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Wacker Neuson Telehandler TH412, Operator'S Manual

The Wacker Neuson Telehandler TH412 Operator's Manual is available for free download from our website. This comprehensive manual provides detailed instructions for the safe and efficient operation of the TH412. Get your manual today for expert guidance on using your telehandler effectively.

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Table of Contents I

BA TH412 *  06/2017 * 4512_0-0_IVZ_en.fm

I-3

7.5 Cleaning and maintenance ...........................................................................................................................  7-23
7.6 Lubrication work............................................................................................................................................  7-26
7.7 Fuel system ..................................................................................................................................................  7-27
7.8 Engine lubrication system.............................................................................................................................  7-32
7.9 Cooling system .............................................................................................................................................  7-35
7.10 Air filter..........................................................................................................................................................  7-40
7.11 V-belt/toothed belt.........................................................................................................................................  7-45
7.12 Hydraulic system ..........................................................................................................................................  7-48
7.13 Electrical system...........................................................................................................................................  7-53
7.14 Heating, ventilation and air conditioning system...........................................................................................  7-62
7.15 Washer system .............................................................................................................................................  7-63
7.16 Axles/traveling drive......................................................................................................................................  7-64
7.17 Brake system ................................................................................................................................................  7-66
7.18 Tires..............................................................................................................................................................  7-67
7.19 Maintenance and servicing work on attachments.........................................................................................  7-70
7.20 Maintenance of options.................................................................................................................................  7-71

8 Malfunctions

8.1 Malfunctions, causes, remedies .....................................................................................................................  8-1

9 Technical data

9.1 Models and trade names ................................................................................................................................  9-1
9.2 Engine.............................................................................................................................................................  9-2
9.3 Axles/travel drive ............................................................................................................................................  9-3
9.4 Brakes.............................................................................................................................................................  9-3
9.5 Tyres...............................................................................................................................................................  9-4
9.6 Steering system ..............................................................................................................................................  9-4
9.7 Work hydraulics ..............................................................................................................................................  9-4
9.8 Electrical system.............................................................................................................................................  9-5

Summary of Contents for Telehandler TH412

Page 1: ...Operator s manual Telehandler TH412...

Page 2: ...00322896 en 1000322898 es 1000322911 et 1000354191 fi 1000322918 fr 1000322899 hr 1000336841 hu 1000322915 it 1000322916 lv 1000354193 nl 1000322900 no 1000322917 pl 1000322912 pt 1000328570 ro 100032...

Page 3: ...Legend Original Operator s Manual Version 1 3 Issue 06 2017 Document BA TH412...

Page 4: ...ent of Wacker Neuson SE Violations of legal regulations in particular of the copyright protection shall be subject to civil and criminal prosecution Wacker Neuson SE keep abreast of the latest technic...

Page 5: ...5 2 5 Lifting gear applications 2 10 2 6 Trailer operation 2 12 2 7 Attachment operation 2 13 2 8 Towing loading and transporting 2 15 2 9 Maintenance 2 18 2 10 Measures for avoiding risks 2 21 3 Int...

Page 6: ...system option 5 24 5 8 Heating and ventilation option 5 25 5 9 Work hydraulics 5 27 5 10 Attachments 5 44 5 11 Work operation 5 55 5 12 Emergency lowering 5 80 5 13 Options 5 84 5 14 Putting out of o...

Page 7: ...stem 7 53 7 14 Heating ventilation and air conditioning system 7 62 7 15 Washer system 7 63 7 16 Axles traveling drive 7 64 7 17 Brake system 7 66 7 18 Tires 7 67 7 19 Maintenance and servicing work o...

Page 8: ...I 4 BA TH412 06 2017 4512_0 0_IVZ_en fm I Table of Contents 9 9 Tightening torques 9 7 9 10 Coolant 9 9 9 11 Noise emissions 9 10 9 12 Vibration 9 10 9 13 Weights 9 12 9 14 Dimensions 9 14 Index...

Page 9: ...zierte Stelle Kenn Nr 0515 DGUV Test Pr f und Zertifizierungsstelle Fachbereich Bauwesen Landsberger Stra e 309 80687 M nchen Germany Directives and standards applied DIN EN 1459 Authorised representa...

Page 10: ...EG 2 BA TH412 06 2017 4512_0 1_Konform_en fm EG Declaration of conformity Notes...

Page 11: ...By reading the Operator s Manual the operator familiarizes himself more quickly with the machine and uses it more safely and efficiently If required the user owner of the machine must supplement the O...

Page 12: ...additional equipment that is not mentioned in the text or not supplied as standard The descriptions illustrations weight indications and technical data are not binding and correspond to the state of t...

Page 13: ...ons and is used for alerting against potential personal hazards Special attention must be paid to the warning instruction texts following this symbol Symbol Explanation Identification of general activ...

Page 14: ...sis of good commercial practice Abbreviation Explanation poss possibly if nec if necessary etc et cetera e g for example max maximum min minimum approx approximately Fig Figure Item Position number in...

Page 15: ..._1 1_Vorwort_en fm 1 5 Weight 1 kg 2 2 lbs 1 g 0 035 oz Pressure 1 bar 14 5 psi 1 kg cm 14 22 lbs in Force output 1 kN 224 81 lbf 1 kW 1 34 hp 1 PS 0 986 hp Torque 1 Nm 0 74 ft lbs Speed 1 kph 0 62 mp...

Page 16: ...factured in accordance with the applicable EC Directives Information The manufacturer supplier shall be not liable for damage resulting from use other than designated Alone the user owner shall bear t...

Page 17: ...in perfect running condition within the framework of our General Terms and Conditions of Business We basically do not offer any further guarantees Any further liability beyond the scope of our General...

Page 18: ...1 8 BA TH412 06 2017 4512_1 1_Vorwort_en fm 1 Preface Notes...

Page 19: ...oided Consequences in case of non observance Avoidance of injury or death WARNING WARNING identifies a situation that can cause death or serious injury if it is not avoided Consequences in case of non...

Page 20: ...operator the authority to refuse instructions by other persons that are contrary to safety Have the vehicle serviced and repaired only by an authorized service center Required knowledge of operator Th...

Page 21: ...cherheit_en fm 2 3 Preparatory measures for the operator Before starting check the vehicle whether it can be driven and operated safely Tie back long hair and remove all jewelry Wear close fitting wor...

Page 22: ...not to put into operation or operate a damaged or malfunctioning vehicle If a damage or malfunction occurs during operation put the vehicle out of operation immediately and secure it against restart H...

Page 23: ...perate the vehicle only with the seat belt fastened and only from the place provided for this Check the condition and the fastening of the seat belt Have malfunctioning seat belts and mounting hardwar...

Page 24: ...a Maintain a safe distance for example from buildings edges of building pits During work in buildings or in enclosed areas look out for Height of the ceiling clearances Width of entries passages Maxim...

Page 25: ...tachments tools is PROHIBITED Carrying passengers on in trailers is PROHIBITED Mechanical integrity The operator and owner are obligated to operate the vehicle only in a safe and working condition Ope...

Page 26: ...ed danger during backward vehicle travel Persons in the blind spot of the machine cannot be seen by the operator Ensure that nobody is in the danger zone when you change the travel direction Never get...

Page 27: ...ifferent steering modes ensure that the mandatory steering mode is selected Stopping the engine of the machine Stop the engine only according to the Operator s Manual Before stopping the engine lower...

Page 28: ...uiding and removing a load Wear protective clothing and equipment when fastening guiding and removing loads for example a hard hat safety glasses protective gloves safety boots Do not place lifting an...

Page 29: ...be nobody under the load Stop the vehicle immediately and stop the engine if persons enter the danger zone Use the machine for lifting gear applications ONLY if the mandatory lifting gear for example...

Page 30: ...f the machine is prohibited Trailer operation changes the machine s operating behavior the operator must be familiar with this and act accordingly Bear in mind the machine s steering mode and the trai...

Page 31: ...re the load Do not overload attachments Check the correct position of the lock Operating Carrying persons on in an attachment is prohibited Installing a work platform is prohibited Attachments and cou...

Page 32: ...with the Operator s Manual Lower the attachment only to firm level ground and secure it to prevent it from tipping over or rolling away Put the vehicle and the attachment into operation only if The p...

Page 33: ...ry must be used as a minimum Furthermore the tractor vehicle must be equipped with a safe braking system and sufficient tractive power Use only towing bars or cables certified by a test certi fication...

Page 34: ...be within sight or sound of him Observe all movements of the machine and lifting gear Secure the vehicle against unintentional movement Raise the vehicle only after it is safely attached and the pers...

Page 35: ...y lifting and fastening gear that is dirty damaged or not of sufficient size In order to secure the machine on the platform use only the fastening points provided for this purpose Ensure that nobody i...

