Sunteți pe pagina 1din 160

GHH Fahrzeuge GmbH

Operating Instructions
Load Haul Dumper LF - 9.3
Vehicle No: 3111-13/8

0-E
07.08

LF-9.3

GHH Fahrzeuge GmbH


1
1.1
1.2
1.3
1.4
1.5

1.6

Contents Introduction
How to use the operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Record of revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Conditions for Mining and Tunnelling Vehicles,
Airport Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tramming capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Travel drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions of vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound-pressure level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Concise description of vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proper use of LF-type loaders powered by diesel engines/electric motors . . .

1E
07.08

LF-9.3

1.1 - 1
1.1 - 3
1.2 - 1
1.3 - 1
1.4 - 1
1.4 - 1
1.5 - 1
1.5 - 1
1.5 - 1
1.5 - 1
1.5 - 1
1.5 - 2
1.5 - 2
1.5 - 3
1.5 - 3
1.5 - 3
1.5 - 3
1.5 - 3
1.5 - 3
1.5 - 4
1.5 - 4
1.5 - 5
1.5 - 6
1.6 - 1
1.6 - 2

1-1

GHH Fahrzeuge GmbH

1.1

How to use the operating instructions

Sections
The operating instructions comprise four sections.

1 = Introduction
2 = Operation
3 = Maintenance
4 = System drawings

Subsections
Sections 1 to 3 are divided into the necessary chapters.
A table of contents is provided at the beginning of every main section.

Pages
The pages of each subsection are numbered.
Example: 2. 4 -- 1
Page
Subsection
Section-Operation

030000E
07.08

LF-9.3

1.1 - 1

GHH Fahrzeuge GmbH


Page numbers
Each page has the number of the main section/chapter and a page number printed in the bottom line of
the page. Each chapter begins with page number 1. The individual pages of the respective chapter are
consecutively numbered.
Code numberr / Issue date
The code number indicated in the left-hand corner at the bottom of each page is used for internal identification. It may be ignored by the user of the operating instructions.
The issue date (month + year) is indicated under the code number.
CAUTION, Warning, Note

Caution

The word Caution is used to draw attention to methods, prosedures or thresholds


which must be carefully observed in order to avoid injury to persons.

Warning

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

Note

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

Illustrations
The illustrations used in the operating instructions serve to explain the text. While they may vary from the
actual vehicle design, they will not basically change the factual information.
Patent, trademarks
The information included in these operating instructions is published regard less of any patent rights.
Trademarks are used without any warranty that they may be used freely.
Liability
The tets and illustrations were compiled with great care. Nevertheless, errors cannot be excluded completely. GHH Fahrzeuge GmbH and the authors cannot either assume any legal responsibility or any liability
for information and the consequences thereaf.
Please contact our Service Department if you have technical queries or if you notice any discrepancies.
The contents of these operating instructions are regularly revised to include technical innovations. We reserve the right of technical changes due to ongoing development without prior notice.
Copyright
Reproduction in any form or translation and storage on electronic media is not permitted without prior written consent by GHH Fahrzeuge GmbH. This also applies to extracts. All rights under copyright laws are
specifically reserved by GHH Fahrzeuge GmbH.
030011E
07.08

LF-9.3

1.1 - 2

GHH Fahrzeuge GmbH


Record of revisions
All revisions issued are listed in this table. Each revision is numbered consecutively together with the date
of issue. The date and the name of the person who inserted the sheets in this manual are also shown in
the table.
Rev.
No.

Revision
Date

Date
Inserted

Name

Rev.
No.

Revision
Date

Date
Inserted

Name

Vehicle no. 3111-13/8

032150E
07.08

LF-9.3

1.1 - 3

GHH Fahrzeuge GmbH


1.2

Preface

These operating instructions include important information on how to operate and keep your vehicle made
by
GHH Fahrzeuge GmbH
in working order.
One copy each of the instructions should at all times be available to both the driver and the maintenance
personnel. Each operation carried out on the vehicle presupposes that the contents of the operating instructions are known and strictly adhered to.
Therefore, please read these instructions carefully and familiarize yourself with the vehicle, in particular
before putting the vehicle into operation for the first time.
Proper operation and maintenance make for lasting operational reliability.
Any downtimes which are due to avoidable maintenance work can be minimized if special attention is paid
to the following:
-

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

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

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

Install only original-spare parts.

Should you have any trouble or questions, or if you wish to order spare parts, please contact:
GHH Fahrzeuge GmbH
Abteilung S
Postfach 10 09 43
D-45809 Gelsenkirchen
Telephone: +49 (0) 209 389 07-300
Telefax: +49 (0) 209 389 07-349
or the representative responsible for your area.
Please state the vehicle type and serial number in all written queries or phone calls.
When making out spare parts orders, please adhere to the ordering instructions included in the spare parts
list.
Never have repairs or alterations carried out by third parties without our approval. You will appreciate that
we cannot be held responsible in any case of non-compliance with the above.

Note

030020E
07.08

Please note our Warranty Conditions for Mining and Tunnelling Vehicles, Airport
Equipment.
LF-9.3

1.2 - 1

GHH Fahrzeuge GmbH


1.3 Warranty Conditions for Mining
and Tunnelling Vehicles,
Airport Equipment
1. We warrant our supplies to the extent that we shall, at our
option, either repair or resupply ex works any part for which
proof can be furnished that it has become unserviceable
during the warranty period due to our fault in design, material selection or workmanship.
Similarily, we accept liability for properties explicitly guaranteed.
In respect on bought-out items used by us in the manufacture, our liability shall be limited to assigning our warranty claims on the supplier.
Of the costs involved directly in repairs and/or replacement
supplies - provided, Purchasers claim proves justified - the
cost of repair and/or of the replacement part shall be to our
account.
All other costs shall be to Purchasers account, among
them, costs for transportation, dismantling/installation and
for furnishing technicians/helpers possibly required.

7. Defects due to natural wear and tear arising on


- V-belts
- Hydraulic, brake and fuel hoses
- Brake liners
- Dynamically stressed seals
- Protective circuit breakers
- Articulations (collars and bolts)
- Batteries as well as
- Tires etc.
furthermore, defects due to
- Use for purposes other than intended
- Non-observance of our operating and maintenance
instructions
- Incorrect storage
- Faulty installation and/or putting into operation
- Excessive stress or strain
- Use of unsuitable operating media
are not covered by the subject warranty.

Parts which are replaced shall become our property.


2. The existence of a defect shall be reported to us in writing
immediately on discovery. Correction of a defect shall be
conditional upon Purchasers complying with his contractual
obligations, especially observing the payment conditions
agreed.

8. The warranty shall cease to be valid if during the warranty


period the Purchaser undertakes modifications or repairs to
the supplied equipment without our prior consent and/or if
no GHH Fahrzeuge GmbH original spare parts are used.

3. Where in cases of emergency Purchaser remedies defects


(repair and replacement supply) for which proof can be
furnished that we are at fault, or has such defects remedied by others, after having obtained our consent to do
so, we shall reimburse the costs, however, not exceeding
the amount that we would have incurred if the defects would
have been remedied by ourselves.

9. Unless contrary arrangements are made, we give the


above vehicle warranty only on condition that commissioning is carried out by our personnel.

4. The warranty period starts on the date the subject of supply


is ready for handing over to Purchaser. For the subject of
supply (complete vehicles, spares, i.e. single parts or complete components such as transmissions, axles, converters, pumps, compressors) the warranty period shall end
2000 working hours or 360 days after commissioning,
whichever occurs first. The warranty period shall expire in
all cases not later than 420 days after readiness for handing
over to Purchaser.
Where second-hand vehicles and complete rebuilt components are concerned the above warranty periods shall be
halved.
5. The number of hours a vehicle has been in service is that
recorded on the operation-hour meter installed in the
vehicle for this specific purpose. The date on which the
2000th or 1000th service hour is clocked up on the meter is
to be intimated to us in writing without delay. Likewise, any
failure or trouble with the meter is to be reported to us
immediately.
6. For repair work, including replacements, the warranty
period shall start on the date of completion of the work and
shall end upon expiry of 180 days or 1000 service hours,
whichever occurs first. The warranty period, however, shall
not end before expiry of the original warranty period for the
subject of supply.

S 0152
07.08

10. The Purchaser has the right of cancellation of contract,


provided
the defects of our equipment supplied being provably of
such grave nature that, because of its restricted serviceability, the equipment is of no use, and
after unsuccessful repair and/or replacement supply, he has
granted us in writing a reasonable additional period of time
for repair of defects for which we are responsible and we
have provably failed to remedy the defect within this additional period of time granted.
In all other respects Purchaser shall be entitled to claim
only a reasonable reduction of purchase price.
11. In addition to the above, Purchaser shall not be entitled to
raise any further claims for damages under the warranty
clause, especially not for indirect damage, with indirect
damage referring to all such damage which does not occur
on the acutal part supplied, especially lost profit, loss of use
and extra cost for use.
This exclusion shall not apply in the event of intention or
gross negligence on the part of bodies or managerial staff,
especially not in the event of fraudulent concealment of a
defect.
Any liability beyond this warranty clause shall be subject to
Article XIII of our General Conditions of Sale (AL 91),
unless different terms have been accepted in writing

LF-9.3

1.3 - 1

GHH Fahrzeuge GmbH


1.4

Vehicle identification

For the specific data of your vehicle please see of the nameplates shown below.
Nameplates
The vehicle nameplate is located in the drivers compartment. All equipment such as engine, torque converter, transmission, axles, etc. have nameplates and may bear stamped equipment numbers.

GHH Fahrzeuge GmbH


Emscherstr. 53
D 45809 Gelsenkirchen
Vehicle type

Year of construction

Serial no

Rated power

kW

Payload

kg

Weight, empty

kg

Please record here VEHICLE NO: ..................... and ENGINE NO:

....................of your vehicle.

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

bar

bar

Type

bar

bar

Please note here Tire pressure drive unit: . . . . . . . . . . . . . . bar

for tire type: ......................

Tire pressure payload unit: . . . . . . . . . . . bar

for tire type: ......................

of your vehicle.

030031E
07.08

LF-9.3

1.4 - 1

GHH Fahrzeuge GmbH


1.5

Technical Data

Length
Width, at the drivers cab
Width, at the bucket
Height, at the drive unit
(above drivers canopy)
Bucket capacity (SAE, heaped)

9 365 mm
2 740 mm
2 600 mm
1 790 mm
2 370 mm
4,5 m3

Weights
Deadweight
Payload
Front-axle load, unladen
Rear-axle load, unladen
Front-axle load, laden
Rear-axle load, laden

25 300 kg
9 500 kg
11 800 kg
13 500 kg
26 530 kg
8 270 kg

Tramming capacities
Maximum tramming speed
laden forward / reverse, on a level roadway
1st gear
2nd gear
3rd gear
4th gear
Maximum admissible gradient
Maximum allowed cross inclination
Maximum tractive force

4.5 km/h
9.2 km/h
15.4 km/h
25.0 km/h
25.0 %
15 %
217 kN

Engine
Manufacturer
Type
Design

DEUTZ
F10L413FW
air-cooled diesel engine two-stage
combustion
170 kW/2300 min-1
Dry air filter
Silencer, exhaust gas catalyst
6.6 kW/24 V
28 V/55 A

Max. power
Air intake system
Exhaust system
Starter power/voltage
Three-phase alternator/voltage

TechdatE
07.08

LF-9.3

1.5 - 1

GHH Fahrzeuge GmbH


Travel drive unit
Torque converter
Manufacturer
Type
Design

Clark
series C8000
single-stage industrial type with auxiliary drives for steering and dump/hoist
hydraulic systems

Power shift transmission


Manufacturer
Type
Design

Clark
series 32 000
power shift transmission with 4 forward
and 4 reverse gears each

Axles
Front axle
Manufacturer
Type
Design

Kessler
D102 PL341/528
rigid planetary axles with differential
gear

Rear axle
Manufacturer
Type
Design

Kessler
D102 PL341/528
rigid planetary axles with differential
gear
10

Swing angle
Wheels and tires
Front wheels
Rim
Size

13.00 - 25/2,5

Tires
Size
Tire filling pressure

18.00-25
6.0 0.1 bar

Rear wheels
Rim
Size

13.00 - 25/2,5

Tires
Size
Tire filling pressure
TechdatE
07.08

18.00-25
3.5 0.1 bar
LF-9.3

1.5 - 2

GHH Fahrzeuge GmbH


Brakes
Design of brake system

wet dual-piston multi-disc brake (WMB)


in the axle ends, with integrated parking
brake (combined brake).

Service brake
Design

wet multi-disc brake, externally cooled,


hydraulically actuated

Parking brake
Design

spring-actuated multi-disk brake, externally cooled, hydraulically released

Steering
Design
Steering angle
Outer clearance circle
Inner clearance circle

swivel-joint hydraulic power steering


40
6 660 200 mm
3 390 200 mm

Hydraulic system
Dump/hoist hydraulic system
83,6+20,9 cm3/U
230 bar
2
1
5.9 sec.
5.5 sec.

Pump delivery flowrate


System pressure
Number of hoist cylinder
Number of dump cylinder
Boom raising
Bucket raising, from dumping position
Steering hydraulic system

83,6+20,9 cm3/U
175 bar
2

Pump delivery flowrate


System pressure
Number of steering cylinder
Electrical equipment
Operating voltage
Battery

24V
2 x 12 V/180 Ah

Lighting system
Main/reversing headlights
Additional headlights

TechdatE
07.08

75/70W
70W

LF-9.3

1.5 - 3

GHH Fahrzeuge GmbH


Filling volumes
Hydraulic tank
Fuel tank
Engine with oil filter
Torque converter/power shift transmission circuit
Front axle differential gear
Front axle planetary gear
Rear axle differential gear
Rear axle planetary gear

TechdatE
07.08

390 l
320 l
appr. 31.5 l
appr. 36.0 l
28.0 l
2 x 6.0 l
26.0 l
2 x 6.0 l

LF-9.3

1.5 - 4

GHH Fahrzeuge GmbH

2950

3360

2050

1610

1790

2370

4615

4930

Dimensions of vehicle

3055

TechdatE
07.08

Spur 1905

2450

1515

9365

LF-9.3

1.5 - 5

GHH Fahrzeuge GmbH


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

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

Measuring points - Diagram


2

4
6

8
1

Measuring distance
-

Measuring points 1-5


lateral distance to vehicle = 2.0 m
measuring point height = upper edge of drive unit

Measuring point 6
measuring point height = height of drivers head

Measuring points 7 and 8


measuring point height = 2 m obove upper edge of drive unit

Operating state
-

service brake actuated

highest reverse gear engaged

for 30 seconds, driving engine at full load and dump/hoist hydraulic against the stop.

Measurement result
Measuring point

db (A)

90

89

90

80

80

89

88

89

Schall
07.08

LF-9.3

1.5 - 6

GHH Fahrzeuge GmbH


1.6

Concise description of vehicle

The Load Haul Dumper is a vehicle with swivel-joint steering and hydrodynamic drive system, consisting
of the drive unit and payload unit.
The drive unit houses the drive system components, engine, converter, transmission, as well as the oil
cooler, tanks, hydraulic system components, brakes and the electrical equipment.
The driven axles are designed as rigid axles with differential gear and planetary gears in the axle ends.
The drivers cabin with its controls and instruments is arranged on the left-hand side of the vehicle, transverse to the tramming direction. The drivers seat is sprung and hydraulically cushioned.
The vehicle is steered by a hydraulic power steering system with one or two double-acting steering cylinders.
The service brake and the parking brake act on all four wheels. The service brake is executed as a dual
circuit braking system with a separate brake circuit for the front and rear axle. The parking brake is a
spring-actuated brake whose brake circuit works indepedently of the service brake.
The bucket and boom are linked to the payload unit. The bucket is tilted forward and backward by hydraulically operated dump/hoist cylinders. Control levers in the drivers cabin operate the boom and bucket.
The vehicle chassis is of welded construction, manufactured according to the applicable DIN standards
and the German Federal Railways DS 952 Code.

1_6-1E
07.08

LF-9.3

1.6 - 1

GHH Fahrzeuge GmbH


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

032140E
07.08

LF-9.3

1.6 - 2

GHH Fahrzeuge GmbH


2

Contents Operation

2.1

Safety instructions for the operation of vehicles made . . . . . . . . . . . . . . . . . . . .


2.1 - 1
by GHH Fahrzeuge GmbH
Safety marking (Sicherheitsbeschilderung) . . . . . . . . . . . . . . . . . . . . drawing 909-4-056556
Functional marking (Funktionsbeschilderung) . . . . . . . . . . . . . . . . drawing 909-4-056557
2.2 Drivers seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 - 1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 - 1
2.3 Drivers cab, operating elements and control instruments . . . . . . . . . . . . . . . . .
2.3 - 1
Changing steering direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 - 1
2.4 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 - 1
2.5 Engine starting, engine switch-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 - 1
Engine starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 - 1
External starter socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 - 1
Engine switch-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 - 2
2.6 Tramming operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 - 1
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 - 1
Changing the tramming direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 - 1
Changing steering direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 - 1
Hints on the torque converter and power transmission . . . . . . . . . . . . . . . . . . . .
2.6 - 2
Tramming on downhill slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 - 3
Downhill driving in converter mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 - 4
Towing the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 - 5
Filling of brake system for towing of vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 - 6
2.7 Dump/hoist operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 - 1
Control of dump/hoist equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 - 1
Bucket filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 - 2
Bucket filling (floating position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 - 2
Emptying the bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 - 2
2.8 Winter operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 - 1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 - 1
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 - 1
Air intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 - 1
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 - 2
Axle gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 - 2
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 - 2
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 - 2
2.9 Shutdown of vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9 - 1
Shut-off of vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9 - 1
Shutdown of vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9 - 1
Putting vehicle back in operation after shutdown . . . . . . . . . . . . . . . . . . . . . . . . .
2.9 - 2
2.10 Loading, attachment points, transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10 - 1
Loading, attachment points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10 - 1
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10 - 1
2E
07.08

LF-9.3

2-1

GHH Fahrzeuge GmbH


2.1 Safety instructions for the
operation of vehicles made
by GHH Fahrzeuge GmbH
General safety instructions:
Please read these safety instructions as well as the
operating instructions carefully before the first starting of the machine and every now and then afterwards.
Handling of GHH Fahrzeuge GmbH vehicles and
the necessary operating material is uncomplicated
if you as the owner have trained the staff responsible for operation, maintenance and attendance
accordingly.
This survey can, of course, only contain general
instructions. Operational specialities may need
deviations or additional amendments. For this
reason these instructions have to be studied thoroughly by operators, supervisory staff, maintenance staff and safety specialists of the corresponding plants together and must be adapted and
amended where necessary.
Deviations from these general safety instructions
prepared by GHH Fahrzeuge GmbH are especially
explained in the operating instructions.
If there are any uncertainties in understanding these
instructions, please do not hesitate to contact our
service department (GHH Fahrzeuge GmbH;
phone +49 (0) 2 09 389 07-300; fax: +49 (0) 2 09
389 07-349).
In addition to these general safety instructions the
special safety instructions referring to the operating
mode of engine and of the vehicle are to be observed. For all work carried out on the vehicle please
observe special the safety instructions for maintenance work.
When operating the vehicle the local accident prevention codes are to be observed. The owner and
driver are responsible for compliance with such
codes.
If necessary, the owner has to amend such accident
prevention codes to reflect the local conditions of
operation.
Referring to the conditions of operation, the safety
instructions of the corresponding employers liability insurance association have to be observed. We
recommend the owner to insist on a written confirmation that the staff has read the operating and
maintenance instructions, these safety instructions
as well as the accident prevention codes and the
030050E
07.08

additional regulations which are to be applied locally


and that they have been trained accordingly. In
addition to this, staff members should always have
the above mentioned regulations at hand to re-read
them.
Because of the relatively high noise level generally
found at almost all operating places of our vehicles
caused by surrounding conditions, perceptive
faculty may be reduced. For this reason vehicles
are to be operated especially carefully at such places.
Get used to handling of the machine and its control
and safety equipment as well as to critical places.
Read in operating instructions where those places
are and how they are marked.
Before each starting check the vehicles functional
and operational safety.
If operational failures occur, find out the reason
immediately. Care for immediate remedy of discovered faults in order to prevent possible accident
hazards and major damage of the vehicle or its
systems. In case of serious defects (failure of brake
system etc.) shut down the vehicle immediately
until the remedy of such a fault is carried out.
Switch off electrical components where risks have
been discovered, especially fault current, undue
rise in temperature, appearance of smoke and electric arcs or which have become inaccessible. Inform
next supervisor or specialist for electrical equipment as soon as possible.
Switch off electrical equipment which is not allowed
to be operated and secure against starting at least
by means of warning signs in places where those
installations could be started. Furthermore make
means for propulsion or control of actuators of
remote controlled switches ineffective.
Faulty electrical equipment and operation material
may not be started or used before being repaired.
Make sure that nobody without special knowledge
will ever operate, maintain, repair or otherwise
handle the machine.
Before leaving the drivers compartment always
apply parking brake. Park the vehicle at a place with
plane surface without descent and without disturbing other operations.
Never allow the engine of the machine run unattended.
LF-9.3

2.1 - 1

GHH Fahrzeuge GmbH


The drivers undivided attention is necessary for
optimal working results and reliable operation of the
machine. For this reason never allow persons to
operate the machine whose reactivity is reduced.
The influence of alcoholic beverages, medicines
and other agents will reduce capability to react as
well as over-tiredness will do and thus the risk of
accidents will increase.

