MERLO P25.6 Instruction Manual Download Page 61 | Manualshive

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MERLO P25.6 Instruction Manual Download Page 61

5 - OPERATING INSTRUCTIONS

5 - 1

INDEX

INTRODUCTION ............................................................................................................................................................................ 2

GENERAL INFORMATION ............................................................................................................................................................. 2

RULES FOR LOAD TRANSPORT .................................................................................................................................................. 2

MACHINE OPERATING AREA ....................................................................................................................................................... 2

HOW TO HANDLE A LOAD ........................................................................................................................................................... 3

INSTRUCTIONS FOR STARTING YOUR MACHINE ..................................................................................................................... 5

INSTRUCTIONS FOR DRIVING YOUR MACHINE ON THE ROAD ............................................................................................ 10

INSTRUCTIONS FOR A CORRECT MACHINE USE IN THE VICINITY OF ELECTRICITY POWER SUPPLY LINES ............... 13

USE OF THE MACHINE DEPENDING ON WIND STRENGTHS ................................................................................................. 13

VISIBILITY .................................................................................................................................................................................... 14

EXTERNAL LONGITUDINAL STABILITY INDICATORS .............................................................................................................. 17

PICK AND CARRY ....................................................................................................................................................................... 17

END OF CHAPTER ...................................................................................................................................................................... 17

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Summary of Contents for P25.6

Page 1: ...ION MANUAL PAN25 07 AU CHASSIS AU KEEP THIS MANUAL WITH THE MACHINE AT ALL TIMES P25 6 Solo 3 moduli C6184487 Solo 3 moduli Solo 3 moduli M3 ZM2 03 EN M2 P256 AU 01 87 TRANSLATION OF THE ORIGINAL INST...

Page 2: ...04 2017 PUBLICATION DATE...

Page 3: ...2 STICKERS WITH CONTROL DESCRIPTIONS LEAFLETS IN THE CABIN 3 CONTROLS AND INSTRUMENTS 4 OPERATING INSTRUCTIONS 5 ORDINARY MAINTENANCE 6 SECURITY PERIODICAL INSPECTIONS 7 ATTACHMENTS AND OPTIONAL EXTRA...

Page 4: ......

Page 5: ...MISSIONING OR RECOMMISSIONING AFTER A LONG SHUTDOWN 3 MACHINE GARAGING 3 TYRES 3 ORIGINAL MERLO SPARES 4 MACHINE SCRAPPING 4 GUARANTEE 4 ORDINARY MAINTENANCE OPERATIONS 4 DRIVING THE MACHINE ON PUBLIC...

Page 6: ......

Page 7: ...contains The operator s manual is an integral part of the machine it shall be written in a language spoken or at least understood by the operator and be held in the document holding pocket behind the...

Page 8: ...nged period of time it shall be garaged in a place where it is not exposed to atmospheric agents and it shall be protected to avoid any damages Before being garaged the machine shall be cleaned down a...

Page 9: ...o the machine without prior written authorization from the Manufacturer always carry out all the maintenance operations prescribed by the Manufacturer always use Merlo original spare parts make sure t...

Page 10: ...at work if you stop your machine on sloping ground place wheel chocks if present under its wheels avoid operating you machine on a muddy sandy or soft ground never use the controls or the pipes on th...

Page 11: ...capacity is always available on board and refill it periodically inform machine operators about the measures to be taken in case of fire note that all fuels and most lubricants and hydraulic fluids ar...

Page 12: ...ced lift trucks whose validity applies at the time of publication of this manual The following table shows the sound power level Lwa measured TYPE OF MEASUREMENT SOUND PRESSURE LEVEL Guaranteed sound...

Page 13: ...ROL PANEL KEY WORDS 4 P1 CONTROL PANEL KEY WORDS 5 DASHBOARD KEY WORDS C 5 DYNAMIC LOAD CONTROL DISPLAY KEY WORDS D 6 DIMENSIONS P25 6 6 LOAD CHART 7 PERFORMANCE AND FEATURES 10 SERIAL NUMBER OF THE M...

Page 14: ...C Left hand side D Right hand side REF DESCRIPTION REF DESCRIPTION 1 Operator cab 8 Lift cylinder of telescopic boom 2 Engine and Battery compartment 9 Forks tilting cylinder 3 Front axle brake calip...

Page 15: ...rgency pump for the release of the parking brake 13 Spirit level 29 Steering selection lever 14 Accelerator pedal 34 Front windscreen wiper and screen washer switch 15 Brake pedal 35 Heating cock 17 S...

Page 16: ...lights switch 4 emergency flashing lights 11 Portable light socket 37 Parking brake selector 40 Push button for retraction of the telescopic boom if the joystick has been damaged or during maintenance...

Page 17: ...eating 209 Indicator lamp showing that button U on the joystick is pressed joystick enable button 226 Adjustment buttons for instrument panel settings C DASHBOARD KEY WORDS C REF DESCRIPTION 58 Coolin...

Page 18: ...6 DYNAMIC LOAD CONTROL DISPLAY KEY WORDS D REF DESCRIPTION 210 Light bar indicating the stability percentage of the machine S1 Display showing the operating functions of the machine P1 P2 P3 P4 P5 Sel...

Page 19: ...chapter ATTACHMENTS of this manual For a better comprehension of the load chart please refer to the example below A Maximum permitted slopes B Indication of the telescopic boom lift height C Name of t...

Page 20: ...L DATA section If it is necessary to replace one type of tyre with another model included in the list of authorised tyres first contact Merlo s Technical Support service since replacing the tyres may...

Page 21: ...2 MACHINE TECHNICAL SPECIFICATIONS 2 9...

Page 22: ...reach mm Speed Km h 1 st gear 2 nd gear 2500 5900 3280 0 35 GOODEAR SUPERKING 0 40 MITAS ENGINE Type KUBOTA V3307 DI T E3 Turbo InterCooler direct injection water cooling Power 55 4 kW 75 HP at 2600r...

Page 23: ...specific code C1190883 code that identifies the manufacturing decade C 2010 2019 the manufacturing year 1 2011 the manufacturing progressive number 1908 and the engine code 83 IDENTIFICATION AND TYPE...