Page 36: ...stall safety equipment again that has been removed Wait for the vehicle to cool down before touching components Personal safety measures Avoid any operational mode that might be prejudicial to safety...

Page 37: ...acement of parts over 9 kg 20 lbs Perform maintenance only if the vehicle is positioned on firm and level ground the machine is secured to prevent it from rolling away for example with the parking bra...

Page 38: ...terminal of the battery before working on the electrical system Modifications and spare parts Do not modify the machine and the work equipment attachment for example the safety equipment lights tires...

Page 39: ...e must have identical tires for example profile revolutions per mile Hydraulic and compressed air system Check all lines hoses and threaded fittings regularly for leaks and visible damage Splashed oil...

Page 40: ...The operating voltage of machine the attachment and the trailer must be the same for example 12 V Battery Batteries contain caustic substances for example sulfuric acid When handling the battery obse...

Page 41: ...rate the machine in enclosed premises or areas for example in pits if there is no suitable ventilation for example exhaust gas filters suction systems Do not operate the vehicle in potentially explosi...

Page 42: ...ly with appropriate personal protective equipment for example with a breathing mask Fire hazard Fuel lubricants and coolants are flammable Do not put the vehicle into operation if there is a fire haza...

Page 43: ...operator must take other safety measures for example switching off the current in agreement with the operating company or owner of the supply lines If supply lines are exposed they must be fastened su...

Page 44: ...ed accordingly Behavior during thunderstorm Stop machine operation if a thunderstorm is gathering stop the machine secure and leave it and avoid being near it Noise Observe the noise regulations for e...

Page 45: ...ove all dirt snow and ice from climbing aids for example handholds footholds handrails Keep the cabin glazing and visual aids clean Keep the light system and reflectors clean Keep the control elements...

Page 46: ...2 28 BA TH412 06 2017 4512_2 1_Sicherheit_en fm 2 Safety Notes...

Page 47: ...n fm 3 1 3 Introduction 3 1 Machine overview Models and trade names overview The machine is identified by two designations Model designation Stamped on the type label Trade name Glued on the machine M...

Page 48: ...3 2 BA TH412 06 2017 4512_3 1_Einleitung_en fm 3 Introduction Machine overview Fig 2 1 2 3 4 7 9 13 14 15 11 10 6 12 8 16 5...

Page 49: ...ngine cover 5 Rear vehicle lighting option 6 ROPS FOPS cab or protective roof 7 Front working light 8 Lift cylinder 9 Front vehicle lighting option 10 Fuel tank filler neck 11 Front wheels 12 Battery...

Page 50: ...ly adjustable hydraulic system Maximum speed 20 km h 28 km h option Hydraulic power steering with emergency steering features 4 wheel steering Front and rear planetary axles rear axle with oscil latio...

Page 51: ...t axle The axles are designed as steering axles with kingpin steering Brakes The drive also has the function of a service brake with effect on the front and rear axles The brake is activated via the b...

Page 52: ...rols machine travel which starts at the rated engine speed and reaches full speed at maximum engine speed Depending on machine load the output of the variable displacement pump is automatically reduce...

Page 53: ...es at a voltage of 12 V Consumers and their supply circuits are protected with fuses Equipment The loader unit consists of the loading frame with integrated mechanical or hydraulic optional quick coup...

Page 54: ...tified immediately The machine is used for picking up and loading material through a forward motion of the machine taking into account the safety instructions regulations and intervals specified by Wa...

Page 55: ...transporting persons Use as a working platform Raising or transporting loads without an attachment required for this purpose The use after incorrect repairs rectification of malfunc tions Use after a...

Page 56: ...intenance contrary to the instructions given in the Operator s Manual Troubleshooting and maintenance with running drives and or a running diesel engine Ignoring safety and warning information on the...

Page 57: ...areas Contaminated areas Fields of application and use of attachments The attachments will decide in the first place how the machine is used Note that not all the indicated attachments comply with loc...

Page 58: ...17 66 4 in 1 bucket 1000290949 1550 61 02 0 36 12 71 1000290950 1550 61 02 0 36 12 71 Light weight materials bucket 1000227362 1500 59 06 0 77 27 19 Loosening picking up transporting and load ing loos...

Page 59: ...0 80 28 25 Picking up transporting and loading loose material whereby the bucket can be tipped sideways also Skeleton bucket 1000345617 1600 62 99 0 33 11 65 Picking up transporting sieving and loadi...

Page 60: ...000335628 1200 47 24 10002281991 1100 43 31 10003264341 1200 4724 Maintenance of green spaces Double blade mower1 1000227475 1500 59 06 Mowing grass and vegetation on level sur faces Fence mower1 1000...

Page 61: ...kinds of material on firm ground 1000359397 2000 78 74 1000359398 2500 98 43 Rotary sweeper1 1000227524 1550 61 02 1000227785 1850 72 83 1000316292 1550 61 02 1000316294 1850 72 83 1000316263 1550 61...

Page 62: ...1000228221 0 11 3 88 Winter service 1000249568 0 17 6 00 1000228222 0 3 10 59 Special applications Waste container1 1000228215 1000 39 37 1 00 35 32 Transporting and dumping shrub cuttings waste etc G...

Page 63: ...0 mm 59 84 in 1 1000199196 152 5 98 1000199197 229 9 02 1000199207 305 12 01 Pot grabber1 1000299104 Grabbing transporting and setting down large plant pots Tree trunk gripper1 1000326396 1450 57 09 R...

Page 64: ...Ges Gew kg Hom Nr zul Anh ngelast kg Art Nr Motorleistung kW zul Achslast vorn kg Baujahr Radlader Made in Germany Typ 1 2 3 4 5 6 8 9 7 10 11 12 13 Fig 3 Item Designation 1 Manufacturer 2 Machine des...

Page 65: ...mation labels WARNING Injury hazard due to missing or damaged labels A missing incomplete or poor indication of danger can cause serious injury or death Never remove warning and information labels Imm...

Page 66: ...3 20 BA TH412 06 2017 4512_3 4_Beschilderung_en fm 3 Introduction Position of warning and information labels Fig 4 W6 W1 W3 W4 W5 W2 H1 H3 W12 W11 W9 W8 W7 H2 W10...

Page 67: ...arning label W1 General risk Caution All persons must stay clear of the danger zone of the machine Located on the left and right of the loader unit and at the rear of machine Warning label W2 Burn haz...

Page 68: ...inte nance Have repair work only performed by authorized personnel Located on the engine cover Warning label W4 Bin under pressure Burn haz ard Caution Do not open radiator is hot and under pressure O...

Page 69: ...Caution Keep a safe distance from the machine Located on the machine frame under the loader unit Warning label W6 Shearing hazard Caution Do not touch any turning parts Perform inspections and mainte...

Page 70: ...or seat Fasten your seat belt during machine operation Ensure machine stability Located near the operator seat Warning label W8 ROPS FOPS protective structures Damaged protective ROPS FOPS structures...

Page 71: ...ion Additional persons riding on the machine can fall off and be injured Never transport persons with the machine Located in the operator s compartment Warning label W10 Loader unit lift cylinder prop...

Page 72: ...hicle to tip forward Retract the telescopic boom first and then lower it Observe the safe load indicator Located on the right window Warning label W12 Injury hazard due to lowering of mast If the righ...

Page 73: ...ttery master switch The battery disconnect switch is located here Observe the description in the Operator s Manual Located on the engine cover Information label H2 Lubrication Lubricate all lubricatio...

Page 74: ...quickhitch for attachments for example a Euro mount then the following must be observed During machine travel without attachments and with the boom fully retracted the quickhitch must not be tilted o...

Page 75: ...public roads Slowly and carefully operate the machine during work operation Keep the climbing aids handholds and footholds free from dirt snow and ice Keep windows front side and rear windows free fr...

Page 76: ...N Crushing hazard due to incorrectly locked door The doors can cause crushing when closing Always lock the cabin doors Use the handholds for closing The cabin has one door on the left Pull the door op...

Page 77: ...ow Use the handholds for closing The side window can be locked in the open position Open and lock the side window with the lever 1 Press the side window against the locking mechanism The side window i...

Page 78: ...Rear window The rear window can be opened and closed with a lever Turn the lever toward O The rear window is open Turn the lever toward C The rear window is closed Information Always check whether th...

Page 79: ...when smashing the window with the emergency hammer Protect your face and eyes from the glass splinters flying around Only smash windows in an absolute emergency Remove the glass splinters before leavi...

Page 80: ...climbing aids clean Use the mandatory climbing aids for entering and exiting the machine Face the vehicle as you enter and leave it Have damaged climbing aids replaced Holding onto the steering wheel...

Page 81: ...requirements for example to your body size and posture This prevents muscle tensions and fatigue during work Adjust the operator seat ensuring that the control levers and pedals are within easy reach...

Page 82: ...d provides a firmer seat suspension turning it clockwise toward provides a softer seat suspension It is not necessary to take the load off the operator seat in order to adjust it however it is easier...

