Model: ________ ____ Serial Number : _____ Year : _____________ USE AND MAINTENANCE INSTRUCTION MANUAL

T10000FS

www.colmarspa.com

Dear Customer, thank you for havi contact us at the following number:

ng chosen our products. In case of need

TELEFAX: 0039 0425 465 052 You find here our telephone numbers to get a quicker service: SPARE PARTS STORE: AFTER-SALES SERVICE: SALES DEPARTMENT: ACCOUNTING DEPARTMENT: 0039 0425 93 21 33-7 0039 0425 93 21 33-8 0039 0425 93 21 33-4 0039 0425 93 21 33-0

In case of after-sal es service or spare parts orders please send us a fax at the above-mentioned number otherwise your requests cannot be taken into account.

important Note:
THIS MANUAL CONTAINS ALL THE INFORMATION NECESSARY TO THE SETTING AT WORK, USE ACCORDING TO T HE SAFETY RULES AND ROUTINE MAINTENANCE OF THE MACHINE. W E SUGGEST YOU RE AD THIS MANUAL CAREFULLY, TO OBSERVE THE INST RUCTIONS IT CONTAINS AND TO KEEP IT I N AN ACCESSIBLE P LACE TO CONSULT IT WHENEVER IT IS NECESSARY. DO NOT HESITATE TO CONTACT COLMAR TECHNIK S.R.L. FOR ANY NECESSARY SPARE PART OR IF YOU NEE D TO CONSULT US ON ANY SPECIAL EQUIPMENT OR IF NEED BE. WE SUGGEST THE F ILLING IN OF THE F OLLOWING FORM TO THE OWNER OF THE MACHINE, AS THE INFORMATION IT CONT AINS ARE NECESSARY FOR B OTH AFTER-SALE SERVICE AND SPARES. MACHINE MODEL: ...................................................................................................................................... MACHINE SERIAL NUMBER:...................................................................................................................... ENGINE SERIAL NUMBER: ........................................................................................................................ YEAR OF MANUFACTURE: ........................................................................................................................ DATE OF PURCHASE: ................................................................................................................................

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INDEX
1 GENERAL DESCRIPTION .................................................................................................... 6
1.1 1.2 1.3 1.4 1.5 PRELIMINARY INFORMATION ................................................................................................... 6 FOREWORD ................................................................................................................................. 7 WARRANTY.................................................................................................................................. 7 LIABILITY ..................................................................................................................................... 8 SAFETY INSTRUCTIONS ............................................................................................................ 9
INSTRUCTIONS FOR USE AND CONSERVATION OF THE MANUAL ...............................................9 PURPOSE AND LIMITS OF THE MANUAL ...........................................................................................9 GENERAL INSTRUCTIONS.................................................................................................................10 DEFINITIONS .......................................................................................................................................10 MAIN PARTS OF THE MACHINE ........................................................................................................11 UNIFIED SAFETY SYMBOLS ON THE MACHINE..............................................................................12 DESCRIPTION OF THE MACHINE......................................................................................................13 OPERATOR TRAINING REQUIREMENTS..........................................................................................14 NOISE ...................................................................................................................................................14 CONFORMITY TO STANDARDS.........................................................................................................15 LIFTING EQUIPMENT ..........................................................................................................................15 MACHINE RUNNING-IN AND TESTING..............................................................................................15 LIFTING POWER DIAGRAM................................................................................................................16 DIMENSIONS FOR ROAD TRANSPORT ............................................................................................17 RAILWAY CONFIGURATION...............................................................................................................17 TRANSFER AND TRANSPORT MASSES...........................................................................................17

1.5.1 1.5.2 1.5.3 1.5.4 1.5.5 1.5.6 1.6.1 1.6.2 1.6.3 1.6.4 1.6.5 1.6.6 1.6.7 1.7.1 1.7.2 1.7.3

1.6

CHARACTERISTICS OF THE MACHINE .................................................................................. 13

1.7

MACHINE DIAGRAMS ............................................................................................................... 17

SAFETY............................................................................................................................... 18
2.1 2.2 SAFETY STANDARDS............................................................................................................... 18 SAFETY WARNINGS ................................................................................................................. 19
ACCIDENT PREVENTION ...................................................................................................................19 ENVIRONMENTAL CONDITIONS SUITABLE TO THE MACHINE.....................................................19 PROHIBITED OPERATIONS ...............................................................................................................20 PERMISABLE OPERATIONS ..............................................................................................................20 CARE AND MAINTENANCE ................................................................................................................21

2.2.1 2.2.2 2.3.1 2.3.2 2.3.3

2.3

GENERAL SAFETY RULES....................................................................................................... 20

2.4

ESSENTIAL OPERATOR INSTRUCTIONS ............................................................................... 22

2.5 INSTRUCTIONS FOR TRANSFERRING THE MACHINE FROM ROAD TO RAILWAY TRACK AND VICE VERSA................................................................................................................................ 23

SPECIFIC CHARACTERISTICS ......................................................................................... 25

3.1 3.2 3.3 TECHNICAL DATA..................................................................................................................... 25 HANDLING SYMBOLS............................................................................................................... 27 INSTRUMENTS........................................................................................................................... 28
CAB .......................................................................................................................................................29 MULTIFUNCTIONAL DISPLAY ............................................................................................................29 Engine error codes................................................................................................................................30

3.3.1 3.3.2 3.3.3

3.4 3.5 3.6

MACHINE IDENTIFICATION ...................................................................................................... 34 MACHINE MAIN WORDINGS .................................................................................................... 35 MACHINE STARTING ................................................................................................................ 36

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3.6.1 3.6.2

START-UP ............................................................................................................................................36 CHECKS AT THE START OF EACH WORKDAY................................................................................37

3.7 3.8

ROAD CIRCULATION ................................................................................................................ 37 PROTECTION AND STORAGE ................................................................................................. 38

MACHINE IDLE FOR A SHORT PERIOD ............................................................................................38 MACHINE IDLE FOR A LONG PERIOD ..............................................................................................38 MACHINE RESTARTING AFTER A LONG IDLE PERIOD..................................................................38

3.8.1 3.8.2 3.8.3

3.9 3.10 3.11 3.12 3.13 3.14 3.15

LIFTING THE MACHINE............................................................................................................. 39 REFUELING ............................................................................................................................ 40 OPERATORS CAB ACCESS................................................................................................. 41 LOADING AND UNLOADING THE MACHINE FOR ROAD/RAIL TRANSPORTATION ....... 41 SCHEMA TUBI IN PUNTA BRACCIO..................................................................................... 42 DIGGING BUCKET ASSEMBLY............................................................................................. 42 BUCKET ASSEMBLY ............................................................................................................. 43

USE OF THE MACHINE...................................................................................................... 44

4.1 4.2 4.3 4.4 4.5 4.6 ENGINE START-UP.................................................................................................................... 44 ENGINE STOP ............................................................................................................................ 44 COLD STARTING ....................................................................................................................... 44 MACHINE ELECTRICAL SYSTEM ............................................................................................ 44 SLEW DRIVE CONTROL CHECK PIN....................................................................................... 45 DRIVING PLACE ........................................................................................................................ 45
SAFETY PUSH BUTTONS...................................................................................................................45 STEERING WHEEL ..............................................................................................................................45 STEERING WHEEL ADJUSTMENT LEVER........................................................................................45 OPERATOR SEAT ADJUSTMENT ......................................................................................................46 FORWARD/REVERSE PEDAL ............................................................................................................49 SERVICE BRAKE PEDAL ....................................................................................................................49 GEARBOX SELECTOR ........................................................................................................................50 PARKING BRAKE BUTTON.................................................................................................................50 THROTTLE SELECTOR.......................................................................................................................50 RAILWAY AXLE LOCKING SELECTOR SWITCH..............................................................................51 ROAD AXLE LOCKING LEVER ...........................................................................................................51 TELESCOPIC COUNTERWEIGHT LEVER .........................................................................................52 TELESCOPIC ARM CONTROL LEVER...............................................................................................53 RAILWAY TRUCK LEVER....................................................................................................................53 LEFT HANDLE......................................................................................................................................54 RIGHT HANDLE ...................................................................................................................................54 DIGGING MECHANISM .......................................................................................................................55 PILING LINE 250 l 280 Bar................................................................................................................56 CAMERA SYSTEM ...............................................................................................................................56

