prohibited. • Installing a work platform is prohibited. – Exception: The vehicle is certified and equipped with the neces- sary safety equipment. • Attachments and counterweights modify handling, as well as the steering behavior and brake capability of the vehicle.
Page 30: Towing, Loading And Transporting
Safety 4.8 Towing, loading and transporting Towing, loading and transporting 4.8.1 Towing • Seal off the danger zone. • Ensure that no one is near the towing bar or cable. The safety dis- tance is equal to 1.5 times the length of the towing equipment. •...
Page 31 Safety Towing, loading and transporting 4.8 4.8.2 Crane-lifting • Seal off the danger zone. • The crane and the lifting gear must have suitable dimensions. • Take into account the vehicle’s overall weight. • Wear protective clothing and equipment when fastening, guiding and removing the vehicle (for example a hard hat, safety glasses, safety boots).
Page 32 Safety 4.9 Maintenance 4.8.3 Transportation • For the safe transportation of the vehicle: – The transport vehicle must have a sufficient bearing load and loading surface. – The maximum weight rating of the transport vehicle must not be exceeded. • Use only lifting and fastening gear certified by a test or certification body, observe the inspection intervals.
Page 33: Maintenance 4.9
Safety Maintenance 4.9 4.9.2 Personal safety measures • Avoid any operational mode that might pose a risk to safety. • Wear protective equipment (for example hard hat, protective gloves, safety shoes). • Tie back long hair and remove all jewelry. •...
Page 34: Measures For Avoiding Risks
Safety 4.10 Measures for avoiding risks 4.9.4 Measures for performing maintenance • Perform only the maintenance described in this operator’s manual. • All work that is not described in this operator’s manual must be per- formed by qualified and authorized technically trained personnel. •...
Page 35 Safety Measures for avoiding risks 4.10 4.10.2 Hydraulic and compressed-air system • Check all lines, hoses and screw connections regularly for leaks and visible damage. • Splashed oil can cause injury and fire. • Leaking hydraulic and compressed-air lines can cause the full loss of the braking effect.
Page 36 Safety 4.10 Measures for avoiding risks 4.10.5 Safety instructions regarding internal combustion engines • Internal combustion engines present special hazards during operation and fueling. • Failure to follow the warnings and safety instructions can cause seri- ous injury or death. •...
Page 37 Safety Measures for avoiding risks 4.10 4.10.8 Fire hazard • Fuel, lubricants, grease and coolants are flammable. • Do not use flammable detergents. • Keep the area around the exhaust system free of flammable materi- als. • Hot vehicle parts and exhaust gases increase the risk of fire. –...
Page 38 Safety 4.10 Measures for avoiding risks 4.10.12 Noise • Observe the noise regulations (for example during applications in en- closed premises). • Bear in mind external sources of noise (compressed-air hammer, concrete saw). • Do not remove the sound baffles of the vehicle and attachment. •...
Page 39: Description Of The Vehicle
Description of the vehicle Vehicle from outside 5.1 Description of the vehicle Vehicle from outside 5.1.1 Vehicle view Fig. 3: Vehicle view from the right 1 Hydraulic oil tank (right)/fuel tank (left) 2 Rear weight 3 Engine cover 4 Cab 5 Work lights 6 Rearview mirror 7 Vehicle chassis front section 8 Front vehicle lights...
Page 40 Description of the vehicle 5.2 Brief description of the vehicle Type designation Trade name The type designation is stamped on The trade name is affixed to the the vehicle chassis and printed on vehicle. the nameplate RL60T 4080T Basic Line 5.2.2 Main components of the vehicle •...
Page 41 Description of the vehicle Brief description of the vehicle 5.2 5.2.4 Cooling system In the engine compartment, there is a combined water/hydraulic oil cooler that cools the diesel engine and hydraulic oil. The radiator fan is mechan- ically driven by the diesel engine via V-belts. Control lights and control displays in the instrument panel of the vehicle ensure that the engine and hydraulic oil temperature can be constantly monitored.
Page 42 Description of the vehicle 5.2 Brief description of the vehicle Steering hydraulics and working hydraulics Steering hydraulics and working hydraulics are supplied with oil by a gear pump. The diesel engine constantly drives the gear pump. The gear pump is flanged to the variable displacement pump of the drive system. The oil flow is led via a priority valve through the steering orbitrol to the control valve of the working hydraulics.
Page 43 Description of the vehicle Brief description of the vehicle 5.2 5.2.9 Loader unit The loader unit consists of a telescoping arm that can be hydraulically ex- tended and retracted in addition to the usual lifting function. The loader unit is equipped with a power coupler system for connecting attachments. The lock of the power coupler is operated hydraulically.
Page 44: Operating Elements At The Operator Station
Description of the vehicle 5.3 Operating elements at the operator station Removing the protective screen ü Preparations for disassembly completed. Loosen the fastening screws of the protective screen. Remove protective screen. Refasten the screws on the protective screen so that they do not get lost.
Page 45 Description of the vehicle Operating elements at the operator station 5.3 NOTICE Defective warning lights and control lights cannot correctly indicate operating states. Warning lights and control lights indicate the operating status of the vehicle. If these lights are defective, possible faults, e.g. in the motor con- trol, cannot be detected.
Page 46 Description of the vehicle 5.3 Operating elements at the operator station 5.3.2 General overview of control elements Fig. 6: General overview of the control elements Operator’s Manual | 4080T Basic Line | 1000408123 | 05/2019 | [en]...
Page 47 Description of the vehicle Operating elements at the operator station 5.3 1 Brake/inching pedal 2 Steering column switch – control lever for light, direction indicator lamp (turn signal) and horn 3 Air vents 4 Switch panel 1 5 Steering wheel 6 Display 7 Switch panel 2 8 Stability indicator...
Page 48 Description of the vehicle 5.3 Operating elements at the operator station 1 Switch for the operation of the third control circuit 2 Switch for the operation of the differential lock Fig. 8: Switch on joystick bottom The label shows the assignment of the joystick. The assignment of the joystick varies depending on the equipment of the vehicle.
Page 49 Description of the vehicle Operating elements at the operator station 5.3 1 Switch for pressure relief of the hydraulic connections 2 Switch for floating position and load stabilizer 3 Switch for continuous operation of the third control circuit 4 Switch spare for option 5 Switch for continuous operation of rear hydraulic connections 6 Switch spare for option Fig. 11: Switch panel 3 in the side...
Page 50 Description of the vehicle 5.3 Operating elements at the operator station 1 Switch for air conditioning system 2 Light switches Fig. 13: Switch panel 5 on instrument panel 1 Switch for hydraulic lock 2 Switch for hazard warning system Fig. 14: Switch panel 6 on instrument panel 5.3.5 Overview: Steering column switch...
Page 51: Attachments For The Vehicle 5.4
Description of the vehicle Attachments for the vehicle 5.4 Attachments for the vehicle 5.4.1 Information on attachments NOTICE Technical damage to the loader unit due to incorrect attachments! Incorrect attachments can overload the vehicle. ► Only mount attachments to the vehicle that are listed in this oper- ator’s manual.
Page 52 Description of the vehicle 5.4 Attachments for the vehicle Material Bulk density t/m³ Barley 0.64 Wheat 0.82 Oats 0.50 Maize 0.80 Rapeseed 0.70 0.78 Grass seed 0.35 Potatoes 0.73 Sugar beet 0.73 Fertilizer/Mineral Urea 0.80 Potash 1.25 Lime 1.30 Lime nitrogen 1.60 Phosphate Super 1.10...
Page 53 Description of the vehicle Attachments for the vehicle 5.4 Material Bulk density t/m³ Waste paper 1.10 Household garbage 0.70 Bulky refuse 1.00 Snow, loose 0.13 Snow, moist 0.65 De-icing salt 1.30 Logs 0.80 Wood chips 0.35 Wood pellets 0.65 Granite 1.80 Sandstone 2.40...
Page 54 Determine load on loader unit The load on the loader unit can be determined with the aid of the bulk densities of materials, volume and weight of the attachments. Weidemann GmbH D-34519 Diemelsee-Flechtdorf Procedure: Determine the bulk density of the material.
Page 55 Description of the vehicle Attachments for the vehicle 5.4 Material number Type Width in mm Capacity in Weight in kg m³ 1000241884 RL60T 1650 0.50 1000345134 RL60T 1900 0.70 1000345135 RL60T 1900 0.70 1000389965 RL60T 1900 0.70 1000286313 RL60T 2000 0.90 1000314548 RL60T...