Warn people in range of danger with the horn. Stop


working, if people do not leave danger area in spite
of warning.
Never stay below lifted and unsecured loads or
machine parts.
For climbing up and down use handles and treads.

Always maintain the machine in technically faultless


condition.

Do not give people a lift on the machine or additional


equipment if there is no device especially designed
for this purpose by the manufacturer.

Care for sufficient level of operating material, especially for engine, gears, axles, converters, brake
systems hydraulic and lubrication equipment, as
well as in cooling circuits.

Keep all the vehicle clean from dirt, residual oil,


lubricant, fuel, and, if necessary, from snow and ice
etc., especially treads, platforms, actuation places,
glass panes etc.

Undue modifications and insufficient maintenance


will impair the machines function, operation safety
and serviceable life. For this reason care for compliance with required maintenance and inspection
intervals. If you want to carry out technical modifications of the machine, please contact GHH Fahrzeuge GmbH in any case in advance.

Only operate controls in drivers compartment from


drivers seat.

The machine is equipped with warning signs or


equipment at specific places of danger. Take care
for proper condition of this warning equipment.
Replace immediately in case of damage or illegibility.
Take special care of the proper condition of all protection and safety equipment on the machine. Do
not remove and replace immediately in case of
damage.
Safety equipment and protection and control installations of the vehicle necessary for safety may not
be made ineffective nor unduly adjusted or modified.
Take care that parts of the body, clothes etc. will not
enter danger area of moving parts.
Always wear close fitting, appropriate working clothes.
If necessary, make use of additional personal protection clothes (protection helmet, protection glasses, ear protection, protection shoes etc.)
Maintain your drivers compartment clean, dry and
clear.
Keep all persons not needed for the working process away from the machine when operating.
When operating the machine take care that nobody
and nothing is in its range of action (driving ways,
swivelling range of kinematics and steering system,
etc.). Take special care of areas with high danger of
crushing.
030050E
07.08

Only operate the machine within the load limits


given by the manufacturer. Undue overloading will
reduce the operating safety and service life of the
machine.
Do not switch off the vehicle immediately after high
loads but let it idle for a certain time if possible, so
that the temperature of systems and components
can be compensated.
Misuse of the complete machine or single devices
thereof may lead to damage and reduction of service life and means in any case: loss of warranty
claims and raise of risk of accidents.
Take special care of appropriate speed when driving
around bends. Besides this, always adjust your driving speed to surrounding conditions, especially to
surface conditions.
When driving around bends, avoid high acceleration and violent steering movements which may
lead to early sliding, reduction of stability, and even
to damage.
Take care for sufficient carrying capacity of the substructure, especially on bridges, vaults, and when
passing over tubes placed under the travel way and
driving in areas which are laterally declining.
Before using the machine, check its fitness for use
especially at working places previously unknown.
Always keep emergency call equipment and emergency material (first-aid box, fire extinguishing
equipment, etc.) ready for use in your immediate
vicinity.
Only authorized people may operate, use, and activate electrical installations and corresponding operating material.
As far as warning signs are fixed on cases of electrical installations, their rules are to be observed.
LF-9.3

2.1 - 2

GHH Fahrzeuge GmbH


When towing another vehicle please take care of
the special instructions in the operating instructions
of both vehicles (e.g. hydrostatics, brake, etc.) and
use only the provided towing lugs and sufficiently
dimensioned towing equipment. Take care of the
required higher brake performance of the towing
vehicle, especially on declining ways with broken
down brake systems of the towed vehicle.
Only use original additional parts and spare parts
from GHH Fahrzeuge GmbH and lubricants and

030050E
07.08

process materials authorized by GHH Fahrzeuge


GmbH to maintain the operational safety and availability of your machine.
GHH Fahrzeuge GmbH is not responsible for
damage caused by installation or application of
equivalent parts of another origin.
Spare parts can be purchased from our service
department (GHH Fahrzeuge GmbH; phone +49
(0) 2 09 389 07-300; fax: +49 (0) 2 09 389 07-349).

LF-9.3

2.1 - 3

GHH Fahrzeuge GmbH


Special safety instructions for combustion
engines:
Exhaust gases from combustion engines are toxic!
For this reason do only operate combustion engines
in places with sufficient fresh air. Observe regulations for installation and operation of engines in clo-

030060E
07.08

sed rooms. Take care of sufficient ventilation and


suction and extraction or cleaning of exhaust gases.
When refilling the machine, switch off engine and
heating, do not smoke, avoid open flames or sources of sparks or heat nearby. Switch off electrical
installation. Remove spilled fuel immediately.
Only use specified, unpolluted and anhydrous fuels.

LF-9.3

2.1 - 4

GHH Fahrzeuge GmbH


Special safety instructions for mining and
tunnelling vehicles:

increase the risk of accidents and danger of tire


damage caused by uneven travelways.

Besides these safety instructions referring to a specific vehicle type, principally observe the general
safety instructions as well as the safety instructions
which correspond to operating mode of the engine.
For all work on the vehicle observe special safety
instructions for maintenance work.

If necessary, secure your load so that uncontrolled


sliding and connected risks of accidents (falling
down of load, turnover of the vehicle, etc.) as well
as shifting of the centre of gravity will be avoided.

Drive up ascents uphill if possible and avoid driving


transverely to the slope in order to avoid slipping
and overturning of the machine.
Take care that the admissible transverse and longitudinal inclination of the machine will not be exceeded.
Always maintain safety distances to stockpiles, pits,
etc..
Pay attention to the condition of stope faces and
especially of topbacks and possible danger caused
by falling or breaking rocks.
Maintain travelways as plane and boulderless as
possible.
Inform yourself about locations of dangerous and
endangering installations in your working area, as
for example high-voltage cables, pipework, electricity distributors, etc.
Care for too high water levels being pumped out.
When driving uphill and downhill care for a reasonable selection of gear respectively speed and thus
avoid superfluous risks of accidents, damage, overheating, and wear out of brakes and driving components. Too high gears may overstrain drive systems
(clutch, transmission, drivelines). Too high gears
during downhill driving require excessive use of brakes. Too high gears during uphill driving, especially
with high loading, result in an excessive rise of temperature of driving components. For this reason pay
attention to temperature indicators and select next
lower gear, if necessary.

Ensure sufficient height in the dumping place so


that crashing of body, bucket or dump/hoist linkage
against the roof will be avoided.
After dumping do not leave the dumping place
before bucket, fork and/or body are brought into
transportation position again.
Working places with special dangers, e.g. caused
by falling articles, require special safety measures
as e.g. remote control for unmanned operation of
the machine.
When working under lifted body, bucket or fork,
always apply safety bolts or supports provided for
safety. Safety bolts are located in the area of the
body or boom bearing.
If necessary, apply the swivel arresters of the swivel
hinge to reduce danger of crushing. Swivel arresters are provided in the area of the swivel hinge.
Park the machine fully unswivelled in straightahead position, preferably on plane surfaces without slopes. When standing on slopes, always park
the machine in a manner such that uncontrolled rolling will be avoided even if holding devices are loosened unintentionally (e.g., with the side of the
vehicle away from the drivers cab swivelled
towards the material face).
Before leaving the machine apply parking brake and
switch off engine. In addition to this make sure that
unauthorized operation will be impossible, e.g. by
withdrawing ignition key. When leaving loaders for
a long time, put bucket or fork to the ground and in
addition to this secure against rolling (e.g. put
chocks in front of wheels).

Carry out transport journeys only in transport mode,


i.e. with completely lowered body/boom, retracted
bucket, fork, etc.

Secure your parked vehicle especially at blind places with much traffic optically to avoid accidents
e.g. crashes.

If piles in body or bucket are too steep, this may lead


to falling out of rocks or conveyed material and thus

For electrically operated machines observe corresponding safety instructions.

030070E
07.08

LF-9.3

2.1 - 5

GHH Fahrzeuge GmbH


Special safety instructions for Fahrlader type
loaders

If possible, carry our loading only with a completely


stretched machine. With swivelled machine, working results will be reduced and the risk of sliding will
increase.
Pay attention, especially during loading, for sliding
and falling rocks or loaded material from the loading
place as well as from the bucket.
Carry out loading principally with lowered lifting
equipment and lowered bucket. Doing this you will
avoid the risk of rocks falling from the bucket onto
the drivers compartment.

030080E
07.08

Emptying the loading place from sides to centre will


avoid lateral sliding of loading material to the
machine, which could encumber the wheels and
would bring you closer to the dangerous area.
Empty the loading place as continuously as possible and with a straight front so that loading material
may slide down slowly and continuously.
If possible, execute dumping only at places without
transverse inclination and with a stretched
machine. With raised boom avoid high acceleration
and deceleration by starting and braking as well as
violent steering movements. If these instructions
are not observed, stability can no longer be guaranteed, danger of turning over arises. In addition to
this, danger caused by loading material falling down
from the bucket will increase.

LF-9.3

2.1 - 6

GHH Fahrzeuge GmbH


2.2

Drivers seat

The drivers cab is equipped with a mechanically suspended drivers seat. To prevent health damage, the
drivers seat must be adjusted to the drivers body before starting the vehicle.
The restraint belt must be used at all times. The belt should be worn as tight as possible to the body. After
an accident the restraint belt must be replaced and the drivers seat and the fastening of the drivers seat
inspected by qualified personnel.

4
Adjustment
1

Lever for backrest adjustment

Lever for height and tilt adjustment

Handwheel for setting the weight

Lever for horizontal adjustment

030090E
07.08

LF-9.3

2.2 - 1

GHH Fahrzeuge GmbH


2.3

Drivers cab, operating elements and control instruments

All the instruments and control instruments necessary to operate the vehicle are arranged in the drivers
cab. The speed adjustment of the driving engine and therefore the adjustment of the driving speed is effected via the right-hand pedal and the operation of the service brake via the left-hand pedal. The built-in
steering wheel is tiltable. The control lever is located on the left side of the steering column. The boom
and the bucket are operated with the control switch (S84) and the gearshift mechanism with the lever that
is located on the left beside the instrument panel.
Changing steering direction
The steering direction of the vehicle thus corresponds to the sense of rotation of the steering wheel, independent of the tramming direction.

forward

reverse
9

gearshift

P2

P3
S87
release
S43
parking brake
apply

N 1

3
4

P1 mounted in drivers door (X9)

St+KonE
07.08

LF-9.3

2.3 - 1

GHH Fahrzeuge GmbH

S72
H2

H3

H1

H5

H6

H10

H17

H18

H19

H12

H7

H8

S80

S70

P2

St+KonE
07.08

S64

P3

LF-9.3

2.3 - 2

GHH Fahrzeuge GmbH

Note

The abbreviations used are:


DT = pushbutton, ML = signal lamp, ST = control switch,
SK = twist switch, SL = key switch, AN = analog indicator

Warning

At each fault indication report to maintenance and determine the cause.

Item

Description

Available braking pressure

P1

AN hour meter (in X9)

P2

AN speedometer

P3

AN revolutions counter
An engine speed of 2480+50 min-1 must never be exceeded.

H1

ML alternator charge control


Goes out when three-phase alternator and controllerare working.
Lights up during operation in case of a defect in the generator or charging circuit. Terminate the operation as quickly as possible and switch off the engine.

H2

ML preheating
Goes out when the engine is preheatet.

H3

ML engine oil pressure


Lights up if the engine pressure drops below 0.5 bar. Shut off engine immediately as
soon as the signal lamp lights up.

H5

ML cylinder head temperature


Lights up if the cylinder head temperature rises above 185C.
Stop vehicle and allow engine to idle for appr. one minutes to cool down. Then turn
off engine.

H6

ML transmission clutch pressure


Lights up if the transmission clutch pressure drops below 16.0 bar.
Stop operation.

H7

ML converter oil temperature


Lights up if the converter oil temperature rises above 120C.
Stop vehicle, shift gear into neutral, idle unloaded engine for a short period and monitor
the temperature indicator (P7) converter oil temperature. If the temperature rises,
switch off the engine immediately; if the temperature falls, let the engine continue to
run. Check converter-transmission oil level, if necessary. Tramming the vehicle with
reduced torque-converter slip.

H8

ML return pressure / brake filter


lights up when the return pressure in the hydraulic system exceeds 1.3 bar. Replace
filter element in return filter of the hydraulic reservoir.
Also lights up when the return pressure in the brake system increases to 0.6 bar. Replace filter element in the pressure filter.
The indications are output with two different brightness levels of the indicator light. Too
high a return pressure is indicated by the indicator light in a brightly illuminated state
and contamination of the pressure filter by the indicator light in a weakly illuminated
state.

St+KonE
07.08

LF-9.3

2.3 - 3

GHH Fahrzeuge GmbH


Item

Description

H10

ML hydraulic oil level


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

H12

ML available braking pressure


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

H17

ML high beam
Lights up if the high beam is on.

H18

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

H19

ML service brake
Lights up if the service brake is activated or when your foot rests lightly on the brake
pedal.

S43

Lever parking brake


Serves to release or to apply the parking brake.
release - move the lever forward
apply
- move the lever backward

S64

SL ignition-/starter switch
Turning position P:
Turning position 0:
Turning position 1:
Turning position 2:
Turning position 3:

not used
OFF
power ON
prehating
engine starting

S70

DT signal lamp test


If used to test function of the signal lamps.
(not applicable to signal lamp for alternator charging control)

S72

SK lighting system
Turning position 0:
Turning position 1:
Turning position 2:
Turning position 3:

S80

DT headlight

S87

DT horn

St+KonE
07.08

OFF
parking light and material face lighting
low beam and material face lighting
high beam and material face lighting

LF-9.3

2.3 - 4

GHH Fahrzeuge GmbH


2.4

Checks

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

Engine oil level

Converter and transmission oil levels

Oil level in hydraulic tank

Tightness of all components and systems

Maintenance indicator of dry air filters

Tire pressure and condition

Function of brake

Function of steering

Function of lighting

Function of bucket and boom, raising/lowering

Function of indicator controls and signal lamps

Note

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

Daily checks after operation:


-

Lower work equipment.

Park vehicle on a level, dry surface, completely levelled. On gradients, park with the side of the vehicle
away from the drivers cab, swivelled towards the material face.

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

Set all control levers to neutral position.

Deactivate battery switch.

Protect vehicle against unauthorized use.

Clean vehicle.

Check vehicle for external damage, loose bolts, etc.

2_4-1E
07.08

LF-9.3

2.4 - 1

GHH Fahrzeuge GmbH


2.5

Engine starting, engine switch-off

Engine starting
Warning

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

external starter socket


-

Turn on battery switch.

Insert key in ignition / starter switch and turn


to positionPower ON.

Shift gear lever to neutral position.

The following indicators will light up:


-

Engine oil pressure.

Alternator charge control

Transmission clutch pressure.

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

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

battery switch

To preheat, set the ignition / starter switch to position Preheating and hold it in this position. Note that
the preheating signal lamp lights.
When the preheating signal lamp goes off, set speed adjustment pedal to approx. 1/4 speed and turn ignnition /starter switch to position Engine starting and hold it in this position.
Note

No preheating is required when the engine is warm.

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

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

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

2_5-1E
07.08

In the event of faults see the engine operating instructions and the appertaining sections
of these operating instructions.
LF-9.3

2.5 - 1

GHH Fahrzeuge GmbH


Engine switch-off

Caution

The parking brake is not applied automatically when switching off the engine. It is therefore important to apply the parking brake manually via the control lever to secure the
vehicle against rolling away.

Set engine speed to idling.

Apply the parking brake.


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

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

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

Deactivate the battery switch.

Note

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

Warning

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

Warning

If the Cylinder head temperature signal lamp lights up in operation, stop loader and
allow engine to cool down by running it at idling speed for appr. one minutes. Then
switch off engine.

2.5 - 2E
07.08

LF-9.3

2.5 - 2

GHH Fahrzeuge GmbH


2.6

Tramming operation

Caution

The vehicles steering system is inoperative when the engine has been stopped.

N=neutral position
N 1
2

Start-up

Start engine.

Set engine speed to idling.

Press the service brake pedal and keep it depressed.

Engage first gear.

Release service and parking brake.


(When the parking brake has been fulkly released, the signal lamp goes out.)

Increase the engine speed.


1st gear
forward

Set gear shift mechanism to neutral position.

1st gear
reverse

Changing the tramming direction.


-

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

Set gear shift mechanism to neutral position.

Engage first gear of opposite tramming direction.

Release service brake.

Changing steering direction


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

2_6-1_2E
07.08

LF-9.3

2.6 - 1

GHH Fahrzeuge GmbH


Hints on the torque converter and power transmission
The torque converter acts as a hydraulic connection of the engine and power shift transmission.
Since improper converter operation may lead to unnecessary heating-up of the converter transmission
system, the following should be observed:
-

Always start in first gear.

Utilize all gears to shifting point.


The point for changing to a higher gear has been reached if, in full throttle position, the speeds listed
below are reached in the individual gear steps.
Point for changing:
2nd 3rd gear
3rd 4th. gear
1st 2nd gear
3.8 km/h
7.5 km/h
12.5 km/h

If the system is excessively loaded, change to a lower gear.


The point for changing to a lower gear has been reached if, in full throttle position, the speeds listed
below are reached in the individual gear steps.
Point for changing:
3rd 2nd gear
2nd 1st gear
4th 3rd gear
12.5 km/h
7.5 km/h
3.8 km/h

Warning

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

In accordance with the shifting points for shifting down, the following gradient ranges can be travelled
in the individual gear steps:
(see annex, gradeability diagram 909-9-047220/106, page 3)
2nd gear
3rd gear
4th gear
1st gear
25 22%%
22% 11%
11% 5%
5% 0%

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

2_6-1_2E
07.08

LF-9.3

2.6 - 2

GHH Fahrzeuge GmbH


Tramming on downhill slopes
Tramming on downhill slopes is preferably carried out with the engine part up front. During downhill driving
this driving direction allows for a better distribution of the axle loads and also prevents axle lift-off caused
by front-drooping.
Tramming on downhill slopes always begins with the lowest gear appropriate for the gradient.
Via the drive train the engine will keep the vehicle at a uniform speed.
-

Never allow vehicle to roll opposite the selected tramming direction.

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

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

When the speed increases change to next lower gear.

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

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

Warning

030162E
07.08

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

LF-9.3

2.6 - 3

GHH Fahrzeuge GmbH


Downhill driving in converter mode
When driving downhill in converter mode the engine idles, which means the speed adjusting mechanism
is not operated. In the process, the engine brakes the converters pump wheel. This causes the turbine
wheel to rotate faster than the pump wheel, with the torque converter reversing and the dumper braked
via the engine, torque converter, transmission, drivelines and axles.
Warning

The brake power is converter into heat and the converter-transmission oil heated up.
The converter-transmission oil temperature indicator therefore has to be
watched.
Should the vehicles maximum converter oil temperature be exceeded, brake it by operating the service brake and allow engine to cool down at idling speed.