4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.6.7 4.6.8 4.6.9 4.6.10 4.6.11 4.6.12 4.6.13 4.6.14 4.6.15 4.6.16 4.6.17 4.6.18 4.6.19

4.7 4.8 4.9

AIR- CONDITIONING (OPTIONAL)............................................................................................ 64 CONVOY AIR BRAKES.............................................................................................................. 64 SAFETY DEVICES...................................................................................................................... 65

CYLINDER SHUT-OFF VALVE ............................................................................................................65 OPERATORS SEAT SAFETY .............................................................................................................65

4.9.1 4.9.2

EMERGENCY ......................................................................................................................66
5.1
5.1.1

MACHINE TOWING .................................................................................................................... 66

PRELIMINARY REMARKS:..................................................................................................................66 PAG. 3

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5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10

SAFETY SOLENOID VALVE...................................................................................................... 67 MACHINE MOVEMENTS SOLENOID VALVE........................................................................... 68 EMERGENCY PUMP .................................................................................................................. 69 FIRE ............................................................................................................................................ 69 EMERGENCY EXIT .................................................................................................................... 70 OPERATORS EXTRACTION FROM THE CAB IN CASE OF ILLNESS .................................. 70 PNEUMATIC BRAKE SOLENOID VALVE................................................................................. 70 EMERGENCY PUSH BUTTON .................................................................................................. 71 WEATHER CONDITIONS........................................................................................................ 71

6 7 8

TROUBLESHOOTING......................................................................................................... 72 SCRAPPING AND DISPOSAL............................................................................................ 73 MAINTENANCE................................................................................................................... 74

8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 FOREWORD ............................................................................................................................... 74 GENERAL MAINTENANCE PROCEDURE ............................................................................... 74 MAINTENANCE CHART ............................................................................................................ 75 HYDRAULIC OIL CHART........................................................................................................... 76 LUBRICATING OIL CHART ....................................................................................................... 77 ENGINE OIL CHART .................................................................................................................. 77 LUBRICATING GREASE CHART .............................................................................................. 78 GREASING ................................................................................................................................. 78 HYDRAULIC SYSTEM................................................................................................................ 80
HYDRAULIC CYLINDERS....................................................................................................................80 CRANE ROTATING JOINTS ................................................................................................................81 HYDRAULIC SYSTEM..........................................................................................................................81 HYDRAULIC OIL...................................................................................................................................81 MAGNETIC ROD ..................................................................................................................................82 HYDRAULIC OIL FILTER .....................................................................................................................82 DIESEL ENGINE AIR FILTER ..............................................................................................................82 DIESEL ENGINE OIL LEVEL AND DIESEL ENGINE OIL FILTER......................................................83 DIESEL ENGINE FUEL FILTER...........................................................................................................83 DIESEL ENGINE WATER SEPARATION FILTER...............................................................................84

8.9.1 8.9.2 8.9.3 8.9.4 8.9.5

8.10

8.10.1 8.10.2 8.10.3 8.10.4 8.10.5

FILTERS .................................................................................................................................. 82

8.11 8.12 8.13 8.14 8.15 8.16 8.17 8.18 8.19 8.20
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DIESEL BELTS........................................................................................................................ 85 GENERAL MECHANICS ......................................................................................................... 85 TELESCOPIC ARM SLIDING BLOCKS ................................................................................. 85 TELESCOPIC COUNTERWEIGHT SLIDING BLOCKS ......................................................... 86 SLEW DRIVE CONTROL REDUCTION GEAR ...................................................................... 86 BATTERIES ............................................................................................................................. 86 SERVICE BRAKE.................................................................................................................... 87 PARKING BRAKE ................................................................................................................... 87 FUSES ..................................................................................................................................... 88 HEAT EXCHANGER................................................................................................................ 89
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8.21 8.22 8.23 8.24 8.25 8.26 8.27 8.28 8.29 8.30 8.31 8.32

TYRES ..................................................................................................................................... 89 RAILWAY TRUCKS................................................................................................................. 89 AXLE DIFFERENTIAL UNIT ................................................................................................... 90 EPICYCLICAL REDUCTION UNIT.......................................................................................... 90 GEARBOX ............................................................................................................................... 90 WINDSCREEN WASHER TANK............................................................................................. 91 WASHING OF THE MACHINE ................................................................................................ 91 CONTROL OF PRESSURE AND VALVE SETTING .............................................................. 91 CONTROL OF PRESSURE AND VALVE SETTING .............................................................. 92 CYLINDER LIFTING SPEED CONTROL ................................................................................ 94 CONVOY PNEUMATIC VALVE CONTROL............................................................................ 94 BRAKE VALVE........................................................................................................................ 94

HYDRAULIC SYSTEM ........................................................................................................ 96

9.1 9.2 COMPONENT LIST .................................................................................................................... 96 HYDRAULIC PLAN..................................................................................................................... 98

10

ELECTRIC SYSTEM ......................................................................................................100

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1 GENERAL DESCRIPTION
1.1 PRELIMINARY INFORMATION This document is the operating and maintenance manual of the machine in accordance with annex V of the Machinery Directive 2006/42/EEC and subsequent amendments and integrations. Do not destroy or alter this manual; integrate only with inserts.

Manual code: Revision No.: Compiling date: Machine type: Model:

M-T10000R-02-05 05 28-01-2013 Self-propelled rail-road loader T10000 FS

List of enclosures: - CE declaration - Declaration of conformity - Diesel engine manual - Manual of crane load lifting device (if the machine is equipped with) - Documentation concerning the machine special equipment (if the machine is equipped with)

CAUTION DO NOT USE THE MACHINE BEFORE HAVING READ THIS ENTIRE MANUAL.

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T10000 FS

1.2 FOREWORD These operating instructions together with the lift capacity charts and pressure tables, form an integral part of the machine. Furthermore, these operating instructions are ad dressed to operators who have already received specific training o n the use of machines of this type and contain all the necessary information for the safe and correct use of the machine. Hurried and inadequate preparations can and usually lead to accidents. Before operating the machine, read the following recommendations carefully: 1. Before operating the machine, familiarise yourself with the machines features and its controls in all permissible operating conditions; 2. Always keep the instruction manual and the lifting duty charts to hand for quick reference; 3. Carefully read the instructions of this manual concerning possible dangerous situations; 4. Plan all routine and extraordinary maintenance operations carefully; 5. Make sure that all the necessary equipment is always a vailable: slings and chain s which hold a current certificate and are in good condition; 6. Acquire all the necessar y information on the wo rk site and how the ma chine is to be used: loadbearing capacity of the ground, weight and dimensions of the loads to be lifted, the lifting heigh t and boom extension required, any restrictions to move ment such as buildings, electrical power lines, etc.; 7. Before starting work check that the safety devices are in good working order; never use the machine if you have any doubt about the operation of a safety device; 8. During road transport, comply with all road traffic regulations (see the logbook of the truck which will transport the machine). 9. Obtain all t he necessary information before starting the machine road travelling : distance, route, level crossing height, bridge weight limits, etc.; 10. Constant and careful preventive maintenance will ensure that the machine is always in a condition of maximum safety; never defer nece ssary repairs and make sure that a ll repairs are carried ou t by qualified personnel. Use original spare parts only. 1.3 WARRANTY Materials supplied by Colmar Technik S.r.l. are warranted for a period of 12 mo nths starting from the date the machine is put into service, as evidenced by the delivery note. The warranty applies according to the Sales and use conditions of Colmar Technik S.r.l. Colmar Technik S.r.l. undertakes to repair or replace parts which it deems defective during the warranty period. The liability of Colmar T echnik S.r.l. is limited to the replacement of defective parts and does not exten d to any costs incurred by the Dealer or the Dealer's cu stomer, or to any damage, either present or future, or to any loss of income, penalty, etc.. Routine and extraordinary maintena nce must be performed in accorda nce with the instructions given in this manual. Any change of the suggested scheduled maintenance operations will render the warranty terms void. The warranty does not cover the parts subject to normal wear, deterioration, wear-out. Spare parts not covered by warranty are engine oil filters, engine air filter, diesel filter, hydraulic oil filters, shear blades, pressure bar and shear guides, all hydraulic cylinders seals. The equipment which h ave not been manufactured by Colmar Technik S.r.l. are warranted by their own manufacturer. The warranty expires by right in the following cases: when the Customer has not respected the contract payment clauses; when the machine is no t used as p er the manufacturers indications (machine tampering, opera tion mistakes, overload, use of non-fit fuel, hydraulic o il, cooling lubricant or water, non-respect o f maintenance standards even during non-operative periods, etc.);