Page 56 Description of the vehicle 5.4 Attachments for the vehicle Material number Type Width in mm Capacity in Weight in kg m³ Road gritter Usage: Winter service 1000228221 RL60T 1000260863 RL60T 1000249568 RL60T 1000377858 RL60T 1000228222 RL60T 1000273495 RL60T Side-tip bucket Usage: Loosening, picking up, transporting and loading loose or solid material, whereby the bulk material can be unloaded to the side.
Page 57 Description of the vehicle Attachments for the vehicle 5.4 Material number Type Width in mm Capacity in Weight in kg m³ 1000316306 RL60T 1850 1000316308 RL60T 1850 1000316309 RL60T 1850 1000316321 RL60T 2050 1000316323 RL60T 2050 1000316326 RL60T 2300 1000316327 RL60T 2300 1000316329...
Page 58: Rl60T 1850
Description of the vehicle 5.4 Attachments for the vehicle Material number Type Width in mm Capacity in Weight in kg m³ 1000325948 RL60T 2400 1.25 1000325950 RL60T 2400 1.25 Lightweight material buckets Usage: Loosening, picking up, transporting and loading loose material 1000227680 RL60T 1800...
Page 59: Rl60T Rl60T Rl60T Rl60T
Description of the vehicle Attachments for the vehicle 5.4 Material number Type Width in mm Capacity in Weight in kg m³ Usage: Mowing grass and vegetation on level surfaces. 1000247489 RL60T 1350 1000251472 RL60T 1350 Fence mower* Usage: Mowing grass and vegetation on level surfaces alongside fences. 1000307033 RL60T 1500...
Page 60: Rl60T 2200
Description of the vehicle 5.4 Attachments for the vehicle Material number Type Width in mm Capacity in Weight in kg m³ Snow blade Usage: Winter service 1000227932 RL60T 2050 1000227937 RL60T 2050 1000335787 RL60T 2050 1000227941 RL60T 2050 1000227977 RL60T 2250 1000227979 RL60T...
Page 61: Rl60T
Description of the vehicle Attachments for the vehicle 5.4 Material number Type Width in mm Capacity in Weight in kg m³ 1000255772 RL60T 1550 1.02 1000227665 RL60T 1750 1.20 1000227666 RL60T 1750 1.54 1000253890 RL60T 1750 1.54 1000338088 RL60T 1550 1.65 1000338089 RL60T...
Page 62: Rl60T 2000
Usage: Leveling riding arenas 1000227929 RL60T 2000 1000227930 RL60T 2000 1000227928 RL60T 2000 Work platform* Usage: Lifting people. Only in combination with a vehicle equipped by Weidemann GmbH 1000228171 RL60T 1300 1000271284 RL60T 1300 1000342552 RL60T 1300 Adapter plates* Usage: Mounting of attachments with other mounts...
Page 63: Type Plates And Stickers 5.5
Description of the vehicle Type plates and stickers 5.5 Material number Type Length in mm Bearing load Weight in kg in kg Pallet forks change the intended use of the vehicle. Pallet forks must be dismantled and transported separately before driving on public roads. This does not apply to pallet forks which have foldable forks. Pallet forks not ap- proved for public roads are marked with *.
Page 64 Description of the vehicle 5.5 Type plates and stickers Weidemann GmbH Weidemann GmbH Mühlhäuser Weg 45-49, 34519 Diemelsee Mühlhäuser Weg 45-49, 34519 Diemelsee Germany, Tel. +49 (0)5633 609 0 Germany, Tel. +49 (0)5633 609 0 info@weidemann.de info@weidemann.de Fahrzeug Seriennummer / serial no. / no. de série Fahrzeug Seriennummer / serial no.
Page 65 Description of the vehicle Type plates and stickers 5.5 5.5.2 Safety label and information labels WARNING Injury hazard due to missing or damaged labels! A missing, incomplete or poor indication of danger can cause serious in- jury or death. ► Never remove safety labels and information labels. ►...
Page 66 Description of the vehicle 5.5 Type plates and stickers Safety label: Maintain a safe distance from the loader unit CAUTION! Risk of injury due to lowering of the raised loader unit. • During operation, no persons may be in the danger zone of the vehicle.
Page 67 Description of the vehicle Type plates and stickers 5.5 Safety label: Standing in the articulation area! CAUTION! Injury hazard in the articulation area of the vehicle. • During operation, no persons may be in the danger zone of the vehicle. Fig. 22: Label articulation area Safety label: Rotating parts CAUTION! Injury hazard - Shear hazard due to rotating parts.
Page 68 Description of the vehicle 5.5 Type plates and stickers Safety label: Do not allow any persons to ride along CAUTION! Risk of injury, additional persons riding on the vehicle can fall off and be injured. • Never transport persons with the vehicle. Fig. 25: Label Accompanying per- sons Safety label: Do not damage ROPS/FOPS protective structure...
Page 69 Description of the vehicle Type plates and stickers 5.5 Safety label: Hot coolant CAUTION! Scalding hazard due to hot engine coolant. At operating temperature the coolant is hot and the cooling system is un- der pressure. • Open the filler cap of the cooling system only after the coolant has cooled down.
Page 70 Description of the vehicle 5.5 Type plates and stickers 5.5.2.2 Information label DON‘T STOP HFKW-R134a GWP 1430 ENGINE ® r . : CONDITIONING 1000379801_02 NOTICE AVISO AVIS Fig. 31: Overview of information stickers Tie-down points The label identifies the tie-down points on the vehicle. Lashing gear can be attached to the tie-down points so that the vehicle can be secured for transport.
Page 71 Description of the vehicle Type plates and stickers 5.5 Battery master switch The vehicle is equipped with a battery master switch. The battery master switch can be used to disconnect the battery supply to the vehicle elec- trical system. This adhesive label identifies the position of the battery master switch.
Page 72 Description of the vehicle 5.5 Type plates and stickers Emergency exit The adhesive label identifies the emergency exit. Fig. 38: Emergency exit label Parking brake The label identifies the position of the parking brake lever. Fig. 39: Label Parking brake Do not stop the engine - Regeneration is running The vehicle is equipped with a system for exhaust gas aftertreatment.
Page 73 Description of the vehicle Type plates and stickers 5.5 Observe lubrication plan The label indicates that all lubrication points must be lubricated regularly according to the lubrication plan in the operator’s manual. Fig. 41: Label Lubricate lubricating points Sulfur content in diesel The label indicates the specification of the diesel engine to be used for the vehicle.
Page 74 Description of the vehicle 5.5 Type plates and stickers Joystick functions The label shows the functions of the joystick. Other chapters describe the functions. Fig. 44: Label Joystick assignment Operator’s Manual | 4080T Basic Line | 1000408123 | 05/2019 | [en]...
Page 75: Commissioning
Commissioning Boarding and disembarking 6.1 Commissioning Boarding and disembarking 6.1.1 Entering the vehicle CAUTION Risk of falling when entering or exiting! Entering or exiting incorrectly can cause injuries. ► Keep the mandatory climbing aids clean. ► Use prescribed climbing aids for entering and exiting. ►...
Page 76 Commissioning 6.1 Boarding and disembarking 6.1.1.1 Open the doors CAUTION Crushing hazard due to unlocked doors! Crushing can be caused by the doors slamming shut. ► Always lock doors. ► Use provided handles for closing. Unlock the lock with the starting key. Pull the door handle.
Page 77 Commissioning Boarding and disembarking 6.1 Close door from outside To prevent third parties from using the vehicle, always lock both doors after getting out and lock them with the starting key. Close the door against the spring pressure. Door locks into the door lock. ð...
Page 78 Commissioning 6.1 Boarding and disembarking Positioning door The doors can be opened to a gap. Fold down the lever. Engage the lever in the lock and lock into place. ð Door is locked open into place. Fig. 51: Position door slightly in open position 6.1.1.4 Opening and closing the side window...
Page 79: Setting Up The Operator Station 6.2
Commissioning Setting up the operator station 6.2 6.1.2 Emergency exit The right door of the cab is provided as an emergency exit if the left door is blocked. The right door is marked with the label shown. Fig. 53: Emergency exit identification Setting up the operator station 6.2.1 Adjusting the seat...