Page 83: ...ired position Moving the operator seat to another position must no longer be possible once it is locked Do not raise the locking lever with your leg or calf 2 Weight adjustment Sit down on the operato...

Page 84: ...osture adjust the backrest angle 15 positions with 2 5 degrees each between 5 and 30 degrees Adjusting the steering wheel option WARNING Accident hazard when adjusting the steering wheel during machin...

Page 85: ...operation 4 BA TH412 06 2017 4512_4 1_Steuerstand_en fm 4 11 1 Press and hold lever 1 downward The steering wheel is unlocked 2 Adjust the steering wheel 3 Release the lever The steering wheel is loc...

Page 86: ...ic roads The field of vision is the area the operator can see from the seat Rearview mirrors or camera systems can be installed on the machine to support the operator Limited field of vision during wo...

Page 87: ...ard about 90 2 Adjust the rearview mirrors The outer edge of the machine must be visible on the inside X The horizon must be visible at the upper edge Y At the lower edge Z the visible area must be as...

Page 88: ...n your clothes Firmly fasten your seat belt over your hips WARNING Injury hazard due to damaged or dirty seat belt A damaged or dirty seat belt can cause serious injury or death Keep the seat belt and...

Page 89: ...ss unlocking lever 1 at the belt reel and put the seat belt over your hips Seat belt must not be twisted 3 Insert buckle latch 2 into buckle 3 and release unlocking lever 1 at the belt reel The seat b...

Page 90: ...d when adjusting the seat belt during machine operation Adjusting the seat belt during machine operation can cause serious injury or death Adjust the seat belt before putting the machine into operatio...

Page 91: ...cure the excess seat belt The seat belt is shortened to the required length Fire extinguisher The fire extinguisher is not included in the machine s standard equipment Subsequent installation must be...

Page 92: ...function and handling of the indicator lights and controls The pages stated in the table refer to the description of the controls Information The machine is not equipped with all options described in...

Page 93: ...ast control lever 5 Rocker switch panel 4 6 Control lever for auxiliary hydraulics 7 Starter 8 Fuse box 9 Accelerator pedal 10 Operator seat 11 Brake inching pedal 12 Rotary knob for manual inching op...

Page 94: ...ers green optional 4 26 21 High beam indicator light blue option 4 27 22 Not assigned 4 27 23 Engine temperature warning light red 4 27 24 Alternator charge function warning light red 4 27 25 Warning...

Page 95: ...ver Fig 34 32 33 35 37 36 34 2 Item Control elements Page 32 Forward reverse control 5 8 33 High speed crawler gear button 5 9 34 Button to extend telescopic boom 5 30 35 Button to retract telescopic...

Page 96: ...vary depending on the combination of different additional equipment Item Rocker switch panel 1 Page 38 Overload protection rocker switch 4 30 5 35 Rocker switch VLS Vertical Lift System 4 30 5 37 39 R...

Page 97: ...cker switch option 4 32 5 21 42 Working lights rocker switch 4 32 5 17 43 Rocker switch for working lights on the mast option 4 33 5 18 Fig 36 41 43 42 Item Rocker switch panel 3 Page 44 Rocker switch...

Page 98: ...for additional hydraulic connections on the mast 4th control cir cuit optional 4 35 5 89 48 Rocker switch for rear hydraulic connec tions option 4 35 5 93 Rocker switch for PTO shaft optional 4 35 5 9...

Page 99: ...e right cabin protective roof pillar Information The safe load indicator only warns against a tipping hazard to the front The sensor does not detect a lateral tipping hazard 40 85 Fig 39 3 Color Stabi...

Page 100: ...lluminates during operation stop the machine immediately and get in touch with an authorized service center The indicator and warning lights illuminate for a self test after engaging the starter Prehe...

Page 101: ...ssigned Engine temperature warning light red Illuminates if the maximum permissible engine temperature is reached Alternator charge function warning light red Illuminates when the key in preheating st...

Page 102: ...ngine oil pressure is too low In this case 1 Stop the vehicle 2 Stop the engine immediately and check the oil level Engine lubrication system on page 7 32 Forward travel direction indicator light gree...

Page 103: ...9 High speed indicator light yellow Illuminates if the high speed gear was enabled with the button 32 Gear shifting on page 5 9 Fuel gage Indicates the current level in the fuel tank The indicator lig...

Page 104: ...al Lift System The rocker switch 38 is located in Rocker switch panel 1 The overload shutdown can be disabled and the working modes of the VLS can be chosen with the rocker switch Disabling the overlo...

Page 105: ...power supply on and off for the electric power outlet on the mast Electric power outlet on the loader unit on page 5 84 Hydraulic lock for attachments rocker switch option The rocker switch 40 is loc...

Page 106: ...gnal horn on page 5 23 Operating the hazard warning system optional on page 5 21 Information When outfitting the vehicle with a lighting system optional the switch for actuating the hazard warning sys...

Page 107: ...witches the mast working light on and off Operating the mast working light option on page 5 18 Rocker switch for window wiper washer system optional The rocker switch 44 is located in Rocker switch pa...

Page 108: ...sing the rocker switch switches the heater fan on and off Operating the blower on page 5 26 Rotating beacon rocker switch option The rocker switch 46 is located in Rocker switch panel 3 Pressing the r...

Page 109: ...hydraulic connections are not sufficient for certain attachments Operate additional hydraulic connections on the mast 4th control circuit on page 5 89 Rocker switch for rear hydraulic connections opti...

Page 110: ...ments requiring a higher oil flow rate If the machine is equipped with the High Flow system then the Detent mechanism for the control lever for the additional hydraulics is fitted as standard Operatin...

Page 111: ...ng column The following functions can be operated with the steering column control lever Turning the lever operates the side marker lights and travel lights Pressing the lever forward backward operate...

Page 112: ...the condition of the machine before starting work Have the machine checked by qualified personnel before putting it into operation again after it has been out of operation over a longer period of tim...

Page 113: ...snow or ice The machine may only be put into operation when the operator is seated Fasten the seat belt lap belt Never get on a moving machine Never jump off the machine Before leaving the machine low...

Page 114: ...tness Check the labels for condition and completeness Check the machine for oil fuel and coolant leaks Check the engine oil level Add oil if necessary Check the hydraulic oil level Add oil if necessar...

Page 115: ...hine travel on public roads and transport them separately Install additional safety equipment for example a front edge protection for buckets with teeth on other attachments WARNING Accident hazard du...

Page 116: ...ne travel ensuring safety Information Before starting machine travel ensure that the machine complies with the relevant local regulations and that it has a valid operation license registration What to...

Page 117: ...e machine upright again Get in touch with an authorized service center The engine needs to be checked by qualified personnel before it can be released and put into operation again Environment Risk of...

Page 118: ...nt mixture Check the cooling system regularly for leaks Check the fan drive regularly Use engine oil with the correct viscosity class Check the engine air filter regularly Information The work is desc...

Page 119: ...Do not connect two batteries in series to create a start voltage of 24 V Measures to be taken at low outside temperatures Take the following measures in order to avoid damage and to start the machine...

Page 120: ...or who are already in it can be injured by work movements Always ensure that nobody is in the danger zone Stop all work movements immediately if persons enter the danger zone WARNING Accident hazard...

Page 121: ...ozen and or dirty windows can cause impaired visibility and injury Clean the windows before starting machine travel Preparations for starting the engine CAUTION Injury hazard Ensure that nobody is in...

Page 122: ...e engine running Ensure that the malfunction is rectified immediately Do not put the machine into operation before rectifying the malfunction Do not suddenly stop the engine after running it under ful...

Page 123: ...osition 0 no operating voltage 3 Turn the starting key to position I The indicator lights illuminate Preheating is automatically enabled by turning the key to position I The preheating indicator light...

Page 124: ...dure If the engine does not start after trying twice search for the cause with the troubleshooting table or contact an authorized service center Avoiding low load engine operation The running performa...

Page 125: ...3 minutes 4 Stop the engine Turn the starting key to position 0 5 Remove the starting key NOTICE Stopping the engine after running it under full load can cause damage Let the engine run at idling spee...

Page 126: ...moved The complete electrical system can quickly separated from the battery in an emergency by means of the battery master switch Switch off the battery overnight to avoid unloading the battery or to...

Page 127: ...can shift out of position respective to each other Stop machine operation immediately Synchronize the steering system Synchronize the steering system as follows 1 Stop the vehicle 2 Turn the steering...

Page 128: ...ed with the drive pedal 9 accelerator pedal This affects the work movements of the loader unit and the attachments the hydraulic functions of the attachments and the travel speed Dirt accumulation and...

Page 129: ...he machine has two speed ranges Press the button 33 to change the speed see Gear shifting on page 5 9 Fig 43 33 Speed range kph mph Recommended Crawl ing speed 0 7 0 4 35 For work requiring pre cise s...