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when a bre akdown depends on the use of accessories/e quipments Colmar Technik S.r.l. has not authorised or when the machine has been modified or repaired without Colmar Technik S.r.l. authorisation; when non-genuine spar es are use d or when interventions of extraordinary main repairing are carried out by personnel non-authorised by Colmar Technik S.r.l. tenance and/or

For all case s not covered by the above and f or all assistance, please contact Colmar Technik S.r.l. directly by registered letter or fax, even in the event of arrangements agreed by telephone. Colmar Technik S.r.l. accepts no liability for any delays in or failure to provide assistance. Colmar Technik S.r.l. accepts no liability for any damage or malfunctions arising from work carried out on the machine by unauthorised personnel. 1.4 LIABILITY Colmar Technik S.r.l. shall not be consequent to the following: liable for any injury to persons or damage to objects sustained

failure to ad here to the instruction s given by Colmar Technik S.r.l. regarding the driving, transport, use and maintenance of the machine; violent actions or incorrect manoeuvres performed during the transport, use and maintenance of the machine; modifications made to the products without prior written authorisation of Colmar Technik S.r.l.; events outside the normal and correct use of the machine.

In the event of a claim for damages resulting from a defect of the machine, the user is re quired to demonstrate that the damage incurred was a principle and direct consequence of such defect. The owner/user of the machine is solely liable for the formation, instructing, training and updating of the personnel who use the machine described in this manual. CAUTION Use exclusively original spare parts for maintenance and repairs. Colmar Technik S.r.l . shall accept no l iability for an y damaged incurred as a consequence of the use of non-original parts. The machine is warranted in accord ance with the contractual agreements stipulated at the time of sale. Failure to adhere to the safety and operating instructions contained in this manual shall render the warranty void.

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T10000 FS

1.5 SAFETY INSTRUCTIONS 1.5.1 INSTRUCTIONS FOR USE AND CONSERVATION OF THE MANUAL The operating instructio ns contained in this manual apply exclusively to the machine COL MAR Model T10000 FS (hereafter referred to as "machine"). Read the manual carefully before starting and operating the machine. The instruction manual must be read and used as follows: - carefully read the instruction manual and consider it as an integral part of the machine; - the instruction manual must be readily avail able to all p ersonnel assigned to t he operation and maintenance of the machine; - the manual must be retained for the entire service life of the machine; - make sure that all the received updates are incorporated in the body of the manual; - the manual must be consigned to any future user or subsequent owner of the machine; - use the manual carefully so as not to damage it; - on no account remove, tear out or overwrite any part of the manual; - keep the manual in a place where it is protected from humidity and heat; - should the manual be lost or in part illegible, obtain a new copy from the manufacturer. Pay attention to the following warnings and to their meaning. The following wordings are used to denote points of particular importance such as : DANGER It indicates hazards associated with the described activity. I n case of "danger" the use of the machine may give rise to the risk of personal injury. CAUTION It indicates hazards associated with the described activity. In case of "caution" the use of the machine may give rise to the risk of damaging the machine. IMPORTANT It indicates important information or suggestions regarding the corr machine and its basic characteristics. ect use of the

1.5.2 PURPOSE AND LIMITS OF THE MANUAL This manual is addressed to owners, users, main tenance engineers, and to anyo ne involved with the use, transport, routine maintenance, and dismantling of the machine COLMAR Mod. T10000 FS. Purpose of this manual is : - to explain the main features and the working of the machine; - to describe norms and instructions for a proper and safe use of the machine; - to supply instructions as regards transport, use, and routine maintenance of the machine; - to be a use ful training instrument for the staff that will u se, transport, maintain, o r dismantle the machine. This manual can in no way replac e the suita ble experience that the operators must have already acquired on similar equ ipment or that they can acquire o n this mach ine under t he guide of already trained staff according to what stated in this manual. The use of the machine is subject to compliance with the pre scriptions contained in this manual and with all safety standards foreseen by the special laws in force in the country in which the machine is used. NOTE: the translation and/or the extract fro m a part o r the whole manual without prior written authorisation of Colmar Technik S.r.l. is forbidden.
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1.5.3 GENERAL INSTRUCTIONS 1. The machine bears a number of adhesive warning signs that convey important information regarding its safe operation. It is essential that these signs are replaced if for any reason they become illegible. 2. The machine must only be operated by person s who have acquired previous expe rience on similar machines. 3. The employer shall pro vide the user of the machine with overalls, etc.) complying with the law in force. individual safety clothin g (gloves, shoes,

4. In situations where the operator does not have a direct view of the working area, he must be assisted by a signaller who has been specifically assigned to the task. 5. Regularly check the wholeness and the working conditi ons of all parts subject to wear (pins, valves, hoses etc.). Replace when necessary with original spare parts. 6. Do not tamper with the hydraulic system and under no circumstances remove th e seals fro m the valves, otherwise the warranty shall be rendered void. For valve calibration, conta ct an authorise d service centre. 7. Do not ta mper with the electrical system b y any reason, otherwise the warranty shall be rendered void. 8. Overheating of the hydraulic f luid causes damage to the seals and deterioration of the fluid itself. Overheating is caused b y oil escaping through the pr essure relief valves. Avoid therefore prolonged operation with the cylinders at the end-of-stroke position or the hydraulic engine rotation locking. 1.5.4 DEFINITIONS Machine = Self-propelled rail-road loader COLMAR Mod. T10000 FS. Equipment = Lifting device. Interface (rotating) = Device used to connect the equipment to the arm of the machine, which allows the load orientation through rotation. Operator = Technical staff in charge of the machine operation under working conditions, of the machine handling and of the normal machine checking and cleaning. He cannot be handicapped or suffer from serious health problem. Skilled personnel or maintenance engineers = Technical staff in charge of the machine ordinary maintenance and of the assembly, disassembly and reassembly of some parts of the machine. He cannot be handicapped or suffer from serious health problem. Operator's assistant = Technical staff who has to help the operator to manouvre the machine (machine handling at yard in case of poor visibility, lorry loading and unloading, etc.). He cannot be handicapped or suffer from any health problem. Authorised personnel = Technical staff in charge of the machine extraordinary mai ntenance and of the assembly, disassembly and reassembly of special parts of the machine. It must be authorised in written to operate on the machine by the Company Colmar Technik S.r.l. Authorised workshop = Workshop formed by the technical staff in charge of the machine extraordinary maintenance and of the assembly, disassembly and reassembly of special parts of the machine. It must be authorised in written to operate on the machine by the Company Colmar Technik S.r.l. Work area = The work area dedicated to the machine working manoeuvres. To define the other terms used in this manual please refer to the standards UNI ISO 12100-1 ISO 12100-2. and UNI

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1.5.5

MAIN PARTS OF THE MACHINE

TURRET

BOOM

CAB

TELESCOPIC COUNTERWEIGHT

TELESCOPIC ARM ARM

RAIL AXLE

RAIL AXLE

ROAD OSCILLATING AXLE

FRAME

ROAD FIXED AXLE

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1.5.6 UNIFIED SAFETY SYMBOLS ON THE MACHINE The following unified symbols are used to indicate possible dangerous manoeuvres or situations which may arise from the use of the machine: the symbols are in different colours according to whether they indicate danger, caution or an important situation. CAUTION Should the adhesive warning signs (above mentioned) become illegible, they must b e replaced with new ones.

Sign showing danger or caution according to its colour and always accompanied by one of the following symbols.

Sign showing that the use and maintenance manual has to be consulted.

Sign showing crushing hazard caused by moving parts such a s hatches, hydraulic cylinders, etc.

Sign showing cutting hazard caused by moving parts such a s hatches, hydraulic cylinders, etc.

Sign showing cutting hazard caused by the engine fan.

Sign showing burn hazard in the high temperature areas near the diesel engin e (muffler, manifolds, etc.).

HIGH TEMPERATURE

Sign showing entangling hazard caused by moving part s such as hatches, hydraulic cylinders, belts, etc.

MOVING PARTS

Sign showing hanging loads falling hazard. Do not stay in the machine range of operation.

Sign showing it is forbidden to get/climb onto the machine. NO CLIMBING

Sign showing people have to keep a safety distance from the machine when it is working.

