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GHH Fahrzeuge GmbH

1LF-9.30-en12.10

Operating Instructions

Load Haul Dumper LF - 9.3Vehicle No: 3168/9

GHH Fahrzeuge GmbH

1 - 1LF-9.31_en12.10

1 Contents “Introduction“

1.1 How to use the operating instructions 1.1 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Record of revisions 1.1 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Preface 1.2 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 Warranty Conditions for Mining and Tunnelling Vehicles,

Airport Equipment 1.3 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 Vehicle identification 1.4 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nameplates 1.4 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 Technical Data 1.5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main dimensions 1.5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Weights 1.5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tramming capacities 1.5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine 1.5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Travel drive unit 1.5 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wheels and tires 1.5 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brakes 1.5 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering 1.5 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic system 1.5 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering hydraulic system 1.5 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical equipment 1.5 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lighting system 1.5 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filling volumes 1.5 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dimensions of vehicle 1.5 - 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sound-pressure level 1.5 - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Concise description of vehicle 1.6 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Proper use of LF-type loaders powered by diesel engines/electric motors 1.6 - 2. . .

GHH Fahrzeuge GmbH

1.1 - 1LF-9.3030000_en12.10

1.1 How to use the operating instructions

Sections

The operating instructions comprise four sections.

1 = Introduction

2 = Operation

3 = Maintenance

4 = System drawings

Subsections

Sections 1 to 3 are divided into the necessary chapters.

A table of contents is provided at the beginning of every main section.

Pages

The pages of each subsection are numbered.

Example: 2. 4 -- 1

Page

Subsection

Section-“Operation“

GHH Fahrzeuge GmbH

1.1 - 2LF-9.3030011_en12.10

Page numbers

Each page has the number of the main section/chapter and a page number printed in the bottom line ofthe page. Each chapter begins with page number “1”. The individual pages of the respective chapter areconsecutively numbered.

Code numberr / Issue date

The code number indicated in the left-hand corner at the bottom of each page is used for internal identifica-tion. It may be ignored by the user of the operating instructions.The issue date (month + year) is indicated under the code number.

CAUTION, Warning, Note

Caution The word “Caution“ is used to draw attention to methods, prosedures or thresholdswhich must be carefully observed in order to avoid injury to persons.

Warning The word “Warning“ draws attention to methods and procedures that must be adheredto in order to avoid damage to the equipment.

Note The word “Note“ draws attention to particular technical matters which the driver mustobserve and which also simplify the work.

Illustrations

The illustrations used in the operating instructions serve to explain the text. While they may vary from theactual vehicle design, they will not basically change the factual information.

Patent, trademarks

The information included in these operating instructions is published regard less of any patent rights.

Trademarks are used without any warranty that they may be used freely.

Liability

The tets and illustrations were compiled with great care. Nevertheless, errors cannot be excluded comple-tely. GHH Fahrzeuge GmbH and the authors cannot either assume any legal responsibility or any liabilityfor information and the consequences thereaf.

Please contact our Service Department if you have technical queries or if you notice any discrepancies.

The contents of these operating instructions are regularly revised to include technical innovations. Wereserve the right of technical changes due to ongoing development without prior notice.

Copyright

Reproduction in any form or translation and storage on electronic media is not permitted without prior writ-ten consent by GHH Fahrzeuge GmbH. This also applies to extracts. All rights under copyright laws arespecifically reserved by GHH Fahrzeuge GmbH.

GHH Fahrzeuge GmbH

1.1 - 3LF-9.3032150_en12.10

Record of revisions

All revisions issued are listed in this table. Each revision is numbered consecutively together with the dateof issue. The date and the name of the person who inserted the sheets in this manual are also shown inthe table.

Rev.No.

RevisionDate

DateInserted

Name Rev.No.

RevisionDate

DateInserted

Name

Vehicle no. 3168/9

GHH Fahrzeuge GmbH

1.2 - 1LF-9.3030020_en12.10

1.2 Preface

These operating instructions include important information on how to operate and keep your vehicle madeby

GHH Fahrzeuge GmbH

in working order.

One copy each of the instructions should at all times be available to both the driver and the maintenancepersonnel. Each operation carried out on the vehicle presupposes that the contents of the operating in-structions are known and strictly adhered to.

Therefore, please read these instructions carefully and familiarize yourself with the vehicle, in particularbefore putting the vehicle into operation for the first time.

Proper operation and maintenance make for lasting operational reliability.

Any downtimes which are due to avoidable maintenance work can be minimized if special attention is paidto the following:

- Never alter without approval any parameters which are either permanently set or specified by the ma-nufacturer, such as hydraulic pressures, tightening torques, etc.

- Perform all specified maintenance and inspection work completely and in good time.

- Use only oil brands and grease types which are in compliance with our recommendations.

- Install only original-spare parts.

Should you have any trouble or questions, or if you wish to order spare parts, please contact:

GHH Fahrzeuge GmbH

Abteilung S

Postfach 10 09 43

D--45809 Gelsenkirchen

Telephone: +49(0)209 38907 300

Telefax: +49(0)209 38907 302

or the representative responsible for your area.

Please state the vehicle type and serial number in all written queries or phone calls.

When making out spare parts orders, please adhere to the ordering instructions included in the spare partslist.

Never have repairs or alterations carried out by third parties without our approval. You will appreciate thatwe cannot be held responsible in any case of non-compliance with the above.

Note Please note our “Warranty Conditions” for Mining and Tunnelling Vehicles, AirportEquipment.

GHH Fahrzeuge GmbH

1.3 - 1LF-9.3S 0152_en12.10

1.3 Warranty Conditions for Miningand Tunnelling Vehicles,Airport Equipment

1. We warrant our supplies to the extent that we shall, at ouroption, either repair or resupply ex works any part for whichproof can be furnished that it has become unserviceableduring the warranty period due to our fault in design, mate-rial selection or workmanship.

Similarily, we accept liability for properties explicitly guaran-teed.

In respect on bought-out items used by us in the manu-facture, our liability shall be limited to assigning our war-ranty claims on the supplier.

Of the costs involved directly in repairs and/or replacementsupplies - provided, Purchaser's claim proves justified - thecost of repair and/or of the replacement part shall be to ouraccount.

All other costs shall be to Purchaser's account, amongthem, costs for transportation, dismantling/installation andfor furnishing technicians/helpers possibly required.

Parts which are replaced shall become our property.

2. The existence of a defect shall be reported to us in writingimmediately on discovery. Correction of a defect shall beconditional upon Purchaser's complying with his contractualobligations, especially observing the payment conditionsagreed.

3. Where in cases of emergency Purchaser remedies defects(repair and replacement supply) for which proof can befurnished that we are at fault, or has such defects re-medied by others, after having obtained our consent to doso, we shall reimburse the costs, however, not exceedingthe amount that we would have incurred if the defects wouldhave been remedied by ourselves.

4. The warranty period starts on the date the subject of supplyis ready for handing over to Purchaser. For the subject ofsupply (complete vehicles, spares, i.e. single parts or com-plete components such as transmissions, axles, convert-ers, pumps, compressors) the warranty period shall end2000 working hours or 360 days after commissioning,whichever occurs first. The warranty period shall expire inall cases not later than 420 days after readiness for handingover to Purchaser.

Where second-hand vehicles and complete rebuilt compo-nents are concerned the above warranty periods shall behalved.

5. The number of hours a vehicle has been in service is thatrecorded on the operation-hour meter installed in thevehicle for this specific purpose. The date on which the2000th or 1000th service hour is clocked up on the meter isto be intimated to us in writing without delay. Likewise, anyfailure or trouble with the meter is to be reported to usimmediately.

6. For repair work, including replacements, the warrantyperiod shall start on the date of completion of the work andshall end upon expiry of 180 days or 1000 service hours,whichever occurs first. The warranty period, however, shallnot end before expiry of the original warranty period for thesubject of supply.

7. Defects due to natural wear and tear arising on- V-belts- Hydraulic, brake and fuel hoses- Brake liners- Dynamically stressed seals- Protective circuit breakers- Articulations (collars and bolts)- Batteries as well as- Tires etc.

furthermore, defects due to- Use for purposes other than intended- Non-observance of our operating and maintenanceinstructions

- Incorrect storage- Faulty installation and/or putting into operation- Excessive stress or strain- Use of unsuitable operating media

are not covered by the subject warranty.

8. The warranty shall cease to be valid if during the warrantyperiod the Purchaser undertakes modifications or repairs tothe supplied equipment without our prior consent and/or ifno GHH Fahrzeuge GmbH original spare parts are used.

9. Unless contrary arrangements are made, we give theabove vehicle warranty only on condition that commission-ing is carried out by our personnel.

10. The Purchaser has the right of cancellation of contract,providedthe defects of our equipment supplied being provably ofsuch grave nature that, because of its restricted serviceabil-ity, the equipment is of no use, andafter unsuccessful repair and/or replacement supply, hehas granted us in writing a reasonable additional period oftime for repair of defects for which we are responsible andwe have provably failed to remedy the defect within thisadditional period of time granted.

In all other respects Purchaser shall be entitled to claimonly a reasonable reduction of purchase price.

11. In addition to the above, Purchaser shall not be entitled toraise any further claims for damages under the warrantyclause, especially not for indirect damage, with indirectdamage referring to all such damage which does not occuron the acutal part supplied, especially lost profit, loss of useand extra cost for use.

This exclusion shall not apply in the event of intention orgross negligence on the part of bodies or managerial staff,especially not in the event of fraudulent concealment of adefect.

Any liability beyond this warranty clause shall be subject toArticle XIII of our General Conditions of Sale (AL 91),unless different terms have been accepted in writing

GHH Fahrzeuge GmbH

1.4 - 1LF-9.3030031_en12.10

1.4 Vehicle identification

For the specific data of your vehicle please see of the nameplates shown below.

Nameplates

The vehicle nameplate is located in the driver's compartment. All equipment such as engine, torque con-verter, transmission, axles, etc. have nameplates and may bear stamped equipment numbers.

GHH Fahrzeuge GmbH

Emscherstr. 53D --45891 Gelsenkirchen

Vehicle type

Serial no

Weight, empty

Year of construction

Rated power

Payloadkg

kW

kg

Please record here VEHICLE NO: ..................... and ENGINE NO: ....................of your vehicle.

The tire pressure plate indicates the tire type and the relevant pressure of the tires on the respective axles.

bar

bar bar

bar

Type

Please note here Tire pressure drive unit: bar for tire type: ....................... . . . . . . . . . . . . .

Tire pressure payload unit: bar for tire type: ....................... . . . . . . . . . .

of your vehicle.

GHH Fahrzeuge GmbH

1.5 - 1LF-9.3Techdat_en12.10

1.5 Technical Data

Main dimensions

Length 9 450 mmWidth, at the driver's cab 2 625 mmWidth, at the bucket 2 300 mmHeight, at the drive unit 1 790 mm(above driver`s canopy) 2 350 mmBucket capacity (SAE, heaped) 4.5 m3

Weights

Deadweight 24 500 kgPayload 9 500 kgFront-axle load, unladen 11 600 kgRear-axle load, unladen 12 800 kgFront-axle load, laden 26 300 kgRear-axle load, laden 7 700 kg

Tramming capacities

Maximum tramming speed

laden forward / reverse, on a level roadway1st gear 4.0 km/h2nd gear 8.2 km/h3rd gear 15.4 km/h4th gear 25.0 km/hMximum admissible gradient 25.0 %Maximum tractive force 227 kN

Engine

Manufacturer DEUTZType F10L413FWDesign air-cooled diesel engine two-stage

combustionMax. power 170 kW/2300 min-1

Reduced power 158 kWAir intake system Dry air filterExhaust system Silencer/Fume diluterStarter power/voltage 6.6 kW/24 VThree-phase alternator/voltage 28 V/55 A

GHH Fahrzeuge GmbH

1.5 - 2LF-9.3Techdat_en12.10

Travel drive unit

Torque converterManufacturer ClarkType series C8000Design single-stage industrial type with auxi-

liary drives for steering and dump/hoisthydraulic systems and lock up

Power shift transmissionManufacturer ClarkType series 32 000Design power shift transmission with 4 forward

and 4 reverse gears each

Axles

Front axleManufacturer ClarkType 19 D 2748 (Posi-Stop)Design rigid planetary axles with differential

gear

Rear axle

Manufacturer ClarkType 19 D 2748 (Posi-Stop)Design rigid planetary axles with differential

gearSwing angle ± 10°

Wheels and tires

Front wheels

RimSize 13.00 - 25/2,5

Tires

Size 18.00-25Tire filling pressure 6.0 ± 0.1 bar

Rear wheels

RimSize 13.00 - 25/2,5

Tires

Size 18.00-25Tire filling pressure 3.5 ± 0.1 bar

GHH Fahrzeuge GmbH

1.5 - 3LF-9.3Techdat_en12.10

Brakes

Design of brake system Wet dual-piston multi-disc brake(WMB) in the axle ends, with integratedparking brake (combined brake)

Service brake

Design Wet multi-disc brake, externally cooled,hydraulically actuated

Parking brake

Design Spring-actuated multi-disk brake,externally cooled, hydraulically relea-sed

Steering

Design swivel-joint hydraulic power steeringSteering angle ± 40°Outer clearance circle 6 660 ± 250 mmInner clearance circle 3 390 ± 250 mm

Hydraulic system

Dump/hoist hydraulic systemPump delivery flowrate 83.6+20.9 cm3/USystem pressure 230 barNumber of hoist cylinder 2Number of dump cylinder 1Boom raising 5.9 sec.Bucket raising, from dumping position 5.5 sec.

Steering hydraulic system

Pump delivery flowrate 83.6+20.9 cm3/USystem pressure 175 barNumber of steering cylinder 2

Electrical equipment

Operating voltage 24VBattery 2 x 12 V/155 Ah

Lighting system

Main/reversing headlights 75/70WAdditional headlights 70W

GHH Fahrzeuge GmbH

1.5 - 4LF-9.3Techdat_en12.10

Filling volumes

Hydraulic tank 390 lFuel tank 320 lEngine with oil filter appr. 31.5 lTorque converter/power shift transmission circuit appr. 36.0 lFront axle differential gear 28 lFront axle planetary gear 2 x 6.0 lRear axle differential gear 26 lRear axle planetary gear 2 x 6.0 l

GHH Fahrzeuge GmbH

1.5 - 5LF-9.3Techdat_en12.10

Dimensions of vehicle

2950 3360 3055

9365

2370

1810

1610 20

50

4615

4930

2450

1375

Spu

r192

0

GHH Fahrzeuge GmbH

1.5 - 6LF-9.3Schall_en12.10

Sound-pressure levelTo determine the sound-pressure level the vehicle is placed outdoors on a reflecting base. The sound-pressure level is measured in accordance with DIN 45636 under the following conditions. The indicatedmeasurement values are the average values from three sound measurements.

Note No reflecting objects must be present on either side of the vehicle.

Measuring points - Diagram

1

2

3

4

5

6

78

Measuring distance

- Measuring points 1-5lateral distance to vehicle = 2.0 mmeasuring point height = upper edge of drive unit

- Measuring point 6measuring point height = height of drivers head

- Measuring points 7 and 8measuring point height = 2 m obove upper edge of drive unit

Operating state- service brake actuated- highest reverse gear engaged- for 30 seconds, driving engine at full load and dump/hoist hydraulic against the stop.

Measurement result

Measuring point 1 2 3 4 5 6 7 8

db (A) 89 92 95 79 84 91 86 89

GHH Fahrzeuge GmbH

1.6 - 1LF-9.3030150_en12.10

1.6 Concise description of vehicle

The Fahrlader is a vehicle with swivel-joint steering and hydrodynamic drivesystem, consistingof thedriveunit and payload unit.

The drive unit houses the drive system components, engine, converter, transmission, as well as the oilcooler, tanks, hydraulic system components, brakes and the electrical equipment.

The driven axles are designed as rigid axles with differential gear and planetary gears in the axle ends.

The driver's cabin with its controls and instruments is arranged on the left-hand side of the vehicle, trans-verse to the tramming direction. The driver's seat is sprung and hydraulically cushioned.

The vehicle is steered by a hydraulic power steering system with one or two double-acting steering cylin-ders.

The service brake and the parking brake acts on all four wheels. It is designed as a two-circuit brake sy-stem with separate circuits for the front and rear axles. The parking brake is a spring-loaded brake whichoperates independently of the service brake.

The bucket and boom are linked to the payload unit. The bucket is tilted forward and backward by hydrauli-cally operated dump/hoist cylinders. Control levers in the driver's cabin operate the boom and bucket.

The vehicle chassis is of welded construction, manufactured according to the applicable DIN standardsand the German Federal Railways' DS 952 Code.

GHH Fahrzeuge GmbH

1.6 - 2LF-9.3032140_en12.10

Proper use of LF-type loaders powered by diesel engines/electric motors

LF-type loaders made by GHH Fahrzeuge GmbH which are powered either by a diesel engine or electricmotor are suitable for underground loading, hauling and dumping of minerals in non explosion-hazardousareas and in areas where no risk of mine gas formation exists. Proper use means that the loaders areoperated exclusively within specially identified and demarcated areas of work, as well as in areas not ac-cessible to unauthorised staff. Loaders must be operated only by specially trained and instructed staff.The notes and technical data contained in the operating and maintenance instructions form the basis forsafe operation of the loader and are part of the description for proper use of the loaders. For applicationsother than those listed above and in the operating and maintenance instructions, the loading and operatinglimits will in individual cases need to be agreed with the manufacturer and confirmed by him in writing.

GHH Fahrzeuge GmbH

2 - 1LF-9.32_en12.10

2 Contents “Operation“

2.1 Safety instructions for the operation of vehicles made 2.1 - 1. . . . . . . . . . . . . . . . . . . .by GHH Fahrzeuge GmbHSafety marking (Sicherheitsbeschilderung) drawing 909-4-056556. . . . . . . . . . . . . . . . . . . .Functional marking (Funktionsbeschiledrung) drawing 909-4-056557. . . . . . . . . . . . . . . .

2.2 Driver`s seat 2.2 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjustment 2.2 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Driver's cab, operating elements and control instruments 2.3 - 1. . . . . . . . . . . . . . . . .Changing steering direction 2.3 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control instruments 2.3 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Checks 2.4 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 Engine starting, engine switch-off 2.5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starting 2.5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .external starter socket 2.5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine switch-off 2.5 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 Tramming operation 2.6 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start-up 2.6 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing the tramming direction. 2.6 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing steering direction 2.6 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hints on the torque converter and power transmission 2.6 - 2. . . . . . . . . . . . . . . . . . .Tramming on downhill slopes 2.6 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Downhill driving in converter mode 2.6 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Towing the vehicle 2.6 - 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 Dump/hoist operation 2.7 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control of dump/hoist equipment 2.7 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bucket filling 2.7 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bucket filling (floating position) 2.7 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Emptying the bucket 2.7 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8 Winter operation 2.8 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine 2.8 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cooling system 2.8 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air intake system 2.8 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel system 2.8 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Axle gear 2.8 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic system 2.8 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical system 2.8 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9 Shutdown of vehicle 2.9 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shut-off of vehicle 2.9 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shutdown of vehicle 2.9 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Putting vehicle back in operation after shutdown 2.9 - 2. . . . . . . . . . . . . . . . . . . . . . . .

2.10 Loading, attachment points, transportation 2.10 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Loading, attachment points 2.10 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transportation 2.10 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GHH Fahrzeuge GmbH

2.1 - 1LF-9.3030050_en12.10

2.1 Safety instructions for theoperation of vehicles madeby GHH Fahrzeuge GmbH

General safety instructions:

Please read these safety instructions as well as theoperating instructions carefully before the first star-ting of the machine and every now and then after-wards.

Handling of GHH Fahrzeuge GmbH vehicles andthe necessary operating material is uncomplicatedif you as the owner have trained the staff responsi-ble for operation, maintenance and attendanceaccordingly.

This survey can, of course, only contain generalinstructions. Operational specialities may needdeviations or additional amendments. For thisreason these instructions have to be studied tho-roughly by operators, supervisory staff, mainte-nance staff and safety specialists of the correspon-ding plants together and must be adapted andamended where necessary.

Deviations from these general safety instructionsprepared by GHH Fahrzeuge GmbH are especiallyexplained in the operating instructions.

If there are any uncertainties in understandingthese instructions, please do not hesitate to contactour service department (GHH Fahrzeuge GmbH;phone +49(0)209 38907 300;fax: +49(0)209 38907 302).

In addition to these general safety instructions thespecial safety instructions referring to the operatingmode of engine and of the vehicle are to be obser-ved. For all work carried out on the vehicle pleaseobserve special the safety instructions for mainte-nance work.

When operating the vehicle the local accident pre-vention codes are to be observed. The owner anddriver are responsible for compliance with suchcodes.

If necessary, the owner has to amend such accidentprevention codes to reflect the local conditions ofoperation.

Referring to the conditions of operation, the safetyinstructions of the corresponding employer's liabi-lity insurance association have to be observed. Werecommend the owner to insist on a written confir-mation that the staff has read the operating andmaintenance instructions, these safety instructionsas well as the accident prevention codes and the

additional regulations which are to be applied locallyand that they have been trained accordingly. Inaddition to this, staff members should always havethe above mentioned regulations at hand to re-readthem.

Because of the relatively high noise level generallyfound at almost all operating places of our vehiclescaused by surrounding conditions, perceptivefaculty may be reduced. For this reason vehiclesare to be operated especially carefully at such pla-ces.

Get used to handling of the machine and its controland safety equipment as well as to “critical places”.Read in operating instructions where those placesare and how they are marked.

Before each starting check the vehicle's functionaland operational safety.

If operational failures occur, find out the reasonimmediately. Care for immediate remedy of disco-vered faults in order to prevent possible accidenthazards and major damage of the vehicle or itssystems. In case of serious defects (failure of brakesystem etc.) shut down the vehicle immediatelyuntil the remedy of such a fault is carried out.

Switch off electrical components where risks havebeen discovered, especially fault current, unduerise in temperature, appearance of smoke and elec-tric arcs or which have become inaccessible. Informnext supervisor or specialist for electrical equip-ment as soon as possible.

Switch off electrical equipment which is not allowedto be operated and secure against starting at leastby means of warning signs in places where thoseinstallations could be started. Furthermore makemeans for propulsion or control of actuators ofremote controlled switches ineffective.