Page 130: ...ing brake is applied Move the control lever 2 into position 0 The parking brake is released Information Pulling control lever 2 alone may not be enough to prevent the machine from rolling away Also pr...

Page 131: ...l use the brake inching pedal to support the braking effect of the drive This avoids damage to the drive and or the diesel engine Reduce engine speed remove your foot from the accelerator pedal Reduce...

Page 132: ...peed before performing downhill machine travel Always fasten your seat belt Ensure that no parts of the body protrude outside the vehicle Carefully steer the machine if the loader unit is raised Do no...

Page 133: ...on when the machine is at a standstill Information The travel direction and speed is indicated with indicator lights Information The operator seat is equipped with an operator presence switch that pre...

Page 134: ...rol Re enabling the travel direction is then necessary Select a travel direction Forward reverse control 32 in the middle position Indicator lights 26 and 27 do not illuminate No travel direction sele...

Page 135: ...ehicle is operated with button 33 Press the button The machine shifts from fast gear to crawler gear Indicator light 28 illuminates Press the button again The machine shifts from crawler gear to fast...

Page 136: ...High engine speed High travel speed Braking and stopping Press brake inching pedal 11 to change the travel speed independently of the engine speed The first part of the pedal travel reduces the drive...

Page 137: ...il the machine comes to a standstill 2 Operate the forward reverse control in the other direction 3 Press the accelerator pedal The machine travels in the opposite direction It is not necessary to ful...

Page 138: ...f the machine is registered as a tractor vehicle Refer to the operation license for the specific requirements on trailer operation Information Trailer operation is only allowed with an attachment inst...

Page 139: ...er zone Stop all work movements immediately if persons enter the danger zone NOTICE Fire hazard In case of a malfunction in its electrical system the parked machine can cause a fire Stop and park the...

Page 140: ...ulic system Cooling system Fuel system Perform a visual check for machine damage in particular of the tires attachments and attachment locks Add diesel fuel Check all fluid levels add fluid if necessa...

Page 141: ...htly to the left and right or change the travel direction to disengage the differential lock 0 NOTICE Gearbox damage due to locked differential Only switch on the differential lock when the wheels are...

Page 142: ...ferentials In other words traction is evenly distributed to all wheels Information If the vehicle is equipped with a differential lock an optional control lever is used as shown in Fig 48 Actuating th...

Page 143: ...avel on public roads Pay attention to national regulations on construction site lighting The machine is equipped with front and rear working lights The working lights are operated with switch 42 in Ro...

Page 144: ...an be outfitted with a working light on the mast The working lights on the mast are operated with the rocker switch 43 in Rocker switch panel 2 Move the rocker switch 43 to position I The telescopic b...

Page 145: ...n the steering column control lever forward II The driving lights are switched on Move the steering column control lever downward III High beam is switched on Indicator light on the indicating instrum...

Page 146: ...eering column control lever forward V The indicator light flashes The right turn indicator flashes Move steering column control lever backward VI The control light flashes The left turn indicator flas...

Page 147: ...cker switch 41 to position I The control light flashes The turn indicators flash on either side Move the rocker switch 41 to position 0 The control light does not flash The turn indicators are switche...

Page 148: ...on the rotating beacon is located in the Rocker switch panel 2 Move the rocker switch 46 to position I The rotating beacon is switched on Move the rocker switch 46 to position 0 The rotating beacon i...

Page 149: ...ase switch 41 The horn no longer sounds Machine with lights option The horn is operated via the steering column control lever 16 Press the switch in steering column control lever The horn sounds Relea...

Page 150: ...4 in the Rocker switch panel 3 Press switch 44 to position 1 The wiper is switched on Move the rocker switch 44 to position 2 In order to do this press slide switch a downward The washer system is swi...

Page 151: ...ted in the engine compartment Fig 59 Open the engine cover to switch the heating on and off see Opening the engine cover on page 7 22 Ventilation With the heating switched off the cabin can be ventila...

Page 152: ...m air keeps the windows free of ice and warms up the cabin Washer system Operating the blower The cabin is equipped with a heating system and fan The blower is operated with the rocker switch 45 in Ro...

Page 153: ...efore performing machine travel on public roads Secure the control lever before leaving the machine WARNING Crushing hazard due to tipping over of machine A tipping vehicle can cause serious injury or...

Page 154: ...e bales or stacks of bales can cause serious or fatal injury Never transport several large bales or boxes at the same time Stacking loads with machines that are not equipped with a protective roof or...

Page 155: ...it Move the control lever 4 toward H The loader unit is raised The telescopic boom is extended Move the control lever 4 toward S The loader unit is lowered The telescopic boom is retracted Attachment...

Page 156: ...control lever 4 Press the button 34 The telescopic boom is extended Press the button 35 The telescopic boom is retracted NOTICE Risk of technical damage Risk of bending the hydraulic cylinder that ext...

Page 157: ...ng vehicle can cause serious injury or death Extend the telescopic boom only if the machine is on firm and level ground Always pay attention to the display of the safe load indicator First raise the l...

Page 158: ...cannot be avoided The safety prop is located at the rear of the machine Installing the safety prop onto the lifting cylinder 1 Park the machine on firm level and dry ground 2 Empty and tilt in the att...

Page 159: ...indicator and overload protection may only be performed by authorized personnel Information The safe load indicator only gives a warning in the event of insufficient stability in the longitudinal dire...

Page 160: ...40 There is no risk of the machine tipping over all travel and work movements can be continued Green up to 85 There is a slight risk of the machine tipping over pay attention to the display of the sa...

Page 161: ...he overload protection is enabled if the load is too heavy Lowering quickly or unevenly can cause the machine to tip over Slowly and carefully lower the boom The overload protection function is deacti...

Page 162: ...der to be able to position loads in the overload range the overload protection can be temporarily bypassed by pressing the rocker switch 38 in the Rocker switch panel 1 and the control lever 4 If the...

Page 163: ...ime The boom does not extend automatically in the upper range In forklift mode the boom does not automatically retract in the lower range Fig 70 The boom can be lowered and extended at the same time T...

Page 164: ...raising and lowering movement of the boom improves machine stability When it is raised the boom only automatically extends in the upper range if forklift mode is switched on Fig 70 When it is lowered...

Page 165: ...tem VLS Before starting work fully raise and lower the unloaded boom once with forklift mode switched on The boom must extend automatically in the upper range When lowered the boom must retract automa...

Page 166: ...before leaving the machine First sit down on the operator seat Then unlock the lifting unit control lever The loader unit control lever can be secured against unintentional operation by means of a loc...

Page 167: ...maintenance plan Ensure that the hydraulic connections are clean Operating hydraulic connections on the loader unit The hydraulic connections on the loader unit are operated with additional control le...

Page 168: ...draulic lock for attachments is operated with the additional control lever 6 1 Move the additional control lever 6 toward R The quickhitch is locked 2 Move the lock a in the rocker switch 40 in Rocker...

Page 169: ...nnections NOTICE Technical damage due to overheating of hydraulic system Always put the additional control lever 6 back to the zero position if continuous operation is not required Continuous operatio...

Page 170: ...authorized attachments ensure machine stability Only authorized attachments avoid machine overload WARNING Accident hazard due to tipping over of machine The weight ratios of the machine change with...

Page 171: ...mation Use only attachments authorized by the manufacturer of the machine The manufacturer of the machine shall not be liable for damage etc if unauthorized attachments are used Avoid overloading the...

Page 172: ...ckward machine travel Adjust the existing visual aids for example the rearview mirrors correctly Work particularly carefully when reversing the machine Interrupt work immediately if persons enter the...

Page 173: ...eased Wear protective clothes NOTICE Damage to the hydraulic system due to dirt Avoid dirt Ensure that the hydraulic connections are clean WARNING Injury hazard due to uncoupled attachments tipping ov...

Page 174: ...t on the loader unit 1 Retract the telescopic boom completely 2 Lower the attachment until it is barely above the ground 3 Remove lock pins 3 4 Approach the machine to the attachment 5 Position pin 1...

Page 175: ...rolling away 1 Retract the telescopic boom completely 2 Lower the attachment until it is barely above the ground 3 Release lock pins 3 and pull them out 4 Lower the loader unit and tilt out the attac...

Page 176: ...s on page 5 42 1 Retract the telescopic boom completely 2 Lower the attachment until it is barely above the ground 3 Approach the machine to the attachment 4 Position pin 1 under catch hooks 2 5 Raise...

Page 177: ...e telescopic boom completely 2 Lower the attachment until it is barely above the ground 3 Move lock a in switch 40 toward b Press and hold switch 40 and move control lever 6 toward L The lock pins 3 a...

Page 178: ...tention immediately if hydraulic oil penetrates the skin or eyes Only open hydraulic systems after the pressure in them has been released Wear protective clothes NOTICE Damage to the hydraulic system...