Page 24: ...YPE OF BOLT 8 8 10 9 12 9 Nm lbft Kgm Nm lbft Kgm Nm lbft Kgm COARSE PITCH M3 x 0 5 1 8 1 0 18 2 6 2 0 27 3 2 0 31 M4 x 0 7 3 1 2 0 32 4 5 3 0 46 5 3 4 0 54 M5 x 0 8 6 1 4 0 62 8 9 7 0 91 10 4 8 1 06...

Page 25: ...3 STICKERS WITH CONTROL DESCRIPTIONS LEAFLETS IN THE CABIN 3 1 INDEX GENERAL REMARKS 2 INSIDE CAB STICKERS 2 OUTSIDE CAB STICKERS 4 LEAFLETS IN THE CAB 5 END OF CHAPTER 5...

Page 26: ...p and water solution Should they be damaged or illegible replace them with new original ones to be ordered from Merlo Technical Support Service and to be placed in the positions shown in the Operator...

Page 27: ...3 STICKERS WITH CONTROL DESCRIPTIONS LEAFLETS IN THE CABIN 3 3 STICKERS OF CONTROL PANEL P...

Page 28: ...3 STICKERS WITH CONTROL DESCRIPTIONS LEAFLETS IN THE CABIN 3 4 OUTSIDE CAB STICKERS...

Page 29: ...ondition Should they be damaged replace them with new ones to be ordered from Merlo Technical Support Service To consult the leaflets in the cab grab their protruding part then lift it and rotate it t...

Page 30: ......

Page 31: ...ESCOPIC BOOM 24 TELESCOPIC BOOM CONTROL JOYSTICK AND SELECTION OF THE DRIVE DIRECTION 1 24 HYDRAULIC OR HYDROSTATIC SYSTEM PRESSURE GAUGE 12 25 PEDALS 14 15 25 LEVER FOR THE ADJUSTMENT OF THE STEERING...

Page 32: ...ing towards the inside fig 3 WARNING The lower part of the driver s cab must always be closed both during transfers with the machine and when working OPENING THE CAB DOOR FROM THE INSIDE To open the c...

Page 33: ...ide of the cab release stop B1 by acting on its tongue C1 fig 8 completely close the upper part of the door and lock it into position by rotating handle A downwards in the direction shown by the arrow...

Page 34: ...then open the window pushing it forward to the desired position REAR WINDOW CLOSING Rotate the lever A on the side to the automatic stop position CAB LIGHTS The cabin internal courtesy light P is loca...

Page 35: ...weight direction R to tighten the suspension direction S to slacken the suspension BACK ADJUSTMENT 4 Sit with your back firmly against the seat back Lift lever L upwards to position the back to the r...

Page 36: ...reaches its maximum limit indicated by a red line and by the yellow light indicator switched on immediately turn off the engine and wait for it to cool down Also check the engine cooling liquid level...

Page 37: ...overturn prevention system The front overturn prevention system is activated and all controls are disabled 55 Crab steering Crab steering is engaged proceed with particular caution during transfers 5...

Page 38: ...that it starts from 0 0 again To reset the partial hour counter press the OK button for 3 seconds The total hour counter shows the total number of machine operating hours the counter starts working af...

Page 39: ...rking brake alarm With the engine running and the parking brake applied the forward reverse drive is selected Flashing Intermittent Front overturn prevention system control Function corresponding to w...

Page 40: ...larm remains off The safety device bypass function can be enabled in any configuration or operating condition of your machine NOTE To enable the emergency controls on your machine you need to turn sel...

Page 41: ...the machine automatically enters a safe mode and locks out the hydrostatic transmission In order to use the hydrostatic transmission again to move the machine forward backward the operator shall sit...

Page 42: ...suction from the outside of the cab lever in B position suction grid C visible air suction from the inside of the cab recirculation WARNING Do not put any object that could obstruct the air inlet of...

Page 43: ...s ensure maximum operating safety The following paragraphs provide all necessary information for the correct operation of the dynamic load control system installed on your machine Before operating you...

Page 44: ...izers if available expressed in metres 216 Telescopic boom lift angle expressed in degrees 219 Coloured indicator green amber red showing the position of the load being lifted on the carriage 220 Dyna...

Page 45: ...brightness in the daytime night illumination mode and the volume of the loudspeaker P2 press button P2 to switch on the video camera installed on the machine available as an option Each time button P2...

Page 46: ...menu bar press button P4 to change over from the daytime mode to the night mode for the illumination of display D and vice versa The system informs the operator about the selected mode by displaying...

Page 47: ...the manual one MANUAL WEIGHING In these conditions the approximate tolerance of the load readout should be about 5 of the maximum rated load The value of the load being lifted is to be considered a m...

Page 48: ...control to set the weighing mode 1 MANUAL 2 AUTOMATIC Is the manual mode selected symbol X appears with the MAN WEIGHING inscription next to it Is the automatic mode selected the Y symbol appears wit...

Page 49: ...the load capacity chart suitable for the machine attachment combination The 4 positions of switch 204 for the selection of the type of attachment installed are the following Fig 1 a AUTO self identifi...

Page 50: ...the cab Fig 5 For a better comprehension of both the self identification system and the manual selection of attachments a table is provided listing all graphic representations shown in field 222 of di...

Page 51: ...chments whose centre of gravity is no more than 1 5 metres ahead of the carriage The attachment installed on your machine is either not equipped with a self identification sensor or it was not automat...

Page 52: ...achine was correctly identified by the system The FLY JIB FLY JIB WITH WINCH attachment installed on the machine was correctly identified by the system Attachments whose centre of load gravity is 4 me...

Page 53: ...ittent audible warning signal in the cab The frequency of the signal increases as the load gets closer to 100 red zone value beyond 100 Fig 3 the machine has reached its longitudinal stability limit a...

Page 54: ...he rotation of thumb wheels R1 and R2 the further the wheel is rotated the faster the movement the rotation speed of the diesel engine the higher the engine rpm the faster the movement The movement st...

