Wacker Neuson KRAMER 5055e Operator's Manual
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Wacker Neuson KRAMER 5055e Operator's Manual

Wheel loader
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5055e / 5055eL
Machine model
From serial no.
Version
Document number
Language
Operator's manual
Wheel loader
357-00S/357-00L
357 00 0001
3.0
1000363191
[en]

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Summary of Contents for Wacker Neuson KRAMER 5055e

  • Page 1 Operator’s manual Wheel loader 5055e / 5055eL Machine model 357-00S/357-00L From serial no. 357 00 0001 Version Document number 1000363191 Language [en]...
  • Page 2 Additional documents Language Order no. [de] 1000371231 Service Booklet [en] 1000371232 [fr] 1000371233 Spare parts list, model 357-00 [de, en, fr] 1000368721 Legend Original Operator’s Manual Translation – of original Operator’s Manual Version Date 07/2017 Document BA 357-00 * Copyright – 2017 Kramer-Werke GmbH Printed in Germany All rights reserved, in particular the copyright, the right of reproduction and the right of distribution applicable worldwide.

  • Page 3: Table Of Contents

    Table of contents Table of contents Table of contents EC Declaration of Conformity ........................EG-1 Declaration of manufacturer........................EG-2 1 Preface 1.1 Operator’s manual ..........................1-1 1.2 Warranty and liability ..........................1-5 2 Safety 2.1 Safety symbols and signal words ......................2-1 2.2 Qualification of operating and maintenance personnel.................
  • Page 4 Table of contents 7 Maintenance 7.1 Information on maintenance ......................... 7-1 7.2 Maintenance overview .......................... 7-6 7.3 Fluids and lubricants........................... 7-14 7.4 Maintenance accesses ........................7-17 7.5 Cleaning and maintenance ......................... 7-19 7.6 Lubrication work..........................7-28 7.7 Battery ..............................7-31 7.8 Cooling system ...........................

  • Page 5: Ec Declaration Of Conformity

    EC Declaration of Conformity EC Declaration of Conformity EC Declaration of Conformity according to Directive 2006/42/EC, appendix II, lit. A Manufacturer Kramer-Werke GmbH, Wacker-Neuson-Str. 1, D-88630 Pfullendorf Product Machine designation Wheel loader Type Version 357-00S 357-00L Trade name 5055e 5055eL Serial number 357 00 _ _ _ _ 357 00 _ _ _ _...

  • Page 6: Declaration Of Manufacturer

    Declaration of manufacturer Declaration of manufacturer Declaration of manufacturer This vehicle is not approved for application within the European Union (EU). Manufacturer Kramer-Werke GmbH, Wacker-Neuson-Str. 1, D-88630 Pfullendorf Product Vehicle designation/model Wheel loader 357 Wheel loader 357 Version 357-00S 357-00L Trade name 5055e 5055eL...

  • Page 7: Preface

    Table of contents Preface Index Preface 1 Preface Operator’s manual Important information about operating personnel This Operator's Manual is only valid for the machine types listed on the title page. The Operator's Manual provides information on the use, settings, operation and maintenance of the machine and is only intended for the operator and the owner.
  • Page 8 1 Preface Important information for the operating company • The buyer/operating company is responsible for the operators’ training in safe working on and with the machine. We recommend repeating training at regular intervals. • The buyer/operating company is responsible for ensuring that any additional safety regulations applicable in the country of use of the machine are followed.
  • Page 9 Preface 1 Explanation of symbols The indication left or right in the descriptions always refers to the travel direction of the machine. Symbols Explanation • Identifies a general list Identifies a list in a table (position numbers) Identifies activities that must be performed in a certain order Identifies results ►...
  • Page 10 1 Preface Abbreviations Abbreviation Explanation Abbreviation Explanation Light Emitter Diode (light diode) (opt) Option Trucks Trucks Fig. Figure Agriculture and forestry National Type National Type Approval (Germany) Approval Sound power level Automatic Transmission max./MAX. maximum Fluid (lubricant) min./MIN. minimal, at least Operator’s manual Motion-Logic-Supply: control German Operational Safety...

  • Page 11: Warranty And Liability

    Preface 1 Warranty and liability Warranty claims can be made only if the conditions of warranty have been observed. They are included in the General Conditions of Sales and Delivery for new machines and spare parts sold by the dealers. Furthermore, the instructions in this Operator’s Manual must be observed.
  • Page 12 1 Preface Notes: BA 357-00 * 3.0 * 35700_01_Vorwort.fm...

  • Page 13: Safety

    Safety Safety 2 Safety Safety symbols and signal words Explanation The following symbols and signal words indicate safety instructions. The corresponding signal word indicates the risk level. DANGER DANGER identifies a situation causing death or serious injury if it is not avoided.

  • Page 14: Qualification Of Operating And Maintenance Personnel

    2 Safety Qualification of operating and maintenance personnel Owner’s duties • Only allow specifically authorized, trained and experienced persons to operate, drive and perform maintenance on the machine in accordance with electro-technical regulations. • Do not allow persons to be trained or instructed by anyone other than an authorized and experienced person.
  • Page 15 Safety 2 Required knowledge of operator • The operator is responsible for other persons. • Avoid any operational mode that might be prejudicial to safety. • The specific national driving license is required. • The vehicle may only be operated by authorized and safety-conscious persons who are fully aware of the risks involved in operating the vehicle.

  • Page 16: Conduct

    2 Safety 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 other persons, or damage to the machine. •...

  • Page 17: Operation

    Safety 2 Operation Preparatory measures • Operation is only allowed with correctly installed and intact protective structures. • Keep the vehicle clean. This reduces injury, accident and fire hazards. • Safely store objects you carry with you in the places provided for this (for example, in the storage compartment, drinks holder).
  • Page 18 2 Safety Job site • The operator is responsible for other persons. • Before starting work, familiarize yourself with the job site. This applies to, for example: - Obstacles in the job site and machine travel area, - any barriers separating the job site from public roads, - soil weight-bearing capacity, - existing overhead and underground lines, - special operating conditions (for example dust, steam, smoke,...
  • Page 19 Safety 2 Carrying passengers • Carrying passengers with the machine is NOT allowed. • Carrying passengers on/in attachments/tools is NOT allowed. • Carrying passengers on/in trailers is NOT allowed. Mechanical integrity • The operator and owner are obligated to operate the vehicle only in a safe and working condition.
  • Page 20 2 Safety Machine travel on public roads/sites • The specific national driving license is required. • Observe the national regulations (for example, the road traffic regulations) during machine travel on public roads/sites. • Ensure that the vehicle is in compliance with the national regulations. •...

  • Page 21: Lifting Gear Applications

    Safety 2 Lifting gear applications Requirements • The machine must be certified for lifting gear applications. • Have loads fastened and the operator guided by a qualified person having specific knowledge of lifting gear applications and the usual hand signals. •...
  • Page 22 2 Safety Lifting gear applications • The machine and the attachment must be certified for lifting gear applications. • Observe the national regulations for lifting gear applications. • Lifting gear applications are procedures involving raising, transporting and lowering loads with the help of lifting and fastening gear. •...

  • Page 23: Trailer Operation

    Safety 2 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. • Carrying passengers on/in trailers is PROHIBITED. • Observe the maximum permissible vertical and trailer load. •...

  • Page 24: Attachment Operation

    2 Safety Attachment operation Attachments • Use only attachments that are certified for the vehicle or its protective device (for example a shatter protection). • All other attachments require the vehicle manufacturer’s release. • The danger zone and the work zone depend on the attachment used –...

  • Page 25: Towing, Loading And Transporting

    Safety 2 Towing, loading and transporting Towing • Seal off the danger zone. • Ensure that no one is near the towing bar or cable. The safety distance is equal to 1.5 times the length of the towing equipment. • Observe the mandatory transport position, permissible speed and itinerary.
  • Page 26 2 Safety Crane-lifting • Seal off the danger zone. • The crane and the lifting gear must have suitable dimensions. • Observe the machine’s overall weight – see “Technical data”. • Wear protective clothing and equipment when fastening, guiding and removing the machine (for example a hard hat, safety glasses, safety boots).
  • Page 27 Safety 2 Transportation • For the safe transportation of the machine: - The transport vehicle must have a sufficient load capacity and platform – see “specifications.” - The maximum weight rating of the transport vehicle must not be exceeded. • Use only lifting and fastening gear certified by a test/certification body, observe the inspection intervals.

  • Page 28: Maintenance

    2 Safety Maintenance Maintenance • Observe the intervals prescribed by law and those specified in this Operator’s Manual for routine checks/inspections and maintenance. • For inspection and maintenance, ensure that all tools and service center equipment are adapted to the performance of the task described in this Operator’s Manual.
  • Page 29 Safety 2 Personal safety measures • Avoid any operational mode that might be prejudicial to safety. • Wear protective clothing and equipment (for example a hard hat, protective gloves, safety boots). • Tie back long hair and remove all jewelry. •...
  • Page 30 2 Safety 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 performed by qualified and authorized, technically trained personnel. • Follow the maintenance plan – see “Maintenance plan”. •...

  • Page 31: Measures For Avoiding Risks

    Safety 2 2.10 Measures for avoiding risks Tires • Have repair work on the tires only performed by trained technical personnel. • Check the tires for correct pressure and visible damage (for example, cracks, cuts). • Check the wheel nuts for tightness. •...
  • Page 32 2 Safety Battery • The charging, maintenance and changing of the battery may only be carried out by persons who are trained to do so. • Always observe the information provided in this Operator's Manual and the instructions provided by the battery manufacturer. •...
  • Page 33 Safety 2 Working near electric supply lines • Before performing any work, the operator must check whether there are any electric supply lines in the job site. • If there are electric supply lines, only a vehicle with cabin may be used (Faraday cage).
  • Page 34 2 Safety Hydraulic system • Check all lines, hoses and screw connections regularly for leaks and visible damage. • Splashed oil can cause injury and fire. • Leaking hydraulic lines can result in loss of brake effect. • Have damage and leaks immediately repaired by an authorized service center.
  • Page 35 Safety 2 Noise • Observe the noise regulations (for example, during applications in enclosed premises). • Bear in mind external sources of noise (compressed-air hammer, concrete saw). • Do not remove the sound baffles of the machine/attachment. • Have damaged sound baffles immediately replaced (for example, an insulating mat, muffler).
  • Page 36 2 Safety Notes: 2-24 BA 357-00 * 3.0 * Sicherheit_E.fm...

  • Page 37: Introduction

    Introduction Introduction 3 Introduction Machine outside view Fig. 1 Designation Bracket for warning stripe (option) Headlight reflectors left/right with turn indicators Radio preparation – antennae (option) Handle for access Window wiper (front window) Left/right rearview mirrors Front working lights (option) FOPS guard grid (category I =>...
  • Page 38 3 Introduction Machine outside view (continuation) Fig. 1 Designation 19 Safety prop for loader unit (option) 20 Additional reflectors (required for attachments larger than 1710 mm (67.3 in) width) (option) 21 Brake, rear and turn indicator lights 22 Reflectors 23 Rear hooks for loading/tying down the machine (left/right) 24 Towing device 25 Rear power socket for rear attachments (option) 26 Door arrester...
  • Page 39 Introduction 3 Models and trade names (overview) The machine is identified by the following designations: • "Model designation", on the type label (field 5) on the machine, front right– see "Type labels" on page 3-26. • "Trade name" “, glued to the machine on the outside. The letter S or L in the designation indicates the version of the loader unit: •...

  • Page 40: Brief Description Of The Machine

    3 Introduction Brief description of the machine Main components of the machine • Stable sheet steel frame accepting main components • ROPS/FOPS tested cabin (roll-over/falling object protection); Category I Series, Category II option) – see chapter 4 “Cabin/control stand” on page 4-1 - ROPS is the abbreviation for the English concept "Roll Over Protective Structure"...
  • Page 41 Introduction 3 Travel drive The drive is delivered through a 3-phase alternating current electric motor (hydraulic motor). The speed of the hydraulic motor is transferred via the single stage transfer gearbox and the cardan shaft to the front and rear axle. The machine has two speed ranges: Turtle and Hare.
  • Page 42 3 Introduction Work hydraulics The machine is equipped with a hydraulic system that is supplied from the hydraulic oil reservoir. A gear pump supplies both the work hydraulics and the steering hydraulics with the required pressure. The gear pump is driven by a 3-phase alternating current electric motor (operating motor).
  • Page 43 Introduction 3 Steering system The standard machine is equipped with 4-wheel steering. Front axle steering is optionally available. Brakes The service brake consists of a brake disc, which is located on the input shaft of the front axle. Through the cardan shaft, it also works on the rear axle.
  • Page 44 3 Introduction Electrical system The machine is operated electrically. The electric current is supplied by an 80 V-battery as direct current. A frequency converter converts the direct current in 3-phase alternating current for the electric motors. The electric traveling drive has an operating voltage of 48 volts, the electrical drive of the hydraulic systems as an operating voltage of 43 volts.