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

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

Note

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

You must not exceed the speed at the several gears above the limits as listed below:
1st gear
4.5 km/h

2_6-4E
07.08

2nd gear
9.2 km/h

3rd gear
15.4 km/h

LF-9.3

4th gear
25.0 km/h

2.6 - 4

GHH Fahrzeuge GmbH


Towing the vehicle

Note

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

In the event of towing over a long distance or over a road gradient section proceed in compliance with the
indications on page 2.6 - 6.
Warning

When the engine is not running, the vehicle cannot be steered.


For towing use only the towing lugs provided and sufficiently dimensioned towing aids.
Make sure that the towing vehicle has the required brake power.

Warning

To avoid chafing of the parking brake in case of too low a release pressure, a manometer
must be installed at test connectors B7.1 and B7.2. If the indicated pressure falls below
120 bar, this causes severe chafing, which may result in heating or even destruction
of the brake.
Towing in compliance with the indications on page 2.6 - 6.

Warning

During towing, monitor the brake pressure present for the service and parking brake on
the manometers in the drivers cab and on test connectors B7.1 and B7.2.

Caution

If the brake pressure for the srvice barke drops below 100 bar, a safe stop with the service brake is no longer guaranteed. The towing procedure must be immediately interrupted and if necessary executed in accordance with the indications on page 2.6 - 6.

A precondition for towing is an operational brake system and a sufficient available brake pressure in the
brake circuits of the service brake.
-

Secure vehicle against any self-initiated movements.

Check brake pressure on the manometers in the drivers cab and test connectors B7.1 and B7.2.
Warning

The available brake pressure for the service and parking brakes must be greater than
120 bar.

Place gearshift in neutral position. Switch on operating voltage and release parking brake.

Remove vehicle blocks and tow the vehicle.

Caution

Safe towing is not possible when the brake system is not operational, i.e. when the available brake pressure for the service brake is insufficient, when the towing vehicle has
a different brake system or as a result of removed component parts.

Warning

If the driving engine fails but the brake system is operational, the parking brake can be
released via the emergency release function (see 3.16 - 5) for towing and single stopping of the vehicle with the parking brake.

2_6-5E
07.08

LF-9.3

2.6 - 5

GHH Fahrzeuge GmbH


Filling of brake system for towing of vehicle
The hydraulic brake system is supplied from the hydraulic reservoir via a hydraulic pump flanged onto the
torque converter.
For towing a vehicle whose brake system does not contain sufficient brake pressure, the vehicles brake
system can be filled by that of the towing vehicle.
Warning

Provided both vehicles are fitted with the same brake system.

Oil is fillled in via the B4 test fittings. A DN 4 hose with suitable connecting couplers is required for this
purpose.
The following work operations are required:
-

Secure vehicle against any self-initiated movements.

Top up hydraulic oil on the hydraulic tank of the towing vehicle to maximum level.

Warning

With each braking operation hydraulic oil is pumped from the brake system of the towing
vehicle into that of the towed vehicle. It is therefore important to ensure that the hydraulic oil in the hydraulic reservoir of the towing vehicle does not fall below the minimum
level.

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

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

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

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

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

Remove the protections provided to secure the vehicle against rolling away.

Place gearshift in neutral position. Release parking brake and tow the vehicle.

Caution

At the end of the towing operation the hydraulic oil level on the hydraulic tank has to be
corrected on both vehicles.

Note

Before the filling hose is removed, the brake pressure in the brake system of both vehicles must be reduced simultaneously by pumping with the parking or service brake.

2_6-6E
07.08

LF-9.3

2.6 - 6

GHH Fahrzeuge GmbH


2.7

Dump/hoist operation

Control of dump/hoist equipment


The boom and bucket operations are controlled by the control switch arranged on the right side of the instrument box.
The stroke of the control switch is proportional to the speed at which the dump/hoist operation is performed, i. e. the further the control switch is shifted out from its middle position, the faster the desired boom/
bucket operation is performed.

Fig. 1

Control switch for


boom/bucket

Effect
boom/bucket

pull
push
left
right
spring-centered middle position

bucked tilted back


bucket tilted forward
boom lowered
boom raised
boom / bucket held in position

position 1
position 2
position 3
position 4

push through (Option)

bucket in floating position

position 5

2_7-1E
07.08

LF-9.3

see
Fig. 1

2.7 - 1

GHH Fahrzeuge GmbH


Bucket filling
-

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

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

Engage forward gear.

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

Warning

Avoid ramming the pile. The bucket should be introduced as far into the pile as is necessary to fill it.

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

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

Bucket filling (floating position)


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

Emptying the bucket


-

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

Set gear shift lever to neutral position.

Tip bucket forward

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

030201E
07.08

LF-9.3

2.7 - 2

GHH Fahrzeuge GmbH


2.8

Winter operation

Low temperatures will aggravate the vehicles operating conditions. To ensure trouble-free operation in
winter, special maintenance and care are required. Preparing for the cold season in good time is of special
importance.
Engine
Engine oil
Too viscous engine oil will lead to starting problems and favour increased wear. Note the oil grades and
change intervals specified in the engine manufacturers operating instructions!
Injection nozzles
Have injection nozzles inspected regularly. Refer to engine manufacturers operating instructions.
Compression
Have compression checked before the winter begins. Insufficient compression will affect starting of the
engine, especially in cold weather.
Cold-starting equipment
Check existing cold-starting equipment regularly. Refer to the engine manufacturers operating instructions.

Cooling system
Coolant
Add a brand-name anti-freeze to the coolant of liquid-cooled engines in good time.
Refer to engine manufacturers operating instructions.

Air intake system


Oil-bath air filter (if installed)
Fill oil bath of oil-bath air filter with the same oil as used for the engine. At extremely low temperatures,
use a mixture of oil and winter diesel fuel.
Refer to engine manufacturers operating instructions.
Dry air filter (if installed)
Refer to engine manufacturers operating instructions.

030210E
07.08

LF-9.3

2.8 - 1

GHH Fahrzeuge GmbH


Fuel system
Fuel
At ambient temperatures below 0C fill up winter diesel fuel. At low temperatures diesel fuel will separate
paraffin. Paraffin, in turn, will clog the fuel lines. For the application of different fuels refer to engine manufacturers operating instructions.
Fuel tank
When the fuel filters are unduly soiled, clean the fuel tank.
Water separator
If installed, drain water separator daily.
Kraftstoffpumpe
Clean fuel pump strainer (if installed) weekly.

Axle gear
Axle gear oil
Fill up axle gear oil according to the lubricant table.

Hydraulic system
Hydraulic oil
Fill up hydraulic oil according to the lubricant table.

Electrical system
Batteries
The starting capacity of the batteries depends on the charge state and the ambient temperature. Check
acid density regularly, charge batteries if necessary. Check for proper contact of terminals.
Alternator
The proper charging capacity of the alternator is especially important in winter. Check condition and tension of the V-belts regularly. Have alternator checked in good time (by specialist workshop).
Starter
Have starter checked if necessary by a specialist workshop. Grease flywheel gear rim if temperatures drop
below -20C.
Refer to engine manufacturers operating instructions.
030210E
07.08

LF-9.3

2.8 - 2

GHH Fahrzeuge GmbH


2.9

Shutdown of vehicle

Shut-off of vehicle

Caution

The parking brake is not applied automatically when switching off the engine. It is therefore important to apply the parking brake manually via the control lever to secure the
vehicle against rolling away.

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

Park vehicle on a level, dry surface, completely levelled. On gradients, park with the side of the vehicle
away from the drivers cab, swivelled towards the material face.

Apply parking brake and set gear shift lever to neutral.

Shut off engine and withdraw ignition key.

Set battery switch to OFF.

Protect vehicle against unauthorised use.

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

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

Set all levers to zero position.

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

Coat bright machinery components with acid-free grease.

Protect the engine in line with the engine operating instructions.

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

For battery care note the following:


-

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

Keep batteries clean and dry on the outside.

Warning
2_9-1E
07.08

Never allow batteries to be stored discharged.


LF-9.3

2.9 - 1

GHH Fahrzeuge GmbH


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

De-preserve engine in line with engine manufacturers operating instructions.

Fill up fresh engine oil.

Remove grease from bright machinery components.

Check battery charge state and liquid level.

Check tire pressure.

Check function of brake system.

Check function of hydraulic system.

Check function of electrical system.

Warning

030230E
07.08

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

LF-9.3

2.9 - 2

GHH Fahrzeuge GmbH


2.10

Loading, attachment points, transportation

Loading, attachment points


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

Note

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

Caution

Secure vehicle against any self-initiated movements and damage.

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

Warning

030241E
07.08

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

LF-9.3

2.10 - 1

GHH Fahrzeuge GmbH


3

Contents Maintenance

3.1
3.2

Safety instructions for maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . .


Maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regular maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Irregular maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold shrinking by nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Irregular maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prior to initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
After initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 List of lubricants and operating agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Checklist- Vehicle no.................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance intervals: daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance intervals: drive engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance intervals: 150/300/450/750 h................. . . . . . . . . . . . . . . . . . . . .
Maintenance intervals: 600/1200/1800/2400 h................. . . . . . . . . . . . . . . . . .
Measuring-point plan, location of the control valves . . . . . . . . . . . . . . . . . . . . . .
Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Maintenance work carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Engine operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8 Air intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9 Exhaust gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust back pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Silencer, exhaust gas catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO-measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking of fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling up fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the intake filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection pump, fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11 Speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diaphragm accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.12 Torque converter, power shift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance of converter-transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking of oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the intake strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the filter element in the pressure filter . . . . . . . . . . . . . . . . . . . . . . . . .

3E
07.08

LF-9.3

3.1 - 1
3.2 - 1
3.2 - 1
3.2 - 1
3.2 - 1
3.2 - 3
3.3 - 1
3.3 - 1
3.3 - 1
3.4 - 1
3.5 - 1
3.5 - 1
3.5 - 2
3.5 - 3
3.5 - 9
3.5 - 20
3.5 - 21
3.6 - 1
3.7 - 1
3.8 - 1
3.9 - 1
3.9 - 1
3.9 - 1
3.9 - 1
3.10 - 1
3.10 - 2
3.10 - 2
3.10 - 2
3.10 - 2
3.10 - 2
3.11 - 1
3.11 - 2
3.11 - 2
3.11 - 2
3.12 - 1
3.12 - 2
3.12 - 2
3.12 - 3
3.12 - 3
3.12 - 4

3-1

GHH Fahrzeuge GmbH


3.13 Drivelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance of drivelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation drawing of drivelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.14 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Planetary gear oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential gear oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking of oil level, Topping up planetary gear oil . . . . . . . . . . . . . . . . . . . . . . .
Checking of oil level, Topping up differential gear oil . . . . . . . . . . . . . . . . . . . . . .
Venting the differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.15 Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units of the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding of hydro brake system (HPB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diaphragm accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diaphragm accumulator in brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure reduction armature and filling device . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the gas preload pressure on the diaphragm accumulator . . . . . . . . .
Correcting the gas preload pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing of in-line filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the filter element in the pressure filter . . . . . . . . . . . . . . . . . . . . . . . . .
Service brake - Checking for disk wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KESSLER+CO installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismounting brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.16 Brake system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Legend to brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional description of hydraulic brake system . . . . . . . . . . . . . . . . . . . . . . . .
Pressure supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Residual brake pressure monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blocking of forward and reverse tramming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External cooling of multi-disk brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitoring of line filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitoring on pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency release of parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.17 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering and dump/hoist hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking of oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Level monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Topping up hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing of hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Venting the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3E
07.08

LF-9.3

3.13 - 1
3.13 - 1
3.13 - 1
3.13 - 2
3.14 - 1
3.14 - 2
3.14 - 2
3.14 - 2
3.14 - 2
3.14 - 2
3.15 - 1
3.15 - 1
3.15 - 1
3.15 - 2
3.15 - 3
3.15 - 4
3.15 - 5
3.15 - 6
3.15 - 7
3.15 - 8
3.15 - 9
3.15 - 10
3.15 - 11
3.15 - 11
3.15 - 12
3.16 - 1
3.16 - 1
3.16 - 2
3.16 - 2
3.16 - 2
3.16 - 2
3.16 - 2
3.16 - 3
3.16 - 3
3.16 - 4
3.16 - 4
3.16 - 5
3.17 - 1
3.17 - 1
3.17 - 1
3.17 - 2
3.17 - 2
3.17 - 2
3.17 - 2
3.17 - 3
3.17 - 3
3-2

GHH Fahrzeuge GmbH

3.18

3.19

3.20
3.21
3.22

3.23
3.24
3.25

3.26

3E
07.08

Steering and dump/hoist hydraulic system pressure test . . . . . . . . . . . . . . . . . .


Changing the filter element in the return filter . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil/air cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering and dump/hoist hydraulic system description . . . . . . . . . . . . . . . . . . . .
Legend to steering and dump/hoist hydraulic system . . . . . . . . . . . . . . . . . . . . .
Pressure oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filtering of hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dump/hoist hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Directional control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control-oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic pilot control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servo valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Float position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converter-transmission hydraulic system description . . . . . . . . . . . . . . . . . . . . .
Converter charging pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power shift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque converter operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
...................................................................
Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical equipment components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three-phase alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit breakers/Plug-in fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External-starting socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
...................................................................
TOTAL powder-type fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake system LCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque converter-power shift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gradeability diagram 909-9-047220/109, page 3 . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Manuel hand pump

LF-9.3

3.17 - 3
3.17 - 4
3.17 - 5
3.18 - 1
3.18 - 1
3.18 - 2
3.18 - 2
3.18 - 2
3.18 - 3
3.18 - 3
3.18 - 3
3.18 - 3
3.18 - 3
3.18 - 3
3.19 - 1
3.19 - 1
3.19 - 1
3.19 - 1
3.19 - 1
3.19 - 1
3.20 - 1
3.20 - 2
3.21 - 1
3.22 - 1
3.22 - 1
3.22 - 1
3.22 - 2
3.22 - 2
3.22 - 2
3.22 - 2
3.22 - 2
3.22 - 2
3.23 - 1
3.24 - 1
3.25 - 1
3.25 - 1
3.25 - 2
3.25 - 3
3.26 - 1

3-3

GHH Fahrzeuge GmbH


3.1

Safety instructions for


maintenance and servicing

Warning

The warranty is immediately void if


any anti-tamper seals or paint seals
attached to the vehicle systems are
detached or destroyed.

The general safety instructions do principally apply


for this chapter as well. The following text consists
of important regulations and additional instructions
for maintenance in order to introduce the necessary
knowledge to prevent accidents with damage of
people, material, and environment. Besides these
regulations also observe regulations which refer to
operation mode of the machine and type of vehicle.
If an accident happens in spite of all precautions,
especially caused by contact with caustic acid,
penetration of fuel into the skin, scalding with hot oil,
antifreeze compound in the eyes, etc. attend a
doctor immediately.
Please let only authorized and trained personal
used to necessary working procedures carry out
adjusting, lubricating, and maintenance work.
Do only use safe tools and working equipment.
Keep clean working place, tools, and operating
equipment.
Park vehicle on plane, dry surface without slopes.
Secure vehicle against self-contained movements
and unauthorized starting.
Carry out lubricating and maintenance work only
with stopped machine. Switch off all propulsion systems, bring additional equipment in inoperative
position.
Carry out lubricating and maintenance work during
which oil and grease may drain off the machine only
in places equipped with oil separators, or use suitable large and unmistakably identified vessels.
Make absolutely sure that oil, fuel, coolant etc do
not penetrate the soil or pass into the sewage system. Danger of drinking water pollution.
Used filter elements or cartridges, coolants and
refrigerants, batteries and other substances hazardous to humans and the environment must be
handled as special waste according to governmental regulations.
Ensure environmentally friendly disposal or recycling of waste material.
Ensure adequate installation of all parts. Replace
worn out, damaged, and unsafe parts.
030253E
07.08

Any changes to load-bearing components, i.e. parts


located in the flow of forces exerted by loads (frame,
kinematic linkage, etc.) must only be made after
written consent of MAN GHH Fahrzeuge GmbH.
This applies in particular to repair welds, torch-cutting and the arrangement of additional or modified
mounting parts.
Switch off the engine for all maintenance work
which does not necessarily require a working
machine and withdraw ignition key. Allow machine
to cool down.
If the operation of certain components of the
machine is necessary for maintenance work, pay
special attention to the related risks (burns, scalds,
poisoning, cauterization, crushing, rotating parts,
chain and belt drives, etc.)
Secure doors and gates provided for carrying out
maintenance work after opening. Secure turning,
swivel and pendulum hinges and joints with provided bolts, brackets, or supports.
Support or mark parts of the machine which have to
be lifted for maintenance work.
Only apply lifting equipment and supporting stands
with sufficient carrying capacity and valid permit.
Never stay under pending loads.
When maintaining or repairing the machine take
care for parts of the machine which are supported
by auxiliary force (oil pressure, compressed air) or
by spring force. Reduce pressures and spring powers and secure parts against undesired movements.
Only work on depressurized hydraulic and pneumatic systems. Take also care for secondary storage systems. Do neither tighten nor loosen pressurized screwed connection of pipework or flexible
tubes!
Only drain liquids at places provided for this purpose out of depressurized installations into suitable
containers and dump without harm for environment.
Be careful with units which become very hot when
operating and thus need a long time to cool down,
danger of burning!
Only work on de-energized electrical installations.
Pull out switch lever at battery main switch or switch
off main switch, or disconnect earth cable of the battery.
LF-9.3

3.1 - 1

GHH Fahrzeuge GmbH


Basically the following rules apply for work on electrical installations:
-

Disconnect from power supply

Secure against reconnection

Determining dead voltage

Earthing and shorting

Cover up any adjacent live parts

Plug and socket connections should only be disconnected and reconnected with the voltage
switched off.

When carrying out welding, cutting and grinding,


special attention is to be paid to inflammability of
inflammable materials (oil, grease, fuel, varnish,
rubber, etc.).
When removing protective coatings, zinc layers,
etc. by means of grinding, burning, or when welding
parts which are covered with such corrosion protection layers, health endangering gases, smokes, and
floating particles may arise. Use necessary protection equipment and, if possible, work outside, in well
ventilated rooms and with suction installations.
Please see further instructions for welding in special
instruction sheets and regulations for prevention of
accidents for welders.

It is prohibited at any time to store any parts especially tools, installation material, clothes, etc. in the
dangerous vicinity of unsecured, uninsulated parts
which are connected to the power supply

Observe manufacturers instructions for handling of


batteries. Accumulator acid is caustic and toxic,
battery gases are explosive.

The use of mended or bypassed fuses is prohibited.

Observe regulations for operation of three-phase


generators, see subsection Electrical equipment
and engine manufacturers operating instructions.

It is not allowed to connect parts to the feeder cable


of machines fitted with cable reel.
Damaged feeder cables must be replaced immediately.
Before starting work on high-voltage capacitors
make sure:
-

The capacitors have cooled down

Make absolutely sure they are fully discharged

Before touching active parts earth and short


each capacitor lead (phase(s) with the relevant
devices (See VDE 0450-T4/5d and IEC
871-1/Point 21).

Dismantled capacitors for transport or storage,


permanently short the connections and connect
to the capacitor housing.

In the event of damage it is possible the capacitor housing may crack, therefore proceed with
extreme care.

When carrying out welding work on the machine,


disconnect battery and electronic control units.
Warning

Plug and socket connections on the


driver position and on electronic
components (e.g. E-gas, control
units of the engine electronics)
should be separated before welding.