Page 55: ...RHEAD LINES in chapter OPERATING INSTRUCTIONS HYDRAULIC OR HYDROSTATIC SYSTEM PRESSURE GAUGE 12 WARNING During normal operating conditions of the machine the instrument must be left disconnected In ca...

Page 56: ...tor 20 next to the steering column is as follows Button F forward drive selection When forward drive is selected the indicator light LF located next to the steering column is steadily illuminated Butt...

Page 57: ...ntrol lever 24 to position 0 TAIL LIGHTS Fig N To switch on the tail lights turn the switch of control lever 24 to position 1 LOW BEAM HEADLIGHTS Fig P To switch on the low beam lights turn the switch...

Page 58: ...wheel to its end stop on one side for a few seconds then repeat on the other side WARNING Such correction can only be carried out when in corrected turn angle or crab mode even if the misalignment occ...

Page 59: ...on the windscreen longitudinal slope indicator B is available on the right window Each indicator is provided with 2 scales main scale X ranging from 35 to 35 with a 5 resolution precision scale Y rang...

Page 60: ......

Page 61: ...LOAD 3 INSTRUCTIONS FOR STARTING YOUR MACHINE 5 INSTRUCTIONS FOR DRIVING YOUR MACHINE ON THE ROAD 10 INSTRUCTIONS FOR A CORRECT MACHINE USE IN THE VICINITY OF ELECTRICITY POWER SUPPLY LINES 13 USE OF...

Page 62: ...one spot to another avoid sharp acceleration and braking while driving your machine from one spot to another always keep a low speed and take all possible safety measures to prevent the load being tr...

Page 63: ...etres Fig 6 rotate the carriage a few degrees upwards and completely retract the telescopic boom Fig 7 MANOEUVRING A CIRCULAR SHAPED LOAD For handling circular shaped loads barrels cans etc installati...

Page 64: ...d approach the load with care lifting and extending the telescopic boom the minimum possible or if necessary slowly advancing the machine Fig 8 position the forks under the load taking care that they...

Page 65: ...ing light on top of the cab never transport passengers in the cab and in no other part of the vehicle always respect the rules in force in the country where you are driving never extend parts of your...

Page 66: ...re no leakages of hydraulic oil roof rotating flashing beacon figure 1 water level in the radiator figure 2 hydrostatic transmission oil level figure 3 tyre pressure and condition figure 4 presence fu...

Page 67: ...R position and carry out the following checks lamp panel figure 7 correct run of all control switches figure 8 front lights and turn indicators figure 9 rear lights and turn indicators figure 10 emerg...

Page 68: ...rake 37 is applied drive direction control 20 is in neutral position N Then turn engine start key 8 as follows turn engine start key 8 to position R to turn on the instrument panel turn engine start k...

Page 69: ...Fully retract the telescopic boom Lower the forks to the ground Let the engine idle for 2 minutes before switching it off Turn the engine start key 8 to the 0 position the engine switches off automati...

Page 70: ...ab window to the operator s right is aligned with the red stripe applied on the telescopic boom make sure that the tool holder carriage is perpendicular to the ground the carriage is in the correct po...

Page 71: ...ing wheel until the rear wheels are parallel with the side of the machine Select front axle steering Should the battery be completely flat connect an external one as described in chapter FAILURES CAUS...

Page 72: ...rew dowel 1 completely with a 4 mm Allen wrench by rotating it counter clockwise up to the end of its thread tighten check nut 2 by rotating it clockwise with a torque of 22 Nm NOTE When you restart t...

Page 73: ...afety distance from such lines from the manager of said lines as well as from the authorities in charge of safety and health in the workplace Please note that the higher the voltage the greater should...

Page 74: ...tial blockage consider alternative carrying means e g palletised load WARNING The operator is advised against using the truck with the boom raised at an angle so as to have the upper face of the forks...

Page 75: ...been performed REAR VIEW MIRRORS Every day before using the truck check the presence and integrity of the rear view mirrors ensure the reflecting surfaces are clean If necessary clean them taking care...

Page 76: ...rtially masks visibility to the rear In this case travel slowly and carefully monitor by direct visibility the rear of the truck paying particular attention to the rear right side of the truck assiste...

Page 77: ...are locked PICK AND CARRY The PICK AND CARRY operating mode refers to load transport with the machine in motion All the information on machine use is provided both in the load charts available in the...

Page 78: ......

Page 79: ...DER 3 FUEL AND LUBRICANTS 3 SCHEDULED MAINTENANCE DURING THE MACHINE BREAK IN PERIOD 6 COVERS 9 NOMENCLATURE ENGINE COMPARTMENT 10 GREASING POINTS ON YOUR MACHINE 11 MERLO PERIODIC MAINTENANCE PROGRAM...

Page 80: ...k on heated fluids or components INFORMATION ON ORIGINAL MERLO SPARES WARNING Maintenance operations on Merlo machines must be carried out using only original and approved spares If non original spare...

Page 81: ...ual pressure stay out of the way during draining operations and always wear protection goggles Slowly unscrew the draining screw by a few turns to let either the condensate or the fluid come out relie...

Page 82: ...cturer or other types available on the market it must however comply with the characteristics indicated in the table Although it is not possible to mix different oil brands it is possible to top up th...

Page 83: ...rmity FM VSS 116 DOT 4 MECHANICAL GROUPS OIL ESSO MOBIL SHELL Q8 OILS SPECIFICATIONS DIFFERENTIALS ESSO GEAR OIL GX 80W 90 MOBILUBE HD 80W 90 SPIRAX HD Q8 T 55 80W 90 SAE 80W 90 MIL L 2105C REDUCTION...

Page 84: ...e indicated points see also the table below Check the correct tightening of components to the indicated torque see also the table below Often check warning lights and indicators light and sound during...

Page 85: ...tighten the columns to a torque of 28 Kgm 280 Nm SCHEDULED MAINTENANCE AFTER THE FIRST 50 HOURS NUTS AND BOLTS OF THE STEERING COMPONENTS FRONT BRIDGE A Tighten to torque 30 kgm 220 lbft 295 Nm screws...

