Kramer 5035 - Maintenance Label

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BA 348-01 * 2.0 * 34801b511.fm 5-41

Maintenance 5

5.21 Maintenance label

Affixed on the loader unit bulkhead

10 h

Täglich

Daily

Tous les jours

50 h

Main Page

Table of Contents3
Declaration of Conformity11
EC Declaration of Conformity12
Introduction13
General Information on the Operator's Manual13
Explanation of Warning Symbols13
Explanations, Abbreviations and Symbols14
Notice on Machine Safety15
Handling the Machine15
Warranty and Liability15
Maintenance, Repair Work, Spare Parts16
Brief Description of the Wheel Loader17
Models and Trade Names17
Use17
Machine Licensing17
Permissible Operating Temperature Range17
Main Components of Wheel Loader18
Hydrostatic Drive18
Operating Hydraulics and 4 Wheel Steering18
Cooling System18
Machine Overview19
Legal Regulations Regarding Wheel Loader Operation20
Principal Regulations for the Operating Personnel20
Driving Licence21
Licence/Identification22
Machine Inspections22
Documents23
On-Board Equipment23
Machine Warning Identification (Option)23
Fields of Application and Using the Wheel Loader with an Attachment24
General Notice on Using the Wheel Loader24
Fitting Attachments Onto the Machine24
Certified Attachments25
Type Labels and Component Numbers26
Explanation of "Book" Symbol26
Serial Number and Type Label26
Cabin Number27
Engine Number28
Variable Displacement Pump Number28
Wheel Motor Number28
Labels and Symbols29
Labels on the Outside of the Machine29
Labels Inside the Cabin32
Labels in the Engine Compartment34
Safety Instructions35
Identification of Warnings and Dangers35
Designated Use and Exemption from Liability36
General Conduct and Safety Instructions37
Organizational Measures37
Selection and Qualification of Personnel, Basic Responsibilities39
Safety Instructions Regarding Operation40
Normal Operation40
Applications with Lifting Gear42
Trailers and Attachments43
Transporting, Towing, Loading43
Safety Instructions for Maintenance44
Maintenance on Protective ROPS and FOPS Structures46
Cabin, Roll-Over Bar, Protective Screen46
Warning of Special Hazards46
Electrical Energy46
Gas, Dust, Steam, Smoke46
Hydraulic System47
Noise47
Oil, Grease and Other Chemical Substances47
Battery47
Tyres47
Operation49
Description of Control Elements49
Inside of Cabin (Overview)50
Instrument Panel, Multifunctional Lever and Drive Lever (Overview)52
Overview: Control Console on the Right53
Functional Description: Indicator Lights54
Indicator Light Check54
Indicator Lights and Warning Lights: Description54
Important Notices before Putting the Machine into Operation57
Operating Personnel57
Running-In Period58
Check Lists59
Starting Checklist59
Operation Checklist60
Parking" Checklist60
Cabin61
Important Safety Instructions61
Locking/Unlocking the Door (Left)62
Locking and Unlocking the Cabin Window on the Right/Left62
Opening the Right/Left-Hand Window to a Gap62
Fully Opening the Side Window63
Locking and Unlocking an Open Side Window63
Side Window Emergency Exit64
Using the Emergency Exit64
Operator Seat65
Important Information65
Seat Adjustment (Overview)66
Weight Adjustment67
Horizontal Adjustment67
Backrest Adjustment67
Operator Seat with Air Suspension68
Important Information68
Weight Adjustment (Air Suspension)68
Horizontal Adjustment (Air Suspension)69
Backrest Adjustment (Air Suspension)69
Backrest Extension (Air Suspension)70
Lumbar Support (Option)70
Heated Seat (Option)70
Seat Belt (Lap Belt)71
Notices on the Seat Belt71
Fastening the Seat Belt71
Unfastening the Seat Belt72
Longer/Shorter Seat Belt Adjustment72
Opening/Closing the Engine Cover73
Battery Master Switch (Option)73
Interrupting Power Supply73
Switching on Power Supply73
Location of Fire Extinguisher (Option)73
Fire Extinguisher Operation73
Key-Based Drive Interlock (Option)74
Key-Based Drive Interlock: Scope of Delivery74
Coding ("Training") New Ignition Keys74
