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Operating Instructions Wheel Loader SKL 834

Contents

1. 1 4 7 10 13 16 2 9 8 11 14 17 3 61 9 14 15 18 1 4 7 10 13 16 19 21 51 8 11 14 17 20 3 6 9 12 13 18 21 N N Se lt X40 CAN BUS Option 1 Power supply Terminal 15 output 2 Central mass Terminal 31 3 CAN HI 4 Ri Se 5 R2 N co Lo 6 CAN LO q X10 Instrument panel 1 or Ca k N er 2 Central mass Terminal 31 cu 3 CANHI 4 ae Mm co tu 5 KS 6 CANLO X90 Programming connection X91 Immobilizer Option o 1 Power supply Terminal 15 output 2 Central mass Terminal 31 SS m ESRDE 3 TXD D O 4 RXD 5 5 CTS ora CN BIO NN 6 RTS cO OQ lt t LQ 0 O gt SKL 834 105 9 Appendix 1 4 7 10 13 25 0 3 6 9 12 19 c 1 4 7 10 13 16 19 2 5 8 11 14 17 20 3 6 9 12 15 18 21 c 12 15 18 C 4 4 7 2 gd 8 3 d H 2 9 8 11 14 17 3 6 9 6 9 12 bd 14 4 7
2. A B Position Ampere assigned to Position Ampere assigned to F 1 15 Heater fan F 1 15 Working floodlight front F2 15 Wash wipe front F2 15 Working floodlight rear F3 15 Wash wipe rear F3 10 Turn signal F4 10 Rotating beacon interior light F 4 10 Hazard warning switch F5 15 Travel forward reverse F5 15 Socket radio F6 10 Reserve F6 15 Reserve F7 10 Reserve F7 10 Horn F8 10 E module inputs F8 10 High beam F9 10 Instruments F9 15 Low beam F 10 10 Radio F 10 10 Side marker light left F 11 15 Reserve F 11 10 Side marker light right C D F 01 50 Fuse K 1 Start relay F 02 80 Starting system K2 Pre heat relay F 03 30 Control module power supply TIK 3 Turn signal flasher relay Colors of fuses 10A red 15A blue 30 A rose 50 A red 80 A white Cable and Plug colors bg beige dgr dark gray hbr light brown rt red bl blue ge yellow bor light gray sw black br brown gn green hr light red vi violet dbl dark blue gr gray nt nature ws white dbr dark brown hb light blue or orange SKL 834 95 9 Appendix Start up Pre heat Shut off Heating Air conditioning 15 sw 109 sw6 09 1111110 30 br ge FO ZSM_ X20 4 1 F02 F03 sw 109 gt 77 Z5ML br ge
3. Fig 37 Engine oil cooler SKL 834 71 7 Care and Maintenance 7 9 4 Fuel system Checking the fuel level Check the fuel level on the fuel gauge 38 27 To prevent condensation from forming before the machine is next put into Operation top up the fuel every day after use Draining water from the fuel filter Open the fuel filter on the water drain valve 39 2 until pure fuel escapes Close again the water drain valve Replacing the fuel filter Clean the outside of the fuel filter 39 1 Release the filter cartridge using a commercially available tool and unscrew Ensure that the fastening stud is firmly secured in the filter head Collect the fuel and dispose of in compliance with regulations Dispose of the filter cartridge in compliance with regulations Check filter head condition and clean Wet the seal on the new filter with oil or fuel respectively and tighten firmly by hand Check tightness The fuel system does not have to be vented Fuel tank Drain water from the fuel tank through the drain plug 40 1 Clean the filler screen 40 2 and check for damage 1824 038 Fig 38 Operation Fig 39 Fuel filter Fig 40 Fuel tank 72 SKL 834 Care and Maintenance 7 Cleaning the fuel pump screen filter Close th
4. 51 4 7 10 13 2 5 8 11 14 3 6 9 12 13 2 5 8 11 14 17 20 31 61 9 12 15 18 21 4 7 10 13 16 19 x LI H 1 4 7 10 13 16 2 5 8 11 14 17 3 6 9 12 15 18 19 2 5 8 1 7 11 4 7 1 215 8 11 14 17 20 3 6 9 12 15 18 21 7 10 13 16 21 5 8 11 14 17 31 61 9 12 15 18 4 A 1 4 7 10 13 16 19 N N X60 Signal inputs engine monitoring Power supply Terminal 15 output Central mass Terminal 31 Charge control generator D Air filter maintenance switch signal Oil pressure switch signal Hydrostatic brake pressure switch signal Transmission switch signal CO N OO Go JP Tank sensor signal c Engine temperature sensor signal indi CH Hydraulic oil temperature sensor signal _ Speed
5. SH L824 032 Fig 32 Inspection and maintenance plan 64 SKL 834 Care and Maintenance 7 Daily Chapter 1 Check hydraulic oil level 7 9 9 2 Check engine oil level 7 9 1 3 Check fuel level fuel gauge on instrument panel 7 9 4 4 Check water level for windshield wiper 7 9 19 5 visual inspection for material cracks external damage completeness etc 6 Check for leaks in pipes hoses control valve hydraulic pumps cylinders etc When tightening hoses or pipeline connections counterlock fittings to prevent turning Check electrical indicating and warning elements and the lighting system Check smooth running of operator controls Weekly Chapter 11 Clean cooling fins of the hydraulic oil cooler 7 9 10 gt In case of extreme exposure to dust shorten cleaning intervals 12 Clean cooling fins of the engine oil cooler 7 9 3 gt In case of extreme exposure to dust shorten cleaning intervals 13 Check that door catches function perfectly 14 Check tire pressure and tightness of wheel nuts 7 9 14 15 Check fastening of axles and propeller shaft 16 Check bushings and bolts of the work equipment 17 Check bolts bushings and the linkage of the articulated steering 18 Check that pneumatic springs of engine hood function perfectly 19 Drain fuel filter 7 9 4 20 Check brak
6. ZSML X61 4 vi ws bn Oe 85 87 b Oe sw4 09 ZSML X20 5 ZSNL X61 5 sw bl rt 2 50 1 9 gn gr gn ws Oneu rt ge d L824 E03 Path SEU Device ed Device ZSML Central control module LEE K2 Pre heat relay Flat type fuse R1 Glow plug 1 1 G1 Generator 1 5 Y1 Engine shutoff 1 1 F02 Flat type fuse 1 7 FA1 Fuse 1 2 F03 Flat type fuse 1 7 S2 Heater switch 1 2 Y29 Excess fuel for starting 1 7 M3 Heating turbocharged engine only 1 2 G2 Battery 12 V 1 8 813 Air conditioning temperat switch 1 3 K1 Start relay 1 8 S30 Air conditioning pressure switch 1 3 M1 Starter 1 8 Y30 Air conditioning relay 1 4 S1 Glow plug and starter switch 96 SKL 834 Appendix 9 Wash wipe system front Wash wipe system rear T T T T T T T T 19 1 19 1 11 1 12 1 13 1 14 1 15 1 16 15 30 1 8 rt Ve 1 FA2 FA3 2 2 SK040 SK030 K 8 J 11 21 20 x 1 5 E 5 z E a oi o 9 ZSML Eau SK030 SKC30 SK03C SKC30 SK030 ZSML X3
7. 240bar Z bar linkage Fig HO1 Hydraulic system parallel boom geometry and SKL 834 108 Appendix 9 Description Hydraulic circuit diagram parallel boom geometry and Z bar linkage Steering cylinder Steering unit Priority valve Steering charge pump Hydraulic oil tank Hydraulic oil cooler Hydraulic oil temperature control Combined hydraulic oil filter Breather Travel motor Travel pump Master brake cylinder Brake front axle SKL 834 109 Y12B A Y13 T 9 Appendix ot CON probe E ti Hd 1 r uc E a c Lu M MEN EE D a 1 i i 1 H 1 1 1 1 1 1 1 n BEE DEE NE a 1 1 l io ii 1 1 1 1 a 1 Qu as i pod Beses cy PS StS tS EE 1 1 i de i 4 tt i 4 re Eeer 14 qme T t amp i a gt A gt A o2 1 n t I 1 1 1 B l 1 ER E MES 1 n s i 1i 4 1a E O H 1 DW 1 1 qd ti i i 1 dj Tope Ld 1 1 i 1 Loy i Esc NS MEE EE E 1 WE H G Rial Va sta a ry Lit L Um 9 GA i
8. 7 2 Intervals First inspection once before first putting into operation Chapter 7 8 1 Daily jobs every 10 operating hours or every work shift Chapter 7 8 2 Weekly jobs weekly or after 50 operating hours Chapter 7 8 2 100 operating hours once after first putting into operation Chapter 7 8 4 Every 500 operating hours after every 500 operating hours or 6 months Chapter 7 8 4 Every 1 000 operating hours after every 1 000 operating hours or 12 months Chapter 7 8 4 Every 2 000 operating hours after every 2 000 operating hours or 2 years Chapter 7 8 4 whichever comes first 2 also applicable when new or overhauled diesel engines are put into operation SKL 834 57 7 Care and Maintenance 7 3 Regular oil analyses Oil analyses are not intended as a substitute for the oil change intervals but apart from a possible reduction of maintenance costs and as a form of preventive maintenance they take into account the increasing environmental awareness Advantages of an oil analysis e Extension of the oil change intervals under standard or light duty operating conditions e Minimum wear of high quality components with optimum use of the lubricants e Periodic laboratory analyses enable an early detection of imminent damage e Repairs performed before they actually become absolutely necessary help prevent serious and unexpected damage e Sequential damage can be avoided Oil analysis
9. V2 t ke mar y L3 il T Ve Pil r A L 21J Al AL I 1 i L L834Z H03 03 09 30 Fig H03 Hydraulic system Z bar linkage SKL 834 112 Appendix 9 14 15 16 17 18 19 20 EA 22 23 24 25 26 27 28 Description of hydraulic circuit diagram Z bar linkage Hydraulic oil tank Loader control lever Pilot control unit Control valve Additional control circuit connection hydraulic quick attach system Hydraulic cylinder lift frame Hydraulic cylinder bucket tilt Load retaining valves Vibration damping Release valve only if Pos 20 amp Pos 21 installed Transmission high speed version Valve Open return Distributor for hand held hammer 4th control circuit Control unit SKL 834 113 9 Appendix 114 SKL 834 DELIVERY AND HANDING OVER INSTRUCTIONS The following checklist is to be followed when handing over the machine to the customer 1 Operating instructions The operating instructions should be read side by side and be explained in detail through practical training on the machine The following items are essential e Accident Prevention Regulations published by the employer s liability insurance associations in the user s country Technical data Operator controls indicating and warning elements Checks before putti
10. 24 SKL 834 Technical Data 3 3 7 Axles Front EE Rear axle standard sisi in Rear axle high speed version Parallel boom geometry Double acting work cylinders one lift cylinder and one tilt cylinder Z bar linkage Double acting work cylinders two lift cylinders and one tilt cylinder Control valve with 3 control circuits Electro hydraulically operated float position for Lower work function Single four way control lever joystick with integrated direction of travel switch float position switch and a switch for additional control circuit 64 l min 230 bar Max oil flow Max operating pressure Thermostatically controlled Rigidly mounted planetary drive axle with self locking differential and integrated center mounted drum brake Oscillating planetary drive axle with self locking differential and integrated reduction gear Oscillating planetary drive axle with self locking differential and integrated 2 stage reduction gear Angle of oscillation 12 3 8 Tires Tire size Type Profile Tire pressure Tire pressure rear front 405 70 R 18 SPT 9 2 5 2 1 12 5 20 MPT 10 PR E 58 2 5 1 8 335 80 R 20 XM 27 TL Michelin 2 5 1 7 335 80 R 20 SPT 9 2 5 2 5 Special tires available on request A The use of solid tires or foamed tires restrictions requires special measures and is subject to The tire pressure refers to
11. low high beam Switch from one to another by lifting the steering column mounted switch 15 1 Blue indicator lamp 15 30 lights up for high beam SKL 834 41 4 Operation 4 7 Hydroinflation of tires When the loader is used with a fork lift attachment the rear wheels may be filled with a water antifreeze mixture to increase the lifting capacity Prepare the mixture in an appropriately sized container Allow it to cool and stir until there are no more lumps Always pour magnesium chloride into the water not the other way round Do not allow the solution to come into contact with eyes skin or clothing caustic substance Recommendation when filled to 7596 with antifreeze protection to 30 C Values per wheel Type of tire MgCl H O Total ca kg I kg 405 70 SPT 55 70 125 12 5 20 MPT 57 74 131 335 80 XM 59 73 132 335 80 SPT 51 66 117 MgCl magnesium chloride H20 water 42 SKL 834 Operation A 4 8 Driv ing steering and braking 4 8 1 Driving A When driving on public roads the wheel loader as a self propelled work machine is subject to legal regulations valid in the user s country e g in the Federal Republic of Germany StVZO and StVO The vehicle has two pre selection switches for the travel direction which are alternately active Change over by means of the multi function switch 16 35 One pre selection swit
12. 1 Switch for direction of travel damaged Repair or replace Solenoids of valve damaged Repair or replace Neutral position has shifted Check re calibrate call Service Agent Replace travel pump 2 3 4 Internal damage to travel pump 5 Excessive engine idling Adjust SKL 834 91 8 Trouble Shooting Fault Possible cause Remedy 8 7 Hydraulic oil exceeds max admissible temperature 1 Thermo switch damaged Replace 2 Oil level too low Top up oil to mark on dipstick 3 Oil cooler clogged or faulty Clean check replace if necessary 4 Suction filter clogged Replace 5 High pressure valves do not respond all Check high pressure valves re adjust or the time or too early replace if necessary 6 Flushing circulation does not function Check pressure of flushing and filling pump possible back pressure in cooling circuit check housing pressure 7 Travel pump or travel motor damaged Replace worn 8 Charge pump worn Replace 9 Main relief valve damaged Replace 8 8 Sluggish acceleration and deceleration too little propulsive power 1 Insufficient engine power Check diesel engine 2 A brake has got stuck Check remedy damage 3 No tank pressurization Check breathers and breathers replace 4 Suction filter clogged Replace filter 5 Fast slow gear does not shift Check power supply and solenoid
13. 88 SKL 834 Care and Maintenance 7 7 10 Shutdown 7 10 1 Preservation temporary shutdown To prevent damage corrosion etc from storage during shutdown periods over three months certain preservation measures must be taken e We recommend keeping the machine in a dry dust free room during the storage period e Clean the inside and outside of the machine thoroughly including the engine e Lubricate the machine in compliance with the lubrication plan e Check the oil levels of all assemblies such as axles transmission s etc and top up if necessary e Check the hydraulic oil level and top up if necessary e Repair paint damage e Fill the diesel tank completely to prevent corrosion of the tank walls e Check the antifreeze level in the coolant and adjust if necessary e Perform all the preservation measures contained in the diesel engine operating instructions e Check the tire pressure in compliance with the prescribed value and protect the tires from direct sunlight e Treat bare piston rods with a commercially available anti corrosion agent e Remove and clean the battery and keep it in compliance with regulations in a dry in winter frost proof room Coat connections with a little pole grease e Seal off the air intake opening of the air filter system and the exhaust pipe opening 7 10 2 During shutdown e When the machine is out of use for 6 months after this time all asse
14. Biodegradable hydraulic oil on synthetic ester base Transmission oil Multi purpose lithium soap based grease Brake oil Specification Standards Quality DIN 51601 ASTM D975 1 D 2 D SAE 15W 40 API CF4 ACEA E3 or E2 HVLP D 68 or SAE 10W 40 Filling in compliance with customer specifications Brand label on machine Do not mix biodegradable oils of different suppliers SAE 85W 90LS API GL 5 K2K 30 DIN 51825 ATF Type A Suffix A Dexron lID Alternative recommendation for other temperature ranges Engine oil in compliance with API CG 4 or CF 4 and in compliance with ACEA E3 or E2 Hydraulic oil Remarks Las Before using RME fuels rape oil methyl ester it is essential to consult your responsible SCHAEFF TEREX dealer for further details See also engine manufacturer s instructions The following viscosity limit values must be kept in compliance with ASTM 445 at 100 C min 10 mm s cSt at 10 C approx 1 500 mm Dis The same viscosity specifications apply as for mineral hydraulic oils When changing from mineral to biodegradable hydraulic oils the tank and hydraulic system must be completely drained cleaned and flushed For further details before changing oils please consult your responsible SCHAEFF TEREX dealer Alternative recommendations SAE 90LS SAE 80W 90LS In conformi