Page 80 Commissioning 6.2 Setting up the operator station 6.2.1.1 Seat MSG95 Sit on the seat to adjust. Adjusting longitudinal direction Pull lever 1 upward and hold. Push the seat forwards or backwards into the desired position. Release lever 1. After adjustment, lever 1 must engage in the desired position. It shall not be possible to move the seat after it has been locked.
Page 81 Commissioning Setting up the operator station 6.2 NOTICE Damage to the compressor. Too long operation of the suspension adjustment can cause damage to the compressor. ► Do not operate the suspension adjustment for more than one minute. The individually desired height can be adjusted up to a minimum spring travel.
Page 82 Commissioning 6.2 Setting up the operator station Adjusting longitudinal direction separately from the side console Pull lever 1 upward and hold. Push the seat forwards or backwards into the desired position. Release lever 1. After adjustment, lever 1 must engage in the desired position. It shall not be possible to move the seat after it has been locked.
Page 83 Commissioning Setting up the operator station 6.2 Adjusting the backrest Pull lever 5 upward and hold. Move the backrest forwards or backwards until the backrest is at the desired angle. Release lever 5. After adjustment, lever 5 must engage in the desired position. Once it is locked in place the backrest must no longer move.
Page 84 Commissioning 6.2 Setting up the operator station Adjusting the curvature of the backrest Turn the setting wheel 7 on the back of the backrest to set the desired curvature of the backrest. Turn setting wheel 7 clockwise. ð Curvature of the backrest is increased. Turn setting wheel 7 counterclockwise.
Page 85 Commissioning Setting up the operator station 6.2 NOTICE Damage to the compressor. Too long operation of the suspension adjustment can cause damage to the compressor. ► Do not operate the suspension adjustment for more than one minute. The individually desired height can be adjusted up to a minimum spring travel.
Page 86 Commissioning 6.2 Setting up the operator station WARNING Risk of accident from adjusting the seat belt while driving! Adjusting the seat belt while driving will distract you. This can cause acci- dents with serious injuries or death. ► Adjust the seat belt before commissioning the vehicle. ►...
Page 87 Commissioning Setting up the operator station 6.2 The height and inclination of the steering column can be individually ad- justed according to body size. Push the lever down and hold it. ð The steering wheel is unlocked. Adjust the steering wheel. Release the lever.
Page 88: Indications In The Display
Commissioning 6.3 Indications in the display Adjusting the rearview mirror Adjust the rearview mirrors as shown. ð In order to prevent the mirror from touching the door, turn the mir- ror bracket sufficiently forward (about 90°). Adjust the rearview mirrors. •...
Page 89 Commissioning Indications in the display 6.3 6.3.2 Reading information on the display Control lights serve as a source of information. The symbols in the dis- play indicate various operating states. The display lights up after switching on the ignition for the self-test. Travel direction indication A symbol illuminates depending on the travel direction se- lected.
Page 90 Commissioning 6.3 Indications in the display Display for continuous operation of third control cir- cuit The symbol indicates that the continuous operation of the third control circuit is active. Switch off continuous opera- tion when it is not required. Differential lock indicator •...
Page 91 Commissioning Indications in the display 6.3 Water in fuel The symbol appears if too much water has accumulated in the water separator on the fuel filter. Drain water in the water separator. Temperature of hydraulic oil too high The symbol appears when the maximum permissible temperature of the hydraulic oil has been reached.
Page 92: Warning Lights And Control Lights
Commissioning 6.4 Warning lights and control lights Warning lights and control lights 6.4.1 Meaning of the warning lights and control lights Warning lights and control lights serve as a source of information. Warning lights warn of damage to the vehicle. If a warning light illumin- ates during operation, immediately shut down the vehicle and contact an authorized service center.
Page 93 Commissioning Warning lights and control lights 6.4 Warning light "Engine electronics" Illuminates or flashes in case of one or more errors in the en- gine electronics – stop the engine if it does not do so itself. • If no error code appears in the vehicle display: –...
Page 94 Commissioning 6.4 Warning lights and control lights “High beam” control light Illuminates when the high beams are switched on or when flashing the headlights. • Vehicle lights on page [} 117] 6.4.2 Stability indicator Vehicles with a telescoping loader unit are equipped with a stability indic- ator.
Page 95: Commissioning The Vehicle 6.5
Commissioning Commissioning the vehicle 6.5 Commissioning the vehicle 6.5.1 Before commissioning Before commissioning, the following requirements must be met: • Read and understand the operator’s manual. • Operate the vehicle only from the operator seat. • Have technically trained personnel instruct you before using the vehicle for the first time.
Page 96 Commissioning 6.5 Commissioning the vehicle NOTICE The starting motor may be damaged! ► Do not start the engine again immediately after stopping it. Wait at least 15 seconds. ► Abort the start attempt after a maximum of 15 seconds if the engine does not start.
Page 97 Commissioning Commissioning the vehicle 6.5 The complete electrical system can quickly separated from the battery in an emergency by means of the battery master switch. Switch off the bat- tery overnight to avoid discharging the battery or to prevent other pos- sible damage.
Page 98 Commissioning 6.5 Commissioning the vehicle 6.5.4 Starting the engine The ignition lock is located on the right of the steering column. Start the engine as follows: ü Parking brake of the vehicle is activated. Insert the starting key in the ignition lock. ð...
Page 99 Commissioning Commissioning the vehicle 6.5 If the engine does not start NOTICE The drive system may be damaged! Due to the hydrostatic drive system, the engine cannot be started by tow- ing the vehicle. ► Do not attempt to start the engine by towing the vehicle. Actuate the starting motor continuously for a maximum of 20 seconds.
Page 100 Commissioning 6.5 Commissioning the vehicle Coding new starting keys New personal starting keys can be coded with the red master key. Store the red master key carefully and separately from the vehicle. Up to ten blue starting keys can be coded. The drive interlock has only one master key.
Page 101 Commissioning Commissioning the vehicle 6.5 Deleting coded keys If a coded blue starting key is lost, all other coded keys must also be de- leted. The master key code is not deleted during the deletion process. After the deletion process, the remaining stating keys can be coded anew.
Page 102 Commissioning 6.5 Commissioning the vehicle Retract the loader unit and lower it to the ground. Secure the vehicle with the parking brake. Switch off all electric consumers. Allow the engine to idle for approx. three minutes. Move starting key to position 0. Remove the starting key.
Page 103 Commissioning Commissioning the vehicle 6.5 1 Discharged vehicle battery 2 Red jumper cable (positive terminal) 3 Charged, current-generating vehicle battery; external power pack 4 Black jumper cable (ground point) An undercharged battery cannot provide the starting motor with sufficient power to prevent the engine from starting. Jump-starting the engine is possible.
Page 104: Operation
Operation 7.1 Braking the vehicle Operation Braking the vehicle 7.1.1 Operating the service brake WARNING Accident hazard due to malfunctioning brakes! Malfunctioning brakes can cause serious and fatal accidents. All repair work on the braking system must be performed by the trained personnel of a qualified service center.
Page 105 Operation Braking the vehicle 7.1 Inching with the brake/inching pedal In the inching range - pedal pressed lightly- the pedal can be used like a car’s clutch. In this case, the drive system is supplied with less hydraulic oil. Braking with the brake/inching pedal ▪...
Page 106: Steering The Vehicle
Operation 7.2 Steering the vehicle Release the parking brake Pull the lever slightly upwards towards X and press button K with your thumb. ð Latch from lever is released. Push the lever down completely. ð The control light goes out. ð...
Page 107: Driving The Vehicle 7.3
Operation Driving the vehicle 7.3 Driving the vehicle 7.3.1 Selecting a drive mode The vehicle has two drive modes. The maximum speed depends on the engine speed selected. Symbol Drive mode Recommended activity Crawler gear: For work requiring precise speed adjust- ment •...
Page 108 Operation 7.3 Driving the vehicle Use the switch to select the drive direction of the vehicle. After starting the engine, the direction switch is in zero position 0, regardless of the switch position. ▪ Set switch to zero position 0. ð...
Page 109 Operation Driving the vehicle 7.3 The pedal controls the engine speed variably. The engine speed affects: • the work movements of the loader unit, • the work movements of the attachment, • the hydraulic functions of the attachment, • the travel speed. The further the pedal is pressed, the more the engine speed increases.
Page 110 Operation 7.3 Driving the vehicle 7.3.6 Operating hand-inching The Hand-inching function can only be used if the crawler travel mode is selected. With the manual override function, the driving speed can be in- dividually adjusted, independent of the engine speed, without having to constantly operate the brake/inching pedal.