  • Page 45: Information And Regulations On Use

    Introduction 3 Information and regulations on use General information on the machine This machine is a versatile and powerful aid on construction sites, in agriculture and for recycling applications. The wide range of attachments allows you to use the machine as a snow plow or construction vehicle, a fork lift for work with palletized goods, or as a tractor for transport applications in agriculture (agricultural or forestry license Possible applications...
  • Page 46 3 Introduction Designated use • The vehicle can be used as a self-propelled work machine or as a tractor if registered accordingly (LoF = Land- oder Forstwirtschaftliche Zulassung [ i.e. agricultural or forestry license] (EC check number– see "Filter category of the cab" on page 3-27).
  • Page 47 Introduction 3 Improper use Not using the machine according to its designated use means that it is used for an application that is not specified by the manufacturer. Therefore, this is misuse in the terms of the Machine Guideline. Alone the user/operating company shall be liable for damage resulting from this.
  • Page 48 3 Introduction Driving license The machine may only be driven by persons who are trained in how to operate it, have proven their driving and load-handling abilities to the operating company or its representative and have been expressly assigned by the company to do the driving. Machines may only be driven on public roads only if the operator has a driving license as defined by national traffic regulations.
  • Page 49 Introduction 3 Vehicle license The machine may be registered in EU member states as "self-propelled work machine" or as agricultural or forestry tractor (LoF). • Possible applications – see "Designated use" on page 3-10. National regulations must be observed for licence certificates for machine travel on public roads (licence certificate, operation licence).
  • Page 50 3 Introduction On-board documents German traffic regulations (StVZO) require to have the following documentation on board: • German ABE (Allgemeine Betriebserlaubnis = general operating license) or data confirmation • Driving license • Test report according to DGUV regulation 70 § 57 clause 2 of the accident prevention regulation "Vehicles“...
  • Page 51 Introduction 3 Machine inspections When operating the machines, the national safety regulations must be followed as well, for example in Germany, the regulations for accident prevention “Deutsche Prüfstelle für Land- und Forsttechnik” (German Test- and Certification-Center for Agriculture and Forest Engineering – DPLF) and the Accident Prevention Regulations on “vehicles”...
  • Page 52 3 Introduction Use of attachments General instructions The attachments will decide in the first place how the machine is used. • Different quickhitches are available for the machine. Refer to the following tables for the certified attachments and the specific requirements: Attachments for KRAMER quickhitch facility on page 3-18, Attachments for SKID STEER quickhitch (currently not available) on...
  • Page 53 Introduction 3 Important Information Information If other attachments are installed and used, conformity (stability test) in accordance with the EC machinery directive or the DIN EN 474-3 standard must be checked and documented by an authorized service center – see chapter 5 “Fitting attachments from other manufacturers (opt)”...
  • Page 54 3 Introduction Attachments for KRAMER quickhitch facility Important information on the quickhitch facility and attachments The machine can be equipped with a standard or an extended loader unit (option). The type of loader unit installed on the machine is specified in the machine’s model designation –...
  • Page 55 Introduction 3 Overview: Attachments for KRAMER quickhitch Width and Description Part no. Capacity Application Vehicle length of attachment (model) m³ (ft³) material density mm (in) Approved attachments for machine travel on public roads (Germany) 1650 (64.96) 1000260472 with ripper teeth 0.5/0.65 357-00S (17.6)/(22.9)
  • Page 56 3 Introduction Width and Description Part no. Capacity Application Vehicle length of attachment (model) m³ (ft³) material density mm (in) Non-approved attachments for machine travel on public roads (Germany) 357-00S 1000237357 1000 (39.37) – 357-00L Pallet forks 357-00S Picking up and transporting 1000237358 1200 (47.24) –...
  • Page 57 Introduction 3 Attachments for SKID STEER quickhitch (currently not available) Important information on the quickhitch facility and attachments The SKID STEER quickhitch can only be installed in connection with the standard loader unit. The machine manufacturer has only certified and released the attachments listed on page 3-22 for this quickhitch!
  • Page 58 3 Introduction Overview of attachments for SKID STEER quickhitch (currently not available) Description of Part no. Width Capacity Application Vehicle attachment (model) mm (in) m³ (ft³) material density Approved attachments for machine travel on public roads (Germany) 1650 (64.96) Loosening, picking up, 1000335701 without ripper teeth Bucket...
  • Page 59 Introduction 3 Attachments for EURO quickhitch Important information on the quickhitch and attachments The machine can be equipped with a standard or an extended loader unit (option). The type of loader unit installed on the machine is specified in the machine’s model designation –...
  • Page 60 3 Introduction Overview: Attachments for EURO quickhitch facility Information 7° In order to ensure the parallel lift of the pallet forks and the correct scraping depth of the bucket, observe the following points before installing EURO attachments. ► Angle A – formed by rear of pallet forks and line between catch hooks and lock bores: 7°...

  • Page 61: Labels

    Introduction 3 Labels Labels (overview) Fig. 4 3-25 BA 357-00 * 3.0 * 35700_03_Einleitung.fm...
  • Page 62 3 Introduction Symbols The "Book" symbol on a label means that the indications and explanations are provided in further detail in this operator's manual. Fig. 5 Type labels Machine The type label is located at the front right of the machine frame (on one side of the loader unit bulkhead).
  • Page 63 Introduction 3 Serial number The chassis number A is stamped on the machine frame (next to the mudguard attachment, at the front right). It is also located on the type label. Fig. 7 Cabin The type label (A) of the cab with the cab number is located on the upper right in travel direction on the beam.
  • Page 64 3 Introduction Hydraulic motor The type label of the hydraulic motor is located on the engine. Fig. 11 Gearbox View; vehicle underside The type label (arrow) is located on the gearbox housing. Fig. 12 Front and rear axles View of lower side of machine. •...
  • Page 65 Introduction 3 Operating motor The type label of the operating motor is located on the engine. Fig. 14 Gear pump of work hydraulics View of lower side of machine. The serial number of the gear pump is located on the pump (arrow). Fig.
  • Page 66 3 Introduction Warning labels WARNING Accident hazard due to damaged or missing warning labels! Can cause serious injury or death. ► Immediately replace damaged or missing warning labels by new ones. High-voltage system Caution! Machine components can result in life-threatening voltages. Covers that carry these warning labels may only be removed by someone with expertise in HV systems.
  • Page 67 Introduction 3 No persons are allowed within the swiveling range of the machine! Caution! During operation, all persons must stay clear of the swiveling range of the machine! Located inside the cabin, above the rear window. Fig. 20 No persons allowed in the working area of the loader unit! Caution! During operation, no one is allowed to loiter in the working area of the loader unit! Persons in the vicinity of the loader unit must keep a sufficient distance!
  • Page 68 3 Introduction Remove the ignition key! Caution! The ignition key must be removed before performing inspection and maintenance on the machine. • Also read the service manual before performing maintenance. • Have repair work performed only by trained technical personnel. Located on the pillar on the left inside the cabin.
  • Page 69 Introduction 3 Information labels WARNING Accident hazard due to damaged or missing information labels! Can cause serious injury or death. ► Immediately replace damaged or missing information labels by new ones. ► This particularly applies to information labels referring to hazards (e.g. load diagrams)! Slinging points and tie-down points The label identifies the slinging points A and the tie-down points B on the machine and the battery.
  • Page 70 3 Introduction Load diagram The load diagram indicates the maximum payload for the attachment – see chapter 9 “Payload/lift capacity/stability” on page 9-18. Located inside the cabin, on left side of front window. Information The load diagram is valid only for applications with the released pallet forks and corresponding tire size.
  • Page 71 Introduction 3 Hydraulic oil The label provides information about the fluids, lubricants and material being used. A Hydraulic oil B Biodegradable hydraulic oil Located near the filler opening on the hydraulic oil reservoir. Other data – see chapter 7 “Important information on operation with Fig.
  • Page 72 3 Introduction Emergency exit! The label indicates the exit in case of an emergency – see chapter 4 “Emergency exit” on page 4-5. Located on the rear window (on machines with agricultural or forestry license Fig. 42 Information label Low-speed control operation! Indicates when the low-speed control can be operated –...

  • Page 73: Putting Into Operation

    Putting into operation Putting into operation 4 Putting into operation Cabin/control stand Important information on the cabin • An open cab (canopy) is standard in the series-produced machine. A closed cab (cabin cpl.) is available as an option. • The machine should only be operated if all windows in the cabin are free of dirt, snow and ice.
  • Page 74 4 Putting into operation Safety instructions on entering and exiting CAUTION Falling hazard when entering or exiting! Entering or exiting incorrectly can cause injury. ► Keep the mandatory climbing aids clean. ► Use the mandatory climbing aids for entering and exiting the machine. ►...
  • Page 75 Putting into operation 4 Securing door in the door arrester 1. Open the door completely and let it lock into place in arrester C. Fig. 49 Release the door out of the arrester 1. Press the button D. The door is released from the lock by spring action. 2.
  • Page 76 4 Putting into operation Opening and closing the window on the right CAUTION Crushing hazard to arms and hands due to unlocked side window! The side window can cause injury by crushing arms and hands when it is being closed. ►...
  • Page 77 Putting into operation 4 Emergency exit WARNING Injury hazard due to being caught up or falling down! The right side of the machine does not have footholds or handholds that ensure a safe exit. Serious injury can occur when exiting the machine. ►...
  • Page 78 4 Putting into operation Using the emergency exit 1. Turn the machine off and remove the ignition key. 2. If possible, ask for help. 3. Open the right side window completely – see "Opening and closing the window on the right" on page 4-4 or, if an emergency hammer is available, smash a pane with the emergency hammer.
  • Page 79 Putting into operation 4 Operator seat Safety instructions DANGER Risk of electric shock from defective components or contact with the parts of the high-voltage system! Causes serious injury or death. ► The operator seat may only be folded forwards by specially trained personnel.
  • Page 80 4 Putting into operation General instructions Information Electronic components such as power electronics and the StVZO module are located under the operator seat. The operator seat can be folded to make these components accessible for maintenance and repair work. • Before folding up the operator seat, the safety instructions for the operator seat must be observed.
  • Page 81 Putting into operation 4 Folding the operator seat forwards 1. Pull handle A and push operator seat fully backwards. 2. Unscrew the 3 hexagon screws B on each side of the operator seat. 3. Fold the operator seat forwards and secure it against falling back. Fig.
  • Page 82 4 Putting into operation Horizontal adjustment 1. Sit down on the operator seat. 2. Pull lever C up and at the same time, move the operator seat forward or backward. 3. Release the lever on reaching the required position. Once the operator seat is adjusted, engage the lever in the required position.
  • Page 83 Putting into operation 4 Air-suspension operator seat (option only available for cabin cpl.) Safety instructions This operator seat must be used for machines with an agricultural and forestry license (only applicable in EU member states)! Please contact your dealer if you require more information on retrofitting. Get informed on and follow the legal regulations of your country.
  • Page 84 4 Putting into operation Adjust the operator seat to individual requirements, for example to body size and posture. This prevents muscle tensions and fatigue during work. Adjust the operator seat so that the control levers and pedals are within easy reach with your back against the backrest. Weight adjustment NOTICE Do not run the air compressor for more than 1 minute to...
  • Page 85 Putting into operation 4 Backrest adjustment 1. Sit down on the operator seat. 2. Pull handle C upward and at the same time, move your back against or away from the backrest. 3. Release the handle when reaching the required position. Fig.
  • Page 86 ► Have the seat belt immediately replaced after every accident and the load-bearing capacity of the fastening points and seat fixtures checked by a Wacker Neuson service center. WARNING Accident hazard when adjusting the seat belt during machine operation! Can cause serious injury or death.
  • Page 87 Putting into operation 4 Information When pulled slowly, the automatic seat belt offers full freedom of movement. It locks however during abrupt braking. The automatic seat belt may also lock when passing through potholes or uneven terrain. Fastening the seat belt 1.
  • Page 88 4 Putting into operation Adjusting the mirrors Limited field of vision The line-of-sight is the area the operator can see from the operator seat. Rearview mirrors or camera systems can be installed on the machine to support the operator. WARNING Accident hazard due to restricted field of vision! Failure to observe this can cause serious injury or death.
  • Page 89 Putting into operation 4 Adjusting the mirror on the left 1. Turn the mirror on the left outward with the long side. When making preliminary adjustments, ensure that the mirror bracket is turned far enough to the front (about 45°) to avoid touching the door window.
  • Page 90 4 Putting into operation Adjusting the mirror on the right 1. Turn the mirror on the right outward with the long side. When making preliminary adjustments, ensure that the mirror bracket is turned far enough to the front (about 45°) to avoid touching the door window.
  • Page 91 Putting into operation 4 Locking the-battery cover plate Opening the battery cover plate DANGER Risk of electric shock from defective components or contact with the high-voltage system! Causes serious injury or death. ► Before opening the battery cover plate, actuate the motor isolating switch and remove the ignition key.
  • Page 92 4 Putting into operation Battery connector DANGER Risk of electric shock from defective components or contact with the high-voltage system! Causes serious injury or death. ► Before opening the battery cover plate, actuate the motor isolating switch and remove the ignition key. ►...
  • Page 93 Putting into operation 4 Disconnecting the battery connector 1. Check to see that the machine has been turned off and the ignition key removed. 2. Opening the battery cover – see "Opening the battery cover plate" on page 4-19. 3. Grasp the plug part A of the battery connector on the handle and pull out of the socket part B of the battery connector horizontally.
  • Page 94 4 Putting into operation Motor isolating switch The entire traction and works electronics can be disconnected or connected with the supply voltage using the motor isolating switch. The parking brake is applied at the same time when the traction and works electronics is disconnected from the supply voltage.
  • Page 95 Putting into operation 4 Immobilizer (option) Important Information The immobilizer is integrated in the ignition lock and can only be disabled with the supplied blue ignition keys! Scope of delivery: • Immobilizer installed in the machine • 2x ignition keys blue (coded) •...
  • Page 96 4 Putting into operation Coding the ignition key The coding of the new ignition key (blue) is performed using the master key (red). The master key can only be used for coding the new ignition key and not for disabling the immobilizer. 1.
  • Page 97 Putting into operation 4 Delete coded ignition key It becomes necessary to delete an ignition key when an ignition key has been lost. 1. Switch on the parking lights – see chapter 5 “Parking lights/low beam” on page 5-19. 2. Insert the master key (red) into the ignition lock, turn to position "II" and leave it in place for at least 20 seconds.
  • Page 98 4 Putting into operation 4-26 BA 357-00 * 3.0 * 35700_04_Inbetriebnahme_01.fm...

  • Page 99: Overview Of Control Elements

    Putting into operation Putting into operation 4 Overview of control elements Inside the cabin Description of control elements You can unfold the pages for a better overview. This chapter describes the controls, and contains information on the function and the handling of the indicator lights and controls in the cabin.
  • Page 100 4 Putting into operation Inside the cabin Inside of cabin (overview) For more information see page Sun visor Front window air vents (left/right) Interior light ..............................5-24 Radio (opt) see the Operator’s Manual of the radio for information on operation ..........................Locking –...
  • Page 101 Putting into operation 4 Indicating instrument, Indicating instrument, joystick, multifunctional lever joystick, multifunctional lever 4-29 BA 357-00 * 3.0 * 35700_04_Inbetriebnahme_02_a3.fm...
  • Page 102 4 Putting into operation Indicating instrument, joystick, multifunctional lever Display instrument For more information see page 38 Warning light (yellow) – error warning ECU .................... 4-34 39 Warning light (red) – error "STOP"......................4-34 40 Indicator light (green) – right/left-hand turn indicators................5-21 41 Warning light (red) –...
  • Page 103 Putting into operation 4 Switch panels Switch panels 4-31 BA 357-00 * 3.0 * 35700_04_Inbetriebnahme_02_a3.fm...
  • Page 104 4 Putting into operation Switch panels Heating/ventilation switch console - Ventilation (optional cabin coupling) For more information see page 57 Rotary switch – heating temperature control....................5-27 58 Rotary switch – warm air fan (heating, ventilation) ..................5-27 Switch panel on front instrument panel For more information see page 59 Rocker switch (green) –...

  • Page 105: Overview Indicator And Warning Lights

    Putting into operation Putting into operation 4 Overview indicator and warning lights Information The indicator lights provide information to the operator. The warning lights warn the operator of damage to the machine. ► If a warning light illuminates during operation, stop the machine immediately and get in touch with an authorized service center.

  • Page 106: Warning Light (Red) - Error "Stop

    4 Putting into operation Description of the indicator and warning lights in the gauge Warning light (yellow) – error The warning light 38 illuminates if the machine electronics report an error during operation. An uninterrupted warning signal sounds for approx. 3 seconds. An error message is displayed for 3 seconds in the digital display 45 in area F as error code.