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T10000 FS

1.6 CHARACTERISTICS OF THE MACHINE 1.6.1 DESCRIPTION OF THE MACHINE The COLMAR Mod. T10000 FS self-propelled r oad and railway loading machine has been designed to handle materials along railways and to maintain the railways themselves by means of suitable equipment. The loading machine is a self-propelled lifting device suitable for use both on roads and on rails. As it is a lifting device it belongs to the category of crane trucks with adjustable and continuously rotating jib. The machine consists of a strong, weld steel construction which forms the road frame (truck). The road frame is the movable pa rt of the structure whose function is t o unload to the ground the forces in duced by the load lifting. The truck is installed on two axles, a fixed one and a steering one. Both axles are driven by a hydraulic engine connected to a gearbox which drives the differential gears. The three gear ratios can be hydra ulically selected from th e operators cab; the constant mesh gearbox allows the machine to make use with any gear of the two axles four-wheel drive. On the front and rear part of the frame there are railway axle gears. The road and railway axles the machine is equi pped with allow a usage versatility o f the machine itself which can quickly cha nge its conf iguration to be used either on railways or on roads. In detail if a temporary gangway is a vailable, the loading machine in its road configuration will be placed astride of the railway and the operator will insert the railway axles by means of a hydraulic control. The articulated joint which controls th e railway axle has been designed so that the axle lowering causes the contact between the iron wheels and the rubber wheels. The steel wheels are driven by friction with the rubber wheels of the corresponding road axl es. The rolling diameter of the steel wheels is 680 mm. If a temporary gangwa y to place the loading machine on th e railway is not available, the operator shall perform this operation making use of the jib as a po int of support on the ground so that the loading machine can be placed on the railway in its road configuration. The position of the steel wheels in comparison with that of the rubber wheels can be adjusted by the operator according to t he working necessities as the railw ay axle lowering is controlled by h ydraulic cylinders equipped with hydraulic locking valves. The front railway axle is mobile. The oscillati on can be stopped by means of hydraulic cylinders controlled from the operators cab. When working on roads the distance between t he railway wheel rim and the ground shall be of about 50 cm. (20) The loading machine is m obile and is therefore equipped with service brake, emergency brake and parking brake. The rotating turret, which is made of sturdy steel structural work, is connected to the frame by means o f a slew ring which allows the 360 degree slewing in both directions. Th e turret is the supporting structure of the jib an d moreover contains the engine and most of the hydraulic equipment. On the rotatin g turret there is also the operators cab. The turret r otates thanks to a axia l piston hydraulic en gine connected to an epicyclic redu ction gear which, in its turn, operates the pinio n gear which engages t he slew ring internal toothing and generates the turret motion. The slew drive control can be restricted on the right or on the left of the truck longitudinal axis to only about 180 by placing cam for the limit switches. Moreover a mechanical stop can be obtained by placing a pin on the rotating turret and a locator on the frame in order to adhere to the road traffic regulations. To make the machine safe even if it works without having been leveled, the slew drive control is eq uipped with a failsafe brake. The brake is automatically released when the engine is let rotate. The jib is made of steel structural work and consists of three coupled elements i.e. the boom, the arm and the tel escopic arm. The single movement of each of the three elements which form the jib is controlled from the control place where the o perator can vary the speed from ze ro to the max. speed value. The jib is equipp ed with a height limiting device. This device is particula rly necessary to use the rail loading machine in case of overhead electric line s. The end of the jib is prearranged to match th e accessories normally used to handle materials. The a ccessories can be changed very quickly as the coupling between the head and the tool is performed by means of a male-female connector with check pin.
T10000 FS PAG. 13

Thanks to the squared coupling the operator himself can match the h ead to the equipment as the f lat face connection easily allows to individuate the coupling position. The hydraulic connections between the rotating head and the accessories are made by means of fle xible pipes equipped with quick couplings to change easily the acce ssory without oil leaka ge. This machine can be used t o dig if the suitable equipment is installed o n the jib; while digging t he telescopic arm has t o be held retracted. In this case either the back digging bucket or the hydraulic demolition hammer. The five hydraulic p umps the loading machine is equipp ed with allo w to perfor m many combined manoeuvres and makes the machine very productive. The operators cab is located on the rotating turret beside the jib. Its position allows the operator to have the max. visibility of the working area and to be protected during the loading. The front windowpane is shielded by an iron grate. The driver seat can be reached by wide accomodation ladders with antislip steps placed at both sides of the truck. The dimensions of the operators cab allow another person to take a seat behind the operator. Therefore the cab is eq uipped with two access doors, one for the driver and the other for the auxiliary operator. Two servo-assisted central floor levers which govern the mai n functions are placed beside the seat in front position. The others are placed at both sides of the driver seat. All the controls governing the loading or the stability of the machine are provided with a deadman control for the central floor levers and with a mechanical interlocking device for the other levers. The machine is outfitted with double keys (ignition, cab, hoods, etc.). One key out of each couple must be given to the operator while the other must be kept in a safe place by the working-place responsible (not inside the ca b!) so that it is possible to help the operator in case o f illness (make reference to chapter 5). If the used machine is resold the customer/user must provide the p urchaser the complete operating and maintenance manual, as well as the check booklet (if required). Colmar Technik S.r.l. accepts no liability for any dam age caused by the incorrect use or any use of the machine other than stated above. 1.6.2 OPERATOR TRAINING REQUIREMENTS All operators must carefully read this manual in its entirety and adhere to the instructions herein. The employer is re sponsible for verifying that ev erybody assigned to o peration of the machine has the necessary aptitude and has studied this manual carefully. Moreover the employer shall provide the user of t he machine with in dividual safety clothing (gloves, shoes, overalls, etc.) complying with the law in force. 1.6.3 NOISE The following acoustic radiation pressure level and acoustic power level have been carrying out to you in the respect of directive 2000/14/EEC. These values must be included in this manual as provided in the Standard for Machine 2006/42/EEC. Equivalent continuous sound pressure level LPA at the work station is equal to 80 dB (A). Equivalent continuous sound power level LWA at the work station is equal to 105 dB (A).

PAG. 14

T10000 FS

1.6.4 CONFORMITY TO STANDARDS The machine has been designed and built in accordance with the req uirements of the EEC directives governing safety and the unif ication of m ember state legislation, specifically directives (where applicable): 2006/42/EEC Standard for Machine and subsequent modifications. Electromagnetic Compatibility (EMC) Directive 2004/108/EEC with the following amendments. Low Voltage Standard Directive 2006/95/EEC with the following amendments. Directive 2000/14/EC on the noise emission in the environment by equipment for use outdoors RIS 1530-PLT Rail Industry Standard for Engineering Acceptance of On-Track Plant and Associated Equipment 1.6.5 LIFTING EQUIPMENT When the machine is used to lift loads through the use of lifting accessories such as buckets, slings etc., the rated loads indicated in the table must be reduced by the weight of the accessories used. These weights are stamped on the rating plates of the accessories supplied with the machine. 1.6.6 MACHINE RUNNING-IN AND TESTING The machine running-in and test are not n ecessary since they h ave already been done by th e manufacturer before the delivery. Carefully use the mach ine during the first 200 working h ours also controlling a ny anomaly arising (loosening of couplings, oil over-use, etc.).

T10000 FS

PAG. 15

1.6.7 LIFTING POWER DIAGRAM

T10000 FS
m
9 8 7 6 5 4 3 2 1 0 -1 -2 0 1 2 3 4 5 6 7 8 -3

ft 30 25 20 15 10 5 0 -5 -10 m
0 1 2 3 4 5 6 7 8

m
9 8 7 6 5 4 3 2 1 0 -1 -2 -3

ft 30 25 20 15 10 5 0 -5 -10

ft 0

10

15

20

25

30

ft 0

10

15

20

25

30

m
9 8 7 6 5 4 3 2 1 0 -1 -2 0 1 2 3 4 5 6 7 8 -3

ft 30 25 20 15 10 5 0 -5 -10 m
0 1 2 3 4 5 6 7 8

m
9 8 7 6 5 4 3 2 1 0 -1 -2 -3

ft 30 25 20 15 10 5 0 -5 -10

ft 0

10

15

20

25

30

ft 0

10

15

20

25

30

NOTE: The lifting power diagrams o f some versions of the l oading machine may di ffer from the above mentioned. Always refer to the lifting power diagram you can find on an adhesive label in the operators cab.