Page 111 Operation Driving the vehicle 7.3 7.3.8 Securing the vehicle Stop the vehicle without jolting by releasing the accelerator pedal or by actuating the brake/inching pedal and secure as described in the follow- ing section. The following activities apply to parking the vehicle after daily use. In ad- dition, the activities for the transport of the vehicle, as well as all mainten- ance and inspection work apply, provided that they are described in these operating instructions.
Page 112 Operation 7.3 Driving the vehicle WARNING Accident hazard due to blinded motorists! With work lights switched on, other road users can be blinded. This may result in accidents that could result in serious injury or death. ► Switch off the work lights when driving on public roads. ►...
Page 113: Driving With A Trailer 7.4
Operation Driving with a trailer 7.4 Driving with a trailer 7.4.1 Safety instructions for trailer operation Observe the safety instructions in the chapter see Trailer operation on page In addition, the following safety instructions apply: • Trailer operation is only permitted with a type-approved, authorized trailer coupling.
Page 114 Operation 7.4 Driving with a trailer 7.4.3 Trailer couplings WARNING Risk of injury to persons in the danger zone! Persons in the area between vehicle and trailer may be overlooked by the operator when coupling and uncoupling and may be seriously or fatally injured.
Page 115 Operation Driving with a trailer 7.4 7.4.3.2 Operating the automatic trailer coupling WARNING Danger of crushing due to unintentional actuation of the trailer coupling! When the trailer coupling lock is actuated, the trailer pin closes abruptly. Limbs within the range of the trailer pin can be crushed and severely in- jured.
Page 116: Operating The Lighting And Signal System
Operation 7.5 Operating the lighting and signal system Close trailer coupling by hand WARNING Danger of crushing due to the trailer coupling pins falling down! The sudden falling of the coupling pin can lead to injuries. ► Do not touch the coupling pin with your hands. ►...
Page 117 Operation Operating the lighting and signal system 7.5 7.5.2 Changing over between low and high beam ▪ Move the steering column switch upwards until it resists and hold it. ð The headlight flasher illuminates. ▪ Release the steering column switch. ð...
Page 118 Operation 7.5 Operating the lighting and signal system 7.5.5 Operating the hazard warning system The switch for the hazard warning system is located in the instrument panel. The switch has two switch positions. ▪ Move the switch to position I. ð...
Page 119 Operation Operating the lighting and signal system 7.5 7.5.7 Operating the work lights WARNING Accident hazard due to blinded motorists! With work lights switched on, other road users can be blinded. This may result in accidents that could result in serious injury or death. ►...
Page 120: Operating The Window Wiper
Operation 7.6 Operating the window wiper Operating the window wiper 7.6.1 Operating the front window wiper The vehicle is equipped with a window wiper for the front window. The window wiper is operated with the rotary switch on the steering column switch.
Page 121: Operating The Heating, Ventilation And Air Conditioning System
Operation Operating the heating, ventilation and air conditioning system Operating the heating, ventilation and air conditioning system 7.7.1 Operating heating The cab is equipped with a fan-assisted heating system. The temperature of the heating is controlled with the rotary switch 1. The temperature can be infinitely adjusted.
Page 122 Operation 7.7 Operating the heating, ventilation and air conditioning system 7.7.3 Using the air conditioning system NOTICE Damage to the air conditioning system! If the air conditioning system is not used for too long, malfunctions may occur. ► In order to avoid malfunctions and possible loss of refrigerant, put the air conditioning system into operation at least once a month.
Page 123: Working With The Vehicle 7.8
Operation Working with the vehicle 7.8 7.7.4 Operating the rear window heating The vehicle is equipped with a heated rear window. With rear window heating, fogging of the rear window can be prevented in cold weather. Rear window heating is operated with a switch in the switch panel in the roof of the cab.
Page 124 Operation 7.8 Working with the vehicle Falling objects WARNING Risk of injury from falling load when the loader unit is raised and ex- tended! Falling load (e.g. large bales or bale stacks) can lead to serious injury or death. ► Never lift or transport several large bales or crates at the same time. ►...
Page 125 Operation Working with the vehicle 7.8 7.8.3 Operating telescoping arm WARNING Risk of accident due to vehicle tipping over! A shifting of the center of gravity may adversely affect the stability of the vehicle. This may result in an accident that could cause serious injury or death.
Page 126 Operation 7.8 Working with the vehicle Safety instructions for working with the telescoping arm Observe the following points when working with the telescoping arm: • When driving: – Only drive with the telescoping arm retracted. – Keep the loader unit lowered when driving. –...
Page 127 Operation Working with the vehicle 7.8 7.8.4 Stability indicator Stability indicator Always watch the stability indicator display when working. The display of the stability indicator shows the steadiness of the vehicle in relation to the lifted load. The stability indicator provides visual and acoustic signals. •...
Page 128 Operation 7.8 Working with the vehicle Measures in case of system errors Stop the vehicle immediately. Note the LED code. Contact an authorized service center. ð The stability indicator must be checked and repaired immediately by an authorized service center. All repairs and adjustment work to be performed to the stability indicator and overload shutdown may only be carried out by authorized qualified personnel.
Page 129 Operation Working with the vehicle 7.8 Operating the locking function of the rocker switch The joystick for the loader unit can be secured against unintentional actu- ation with the locking function. When the locking function is activated, it is not possible to operate the loader unit. When the locking function is on, the control light in the switch illuminates.
Page 130 Operation 7.8 Working with the vehicle The differential is locked with the differential lock. This avoids uneven wheel spin. The differential lock in the axles prevents the differential gear from having a compensating effect, i.e. the driving force acts uniformly on all wheels.
Page 131 Operation Working with the vehicle 7.8 Permitted attachments NOTICE Damage caused by non-approved attachments. To avoid damage to the vehicle, only the attachments listed in the chapter "Attachments for the vehicle" are permitted. ► For the installation of attachments which are not listed there, ap- proval must be obtained from the manufacturer of the vehicle and an EBE (individual type approval) from the competent authorities is re- quired.
Page 132 Operation 7.8 Working with the vehicle Coupling the attachment with the hydraulic power coupler ü The locking pins 3 must be fully retracted so that an attachment can be coupled. Retract to the locking pin: see Uncoupling attachments on page 135.
Page 133 Operation Working with the vehicle 7.8 Release hydraulic connections with the switch on the joystick In this version, the hydraulic connections are depressurized using the switch on the joystick. Stop the engine of the vehicle. Switch ignition of the vehicle to position I. Move the switch on the joystick repeatedly in either direction.
Page 134 Operation 7.8 Working with the vehicle A Hydraulic connection left - flow B Hydraulic connection right - return flow Coupling hydraulic connections In order to be able to use hydraulically actuated attachments, the hy- draulic connections of the attachment must be coupled to the hydraulic connections on the loader unit.
Page 135 Operation Working with the vehicle 7.8 7.8.11 Uncoupling attachments CAUTION Injuries due to tipping over of removed attachments! Attachments that tip over can cause injury to persons. ► Ensure that no one is in the danger zone. ► Only park the attachments on firm and level ground. ►...
Page 136: Operating The Front Hydraulic Connections
Operation 7.9 Operating the front hydraulic connections Operating the front hydraulic connections 7.9.1 Hydraulic connections on the loader unit NOTICE Soiled hydraulic connections can cause dirt to penetrate into the hy- draulic system and cause damage! ► Clean hydraulic connections before connecting or disconnecting. ►...
Page 137 Operation Operating the front hydraulic connections 7.9 7.9.3 Standard hydraulic connections in continuous operation NOTICE Damage due to overheating of the hydraulic system! When continuous operation is switched on and no attachment is connec- ted, the hydraulic system overheats very quickly. ►...
Page 138 Operation 7.9 Operating the front hydraulic connections Switch off continuous operation of hydraulic connections If continuous operation is no longer needed, proceed as follows: ▪ Move the switch to position 0. ð Symbol illuminates in the display. ð Continuous operation is switched off. 7.9.4 Operating additional hydraulic connections With the fourth control circuit function, the additional hydraulic connec-...
Page 139 Operation Operating the front hydraulic connections 7.9 7.9.4.1 Operating additional hydraulic connections with the scroll wheel Releasing the pressure on additional hydraulic connections To couple the additional hydraulic connections, they must first be depres- surized. Switch off the engine of the vehicle. Move starting key to position I.