Page 179: ...ely 2 Lower the attachment until it is barely above the ground 3 Stop the engine 4 Move the control lever 6 back and forth several times The pressure on the hydraulic connections on the loader unit is...

Page 180: ...ulic connec tions on the loader unit with control lever 6 Uncoupling 1 Retract the telescopic boom completely 2 Lower the loader unit until it is barely above the ground 3 Stop the engine 4 Move the c...

Page 181: ...achine Extend the telescopic boom only if the machine is on firm and level ground Always pay attention to the display of the safe load indicator First raise the loader unit fully then extend the teles...

Page 182: ...The safe load indicator gives visual and acoustic signals 1 Green up to 40 There is no risk of the machine tipping over all travel and work movements can be continued Green up to 85 There is a slight...

Page 183: ...n your seat belt Ensure that no parts of the body protrude outside the vehicle Carefully steer the machine if the loader unit is raised Do not exceed the permissible payloads CAUTION Accident hazard d...

Page 184: ...he given conditions Avoid too much wheel spin Tire wear and fuel consumption is unnecessarily increased and machine output cannot be fully used This Operator s Manual only describes the use of the fol...

Page 185: ...oil and rock Designated use The designated use of the lightweight material earth bucket is loosening picking up transporting and dumping material Transporting persons in the bucket is not in complianc...

Page 186: ...movements can be performed at the same time if required for example Raising and Tilting out or Lowering and Tilting in To do this the movements must be superimposed on the control lever 4 H raise S lo...

Page 187: ...rial earth bucket parallel to the ground Travel into the material Pay attention to the travel speed Raise the loader unit slightly to apply some load to the front axle of the machine Wheel spin can al...

Page 188: ...tweight material bucket earth bucket to penetrate into the material Excavation work Soft ground Lower the lightweight material bucket earth bucket to the ground for digging in soft material Tilt out t...

Page 189: ...erial bucket earth bucket to the front until reaching an appropriate digging angle Press the lightweight material bucket earth bucket slightly downward as you travel forward so that the bucket can pen...

Page 190: ...ins for raising and transporting loads with a load hook The load must be freely suspended on the load hook The chain must not rub against the cutting edge Refer to the bucket s type label for the load...

Page 191: ...pling hydraulic connections from the mast on page 5 52 Control elements Operate the 4 in 1 bucket with the control4 lever Loader unit control lever on page 5 29 Operating hydraulic connections on the...

Page 192: ...objects 1 Open the 4 in 1 bucket 2 Position the 4 in 1 bucket over the object to be grabbed 3 Lower the loader unit 4 Close the 4 in 1 bucket The object can be transported Grabbing bulky material Bul...

Page 193: ...rieb_en fm 5 67 Pulling out and replacing posts 1 Open the universal bucket and lower it over the post Close the bucket to grip the post firmly 2 Loosen the post with careful up and down movements 3 R...

Page 194: ...ticularly carefully when reversing the machine Interrupt work immediately if persons enter the danger zone Information During dozer blade work in the reverse direction the telescopic boom can pull out...

Page 195: ...he lift hydraulics 4 Set the angle of the rear cutting edge 5 Grade the surface by performing forward machine travel Drawing material backward 1 Fold up the front half of the bucket 2 Lower the univer...

Page 196: ...with the lift hydraulics 5 Pick up material by performing forward machine travel The material rolls into the bucket and is picked up at the same time This position makes it possible to strip material...

Page 197: ...rting and loading materials such as silage hay round bales green fodder and manure Installing the manure forks Re equipping attachments on page 5 46 Control elements Operate the dung fork with the con...

Page 198: ...ightly raise the loader unit A load is applied to the front axle of the machine If the material is solid such as compacted manure the manure forks can be tilted in to loosen the load 1 Travel to the u...

Page 199: ...ure Transporting tree trunks stones and similar material is not in accordance with its designated use Installing the fork and grab Re equipping attachments on page 5 46 Coupling uncoupling hydraulic c...

Page 200: ...nit A load is applied to the front axle of the machine 5 Close the fork and grab attachment If the material is solid such as compacted manure the fork and grab attachment can be tilted in to loosen th...

Page 201: ...hine is at a standstill Do not tilt in the attachment to the limit with a raised and extended loader unit CAUTION Accident hazard due to tipping over of machine Shifting the center of gravity can affe...

Page 202: ...et forks Re equipping attachments on page 5 46 Control elements Operate the pallet fork with the control lever 4 Operation on page 5 60 Operation Select forklift mode see Selecting the operating mode...

Page 203: ...h the sliding surface of the fork frame when shifting the fork arms Wear protective equipment 1 Raise the pallet forks 10 30 cm above the ground 2 Set the fork lock to position 1 The lock is released...

Page 204: ...ne and pallet forks is appropriate for the weight of the load 2 Adjust the fork spacing and lock the forks 3 Approach the material in a straight line 4 Set the pallet forks to the required height in a...

Page 205: ...height that allows moving the pallet forks across uneven ground without touching it Adjust the height during transportation if necessary 2 During machine travel up or down a slope the load must alway...

Page 206: ...oader unit can cause accidents Immediately and carefully lower the loader unit to the ground in the event of power loss of the machine Release the residual pressure in separate control circuits of the...

Page 207: ...the telehandler as follows 1 Keep all persons away from the area around the telehandler 2 Apply the parking brake 3 Set all control levers buttons and switches to the zero position 4 Switch on the ha...

Page 208: ...them has been released Wear protective clothes Proceed as follows to the release residual pressure in the hydraulic system observe the order of the work steps 1 Fully lower the loader unit 2 Stop the...

Page 209: ...after shutting down the machine release the pressure in the hydraulic system first The loader unit can be operated during a limited period of time in case of engine malfunction Immediately after iden...

Page 210: ...nnection of attachments on which certain functions are operated with an electric changeover valve The electric power outlet on the mast is switched with the rocker switch 39 in Rocker switch panel 1 M...

Page 211: ...ectric power outlet at the rear This power outlet is used for connecting lights turn indicators and electrical devices on the trailer or attachment Always install additional lights on an attachment if...

Page 212: ...Some attachments require a return without pressure The connection for the reverse travel without pressure is located at the front left on the mast The design of the connection makes it impossible to c...

Page 213: ...control lever 4 Control lever 4 does not need to be released to operate the hydraulic connections This function is operated with button 36 on the control lever 4 Press button 36 The function Tilt in...

Page 214: ...hydraulic connections can then also be operated with control lever 6 Coupling the additional hydraulic connections requires releasing the pressure on them first Proceed as follows for this 1 Stop the...

Page 215: ...ions are in operation Move the rocker switch 47 to position I The additional hydraulic connections are in operation If the additional hydraulic connections are switched on Move control lever 6 toward...

Page 216: ...outside section and cannot be extended with the telescopic boom The High Flow hydraulic connections are located on the right of the loader unit Red connection F feed Blue connection R return Informati...

Page 217: ...The High Flow hydraulic connections are operated with switch 49 in Rocker switch panel 4 Switch on the High Flow hydraulic connection Press switch 49 to position I Move the control lever 6 toward L u...

Page 218: ...operated with the control lever 6 for the auxiliary hydraulics Information With this type of connection the hydraulic connections on the loader unit and at the rear of the machine are operated at the...

Page 219: ...es releasing the pressure on them first Proceed as follows 1 Stop the engine 2 Switch on the starter position I 3 Press the rocker switch 48 in both directions The pressure on the rear hydraulic conne...

Page 220: ...ading The max authorized mounting weight max for the rear 3 point mount is 500 kg Only use attachments approved by Wacker Neuson Wacker Neuson shall not be liable for the use of other attachments NOTI...

Page 221: ...ally lowers the rear 3 point mount to the lowest position Position II raises the 3 point mount as long as switch 50 is pressed Move the rocker switch 50 to position I The switch remains in position I...

Page 222: ...slowly with this throttle This makes it possible to reduce the lowering speed of the rear 3 point mount by closing the throttle if heavy attachments are installed so that the load is not abruptly low...

Page 223: ...n 1 Lower the rear 3 point mount 2 Raise the upper linkage of the rear 3 point mount fasten it with the pin B and secure the pin 3 Remove both pin locks from the lower linkage pins U and pull out the...

Page 224: ...se cardan shafts with working protective devices Check before use whether the protective devices are installed and functional Replace damaged or missing protective devices Check before use whether the...

Page 225: ...haft The PTO shaft is operated with switch 48 in Rocker switch panel 4 Press switch 48 to position I The PTO shaft is switched on Press switch 48 to position 0 The PTO shaft is switched off Informatio...

Page 226: ...ailer load Do not exceed the permissible trailer speed Before coupling and uncoupling a trailer secure it with the parking brake and suitable wheel chocks to prevent it from rolling away There must be...