When welding take care that the earthing terminal


of the welding apparatus is near the welding point
and that welding current is not led through bearings,
earthing wire of the vehicle, etc.
030253E
07.08

Change oil at operating temperature. High danger


of burning or scalding with hot oil, oil drainage
screws and oil filter!
Open coolant circuit only when engine is cooled
down. Cooling systems are pressurized when hot,
hot coolants may lead to scalding. If opening at
operating temperature is absolutely necessary, see
engine manufacturers operating instructions.
If there is danger of freezing, drain coolant and
water circulation pump if necessary, when engine is
not in use.
Never fill cold cooling liquid into an overheated
engine.
When using compressed air, e.g. for cleaning air filters etc., wear protective glasses.
When dealing with damage or checking high-pressure systems, e.g. injectors, keep parts of your
body, especially hands and face away from pressure jets. Liquids under high pressure may have the
same effects as cutting tools.
Replace damaged flexible protection tubes or flexible pressure tubes immediately. Faulty flexible
tubes represent especially high danger of bursting
and scalding and danger from pressure jets.
The period of use of a flexible tube, including any
storage period of the flexible-tube line, should not
exceed six years, with the period of storage alone
not to exceed two years.
Do not inhale oil and fuel mist, battery gases, coolant and vapours from exhaust scrubber.
Never operate vehicle components without prescribed operating material. Take care for filling levLF-9.3

3.1 - 2

GHH Fahrzeuge GmbH


els of oils, coolants, etc. especially in engine, gearbox, converter, axles, brake system, hydraulic and
lubrication installation as well as coolant circuits.

When filling the tires never stand beside the wheel


because you may be endangered by snap rings
coming off.

Never exceed filling levels, especially for motor oil.

Have only specially trained people carry out repairs


of tires, especially mounting and dismantling to and
from wheel rims. Snap rings may often be prestressed to a very high extent and are to be handled
with special care.

Never operate pumps unlubricated and without


pumped fluids.
Always make sure that check and supervisory
devices work faultlessly (charge control, oil pressure, coolant temperature, etc.).
Do only demand as much from the engine as it has
to perform when properly employed. Please see
detailed information in sales documents.
Modifications of setpoints preset by the manufacturer, especially injection pumps, current limiters,
and pressure limiters of hydraulic units, may only be
executed after written consent of GHH Fahrzeuge
GmbH.

030253E
07.08

Never carry out work with open flames, welding,


cutting and flame-cutting of wheel rims as long as
tires are still mounted.
Some of the parts or operating materials in the
machines which are absolutely necessary for
operation are hazardous for humans and the environment. Therefore observe operating instructions
and manufacturers instructions on enclosures,
stickers and manuals.

LF-9.3

3.1 - 3

GHH Fahrzeuge GmbH


3.2

Maintenance and servicing

Warning

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

Warning

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

Regular maintenance and servicing


The time for carrying out this type of work depends on the vehicle operating hours. See Checklist-regular
maintenance according to service hours.
Irregular maintenance and servicing
The irregular work is divided into the following subgroups:
-

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

Maintenance and servicing of individual components which are particularly affected by varying operating conditions.

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

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

General remarks
The work specified in the check lists will be detailed in the various sections of the maintenance and servicing instructions.
Various items of the specified work may involve identical work steps. To avoid repetitions in the descriptions, these work steps are described below.
-

Safety at work
Note safety instructions for maintenance and servicing.

Cleaning the vehicle


Before starting any work, clean components located in the respective work area. The selection of the
proper cleaning agent depends on the material of the parts to be cleaned. For example, rubber or electrical parts should not be cleaned with benzene or steam jet.

After cleaning with steam jet, lubricate all bearings.

Covering all mounting areas


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

030260E
07.08

LF-9.3

3.2 - 1

GHH Fahrzeuge GmbH


-

Corrosion protection
Touch up damaged painted surfaces, grease bright spots regularly.

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


Exchange defective parts in good time to avoid major damage.

Protecting the electrical system


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

Checking of oil level


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

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

Check sealing elements


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

Check sealing faces


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

Check locking elements


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

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

030260E
07.08

LF-9.3

3.2 - 2

GHH Fahrzeuge GmbH


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

Safety notes
Liquid nitrogen has a temperature of -196C, which is why any contact with liquid nitrogen and undercooled
material must be avoided. To do so, protective clothing suiting the requirements (but at least protective
goggles and protective gloves) shall be worn.
Liquid nitrogen may be processed in well-ventilated rooms only, so as to avoid lack of oxygen caused by
the breathing air being enriched with too much nitrogen. Gaseous nitrogen is a colourless, tasteless and
odourless gas contained in the normal ambient atmosphere at a rate of 78%. Provided that sufficiently
large amounts of fresh air are supplied, the nitrogen, which upon heating of the frigorific mixture has changed to the gaseous phase, poses no special risk.
Inserting and withdrawing work pieces should preferably be done with the help of equipment made from
materials tough at subzero temperatures, such as hemp ropes, copper wire, tongs and hooks made of
suitable stainless steel grades (1.4541), as far as these are subjected to the influence of liquid nitrogen.
When exposed to subzero temperatures, ordinary structural steels lose their toughness and become coldbrittle.

Preparation and execution of shrink joint:


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

Wall thickness/diameter in mm

50

100

200

Immersion time in minutes

10

20

Warning

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

After its removal from the bath, the work piece must be processed immediately, i.e., positioned as shown
in the fabrication documents and fixed in the specified position, if any. What must be observed especially
with smaller, thin-walled work pieces is that these may adjust to the ambient temperature and therefore
lose their joining tolerance already after a short time.
While joining undercooled materials, no impacts must be applied to the work piece, as this would increase
the materials sensibility to brittle fracture

033050E
07.08

LF-9.3

3.2 - 3

GHH Fahrzeuge GmbH


3.3

Irregular maintenance and servicing

Prior to initial operation


-

Check all oil levels.

Check lubrication of all lubricating points.

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

Check tightening torques of wheel nuts.

Check tire pressure.

Check function of electrical system.

Check function of operating elements and control instruments.

Check function of brake system.

Check function of dump/hoist and steering hydraulic system.

After initial operation


of the complete vehicle or of individual components, up to the start of regular maintenance.
Engine
Refer to engine operating instructions.
Wheel nuts
Check tightening torque after 10 operating hours.
Air filter
For air filter maintenance see 3.8-1 intake system.
Lubrication
The lubrication intervals of the grease lubrication points depend on the operating conditions (see regular
maintenance and servicing). Lubricate vehicle after each steam-jet cleaning.
Fuel tank
Extract sludge at the bottom of the fuel tank once a year. Flush the tank and clean the intake filter.
Hydraulic oil return filter
Change filter if with hydraulic system at operating temperature the Return pressure signal lamp lights
up or the Return pressure analog indicator indicates a pressure of > 1.3 bar.

Warning
030270E
07.08

Filter element cannot be washed.


LF-9.3

3.3 - 1

GHH Fahrzeuge GmbH


3.4

List of lubricants and operating agents

Warning

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

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

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

Lubricant
and operating agents

Spezification

Ambient
temperature
(C)

Classification/
Mixing ratio

Subassembly/ Remark
Component

Engine oil

API
CF-4 1)
CG-4; CH-4 2)

-25

+20

SAE 10 W-30

Lubrication of
drive engine

-25

+25

-20

+25

SAE-viscosity class
according toDIN 51511

-20

+>30

Lubricants
referred to
in comparable specifications, not
listed here,
may also be
used.

Cooling system additive


DEUTZ 0101 1490
DEUTZ 1221 1500

Frostproof
-22

65 % Water/
35 % additive

Cooling system
of drive engine

The mixing
ratio may vary
according to
the climatic
conditions.

Ethyl glykol may also


Frostproof
be used as anticorro -28
sive agent/antifreeze 3).

60 % Water/
40 % additive

Frostproof
-35

55 % Water/
45 % additive

>0

Summer diesel

ACEA
E2-96 *
E3-96; E4-98 2)

Coolant

Fuel

Diesel fuel according to


DIN 51601, Cetan
number not below 45
ASTM D975-88
1-D and 2-D

BS 2869, A1 and A2

1)
2)
3)

-20

SAE 10 W-40
SAE 15 W-30
SAE 15 W-40

Warning:

Too high a
percentage
of protective
agent decreases the
cooling performance.
Fuel system of
drive engine

100%
Winter diesel
(four-star diesel)
Make sure to add
petroleum at temperatures below
-15C or -20C 3).

admissible for suction engines


to be used for supercharged engines
refer to engine operating instruction

SchmierE
07.08

LF-9.3

3.4 - 1

GHH Fahrzeuge GmbH


List of lubricants and operating agents
Lubricant
and operating agents

Spezification

Ambient
temperature
(C)

Brake fluid

DOT 4/
SAE J 1703

all year

Hydraulic oil

HVLP
DIN 51524 T3

-35

+15

ISO VG 15

-28

+25

ISO VG 22

-22

+33

ISO VG 32

-15

+45

ISO VG 46

-5

+50

ISO VG 68

+60

ISO VG 100

HLP
DIN 51524 T2

ATF

Subassembly/
Component

Remark

Speed
adjustment

-22

+20

ISO VG 22

-15

+30

ISO VG 32

-10

+40

ISO VG 46

Transmission oil

Classification/
Mixing ratio

+50

Steering and
dump/hoist
hydraulic system

ISO VG 68

+7

+57

ISO VG 100

-20

+10

C4, TO-4, J20 C/D Converter-transmission hydraulic


MIL-PRF-2104G
system
Grade 10

+ 35

C4, TO-4, J20 C/D


MIL-PRF-2104G
Grade 10

Note

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

Note

On some transmissions and torque converters with a throughshift clutch no ATF oils
Dextron II D may be used. The oils based on this specification are not compatible with
graphitic friction linings. That is why these oils shall only be used after prior consultation
with our Service department or the manufacturer of the component.
Dextron is a registered trademark of the General Motors Corporation.
API GL5, Dexron III and multiviscosity oils with a temperature range of more than 10
points, e.g. 10W30, shall, as a rule, not be used.

SchmierE
07.08

LF-9.3

3.4 - 2

GHH Fahrzeuge GmbH


List of lubricants and operating agents
Lubricant
and operating agents

Spezification

Ambient
temperature
(C)

Classification/
Mixing ratio

Subassembly/
Component

Transmission oil

Hypoid-gear oil
MIL-L - 2105 B
API GL5
API GL5 LS

> +30

SAE 140

Axle
planetary gear

Hypoid multigrade
oil
MIL-L - 2105 C / D
API GL5

-10

+30

SAE 90

-35

+38

SAE 75W-90

-26

+38

SAE 80W-90

-35

>+60

SAE 75W-140

-26

>+60

SAE 80W-140

-12

>+60

SAE 85W-140

differential gear

Lubricating
grease:

Lithium grease of
NLGI class 2 4)

-30

+130

K2K-30
DIN 51502

grease fittings
bearings
drivelines

Lubricating
grease:

Graphite
K2K DIN 51502

-30

+130

K2K DIN 51502

sliding surface
metal / metal

4)

Remark

Lithium-saponified greases with a penetration of 265/295 and a thawpoint of approx. 180C.


The lubricants must not contain any MoS2 additives.

Note

SchmierE
07.08

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

LF-9.3

3.4 - 3

GHH Fahrzeuge GmbH


3.5

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

Maintenance intervals: daily

Maintenance work

Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Note of
performance

1. Lubricating points
1.1 Lubricating bearing positions
with hand pump

see LEERER MERKER

Remarks:

Remarks:

Remarks:

Remarks:

Remarks:

Remarks:

Warning

3.5-1E
07.08

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

LF-9.3

3.5 - 1

GHH Fahrzeuge GmbH


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

Maintenance work

check
change
clean

Maintenance intervals: - drive engine


Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Note of
performance

1. Drive engine
All engine maintenance work according to engine
manufacturers maintenance plan.
Remarks:

Remarks:

Remarks:

Remarks:

Remarks:

3.5-2E
07.08

LF-9.3

3.5 - 2

GHH Fahrzeuge GmbH


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

The position of the measuring points for the individual pressure measurements shall be
taken from the relevant system drawing and the measuring points plan, see page
3.5 - 22. As a rule, only calibrated measurement instruments shall be used.

Maintenance intervals
150 Bh

300 Bh

450 Bh

750 Bh

900 Bh

1050 Bh 1350 Bh 1500 Bh

etc. see section 3.6

Maintenance work

check
change
clean

All maintenance work marked with a grey background field


on the side only has to be carried
out at the 300 Bh / 900 Bh / 1500 Bh .......... maintenance intervals.
Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Note of
performance

1. Axles
1.1 Visual check for leaks
o
1.2 Breather

In case of leaks find cause


and, if necessary, change component.
o Check for damage,
if necessary, change component. see 3.14 - 2

Remarks:

2. Wheels
2.1 Wheel nuts for completeness and firm
seating

Tighten, if necessary
front
right/left

( 445 Nm )

rear

( 445 Nm )

Replace, if necessary
front
right/left

right/left

Note
In case of wheel change
and when replacing/retightening wheel nuts observe
the tightening torques.
2.2 Condition of tyres

rear
2.3 Tyre filling pressure
o

right/left

Correct, if necessary
front
right/left

6.0 0.1 bar

rear

6.0 0.1 bar

right/left

Remarks:

3_5-3_8E
07.08

LF-9.3

3.5 - 3

GHH Fahrzeuge GmbH


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

Maintenance work

check
change
clean

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


Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Note of
performance

Vehicle in general

3.1 Bolt locks for complete o


ness, condition and
o
firm seating.
o

steering cylinder right/left


hoist cylinder

right/left

dump cylinder

bucket-connecting link

boom-stabilizer link

swivel joint

payload unitboom

right/left

boombucket

right/left

top/bottom

Remarks:

3.2 Connecting screws for o


completeness and firm
o
seating
Note
When replacing/retightening o
connecting screws observe
o
the tightening torques.

engine mounting base

( 295 Nm )

transmission fastening

M10- ( 48 Nm )
3/4- ( 525 Nm )
M16- ( 90Nm )

flexible supporting
torque converter fastening

( 48 Nm)

axle fastening

M24x1,5
( 1160 Nm )
M30x2
( 2206 Nm )

Connecting of drivelines
o
intermediate driveline

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

Remarks:

3_5-3_8E
07.08

LF-9.3

3.5 - 4

GHH Fahrzeuge GmbH


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

Maintenance work

check
change
clean

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


Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Note of
performance

4. Steering and dump/hoist hydraulic system


4.1 Connections, lines and
hoses for leaks.
o

In case of leaks find cause


and, if necessary, change
component.

4.2 Oil level in


hydraulic oil tank.

On the level indicator with driving engine running and retracted cylinders.
Top up oil, if necessary
see 3.17 - 1 and 3.17 - 2

Remarks:

5. Converter-transmission hydraulic system


5.1 Connections, lines and
hoses for leaks.
o

In case of leaks find cause


and, if necessary, change component.

5.2 Oil cooler

o Blow through with compressed


air

5.3 Oil level


converter-transmission

Check oil level at service temperature and with driving engine running. Oil level between
MIN and MAX marks on dipstick.
Top up oil, if necessary.
see 3.12 - 2

5.4 Oil filter cartridge


5.5 Converter and transmission ventilation

o
o

see 3.12 - 4
Check for damage, if necessary, change component.
see 3.12 - 1

Remarks:

3_5-3_8E
07.08

LF-9.3

3.5 - 5

GHH Fahrzeuge GmbH


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

Maintenance work

check
change
clean

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


Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Note of
performance

6. Service brake
6.1 Connections, lines and
hoses for leaks.
o

In case of leaks find cause


and, if necessary, change component.

6.2 Brake pressure


Treadle brake valve

Test fitting B6 front axle.


see section 4, drawing for
brake system.

70+3 bar

Test fitting B5 rear axle.


see section 4, drawing for
brake system.

70+3 bar

Test fitting B24 and B25


front axle.
see section 4, drawing for
brake system

max. 1.0 bar, at


high idling speed.

Test fitting B26 and B27


rear axle.
see section 4, drawing for
brake system

max. 1.0 bar, at


high idling speed.

Test fitting B11.


see 3.16 - 3 and section 4,
drawing for brake system

min. 0,5, at idling


speed.

6.3 Cooling pressure


o

6.4 Dynamic pressure


o

Residual pressure
max. 0,5 bar, at
high idling speed.

Residual pressure
max. 0,5 bar, at
high idling speed.

parking brake actueted max. 5.0


bar, at high idling
speed.

parking brake actueted max. 5.0


bar, at high idling
speed.

15 5 bar, at high
idling speed.
Remarks:

3_5-3_8E
07.08

LF-9.3

3.5 - 6

GHH Fahrzeuge GmbH


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

Maintenance work

check
change
clean

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

6.5 Pressure switch S53


o

6.6 Available brake pressure, switching pressure of shut-off valve.

Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Test fitting B4.


Available pressure of brake
system = 1453.5 bar, operating voltage switched on. Reduce the pressure by repeatedly actuating the service
brake.
see section 4, drawing for
brake system

Warning lamp
available braking
pressure in drivers cab lights up
when pressure
drops below
1003 bar

Test fitting B4.


see section 4, drawing for
brake system

1173.5 bar- ON
1453.5 bar-OFF

Test fitting B4.


Parking brake released, available pressure of brake system
= 1453.5 bar, driving engine
switched off. Service brake
actueted 5 times with max.
pressure at 10 sec intervals.
see section 4, drawing for
brake system

Residual pressure
min. 75 bar

Test fitting B4.


Available pressure of brake
system = 1453.5 bar. Driving
engine switched off.
see section 4, drawing for
brake system

After one-hour
immobilization
time:
min. 100 bar

Note of
performance

Check pressure gauge


manometer/indicator
6.7 Functional test of
diaphragm accumulator
o

6.8 Brake system for


leakage
o
Remarks:

Remarks:

3_5-3_8E
07.08

LF-9.3

3.5 - 7

GHH Fahrzeuge GmbH


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

Maintenance work

check
change
clean

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


Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Note of
performance

7. Electrical system
7.1 Function of instruments
and signal lamps in the
drivers cab.
o
7.2 Function of the lighting
system
o

When driving engine running.


Press signal lamp test pushbutton
front
rear

Remarks:

8. Lubricating points
8.1 Lubrication of drivelines

converter-transmission

2 grease fitting

Note
see 3.13

transmissionintermediate driveline

2 grease fitting

intermediate drivelinefront axle

2 grease fitting

transmission-rear axle

2 grease fitting

clevis speed adjustment

2x

8.2 Lubrication of bearings


Remarks:

Remarks:

Warning

3_5-3_8E
07.08

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

LF-9.3

3.5 - 8

GHH Fahrzeuge GmbH


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

The position of the measuring points for the individual pressure measurements shall be
taken from the relevant system drawing and the measuring points plan, see page
3.5 - 22. As a rule, only calibrated measurement instruments shall be used.

Maintenance intervals:
600 Bh

1200 Bh 1800 Bh 2400 Bh 3000 Bh 3600 Bh 4200 Bh 4800 Bh

etc. see section 3.6

Maintenance work

check
change
clean

All maintenance work marked with a grey background field


on the side only has to be carried
out at the 1200 Bh / 2400 Bh / 3600 Bh .......... maintenance intervals.
Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Note of
performance

1. Axles
1.1 Visual check for leaks

In case of leaks find cause


and, if necessary, change
component.

o
1.2 Oil level
differential gear

1.3 Oil level


planetary gear
o

Oil level up to lower edge of


check hole.
Top up oil, if neseccary.
see 3.14 - 2

front axle

Oil level up to lower edge of


check hole
Top up oil, if neseccary.
see 3.14 - 2

front axle
right
left

rear axle

rear axle
right
left
1.4 Breather

o Check for damage,


if necessary, change component. see 3.14 - 2

1.5 Oil differential gear


o

1.6 Oil planetary gear


o

Drain oil while still warm.


Top up oil to lower edge of
check hole.
Check oil level again after
waiting for a few minutes.
see 3.14 - 2

front axle
filling volume 28.0 l

Drain oil while stillwarm.