Faulty electrical equipment and operation materialmay not be started or used before being repaired.

Make sure that nobody without special knowledgewill ever operate, maintain, repair or otherwisehandle the machine.

Before leaving the driver's compartment alwaysapply parking brake. Park the vehicle at a place withplane surface without descent and without distur-bing other operations.

Never allow the engine of the machine run unatten-ded.

GHH Fahrzeuge GmbH

2.1 - 2LF-9.3030050_en12.10

The driver's undivided attention is necessary foroptimal working results and reliable operation of themachine. For this reason never allow persons tooperate the machine whose reactivity is reduced.The influence of alcoholic beverages, medicinesand other agents will reduce capability to react aswell as over-tiredness will do and thus the risk ofaccidents will increase.

Always maintain the machine in technically faultlesscondition.

Care for sufficient level of operating material, espe-cially for engine, gears, axles, converters, brakesystems hydraulic and lubrication equipment, aswell as in cooling circuits.

Undue modifications and insufficient maintenancewill impair the machine's function, operation safetyand serviceable life. For this reason care for com-pliance with required maintenance and inspectionintervals. If you want to carry out technical modifica-tions of the machine, please contact GHH Fahr-zeuge GmbH in any case in advance.

The machine is equipped with warning signs orequipment at specific places of danger. Take carefor proper condition of this warning equipment.Replace immediately in case of damage or illegibi-lity.

Take special care of the proper condition of all pro-tection and safety equipment on the machine. Donot remove and replace immediately in case ofdamage.

Safety equipment and protection and control instal-lations of the vehicle necessary for safety may notbe made ineffective nor unduly adjusted or modi-fied.

Take care that parts of the body, clothes etc. will notenter danger area of moving parts.

Always wear close fitting, appropriate working clo-thes.

If necessary, make use of additional personal pro-tection clothes (protection helmet, protection glas-ses, ear protection, protection shoes etc.)

Maintain your driver's compartment clean, dry andclear.

Keep all persons not needed for the working pro-cess away from the machine when operating.

When operating the machine take care that nobodyand nothing is in its range of action (driving ways,swivelling range of kinematics and steering system,etc.). Take special care of areas with high dangerof crushing.

Warn people in range of danger with the horn. Stopworking, if people do not leave danger area in spiteof warning.

Never stay below lifted and unsecured loads ormachine parts.

For climbing up and down use handles and treads.

Do not give people a lift on the machine or additionalequipment if there is no device especially designedfor this purpose by the manufacturer.

Keep all the vehicle clean from dirt, residual oil,lubricant, fuel, and, if necessary, from snow and iceetc., especially treads, platforms, actuation places,glass panes etc.

Only operate controls in driver's compartment fromdriver's seat.

Only operate the machine within the load limitsgiven by the manufacturer. Undue overloading willreduce the operating safety and service life of themachine.

Do not switch off the vehicle immediately after highloads but let it idle for a certain time if possible, sothat the temperature of systems and componentscan be compensated.

Misuse of the complete machine or single devicesthereof may lead to damage and reduction of ser-vice life and means in any case: loss of warrantyclaims and raise of risk of accidents.

Take special care of appropriate speed when dri-ving around bends. Besides this, always adjust yourdriving speed to surrounding conditions, especiallyto surface conditions.

When driving around bends, avoid high accelera-tion and violent steering movements which maylead to early sliding, reduction of stability, and evento damage.

Take care for sufficient carrying capacity of the sub-structure, especially on bridges, vaults, and whenpassing over tubes placed under the travel way anddriving in areas which are laterally declining.

Before using the machine, check its fitness for useespecially at working places previously unknown.

Always keep emergency call equipment and emer-gency material (first-aid box, fire extinguishingequipment, etc.) ready for use in your immediatevicinity.

Only authorized people may operate, use, and acti-vate electrical installations and corresponding ope-rating material.

As far as warning signs are fixed on cases of electri-cal installations, their rules are to be observed.

GHH Fahrzeuge GmbH

2.1 - 3LF-9.3030050_en12.10

When towing another vehicle please take care ofthe special instructions in the operating instructionsof both vehicles (e.g. hydrostatics, brake, etc.) anduse only the provided towing lugs and sufficientlydimensioned towing equipment. Take care of therequired higher brake performance of the towingvehicle, especially on declining ways with brokendown brake systems of the towed vehicle.

Only use original additional parts and spare partsfrom GHH Fahrzeuge GmbH and lubricants and

process materials authorized by GHH FahrzeugeGmbH to maintain the operational safety and avai-lability of your machine.

GHH Fahrzeuge GmbH is not responsible fordamage caused by installation or application of“equivalent” parts of another origin.

Spare parts can be purchased from our servicedepartment (GHH Fahrzeuge GmbH; phone+49(0)209 38907 300; fax: +49(0)209 38907 302).

GHH Fahrzeuge GmbH

2.1 - 4LF-9.3030060_en12.10

Special safety instructions for combustionengines:

Exhaust gases from combustion engines are toxic!For this reason do only operate combustion enginesin places with sufficient fresh air. Observe regula-tions for installation and operation of engines in clo-

sed rooms. Take care of sufficient ventilation andsuction and extraction or cleaning of exhaust gases.

When refilling the machine, switch off engine andheating, do not smoke, avoid open flames or sour-ces of sparks or heat nearby. Switch off electricalinstallation. Remove spilled fuel immediately.

Only use specified, unpolluted and anhydrous fuels.

GHH Fahrzeuge GmbH

2.1 - 5LF-9.3030070_en12.10

Special safety instructions for mining andtunnelling vehicles:

Besides these safety instructions referring to a spe-cific vehicle type, principally observe the generalsafety instructions as well as the safety instructionswhich correspond to operating mode of the engine.For all work on the vehicle observe special safetyinstructions for maintenance work.

Drive up ascents uphill if possible and avoid drivingtransverely to the slope in order to avoid slippingand overturning of the machine.

Take care that the admissible transverse and longi-tudinal inclination of the machine will not be excee-ded.

Always maintain safety distances to stockpiles, pits,etc..

Pay attention to the condition of stope faces andespecially of topbacks and possible danger causedby falling or breaking rocks.

Maintain travelways as plane and boulderless aspossible.

Inform yourself about locations of dangerous andendangering installations in your working area, asfor example high-voltage cables, pipework, electri-city distributors, etc.

Care for too high water levels being pumped out.

When driving uphill and downhill care for a reasona-ble selection of gear respectively speed and thusavoid superfluous risks of accidents, damage, over-heating, and wear out of brakes and driving compo-nents. Too high gears may overstrain drive systems(clutch, transmission, drivelines). Too high gearsduring downhill driving require excessive use of bra-kes. Too high gears during uphill driving, especiallywith high loading, result in an excessive rise of tem-perature of driving components. For this reason payattention to temperature indicators and select nextlower gear, if necessary.

Carry out transport journeys only in transport mode,i.e. with completely lowered body/boom, retractedbucket, fork, etc.

If piles in body or bucket are too steep, this may leadto falling out of rocks or conveyed material and thus

increase the risk of accidents and danger of tiredamage caused by uneven travelways.

If necessary, secure your load so that uncontrolledsliding and connected risks of accidents (fallingdown of load, turnover of the vehicle, etc.) as wellas shifting of the centre of gravity will be avoided.

Ensure sufficient height in the dumping place sothat crashing of body, bucket or dump/hoist linkageagainst the roof will be avoided.

After dumping do not leave the dumping placebefore bucket, fork and/or body are brought intotransportation position again.

Working places with special dangers, e.g. causedby falling articles, require special safety measuresas e.g. remote control for unmanned operation ofthe machine.

When working under lifted body, bucket or fork,always apply safety bolts or supports provided forsafety. Safety bolts are located in the area of thebody or boom bearing.

If necessary, apply the swivel arresters of the swivelhinge to reduce danger of crushing. Swivel arre-sters are provided in the area of the swivel hinge.

Park the machine fully unswivelled in straight-ahead position, preferably on plane surfaces with-out slopes. When standing on slopes, always parkthe machine in a manner such that uncontrolled rol-ling will be avoided even if holding devices are loo-sened unintentionally (e.g., with the side of thevehicle away from the driver's cab swivelledtowards the material face).

Before leaving the machine apply parking brakeandswitch off engine. In addition to this make sure thatunauthorized operation will be impossible, e.g. bywithdrawing ignition key. When leaving loaders fora long time, put bucket or fork to the ground and inaddition to this secure against rolling (e.g. putchocks in front of wheels).

Secure your parked vehicle especially at blind pla-ces with much traffic optically to avoid accidentse.g. crashes.

For electrically operated machines observe corres-ponding safety instructions.

GHH Fahrzeuge GmbH

2.1 - 6LF-9.3030080_en12.10

Special safety instructions for vehicles typeloaders

If possible, carry our loading only with a completelystretched machine. With swivelled machine, wor-king results will be reduced and the risk of sliding willincrease.

Pay attention, especially during loading, for slidingand falling rocks or loaded material from the loadingplace as well as from the bucket.

Carry out loading principally with lowered liftingequipment and lowered bucket. Doing this you willavoid the risk of rocks falling from the bucket ontothe driver's compartment.

Emptying the loading place from sides to centre willavoid lateral sliding of loading material to themachine, which could encumber the wheels andwould bring you closer to the dangerous area.

Empty the loading place as continuously as possi-ble and with a straight front so that loading materialmay slide down slowly and continuously.

If possible, execute dumping only at places withouttransverse inclination and with a stretchedmachine. With raised boom avoid high accelerationand deceleration by starting and braking as well asviolent steering movements. If these instructionsare not observed, stability can no longer be guaran-teed, danger of turning over arises. In addition tothis, danger caused by loading material falling downfrom the bucket will increase.

CAD-ZeichnungZul.Abw. DIN 7168 - mittelOberfl. DIN ISO 1302

Verwendungsbereich

Tag NameBearb.:Gepr.NormDiese Zeichnung ist Eigentum der GHH Fahrzeuge GmbH und nur mit ihrem Einvernehmen zu verwenden.

verfilmt Bchst Anzahl

TypHEZAbt

Zchngs-Nr.d.Empfängers WerkstoffModell-Nr

Art der Änderung

MaßstabUEZBenennung

BGGewicht kg

TA

Tag Bearb/Gepr

verfilmt

Bl.

Bl.

Zeichnungs-Nr

Entst.aus Ers. für

FAHRZEUGE201013.08. Ljubicic

T

909-4-065188

SICHERHEITSBESCHILDERUNGin englischer Sprache

909-4-056556 a

LF-9.3909

LF93SICE.CDR

13.08. Weigardt

1 2 4 5

6 7 9

1011

12

13

3

14

8

1,10

2 3

3

4

5,16,176-9,20

11 12

13 1415 15

1515

15

16 17

18

1: TYPENALL.DRW Al (A)2: HITZE.CDR ge/sw3: QUETSCH.CDR ge/sw4: MASCHINE.CDR ge/sw5: GEHOERSC.CDR bl/we6: AUFSITZ.CDR ge/sw7: FAHRERST.CDR ge/sw8: LENKUNG.DRW ge/sw9: SICHGURT.DRW ge/sw10 - 14: TRANS93.DRW we/sw15: GEFAHAUF.CDR ge/sw16: MEMBRAN.DRW ge/sw17: ELEKTRON.DRW ge/sw18: TRANS93.DRW we/sw

18

80kN

Maximum load of

transporteyes

25kN

Maximum load of

transporteyes

Maximum load oftransport device

vertical

withfittet boom locking bolt

100kN

Maximum load of

towing device:

horizontal 100kN 30kN

Maximum load of

transporteyes

Maximum loads of transport eyes:Before shaft transport the vehicle has to be dismanteled in its main parts!

80kN

Maximum load of

transporteyes

Maximum load of

towing device:

horizontal 100kN

Maximum load oftransport device

vertical

withfittet boom locking bolt

100kN 30kN

Maximum load of

transporteyes

25kN

Maximum load of

transporteyes

Operating of machine only by

driver, sitting in driver´s cabin !

Before leaving driver´s cabin

lock parking brakes

and shut off engine!

Fastenseat belt !

Staying in danger area of

vehicle is forbidden !

Attention !Steering only operable,

while engine is running !

ATTENTION!Before carrying out welding, connections

on electronic components andaccumulator must be separated!

Earthing terminal of welding apparatus should be placednear welding point!

Diaphragm accumulators inhydraulic- and brakesystem!

Before starting work at hydraulic- orbrakesystem depressurize systems

and check pressure!

GHH Fahrzeuge GmbHEmscherstraße 53D - 45891 Gelsenkirchen

(nur bei Maschinen imGeltungsbereich derEG-Maschinenrichtlinie)

19Hinweis:

20

Anbringung amLagerbock derGelenkwelle

19 3

CAD-ZeichnungZul.Abw. DIN 7168 - mittelOberfl. DIN ISO 1302

Verwendungsbereich

Tag NameBearb.:Gepr.NormDiese Zeichnung ist Eigentum der GHH Fahrzeuge GmbH und nur mit ihrem Einvernehmen zu verwenden.

verfilmt Bchst Anzahl

TypHEZAbt

Zchngs-Nr.d.Empfängers WerkstoffModell-Nr

Art der Änderung

MaßstabUEZBenennung

BGGewicht kg

TA

Tag Bearb/Gepr

verfilmt

Bl.

Bl.

Zeichnungs-Nr

Entst.aus Ers. für

FAHRZEUGE201013.08. Ljubicic

T

909-4-065189

FUNKTIONSBESCHILDERUNGin englischer Sprache

909-4-056557 a

LF-9.3909

LF93FUNE.CDR

13.08. Weigardt

1,2

GHH Fahrzeuge GmbHEmscherstraße 53D - 45891 Gelsenkirchen

Baujahr

Nennleistung

Nutzlast

kW

kg

Fahrzeugtyp

Serien Nr.

Leergewicht kg

3.5 bar 6.0 bar

TYP 18.00 R 25

2

1

mit geänderten Wertenje nach Kundenwunsch

3

4 DIESEL FUEL

HYDRAULIC OIL

5

7

8

6

1: TYPENALL.DRW Al (A)2: REIFLFMK.DRW we/sw3-4: FLUIDE.CDR bl/we5-8: SYSTUEB1.CDR

3

4 5-8

GHH Fahrzeuge GmbH

2.2 - 1LF-9.3030090_en12.10

2.2 Driver`s seat

The driver's cab is equipped with a mechanically suspended driver's seat. To prevent health damage, thedriver's seat must be adjusted to the driver's body before starting the vehicle.

The restraint belt must be used at all times. The belt should be worn as tight as possible to the body. Afteran accident the restraint belt must be replaced and the driver's seat and the fastening of the driver's seatinspected by qualified personnel.

3

4

2 1

Adjustment

1 Lever for backrest adjustment

2 Lever for height and tilt adjustment

3 Handwheel for setting the weight

4 Lever for horizontal adjustment

GHH Fahrzeuge GmbH

2.3 - 1LF-9.3St+Kon_en12.10

2.3 Driver's cab, operating elements and control instruments

All the instruments and control instruments necessary to operate the vehicle are arranged in the driver'scab. The speed adjustment of the driving engine and therefore the adjustment of the driving speed is ef-fected via the right-hand pedal and the operation of the service brake via the left-hand pedal. The gearshiftmechanism is operated with the control switch (S44), while the boom and the bucket are operated withthe control switch (S84) located right next to the driver's seat. The driving engine is stopped via theBowden cable “Engine stop”.

Changing steering direction

The steering direction of the vehicle thus corresponds to the sense of rotation of the steering wheel, inde-pendent of the tramming direction.

Control instruments

P2 P3S71

S72

S84

P12

S80

H5H2 H3 H1 H6

H17 H18 H19 H12 H7

km/h U/min

01

23

BowdenzugMotor Stop

H10

H8

S70

Test

S43

S86

forward reverse

gearshift

N2

34

1

P1 mounted in driver`s door (X9)

GHH Fahrzeuge GmbH

2.3 - 2LF-9.3St+Kon_en12.10

Note The abbreviations used are:DT = pushbutton, ML = signal lamp, ST = control switch,SK = twist switch, SL = key switch, AN = analog indicator

Warning At each fault indication report to Maintenance and determine the cause.

Item Description

A1 AN exhaust gas back pressureA back pressure of 150 mbar must not be exceeded.If the limit value is exceeded the filter regeneration described in sectionLEERER MERKER ”Measures to be taken after a failure” must be carried out.

P1 AN hour meterP2 AN speedometerP3 AN revolutions counter

An engine speed of 2480+50 min-1 must never be exceeded.P4 AN fuel level

P12 AN Available brake pressure indicatorIndicates the available pressure of the brake system.If the available brake pressure drops below 100 bar, stop vehicle immediately,apply parking brake and stop operation.

H1 ML alternator charge controlGoes out when three-phase alternator and controllerare working.Lights up during operation in case of a defect in the generator or charging circuit. Ter-minate the operation as quickly as possible and switch off the engine.

H2 ML preheat indicatorGoes out when the engine is preheatet.

H3 ML engine oil pressureLights up if the engine pressure drops below 0.5 bar. Shut off engine immediately assoon as the signal lamp lights up.

H5 ML cylinder head temperatureLights up if the cylinder head temperature rises above 185C.Stop vehicle and allow engine to idle for appr. one minutes to cool down. Then turnoff engine.

H6 ML transmission clutch pressureLights up if the transmission clutch pressure drops below 16.0 bar.Stop operation.

H7 ML converter oil temperatureLights up if the converter oil temperature rises above 120°C.Stop vehicle, set transmission to neutral and allow engine to idle for a few minutes tocool down. Check converter-transmission oil level, if necessary. Tramming the vehiclewith reduced torque-converter slip.

H8 ML return pressure / brake filterLights up if the return pressure rises above 1.3 bar, replace filter element in return filterof hydraulic oil reservoir. Also lights up if the line filter in the brake system is fouled.Replace filter element in the line filter.The indications are output with two different brightness levels of the indicator light. Toohigh a return pressure is indicated by the indicator light in a brightly illuminated stateand contamination of the line filter by the indicator light in a weakly illuminated state.

GHH Fahrzeuge GmbH

2.3 - 3LF-9.3St+Kon_en12.10

Item Description

H10 ML Hydraulic oil levelLights up if the oil level in the hydraulic oil reservoir drops below minimum.Check the hydraulic system for leaks. If no visible leak is present, top up oil to the top-level mark on the level gauge. In case of visible leaks, stop the operation.

H12 ML available braking pressureLights up if the available brake pressure drops to less than 100 bar.Stop vehicle immediately, apply parking brake and stop operation.

H17 ML high beamLights up if the high beam is on.

H18 ML parking brakeLights up if the parking brake is applied or is not fully released. It goes out as soon asthe parking brake is fully released.

H19 ML service brakeLights up if the service brake is activated or when your foot rests lightly on the brakepedal.

S43 Lever parking brakeServes to release or to apply the parking brake.

release - move the lever forwardapply - move the lever backward

S44 ST gear shift assembly

S64 SL voltage on / off

S70 DT signal lamp testServes to test function of the signal lamps.(not applicable to signal lamp for alternator charging control)

S72 SK lighting systemTurning position 0: OFFTurning position 1: parking light and material face lightingTurning position 2: low beam and material face lightingTurning position 3: high beam and material face lighting

S80 DT Work light.Serves to switch on and off the work light at the driver's cabin.

S84 ST boom / bucket

S86 DT Horn (on steering wheel)

S91 SL Windscreen wiper (Optional)

GHH Fahrzeuge GmbH

2.4 - 1LF-9.32_4-1_en12.10

2.4 Checks

Before daily operation for reasons of safety and reliability of the vehicle perform the following checks:

- Engine oil level

- Converter and transmission oil levels

- Oil level in hydraulic tank

- Tightness of all components and systems

- Maintenance indicator of dry air filters

- Tire pressure and condition

- Function of brake

- Function of steering

- Function of lighting

- Function of bucket and boom, raising/lowering

- Function of indicator controls and signal lamps

Note All maintenance work on the vehicle frame, sub-assemblies and systems shall be car-ried out in accordance with the checklists in section 3.5.

Daily checks after operation:

- Lower work equipment.

- Park vehicle on a level, dry surface, completely levelled. On gradients, park with the side of the vehicleaway from the driver's cab, swivelled towards the material face.

- As a rule, the parking brake applies via the ”parking brake” control lever (S43).

- Set all control levers to neutral position.

- Deactivate battery switch.

- Protect vehicle against unauthorized use.

- Clean vehicle.

- Check vehicle for external damage, loose bolts, etc.

GHH Fahrzeuge GmbH

2.5 - 1LF-9.32_5-1_en12.10

2.5 Engine starting, engine switch�off

Engine starting

Warning If the engine is started using an external power supply through the external start socket,it is essential to ensure that this power supply has the same voltage (24V) and that thecapacity is not greater than the batteries fitted. Do not isolate discharged batteries fromthe electrical network.

- Turn on battery switch.

- Insert key in ignition / starter switch and turnto position“Power ON“.

- Shift gear lever to neutral position.

The following indicators will light up:

- Engine oil pressure.

- Alternator charge control

- Transmission clutch pressure.

- Parking brake not released (goes out as soon as the parking brake is fully released).

- Available braking pressure (if the available brake pressure be insufficient).

To preheat, set the ignition / starter switch to position “Preheating“ and hold it in this position. Note thatthe preheating signal lamp lights.

When the preheating signal lamp goes off, set speed adjustment pedal to approx. 1/4 speed and turn ignni-tion /starter switch to position “Engine starting” and hold it in this position.

Note No preheating is required when the engine is warm.

As soon as the engine is running, release the ignition-/starter switch and ease back the speed adjustmentpedal to such an extent that the engine runs smoothly at medium speed.

Warning Do not start longer than 20 seconds; repeat the starting sequence if necessary.Leave a one-minute pause between two starting sequences. If the engine has notstarted after two starting sequences, inform maintenance and determine the cause.The cold engine should not be operated at high speeds.

After the engine has fired and the various pressures have been built up, the indicators will go out.

Note In the event of faults see the engine operating instructions and the appertainingsectionsof these operating instructions.

battery switch external starter socket

GHH Fahrzeuge GmbH

2.5 - 2LF-9.32.5 - 2_en12.10

Engine switch-off

Caution The parking brake is not applied automatically when switching off the engine. It is there-fore important to apply the parking brake manually via the control lever to secure thevehicle against rolling away.