Enabling (Locking) the Drive Interlock75
Disabling (Releasing) the Drive Interlock75
Deleting Coded Keys75
Safety Functions76
Drive Interlock with Code Input (Option)77
Keypad for Entering Codes (Overview)77
Entering/Changing the Personal Code78
Enabling the Drive Interlock78
Disabling the Drive Interlock79
Putting the Drive Interlock out of Operation80
Putting the Drive Interlock Back into Operation Again80
Interruption of Drive Interlock Power80
Drive Interlock Maintenance80
Oil and Fuel Preheater (Option)81
Oil Preheater Operation81
Fuel Preheater Operation81
Putting the Diesel Engine into Operation82
Notices on Preparing to Start the Engine82
Preparing to Start the Engine83
Notices on Starting the Engine83
Starting the Engine84
Avoiding Running the Engine under Low-Load Conditions85
Stopping the Engine85
Jump-Starting the Engine (External Battery)86
Safety Instructions Regarding External Starting Aids86
Providing External Starting Aid86
Preparatory Work - Putting the Machine into Operation87
Notices on Putting into Operation87
Preparing for Driving on Public Roads88
Functional Check of All Control Elements89
Transport Position of Attachments on Public Roads89
Lock for Loader Unit Control Lever and Mechanical Locking of 3Rd Control Circuit (Standard)90
Lock for Loader Unit Control Lever and Electrical Lock for 3Rd Control Circuit Lever (Option)91
Steering System92
Checking the Steering System92
Wheel Synchronization93
Accelerator Pedal93
Speed Control with the Accelerator Pedal93
Manual Throttle (Option)94
Actuating the Manual Throttle94
Low-Speed Control (Option)95
Setting the Travel Speed with the Low-Speed Control95
Brake/Inching Pedal96
Specific Notices on Brake/Inching Pedal Operation96
Inching with the Brake/Inching Pedal97
Braking with the Brake/Inching Pedal97
Parking Brake98
Notice on the Parking Brake98
Applying the Parking Brake98
Putting the Machine into Operation99
Selecting a Travel Direction and Starting Machine Travel99
Changing Direction (Forward/Reverse)99
Stopping/Parking the Machine100
Load Stabilizer (Option)101
Notices on the Load Stabilizer Function101
Switching the Load Stabilizer on and off102
Front/Rear Socket (Option)103
Continuous Operation of Front Socket103
Brief Operation of Front Socket103
Backup Warning System (Option)104
Notice on the Backup Warning System104
Differential Lock (Option)104
Switching the Differential Lock on or off104
Machine Lights (Option)105
Machine Lights Operation105
Working Lights106
Working Lights Operation106
Signalling System107
Turn Indicator Operation (Option)107
Horn Operation107
Hazard Warning System Operation107
Rotating Beacon (Option)108
Rotating Beacon Operation108
Rear Window Heating (Option)108
Cabin Heating and Ventilation109
Operation of the Heating and Ventilation System109
Washer System (Option)110
Front Wiper Operation110
Front/Rear Washer Pump Operation110
Rear Washer System Operation110
Washer System Reservoir111
Loader Unit Control Lever (Overview)112
Control Lever (Joystick) for Lift and Tilt Rams112
Operating and Securing the 3Rd Control Circuit (Standard)113
Operation of 3Rd Control Circuit (Standard)113
Control Lever for 3Rd Control Circuit in Continuous Operation114
Electrical Operation and Locking of 3Rd Control Circuit (Option)115
Important Safety Instructions115
Operation of 3Rd Control Circuit (Electrical, Option)116
Operation of Attachments with Hydraulic Functions117
Continuous Operation of 3Rd Control Circuit and Additional Control Circuit117
Attachments by Other Manufacturers on SKID STEER Quickhitch (Option)118
Emergency Lowering of the Loader Unit with the Engine Stopped119
Lowering or Raising119
Pressure Relief on the Quick Couplers and the Quickhitch120
Equipping the Machine with a Standard Bucket121
Field of Application and Use of Bucket121
Checking the Mounting Bore of the Attachment121
Fitting a Standard Bucket Onto the Quickhitch122