Top up oil to lower edge of
check hole.
Check oil level again after
waiting for a few minutes.
see 3.14 - 2

front axle: filling


volume 2 x 6.0 l

rear axle
filling volume 26.0 l

rear axle: filling


volume 2 x 6.0 l

Bemerkungen:

3_5-9_19E
07.08

LF-9.3

3.5 - 9

GHH Fahrzeuge GmbH


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

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

Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Tighten, if necessary
front
right/left

( 445 Nm )

rear

( 445 Nm )

Replace, if necessary
front
right/left

check
change
clean

Maintenance work

Note of
performance

2. Wheels
2.1 Wheel nuts for completeness and firm
seating

right/left

Hinweis
In case of wheel change
and when replacing/retightening wheel nuts observe
the tightening torques.
2.2 Condition of tyres

rear
2.3 Tyre filling pressure
o

right/left

Correct, if necessary
front
right/left

6.0 0.1 bar

rear

6.0 0.1 bar

right/left

Remarks

Vehicle in general

3.1 Bolt locks for copleteness, condition and


firm seating.

steering cylinder right/left

hoist cylinder

dump cylinder

bucket-connecting link

boom-stabilizer link

swivel joint

payload unitboom

right/left

boombucket

right/left

right/left

top/bottom

Remarks

3_5-9_19E
07.08

LF-9.3

3.5 - 10

GHH Fahrzeuge GmbH


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

Maintenance work

check
change
clean

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

3.2 Connecting screws for o


completeness and firm
o
seating

Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

engine mounting base

( 295 Nm )

transmission fastening

M10- ( 48 Nm )
3/4- ( 525 Nm )
M16- ( 90Nm )

flexible supporting

Note
When replacing/retightening o
connecting screws observe
o
the tightening torques.

torque converter fastening

( 48 Nm)

axle fastening

M24x1,5
( 1160 Nm )

Note of
performance

M30x2
( 2206 Nm )
Connecting of drivelines
o
intermediate driveline
3.3 Speed adjustment

For ease of movement and


tradle stop.
Indicator engine speed on the
drivers cab.

3.4 Ventilation filter


on fuel tank

M12- ( 120 Nm )
M14- ( 195 Nm )
M16- ( 210 Nm )
engine speed
2480 50 min-1

see 3.10 - 1

Remarks

4. Steering and dump/hoist hydraulic system


4.1 Connections, lines and
hoses for leaks.
o

In case of leaks find cause


and, if necessary, change component.

4.2 Oil level in


hydraulic oil tank.

On the level indicator with driving engine running and


retracted cylinders.
Top up oil, if necessary
see 3.17 - 1 and 3.17 - 2

Remarks

3_5-9_19E
07.08

LF-9.3

3.5 - 11

GHH Fahrzeuge GmbH


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

Maintenance work

check
change
clean

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

4.3 Aeration/ventilation filter on hydraulic oil tank.

4.4 Oil/air cooling system

Operat. agents/
Quantity/
Dimensions

Note of
performance

see 3.17 - 1
Clean the magnet
o see 3.17 - 5

4.5 Oil on hydraulic oil


tank.
o

4.6 Steering pressure


steering direction left

4.7 Steering pressure


steering direction
right

Measures/
Remarks/
Cross references

Drain oil while still warm.


With driving engine switched
off and retracted cylinders.
Vent hydraulik system after
each change of hydraulic oil.
see 3.17 - 3

filling volume
390 l

Measuring point H1.


175 +10/-5 bar
Steering at end stop.
engine speed
see 3.17 - 3 and section 4, dra- 1500 min-1
wing for steering and dump/
hoist hydraulic system.

Measuring point H1.


175 +10/-5 bar
Steering at end stop.
engine speed
see 3.17 - 3 and section 4, dra- 1500 min-1
wing for steering and dump/
hoist hydraulic system.

Measuring point H1 and H2.


230 +10/-5 bar
Hoist cylinder extendet
engine speed
see 3.17 - 3 and section 4, dra- 1500 min-1
wing for steering and dump/
hoist hydraulic system.

Measuring point H1 and H2.


230 +10/-5 bar
Dump cylinder retracted
engine speed
see 3.17 - 3 and section 4, dra- 1500 min-1
wing for steering and dump/
hoist hydraulic system.

4.8 Working pressure

Remarks

Remarks

3_5-9_19E
07.08

LF-9.3

3.5 - 12

GHH Fahrzeuge GmbH


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

Maintenance work

check
change
clean

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


Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Note of
performance

5. Converter-transmission hydraulic system


5.1 Connections, lines and
hoses for leaks.
o

In case of leaks find cause


and, if necessary, change component.

5.2 Oil level


converter-transmission

Check oil level at service temperature and with driving


engine running. Oil level between MIN and MAX marks on
dipstick.
Top up oil, if neseccary.
see 3.12 - 2

5.3 Oil cooler

o Blow through with compressed


air

5.4 Oil filter cartridge


5.5 Converter and transmission ventilation

Check for damage, if necessary, change component.


see 3.12 - 1

5.6 Oil converter-transmission


o

5.7 Intake strainer

see 3.12 - 4

Drain oil while still warm.


Check oil level at service temperature and with driving
engine running. Oil level between MIN and MAX marks on
dipstick.
see 3.12 - 3

filling volume
circuit 36.0 l

o on transmission sump
see 3.12 - 1 and 3.12 - 3

Remarks

6. Betriebsbremse
6.1 Connections, lines and
hoses for leaks.
o

In case of leaks find cause


and, if necessary, change component.

Remarks

3_5-9_19E
07.08

LF-9.3

3.5 - 13

GHH Fahrzeuge GmbH


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

Maintenance work

6.2 Brake pressure


Treadle brake valve

check
change
clean

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

6.3 Cooling pressure


o

6.4 Dynamic pressure


o

Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Measuring point B6 front axle.


see section 4, drawing for
brake system.

70+3 bar

Measuring point B5 rear axle.


see section 4, drawing for
brake system.

70+3 bar

Measuring point B24 and B25


front axle.
see section 4, drawing for
brake system

max. 1.0 bar, at


high idling speed.

Measuring point B26 and B27


rear axle.
see section 4, drawing for
brake system

max. 1.0 bar, at


high idling speed.

Measuring point B11.


see 3.16 - 3 and section 4,
drawing for brake system

min. 0,5, at idling


speed.

Note of
performance

Residual pressure
max. 0,5 bar, at
high idling speed.

Residual pressure
max. 0,5 bar, at
high idling speed.

parking brake actueted max. 5.0


bar, at high idling
speed.

parking brake actueted max. 5.0


bar, at high idling
speed.

15 5 bar, at high
idling speed.
6.5 Pressure switch S53
o

Measuring point B4.


Available pressure of brake
system = 1453.5 bar, operating voltage switched on. Reduce the pressure by repeatedly actuating the service
brake.
see section 4, drawing for
brake system

Warning lamp
available braking
pressure in drivers cab lights up
when pressure
drops below
1003 bar

Remarks

3_5-9_19E
07.08

LF-9.3

3.5 - 14

GHH Fahrzeuge GmbH


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

Maintenance work

6.6 Available brake pressure, switching pressure of shut-off valve.


Check pressure gauge
manometer/indicator

check
change
clean

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

6.7 Functional test of


diaphragm accumulator
o

6.8 Brake system for


leakage
o
6.9 Pressure gradient
o

6.10 Pressure relief valve


item 27
forward/reverse
interlock

3_5-9_19E
07.08

Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Measuring point B4.


see section 4, drawing for
brake system

1173.5 bar- ON
1453.5 bar-OFF

Measuring point B4.


Parking brake released, available pressure of brake system
= 1453.5 bar, driving engine
switched off. Service brake
actueted 5 times with max.
pressure at 10 sec intervals.
see section 4, drawing for
brake system

Residual pressure min. 95 bar

Measuring point B4.


Available pressure of brake
system = 1453.5 bar. Driving
engine switched off.
see section 4, drawing for
brake system

After one-hour
immobilization
time:
min. 100 bar

Measuring point

pressure
B24 > B28
B25 > B29
B26 > B30
B27 > B31
at high idling
speed.

B24 and B28


B25 and B29
B26 and B30
B27 and B31
see section 4, drawing for
brake system
Measuring point B5.
Drive the vehicle at low speed
and stop with the service
brake. Shift into 1st gear of the
opposite driving direction and
raise the brake pressure.
see section 4, drawing for
brake system.

LF-9.3

Note of
performance

Change-over of
driving direction
at a brake pressure > 51 bar

3.5 - 15

GHH Fahrzeuge GmbH

6.11 Pressure relief valve


item 10
only at Bh
2400 / 4800 / 7200 .....

Remove the pressure switch


and check the adjusted pressure point on a adequate test
equipment. If necessary,
change component.
see section 4, drawing for
brake system.

Switch activating
point at 180+5
bar rising.

Remarks

3_5-9_19E
07.08

LF-9.3

3.5 - 16

GHH Fahrzeuge GmbH


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

Maintenance work

6.12 Pressure relief valve


item 11

check
change
clean

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

only at Bh
2400 / 4800 / 7200 .....

6.13 Wear of the multi-disk


o

Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Remove the pressure switch


and check the adjusted pressure point on a adequate test
equipment. If necessary,
change component.
see section 4, drawing for
brake system.

Switch activating
point at 140+10
bar rising.

Dimensional check based on


the emboossed marking.
Brake pedal depressed.

Actual dimension
= 2.0 mm greater
than control dimension. Inspect
brake.

rear wheel
right/left
front wheel
right/left
if necessary, change component. see 3.15 - 10
6.14 Braking deceleration
o

6.15 Brake response time


o

Dynamic brake measurement,


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

min. 40%

Dynamic brake measurement,


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

1 sec. after
actuating the
brake the retardation must have
reached 35%

Note of
performance

Remarks

7. Parking brake

3_5-9_19E
07.08

LF-9.3

3.5 - 17

GHH Fahrzeuge GmbH

7.1 Pressure switch S51


o

Measuring point B7.1 and B7.2


Driving engine started and parking brake applied.
Slowly move hand brake valve
into the release position.
Slowly move hand brake valve
into the applied position.
see section 4, drawing for
brake system.

Warning lamp
parking brake in
drivers cab goes
out when pressure rises above
115-3 bar.
Warning lamp
lights up when
pressure drops
below 1043 bar

Remarks

3_5-9_19E
07.08

LF-9.3

3.5 - 18

GHH Fahrzeuge GmbH


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

Maintenance work

7.2 Release pressure

check
change
clean

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

7.4 Braking deceleration


o

7.5 Brake response time


o

Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Measuring point B7.1 and


B7.2.
see section 4, drawing for
brake system.

released
min. 115 bar

Dynamic brake measurement,


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

min. 53%

Dynamic brake measurement,


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

1 sec. after
actuating the
brake the retardation must have
reached 35%

Note of
performance

applied
max. 0,5 bar

Remarks

8. Electrical system
8.1 Battery
o
o

Check visually for leaks and


firm seating of connections.
Liquid level.
Top up with distelled water if
necessary
o Coat poles with grease.
Use acidproof grease.

8.2 Function of instruments


and signal lamps in the
drivers cab.
o
8.3 Function of the lighting
system
o

When driving engine running.


Press signal lamp test pushbutton
front
rear

Remarks

3_5-9_19E
07.08

LF-9.3

3.5 - 19

GHH Fahrzeuge GmbH


Checklist - Vehicle no....................
Maintenance intervals: 600/1200/1800/2400 Bh ..........
Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

9.1 Lubrication of drivelines

converter-transmission

2 grease fitting

Note
see 3.13

transmissionintermediate driveline

3 grease fitting

intermediate drivelinefront axle

2 grease fitting

transmission-rear axle

2 grease fitting

check
change
clean

Maintenance work

Note of
performance

9. Lubricating points

9.2 Lagerstellen mittels Handpumpe abschmieren.

see LEERER MERKER

9.3 Lubrication of bearings

Radiator grill

2 grease fitting

clevis speed adjustment

2x

Remarks

Warning

3_5-9_19E
07.08

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

LF-9.3

3.5 - 20

GHH Fahrzeuge GmbH


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

Maintenance work

check
change
clean

Maintenance intervals: according to maintenance indicator


Measures/
Remarks/
Cross references

Operat. agents/
Quantity/
Dimensions

Note of
performance

Steering and dump/hoist hydraulic system


Return filter cartridge

Filter cartridge is integrated


with the hydraulics oil tank. see 3.17 - 4

In-line filter cartridge

see 3.15 - 8

Pressure filter cartridge

see 3.15 - 9

Remarks

Service brake

Remarks

Remarks

Remarks

Remarks

Remarks

3_5-9_19E
07.08

LF-9.3

3.5 - 21

GHH Fahrzeuge GmbH


Measuring-point plan, location of the control valves
B4, B11
(10, 12, 15)

B5, B7.1
B27, B31

B26, B30

11

14

H24, H25 (2)

H1 (4)

13

H2

B6, B7.2
B25, B29

H10-H13
H20-H23
(3)

B24, B28

Measuring-points
Steering- dump/hoist hydraulic system

Brake system

H1 system pressure steering- dump/hoist hydraulic

B4

available brake pressure,

H2 system pressure dump/hoist hydraulic

switching pressure of shut-off valve.

H10-13 servo pressure directional control valve

pressure switch S53, accumulator test

H20 secondary pressure hoist cylinder

pressure switch S51

H21 secondary pressure hoist cylinder

B5

brake pressure rear axle

H22 secondary pressure dump cylinder

B6

brake pressure front axle

H23 secondary pressure dump cylinder

B7.1+7.2 release pressure parking brake

H24 secondary pressure steering cylinder


H25 econdary pressure steering cylinder

rear and front axle


B11 dynamic pressure cooling multi-disk brake
B24-B27 and B28-B31
cooling pressure, pressure gradient

Location of the valves


Steering- dump/hoist hydraulic system

Brake system

booster valve with integrated

10

accumulator charge valve item3

priority valve item15

11

relay valve item6

pressure relief valve item13

12

pressure relief valve item10

directional control valve item18

13

pressure relief valve item11

valve unit with accumulator item21

14

pressure relief valve item27

15

distributor block item722

3_5-20E
07.08

LF-9.3

3.5 - 22

GHH Fahrzeuge GmbH


Lubrication points

16,17 21

1,2
1

5,6

10

14,15

22 18,19,20

23

24

7,8

Swing axle bearing (on dristributor)

13

Hoist cylinder bearing

Swing axle bearing (on dristributor)

14

Hoist cylinder bearing

Swivel joint bearing top (on dristributor)

15

Hoist cylinder bearing

Swivel joint bearing bottom (on dristributor)

16

Bucket bearing

Steering cylinder bearing

17

Bucket bearing

Steering cylinder bearingr

18

Stabilizer link bearing

Steering cylinder bearing

19

Stabilizer link bearing

Steering cylinder bearing

20

Dump cylinder bearing

Dump cylinder bearing

21

Connecting link bearing

10

Boom bearing

22

Stabilizer link bearing

23

Flange bearing driveline

24

Flange bearing driveline

11
12

Hoist cylinder bearing

12,13

3,4

7,8
right and left

3_5-22E
07.08

LF-9.3

3.5 - 23

GHH Fahrzeuge GmbH


3.6

Maintenance work carried out

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


Hours in
service

150
300
450
750
900
1050
1350
1500
1650
1950
2100
2250
2550
2700
2850
3150
3300
3450
3750
3900
4050
4350
4500
4650
4950
5100
5250
5550
5700
5850
6150
6300
6450
6750
6900
7050
7350
7500
7650
030381E
07.08

Data

Signature

Hours in
service

Data

Signature

7950
8100
8250
8550
8700
8850
9150
9300
9450
9750
9900
10050
10350
10500
10650
10950
11100
11250
11550
11700
11850
12150
12300
12450
12750
12900
13050
13350
13500
13650
13950
14100
14250
14550
14700
14850
15150
15300
15450

Hours in
service

Data

Signature

15750
15900
16050
16350
16500
16650
16950
17100
17250
17550
17700
17850
18150
18300
18450
18750
18900
19050
19350
19500
19650
19950
20100
20250
20550
20700
20850
21150
21300
21450
21750
21900
22050
22350
22500
22650
22950
23100
23250
LF-9.3

3.6 - 1

GHH Fahrzeuge GmbH


Maintenance work carried out
Maintenance intervals: 600/1200/1800/2400 Bh ............
Hours in
service

600
1200
1800
2400
3000
3600
4200
4800
5400
6000
6600
7200
7800

030381E
07.08

Data

Signature

Hours in
service

Data

Signature

8400
9000
9600
10200
10800
11400
12000
12600
13200
13800
14400
15000
15600

Hours in
service

Data

Signature

16200
16800
17400
18000
18600
19200
19800
20400
21000
21600
22200
22800
23400

LF-9.3

3.6 - 2

GHH Fahrzeuge GmbH


3.7

Engine operating instructions

Before carrying out any maintenance and servicing work on the diesel engine, please carefully read the
attached engine manufacturers operating instructions.

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

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

Warning

030390E
07.08

It is recommended to contact the GHH Fahrzeuge GmbH customer service to eliminate


failures and to carry out checks, adjustment or repair works. As regards inquiries by
phone mind page 1.2-1.

LF-9.3

3.7 - 1

GHH Fahrzeuge GmbH


3.8

Air intake system

Note

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

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

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

Note

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

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

Dust collecting vessel (2) (fig. 1)

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

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

Fig. 2

Fig. 1
9

Fig. 3

Fig. 4

3_8-1_2E
07.08

LF-9.3

3.8 - 1

GHH Fahrzeuge GmbH


Filter servicing includes following operations:

Note

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

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

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

Note

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

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

The safety element must not be cleaned and reused.

Cleaning with compressed air


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

Warning

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

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

Install main element respectively main element and safety element.

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

Reset vacuum indicator (6) to its initial position by pressing the reset button (7). The indicator in the
display window (8) changes to green.

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

3_8-1_2E
07.08

LF-9.3

3.8 - 2

GHH Fahrzeuge GmbH


3.9

Exhaust gas system

Note

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

Exhaust back pressure measurement


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

MAN engine

MWM engine

DB engine

F6 L 413 F/FW

max. 650 mm WC

F8 L 413 F/FW

max. 750 mm WC

F10 L 413 F/FW

max. 750 mm WC

F12 L 413 F/FW

max. 750 mm WC

BF 4 L 1011

max. 750 mm WC

BF 12 L 413 FW

max. 750 mm WC

F6 L 912 W

max. 750 mm WC

F6 L 914

max. 750 mm WC

D 0826 LF

max. 600 mm WC

D 2865 LF

max. 600 mm WC

D 2866 LF

max. 600 mm WC

D 2866 LUH

max. 600 mm WC

D 916-6

max. 980 mm WC

D 932-V8

max. 980 mm WC

D 932-V12

max. 980 mm WC

OM 421 A

max. 610 mm WC

Caterpillar engine 3304 PC-NA

max. 860 mm WC

The exhaust back-pressure limit values also apply to the use of catalytic converters. Check exhaust back
pressure at regular intervals.
Silencer, exhaust gas catalyst
The silencer and catalytic converter require no special maintenance and have to be replaced if defective.
Check regularly for proper condition and firm seating.
CO-measurement
The maximum admissible CO level depends on the official regulations applicable at the jobsite.
030420E
07.08

LF-9.3

3.9 - 1

GHH Fahrzeuge GmbH


3.10

Fuel system

1
2
4

Screw cap

Intake nozzle

Drain plug

Tank lid

Intake filter

Ventilation filter

030430E
07.08

LF-9.3

3.10 - 1

GHH Fahrzeuge GmbH

Caution

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

Checking of fuel level


-

Clean intake nozzle and screw cap.

Turn screw cap open and remove strainer.

Check fuel level with a clean dipstick.

Note

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

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

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

Draining fuel
Use the drain plug on the tank underside to drain fuel or slurry. Make sure that the plug seals well.
Cleaning the intake filter
-

Clean surroundings of the intake nozzle.

Mark location of nozzle relative to the tank.

Release fuel lines from tank lid and plug.

Release tank lid and lift off filler nozzle. Wash out intake filter with diesel fuel.
Mount nozzle and, while doing so, make sure that the gasket is properly seated. Replace gasket, if required.
Warning

Do not mix up lines.

Injection pump, fuel filter


Clean injection pump strainer and fuel filter cartridge. See engine manufacturers operating instructions.
030430E
07.08

LF-9.3

3.10 - 2

GHH Fahrzeuge GmbH


3.11

Speed adjustment

Speed adjustment of the diesel engine between idling and full load speed is accomplished with the footoperated treadle on the drivers place floor, via a hydraulic system

Note

Check treadle for ease of movement.