Page 140 Operation 7.9 Operating the front hydraulic connections Operating additional hydraulic connections on the mast Switch 1 in the switch panel can be used to switch from the standard hy- draulic connections to the additional hydraulic connections. The addi- tional hydraulic connections can be actuated using the control wheel on the joystick.
Page 141 Operation Operating the front hydraulic connections 7.9 Coupling the hydraulic connections multi-quick coupler ü The hydraulic connections are depressurized. Push in the red safety button. ð The locking clip is unlocked. Flip the locking clip over. Open the protective cap. Install the counterpart of the attachment.
Page 142: Operating The Rear Hydraulic Connections
Operation 7.10 Operating the rear hydraulic connections The hydraulic connection for pressureless return flow is located on the loader unit. The design of the hydraulic connection makes it impossible to confuse it with other hydraulic connections. Return without pressure For certain attachments on which components are driven by a hydraulic oil engine , a pressureless return flow is required.
Page 143 Operation Operating the rear hydraulic connections 7.10 7.10.2 Double-acting rear hydraulic connections Fig. 131: Rear hydraulic connections Operating the rear hydraulic connections 1 and 2 The rear hydraulic connections are operated with the switch in the switch panel on the side console. The switch has three positions. When the switch is released, it automatically switches to position 0.
Page 144 Operation 7.10 Operating the rear hydraulic connections The rear hydraulic connections in continuous operation are operated with the switch in the switch panel on the side console. The switch has three positions. The hydraulic connections are fitted with red protective caps. ▪...
Page 145 Operation Operating the rear hydraulic connections 7.10 The function is switched via the button in the switch panel in the side con- sole. The switch has two switch positions. ▪ Move the switch to position I. ð Rear hydraulic connections can be operated using the joystick scroll wheel.
Page 146: Operating Electrical Functions
Operation 7.11 Operating electrical functions 7.11 Operating electrical functions 7.11.1 Operating the 3-pole plug receptacle at the loader unit The 3-pole plug receptacle on the loader unit is required for connecting attachments on which certain functions are electrically operated. The 3-pole plug receptacle on the loader unit is operated with buttons 1 and 2 on the joystick.
Page 147 Operation Operating electrical functions 7.11 7.11.3 230 volt plug receptacle in the cab WARNING Risk of injury due to electric shock! The mains plug is operated with 230 volts. Defective cables can lead to electric shocks which can result in death or serious injury. ►...
Page 148: Working With Attachments
Operation 7.12 Working with attachments 7.11.5 7-pole plug receptacle at the rear This plug receptacle is used for connecting lights, turn signals and elec- trical devices on the trailer or attachment. Always install additional lights on an attachment if the rear lights and other lights are covered by the at- tachment.
Page 149 Operation Working with attachments 7.12 Information Adjust the travel speed when driving into the material to be loaded ac- cording to its type and the given conditions. Avoid too much wheel spin. Tire wear and fuel consumption increase un- necessarily and the vehicle's output is not fully utilized. 7.12.2 Described attachments WARNING...
Page 150 Operation 7.12 Working with attachments 7.12.3 Level indicator for buckets The level indicator for attachments allows you to better estimate the tilt position of the attachment. Observe the angle attached to the attachment to better estimate the tilt position of the attachment. Fig. 142: Display of bucket position 7.12.4 Indicator for the position of the loader unit...
Page 151 Operation Working with attachments 7.12 Working with the lightweight material or earth bucket The bucket can be used for loading or excavation work. Practice working with the bucket on free and safe terrain before starting work for the first time. Loading work Pick up material: Lower the attachment and align it parallel to the ground.
Page 152 Operation 7.12 Working with attachments Excavation work Lower attachment. Slightly tilt out the attachment. ð A digging angle is established. Travel forward. Press the loader unit slightly downwards with the joystick. ð The attachment penetrates the ground. Make the digging angle flatter. ð...
Page 153 Operation Working with attachments 7.12 Working with the 4-in-1 bucket Orientation aids are affixed to the attachment. The fastening screw for the cylinder lock is marked in color. Marks are attached to the bucket itself next to the hydraulic cylinders. The marks indicate how far the bucket is open.
Page 154 Operation 7.12 Working with attachments Grading NOTICE Damage to the loader unit! Avoid damage to the telescopic boom! When loading, leveling and digging with the telescopic boom extended, large lever forces occur which can damage the telescopic boom and the hydraulic cylinders.
Page 155 Operation Working with attachments 7.12 Scraping work Set a flat digging angle. Fold up the front half of the bucket by about 10 to 15 cm. Lower the bucket to the ground. Set the depth of the layer you want to remove with the lift hydraul- ics.
Page 156 Operation 7.12 Working with attachments Working with the manure forks Lower attachment. Set the attachment parallel to the ground. Drive into the material to be loaded. ð Pay attention to the travel speed. Slightly raise the loader unit. ð A load is applied to the front axle of the vehicle. ð...
Page 157 Operation Working with attachments 7.12 Working with the fork-and-grab attachment Open the attachment. Lower attachment. Set the attachment parallel to the ground. Drive into the material to be loaded. ð Pay attention to the travel speed. Slightly raise the loader unit. ð...
Page 158 Operation 7.12 Working with attachments Designated use The pallet fork attachment is used for raising, transporting and setting down loads. Any other use of the pallet forks is not in accordance with its designated use. The pallet forks consist of the fork carriage and forks. The forks must always be used in pairs as delivered.
Page 159 Operation Working with attachments 7.12 Lift the attachment. ð Recommended height is approx. 10 to 30 cm. Move the forks to position 1 . ð Locking is released. Push the forks into the required position. ð Handle forks only as shown in position 2. Move the forks to position 3.
Page 160 Operation 7.12 Working with attachments Picking up a load Check whether the permissible bearing load of the vehicle and pallet forks is appropriate for the weight of the load. ü Adjust the fork spacing and lock the forks. Approach the load in a straight line. Set the pallet forks to the required height (1) in a horizontal position (2).
Page 161 Operation Working with attachments 7.12 7.12.10 Work platform The attachment of a working platform to this vehicle is prohibited. [en] | 05/2019 | 1000408123 | 4080T Basic Line | Operator’s Manual...
Page 162: Transportation
Transportation 8.1 Towing the vehicle Transportation Towing the vehicle 8.1.1 Warnings for towing WARNING Risk of accident due to towing of the vehicle! Towing the vehicle may cause situations that cannot be foreseen. This may result in accidents that could result in serious injury or death. ►...
Page 163 Transportation Towing the vehicle 8.1 Getting ready for towing Apply the parking brake. Switch off the ignition and remove the starting key. Open the engine cover. Raising the cab sideways: see Cab on page 180 ð The variable displacement pump 1 becomes accessible. Fig. 160: Position of the variable dis- placement pump NOTICE...
Page 164: Towing The Vehicle
Transportation 8.1 Towing the vehicle Enable bypass A4VG56DA ü Required tools: Hexagon socket wrench width 4 mm and wrench wrench width 13 mm Loosen hexagon nuts 2 of the bypass valves. Screw in threaded bolts 1 until they are flush with the hexagon nuts. To tow the vehicle, tilt the cab back and secure it.
Page 165 Transportation Towing the vehicle 8.1 Enable bypass A4VG71DA ü Required tools: Hexagon socket screw,wrench size 5 mm Remove the plastic caps 1 from the high-pressure limiting valves. Turn screw 2 counterclockwise and unscrew it two turns. To tow the vehicle, tilt the cab back and secure it. Close the engine cover.
Page 166 Transportation 8.1 Towing the vehicle Use the vehicle's towing devices for towing the vehicle. ü Bypass valves of the variable displacement pump must be enabled. Release the pins. Pull out the pins. Bring the towing gear (e.g. tow bar) into the towing fixture. Insert the pins.
Page 167: Loading The Vehicle 8.2
Transportation Loading the vehicle 8.2 Loading the vehicle 8.2.1 Information on loading the vehicle WARNING Accident hazard due to incorrect loading! Incorrect loading can cause the vehicle to tip over, for example. This may result in accidents that could result in serious injury or death. ►...
Page 168 Transportation 8.2 Loading the vehicle 8.2.2 Loading the vehicle < 25° Fig. 164: Loading vehicle The prerequisites for loading are listed in the following: • Secure the transport vehicle with wheel chocks to prevent it from rolling away. • Place the access ramps at the smallest possible angle. –...