Page 86: ...below SCHEDULED MAINTENANCE AFTER THE FIRST 100 HOURS CARDAN JOINTS Grease the front F and rear R cardan jonts at the indicated points A grooved profiles B crossings HYDROSTATIC TRANSMISSION OIL FILT...

Page 87: ...ER 4 which is placed in the rear part of the machine there are the components of the telescopic boom sliding pads extension cylinder lock valve etc To remove COVER 4 use a proper spanner to unscrew th...

Page 88: ...ten fixing screws V COVER 8 Inside COVER 8 which is placed in the rear part of the machine there are both the hydrostatic motor and the oil filling oil level check plug of the rear differential To ope...

Page 89: ...sing points on your machine that feature a greasing nipple Some of these points marked with symbol are described in the planned maintenance schedule because they require more detailed explanations For...

Page 90: ...6 ORDINARY MAINTENANCE 6 12...

Page 91: ...bined as follows 1 EVERY 10 HOURS OR DAILY 2 EVERY 50 HOURS OR WEEKLY 3 EVERY 500 HOURS OR 6 MONTHS 4 EVERY 1000 HOURS OR 12 MONTHS 5 EVERY 1500 HOURS OR 18 MONTHS The operator must perform routine ma...

Page 92: ...r pads Check Plunger for quick uncoupling of attachments Greaser Axle shaft bearings Grease ITEM EVERY 500 HOURS DESCRIPTION Hydraulic sump bleed filter Replace Reduction hub oil Check level Different...

Page 93: ...old Then turn the cap slowly to it s stop Release all pressure before you fully remove cap The hydrostatic oil level must be visible within the glass C that is close to the filling cap If the level is...

Page 94: ...action cycles so as to evenly distribute the grease inside the shoes REDUCTION HUB ARTICULATION To ensure optimal performance of the wheel reducers it is necessary to grease them as follows Stop the m...

Page 95: ...ck studs B tighten to 28 Kgm 280 Nm WARNING The tyres which can be used on the machine are those indicated in the Merlo List and or in the machine registration document if provided CAB VENTILATION SYS...

Page 96: ...seat by removing the wing nut F The filter cartridge B can be cleaned by following the instructions here below turn a jet of compressed air not over 5 bar 72 psi from the inner side to the outer side...

Page 97: ...ecks on all the outer sliding pads of each boom 1 visual inspection of outer sliding pads to check for wear 2 visual inspection of outer sliding pads to check for wear uniformity 3 visual inspection o...

Page 98: ...machine apply 0 5 fl oz 15ml of specific grease see paragraph FUELS AND LUBRICANTS with lubricator A repeat the operation for the other axle shafts of the machine Perform a few forward reverse drive...

Page 99: ...g P1 filling cap Remove caps P and P1 to access the caps P and P1 on rear axle you need to remove COVER 8 first see paragraph COVERS in this chapter Check that the differential oil reaches the edge of...

Page 100: ...rneath discharge cap A Loosen discharge cap A using an appropriate hexagonal wrench Discharge the water and sediments contained in the tank Tigthen discharge cap A Tighten to torque 15Nm 11 lbft HYDRO...

Page 101: ...lifting it with handle M replace filter B reinstall all components without damaging gaskets reinstall the filter cap by tightening the 4 fastening screws AIR CLEANER A cover B filter cartridge C safe...

Page 102: ...ER Check if the diesel filter A is obstructed by proceeding as follows Stop the machine engine Lie under the engine in the area towards the centre of the frame and inspect the diesel filter A through...

Page 103: ...joints of the indicated components which do not have a greaser A Wheel reducers B Front bridge C Rear bridge D Boom E Carriage F Fork jack G Lifting jack H Compensation jack WARNING If you need to us...

Page 104: ...y AIR VENTILATION FILTER Replace the cab ventilation system filter as follows Unscrew fastening screws V Extract the cab ventilation filter Replace the filter with a new one with the same features Mou...

Page 105: ...ngine to switch off screw out the caps of both radiator A and hydrostatic oil tank B remove filter E and drain oil into a container to carry out this operation use a chain or band extractor install a...

Page 106: ...SCRIPTIONS LEAFLETS IN THE CABIN Check oil level in the tank quite frequently and if necessary top it up HYDRAULIC OIL To properly carry out the hydraulic system oil replacement follow the instruction...

Page 107: ...N HUB OIL To perform the reduction hub oil change correctly please follow the instructions below work on one reduction hub at a time place the machine in such a way that the level plug A is facing dow...

Page 108: ...n order to lift the second boom section bringing it in contact with the first In both cases do not force the contact manoeuvre between the booms so as not to risk damage to the structure of the telesc...

Page 109: ...nical Support Service and request it as a spare part remove clamp C and disconnect duct D from the radiator remove drain plug E of the engine block located in the inner part of the engine compartment...

Page 110: ...e check that the straw protection grid is correctly in place ENGINE OIL Periodically check the engine oil as follows Place the machine on a flat ground and switch off the diesel engine Wait a few minu...

Page 111: ...the suitable protective means gloves masks glasses overalls etc do not use inflammable liquids and acids or products which could chemically attack the vehicle parts do not clean moving or overheated...

Page 112: ...d at start Let the oil warm up Leak in the system Eliminate the leak Presence of air in the oil Eliminate air Hoses are throttled Eliminate throttling Return filter is dirty clogged Replace the filter...

Page 113: ...be possible to release the parking brake using the emergency pump act as follows see paragraph TOWING OF THE MACHINE in the section OPERATING INSTRUCTIONS chock the wheels to lock the machine in place...

Page 114: ......

Page 115: ...CKING OF THE MOVEMENTS OF THE ROLL OVER PROTECTION SYSTEM 3 STEERING MODES OPERATION 3 PLATES AND INSTRUCTIONS 3 INSTRUCTION HANDBOOK FOR OPERATING AND MAINTENANCE 3 POWER STEERING PRESSURE CALIBRATIO...

Page 116: ...ours or 1 year Check Date Restoration Date Check Date Restoration Date Check Date Restoration Date Check of the overload prevention system acustic alarm Check of the overload prevention system visual...

Page 117: ...nce is 400 mm with respect to what is described in the diagram fig 7 The only movement allowed is the retraction of the arm If this is not the case contact the local Distributor or Dealer to get techn...