- Set engine speed to idling.

- Apply the parking brake.Move the control lever ”parking brake” backward until it locks into place.

- Place the gearshift lever in neutral position and switch off all consumers.

- Pull “Engine Stop“ Bowden cable. When the engine has come to a standstill, the “alternator chargecontrol, engine oil pressure and transmission clutch pressure” signal lamp will light up again.

- Switch-off the ignition, turn the ignition/starter switch (S64) to position 0 and remove the key.

- Deactivate the battery switch.

Note Unless there is an emergency, do not switch off engine suddenly from full load. Allowengine to cool down by running it at idling speed for a few minutes.

Warning Switch off engine immediately if the “engine oil pressure” signal lamps light up in opera-tion.If the signal lamp ”alternator charge control” lights up during operation, terminate theoperation as quickly as possible and switch off the engine.

Warning If the “Cylinder head temperature” signal lamp lights up in operation, stop loader andallow engine to cool down by running it at idling speed for appr. one minutes. Thenswitch off engine.

GHH Fahrzeuge GmbH

2.6 - 1LF-9.32_6-1_2_en12.10

2.6 Tramming operation

Caution The vehicle's steering system is inoperative when the engine has been stopped.

Start�up

- Start engine.

- Set engine speed to idling.

- Engage first gear.

- Release parking brake. (When the parking brake hasbeen released, the signal lamp goes out.)

- Press the service brake pedal and than release.

- Increase the engine speed.

Changing the tramming direction.

- Apply service brake to brake the loader to standstill. Keep service brake pedal depressed.

- Set gear shift mechanism to neutral position.

- Engage first gear of opposite tramming direction.

- Release service brake.

Changing steering direction

Changing the tramming direction causes automatically the steering direction of the vehicle to be changed,via the 4/2-way directional control valve. The steering direction of the vehicle thus corresponds to thesense of rotation of the steering wheel, independent of the tramming direction.

gear shift assembly

parking brake

GHH Fahrzeuge GmbH

2.6 - 2LF-9.32_6-1_2_en12.10

Hints on the torque converter and power transmission

The torque converter acts as a hydraulic connection of the engine and power shift transmission.

Since improper converter operation may lead to unnecessary heating-up of the converter transmissionsystem, the following should be observed:

- Always start in first gear.

- Utilize all gears to shifting point.The point for changing to a higher gear has been reached if, in full throttle position, the speeds listedbelow are reached in the individual gear steps.Point for changing:1st → 2nd gear 2nd → 3rd gear 3rd → 4th. gear

3.5 km/h 7.2 km/h 12.5 km/h

- If the system is excessively loaded, change to a lower gear.The point for changing to a lower gear has been reached if, in full throttle position, the speeds listedbelow are reached in the individual gear steps.Point for changing:4th → 3rd gear 3rd → 2nd gear 2nd → 1st gear

12.5 km/h 7.2 km/h 3.5 km/h

Warning If the speeds in the individual gear steps fall below the minimum values specified forthe shifting point, this will cause excessive heating in the converter-transmission circuitand consequently cause damage to the converter and the transmission.

- In accordance with the shifting points for shifting down, the following gradient ranges can be travelledin the individual gear steps:(see annex, gradeability diagram ”909-9-047220/105”, page 3)1st gear 2nd gear 3rd gear 4th gear25→ 23%% 23%→ 12% 1% → 6% 6% → 0%

- If the loader should be braked or stopped to standstill by changing to a lower gear, the point for chan-ging to a lower gear is at an engine speed of < 800 min-1.

GHH Fahrzeuge GmbH

2.6 - 3LF-9.3030162_en12.10

Tramming on downhill slopes

Tramming on downhill slopes is preferably carried out with the engine part up front. During downhill drivingthis driving direction allows for a better distribution of the axle loads and also prevents axle lift-off causedby front-drooping.

Tramming on downhill slopes always begins with the lowest gear appropriate for the gradient.

Via the drive train the engine will keep the vehicle at a uniform speed.

- Never allow vehicle to roll opposite the selected tramming direction.

- Tramming on downhill slopes must never be done using the service brake. The brake will overheat !!

- On all ranges of downhill slopes, for the same load (empty/laden), maximum the same gear and maxi-mum the same driving speed as on uphill slopes shall be selected.

- When the speed increases change to next lower gear.

- In the individual gears the maximum speed indicated in the technical data must not be exceeded.

- When changing down to a lower gear, first brake to the switching gear using the service brake.

Warning After changing to a lower gear, the rotational speed at the converter output/transmis-sion input is doubled (at least for a short time).As a reference, the engine speed for changing to a lower gear is < 800 min-1.

GHH Fahrzeuge GmbH

2.6 - 4LF-9.32_6-4_en12.10

Downhill driving in converter mode

When driving downhill in converter mode the engine idles, which means the speed adjusting mechanismis not operated. In the process, the engine brakes the converter's pump wheel. This causes the turbinewheel to rotate faster than the pump wheel, with the torque converter reversing and the dumper brakedvia the engine, torque converter, transmission, drivelines and axles.

Warning The brake power is converter into heat and the converter-transmission oil heated up.The “converter-transmission oil” temperature indicator therefore has to bewatched.Should the vehicle's maximum converter oil temperature be exceeded, brake it by oper-ating the service brake and allow engine to cool down at idling speed.

In pushing mode, the converter output/transmission input speed is substantially higher than the enginespeed, as indicated at the revolution counter.

Warning In pushing mode, the speed at the converter output/transmission input is about twiceas high as the engine speed.Therefore, the maximum admissible engine speed is 1500 min-1.

Note For extensive driving on downhill slopes, sustained-action brakes (exhaust brakes, re-tarder brakes) should be used, or else a detrimental heat-up within the converter-trans-mission system may arise.

You must not exceed the speed at the several gears above the limits as listed below:

1st gear 2nd gear 3rd gear 4th gear4.5 km/h 9.0 km/h 15.4 km/h 25.0 km/h

GHH Fahrzeuge GmbH

2.6 - 5LF-9.3031351_en12.10

Towing the vehicle

Note Tow the vehicle only at walking speed and over short distances.

In the event of towing over a long distance or over a road gradient section proceed in compliance with theindications on page 3.16 - 5.

Warning When the engine is not running, the vehicle cannot be steered.For towing use only the towing lugs provided and sufficiently dimensioned towing aids.Make sure that the towing vehicle has the required brake power.

Note When the engine is not running and a brake pressure is min. 140 bar, the filled dia-phragm accumulators of the brake system are sufficent for at least five full brake ap-plications using the service brake. The storage volume for the parking brake is sufficientfor at least three releases.

- Secure vehicle against any self-initiated movements and damage.

- Determine the brake pressure on manometer (P12) in the driver position.

Warning The brake pressure must be higher than 100 bar.

- Put the gear shift in neutral position and release the parking brake.Switch on operating voltage for release the parking brake.

Caution If the brake pressure drops below 100 bar, a safe stop with the service brake is no longerguaranteed. The towing procedure must be immediately interrupted and if necessaryexecuted in accordance with the indications on page 3.16 - 5.

Note If the brake pressure drops below 100 bar, the driver will be warned by the lighting upof indicator (H12).

GHH Fahrzeuge GmbH

2.7 - 1LF-9.32_7-1_en12.10

2.7 Dump/hoist operation

Control of dump/hoist equipment

The boom and bucket operations are controlled by the control switch arranged on the right side of the in-strument box.

The stroke of the control switch is proportional to the speed at which the dump/hoist operation is perfor-med, i. e. the further the control switch is shifted out from its middle position, the faster the desired boom/bucket operation is performed.

Fig. 1

Control switch forboom/bucket

Effectboom/bucket

seeFig. 1

pullpushleftrightspring-centered middle position

push through (Option)

bucked tilted backbucket tilted forwardboom loweredboom raisedboom / bucket held in position

bucket in floating position

position 1position 2position 3position 4

position 5

GHH Fahrzeuge GmbH

2.7 - 2LF-9.3030201_en12.10

Bucket filling

- Brake loader in straight-ahead position in front of the pile.

- Lower the boom to its stop, tip bucket forward until it is a few centimeters above the ground.

- Engage forward gear.

- Drive evenly into the pile. Give full acceleration when the bucket penetrates the pile.

Warning Avoid ramming the pile. The bucket should be introduced as far into the pile as is neces-sary to fill it.

- Avoid spinning of wheels. Observe front wheels. If they start to spin, tip back bucket by inducing lightjerking movements on the control switch/operating lever. This will reduce penetration resistance andincrease the load on the wheels.

- Before the front wheels enter the pile, the bucket should be fully tipped back and loaded.

Bucket filling (floating position)

For loading on uneven ground fully depress control switch/operating lever or respectively, press buttonin control switch (see 2.7 - 1). This will set the bucket to the floating position. In this position the directionalcontrol valve is on free flow. The bucket adapts to the uneven ground as a result of the external forcesacting on it.

Emptying the bucket

- Travel to the dumping point. Before reaching the dumping point use service brake to brake the loaderand raise the bucket to the necessary height for tipping it forward.

- Set gear shift lever to neutral position.

- Tip bucket forward

- Tip back empty bucket and at the same time lower the boom to the stop.

GHH Fahrzeuge GmbH

2.8 - 1LF-9.3030210_en12.10

2.8 Winter operation

Low temperatures will aggravate the vehicle's operating conditions. To ensure trouble-free operation inwinter, special maintenance and care are required. Preparing for the cold season in good time is of specialimportance.

Engine

Engine oil

Too viscous engine oil will lead to starting problems and favour increased wear. Note the oil grades andchange intervals specified in the engine manufacturer's operating instructions!

Injection nozzles

Have injection nozzles inspected regularly. Refer to engine manufacturer's operating instructions.

Compression

Have compression checked before the winter begins. Insufficient compression will affect starting of theengine, especially in cold weather.

Cold-starting equipment

Check existing cold-starting equipment regularly. Refer to the engine manufacturer's operating instruc-tions.

Cooling system

Coolant

Add a brand-name anti-freeze to the coolant of liquid-cooled engines in good time.

Refer to engine manufacturer's operating instructions.

Air intake system

Oil-bath air filter (if installed)

Fill oil bath of oil-bath air filter with the same oil as used for the engine. At extremely low temperatures,use a mixture of oil and winter diesel fuel.


Dry air filter (if installed)


GHH Fahrzeuge GmbH

2.8 - 2LF-9.3030210_en12.10

Fuel system

Fuel

At ambient temperatures below 0 °C fill up winter diesel fuel. At low temperatures diesel fuel will separateparaffin. Paraffin, in turn, will clog the fuel lines. For the application of different fuels refer to engine manu-facturer's operating instructions.

Fuel tank

When the fuel filters are unduly soiled, clean the fuel tank.

Water separator

If installed, drain water separator daily.

Kraftstoffpumpe

Clean fuel pump strainer (if installed) weekly.

Axle gear

Axle gear oil

Fill up axle gear oil according to the lubricant table.

Hydraulic system

Hydraulic oil

Fill up hydraulic oil according to the lubricant table.

Electrical system

Batteries

The starting capacity of the batteries depends on the charge state and the ambient temperature. Checkacid density regularly, charge batteries if necessary. Check for proper contact of terminals.

Alternator

The proper charging capacity of the alternator is especially important in winter. Check condition andtension of the V-belts regularly. Have alternator checked in good time (by specialist workshop).

Starter

Have starter checked if necessary by a specialist workshop. Grease flywheelgear rim if temperatures dropbelow -20 °C.


GHH Fahrzeuge GmbH

2.9 - 1LF-9.32_9-1_en12.10

2.9 Shutdown of vehicle

Shut-off of vehicle

Caution The parking brake is not applied automatically when switching off the engine. It is there-fore important to apply the parking brake manually via the control lever to secure thevehicle against rolling away.

- Lower dump/hoist equipment, i.e. retract all hydraulic cylinders.

- Park vehicle on a level, dry surface, completely levelled. On gradients, park with the side of the vehicleaway from the driver's cab, swivelled towards the material face.

- Apply parking brake and set gear shift lever to neutral.

- Shut off engine and withdraw ignition key.

- Set battery switch to “OFF”.

- Protect vehicle against unauthorised use.

Shutdown of vehicle

If the vehicle is to be shut down for a longer period of time, the following work is to be carried out:

- Jack up vehicle so that the tires do not touch the ground. Release parking brake.

- Set all levers to zero position.

- Lower dump/hoist equipment, i.e. retract all hydraulic cylinders.

- Coat bright machinery components with acid-free grease.

- Protect the engine in line with the engine operating instructions.

- Remove batteries and store in a dry room at approx. 20 °C.

For battery care note the following:

- Check acid density and re-charge battery, if necessary. - see 3.22-1

- Keep batteries clean and dry on the outside.

Warning Never allow batteries to be stored discharged.

GHH Fahrzeuge GmbH

2.9 - 2LF-9.3030230_en12.10

Putting vehicle back in operation after shutdown

Before putting the vehicle back in operation again after an extended period of shutdown:

- De-preserve engine in line with engine manufacturer's operating instructions.

- Fill up fresh engine oil.

- Remove grease from bright machinery components.

- Check battery charge state and liquid level.

- Check tire pressure.

- Check function of brake system.

- Check function of hydraulic system.

- Check function of electrical system.

Warning Generally, the usual preparations as for initial start-up of the vehicle must be made.

GHH Fahrzeuge GmbH

2.10 - 1LF-9.3030241_en12.10

2.10 Loading, attachment points, transportation

Loading, attachment points

To load the vehicle by means of a crane, attachment points are provided at its front and rear end. Beforelifting the vehicle, insert locking bars arranged in swivel hinge area.

Note Permissible load of transport rings see section 2.1. Drawing safety-marking.

Caution Secure vehicle against any self-initiated movements and damage.

Transportation

To ensure maintenance of the loading dimensions, we recommend that a company experienced in thisfield be consulted for transport.

Warning Before transport the vehicle must be protected in a suitable way to prevent damage.

GHH Fahrzeuge GmbH

3 - 1LF-9.33_en12.10

3 Contents “Maintenance“

3.1 Safety instructions for maintenance and servicing 3.1 - 1. . . . . . . . . . . . . . . . . . . . . . .3.2 Maintenance and servicing 3.2 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regular maintenance and servicing 3.2 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Irregular maintenance and servicing 3.2 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General remarks 3.2 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cold shrinking by nitrogen 3.2 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Irregular maintenance and servicing 3.3 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prior to initial operation 3.3 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .After initial operation 3.3 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 List of lubricants and operating agents 3.4 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 Checklist- Vehicle no.................... 3.5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance intervals: daily 3.5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance intervals: drive engine 3.5 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance intervals: 150/300/450/750 h................. 3.5 - 3. . . . . . . . . . . . . . . . . . . .Maintenance intervals: 600/1200/1800/2400 h................. 3.5 - 9. . . . . . . . . . . . . . . . .Maintenance intervals: according to maintenance indicator 3.5 - 20. . . . . . . . . . . . . . .Measuring-point plan, location of the control valves 3.5 - 21. . . . . . . . . . . . . . . . . . . . . .Lubrication points 3.5 - 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Maintenance work carried out 3.6 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7 Engine operating instructions 3.7 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8 Air intake system 3.8 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9 Exhaust gas system 3.9 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation diagram of exhaust system 3.9 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation diagram of diesel particle filter 3.9 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Measures in case of malfunction 3.9 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Fuel system 3.10 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking of fuel level 3.10 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filling up fuel 3.10 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Draining fuel 3.10 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning the intake filter 3.10 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Injection pump, fuel filter 3.10 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11 Speed adjustment 3.11 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation instructions 3.11 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Final check 3.11 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12 Torque converter, power shift transmission 3.12 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of converter-transmission 3.12 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking of oil level 3.12 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing oil 3.12 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning the intake strainer 3.12 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing the filter element in the pressure filter 3.12 - 4. . . . . . . . . . . . . . . . . . . . . . . . .

GHH Fahrzeuge GmbH

3 - 2LF-9.33_en12.10

3.13 Drivelines 3.13 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of drivelines 3.13 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubrication 3.13 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation drawing of drivelines 3.13 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.14 Axles 3.14 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Planetary gear oil change 3.14 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Differential gear oil change 3.14 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking of oil level, Topping up planetary gear oil 3.14 - 2. . . . . . . . . . . . . . . . . . . . . .Checking of oil level, Topping up differential gear oil 3.14 - 2. . . . . . . . . . . . . . . . . . . . .Venting the differential gear 3.14 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15 Brake system 3.15 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Units of the brake system 3.15 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General notes 3.15 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bleeding of hydro brake system (HPB) 3.15 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diaphragm accumulator 3.15 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diaphragm accumulator in brake system 3.15 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure reduction armature and filling device 3.15 - 5. . . . . . . . . . . . . . . . . . . . . . . . . .Checking the gas preload pressure on the diaphragm accumulator 3.15 - 6. . . . . . . . .Correcting the gas preload pressure 3.15 - 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing of in-line filter element 3.15 - 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service brake Checking of multiple plates for wear 3.15 - 9. . . . . . . . . . . . . . . . . . . . . .Setting of wear check facility with new multiple plates 3.15 - 9. . . . . . . . . . . . . . . . . . . .

3.16 Brake system description 3.16 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Legend to brake system 3.16 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Functional description of hydraulic brake system 3.16 - 2. . . . . . . . . . . . . . . . . . . . . . . .Pressure supply system 3.16 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service brake 3.16 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blocking of forward and reverse tramming 3.16 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Residual brake pressure monitoring 3.16 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External cooling of multi-disk brakes 3.16 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitoring of the filter 3.16 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Parking brake 3.16 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filling of brake system for towing of vehicle 3.16 - 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.17 Hydraulic system 3.17 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering and dump/hoist hydraulic system 3.17 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic tank 3.17 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking of oil level 3.17 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Level monitoring 3.17 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Topping up hydraulic oil 3.17 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Return filter 3.17 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing of hydraulic oil 3.17 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Venting the hydraulic system 3.17 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering and dump/hoist hydraulic system pressure test 3.17 - 3. . . . . . . . . . . . . . . . . .Changing the filter element in the return filter 3.17 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . .

3.18 Steering and dump/hoist hydraulic system description 3.18 - 1. . . . . . . . . . . . . . . . . . . .Legend to steering and dump/hoist hydraulic system 3.18 - 1. . . . . . . . . . . . . . . . . . . . .

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Pressure oil supply 3.18 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filtering of hydraulic oil 3.18 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering hydraulic system 3.18 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dump/hoist hydraulic system 3.18 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Directional control valve 3.18 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control-oil supply 3.18 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic pilot control 3.18 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servo valve 3.18 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Float position 3.18 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.19 Converter-transmission hydraulic system description 3.19 - 1. . . . . . . . . . . . . . . . . . . . .Converter charging pump 3.19 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure filter 3.19 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torque converter 3.19 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil cooler 3.19 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power shift transmission 3.19 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.20 Torque converter operation 3.20 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description of torque converter 3.20 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.21 3.21 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22 Electrical equipment 3.22 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical equipment components 3.22 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery 3.22 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Three-phase alternator 3.22 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Circuit breakers/Plug-in fuses 3.22 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery switch 3.22 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External-starting socket 3.22 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lighting system 3.22 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Warning equipment 3.22 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.23 3.23 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24 TOTAL powder-type fire extinguisher 3.24 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25 Fault-finding table 3.25 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26 Appendix 3.26 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

gradeability diagram “909-9-047220/108”, page 3 . . . . . . . . . . . . . . . . . . . . . . . . .

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3.1 Safety instructions formaintenance and servicing

Warning The warranty is immediately void ifany anti-tamper seals or paint sealsattached to the vehicle systems aredetached or destroyed.

The general safety instructions do principally applyfor this chapter as well. The following text consistsof important regulations and additional instructionsfor maintenance in order to introduce the necessaryknowledge to prevent accidents with damage ofpeople, material, and environment. Besides theseregulations also observe regulations which refer tooperation mode of the machine and type of vehicle.

If an accident happens in spite of all precautions,especially caused by contact with caustic acid,penetration of fuel into the skin, scalding with hot oil,antifreeze compound in the eyes, etc. attend adoctor immediately.Please let only authorized and trained personalused to necessary working procedures carry outadjusting, lubricating, and maintenance work.

Do only use safe tools and working equipment.

Keep clean working place, tools, and operatingequipment.

Park vehicle on plane, dry surface without slopes.

Secure vehicle against self-contained movementsand unauthorized starting.

Carry out lubricating and maintenance work onlywith stopped machine. Switch off all propulsion sys-tems, bring additional equipment in inoperativeposition.

Carry out lubricating and maintenance work duringwhich oil and grease may drain off the machine onlyin places equipped with oil separators, or use suit-able large and unmistakably identified vessels.

Make absolutely sure that oil, fuel, coolant etc donot penetrate the soil or pass into the sewage sys-tem. Danger of drinking water pollution.

Used filter elements or cartridges, coolants andrefrigerants, batteries and other substances haz-ardous to humans and the environment must behandled as special waste according to governmen-tal regulations.

Ensure environmentally friendly disposal or recycl-ing of waste material.

Ensure adequate installation of all parts. Replaceworn out, damaged, and unsafe parts.

Any changes to load-bearing components, i.e. partslocated in the flow of forces exerted by loads (frame,kinematic linkage, etc.) must only be made afterwritten consent of GHH Fahrzeuge GmbH. Thisapplies in particular to repair welds, torch-cuttingand the arrangement of additional or modifiedmounting parts.

Switch off the engine for all maintenance workwhich does not necessarily require a workingmachine and withdraw ignition key. Allow machineto cool down.

If the operation of certain components of themachine is necessary for maintenance work, payspecial attention to the related risks (burns, scalds,poisoning, cauterization, crushing, rotating parts,chain and belt drives, etc.)

Secure doors and gates provided for carrying outmaintenance work after opening. Secure turning,swivel and pendulum hinges and joints with pro-vided bolts, brackets, or supports.

Support or mark parts of the machine which have tobe lifted for maintenance work.

Only apply lifting equipment and supporting standswith sufficient carrying capacity and valid permit.

Never stay under pending loads.