Page 169 Transportation Loading the vehicle 8.2 Carry out loading Carefully drive the vehicle onto the middle of the transport vehicle. Lower the loader unit until the attachment rests on the loading sur- face of the transport vehicle. Switch the drive system to neutral. Apply the parking brake.
Page 170 Transportation 8.2 Loading the vehicle 8.2.4 Safety instructions regarding crane-lifting Only use crane eyelets marked with the labels to attach the loading gear. Fig. 166: Information label crane eyelets In order to avoid injury or accidents, observe the following instructions when loading the vehicle. •...
Page 171 Transportation Loading the vehicle 8.2 8.2.5 Crane-lifting the vehicle DANGER Fatal hazard from falling objects or falling vehicle! Unsecured objects or an incorrectly fastened vehicle may fall. If persons are hit by these parts or the vehicle, serious or fatal injuries may result. ►...
Page 172: Transporting The Vehicle
Transportation 8.3 Transporting the vehicle Transporting the vehicle 8.3.1 Tying down the vehicle Only use lashing eyelets marked with the labels to attach the lashing straps or chains. Fig. 169: Information label lashing lugs Operator’s Manual | 4080T Basic Line | 1000408123 | 05/2019 | [en]...
Page 173 Transportation Transporting the vehicle 8.3 Safety instructions on tying down the vehicle • The transport vehicle must have a sufficient bearing load and a suit- able loading surface. • The loading surface of the transport vehicle must be clean. • The gross weight rating and the axle loads of the transport vehicle must not be exceeded.
Page 174 Transportation 8.3 Transporting the vehicle Tying down the vehicle Stopping and securing the vehicle. Block the articulated pendulum joint see Blocking articulated pendu- lum joint on page 169 Secure all wheels of the vehicle at the front and rear with wheel chocks.
Page 175: Maintenance
Maintenance Safety instructions for maintenance 9.1 Maintenance Safety instructions for maintenance 9.1.1 Responsibilities and prerequisites • The maintenance and inspection personnel must have specialized knowledge about the maintenance and inspection work on the vehicle. – The necessary expertise can be obtained at training sessions from our Service department.
Page 176 Maintenance 9.1 Safety instructions for maintenance Information on tools • Only work with suitable and functional tools. Information on cleaning work • Clean units in the work area before starting work. The choice of the cleaning agents depends on the material of the parts to be cleaned. •...
Page 177 Maintenance Safety instructions for maintenance 9.1 Information on residual pressure in the hydraulic system • A fine jet of hydraulic oil under high pressure can penetrate through the skin. Seek medical attention immediately if oil penetrates the skin or eyes. •...
Page 178: Daily And Weekly Maintenance
Maintenance 9.2 Daily and weekly maintenance Information on batteries • Batteries give off explosive gases. – Avoid smoking, fire or open flames near batteries. • Do not place any tools on batteries. Short-circuiting the terminals pro- duces sparks that ignite escaping battery acid vapors. •...
Page 179: Maintenance Accesses On The Vehicle 9.3
Maintenance Maintenance accesses on the vehicle 9.3 Maintenance cycle Personnel For further information, please contact [} 195] Lubricating the vehicle [} 200] Cleaning the air filter [} 203] Check air intake line [} 204] Cleaning the radiator [} 205] Cleaning the condenser [} 207] Checking steering system for function [} 207] Checking the steering column adjustment [} 208]...
Page 180 Maintenance 9.3 Maintenance accesses on the vehicle Opening the engine cover Open the engine cover with the handle. The handle is lockable. Unlock engine cover with key. Open the engine cover by pressing button 1. ð The engine cover is unlocked. Raise the engine cover by pulling the handle.
Page 181 Maintenance Maintenance accesses on the vehicle 9.3 Preparing to tilt cab Remove loose objects from the cab. Ensure that there is enough space to the right of the vehicle. Loosen and unscrew fastening screws 1 and 2. Close or unhinge cab doors. Open the engine cover.
Page 182: Performing A Visual Inspection
Maintenance 9.4 Performing a visual inspection Performing a visual inspection 9.4.1 Checking components Check the following components daily: • Check all steel parts for damage and loose threaded fittings, in partic- ular the protective ROPS/FOPS structure. • Check the condition and function of the seat belt. •...
Page 183: Tables For Operating Materials And Filling Quantities 9.5
Maintenance Tables for operating materials and filling quantities 9.5 9.4.2 Leakage check Check the following components to see if they are tight: • Check air intake line from air filter to engine. • Check the hose pipes of the cooling system. •...
Page 184: Checking Fill Levels
Maintenance 9.6 Checking fill levels Vehicle fluids for the engine Deutz TCD 2.9 L4 (55.4 kW) Position Capacity Fluid Specification Fuel tank 82 l Diesel fuel EN 590 (EU) BS 2869:2010 class A2 (GB) ASTM 0975, class 2D S15 Engine oil with filter 8.8 l Engine oil SAE 10W40 Low-soot engine oil...
Page 185 Maintenance Checking fill levels 9.6 9.6.1.1 Refueling The fill opening is located at position 1 on the vehicle. Retract the loader unit and lower it to the ground. Switch off the ignition and remove the starting key. Open the engine cover. Open the lid of the fill opening and unscrew it.
Page 186 Maintenance 9.6 Checking fill levels The vehicle is equipped with a water separator on the fuel filter. Water in the fuel may cause functional disruptions and damage. The water separ- ator on the fuel filter must be checked regularly. If the symbol appears on the display, check the fuel filter immediately.
Page 187 Maintenance Checking fill levels 9.6 9.6.2 Check fill level of brake fluid. WARNING Accident hazard due to malfunctioning brakes! The braking system is a crucial safety component. Improper maintenance can lead to failure of the braking system. This may result in accidents that could result in serious injury or death.
Page 188 Maintenance 9.6 Checking fill levels Preparation for maintenance In the engine compartment Park the vehicle on a stable, level and dry surface. Secure the vehicle with the parking brake. Retract the loader unit and lower it to the ground. Switch off the ignition and remove the starting key. Let the engine cool down.
Page 189 Maintenance Checking fill levels 9.6 If the oil level is below the MAX mark, the engine oil must be refilled at the fill opening 1. ü Engine oil level was checked. Open the cover of the fill opening for engine oil. Add engine oil.
Page 190 Maintenance 9.6 Checking fill levels Preparation for maintenance In the engine compartment Park the vehicle on a stable, level and dry surface. Secure the vehicle with the parking brake. Retract the loader unit and lower it to the ground. Switch off the ignition and remove the starting key. Let the engine cool down.
Page 191 Maintenance Checking fill levels 9.6 NOTICE Technical damage due to insufficient filling level! ► Check or refill the filling level according to the service intervals spe- cified in these operating instructions. ► Add the coolant when the symbol appears on the display between service intervals.
Page 192 Maintenance 9.6 Checking fill levels 9.6.5 Fill level of hydraulic oil NOTICE Damage to hydraulic system due to incorrect fill level! ► The hydraulic oil level must never fall below the MIN mark on the oil dipstick. ► When filling, never exceed the MAX mark on the oil dipstick. ►...
Page 193 Maintenance Checking fill levels 9.6 9.6.5.1 Check the hydraulic oil level The oil dipstick for the hydraulic oil is fixed to the breather filter. ü Preparations for maintenance in the engine compartment were car- ried out. Unscrew the breather filter. Pressure is released from the tank when this is done.
Page 194 Maintenance 9.6 Checking fill levels 9.6.5.3 Bleeding the hydraulic system WARNING Injury hazard due to uncontrolled movements of the loader unit! Air inclusions in the hydraulic system can cause uncontrolled movements of the loader unit due to pressure loss. This may result in accidents that could result in serious injury or death.
Page 195: Lubricating The Vehicle And Attachment 9.7
Maintenance Lubricating the vehicle and attachment 9.7 Refilling window wiper water ü Preparations for maintenance in the engine compartment were car- ried out. Open the fill opening on the container. ð Use filling aid, e.g. hose, if necessary. Fill with water, if necessary mixed with window cleaner or anti- freeze.
Page 196 Maintenance 9.7 Lubricating the vehicle and attachment Fig. 187: Lubrication plan Lubrication point and number [x] 1 Automatic trailer hitch (option) 2 Rear cab tilt hinge 3 Bearing of the brake pedal (in cab) Bearing of the brake pedal (under cab) 4 Bearing of gas pedal (in cab) 5 Front cab tilt hinge 6 Bearing of the central joint at the top...