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T10000 FS

1.7 MACHINE DIAGRAMS 1.7.1 DIMENSIONS FOR ROAD TRANSPORT

1.7.2 RAILWAY CONFIGURATION

2480 1695 7302

1945

RAILWAY TRACK 1500 1960 2525 2900 4168

1.7.3 TRANSFER AND TRANSPORT MASSES Max. weight of the counterweighted machine

31500 daN. (69445lbs)

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PAG. 17

2 SAFETY
2.1 SAFETY STANDARDS

ACQUIRE A THOROUGH KNOWLEDGE OF THE MACHINE The machine must only be used by qualified personnel. The operator must kn ow the positions and the functions of all the controls, instruments, indicators, pilot lights and of the various labels.

WEAR SAFETY CLOTHING Wear close-fitting clothing and use equipment according to the law in force. safety

WARNINGS FOR TESTING AND MAINTENANCE Attach a "MACHINE UNDER TEST" sign to the door of the cab or to the handles. During maintenance operations, always rest the end of the boom directly on the ground (never rest it on other supports such as stacks of materials, containers, vehicles, etc.)

USE SAFETY EQUIPMENT Keep a first aid box and a fire extinguisher in the machine. Make sure that the fire extinguisher is always fully charged an d use it according to th e law in force.

TESTING THE MACHINE Test the machine each day it is star ted following the list of o perations contained in this manu al. Start and operate the machine only from the drivers seat. Never allow any people to climb on board when the machine is working. To climb or to go down from the cab use t he provided steps a nd handholds. Only start the engine in ventilated areas. Before starting the machine make sure there are no people in its range of action.

PAG. 18

T10000 FS

2.2 SAFETY WARNINGS The machine has been designed and built in accordance with the current state of the art and re gulations governing the self-prop elled loading machine for yard and rail use w hose purpose is the lo ading of materials. All applicable legal requirements, prescriptions, ordinances and directives have been observed. The materials and comp onents used, as well as the production and quality control processes, meet the most stringent requirements for safety and reliability. Providing the machine is used only for the purposes specified in this manual, and is operated with due care and at tention, and is maintain ed and ser viced in a workmanlike manner, it can be expected to provide high performance, continuity of service and a long lifetime. When using the machine on the public highway, observe all applicable road traffic regulations. When the machine circulates on railways, the rules and provisions of the railwa y owner have to be observed. 2.2.1 ACCIDENT PREVENTION The manufacturer accepts no liability for any accidents, operating anomalies and/or damages which may occur during the use of the machine as result of the failure of the use r to observe laws, requirements, prescriptions, and regulations governing machines for the lifting of materials. 2.2.2 ENVIRONMENTAL CONDITIONS SUITABLE TO THE MACHINE The standard configuration machine has been designed to be used in the following temperature range: Operative temperature: + 25C (+ 77F) Max. permissible temperature: + 40C (+ 104F) Min. permissible temperature: 20C ( 4F) Relative humidity: 20% - 80% (without condensate) The standard configuration machine shall not b e used under environmental cond itions exceeding this range. CAUTION It is forbid den to use the stand ard configuration machine under environmental conditions different from those above mentioned. The possible use of the machine under unsuitable environmental conditions may cause the malfunction or the breaking of hydraulic or electrical parts of the machine itself. Special equipment of the machine are requir ed if there are the fo llowing elements in the work environment: Temperatures higher than + 40C (+ 104F) Temperatures lower than 20C ( 4F) Condensate Brackish water Corrosive agents (acid or basic) Deflagration hazard in the environment Environments full of dust Radiations Insufficient lighting/illumination Rooms without openings and/or scarcely ventilated (tunnels, subways, sheds, etc.) Specific custom-made equipment are available, to different from standard. allow the machine to oper ate under conditions

T10000 FS

PAG. 19

2.3 GENERAL SAFETY RULES 2.3.1 PROHIBITED OPERATIONS 1. The machine is used for purposes other than those for which it is intended. 2. The machine is not ha ndled, manoeuvred and operated in accordan ce with the operating/safety instructions. 3. The machine is not cared for and/or maintained in the prescribed manner or non-original spare pa rts are used. 4. Using the machine under environmental conditions exceeding the allowed range. 5. Lifting loads with unsuitable tools. 6. Using the machine when its safety devices have been cut out or tampered with. 7. Using the machine after it has be en modified wit hout the prior writte n consent of Colmar Te chnik S.r.l. 8. Lifting loads higher than the machine max. lifting power. 9. Using the machine to perform non-vertical lifting manoeuvers and towing. 10. Using the machine on railways without observing the provisions of the railway owner. 11. Using the machine on r ailways without letting in the arm height limitin g device in case of pow ered electric lines. 12. Using the machine on railways without letting in the slew drive control limiting device in case trains can freely circulate on the adjacent track. 13. It is proh ibited travel on or off rail with the axles locked, t his can lead to the ma chine becoming unstable. 14. It is prohibited to carry a load in road or rail mode with the Safe Working Load Indicator switched off. 15. Moving the machine, both on road and on railway, to handle loads with speed exceeding 4 km/h (2.5 mph). 16. It is prohibit ed to use the machine with the counter weight extended when the Saf e Working Load Indicator is switched off. 17. Using the machine as a lifting device without havi ng let in t he load limiting device by means of the push button on the control panel. 18. Performing abrupt movements and/or accelerations of the jib and of the turret. 19. Using the machine when the operators cab has been taken apart or when the door is open or disassembled. 20. Leaving the machine without removing the switch key from the control panel. 21. Using the machine to lift or transport people. 22. Lifting loads over transit areas. Should this not be avoided, inform by means of warning signals about the starting of operation. 23. Leaving the machine during its normal working. 2.3.2 PERMISABLE OPERATIONS 1. Using the machine as self propelled rail-road loader equipped only with compatible tools under the specified pressure and loading co nditions. Any other atta chments must be authorized by Colmar Technik S.r.l. 2. It is compulsory to always respect the safety rules provided for by the railway authority where the machine is operating. 3. Lifting loads obsering the lifting power diagram and using t he allowed equipment. Any other u se of the machine has to be considered unsuitable.

PAG. 20

T10000 FS

2.3.3 CARE AND MAINTENANCE Many accidents and cases of machine damage can be attributed to inadequate maintenance, such as: lack of oil, grease and antifreeze; lack of cleaning; hydraulic system faults (damage to hoses, loose fittings, worn gaskets, etc..). Careful maintenance of the machine is also necessary to ensure the operator safety. Never defer repairs. Only allow qualified personnel to carry out repairs to the machine. The following safety rules must always be observed, even by experienced operators: 1. Confirm the running speed the ma chine prior to travelling to site. Pay attention to the height of underpasses, roofs, electric conduits, etc. 2. Always keep the windows of the operators cab clean at all times. 3. Before starting work, check that all machine operations are working correctly. 4. Check that the deadman control works perfectly (controls on zero position and lever mechanical lock if the pushbutton on the handles has not been operated). Constantly check that nobody is within the range of op eration of the machine. Call out or sound the horn to warn people to keep clear of the machine and interrupt work immediately if people do not leave the danger zone! 5. Unauthorized people must not get into the operators cab. 6. Transporting a person in the proper seat placed behind the operators seat is allowed only to transfer the loading machine to the track and only if the provisions given by the railway owner are observed. 7. Do not use the machine to lift people. 8. Do not leave the operators cab when the load is being lifted or the engine is on. 9. When the machine is working as a crane keep a constant eye on both the load and the hook. 10. Only use current certified slings and lifing equipment.