When maintaining or repairing the machine takecare for parts of the machine which are supportedby auxiliary force (oil pressure, compressed air) orby spring force. Reduce pressures and spring pow-ers and secure parts against undesired move-ments.

Only work on depressurized hydraulic and pneu-matic systems. Take also care for secondary stor-age systems. Do neither tighten nor loosen pressur-ized screwed connection of pipework or flexibletubes!

Only drain liquids at places provided for this pur-pose out of depressurized installations into suitablecontainers and dump without harm for environment.

Be careful with units which become very hot whenoperating and thus need a long time to cool down,danger of burning!

Only work on de-energized electrical installations.Pull out switch lever at battery main switch or switchoff main switch, or disconnect earth cable of the bat-tery.

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Basically the following rules apply for work on elec-trical installations:

- Disconnect from power supply

- Secure against reconnection

- Determining dead voltage

- Earthing and shorting

- Cover up any adjacent live parts

- Plug and socket connections should only be dis-connected and reconnected with the voltageswitched off.

It is prohibited at any time to store any parts espe-cially tools, installation material, clothes, etc. in thedangerous vicinity of unsecured, uninsulated partswhich are connected to the power supply

The use of mended or bypassed fuses is prohibited.

It is not allowed to connect parts to the feeder cableof machines fitted with cable reel.Damaged feeder cables must be replaced imme-diately.

Before starting work on high-voltage capacitorsmake sure:

- The capacitors have cooled down

- Make absolutely sure they are fully discharged

- Before touching active parts earth and shorteach capacitor lead (phase(s) with the relevantdevices (See VDE 0450-T4/§5d and IEC871-1/Point 21).

- Dismantled capacitors for transport or storage,permanently short the connections and connectto the capacitor housing.

- In the event of damage it is possible the capaci-tor housing may crack, therefore proceed withextreme care.

When carrying out welding work on the machine,disconnect battery and electronic control units.

Warning Plug and socket connections on thedriver position and on electroniccomponents (e.g. E-gas, controlunits of the engine electronics)should be separated before welding.

When welding take care that the earthing terminalof the welding apparatus is near the welding pointand that welding current is not led through bearings,earthing wire of the vehicle, etc.

When carrying out welding, cutting and grinding,special attention is to be paid to inflammability ofinflammable materials (oil, grease, fuel, varnish,rubber, etc.).When removing protective coatings, zinc layers,etc. by means of grinding, burning, or when weldingparts which are covered with such corrosion protec-tion layers, health endangering gases, smokes, andfloating particles may arise. Use necessary protec-tion equipment and, if possible, work outside, in wellventilated rooms and with suction installations.Please see further instructions for welding in specialinstruction sheets and regulations for prevention ofaccidents for welders.Observe manufacturer's instructions for handling ofbatteries. Accumulator acid is caustic and toxic,battery gases are explosive.Observe regulations for operation of three-phasegenerators, see subsection “Electrical equipment”and engine manufacturer's operating instructions.Change oil at operating temperature. High dangerof burning or scalding with hot oil, oil drainagescrews and oil filter!Open coolant circuit only when engine is cooleddown. Cooling systems are pressurized when hot,hot coolants may lead to scalding. If opening atoperating temperature is absolutely necessary, seeengine manufacturer's operating instructions.If there is danger of freezing, drain coolant andwater circulation pump if necessary, when engine isnot in use.Never fill cold cooling liquid into an overheatedengine.When using compressed air, e.g. for cleaning air fil-ters etc., wear protective glasses.When dealing with damage or checking high-pres-sure systems, e.g. injectors, keep parts of yourbody, especially hands and face away from pres-sure jets. Liquids under high pressure may have thesame effects as cutting tools.Replace damaged flexible protection tubes or flex-ible pressure tubes immediately. Faulty flexibletubes represent especially high danger of burstingand scalding and danger from pressure jets.The period of use of a flexible tube, including anystorage period of the flexible-tube line, should notexceed six years, with the period of storage alonenot to exceed two years.Do not inhale oil and fuel mist, battery gases, cool-ant and vapours from exhaust scrubber.Never operate vehicle components without pre-scribed operating material. Take care for filling

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levels of oils, coolants, etc. especially in engine,gearbox, converter, axles, brake system, hydraulicand lubrication installation as well as coolant cir-cuits.

Never exceed filling levels, especially for motor oil.

Never operate pumps unlubricated and withoutpumped fluids.

Always make sure that check and supervisorydevices work faultlessly (charge control, oil pres-sure, coolant temperature, etc.).

Do only demand as much from the engine as it hasto perform when properly employed. Please seedetailed information in sales documents.

Modifications of setpoints preset by the manufac-turer, especially injection pumps, current limiters,and pressure limiters of hydraulic units, may only beexecuted after written consent of GHH FahrzeugeGmbH.

When filling the tires never stand beside the wheelbecause you may be endangered by snap ringscoming off.

Have only specially trained people carry out repairsof tires, especially mounting and dismantling to andfrom wheel rims. Snap rings may often be pre-stressed to a very high extent and are to be handledwith special care.

Never carry out work with open flames, welding,cutting and flame-cutting of wheel rims as long astires are still mounted.

Some of the parts or operating materials in themachines which are absolutely necessary foroperation are hazardous for humans and the envi-ronment. Therefore observe operating instructionsand manufacturer's instructions on enclosures,stickers and manuals.

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3.2 - 1LF-9.3030260_en12.10

3.2 Maintenance and servicing

Warning Trouble-free operation and a long service life require regular and proper maintenanceand servicing.

Warning The warranty is immediately void if any anti-tamper seals or paint seals attached to thevehicle systems are detached or destroyed.

Regular maintenance and servicing

The time for carrying out this type of work depends on the vehicle operating hours. See Checklist-regularmaintenance according to service hours.

Irregular maintenance and servicing

The irregular work is divided into the following subgroups:

- Maintenance and servicing of new vehicles, after a basic overhaul, after installation of replaced compo-nents, etc. up to the time at which regular work is to be carried out.

- Maintenance and servicing of individual components which are particularly affected by varying opera-ting conditions.

- Maintenance and servicing work which cannot either be determined by the number of operating hours,or whose intervals deviate from the usual apportioning into the number of operating hours.

- Special measures for operation at low temperatures see 2.8 - 1 winter operation.

General remarks

The work specified in the check lists will be detailed in the various sections of the maintenance and servi-cing instructions.

Various items of the specified work may involve identical work steps. To avoid repetitions in the descrip-tions, these work steps are described below.

- Safety at workNote safety instructions for maintenance and servicing.

- Cleaning the vehicleBefore starting any work, clean components located in the respective work area. The selection of theproper cleaning agent depends on the material of the parts to be cleaned. For example, rubber or elec-trical parts should not be cleaned with benzene or steam jet.

- After cleaning with steam jet, lubricate all bearings.

- Covering all mounting areas

To avoid the ingress of dirt, cover all open bores, connections and housings in a suitable manner imme-diately.

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- Corrosion protection

Touch up damaged painted surfaces, grease bright spots regularly.

- Exchanging parts (in-shrunk bushings see Section 3.2 - 3)

Exchange defective parts in good time to avoid major damage.

- Protecting the electrical system

Where the danger of electric conductors coming into contact with tools, spare parts, vehicle frame, etc.exists, turn off the main switch.

- Checking of oil level

Unless indicated otherwise, the oil level is to be checked invariably on an even surface and after theengine has been at standstill for approx. 10 minutes.

- Oil change

Drain oil from warm components only. Clean surrounding of the filling port. Fill up oil from clean contai-ners only. Do not remove strainers from filling ports.Check oil level after a brief trial run.

- Check sealing elements

When removing caps, plug screws, etc., pay attention to existing sealing elements. Replace seal rings,if required. Upon re-assembly make sure that they are properly seated.

- Check sealing faces

Prior to re-assembly, clean all sealing surfaces and check for leaks after assembly.

- Check locking elements

Pay attention to existing locking elements while disassembling parts (lock washers, cotter pins, etc.).Check locking elements and replace, if required.

- Lubrication

Clean grease fittings before and after lubrication. Remove any excess grease from lubrication points.

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Cold shrinking by nitrogen

For the processing of parts which are made from steel, bronze and polyester resin fabric-type compoundmaterials and which are to be cold-shrunk by liquid nitrogen, observation of the following safety notesand processing sequences is mandatory:

Safety notes

Liquid nitrogen has a temperature of -196 °C, which is why any contact with liquid nitrogen and undercoo-led material must be avoided. To do so, protective clothing suiting the requirements (but at least protectivegoggles and protective gloves) shall be worn.

Liquid nitrogen may be processed in well-ventilated rooms only, so as to avoid lack of oxygen caused bythe breathing air being enriched with too much nitrogen. Gaseous nitrogen is a colourless, tasteless andodourless gas contained in the normal ambient atmosphere at a rate of 78%. Provided that sufficientlylarge amounts of fresh air are supplied, the nitrogen, which upon heating of the frigorific mixture haschanged to the gaseous phase, poses no special risk.

Inserting and withdrawing work pieces should preferably be done with the help of equipment made frommaterials tough at subzero temperatures, such as hemp ropes, copper wire, tongs and hooks made ofsuitable stainless steel grades (1.4541), as far as these are subjected to the influence of liquid nitrogen.When exposed to subzero temperatures, ordinary structural steels lose their toughness and become cold-brittle.

Preparation and execution of shrink joint:

The dimensions of the insulating tank to be used should preferably match the work piece. The work pieceto be cooled down is submerged into liquid nitrogen. On account of the high differential temperature thiswill first cause vigorous boiling of the nitrogen bath. While the bath cools down, the shrink-joint surfacemust remain evenly wetted with liquid nitrogen. As soon as boiling stops, the work piece has shrinkagetemperature any may be removed from the bath. Cooling-down times depend on the material and on thework piece dimensions. For steel, e.g., the estimative values in the table below apply:

Wall thickness/diameter in mm 50 100 200

Immersion time in minutes 5 10 20

Warning The maximum admissible immersion time for sleeves made of polyester-resin fabric-type compound materials is 10 minutes.

After its removal from the bath, the work piece must be processed immediately, i.e., positioned as shownin the fabrication documents and fixed in the specified position, if any. What must be observed especiallywith smaller, thin-walled work pieces is that these may adjust to the ambient temperature and thereforelose their joining tolerance already after a short time.

While joining undercooled materials, no impacts must be applied to the work piece, as this would increasethe material's sensibility to brittle fracture

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3.3 Irregular maintenance and servicing

Prior to initial operation

- Check all oil levels.

- Check lubrication of all lubricating points.

- Check all tanks, housings, lines, etc., for leaks.

- Check tightening torques of wheel nuts.

- Check tire pressure.

- Check function of electrical system.

- Check function of operating elements and control instruments.

- Check function of brake system.

- Check function of dump/hoist and steering hydraulic system.

After initial operation

of the complete vehicle or of individual components, up to the start of regular maintenance.

Engine

Refer to engine operating instructions.

Wheel nuts

Check tightening torque after 10 operating hours.

Air filter

For air filter maintenance see 3.8-1 intake system.

Lubrication

The lubrication intervals of the grease lubrication points depend on the operating conditions (see regularmaintenance and servicing). Lubricate vehicle after each steam-jet cleaning.

Fuel tank

Extract sludge at the bottom of the fuel tank once a year. Flush the tank and clean the intake filter.

Hydraulic oil return filter

Change filter if with hydraulic system at operating temperature the “Return pressure” signal lamp lightsup or the “Return pressure” analog indicator indicates a pressure of > 1.3 bar.

Warning Filter element cannot be washed.

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3.4 - 1LF-9.3Schmier_en12.10

3.4 List of lubricants and operating agents

Warning The use of operating agents not specified herein must, if necessary, be clarified withthe manufacturer of the component/unit.

The use of additives in combination with the operating agents specified (e.g. flow improving agents fordiesel fuels, oil additives etc.) shall, as a rule, be agreed on beforehand with the manufacturer of the com-ponent or assembly.

Note For high reliability and minimal wear of your machine, always use high-viscosity lubri-cants suited to the season and the ambient temperature.

Lubricantand opera-ting agents

Spezification Ambienttemperature(°C)

Classification/Mixing ratio

Subassembly/Component

Remark

Engine oil APICF-4 1)

CG-4; CH-4 2)

ACEAE2-96 1)

E3-96; E4-98 2)

SAE-viscosity classaccording toDIN 51511

-25 ⇒ +20 SAE 10 W-30Lubrication ofdrive engine

Lubricantsreferred toin compar-able specifi-cations, notlisted here,may also beused.

-25 ⇒ +25 SAE 10 W-40

-20 ⇒ +25 SAE 15 W-30

-20 ⇒ +>30 SAE 15 W-40

Coolant Cooling system addi-tiveDEUTZ 0101 1490DEUTZ 1221 1500

Ethyl glykol may alsobe used as anticorro-sive agent/antifreeze 3).

Frostproof⇒ -22

65 % Water/35 % additive

Cooling systemof drive engine

The mixingratio may varyaccording tothe climaticconditions.

Warning:Too high apercentageof protectiveagent de-creases thecooling per-formance.

Frostproof⇒ -28


Frostproof⇒ -35


Fuel Diesel fuel according toDIN 51601, Cetannumber not below 45

ASTM D975-881-D and 2-D

BS 2869, A1 and A2

> 0 Summer diesel Fuel system ofdrive engine

0 ⇒ -20 100%Winter diesel(four-star diesel)

Make sure to addpetroleum at tem-peratures below-15°C or -20°C 3).

1) admissible for suction engines2) to be used for supercharged engines3) refer to engine operating instruction

GHH Fahrzeuge GmbH

3.4 - 2LF-9.3Schmier_en12.10

List of lubricants and operating agents





Remark

Brake fluid DOT 4/SAE J 1703

all year Speedadjustment

Hydraulic oil HVLPDIN 51524 T3

-35 ⇒ +15 ISO VG 15 Steering anddump/hoisthydraulic system

-28 ⇒ +25 ISO VG 22

-22 ⇒ +33 ISO VG 32

-15 ⇒ +45 ISO VG 46

- 5 ⇒ +50 ISO VG 68

0 ⇒ +60 ISO VG 100

HLPDIN 51524 T2

-22 ⇒ +20 ISO VG 22

-15 ⇒ +30 ISO VG 32

-10 ⇒ +40 ISO VG 46

0 ⇒ +50 ISO VG 68

+ 7 ⇒ +57 ISO VG 100

Transmission oil ATF -20 ⇒ +10 C4, TO-4, J20 C/DMIL-PRF-2104GGrade 10

Converter-trans-mission hydraulicsystem

0 ⇒ + 35 C4, TO-4, J20 C/DMIL-PRF-2104GGrade 10

Note For transmissions that are executed with a clutch modulation, the suffix ”with modula-tion” is added to the type desgination in the technical data.

Note On some transmissions and torque converters with a throughshift clutch no ATF oils®Dextron II D may be used. The oils based on this specification are not compatible withgraphitic friction linings. That is why these oils shall only be used after prior consultationwith our Service department or the manufacturer of the component.®Dextron is a registered trademark of the General Motors Corporation.

API GL5, ®Dexron III and multiviscosity oils with a temperature range of more than 10points, e.g. 10W30, shall, as a rule, not be used.

GHH Fahrzeuge GmbH

3.4 - 3LF-9.3Schmier_en12.10

List of lubricants and operating agents





Remark

Transmission oil Hypoid-gear oilMIL-L - 2105 BAPI GL5API GL5 LS

Hypoid multigradeoilMIL-L - 2105 C / DAPI GL5

> +30 SAE 140 Axleplanetary gear

differential gear-10 ⇒ +30 SAE 90

-35 ⇒ +38 SAE 75W-90

-26 ⇒ +38 SAE 80W-90

-35 ⇒ >+60 SAE 75W-140

-26 ⇒ >+60 SAE 80W-140

-12 ⇒ >+60 SAE 85W-140

Lubricatinggrease:

Lithium grease ofNLGI class 2 4)

-30 ⇒ +130 K2K-30DIN 51502

grease fittingsbearingsdrivelines

Lubricatinggrease:

GraphiteK2K DIN 51502

-30 ⇒ +130 K2K DIN 51502 sliding surfacemetal / metal

4) Lithium-saponified greases with a penetration of 265/295 and a thawpoint of approx. 180 °C.The lubricants must not contain any MoS2 additives.

Note For axles with a multi-disc self-locking differential (limited slip differential) (see typedesignation in the technical data sheet), lubricant ”API GL5 LS” shall, as a rule, be used.Optionally, the lubricant can also be used for axles with no multi-disc self-locking differ-ential.

GHH Fahrzeuge GmbH

3.5 - 1LF-9.33_5-1_en12.10

3.5 Checklist - Vehicle no....................

Maintenance intervals: daily

Maintenance work Measures/Remarks/Cross references

Operat. agents/Quantity/Dimensions

Note ofperfor-mance

1. Lubricating points1.1 Lubrication of bearings

Notesee 3.5 - 23

steering cylinder 4 grease fittings

hoist cylinder 4 grease fittings

dump cylinder 2 grease fittings

boom-stabilizer link 1 grease fitting

bucket-connecting link 1 grease fitting

connecting link -stabilizer link 2 grease fittings

swivel joint top

bottom

1 grease fitting

1 grease fitting

swing axle front

rear

1 grease fitting

1 grease fitting

boom-payload unit 2 grease fittings

boom-bucket 2 grease fittings

Remarks:

Remarks:

Warning Lubricants with solid additives (e.g. molybdenum bisulphide) shall never be applied tobearing positions where polyester resin fabric composite materials are used.

GHH Fahrzeuge GmbH

3.5 - 2LF-9.33_5-2_en12.10

Checklist - Vehicle no....................

Maintenance intervals: - drive engine

Maintenance work

check

change

clean

Measures/Remarks/Cross references


Note ofperform-ance

1. Drive engineAll engine mainte-nance work accord-ing to enginemanufacturer's main-tenance plan.Remarks:

Remarks:

Remarks:

Remarks:

Remarks:

GHH Fahrzeuge GmbH

3.5 - 3LF-9.33_5-3_8_en12.10


Note The position of the measuring points for the individual pressure measurements shall betaken from the relevant system drawing and the measuring points plan, see page3.5 - 21. As a rule, only calibrated measurement instruments shall be used.

Maintenance intervals

150 h 300 h 450 h 750 h 900 h 1050 h 1350 h 1500 h etc. see section 3.6

All maintenance work marked with a grey background field on the side only has to be carriedout at the 300 h / 900 h / 1500 h .......... maintenance intervals.

Maintenance work

check

change

clean



Note ofperform-ance

1. Axles1.1 Visual check for leaks

oIn case of leaks find causeand, if necessary, changecomponent.

1.2 Breather o Check for damage,if necessary, change compo-nent. see 3.14 - 2

Remarks:

2. Wheels2.1 Wheel nuts for com-

pleteness and firmseating

NoteIn case of wheel changeand when replacing/retigh-tening wheel nuts observethe tightening torques.

o

Tighten, if necessaryfront right/left

rear right/left

( 445 Nm )

( 445 Nm )

2.2 Condition of tyreso

Replace, if necessaryfront right/left

rear right/left

2.3 Tyre filling pressureo

Correct, if necessaryfront right/left

rear right/left

6.0 ± 0.1 bar

3.5 ± 0.1 bar

Remarks:

GHH Fahrzeuge GmbH

3.5 - 4LF-9.33_5-3_8_en12.10


Maintenance intervals: 150/300/450/750 Bh .............

Maintenance work

check

change

clean



Note ofperform-ance

3 Vehicle in general3.1 Bolt locks for coplete-

ness, condition andfirm seating.

o steering cylinder right/left

o hoist cylinder right/left

o dump cylinder top/bottom

o bucket-connecting link

o boom-stabilizer link

o swivel joint top/bottom

o payload unit- right/leftboom

o boom- right/leftbucket

Remarks:

3.2 Connecting screws forcompleteness and firmseating

NoteWhen replacing/retighteningconnecting screws observethe tightening torques.

o engine mounting base ( 296 Nm )

o transmission fastening

flexible supporting

M10- ( 50 Nm )3/4”- ( 525 Nm )M16- ( 90Nm )

o torque converter fastening ( 48 Nm)

o axle fastening M24x1,5( 1160 Nm )

M30x2( 2206 Nm )

oConnecting of drivelines

an axle flange see 3.13 - 2flange bearing

M12- ( 120 Nm )M14- ( 195 Nm )M14- ( 225 Nm )M16- ( 210 Nm )

Remarks:

GHH Fahrzeuge GmbH

3.5 - 5LF-9.33_5-3_8_en12.10



Maintenance work

check

change

clean



Note ofperform-ance

4. Steering and dump/hoist hydraulic system4.1 Connections, lines and

hoses for leaks. oIn case of leaks find causeand, if necessary, changecomponent.

4.2 Oil level inhydraulic oil tank.

o

On the level indicator with driv-ing engine running and re-tracted cylinders.Top up oil, if necessarysee 3.17 - 1 and 3.17 - 2

Remarks:

5. Converter-transmission hydraulic system5.1 Connections, lines and


5.2 Oil cooler o Blow through with compressedair

5.3 Oil levelconverter-transmission

o

Check oil level at service tem-perature and with driving en-gine running. Oil level betweenMIN and MAX marks on dip-stick.Top up oil, if necessary.see 3.12 - 2

5.4 Oil filter cartridge o see 3.12 - 4

5.5 Converter and trans-mission ventilation o

Check for damage, if necess-ary, change component.see 3.12 - 1

Remarks:

GHH Fahrzeuge GmbH

3.5 - 6LF-9.33_5-3_8_en12.10



Maintenance work

check

change

clean



Note ofperform-ance

6. Service brake6.1 Connections, lines and


6.2 Brake pressureTreadle brake valve o

Test fitting B5 front axle.see section 4, drawing forbrake system.

110+/-3.5 bar

Residual pressuremax. 0,5 bar, athigh idling speed.

oTest fitting B6 rear axle.see section 4, drawing forbrake system.