Removing a Standard Bucket from the Quickhitch123
Working with the Standard Bucket124
Safety Instructions on Work Operation124
Travelling with a Standard Bucket During Work Operation125
Safety Instructions Regarding Work with a Full Standard Bucket126
Practical Hints for Digging127
Loading Loose Material127
Loading if the Material Is Hard to Penetrate128
Removing Material/Digging in Soft Soil129
Removing Material/Digging in Hard Soil130
Grading130
Loading Heaped Material (Non-Compacted Material)130
Loading Heaped Material (Compacted Material)131
Practical Hints for Loading Vehicles131
Freeing the Machine131
Installing a Multipurpose Bucket and Hydraulic Attachments132
Fields of Application for Multipurpose Bucket132
Installing a Multipurpose Bucket132
Connecting Hydraulic Lines to the Wheel Loader133
Checking the Function of the Multipurpose Bucket134
Setting down the Multipurpose Bucket135
Working with the Multipurpose Bucket136
Safety Instructions on Work Operation136
Travelling with a Multipurpose Bucket During Work Operation137
Safety Instructions Regarding Work with a Full Multipurpose Bucket138
Practical Hints for Digging139
Grading and Scraping139
Stripping in Thin Layers (Scraper)140
Spreading Material in Thin Layers140
Pulling out Material from Slopes140
Moving Material with Longer Reach141
Picking up Remaining Material Completely141
Grabbing Bulky Material or Large Objects142
Pulling out and Setting Posts142
Backfilling Round Gravel and Precise Unloading143
Unloading from the Bottom of the Bucket for Increased Tilt-Out Heights143
Fitting Pallet Forks144
Fields of Application for Pallet Forks144
Picking up Pallet Forks with the Quickhitch144
Machine Travel on Public Roads with the Pallet Forks145
Removing the Pallet Forks from the Quickhitch145
Adjusting the Fork Arms146
Working with the Pallet Forks147
General Safety Instructions Regarding the Pallet Forks147
Specific Safety Instructions149
Brief Instructions for Fork Arms150
Safety Instructions Regarding Work with Pallet Forks151
Load Diagram for Pallet Forks152
Picking up Loads with the Pallet Forks153
Transporting Loads with the Pallet Forks154
Working with an Attachment Adapter (Option)155
Installing and Removing an Attachment Adapter155
Using an Attachment Adapter with an Attachment from Another Manufacturer155
Additional Front/Rear Control Circuit (Option)156
Overview of Quick Couplers 40 L/Min (40 - 60 L/Min)156
Operation of Additional Control Circuit157
Hose Burst Valve Safety Feature (Option)158
Important Information on the Hose Burst Valve158
Trailer Couplings (Option)159
Important Information on Trailer Operation159
Description of Automatic Trailer Coupling160
Coupling the Trailer Onto the Machine160
Uncoupling the Trailer from the Machine161
Ball Coupling (Option)161
Towing and Transporting the Machine162
Safety Instructions for Towing Away162
Getting Ready for Towing163
Towing the Machine164
Once Towing Is over164
Crane-Lifting the Machine165
Safety Instructions Regarding Crane-Lifting165
Crane-Lifting the Machine166
Loading and Transporting the Machine on a Transport Vehicle167
Safety Instructions Regarding Loading on a Transport Vehicle167
Loading and Tying down the Machine168
Putting the Machine out of Operation Temporarily169
Stopping/Parking the Machine169
Putting the Machine out of Operation for Longer Time169
Putting the Machine out of Operation Permanently170
Notice on Decommissioning170
Preparing Disposal170
Disposal170
Troubleshooting171
Engine Malfunctions171
Maintenance173
Notice on Maintenance and Servicing173
Maintenance Personnel173
Important Information on Maintenance174
Fuel System175
Specific Safety Instructions Regarding Refuelling175
Diesel Fuel Specification175
Refuelling175
Stationary Fuel Pumps176
Bleeding the Fuel System176
Checking/Cleaning the Water Separator176
Engine Lubrication System177
Checking the Engine Oil Level177
Adding Engine Oil178