T10000 FS

PAG. 21

2.4 ESSENTIAL OPERATOR INSTRUCTIONS

ESSENTIAL INSTRUCTIONS FOR THE USE OF THE MACHINE

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. The machine shall be operated and used only by authorized people. Make sure that the control levers are in neutral position before starting the engine. Don't use the machine with the cabin doors open. Make sure that there are nobody within the ra nge of op eration of the machine before starting any manoeuvre. If necessary signal the machine operation by means of a warning horn. Constantly check the working area for dangerous points such as demolition areas, means or persons transit areas. Put no object in the driver's cab; put the maintenance tools back in their special compartment. The machine shall be positioned on even, practically horizontal and consistent floor. Do not use the machine when there are unsteady stacks or heaps of materials nearby that might collapse onto the machine. Stop the e ngine when leaving the driving position and take the switch key out of the d ashboard. Lock the door of the drivers cab if you leave the machine for long time. Stop the diesel engin e and take the switch key out of the dash board before performing any maintenance operation. The capacities on tyres are valid when the inflation pressure is equal to the data shown on the plate near the tyres. During the translation on road, the bogies must be completely up. During the idle translation, both on rail and on road, unlock the cylinders that lock the rail/road front axl e swinging. When the machine is under load, either still or moving, either on rail or o n road, lock the cylinders that lock the rail/road front axle swinging. Handle loads, both in case of road and of railway transport, in first gear (at a speed not higher than 4 km/h) with the load a bit raised from the ground and the arm positioned along the longitudinal axis. When using the machine as lift loader, switch on the load limit device positioned on the dash board. When the loader is on the rails, switch on the boom height and turret rotation limit switch. When the loader is on the canted rails, the telescopic counterweight must be completely re-entered. When using the machine avoid sudden accelerations, starting and quick movements of the arm. Do not use the machine and the equipment to lift or transport people. Never lift loads higher than the machine lifting capacity. Do not perform non-vertical lifting manoeuvres and towing. The lifting of different kinds of load shall be performed only by means of equipment suitable to the use. When working with the to ols, consider the weight labelled on each of them and take it off from the lifting capacity stated in the lifting capacity diagram in he drivers cab. Do not lift or transport loads over working or transit areas. Should this not be avoided inform by means of warning signals about the starting of operation and the transit of the load. When working with equipment such as a grapple or clamps make sure that the people by the work area keep a safe distance of at least 20 m [65 ft] from the loading machine. The manoeuvres concerning the turret rotation and the arm movements are proportional. In proximity to the max. lifting capacity reduce the movement speed. In case of transport on trucks the check pin has to be inserted to lock the turret rotation.

CAUTION Since a complete list of all possible safety rules cannot be supplie d, we trust in the common sense of the operator, whose carefu l and prudent behaviour assures t he machine working under the best safety conditions.

PAG. 22

T10000 FS

2.5 INSTRUCTIONS FOR TRANSFERRING THE MACHINE FROM ROAD TO RAILWAY TRACK AND VICE VERSA Setting on the track Operations: Removal from the track Transfer of the machine from road to railway track, for travel on railway wheels Transfer of the machine from railway track to road, for travel on tyre wheels

Cases: A) Depressed track (sunken track with the to p of the ra ils level with the ground, as shown in the figure)

B) Undepressed track (track laid o n top of ground, as sho wn in figure)

IMPORTANT SETTING ON THE TRACK: When positioning the machine on the track, always set the fixed end / non-steering road axle on the track first. REMOVAL FROM THE TRACK: When transferring the machine from the track to the road, always remove the steering road axle from the track first. DANGER Rises and descents o n an overla nd track must be avoided. The track slope may cause transverse shiftings beyond control. Should it be necessary to t ransfer the loading machine to or from an o verland track, manoeuvre with the greatest attention. Should the manoeuvre be particularly diffi cult, rise/descent ramps shall b e prearranged. NOTES FOR OPERATIONS: Put the machine preferably on a flat track. On the following pages, you will find descriptions about the steps to be done in order to put the machine on undepressed track. During the operations of connection and disconnection of the machine: - Ensure the on tracking point has been boarded or filled with ballast to p rotect the rail, fixing and tyres of the machine. - Use first gear when the machine passes on crossing point and on the rail track. - The track must be closed to the railway traffic. - It is forbidden to operate near the railway points. - Use breaks when needed, to avoid not controlled movements of the machine. - The maximum suggested gradient is 50 mm. (2) it is also po ssible to get on a track with a bigger gradient (max 150 mm 6) but the operation is not suggested. In this case do not lean the boom on structures or parts that might be damaged (sleepers, railways, etc)

T10000 FS

PAG. 23

HOW TO MANOEUVRE (the sequence of the operations are shown in the following pictures) Setting on the track (A Depressed track) 1. With the road axle sta bilizers unlocked, position the machine inline with the track. 2. Lock the road axle stabilizers. 3. Lower the rear railway axle to the line first, but just ra ise the machine approximately 25 mm (1) above rail level. Drive forwards or backwards t o align the front rail wheels. 4. Lower the front railway a xle until fully engaged with the road wheels. Align the steer ing road wheels with the track or rail wheels and engage the steering lock. 5. Lock the r ail axle sta bilizers with the bo om oriented along the track axis. 6. Unlock the rail axle stabilizers with the boom oriented along the track axis. Turn the rail lights on for the desired direction of travel. THE MACHINE IS NOW READY TO TRAVEL ON THE RAILWAY LINE. 7. Before starting to perform lifting operations on the track, lock the stabilizers on the railway axle with the boom oriented along the track axis. Before working on the track follow the instructions listed below to verify that no locking piston or oscillation pin are seized: - Orient the boom leftwards compared to the machine position and perpendicularly along the track longitudinal axis. - Gently rest the boom on the ground. - Raise the left side of some centimeters and check that the left front railway wheel does not rise from the track. - If the left front wheel rises from the track, check that the locking pistons and/or the oscillation pin of the railway axle are not seized. - Repeat the same istructions on the right side, that is: orient the boom rightwards compared to the machine position and perpendicularly along the track longitudinal axis. - Gently rest the boom on the ground. - Raise the right side of some centimeters and check that the right front railway wheel does not rise from the track. - If the right front wheel rises from the track, che ck that the locking pisto ns and/or the oscillat ion pin of the railway axle are not seized. Removal from the track (A Depressed track) 1. Lock the road axle stabilizers. 2. Lock the rail axle stabilizers. 3. Raise the front railway axle. 4. Raise the rear railway axle. 5. Unlock the road axle stabilizers and disengage the steering lock. 6. Unlock the rail axle sta bilizers. THE MACHINE IS NOW READY TO TRAVEL ON THE ROAD WHEELS

5 6

3 4

5 6

PAG. 24

T10000 FS

3 SPECIFIC CHARACTERISTICS
3.1 TECHNICAL DATA DIESEL ENGINE Make and model Cycle No. of strokes Cylinders Injection Bore x stroke Displacement Max. power Calibration speed Pull-in torque Specific consumption Cooling Air filter Engine compartment ELECTRICAL SYSTEM Working voltage Alternator Starter motor 12 V batteries in series 24 V 40 A 4 kW 2x100 Ah DEUTZ TCD2012L062V Supercharged diesel engine 4 6 Direct 101 x 126 mm [4 x 5,2] 6057 cm3 [395 cu inches] 150 kW [204 HP] 2300 rpm 650 Nm 238 gr/kWh Water Dry Sound-proofed with engine mounted on vibration-damping mountings

HYDRAULIC SYSTEM Piston variable delivery twin-pump by pressure control th rough sums of pressur e having at steady power. Single-body distributor with automatic device to sum the oil capacities. Max. flow rate Max. lifting circuit pressure Max. travel circuit pressure Max. auxiliary circuit pressure Max. servo control circuit pressure 184 + 184 lt/min 260 bar 300 bar 150 bar 30 bar

The independent servo control circuit is powered by a gear pump with pressure accumulator to allo w movements with the engine off. Hydraulic oil cooling with large-capacity air-oil heat exchanger. HYDRAULIC CYLINDERS Boom: (Nr. 2) bore x stroke 125 x 935 mm Arm: bore x stroke Telescopic arm: bore x stroke 150 x 1200 mm 80 x 1000 mm

Circuit with flexible multispiral hoses, bonded steel pipes, Jic fittings, safety valves on main circuits in conformance with safety regulations. Height limiting device with hydraulic block to work under electrified railways.
T10000 FS PAG. 25

SLEW MECHANISM Slewing obtained by axi al-piston hydraulic motor thr ough epicyclical reduction unit with pinion driving a slew ring with internal teeth and twin ball races. Cross-over relief valves with anti-cavitations valve. Slew ring diameter Slew speed 1340 mm 10 rpm