110+/-3.5 bar


6.3 Cooling pressureo

Test fitting B24 and B25front axle.Service brake actuated.see section 4, drawing forbrake system

max. 0.7 bar, athigh idling speed.

oTest fitting B26 and B27rear axle.Service brake actuated.see section 4, drawing forbrake system


6.4 Dynamic pressureo

Test fitting B11.see 3.16 - 3 and section 4,drawing for brake system

max 10 bar, athigh idling speed.min 15 bar, athigh idling speed,1 nozzle closed

6.5 Pressure switch S53

o

Test fitting B4.Available pressure of brakesystem = 140+10 bar, operat-ing voltage switched on. Re-duce the pressure by repeat-edly actuating the servicebrake.see section 4, drawing forbrake system

Warning lamp“available brakingpressure” in dri-ver's cab lights upwhen pressuredrops below100 bar

Remarks:

GHH Fahrzeuge GmbH

3.5 - 7LF-9.33_5-3_8_en12.10



Maintenance work

check

change

clean



Note ofperform-ance

6.6 Available brake pres-sure, switching pres-sure of shut-off valve.

Check pressure gaugemanometer/indicator

o Test fitting B4.see section 4, drawing forbrake system

120+10 bar- ON140+10 bar-OFF

6.7 Functional test ofdiaphragm accumula-tor

o

Test fitting B4.Available pressure of brakesystem = 140+10 bar, drivingengine switched off. Parkingbrake released. 4 times withmax. pressure at 10 sec inter-vals.see section 4, drawing forbrake system

Residual pressuremin. 90 bar

6.8 Brake system forleakage

o

Test fitting B4.Available pressure of brakesystem = 140+10 bar. Drivingengine switched off. Parkingbrake released.see section 4, drawing forbrake system

After one-hourimmobilizationtime:min. 100 bar

Remarks:

7. Electrical system7.1 Function of instruments

and signal lamps in thedriver's cab. o

When driving engine running.Press signal lamp test pushbut-ton

7.2 Function of the lightingsystem o

front

rear

Remarks:

GHH Fahrzeuge GmbH

3.5 - 8LF-9.33_5-3_8_en12.10



Maintenance work

check

change

clean



Note ofperform-ance

8. Lubricating points8.1 Lubrication of drivelines

Notesee 3.13

converter-transmission 2 grease fittings

transmission-intermediate driveline

2 grease fittings

intermediate driveline-front axle

2 grease fittings

transmission-rear axle 2 grease fittings

flange bearing 2 grease fittings

8.2 Lubrication of bearings

Notesee 3.5 - 23






connecting link-stabilizer link 2 grease fittings

swivel joint top

bottom

1 grease fitting

1 grease fitting

swing axle front

rear

1 grease fitting

1 grease fitting

boom-payload unit 1 grease fitting


Door on the driver's cab 2 grease fittings

Remarks:


GHH Fahrzeuge GmbH

3.5 - 9LF-9.33_5-9_20_en12.10


Note The position of the measuring points for the individual pressure measurements shall betaken from the relevant system drawing and the measuring points plan, see page3.5 - 21. As a rule, only calibrated measurement instruments shall be used.

Maintenance intervals:

600 Bh 1200 Bh 1800 Bh 2400 Bh 3000 Bh 3600 Bh 4200 Bh 4800 Bh etc. see section 3.6

All maintenance work marked with a grey background field on the side only has to be carriedout at the 1200 Bh / 2400 Bh / 3600 Bh .......... maintenance intervals.

Maintenance work

check

change

clean



Note ofperfor-mance

1. Axles1.1 Visual check for leaks

oIn case of leaks find causeand, if necessary, changecomponent.

1.2 Oil leveldifferential gear o

Oil level up to lower edge ofcheck hole.Top up oil, if neseccary.see 3.14 - 2

front axle

rear axle

1.3 Oil levelplanetary gear

o

Oil level up to lower edge ofcheck holeTop up oil, if neseccary.see 3.14 - 2

front axlerightleft

rear axlerightleft

1.4 Breather o Check for damage,if necessary, change compo-nent. see 3.14 - 2

1.5 Oil differential gear

o

Drain oil while still warm.Top up oil to lower edge ofcheck hole.Check oil level again afterwaiting for a few minutes.see 3.14 - 2

front axlefilling volume 29.8 l

rear axlefilling volume 29.8 l

1.6 Oil planetary gear

o

Drain oil while stillwarm.Top up oil to lower edge ofcheck hole.Check oil level again afterwaiting for a few minutes.see 3.14 - 2

front axle: fillingvolume 2 x 4.7 l

rear axle: fillingvolume 2 x 4.7 l

Bemerkungen:

GHH Fahrzeuge GmbH

3.5 - 10LF-9.33_5-9_20_en12.10


Maintenance intervals: 600/1200/1800/2400 Bh ..........

Maintenance workcheck

change

clean



Note ofperfor-mance

2. Wheels2.1 Wheel nuts for com-

pleteness and firmseating

HinweisIn case of wheel changeand when replacing/retigh-tening wheel nuts observethe tightening torques.

o

Tighten, if necessaryfront right/left

rear right/left

( 445 Nm )

( 445 Nm )

2.2 Condition of tyreso

Replace, if necessaryfront right/left

rear right/left

2.3 Tyre filling pressureo

Correct, if necessaryfront right/left

rear right/left

6.0 ± 0.1 bar

3.5 ± 0.1 bar

Remarks

3 Vehicle in general3.1 Bolt locks for comple-

teness, condition andfirm seating.

o steering cylinder right/left

o hoist cylinder right/left

o dump cylinder

o bucket-connecting link

o boom-stabilizer link

o swivel joint top/bottom

o payload unit- right/leftboom

o boom- right/leftbucket

Remarks

GHH Fahrzeuge GmbH

3.5 - 11LF-9.33_5-9_20_en12.10



Maintenance work

check

change

clean



Note ofperfor-mance

3.2 Connecting screws forcompleteness and firmseating

NoteWhen replacing/retighteningconnecting screws observethe tightening torques.

o engine mounting base ( 296 Nm )

o transmission fastening

flexible supporting

M10- ( 50 Nm )3/4”- ( 525 Nm )M16- ( 90Nm )

o torque converter fastening ( 48 Nm)

o axle fastening M24x1,5( 1160 Nm )

M30x2( 2206 Nm )

oConnecting of drivelines

an axle flange see 3.13 - 2flange bearing

M12- ( 120 Nm )M14- ( 195 Nm )M14- ( 225 Nm )M16- ( 210 Nm )

3.3 Speed adjustmento

For ease of movement andtradle stop.Indicator engine speed on thedriver's cab.

engine speed2480 ± 50 min-1

Remarks

4. Steering and dump/hoist hydraulic system4.1 Connections, lines and


4.2 Oil level inhydraulic oil tank.

o

On the level indicator with dri-ving engine running andretracted cylinders.Top up oil, if necessarysee 3.17 - 1 and 3.17 - 2

4.3 Aeration/ventilation fil-ter on hydraulic oil tank.

o see 3.17 - 1

Remarks

GHH Fahrzeuge GmbH

3.5 - 12LF-9.33_5-9_20_en12.10



Maintenance work

check

change

clean



Note ofperfor-mance

4.4 Oil on hydraulic oiltank.

o

Drain oil while still warm.With driving engine switchedoff and retracted cylinders.Vent hydraulik system aftereach change of hydraulic oil.see 3.17 - 3

filling volume350 l

4.5 Steering pressuresteering direction left

o

Measuring point H1.Steering at end stop.see 3.17 - 3 and section 4, dra-wing for steering and dump/hoist hydraulic system.

175 +10/-5 barengine speed1500 min-1

4.6 Steering pressuresteering directionright o

Measuring point H1.Steering at end stop.see 3.17 - 3 and section 4, dra-wing for steering and dump/hoist hydraulic system.


4.7 Working pressure

o

Measuring point H2.Hoist cylinder extendetsee 3.17 - 3 and section 4, dra-wing for steering and dump/hoist hydraulic system.


o

Measuring point H2.Dump cylinder retractedsee 3.17 - 3 and section 4, dra-wing for steering and dump/hoist hydraulic system.


Remarks

Remarks

GHH Fahrzeuge GmbH

3.5 - 13LF-9.33_5-9_20_en12.10



Maintenance work

check

change

clean



Note ofperfor-mance

5. Converter-transmission hydraulic system5.1 Connections, lines and


5.2 Oil levelconverter-transmission

o

Check oil level at service tem-perature and with drivingengine running. Oil level bet-ween MIN and MAX marks ondipstick.Top up oil, if neseccary.see 3.12 - 2

5.3 Oil cooler o Blow through with compressedair

5.4 Oil filter cartridge o see 3.12 - 4

5.5 Converter and trans-mission ventilation o

Check for damage, if neces-sary, change component.see 3.12 - 1

Remarks

5.6 Oil converter-transmis-sion

o

Drain oil while still warm.Check oil level at service tem-perature and with drivingengine running. Oil level bet-ween MIN and MAX marks ondipstick.see 3.12 - 3

filling volumecircuit 36.0 l

5.7 Intake strainer o on transmission sumpsee 3.12 - 1 and 3.12 - 3

Remarks

GHH Fahrzeuge GmbH

3.5 - 14LF-9.33_5-9_20_en12.10



Maintenance work

check

change

clean



Note ofperfor-mance

6. Service brake6.1 Connections, lines and


6.2 Brake pressureTreadle brake valve o

Measuring point B6 front axle.see section 4, drawing forbrake system.

110+/-3.5 bar


oMeasuring point B5 rear axle.see section 4, drawing forbrake system.

110+/-3.5 bar


6.3 Cooling pressureo

Measuring point B24 and B25front axle.Service brake actueted.see section 4, drawing forbrake system


oMeasuring point B26 and B27rear axle.Service brake actueted.see section 4, drawing forbrake system


6.4 Dynamic pressureo

Measuring point B11.see 3.16 - 3 and section 4,drawing for brake system

10 + 2 bar, at highidling speed.

6.5 Pressure switch B53

o

Measuring point B4.Available pressure of brakesystem = 140+10 bar, operat-ing voltage switched on. Re-duce the pressure by repeat-edly actuating the servicebrake.see section 4, drawing forbrake system

Warning lamp“available brakingpressure” in dri-ver's cab lights upwhen pressuredrops below100 bar

Remarks

GHH Fahrzeuge GmbH

3.5 - 15LF-9.33_5-9_20_en12.10



Maintenance work

check

change

clean



Note ofperfor-mance

6.6 Available brake pres-sure, switching pres-sure of shut-off valve.

Check pressure gaugemanometer/indicator

o Measuring point B4.see section 4, drawing forbrake system

120+10 bar- ON140+10 bar-OFF

6.7 Functional test ofdiaphragm accumula-tor

o

Measuring point B4.Available pressure of brakesystem = 140+10 bar, drivingengine switched off. Parkingbrake released. 4 times withmax. pressure at 10 sec inter-vals.see section 4, drawing forbrake system

Residual pressu-re min. 90 bar

6.8 Brake system forleakage

o

Measuring point B4.Available pressure of brakesystem = 140+10 bar. Drivingengine switched off. Parkingbrake released.see section 4, drawing forbrake system

After one-hourimmobilizationtime:min. 100 bar

6.9 Pressure gradiento

Measuring pointB24 and B28B25 and B29B26 and B30B27 > B31

Service brake actuated.see section 4, drawing forbrake system

pressureB24 > B28B25 > B29B26 > B30B27 > B31at high idlingspeed.

Remarks

Remarks

GHH Fahrzeuge GmbH

3.5 - 16LF-9.33_5-9_20_en12.10



Maintenance work

check

change

clean



Note ofperfor-mance

6.10 Pressure switch B55forward/reverse inter-lok

o

Measuring point B6.Drive the vehicle at low speedand stop with the servicebrake. Shift into 1st gear of theopposite driving direction andraise the brake pressure.see section 4, drawing forbrake system.

Change-over ofdriving directionat a brake pres-sure 40+2 bar

6.11 Pressure relief valveitem 10

only at Bh2400 / 4800 / 7200 .....

oRemove the pressure switchand check the adjusted pres-sure point on a adequate testequipment. If necessary,change component.see section 4, drawing forbrake system.

Switch activatingpoint at 180+5bar rising.

6.12 Wear of the multi-disko

Dimensional check.Brake pedal depressed.

rear wheel right/left

front wheel right/leftif necessary, change compo-nent. see 3.15 - 9

adjusted dimen-sion = 7.6 mm

6.13 Braking decelerationo

Dynamic brake measurement,with recording instrument.Brake test in highest gear,vehicle laden.Inspect brake, if necessary.

min. 55%

6.14 Brake response time

o

Dynamic brake measurement,with recording instrument.Brake test in highest gear,vehicle laden.Inspect brake, if necessary.

1 sec. afteractuating thebrake the retarda-tion must havereached 38%

Remarks

Remarks

GHH Fahrzeuge GmbH

3.5 - 17LF-9.33_5-9_20_en12.10



Maintenance work

check

change

clean



Note ofperfor-mance

7.Remarks

Remarks

GHH Fahrzeuge GmbH

3.5 - 18LF-9.33_5-9_20_en12.10



Maintenance work

check

change

clean



Note ofperfor-mance

8. Electrical system8.1 Battery

oCheck visually for leaks andfirm seating of connections.

oLiquid level.Top up with distelled water ifnecessary

o Coat poles with grease.Use acidproof grease.

8.2 Function of instrumentsand signal lamps in thedriver's cab. o

When driving engine running.Press signal lamp test push-button

8.3 Function of the lightingsystem o

front

rear

Remarks

9. Lubricating points8.1 Lubrication of drivelines

Notesee 3.13

converter-transmission 2 grease fittings

transmission-intermediate driveline

2 grease fittings

intermediate driveline-front axle

2 grease fittings

transmission-rear axle 2 grease fittings

flange bearing 2 grease fittings

Remarks

Remarks

GHH Fahrzeuge GmbH

3.5 - 19LF-9.33_5-9_20_en12.10



Maintenance work

check

change

clean



Note ofperfor-mance

8.2 Lubrication of bearings

Notesee 3.5 - 23






connecting link-stabilizer link 2 grease fittings

swivel joint top

bottom

1 grease fitting

1 grease fitting

swing axle front

rear

1 grease fitting

1 grease fitting

boom-payload unit 1 grease fitting


Door on the driver's cab 2 grease fittings

Remarks:

Remarks:

Remarks:


GHH Fahrzeuge GmbH

3.5 - 20LF-9.33_5-9_20_en12.10


Maintenance intervals: according to maintenance indicator

Maintenance work

check

change

clean



Note ofperfor-mance

Steering and dump/hoist hydraulic systemReturn filter cartridge o Filter cartridge is integrated

with the hydraulics oil tank. -see 3.17 - 4

Remarks

Service brakeIn-line filter cartridge o see 3.15 - 8

Remarks

Remarks

Remarks

Remarks

Remarks

GHH Fahrzeuge GmbH

3.5 - 21LF-9.33_5-21_22_en12.10

Measuring-point plan, location of the control valves

H2 H10-H13H20-H23

(3)

H24, H25 (2)

H1 (4)H9

1B6, B27,

B31B5, B25,

B29

B26,B30, B6

B24,B28, B5

B4, B11(10, 12, 15,17, 19, 20,21, 30, 34,

35, 36)

13, 16

31, 32

18, 34 6

18

Measuring-points

Steering- dump/hoist hydraulic system Brake system

H1 system pressure steering hydraulic B4 available brake pressure,

H2 system pressure dump/hoist hydraulic switching pressure of shut-off valve.

H9 control pressure pressure switch B53.1 and 53.2, accumu-lator test

H10-13 servo pressure directional control valve B5 brake pressure front axle

H20 secondary pressure hoist cylinder B6 brake pressure rear axlepressure switch B51, B52, B53

H21 secondary pressure hoist cylinder B11 dynamic pressure cooling multi-disk brake

H22 secondary pressure dump cylinder B24-B27 and B28-B31

H23 secondary pressure dump cylinder pressure gradient, cooling pressure

H24 secondary pressure steering cylinder

H25 secondary pressure steering cylinder

GHH Fahrzeuge GmbH

3.5 - 22LF-9.33_5-21_22_en12.10

Location of the valves

Steering- dump/hoist hydraulic system Brake system

1 priority valve item 15 10 shut-off valve item 3

2 pressure relief valve item 13 12 pressure relief valve item 10

3 directional control valve item 18 15 distributor block item 800

4 valve unit with accumulator item 21 16 hand pump item 29

6 reverse-flow filter item 40 17 high pressure filter item 2

18 ball cock item 27

19 accumulator item 8

20 valve item 15

21 valve item 26

30 pressure switch B51



34 pressure switch B47.1



GHH Fahrzeuge GmbH

3.5 - 23LF-9.33_5-22_en12.10

Lubrication points

1 2 3 9 10 18,19,20

2116,17

22

12,137,845,6

14,15

23 24

1,2

1 Swing axle bearing (on dristributor) 13 Hoist cylinder bearing

2 Swing axle bearing (on dristributor) 14 Hoist cylinder bearing

3 Swivel joint bearing top (on dristributor) 15 Hoist cylinder bearing

4 Swivel joint bearing bottom (on dristributor) 16 Bucket bearing

5 Steering cylinder bearing 17 Bucket bearing

6 Steering cylinder bearingr 18 Stabilizer link bearing

7 Steering cylinder bearing 19 Stabilizer link bearing

8 Steering cylinder bearing 20 Dump cylinder bearing

9 Dump cylinder bearing 21 Connecting link bearing

10 Boom bearing 22 Stabilizer link bearing

11 23 Flange bearing driveline

12 Hoist cylinder bearing 24 Flange bearing driveline

7,8 3,4right and left

GHH Fahrzeuge GmbH

3.6 - 1LF-9.3030381_en12.10

3.6 Maintenance work carried outMaintenance intervals: 150/300/450/750 Bh .............

Hours inservice

Data SignatureHours inservice


Data Signature

150 7950 15750300 8100 15900450 8250 16050750 8550 16350900 8700 16500

1050 8850 166501350 9150 169501500 9300 171001650 9450 172501950 9750 175502100 9900 177002250 10050 178502550 10350 181502700 10500 183002850 10650 184503150 10950 187503300 11100 189003450 11250 190503750 11550 193503900 11700 195004050 11850 196504350 12150 199504500 12300 201004650 12450 202504950 12750 205505100 12900 207005250 13050 208505550 13350 211505700 13500 213005850 13650 214506150 13950 217506300 14100 219006450 14250 220506750 14550 223506900 14700 225007050 14850 226507350 15150 229507500 15300 231007650 15450 23250

GHH Fahrzeuge GmbH

3.6 - 2LF-9.3030381_en12.10

Maintenance work carried outMaintenance intervals: 600/1200/1800/2400 Bh ............

Hours inservice



Data Signature

600 8400 162001200 9000 168001800 9600 174002400 10200 180003000 10800 186003600 11400 192004200 12000 198004800 12600 204005400 13200 210006000 13800 216006600 14400 222007200 15000 228007800 15600 23400

GHH Fahrzeuge GmbH

3.7 - 1LF-9.3030390_en12.10

3.7 Engine operating instructions

Before carrying out any maintenance and servicing work on the diesel engine, please carefully read theattached engine manufacturer's operating instructions.

Satisfactory operation of the diesel engine in the long term can only be ensured by investing a certainamount of work in maintenance.

This work is a prerequisite for long engine service life and for maintaining the performance, consumptionlevel and exhaust gas quality.

Warning It is recommended to contact the GHH Fahrzeuge GmbH customer service to eliminatefailures and to carry out checks, adjustment or repair works. As regards inquiries byphone mind page 1.2-1.

GHH Fahrzeuge GmbH

3.8 - 1LF-9.33_8-1_2_en12.10

3.8 Air intake system

Note The vehicle is equipped with a dry-air filter. Whenever the filter is serviced, the connec-ting points of the intake pipes have to be checked for leaks.

The dry air filter is equipped with an integrated pre-separator, a 6-stage vacuum indicator and, dependingon the type, a main and safety element. The main element respectively main element and safety elementmust also be replaced outside the maintenance intervals as soon as the display of the underpressure indi-cator changes to the red area.

Note The maximum service life of the main element must not exceed one year.Damaged filter elements and seals must be in any case be replaced forthwith.

Note With every third maintenance of the main element, the safety element, if present, mustbe replaced as well. The number of maintenances must be marked on the safety el-ement, e.g. by means of a bar drawn with a felt-tip pen.

Depending on the filter type, either a dust collecting vessel or a dust discharge valve is fitted.

- Dust collecting vessel (2) (fig. 1)

- Dust discharge valve (5) (fig. 2).

To protect the paper cartridge from overloading, the dust collecting vessel should be emptied when halffull, however, at least once a day. For emptying, remove the lid of the dust collector (see fig. 3). On thisfilter type, however, the discharge slot of the dust discharge valve should be cleaned periodically. Anybaked dust that may be present must be removed by compressing the valve.

Fig. 1Fig. 2

Fig. 3

1 32

5

4

9

8

Fig. 4

76

Fig. 4

filter ready for operationfilter servicing required

GHH Fahrzeuge GmbH

3.8 - 2LF-9.33_8-1_2_en12.10

Filter servicing includes following operations:

Note All maintenance work on the air intake system must be carried out with the engineturned off. Do not start the engine when the main element has been removed.

- Loosen clamp ring (9) and remove the dust collector (1) or loosen the wing nuts on the lid (4) and re-move the main element (2). The safety element (3) remains in the filter housing.

- Dispose of the main element in accordance with the applicable regulations. Clean the filter housing,especially the sealing area for the main element, using a damp cloth.

Note The main element (2) may be cleaned up to 6 times. Cleaned elements are, however,no longer covered by the warranty. To protect the engine, we recommend the use ofnew main elements.

- With every third replacement of the main element (2) the safety element (3) must be removed and re-placed as well.

Note The safety element must not be cleaned and reused.

- Cleaning with compressed airA pipe with its end angled at 90° should be fitted to the air pistol for cleaning the filter cartridge withcompressed air. The pipe should be long enough to reach the element bottom. Blow out the main el-ement from the inside to the outside using compressed air of max. 5 bar until no more dust is formed.

Warning Never wash or brush out the main element. When blowing out, make sure that no dustgets on the inside of the main element.

- Prior to fitting, the cleaned main element should be checked for any damage.

- Install main element respectively main element and safety element.

- Fit dust collector and secure with clamp ring or screw on lid with the wing nuts.

- Reset vacuum indicator (6) to its initial position by pressing the reset button (7). The indicator in thedisplay window (8) changes to ready for operation.

See operating instructions issued by the engine manufacturer for further information.