Engine and Hydraulics Cooling System179
Specific Information on Cooling System Maintenance179
General Checks and Cleaning Work179
Cleaning the Radiator Fins of the Oil/Water Radiator180
Checking the Coolant Level/Filling up Coolant181
Air Filter182
Checking the Air Filter for Dirt182
Replacing the Air Filter Cartridge183
V-Belt184
Checking the V-Belt184
Retightening the V-Belt184
Hydraulic System185
Specific Safety Instructions Regarding the Hydraulic System185
Monitoring the Hydraulic Oil and the Return Filter186
Important Information on the Use of Biodegradable Oil187
Checking the Hydraulic Oil188
Adding Hydraulic Oil188
Checking Hydraulic Pressure Lines189
Specific Safety Instructions Regarding Pressure Line Checks189
Lubrication Work on the Axles190
Lubricating the Rear Axle Oscillation-Type Bearing190
Lubricating the Wheel Motor Bearings (Front/Rear Axles)190
Lubrication Work on the Loader Unit191
Loader Unit Lubrication Points191
Maintenance of the Braking System193
Specific Safety Instructions Regarding the Braking System193
General Notice on the Service Brake193
General Instructions Regarding the Parking Brake193
Tyres194
Daily Tyre Checks194
Changing Wheels195
Heating and Ventilation System Maintenance196
Important Notice on the Heating and Ventilation System196
Cleaning/Replacing the Fine-Dust Filter (up to Date of Construction 42/2013)196
Cleaning/Replacing the Fine-Dust Filter (from Date of Construction 43/2013)197
Maintenance of the Electrical System198
Important Information198
Safety Instructions Regarding the Electrical System and the Battery198
Checking/Replacing the Battery199
Replacing the Battery200
Inspections and Maintenance on the Electrical System at Regular Intervals201
Checking/Replacing Relays and Fuses201
Checking/Replacing the Main Fuse Box and the Switching Relays202
Checking the Alternator202
Servicing and Maintenance203
Important Safety Instructions Regarding Cleaning Work203
Cleaning Inside the Cabin204
Cleaning the Pedals204
Cleaning the Door Locks and Arresters205
Cleaning the Seat Belt205
Cleaning the Exterior of the Machine205
Cleaning the Engine Compartment206
Checking Threaded Fittings206
Checking Pivots and Hinges206
Maintenance and Servicing of the Attachments206
Maintenance of the Automatic Trailer Coupling (Option)207
Cleaning and Lubricating the Trailer Coupling207
Check the Trailer Coupling for Wear207
Maintenance "Aggressive Media" (Option)208
Anticorrosion Protection Applied in the Factory208
Components Coated with Anticorrosive Wax208
Measures for Maintaining Anticorrosive Protection209
Applying the Protective Anticorrosion Coating210
Treatment of Oxidized Surfaces210
Fluids and Lubricants211
Explanation of Symbols on the Maintenance Label212
Maintenance Label213
Maintenance Plan214
Important Information on the Maintenance Plan214
Maintenance Plan Overview214
Technical Data217
Models and Trade Names (Overview)217
Frame217
Engine217
Travelling Drive218
Variable Displacement Pump218
Front/Rear Axle219
Front Axle219
Wheel Motors219
Brakes220
Service Brake220
Parking Brake220
Steering System220
Operating Hydraulics221
Hydraulic Pump, Control Valve, Hydraulic Oil Reservoir221
Lift and Tilt Rams221
Lift and Tilt Ram Speed222
Usable Consumer Pressure at 3Rd Control Circuit222
Usable Consumer Pressure at Additional Control Circuit (Option)222
Electrical System223
Electric Units223
Fuse Assignment Overview223
Main Fuse Box with Relays224
Relays (Overview)224
Tyres225
Weights225
Noise Levels226
Vibrations, Oscillation and Acceleration Value226
Coolant Compound Table226
Tightening Torques227
General Tightening Torques227
Specific Tightening Torques227
Payloads228
Loader Unit with Bucket228
Payload with Pallet Forks228
Trailer Weight/Drawbar Load: Trailer Couplings (Option)229
Dimensions with Bucket230
Index233

Kramer 5035 - Maintenance Label

Table of Contents

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