Page 118: ...essure is ended disconnect the small hose from the pump and rearrange it in the engine compartment RAMS STOP VALVES Start the engine Take a load using the forks with a weight of at least 2 3 of the ma...

Page 119: ...mm as illustrated level the machine using the relative devices mounted on the machine stabilizers tilting or suspension type Should the machine not be fitted with any such devices move the machine to...

Page 120: ......

Page 121: ...OW HOOK 4 TONS 5 WINDSCREEN WIPER ON ROOF 5 CAR RADIO 5 SUNBLIND 5 WORK LIGHTS 6 MIXER BUCKET 6 CONTROL SELECTOR FOR THE CONTINUOUS DELIVERY OF HYDRAULIC OIL 6 REAR SERVICE LINE 7 REAR ELECTRIC SOCKET...

Page 122: ...r to the CAB TYPE APPROVAL PLATE in chapter TECHNICAL DATA OF YOUR MACHINE PREVENTION OF CONTACT WITH HAZARDOUS SUBSTANCES Prevention level 1 in compliance with the EN 15695 1 2009 standards Cab not s...

Page 123: ...HINE MACHINE TOW CAPACITY kg VERTICAL LOAD ON THE HOOK kg NO BRAKING MECHANICAL BRAKING INERTIA BRAKING HYDRAULIC BRAKING PNEUMATIC BRAKING P25 6 2500 5000 6000 12000 NO 420 TABLE FOR THE DETERMINATIO...

Page 124: ...gnment is shown by indicator A which lights up on control panel P1 Before carrying out a transfer on public roads select steering on the front axis lever 29 in position B SUPPORT BRACKET FOR THE TRAIL...

Page 125: ...roads WINDSCREEN WIPER ON ROOF To activate the windscreen wiper on the vehicle roof press button C located on the electric motor of the wiper itself CAR RADIO The radio is installed in the compartmen...

Page 126: ...rete Engage the propeller rotation function Engage the unloading function using the radio control supplied see paragraph relative to the equipment manual CONTROL SELECTOR FOR THE CONTINUOUS DELIVERY O...

Page 127: ...aulic services would be actioned REAR ELECTRIC SOCKET For the electrical connection of the direction indicators and all the lights of the towed equipment Consult the wiring diagram enclosed for electr...

Page 128: ...is oil table replaces and supersedes the one found in chapter STICKERS WITH CONTROL DESCRIPTIONS LEAFLETS IN THE CABIN HOT CLIMATE OIL This oil table replaces and supersedes the one found in chapter S...

Page 129: ...hicle parking brake 37 the trailer keeps on being non braked In case of stop while the engine is off the vehicle parking brake is automatically engaged the trailer keeps on being non braked disconnect...

Page 130: ...ible to combine movements JOYSTICK LEVER 1 IN POSITION A raising of the telescopic boom B lowering of the telescopic boom C downward tilt of the forks D upward tilt of the forks CONTROL ROLLER R1 1 ex...

Page 131: ...telescopic boom C downward tilt of the forks D upward tilt of the forks CONTROL ROLLER R1 1 extension of the telescopic boom 2 retraction of the telescopic boom CONTROL ROLLER R2 AUX 3 uncoupling cont...

Page 132: ...the tilt angle of the joystick the further the joystick is moved the faster the movement the rotation of thumb wheels R1 R2 R3 the further the wheel is rotated the faster the movement the rotation sp...

Page 133: ...r to the instructions in the paragraph FORWARD REVERSE DRIVE SELECTOR 20 in this chapter CAUTION It is only possible to change the drive direction when the machine is travelling in first gear slow tra...

Page 134: ...djust the desiderd lumbar support level 4 SUSPENSION ADJUSTMENT This pneumatic seat can automatically adjust to the ideal height and suspension level according to your body weight To correctly adjust...

Page 135: ...ension direction S to slacken the suspension Back adjustment 4 Sit with your back firmly against the seat back Lift lever L upwards to position the back to the required angle Document holder pocket 5...

Page 136: ...rate have the coolant quantity checked by qualified and skilled personnel COMPONENTS handle 35 in position A heating on handle 35 in position C heating off selector A in position 0 air conditioning of...

Page 137: ...9 HYDRAULIC CIRCUITS DIAGRAMS 9 1 INDEX HYDROSTATIC TRANSMISSION CIRCUIT 2 HYDRAULIC SYSTEM 4 END OF CHAPTER 5...

Page 138: ...9 HYDRAULIC CIRCUITS DIAGRAMS 9 2 HYDROSTATIC TRANSMISSION CIRCUIT...

Page 139: ...c pump variable delivery type 7 Heat exchanger 9 Hydrostatic motor variable displacement 60 Filter carrying block 61 Bypass 84 Rams for differential lock OPTIONAL 85 Servo brake OPTIONAL 86 Cartridge...

Page 140: ...9 HYDRAULIC CIRCUITS DIAGRAMS 9 4 HYDRAULIC SYSTEM...

Page 141: ...valve for the boom extension cylinder 25 Lift cylinder 27 Boom extension cylinder 30 Forks compensation valve 31 Compensation cylinder 32 Lock valve for fork cylinder 33 Fork cylinder 36 Front quick...

Page 142: ......

Page 143: ...10 ELECTRICAL SYSTEM 10 1 INDEX GENERAL FEATURES 2 BATTERY 2 FUSES 4 END OF CHAPTER 5...

Page 144: ...harnesses and electrical connections WARNING All inductive loads electric motors solenoid valves etc are protected by internal diodes in order to avoid current peaks when switched off for this reason...

Page 145: ...turn battery cut off switch D to position ON under these conditions it is possible to start the engine again WARNING Never use the battery cut off switch when either the diesel engine is running or t...

Page 146: ...e overturn prevention F8 20A Power supply to the PCB for the rear 3 point linkage with ignition key in position R instrument panel on not available on this model F9 15A Rear window wiper roof window w...

Page 147: ...ower supply to optional accessories F33 10A Stop lights F34 7 5A Front right and rear left parking lights number plate light F35 5A Left blinker of the trailer F36 5A Right blinker of the trailer F37...