Page 197 Maintenance Lubricating the vehicle and attachment 9.7 Lubrication point and number [x] 19 Bearing of the central joint top (remote lubrication at entry) 20 Bearing of the steering cylinder at the rear (remote lubrication at entry) 21 Bearing of the central joint bottom 22 Bearing of steering cylinder front 23 Drive shaft front 24 Bearing of lifting cylinder front...
Page 198 Maintenance 9.7 Lubricating the vehicle and attachment Lubrication times and break times The break time and the lubrication time are set by means of ratchet switches S and P in the control viewing window. To set the time, remove the frame on the pump of the central lubric- ation system with a flat screwdriver.
Page 199 Maintenance Lubricating the vehicle and attachment 9.7 9.7.3 Lubricating attachments Pallet fork Fork-and-grab attachment 4-in-1 bucket Correct maintenance and service is absolutely necessary for smooth and continuous operation, and for a long service life of the attachments. The lubrication, maintenance and care instructions in the corresponding oper- ator’s manual for the attachments must be observed.
Page 200: Cleaning And Maintaining Vehicle
Maintenance 9.8 Cleaning and maintaining vehicle Cleaning and maintaining vehicle 9.8.1 Information on cleaning and care NOTICE Damage to vehicle due to cleaning work! ► When cleaning the vehicle, pay particular attention to the underside of the vehicle. Do not allow dirt to collect on the engine or gearbox. ►...
Page 201 Maintenance Cleaning and maintaining vehicle 9.8 The vehicle is equipped with an engine air filter for filtering the engine in- take air. The air filter consists of a main filter and a safety filter. Replace the main filter in time. If it is allowed to get too dirty, exhaust gas emissions will increase.
Page 202 Maintenance 9.8 Cleaning and maintaining vehicle 9.8.2.2 Maintenance display for air filter Clean or replace the engine air filter when the symbol appears in the display instrument between maintenance intervals. Fig. 196: Contaminant display of the air filter 9.8.2.3 Removing and cleaning the main filter Removing the main filter ü...
Page 203 Maintenance Cleaning and maintaining vehicle 9.8 1 Cover of the housing 2 Main filter 3 Safety filter 4 Housing Remove safety filter ü Preparations for maintenance in the engine compartment were car- ried out. Remove the fasteners on the cover. Remove the cover.
Page 204 Maintenance 9.8 Cleaning and maintaining vehicle 9.8.3 Radiator A combination radiator is located in the engine compartment. It consists of several parts. One part cools the hydraulic oil, the second part is inten- ded for engine cooling and possibly another part cools the combustion air of the engine.
Page 205 Maintenance Cleaning and maintaining vehicle 9.8 9.8.5 Cleaning the condenser NOTICE Damage to the engine due to overheating when equipped with an air conditioning system! If the vehicle is equipped with air conditioning, the condenser must be re- moved to clean the radiator and condenser of the air conditioning system. ►...
Page 206: Brake System Maintenance
Maintenance 9.9 Brake system maintenance Brake system maintenance 9.9.1 Checking the service brake and parking brake for function WARNING Accident hazard due to malfunctioning brakes! The braking system is a crucial safety component. Improper maintenance can lead to failure of the braking system. This may result in accidents that could result in serious injury or death.
Page 207: Steering System Maintenance 9.10
Maintenance Steering system maintenance 9.10 9.10 Steering system maintenance 9.10.1 Checking steering system for function WARNING Accident hazard due to steering system not working correctly! Driving with a defective steering system can lead to accidents and injur- ies or death. ►...
Page 208: Electrical System Maintenance
Maintenance 9.11 Electrical system maintenance 9.11 Electrical system maintenance 9.11.1 Checking the lighting Switch on the following lights and check that they function correctly: • Vehicle lights – Parking light – Low beam – High beam – Reversing lights and rear lights –...
Page 209 Maintenance Electrical system maintenance 9.11 WARNING Danger of explosion due to defective batteries! Batteries give off explosive gases that can cause deflagrations if ignited. ► Do not smoke, avoid fire and open flames. ► Do not place any tools on the battery. NOTICE Short-circuit in the electrical system due to incorrect sequence when connecting and disconnecting!
Page 210: Working Hydraulics Maintenance
Maintenance 9.12 Working hydraulics maintenance Battery maintenance Observe the operator’s manual of the battery. The operator’s manual of the battery is fastened on one side of the battery. – Always keep the terminal heads of the battery and the terminals of the connecting cables clean and lubricate with anti-corrosion grease.
Page 211: Engine Maintenance 9.13
Maintenance Engine maintenance 9.13 9.13 Engine maintenance 9.13.1 Checking the belts NOTICE Cracked and stretched belts cause engine damage! ► Service the belts according to the maintenance intervals in this oper- ator’s manual. ► Observe the operator’s manual of the engine. ►...
Page 212: Exhaust Gas Aftertreatment System
Maintenance 9.14 Exhaust gas aftertreatment system 9.14 Exhaust gas aftertreatment system 9.14.1 Information on exhaust gas aftertreatment The vehicle may be fitted with a system for exhaust gas aftertreatment. The system may vary depending on the engine option, the system. Engines with diesel oxidation catalytic converter: •...
Page 213 Maintenance Exhaust gas aftertreatment system 9.14 If the vehicle is equipped with a diesel oxidation catalyst, the operator does not have to carry out any work. Maintenance and repair on the diesel oxidation catalyst may only be per- formed by an authorized service center. Fig. 207: Position of the diesel oxida- tion catalyst 9.14.3...
Page 214 Maintenance 9.14 Exhaust gas aftertreatment system NOTICE Damage to the diesel particulate filter! If the soot load in the diesel particulate filter reaches a critical value, this can lead to damage to the diesel particulate filter or the engine. For safety reasons, the engine power is reduced.
Page 215 Maintenance Exhaust gas aftertreatment system 9.14 9.14.4.2 Operating states of the regeneration During use of the vehicle, soot particles are deposited in the diesel partic- ulate filter. This soot load increases and is removed from the diesel par- ticulate filter by regeneration. Operating states engine Deutz TCD 2.9 •...
Page 216 Maintenance 9.14 Exhaust gas aftertreatment system Symbol Meaning Maximum soot load exceeded The soot load of the diesel particulate filter is too high. The engine switches off automatically every 30 seconds. luminates • A regeneration or repair can only be performed by the service department. flashes illuminates Regeneration interrupted...
Page 217 Maintenance Exhaust gas aftertreatment system 9.14 The "Automatic regeneration" mode is preset when the engine is started. Diesel particulate filter regeneration is only started when the engine is at operating temperature. If the diesel particulate filter reaches a certain soot load, an automatic re- generation is triggered.
Page 218 Maintenance 9.14 Exhaust gas aftertreatment system 9.14.4.4 Reduced engine output Repeated interruption of regeneration increases the soot load in the diesel particulate filter. From a soot load of more than 143 %, the engine automatically lowers the engine output by 30 %. In the display, the control light and the control light ...
Page 219 Maintenance Exhaust gas aftertreatment system 9.14 Interrupting manual regeneration Manual regeneration can be interrupted in case of an emergency. Inter- rupting manual regeneration may cause damage to the diesel particulate filter. ▪ Hold the switch in position I for at least three seconds. ð...
Page 220: Cab Maintenance
Maintenance 9.15 Cab maintenance 9.15 Cab maintenance 9.15.1 Checking the seat ▪ Check the correct fastening of the seat, check the fastening screws. ð The seat must not wobble or be able to be lifted. ▪ Check all seat positions and their locks. ð...
Page 221 Maintenance Cab maintenance 9.15 9.15.3 Checking function of seat switch The seat switch is a safety component. If the driver's seat is relieved when the drives are running, the drive system and working hydraulics are deactivated after a few seconds. Perform check: Sit down on the operator seat.
Page 222: Tire Maintenance
Maintenance 9.16 Tire maintenance 9.16 Tire maintenance 9.16.1 Safety instructions for tires WARNING Danger to life due to improper installation! Improper installation of tires and rims can cause accidents which can lead to serious or fatal injuries. ► Have assembly work performed by an authorized service center only.
Page 223 Maintenance Tire maintenance 9.16 9.16.2 Inflating the tires WARNING Injury hazard due to bursting tires! Inflating the wheels can cause accidents resulting in serious injury or death. ► Use only filling devices with calibrated pressure gages to inflate the tires. ►...