Page 227: ...the trailer This Operator s Manual describes how to use and operate the following trailer couplings Maneuvering coupling Automatic trailer coupling Autohitch coupling See chapter Trailer operation on...

Page 228: ...g WARNING Danger of crushing due to unintentional actuation of the trailer coupling The trailer pin closes abruptly and can cause serious injury Keep all parts of the body away from the range of actio...

Page 229: ...move the trailer coupling Assembly is performed in the reverse order In order to ensure the required swivel angle when coupled use the trailer coupling only in connection with lugs in compliance with...

Page 230: ...chanism 4 Check the correct locking 5 Remove the equipment chocks support wheel used for securing the trailer 6 Connect the trailer supply lines to the machine Uncoupling the trailer from the machine...

Page 231: ...lever Fig 122 Move the lever backward Engine speed is reduced Move the lever forward Engine speed increases Manual inching This function makes it possible to adapt travel speed individually with no n...

Page 232: ...t has a data memory for saving the times that have been set or that have elapsed The time is taken and saved if the starter is switched off during lubrication or during a break The remaining lubricati...

Page 233: ...brication at any given time if the ignition is switched on This also serves as a functional check The pump then immediately starts with the lubrication cycle The lubrication or break time that has ela...

Page 234: ...cation time S with a flat screwdriver Install the cover once setting is over Setting lubrication times S 1 to 16 minutes 16 notches 1 minute each Setting break times P 0 5 to 8 h 16 notches 0 5 h each...

Page 235: ...volts Run the engine and hydraulic oil preheating only in a dry place The machine can be fitted with an engine and hydraulic oil preheating It preheats the coolant hydraulic oil The following operati...

Page 236: ...cartridge can burn out Check for leaks including on a warm machine The coolant must always have a sufficient amount of antifreeze Check cables regularly for damage or aging Immediately replace a damag...

Page 237: ...ent circuit breaker 2 Open the engine cover 3 Connect special cable A supplied with the machine with machine power outlet B 4 Connect the plug to a 230 V mains power outlet The engine and hydraulic oi...

Page 238: ...satellite 28 kph version Information Operators owners of machines with a design specific maximum speed over 20 kph must comply with special driving license and insurance requirements The machine may...

Page 239: ...nticorrosion agent onto bare metal parts of the machine for example piston rods of hydraulic cylinders if they are not retracted 7 Preserve the engine Preserving the engine 1 Clean the engine with a h...

Page 240: ...of the engine 2 Remove the anti corrosion agent from the pulleys 3 Install the fan belt 4 Drain the preservation oil and add engine oil 5 Start up the engine 6 Check the V belt tension after running...

Page 241: ...icable regulations Prior to disposal Observe all applicable safety regulations regarding putting the machine out of operation Ensure that the machine cannot be operated between putting it out of opera...

Page 242: ...state of the art standards applicable at the time of recycling and in compliance with the safety regulations regarding accident prevention All parts must be disposed of in the correct waste disposal s...

Page 243: ...are fully functional Only tow the machine with towing gear of sufficient dimensions No persons are allowed to stay in the range of action of the towing gear during towing Secure the machine against un...

Page 244: ...E Damage to the hydraulic system when towing the machine The engine cannot be started under any circumstances by towing the machine Bypassing the drive NOTICE Risk of damage to the hydraulic system Do...

Page 245: ...able displacement pump can be accessed from the lower side of the machine Before towing the machine 1 Unscrew the lower cover plate 2 Loosen hexagon nuts 2 of the high pressure limiting valves 3 Screw...

Page 246: ...ransportation Towing gear WARNING Accident hazard when pulling trailer loads Towing trailer loads can cause accidents Do not use the towing gear to tow trailer loads Only hitch trailer loads if the ma...

Page 247: ...ing it Use transport equipment with corresponding load carrying capacity Pay attention to the machine s operating weight Proceed with special care when loading the machine in conditions of snow and ic...

Page 248: ...axle load of the transport vehicle must not be exceeded during loading or transportation Ensure that the load does not fall short of the minimum axle load of the transport vehicle otherwise the steeri...

Page 249: ...hine are free of snow ice oil or grease 5 Check the engine oil level of the machine to be loaded The oil level must be visible at the MAX mark of the oil dipstick Loading 1 Start the vehicle 2 Raise t...

Page 250: ...t observe all movements of the load and the lifting gear Secure the vehicle against unintentional movement The crane operator may move a load only after making sure that the load is safely fastened an...

Page 251: ...Transportation 6 BA TH412 06 2017 4512_6 2_Verladen_en fm 6 9 Crane eyelets For hitching the lifting gear use only the slinging points identified with the labels Fig 129 Fig 130 Fig 129 Fig 130...

Page 252: ...Empty tilt in and lower the attachment to transport position 3 Set all control levers and switches to the zero position 4 Stop the engine and remove the starting key 5 Apply the parking brake 6 Leave...

Page 253: ...6 2017 4512_6 3_Transportieren_en fm 6 11 6 3 Transporting the vehicle Tie down points on machine For tying down the machine use only the slinging points identified with the labels Fig 132 Fig 133 Fig...

Page 254: ...wheel chocks 2 Secure the machine at the tie down hooks 3 Close the outlet of the muffler with a suitable cap or adhesive tape 4 Ensure that the driver of the transport vehicle knows the overall heig...

Page 255: ...case of high noise levels Safety instructions Information on maintenance Only perform maintenance and inspection work after having read and understood the Operator s Manual Pay attention to the basic...

Page 256: ...ponents that are to be attached or removed or whose installation position is to be changed with the aid of suitable lifting gear or with mounting or support devices to prevent uninten tional movement...

Page 257: ...ndling fuels oils and greases Burn hazard due to hot lubricating oil or hydraulic oil Avoid skin and eye contact with oil and grease Wear protective equipment Do not use fuel or solvents to clean your...

Page 258: ...nd or tilt cylinder open the valves in order to lower the loader unit see Releasing residual pressure in the hydraulic system on page 5 82 Information on hardware pipeline hydraulic hoses Replace hydr...

Page 259: ...d separately from other waste Information on the electrical system Always follow the correct sequence when discon necting the battery To disconnect First the negative terminal and then the positive te...

Page 260: ...ecking the engine oil level Check the engine for leaks Check the hydraulic oil level Check the tire condition and pressure Check all bolts for tightness Check the wheel bolts Check the braking system...

Page 261: ...ents Check the protective ROPS FOPS structure Clean the preliminary separator of the fuel filter Check the machine axles for leaks Check the hydraulic oil and water radiator for leaks and dirt clean i...

Page 262: ...operating hours Check the gearbox engine and hydraulic system for leaks Check the hydraulic water and engine oil radiator for dirt Check the coolant level and antifreeze Check the tension and conditi...

Page 263: ...hanism for correct operation Check the protective ROPS structure Check the tire condition Replace the engine oil and engine oil filter Clean the air filter replace it if necessary Replace the hydrauli...

Page 264: ...12 months after putting the machine into operation Work to be performed by an authorized service center after 500 operating hours Check the gearbox engine and hydraulic system for leaks Check the engi...

Page 265: ...es Check the pin bearing of the center joint Check the idling speed Check the engine cover and door locking mechanisms for correct function adjust them if necessary Check the tire condition and tire p...

Page 266: ...he axles Perform grease lubrication according to the lubrication plan Lubricate the cardan shaft Lubricate with oil all levers Bowden cables and hinges Check all oil fluid levels The following inspect...

Page 267: ...reached or the time interval specified in the schedule is reached Work to be performed by an authorized service center Operatinghours 250 750 1000 1250 1750 2000 2250 2750 3000 etc Operating hours 150...

Page 268: ...ck the electrical system Check the service brake and parking brake adjust them if necessary Check the hydraulic steering Check the light system if equipped Check the exhaust system Check the pivot pin...

Page 269: ...d tire pressure Replace the engine oil and engine oil filter Yanmar engines every 250 operating hours Replace the fuel filter clean the pre filter Clean the air filter replace it if necessary Replace...

Page 270: ...liding joint Lubricate with oil all levers Bowden cables and hinges Check all oil fluid levels Clean the cabin breather filter replace it if necessary Check according to the Ordinance on Industrial Sa...

Page 271: ...Maintenance 7 BA TH412 06 2017 4512_7 1_Hinweise_en fm 7 17...

Page 272: ...7 18 BA TH412 06 2017 4512_7 2_Schmierplan_en fm 7 Maintenance Lubrication plan Preparation for lubricating See page 7 26 4 7 8 1 3 2 9 13 W 10 12 11 1 2 3 5 6 Fig 135 Maintenance...

Page 273: ...ubrication 1 8 Rear center axis pin remote lubrication 1 9 Rear kingpin 4 10 Front kingpin 4 11 Traction bar 2 12 Front tilt cylinder 1 13 Front compensating cylinder remote lubrication 1 W Angle sens...