  • Page 107: Indicator Light (Blue) - High Beam

    Putting into operation 4 Indicator light (blue) – high beam The indicator light 42 illuminates if the high beam is switched on or if the headlight flasher is actuated – see "High beam/headlight flasher" on page 5-20. Warning light (red) – temperature A warning signal sounds and the warning light 43 illuminates if the allowable temperature of one of the following components has been exceeded:...

  • Page 108: Indicator Display Battery Charge Condition

    4 Putting into operation Indicator display – battery charge condition The indicator display shows the battery charge condition. The battery charge condition is displayed via 7 LEDs. The indicator lights go out from right to left the more the battery is discharged. NOTICE Battery damage! The battery can be damaged if it is over-discharged.
  • Page 109 Putting into operation 4 Description of the digital display on gauge The gauge is equipped with a warning sound display as well as a digital display 45. The digital display provides information on active functions, current operating states, service information, machine status and error codes.
  • Page 110 4 Putting into operation Main display Indication Meaning Indicator display – high speed range (hare) Illuminates if high speed is enabled with switch 62 – see chapter 5 “Overview of speed ranges” on page 5-11. Indicator display – work speed range (turtle) Illuminates if the working speed range is enabled with switch 62 –...
  • Page 111 Putting into operation 4 Indication Meaning Indicator display – forward travel direction Illuminates if the forward travel direction is enabled. – see chapter 5 “Selecting a travel direction and starting machine travel” on page 5-13 Indicator display – reverse travel direction Illuminates if the reverse travel direction is enabled.
  • Page 112 4 Putting into operation Indication Meaning Indicator display – 3rd control circuit in jog mode Illuminates if the 3rd control circuit is enabled – see chapter 5 “Operation of 3rd control circuit” on page 5-42. Indicator display – 3rd control circuit in continuous operation Illuminates if the 3rd control circuit is enabled in continuous operation...
  • Page 113 Putting into operation 4 Indication Meaning Indicator display – differential lock Illuminates if the differential lock is enabled – see chapter 5 “Lighting /signaling system” on page 5-19. Indicator display – turn indicator right/left for rear attachment/trailer The indicator light flashes periodically if the turn indicator is actuated Fig.
  • Page 114 4 Putting into operation Indication Meaning Indicator display – holding function (active standstill control) Illuminates when the holding function is enabled – see chapter 5 “Parking brake” on page 5-6. Warning indicator – hydraulic oil filter contamination Illuminates if the resistance of the oil flow in the return filter is too high Fig.
  • Page 115 Putting into operation 4 Service indication In order to call the contents of the service indication, press push button 47. The startup screen displaying the number of hours until the next inspection F is displayed in the display. Fig. 86 By pressing on the push button 46, the digital display will scroll down one level in the service indication.

  • Page 116: Preparatory Work

    4 Putting into operation Preparatory work Important information before putting the machine into operation WARNING Risk of injury when working with the machine! Can cause injury or death. ► Ensure that nobody is in the danger zone. ► Operate the machine only from the operator seat. ►...
  • Page 117 Putting into operation 4 Requirements and information for the operating personnel • The operating personnel (operator) must have read and understood this Operator’s Manual before putting the machine into operation. • The machine may only be put into operation by authorized personnel that have been instructed.
  • Page 118 4 Putting into operation Notes about low and high external temperatures • Caution during machine travel on snow and ice. Adjust travel speed to the conditions on the road. • At low external temperatures, the available capacity of the battery decreases and the battery charge time extends.
  • Page 119 Putting into operation 4 Information on the checklists These checklists are not intended to be exhaustive. They are only intended to help you to fulfill your obligation to exercise due care. The checking and monitoring work listed below is described in greater detail in the following chapters of the Operator’s Manual.
  • Page 120 4 Putting into operation "Machine Operation" checklist Designation Engine oil pressure indicator light extinguished? Braking effect sufficient? Steering system working properly? Anyone in the danger zone of the machine? Attachment locked in quickhitch? During machine travel on public roads, particular attention should be paid to the following points: Bucket or attachments in transport position? Transport locks installed?
  • Page 121 Putting into operation 4 Preparations for driving on public roads Instructions for machine travel on public roads Information When driving on public roads in Germany, equip the machine only with attachments that are certified for this machine! Attachments that are not certified for machine travel on public roads must be removed and transported with a suitable means of transportation –...
  • Page 122 4 Putting into operation Preparatory measures • Remove attachments that are not authorized for travel on public roads – see chapter 3 “Use of attachments” on page 3-16. • Empty the attachment completely and secure it (front-edge protection, fold up fork arms). •...
  • Page 123 Putting into operation 4 Locking/unlocking the control lever (joystick) WARNING Accident hazard due to unintentional loader unit operation! Uncontrolled movements of the loader unit can cause serious injury or death during machine travel on public roads. ► Secure the joystick against unintentional actuation before performing machine travel on public roads.
  • Page 124 4 Putting into operation Functional check of all control elements • – see chapter 5 “Checking the steering system” on page 5-1 • – see chapter 5 “Service brake” on page 5-5 • – see chapter 5 “Lighting /signaling system” on page 5-19 •...

  • Page 125: Putting The Machine Into Operation

    Putting into operation 4 Putting the machine into operation Important information before putting the machine into operation WARNING Accident hazard due to persons in the danger zone! Serious injury or death can be caused by not staying clear of the danger zone of the machine.
  • Page 126 4 Putting into operation Turn on the machine 1. Switch on the motor isolating switch – see "Motor isolating switch" on page 4-22. 2. Insert the ignition key. In position 0 – no operating voltage. 3. Turn the ignition lock 18 to position "II" and wait. The battery charge condition and the operating hours are displayed.

  • Page 127: Operation

    Operation Operation 5 Operation Steering system Checking the steering system WARNING Accident hazard due to leaking steering system not working correctly! Can cause serious injury or death. ► A leaking steering system that leaks or does not work correctly must be immediately repaired by an authorized service center.
  • Page 128 5 Operation Front axle steering (opt) Front axle steering is used for fast transport and road travel. WARNING Accident hazard when changing steering mode during machine travel! Can cause serious injury or death. ► Change steering mode only at machine standstill. ►...
  • Page 129 Operation 5 Synchronizing the steering system Due to internal leakage in the steering hydraulics, the front and rear axle wheels of the machine no longer follow the same track during straight-ahead machine travel after extended operation. The steering system must be synchronized from time to time. WARNING Accident hazard when synchronizing the steering system during machine travel!

  • Page 130: Drive Operation

    5 Operation Drive operation Accelerator pedal WARNING Accident hazard due to blocked or dirty pedal! Can cause serious injury or death. ► Keep the accelerator pedal clean and do not deposit any objects in the area of the pedal. Accelerator pedal 6 is located on the right in the cabin. Engine and machine speed is continuously adjusted with accelerator pedal.

  • Page 131: Brake

    Operation 5 Brake Service brake DANGER Accident hazard due to blocked or dirty pedal! Can cause serious injury or death. ► Keep the brake pedal clean and do not deposit any objects in the area of the pedal. WARNING Accident hazard when moving down a slope too fast! Can cause serious injury or death.
  • Page 132 5 Operation Parking brake Automatic parking brake An automatic parking brake is installed in the machine, which is activated as soon as the machine comes to a standstill or the operator presence switch has been relinquished for 3 seconds. If the machine comes to a standstill, a holding function "active standstill control"...
  • Page 133 Operation 5 Manual parking brake CAUTION Accident hazard if the parking brake is applied during machine travel. The machine is braked abruptly! Can cause injury. ► Apply the parking brake only at machine standstill. ► In machine travel operation use only the brake pedal to brake. ►...

  • Page 134: Machine Travel Operation

    5 Operation Machine travel operation Important safety instructions for machine travel operation WARNING Accident hazard due to persons in the danger zone! Serious injury or death can be caused by not staying clear of the danger zone of the machine. ►...
  • Page 135 Operation 5 WARNING Accident hazard due to jamming or slipping! Loose objects in the cab or a dirty machine can cause accidents with serious injuries or death. ► Fasten or remove all loose objects in the cab. ► Keep the control elements clean. ►...
  • Page 136 5 Operation Important safety instructions for machine travel operation Information The operating time of the battery depends on the battery charge condition, the respective operating conditions, the application and on how machine travel is performed. – see "Operating time of battery" on page 5-69.
  • Page 137 Operation 5 Overview of speed ranges The machine has two speed ranges (see table). Speed Travel speed Recommended range Used for work involving short loading cycles; in other words, a rapid succession of loading and unloading operations, for 0-7 km/h (0-4.35 m/h) example onto a truck, and for work requiring precise speed adjustment, for example rotary...
  • Page 138 5 Operation Selecting a speed range WARNING Accident hazard during downhill travel! Serious injury or death can be caused by travelling too fast. Excessive engine speed can cause damage to the travel drive. ► Select the next lower speed range “Turtle” before performing downhill machine travel.
  • Page 139 Operation 5 Selecting a travel direction and starting machine travel WARNING Risk of injury to persons in the danger zone of the machine! Persons in the danger zone can be overlooked and seriously injured or killed during backward machine travel. ►...
  • Page 140 5 Operation Machine travel The travel speed of the machine is proportional to the setting of the accelerator pedal. The more the pedal is pressed, the higher the travel speed. The adjustment control performed within the selected speed range is infinitely variable. Changing travel direction WARNING Accident hazard when changing travel direction during machine...
  • Page 141 Operation 5 Slowing the machine and stopping 1. Reduce the engine speed of the hydraulic motor. Remove your foot from the accelerator pedal. 2. If necessary, slow the vehicle using the service brake and stop. 3. Press button 56 on the joystick Indicator light A or B (arrow) and the indicator display B/1 or B/2 go out in the digital display in the gauge.
  • Page 142 5 Operation Switching on the differential lock Information The differential lock can only be enabled by pressing push button 51 in the joystick and the brake pedal in combination! 1. Stop the vehicle. 2. Press and hold push button 51 on the joystick. 3.

  • Page 143: Stopping And Securing The Machine

    Operation 5 Stopping and securing the machine Important notice on stopping/securing WARNING Accident hazard from machine tipping over or rolling away! Serious injury or death can be caused by an unsecured machine. ► Stop the machine on firm, level, and horizontal ground. ►...
  • Page 144 5 Operation Machine stopping/securing 1. Remove dirt from the machine. 2. Stop the machine smoothly by releasing the accelerator pedal and pressing the brake pedal. 3. Apply the parking brake – see "Parking brake" on page 5-6. 4. Move the travel direction lever to neutral. 5.

  • Page 145: Lighting /Signaling System

    Operation 5 Lighting /signaling system Parking lights/low beam The press switch for the machine lights are located on the front switch panel to the right, next to the operator seat. Side marker light operation Function Press switch 66 to Indicator light in the position A.
  • Page 146 5 Operation High beam/headlight flasher WARNING Accident hazard due to blinded motorists! During machine travel on public roads, the enabled high beam or flashing headlights can blind other motorists. This can cause serious injury or death. ► Dim the headlights in time when oncoming traffic approaches. ►...
  • Page 147 Operation 5 Turn indicators NOTICE If the indicator light 40 or indicator display E/2 in the digital display in the indicating instrument flashes approx. twice as fast as normal, the turn indicator system is faulty! ► Have the turn indicator system repaired. Operating the turn indicators Function Indicator light 40 in gauge...
  • Page 148 5 Operation Hazard warning system The hazard warning switch is located on the rear switch console on the right, next to the seat. Hazard warning system operation Function The indicator light in the press switch flashes. Indicator light 40 in indicating instrument Press the rocker switch flashes.
  • Page 149 Operation 5 Working lights The machine is equipped with working lights in different versions to ensure optimal light conditions of the work area: • 1x rear working light (standard) • 2x front and/or 2x rear working lights (opt) The press switches for operating the working lights are located on the right in the control lever console beside the operator seat.
  • Page 150 5 Operation Rotating beacon (option) The press rocker switch 68 for the rotating beacon (opt) is located on the front switch panel to the right, next to the operator seat. Rotating beacon operation Function Press switch 68 to The indicator light in the position A switch illuminates.
  • Page 151 Operation 5 Horn Operating the horn Function Press push button 48. The horn sounds. Fig. 117 Backup warning system (opt) The backup warning system (opt) consists of signal transmitter A fitted at the rear top left of the cabin. Signal transmitter A generates a clearly audible warning signal when shifting into reverse.

  • Page 152: Wiper/Wash System (Only In Cabin Cpl.)

    5 Operation Wiper/wash system (only in cabin cpl.) Washer system operation Front wiper Function Turn rotary switch 49 on the multifunctional lever Intermittent wipe. counter-clockwise to the 1st position. Turn rotary switch 49 on the multifunctional lever Continuous wiping. counter-clockwise to the 2nd position.

  • Page 153: Heating, Ventilation And Air Conditioning (Only In Cabin Cpl.)

    Operation 5 Heating, ventilation and air conditioning (only in cabin cpl.) Heater and ventilation Information The heating and ventilation system is an electrical air-heating. The system is supplied with power by the battery. The higher the performance of the heating and ventilation system, the higher the energy consumption. This means that with increasing system output, the operating time of the battery diminishes accordingly.
  • Page 154 5 Operation Air conditioning (optional) (currently not available) Information on putting the air conditioning into operation When cooling, as well as when heating, the air conditioning system supplies dehumidified and purified air to the cabin. In order to achieve best air conditioning results: •...
  • Page 155 Operation 5 Air conditioning operation The rocker switch 70 for switching on the air conditioning is located on the front switch console on the right, next to the operator seat. Air conditioning operation Function The indicator light in the Press switch 70 to switch illuminates.