Page 224: After Daily And Weekly Maintenance
Maintenance 9.17 After daily and weekly maintenance Preparations for work on tires and axles Park the vehicle on a stable, level and dry surface. Secure the vehicle with the parking brake. Retract the loader unit and lower it to the ground. Switch off the ignition and remove the starting key.
Page 225: Malfunctions
Malfunctions Faults, causes, remedy 10.1 Malfunctions 10.1 Faults, causes, remedy 10.1.1 Information on malfunctions NOTICE Ignoring a fault or error message Ignoring a fault or an error message can result in damage to the vehicle. ► If the fault cannot be rectified by the measures described, contact an authorized service center and have the fault or error rectified.
Page 226: Faults, Causes, Remedy
Malfunctions 10.1 Faults, causes, remedy Error/fault Possible cause Remedy Engine does not start Operator is not sitting on the seat. Sit down on the operator seat. Engine stops during operation Malfunctioning seat switch Have the seat switch replaced. Continuous operation of the hy- Switch off continuous operation of draulic connections is switched on the hydraulic connections.
Page 227: Fault Indications On The Display 10.2
Malfunctions Fault indications on the display 10.2 Error/fault Possible cause Remedy Vehicle does not have enough out- Inching is stuck Contact an authorized service cen- Manual Inching is actuated Switch off manual inching Continuous operation of the hy- Switch off continuous operation of draulic connections is switched on the hydraulic connections.
Page 228 Malfunctions 10.2 Fault indications on the display Warning light for vehicle electronics If the warning light lights up during operation, switch off the engine and switch on the ignition. • If no error code appears in the vehicle display: – Start the engine and resume vehicle travel. •...
Page 229 Malfunctions Fault indications on the display 10.2 Error messages with symbol Dirt accumulation on air filter The symbol appears when the air filter contamination level is too high. Clean the air filter and replace it if necessary. Temperature of coolant too high The symbol appears if the temperature of the coolant is too high.
Page 230 Malfunctions 10.2 Fault indications on the display If the vehicle electronics issues an error, an error code is displayed in the indicating instrument. Note down the error code before stopping the en- gine. Some error codes no longer appear after the ignition is switched off, although the error may still exist.
Page 231: Decommissioning
Decommissioning Temporary decommissioning 11.1 Decommissioning 11.1 Temporary decommissioning 11.1.1 Putting the vehicle out of operation The measures indicated below refer to putting the vehicle out of operation and back into operation again after a longer period of time. • Stopping and securing the vehicle. •...
Page 232: Permanent Decommissioning
Decommissioning 11.2 Permanent decommissioning 11.1.4 Removing engine preservation • Remove the covers from the intake and exhaust openings of the en- gine. • Remove the anti-corrosion agent from the pulleys. • Install the fan belt. • Drain the preservation oil and add engine oil. •...
Page 233 Decommissioning Permanent decommissioning 11.2 11.2.3 Disposing of the vehicle • Further recycling of the vehicle must be carried out in accordance with the state of the art valid at the time of recycling and in compli- ance with the accident prevention regulations. •...
Page 234: Technical Data
Technical data 12.1 Dimensions Technical data 12.1 Dimensions 12.1.1 Vehicle dimensions Fig. 217: Dimension sheet for the vehicle Operator’s Manual | 4080T Basic Line | 1000408123 | 05/2019 | [en]...
Page 235: Weights 12.2
Technical data Weights 12.2 Item Designation Value in mm 4080T Basic Line Overall length with standard bucket 5929 Overall length with pallet forks 6451 Overall length without attachment 5180 Center of axle to bucket pin 1394 Wheelbase 2189 Rear overhang 1531 Height above cab LK115-1 2485...
Page 236 Technical data 12.2 Weights 12.2.2 Payload, bearing load and axle load The payload and bearing load data refer to criteria in which the vehicle is located on level and load-bearing ground. If the vehicle is used under conditions which deviate from these criteria, e.g. on soft or uneven ground, on slopes or if loads can slip, these conditions must be observed by the operator.
Page 237: Engine
Technical data Engine 12.3 12.2.2.2 Load diagrams 1570 kg 0,5 m 1359 kg 1040 kg 930 kg -0,5 Fig. 220: Working load diagram 12.3 Engine 12.3.1 Engine data Deutz TCD 2.9 Exhaust-emission level EU level IV Design Straight diesel engine Number of cylinders Charging Turbocharger Type designation...
Page 238: Electrical System
Technical data 12.4 Electrical system 12.4 Electrical system 12.4.1 Technical data Operating voltage: 12 V Battery: 100 Ah Alternator: 85 A Battery master switch: see Battery master switch on page 96 12.4.2 Fuses The different electrical circuits are protected with fuses with different cur- rent ratings.
Page 239 Technical data Electrical system 12.4 12.4.4 Fuse assignment of the side console Item Protected function Fuse Tilt-in switch-off, third control circuit pressure re- 15 A lief, load stabilizer/floating position, high flow, rear hydraulic connections, options Wiper/wash pump rear, rotating beacon, third / 15 A fourth control circuit changeover, third control cir- cuit / hydraulic connections changeover at rear,...
Page 240: Drive System
Technical data 12.5 Drive system 12.4.5 Fuse assignment in engine compartment Item Protected function Fuse Not assigned Not assigned Not assigned Not assigned Not assigned Not assigned Not assigned Not assigned F301 Instrument panel 40 A F302 50 A F303 Fuel pump 20 A F304...
Page 241: Hydraulics
Technical data Hydraulics 12.6 Description of the brake Design Hydraulically operated disc or drum brake, acting on both axles via drive shaft. Parking brake Location Front axle Design Mechanical braking effect on service brake via Bowden cable. Actuation via handbrake lever. 12.5.3 Air pressure table for the tires NOTICE...
Page 242: Emissions
Technical data 12.7 Emissions Data Travel speed Option 1 0 km/h to 30 km/h 12.6.1.1 Tightening torques for high-pressure valves Thread Tightening torque 22 Nm 10 Nm 12.6.2 Data of working hydraulics Component Value Displacement 57.5 l/min Displacement Option 1 73.6 l/min Displacement Option 2 82.8 l/min Displacement Option 3 103 l/min...
Page 243 Technical data Emissions 12.7 12.7.3 Vibration 1) 2) Vibrations Total vibration value of the upper limbs < 2.5 m/s² Maximum effective value of weighted acceleration for < 0.5 m/s² body 2 4) < 1.28 m/s 1) Inform or instruct operators on the hazards of vibrations 2) Uncertainty of measurement of the vibration measurement according to DIN EN 474-1:2014-03 and EN 12096:1997.
Page 244 Index Index Numeric 4-in-1 bucket............ 153 Designated use ............. 14 Differential lock ............ 130 Dimensions............ 234 Drive mode ............ 107 Abbreviations............ 11 Add fuel ............... 185 Adding hydraulic oil .......... 193 Adjusting the rearview mirrors ....... 88 Attachments ............ 150 Attachments Electrical system Coupling ............ 132 Battery ............ 209 Coupling hydraulic connections...... 134 Maintenance........... 208 Fork-and-grab attachment...... 156 Engine...
Page 245 Index Hitching a trailer Maintenance Automatic trailer coupling ....... 115 Attachments ........... 199 Hydraulic system Battery maintenance ........ 210 Breather filter.......... 193 Bleeding the hydraulic system...... 194 Capacities/Specification ......... 183 Braking system.......... 206 Data of steering hydraulics...... 242 Check antifreeze compound...... 191 Data of working hydraulics ...... 242 Check the brake fluid........ 187 Drive hydraulics data........ 242 Exhaust gas aftertreatment ...... 212 Hydraulic oil............ 193...
Page 246 Index Rear wiper ............ 120 Uncoupling the trailer Refueling ............. 185 Automatic trailer coupling ....... 115 Replacing attachments ........ 132 Reversing warning buzzer ........ 108 Rotating beacon .......... 118 Vehicle Cleaning ............ 200 Description ............ 40 Safety instructions Dimensions............. 234 Symbols............ 20 drive on public roads ........ 112 Seat belt .............. 86 Labels............... 65 Setting load with crane .......... 171...
Page 247 Index [en] | 05/2019 | 1000408123 | 4080T Basic Line | Operator’s Manual...
Page 250 Weidemann GmbH Mühlhäuser Weg 45-49 D-34519 Diemelsee Tel.: +49 5633 609-0 EMail: info@weidemann.de www.weidemann.de Material number: 1000408123 Language: [en]...

Weidemann Basic line 4080T Operator's Manual

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