Turret safety lock to circulate on roads. 180 alternate electro-hydraulic and mechanic locks to w orks on adjacent tracks. Hydraulic self-locking failsafe brake. Emergency device to return to safety position. STEERING Hydrostatic power steering with safety valves, powered by gear pump. Double-acting, dual-rod cylinder integral with the front swinging/steering axle. BRAKES Pedal operated, hydraulically controlled service, emergency and work brakes. Twin circuit acting on all fo0ur wheels. Hydraulica lly controlled negative action parking brake, o perated from the cab. TRANSMISSION Double drive with hydrostatic tran smission and self-adjustable variable displacement axial piston s hydraulic engine. Over speed and anticavitation valves. Axles complete with hub epicyclica l reduction gears. Rear rigid axle. Front oscillating axle with hydraulic lock. Three-speed gearbox. The speed can be hydraulically selected from the drivers cab . Rail transmission by contact between rail wheels an d tyres, contact pressure register and steering wheel hydraulic lock when the machine is on rail trim. Front and back independent rail boogies o perated hydraulically from the cab. Swinging front rail axle and independent back rail axle with hydraulic cylinders to lock the swinging. 1st gear work speed 2 gear work speed 3 gear max. travel speed TYRES Twin front and rear OPERATORS CAB The soundproof cab, with automatic turnover, is made of sheet steel and has a wide visibilit y range, safety windowpanes, windshield wiper and saf eguard, adjustable anatomic seat, instrument board with engine oil p ressure gauge, fuel gauge, hour-me ter, working control lamps and swit ches, homologated acoustic and light alarm system, control stick servo-asisted controls. FUEL AND FLUID CAPACITIES Gasoline Diesel engine oil Rotation reduction gear Gearbox Axle differential unit Epicyclical reduction unit Hydraulic oil tank capacity Hydraulic circuit total capacity 210 lt. 26 lt. 4,5 lt. 6,5 lt. 2 x 15 lt. 4 x 2 lt. 210 lt. 340 lt. 9.00 x 20
rd nd

4 km/h (2.5 mph) 12 km/h (7.5 mph) 25 km/h (15.5 mph)

PAG. 26

T10000 FS

3.2 HANDLING SYMBOLS

T10000 FS

PAG. 27

3.3 INSTRUMENTS 1. Multifunctional display 2. Multifunctional display setting button 3. Fuel level 4. Direction lights 5. Railway configuration 6. Power reduction switch in (0 50% in position 0, 100% in position 1) 7. Rail axle locked lamp 8. Rail axle unlocked lamp 9. Rail axle lock lever 10. Emergency lights 11. Starter 12. Throttle control 13. Horn 14. Road front axle lock lever 15. Parking brake selector 16. Lights 17. Telescopic counterweight lever 18. Gearbox selector 19. RS 232 service port 20. Digital hour meter 21. Dipped headlights indicator lamp 22. Battery charging indicator lamp 23. Water in fuel alarm lamp 24. Direction lights lamp 25. Low fuel indicator lamp 26. Air filter clogging indicator lamp 27. Brake system fault lamp 28. Engine preheating lamp 29. Digging selector 30. Piling selector 31. Switch 0 - Telescopic arm 1 - Railway front axle 2 - Railway rear axle 32. Control lever for telescopic arm and railway axles
32
0 1 0 1

26 25 24 23

27 28 1 21 22 20 2 3 19 4 17 18 5 6 15
P

16 9

8 13 14 10

12

11

29
1 0 2

30

31

PAG. 28

T10000 FS

3.3.1

CAB

1. Right working lamp switch 2. Right working lamp switch 3. Rear working lamp switch 4. Boom working lamp switch 5. Rotating lamp switch 6. Windshield washer switch 7. Air conditioning control panel (Optional) 3.3.2 MULTIFUNCTIONAL DISPLAY Starting page with firmware and software version.
1 2 3 4 5 6 7

Main screen: on this page are constantly displayed: - Engine oil pressure - Engine water temperature - Gear - Parking brake lamp (when activated) - Min. engine oli pressare (when necessary) - Warning when 2 or more engine errors are activated. To see the errors push button N 2 on dashboard - Engine RPM

Second screen, (by pressing button N 2) on this page are constantly displayed: - Engine RPM - SPN e FMI (engine errors codes) If there are one or more engine errors, the displa y will show t he screens and such errors in a sequential manner. The most serious error s automatically lead to the error page. To view the main page for 20 seconds, press the button N 2 on the dashboard.

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PAG. 29

3.3.3
SPN 29 84 91 91 91 94 94 97 97 100 100 100 100 102 102 105 105 107 108 110 110 111 157 157 158 168 168 174 174 175 175 190 190 190 190 190 190 520 563

Engine error codes

FMI 2, 3, 4, 11 Componente / Position Manual accelerator Description Short circuit or interrupted wire, conflicting signal Out of range speed, absence or conflicting signal Short circuit or interrupted wire, conflicting signal (analogig pedal) Short circuit or interrupted wire, conflicting signal (digital pedal) Bad PWM signal Interrupted or short circuit wire Signal under admitted limit Interrupted or short circuit wire Signal over admitted limit Interrupted or short circuit wire Low or not compatible pressure Signal over admitted limit Signal under admitted limit Interrupted or short circuit wire Out of target value Interrupted or short circuit wire Signal over admitted limit Suction pressure over admitted limit Air pressure air problem Interrupted or short circuit wire Out of target value Out of target value Interrupted or short circuit wire Out of range signal durig start ON injection signal not detected Under range voltage Signal over admitted limit Interrupted or short circuit wire Signal over admitted limit Interrupted or short circuit wire Signal under admitted limit Engine only with camshaft speed signal Camshaft speed signal lost or defected Crankshaft speed signal lost or defected Camshaft and crankshaft speed signal outphased Overspeed engine Overload Lost (message TSC1-TR) Emergency shutdown or short circuit (relay 3)

0, 8, 12, 14 Speed signal 2, 3, 4, 11 2, 8 8, 11 3, 4, 11 2, 11 3, 4, 11 11, 12 0, 2, 3, 4 1, 11 0, 11 1, 11 2, 3, 4 2, 11 2, 3, 4, 11 0, 11 0, 11 2, 3, 4, 11 2, 3, 4 0, 11 1, 11 3, 4, 11 0, 1, 11 11, 12 0, 1, 11 2, 11 3, 4, 11 0, 11 2, 3, 4 0, 11 11, 12 8, 11, 12 8, 11, 12 2, 11 0, 11 11, 14 11, 12 7, 11, 12 Accelerator pedal Accelerator pedal Accelerator pedal Fuel low pressure sensor Fuel low pressure sensor Water on fuel level sensor Water on fuel level Oil pressure sensor Oil pressure sensor Oil pressure Oil pressure Air pressure sensor Air pressure Air temperature sensor Air temperature Air filter conditions ECU internale error Cooling sensor temperature Cooling sensor temperature Cooling level Rail pressure sensor Rail pressure sensor Terminal 15 Battery Battery volts Fuel temperature sensor Fuel temperature Oil temperature sensor Oil temperature Speed sensor Speed sensor Speed sensor Speed sensor Overspeed Overload CAN message Main relay

PAG. 30

T10000 FS

624 630 639 651 651 652 652 653 653 654 654 655 655 656 656 657 657 658 658 676 676 677 677 701 701 701 702 702 702 703 704 705 729 730 898 923 975 1072 1074 1079 1080 1081 1109 1231

2, 3, 4, 5 11, 12 11, 14 5, 13 5, 13 5, 13 5, 13 5, 13 5, 13 5, 13 5, 13 4, 11 2, 5, 11 3, 4, 11 3, 4, 5, 11 11 11 11 11 11 11 2, 3, 4, 5 11 2, 3, 4, 5 3, 4, 5, 11 3, 4, 5, 11 11, 12 2, 3, 4, 5 2, 3, 4, 5 3, 4, 5, 11 3, 4, 5, 11 3, 4, 11 3, 4, 11 2, 3, 4, 5 2, 11 11, 14

Diagnostic spy ECU internal error CAN bus off Injector Injector Injector Injector Injector Injector Injector Injector Air heating relay Air heating relay Starting relay Starting relay Reserved outputs Reserved outputs Reserved outputs Reserved outputs Reserved outputs Reserved outputs Running engine spy Cooling alarm spy Oil pressure warning spy Air heating relay Magnetic valve heather relay CAN Message Power Output Fan actuator Internal engine brake Engine brake actuator flap ECU internal error ECU internal error Preheating spy Shut off request CAN bus off