  • Page 156: Operating Hydraulics

    5 Operation Operating hydraulics Important safety instructions on loader unit operation DANGER Electric shock due to overhead electric lines! Caution, danger! Electric arcs can form when approaching overhead electrical lines. ► Keep away from overhead electric lines. ► Contact the energy supplier before working under overhead electric lines.
  • Page 157 Operation 5 WARNING Crushing hazard due to tipping over of machine! A tipping vehicle can cause serious injury or death. ► Lower the loader unit to transport position during machine travel. ► Adapt the travel speed to the prevailing conditions. ►...
  • Page 158 5 Operation Control lever (joystick) overview Operation Function To the left Tilts in the attachment To the right Tilts out the attachment Forwards Lowering the loader unit Backward Raises the loader unit Push button (opt) Extended function front socket Switch (opt) No function Switch Forwards/reverse driving direction...
  • Page 159 Operation 5 Pressure relief – plug couplings Information The hydraulic system of the machine is still pressurized even when the machine is switched off! The hydraulic plug couplings can be released, however they cannot be re-attached because the pressure in the hydraulic lines has not been released.
  • Page 160 5 Operation Hydraulic control circuits/plug couplings (overview) The machine has several hydraulic connections depending on the equipment. The operation of the hydraulic connections can be found in the following pages. NOTICE In order to avoid leaks on the plug couplings and dirt in the hydraulic oil: ►...
  • Page 161 Operation 5 KRAMER quickhitch plug couplings Hydraulic Operation, Control circuits: connections: see page: 3rd control circuit 5-42 A + B Continuous operation of 3rd control 5-44 circuit Fig. 126 Plug coupling for leak oil line and return without pressure to the reservoir (installed laterally on the loader unit [opt]) Hydraulic Control circuits:...
  • Page 162 5 Operation Oil volume setting Using the oil volume setting during continuous operation of the 3rd control circuit (– see "Continuous operation of 3rd control circuit" on page 5-44) to set the rpm of the operating motor and thus indirectly the flow rate of the hydraulic pump.
  • Page 163 Operation 5 Modifying the oil volume 1. Switch on 3rd control circuit continuous operation – see "Continuous operation of 3rd control circuit" on page 5-44. 2. Set the oil volume. To do this, turn the rotary switch 75 counterclockwise (-) or clockwise (+) until you have reached the desired setting.
  • Page 164 5 Operation Important information on connecting and operating the hydraulic control circuits WARNING Connecting the flexible lines incorrectly results in malfunctions and/ or uncontrolled movements of the attachment! Failure to observe this can cause serious injury or death. ► Ensure that the flexible lines of the attachment are correctly connected to the machine.
  • Page 165 Operation 5 NOTICE In order to avoid hydraulic damage to the machine and/or attachment, check the flow rate of the attachment before putting it into operation. ► Flow rate indications and consumer pressure on the plug couplings of the machine –...
  • Page 166 5 Operation Connecting hydraulic lines between machine and attachment 1. Pick up the attachment and safely lock it – see "Attachments" on page 5-48. 2. Release the pressure in the hydraulic lines – see "Pressure relief – plug couplings" on page 5-33.
  • Page 167 Operation 5 Important information on operation of the 3rd control circuit The 3rd control circuit hydraulically locks the attachment in the quickhitch KRAMER and secures it against unintentional unlocking. By changing over the flexible lines on the hydraulic attachment (for example a multipurpose bucket), it can be operated with the 3rd control circuit –...
  • Page 168 5 Operation Operation of 3rd control circuit Locking the attachment 1. Pick up the attachment – see "Attachment on KRAMER quickhitch" on page 5-56, Attachment on SKID STEER quickhitch (opt) on page 5-61 Attachments for EURO quickhitch (optional) on page 5-65.
  • Page 169 Operation 5 Unlocking the attachment Information The attachment locked in the quickhitch is secured against unintentional unlocking for safety reasons. You can only unlock the attachment with both hands. Information In order to avoid damage to the mounting bore and attachment lock during unlocking, follow the operation sequence exactly.
  • Page 170 5 Operation Continuous operation of 3rd control circuit Using the 3rd control circuit in continuous operation Continuous operation is used for movements/procedures over a long period of time or operation of hydraulic motors (for example a rotary broom) or for operation of attachments with an integrated control valve adjusted to maximum oil flow, with an unpressurized return.
  • Page 171 Operation 5 Switching off the 3rd control circuit in continuous operation – KRAMER attachments Activity Function 1. Switch off continuous operation of the Indicator display C/2 in 3rd control circuit. To do this, push the the digital display in the rocker switch 73 into position A.
  • Page 172 5 Operation Switching on the 3rd control circuit in continuous operation – SKID STEER attachments Activity Function 1. Connect the flexible lines of the attachment to plug couplings A + B of Indicator display C/1 in the distributing block. the digital display 2.
  • Page 173 Operation 5 Switching off the 3rd control circuit in continuous operation – SKID STEER attachments Activity Function 1. Switch off continuous operation of the Indicator display C/2 in 3rd control circuit. To do this, push the the digital display in the rocker switch 73 into position A.

  • Page 174: Attachments

    5 Operation 5.10 Attachments Only the following attachments are described in this Operator’s Manual. • Standard bucket • Multipurpose bucket • Pallet forks Refer to the respective operation manuals for the function and fitting of further attachments. Information on attachments WARNING Accident hazard due to incorrect attachments! Using wrong or unauthorized attachments can cause accidents or death.
  • Page 175 Operation 5 Notes on conversion WARNING Risk of injury to persons in the danger zone! Persons in the danger zone are possibly not seen when reversing the machine. Can cause serious injury or death. ► Adjust the existing visual aids (for example the rearview mirrors) correctly.
  • Page 176 5 Operation Fields of application of the standard bucket Important notice on standard bucket applications WARNING Danger of accident due to installing lifting gear on the attachment without proper authorization! Can cause serious injury or death. ► The attachment is not certified for lifting gear applications. ►...
  • Page 177 Operation 5 Use of standard bucket • The standard bucket is mainly used for digging earth, and for loosening, picking up, transporting and loading loose or solid materials. • Machine travel on public roads with a full standard bucket is prohibited in Germany! •...
  • Page 178 5 Operation Field of application of multipurpose bucket Important notice on multipurpose bucket applications WARNING Danger of accident due to installing lifting gear on the attachment without proper authorization! Can cause serious injury or death. ► The attachment is not certified for lifting gear applications. ►...
  • Page 179 Operation 5 Use of multipurpose bucket • The multipurpose bucket is mainly used for digging earth, and for loosening, picking up, transporting and loading loose or solid materials. • Machine travel on public roads with a full standard bucket is prohibited in Germany! •...
  • Page 180 5 Operation Fields of application of pallet forks Important notice on pallet fork applications WARNING Danger of accident due to installing lifting gear on the attachment without proper authorization! Can cause serious injury or death. ► The attachment is not certified for lifting gear applications. ►...
  • Page 181 Operation 5 Use of pallet forks • The pallet forks are mainly used for picking up, transporting and loading palletized material, pallets and other stacked material. • Pallet forks with fixed fork arms are not certified for travel on public roads in Germany.
  • Page 182 5 Operation Attachment on KRAMER quickhitch Important information on locking the attachment The attachment locked onto the quickhitch is secured against unintentional operation of switch on the joystick. The attachment can only be unlocked from the quickhitch by means of the two-hand controls –...
  • Page 183 Operation 5 Fit and lock attachments without any hydraulic function to KRAMER quickhitch 1. Approach the machine to the attachment. 2. Lower the loader unit. To do this: push the joystick forward C. 3. Tilt the quickhitch forward. To do this, press the joystick to the right B. 4.
  • Page 184 5 Operation Remove the attachment without any hydraulic function from the KRAMER quickhitch WARNING The attachment can tip over after lowering it to the ground! Can cause serious injury or death. ► Lower the attachment to the ground and ensure it cannot tip over. 1.
  • Page 185 Operation 5 Fitting attachments with hydraulic function to KRAMER quickhitch A hydraulic attachment (for example a multipurpose bucket) can be operated with the 3rd control circuit. To do this, connect the flexible lines. NOTICE In order to avoid damage, do not connect the hydraulic lines crosswise, otherwise the attachment functions are inverted and the hydraulic lines are squeezed by tilting the attachment in and out.
  • Page 186 5 Operation Remove the attachment with hydraulic function from the KRAMER quickhitch NOTICE Damage hazard to the machine and/or the attachment! ► When removing the attachment, always ensure that all hydraulic lines are disconnected. Information If the attachment is placed in direct sunlight after having been taken off, the oil in the hydraulic cylinders will warm up.
  • Page 187 Operation 5 Attachment on SKID STEER quickhitch (opt) Important information on locking the attachment The attachment locked onto the quickhitch is secured against unintentional operation of switch on the joystick. The attachment can only be unlocked from the quickhitch by means of the two-hand controls –...
  • Page 188 5 Operation Pick up and lock the attachment to the SKID STEER quickhitch 1. Approach the machine to the attachment. 2. Lower the loader unit. To do this, push the joystick forward C. 3. Tilt the quickhitch facility forward. To do this, press the joystick to the right B.
  • Page 189 Operation 5 Important information on removing attachments WARNING The attachment can tip over after lowering it to the ground! Can cause serious injury or death. ► Uncouple all flexible lines from the attachment. ► Lower the attachment to the ground and ensure it cannot tip over. Information If the attachment is placed in direct sunlight after having been taken off, the oil in the hydraulic cylinders will warm up.
  • Page 190 5 Operation Removing an attachment from a SKID STEER quickhitch 1. Empty the attachment and drive it to the drop-off position. 2. Set the attachment parallel to the ground. To do this, press the joystick to the left A. 3. Lower the loader unit until attachment is approx. 5 – 10 cm (2 –...
  • Page 191 Operation 5 Attachments for EURO quickhitch (optional) Important information on locking the attachment The attachment locked onto the quickhitch is secured against unintentional operation of switch on the joystick. The attachment can only be unlocked from the quickhitch by means of the two-hand controls –...
  • Page 192 5 Operation Removing an attachment from a EURO quickhitch facility WARNING The attachment can tip over after lowering it to the ground! Can cause serious injury or death. ► Uncouple all flexible lines from the attachment. ► Lower the attachment on level ground and ensure it cannot tip over. Information It is removed in the same way as with the KRAMER quickhitch –...

  • Page 193: Work Operation

    Operation 5 5.11 Work operation Important safety instructions for work operations WARNING The machine risks tipping over if sinks or falls into a pit! Can cause serious injury or death. ► Never drive up to the edge of a pit from outside. ►...
  • Page 194 5 Operation WARNING Accident hazard if machine is not parked safely! Can cause serious injury or death. ► Before leaving the machine, lower the attachment to the ground, turn off the machine and remove the ignition key. WARNING Accident hazard due to unlocked attachment! The attachment can come off unexpectedly and cause serious injury or death.
  • Page 195 Operation 5 Hose burst valve (partly opt) The hose burst valve prevents the loader unit from being lowered or tilted out without being braked, in the event of a bursting hose or pipe! The lift or tilt cylinders are locked and can no longer be operated. –...
  • Page 196 5 Operation Machine travel on public roads Instructions for machine travel on public roads Information When driving on public roads in Germany, equip the machine only with attachments that are certified for this machine! Attachments that are not certified for machine travel on public roads must be removed and transported with a suitable means of transportation –...
  • Page 197 Operation 5 Working with the bucket Safety instructions regarding work with a bucket WARNING Crushing hazard due to tipping over of machine! Can cause serious injury or death. ► If the bucket is full, lower the loader unit to transport position and fully tilt before starting machine travel.
  • Page 198 5 Operation Safety instructions regarding work with a bucket Information Use only the released buckets with the certified material densities – see chapter 3 “Use of attachments” on page 3-16. Information If the material is supposed to be picked up, turn off the load stabilizer, since the loader unit otherwise yields very easily, making it difficult to perform any precise lifting movement.
  • Page 199 Operation 5 Information When picking up and loading, two work movements can be executed simultaneously if necessary, e.g. "Raise" and "Tilt" or "Lower" and "Empty". To do this, the movements must be "blended" the on joystick. Failure to observe the instructions specified above can cause serious damage to the machine.
  • Page 200 5 Operation Loading loose material 1. Align the blade parallel with the ground. 2. Lower the loader unit to the ground. To do this, push the joystick forward C. Fig. 151 3. Drive forward into the material. When machine output is reduced due to too much material: 4.
  • Page 201 Operation 5 Removing material/digging in soft soil 1. Align the blade parallel with the ground. 2. Lower the loader unit to the ground. To do this, push the joystick forward C. Fig. 155 3. Setting the digging angle. To do this, press the joystick to the right B. 4.
  • Page 202 5 Operation Removing material/digging in hard soil 1. Place the bucket horizontally on the ground. To do this, push the joystick forward C. 2. Set a slightly flatter digging angle than for digging in soft soil. To do this, press the joystick to the left A. 3.
  • Page 203 Operation 5 Loading heaped material (non-compacted material) 1. Align the blade parallel with the ground. To do this, move the joystick to the left A or right B. 2. Place the bucket horizontally on the ground. To do this, push the joystick forward C.
  • Page 204 5 Operation Loading vehicles 1. If possible, the truck and the working direction of the machine should form an angle of 45°. 2. Only raise the full bucket to the tilt-out height when the vehicle travels in a straight line toward the truck. Fig.
  • Page 205 Operation 5 Working with the multipurpose bucket Safety instructions for working with the multipurpose bucket WARNING Crushing hazard due to tipping over of machine! Can cause serious injury or death. ► If the bucket is full, lower the loader unit to transport position and fully tilt before starting machine travel.
  • Page 206 5 Operation Safety instructions for working with the multipurpose bucket Information Use only the released buckets with the certified material densities – see chapter 3 “Use of attachments” on page 3-16. Information If the material is supposed to be picked up, turn off the load stabilizer, since the loader unit otherwise yields very easily, making it difficult to perform any precise lifting movement.
  • Page 207 Operation 5 Information When picking up and loading, two work movements can be executed simultaneously if necessary, e.g. "Raise" and "Tilt" or "Lower" and "Empty". To do this, the movements must be "blended" the on joystick. Failure to observe the instructions specified above can cause serious damage to the machine.
  • Page 208 5 Operation Grading 1. Fold up the front half of the bucket. 2. Set the depth of the layer you want to remove with the lift hydraulics. 3. Set the angle of the rear cutting edge. 4. Grade the surface performing forward machine travel. Ansicht_009.iso Fig.
  • Page 209 Operation 5 Pulling out material from slopes Information This position allows to pull material out of slopes or roadside ditches with maximum safety and to spread it as required. Ansicht_006.iso Fig. 169 Moving material with longer reach Information This position allows to move material without damaging slopes or structures.
  • Page 210 5 Operation Grabbing bulky material • The multipurpose bucket can be used to grab building timber, reinforcement bars, packaging bands, wire, etc. This ensures safe loading and transport. Ansicht_002.iso Fig. 172 • The multipurpose bucket allows to grab large objects. This ensures safe loading and transport.
  • Page 211 Operation 5 Backfilling round gravel and precise unloading • Precise dosing and placement of pourable material. Ansicht_012.iso Fig. 175 Advantage of working method: • Teeth move back from the wall as the bucket opens. Ansicht_011.iso Fig. 176 Unloading from the bottom of the bucket for increased tilt-out heights Advantage of working method: •...
  • Page 212 5 Operation Working with the pallet forks Important safety instructions for working with the pallet forks WARNING Accident hazard from the pallet fork arms! Pallet fork arms can cause serious injury or death during machine travel on public roads. ► Remove fork arms from the pallet forks before machine travel on public roads and transport them separately.
  • Page 213 Operation 5 Important safety instructions for machine travel on public roads with the pallet forks In Germany, machine travel on public roads with attached pallet forks that do not have foldable fork arms is prohibited! Do not transport the pallet forks in a bucket fitted onto the machine! •...
  • Page 214 5 Operation Important information on load transport • Always tilt in the attachment a little (toward the machine) for transport! • Always transport the load close to the ground! • Always adapt the transport speed to the load you are transporting and to the ground conditions! •...
  • Page 215 Operation 5 Brief instructions for fork arms The following brief instructions are based on the “Guidelines for testing and repairing fork arms” (© by VETTER Umformtechnik GmbH): • Use fork arms only according to their designated use. • Do not exceed the load center and the load-bearing capacity. •...
  • Page 216 5 Operation Load diagram for pallet forks The load diagram in the cabin is only valid for applications with the released pallet forks – see chapter 9 “Payload/lift capacity/stability” on page 9-18! The load diagram is located inside the cabin on the left of the front window or on the front trim.
  • Page 217 Operation 5 Adjusting the fork arms of the pallet forks WARNING Accident hazard if the fork arms are not correctly locked on the fork frame! The fork arms can come off and cause serious injury or death. ► Check before working whether locking levers A on both fork arms are folded down and safely engaged in the fork frame! ►...
  • Page 218 5 Operation Picking up a load WARNING Tipping hazard of machine due to failure to pay attention to the load diagram! Can cause serious injury or death. ► Observe the payloads specified in the load diagram. Information To guarantee that the load can be picked up with precision, switch off the load stabilizer (opt)! 1.
  • Page 219 Operation 5 Safety instructions on transporting material WARNING The load can tip backward if it is not secured and if the loader unit is raised! Can cause serious injury or death. ► Do not transport loads with a raised loader unit. ►...
  • Page 220 5 Operation Transporting material • Move the load only when it is safely placed on the fork arms. • Start, turn and stop smoothly. • Concentrate on your work, avoid distractions. • When moving and transporting loads, always tilt it slightly back toward the machine and raise or lower it to transport position (bear in mind the ground clearance).
  • Page 221 Operation 5 Fitting attachments from other manufacturers (opt) Quickhitches for attachments from other manufacturers • The following quickhitches can be purchased from your dealer and installed by an authorized service center: - Quickhitch for EURO attachments - Quickhitch for SKID STEER attachments •...
  • Page 222 5 Operation Important information on fitting attachments from other manufacturers KRAMER WARNING Accident hazard if the attachments are not locked! Can cause serious injury or death. ► After locking an attachment, check whether catch bolts E of the quickhitch can be seen on either side in the mounting bores of the attachment.
  • Page 223 Operation 5 Stability calculations for attachments from other manufacturers Overview with bucket according to ISO 14397-1 Overview with pallet forks according to ISO 14397-1 Fig. 191 5-97 BA 357-00 * 3.0 * 35700_05_Bedienung.fm...
  • Page 224 5 Operation Table for values that have been determined Enter the values that have been determined in the column “Entry”. Designation Measure/determine Entry Enter the calculated values in the load diagram Maximum authorized payload kg/lbs – see "Calculation formula for stability (load diagram)"...
  • Page 225 Operation 5 Required safety factors (S) Pallet forks DIN EN 474-3 Rough terrain 60 % S = 0.6 Firm and level ground S = 0.8 Bucket ISO 14397-1 – 50 % S = 0.5 Calculation formula for stability (load diagram) GA x L1 F2 = GH = F1 −...
  • Page 226 5 Operation Load diagram (sample) Enter the calculated values “GN” in the load diagram. Information Affix the completed load diagram in the cabin in a water-proof position that is easily visible for the user/operator. GN = GN = GN = GN = GN = GN =...