15. Earth moving machines are only to be used where there is a danger of falling objects if the drivers stand has a canopy FOPS A front guard must be employed if there is a risk of materials breaking into the cab In front of walls e g of stacked materials earth moving machines must be positioned and operated in such a way that the driver s seat and entry to the drivers seat are not situated on the side facing the wall Demolition work is only to be performed by earth moving machines where there is no danger to persons and if the machine is equipped with canopy cab mounted front guard and the appropriate work implement See regulations book Demolition work ZH 1 614 published by the Tiefbau Berufsgenossenschaft the employer s liability insurance association 2 12 Working in the vicinity of underground power lines Before commencing excavating work using earth moving machines it must be determined whether any underground power lines are present in the intended working zone which may present a danger to persons If underground power lines are present their exact position and course must be determined in consultation with the proprietor or operator of the lines and the necessary safety precautions decided and implemented The course of power lines in the work area must be clearly marked under supervision before commencing any earth moving work If the position of lines cannot be determined search ditches must be du
16. 10 2 5 8 11 3 c 1 4 7 10 13 18 2 5 8 11 14 17 3 6 9 12 15 18 4 T 10 13 16 19 2 5 8 11 14 17 20 3 6 9 12 15 18 21 d E N lt E X31 Module power supply working floodlights rotating beacon wiper 1 n 2 3 Reserve digital output 4 Relay K11 87a N C contact output 5 Relay K11 87 N O contact output 6 Reserve digital output 7 Relay K12 87 N O contact output 8 Relay K12 power supply Terminal 15 input 9 Relay K12 87a N C contact Output 10 Power supply Terminal 15 input working floodlight front 11 Relay K11 power supply Terminal 15 input 12 Reserve PWM output 13 Power supply Terminal 15 input working floodlight rear 14 Reserve PWM output 15 Reserve PWM output 16 Power supply Terminal 30 input rotating beacon 17 Reserve Digital output 18 Reserve PWM output 19 Power supply Terminal 15 input wash wipe rear 20 Power supply Terminal 15 input travel 21 Power supply Terminal 15 input wash wipe rear X70 Working floodlights Wipers 1 Brake light switch Terminal 15 output 2 m 3 Working floodlight front output 4 Working floodlight rear o
17. 13 2 4 14 4 4 FA11 FA7 FA6 1 el 2 2 FAt1 3 5 2 2 a un X130 X130 X130 X130 17X130 18 x130 12 13 14 15 16 17 18 E 5 c SS E i E E E 5 5 E E E ZSNL ZSML Z5ML ZSV_ ZSML ZSML ZSVL X30 6 X30 7 X30 8 X30 9 X30 10 X30 11 X30 12 Z5NL zsm zsw aw zsw zswL Zau ZSML zsw zsw za x31 3 X81 6 x31 17 X31 12 x81 14 X81 15 X31 18 X314 X315 X319 X817 a Ki E d 2 s 8 3 d 8 8 El z 3 5 E i S E L L D Ei e c amp t a Ke a 1 2 3 4 5 6 7 8 9 10 11 X1308 x1301 x1301 x1308 x1g01 x1308 X130 vam vuan oan X130 L824 E06 Designati on Designati on 2 8 FA11 Reserve fuse 2 15 FA6 Reserve fuse 2 14 FA7 Reserve fuse SKL 834 99 9 Appendix Ww HT TT 1 H Travel Travel Float position Additional control circuit fuse T T T T T T 3 1 32 33 34 33 36 37 38 33 15 30 4 9 2 15 FA4 FAS D to M rt 1 FA5 sl 5 o ZSML Ston ZSML X31 20 K 18 X201 5 t gt 3 10
18. 6 9 12 15 18 1147 A N N 0 ES X61 Rear end 1 e 2 oe 3 Starting Terminal 50a output 4 Pre heat output 5 Engine shutdown output 6 Brake light output 7 Travel direction recognition output 8 Travel FAST SLOW output 9 Transmission 1 output 10 Travel forward output 11 Transmission 2 output 12 Working hydraulics output 13 Travel reverse output 14 Back up lamp output 15 Travel motion alarm output 16 Ride control system 3 output 17 Float position output 18 Additional control circuit output 19 Additional control circuit output 20 Ride control system 1 2 output 21 Rear fog lamp output X20 Panel right 1 Power supply Terminal 15 output 2 SS 3 Starting Terminal 50a signal 4 Pre heat signal 5 Engine shutdown signal 6 Ride control system signal 7 Additional control circuit signal 8 Additional control circuit signal 9 Float position 1 signal 10 Float position 2 signal 11 4 control circuit signal 12 4 control circuit signal 13 Rotating beacon signal 14 Working floodlight front signal 15 Working floodlight rear signal X5 Power supply SKL 834 107 9 Appendix 9 2 Hydraulic system Hydraulic system includes options L L834 H01 03 09 30
19. Too little hydraulic oil in tank Top up to mark on dipstick 2 Mechanical connection to diesel engine Check repair faulty motor and axle interrupted 3 Filling pump damaged no filing Remove pump and examine install new pressure pump if necessary Switch for direction of travel damaged Repair and replace if necessary Solenoid valve for direction of travel Repair and replace if necessary damaged Suction filter clogged Replace filter Suction line between tank and pump Check and eliminate kink kinked 8 Power supply to switch for direction of Remedy cause of interruption travel and solenoid valve interrupted 9 Internal damage to travel pump or travel Replace units completely motor 10 Mechanical connection between travel Check repair 8 11 Loader installation is not working 1 Oil supply to pump interrupted Check suction line and repair if necessary 2 Main relief valve damaged Check and replace if necessary 3 Hydraulic pump damaged Check repair or replace 4 Hydraulic pump drive mechanically Check and repair interrupted SKL 834 93 8 Trouble Shooting Fault Possible cause Remedy 8 12 Decrease in machine s performance loader installation 1 Insufficient engine power Check diesel engine and adjust if necessary 2 Hydraulic oil level too low Top up hydraulic oil to the mark on the dipstick 3 Pump is sucking u
20. 311 1 14 gt 3 10 o D 1 art 3 T 3 21 2 21 3 Th BAM 7 S10 To 91 5 2 ji o z t zZ L E al 3 Eel a a Z5ML Z5ML SK030 5K030 sK030 ZSML ZSML Z5ML ZSML ZEML ZSVL SM X80 3 X80 4 K 5 K 15 J 4 X80 5 X20 9 X20 10 X80 6 X80 7 X20 7 X20 8 ZE ML Z amp ML ZEML Z8N ZSML ZEML ZEML X6130 x61 13 X61 15 X617 X61 17 X6118 X61 19 E 5 E 8 E 5i 8 5 5 ka a a al 51 1 Al 4 ol 1 ST ya Ui va oa vq Me Gara Was 92 2 L 2 2 2 amp amp E 5 5 n 5 L824 E07 i Designati on Designati on Fuse Device Float position switch Travel forward Float position Switch for travel forward reverse Float position switch Travel reverse Additional control circuit 1 Travel motion alarm Additional control circuit switch 3 4 S16 Switch for travel Additional control circuit 2 forward reverse 3 4 Y2 Travel direction recognition 3 9 S9 Additional control circuit 100 SKL 834 Appendix 9 Travel speed Ride control system 4 control circuit Working Manual transmission hydraulics 3 10 3 11 3 12 33 3 14 3 15 3 16 15 30 900 4 9 SK03C lt 030 Z amp ML Z8M ESO SKC30 SKO3C SK030 SK0
21. 834 61 7 Care and Maintenance 62 SKL 834 Care and Maintenance 7 7 8 Checking maintenance and inspection plans 7 8 1 Initial inspection delivery handing over inspection 1824 031 Fig 31 Initial inspection Jobs to be carried out by trained dealer service personnel Chapter 1 Check whether machine specific instruction book is in the machine 2 Check engine oil level 7 9 1 3 Hydraulic oil level 7 9 9 4 Check fuel level 7 9 4 5 Oil level check differential and axle hubs 7 9 13 6 Check tire pressure and tightness of wheel nuts 7 9 14 7 Check brake oil level 7 9 8 8 Battery electrolyte level and charge condition 7 9 17 9 Top up windshield washer system 7 9 19 10 Grease machine all lubricating points 7 8 3 11 Test run hydraulic function check and test work 12 Visual inspection for tightness of all hoses pipes cylinders etc 13 Check function of electrical indicating and warning elements and the lighting E system 14 Initial delivery handing over certificate and return to manufacturer SKL 834 63 7 Care and Maintenance 7 8 2 Daily and weekly tasks Inspection and maintenance jobs to be performed by operating personnel 14 15 3 1617 1315 22 4 1 20 5 18 14 219
22. The manufacturers instructions must be complied with for operation maintenance repair assembly and transportation The plant operator must provide additional special safety instructions wherever necessary for specific local conditions The operating instructions and any information pertaining to safety must be carefully kept in the driver s cab The operating instructions and safety notes must be complete and fully readable Safety devices on earth moving machines shall not be deactivated or removed Protective work clothing must be worn during operation Rings scarves and unbuttoned jackets are to be avoided Protective goggles protective boots helmets gloves reflecting jackets ear muffs etc may be required Before commencing work information must be obtained on first aid and possible means of rescue ambulance fire brigade helicopters A check must be carried out to ensure that the first aid box is at hand and that its contents comply with regulations Personnel must be aware of the location and method of operation of the fire extinguishers on the earth moving machine as well as on site fire warning and fire fighting equipment Loose parts such as tools or other accessories must be secured to the earth moving machine Open doors windows covers flaps etc must be closed or secured so that they cannot slam shut 2 4 Operation Earth moving machines are only to be independently operated and serv
23. after the machine is used for the first time or when newly painted to avoid damage to the paint Do not use aggressive detergents for cleaning the machine We recommend using commercially available cleaning agents for passenger cars When cleaning with a steam jet appliance the hot water jet is not to exceed 80 C and a spray pressure of 70 bar Linings insulating materials etc are not to be exposed directly to water steam or high pressure jets When cleaning with water or steam jets take care not to spray exhaust gas and air filter openings If cleaning the engine with water or steam jets do not expose sensitive engine parts such as generator cabling oil pressure switch etc directly to the jet After each wet clean the machine must be lubricated in accordance with the lubricating plan and a test of all work cycles steering and driving functions carried out 7 7 Notes for winter operation The following points and the relevant notes in the engine instruction book should be observed during winter operation Hydraulic oil H the machine is not used for longer periods at temperatures around and below freezing warm up the engine by running at medium revs for approx 3 5 min Engine oil The oil viscosity SAE class should be selected in compliance with the ambient temperature at the machine s place of operation Battery charge A good cold start performance requires a well charged battery B
24. diesel engine is not running the hydraulic pump is damaged or hydraulic oil has been lost only the EMERGENCY functions e manual steering without power assistance and lower work equipment only if ignition is switched on can still be performed SKL 834 15 2 Safety and Prevention of Accidents 16 SKL 834 Technical Data 3 3 Technical data 3 1 Views Fig 3 Dimensioned drawing machine equipped with general purpose bucket and parallel boom geometry 405 70 R18 tires SKL 834 17 3 Technical Data E e 9 x a a e Al ES gt Q S i lt l 2 i z o T i o 3 oC Wo o 1 T gt o M i 1 xp 2100 1175 WI L 4970 d 80 1780 A re GAN NS FXL Fig 4 Dimensioned drawing machine equipped with multi purpose bucket and parallel boom geometry 405 70 R18 tires SKL 834 Technical Data 3 3020 2670 ml 1780 4080 Fig 5 Dimensioned drawing machine equipped with fork lift attachment and parallel boom geometry 405 70 H18 tires SKL 834 3 Technical Data 1 N N R co o O D A LO a Ke 110 Fig 6 Dimensioned
25. drawing with general purpose bucket and Z bar linkage 405 70 R18 tires 20 SKL 834 Technical Data 3 3220 2670 Fig 7 Dimensioned drawing with multi purpose bucket and Z bar linkage 405 70 R 18 tires SKL 834 21 3 Technical Data 2670 Fig 8 Dimensioned drawing with fork lift attachment and Z bar linkage 405 70 H 18 tires 22 SKL 834 Technical Data 3 3 2 Diesel engine Re le EE RE en E Max ere EE Specific fuel consumption at nominal engine E 111 ii e e a E n Rit CA Lighting SOM as 3 4 Travel drive Deutz F4M2011 4 cylinders in line Four stroke diesel engine with direct injection optimized for emissions reduction COM II EPA II 3 100 cm 44 0 kW at n 2 400 rpm 195 Nm 1 700 rpm 218 g kWh Engine oil air with external oil cooler Fresh air with heat exchanger connected to engine oil circuit 12V 12 V 74 Ah 680 A EN 400 A DIN 14V 5A 2 3 kW Heater plug to German Regulations Authorizing the Use of Vehicles for Road Traffic StVZO Variable displacement pump flange mounted directly onto diesel engine two stage variable displacement motor with power shift on rear axle reduction gear High speed version featuring rear axle manual transmission shiftable in standstill position Suction return filter in the form of a tank insert filter Forwar
26. e ED NERA A Teen e 24h 91 8 2 il 91 8 3 No steering Movement EE 91 8 4 Insufficient performance of service brake AANEREN 91 8 5 Insufficient performance of parking Drake 91 8 6 Hydrostatic drive has no neutral position EE 91 8 7 Hydraulic oil exceeds max admissible Temperature 92 8 8 Sluggish acceleration and deceleration too little propulsive Dower ss 92 8 9 Transmission works in one direction only emen 93 8 10 Transmission works in neither drechon ee 93 8 11 Loader installation is not working WEE 93 8 12 Decrease in machine s performance loader mstallatont iiic iiri ines 94 8 13 Working cylinders are not working satisfactorily oooooonnncninnicinnnccnnncccnoncccnoncccnnnccnonnncnnnnccnnns 94 8 14 Trouble in the electrical SySIBITI ous eere ci pa ei tete s is 94 CR TEE 95 91 ElSCIMCALS EE 95 9 2 Hydraulics Tata 108 SKL 834 Table of Contents SKL 834 Introduction 1 1 Introduction 1 1 General You decided to buy a SCHAEFF TEREX SKL 834 Wheel Loader The confidence placed in this model will be rewarded by the efficient and economical performance of the machine These operating instructions contain all information necessary for the correct use of the machine Please read them carefully before putting the machine into operation and make sure that they are kept at hand at all times Should you need further explanations or should anything be unclear please contact your dealer
27. for the purpose of replacement e Note down the date of maintenance in the appropriate sections of the safety cartridge 45 3 e Insert the new or cleaned main cartridge carefully into the filter housing starting with the open side and check that it is correctly positioned e Fit the lower part of the housing Pay attention to the position of the dust extraction valve e Place the wire fasteners in the groove of the flange on the filter housing and tighten Safety cartridge e Remove the main cartridge Do not clean the safety cartridge and once it has been removed do not use it again e Using a suitable tool e g screwdriver pierce the seal 45 5 of the safety cartridge 45 3 from the inside then lift up the two clips 45 6 e Grasp the safety cartridge 45 3 by the HR32 053 two clips 45 6 withdraw by twisting Fig 45 Air filter cartridge replacement slightly to and fro and dispose of it e Insert a new safety cartridge and check that it is correctly positioned e Install the main cartridge SKL 834 75 7 Care and Maintenance 7 9 5 5 Cleaning the main cartridge Never wash or brush out the main cartridge When blowing out ensure that dust does not land on the inside of the main cartridge The main cartridge can be cleaned up to five times if necessary It must be replaced once it reaches its maximum service life of two years at the latest The number of time
28. immediately Special equipment and attachments are not included in these operating instructions We reserve the right to make improvements on the machine within the scope of impending technical developments without incurring any obligation to change these operating instructions Any modifications of SCHAEFF AN TEREX products and their equipment using extras and work attachments which are not included in our product range require our written approval If our approval is not sought our warranty expires as does our product liability for any resulting consequential damage Please state the vehicle type and the vehicle identification number when making inquiries or orders and in all written correspondence The vehicle identification number of the machine is stamped on the identification plate 1 1 Fig 1 Identification plate L824 001 SKL 834 1 Introduction 1 2 Warranty and Maintenance The warranty period covers 1 000 operating hours not exceeding a maximum of twelve months whichever comes first beginning with the day the machine is handed over or put into operation Safe working conditions and good working order of the machine are prerequisites for efficient work Your SCHAEFF TEREX Wheel Loader fulfills these requirements when correctly handled and when serviced and maintained as specified Careful observation of the machine whilst in function and the use of the specified fuels lubrican