Page 148: ......

Page 149: ...M2 M2 P256 AU 01 1...

Page 150: ...M2 2 M2 P256 AU 01...

Page 151: ...M2 M2 P256 AU 01 3...

Page 152: ...M2 4 M2 P256 AU 01...

Page 153: ...M2 M2 P256 AU 01 5...

Page 154: ...M2 6 M2 P256 AU 01...

Page 155: ...M2 M2 P256 AU 01 7...

Page 156: ...M2 8 M2 P256 AU 01...

Page 157: ...M2 M2 P256 AU 01 9...

Page 158: ...M2 10 M2 P256 AU 01...

Page 159: ...M2 M2 P256 AU 01 11...

Page 160: ...M2 12 M2 P256 AU 01...

Page 161: ...M2 M2 P256 AU 01 13...

Page 162: ......

Page 163: ...MODULE M3 ATTACHMENTS FOR MERLO ZM2 CARRIAGE...

Page 164: ......

Page 165: ...has supplied the load chart for the machine attachment combination in the CHART DOSSIER CONTAINER 2 in the cab and in MODULE 2 CHART DOSSIER DO NOT modify the attachments and DO NOT use it for purpos...

Page 166: ......

Page 167: ...Y C CH HE EC CK KS S 6 6 M MA AI IN NT TE EN NA AN NC CE E 6 6 A AT TT TA AC CH HM ME EN NT T L LI IF FT TI IN NG G 6 6 I IN NS ST TA AL LL LA AT TI IO ON N 7 7 OPERATION OF THE QUICK COUPLING CYLIND...

Page 168: ...MODULE 3 INDEX FLY JIB A1200B A1210B A1230B 52 FLY JIB WITH WINCH A1300B A1310B A1330B A1215B 55 CARRIAGE MOUNTED WINCH LIFT SW A2765 58 P PL LA AT TF FO OR RM MS S 6 61 1...

Page 169: ...selector 20 in neutral N Rotate the carriage downwards Extend the boom almost as far as the attachment s couplings Lift the boom and at the same time turn the carriage upwards until the carriage hooks...

Page 170: ...own the service brake 15 Position the gear selector 19 and the direction selector 20 in neutral N Engage the parking brake 37 Disengage the service brake 15 Lower the boom to rest the attachment on th...

Page 171: ...lb kg lb WEIGHT 77 170 85 188 87 192 87 192 CAPACITY 1750 3860 2250 4970 1750 3860 2250 4970 mm in mm in mm in mm in K 1200 47 1200 47 1200 47 1200 47 A 1327 52 1331 52 1327 52 1331 52 B 615 24 620 24...

Page 172: ......

Page 173: ...REACH TRUCK 10 Model interface MERLO ZM 11 complies with all the applicable provisions of Directive 2006 42 CE 12 This declaration of EC conformity concerns exclusively the machine placed on the mark...

Page 174: ...Make sure the controls function correctly If this is not the case DO NOT USE the attachment and contact the Area Distributor or Dealer for technical assistance M MA AI IN NT TE EN NA AN NC CE E EVERY...

Page 175: ...er P itself and the risk of uncoupling the attachment Make sure that the machine s hydraulic pipeline C controlling the small cylinder P is connected to the hydraulic connector A If installed Press an...

Page 176: ...nserted in the attachment s couplings Retract the quick coupling piston P as described in the previous paragraph Turn the carriage upwards until the attachment rests on the carriage Release the contro...

Page 177: ...A Connect the second pipeline from the attachment to the hydraulic connector B E EL LE EC CT TR RI IC CA AL L C CO ON NN NE EC CT TI IO ON N Remove the pin B from position X and connect it to the sup...

Page 178: ...MODULE 3 SECTION 2 ATTACHMENT IDENTIFICATION Press and hold down the service brake 15 Place the gearbox selector switch 19 and the driving direction selector switch 20 in the neutral position N Engage...

Page 179: ...e commands on the joystick 1 Retract the quick coupling cylinder P Rotate the carriage downwards and then slide it out of the couplings A on the attachment If necessary slightly lower the boom further...

Page 180: ...attachment installed observe the Highway Code of the country where the machine is used and wherever so envisaged refer to the type approval documents A AD DD DI IT TI IO ON NA AL L C CA AR RR RI IA A...

Page 181: ...3 3 Z ZM M2 2 0 03 3 E EN N 13 EXTRA WIDE FORK CARRIAGE WITH STANDARD FORKS A0100 MERLO CODE A0100 mm in A 1895 75 B 280 11 C 490 19 D 1790 70 E 510 20 kg lb Weight 132 291 To install the standard for...

Page 182: ...FEM III FORKS A0200 A0201 A0210 A0211 MERLO CODE A0200 A0201 A0210 A0211 mm in mm in mm in mm in A 1500 59 1500 59 2000 79 2000 79 B 225 9 250 10 245 9 10 250 10 C 525 21 630 25 525 20 630 25 D 510 2...

Page 183: ...the safety pin A of the forks Manually insert the forks in the required position on the carriage Insert the safety pin A in one of the grooves used to lock the fork s position MERLO CODE A0500 mm in K...

Page 184: ...0292 MERLO CODE A0291 A0292 mm in mm in A 1200 47 1200 47 B 1560 61 1565 62 C 1200 47 1300 51 D 990 39 990 39 E 295 12 295 12 F 355 14 355 14 G 1200 47 1200 42 H 480 19 580 23 X 120 5 120 5 Y 50 2 50...

Page 185: ...mm in mm in A 1200 47 1200 47 B 1560 61 1565 62 B1 660 26 697 28 C 1200 47 1300 51 C1 1747 69 1747 69 D 990 39 990 39 E 295 12 295 12 F 355 14 355 14 G 1200 47 1200 42 H 480 19 580 23 X 120 5 120 5 Y...

Page 186: ...rotection for road circulation 5 Remove the locking pin H and the pin 3 from the rest position on the protective grid of the forks perform the operation for both forks Rotate the carriage forward unti...