  • Page 227: Emergency Lowering

    Operation 5 5.12 Emergency lowering Emergency lowering of loader unit in case of operating motor breakdown WARNING Imminent accident hazard when lowering the loader unit in an emergency! Can cause serious injury or death! ► Secure the danger zone. ► Do not try to repair the machine under a raised load. ►...

  • Page 228: Options

    5 Operation 5.13 Options Hose burst valve (partly opt) Important safety instructions The hose burst valve prevents the loader unit from being lowered or tilted out without being braked, in the event of a bursting hose or pipe! The lift or tilt rams are locked and can no longer be operated. WARNING Accident hazard when lowering the loader unit in an emergency! Can cause serious injury or death!
  • Page 229 Operation 5 Low-speed control with regulated travel speed (opt) Important information on the low-speed control with regulated travel speed (CSD = Constant Speed Drive) Using this function, an even driving speed can be achieved. The selected driving speed is largely self-contained of the driving resistance. When operating hydraulically enabled attachments (e.g.
  • Page 230 5 Operation Operation of low-speed control Operating Lever position Result Select a speed – see "Selecting a speed range" on page 5-12. range. 1. Pull the sliding heater Driving speed control 76 all the way = 0 km/h (0 mph). to the rear B.

  • Page 231: Digital Display

    Operation 5 Operating Lever position Result 1. Push the slide Speed is reduced to control 76 all the way 0 km/h (0 mph). to the rear B. 2. Once the work operation is Symbol B/3 completed, press the appears on the touch button 56 digital display.
  • Page 232 5 Operation Electric connection – 7-pole front socket (opt) Putting the front socket into operation The machine can be equipped with a 7-pole socket E (at the front left on the loader unit). Two separate electrical circuits can be switched on via the 7-pole socket, e.g.
  • Page 233 Operation 5 Operation Function Indicator display D/2 illuminates in the digital display in the indicating Press rocker switch 61 to instrument. position B. Circuit 2 (standard) is enabled. Indicator display D/2 Push-button extinguishes in the operation digital display in the indicator display D/1 Press and hold illuminates.
  • Page 234 5 Operation Load stabilizer for loader unit (opt) During machine travel over longer distances, off-road or on public roads, the load stabilizer dampens the movements of the loader unit and avoids pitching movements of the machine. This increases drive comfort and safety. WARNING Accident hazard due to pitching movements of the machine during machine travel on public roads.
  • Page 235 Operation 5 Switching the load stabilizer ON and OFF Information When switching the load stabilizer on or off, the loader unit is subject to compensation movements from pressure or loading balancing! ► We therefore recommend always turning off the load stabilizer before working with pallet forks.

  • Page 236: Decommissioning//Recommissioning

    5 Operation 5.14 Decommissioning//recommissioning Notes for decommissioning the machine WARNING Accident hazard if machine tips over or rolls away after parking it! Can cause serious injury or death. ► Stop the machine on firm, level, and horizontal ground. ► Secure the machine accordingly (chocks, for example). NOTICE To avoid engine damage or damaging the electronics, allow the machine to run for a while after operation under full load, so that the...
  • Page 237 Operation 5 Activities in preparation for decommissioning 1. Charge the battery. 2. Clean the machine thoroughly. 3. Lower the loader unit completely and set the attachment horizontally with the ground. 4. Set the drive to a neutral position – see "Slowing the machine and stopping" on page 5-15.
  • Page 238 5 Operation Undertaking decommissioning for longer periods of time 1. Perform all the measures related to decommissioning – see "Activities in preparation for decommissioning" on page 5-111. 2. If possible, retract the piston rods of the hydraulic rams to protect them against damage.

  • Page 239: Final Decommissioning

    Operation 5 5.15 Final decommissioning Notes for finally decommissioning the machine If the machine is no longer used according to its designated use, ensure that it is put out of operation and disposed of according to applicable regulations. Environment Avoid environmental damage! Do not allow the oil and oily wastes to get into the ground or stretches of water! Dispose of different materials and consumables separately and in an environmentally friendly manner!
  • Page 240 5 Operation Disposal Further recycling of the loader must be made in accordance with state-of-the-art standards applicable at the time of recycling, and in compliance with the safety regulations regarding accident prevention! Get informed and follow the legal regulations of your country. •...

  • Page 241: Transport

    Transport Transport 6 Transport Towing the machine Information on towing WARNING Accident hazard due to towing! Towing the machine can cause accidents in certain situations, and serious injury or death. ► Only tow the machine if the steering and braking systems are functional.
  • Page 242 6 Transport Before towing away In case of power failure, the automatic parking brake must be released manually. To do this, two cheese-head M 6x60 mm screws are needed (DIN EN ISO 4762). The screws are included in the scope of delivery of the vehicle.
  • Page 243 Transport 6 Release the parking brake 1. Turn the machine off and remove the ignition key. 2. Disconnect the battery connector. 3. Secure the machine to prevent it from rolling away, e.g. with wheel chocks. 4. Insert two M6x60 screws in the threads A on the parking brake B and screw in clockwise, alternating between one and the other, about 1.5 turns.
  • Page 244 6 Transport Towing Safety instructions for towing away – see chapter 2 “Towing” on page 2-13. Tow away the machine as follows: Information The towing device at the rear A and front B of the vehicle is certified only for holding and towing the machine. They are not certified as a trailer coupling, for fitting attachments or for raising, loading and tying down the machine.
  • Page 245 Transport 6 Once towing is over Put the machine back into operation only after correct repairs have been performed. NOTICE The brake can jam when unscrewing the hexagon socket protrude screw. ► Unscrew both hexagon socket protrude screws at the same time. To do this, alternately unscrew each screw a maximum of one turn at a time.

  • Page 246: Loading The Vehicle

    6 Transport Loading the vehicle Loading the machine on a transport vehicle Safety instructions regarding loading WARNING Accident hazard due to incorrect loading! Incorrect loading can cause accidents and serious injury or death. ► The transport vehicle must be of appropriate size – refer to chapter Technical data on page 9-1 for the dimensions and weights of the machine to be loaded.
  • Page 247 Transport 6 Loading the machine 1. Secure the transport vehicle with chocks to prevent it from rolling. 2. Place the access ramps at the smallest possible angle. Do not exceed an angle of 20°. Use access ramps only with an antiskid surface. 3.
  • Page 248 6 Transport Crane-lifting the machine Safety instructions regarding crane-lifting WARNING Accident hazard due to incorrect loading! Incorrect loading can cause accidents and serious injury or death. ► Ensure that no one remains in the machine that is to be loaded! ►...
  • Page 249 Transport 6 Loading process WARNING Risk of injury due to falling machine or parts of it! Falling objects can cause serious or fatal injury. ► Use tested, intact lifting gear of sufficient dimensions. ► Check that the lifting gear is safely fastened. ►...

  • Page 250: Transporting The Vehicle

    6 Transport Transporting the vehicle Safety instructions on tying down the machine • Match the travel speed of the transport vehicle to the load, road and traffic conditions and to the driving characteristics. • The transport vehicle must be of sufficient size –...
  • Page 251 Transport 6 Tying down the machine Tie down as follows 1. Secure all tires of the machine with chocks in front of and behind each wheel. 2. Firmly tie down the machine at the eye hooks (symbol A) – see chapter 3 “Machine outside view” on page 3-1 –...
  • Page 252 6 Transport Notes: 6-12 BA 357-00 * 3.0 * 35700_06_Transport.fm...

  • Page 253: Maintenance

    Maintenance Maintenance 7 Maintenance Information on maintenance Responsibilities and prerequisites • Operational readiness and the service life of the machine are heavily dependent on maintenance. • The "daily maintenance" and "work every 20 hours of operation" indicated in the maintenance schedule have to be performed by a specially trained operator.
  • Page 254 7 Maintenance Important safety instructions regarding maintenance WARNING Accident hazard due to electric current! Only work on the machine when it is in a de-energized state. ► Before starting maintenance: - Park the machine securely – see chapter 5 “Stopping and securing the machine” on page 5-17.
  • Page 255 Maintenance 7 WARNING Risk of injury due to chemicals! Batteries can release explosive gases that can explode if they ignite. The squirting battery acid can then cause serious burns. ► Do not smoke, avoid fire and open flames. ► Do not put any tools or other metallic objects on the battery that could cause a short circuit.
  • Page 256 7 Maintenance CAUTION Risk of injury due to hot parts! The power electronics and the electric motors can become hot during operation. ► Before folding up the operator seat, allow the components to cool down. ► Wear protective equipment. NOTICE Damage from loose parts in the battery compartment.
  • Page 257 Maintenance 7 Safety prop for loader unit (opt) WARNING Danger of crushing during maintenance work on a raised loader unit that is not secured! Can cause serious injury or death. ► Lower the loader unit to the ground during maintenance. ►...

  • Page 258: Maintenance Overview

    7 Maintenance Maintenance overview Maintenance plan Important information on the maintenance plan For warranty claims to be acknowledged, the maintenance, "delivery inspection" and inspection "A" 1st inspection after 100 o/h, "B" 2nd inspection subsequently every 500 o/h and "C" every 1500 o/h (annually) must be performed by an authorized service center.
  • Page 259 Maintenance 7 Service User/operator Service center Work description center Inspection work ( Check hydraulic oil level Check gearbox oil level in front and rear axle differential Check gearbox oil level in front and rear axle, left and right planetary drives Check gearbox oil level in gearbox at the hydraulic motor 2, 3...
  • Page 260 7 Maintenance Service User/operator Service center Work description center Inspection work ( Check the brake lining of the service brake and renew if necessary Check parking brake and renew parts if necessary every 2 years Tire check (damage, inflation pressure, tread depth) Electrical system: check electric and ground connections, chafing on wiring harnesses, battery terminals Check the battery, cable and battery connector for...
  • Page 261 Maintenance 7 Service User/operator Service center Work description center Lubrication (Note: lubricate more frequently when in heavy-duty operation!) Hinges, joints (for example door arresters) Rear axle oscillating bearing Front and rear axle planetary drive bearings (left and right) Loader unit –...
  • Page 262 7 Maintenance Service User/operator Service center Work description center Check bolts and nuts for tightness, re-tighten them if necessary: Engine and engine bearing Steering system Hydraulic system Loader unit (pin locking) Axle mounting, axle suspension Battery bolting Fastening screws of cardan shafts Fastening screws of cabin Wheel nuts Safety part! Have maintenance and repairs performed only by an authorized service center...
  • Page 263 Maintenance 7 Service indication Maintenance intervals indication The maintenance intervals are displayed by the maintenance indicator display F/2 in the gauge on the instrument panel. If less than 20 operating hours remain before the next inspection is due, the remaining number of hours until inspection is displayed here for 10 seconds when the starter is engaged.
  • Page 264 7 Maintenance Maintenance label Affixed on the cabin 7-12 BA 357-00 * 3.0 * 35700_07_Wartung.fm...
  • Page 265 Maintenance 7 Explanation of symbols on the maintenance label Symbol Explanation Before starting maintenance, follow the safety instructions in the Operator’s Manual! Before starting maintenance, read the “Maintenance” chapter in the Operator’s Manual! Perform a functional check of the light system! Check tires for damage, inflation pressure and tread depth! Check the brake fluid.

  • Page 266: Fluids And Lubricants

    7 Maintenance Fluids and lubricants Overview: Fluids and lubricants (part 1) Component/ SAE grade Season/ Capacities Fluid/lubricant application Specification temperature Gearbox 0.8 l (0.21 gal) Universal gearbox oil SAE 80 – 90 GL5 Year-round Front or rear axle 3.0 l (0.8 gal) each SAE 90 LS differentials Gearbox oil...
  • Page 267 Maintenance 7 Overview: Fluids and lubricants (part 2) Component/ SAE grade Season/ Capacities Fluid/lubricant application Specification temperature Braking system 0.5 l (0.13 gal) Brake fluid ATF Suffix type A – Water 0.5 l (0.13 gal) Year-round Washer system Cleaning agent Water + antifreeze Antifreeze −20 °C (−4 °F)
  • Page 268 7 Maintenance Important information on operation with biodegradable oils • Use only the tested and approved biodegradable hydraulic fluids – see "Fluids and lubricants" on page 7-14. Always contact the manufacturer for the use of products other than those that have been recommended.