29. in the proper manner This should also apply with regard to drivers licenses 2 9 Operation Daily before commencing work and after every change of work attachments the machine operator must check the correct fastening of the work attachments as well as the correct lock of the quick mount hitch Work attachments are to be carefully moved at low height During this check the danger zones of earth moving machines have to be free of personnel The machine operator is only to swing the work equipment over occupied driver s seats operator consoles and workplaces of other machines if these are protected by canopies FOPS If a cab does not have the required protection the driver of this vehicle must leave the drivers stand when equipment has to be slewed overhead The vehicles must be loaded in such a manner as to ensure that there is no overloading and no material can be lost during travel The vehicle must be loaded from the lowest possible height At dumping points earth moving machines are only to be operated if suitable measures have been taken to prevent rolling or falling SKL 834 Safety and Prevention of Accidents 2 2 10 Guides Guides must be easily recognizable e g by means of reflective clothing They must remain within the machine operator s field of sight While guiding the machine guides shall not be given other jobs which may distract them from their task 2 11 Danger of falling objects
30. it is impossible to maintain sufficient distance from overhead power lines and trolley wires the plant operator must consult with the proprietor or operator of the overhead lines to find other safety precautions to prevent current overspill Such measures could be e g Switching off the current Re routing the overhead line Cabling or Limiting the work zone of earth moving machines 2 14 Operation in closed rooms If earth moving machines are to be used in closed rooms these areas must be sufficiently ventilated and the special regulations observed 2 15 Work stoppages Before rest periods and at the end of the working day the driver of the earth moving machine must park the machine on ground which has sufficient carrying capacity and is as level as possible and must secure it against unintended movement Before rest periods and at the end of the working day the driver must lower the work equipment onto the ground or secure it so that it Cannot move The driver shall not leave the earth moving machine when the work equipment has not been lowered to the ground or secured Earth moving machines are only to be parked in places where they do not present an obstacle e g on the construction site or to plant traffic Warning devices e g triangles warning cordons flashing or hazard lights are to be used if necessary Before leaving the operator stand the driver must bring all operating equipment into home positio
31. lift attachment upward lock in place and secure against lateral shifting Rigid forks must be dismounted 390140 h e Raise the lift frame as far as the height color mark 18 1 until sufficient ground clearance is secured e Set the direction of travel pre selection switches on the joystick 20 7 and the instrument panel 20 36 to 0 neutral position e Switch off the working hydraulics 20 35 Ce Only press if machine is stationary e Check the function of the direction indicators hazard warning lights horn low high beam e Close the cab door 1824 020 Fig 20 Operation 46 SKL 834 Operation A 4 8 5 Parking the machine e Set the direction of travel pre selection rocker switches 21 7 and 21 36 to 0 e Lower the work equipment to the ground e Switch off working hydraulics 21 35 e Apply the parking brake 21 9 QDOIA4 D h e Switch off the engine and remove the ignition key e Lock the cab after finishing work to keep unauthorized persons from getting in If necessary secure the machine with chocks so that it cannot roll away L824 021 Fig 21 Operation SKL 834 47 4 Operation 48 SKL 834 Loading Operation 5 5 Loading Operation 5 1 General Every day before commencing work an
32. of front and rear axles oil check X O X X or oil change 38 Grease machine in compliance with overview O O of lubricating points 39 Check function condition and completeness O O of safety equipment 40 Hydraulic function check with pressure O O function test 41 Test run and test work O O 42 Initial inspection cards and return to O O manufacturer 23 Check bearing bushings and bolts of work equipment and replace if necessary O O ojo 24 Check bushings and bolts of the articulation and the articulated steering and replace if necessary o 1 atleast every 2 years 2 Extension of oil change intervals in compliance with oil sample analysis and lab report For further information see Chapter 7 3 Every 5 years or 5 000 operating hours respectively within warranty 3 4
33. shall not either in whole or in part be reproduced transmitted or used for the purpose of competition without our prior written permission SKL 834 1 Introduction 6 SKL 834 Safety and Prevention of Accidents 2 2 Safety and Prevention of Accidents 2 1 Introductory remarks C Certificate of Conformity The machine complies with the fundamental requirements stipulated in the applicable European guidelines Conformity has been proven The respective documents and the original of the Certificate of Conformity are deposited with the manufacturer A copy of the Certificate of Conformity is attached to the sales documents Before putting the earth moving machine into Operation read these operating instructions carefully and strictly observe the indicated references for safe operation National safety regulations e g the Accident Prevention Regulations Earth Moving Machinery VBG 40 and Vehicles VBG 12 in the Federal Republic of Germany must also be complied with when operating the earth moving machine In addition to the operating instructions legal regulations governing road traffic and road safety measures must also be observed Such requirements could also apply in respect of handling hazardous goods or the wearing of personal safety gear for example Furthermore safety laws governing work in particular locations tunnels adits quarries pontoons contaminated areas etc m
34. the danger zone despite the warning To ensure no danger of crushing a sufficient safety distance min 0 5 m must be kept from solid objects e g buildings excavation slopes scaffolding other machines etc If the above safety distance cannot be maintained the area between solid objects and the working zone of the earth moving machine must be blocked off If conditions are such that the machine operators view of the driving and working zone is restricted he must be guided or the driving and working zone must be marked by a solid barricade 2 6 Transport of persons The transport of persons on the machine is forbidden 2 7 Stability The earth moving machine must be used driven and operated in such a manner that its stability against overturning is ensured at all times The machine operator must drive at speeds which are suitable for local conditions The permitted payload of the earth moving machine shall not be exceeded The earth moving machine must remain at a sufficient distance from the edges of quarries pits mounds and slopes to ensure there is no risk of falling Earth moving machines must be secured so that they cannot roll or slip when in the vicinity of excavations shafts ditches pits and slopes SKL 834 2 Safety and Prevention of Accidents 2 8 Travel operation Before putting the earth moving machine into operation the drivers seat mirrors and operator s controls must be adj
35. the left hand side as seen in the direction of travel The right hand cab door acts as an emergency exit If the cab is entered by the right hand door the joystick may be operated unintentionally If you are not familiar with the operator controls and display elements of this machine read this Chapter carefully before operating the machine This Chapter deals with all functions Before driving and working with the machine it is necessary to thoroughly familiarize yourself with the operator controls and display elements Each time before putting the machine into operation it must be subjected to a thorough visual inspection Ensure that there is no damage loose or missing screws oil accumulation oil or fuel leakage Faults must be remedied immediately In the event of shortcomings which jeopardize the operating safety the machine is not to be put into operation until these have been eliminated Each time before putting the machine into operation the inspections in compliance with Chapter 7 8 must be carried out SKL 834 33 4 Operation 4 2 Operator controls and display elements The following list includes non standard equipment 14 1 2 3 4 0 N O C 10 11 12 Fig 10 1 Operator controls 34 SKL 834 Operation A N OORA O N 10 11 12 13 1
36. valve electrically or mechanically repair and replace if necessary Check travel motor 6 Fault in brake inching device Check adjust replace 7 Filling pump sucks up air Check eliminate leakage 8 Travel pump mis adjusted Re adjust travel pump 9 Filling or supply pressure too low Check pressure adjust 10 Pressure relief valve of filling circuit Check re adjust or replace clogged or faulty 11 High pressure too low Check high pressure pressure cut off and re adjust high pressure valves or replace if necessary 12 Travel pump does not open fully pilot Nozzles clogged check repair pressure too low 13 Internal damage to travel pump or travel Replace units motor 14 Travel motor mis adjusted Re adjust travel motor 92 SKL 834 Trouble Shooting 8 Fault Possible cause Remedy 8 9 Transmission works in one direction only 1 Switch for direction of travel damaged Repair or replace if necessary 2 Solenoid valve sticks or is damaged Repair or replace if necessary Power supply towards switch for direction of travel or solenoid valve interrupted Check and repair incl ground connection Pilot pressure too low on one side Nozzles clogged check clean High pressure relief valve is faulty or incorrectly set Swap valves around If machine now travels in the other direction examine valve clean and replace if necessary 8 10 Transmission works in neither direction 1
37. with the machine being in warm condition The inspections are obligatory If omitted this may affect the warranty covered by us The machine must be thoroughly cleaned before inspection takes place Inspection Table To be carried out by trained dealer service technician O Checking maintenance X Replacement Perform work with machine at operating temperature Operating hours after 100 every 500 every 1000 every 2000 min 2x yearly min 1x yearly O Checking maintenance X Replacement Operating hours Check whether machine specific instruction book is in the machine O O min min Change engine oil X Change engine oil filter X Drain water from fuel tank Change fuel filter X woj o oO1 3 C05 nm5 Clean fuel pump and screen filter Check air intake Change air filter main cartridge Change air filter safety cartridge Clean cooling fins of hydraulic oil cooler AN In case of high exposure to dust shorten the cleaning intervals to se asre o quired o e 1 rvice indicator 11 Clean cooling fins of engine oil cooler IN In case of high exposure to dust shorten the cleaning intervals 12 Check V belt tension 13 Check engine mounts and pump attachments 14 Check engine speed adjustment top end and low idle speed ojojo 15 Chec
38. 1 X68 d In 2 5 e E14 E1 gt 5 L824 E09 Design Device Path Design Device ation ation E8 Interior light E1 Lighting front left FB4 Fuse 12 Light switch 4 4 4 5 Fuse 4 5 Lighting rear left Direction indicator switch Fuse hazard warning switch Flasher transmitter 4 6 Fuse 4 6 Lighting front right 25 Brake light switch 4 7 E4 Lighting rear right 4 7 23 Hand brake switch E14 License plate illumination 102 SKL 834 Appendix 9 Rotating beacon Working Instrument Radio Socket floodlights panel 4 16 4 2 F15 1 FBS 1 XSD ZSML ZEML X10 6 X10 3 br vi ws Ge E7 T br L824 E10 Fuse i Working floodlight rear Rotating beacon switch Fuse Rotating beacon B Instrument panel Fuse Fuse Working floodlight front Loudspeaker Working floodlight front Radio Working floodlight front Fuse 4 11 FB2 Fuse B3 Loudspeaker 4 11 S6 Working floodlight rear FB5 Fuse 4 11 E5 Working floodlight rear i XSD Socket SKL 834 103 9 Appendix Central control module ZSML
39. 1 19 K 2 K 16 J10 K4 K17 J12 X31 21 ZSML ZSML ZSML ZSNL Z5M_ ZSML ZSML Z5ML ZSML X70 7 X70 8 X70 6 X70 10 X70 11 X70 13 X707 X70 16 X70 14 E 5 El b EI mS TO E 5 5 a L824 E04 K G on on ZSML Central control module 1 11 S20 Washer switch front rear Instrument panel Washer pump rear Fuse Wiper switch rear Washer pump front Wiper rear Wiper switch front Fuse 1 10 M6 Wiper front SKL 834 97 9 Appendix Monitoring EN 22 ER 24 2 5 26 Designati on ZSML X60 1 8j e 5 6 2964 wal 06 ON B Ke S33 E S26 11 KH PA S e I E 7X68 Ed D E kal psa Ki Ke a ZSM ZENL ZEIL ZSML ZSML Z5ML ZSV X60 7 X60 18 X60 9 X60 10 X60 4 X60 5 X60 6 SK030 SK030 5KC30 W 3 WA WS Device Designati on Fuse L824 E05 Device Tank sensor Engine temperature sensor Hydraulic oil temperature sensor Engine temperature indicator Air filter maintenance switch Transmission position Speed Oil pressure switch Hydrostatic brake switch 2 3 P2 Fuel tank indicator 98 SKL 834 Appendix 9 Monitoring T T T T T T T T T 28 29 2 10 211 212 243 244 245 2 16 8 N 27 PAG
40. 2 le C A As A A elo 57 7 3 Regular eil analyses oto epe de Ox Ere ted dd 58 G AE LEE 58 7 5 Inspection parts and GIGS EE 59 76 GALS AN cleaning BEE 60 7 7 Notes for Winter operation sectaria ii 60 7 8 Checking maintenance and inspection plange 63 7 8 1 Initial inspection delivery handing over mepechon issic esce sces ire 63 7 8 2 Daily and EN 64 7 8 3 Overview of lubricating points entretient hene ha teneant nn dk laicas 66 1 04 lee mec loa a 68 SKL 834 Table of Contents 7 9 Inspection and maintenance WOKK ccccceeeseenceeeeeeeeeeeeeeeceeeeeseeeeeeeesaeeeeeseeeeeeeesseneeeesseeeneess 70 4 9 PICO OIL oic o cox A Ee 70 1 9 2 E Et LEE 71 E93 E e e Ee TEE 71 POA E tt E 72 FRSA TIET air intake teases ete Stet a e teet Be E39 74 7 9 6 NEES E 77 7 9 7 Checking the valve lashiz ette ee bean 78 LIS Brakes cu Ea pe E NIAE duit Ue NIE anu a edd E RE Rm Rede 79 KE Re Kl UE 80 73 10 Hydraulic e ee e EE 81 FSA Hydraulic OU Lut EE 82 ROTA Breathe EE 83 KE 84 yae Paa le 86 E Ee EE 87 7 9 16 Toothed Kelten e EE 87 9 17 El ctrical equip MOM EE 87 7 9 18 Gab ventilation DUST o las aid 88 7 9 19 Windshield washer EE 88 FO cs UL ie EE 89 7 10 1 Preservation temporary Sh lgdOWr esci oed tenete KASS 89 710 2 IM A ere AT 0D A N RET DL AAA a ETS E 89 721023 After SALON arica dd reales 89 8 TFOUDIS SHOOUNG iii a VER cud e 91 A iet Tard det E An Re Ab AD a a
41. 30 J 5 J1 x20 6 x20 11 X20 12 K 11 J 3 K 6 J2 ZSV ZSVL ZSML ZSML ZSM ZSML X61 8 X61 20 x61 16 x61 12 X61 9 x61 11 a 2 5 Er d E E 2 z 5 S S 8j xes Ai xea p 2 E D 8 E 3 4 5 2 Kai a 1 1 1 1 H H 5 H 1 D H Y6 Y11 Y15 Y16 Y5 Y12 TIS D t Je Te fe 12 72 2 fo S 5 a 3 a a 3 L824 E08 Travel SLOW 4 control circuit Travel SLOW Working hydraulics Ride control system switch Working hydraulics Ride control system 1 Manual transmission Ride control system 2 Ride control system 3 Manual transmission 1 Manual transmission 2 SKL 834 101 9 Appendix Lighting and signaling T T T T T T T 41 42 43 44 45 48 47 48 15 30 4 16 Q Fis s 8 z tl e nto rt S12 pz 1 1 1 FB4 FB3 FB7 2 2 2 Al ShazoTr 5 al 15 2 9 sg 3 EE T X170 ZSN ZSNL 7 dle X70 1 X70 9 5 N 9 4 5 Sl 56a 7 al E ot al ES 1 0 FB8 a w gn 1 Sa Ur 2 t 2 2 a 1 X150 2 0 3 4 ZSML ZSML ee 2 X70 18 X70 12 4 6 ZSML 61 6 250 14 6 Ew ws 1 150 x160 d Z3ML I gr sw X30 4 150 Coen h Wo ZSML E X61 21 1
42. 3B22 52 SKL 834 Loading Operation 5 Procedure for changing work attachments with hydraulic quick attach system A Lower the work attachment to the ground so that it cannot overturn Switch off the diesel engine Operate the push button switches 25 5 for pressure relief In the case of a hydraulically actuated work attachment the hydraulic connections on both manifold blocks must be disconnected Set ball valve 26 1 to Unlock quick mount hitch position Start the diesel engine Unlock the quick mount hitch 25 5 and move out of the work attachment Take up new work attachment and lock by pressing the push button switch 25 5 Visual check to ensure that the quick mount hitch is correctly locked Switch off diesel engine Operate push button switches 25 5 for pressure relief Set ball valve 26 1 to Quick mount hitch locked Connect hydraulically actuated work attachment to connection of additional control circuit The additional control circuit 25 47 must be switched off unless a hydraulically actuated additional attachment is connected Fig 25 Operation L86325 Fig 26 Hydraulic quick attach system SKL 834 53 5 Loading Operation 5 4 Notes on how to work with the machine 5 4 1 Loading During transport the bucket either filled or empty must be kept as close to the ground as possible If possible