Page 274: ...intenance Special lubrication points for the Vertical Lift System VLS In order to ensure trouble free operation of the Vertical Lift System VLS the ball hitches of angle sensor K on the loader unit mu...

Page 275: ...ing system contents TH412cc40 TH412cc35 8 5 liters 2 24 gal 8 3 liters 2 19 gal Water with commercially available HD coolant antifreeze HD coolant antifreeze ASTM D 4985 Front axle Rear axle Transfer...

Page 276: ...ing Let the engine cool down Wear protective equipment NOTICE Engine damage due to loose objects in the engine compartment Remove all tools and objects from the engine compartment before closing the e...

Page 277: ...machine due to cleaning work Pay attention to the lower side in particular when cleaning the machine Do not allow dirt to collect on the engine or gearbox Ensure that the spaces between the radiator f...

Page 278: ...Information on cleaning Information Clean a new machine only with a sponge for the first three months As the bottom layers of the paintwork are not fully hardened yet the paintwork can be damaged if c...

Page 279: ...n of the seat belt Check the quickhitch for the attachments Check whether all pivot pins are in their correct positions and secured with their locks Check the climbing aids and handholds for correct p...

Page 280: ...telescopic loader unit until all lubrication points can be accessed from the ground Stop the engine and remove the starting key Operate and remove the battery master switch Information Lubricate the l...

Page 281: ...ts Hot and moving engine parts can cause injury Do not open the engine cover if the engine is running Let the engine cool down Wear protective equipment WARNING Burn hazard due to deflagrations Fuels...

Page 282: ...ality diesel fuel Do not add gasoline After working on the fuel system clean the engine and the engine mountings of any adhering fuel Use a fine filter in the fueling line of the diesel fuel Fuel syst...

Page 283: ...d due to diesel fuel Diesel fuel gives off flammable vapors Do not smoke avoid fire and open flames Adding gasoline is prohibited Environment Diesel fuel is harmful to the environment Avoid releasing...

Page 284: ...located in position D on the machine Fig 139 The tank cap is lockable 1 Lower the loader unit to the ground 2 Stop the engine 3 Unlock and unscrew the filler cap of the filler inlet 4 Refuel the vehi...

Page 285: ...ug from the filter The collected water now drains 3 Firmly re tighten the drain plug 4 Bleed the fuel system Bleeding the fuel system 1 Add fuel to the fuel tank 2 Turn the starting key to position I...

Page 286: ...ts Hot and moving engine parts can cause injury Do not open the engine cover if the engine is running Let the engine cool down Wear protective equipment Checking the engine oil level NOTICE Damage due...

Page 287: ...Wait one minute 5 Open the engine cover Checking the engine oil level 1 Pull out the engine oil dipstick 1 Fig 142 2 Wipe the engine oil dipstick with a clean and lint free cleaning cloth 3 Re insert...

Page 288: ...ine oil type see Fluids and lubricants on page 7 21 Add engine oil if the oil level is below the Max mark 1 Open the engine oil filler inlet 2 Fig 143 2 Add engine oil 3 Check the engine oil level If...

Page 289: ...e engine compartment Fig 144 It consists of two parts One part cools the hydraulic oil the other part the engine Check the following if the machine overheats during longer work operation or at high ou...

Page 290: ...tive equipment NOTICE Damage to the engine and cooling system The coolant should be made up to equal parts of water and antifreeze This mixture ensures the best possible ratio between cooling performa...

Page 291: ...onmental damage Avoid releasing antifreeze and coolant Collect antifreeze and coolant and dispose of them in an environmentally friendly manner Information Adapt the water coolant mixture to the local...

Page 292: ...l corrosion in the engine and radiator Ensure a sufficient amount of coolant in the cooling circuit at all times Checking the antifreeze mixture The antifreeze prevents the coolant from freezing at te...

Page 293: ...ng the radiator Carefully straighten any bent cooling fins Environment Risk of damage to the environment Only clean the machine in a suitable place where the waste water can be collected in an environ...

Page 294: ...n Wear protective equipment NOTICE Engine damage due to dirty air intake system Engine damage can occur if the engine draws in unfiltered air Do not let the engine run if parts of the air intake syste...

Page 295: ...nce 7 BA TH412 06 2017 4512_7 10_Luftfilter_en fm 7 41 Environment Avoid environmental damage Replace the main air filter element in time If it is allowed to get too dirty exhaust gas emissions will i...

Page 296: ...ir filter Checking cleaning replacing the main engine air filter Information Technical damage due to dirty engine air filter Clean or replace the engine air filter according to the maintenance interva...

Page 297: ...ne air filter S is not removed 3 Check the intake line between the engine air filter and the engine Check for leaks Check for tightness 4 Clean the main engine air filter H by knocking it gently and b...

Page 298: ...for the fifth time under all circumstances If engine air filter maintenance shows that there is a maintenance error or that the main engine air filter is damaged replace the safety engine air filter...

Page 299: ...Do not open the engine cover if the engine is running Let the engine cool down Wear protective equipment NOTICE Risk of technical damage Cracked and stretched V belts cause engine damage Perform maint...

Page 300: ...en fm 7 Maintenance Preparations 1 Park the machine on firm level and dry ground 2 Apply the parking brake 3 Fully lower the loading frame to the ground 4 Stop the engine 5 Wait one minute 6 Open the...

Page 301: ...een the pulleys by no more than about 10 mm Fig 151 Tensioning the V belt 1 Loosen fastening screws 2 of the alternator and set screw 1 Fig 152 2 Apply pressure to the alternator with a suitable tool...

Page 302: ...cool down Wear protective equipment Hydraulic oil radiator The hydraulic oil radiator is located in a combined radiator The radiator is installed in the engine compartment Fig 153 One part cools the h...

Page 303: ...ulic oil reservoir when the hydraulic oil level varies The breather filter contains a filter element that prevents dust and dirt from entering and squirts of oil from escaping The breather filter cont...

Page 304: ...ion window with the mast lowered NOTICE Damage to hydraulic system due to incorrect or dirty hydraulic oil Use hydraulic oil as specified in Fluids and lubricants overview on page 7 21 If the oil is c...

Page 305: ...proper oil type See chapter Fluids and lubricants overview on page 7 21 Carefully open the hydraulic oil filler neck to release the pressure in the hydraulic oil reservoir Add hydraulic oil if there...

Page 306: ...nly when seated on the operator seat Ensure that no one is in the danger zone of the machine 1 Check the hydraulic oil level in the hydraulic oil reservoir If necessary add hydraulic oil until the oil...

Page 307: ...or contacts Do not clean very sensitive electrical components with a high pressure cleaner Do not touch light bulbs or headlight reflectors with your fingers Information Have all problems in the elec...

Page 308: ...malfunctioning batteries Batteries give off explosive gases that can cause deflagrations if ignited Do not smoke avoid fire and open flames Do not place any tools on the battery WARNING Risk of injur...

Page 309: ...environmental damage Dispose of old batteries in an environmentally friendly manner and separately from other waste Removing the battery NOTICE Short circuit due to wrong order when disconnecting the...

Page 310: ...the zero position 6 Switch off all electrical consumers and the battery master switch 7 Remove the starting key Way of proceeding 1 Open the engine cover 2 Unscrew the line from the negative terminal...

Page 311: ...is fastened on one side of the battery 1 Always keep the terminals on the battery and connecting cables clean and lubricate them with anti corrosion grease Ensure that the cover of the positive termi...

Page 312: ...e machine Ensure that the vehicle giving a jump start and the machine do not touch Do not jump start the machine if the battery is malfunctioning or frozen Do not connect two batteries in series Use o...

Page 313: ...ning battery Do not start the machine in this case Install a functional battery Preparations 1 Set all control levers and switches to the zero position 2 Turn the starting key to position 0 The electr...

Page 314: ...attery L then connect the other end to the positive terminal of the starting battery V 3 Connect one end of the black battery jumper cable to the negative terminal of the starting battery V 4 Connect...

Page 315: ...art If the engine of the machine does not start after 15 seconds wait one minute and repeat the procedure Disconnecting the battery jumper cables Follow the order of the activity 1 First disconnect th...

Page 316: ..._Heizung_en fm 7 Maintenance 7 14 Heating ventilation and air conditioning system Maintenance Information This option does not require any special maintenance An air conditioning system is not availab...

Page 317: ...asher system Filling up the washer system reservoir The washer system container is located in position 1 Fig 162 on the machine Information Ensure that there is always enough water in the washer syste...

Page 318: ...an be checked on the differential housing and on the wheel reduction gears Information Check plugs are located in the same positions on the front and rear axles Perform maintenance on the gearbox and...

Page 319: ...Maintenance 7 BA TH412 06 2017 4512_7 16_Achsen_en fm 7 65 Fig 163 a b Fig 164 c...