Page 187: ...to aid the subsequent assembly operations Insert the front protection for circulation on the road 5 by hooking it to the protective grid of the forks by means of the appropriate lateral spring latches...

Page 188: ...90 39 E 295 12 295 12 F 355 14 355 14 G 1200 47 1200 47 H 480 19 580 23 X 100 4 100 4 Y 35 1 35 1 kg lb Kg lb Weight 220 485 230 507 Capacity 1500 3310 1500 3310 of the attachment not of the individua...

Page 189: ...FT ON STANDARD CARRIAGE A0281 A0282 MERLO CODE A0281 A0282 mm in mm in A 1355 53 1355 53 B 300 12 300 12 C 1250 49 1250 49 D 154 6 154 6 E 525 21 425 17 F 717 28 717 28 kg lb Kg lb Weight 410 904 380...

Page 190: ...to avoid possible punctures or damage WARNING LOADER WITH GRAB Pay close attention when closing the grab to prevent the material loaded damaging the tips WARNING LOAD CHARTS A specific machine s load...

Page 191: ...ne s boom in order to suspend the lifting accessory with the free end at the specific lifting point of the attachment refer to MODULE 3 SECTION 2 LIFTING OPERATOR 2 Couple the free end of the lifting...

Page 192: ...ucket loader work area filled to max available capacity with material having the specific weight indicated in column 24 22 Bucket loader work area with load indicated in the corresponding column 23 23...

Page 193: ...LLS POTATOES BEANS MATERIALS WITH DENSITY 900 1 800 kg m3 ICE MAGNESIUM SULPHATE POTASSIUM CHLORIDE ALUMINIUM OXIDE OIL WET PEAT IRON SULPHATE LIME LEATHER TAR WOOL LIMESTONE RUBBER LOOSE STONES BAKEL...

Page 194: ...E A0699 A0700 A0701 A0706 mm in mm in mm in mm in A 1840 72 2000 79 2240 88 2440 96 B 950 37 1100 43 1100 43 1100 43 C 940 37 1020 40 1020 40 1020 40 D 675 27 760 30 760 30 760 30 kg lb kg lb kg lb kg...

Page 195: ...CKET A0710 A0712 A0715 MERLO CODE A0710 A0715 A0712 mm in mm in mm in A 2240 88 2240 88 2400 94 B 1330 52 1245 49 1330 52 C 1140 45 1060 42 1140 45 D 880 35 835 33 880 35 kg lb kg lb kg lb Weight 390...

Page 196: ...in A 1840 72 2000 79 2240 88 2400 95 2400 95 2500 98 B 1600 63 1590 63 1600 63 1600 63 1760 69 1935 76 C 1085 43 1100 43 1085 43 1085 43 1190 47 1375 54 D 1035 41 1050 41 1035 41 1035 41 1130 44 1305...

Page 197: ...245 49 D 765 30 765 30 845 33 1195 47 970 38 kg lb kg lb kg lb kg lb kg lb Weight 720 1587 630 1389 780 1720 1220 2690 840 1582 l gal l gal l gal l gal l gal Load capacity 800 211 600 159 1000 264 300...

Page 198: ...840 33 975 38 840 33 835 33 995 39 D 1550 61 1725 68 1635 64 1635 65 1910 75 E 1255 49 1380 54 1330 52 1330 53 1650 65 kg lb kg lb kg lb kg lb kg lb Weight 497 1096 660 1455 605 1334 570 1257 700 154...

Page 199: ...With the boom retracted DO NOT SLANT the carriage excessively downwards the tips may interfere with the tyres WARNING RISK OF TIPPING OVER Arrange the load uniformly inside the attachment WARNING RIS...

Page 200: ...K WITH GRAPPLE A2300 A2301 MERLO CODE A2300 A2301 mm in mm in A 2280 90 1945 77 B 1285 51 1275 50 C 955 38 955 38 D 1755 69 1755 69 E 1380 54 1380 54 Z 795 31 795 31 kg lb kg lb Weight 580 1280 518 11...

Page 201: ...A2231 A2232 A2233 A2234 MERLO CODE A2331 A2332 A2333 A2334 mm in A 1390 55 B 470 19 C 1035 1235 1415 1415 41 49 56 56 D 840 1040 1200 1200 33 41 47 47 E 800 31 F 1240 49 G 1630 64 kg lb Weight 220 230...

Page 202: ...NES BALE FORK WITH HYDRAULIC SLIDING PROTECTION A2340 MERLO CODE A2340 mm in A 1720 68 B 450 18 C 1320 1900 52 75 D 1040 41 E 1570 62 F 550 22 G 1190 47 kg lb Weight 320 705 Capacity 1500 3310 of the...

Page 203: ...S BALE FORK WITH GRAB 02320 MERLO CODE A2320 mm in A 1195 47 B 840 33 C 1865 2790 73 110 D 1040 41 E 1170 46 F 730 29 G 2575 101 Kg lb Weight 240 530 Capacity 1500 3310 of the attachment not of the in...

Page 204: ...may be lower than the machine s maximum capacity or the rated capacity of the attachment may be lower than the machine s maximum capacity WARNING RISK OF TIPPING OVER Arrange the load on the attachmen...

Page 205: ...S SECTION 2 MODULE 3 M M3 3 Z ZM M2 2 0 03 3 E EN N 37 DOUBLE LOG GRIPPER A2200 MERLO CODE A2220 mm in A 1215 48 B 1420 56 C 1345 53 D 1890 74 E 1710 67 E 150 1000 6 39 Kg lb Weight 590 1300 Capacity...

Page 206: ...2 1055 41 1655 65 1835 72 1690 67 1835 72 B 1485 58 1485 58 1495 59 1495 59 1215 48 1200 47 C 800 31 1850 73 905 36 725 29 680 27 905 36 F 1200 2000 47 79 1200 2000 47 79 1200 2000 47 79 1200 2000 47...

Page 207: ...ATTACHMENTS SECTION 2 MODULE 3 M M3 3 Z ZM M2 2 0 03 3 E EN N 39 BARREL GRIPPER A2210 MERLO CODE A2210 mm in A 600 700 24 28 C 590 23 D 725 29 H 230 9 kg lb Weight 275 606 Capacity 600 1325...