43. 4 15 Direction indicator horn low high beam steering column mounted switch Brake inching pedal Accelerator pedal Tilt adjustment of steering wheel option height adjustment Actuation of additional control circuit Control lever loader installation Direction of travel pre selection without function if working hydraulics are disabled Impulse mode float position Parking brake Socket Fuse carrier Fan fresh air re circulating air Radio Control rod for mechanical quick attach system Washer tank SKL 834 35 4 Operation 24 25 26 27 28 33 34 35 36 37 38 39 40 41 42 eo S Version 61 58 DR 12 Km h 00014 0 h 1 59 P 12 Km h 00014 0 h 60 NE 0 Km h i 00014 0 h ee ee ned L824 010 1 Fig 10 2 Instrument panel 36 SKL 834 Operation 4 20 not assigned 44 Fan switch heater 21 ORANGE pre heating monitor 45 not assigned 22 RED battery charge indicator 46 not assigned 23 RED parking brake 47 Pre selection switch for actuation of 94 GREEN travel direction forward additional control circuit Pos 5 95 Coolant temperature 48 rail switch for float ition 26 Operating hour meter OFF Impulse Continuous mode 27 Fuel gauge
44. 49 not assigned 28 GREEN travel direction reverse 50 Glow plug and starter switch 29 GREEN direction indicator 51 Hazard warning switch 30 BLUE high beam 52 Working floodlight front 31 RED engine oil pressure 53 Working floodlight rear 32 RED air filter indicator 54 not assigned A 33 Travel speed fast slow 55 not assigned 34 Change over switch for high gear 56 not assigned Only press if machine is at 57 Heater control standstill j j j j 58 Monitor manual transmission 35 Multi function switch with lock for indicator range work equipment cut off and change ee over of the direction of travel pre 59 Monitor manual transmission selection switches from Pos 07 to indicator range Il Pos 36 60 Monitor manual transmission Only press if machine is at indicator range disabled standstill If this symbol comes up the Tu manual transmission is in an 36 Pre selection of travel direction imermedials position The Function only active if working machine is hie read jor hydraulics are disabled operation This pid be 37 not assigned remedied by performing brief 38 DEER steering movements until the g manual transmission 39 not assigned engages 40 Windshield wash function front rear 61 Speed indicator 41 Windshield wiper front for non standard equipment 42 Windshield wiper rear 43 Switch for air conditioning and temperature control SKL 834 37 4 Operation 4 3 Engine 4 3 1 Starting th
45. 5 2 Air intake e Check the air filter attachment and retaining straps for damage e Check the tightness of the air intake between the air filter and the engine e Examine rubber parts for damage Ce Replace damaged parts immediately 7 9 5 3 Cartridge maintenance interval Air filter Main cartridge e The air filter main cartridge must be replaced as soon as the filter maintenance indicator lamp 44 32 on the instrument panel lights up during operation e Brief delay in maintenance does not result in lower filter efficiency Air filter Safety cartridge The air filter safety cartridge must be replaced in the following cases e After the fifth maintenance of the main cartridge e After 2 years of operation at the latest e f the service indicator switches on after the main cartridge has just been serviced e f the main cartridge is damaged e f the safety cartridge is damaged S515 41 Fig 43 Air filter oe dz O D0014 0 h OTE L824 044 Fig 44 Operation 74 SKL 834 Care and Maintenance 7 7 9 5 4 Replacing cartridges Main cartridge e Release the wire fasteners 45 1 and remove the bottom of the housing 45 4 e Withdraw the main cartridge 45 2 by twisting slightly to and fro e Check whether the safety cartridge 45 3 must be replaced Remove safety cartridge only in the case of necessary maintenance work Only open the seal 45 5 of the safety cartridge
46. 8 8 Trouble Shooting 8 1 General Operating problems are often the result of incorrect handling of the machine the use of unsuitable materials or irregular maintenance The following table presents a summary of a range of problems and their probable causes If a problem can only be eliminated through repair then the responsible Service Agent must be called in 8 2 Engine All faults in the diesel engine must be examined as described in their specific engine operating instructions During the warranty period malfunctions must be dealt with by the responsible Service Agent or a specialist workshop Fault Possible cause Remedy 8 3 No steering movement 1 Oil supply to pump interrupted Check and repair suction line 2 Hydraulic pump damaged Repair or replace 3 Priority valve damaged Remedy fault call Service Agent 4 Steering control unit damaged Remedy fault call Service Agent 5 Steering cylinders damaged Repair 6 Mechanical fault Repair 8 4 Insufficient performance of service brake 1 Wear of drum brake Adjust or repair call Service Agent 2 Master brake cylinder damaged Repair or replace call Service Agent 3 Mechanical fault Repair call Service Agent 8 5 Insufficient performance of parking brake 1 Wear of drum brake Adjust or repair 2 Mechanical fault in brake actuation Repair and or re adjust 8 6 Hydrostatic drive has no neutral position
47. as crosswise stacks of planks square timbers or steel trusses Earth moving machines which are raised with work equipment must be stabilized by a supporting structure immediately after lifting Work under raised machines which are only supported by their hydraulics is forbidden The engine motor s must be turned off prior to all maintenance and repair work These requirements are only to be ignored in the case of maintenance or repair work which cannot be performed without the engine motor s running When performing maintenance and repair work on the hydraulic system it must be relieved of pressure With the engine turned off lower the work equipment to the ground and actuate all hydraulic control levers until there is no pressure in the hydraulic system Before working on the electrics or when performing arc welding on the machine the connection to the battery must be disconnected When disconnecting the battery first the negative pole then the positive pole must be disconnected The battery must be re connected in reverse order During repair work around the battery the battery must be covered with insulating material tools should never be placed on or near the battery Protective devices of moving machine parts are only to be opened or removed if the drive has been switched off and cannot be switched on again by unauthorized persons Protective devices are e g engine motor covers doors protective grating tr
48. ate the generator 47 2 until the tension is correct e Re tighten the fastening screws e Check the tension once more Replacing V belts e Slacken the fastening screws 47 1 e Swivel the generator against the direction of tensioning e Remove the used V belt and fit a new one e Swivel the generator 47 2 in the direction of the arrow until the V belt tension is correct e Re tighten fastening screws e Check tension once again When new V belts are fitted their tension must be checked and adjusted if necessary after the first 15 min L824 047 Fig 47 V belts SKL 834 77 7 Care and Maintenance 7 9 7 Checking the valve lash e The valve lash 48 1 is tested by means of a reed gauge placed between the upper part of the valve stem 48 3 and the rocker arm 48 2 on the cold engine e The correct valve lash is 0 30 mm for the inlet valve and 0 50 mm for the exhaust valve Valve setting e Remove the cylinder head cover Crankshaft position 1 e Turn the crankshaft until both valves intersect at the 1 cylinder exhaust valve not yet closed inlet valve begins to open e The valves marked black can be adjusted To check the completed adjustment mark the respective rocker arm with chalk If required adjust valve lash To do so proceed as follows gt Slacken the lock nut 48 4 Using a screwdriver adjust the setting screw 48 5 in such a manner tha
49. ato at AS ee 10 2 9 Operation m E 10 EUER C C te td is 11 2 11 Danger of falling objects EE 11 2 12 Working in the vicinity of underground power lines sseseseeeemm 11 2 13 Working in the vicinity of overhead power lines mm 12 2 14 Operation in closed rooms due ii 12 2 15 Work Stoppages E 12 2 16 Change of work attachments maintenance report 13 2 17 Recovery loading transportation il 14 2 18 Monitoring and 1nspecllo bis oon eege 14 2 19 IRE le Le e EE 15 220 Emergency EE 15 2 21 Other dangers x lt asse E E AA RNE dA A R RNE dead EE 15 3 Tech ical dala uten du aec Une dos 17 SEG I PEE 17 3 2 DISSE LE NOING eMe 23 3 3 Electrical SS E 23 SE TRAV CI E 23 3 5 TARO Sax Eege Ehe Leg eher EES 24 3 6 Hydraulic KEE 24 SEI EE 25 3 8 MS A tC 0 T ENT 1A ARGA A T E Ven AA E CRA GES FSE 25 3 9 Fuels lubricants and co061amtS cccccccccecessessseeeeeeceteatesseneeeeeesesesnsesseeeeceseneaaeeseeeeeeteesaneeeaes 26 3 9 1 Filling quantities da 26 3 9 2 Fuel lubricant and coolant specifications uk 27 3 10 Permissible loads in compliance with German Regulations StVZO sssss 28 3 11 Sound level values ViDa cei EES 28 3 12 Dimensions nd Le Lu 28 3 13 Front loader installation WEE 29 3 14 Loading Wa EE 29 3 15 ll a E 30 3 16 Optional aACCessories geed ee 31 SKL 834 Table of Contents A Ope
50. avoid long transport distances For loading lower the bucket and position the cutting edge parallel to the ground Reduce speed by inching as required Penetrate the bucket in the material to be loaded As soon as the bucket is filling slightly raise the lift frame and tilt back the bucket For dumping raise the bucket until it is above the location where to unload the material and then start to unload 5 4 2 Scraping grading Lower the lift frame and move the cutting edge in the ground with flat angle of inclination Do not penetrate too deeply to ensure jolt free removal of earth During this work the depth is only to be leveled by moving the bucket in and out 5 4 3 Excavation work To excavate the ditch for the foundation attempt to dig layers which are as regular as possible Plan the excavation in such a way as to enable the machine to leave the ditch for the foundation forward with the full bucket Attempt to keep the outward run of the ditch for the foundation as flat as possible 54 SKL 834 Recovery and Transport 6 6 Recovery and Transport of the Machine 6 1 Recovery of the machine Towing of the wheel loader must be restricted to clearing a junction or a road to prevent damage to the hydrostatic drive If possible let the diesel engine run at low idle during towing Towing lugs Front right and left on the axle plates Rear right and left bottom side plates of the rear e
51. ch for the travel direction 16 36 is located on the instrument panel and another such switch on the joystick 16 7 for the working hydraulics The multi function switch 16 35 is only to be pressed if the machine is at a standstill and when both travel direction pre selection switches are in neutral position If the two direction of travel pre selection switches are pressed in a contradictory manner the machine stops When driving on roads the joystick 16 7 for the work equipment must be deactivated by operating the multi function switch 16 35 By doing so the travel direction pre selection switch on the joystick 16 7 is without function too The direction of travel is pre selected using the switch 16 36 on the instrument panel In working mode the joystick 16 7 for the work equipment must be activated using the multi function switch 16 35 By doing so the switch 16 36 on the instrument panel is without function The direction of travel is pre selected using the travel direction pre selection switch on the joystick 16 7 Si JEES 1824 016 Fig 16 Operation SKL 834 43 4 Operation Driving off e Set the travel direction pre selection rocker switch located on the joystick 17 7 and the instrument panel 17 36 to O neutral position e The indicator lamps 17 24 amp 17 28 must not light up e Start the engine e Raise th
52. correct function of the lighting equipment e Check the correct function of the indicator lamps e Check the correct function of the warning equipment 1824 059 Fig 59 Battery SKL 834 87 7 Care and Maintenance 7 9 18 Cab ventilation dust filter e The air intake for the heating and the fresh air supply of the cab features a dust filter or optionally a charcoal pollen filter Removal e Remove the ventilation grid 60 1 e Remove the angle bracket 60 2 e Take out the dust filter 60 3 e Clean the filter or replace it Cleaning the dust filter Ce Never wash or brush out the filter e Knock the filter with the intake side side covered by expanded metal several times on a flat and hard surface e Using dry compressed air max 5 bar blow against the direction of flow e Check the filter for damage to the paper bellows and seals Never continue to use damaged dust filters Re installation e Re insert new or cleaned dust filter until the stop Observe the mounting position The air flow arrows must point towards the cab e Fasten the dust filter with the angle bracket e Re fit the ventilation grid 7 9 19 Windshield washer system e Top up the washer tank 61 1 as required e Add antifreeze when temperatures are around or below freezing 1824 060 Fig 60 Dust filter for cab ventilation 1824 061 Fig 61 Windshield washer tank
53. d reverse SKL 834 SKL 834 S Transmission Transmission range range Il Gear range 0 7km h 0 7 0km h 0 14 km h Work Gear range 0 20 km h 0 18 km h 0 36 km h Road SKL 834 23 3 Technical Data 3 5 Brakes Service brake Parking brake 3 6 Hydraulic system Hydraulic nl e HE Steering Total steering angle Hydrostatic transmission with advanced driving automatics Automatic adjustment of propulsive force and speed Continuous speed regulation forward and in reverse Four wheel drive via propeller shaft connection 440 bar Hydraulically actuated center mounted drum brake combined with hydrostatic brake of travel drive The brake acts on all four wheels via four wheel drive Mechanically actuated center mounted drum brake on front axle The hydrostatic travel drive in the closed circuit acts as an additional non wearing brake Gear pump on the throughdrive of the variable displacement pump Max pump capacity 64 l min Operating pressure steering 175 bar Operating pressure loading 250 bar Priority supply of hydraulic oil to steering through load sensing system ensuring that all the available oil can be provided if necessary Rapid steering movements are possible even at low engine revs Fully hydraulic proportionally acting articulated steering One double acting steering cylinder 80
54. d after each change of equipment a check must be carried out to ensure that the work attachment is correctly fastened and the quick mount hitch is properly locked The bucket must be moved carefully at a low height e Before commencing loading work memorize the lever controls well e During loading work driving and work movements should flow in smooth Succession e Drive slowly when familiarizing yourself with the controls 5 2 Loader operation e Switch on the work equipment 22 35 Operation Bucket e With joystick 22 6 Operation Additional control circuit e Switch on additional control circuit 22 47 Step 1 e Press right hand left hand push button switch 22 5 e g opem close multi purpose bucket The additional control circuit must always be switched off unless additional equipment is actuated Continuous operation of additional control circuit e Set the additional control circuit 22 47 to step 2 The red indicator lamp lights up Observe the operating direction of the attachment e g direction of rotation of sweeper The additional control circuit must always be switched off unless additional equipment is actuated BS on EEIEIEE NS L824 022 Fig 22 Operation SKL 834 49 5 Loading Operation Operation of float position The float position must always be switched o