GHH Fahrzeuge GmbH

3.9 - 1LF-9.3030420_en12.10

3.9 Exhaust gas system

Note Check exhaust manifold and pipe regularly for firm seating and leaks.

Exhaust back pressure measurement

The max. exhaust back pressures indicated here refer to rated power and rated speed per exhaust gasside. They are measured at the converter stall torque. To do so, connect a suitable measuring instrument(e.g. U-tube filled with water) to the socket (G 3/8”) arranged right on the exhaust pipe flange.

The following exhaust back pressure values are admissible:

DEUTZ engine F6 L 413 F/FW max. 650 mm WC

F8 L 413 F/FW max. 750 mm WC



BF 4 L 1011 max. 750 mm WC

BF 12 L 413 FW max. 750 mm WC

F6 L 912 W max. 750 mm WC

F6 L 914 max. 750 mm WC

MAN engine D 0826 LF max. 600 mm WC

D 2865 LF max. 600 mm WC

D 2866 LF max. 600 mm WC

D 2866 LUH max. 600 mm WC

MWM engine D 916-6 max. 980 mm WC

D 932-V8 max. 980 mm WC

D 932-V12 max. 980 mm WC

DB engine OM 421 A max. 610 mm WC

Caterpillar engine 3304 PC-NA max. 860 mm WC

The exhaust back-pressure limit values also apply to the use of catalytic converters. Check exhaust backpressure at regular intervals.

Silencer, exhaust gas catalyst

The silencer and catalytic converter require no special maintenance and have to be replaced if defective.Check regularly for proper condition and firm seating.

CO-measurement

The maximum admissible CO level depends on the official regulations applicable at the jobsite.

GHH Fahrzeuge GmbH

3.10 - 1LF-9.3030430_en12.10

3.10 Fuel system

1

3

4

2

5

1 Screw cap

2 Intake nozzle

3 Drain plug

4 Tank lid

5 Intake filter

GHH Fahrzeuge GmbH

3.10 - 2LF-9.3030430_en12.10

Caution Shut off engine before working on the fuel system, including filling up fuel and checkingthe fuel line.Do not smoke or use open flame.Do not spill fuel on hot engine parts (exhaust pipe, etc.).

Checking of fuel level

- Clean intake nozzle and screw cap.

- Turn screw cap open and remove strainer.

- Check fuel level with a clean dipstick.

Note Never let the fuel tank run completely dry. If, for example, the tank is emptied for clea-ning, the fuel system has to be vented.

Filling up fuel

Never remove the strainer when filling up fuel and do not extract fuel from the bottom of a barrel as thiswill stir up the slurry at the bottom of the barrel. Provide a fine-mesh filter in the filling hose, if possible.

Note To prevent inflammation due to static charges, the intake nozzle and the mouth of thefilling nose must be in contact with each other.

Draining fuel

Use the drain plug on the tank underside to drain fuel or slurry. Make sure that the plug seals well.

Cleaning the intake filter

- Clean surroundings of the intake nozzle.

- Mark location of nozzle relative to the tank.

- Release fuel lines from tank lid and plug.

Release tank lid and lift off filler nozzle. Wash out intake filter with diesel fuel.

Mount nozzle and, while doing so, make sure that the gasket is properly seated. Replace gasket, if requi-red.

Warning Do not mix up lines.

Injection pump, fuel filter

Clean injection pump strainer and fuel filter cartridge. See engine manufacturer's operating instructions.

GHH Fahrzeuge GmbH

3.11 - 1LF-9.3032000_en12.10

3.11 Speed adjustment

The diesel engine speed is adjusted between idling and full load by depressing the treadle on the floorof the driver's cab, via a Bowden cable.

With depressed treadle and the engine at maximum speed, the full-load stop must be clearly felt at thestop screw arranged under the treadle.

Note Check treadle for ease of movement.

B

C, G

A

E

F

FH

Overstroke 2-3 mm

Secure sealing sleeves by clip andcable strap and check for leaks

Full load Idling

5

GHH Fahrzeuge GmbH

3.11 - 2LF-9.3032000_en12.10

Installation instructions

A Screw in treadle stop screw M5 down to its head and lock.

B Set treadle at 45° and lock.

C Remove treadle stop screw.

D Install complete treadle in vehicle.

E Mount end support with angle to the treadle.

F Install Bowden cable and adjust at clamping points “F”until the accelerator cable no longer sagsat both ends.

G Screw in new treadle stop screw M8x55 with lock nut as deep as possible.

- Depress treadle to full-load stop of injection pump and unscrew treadle stop screw until ittouches the treadle.

- Release treadle, unscrew treadle stop screw by another 3 revolutions and lock.

H With depressed treadle, a clearance (overstroke) of approx. 2 to 3 mm must exist at the enginethrottle linkage when the cable is pulled by hand.

Final check

Start engine and check speeds. Idling speed 600 +50 min-1(adjust on stop screw of injection pump adjusting lever).

High idling speed according to engine specification.

GHH Fahrzeuge GmbH

3.12 - 1LF-9.3033420_en12.10

3.12 Torque converter, power shift transmission

6

5

1

2

7

4

3

6

1 Oil dipstick Tightening torques2 Oil drain Fastening screws

3 Transmission vent Torque converter 48 Nm

4 Intake strainer Drive-plate / engine 70 Nm

5 Converter-transmission oil filter Drive-plate / torque converter 75 Nm

6 Oil cooler

7 Oil filler nozzle

GHH Fahrzeuge GmbH

3.12 - 2LF-9.3030462_en12.10

Maintenance of converter-transmission

Warning Ensure absolute cleanliness when working on the converter and transmission system.No foreign matter is allowed to penetrate the system.

The oil content in the converter-transmission circuit is to a large extent determined by the associated com-ponents (converter, transmission, cooler, piping and hosing).When the drive engine is switched off, part of the oil in the circuit flows back into the transmission, so thatthe oil level exceeds the MAX marking on the dipstick and as such is not relevant for the oil level check.The amount of oil that flows back depends upon the size and the position of the components used.When the drive engine is started, first the converter-transmission circuit is filled again. The residual oil inthe transmission sump then represents the actual oil level, which with idling engine must always be be-tween the MAX and MIN markings on the dipstick and may never fall below the MIN marking.

Warning Too low an oil level causes damage to the components.

To prevent dry-running of the pumps when topping up the oil after maintenance or repair works, make surethat the oil level with the drive engine running does not fall below the MIN marking on the dipstick. Thisis also the first step to be performed when refilling the system. That is why, based on the experiencegainedwith the vehicle, the oil level should be topped up with the drive engine switched off, if necessary via theMAX marking on the dipstick.

Checking of oil level

Torque converter and power shift transmission have a common oil circuit. Theoil is to bechecked at opera-ting temperature (82-93 °C) with the engine running. (idling speed)

Warning Under no circumstances check oil level with cold hydraulic oil.

The following work is to be performed:

- Park the vehicle on a level surface and run engine at idling speed for two minutes.

- Pull out the oil dipstick and wipe it off with a lint-free cloth.

- Insert the oil dipstick up to the stop, pull it out and check the oil level between the markings on thestick.

GHH Fahrzeuge GmbH

3.12 - 3LF-9.3030462_en12.10

Changing oil

Note Park the vehicle on a level surface. The converter-transmission hydraulic oil is to bedrained with the oil at operating temperature.

The following work is to be performed:

- Turn out transmission oil drain plug and allow oil to drain completely.

Note Also drain all oil in the circuit of the multi-disk brakes when the oil is supplied from theconverter-transmission hydraulics.

- screw cleaned oil drain plug back on and tighten. Replace seal.

- top up the oil through the filling orifice at least up to the MAX marking on the dipstick. If necessary,based on the experience gained, top up to beyond the MAX marking. Remove dipstick and wipe offusing a lint-free cloth.

- start engine and let run briefly (3 to 5 seconds) at idling speed to fill the torque converter and the hy-draulic lines with oil. Turn off engine.

- just before turning off the engine, fully insert the dipstick and immediately pull it out again. Check theoil level.

- if the oil level has fallen below the MIN marking, top up, again let the engine run briefly and repeat theoil level check.

- if the oil level exceeds the MIN marking, let the engine run twice as long (approx. 10 seconds) andrepeat the oil level check.

Note Repeat starting the engine, letting it run briefly and checking the oil level unitl the oil levelexceeds the MIN marking when the engine is running.

- Check the oil level when the engine is running (at idling speed).

- After the operating temperature (82-93 °C) is reached, check the oil level again and top up to the MAXmarking on the dipstick.

Cleaning the intake strainer

Remove intake strainer, clean and re-install with new gasket fitted.

GHH Fahrzeuge GmbH

3.12 - 4LF-9.3033710_en12.10

Changing the filter element in the pressure filter

Replace filter element also outside the maintenance intervals if the marking in the maintenance indicatoris located in the red area.The following work must be performed to replace the filter element:

- Stop the system and relieve the filter on the pressure side.

- Clean the complete filter on the outside.

- Screw off cover (1), remove spring (3) and the complete filter insert consisting of (4 - 7, 9 and 10).

- Screw off drain plug (12) on filter housing (8) and drain the oil.

- Clean filter housing with suitable medium and screw on drain plug (12); use new gasket (11) ifnecessary.

- Disassemble filter insert by unscrewing the fixing nut (10) and pulling off the filter element (7).

- Dispose of the filter element in an environmentally-friendly manner. Clean the remaining parts of thefilter insert.

- Assemble filter insert using new filter element (7) and new gaskets (6, 9).

- Install filter insert in the filter housing (8) with new gasket (5). Make sure that the gasket sits correctly.

- Install spring (3), screw on cover (1) with new gasket (2) and tighten up.

6

5

2

1

3

7

8

11

12

10

4

9

green area red area

marking

Maintenace indicator

GHH Fahrzeuge GmbH

3.13 - 1LF-9.3030473_en12.10

3.13 Drivelines

The vehicle is fitted with three driveline assemblies:

Converter-transmissionTransmission-front axleTransmission-rear axle

Maintenance of drivelines

All drivelines are fitted with taper grease fittings. Each universal joint is lubricated by one grease fitting;a third fitting serves for lubrication of the spline profile, which is dispensed with where plastic-coated lengthequalisers are provided. Pedestal and flange bearings are each fitted with a grease fitting.

Double-joint drivelines with locating bearing

These double-joint drivelines consist of two individual joints whose outer carriers are connected to eachother by a locating bearing in an articulated arrangement. Both individual joints and the locating bearingare each furnished with a grease fitting.

Grease fitting ofindividual joint

Grease fitting oflocation bearing

Grease fitting

Lubrication

Drivelines and intermediate bearing points have to be greased at regular intervals according to the manu-facturer's maintenance instructions. As the lubrication path extending within the spider and through thespaces between the rolling elements is long and narrow, the grease takes time to expand. Only slow grea-sing at low pressure will ensure a uniform distribution of the grease.

Warning Clean grease fittings before lubrication!Use only lithium-saponified greases!Lubricate needle bearings until used grease comes out at the rubber seals.To prevent damage to the seals, avoid pressure shocks while greasing.

GHH Fahrzeuge GmbH

3.13 - 2LF-9.3030473_en12.10

Universal joints with pressure relief valve

Drive lines with universal joints of special design are provided with a pressure relief valve located next tothe grease fitting. Because of the special-design sealing, the gaskets must be protected from damage dueto excessive pressure when lubricating is performed.For this reason, this type of drive line requires stopping of the greasing operation when grease emergesat the pressure relief valve.

Whenever lubrication is performed, the drivelines must be checked for external damage and the universaljoints for inadmissible clearance. The bolted connections of the drivelines must be checked for firm sea-ting.

Warning Replace damaged drivelines immediately. Repaired drivelines must be balanced.

Lubricants

For lubrication use only lithium-saponified greases with a penetration of 265/295 and a thawpoint of ap-prox. 180 °C. The lubricants must not contain any MoS2 additives.

Installation drawing of drivelines

drive unit payload unit

converter front axletransmissionrear axle

tightening torques225 Nm

tightening torques225 Nm

GHH Fahrzeuge GmbH

3.14 - 1LF-9.3030480_en12.10

3.14 Axles

1+2 3 1+2 3

Differential

Fig. 1

1-3 1+2

3

Planetary gear

Fig. 2 Fig. 3

1 = Oil filling port

2 = Checking screw

3 = Drain plug

GHH Fahrzeuge GmbH

3.14 - 2LF-9.3030480_en12.10

Note To check the oil level and change the differential and planetary gear oil, park the vehicleon a level surface.

Note Drain differential and planetary gear oil while still warm.

Planetary gear oil change

To drain the oil, turn the wheel end so that the drain plug is at the lowest point possible. To change theoil, unscrew drain screw and drain oil. Clean the drain plug (replace if necessary) and fill up with fresh oil.

See Checking of oil level, Topping up planteary gear oil. For filling volume see Technical Data.

Differential gear oil change

To change the oil, unscrew drain screw and drain oil. Clean the drain plug (replace if necessary) and fillup with fresh oil.See Checking of oil level, Topping up differential gear oil. For filling vollume see Technical Data.

Warning Whenver oil has been changed: Check differential and planetary gear oil level again af-ter waiting for a few minutes.

Checking of oil level, Topping up planetary gear oil

Version including planetary cover with cast-on arrow - Fig. 2

To check the planetary gear oil level, turn the wheel end so that the arrow cast to the gearbox cover pointsdownward. Remove the checking screw. The oil level should be at the bottom edge of the bore (top upwith oil, if necessary).

Version including planetary cover without arrow - Fig. 3

To check the planetary gear oil level, turn the wheel end so that the drain plug is at the lowest point possi-ble. Remove the checking screw. The oil level should be at the bottom edge of the bore (top up oil, if neces-sary).

Checking of oil level, Topping up differential gear oil

To check the oil level remove the check screw. The oil level should be at the bottom edge of the bore (topup oil, if necessary).

Warning Whenver oil has been topped up: Check differential and planetary gear oil level againafter waiting for a few minutes.

Venting the differential gear

A vent/breather fitted with a cap is provided on the differential gear. Clean vent/breather at regular inter-vals.

GHH Fahrzeuge GmbH

3.15 - 1LF-9.3033671_en12.10

3.15 Brake system

The vehicle is equipped with a fully hydraulic, low-maintenance service and parking brake.

Brake system : Three-circuit hydraulic power brake system with distribution viacircuits I + II over the service brake component of the front and rearaxles, with circuit III being used as release pressure for the parkingbrake components.

Units of the brake system

Service brake: Front axle, hydraulically actuated multi-disk brake

Rear axle, hydraulically actuated multi-disk brake

Parking brake: Multidisk brake integrated in power shift transmission, acting onall 4 wheels via the drivelines. Spring-operated, released hydrauli-cally.

General notes

Caution Prior to works on the brake system, release pressure on the diaphragm accumulatoron the fluid side and check that the system is pressure-free.Always bear in mind that the pressure-free condition indicated on the manometer (P12)in the swivel joint does not mean that the entire system is pressure-free.

Note For setting data, check points and notes see “Brake system drawing”.

All instructions relating to the maintenance, disassembly and re-assembly of brakes and brake compo-nents are issued on the condition that the relevant work is carried out by trained personnel.

- Brakes are first-rank components in terms of safety

- Work carried out improperly may lead to failure of brakes.

- Brake disks that have reached the wear limit must be replaced.

- Use only manufacturer-approved original spares.

- Replace tension springs at the latest during the second special brake examination or two years of ope-ration.

- Replace seal rings at the latest after two years of operation.

- Where mineral oil is used as brake fluid, mineral-oil resistant rubber parts must be used in the brakesand wheel cylinders.

- Bleed complete brake system and check for leaks after maintenance work has been carried out.

GHH Fahrzeuge GmbH

3.15 - 2LF-9.3031512_en12.10

Bleeding of hydro brake system (NLB)

Caution Secure vehicle against any self-initiated movements by placing wedges or similar ob-jects in front of the wheels. Make sure the pressure in the system has dropped.

Warning Before starting the unit for the first time and after repair work has been carried out onthe hydraulic pump or on the intake line, oil has to be filled up at the filling connectorof the intake line.

Bleed brake at all four bleed valves of the wheel brake using a portable hose and on all four existing testfittings using a Minimeß hose.

Note Collect the oil in a suitable container.

Bleeding of service brake

Note When bleeding the individual wheel brakes, you must also bleed the stub pipes, if pres-ent.

- Use a pedal arrestor or a suitable object to block the brake pedal in fully depressed position.

- Mount hose to the appropriate bleed or test connections. (Several bleed points may be operated ata time.)

- Start engine and shut off immediately when the pressure gauge indicates an “available pressure” of50 to 60 bar.

- Open bleeder valve, drain prestressed oil and close valve again when the pressure reading on the ma-nometer indicates zero bar. Repeat operation at all vent points until the oil comes out bubble-free.

Bleeding of parking brake

- Set parking brake to “Release”. The hand brake valve thus has free flow to the spring brake cylinder.

- Connect the transparent hose to the appropriate bleed port. (Note that several points canbe bledsimul-taneously).

- Start the motor and continue bleeding the system as described under Bleeding of service brake.

Checks

Check the bleeder valves for leakage.

Check oil level of converter transmission hydraulic system.

With the engine running, charge brake system up to the shut-off pressure of the shut-off valve and withdepressed service brake and released parking brake check tightness of bleed points.

Operate service brake and parking brake for 2 to 3 times. Repeat bleeding operation if there is a creakynoise in the treadle or hand brake valve.

Checkfunction ot the service brake and parking brake.

GHH Fahrzeuge GmbH

3.15 - 3LF-9.33_15-3_4_en12.10

Diaphragm accumulator

Warning When using diaphram accumulators (pressure vessels), attention must, as a matter ofprinciple, be paid to the pressure vessel regulations in force in the country in question.

The diaphram accumulators are preloaded with nitrogen to a predefined pressure. As certain gas lossesoccur during operation, it is necessary to check and, when appropriate, correct the preload pressure atregular intervals. The periods for the periodic tests must be determined by the operator in accordance withthe legal provisions.

Because of its safety-critical function and taking into account the service conditions, the diaphragm accu-mulator shall not be used for more than three years. Experience may, however, show that it needs to bereplaced at shorter intervals.

Caution Prior to working on equipment fitted with diaphram accumulators, it is essential to re-duce the pressure in the appropriate system.

Caution The gas preload pressure may be corrected by authorized personnel only.Only nitrogen may be used at the filling gas.Risk of explosion if oxygen or air is used.

Note The diaphram accumulator filling device for checking or correcting the preload pressureis obtainable from our after-sales service department.

Diaphragm accumulator in Diaphragm accumulator in brake systemsteering-dump/hoist hydraulic

- gas preload pressure 10±1 bar - gas preload pressure 55±5 bar

GHH Fahrzeuge GmbH

3.15 - 4LF-9.33_15-3_4_en12.10

Diaphragm accumulator in brake system

Note During this following check several interconnected diaphragm accumulators arechecked in one operation, so that only provide a coarse indication of the operativenessof the diaphragm accumulators is obtained. It is thus not possible to check each individ-ual diaphraghm accumulator.Checking the gas preload pressure in the individual diaphragm accumulators is onlypossible with the aid of a suitable device. (see page 3.15 - 6).

Checking the gas preload pressure of the diaphragm accumulators on the analog indicator in the driver'scab.

- Start the driving motor and switch off again when the analog indicator displays a available braking pres-sure of at least 100 bar.

- Repeatedly actuate the brake pedal to decrease the available braking pressure. Actuate the brakepedal so that the pressure decreases slowly.

- The indicator on the manometer abruptly drops to zero when the available braking pressure falls belowa gas preload pressure of 55±5 bar.

Note If the indicator on the manometer abruptly drops to zero outside the specified tolerancerange, the gas precompression must be corrected (see page 3.15 - 7).

Diaphragm accumulator in hydraulic system (steering and dump/hoist hydraulic system)

- Install pressure gauge at test connection “H 9“.

Note If dump/hoist device is controlled electrically, activate vehicle voltage system.

- Reduce stored pressure by operating the dump/hoist device. The available pressure can be read offon the pressure gauge.

- The indicator on the manometer abruptly drops to zero when the available braking pressure falls belowa gas preload pressure of 10±1 bar.

Note If the indicator on the manometer abruptly drops to zero outside the specified tolerancerange, the gas precompression must be corrected (see page 3.15 - 7).

GHH Fahrzeuge GmbH

3.15 - 5LF-9.33_15-5_7_en12.10

Pressure reduction armature and filling device

15

GHH Fahrzeuge GmbH

3.15 - 6LF-9.33_15-5_7_en12.10

Checking the gas preload pressure on the diaphragm accumulator

Note The gas preload pressure must be checked with the driving motor switched off.

- Relieve the diaphragm accumulator to zero bar on the fluid side and check the unpressurized condition.

- Remove the protective cap (2) from the diaphragm accumulator and loosen the gas filling screw (4)max. one-quarter turn using a hexagon socket wrench.

- Lock up the drain screw (5) on the filling device (6) by screwing it in as far as the stop.

- Screw the filling device (6) without hose (7) onto the diaphragm accumulator, making sure that the O-ring (8) is located in the groove.

Warning The non-return valve (9) mounted on the hose connection is only active if the hose (7)is not screwed on.

- Move the toggle (11) to and fro until the screwdriver (10) clicks into hexagon socket of the gas fillingscrew (4).

- Loosen the gas filling screw (4) as far as necessary to allow the gas to flow into the filling device (6).

Note When the filling device is screwed on completely the gas filling screw (4) cannot beturned out of the threaded hole.

- On the manometer (12) read off the gas preload pressure present in the diaphragm accumulator.

Note If the gas preload pressure outside the specified tolerance range, the gas preload pres-sure must be corrected (see section “Correcting the gas preload pressure”).Gas preload pressure of the individual diaphragm accumulators (see page 3.15 - 3).

- Screw down the gas filling screw (4) using the screwdriver (10). Open the drain screw (5) and let ni-trogen escape from the filling device (6).

- Unscrew filling device (6) from the diaphragm accumulator.

- Retighten the gas filling screw (4) with a hexagon socket wrench and press on the protective cap (2).

Warning If the measured gas preload pressure lies more than 25% below the set pressure, itmust be assumed that the diaphragm accumulator is defective. Replace the diaphragmaccumulator.