71

Control cylinder

adjusting screw
working pressure (G2) (IS)

51

P = inlet
A = outlet
T = drain
P
A
T

13

adjusting screw
working pressure (G2) (HI)

connection lever
injection pump
49

swivel head

rod

29
HI = High
idling speed

Check points

IS = idling speed

Meassuring Rat. value


points
(bar)

Connection transmission clutch pressure

Operating pressure

G1

Working pressure

G2

Return pressure

G3

Connection regulating valve assy. 2303

17.0 -- 20.0
at IS+HI
IS max. 2.7
HI min. 141
max. 0.7

G1

G3
return line transmission sump

G2

3_11-1_2E
07.08

LF-9.3

3.11 - 1

GHH Fahrzeuge GmbH


Installation instructions
-

Fit rod on the threaded rod leading to the lever of the injection pump.

Align the length of the rod so that the hole in the lever of the setting cylinder and the hole in the swivel
head register perfectly as shown on the drawing.

Mount the pin. It must be possible to insert the pin without applying any force.

Lock up the rod setting.

Remove the pin again and start engine.

Depress the pedal as far as the stop and hold.


During this operation the selected hole in the lever of the setting cylinder travels approx. 50 mm.

Pull rod by hand until the lever of the injection pump is positioned at the mechanical stop.

At the selected hole in the lever of the setting cylinder there must be an overtravel of min. 3 mm with
respect to the rod.

Note

If the overtravel is less than 3 mm, the basic setting of the rod length must be adjusted
to another hole in the lever of the setting cylinder and the overtravel checked again.

Release accelerator pedal and refit and fasten rod on lever of the setting cylinder, using the hole to
which the rod length has been adjusted.

Final check
Start engine and check speeds.
Idling speed = 650 50 min-1
High idling speed = 2480 50 min-1

Diaphragm accumulator
Checking the diaphragm accumulators see page 3.15 - 3 and 3.15 - 6.

3_11-1_2E
07.08

LF-9.3

3.11 - 2

GHH Fahrzeuge GmbH


3.12

Torque converter, power shift transmission

3
6

Oil dipstick

Tightening torques

Oil drain

Fastening screws

Transmission vent

Torque converter 48 Nm

Intake strainer

Drive-plate / engine 70 Nm

Converter-transmission oil filter

Drive-plate / torque converter 75 Nm

Oil cooler

Oil filler nozzle

033420E
07.08

LF-9.3

3.12 - 1

GHH Fahrzeuge GmbH


Maintenance of converter-transmission

Warning

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

Checking of oil level


Torque converter and power shift transmission have a common oil circuit. The oil is to be checked at operating temperature (82-93 C) with the engine running. (idling speed)
Warning

Under no circumstances check oil level with cold hydraulic oil.

The following work is to be performed:


-

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

Where an oil dipstick is provided:


-

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

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

Where an oil level control screw is provided:

Unscrew the upper oil level checking screw.

The oil fill is to reach up to the bottom edge of the control screw.

If required, top up oil as per lubricant table through the filling port.

030461E
07.08

LF-9.3

3.12 - 2

GHH Fahrzeuge GmbH


Changing oil

Note

The converter-transmission hydraulic oil is to be drained with the oil at operating temperature.

The following work is to be performed:


-

Turn out transmission oil drain plug.

Allow oil to drain completely.

Firmly tighten oil drain plug again.

Where an oil dipstick is provided:


-

Fill up oil through the filling port until the oil level is at the lower dipstick mark.

Start engine and run at idling speed for two minutes to fill the torque converter and hydraulic lines with
oil.

Check oil level with engine runnig (idling speed) and top up oil to lower dipstick mark.

On reaching the operating temperature (82-93 C), recheck oil level and top up oil to the upper dipstick
mark.

Where an oil level control screw is provided:


-

Remove oil level control screws and fill up oil through the filling port until oil comes out of the lower
control bore.

Start engine and run at idling speed for two minutes to fill the torque converter and hydraulic lines with
oil.

Top up oil until it comes out of the lower control bore.

Screw in lower oil level control screw, start engine and as the operating temperature (82-93 C) is reached, top up oil until it comes out of the upper control bore.

Screw in upper oil level control screw.

Warning

Under no circumstances check oil level with cold hydraulic oil.

Cleaning the intake strainer


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

030461E
07.08

LF-9.3

3.12 - 3

GHH Fahrzeuge GmbH


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

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

Clean the complete filter on the outside.

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

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

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

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

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

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

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

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

Maintenace indicator
green area

red area

3
4
5
marking

6
7

8
9
10

11
12

033710E
07.08

LF-9.3

3.12 - 4

GHH Fahrzeuge GmbH


3.13

Drivelines

The vehicle is fitted with three driveline assemblies:


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

Double-joint drivelines with locating bearing


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

Grease fitting

Grease fitting of
individual joint

Lubrication
Drivelines and intermediate bearing points have to be greased at regular intervals according to the manufacturers maintenance instructions. As the lubrication path extending within the spider and through the
spaces between the rolling elements is long and narrow, the grease takes time to expand. Only slow greasing at low pressure will ensure a uniform distribution of the grease.
Warning

030473E
07.08

Clean grease fittings before lubrication!


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

LF-9.3

3.13 - 1

GHH Fahrzeuge GmbH


Universal joints with pressure relief valve
Drive lines with universal joints of special design are provided with a pressure relief valve located next to
the grease fitting. Because of the special-design sealing, the gaskets must be protected from damage due
to excessive pressure when lubricating is performed.
For this reason, this type of drive line requires stopping of the greasing operation when grease emerges
at the pressure relief valve.
Whenever lubrication is performed, the drivelines must be checked for external damage and the universal
joints for inadmissible clearance. The bolted connections of the drivelines must be checked for firm seating.
Warning

Replace damaged drivelines immediately. Repaired drivelines must be balanced.

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

Installation drawing of drivelines

drive unit

converter

030473E
07.08

rear axle

payload unit

transmission

LF-9.3

front axle

3.13 - 2

GHH Fahrzeuge GmbH


3.14

Axles

Differential

Fig. 1

1+2

1+2

Planetary gear

1+2

3
Abb. 2

1 = Oil filling port


2 = Checking screw
3 = Drain plug
031580E
07.08

LF-9.3

3.14 - 1

GHH Fahrzeuge GmbH

Note

To check the oil level and change the differential and planetary gear oil, park the vehicle
on a level surface.

Note

Drain differential and planetary gear oil while still warm.

Planetary gear oil change


To drain the oil, turn the wheel end so that the drain plug is at the lowest point possible. To change the
oil, unscrew drain screw and drain oil. Clean the drain plug (replace if necessary) and fill up with fresh oil.
See Checking of oil level, Topping up planteary gear oil. For filling volume see Technical Data.

Differential gear oil change


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

Whenver oil has been changed: Check differential and planetary gear oil level again after waiting for a few minutes.

Checking of oil level, Topping up planetary gear oil


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

Checking of oil level, Topping up differential gear oil


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

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

Venting the differential gear


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

031730E
07.08

LF-9.3

3.14 - 2

GHH Fahrzeuge GmbH


3.15

Brake system

All four wheels of the vehicle are equipped with combined brakes. Each combined brake consists of a service and a parking brake component that act on the oil-cooled brake disks. When operated, hydraulic pressure is admitted into the service brake, whereas the parking brake is spring-actuated and released hydraulically.
Brake system :

Three-circuit hydraulic power brake system with distribution via


circuits I + II over the service brake component of the front and rear
axles, with circuit III being used as release pressure for the parking
brake components.

Units of the brake system


Service brake:

Front axle, hydraulically actuated multi-disk brake


Rear axle, hydraulically actuated multi-disk brake

Parking brake:

Spring-loaded brake acting on the oil-cooled brake disks of the


service brake (combined brake) at the front and rear wheels.

General notes

Caution

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

Note

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

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

Brakes are first-rank components in terms of safety

Work carried out improperly may lead to failure of brakes.

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

Use only manufacturer-approved original spares.

Pressure and tension springs as well as sealing rings, protective caps and bellows must be replaced
after a service life of no more than two years.

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

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

Warning

3_15-1E
07.08

Mounting and dismounting the brakes must be carried out in accordance with the
Kessler+CO installation instructions (see page 3.15 - 11).
LF-9.3

3.15 - 1

GHH Fahrzeuge GmbH


Bleeding of hydro brake system (HPB)

Caution

Secure vehicle against movement by placing chocks etc. in front of the wheels. Check
that system is pressure-free.

Warning

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

Bleed brake at all bleed valves of the four wheel brakes using a portable hose and on all four existing test
fittings using a Minime hose.
Bleeding of service brake
Note

When bleeding the individual wheel brakes, make sure to bleed any stub lines that may
be present, as well.

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

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

Start engine and shut off immediately when the pressure gauge indicates an available pressure of
50 to 60 bar.

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

Catch oil in suitable containers.

Bleeding of parking brake


Warning

All four parking brakes must be vented at the corresponding vent nipples of each wheel.

Switch on operating voltage and release parking brake. The 3/2 way valve is then opened to the spring
brakes on the front and rear wheels.

Connect the transparent hose to the appropriate bleed port. (Note that several points can be bled simultaneously).

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

Checks
Check the bleeder valves for leakage.
Check oil level on the hydraulic tank.
With the engine running, charge brake system up to the shut-off pressure of the shut-off valve and with
depressed service brake and released parking brake check tightness of bleed points.
Operate service brake and parking brake for 2 to 3 times. Repeat bleeding operation if there is a creaky
noise in the treadle or hand brake valve.
Checkfunction ot the service brake and parking brake.
3_15-2E
07.08

LF-9.3

3.15 - 2

GHH Fahrzeuge GmbH


Diaphragm accumulator

Warning

When using diaphram accumulators (pressure vessels), attention must, as a matter of


principle, be paid to the pressure vessel regulations in force in the country in question.

The diaphram accumulators are preloaded with nitrogen to a predefined pressure. As certain gas losses
occur during operation, it is necessary to check and, when appropriate, correct the preload pressure at
regular intervals. The periods for the periodic tests must be determined by the operator in accordance with
the legal provisions.
Because of its safety-critical function and taking into account the service conditions, the diaphragm accumulator shall not be used for more than three years. Experience may, however, show that it needs to be
replaced at shorter intervals.

Caution

Prior to working on equipment fitted with diaphram accumulators, it is essential to reduce the pressure in the appropriate system.

Caution

The gas preload pressure may be corrected by authorized personnel only.


Only nitrogen may be used at the filling gas.
Risk of explosion if oxygen or air is used.

Note

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

Diaphragm accumulator in
steering-dump/hoist hydraulic

Diaphragm accumulator in brake system

gas preload pressure 101 bar

gas preload pressure 555 bar

Diaphragm accumulator in speed adjustment (bottom of transmission compartment)


-

gas preload pressure 61 bar

3_15-3_4E
07.08

LF-9.3

3.15 - 3

GHH Fahrzeuge GmbH


Diaphragm accumulator in brake system
Note

During this following check several interconnected diaphragm accumulators are


checked in one operation, so that only provide a coarse indication of the operativeness
of the diaphragm accumulators is obtained. It is thus not possible to check each individual diaphraghm accumulator.
Checking the gas preload pressure in the individual diaphragm accumulators is only
possible with the aid of a suitable device. (see page 3.15 - 6).

Checking the gas preload pressure of the diaphragm accumulators on the analog indicator in the drivers
cab.
-

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

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

The indicator on the manometer abruptly drops to zero when the available braking pressure falls below
a gas preload pressure of 555 bar.
Note

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

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


-

Install pressure gauge at test connection H 9.


Note

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

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

The indicator on the manometer abruptly drops to zero when the available braking pressure falls below
a gas preload pressure of 101 bar.
Note

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

Diaphragm accumulators speed adjustment


-

Driving engine switched off

Install manometer on the measuring point G1.

Repeatedly actuate the travel pedal to decrease the available pressure. Actuate the travel pedal so
that the pressure decreases slowly.

The indicator on the manometer abruptly drops to zero when the available braking pressure falls below
a gas preload pressure of 61 bar.
Note

3_15-3_4E
07.08

If the indicator on the manometer abruptly drops to zero outside the specified tolerance
range, the gas precompression must be corrected (see page 3.15 - 7).
LF-9.3

3.15 - 4

GHH Fahrzeuge GmbH


Pressure reduction armature and filling device

15

3_15-5_7E
07.08

LF-9.3

3.15 - 5

GHH Fahrzeuge GmbH


Checking the gas preload pressure on the diaphragm accumulator

Note

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

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

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

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

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

Warning

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

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

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

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

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

Note

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

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

Unscrew filling device (6) from the diaphragm accumulator.

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

Warning

3_15-5_7E
07.08

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

LF-9.3

3.15 - 6

GHH Fahrzeuge GmbH


Correcting the gas preload pressure
Pressure reduction
-

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

If the manometer (12) indicates the correct gas preload pressure, lock up the drain screw (5) until no
more nitrogen escapes.

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

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

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

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

Pressure increase
-

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

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

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

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

Open the shut-off valve (17).

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

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

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

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

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

Unscrew filling device (6) from the diaphragm accumulator.

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

3_15-5_7E
07.08

LF-9.3

3.15 - 7

GHH Fahrzeuge GmbH


Changing of in-line filter element
Replace filter element when at normal operating temperature and high idling speed the red pin projects
out of the maintenance indicator (see 3.16 - 3). If the vehicle is fitted with an electric-type maintenance
indicator, the necessary change of filter is indicated to the driver by a signal lamp in the drivers cab.
The following work must be performed to replace the filter element:
-

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

Clean the complete filter on the outside.

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

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

Replace filter element.

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

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

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

Maintenance indicator elktr.


Maintenance indicator visual

plug
5

3_15-8E
07.08

LF-9.3

3.15 - 8

GHH Fahrzeuge GmbH


Changing the filter element in the pressure filter
The following work must be performed to replace the filter element:
Also outside the maintenance intervals the filter element must be replaced whenever the indicator light
(H8) return pressure/brake filter lights up weakly (see 3.16 - 4).
-

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

Clean the complete filter on the outside.

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

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

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

Disassemble filter insert by unscrewing the fixing nut (10) and pulling off the sleeve (7) together with
the filter element (6). Make sure that the sleeve (7) is not damaged.

Remove filter element (6) from the sleeve (7) and dispose of the filter element in an environmentallyfriendly manner. Clean the remaining parts of the filter insert.

Fit new filter element (6) in the sleeve (7). Make sure that the filter element stands upright on the bottom
of the sleeve and comes flush with the upper side of the sleeve.

Assemble filter insert (4, 6, 7 and 10) and fit in the filter housing (8) with new gasket (5). Make sure
that the gasket sits correctly.

Install spring (3), screw on cover (1) with new gasket (2) and tighten up.
1
2
3
4
5
6

7
8
10

11

3_15-9E
07.08

12

LF-9.3

3.15 - 9

GHH Fahrzeuge GmbH


Service brake - Checking for disk wear

Warning

Checking for disk wear is to be performed with the brake pedal depressed.

The reference dimension for the disk wear check is stamped on the axle housing below the measuring
hole.
The reference dimension X is measured on the piston through the measuring hole.
-

Remove dirt, paint or any burrs in the vicinity of the measuring hole.

Remove plug from measuring hole.

Using an appropriate measuring instrument, measure the distance from the housing surface to the piston.

If the distance measured exceeds the reference dimension X by more than 2.0 mm, check the brake
and replace, if necessary.

After the works, screw in the plug and tighten.

housing
surface

Measuring hole

Warning

After replacement of brake disks restamp new control dimension, if necessary.

031821E

LF-9.3

07.08

3.15 - 10

GHH Fahrzeuge GmbH


KESSLER+CO installation instructions

Warning

Preloading or unloading of the springs shall not be carried out via the brake screwing
(12). Opening of the brakes should preferably be carried out at Kessler+Co.
The complete brake can be removed from the axle trumpet by loosening the screwing
(13).

12

11

10

13

3
5
2
1

Mounting brakes
1.

Check brake parts for cleanliness and burrs.

2.

Oil centering and sealing surfaces.

3.

Insert internal and external discs (2,3) into the brake housing (1) according to the lateral wheel drawing.

4.

Fit piston seals and guide rings (7) in intermediate piece (6).

5.

Mount O-ring (4) on the brake housing.

6.

Fit intermediate piece (6) taking into account the hole spacing on the brake housing (1).

7.

Fit piston (5) taking into account the hole pattern of the springs and the screw holes of the intermediate part (6). Caution: do not tilt the piston!

8.

Insert springs (8) into the piston. The number of springs is indicated on the installation drawing.
(When using fewer springs than the number of holes provided, make sure that they are distributed
symmetrically!)

9.

Mount O-ring (9) on the brake support (10).

10.

Put brake support (10) on the springs (8). Pay attention to the location of the cooling oil inlet or oil
outlet hole! Screw in partially 4 screws (12) for accurate positoning of the brake support.

11.

Using an appropriate press and die (11), press together the brake support (10) and the brake housing (1). For the required preloading force, see installation drawing.

12.

Put all screws under the press (11) and screw down at the specified tightening torque. Slowly raise
the press die.

13.

Fix the warning plate to the brake and imprint the preloading force as indicated on the installation
drawing.

3_15-11_12E
07.08

LF-9.3

3.15 - 11

GHH Fahrzeuge GmbH


Dismounting brakes
Dismounting of the brakes occurs in the reverse order specified in the installation instructions for mounting
of the brakes.

Caution

3_15-11_12E
07.08

The brake is preloaded. Preloading force see warning plate. Before loosening the
screwing (12) of the brake, the brake must be held together using a press and die (11)
suitable for the preloading force specfiied. After all screws have been removed, the
press die (11) can be slowly raised until the springs are unloaded.

LF-9.3

3.15 - 12

GHH Fahrzeuge GmbH


3.16

Brake system description

Legend to brake system


Item.

Qty.

Description

gear pump

high-pressure filter

accumulator charge valve

treadle brake valve

relay valve

diaphragm accumulator, preload pressure 55 bar

pressure gauge

10

pressure relief valve

11

pressure relief valve

12

non-return valve

13

non-return valve

18

hand pump

19

parking brake valve

23

nozzle

26

pressure filter

27

pressure relief valve

30

pressure switch

31

pressure switch

32

pressure switch

33

pressure switch

720

hydraulic block

722

distributor block

723

hydraulic block

LebremsE
07.08

LF-9.3

3.16 - 1

GHH Fahrzeuge GmbH


Functional description of hydraulic brake system
Pressure supply system
The operating fluid is tapped from the hydraulic tank. For pressure supply a gear pump (1) is flanged to
the torque converter.
Via the suction line the hydraulic oil is drawn from the hydraulic reservoir and directed via the line filter
(2), the shut-off valve (3) and the hydraulic block (720) to the diaphragm accumulators.
After the cut-off pressure is reached, the shut-off valve (3) redirects the entire pump flow to the hydraulic
reservoir via the cooling system of the multi-disk brakes and the pressure filter incorporated into the return
line to the hydraulic reservoir.
After the cut-off pressure has fallen by approx. 15%, the diaphragm accumulators are recharged via the
shut-off valve (3).
The pressure is indicated to the drive by a pressure gauge (9). At a pressure drop to below the cut-in pressure, the Available pressure signal lamp in the drivers cabin lights up as a warning, turned on by the
pressure switch (32) (S53).
The pressure relief valve (10) protects the whole system against excess pressures.

Service brake
To operate the service brake, the brake pedal (5) is depressed. The hydraulic pressure controlled by the
force exerted by the foot flows via circuits I+II to the front-axle brakes and rear-axle brakes. As the brakes
are released, the brake pressure is decreased towards the hydraulic tank.
A mechanical stop on the running plate limits the brake pressure and a further stop ensures the pressureless condition of the service brake.
Residual brake pressure monitoring
Connection 24 of the pedal-type brake valve has a built-in pressure switch (31) (S52). At a hydraulic
brake pressure of 3-6 bar, this switch causes the indicator light service brake to be displayed in the drivers field of vision.
This device is intended to remind the driver to take his foot off the brake pedal after each braking operation.