Page 208: ...MENT For instructions on the use of the attachment refer to MODULE 1 SECTION 3 JOYSTICK Unloading and loading material must be performed from the exterior of the attachment and in the presence of an o...

Page 209: ...0 A1410 A1420 A1430 MERLO CODE A1400 A1410 A1420 A1430 mm in mm in A 1035 41 1035 41 B 1470 58 1470 58 C 1250 49 1450 57 D 1300 51 1300 51 E 810 32 810 32 F 480 19 480 19 G 740 29 740 29 kg lb kg lb W...

Page 210: ...et with hydraulic aperture For the hydraulic connection refer to MODULE 3 SECTION 2 INSTALLING THE ATTACHMENT HYDRAULIC CONNECTION WARNING LOAD CHART Refer to the load chart for the machine with STAND...

Page 211: ...720 67 7 2230 88 B 1500 59 1500 59 1500 59 C 1140 1400 45 55 1140 1400 45 55 1140 1400 45 55 D 1300 51 1170 46 1170 46 E 1270 1610 50 63 1270 1610 50 63 1270 1610 50 63 F 1060 42 1710 67 2225 88 G 620...

Page 212: ...F HYDRAULIC OIL Turn the selector switch MC to position 2 when the front guard is completely open continuous propeller rotation is activated refer to MODULE 1 SECTION 5 CONTINUOUS DELIVERY OF HYDRAULI...

Page 213: ...he specific grille A or place a bag of cement on the blade B to open it WARNING MAXIMUM BUCKET CAPACITY Maximum capacity is reached with the carriage in a vertical position when the material reaches t...

Page 214: ...te in its seat on the upper part of the attachment WARNING RISK OF DAMAGE TO THE CHUTE DO NOT OPERATE front guard aperture when the chute is in the transport position Unloading concrete Tilt the bucke...

Page 215: ...arings on both sides of the propeller using the grease unit A until grease emerges from hole B Close the bucket s front guard Start propeller rotation and grease the chain using the grease unit D Unlo...

Page 216: ...the machine is equipped with load limiter refer to MODULE 1 SECTION 3 LOAD LIMITER WITHATTACHMENTFORSUSPENDEDLOADS WARNING RISK OF ACCIDENTS Violent blows to the attachment can cause serious damage t...

Page 217: ...0 MERLO CODE A1000 mm in A 725 29 B 430 17 C 495 19 D 560 22 E 190 7 kg lb Weight 100 220 Capacity 4500 9900 PRECAUTION RISK OF ACCIDENTS Always operate with the attachment levelled WARNING RISK OF AC...

Page 218: ...EN N L LI IF FT TI IN NG G B BO OO OM M A A1 11 11 18 8B B MERLO CODE A1118B mm in A 1485 58 B 495 19 C 815 32 D 1335 52 E 365 14 F 1030 46 G 140 6 kg lb Weight 125 275 Capacity 2200 4850 PRECAUTION R...

Page 219: ...3 E EN N 51 TELESCOPIC LIFTING BOOM A1123B MERLO CODE A1123B mm in A 1580 62 B 475 19 C 810 32 D 1445 57 E 355 14 F 1160 46 G 170 7 H 725 29 kg lb Weight 220 485 Capacity 1500 3310 PRECAUTION RISK OF...

Page 220: ...LO CODE A1200B A1210B A1230B mm in mm in mm in A 3470 137 2115 83 3470 137 B 400 16 440 17 400 16 C 940 37 575 23 970 38 D 3225 127 1910 75 3225 126 E 135 5 155 6 135 5 kg lb kg lb kg lb Weight 112 24...

Page 221: ...and turn the front support A outwards figure 1 Remove the wrench and the pins P Connect the 2 lifting accessories at the specific points G on the attachment refer to section LIFTING THE ATTACHMENT fig...

Page 222: ...and position the specific retainer B on the front support T Insert the screw R and lock the position with the cotter S figure 5 To open the engine compartment with the fly jib positioned figure 6 rem...

Page 223: ...44 2230 88 3645 144 1660 65 B 540 21 580 23 540 21 735 29 C 1000 39 680 27 1000 39 805 32 D 3535 139 1975 78 3535 139 1550 61 cable 7 1 4 7 1 4 7 1 4 10 3 8 kg lb kg lb kg lb kg lb Weight 202 445 288...

Page 224: ...OT use the attachment with the carriage rotated downwards because interference between the cable and the cable guide may damage it PRECAUTION RISK OF DAMAGE TO THE CABLE DO NOT FORCE the cable descent...

Page 225: ...ION 2 MODULE 3 M M3 3 Z ZM M2 2 0 03 3 E EN N 57 MAINTENANCE EVERY 50 HOURS Hoist grease nipples 1 and 2 Limit switch Grease the screw Block pulley Grease the pin indicated Cable drive pulley Grease t...

Page 226: ...I IA AG GE E M MO OU UN NT TE ED D W WI IN NC CH H L LI IF FT T S SW W A A2 27 76 65 5 MERLO CODE A2765 A 1105 44 B 830 33 C 635 25 cable 12 1 2 kg lb Weight 430 950 Capacity 4000 8800 m ft Cable leng...

Page 227: ...scent or boom lowering command when the load is resting on the ground to avoid unwinding the cable incorrectly TRANSPORTING THE ATTACHMENT FOR CIRCULATION ON PUBLIC ROADS only ROTO models WARNING POSI...

Page 228: ...gure 2 Use the boom s movements to lift and handle the attachment until it is coupled with the support figures 3 and 4 OPERATOR 2 From the ground manually guide the positioning of the attachment until...

Page 229: ...k G Reducer oil level The level indicator must be completely submerged H Cable guide block wear L Cable guide block bushing wear P PL LA AT TF FO OR RM MS S Refer to the relative manual WARNING RISK O...

Page 230: ...MODULE 3 SECTION 2 ATTACHMENTS 62 M M3 3 Z ZM M2 2 0 03 3 E EN N...

Page 231: ...ATTACHMENTS FOR MERLO ZM2 CARRIAGE M3...

Page 232: ......

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