GHH Fahrzeuge GmbH

3.15 - 7LF-9.33_15-5_7_en12.10

Correcting the gas preload pressure

Pressure reduction

- To drain the nitrogen, slowly open the drain screw (5) until the nitrogen escapes.

- If the manometer (12) indicates the correct gas preload pressure, lock up the drain screw (5) until nomore nitrogen escapes.

- After about one minute check the gas preload pressure again and correct if necessary.

- Screw down the gas filling screw (4) using the screwdriver (10). Open the drain screw (5) and let thenitrogen escape from the filling device (6).

- Unscrew the filling device (6) from the diaphragm accumulator.


Pressure increase

- Screw the pressure reduction armature (15) onto the nitrogen bottle valve (16). Make sure that theshut-off valve (17) and the adjusting screw (18) are locked up.

- Screw down the gas filling screw (4) using the screwdriver (10), so that the gas valve is closed.

- Connect the pressure reduction armature (15) and the filling device (6) with the hose (7).

- Open the nitrogen bottle valve (16) and set the required gas preload pressure of the diaphragm accu-mulator with the aid of the adjusting screw (18) and under control of the manometer (19).

- Open the shut-off valve (17).

- Loosen the gas filling screw (4) as far as necessary to allow the gas in the diaphraghm accumulatorto overflow.

- Let the gas overflow until the manometer (12) indicates the required gas preload pressure.

- Close the shut-off valve (17), unscrew hose (7) from the filling device (6) and wait for temperatureequalization in the diaphragm accumulator.

- In case of pressure decrease, repeat the filling sequence; in case of pressure increase, reduce the toohigh gas precompression to the required value via the drain screw (5).

- Screw down the gas filling screw (4) using the screwdriver (10). Open the drain screw (5) and let ni-trogen escape from the filling device (6).

- Unscrew filling device (6) from the diaphragm accumulator.


GHH Fahrzeuge GmbH

3.15 - 8LF-9.33_15-8_en12.10

Changing of in-line filter element

Also outside the maintenance intervals the filter element must be replaced whenever the indicator light(H8) ”return pressure/brake filter” lights up weakly. (see LEERER MERKER).

The following work must be performed to replace the filter element:

- Stop the system and relieve the filter on the pressure side.

- Clean the complete filter on the outside.

- Remove filter cup (1) and filter element (3).

- Pull out filter element (3) and clean filter cup (2) with suitable fluid.

- Replace filter element.

- Check the O-ring (2) for damage. If necessary, replace these parts.

- Re-install filter element and filter cup. Pay special attention to proper position.

Warning After works on the brake system, bleed the entire brake system and check for leaks andoperation.

4

3

5

2

1

plug

Maintenance indicator elktr.

Maintenance indicator visual

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3.15 - 9LF-9.3030960_en12.10

Service brake Checking of multiple plates for wear

Warning Check wear of multiple plates with depressed brake pedal.

When checking the multiple plates for wear, the distance between the check nut and the contact face onthe brake housing as indicated in the brake system drawing has to be used as a reference.

As the wear of the multiple plates increases, the distance between the check nut and the contact face onthe brake housing decreases. When the check nut touches the brake housing, the multiple plates haveto be exchanged.

Setting of wear check facility with new multiple plates

Warning The wear check facility has to be set with depressed brake pedal.

Set check nut according to brake system plan to the distance between nut and contact face on the brakehousing and lock by the second nut. Cut off projecting end of bolt.

Contact faceBrake housing

Check nut

For distance seebrake system plan

GHH Fahrzeuge GmbH

3.16 - 1LF-9.3Lebrems_en12.10

3.16 Brake system description

Legend to brake system

Item. Qty. Description

1 1 gear pump

2 1 high-pressure filter

3 1 accumulator charge valve

5 1 brake valve

8 8 diaphragm accumulator, preload pressure 55 bar

9 1 pressure gauge

10 1 pressure relief valve


12 1 non-return valve



15 1 directional control valve

16 1 emergency release device

18 1 non return valve


21 1 Pressure relief valve

23 4 nozzle

24 1 nozzle


27 1 ball tap


800 - 805 1 hydraulic block

GHH Fahrzeuge GmbH

3.16 - 2LF-9.33_16-2_en12.10

Functional description of hydraulic brake system

Pressure supply system

The operating fluid is tapped from the converter transmission hydraulic system. For pressure supply agear pump (1) is flanged to the diesel engine.

Via the suction line, which is equipped with a suction filter the oil is sucked in from the transmission sumpand supplied to the diaphragm accumulators (8) of the service and parking brake (circuits I, II, III) via thehigh-pressure filter (2) and the accumulator charge valve (3).

After the shut-off pressure has fallen by approx. 15%, first the diaphragm accumulators (8) of brake cir-cuits I, II and III are filled again followed by the diaphragm accumulators (8) of additional brake).

The pressure level of brake circuits I, II and III is displayed to the operator via a manometer (9). Whenthe pressure falls below the cut-in pressure, the ”brake-air pressure” signal lamp (H12) is activated aswarning in the driver's cabin via the pressure switch (30) (B53).

The pressure relief valve (11) protects the whole system against excess pressures.

Service brake

To operate the service brake, the brake pedal (5) is depressed. The hydraulic pressure controlled by theforce exerted by the foot flows via circuit I to the front-axle brakes and via circuit II to the rear-axle brakes.As the brakes are released, the brake pressure is decreased towards the transmission sump.

A mechanical stop on the running plate limits the brake pressure and a further stop ensures the pressure-less condition of the service brake.

Blocking of forward and reverse tramming

A built-in pressure relief valve inside of hydraulic-block (20) of the converter-transmission hydraulic (seesystem drawing) emits, after applying the service brake and upon reaching the pressure set on the valve,a pulse in order to enable the forward/reverse interlock.Prior to each driving direction change you must step on the service brake, with the gearshift lever in neu-tral, and hold it until the gearshift pressure is reached. The hydraulic interlock of the gearshift mechanismis then deactivated via the pressure relief valve (10).

Residual brake pressure monitoring

A brake lights switch (B52) is fitted on the brake pedal valve (5). When the brake is operated, this switchturns on the signal lamp “Service brake” in driver's range of vision..

This device is intended to remind the driver to take his foot off the brake pedal after each braking operation.

Caution In case the foot remains slightly leaned against the brake pedal after braking, a residualbrake pressure will remain. This pressure causes severe dragging which will heat upthe brakes and may lead to their destruction.

GHH Fahrzeuge GmbH

3.16 - 3LF-9.33_16-3_4_en12.10

External cooling of multi-disk brakes

Caution Operation without cooling will destroy the multi-disk brakes.

The pump flow is distributed via the shut-off valve for charging of the diaphragm accumulator and coolingof the disk brakes. With filled diaphragm accumulators of the pressure supply system, the entire pumpflow is routed via the shut-off valve and the accumulator charge valve (4) to the distributor block (701)where the hydraulic pressure is built up and evenly distributed over the multidisk brakes via 4 nozzles (23).

The cooling flow is introduced at the centre of the multi-disk brake and flows through the disks. Throughthe outlet arranged on top the cooling flow is returned to the transmission oil sump. A sufficient oil flowis a precondition for cooling of the disk brakes.

Fouling of the nozzles or any restriction in the cooling pipes causes the built-up pressure in the distributorblock to rise.

Warning If the “LCB cooling dynamic pressure” as measured during maintenance should be inexcess of the maximum pressure indicated in the system drawing, check the coolingsystem and repair a fault.

In case the nozzles should be clogged completely, the pump flow returns to the transmission oil sump viathe pressure relief valve (11) and the brakes are uncooled.This is indicated to the driver by the pressure as indicated by the pressure gauge (9) rising to 180 bar.

To avoid damage to the seals of the disk brake, the cooling pressure within the brake housing shall notexceed 1.0 bar at high idling speed.

Monitoring of high-pressure filter

To protect the brake system against damage caused by contamination, a line filter (2) with a fine-filter el-ement is mounted between the gear pump (1) and the shut-off valve. An optical or optico-electrical main-tenance indicator is used to monitor the filter plugging. As the filter element becomes more plugged thepressure difference between the input and the output side increases. When a pressure difference of 4.0bar is reached the maintenance indicator indicates the necessary filter-element change.

Warning If the differential pressure rises to 5.0 bar due to further fouling, the integrated safetyvalve opens and lets the medium flow unfiltered into the circuit of the brake system. Thismay cause damage to the components of this system and lead to failure of the servicebrake.

GHH Fahrzeuge GmbH

3.16 - 4LF-9.33_16-3_4_en12.10

Parking brake

Warning When exiting the driver's cab the parking brake should, as a rule, be applied manuallyvia the control lever.

To release the parking brake, pull the control lever out of the detent and move forward. From connection”21” of the hand brake valve the hydraulic release pressure flows to the spring accumulator cylinder andneutralises the spring force acting on the parking brake.When applying the parking brake the pressure towards the transmission oil sump is reduced via the handbrake valve. To apply the parking brake, move the control lever backward until it locks into place.

The vehicle may only be moved when the parking brake is completely released.

Caution If the parking brake is not released completely there will remain a residual brake pres-sure. This pressure causes significant scuffing, which may heat up and even destroythe brakes.

The pressure switch activates the indicator light ”parking brake” in the driver's cab to indicate that the park-ing brake is not released completely.

Emergency release of parking brake

Release without electrical system and without available brake pressure.

Ignition off; brake accumulators evacuated

- Emergency operation lever in position “brake”- Parking brake valve K52a emergency release (turn in releasing screw on valve K52a)- ensure pressure supply (maybe through manual pump ); on pressure gauge of the pump 140bar- the parking brake may be released by activate the emergency operation lever in drivers cabin in position“drive”.

- brake is released (pressure gauge >83bar)- the vehicle can be towed. Activating the emergency operation lever in position “brake” the vehicle can

be stopped.- to secure the vehicle activate the emergency operation lever in position ”brake”.- Secure vehicle. Supply voltage off.- Deactivate the emergency release on K52a. Unscrew the releasing screw and secure.- Emergency release in position “drive”- Before starting the vehicle carry out a functional check of the parking brake.

GHH Fahrzeuge GmbH

3.16 - 5LF-9.3031310_en12.10

Filling of brake system for towing of vehicle

The hydraulic brake system is supplied with oil from the converter transmission circuit by a hydraulic pumpflanged to the diesel engine.

For towing over longer distances and on slopes the brake system of the loader being towed may be char-ged from the towing vehicle, provided both vehicles are fitted with the same brake system.

Oil is fillled in via the B4 test fittings. A DN 4 hose with suitable connecting couplers is required for thispurpose.

The following work operations are required:

- n the vehicle to be towed, top up hydraulic oil of converter transmission hydraulic system to maximumlevel.

Warning Absolute care must be taken to ensure that the hydraulic oil in the converter transmis-sion system of the towing vehicle does not drop below minimum level.

- Decrease available brake pressure of brake system by pumping with the brake pedal. This has to bedone on both vehicles.

- First connect filling hose to connection B4 of the vehicle being towed and vent hose by starting theengine. (Hydraulic oil comes out bubble-free).

- Connect hose to test fitting B4 of vehicle to be towed.

- Restart engine of towing vehicle and charge brake system of both vehicles.

- Turn on the electrical master and control switch of the vehicle to be towed. The service and parkingbrakes are now ready for operation.

At approx. 10 full brake applications, roughly the amount of hydraulic oil which corresponds to the dif-ference between maximum and minimum fill-level mark on the transmission oil dipstick is pumped outof the brake system of the towing vehicle into that of the vehicle being towed.

Caution At the end of the towing operation the hydraulic oil level of the converter transmissionhydraulic system has to be corrected on both vehicles.

GHH Fahrzeuge GmbH

3.17 - 1LF-9.3030540_en12.10

3.17 Hydraulic system

The hydraulic system includes the

Steering and dump/hoist hydraulic systems

Converter transmission hydraulic system

The steering and dump/hoist hydraulic systems are supplied with oil by a pump from a common hydraulictank. The hydaulic tank is mounted to the engine chassis and in addition to all connections includes thefill-level indicators and the oil return filter.

Steering and dump/hoist hydraulic system

The vehicle is equipped with a swivel-joint hydraulic power steering system. The oil flow from the pumpsis directed to the steering valve and to the dump/hoist valve. The steering valve or a steering lever opera-tes the steering valve, while the control lever (dump/hoist control) operates the dump/hoist valves andpressurizes the hydraulic cylinders.

Hydraulic tank

1

3 4 5

6

2

7

8

Relief valve

Aeration/ventilation filter

min.

max

1 Filler screw cap

2 Level indicator

3 Screw

4 Bar

5 Cover

6 Return filter

7 Drain plug

8 Aeration/ventilation filter unit

GHH Fahrzeuge GmbH

3.17 - 2LF-9.33_17-2_3_en12.10

Checking of oil level

Note To check the oil level, park the vehicle on a level surface. Check the oil level with theengine running and with retracted cylinders.

The oil level check must be carried out on the level gauge of the hydraulic reservoir. The oil level mustlie between the top and bottom level marks. If the oil has dropped below the bottom level, the hydraulicsystem must be checked for leaks and the oil topped up to the top level mark on the level gauge.

Level monitoring

The oil level in the hydraulic tank is continuously monitored by a level switch. If the oil drops below themin. level, this is indicated by signal lamp (H10) ”Hydraulic oil level”. Check the hydraulic system for leaksand top up oil to the max. mark on the oil level indicator.

Topping up hydraulic oil

Note Top up hydraulic oil to maximum mark with engine stopped and retracted cylinders.

The oil may only be topped up at the special filling screw plug on the hydraulic tank. Only here is it ensuredthat impurities are filtered out by the return filter before the oil flows into the hydraulic tank.

Return filter

To protect the hydraulic system against fouling damage a return filter with magnetic element has beenfitted in the hydraulic reservoir. An electric service signal monitors the filter plugging. As the plugging ofthe filter element increases the filter flow resistance also increases. If the flow resistance in the return flowfilter is too high, the indicator lamp (P8) ”return pressure / pressure filter” will light brightly up to indicatethat the filter insert has to be renewed. To prevent the filter inset from bursting it releases itself under ex-cessive overpressure and allows the oil to flow unfiltered in the reservoir chamber. This may cause thehydraulic components to be damaged.The signal lamp ”return pressure / brake filter” monitors the line filter for the brake system and the returnflow filter for the hydraulic system.The indications are output with two different brightness levels of the indicator light. Too high a return pres-sure is indicated by the indicator light in a brightly illuminated state and contamination of the line filter bythe indicator light in a weakly illuminated state.

GHH Fahrzeuge GmbH

3.17 - 3LF-9.33_17-2_3_en12.10

Changing of hydraulic oil

Note Change hydraulic oil with stopped engine and the hydraulic cylinders retracted.

The drain plug is arranged on the underside of the hydraulic tank. After the tank has been completely emp-tied and cleaned, fill up to the maximum mark.

Warning Vent hydraulic system after each change of hydraulic oil.

Venting the hydraulic system

After components of the hydraulic system have been replaced, it is necessary to expel the air that hasentered.

To do so, subject the hydraulic tank to a slight overpressure of 0.5 bar. As soon as oil flows out of the ventport bubble-free, screw on plug and tighten firmly. Only then is the tank to be de-pressurized. After chan-ging the oil, start engine and operate hydraulic equipment. Check oil level again and top up, if necessary.

The cylinder lines and the cylinders themselves should be vented well to prevent the diesel effect and topreserve the sleeves. Under pressure, the oil contained in the system dissolves in the hydraulic oil. Thisoil penetrates the sleeve fabric. As soon as the system pressure drops, the air comes out of the sleeveagain and destroys it.

The intake pipes must be observed with special care.

- If there is an intake pipe leak, the vacuum in the pipes will draw in air. Air in the hydraulic system causescavitation damage to pumps, valves and cylinder seals.

- A restricted suction cross-section, caused for example by a restricted hose, causes an increased in-take vacuum and hydraulic pump failure.

Steering and dump/hoist hydraulic system pressure test

Note Carry out pressure measurements while the hydraulic oil is at operating temperature.

To measure the steering pressure, a pressure gauge with a measuring range between 0 and 250 bar hasto be connected to the measuring points provided. The pressure indicated is the currently used steeringpressure. With the steering mechanism fully locked, the maximum pressure is measured.

To measure the working pressure, a pressure gauge with a measuring range between 0 and 250 bar hasto be connected to the measuring points provided. The pressure indicated is the currently used workingpressure. The maximum pressure is measured when the respective cylinder is operated against its stop.

GHH Fahrzeuge GmbH

3.17 - 4LF-9.33_17-4_en12.10

Changing the filter element in the return filter

Also outside the maintenance intervals the filter element must be replaced whenever the indicator light(H8) ”return pressure/brake filter” lights up brightly.

To change the filter element, open the cover on the hydraulic oil tank by loosening the screws and remov-ing the catch (see page 3.17-1).

The following work must be performed to replace the filter :

- Remove spring (3) and the complete filter insert consisting of (2 -5, 7 and 8).

- Disassemble filter insert by unscrewing the fixing nut (8) and pulling off the filter element (5).

- Dispose of the filter element (5) in an environmentally-friendly manner. Clean the remaining parts ofthe filter insert.

- Assemble filter insert using new filter element (5) and new gaskets (4, 7).

- Install filter insert in the hydraulic oil tank with new gasket (3). Make sure that the gasket sits correctly.

- Install spring (1) and assemble the cover on the hydraulic oil tank by using the screw and the catch.

9

5

2

1

3

6

8

4

7

Gasket forhydraulic oil tank

GHH Fahrzeuge GmbH

3.18 - 1LF-9.3Lehydr_en12.10

3.18 Steering and dump/hoist hydraulic system description

Legend to steering and dump/hoist hydraulic system

Item Qty. Description

1 2 steering cylinder

2 2 hoist cylinder

3 1 dump cylinder

6 1 gear pump


15 1 flow amplifier

16 1 Orbitrol

18 1 mobile valve

20 1 tank breather

21 1 valve unit with accumulator, preload pressure 10 bar

22 1 pressure reducer valve

24 1 direction control valve



40 1 filter

42 1 shuttle valve block

GHH Fahrzeuge GmbH

3.18 - 2LF-9.3032020_en12.10

Pressure oil supply

The steering and dump/hoist hydraulic system is supplied with pressure oil by the pumps mounted on thetorque converter.

The intake of each pump is connected to the hydraulic tank via the intake pipes. With the steering mecha-nism not operated, the pump delivery flow is routed on via the priority valve to the dump/hoist hydraulicsystem.

When the steering wheel is operated, an LS-signal is applied to the priority valve via the Orbitrol valve.The pump's delivery flow is thus available to the steering hydraulic system.

The system pressure of the steering hydraulic system is limited by the primary pressure control valve inte-grated in the priority valve. Once the system pressure has been reached, the pump delivery flow is routedon to the dump/hoist hydraulic system.

Filtering of hydraulic oil

A full-flow return filter is installed in the return chamber of the hydraulic reservoir for filtration of the entirepump delivery flow.

Filter Filter mesh Soiling indicator

Return filter 10 μm

electrical typeor

analog indicatorsee Section 2.3

Steering hydraulic system

The steering system is designed as a hydraulic power steering system.

It is activated via a steering wheel-operated rotary slide valve (Orbitrol valve) and downstream boostervalve with integrated priority valve.

When operating the steering wheel, pressure oil is routed to the booster valve through the metering pumpinstalled in the Orbitrol valve. At the same time, via connection “LS”, the control signal for the priority valveis transmitted. The priority valve is reversed and the pump delivery flow reaches the booster valve. Thebooster valve boosts the volume flow of the metering pump at a ratio of 1:5, delivering the flow in line withthe direction controlled by the steering wheel, to the steering cylinders via connection “CL” or “CR”.

The pressure control valve installed in the delivery line towards the steering cylinders protects the secon-dary side of the steering mechanism against pressure shocks transmitted from the roadway to the steeringsystem.

GHH Fahrzeuge GmbH

3.18 - 3LF-9.3033240_en12.10

Dump / hoist hydraulic system

Directional control valve

In the dump/hoist valve two hydraulically operated directional control slides for boom or bucket operation,respectively, are installed. For finger-tip bucket and boom control, fine- control grooves are provided inthe piston, which will permit the driver to set any lifting and lowering speed or any bucket tilt-back/dump-outspeed between zero and maximum.

If both slides are operated simultaneously, the operation requiring the lowest pressure will be carried outfirst, followed by the other operation.

Control-oil supply

Control oil is supplied from the control oil unit, an accumulator which is charged from the pump deliveryline.

Hydraulic pilot control

The driver controls the required bucket and boom functions via the (dump-hoist) control lever direction.The movement of the control lever determines the amount of pressure applied to the master piston of thedump-hoist valve.

Servo valve

The servo valve includes four pressure-reducing valves to activate the “tilt back bucket” and “raise/lowerboom” functions, as well as one directional control valve for activation of the float position.

With the control lever not operated, all control-pressure lines towards the hydraulic oil tank are depressuri-zed.

When moving the control lever, a control pressure proportional to the control lever movement is built upin the outlet duct of the activated pressure-reducing valve.

Two pressure-reducing valves at a time can be activated by a diagonal movement of the control lever.

Caution Even with the engine shut off, the control manifolds may be activated because of theaccumulator installed in the control oil supply system. Of course, only movements dueto bucket and boom deadweight can be performed. Before starting maintenance workon the control system the accumulator has to be discharged by operating the controllever several times.

Float position

If the control lever is operated in “Lower bucket” direction beyond the pressure point, outlet “five” of theservo valve is pressurized and the directional control valve activated. This will set the bucket to floatingposition. Through the directional control valve the secondary valves are depressurized towards the dumpcylinder.

GHH Fahrzeuge GmbH

3.19 - 1LF-9.3033521_en12.10

3.19 Converter-transmission hydraulic system description

Converter charging pump

The converter charging pump is mounted to the torque converter and is directly driven by the diesel en-gine. The pump takes in oil from the transmission sump and delivers it via the pressure filter into the con-verter housing.

Pressure filter

The pressure oil is cleaned by the pressure filter. If the filter is soiled, the overflow valve allows the oil topass unfiltered.

Torque converter

The torque converter is bolted to the drive engine to form a unit.

The rotating parts are coupled to the engine flywheel via an elastic coupling. At the rear end of the torqueconverter, flanging points for the connection of hydraulic pumps are provided in addition to the outputflange for the drive unit.