  • Page 269: Maintenance Accesses

    Maintenance 7 Maintenance accesses Battery cover plate Opening the battery cover plate DANGER Risk of electric shock from defective components or contact with the high-voltage system! Causes serious injury or death. ► Before opening the battery cover plate, actuate the motor isolating switch and remove the ignition key.
  • Page 270 7 Maintenance Operator seat Folding the operator seat forwards 1. Pull handle A and push operator seat fully backwards. 2. Unscrew the 3 hexagon screws B on each side of the operator seat. Fig. 210 3. Fold the operator seat forward and secure against falling back, e.g.

  • Page 271: Cleaning And Maintenance

    Maintenance 7 Cleaning and maintenance Important information on cleaning and maintenance The wrong choice of cleaning equipment and agents can impair the operating safety of the machine on the one hand, and on the other put the health of the persons in charge of cleaning the machine at risk. Therefore always observe the following instructions.
  • Page 272 7 Maintenance Cleaning with washing solvents • Ensure sufficient room ventilation. • Wear appropriate protective equipment. • Do not use flammable liquids, such as gasoline or diesel. Cleaning with compressed air • Work carefully. • Wear safety glasses and protective clothing. •...
  • Page 273 Maintenance 7 Cleaning inside the cabin NOTICE In order to avoid damage to the machine's electrical system, never use high-pressure cleaners, steam jets or high-pressure water to clean inside the operator's cabin. ► Water under high pressure can penetrate into the electrical system and cause short circuits.
  • Page 274 7 Maintenance Cleaning the pedals WARNING Accident hazard due to dirt or malfunction of the pedals. Can cause serious injury or death. ► Keep the floor under the pedals clean. ► Do not place any objects in the leg room. ►...
  • Page 275 Maintenance 7 Cleaning the exterior of the machine NOTICE Damage to machine due to cleaning work. ► Pay attention to the lower side in particular when cleaning the machine. The cooling of components is impaired by a strong accumulation of dirt on the engines and on the transmission.
  • Page 276 7 Maintenance Cleaning the engines CAUTION Risk of injury due to hot and moving engine parts! Hot and moving engine parts can cause injury. ► Let the engine cool down. ► Wear protective equipment. NOTICE The humidity penetrating while cleaning the motors causes the electronics to fail and leads to engine damage! ►...
  • Page 277 Maintenance 7 Cleaning the battery Cleaning the cell array, battery tray and insulators is necessary in order to maintain the required insulation of the cells against each other, against ground or foreign, conductive objects. In addition, damages and accidents from corrosion and leakage currents are avoided. Leakage currents can arise if the dust deposits on the battery combine into a conductive layer with small amounts of electro-particles, which may leak when charging the battery.
  • Page 278 7 Maintenance WARNING Risk of explosion from static charging! Cleaning with a feather duster or dry cloths made of synthetic fibers can lead to static charging and thus to a gas explosion. Serious injuries and death can result. ► Only clean the battery surfaces with cotton or paper towels moistened with water.
  • Page 279 Maintenance 7 The following aids are recommended for cleaning: • Water • Moist cloths (made of cotton or paper) Cleaning 1. Place a suitable container below to catch possible resulting flush water that may contain electrolytes; dispose of this water in an environmentally friendly manner.

  • Page 280: Lubrication Work

    7 Maintenance Lubrication work Lubricating the rear axle oscillation-type bearing Information Maintenance intervals – see "Maintenance plan" on page 7-6. Lubricant – see chapter 7 “Fluids and lubricants” on page 7-14. 1. Park the machine on level ground. 2. Apply the parking brake. 3.
  • Page 281 Maintenance 7 Lubricating the door arrester Information Maintenance intervals – see "Maintenance plan" on page 7-6. Lubricant – see chapter 7 “Fluids and lubricants” on page 7-14. 1. Apply a thin coat of grease to door arrester B. Fig. 214 Lubricate the window lock Information Maintenance intervals...
  • Page 282 7 Maintenance Lubricating the loader unit Loader unit lubrication points (overview) A Lubricate the grease zerk of the tilt cylinder bearing on the frame every 10 operating hours. Lubricate more frequently when in heavy-duty operation. B Lubricate the grease zerk of the loader unit bearing every 10 operating hours.

  • Page 283: Battery

    Maintenance 7 Battery The battery is located in the battery compartment in the rear section of the machine. The battery is firmly installed in a battery tray and is low-maintenance. The battery weight (in the battery tray) is specified on the type label of the battery.
  • Page 284 7 Maintenance WARNING Risk of injury from touching live parts! Touching live parts while charging the battery can result in serious injury or death. ► While charging, do not touch any live parts of the machine. WARNING Accident hazard from using unsuitable batteries! The use of unsuitable batteries can result in serious injury or death.
  • Page 285 Maintenance 7 General instructions on handling the battery Environment Always observe the national environmental-protection guidelines or waste disposal laws when disposing of used batteries. Always follow the manufacturer’s indications on disposal. Information The battery weight is specified on the type label of the battery. 7-33 BA 357-00 * 3.0 * 35700_07_Wartung.fm...
  • Page 286 7 Maintenance Charging the battery Safety instructions when loading the battery WARNING Risk of explosion from resulting gases during charging! A mixture of oxygen and hydrogen (oxyhydrogen) is released by the battery during charging. This gas mixture is highly explosive. Serious injuries or even death can result if the gas ignites.
  • Page 287 Maintenance 7 WARNING Hazard due to electric current! The battery charger works with electric current and voltages that are dangerous for human beings. ► The battery charger may be opened and repaired only by qualified electricians. ► Do not perform any modifications on the battery charger. ►...
  • Page 288 7 Maintenance NOTICE Battery damage from discharge! The battery can be damaged if the machine is parked several days with a discharged battery. ► Do not park the machine with a discharged battery. ► Always hook up the battery charger to a suitable power source when the machine is parked.
  • Page 289 Maintenance 7 Charging preparation The battery must be charged if the control display of the battery charge condition indicates a weak charge state or if the battery performance decreases. 1. Check whether the plug receptacle provided for connecting the battery charger is designed for 16 A and the supply line is secured with 16 A.
  • Page 290 7 Maintenance Connecting the battery charger NOTICE If the battery cover plate is closed during charging, the power cable can be damaged. ► When closing the battery cover plate, ensure that the power cable is not damaged. 1. If the machine was not used prior to charging the battery, run a test of the insulation.
  • Page 291 Maintenance 7 Removing the battery charger As soon as charging is finished and the machine is to be used again, the battery charger must be separated from the power source. 1. If the battery cover plate was closed, carefully open the battery cover plate.
  • Page 292 7 Maintenance Battery installation and removal with pallet forks Safety instructions for installation and removal The battery may only be replaced by people who are trained on the vehicle. The battery is firmly installed in a battery tray. The entire battery tray is replaced when replacing the battery.
  • Page 293 Maintenance 7 Preliminary work 1. Park the machine on firm, level and dry ground. 2. Apply the parking brake. 3. Lower the loader unit to the ground. 4. Switch off motor isolating switch. 5. Turn the machine off and remove the ignition key. 6.
  • Page 294 7 Maintenance Removal 1. Unscrew the retaining screws A (M16) to the right, left and front on the battery tray and remove with sleeves. Fig. 225 2. Approach the battery with pallet fork from the rear of the machine. 3. Move the fork tines as far as possible carefully into the supports B on the battery tray.
  • Page 295 Maintenance 7 Installation 1. Carefully approach the battery tray with pallet forks from behind as far as possible until stopped on the rear of the machine. Pay attention that the battery tray engages in the front clamp. 2. Driving in reverse, carefully draw the pallet forks backwards out of the supports B on the battery tray.
  • Page 296 7 Maintenance Installing the rear part 1. Place the rear part A from behind onto the centering bolts. 2. On each side 3, screw in the screws B and tighten them hand-tight. 3. Align the rear part. 4. Tighten the fastening screws. 5.
  • Page 297 Maintenance 7 Battery installation and removal with crane Safety instructions for installation and removal The battery may only be replaced by people who are trained on the vehicle. The battery is firmly installed in a battery tray. The entire battery tray is replaced when replacing the battery.
  • Page 298 7 Maintenance Preliminary work 1. Park the machine on firm, level and dry ground. 2. Apply the parking brake. 3. Lower the loader unit to the ground. 4. Switch off motor isolating switch. 5. Turn the machine off and remove the ignition key. 6.
  • Page 299 Maintenance 7 Removal 1. Unscrew all of the retaining bolts A (M16) on the battery tray and remove them with the sleeves. Fig. 235 2. Knock the crane gear perpendicular onto the supports A on the battery tray. To do this: attach the hooks so they cannot fall on battery cells when the crane gear is loosened.
  • Page 300 7 Maintenance Installation 1. Knock the crane gear perpendicular onto the supports A on the battery tray. To do this: attach the hooks so they cannot fall on battery cells when the crane gear is loosened. 2. Carefully drive the battery from the rear as far as possible into the machine.
  • Page 301 Maintenance 7 Installing the battery cover plate CAUTION Risk of injury from loosened battery cover plate. Persons can be injured by the loosened battery cover plate falling off. ► Secure the battery cover plate against falling off, until the hinges have again been screwed to the frame.

  • Page 302: Cooling System

    7 Maintenance Cooling system Safety instructions regarding the cooling system The hydraulic oil radiator (option) is located in the cabin on the left. It cools the hydraulic oil of the steering and operating hydraulics. WARNING Caustic injury hazard! Risk of swallowing when handling hydraulic oil! Can cause serious injury or death ►...
  • Page 303 Maintenance 7 Clean the hydraulic oil radiator (optional) CAUTION Burn hazard during maintenance on a hot engine and radiator! Failure to observe this can cause serious injury. ► Wear protective gloves and eye protection. ► Let the radiator cool down at least 10 minutes after stopping the machine.

  • Page 304: Hydraulic System

    7 Maintenance Hydraulic system Important information on the hydraulic system CAUTION Burn hazard due to hot hydraulic oil! Hot hydraulic oil can cause burns to the skin. ► Release the residual pressure in the hydraulic system. ► Allow the hydraulic system to cool down. ►...
  • Page 305 Maintenance 7 NOTICE Contaminated hydraulic oil, lack of oil or wrong hydraulic oil poses a risk of serious damage to the hydraulic system! ► Ensure utmost cleanliness during maintenance work on the hydraulic system! ► Always add hydraulic oil using the filling screen! ►...
  • Page 306 7 Maintenance Monitoring the hydraulic oil filter The following indicator lights and indicators are located on the gauge and monitor contamination of the hydraulic oil filter and the oil temperature: • Warning light 43 temperature • Warning indicator G/2 – dirt in hydraulic oil filter •...
  • Page 307 Maintenance 7 Checking the hydraulic oil level The oil level glass is integrated into the hydraulic oil reservoir. CAUTION Burn hazard due to hot hydraulic oil! Hot hydraulic oil can cause burns to the skin. ► Release the residual pressure in the hydraulic system. ►...
  • Page 308 7 Maintenance Adding hydraulic oil Important information CAUTION Burn hazard due to hot hydraulic oil! Hot hydraulic oil can cause burns to the skin. ► Release the residual pressure in the hydraulic system. ► Allow the hydraulic system to cool down. ►...
  • Page 309 Maintenance 7 1. Park the machine on level ground. 2. Retract all hydraulic cylinders. 3. Apply the parking brake. 4. Turn the machine off and remove the ignition key. 5. Clean the area around breather filter B. 6. Place a container under the hydraulic oil reservoir to collect the oil. 7.
  • Page 310 7 Maintenance Hydraulic System – Checking pressure lines for leaks Important safety instructions regarding pressure line checks WARNING Burn and injury hazard due to hot hydraulic oil escaping under high pressure! Hydraulic oil escaping under high pressure can catch fire, damage property, penetrate the skin, and cause serious burns.
  • Page 311 Maintenance 7 Hydraulic system – checking membrane accumulators Important safety instructions for checking the membrane accumulators WARNING Risk of suffocation through uncontrolled release of large quantities of gas and risk of injury due to entrained components. Failure to observe this can cause serious injury or death. ►...
  • Page 312 7 Maintenance Checking hydraulic hoses for damage and aging Important information for the owner of the machine Information Observe the maintenance intervals – see "Maintenance plan" on page 7-6. The entrepreneur/owner of the machine must ensure that hose pipes are replaced in appropriate intervals, even if no safety-relevant malfunctions can been detected on the hose pipe.

  • Page 313: Electrical System

    Maintenance 7 7.10 Electrical system Qualification of maintenance personnel Replacement and repair work on the electrical system may be performed only by an authorized service center! Checks and service work, as well as the replacement of light bulbs or fuses must be performed by a specifically trained operator. Information on the electrical system WARNING Accident hazard due to electric current!
  • Page 314 7 Maintenance NOTICE Damage to the electrical system due to short circuit. ► Always disconnect the battery before performing work on the electrical system in which tools, spare parts, etc. can touch electrical components or contacts. ► Take off and set aside any rings, metal bracelets, etc.
  • Page 315 Maintenance 7 Regular checks and service work on the electrical system CAUTION Fire hazard! Blown fuses indicate overloading or short circuits of an electrical component. Can cause injury. ► Have the electrical system checked by an authorized service center before inserting new fuses. ►...
  • Page 316 7 Maintenance Machine fuses NOTICE Blown fuses indicate overloading or short circuits of an electrical component. ► If a fuse blows out again shortly after replacement, have the electrical system checked by an authorized service center before installing a new fuse. ►...
  • Page 317 Maintenance 7 Checking/replacing fuses on the fuse panel The fuses 17 are located under the cover A on the right in the control lever console. Fuse assignment: see label B on the side in the cabin. 1. Lower the loader unit. 2.
  • Page 318 7 Maintenance Checking/replacing fuses on the power electronics WARNING Accident hazard due to high electrical voltages! Improper performance of work on the electrical system can result in serious injury or death. ► Maintenance that does not involve HV components (e.g. replacing fuses), where the maintenance personnel must work near HV components and, in the event of an error, could trigger an electrical hazard, must be performed by "electrically trained persons".
  • Page 319 Maintenance 7 The power electronics is installed under the operator seat. The fuses are located in the fuse boxes A and B of the power electronics under the covers. Fuse assignments – see chapter 9 “Power electronics” on page 9-12. Removing a fuse 1.
  • Page 320 7 Maintenance Checking/replacing the fuses on the road traffic module WARNING Accident hazard due to high electrical voltages! Improper performance of work on the electrical system can result in serious injury or death. ► Maintenance that does not involve HV components (e.g. replacing fuses), where the maintenance personnel must work near HV components and, in the event of an error, could trigger an electrical hazard, must be performed by "electrically trained persons".
  • Page 321 Maintenance 7 The road traffic module is installed under the operator seat. The fuses are located under the cover A of the road traffic module. Fuse assignments – see chapter 9 “Road traffic module” on page 9-13. Removing a fuse 1.