55. e engine Each time before putting the machine into operation the inspections in compliance with Chapter 7 8 must be carried out Before switching on the engine ensure that no one is in the immediate vicinity of the machine or in the danger zone e All shift levers must be put into neutral position e Parking brake 11 9 applied direction of travel pre selectors 11 7 11 36 in O position e Insert ignition key in glow plug and starter switch 11 50 e Turn clockwise to 1 the indicator lamps 11 22 11 31 light up e Pre ignition starts the indicator lamp 11 21 lights up e Press the accelerator pedal 11 3 completely down for normal start and to the quarter open position for hot start e After the indicator lamp 11 21 has gone out turn the glow plug and starter switch to Start As soon as the engine is running turn the ignition key to 1 and decrease the revs to low idle speed The indicator lamps should go out e H the engine has not started after max 20 seconds turn the ignition key to 1 or 0 and pause for at least 1 minute before trying again Repeat the start up procedure 1824 011 Do not drive the engine at full throttle EE straight away Drive with restraint until the operating temperature of the engine has been reached 38 SKL 834 Operation 4 4 3 2 Monitoring du
56. e fuel shut off Loosen the hex head screw 41 1 and unscrew Take out the fuel screen 41 2 cover and screen in one unit Clean the fuel screen in fuel Replace if required Insert the seal rings properly 41 3 41 4 Mount the cover fuel screen 41 2 and tighten the screw Open the fuel shut off Check the tightness Replacing the fuel leak oil pipe Close the fuel shut off Separate the rubber hoses 42 3 from the injection valves Separate the rubber hose 42 1 from the fuel tank Separate the rubber hoses 42 4 42 8 42 1 from the couplings 42 2 Dispose of the rubber hoses 42 4 42 3 42 1 in compliance with regulations Connect the new rubber hoses with the couplings Connect the rubber hoses 42 3 to the injection valves Connect the rubber hose 42 1 to the fuel tank Open the fuel shut off Check tightness L824 041 Fig 41 Fuel pump Fig 42 Fuel leak oil pipes SKL 834 73 7 Care and Maintenance 7 9 5 Air filter air intake All maintenance work on the air intake system must be carried out with the engine off Do not start the engine while the filter cartridge is removed 7 9 5 1 Dust extraction valve e Dust extraction valves 43 1 are largely maintenance free e Any baked on dust can be removed by squeezing the valve together 7 9
57. e lift frame as far as the Travel height mark 18 1 e Select fast or slow range 17 33 as required e High speed version option Select gear range or Il Observe the indicator lamp 17 58 60 e Release the parking brake 17 9 e Set the desired travel direction using the pre selection switches for the travel direction 17 7 or 17 36 e The indicator lamp 17 24 or 17 28 lights up e Press the accelerator pedal 17 3 The machine only drives off once a certain engine speed is reached e Travel speed is increased and decreased using the accelerator pedal Travel speed directly depends on engine speed e The direction of travel may be changed quickly by operating the pre selectors 17 7 17 36 Coming to a halt e Travel speed is reduced by releasing the accelerator pedal The hydrostatic drive acts as a non wearing auxiliary brake e Operate the braking inching pedal 17 2 as required e See also Chapter 4 8 3 Brakes Option S Version 150 Basel 1824 017 Fig 17 Operation L824 018 Fig 18 Height mark 44 SKL 834 Operation A 4 8 2 Steering e The wheel loader has fully hydraulic proportionally acting articulated steering e Priority supply of hydraulic oil to steering through load sensing system In the event of steering malfunctions determine the cause immediately se
58. e lower Sec 3 2 3 4 Dumping in uppermost position in out sec 1 1 1 1 in compliance with ISO 8313 Stability in conformity with DIN 24094 3 14 Loading bucket Width Capacity Max density y heaped mm m per t m General purpose bucket 1 850 0 8 1 8 Multi purpose bucket 1 850 0 75 1 6 Earth bucket 1 850 0 9 1 6 Light material bucket 1 850 1 0 1 2 Super light material bucket 1 950 1 2 0 8 Side dump bucket 1 850 0 7 1 8 High tip bucket 1 850 0 7 1 2 SKL 834 29 3 Technical Data 3 15 Fork lift attachment Fork connection to ISO FEM Class 2 FormB DIN 15 173 and ISO 2328 respectively Width of fork carrier Length of forks Fork cross section Max stacking height The stated carrying capacity is based on the machine traveling over level ground with a stability mm mm mm mm factor of 1 25 or 80 of the tipping load The payloads are valid for the machine fitted with 405 70 R 18 SPT 9 tires and the equipment 1 240 1 120 100 x 45 3 020 condition as described in compliance with ISO 6016 Total lift range S 2 0 921 25 TO Aneh kg 1 250 2 000 lbs 2 750 4 400 kg 1 380 2 200 Ibs A E lbs 3 030 4 840 0 5bar kg Kg 7 3psi lbs Transport position S 1 67 S 1 25 500mm kg 1 720 2 300 los 3 790 5 060 E kg 1 870 2 500 Se Al Ge 7 3psi Ibs 4 120 5 500 A lbs kg lbs A When screw on rear axle weig
59. e oil level 7 9 8 21 Check function of brakes 22 Checkif the dust filter for cab ventilation is dirty and clean if required 7 9 18 C In case of extreme exposure to dust shorten cleaning intervals 23 _ Check function condition and completeness of safety devices 24 _ Grease machine in compliance with overview of lubricating points 7 8 3 SKL 834 65 7 Care and Maintenance 7 8 3 Overview of lubricating points N Replace damaged grease nipples immediately and check if grease passes through 3 6 4 5 15 Au V a LI sa Rss B ES VE Tha e AD CHA ts 743 05 E Lu NM o 7 11 12 13 14 E E z 1824 033 Fig 33 Lubrication chart 66 SKL 834 Care and Maintenance 7 Grease all lubricating points with multi purpose grease The intervals stated are valid for one shift operation S 3 Lubricating point daily weekly Chapter ch Tilt cylinder Tilt lever x lt Lift frame Tilt lever Lift cylinder Lift frame Tilt cylinder Front end Lift frame Front end Lift cylinder Front end Lift frame Quick mount hitch Linkage Quick attach system Tilt lever Linkage O 0 IN O 01 A 0 rn 11 Quick mount bitch mechanical Quick mount bitch hydraulic Steering cylinder Front e
60. e trouble shooting table and call for service personnel if necessary 4 8 3 Braking Service brake and auxiliary brake e To bring the machine to a halt release the accelerator pedal 19 3 The hydrostatic drive then acts as an auxiliary brake e Press the brake inching pedal 19 2 as required Parking brake e Only apply the parking brake 19 9 if the machine is stationary With the parking brake 19 9 applied the transmission is disabled Brake inching mechanism e The machine features a brake inching mechanism altering the relationship between travel speed and engine speed e When the brake inching pedal 19 2 is pressed travel speed is reduced irrespective of engine speed until the machine comes to a stop This permits sensitive driving at maximum engine speed e g when loading a truck where fast working cycles are required c 3 7 S t EE 1 L824 019 Fig 19 Operation SKL 834 45 4 Operation 4 8 4 Road travel Before driving on open roads the following points have to be observed The wheel loader must be equipped as Stipulated by the regulations authorizing the use of vehicles for road traffic in the user s country e Empty the bucket and tilt back completely e Attach the protective device on the front bucket edge e Secure the side dump bucket with socket pins 824 018 e Completely retract the high tip bucket e Fold the forks of the fork
61. e using cold detergent or a steam jet device on a suitable surface with an oil separator Do not expose the generator to direct water or steam jet After cleaning bring the engine to operating temperature to prevent corrosion Fig 52 Hydraulic oil cooler SKL 834 81 7 Care and Maintenance 7 9 11 Hydraulic oil filter After a larger repair job following the test run the filter cartridge of the hydraulic oil filter must be renewed as well Replacing the filter insert Unscrew the oil dipstick 51 1 With the aid of a tool remove the filter cover 53 1 Remove the filter element 53 5 along with the inlet connection 53 3 by pulling and turning at the same time Remove the filter element from the inlet connection and dispose of in compliance with regulations Ensure that the seal 53 2 in the cover and the O ring 53 4 on the inlet connection are in faultless condition and replace any damaged parts Insert a new filter element on the inlet connection and insert together in filter Screw on the filter cover 53 1 and tighten 20 Nm Screw back in the oil dipstick Check the tightness of the filter by means of a test run L834 051 1 L834 053 Fig 53 Hydraulic oil filter 82 SKL 834 Care and Maintenance 7 7 9 12 Breather Replace the breather if it i
62. ent must be secured against unwanted movement The traveling gear and track laying gear of earth moving machines must be sufficiently cleaned of mud snow and ice to ensure that ramps can be driven up without risk of slipping When transporting the earth moving machine on trucks flatbed trailers or by rail it must be sufficiently secured with chocks and by attachment to the lashing points Before setting off the route to be taken must be examined to determine whether the roads are wide enough entrances and passages under bridges are large enough and that roads and bridges have sufficient carrying capacity 2 18 Monitoring and inspections The machine must be submitted to a general inspection in compliance with the existing UVV regulations Accident Prevention Regulations This inspection must be carried out by an expert e g machine engineer or machine foreman e before the machine is put into operation for the first time and before the machine is again put into operation after essential modifications have been made e atleast once a year e in the meantime in compliance with operating conditions and local environments The results of this inspection have to be recorded in writing and this record has to be kept until the next inspection takes place Prior to every work shift the machine operator must check the earth moving machine in compliance with the inspection and maintenance plan Hydraulic hoses must be r
63. eplaced as soon as the following damage is recognized e Damage to the outer layer which reaches the intermediate layer e Embrittled patches on the outer layer e Deformations when under pressure or without pressure which differ from the original shape of the installed hose e Leaks e Damage to hose fittings or to the connection between the fitting and the hose The coolant level is only to be checked after the engine has cooled down the cap must be turned carefully to let off excess pressure Prior to operations the machine operator must check the function of the safety devices The machine operator must advise the supervisor immediately and his replacement if there is a change of operator with regard to any shortcomings In the event of shortcomings which jeopardize the operating safety of the earth moving machine it shall not be used until these have been eliminated SKL 834 Safety and Prevention of Accidents 2 2 19 Fire protection e Before refueling the tank of the machine the engine must be stopped Exercise special caution as long as the engine is hot e Never smoke or handle open flames whilst refueling the tank of the machine s The fire extinguisher must be kept in the cab and the fire extinguisher symbol be attached 2 20 Emergency exit The right hand cab door acts as an emergency exit 2 21 Other dangers Failure of hydraulic system If the hydraulic system fails because the
64. ering seat Raise seat as far as the stop it then sinks to its lowest position Tilt adjustment of steering wheel e Press lever 14 4 downward e Adjust steering wheel tilt wise e Release lever Height option adjustment of steering wheel e Draw lever 14 4 upward e Adjust steering wheel height wise e Release lever L86313 L824 014 Fig 14 Operation 40 SKL 834 Operation 4 4 5 Heating Ventilation Heating e The heater is connected to the engine oil circuit e The fan is operated using the switch 15 44 Temperature is adjusted using the Kee TUE switch 15 57 and can be operated with fresh air and re circulating air e Open aspirating hole 15 12 for re circulating air mode e The air is distributed and aimed as desired by adjusting the air vents Ventilation e In ventilation mode the valve towards the engine oil circuit remains closed e The fan is operated using the switch 15 44 e The air is distributed and aimed as desired by adjusting the air vents Air conditioning option e Operate the air conditioning system using the switch 15 43 4 6 Light switch in compliance with StVZO The loader s lighting is switched on and off by turning the steering column mounted switch 15 1 Setting 0 Light off Setting 1 Parking light L824 015 Setting 2 Headlamps Fi WE
65. ff unless actuated Set switch 23 48 to O Impulse mode e Set float position switch 23 48 to 1 e Place bucket on ground e Press switch 23 8 Float position is activated Continuous mode e Place bucket on ground e Set switch 23 48 to 2 The green indicator lamp lights up r i 7 f t ma a i 1 La24 023 Fig 23 Operation 50 SKL 834 Loading Operation 5 5 3 Changing work attachments 5 3 1 General To achieve maximum utilization of the machine for a variety of applications a great number of work attachments and accessories are available The machine is equipped with a quick attach system to shorten the time it takes to change attachments When mounting a multi purpose bucket front sweeper etc an additional control circuit is required It is possible to use under certain circumstances the work attachments of predecessor models for our machines When mounting the work attachments of predecessor models they may have to be adjusted and or are subject to utilization restrictions The mounting of work attachments which are not included in our product range requires our written approval It is essential to consult your dealer before mounting such a work attachment When attachments have been removed they must be secured against overturning to avoid possible injury to persons SKL 834 51 5 Loading Operation 5 3 2 Assembly of wo
66. g manually if needed If underground power lines are encountered unexpectedly or they or their protective covers are damaged the machine operator must discontinue work immediately and notify the supervisor SKL 834 11 2 Safety and Prevention of Accidents 2 13 Working in the vicinity of overhead power lines When the earth moving machine is being used in the vicinity of overhead power lines and trolley wires a safety distance which varies depending upon the nominal voltage of the overhead line must be maintained between the lines and the earth moving machine and its work equipment to prevent current overspill This also applies to the distance between these lines and attached implements or loads The safety distances specified below must be complied with Nominal voltage in Safety distance in Volt meters 1000 V 1 0m over 1 kV 110 kV 3 0m over 110 kV 220 kV 4 0m over 220 kV 380 kV 5 0 m nom voltage 5 0 m unknown In the observation of safety distances all working movements of earth moving machines e g positions of the work equipment and the dimensions of attached loads must be taken into consideration Uneven ground which would cause the earth moving machine to be inclined and thus nearer to overhead lines must also be taken into account During work in windy conditions both overhead lines and work equipment may swing out thus reducing the safety distance If
67. he axle oil level e Remove the inspection plug 56 1 check and top up oil if required Changing axle oil The rear axle differential and the transmission have combined oil filling e Park the machine on level ground e Open the inspection filler plug 56 1 e Open the drain plugs on the differential 56 2 and the transmission 56 3 and drain the oil e Flush out the axle if necessary e Carefully close both drain plugs e Pour in oil via the inspection filler hole 56 1 until oil escapes e Carefully close the inspectior filler plug L834 056 Fig 56 Rear axle SKL 834 85 7 Care and Maintenance 7 9 13 3 Wheel hub Checking the axle oil level Remove the inspection plug 57 1 check and top up oil if required Changing axle oil The wheel hub has a combined inspection filler and drain plug Turn the wheel until the screw plug 57 1 on the hub is at the bottom Open the screw plug and catch the escaping oil Flush out if necessary Turn the wheel to the filling and inspection position The inspection mark must be horizontal Fill in oil up to the lower edge of the hole Carefully close the screw plug 7 9 14 Wheels Checking the tire pressure Check the tire pressure in accordance with the pressure chart Chapter 3 8 Tightness of wheel nuts During the first 50 operating hours check the tightness of the wheel nuts M 20 x 1 5 dai