Caution

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

Blocking of forward and reverse tramming


The brake has a built-in pressure relief valve (27), which, after applying the service brake and upon reaching the pressure set on the valve, emits a pulse in order to enable the forward/reverse interlock.
Prior to each driving direction change you must step on the service brake, with the gearshift lever in neutral, and hold it until the gearshift pressure is reached. The hydraulic interlock of the gearshift mechanism
is then deactivated via the pressure limiting valve (27).

3_16-2_5E
07.08

LF-9.3

3.16 - 2

GHH Fahrzeuge GmbH


External cooling of multi-disk brakes

Caution

Operation without cooling will destroy the multi-disk brakes.

The pump flow is distributed via the shut-off valve (3) for charging of the diaphragm accumulator and cooling of the disk brakes. With filled diaphragm accumulators of the pressure supply system, the entire pump
flow is routed via the shut-off valve (3) to the distributor block (722) where the hydraulic pressure is built
up and evenly distributed over the multidisk brakes via 4 nozzles (23).
The cooling flow is introduced at the centre of the multi-disk brake and flows through the disks. Through
the outlet arranged on top the cooling flow is returned to the transmission oil sump. A sufficient oil flow
is a precondition for cooling of the disk brakes.
Fouling of the nozzles or any restriction in the cooling pipes causes the built-up pressure in the distributor
block to rise.
Warning

If the LCB cooling dynamic pressure as measured during maintenance should be in


excess of the maximum pressure indicated in the system drawing, check the cooling
system and repair a fault.

In case the nozzles should be clogged completely, the pump flow returns to the hydraulic tank via the pressure relief valve (10) and the brakes are uncooled.
This is indicated to the driver by the pressure as indicated by the pressure gauge (9) rising to 180 bar.
To avoid damage to the seals of the disk brake, the cooling pressure within the brake housing shall not
exceed 1.0 bar at high idling speed.

Monitoring of line filter


To protect the brake system against damage caused by contamination, a line filter (2) with a fine-filter element is mounted between the gear pump (1) and the shut-off valve (3). An optical maintenance indicator
is used for monitoring the filter contamination. Increasing contamination of the filter element results in an
increased differential pressure between the inlet and outlet side. As soon as the differential pressure has
reached the max. permissible value, the maintenance indicator indicates that the filter element has to be
replaced.

Warning

3_16-2_5E
07.08

If further contamination causes the differential pressure to increases beyond the max.
permissible value, the built-in safety valve will open to allow the medium to flow unfiltered into the brake system circuit. This may cause damage to the components of this
system and lead to failure of the service brake.

LF-9.3

3.16 - 3

GHH Fahrzeuge GmbH


Monitoring on pressure filter
To protect the hydraulic system from contamination damage, a pressure filter (42) and a pressure switch
(S47.2) have been built into the return line from the brake system to the hydraulic reservoir. The pressure
switch (33) (S47.2) is used for monitoring the return pressure (filter contamination). If the pressure present
at the pressure switch increases beyond 0.6 bar, the indicator light (H8) return pressure/brake filter lights
up weakly to indicate that the filter element must be replaced. To prevent the filter element from bursting,
the latter cuts out when an excess pressure is present to let the oil flow unfiltered into the hydraulic reservoir. This may result in damage to all hydraulic components.

Parking brake
Warning

When exiting the drivers cab the parking brake should, as a rule, be applied manually
via the control lever.

To release the parking brake, pull the control lever out of the detent and move forward. From connection
2 of the hand brake valve (19) the hydraulic release pressure flows to the spring accumulator cylinder
and neutralises the spring force acting on the parking brake.
When applying the parking brake the pressure towards the hydraulic reservoir is reduced via the hand
brake valve (19). To apply the parking brake, move the control lever backward until it locks into place.
The vehicle may only be moved when the parking brake is completely released.

Caution

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

The pressure switch (30 (S51) activates the indicator light parking brake in the drivers cab to indicate
that the parking brake is not released completely.

3_16-2_5E
07.08

LF-9.3

3.16 - 4

GHH Fahrzeuge GmbH


Emergency release of parking brake

Caution

Emergency release of the parking brake may only be performed on an operational parking brake system. After the emergency release only restricted operation without cooling
of the brakes will be possible.

In case of a driving engine failure, the parking brake can be released by means of the hand pump fitted
on the right side and after checking the release pressure indicated on the manometer.
Warning

Prior to the emergency release, check the oil level in the hydraulic reservoir and top up
to the Max. mark, if necessary.

Secure the vehicle against rolling away.

Place gearshift in neutral, switch on operating voltage and put lever for the parking brake in the release
position.

Plug the lever on the fitting of the hand pump and manually build up the pressure in the parking brake
circuit until the manometer indicates a pressure of > 120 bar.

Tow vehicle, see section 2.6, page 2.6 - 5.

Warning

After releasing the parking brake, the vehicle can be stopped once by applying the parking brake. To release the parking brake again, the pressure must again be built up to
> 115 bar.

fitting
hand pump

3_16-2_5E
07.08

manometer

LF-9.3

lever

3.16 - 5

GHH Fahrzeuge GmbH


3.17

Hydraulic system

The hydraulic system includes the


Steering and dump/hoist hydraulic systems
Converter transmission hydraulic system
The steering and dump/hoist hydraulic systems are supplied with oil by a pump from a common hydraulic
tank. The hydaulic tank is mounted to the engine chassis and in addition to all connections includes the
fill-level indicators and the oil return filter.
Steering and dump/hoist hydraulic system
The vehicle is equipped with a swivel-joint hydraulic power steering system. The oil flow from the pumps
is directed to the steering valve and to the dump/hoist valve. The steering valve or a steering lever operates
the steering valve, while the control lever (dump/hoist control) operates the dump/hoist valves and pressurizes the hydraulic cylinders.
Hydraulic tank
8

Aeration/ventilation filter

1
max

min.

Filler screw cap

Level indicator

Screw

Bar

Cover

Return filter

Drain plug

Aeration/ventilation filter unit

3_17-1E
07.08

LF-9.3

3.17 - 1

GHH Fahrzeuge GmbH


Checking of oil level
Note

To check the oil level, park the vehicle on a level surface. Check the oil level with the
engine running and with retracted cylinders.

The oil level check must be carried out on the level gauge of the hydraulic reservoir. The oil level must
lie between the top and bottom level marks. If the oil has dropped below the bottom level, the hydraulic
system must be checked for leaks and the oil topped up to the top level mark on the level gauge.

Level monitoring
The oil level in the hydraulic tank is continuously monitored by a level switch. If the oil drops below the
min. level, this is indicated by signal lamp (H10) Hydraulic oil level. Check the hydraulic system for leaks
and top up oil to the max. mark on the oil level indicator.

Topping up hydraulic oil


Note

Top up hydraulic oil to maximum mark with engine stopped and retracted cylinders.

The oil may only be topped up at the special filling screw plug on the hydraulic tank. Only here is it ensured
that impurities are filtered out by the return filter before the oil flows into the hydraulic tank.

Return filter
To protect the hydraulic system against fouling damage a return filter with magnetic element has been
fitted in the hydraulic reservoir. An electric service signal monitors the filter plugging. As the plugging of
the filter element increases the filter flow resistance also increases. At a flow resistance in excess of 1.3
bar, the indicator light (H8) return pressure/brake filter lights up brightly to indicate that the filter element
must be replaced. To prevent the filter inset from bursting it releases itself under excessive overpressure
and allows the oil to flow unfiltered in the reservoir chamber. This may cause the hydraulic components
to be damaged.

3_17-2_3E
07.08

LF-9.3

3.17 - 2

GHH Fahrzeuge GmbH


Changing of hydraulic oil
Note

Change hydraulic oil with stopped engine and the hydraulic cylinders retracted.

The drain plug is arranged on the underside of the hydraulic tank. After the tank has been completely emptied and cleaned, fill up to the maximum mark.
Warning

Vent hydraulic system after each change of hydraulic oil.

Venting the hydraulic system


After components of the hydraulic system have been replaced, it is necessary to expel the air that has
entered.
To do so, subject the hydraulic tank to a slight overpressure of 0.5 bar. As soon as oil flows out of the vent
port bubble-free, screw on plug and tighten firmly. Only then is the tank to be de-pressurized. After changing the oil, start engine and operate hydraulic equipment. Check oil level again and top up, if necessary.
The cylinder lines and the cylinders themselves should be vented well to prevent the diesel effect and to
preserve the sleeves. Under pressure, the oil contained in the system dissolves in the hydraulic oil. This
oil penetrates the sleeve fabric. As soon as the system pressure drops, the air comes out of the sleeve
again and destroys it.
The intake pipes must be observed with special care.
-

If there is an intake pipe leak, the vacuum in the pipes will draw in air. Air in the hydraulic system causes
cavitation damage to pumps, valves and cylinder seals.

A restricted suction cross-section, caused for example by a restricted hose, causes an increased intake vacuum and hydraulic pump failure.

Steering and dump/hoist hydraulic system pressure test

Note

Carry out pressure measurements while the hydraulic oil is at operating temperature.

To measure the steering pressure, a pressure gauge with a measuring range between 0 and 250 bar has
to be connected to the measuring points provided. The pressure indicated is the currently used steering
pressure. With the steering mechanism fully locked, the maximum pressure is measured.
To measure the working pressure, a pressure gauge with a measuring range between 0 and 250 bar has
to be connected to the measuring points provided. The pressure indicated is the currently used working
pressure. The maximum pressure is measured when the respective cylinder is operated against its stop.

3_17-2_3E
07.08

LF-9.3

3.17 - 3

GHH Fahrzeuge GmbH


Changing the filter element in the return filter
Also outside the maintenance intervals the filter element must be replaced whenever the indicator light
(H8) return pressure/brake filter lights up brightly.
To change the filter element, open the cover on the hydraulic oil tank by loosening the screws and removing
the catch (see page 3.17-1).
The following work must be performed to replace the filter :
-

Remove spring (3) and the complete filter insert consisting of (2 -5, 7 and 8).

Disassemble filter insert by unscrewing the fixing nut (8) and pulling off the filter element (5).

Dispose of the filter element (5) in an environmentally-friendly manner. Clean the remaining parts of
the filter insert.

Assemble filter insert using new filter element (5) and new gaskets (4, 7).

Install filter insert in the hydraulic oil tank with new gasket (3). Make sure that the gasket sits correctly.

Install spring (1) and assemble the cover on the hydraulic oil tank by using the screw and the catch.

1
2

3
4

6
Gasket for
hydraulic oil tank

8
9

3_17-4E
07.08

LF-9.3

3.17 - 4

GHH Fahrzeuge GmbH


Oil/air cooling system
The cooling system is normally maintenance-free. Under specific conditions, however, contaminations
may occur.
Removal of contaminations:
-

Minor contaminations can be brushed off.

In case of major contaminations, clean the radiator net against the air flow direction, using compressed
air or a steam-jet cleaner (a cold-cleaning compound can be added).
If necessary, dismount the cooling system and remove fan and drive.

Warning

Make sure not to damage the fins of the radiator net.

If necessary, complete the cooling system, i.e. fit fan and drive.

If necessary, reinstall the cooling system. Check fan for direction of rotation (see identification) and
smooth operation.

Warning

033650E
07.08

After replacing parts and topping up, the system must be vented. Air in the system may
lead to reduced performance and vapour locks.

LF-9.3

3.17 - 5

GHH Fahrzeuge GmbH


3.18

Steering and dump/hoist hydraulic system description

Legend to steering and dump/hoist hydraulic system


Item

Qty.

Description

steering cylinder

hoist cylinder

dump cylinder

gear pump

hydraulic motor

13

pressure relief valve

15

booster valve with integrated priority valve.

16

Orbitrol

17

cooler without motor

18

directional control valve

20

filter

21

valve unit with accumulator, preload pressure 10 bar

22

pressure reducer valve (servo valve)

24

direction control valve

28

direction control valve

29

direction control valve

36

non-return valve

39

non-return valve

40

filter

42

shuttle valve block

66

hydraulic block

LehydrE
07.08

LF-9.3

3.18 - 1

GHH Fahrzeuge GmbH


Pressure oil supply
The steering and dump/hoist hydraulic system is supplied with pressure oil by the pumps mounted on the
torque converter.
The intake of each pump is connected to the hydraulic tank via the intake pipes. With the steering mechanism not operated, the pump delivery flow is routed on via the priority valve to the dump/hoist hydraulic
system.
When the steering wheel is operated, an LS-signal is applied to the priority valve via the Orbitrol valve.
The pumps delivery flow is thus available to the steering hydraulic system.
The system pressure of the steering hydraulic system is limited by the primary pressure control valve integrated in the priority valve. Once the system pressure has been reached, the pump delivery flow is routed
on to the dump/hoist hydraulic system.

Filtering of hydraulic oil


A full-flow return filter is installed in the return chamber of the hydraulic reservoir for filtration of the entire
pump delivery flow.

Filter

Filter mesh

Soiling indicator

10 m

electrical type
or
analog indicator
see Section 2.3

Return filter

Steering hydraulic system


The steering system is designed as a hydraulic power steering system.
It is activated via a steering wheel-operated rotary slide valve (Orbitrol valve) and downstream booster
valve with integrated priority valve.
When operating the steering wheel, pressure oil is routed to the booster valve through the metering pump
installed in the Orbitrol valve. At the same time, via connection LS, the control signal for the priority valve
is transmitted. The priority valve is reversed and the pump delivery flow reaches the booster valve. The
booster valve boosts the volume flow of the metering pump at a ratio of 1:5, delivering the flow in line with
the direction controlled by the steering wheel, to the steering cylinders via connection CL or CR.
The pressure control valve installed in the delivery line towards the steering cylinders protects the secondary side of the steering mechanism against pressure shocks transmitted from the roadway to the steering
system.

032020E
07.08

LF-9.3

3.18 - 2

GHH Fahrzeuge GmbH


Dump/hoist hydraulic system
Directional control valve
In the dump/hoist valve two hydraulically operated directional control slides for boom or bucket operation,
respectively, are installed. For finger-tip bucket and boom control, fine- control grooves are provided in
the piston, which will permit the driver to set any lifting and lowering speed or any bucket tilt-back/dump-out
speed between zero and maximum.
If both slides are operated simultaneously, the operation requiring the lowest pressure will be carried out
first, followed by the other operation.
Control-oil supply
Control oil is supplied from the control oil unit, an accumulator which is charged from the pump delivery
line.
Hydraulic pilot control
The driver controls the required bucket and boom functions via the (dump-hoist) control lever direction.
The movement of the control lever determines the amount of pressure applied to the master piston of the
dump-hoist valve.
Servo valve
The servo valve includes four pressure-reducing valves to activate the tilt back bucket and raise/lower
boom functions, as well as one directional control valve for activation of the float position.
With the control lever not operated, all control-pressure lines towards the hydraulic oil tank are depressurized.
When moving the control lever, a control pressure proportional to the control lever movement is built up
in the outlet duct of the activated pressure-reducing valve.
Two pressure-reducing valves at a time can be activated by a diagonal movement of the control lever.

Caution

Even with the engine shut off, the control manifolds may be activated because of the
accumulator installed in the control oil supply system. Of course, only movements due
to bucket and boom deadweight can be performed. Before starting maintenance work
on the control system the accumulator has to be discharged by operating the control
lever several times.

Float position
If the control lever is operated in Lower bucket direction beyond the pressure point, outlet five of the
servo valve is pressurized and the directional control valve activated. This will set the bucket to floating
position. Through the directional control valve the secondary valves are depressurized towards the dump
cylinder.

033240E
07.08

LF-9.3

3.18 - 3

GHH Fahrzeuge GmbH


3.19

Converter-transmission hydraulic system description

Converter charging pump


The converter charging pump is mounted to the torque converter and is directly driven by the diesel engine. The pump takes in oil from the transmission sump and delivers it via the pressure filter into the converter housing.

Pressure filter
The pressure oil is cleaned by the pressure filter. If the filter is soiled, the overflow valve allows the oil to
pass unfiltered.

Torque converter
The torque converter is bolted to the drive engine to form a unit.
The rotating parts are coupled to the engine flywheel via an elastic coupling. At the rear end of the torque
converter, flanging points for the connection of hydraulic pumps are provided in addition to the output
flange for the drive unit.
The oil flow from the converter charging pump is preloaded to 16.8 to 19.6 bar by a valve mounted to the
converter. This pressure is admitted to the multi-disc clutches in the power shift transmission.
The surplus oil flows to the torque converter for filling and cooling it. A safety valve protects the internal
parts of the torque converter against excessive pressure. The spur gears in the converter housing are
lubricated by spray nozzles. The oil flowing off is collected in the converter oil sump from where it flows
unpressurized to the transmission.
The second stage of the converter pump is used to drain the converter. The pump conveys oil from the
converter sump to the transmission sump.

Oil cooler
The oil flowing out of the torque converter has the highest temperature and is directed straight to the oil
cooler. The cooled oil flows to the lubricant distributor of the power shift transmission. The maximum temperature of the converter/transmission hydraulic system must not exceed 120

Power shift transmission


The travel direction valve switches the neutral position or pressurizes the forward or reverse clutch, respectively.
Depending on the gear selected, the gear selector valve pressurizes the relevant clutches. The lubricant
distributor distributes the oil coming from the cooler over the lubrication points of the power shift transmission.
033521E
07.08

LF-9.3

3.19 - 1

GHH Fahrzeuge GmbH


3.20

Torque converter operation

2
3

6
5

Driven by the engine

Turbine wheel

Stator (nozzle ring)

Hydraulic pump

Auxiliary drive main gear

To transmission

030580E
07.08

LF-9.3

3.20 - 1

GHH Fahrzeuge GmbH


Description of torque converter

Configuration and requirements


The torque converter is connected to the drive engine. Flanging points for hydraulic pumps are located
on the rear end of the torque converter together with the output flange for the transmission.
The primary function of the torque converter is to ensure smooth tramming over the selected speed ranges, to automatically match the vehicle speed to changes in tramming and gradient negotiation resistance
and to increase the torque to a multiple of engine torque.
The actual converter section comprises the following three major items which form the hydraulic transmission:
impeller
turbine wheel
Stator (nozzle ring)
In the impeller, which is rigidly coupled to the engine flywheel, the fluid (ATF oil) is accelerated outwards
and then led to the turbine wheel where it is decelerated again owing to the arrangement and curvature
of the blades. This causes the kinetic energy of the fluid to be converted back to mechanical torque and
speed. The turbine is coupled to the converter output flange which in turn is coupled to the transmission
input. The output torque of the torque converter is a function of to which extent the input speed exceeds
or falls below the output speed.
Oil delivered by the turbine is led to the stator which is stationary in the converter and has the task of delivering oil to the impeller by means of its blades such that the inlet losses on the impeller are reduced to a
reasonable level. At this point, too, torques occur which are not utilized, however. The sum of all torques
in the converter is zero, which means that the stator absorbs the difference between impeller and turbine
torque.
High relative velocities occur in the converter section between impeller, turbine and stator, resulting in oil
turbulences which, in turn, cause localized pockets of insufficient pressure which suddenly collapse. This
collapse of the resulting vapor locks causes pressure peaks of such an intensity that the blading would
be subject to excess mechanical loading. For this reason the fluid is preloaded, thus preventing vapor
locks and their resulting negative consequences (cavitation). Oil leaving the hydraulic transmission has
gained temperature in the converter substantially and is directed to the oil cooler.
From the preloaded converter section, ducts branch off to provide sufficient lubrication to roller bearings
and gears by means of injector nozzles.
Pump drives
Torque converters in our loaders always also accomodate the pumps for filling the converter and supplying
the transmission, steering and dump/hoist pumps. As can be seen from the diagram, the pumps are directly driven by the engine.
The power flow is from the impeller to the central auxiliary drive main gear. Each pump drive, in turn, is
provided with its own gear which is coupled to the corresponding pump and mates with the main gear.
Hints on operation
The torque converter considerably facilitates vehicle control to the operator.
The operator, therefore, need not change gears immediately for a change of incline. The operator may
also run the engine at a reatively high speed, thus ensuring that sufficient quantities of oil are always available for the steering and dump/hoist hydraulic systems. In normal operation the oil temperature should
be between 80 and 90C. It may be heated up to 120C for short periods of time.
030580E
07.08

LF-9.3

3.20 - 2

GHH Fahrzeuge GmbH


3.21

3_21E
07.08

LF-9.3

3.21 - 1

GHH Fahrzeuge GmbH


3.22

Electrical equipment

Caution

Disconnect electrical equipment before beginning to work on it and protect it against


unauthorized restarting.