Page 320: ...ake system Information on the braking system The brakes are a safety part of the first level improper maintenance can cause the brakes to fail All repair work on the braking system must be performed b...

Page 321: ...ficient lift capacity Secure the machine with trestles DANGER Risk of death due to incorrect assembly work Incorrect assembly work of tires and rims causes serious injury or death Have assembly work p...

Page 322: ...pressure table on page 9 4 This work may only be performed by an authorized service center in case of a complete pressure loss Inflating the tires Preparations 1 Park the machine on firm level and dr...

Page 323: ...t to the wheel to be changed Ensure that the machine cannot slip off the jack Secure the machine with additional supports if necessary 2 Loosen the wheel bolts 3 Raise the jack until the wheel is bare...

Page 324: ...ect maintenance and service is absolutely necessary for smooth and continuous operation and for a long ser vice life of the attachments Observe the lubrication and maintenance instructions in the Oper...

Page 325: ...ubricant escapes at position 1 on the central lubrication system one or more lubrication points will not be lubricated Get in touch with an authorized service center in this case NOTICE Damage to cent...

Page 326: ...o ensure the correct function of the trailer coupling coupling pin A must be closed before cleaning with a high pressure cleaner 1 Close the trailer coupling 2 Apply tough water proof grease to coupli...

Page 327: ...formation on troubleshooting The information given in this chapter is provided for the fast and reliable detection of malfunctions and their appropriate repair Please contact your dealer if the malfun...

Page 328: ...ation of hydraulic connections Operator not sitting in the operator s seat mal functioning operator presence switch Sit down on the operator seat have the opera tor presence switch replaced Empty fuel...

Page 329: ...e Take the machine to a service center Oil level too low or too high Adjust the oil level Air in the cooling system Bleed the cooling system Engine does not have enough output Continuous operation of...

Page 330: ...Release the parking brake The inching cartridge is not in the 0 position Check and if necessary have the inching car tridge repaired Malfunctioning electronics control box Have the electronics control...

Page 331: ...ic connec tions is switched on and operates against pressure Switch off continuous operation of hydraulic connections Dirty hydraulic oil radiator Cleaning Insufficient V belt tension Tensioning the V...

Page 332: ...8 6 BA TH412 06 2017 4512_8_Stoerungen_en fm 8 Malfunctions Notes...

Page 333: ...Technical data 9 BA TH412 06 2017 4512_9_Tech_Daten_en fm 9 1 9 Technical data 9 1 Models and trade names Overview Models Trade name T4512 TH412 Technical data...

Page 334: ...inclination the machine can travel on 7 with a raised loader unit Engine Manufacturer Yanmar Design 3 cylinder diesel engine Type 3 TNV82A BDWM Displacement 1331 cm 81 22 in Cooling Water cooled Rpm 3...

Page 335: ...e Parking brake Machine travel hydraulics Flow rate 84 l min 22 19 gal min operating pressure 360 bar 5221 35 psi Service brake Design Foot operated mechanical disk brake via linkage with the brake in...

Page 336: ...9 7 Work hydraulics Overview Tires Air pressure bar psi 10 0 75 15 3AS 3 1 45 10 16 5 EM 3 6 61 31 x 15 50 15AS 3 1 45 31 x 13 50 15RP 3 1 45 Steering system Fully hydraulic kingpin steering on front...

Page 337: ...ystem Electrical system Fuse assignment The fuse box is located in the instrument panel next to the ignition lock See on page 7 54 Fuses in the chapter Maintenance Battery Voltage 12 V Capacity 77 Ah...

Page 338: ...15 F4 Rear working lights loader unit working light 15 F5 Vertical Lift System overload protection 15 F6 Engine 7 5 F7 Options rotating beacon electrical connec tion of loader unit additional control...

Page 339: ...6 10 7 37 14 10 32 16 11 80 M8 23 16 96 34 25 07 40 29 50 M10 46 33 92 67 49 41 79 58 26 M12 79 58 26 115 84 81 135 99 57 M14 125 92 19 185 136 44 220 162 26 M16 195 143 82 290 213 89 340 250 77 M18 2...

Page 340: ...TH412 06 2017 4512_9_Tech_Daten_en fm 9 Technical data Specific tightening torques Designation Tightening torques in Nm ft lbs Wheel nut M18x1 5 285 210 02 Nuts of high pressure limit ing valves M8 22...

Page 341: ...of the radiator and the engine The coolant should be made up to equal parts of water and antifreeze This mixture ensures the best possible ratio between cooling performance antifreeze and anti corrosi...

Page 342: ...accordance with its designated use full body vibrations vary from less than 0 5 m s 19 69 in s up to a momentary maximum value When calculating the vibration values in accordance with ISO TR 25398 200...

Page 343: ...at ing weight 4500 kg 9920 8 lbs Load carry load ing and transporta tion work 0 84 m s 2 76 ft s 0 81 m s 2 66 ft s 0 52 m s 1 71 ft s 0 23 m s 0 76 ft s 0 20 m s 0 66 ft s 0 14 m s 0 46 ft s Use in e...

Page 344: ...s Permissible axle loads per axle 2000 kg 4409 lbs Permissible payload with pallet fork 1000227130 according to EN 1459 Annex B telescopic boom retracted 1200 kg 2645 lbs Permissible payload with pall...

Page 345: ...Technical data 9 BA TH412 06 2017 4512_9_Tech_Daten_en fm 9 13 Load diagram Fig 170...

Page 346: ...9 14 BA TH412 06 2017 4512_9_Tech_Daten_en fm 9 Technical data 9 14 Dimensions Dimensions of 29 9 kW machine Fig 171...

Page 347: ...1961 77 20 H Seat height 973 38 31 J Total work height bucket 5238 206 22 Total work height pallet forks 5010 197 24 K Max height of attachment pivot 4551 179 17 L1 Load over height with extended boo...

Page 348: ...9 16 BA TH412 06 2017 4512_9_Tech_Daten_en fm 9 Technical data Vehicle dimensions 29 9 KW part 2 Fig 172...

Page 349: ...boom pallet forks 920 36 22 O Scraping depth 94 3 70 P Overall width 1560 61 42 Q Track 1296 51 02 S Ground clearance 306 12 05 T Max radius bucket 3517 138 46 T1 Max radius pallet forks 3409 134 21...

Page 350: ...9 18 BA TH412 06 2017 4512_9_Tech_Daten_en fm 9 Technical data Dimensions of 22 6 kW machine Fig 173...

Page 351: ...1941 76 42 H Seat height 953 37 52 J Total work height bucket 5218 205 43 Total work height pallet forks 4990 196 46 K Max height of attachment pivot 4531 178 39 L1 Load over height with extended boo...

Page 352: ...9 20 BA TH412 06 2017 4512_9_Tech_Daten_en fm 9 Technical data Vehicle dimensions 22 6KW part 2 Fig 174...

Page 353: ...boom pallet forks 920 36 22 O Scraping depth 94 3 70 P Overall width 1560 61 42 Q Track 1296 51 02 S Ground clearance 286 11 26 T Max radius bucket 3517 138 46 T1 Max radius pallet forks 3409 134 21...

Page 354: ...9 22 BA TH412 06 2017 4512_9_Tech_Daten_en fm 9 Technical data Notes...

Page 355: ...em Main filter element 7 42 Attachments 4 in 1 bucket 5 65 Coupling hydraulically 5 50 Coupling mechanically 5 48 Coupling hydraulic connections 5 52 Fork and grab attachment 5 73 Lightweight material...

Page 356: ...Description of switches 4 30 Designated use 3 8 Door 4 2 E Electrical system Fuses 7 53 Engine Adding engine oil 7 34 Checking the engine oil level 7 32 Malfunctions 8 2 Preheating 5 109 Preserving 5...

Page 357: ...vel 7 50 Malfunctions 8 5 I Indicator lights and warning lights 4 26 Inflating the tires 7 68 Inspection work 4 40 Installing the pallet forks 5 76 L Labels Other type labels 3 19 Type labels 3 18 Loa...

Page 358: ...s 5 19 Machine travel operation 5 6 Parking brake 5 4 Rotating beacon 5 22 Service brake 5 5 Telescopic boom 5 30 Travel direction selection 5 8 Turn indicators 5 20 5 21 Wiper 5 24 Working lights 5 1...

Page 359: ...7 24 Loading 6 5 Lubrication 7 26 Machine travel 5 10 Permanently putting out of operation 5 115 Putting into operation 4 38 Secure 5 14 Towing 6 1 Tying down 6 12 W Water separator 7 31 Weather cond...

Page 360: ...S 6 BA TH412 06 2017 4512_SIX_en fm S Index...

Page 361: ......

Page 362: ...Order number 1000322898 Language en Wacker Neuson SE Preussenstr 41 D 80809 Munich Tel 0 800 783185 06 www wackerneuson com...

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