68. hts or rear tires with hydroinflation are used g Ibs During fork lift operations the tire pressure of the front wheels must be increased by at least 0 5 bar 30 SKL 834 Technical Data 3 3 16 Optional accessories e Orthopedic air cushioned driver s seat e Fire extinguisher e Height and tilt adjustable steering wheel e Pressurized cab e Air conditioning e Engine independent diesel heater with timer e Diverse electrical accessories such as working floodlights rotating beacon radio etc e FOPS roof guard e Sliding window right hand door e Diesel exhaust cleaner e Catalytic converter e High speed version e Anti theft device e Back up alarm system e Electric tank refueling pump e Quick attach system hydraulically actuated e Snow blade e Sweeper e Load hook for attaching to forks e Rear axle weights e Outlet for hydraulic hand hammer e Filling with biodegradable hydraulic oil ester based BIO E HYD HEES Further optional equipment available on request Any modifications of SCHAEF TEREX products and their equipment using extras and work attachments which are not included in our product range require our written approval If our approval is not sought our warranty expires as does our product liability for any resulting consequential damage SKL 834 31 3 Technical Data 32 SKL 834 Operation 4 4 Operation 4 1 First commissioning The machine must be entered from
69. i I e l fee rel re ha ER i 1 T 1 UNE Li e WW SE Pa I 1 1 T E 1 or 1 i H i pa i E 1 bog 1 ko i 1 In L I H RS qi 1 FE Fi i SI III eee Lone de A e o yb a al i r E REM c D i it d EN ee bee wee Ld QJ ip E oem 1 T anda 1 i i Qt 4 i ME rd e e i i el i ag 1 Ni 1 I 1 Stes aj de o H 14 c 88 roo E E i 23 1 1 FI een E er TE Loe i Bei 3 de 1 a if E Dod E 1 ji 5 i L S T 2 14 i i N In 1 e Ex 1 Li 1 ry 1 CT 1 Ya 1 bg 1 Ta 1 Ya 1 bg 1 EET 1 Pa 1 ba In i E 1 La In i E 1 Uu 1 blau 1 Pa 1 Vg bg 1 i i ba Ea re 1 L Y SKL 834 L834 H02 03 09 30 Fig H02 Hydraulic system parallel boom geometry 110 Appendix 9 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Description of hydraulic circuit diagram parallel boom geometry Hydraulic oil tank Loader control lever Pilot control unit Control valve Additional control circuit connection hydraulic quick attach system Hydraulic cylinder lift frame Hydraulic cylinder bucket tilt Load retaining valves Vibration damping Release valve only if Pos 20 amp Pos 21 installed Transmission high speed version Valve Open return Distributor for hand held hammer 4th control circuit Control unit SKL 834 111 9 Appendix
70. iced by persons who e are physically and mentally suitable e have been instructed in the operation or maintenance of earth moving machines and have demonstrated this ability to the plant operator e can be expected to perform their allocated duties reliably All such persons must be of the legal minimum age They must be designated by the plant operator to operate or service the earth moving machine Operating equipment is only to be operated from the driver s seat The earth moving machine is only to be ascended and entered using the entrances and surfaces intended for this purpose It is the driver s responsibility to ensure that the operators stand entrances and other surfaces of the earth moving machine which have to be stepped on are free of dirt grease oil ice and snow SKL 834 Safety and Prevention of Accidents 2 2 5 Danger zone No one is to enter the danger zone of earth moving machines The danger zone encompasses the area around the earth moving machine in which persons may be injured by movements of the earth moving machine during Operation its work implements and attachments or by swinging out or falling loads The machine operator is only to work the earth moving machine if the danger zone is free of personnel The machine operator must give a warning signal to persons who may be in danger The machine operator shall stop work with the earth moving machine if anyone remains in
71. im Upon completion of assembly maintenance or repair work all protective devices must once more be attached in the proper manner Load bearing parts of earth moving machines are only to be welded following consultation with the manufacturer and in accordance with recognized welding principles Protective structures ROPS FOPS shall not be welded or drilled in any way SKL 834 13 2 Safety and Prevention of Accidents Before commencing work on the hydraulic system the operating pressure pilot pressure back pressure and pressure inside the tank must be let off Alterations such as welding of the hydraulic system are only to be undertaken with the manufacturer s permission Swallowing lubricants or long and repeated skin contact can be hazardous to health When used properly there is no particular danger to health The safety specification sheets from the mineral companies must be observed Only the hoses specified by the manufacturer are to be used Hydraulic hoses must be routed and assembled by expert personnel In the vicinity of fuel or batteries smoking and naked flames are prohibited 2 17 Recovery loading transportation Earth moving machines are only to be loaded onto recovery vehicles if adequate towing vehicles are used The tow fixing points specified by the manufacturer must be employed For loading and transportation earth moving machines and all necessary auxiliary equipm
72. intervals Periodic oil analyses reveal trends in the condition of the oil and the machine When the scheduled oil change intervals have been reached the oils should be analyzed in the following intervals to check their quality and thus extend the oil change intervals e Hydraulic oil 1 000 operating hours e Transmission oil 500 operating hours e Engine oil 100 operating hours Based on the first results the laboratory recommends the interval for the next sampling Ask your SCHAEFF TEREX dealer for an information booklet detailing the scope and procedures of the oil analysis 7 4 Warranty During the warranty period thorough inspections are stipulated which are obligatory and which must be carried out by trained specialist dealer personnel The inspections are obligatory and must be paid for The performance of the obligatory inspections must be confirmed on the inspection cards in the warranty handing over certificate If they are omitted the warranty may be subject to restrictions 58 SKL 834 Care and Maintenance 7 7 5 Inspection parts and aids Service parts Spare parts number Hydraulic oil filter insert suction filter 5 003 659 218 Breather with screen element 5 003 650 362 en UE uh 5 411 656 547 Fuel filter with sel 5 411 656 301 Air filter main cartridge ici ir 5 501 660 912 Air filter safety cartridge oooooncccnnnccc
73. k valve lash of engine and adjust if necessary 16 Check injection valves 17 Check fuel leak oil necessary pipe and replace if x 18 Replace toothed belt 2 19 Check crankcase breather in valve cover 20 Check acid level and battery connections 21 Check condition of tires tire pressure and tightness of wheel nuts 22 Check secure fastening of axles and propeller shaft Perform work with machine at operating after every every every yearly yearly temperature 100 500 1000 2000 25 Check that door catches function perfectly O O and replace if necessary 26 Clean or replace the dust filter for cab O X X ventilation 27 Check electrical indicating and warning O O elements and lighting system 28 Check smooth running of operator controls O O and adjust if necessary 29 Check tightness of all pipes hoses control O O valve hydraulic pumps cylinders etc When tightening hose and pipe connections screwin couplings must be locked to prevent rotation 30 Check or change hydraulic oil o o x X 31 Replace insert of hydr oil return suction filter X X X 32 Replace breather X X 33 Check function of brakes and replace brake O O X X oil 34 Bleed brake O O 35 Rear axle differential with transmission X O X X option transmission oil check or oil change 36 Front axle differential oil check or oil change X O X X 37 Wheel hubs
74. l level and top up oil if necessary empty cooler has filled with oil Start the engine and run at low idle speed for approx 2 minutes Switch off the engine Check the oil level and top up oil if required Fig 35 Engine oil 70 SKL 834 Care and Maintenance 7 7 9 2 Engine oil filter The engine oil filter must be replaced with every engine oil change Place oil drip pan below the engine oil filter Clean the outside of the engine oil filter Unscrew the filter cartridge 36 4 using a commercially available tool and check that the fastening stud is firmly secured in the filter head Dispose of the filter cartridge in compliance with regulations Check filter head condition and clean Fill the new filter with oil wet the sealing ring with oil and tighten firmly by hand After a test run check the tightness of the engine oil filter cartridge 7 9 3 Engine oil cooler Only clean the cooler with the engine switched off and cooled down Clean the engine oil cooler 37 1 from the Outlet side with compressed air If necessary clean with cold detergent or steam jet on a suitable surface with an oil separator Do not expose the generator directly to the water or steam jet Bring engine to operating temperature to prevent corrosion Fig 36 Engine oil filter
75. ls 11 Clean cooling fins of engine oil cooler o O O 7 9 3 In case of high exposure to dust shorten the cleaning intervals 12 Check V belt tension O O 7 9 6 13 Check engine mounts and pump attachments o O 14 Check engine speed adjustment top end and O O low idle speed 15 Check valve lash of engine and adjust if O 7 8 7 necessary 16 Check injection valves O 7 9 15 17 Check fuel leak oil pipe and replace if O x 7 9 4 necessary 18 Replace toothed belt 7 9 16 19 Check crankcase breather in valve cover o gt 20 _ Check acid level and battery connections O O 7 9 17 21 Check condition of tires tire pressure and O lO 7 9 14 tightness of wheel nuts 22 Check secure fastening of axles and propeller O O shaft 23 Check bearing bushings and bolts of worklo O equipment and replace if necessary 24 Check bushings and bolts of the articulation O O and the articulated steering and replace if necessary 68 SKL 834 Care and Maintenance 7 O Checking Maintenance Operating hours X Replace Pain anin Perform work with machine at operating afer every every every yea yearl Chapte temperature 100 500 1 000 2000 r 25 Check that door catches function perfectly and O O replace if necessary 26 Clean or replace the dust filter for cab O X X 7 9 18 ventilation 27 Check electrical indicati
76. ly and subsequently every week and tighten to the correct torque if necessary C Tightening torque 460 Nm When fitting a wheel tighten the nuts to the correct torque crosswise in several stages AblaBstellung Drain Fig 57 Wheel hub 86 SKL 834 Care and Maintenance 7 7 9 15 Injection valves e Injection valves must be checked by your service specialist 7 9 16 Toothed belt for engine e The toothed belt must be replaced by your service specialist 7 9 17 Electrical equipment Battery The instructions of the battery manufacturer must be observed when using the battery for the first time e The acid level should be approx 10 mm above the edges of the plates If necessary top up with pure distilled water e Only check the battery with the engine off With maintenance free batteries this check can be omitted Removing the battery e Disconnect first the battery ground cable then the positive cable e Detach the clamping bracket 59 1 e Lift out the battery Installing the battery e Lay the battery in the machine and secure with the clamping bracket e First connect the positive cable then the battery ground cable Ensure that the negative terminal is N connected to the negative pole and the positive terminal to the positive pole In winter in particular the battery charge should be closely monitored Lighting and warning equipment e Check the
77. mblies must be brought to operating temperature and maneuvered for approx 15 minutes e Beforehand the anti corrosion coat must be removed from the piston rods and the openings of the air filter system and the exhaust pipe freed e After the maneuvering cycle preserve the machine once more as previously described 7 10 3 After shutdown Before putting the machine into operation once more the following measures must be carried out e Anti corrosion coat must be cleaned from the piston rods e Seal off the air intake opening of the air filter and the exhaust pipe opening e Remove the air filter insert check its condition and replace if necessary e Check the condition of the air filter main cartridge safety cartridge and replace if required e Clean the machine with a neutral detergent e Check and if required re charge and re install the battery e Carry out all measures for putting the diesel engine back into operation stated in the engine operating instructions e H the machine has been out of use for more than 6 months the oil in the assemblies such as axles transmission s etc must be changed e f hydraulic oil filters such as suction and return filters as well as breathers have been out of use for more than 6 months they must be replaced e Lubricate the machine in compliance with the lubrication plan SKL 834 89 7 Care and Maintenance 90 SKL 834 Trouble Shooting
78. n switch off the working hydraulics and apply the brakes If the driver is leaving the earth moving machine unattended he must first turn off the engine and ensure that it cannot be started up by unauthorized persons e g removing ignition keys SKL 834 Safety and Prevention of Accidents 2 2 16 Change of work maintenance repair attachments Earth moving machines are only to be converted maintained or serviced under the guidance of a suitable person designated by the plant operator and following the manufacturer s operating instructions After every change of work attachments the driver must convince himself that the quick mount hitch is correctly fastened and locked Work on e g e braking e steering e hydraulic and e electric systems of the machine is only to be carried out by expert personnel specialy trained in these areas Stability must be ensured during all type of work on the machine at all times The work equipment must be secured against movement by lowering it to the ground or equivalent measures e g cylinder supports trestles With the engine running the unprotected articulation range of articulated loaders shall not be entered When jacking up earth moving machines jacking devices must be positioned so that they cannot slip Jacks must be positioned and applied absolutely straight without tilting Raised earth moving machines must be supported by suitable structures such
79. nd 12 Pivot point 13 Steering cylinder Rear end 14 Rear axle bearing ch 15 Door hinges 16 Multi purpose bucket 17 Multi purpose bucket cylinder AOm e X X X X X X X XX X X X X Xx x x o gt o Z bar linkage We recommend that for special operations e g on sandy ground the lubrication intervals are shortened Increased frequency of lubrication helps self cleaning of bearing points SKL 834 67 7 Care and Maintenance 7 8 4 Inspection plan To be carried out by trained specialist dealer personnel O Checking Maintenance Operating hours X Replace mnim pmi Perform work with machine at operating after every every every year yearl Chapte temperature 100 500 1 000 2000 r 1 Check whether machine specific instruction O O book is in the machine 2 Change engine oil X X 7 9 1 3 Change engine oil filter X X 7 9 2 4 Drain water from fuel tank O O O 7 9 4 5 Change fuel filter X X 7 9 4 6 Clean fuel pump and screen filter O 7 9 4 7 Check air intake o O 7 9 5 8 Change air filter main cartridge to service indicator X 1795 9 Change air filter safety cartridge as required 7 9 5 10 Clean cooling fins of hydraulic oil cooler O O O 7 9 10 In case of high exposure to dust shorten the cleaning interva