  • Page 322: Heating And Ventilation

    7 Maintenance 7.11 Heating and ventilation Important information on cabin ventilation The cabin is equipped with a fine-dust filter. CAUTION Risk to health if fine-dust filter is not correctly mounted or damaged! An incorrectly mounted or damaged fine-dust filter can cause health damage to respiratory tracts.
  • Page 323 Maintenance 7 Cleaning/replacing the fine-dust filter of the cabin ventilation Information Observe the maintenance intervals – see "Maintenance plan" on page 7-6. Replace the fine-dust filter every 500 o/h (operating hours) by a new one. The fine=dust filter is located in the leg room on the left in travel direction behind trim A.

  • Page 324: Window Washer System (Only In The Cabin Cpl.)

    7 Maintenance 7.12 Window washer system (only in the cabin cpl.) Washer system reservoir Filler inlet 34 of the reservoir is located on the left in the cabin. The level in the reservoir is visible in inspection window A. Information Add only clean tap water! Add a suitable cleaning agent if required.

  • Page 325: Axles / Drive

    Maintenance 7 7.13 Axles / drive Maintenance on axles/drive Information Maintenance on the axles and drive may only be performed by an authorized service center for reasons of safety, warranty and liability. Observe the maintenance intervals – see "Maintenance plan" on page 7-6.

  • Page 326: Braking System

    7 Maintenance 7.14 Braking system Important safety instructions regarding the brake system WARNING Accident hazard due to malfunctioning brakes! Damaged brakes can result in serious injury or death. ► Damaged brake lines or hoses must immediately be replaced by an authorized service center.
  • Page 327 Maintenance 7 Checking/adding brake fluid The brake-fluid reservoir is located inside the cabin to the left of the operator seat. The check marks “MAX” and “MIN” are located on the side of the reservoir. WARNING An incorrect brake fluid grade or an insufficient brake fluid level can impair the safety of the braking system.

  • Page 328: Tires

    7 Maintenance 7.15 Tires Important information on the tires WARNING Accident hazard from improper attaching tires or repair work on the rims! Improper mounting or repair work can cause serious injury or death. ► Only allow assembly work to be performed by an authorized service center.
  • Page 329 Maintenance 7 Tire and compressed air check Information Observe the maintenance intervals – see "Maintenance plan" on page 7-6. Regular checks for damage and of the tire pressure increase operational safety and the service life of the tires, and reduce the machine’s downtimes.
  • Page 330 7 Maintenance Installing/removing wheels Important safety instructions WARNING Crushing hazard due to tipping over of machine! Serious injury or death can be caused by the raised machine tipping over. ► Park the machine on level and firm ground. ► Seal off the job site and ensure constant supervision of the machine. ►...
  • Page 331 Maintenance 7 Removing the wheel 1. Park the machine on level and firm ground. 2. Lower the loader unit to the ground. 3. Apply the parking brake. 4. Turn the machine off and remove the ignition key. 5. Prevent the machine from rolling away (wheel chocks). 6.

  • Page 332: Maintenance And Care Of Attachment Devices

    7 Maintenance 7.16 Maintenance and care of attachment devices Correct maintenance and servicing is absolutely necessary for smooth and continuous operation, and for an increased service life of the attachments. Observe the lubrication and maintenance instructions in the Operator’s Manuals of the attachments! Clean attachments after using them and check them for damage.

  • Page 333: Maintenance Of Options

    Maintenance 7 7.17 Maintenance of options Air conditioning (opt) (currently not available) Responsibilities and prerequisites • Functional and visual checks must be performed by the operator/user. • All maintenance and repair work may only be performed by the trained personnel of an authorized service center. Important safety instructions regarding the air conditioning system CAUTION...
  • Page 334 7 Maintenance Filling the air conditioning system by an authorized service center Only have the air conditioning system filled and serviced by trained personnel in an authorized service center! • Information for the initial filling of the air conditioning system is entered on the type label, which is located in the vicinity of the air conditioning system.
  • Page 335 Maintenance 7 Cleaning the heat exchanger (condenser) CAUTION Risk of injury due to hot parts! Touching hot components can result in injury. ► Allow the machine to cool down. ► Wear protective equipment. 1. Apply the parking brake. 2. Turn the machine off and remove the ignition key. 3.

  • Page 336: Machine Preservation

    7 Maintenance 7.18 Machine preservation Anti-corrosion protection (opt) NOTICE Corrosion on electric connections or components can cause hazardous operating malfunctions. ► Check the machine regularly for corrosion. ► If you replace elements, check whether they are classified as in the table "Components coated with anti-corrosive wax on page 7-85"...
  • Page 337 Maintenance 7 Components coated with anti-corrosive wax Component Remarks Before applying the wax: All electric plug • Disconnect the plug-and-socket connections, ground connection, apply contact spray to contacts and contact surfaces and reconnect the crimp connections plug-and-socket connections. with the exception of: •...
  • Page 338 7 Maintenance Measures for maintaining anticorrosive protection WARNING Special hazards during anti-corrosion protection! Handling chemical substances can cause serious injury or death. ► When handling chemical substances of any kind, such as solvents, wax, etc., observe the specific product-related safety regulations (safety data sheet).
  • Page 339 Maintenance 7 Applying the anti-corrosion protection Bear in mind the following instructions as you apply the anti-corrosion protection: • Carefully cover all fastening surfaces and components to which the anti-corrosion protection may not be applied – see "Components coated with anti-corrosive wax" on page 7-85.
  • Page 340 7 Maintenance Notes: 7-88 BA 357-00 * 3.0 * 35700_07_Wartung.fm...

  • Page 341: Malfunctions

    Malfunctions Malfunctions 8 Malfunctions The information given in this chapter is provided for the fast and reliable detection of malfunctions. Please contact an authorized service center if the malfunction cannot be remedied. Repairs may only be carried out by an authorized service center and only by trained personnel.

  • Page 342: Malfunctions Of The Hydraulic System

    8 Malfunctions Errors/malfunctions Possible causes Remedy/avoidance Hydraulic motor overheats. Temperature warning system Allow the machine to cool down. responds. Temperature sensor responded Contact an authorized service – Hydraulic motor has center if necessary. insufficient engine power Allow the machine to cool down. Hydraulic motor overheats.

  • Page 343: Malfunctions Of The Electrical System

    Malfunctions 8 Malfunctions of the electrical system Important information Repairs on the electrical system may only be performed by an authorized service center. See also Electrical system on page 7-61. Error display of machine electronics in gauge The warning lights 38 and 39 indicating errors that are recorded by the machine electronics.
  • Page 344 8 Malfunctions Description of indications in display The machine electronics save the active and passive errors. • Active errors are immediately displayed in the gauge display in field 45 F/3 when the error occurs. • Passive errors are not displayed when the error occurs. Passive errors are only displayed during queries of the error memory in the service display.
  • Page 345 Malfunctions 8 Displays Information The numbers in the presented illustrations are offered as examples. Other figures are displayed in reality. Error display 1. Error type active / passive with running number 2. SPN error code (component) 3. FMI error code (error type) 4.
  • Page 346 8 Malfunctions Navigation in the display screen If the error menu is completely gone through with the push button 46, the display will return to the service display B again. By using push button 47, one can return to the main display A at any time during the error query.
  • Page 347 Malfunctions 8 Error codes If the machine electronics report an error, a warning light 38 or 39 illuminates in the gauge and an error code is displayed for 3 seconds in the display of the gauge 45 in field F.t. Fig.
  • Page 348 8 Malfunctions Error code tables Main controls Warn- Error code FMI Error description Remedy ing light Error 1. Turn off the machine and N004 – MLS Master (main controller): then turn it on again. Missing signal Yellow 2. If the error occurs again: –...
  • Page 349 Malfunctions 8 Main controls (continuation) Warning Error code FMI Error description Remedy light N004 – MLS Interface A/B (I/O controller): Missing signal Yellow – Both electric engines go via ramp into emergency shutdown N004 – MLS Interface A/B (I/O controller): Error description not identifiable Yellow –...
  • Page 350 8 Malfunctions Main controls (continuation) Warning Error code FMI Error description Remedy light Error 1. Turn off the machine and N004 – MLS Drive 2 (controller): then turn it on again. Missing signal Yellow 2. If the error occurs again: –...
  • Page 351 Malfunctions 8 Main controls (continuation) Warning Error code FMI Error description Remedy light Error 1. Turn off the machine and N004 – MLS Safe A/B (safety controller): then turn it on again. Missing signal Yellow 2. If the error occurs again: –...
  • Page 352 8 Malfunctions Main controls (continuation) Warning Error code FMI Error description Remedy light N004 – ICE_PIO (controller StVZO module): Missing signal Yellow – Both electric motors go via ramp into emergency shutdown N004 – ICE_PIO (controller StVZO module): Error Error description not identifiable Yellow –...
  • Page 353 Malfunctions 8 Insulation monitoring (opt) Warning Error code FMI Error description Remedy light N039: Signal range exceeded or short circuit to positive supply voltage – Machine can continue to be operated Critical error N039: Signal range exceeded or short circuit to 1.
  • Page 354 8 Malfunctions Main contactor Warning Error code FMI Error description Remedy light K117 – Contact battery voltage Critical error Signal is faulty or irregular 1. Unlock motor isolating – Machine goes into emergency shutdown switch K117 – Contact battery voltage 2.
  • Page 355 Malfunctions 8 Operator presence switch Warning Error code FMI Error description Remedy light S104: Signal range exceeded or short circuit to Error Yellow machine ground/sensor ground – Machine travel function is blocked 1. Turn off the machine and then turn it on again. S104: Signal outside of the valid range 519053 Yellow...
  • Page 356 8 Malfunctions Steering system Warn- Error code FMI Error description Remedy light S022 – Switch (steering mode changeover): Signal range exceeded or short circuit to positive Yellow supply voltage – only all-wheel drive possible S022 – Switch (steering mode changeover): 518971 Yellow Signal outside of the valid range...
  • Page 357 Malfunctions 8 Hydraulic motor Warning Error code FMI Error description Remedy light Critical error 1. Turn off the machine and N004: Control error (controller) then turn it on again. 518431 – Machine immediately goes into emergency 2. If the error occurs again: shutdown have the error corrected by an authorized service...
  • Page 358 8 Malfunctions Hydraulic engine (continuation) Warning Error code FMI Error description Remedy light Error 1. Turn off the machine and N004 – Threshold exceeded by far then turn it on again. Yellow – Machine immediately goes into emergency 2. If the error occurs again: shutdown have the error corrected by an authorized service...
  • Page 359 Malfunctions 8 Travel drive Warning Error code FMI Error description Remedy light Critical error 1. Turn off the machine and B042 – Potentiometer (joystick): then turn it on again. Signal 1: Signal is faulty or irregular 2. If the error occurs again: –...
  • Page 360 8 Malfunctions Speed ranges (switch speed ranges) Warning Error code FMI Error description Remedy light S021 – Signal range exceeded or short circuit to Error Yellow positive supply voltage 1. Turn off the machine and – only speed range "turtle" possible then turn it on again.
  • Page 361 Malfunctions 8 Service brake (brake pressure switch) Warning Error code FMI Error description Remedy light S009: Signal range exceeded or short circuit to Error Yellow positive supply voltage 1. Turn off the machine and – Differential lock without function then turn it on again. 518958 S009: Signal outside of the valid range 2.
  • Page 362 8 Malfunctions Parking brake Warning Error code FMI Error description Remedy light S199 – Switch spring-applied brake: Signal is faulty or irregular – Machine travel function is blocked S199 – Switch spring-applied brake: Signal range exceeded or short circuit to positive 518148 supply voltage S199 –...
  • Page 363 Malfunctions 8 Differential lock Warning Error code FMI Error description Remedy light S025 – Push button (joystick): Signal range exceeded or short circuit to positive Yellow supply voltage – Differential lock without function S025 – Push button (joystick): 518972 Yellow Open circuit or short circuit to ground Error –Differential lock without function...
  • Page 364 8 Malfunctions Operating motor Warning Error code FMI Error description Remedy light Critical error 1. Turn off the machine and N004: Control error (controller) then turn it on again. 518441 – Machine immediately goes into emergency 2. If the error occurs again: shutdown have the error corrected by an authorized service...
  • Page 365 Malfunctions 8 Operating engine (continuation) Warning Error code FMI Error description Remedy light N004 – Threshold exceeded by far – Operating engine immediately goes into Yellow emergency shutdown – Drive engine goes via ramp into emergency shutdown N004: Control error (controller) –...
  • Page 366 8 Malfunctions Hydraulic oil temperature monitoring (temperature sensor) Warning Error code FMI Error description Remedy light B007: Signal range exceeded or short circuit to Error machine ground/sensor ground Yellow 1. Turn off the machine and – Gear pump hydraulics only runs at minimum then turn it on again.
  • Page 367 Malfunctions 8 Quickhitch unlocking mechanism Warning Error code FMI Error description Remedy light S040 – Switch release unlocking: Signal range exceeded or short circuit to positive supply voltage – Quick unlocking without function S040 – Switch release unlocking: 518989 Signal outside of the valid range Error –...
  • Page 368 8 Malfunctions 3rd control circuit Warning Error code FMI Error description Remedy light Critical error 1. Turn off the machine and B041 – Potentiometer rocker switch (joystick): then turn it on again. Signal is faulty or irregular 2. If the error occurs again: –...
  • Page 369 Malfunctions 8 3rd control circuit (continuation) Warning Error code FMI Error description Remedy light S032 – Switch operation: Signal range exceeded or short circuit to positive Yellow supply voltage – 3rd control circuit and quick unlocking without function S032 – Switch operation: 518982 Signal outside of the valid range Yellow...
  • Page 370 8 Malfunctions Pressure relief of 3rd control circuit (button) Warning Error code FMI Error description Remedy light S127: Signal range exceeded or short circuit to Error Yellow positive supply voltage 1. Turn off the machine and – Pressure relief without function then turn it on again.
  • Page 371 Malfunctions 8 Load stabilizer Warning Error code FMI Error description Remedy light S044 – Button: Signal range exceeded or short circuit to positive Yellow supply voltage – Load stabilizer without function S044 – Button: 518993 Yellow Signal outside of the valid range –...
  • Page 372 8 Malfunctions Hose burst valve Warning Error code FMI Error description Remedy light Y022 – Bypass valve: Power too low or open wiring Error Yellow – Hose burst re-routing without function 1. Turn off the machine and – Hose burst safety keeps functioning then turn it on again.
  • Page 373 Malfunctions 8 7-pole front power outlet Warning Error code FMI Error description Remedy light S027 – Rocker switch: 518976 Yellow Signal outside of the valid range – Front power outlet without function S067 – Button joystick: Signal range exceeded or short circuit Yellow Error to positive supply voltage...
  • Page 374 8 Malfunctions Immobilizer (continuation) Warning Error code FMI Error description Remedy light N021 – – Relays 1 Status: short circuit (voltage if relays contacts are open) 518082 N021 – – Relays 1 Status: open circuit (no voltage if relays contacts are closed) N021 –...
  • Page 375 Malfunctions 8 Fault indications in the power electronics Safety instructions WARNING Accident hazard due to high electrical voltages! Improper performance of work on the electrical system can result in serious injury or death. ► Maintenance on the electrical system that does not involve HV components (e.g.
  • Page 376 8 Malfunctions Displays There are 7 LED indicator lights in total located under the operator seat on the front side of the control. The indicator lights act as a minimal diagnosis. Designation Area Function 1H10 Indicator display travel drive 1H11 Indicator display hydraulic system Diagnosis indicator fuse box 1 Indicator display control...
  • Page 377 Malfunctions 8 Fuse box 2 (E) Flash code LED H7 (F) Defective fuse 9F14 2F14 9F33 Fig. 268 5F11.2 5F11 5F11.3 5F11.1 8-37 BA 357-00 * 3.0 * 35700_08_Betriebsstörung.fm...
  • Page 378 8 Malfunctions Fault indications in the StVZO module Safety instructions WARNING Accident hazard due to high electrical voltages! Improper performance of work on the electrical system can result in serious injury or death. ► Maintenance on the electrical system that does not involve HV components (e.g.
  • Page 379 Malfunctions 8 Displays There are 2 LED indicator lights in total located under the operator seat on the front side of the StVZO module. The indicator lights act as a minimal diagnosis. Designation LED Function 5H18 Diagnosis indicator fuse box A 5H19 Indicator display control B Burned out or missing fuses are indicated by means of flash codes via the...