The alternator, which is driven directly by the engine, supplies 24V for the vehicles electrical equipment.
Two series-connected batteries will assist in starting the engine.
Electrical equipment components
Battery
The two series-connected 12 V batteries of the electrical system are arranged in the battery compartment.
For maintenance and servicing of batteries observe the following:
-

Keep batteries clean and dry to avoid leakage currents.

The terminals of the batteries must have good contact.

Loose clamps or sulphatized battery poles (green-white coating) will affect current transmission.

Keep contact faces clean and grease with acid-proof grease.

Check liquid level and charging condition of batteries regularly.

There must be an approx. 10 mm liquid level on top of the battery lead plates.

Top up with distilled water only.

Check charging condition using a voltage tester or an acid siphon.

Make sure that there is correct polarity when changing batteries.

Charging the batteries


The batteries can be re-charged either by operating the vehicle for several hours (via alternator and controller) or by using an externally connected charger.
For re-charging with a charger note the following:
-

Disconnect batteries from onboard system (battery switch).

Maximum charging current: 10 % of battery capacity (e.g. charge 165 Ah battery with a maximum charging current of 16.5 A).

Check acid level, fill up distilled water, if necessary.

Caution

3_22-1_2E
07.08

Explosive gases are developed during charging. Do not smoke, use open flame and
make sure there are no sparks.
LF-9.3

3.22 - 1

GHH Fahrzeuge GmbH


Three-phase alternator
Apart from regularly servicing the V-belts, mind the following instructions:
-

Operate the alternator only with appertaining controller and connected battery.

When testing the engine without batteries, disconnect V-belt and cables from alternator.

Before carrying out electric arc welding on the vehicle disconnect all cables from the alternator.

The resistor connected in parallel to the LED of the alternator charging control lamp serves for pre-excitation of the alternator.

Circuit breakers/Plug-in fuses


Circuit breakers or plug-in fuses protect the various circuits.

Battery switch
The battery switch installed in the battery box insolates the two series-connected batteries from the onboard elecrical system. The battery switch should only be switched on or off when the engine is standing
still.

External-starting socket
If the battery is discharged, the engine of the vehicle can be started using an external power supply and
jump-start cable at the external starter socket.

Lighting system
The vehicle is equipped at the front and rear with respectively two and four headlamps with parking light,
low beam and high beam. Three headlamps for material face lighting are fitted on the roof of the drivers
cab.
The lighting system is switched on and off with the three-position rotary switch (S72) in the drivers cab.
In the first position, the parking light in the front and rear headlamps and the material face lighting are
switched on. In the second and third positions, the low beam and the high beam in the front and rear headlamps are switched on.

Warning equipment
An audible warning device is installed in the form of a horn, which sounds when the horn push-button (S86)
is pressed.

3_22-1_2E
07.08

LF-9.3

3.22 - 2

GHH Fahrzeuge GmbH


3.23

3_23E
07.08

LF-9.3

3.23 - 1

GHH Fahrzeuge GmbH


3.24

TOTAL powder-type fire extinguisher

A hand fire extinguisher is installed at the front left of the fender.

6
9

2
1
3

4
10
5

8
2
Fig. 2
Hand fire extinguisher
1
Quick-release lock

Filling opening with striking valve

2
3

Hose with extinguishing pistol


CO2-bottle

7
8

Safety valve
Handle

4
5

Dunlop-valve
Riser pipe

9
10

Hinged protective cap


Extinguishing-substance vessel

031981E
07.08

LF-9.3

3.24 - 1

GHH Fahrzeuge GmbH


Handling of TOTAL powder-type fire extinguisher

Caution

It is absolutely necessary to follow, in the g iven order, the notes on the extinguisher for
operating the device.

For an extinguishing service open the quick-release lock of the protective cap, fold up the cap and clear
the hose with the extinguishing pistol. Then press down with force the nickel-plated button of the striking
valve or strike it down by hand. This will cause piercing of the seal foil of the CO2 bottle inside the outer
container of the extinguisher. The carbon dioxide (CO2) will then flow into the holding chamber of the CO2
bottle and is discharged, via the Dunlop valve attached to the chamber, into the extinguishing-substance
vessel, where it fluidizes the extinguishing powder and pressurizes at the same time the vessel to the necessary service pressure. Only then, i.e. after pressing down the striking valve, must the extinguishing
pistol be operated and the fire be fought with the emerging powder cloud.
The extinguishing pistol can be stopped, allowing for repeated interruption of the extinguishing procedure
for short times.

Warning

As a matter of principle, the extinguisher must be refilled after each use, even if the fill
has not been completely used up. Only this will ensure complete readiness for service
at any time.

Note

The easily destructible green control foil under the striking head serves for checking
whether the valve has been actuated.

031981E
07.08

LF-9.3

3.24 - 2

GHH Fahrzeuge GmbH


Refilling of the extinguisher
-

Release the extinguishing-substance vessel and hose from pressure after each extinguishing service,
by operating the extinguishing pistol

First loosen lightly the closing cap with striking valve, using a suitable spanner, by 1 - 2 turns, to let
escape any pressure still present through the pressure release holes provided at the side of the closing
cap.

Open the closing cap, completely and remove the striking valve together with the CO2 bottle and the
holding chamber from the extinguisher vessel. Take off the rubber guide sleeve loosely placed on the
neck of the CO2 bottle and put it aside for placing it on the new, filled bottle.

Unscrew the pressure hose from the vessel and remove powder remainders still present in the hose
and in the riser pipe and also the pierced control foil.

Empty completely the extinguishing-substance vessel.

Clean the extinguishing-substance vessel, the fittings and the hose


Note

Never rinse with water.

Fit riser pipe and new control foil and screw the hose tightly on the nipple of the vessel top. Check extinguishing pistol for proper functioning, i.e. for free movement.

Fill 10 kg of well fluidized dry extinguishing powder, preferably by using a strainer funnel, into the vessel
(dont tamp it).

Warning

Only the TOTALIT-G-type extinguishing powder from TOTAL Foerstner & Co. must be
used.

Fit new CO2 bottle (original charge from manufacturers works) into the holding chamber, after placing
the rubber guide sleeve onto the bottle neck, i.e. with the metal plate facing upwards.
Note

Ensure, by weighing, that the CO2 bottle (without sleeve) contains the specified charge
weight. The charge weight is stamped on the bottle.

Fit the holding chamber with the CO2 bottle into the extinguishing-substance vessel. Make sure that
the flange edge of the chamber is properly and flatly supported and that the sealing face is free from
any powder residues.

Screw on tightly closing cap with striking valve and seal it together with the screwed cap of the spraying
hose.

Place the green control foil around the striking valve between striking head and cap, and seal it likewise.

Place the hose without kinks on the top part. When doing so, take care that the striking head remains
clear and avoid its actuation. Finally, close the protective cap and seal the quick-release lock tightly.
Note

031981E
07.08

Always heed the safety guidelines for inspection and maintening the fire extinguisher.
Refer to the inspection service of TOTAL for any further questions arising.
LF-9.3

3.24 - 3

GHH Fahrzeuge GmbH


3.25

Fault-finding table

Brake system LCB


Service brake
Fault
Insufficient effect

Overbraking - brakes blocked

031050E
07.08

Reason

Remedy

Low brake pressure

Check and correct available


pressure and brake pressure

Brake disks worn

Check for wear, replace brake


disks

Air in brake hydraulic system

Bleed brake system

Unsuitable brake disks

Use original GHH Fahrzeuge


GmbH spares

Annular piston stuck in brake


disk housing

Remove multi-disk brake and


repair

Excessive brake pressure

Check and correct available


pressure and brake pressure

Brakes overheated

Check coolant flow to brake


disks
Check residual brake pressure
with released brake - max. 0.5
bar
The driver must take his foot off
the brake pedal after each braking operation

LF-9.3

3.25 - 1

GHH Fahrzeuge GmbH


Hydraulic system
Fault
Noise in hydraulic system

Movements of dump/hoist equipment or steering too sluggish

Hydraulic system too hot

Low hoisting or steering force

No oil pressure

Reason

Remedy

Not enough oil in hydraulic tank

Top up with same oil grade

Pump draws air

Check intake pipe

Oil foaming

Check intake pipe

Pressure pipes vibrating

Tighten clip

Pressure relief valve buzzing

Check valve, replace if necessary

Air in system

Check oil level


Check intake pipe

Hydraulic activation faulty

Check activation

*) Electric activation faulty

Check activation

Pipe cross-section restricted

Replace pipe

Low hydraulic pressure

Adjust pressure

Pump defective

Replace pump

Not enough oil in hydraulic tank

Top up with same oil grade

Hydraulic activation is not reset.

Check activation

*) Electrical activation is not reset.

Check activation

Control piston of dump/hoist valve


will not return to neutral position

Replace valve

Pipe cross-section restricted

Replace pipe

Check laying of lines

Remove bends in lines laid

Pressure valve soiled

Clean valve, adjust pressure

Pressure valve misadjusted

Adjust pressure

Activation of raising function


defective

Check activation

Pump defective

Replace pump

Piston seal rings of hydraulic cylinders defective

Replace piston seal rings

Pump defective

Replace pump

Not enough oil in hydraulic tank

Top up with same oil grade

Clutch between converter and


pump defective

Replace clutch

*) For electric-hydraulic activation only.

030630E
07.08

LF-9.3

3.25 - 2

GHH Fahrzeuge GmbH


Torque converter-power shift transmission
Fault
Low clutch pressure

Low clutch pressure in one gear

Low converter pump power strainer

Converter operates noisily

High converter oil temperature

Insufficient power

Transmission cannot be shifted

Vehicle will not tram with gear


engaged

Reason

Remedy

Low oil level

Top up with same oil grade

Valve slide on clutch pressure control valve jammed open

Clean vlve slide and housing

Charging pump defective

Replace charging pump

Piston seal rings broken or worn

Replace seal rings

Clutch defective

Repair clutch

Low oil level

Top up with same oil grade

Intake strainer clogged

Clean intake strainer

Charging pump draws air

Tighten connections
Check intake pipe

Charging pump defective

Replace charging pump

Clutch wheels worn out

Replace clutch wheels

Charging pump defective

Replace charging pump

Bearings damaged in converter

Repair converter

Converter oil cooler soiled

Clean oil cooler

Low oil level

Top up with same oil grade

Charging pump draws air

Tighten connections
Check intake pipe

Oil seals worn

Repair converter

Charging pump defective

Replace charging pump

Low engine speed

Adjust engine

Converter overheated

see - High converter oil temperature

Electric activation faulty

Check electric activation

Control valve defective

Repair control valve

*) Gear shift lever or rod jammed


or movement restricted

Adjust gear shift lever or rod

*) Gear shift lever or rod bent

Straighten gear shift lever or rod

Electric activation faulty

Check electric activation

Directional control valve not activated

Check electric activation

Directional control valve soiled

Repair directional control valve

Low clutch pressure

see - Low clutch pressure

Clutch defective

Repair clutch

*) For mechanical gear shifting only.

030640E
07.08

LF-9.3

3.25 - 3

GHH Fahrzeuge GmbH


3.26

3_26E
07.08

Appendix

LF-9.3

3.26 - 1

GHH Fahrzeuge GmbH


4

System drawings

Service brake
Translation sheet pertaining to drwg. 909-1-055564

909-1-055564 D

Converter-transmission hydraulic system


Translation sheet pertaining to drwg. 909-1-055423

909-1-055423 E

Steering-dump/hoist hydraulic system


Translation sheet pertaining to drwg. 909-1-060145

909-1-060145

Electrical equipment

909-3-061249, sheets 1-15

4E
07.08

LF-9.3

4-1

GHH Fahrzeuge GmbH


Translation sheet pertaining to drwg. 909-1-055564
(Service brake)
Bauteil
Component

Messpunkt
Measuring point

Druck (bar)
Pressure

Ttigkeit
Activity

Abschaltventil
Shut-off valve

B4

Ein
on

kontrollieren
check

Trittplattenbremsventil
Treadle brake valve

B5+B6

Restdr. Bremse
Residual brake pressure

B5+B6

max. 0.5
kontrollieren
bei hohem Leerlauf check
at high idling speed

Drucksch. S51
Pressure switch

B7.1 / B7.2

steigend / fallend
rising / falling

auf Prfst. einstellen


set on testing stand

Drucksch. S53
Pressure switch

B4

fallend
falling

auf Prfst. einstellen


set on testing stand

steigend
rising

auf Prfst. einstellen


set on testing stand

Drucksch. S47.2
Pressure switch

Aus
off

einstellen
set

Druckbegrenz. Pos. 11
pressure relief valve

B5
Manometer

Druckbegrvent. Pos. 27
pressure relief valve

B5

Vorratsdruck
Available pressure

Manom. Pos.9
gauge item 9

Pumpe Saugdruck
Pump intake pressure

B9

max. 0.3
kontrollieren
bei hohem Leerlauf check
at high idling speed

Kuehldruck
Cooling pressure

BB24-B27

max. 1.0 / 5
kontrollieren
bei hohem Leerlauf check
und Feststellbremse aufgelegt.
at high idling speed and applied parking brake

Druckgeflle
Pressure gradient

B24 + B28
B25 + B29

B24 groess. als B28 kontrollieren


B25 larger than B29 check

Druckgeflle
Pressure gradient

B26 + B30
B27 + B31

B26 groess. als B30 kontrollieren


B27 larger than B31 check

Staudruck
Dynamic pressure

B11

hoh. Leerl.
kontrollieren
at high idling speed check

Speichertest
Test of diaphragm
accumulator

B4

145 nach
kontrollieren
5 Bremsungen min. check
95 bei Motor aus
after 5 brakes min. 95 engie switched off

Dichtigkeit
For leakage

B4

145 nach 1Std. min. kontrollieren


100 bei Motor aus check
after one hour min. 100 engie switched off

Feststellbremse
Parking brake

B7.1 + 7.2

gelst min.115
kontrollieren
aufgelegt max.0,5 check
released min.115 / applied max.0.5

4E
07.08

einstellen
set
(Umschaltung)
(switching)

auf Prfst. einstellen


set on testing stand
kontrollieren
check

LF-9.3

4-2

GHH Fahrzeuge GmbH


Motorteil / Lastteil
Drive unit / payload unit
Anschlsse Bremse / Brake connections
Khlung Rcklauf / Cooling outlet
Khlung Zulauf / Cooling inlet
Entlftung Betriebsbremse / Feststellbremse
Bleeding of service brake / parking brake
lablass / oil drain
Verschleissanzeige
Wear indicator
ACHTUNG
WARNING
Bremse steht unter Federvorspannung. (Vorspannkraft = 282 000 N). Arbeiten an der Bremse unter
Beachtung der Betriebsanleitung des Fahrzeugs und der Anleitung des Bremsenherstellers (Anweisung
Kessler 10.2506.3.)
The brake is preloaded. (Preloading force = 282 000 N). Mounting and dismounting the brakes must be
carried out in accordance with the Kessler+CO installation instructions 10.2506.3 (see Operating instruction page 3.15 - 11).
ACHTUNG
WARNING
Vor Arbeiten an der Bremsanlage an den Ventilen Pos.5 und Pos.19 durch mehrmaliges Bettigen,
Speicher entlasten.
Before working on the valves item 5 and item 19 of the brake system, depressurize accumulator by operating the brake several times.
Verschleissanzeige Kontrollmass:
Wear indicator control dimension
Bei betaetigter Bremse wird durch die Kontrollmassmessbohrung auf den Kolben gemessen. Das Kontrollmass neu ist im Gehaeuse unterhalb der Bohrung eingeschlagen. Ist das gemessene Mass um mehr
als 2,0 mm groesser, ist die Bremse zu kontrollieren und gegebenenfalls zu erneuern.
Actuate the brake and measure the checking dimension through the bore on the piston. The checking dimension new is marked on the housing below the bore. If the measured dimension exceeds this dimension by more than 2.0 mm, check the brake and replace, if necessary.
Bei Arbeiten an der Bremsanlage ist das Fahrzeug fachgerecht zu sichern.
Membranspeicher und Teile des Bremssystems stehen unter Vorspannung. Vor Arbeiten an der Bremsanlage ist daher der Druck im System abzubauen.
Nach Arbeiten an der Bremsanlage ist diese fachgerecht zu entlften und zu berprfen.
When working on the brake system the vehicle must be secured professionally.
The diaphragm accumulator and parts of the brake system are pressurised. Prior to working on the brake
system, the pressure in the system must be reduced to 0 bar.
After working on the brake system, it must be bled professionally and checked professionally before the
vehicle is put into service.

4E
07.08

LF-9.3

4-3

GHH Fahrzeuge GmbH


Pumpe ist nicht selbstansaugend
Pump not self-priming
Vor dem 1.Start und nach Reparaturen an der Pumpe, ist die Saugleitung der Pumpe mit l zu fllen.
Before starting the unit for the first time and following repairs of the pump, fill pump intake line with oil.
Trockenlauf zerstrt die Pumpe.
Dry running will destroy the pump.
Notlsung Feststellbremse
Beim Notlsen Handbremsventil in Stellung Lsen stellen. Vor Beginn der Notlsung auf ausreichenden
lstand im Hydraulikbehlter achten.
Nur eingeschrnkter Notbetrieb mglich: ohne Bremsenkhlung.
Abbremsung nur mit Feststellbremse mglich.
Emergency release of parking brake
For emergency release, put hand brake valve in position release. Prior to emergency release, check oil
level in the hydraulic reservoir.
Only restricted emergency operation possible: no cooling of brakes.
Braking only possible with parking brake.
Betriebsbremse + Feststellbremse jeweils separat an den entsprechenden Entlfternippeln jeder Bremse
einzeln entlftet.
B5* separat entlfetet.
Service brake + parking brake to be bled separately via the corresponding bleed nipple of each brake.
B5* to be bled separately.

4E
07.08

LF-9.3

4-4

GHH Fahrzeuge GmbH


Translation sheet pertaining to drwg. 909-1-055423
(Converter-transmission hydraulic system)
Lfteraufsatz(3/8 NPT, vom Getriebe) am hchsten Punkt zwischen Wandler und Getriebe montieren.
Mount fan support (3/8 NPT, on the transmission) at highest point between converter and transmission.
Anschluesse Regulationsventil / Connections regulating valve
Lastschaltgetriebe / Power shift transmission
Gang / Gear
Durchfluss von aussen nach innen / Flow from inside to outside.
Getriebe-Kupplungsdruck / Transmission clutch pressure
Regulationsventil in BG. 2701 / Regulating valve in assy. 2701
Anschluesse Getriebe / Connections transmission
Anschluesse Schaltventil / Connections speed change valve
Temperaturfhler / Temperature sensor
Sumpf / Transmission sump
Sauganschl. / Intake line connection
Anschlu B vom Regulationsventil / Connection B from regulating valve
vom Khler / from cooler
Sauganschl. Pumpe / Intake line pump
Translation sheet pertaining to drwg. 909-1-055421
(Steering-dump/hoist hydraulic system)
Lastteil / Motorteil - Payload unit / drive unit
Kippzylinder / Dump cylinder
Hubzylinder / Hoist cylinder
Lenkzylinder / Steering cylinder
Fahrerstand / Drivers cab
Zur Begrenzung Hubarm senken zwei Scheiben A8 unterlegen.
To limit lowering of boom, fit two washers A8.
Achtung
Beim Anschlu des Lftermotors die Drehrichtungsangabe auf dem Khler beachten.
When connecting the fan motor, note the direction of rotation as indicated on the radiator.
Wandler / Converter
SAUGROHR / Intake pipe
Rcklaufdruck / Return pressure
Lenkung links / rechts / Steering left / right
Hubarm heben / senken - Boom raised / lowered
Schaufel heben / senken - Bucket raised / lowered

4E
07.08

LF-9.3

4-5