80. nd Max load capacity of towing lugs approx 5 300 kg e Whenever the wheel loader has to be towed for whatever reason the Travel oil circuit must be opened so that the hydrostatic transmission no longer acts as an auxiliary brake e At the two high pressure relief valves 27 1 with bypass in the connecting plate of the hydraulic pump loosen the nut 28 1 and screw in screw 28 2 until it is level with the nut e Tighten the nut 28 1 e After towing screw back screw 28 2 until the stop e Re tighten the nut 28 1 Absolute cleanliness is essential when working on the hydraulic system Always secure the machine with chocks and relieve the hydraulic system of pressure before carrying out maintenance and repair work Fig 27 Hydraulic pump Lagn3328 Fig 28 HP relief valve SKL 834 55 6 Recovery and Transport 6 2 Loading the machine using a crane N Use a crane harness and a crane with sufficient lifting capacity To load the machine by use of a crane the following steps must be taken e Empty the bucket and tip back e Move the lift frame to travel position e Apply the pin of the articulation lock 29 1 e Turn off the engine e Dismount from the machine and close the doors e Attach the loader to the hoisting appliance at the specified marked points Fig 29 in the correct manner 6 3 Transporting
81. ndard equipment approx kg 4 800 4 800 Total length on ground mm 4 955 4 995 Total width mm 1 850 1 850 Height over cab mm 2 670 2 670 Wheel base mm 2 100 2 100 Tread width front and rear mm 1 380 1 380 Rear overhang angle i 40 40 Ground clearance beneath propeller shaft mm 435 435 Turning radius at outside edge of bucket in transport inm 4 135 4 150 position Turning radius at outside edge of tires mm 3 780 3 780 Turning radius at inside edge of tires mm 1 980 1 980 28 SKL 834 Technical Data 3 3 13 Front loader installation Values based on general purpose bucket and 405 70 R18 tires Parallel Z bar boom linkage geometry Width of bucket mm 1 850 1 850 Capacity in compliance with DIN ISO 7546 max density approx m 0 8 0 8 1 8 t m Payload in bucket kg 1 440 1 440 Dumping height at 45 dumping angle approx mm 2 950 2 550 Dumping reach at max dumping height approx mm 700 710 Max bucket hinge pin height approx mm 3 200 3 220 Tilt back angle 50 50 Dumping angle at max dumping height 5 45 45 Digging depth horizontal bucket approx mm 100 110 Lift capacity at ground level approx N 48 000 48 400 Ripping force at cutting edge of bucket approx N 45 000 47 300 Tipping load straight approx kg 3 500 3 500 Tipping load articulated approx kg 3 150 3 150 Work cycle times EENS iii lift Sec 4 7 4 9 Mug Me toco d ina C DE AA e o
82. ne oil temperature cl Engine oil level Coolant temperature de eo z Coolant level ap Air filter MA Hydraulic oil Hydraulic oil level Hydraulic oil temperature er t 9 EF Hydraulic oil filter clogging indicator T L SKL 834 1 Introduction Heater Ventilation Symbol Description Symbol Description Horn Hazard warning system WW a Fuel H h Operating hour meter Fuel level Operating hours Se Fan Lashing points EC Windshield wash wipe system Suspension points for loading by crane 00 Parking brake First aid kit Direction indicator left right Working floodlight s AS Fire extinguisher High beam indicator On machine Safety distance gt Rotating beacon A 4 4 Direction of travel forward E reverse Z ad Tl Danger of crushing Travel speed fast Travel speed slow Working hydraulics cut off AR Danger of injury N rr Observe notes in the AN LI Operating Instructions Fe 2 Grease gun Lubricating point Unlocked Locked Float position SKL 834 Introduction 1 1 6 Copyright This instruction book is intended for use by personnel responsible for operation maintenance repair and supervision of the machine These operating instructions are copyrighted and
83. ng and warning O O elements and lighting system 28 Check smooth running of operator controls and O O adjust if necessary 29 Check tightness of all pipes hoses control O O valve hydraulic pumps cylinders etc When tightening hose and pipe connections screw in couplings must be locked to prevent rotation 30 Check or change hydraulic oil O O X 7 9 9 31 Replace insert of hydraulic oil return suction X X X 7 9 11 filter 32 Replace breather X 7 9 12 33 Check function of brakes and replace brake oil O O X 7 9 8 34 Bleed brake O O 7 9 8 35 Rear axle differential with transmission option X O X X 7 9 13 manual transmission oil check or oil change 36 Front axle differential oil check or oil change X O X X 7 9 13 37 Wheel hubs of front and rear axles oil check or X O X X 7 9 13 oil change 38 Grease machine in compliance with overview of O O 7 8 3 lubricating points 39 Check function condition and completeness of O O safety equipment 40 Hydraulic function check with pressure function O O test 41 Test run and test work 0 Oo 42 Initial inspection cards and return tolo o 7 4 manufacturer 1 at least every 2 years 2 Extension of oil change intervals in compliance with oil sample analysis and lab report For further information see Chapter 7 3 3 Every 5 years or 5 000 operating hours respectively 4 within warranty Ce Observe our offer about Service Packs for inspections Contact
84. ng the machine into operation Specifications for diesel engine start up Starting and switching off the diesel engine Explanation of hydrostatic drive Driving speed ranges and notes for driving on roads Recovery and transport of the machine Operation of all functions Actuation of the quick attach system Explanation of maintenance and inspection intervals in compliance with Maintenance and Inspection Plan by demonstrating maintenance points on machine e Lubrication intervals and points of lubrication in compliance with lubrication chart and demonstration of these points on the machine e Handing over the diesel engine operating instructions 2 Spare parts list e Structure of spare parts list of Figure s and the respective descriptions e Instructions for ordering spare parts always state the type of machine the vehicle identity number Fz Id Nr parts designation complete spare part number piece number delivery address etc 3 Warranty e Explanation of warranty covered by manufacturer e Explanation of inspection cards and note on maintenance and inspection plan e The warranty handing over card must be filled out correctly and returned Wheel Loader SKL 834 Maintenance and Inspection Plan The careful performance of all prescribed inspections is the best prerequisite for the machine s continuous readiness for operation All maintenance work mentioned should therefore be performed in the prescribed sequence
85. nnnnccnonocononnnnnnannno 5 501 660 914 V belt AA eL ORE OUR elio 5 411 657 050 Cylinder head gasket Au 5 411 656 457 Service Packs Service Pack Classic inspection after 100 h MPS 834 001C Service Pack Classic inspection every 500 h MPS 834 002C Service Pack Classic inspection every 1 000 h MPS 834 003C Extras SCHAEFF TEREX hydraulic oil mineral 4 312 005 050 SCHAEFF TEREX hydraulic oil biodegradable For further information please contact your SCHAEFF TEREX dealer Transmission ol 4 314 005 775 Engirie oll acci tte ptt rea t akt pitur es 4 312 905 759 Maintenance parts for inspections should be ordered well in advance Observe our offer about Service Packs for inspections Contact your dealer Lubricants e The machine s life expectancy and operating condition largely depend on the use of the specified lubricants and compliance with the service intervals e f lubricants which do not conform to our recommendations are used consequential damage may occur for which we will not assume liability even inside the warranty period e For lubricant specifications see Chapter 3 9 SKL 834 59 7 Care and Maintenance 7 6 Care and cleaning The machine must be cleaned on a suitable surface with an oil separator Neither a steam jet appliance nor a high pressure cleaning apparatus are to be used for cleaning during the first two months
86. ol is employed for information containing important notes about the correct use and or how to proceed Non compliance may lead to malfunction SKL 834 Introduction 1 1 4 Environmental requirements Applicable environmental requirements must be observed for all tasks performed on and with the machine During installation repair and maintenance tasks particular care must be taken that substances that would damage the environment such as e Lubricating grease and oil e Hydraulic oil e Fuel e Coolants e Cleaning fluids containing solvents are not allowed to come in contact with the soil or the water system These substances must be stored in suitable containers and must be properly transported collected and disposed of If the substances listed above do reach the soil the leak or outlet must be stopped immediately and the fluid must be cleaned up with a suitable absorbent material If necessary the soil involved must be removed Absorbent materials and removed soil must be disposed of properly Applicable environmental requirements must be observed 1 5 Pictograms The following table explains the meaning of the pictograms which may be attached to your machine o lt 3 T Q Description P Danger P N In Operating Instructions Warning On machine Caution Attention Battery charge indicator WE Pre heating 9 Engine oil pressure T Engi
87. p air Tighten hose connections Replace O ring or seals 4 Insufficient operating pressure Re adjust main relief valve replace if necessary Wear of pump Replace pump Incorrect hydraulic oil Quality of hydraulic oil must conform to our recommendation 8 13 Working cylinders are not working satisfactorily 1 Seals in cylinders worn Re seal cylinders 2 Secondary valves faulty Check secondary valves and replace completely if necessary 8 14 Trouble in the electrical system 1 Outside and or internal lighting Check cables connections bulbs and fuses damaged 2 Windshield wiper does not work Check cables connections and fuses Examine windshield wiper for mechanical damage Replace complete wiper if necessary 3 Horn does not work Check cables connections and fuses Replace complete horn 4 Control organs are imprecise Determine the fault or source of the problem call Service Agent if necessary 5 Starting system does not work Check charge capacity of battery satisfactorily Test starter function Check connection and condition of power and battery ground cables Check function of ignition lock replace if necessary 94 SKL 834 Appendix 9 9 Appendix 9 1 Electrical system Fuse box Assignment diagram L824 E01 02 10 15 D A B
88. ratio RE 33 Al ee nee e e EE EE 33 4 2 Operator controls and display elements eiii 34 4 3 ne EE 38 4 3 4 Starting the EE 38 4 3 2 Monitoring during Operativas rada 39 4 3 3 Switching off the engine ti a 39 4 4 Driver s seat Steering wheel tilt adjustment eee eee e cence eeeeeeeeeeeeteeeee teense eeneeeeneeeeeneeeeeneees 40 A EE 41 4 6 Light switch in compliance with GV ZO REENEN 41 4 7 Hydroinflation Of ties oce etl pt rbd crx etude nmi deter tc e ru ir ead 42 4 8 Driving steering and braking uses Ue it 43 481 DIVINO TEE 43 283242 51 O A C V 45 4 90 ue p ae oete 45 4 8 4 Road EE 46 28 5 Parking the Enn 47 5 Loading Operation ainia 49 Seri E 49 Ao ee e e e ME 49 5 3 Changing work attachments uk 51 BVO EE 51 5 3 2 Assembly Of work ee 52 5 4 Notes on how to work with the Tree euegedgesruugeeeredee de eden taste Seege deEteEESEEE ER 54 ALG AGING EE 54 54 2 Scraping A Rotes der rae telah der Cad ce c ae Mee 54 5 4 3 ExcavaliolWOoe E 54 6 Recovery and Transport of the Machine Leeeeeeeeeeeeerreeeneeeenn nn 55 6 1 Recovery of the machitie ee ne eta Ro de dre toner pq pn ted pan e DU E ERA SEES 55 6 2 Loading the machine using a crane sco te De Eb PU qb e P ob n en sS 56 6 3 Transporting Bien tel 56 T Gare and Maintenance adipi ear kanevir iaai i SZ is 57 Pal General olestie ee gees 57 7
89. ring operation If the engine and the machine are put N into operation without prior remedy of the fault severe damage to the engine may result e f the battery charge 12 22 or engine oil pressure indicator lamp lights up 12 31 switch off the engine immediately and determine the cause or call for service personnel e f the permitted engine oil temperature 12 25 is exceeded stop work open the engine hood and keep the engine running at low idle to allow it to cool down Once the engine has cooled down turn it off and determine the cause of overheating or call for service personnel e H the air filter indicator lamp 12 32 lights LL up perform the necessary air filter Fig 12 Operation maintenance 4 3 3 Switching off the engine Do not switch the engine off when running at full throttle but allow it to run for a short time without load at low idle running speed e Turnthe ignition key to O e The engine stops automatically SKL 834 39 4 Operation 4 4 Driver s seat Steering wheel tilt adjustment Driver s seat e The comfort seat is spring mounted with oil pressure operated shock absorbers e The seat meets international quality and safety standards in compliance with ISO 7096 and ISO 6683 Fig 13 1 Horizontal adjustment 2 Weight adjustment 3 Seat back adjustment 4 Vertical adjustment Raising seat Raise seat until it clicks audibly into place Low
90. rk attachments The bearings of the lift frame the work attachment and the quick mount hitch must be free from dirt Before disconnecting hydraulic connections the system must be released from pressure Procedure for changing directly mounted work attachments In the event of a hydraulically actuated attachment first of all the hydraulic connection must be disconnected system must be without pressure e Rest the attachment on the ground so that it cannot overturn e Remove the pin of the linkage and the pin of the lift frame e Move the lift frame out of the work attachment and insert a new one Procedure for changing work attachments with mechanical quick attach system In the event of a hydraulically actuated attachment first of all the hydraulic connection must be disconnected system must be without pressure e Lower the work attachment to the ground so that it cannot overturn e Raise pin 24 2 and open the quick mount hitch using the control rod 24 1 until the locking bolts are completely retracted e Check the function of the quick mount hitch lock and lubricate the pins if required e Attach another work attachment and close the quick mount hitch until the locking bolts are completely extended and the pin clicks in e Ensure that the work tool and the lock are properly seated e The control rod is kept in the left hand storage box in the driver s cab Fig 24 Quick mount hitch L82
91. s dirty e g due to hydraulic oil vapor e Unscrew the oil dipstick 54 1 e Remove the breather 54 2 and dispose of in compliance with regulations e Clean the screen 54 4 and check for damage Replace if required e Screw in new breather 54 2 with O ring 54 3 and tighten by hand e Screw back in the oil dipstick L834 054 Fig 54 Breather SKL 834 83 7 Care and Maintenance 7 9 13 Axles General The axle oil must be changed at operating temperature Collect waste oil do not allow it to seep into the ground Dispose of in compliance with regulations After filling the axles with oil move the machine for approx 5 minutes to ensure that the oil is evenly distributed Check the oil level again and top up if necessary 7 9 13 1 Front axle differential Checking the axle oil level Remove the inspection plug 55 1 check and top up oil if required Changing axle oil Park the machine on level ground Open the inspection filler plug 55 1 Open the drain plug 55 2 on the differential and drain oil Flush out the axle if necessary Carefully close the drain plug Pour in oil via the inspectior filler hole until oil escapes Carefully close the inspection filler plug Fig 55 Front axle L824 055 84 SKL 834 Care and Maintenance 7 7 9 13 2 Differential of rear axle with transmission Checking t
92. s it is cleaned must be marked For cleaning 46 1 a pipe the end of which is bent at 90 should be attached to a compressed air pistol It must be sufficiently long to reach the floor of the cartridge Blow out the main cartridge from the inside to the outside with dry compressed air max 5 bar by moving the pipe up and down in the cartridge Continue until no more dust escapes Check the clean main cartridge for damage to the paper bellows and rubber seals 46 2 Tears and perforations in the paper bellows can be determined using a torch A Never continue to use damaged main cartridges If in doubt use a new one Fig 46 Cleaning the main cartridge 76 SKL 834 Care and Maintenance 7 7 9 6 V belts Checking the condition of V belts Only check and tension V belts with die d the engine off Danger of injury e Visual check of the complete V belts Replace worn or damaged V belts immediately Checking the V belt tension To check the V belt tension a tension gauge is recommended Check the tension in compliance with the manufacturer s operating instructions Checking the V belt tension without a tension gauge e To check the tension press the V belt with your thumb in the middle of the greatest free length and measure the sag e Using medium thumb pressure of approx 45 N the V belt sag A should equal 10 15 mm Tensioning V belts e Slacken the fastening screws 47 1 e Rot