  • Page 380: Malfunctions In The Air Conditioning System (Opt)

    8 Malfunctions Malfunctions in the air conditioning system (opt) Only authorized service centers and trained personnel may perform repairs, and fill up and empty the air conditioning system! Malfunctions in Possible causes Remedy the air conditioning system page Malfunctioning or loose fuse Replace fuses 7-64 Interrupted line...
  • Page 381 Malfunctions 8 Malfunctions in Possible causes Remedy the air conditioning system page Interruption of refrigerant line – Loss of refrigerant System leak – Clogged fan duct – Insufficient refrigerating output Refrigerant level too low – Humidity in system – Line interruption, insufficient Contact an authorized service –...
  • Page 382 8 Malfunctions 8-42 BA 357-00 * 3.0 * 35700_08_Betriebsstörung.fm...

  • Page 383: Technical Data

    Technical data Technical data 9 Technical data Information The measurements in the brackets (...) are standard units of US measurement. DIN/EN – American measures Torques 1 Nm (Newton meter) 0.737 ft lb (Foot-pound-force) Pressure 1 bar (Bar) 14.29 psi (Pound per square inch) Speed 1 km/h (Kilometers per hour) 0.62 mph (Miles per hour)

  • Page 384: Models And Trade Names

    9 Technical data Models and trade names Information The letter S or L in the designation indicates the version of the loader unit: • S = standard loader unit • L = extended loader unit Model designation Trade name 357-00S 5055e 357-00L 5055eL...

  • Page 385: Travel Drive/Axles

    Technical data 9 Travel drive/axles Hydraulic motor Designation Product Juli Motorenwerk Type AF 4/7-R1 3-phase alternating current asynchronous Design motor Housing protection IP 54 max. operating voltage / 48 V/226 A current rating 15 kW S 2-60 minn (20.4 hp) Power at 2110 min (maximal 34 kW (46.2 hp))
  • Page 386 9 Technical data Front axle Designation Planetary steering and drive axle, rigid Design screw connection with chassis Traction is evenly distributed to all 4-wheels Differential lock (100 %) by means of the cardan shaft King-pin inclination 7° Camber 1.5° Steering angle Max.

  • Page 387: Brakes

    Technical data 9 Brakes Service brake Designation Design Foot-operated hydrostatic disc brake Location Input shaft – front axle input Effect On both axles via cardan shaft In stand still the motor is regulated so that it Active works against the transmission of external standstill control torques (e.g.

  • Page 388: Tires

    9 Technical data Tires Tire pressure Wheel rims (bar/psi) Tire size Wheel Front Rear Size offset (mm/in) 12.0-18 9x18 NHS 12PR 145A6 A317 (43 psi) (36 psi) (0.15 in) 325/70 R18 MPT 11x18 AC70G TL125G (50 psi) (43 psi) (0.1 in) 365/70 R18 135B/146A2 EM-01 340/80 R 18 550...

  • Page 389: Operating Hydraulics

    Technical data 9 Operating hydraulics Operating motor Designation Product Jungheinrich Type AP4H6-L3 3-phase alternating current Design asynchronous motor Housing protection IP 54 max. operating voltage / 43 V/380 A current rating 22 kW S3-15% (29.9 hp) Power at 2560 min 200 Nm (147.5 ft lb) Max.
  • Page 390 9 Technical data Hydraulic protection on control valve Designation 19 cm³/U  54 l/min Hydraulic pump /U 14.26 gpm) 3000 min (1.16 in Max. operating pressure 235 bar (3408 psi) Tilt cylinder Rod side 260 bar (3715 psi) Secondary protection: Base side 120 bar (1715 psi) Lifting cylinder None on rod side...

  • Page 391: Electrical System

    Technical data 9 Electrical system Battery Type Designation Manufacturer Hoppecke Designation trak \ systemize Rated voltage 80 V 416 Ah / Nominal capacity 40 cell blocks Weight 1240 kg (2734 lb) Operating temperature -15 to +45° (5 to 113 °F) 2, 3 Storage temperature -15 to +45 °C...
  • Page 392 9 Technical data HV components Power electronics Designation Housing protection IP 64 Fan protection IP 55 -10 to +45 °C Operating temperature (14 to 113 °F) -40 to +85 °C Storage temperature (-40 to 185 °F) Weight 12 kg (26.45 lb) Input voltage 80 V DC Max.
  • Page 393 Technical data 9 Fuses Master fuse The master fuse is located on the motor isolating switch. Rated Item Fuse Protected circuit current (A) F001 Main fuse (cabin supply) Fig. 270 Fuse panel The fuse panel is located on the right on the control lever console. Rated Item Fuse...
  • Page 394 9 Technical data Power electronics The fuses are located in both fuse boxes A and B of the power electronics under the covers. Rated cur- Item Fuse Protected circuit rent (A) DC/DC-converter (iCE-PIO) 7F11 – Not assigned Voltage converter (80V/12V) –...
  • Page 395 Technical data 9 Road traffic module The fuses are located in the fuse box under the cover. Rated Item Fuse Protected circuit current (A) 4F6.1 Brake light (left) 5F5.3 Low beam (right) 5F5.1 Low beam (left) 4F6.2 Brake light (right) 4F5.1 Turn indicators (left) Turn indicator (right),...

  • Page 396: Tightening Torques

    9 Technical data Tightening torques General tightening torques Tightening torques Screw dimensions 10.9 12.9 3 Nm (2.2 ft lb) 4 Nm (2.9 ft lb) 5 Nm (3.7 ft lb) 5.5 Nm (4.1 ft lb) 8 Nm (5.9 ft lb) 10 Nm (7.4 ft lb) 10 Nm (7.4 ft lb) 14 Nm (10.3 ft lb) 16 Nm (11.8 ft lb)

  • Page 397: Noise Emissions

    Technical data 9 9.11 Noise emissions Noise level (self-propelled work machine) Outside noise level Machine model Sound power level Measured value 80.9 with cabin Guaranteed value Measured value 80.9 with canopy Guaranteed value Operator-perceived noise level Machine model Sound pressure level (LPA) with cabin Guaranteed value with canopy...
  • Page 398 9 Technical data Noise levels (agricultural and forestry tractors) Applies only to EU member states. Observe and follow the legal regulations of your country. Outside noise level Machine model Sound pressure level (LPA) Stationary 80.9 with cabin Moving Stationary with canopy Moving Operator-perceived noise level Machine model...

  • Page 399: Vibration

    Technical data 9 9.12 Vibration 1, 2 Vibration Overall vibration value for upper < 2.5 (< 8.2 feet/s²) ----- - extremities of the body Maximum effective value < 0.5 (< 1.64 feet/s²) ----- - of weighted acceleration for body Instruct or inform the operator of dangers arising from vibrations Uncertainty of measurements in accordance with the requirements of DIN EN 474-1 and EN 12096 9.13 Weight S = standard...

  • Page 400: Payload/Lift Capacity/Stability

    9 Technical data 9.14 Payload/lift capacity/stability Tilting limit of the vehicle Designation Value Lateral tilting limit 20° Machine with bucket (KRAMER quickhitch) S = standard L = extended Description loader unit loader unit 0.5 / 0.65 0.4 / 0.55 Bucket capacity : m³...
  • Page 401 Technical data 9 Machine with pallet fork (KRAMER quickhitch) Fig. 275 S = standard L = extended Designation loader unit loader unit Payload 1750 kg 1600 kg safety factor 1.25 (A) (3858 lb) (3528 lb) Payload 1310 kg 1200 kg safety factor 1.67 (B) (2889 lb) (2646 lb)
  • Page 402 9 Technical data Machine with pallet fork (EURO quickhitch) S = standard L = extended Designation loader unit loader unit Payload 1750 kg 1600 kg safety factor 1.25 (A) (3858 lb) (3528 lb) Payload 1310 kg 1200 kg safety factor 1.67 (B) (2889 lb) (2646 lb) Movable payload...

  • Page 403: Dimensions

    Technical data 9 9.15 Dimensions Dimensions with KRAMER bucket H I J Fig. 276 S = standard L = extended Dimensions with bucket loader unit loader unit 1, 2 A Overall length 4950 mm (194.9 in) 5140 mm (202.3 in) B Overall width 1650 mm (64.9 in) 3, 4, 5...
  • Page 404 9 Technical data Dimensions with KRAMER pallet forks Fig. 277 S = standard L = extended Dimensions with pallet forks loader unit loader unit 3050 mm 3300 mm 1, 2 Pin height (120.8 in) (129.9 in) 2830 mm 3050 mm 1, 2 Pallet height (111.4 in)
  • Page 405 Technical data 9 Dimensions with SKID-STEER bucket (opt) (currently not available) H I J Fig. 278 Dimensions with bucket S = standard loader unit 1, 2 A Overall length 4950 mm (194.9 in) B Overall width 1650 mm (64.9 in) 3, 4, 5 C Overall height with cabin 2380 mm (93.7 in)
  • Page 406 9 Technical data Dimensions with SKID-STEER pallet forks (opt) (currently not available) Fig. 279 Dimensions with pallet forks S = standard loader unit 3050 mm 1, 2 Pin height (120.8 in) 2830 mm 1, 2 Pallet height (111.4 in) Tilt-in angle in transport position 15 °...
  • Page 407 Technical data 9 Dimensions with EURO pallet forks (opt) Fig. 280 S = standard L = extended Dimensions with bucket (EURO) loader unit loader unit 1, 2 Pin height 3050 mm (120 in) 3300 mm (130 in) 1, 2 Pallet height 2950 mm (116.1 in) 3200 mm (126 in) Tilt-in angle in transport position...
  • Page 408 9 Technical data 9-26 BA 357-00 * 3.0 * 35700_09_Technische_Daten.fm...

  • Page 409: Index Index

    Index Index Index Index Braking system Check the brake fluid ........7-75 Abbreviations ............1-4 Description ............3-7 Accelerator pedal ........... 5-4 Maintenance ............ 7-74 Additional equipment .......... 5-102 Safety instructions ........... 7-74 Adhesive label maintenance plan ......7-12 Technical data ........... 9-5 Adjusting the fork arms of the pallet forks ....
  • Page 410 Index EURO quickhitch Lower the attachment ........5-66 Danger zone ............2-6 Pick up the attachment ........5-65 Declaration of conformity ........EG-1 Explanation of symbols .......... 1-3 Decommissioning final ............... 5-113 longer periods of time ........5-112 Fastening, guiding and removing loads ....2-9 temporarily ............
  • Page 411 Index Hydraulic system 3rd control circuit Labels ..............3-25 Continuous operation ........5-44 Liability ..............1-5 Locking/unlocking ........... 4-51 License ..............3-13 Operation ............5-41 Lift and tilt ram speed ..........9-8 Usable consumer pressure ....... 9-8 Lift capacity ............9-18 Adding hydraulic oil .........
  • Page 412 Index Maintenance ............7-1 Adding hydraulic oil ......... 7-56 Neutral position, travel direction ......5-15 Anti-corrosion protection ......... 7-86 Noise ..............2-23 Attachments ............ 7-80 Noise emissions ........... 9-15 Axles/travel drive ..........7-73 Noise levels ..........9-15, 9-16 Braking system ..........7-74 Change wheels ..........
  • Page 413 Index Overview Attachments ............ 3-18 Rear axle ..............9-4 Control elements ..........4-27 Rear wiper ............5-26 Control lever (joystick) ........5-32 Rearview mirrors ..........4-16 Fluids and lubricants ........7-14 Adjusting the mirrors on the left ...... 4-17 Hydraulic control circuits ......... 5-34 Adjusting the mirrors on the right ....
  • Page 414 Index Adjustment ............4-15 Fastening the seat belt ........4-15 Technical data ............9-1 Safety instructions ........... 4-14 Axles ..............9-3 Setting down ........... 4-15 Battery ............... 9-9 Serial number ............3-27 Coolant ............9-14 Cabin number ..........3-27 Counter shaft ............. 9-3 Front and rear axles ........
  • Page 415 Index Travel drive High-voltage system ........3-30 Components ............3-4 No lifting eyes for machine loading ....3-31 Description ............3-5 No naked flames ..........3-32 Maintenance ........... 7-73 No passengers ..........3-31 Technical data ........... 9-3 No transport of persons ........3-31 Travel speed ............
  • Page 416 Index BA 357-00 * 3.0 * BA_35700_V3_enSIX.fm...
  • Page 417 Index BA 357-00 * 3.0 * BA_35700_V3_enSIX.fm...
  • Page 418 Index S-10 BA 357-00 * 3.0 * BA_35700_V3_enSIX.fm...
  • Page 419 KRAMER-WERKE GmbH keep abreast of the latest technical developments and constantly improve their products. For this reason, we may from time to time need to make changes to figures and descriptions in this documentation that do not reflect products that have already been delivered and that will not be implemented on these vehicles.
  • Page 420 Kramer-Werke GmbH Wacker-Neuson-Str. 1 D-88630 Pfullendorf Phone +49 7552 9288-0 E-mail info@kramer.de www.kramer.de Order no. 1000363191 Language [en]...

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