The oil flow from the converter charging pump is preloaded to 16.8 to 19.6 bar by a valve mounted to theconverter. This pressure is admitted to the multi-disc clutches in the power shift transmission.

The surplus oil flows to the torque converter for filling and cooling it. A safety valve protects the internalparts of the torque converter against excessive pressure. The spur gears in the converter housing arelubricated by spray nozzles. The oil flowing off is collected in the converter oil sump from where it flowsunpressurized to the transmission.The second stage of the converter pump is used to drain the converter. The pump conveys oil from theconverter sump to the transmission sump.

Oil cooler

The oil flowing out of the torque converter has the highest temperature and is directed straight to the oilcooler. The cooled oil flows to the lubricant distributor of the power shift transmission. The maximum tem-perature of the converter/transmission hydraulic system must not exceed 120 °C.

Power shift transmission

The travel direction valve switches the neutral position or pressurizes the forward or reverse clutch, re-spectively.

Depending on the gear selected, the gear selector valve pressurizes the relevant clutches. The lubricantdistributor distributes the oil coming from the cooler over the lubrication points of the power shift transmis-sion.

GHH Fahrzeuge GmbH

3.20 - 1LF-9.3030580_en12.10

3.20 Torque converter operation

1

2

3

4

6

5

1 Driven by the engine

2 Turbine wheel

3 Stator (nozzle ring)

4 Hydraulic pump

5 Auxiliary drive main gear

6 To transmission

GHH Fahrzeuge GmbH

3.20 - 2LF-9.3030580_en12.10

Description of torque converter

Configuration and requirements

The torque converter is connected to the drive engine. Flanging points for hydraulic pumps are locatedon the rear end of the torque converter together with the output flange for the transmission.

The primary function of the torque converter is to ensure smooth tramming over the selected speedranges, to automatically match the vehicle speed to changes in tramming and gradient negotiationresistance and to increase the torque to a multiple of engine torque.

The actual converter section comprises the following three major items which form the hydraulic transmis-sion:

impeller

turbine wheel

Stator (nozzle ring)

In the impeller, which is rigidly coupled to the engine flywheel, the fluid (ATF oil) is accelerated outwardsand then led to the turbine wheel where it is decelerated again owing to the arrangement and curvatureof the blades. This causes the kinetic energy of the fluid to be converted back to mechanical torque andspeed. The turbine is coupled to the converter output flange which in turn is coupled to the transmissioninput. The output torque of the torque converter is a function of to which extent the input speed exceedsor falls below the output speed.

Oil delivered by the turbine is led to the stator which is stationary in the converter and has the task of delive-ring oil to the impeller by means of its blades such that the inlet losses on the impeller are reduced to areasonable level. At this point, too, torques occur which are not utilized, however. The sum of all torquesin the converter is zero, which means that the stator absorbs the difference between impeller and turbinetorque.

High relative velocities occur in the converter section between impeller, turbine and stator, resulting in oilturbulences which, in turn, cause localized pockets of insufficient pressure which suddenly collapse. Thiscollapse of the resulting vapor locks causes pressure peaks of such an intensity that the blading wouldbe subject to excess mechanical loading. For this reason the fluid is preloaded, thus preventing vaporlocks and their resulting negative consequences (cavitation). Oil leaving the hydraulic transmission hasgained temperature in the converter substantially and is directed to the oil cooler.

From the preloaded converter section, ducts branch off to provide sufficient lubrication to roller bearingsand gears by means of injector nozzles.

Pump drives

Torque converters in our loaders always also accomodate the pumps for filling theconverter andsupplyingthe transmission, steering and dump/hoist pumps. As can be seen from the diagram, the pumps are di-rectly driven by the engine.

The power flow is from the impeller to the central auxiliary drive main gear. Each pump drive, in turn, isprovided with its own gear which is coupled to the corresponding pump and mates with the main gear.

Hints on operation

The torque converter considerably facilitates vehicle control to the operator.

The operator, therefore, need not change gears immediately for a change of incline. The operator mayalso run the engine at a reatively high speed, thus ensuring that sufficient quantities of oil are alwaysavailable for the steering and dump/hoist hydraulic systems. In normal operation the oil temperatureshould be between 80° and 90 °C. It may be heated up to 120 °C for short periods of time.

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3.21 - 1LF-9.33_21_en12.10

3.21

GHH Fahrzeuge GmbH

3.22 - 1LF-9.33_22-1_2_en12.10

3.22 Electrical equipment

Caution Disconnect electrical equipment before beginning to work on it and protect it againstunauthorized restarting.

The alternator, which is driven directly by the engine, supplies 24V for the vehicle's electrical equipment.Two series-connected batteries will assist in starting the engine.

Electrical equipment components

Battery

The two series-connected 12 V batteries of the electrical system are arranged in the driver's canopy.For maintenance and servicing of batteries observe the following:

- Keep batteries clean and dry to avoid leakage currents.

- The terminals of the batteries must have good contact.

- Loose clamps or sulphatized battery poles (green-white coating) will affect current transmission.

- Keep contact faces clean and grease with acid-proof grease.

- Check liquid level and charging condition of batteries regularly.

- There must be an approx. 10 mm liquid level on top of the battery lead plates.

- Top up with distilled water only.

- Check charging condition using a voltage tester or an acid siphon.

- Make sure that there is correct polarity when changing batteries.

Charging the batteries

The batteries can be re-charged either by operating the vehicle for several hours (via alternator and con-troller) or by using an externally connected charger.

For recharging with a charger note the following:

- Disconnect batteries from onboard system (battery switch).

- Maximum charging current: 10% of battery capacity (e.g. charge 165 Ah battery with a maximum char-ging current of 16.5 A).

- Check acid level, fill up distilled water, if necessary.

Caution Explosive gases are developed during charging. Do not smoke, use open flame andmake sure there are no sparks.

GHH Fahrzeuge GmbH

3.22 - 2LF-9.33_22-1_2_en12.10

Three-phase alternator

Apart from regularly servicing the V-belts, mind the following instructions:

- Operate the alternator only with appertaining controller and connected battery.

- When testing the engine without batteries, disconnect V-belt and cables from alternator.

- Before carrying out electric arc welding on the vehicle disconnect all cables from the alternator.

- The resistor connected in parallel to the LED of the alternator charging control lamp serves for pre-exci-tation of the alternator.

Circuit breakers / Plug-in fuses

Circuit breakers or plug-in fuses protect the various circuits.

Battery switch

The battery switch installed in the battery box insolates the two series-connected batteries from the on-board electrical system. The battery switch should only be switched on or off when the engine is standingstill.

External-starting socket

If the battery is discharged, the engine of the vehicle can be started using an external power supply andjump-start cable at the external starter socket.

Lighting system

The vehicle is equipped at the front and rear with two headlamps with parking light, low beam and highbeam. A headlamp for the material face lighting is provided on the left-hand side of the vehicle and twowork lights are attached at the driver's cabin.

The lighting system is switched on and off with the twist switch (S72) in the driver's cab.If the gear lever is in neutral or forward-drive position the front headlight (low beam or high beam), the rearparking light and the material face lighting are switched on. If the gear lever is shifted to reverse motionthe rear light is switched on.The work lights at the driver's cabin are switched on and off with the pushbutton (S80).

Warning equipment

An audible warning device is installed in form of a horn, which sounds when the horn push-button (S86)is pressed.

GHH Fahrzeuge GmbH

3.23 - 1LF-9.33_23_en12.10

3.23

GHH Fahrzeuge GmbH

3.23 - 2LF-9.3031981_en12.10

TOTAL powder-type fire extinguisher

6

2

3

5

4

7

28

9

1

10

Fig. 2 Hand fire extinguisher

1 Quick-release lock 6 Filling opening with striking valve

2 Hose with extinguishing pistol 7 Safety valve

3 CO2-bottle 8 Handle

4 Dunlop-valve 9 Hinged protective cap

5 Riser pipe 10 Extinguishing-substance vessel

GHH Fahrzeuge GmbH

3.23 - 3LF-9.3031981_en12.10

Handling of TOTAL powder-type fire extinguisher

Caution It is absolutely necessary to follow, in the g iven order, the notes on the extinguisherfor operating the device.

For an extinguishing service open the quick-release lock of the protective cap, fold up the cap and clearthe hose with the extinguishing pistol. Then press down with force the nickel-plated button of the strikingvalve or strike it down by hand. This will cause piercing of the seal foil of the CO2 bottle inside the outercontainer of the extinguisher. The carbon dioxide (CO2) will then flow into the holding chamber of the CO2bottle and is discharged, via the Dunlop valve attached to the chamber, into the extinguishing-substancevessel, where it fluidizes the extinguishing powder and pressurizes at the same time the vessel to the ne-cessary service pressure. Only then, i.e. after pressing down the striking valve, must the extinguishingpistol be operated and the fire be fought with the emerging powder cloud.

The extinguishing pistol can be stopped, allowing for repeated interruption of the extinguishing procedurefor short times.

Warning As a matter of principle, the extinguisher must be refilled after each use, even if the fillhas not been completely used up. Only this will ensure complete readiness for serviceat any time.

Note The easily destructible green control foil under the striking head serves for checkingwhether the valve has been actuated.

GHH Fahrzeuge GmbH

3.23 - 4LF-9.3031981_en12.10

Refilling of the extinguisher

- Release the extinguishing-substance vessel and hose from pressure after each extinguishing service,by operating the extinguishing pistol

- First loosen lightly the closing cap with striking valve, using a suitable spanner, by 1 - 2 turns, to letescape any pressure still present through the pressure release holes provided at the side of the closingcap.

- Open the closing cap, completely and remove the striking valve together with the CO2 bottle and theholding chamber from the extinguisher vessel. Take off the rubber guide sleeve loosely placed on theneck of the CO2 bottle and put it aside for placing it on the new, filled bottle.

- Unscrew the pressure hose from the vessel and remove powder remainders still present in the hoseand in the riser pipe and also the pierced control foil.

- Empty completely the extinguishing-substance vessel.

- Clean the extinguishing-substance vessel, the fittings and the hose

Note Never rinse with water.

- Fit riser pipe and new control foil and screw the hose tightly on the nipple of the vessel top. Check extin-guishing pistol for proper functioning, i.e. for free movement.

- Fill 10 kg of well fluidized dry extinguishing powder, preferably by using a strainer funnel, into the vessel(don't tamp it).

Warning Only the TOTALIT-G-type extinguishing powder from TOTAL Foerstner & Co. must beused.

- Fit new CO2 bottle (original charge from manufacturer's works) into the holding chamber, after placingthe rubber guide sleeve onto the bottle neck, i.e. with the metal plate facing upwards.

Note Ensure, by weighing, that the CO2 bottle (without sleeve) contains the specified chargeweight. The charge weight is stamped on the bottle.

- Fit the holding chamber with the CO2 bottle into the extinguishing-substance vessel. Make sure thatthe flange edge of the chamber is properly and flatly supported and that the sealing face is free fromany powder residues.

- Screw on tightly closing cap with striking valve and seal it together with the screwed cap of the sprayinghose.

- Place the green control foil around the striking valve between striking head and cap, andseal it likewise.

- Place the hose without kinks on the top part. When doing so, take care that the striking head remainsclear and avoid its actuation. Finally, close the protective cap and seal the quick-release lock tightly.

Note Always heed the safety guidelines for inspection and maintening the fire extinguisher.Refer to the inspection service of TOTAL for any further questions arising.

GHH Fahrzeuge GmbH

3.24 - 1LF-9.3031050_en12.10

3.24 Fault-finding table

Brake system LCB

Service brake

Fault Reason Remedy

Insufficient effect Low brake pressure

Brake disks worn

Air in brake hydraulic system

Unsuitable brake disks

Check and correct availablepressure and brake pressure

Check for wear, replace brakedisks

Bleed brake system

Use original GHH FahrzeugeGmbH spares

Overbraking - brakes blocked Annular piston stuck in brakedisk housing

Excessive brake pressure

Brakes overheated

Remove multi-disk brake andrepair

Check and correct availablepressure and brake pressure

Check coolant flow to brakedisksCheck residual brake pressurewith released brake - max. 0.5barThe driver must take his foot offthe brake pedal after each brak-ing operation

GHH Fahrzeuge GmbH

3.24 - 2LF-9.3032200_en12.10

Parking brake

Fault Reason Remedy

Insufficient effect Excessive stroke of springbrake cylinder.

Multiple plates worn ordestroyed

Spring brake cylinder defective

Brake mechanism stuck

Adjust parking brake.

Check wear of multiple plates.Replace multiple plates.

Replace spring brake cylinder

Make linkage work smoothly

Parking brake cannot bereleased,overheating whiletramming

Low release pressure

Incorrect setting

Spring brake cylinder defective

Observe pressure gauge,check hydraulic releasepressure

Check setting

Replace spring brake cylinder

GHH Fahrzeuge GmbH

3.24 - 3LF-9.3030630_en12.10

Hydraulic system

Fault Reason Remedy

Noise in hydraulic system Not enough oil in hydraulic tank

Pump draws air

Oil foaming

Pressure pipes vibrating

Pressure relief valve buzzing

Top up with same oil grade

Check intake pipe

Check intake pipe

Tighten clip

Check valve, replace if necessary

Movements of dump/hoist equip-ment or steering too sluggish

Air in system

Hydraulic activation faulty

*) Electric activation faulty

Pipe cross-section restricted

Low hydraulic pressure

Pump defective

Check oil levelCheck intake pipe

Check activation

Check activation

Replace pipe

Adjust pressure

Replace pump

Hydraulic system too hot Not enough oil in hydraulic tank

Hydraulic activation is not reset.

*) Electrical activation is not reset.

Control piston of dump/hoist valvewill not return to neutral position

Pipe cross-section restricted

Check laying of lines


Check activation

Check activation

Replace valve

Replace pipe

Remove bends in lines laid

Low hoisting or steering force Pressure valve soiled

Pressure valve misadjusted

Activation of raising functiondefective

Pump defective

Piston seal rings of hydraulic cylin-ders defective

Clean valve, adjust pressure

Adjust pressure

Check activation

Replace pump

Replace piston seal rings

No oil pressure Pump defective

Not enough oil in hydraulic tank

Clutch between converter andpump defective

Replace pump


Replace clutch

*) For electric-hydraulic activation only.

GHH Fahrzeuge GmbH

3.24 - 4LF-9.3030640_en12.10

Torque converter-power shift transmission

Fault Reason Remedy

Low clutch pressure Low oil level

Valve slide on clutch pressure con-trol valve jammed open

Charging pump defective


Clean valve slide and housing

Replace charging pump

Low clutch pressure in one gear Piston seal rings broken or worn

Clutch defective

Replace seal rings

Repair clutch

Low converter pump power strainer Low oil level

Intake strainer clogged

Charging pump draws air



Clean intake strainer

Tighten connectionsCheck intake pipe


Converter operates noisily Clutch wheels worn out


Bearings damaged in converter

Replace clutch wheels


Repair converter

High converter oil temperature Converter oil cooler soiled

Low oil level

Charging pump draws air

Oil seals worn


Clean oil cooler


Tighten connectionsCheck intake pipe

Repair converter


Insufficient power Low engine speed

Converter overheated

Adjust engine

see - High converter oil temperature

Transmission cannot be shifted Electric activation faulty

Control valve defective

*) Gear shift lever or rod jammedor movement restricted

Check electric activation

Repair control valve

Adjust gear shift lever or rod

Vehicle will not tram with gearengaged

*) Gear shift lever or rod bent

Electric activation faulty

Directional control valve not acti-vated

Directional control valve soiled

Low clutch pressure

Clutch defective

Straighten gear shift lever or rod



Repair directional control valve

see - Low clutch pressure

Repair clutch

*) For mechanical gear shifting only.

GHH Fahrzeuge GmbH

3.25 - 1LF-9.33_26_en12.10

3.25 Appendix

GHH Fahrzeuge GmbH

4 - 1LF-9.34_en12.10

4 System drawings

Service brake 909-1-065156 ATranslation sheet pertaining to drwg. 909-1-065156

Converter-transmission hydraulic system 909-1-065195 ATranslation sheet pertaining to drwg. 909-1-065195

Steering-dump/hoist hydraulic system 909-1-060147 CTranslation sheet pertaining to drwg. 909-1-060147

Electrical equipment 909-3-065171

GHH Fahrzeuge GmbH

4 - 2LF-9.34_en12.10

Translation sheet pertaining to drwg. 909-1-065156(Service brake)

Bauteil Messpunkt Druck (bar) TätigkeitComponent Measuring point Pressure Activity

Abschaltventil B4 Ein Aus kontrollierenShut-off valve on off check

Vorratsdruck B4 kontrollierenAvailable pressure check

Trittplattenbremsventil B5+B6 einstellenTreadle brake valve set

Restdr. Bremse B5+B6 max. 0.5 kontrollierenResidual brake pressure bei hohem Leerlauf check

at high idling speed

Drucksch. S51 B7 fallend kontrollierenPressure switch falling check

Drucksch. S53 B4 fallend kontrollierenPressure switch falling check

Drucksch. S55 B6 steigend einstellenPressure switch rising set

Pumpe Saugdruck B9 max. 0.3 kontrollierenPump intake pressure bei hohem Leerlauf check

at high idling speed

Kühldruck B24+B25 max. 0.3 kontrollierenCooling pressure B26+B27 bei hohem Leerlauf check

Druckgefälle B24 + B15 B24 groess. als B15 kontrollierenPressure gradient B25 + B15 B25 larger than B15 check

Druckgefälle B26 + B16 B26 groess. als B16 kontrollierenPressure gradient B27 + B16 B27 larger than B16 check

Staudruck LCB Kühlung B11 max. 12±2 kontrollierenDynamic pressure hoh. Leerl. checkcooling LCB at high idling speed

Speichertest B4 140 nach kontrollierenTest of diaphragm 5 Bremsungen min. checkaccumulator 85 bei Motor aus

after 5 brakes min. 85 engie switched off

Dichtigkeit B4 140 nach 1Std. min. kontrollierenFor leakage 100 bei Motor aus check

after one hour min. 100 engie switched off

Feststellbremse B7 gelöst min.120 kontrollierenParking brake aufgelegt max.0,5 check

released min.120 / applied max.0.5

GHH Fahrzeuge GmbH

4 - 3LF-9.34_en12.10

MotorteilDrive unit

Einstellung der Verschleißkontrolle bei neuen Lamellen.Setting of wear check facility with new multiple plates

Bei getretener Bremse Kontermutter auf 7,6 mm einstellen.With depressed brake set lock nut at 7.6 mm.

Wenn Kontermutter anliegt, Bremslamellen wechseln.When the check nut touches the brake housing, the multiple plates have to be exchanged.

ACHTUNGWARNINGVor Arbeiten an der Bremsanlage, an dem Ventil Pos.5 durch mehrmaliges Betätigen, Speicher entlasten.Before working on the valve item 5 of the brake system, depressurize accumulator by operating the brakeseveral times.

Pumpe ist nicht selbstansaugendPump not self-priming

Vor dem 1.Start und nach Reparaturen an der Pumpe, ist die Saugleitung der Pumpe an B9 mit Oel zufüllen. Die 4 Druckspeicher sind zu entleeren.Before starting the unit for the first time and following repairs of the pump, fill pump intake line with oil.All pressure accumulators to be discharged.

Trockenlauf zerstört die Pumpe.Dry running will destroy the pump.

mit Gefälle zum Getriebe verlegt.To be laid with a gradient to the transmission.

Einbaulage senkrechtPosition of installed: vertical

Messpunkt B9 nur zur Messung eingebaut. Fülleitung mit Pos. 238 und 259 verschließen.Nach Messung ausgebaut. (Pumpe saugt durch Messanschluß Luft)Measuring point B9 is installed for measurements only. Filling pipe is to be plugged with item 238 and 259It has to be removed after measurement. (Pump takes in air through measuring connection).

LCB-Bremse / LCB-brake - linke/rechte Seite / LH/RH side

21 Bremsdruck zur Vorderachse / Brake pressure to front axle

22 Bremsdruck zur Hinterachse / Brake pressure to rear axle

3 Bremsdruck zur Feststellbremse / Brake pressure to parking brake

5 Ruecklauf / Return flow

P Bremsdruckversogung / Supply pressure for brake

KV1-4 Kuehlung-Vorlauf / Cooling inlet

KR1-2 Kuehlung-Ruecklauf / Cooling outlet

LastteilPayload unit

Anschlüsse Bremse / Brake connections

Kühlung Auslaß / Cooling outlet

Entlüftung / Bleeding of brake

Kühlung Einlaß / Cooling inlet

Ölablaßstopfen / Drain plug

GHH Fahrzeuge GmbH

4 - 4LF-9.34_en12.10

Translation sheet pertaining to drwg. 909-1-065195(Converter-transmission hydraulic system)

Durchfluss von aussen nach innen / Flow from inside to outside.

Lüfteraufsatz(3/8” NPT, vom Getriebe) am höchsten Punkt zwischen Wandler und Getriebe montieren.Mount fan support (3/8” NPT, on the transmission) at highest point between converter and transmission.

Anschlüsse Regulationsventil / Connections regulating valve

Lastschaltgetriebe / Power shift transmission

Gang / Gear

Rücklauf / Return flow

Regulationsventil in BG. 2701 / Regulating valve in assy. 2701

Wandler / Converter

Anschluss Wandlerbelüftung / Connection for converter ventilation

Temperaturfühler / Temperature sensor

Sumpf / Transmission sump

Translation sheet pertaining to drwg. 909-1-060147(Steering-dump/hoist hydraulic system)

Lastteil / Motorteil - Payload unit / drive unit

Kippzylinder / Dump cylinder

Hubzylinder / Hoist cylinder

Lenkzylinder / Steering cylinder

Fahrerstand / Driver's cab

Zur Begrenzung Hubarm senken zwei Scheiben A8 unterlegen.To limit lowering of boom, fit two washers A8.

Wandler / Converter

Saugrohr BG1602 / Intake pipe assy. 1602

Hubarm heben / senken - Boom raised / lowered

Schaufel heben / senken - Bucket raised / lowered

aus Ladestellung / aus Kippstellung - from loading position / dumping position

Zeit / Steuerdruck - Time / control pressure

operatinginstructions - teikom.rs · - install only original-spareparts. should you have any...

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