93. signal generator W signal _ N h Co Co al ak OH N 4 CO Speedometer signal sensor X30 Signal inputs Lighting Power supply Terminal 15 output Parking light Terminal 15 input High beam signal Direction indicator control signal Reserve Reserve DO o JO IN J Reserve c Reference voltage Reserve Analog Reserve Analog ala ich 10 Reserve Analog X80 Coordinate lever Power supply Terminal 15 output Central mass Terminal 31 Travel forward signal Travel reverse signal Float position signal Additional control circuit signal Additional control circuit signal Reserve Analog o IN HD c1 o m Reserve Analog 104 SKL 834 Appendix 9
94. standard equipment During fork lift operations the tire pressure of the front wheels must be increased by at least 0 5 bar SKL 834 25 3 Technical Data 3 9 Fuels lubricants and coolants 3 9 1 Filling quantities Fuel tank approx 75 0 Diesel fuel Engine with oil filter approx 13 0 Engine oil change quantity Hydraulic oil tank and system approx 55 0 Hydraulic oil Hydraulic oil tank approx 46 0 Hydraulic oil change quantity Service brake approx 0 25 ATF oil Front axle center housing approx 4 0 Transmission oil Rear axle center housing and transmission approx 4 5 Transmission oil standard Rear axle center housing and transmission approx 5 0 Transmission oil high speed version Wheel hubs front rear axles each 0 3 Transmission oil approx The hydraulic oil quantity depends on the equipment level of the machine All values stated are approximate The level marking is always the decisive factor 26 SKL 834 Technical Data 3 3 9 2 Fuel lubricant and coolant specifications Prescribed fuels lubricants and coolants for Central Europe Application Hydraulic system Axles Lubricating points Brake 1 Industry e V Code designation in compliance with Bi EO 1540 A HYD 1040 BIO E HYD HEES GO 90 LS MPG A ATF Designation Diesel fuel Engine oil Hydraulic oil or multi grade engine oil
95. t the correct valve lash 48 1 is obtained when the lock nut is tightened S515 47 Fig 48 Valve setting Crankshaft position 2 Crankshaft position 1 e Turn the crankshaft further by one full turn Crankshaft position 2 360 e The valves marked black can now be adjusted e Re mount the cylinder head cover with the new seal 78 SKL 834 Care and Maintenance 7 7 9 8 Brakes Checking the brake oil level e Visual inspection 49 1 of the brake oil level Only top up with ATF oil Changing brake oil and bleeding the brake Collect the waste oil do not allow it to seep into the ground Dispose of in compliance with regulations besen A bleeding device must be employed Fig 49 Brake oil when changing brake oil and bleeding brakes e Remove the cover up front above the axle e Release the bleeder screw 50 1 connect the bleeder hose and insert it into collecting bottle e Connect the bleeding device on the brake oil container 49 1 e Change brake oil and bleed the brake in compliance with the bleeding device instruction book e Remove the bleeder hose and re tighten the bleeder screw e Release the bleeder screw 50 2 on the inch valve of the travel hydraulic pump connect the bleeder hose and insert it in the collecting bottle e Start to bleed e Remove the bleeder hose and tighten the bleeder screw e Dismo
96. the machine To transport the machine onto a flat bed trailer railway goods wagon etc the following steps must be taken e Empty and fold in the bucket e Move the machine onto the flat bed trailer goods wagon etc or lift by crane if required e Apply the articulation lock 30 1 e Place the work equipment on the ground e Stop the engine e Dismount from the machine and close the doors e Attach the machine at the points illustrated Fig 30 in the correct manner N Be aware of the total transport height Risk of accident when driving in tunnels under bridges etc Fig 30 Lashing for transport 56 SKL 834 Care and Maintenance 7 7 Care and Maintenance 7 1 General notes The good operating condition and life expectancy of machines are largely influenced by care and maintenance For this reason it is in every machine owner s interest to perform the specified maintenance work and comply with the service intervals This Chapter deals in detail with periodic maintenance inspection and lubricating tasks The type specific maintenance and inspection plan lists all work to be performed on the machine at regular intervals Maintenance and inspection plans for this purpose are contained in every instruction book It is essential that the recommendations in Chapter 2 Safety and Prevention of Accidents are observed
97. ts and coolants will prevent malfunction Trained specialist personnel are responsible for any servicing of the machine which requires expert knowledge Inspections and repairs must therefore be carried out by your dealer s customer service In respect of possible claims for damages during the warranty period all work specified in the maintenance and inspection plan must be carried out at the specified intervals After the warranty period too regular maintenance must be performed to ensure that the machine is constantly in good working order and enjoys a reasonable service life Insist that only original SCHAEFF TEREX spare parts are used in the event of any repair work In this way you will have a product of lasting high quality thereby ensuring that your machine maintains its original condition 1 3 Notes on using the instruction book References to pictures and items The references to pictures and items contained in the text such as Figure 12 4 or 12 4 mean Figure 12 Item 4 Bild Figure The figures shown in this list partly contain additional equipment DANGER Symbol This symbol is employed for a high IS risk of injury to persons It is essential that the safety notes are observed WARNING Symbol This symbol is employed for information whose non compliance may lead to severe material damage It is essential that the safety notes are observed ATTENTION Symbol Ce This symb
98. ty with the regulation lubricants of the Main Association of the German Building in compliance with DIN 51524 T3 HVLP 30 20 22 4 Umgebungstemperatur Ambient temperature Temp rature ambiante 10 0 10 20 30 CG 14 32 50 68 88 F HVLP 22 HVLP 32 HVLP 46 HVLP 68 Viskohyd HVLF 100 30 20 10 0 10 20 30 40 50 C 22 4 14 32 50 68 88 104 122 F Umgebungstemperatur Ambient temperature Temp rature ambiante SKL 834 27 3 Technical Data 3 10 Permissible loads in compliance with German Regulations StVZO Permissible gross weight c see identification plate Permissible axle load front or Permissible axle load rear c General Operating License 3 11 Sound level values vibration Sound level values in compliance with directive 2000 14 EC and EN 474 Guaranteed sound power level Lwa 101 dB A Sound pressure level at driver s ear Lea 76 dB A Vibration values in compliance with directive 98 37 EEC and EN 474 Weighted r m s value of acceleration is below 0 5 m s for entire body DEn 2 5 m s for upper limbs 3 12 Dimensions and weights Values refer to general purpose bucket and 405 70 R18 tires Parallel Z bar boom linkage geometry Operating weight sta
99. unt the bleeding device and close the brake oil container with its original SS cover Fig 50 Bleeding the brake e Re fit the cover up front SKL 834 79 7 Care and Maintenance 7 9 9 Hydraulic oil Checking the hydraulic oil level e Check the oil level using the oil dipstick 51 1 Top up hydraulic oil if required Hydraulic oil change Danger of scalding from hot oil STOP e Retract all hydraulic cylinders e Stop the engine e Unscrew the oil dipstick 51 1 e Remove the drain plug 51 4 from the hydraulic oil tank and drain oil into a clean container Collect the waste oil do not allow it to seep into the ground Dispose of in compliance with regulations e Flush and clean the hydraulic oil tank as required to do so remove the complete suction filter 51 2 e Screw back on the drain plug carefully e Fill up with clean hydraulic oil via the i breather To do so remove filter head Jan E TM 51 3 e Screw back on the breather head Fig 51 Hydraulic oil tank e Screw back in the oil dipstick 80 SKL 834 Care and Maintenance 7 7 9 10 Hydraulic oil cooler Ce Dirt accumulation in coolers causes the hydraulic oil to overheat Only clean coolers with the engine turned off and cooled down e The hydraulic oil cooler 52 1 is cleaned from the outlet side with compressed air If necessary clean the machin
100. ust likewise be observed 2 2 Proper use The earth moving machine with standard loader bucket equipment is intended solely for work which is suitable for the function of the machine and its work implements Such work involves loosening taking up transporting and dumping soil rock or other materials as well as loading these materials on trucks conveyor belts or other means of transport when the transport of the material is normally done by positioning the earth moving machine The mounting of special work implements such as multi purpose buckets side dump buckets sweepers fork lift attachments etc allows the machine to perform above mentioned work Any usage above and beyond that specified here e g the transport of persons or the usage of the lift equipment as work platform and any non compliance with the manufacturers instructions is regarded as improper use The manufacturer shall not be liable for damage resulting from improper use This risk is borne solely by the plant operator Compliance with the operating and maintenance instructions the performance of maintenance work as specified and adherence to replacement intervals all form part of the concept of proper use SKL 834 2 Safety and Prevention of Accidents 2 3 General safety notes It is important to refrain from any working methods which impair safety The earth moving machine is only to be used if itis in a safe operational condition
101. usted so as to ensure safe working A safety belt seat belt if installed must always be fastened The windows must be clean and free of ice Driving tracks must be designed so as to ensure smooth safe operation i e they must be sufficiently wide on ground which has as few slopes as possible and sufficient carrying Capacity Downhill tracks must be set out in such a way that earth moving machines can be safely braked Before driving downhill the appropriate transmission mode for the terrain must be selected and the gear lever shall not be moved during downhill travel high gear or low gear On steep drops and uphill gradients the load must be carried on the uphill side if possible to increase stability The carrying capacity of bridges cellar roofs vaults etc must be verified before the earth moving machine can drive over them The internal dimensions of constructions must be noted before entering underground passages tunnels etc It is the plant operators responsibility to ensure that equipment such as first aid box warning triangle hazard lights are kept with the machine in compliance with the traffic regulations valid in the users country e g in Germany StVZO and that the driver has the appropriate license as required by the national traffic laws of the country in question Outside areas covered by general traffic regulations e g on construction sites traffic regulations should be applied
102. utput 5 Rotating beacon output 6 Wiper Terminal 53b 2 setting output 7 Washer pump front output 8 Wiper Terminal 31b output 9 Interior lamp Terminal 30 output 10 Wiper Terminal 53 output 11 Wiper Terminal 53a output 12 Hand brake switch signal input 13 Washer pump rear output 14 Rear wiper Terminal 53a output 15 16 Rear wiper Terminal 31b output 17 Rear wiper Terminal output 18 Brake light switch signal input 106 SKL 834 Appendix 9 10 13 7 2 5 8 11 14 3 6 9 12 15 1 4 7 1 10 13 16 19 2 5 8 11 14 17 20 3 6 9 12 15 18 21 7 147 1 E 4j 7 2 d 8 3 d 9 6 9 12 11 41 7 10 21 Dr 8 11 3 3 6 9 12 15 18 21 10 13 16 19 2 5 8 11 14 17 20 7 1 4 7 10 13 16 2 5 8 11 14 17 3
103. y warming the battery to approx 20 remove the battery after the engine has been turned off and store it in a warm room the minimum starting temperatures can be lowered by 4 5 C When installing the battery ensure good contact of terminal connections Only tighten terminal screws so that they are hand tight to prevent deformation of the terminal posts 60 SKL 834 Care and Maintenance 7 Fuel Only use commercially available brand name diesel fuel with a sulfur content of less than 0 5 In winter only use winter diesel fuel to prevent clogging of the fuel system due to paraffin separation Even if winter diesel fuel is used disturbing paraffin separations jelling can occur at very low temperatures If only summer diesel is available or if winter diesel must be used at very low temperatures we recommend the addition of petroleum Fig 36 or additives These mixtures should only be used temporarily not for longer periods Only mix the components in the tank First fill in the necessary quantity of petroleum then add the diesel Additives should be chosen in compliance with the recommendations of your fuel supplier STOP Petrol is not to be added Danger of explosion Fig 36 Table for the addition of petroleum or additives A Summer diesel B Winter diesel C Added proportion of petroleum D Outside temperature SKL
104. your dealer SKL 834 69 7 Care and Maintenance 7 9 Inspection and maintenance work 7 9 1 Engine oil Checking the engine oil level Check the oil level daily before starting with the machine parked on level ground The notches on the oil dipstick 35 1 indicate the min and max oil levels If necessary top up engine oil Unscrew the cap 35 2 and top up oil using a clean container Changing engine oil Collect the waste oil do not allow it to seep into the ground Dispose of in compliance with regulations Run the engine until it reaches operating temperature engine oil temperature approx 80 C Park the machine on a level surface Stop the engine Remove the cover on the bottom of the rear end Place suitable oil drip pans below the opening Screw the oil drain hose onto the oil change valve 35 3 Danger of scalding when hot oil is drained Open the drain plug 35 5 on the oil cooler Remove the oil drain hose and screw the protective cap onto the valve Carefully close the drain plug on the oil cooler Close the service opening with the cover To change the engine oil filter 35 4 see Chapter 7 9 2 Top engine oil up to the MAX mark on the oil dipstick 35 1 using the filler hole 35 2 Start the engine and run at low idle speed for approx 2 min Open the vent valve 35 6 to eliminate the air from the oil cooler Switch off the engine Check the oi
105. zx Operating Instructions TEREX SCHAEFF Wheel Loader SKL 834 Keep behind driver s seat for later use AUSGABE e EDITION 2003 10 G LTIG AB FZ ID NR e VALID FROM SERIAL NO e A PARTIR DU NO DE SERIE 834 0099 gt SCHAEFF TEREX GMBH amp CO KG e D 74595 LANGENBURG Hauptverwaltung V erkauf Kundendienst Ersatzteile Direction g n rale Vente Service apr s vente Pi ces de rechange Central administration Sales Service department Spare parts Schaeff Terex GmbH amp Co KG Terex Deutschland GmbH Schaeff Ersatzteile Service GmbH amp Co KG Postfach 61 D 74595 Langenburg Schaeffstr 8 D 74595 Langenburg Phone 07905 58 0 Fax 07905 58 114 Postfach 12 64 D 91534 Rothenburg Erlbacher Str 113 D 91541 Rothenburg Phone 09861 972 451 Fax 09861 972 460 Postfach 12 64 D 91534 Rothenburg Erlbacher Str 115 D 91541 Rothenburg Phone 09861 972 0 Fax 09861 972 410 Order no 5 780 110 022 englisch Table of Contents Buden e d o p EE 1 LEE E 1 1 2 Warranty and NO ien e 2 1 3 Notes on using the instruction DOOK EE 2 1 4 Environmental requirements ia ia 3 A TERN 3 T5 GODVIO ER 5 2 Safety and Prevention of Accidents eeeeeeeeeeeeeeeeeerereenereenene nnn 7 2 le dee stole MEI erm 7 ee 7 2 3 General safety notes EE 8 2 4 OPEration EE 8 RE e e 9 2 6 Transport OF PETSONS sip ai 9 27 Stability P 9 2 8 ravel oper

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