Interrupterd wire or short circuit from ECU Memory access EEPROM Interrupted wire or short circuit(CAN bus A) Short circuit (injector 1) Interrupted wire (injector 1) Short circuit (injector 2) Interrupted wire (injector 2) Short circuit (injector 3) Interrupted wire (injector 3) Short circuit (injector 4) Interrupted wire (injector 4) Short circuit (injector 5) Interrupted wire (injector 5) Short circuit (injector 6) Interrupted wire (injector 6) Short circuit (injector 7) Interrupted wire (injector 7) Short circuit (injector 8) Interrupted wire (injector 8) Bad connection or interrupted wire Inoperable during shut off Ignition relay short circuit Ignition relay: interrupted wire or short circuit disabled from ECU Short circuit (output 1) Short circuit (output 1) Interrupted wire or ECU error (output 1) Short circuit (output 2) Short circuit (output 2) Interrupted wire or ECU error (output 2) Interrupted wire or ECU error Interrupted or short circuit wire Interrupted or short circuit wire Interrupted or short circuit wire Interrupted or short circuit wire Message absence CAN TSC1-TE Engine power output: short circuit or interrupted wire Engine power output: short circuit or interrupted wire Internal engire brake: short circuit or interrupter wire Engine brake flap actuator: short circuit or interrupted or short circuit Wrong voltage (source 1) Wrong voltage (source 2) Interrupted or short circuit wire Shut off request ignored from operator Interrupted wire or short circuit (CAN bus B) PAG. 31

3, 4, 11, 13 Injector 3, 4, 11, 13 Injector 3, 4, 11, 13 Injector 3, 4, 11, 13 Injector 3, 4, 11, 13 Injector 3, 4, 11, 13 Injector 3, 4, 11, 13 Injector 3, 4, 11, 13 Injector

T10000 FS

1235 1237 1322 1323 1324 1325 1326 1327 1328 1346 1450 1451 1638 1638 2634 2634 2634 2634 2791 2791 2791 2791 523212 523216 523218 523222 523238 523239 523240 523351 523353 523355 523370 523420 523450 523451 523452 523470 523500 PAG. 32

11, 14 2, 11 11, 12 11, 12 11, 12 11, 12 11, 12 11, 12 11, 12 0, 11 11, 12 11, 12 2, 11 3, 11 4, 11 7, 11, 12 7, 11, 12 3, 11 4, 11 2, 5, 11 2, 3, 4, 5 11, 12 11, 12 11, 12 11, 12 11, 12 2, 12 11, 12 5, 13 5, 13 12 11, 14 11, 14 2, 3, 4, 11 2, 3, 4, 11 2, 3, 4, 11 11, 12 11, 12

CAN bus off Override switch Multiple cylinders Single cylinder Single cylinder Single cylinder Single cylinder Single cylinder Single cylinder Misfire Single cylinder Single cylinder Customer temperature Main relay Main relay Main relay Main relay EGR actuator EGR actuator EGR actuator EGR actuator CAN message CAN message CAN message CAN message CAN message CAN message CAN message Multiple injectors Multiple injectors ECU internal error Rail pressure ECU internal error Multi state switch Multi state switch Multi state switch Rail pressure limiter valve CAN message

Interrupted wire or short circuit (CAN bus C) Commutation Defect ignition Defect ignition (cylinder 1) Defect ignition (cylinder 2) Defect ignition (cylinder 3) Defect ignition (cylinder 4) Defect ignition (cylinder 5) Defect ignition (cylinder 6) Misfire Misfire (cylinder 7) Misfire (cylinder 8) Interrupted wire or short circuit (sensor 2) Out of range temperature(temperature 2) Short circuit (reley 1) Short circuit or interrupted wire(relay 1) Short circuit or emergency shutdown(relay 2) Short circuit or emergency shutdown(relay 3) Short circuit Short circuit ECU short circuit or interrupted wire Short circuit or interrupted wire Lost (EngPrt=engine protection) Lost (PrHtEnCmd=preheating command) Lost (RxCCVS = cruise control) Lost (TCO1= speed signal) Lost (SwtOut= change output) Lost (DecV1) Lost (FunModCtl) Short circuit (cylinder 1) Interrupted wire (cylinder 1) Short circuit (cylinder 2) Interrupted wire (cylinder 2) Injector power (A) Injector power (B) Rail pressare monitoring Over max contator Interrupted wire or Short circuit or voltage out of range (1) Interrupted wire or Short circuit or voltage out of range (2) Interrupted wire or Short circuit or voltage out of range (3) Opening problem Opening problem Repeating shut off conditions Time-out

3, 4, 11, 12 Customer sensor

523350 3, 4, 11, 13 Multiple injectors 523352 3, 4, 11, 13 Multiple injectors 523354 2, 3, 12, 14 ECU internal error

523470 2, 11, 12, 14 Rail pressure limiter valve 523490 3, 4, 11, 12 ECU internal error

T10000 FS

523550 523550 523561 523562 523563 523564 523565 523566 523567 523568 523600 523601 523602 523604 523605 523606 523607 523608 523609 523610 523611 523612 523612 523612 523612 523612 523613 523613 523613 523613 523613 523613 523615 523615 523615 523615 523617 -

11, 12 2, 11 2 2 2 2 2 2 2 2 11, 12 3, 4, 11 2, 11 11, 12 11, 12 11, 12 11, 12 11, 12 11, 12 11, 12 11, 12 11, 14 11, 14 11, 14 3, 11 4, 11 0, 11 0, 11 0, 11 1, 11 0, 11 2, 11 3, 4, 11 5, 11, 12 11, 12 11, 12 11, 12 2, 3, 4, 11 2, 11

Terminal 50 ECU internal error Injection start Injection start Injection start Injection start Injection start Injection start Injection start Injection start ECU internal error ECU internal error Fan speed CAN message CAN message CAN message CAN message CAN message CAN message CAN message CAN message ECU hardware monitoring ECU hardware monitoring ECU hardware monitoring ECU hardware monitoring ECU hardware monitoring Rail pressure Rail pressure Rail pressure Rail pressure Rail pressure Rail pressure Metering unit valve Metering unit valve Metering unit valve Metering unit valve ECU internal error Customer sensor Customer temperature

Start switch problem CPU defect Out of target or lost (cylinder 1) Out of target or lost (cylinder 2) Out of target or lost (cylinder 3) Out of target or lost (cylinder 4) Out of target or lost (cylinder 5) Out of target or lost (cylinder 6) Out of target or lost (cylinder 7) Out of target or lost (cylinder 8) Serial interface communication defect Wrong voltage Signal over admitted limit Lost (message RxEngTemp ) Lost (message TSC1-AE ) Lost (message TSC1-AR ) Lost (message TSC1-DE ) Lost (message TSC1-DR ) Lost (message TSC1-PE ) Lost (message TSC1-VE ) Lost (message TSC1-VR ) Recovery Recovery Recovery High voltage Low voltage Positive derivation respect admitted range (depending to flow rate) Positive derivation respect admitted range (depending to flow speed) Positive derivation respect admitted range (depending to flow rate) Positive derivation respect admitted range (depending to flow speed) Pressure up to admitted range Not correct (blocked injector) Flow rate out of range Output disconnected or disabled Short circuit Short circuit Bad communication with chip CJ940 Interrupted wire o Short circuit (sensore 1) Out of range temperature(temperature 1)

T10000 FS

PAG. 33

3.4 MACHINE IDENTIFICATION

The serial number is stamped on the top o f the undercarriage on the right-hand side at the front relative to the operator position. The serial n umber of the diesel en gine is marked on a metal plate on the engine block.

CE Plate placed u nder the column (actual dimensions 95 x 125 mm [3.7 x 5]).

INDEX LEVEL (Actual dimensions 75 x 85 mm [3 x 3 ] )

L
PAG. 34

A P

ACOUSTIC POWER (Actual dimensions 75 x 85 mm [3 x 3 ] )

A W
T10000 FS

3.5 MACHINE MAIN WORDINGS

T10000 FS

MOVING PARTS

HIGH TEMPERATURE

NO CLIMBING

T10000 FS

PAG. 35

3.6 MACHINE STARTING 3.6.1 START-UP At start-up perform what follows: 1. Make sure that the machine has its own: - CE declaration - Declaration of conformity - Diesel engine manual - Manual of crane load lifting device (if the machine is equipped with) - Documentation concerning the machine special equipment (if the machine is equipped with) 2. General visual check of the machine 3. Verify the adhesive identification and warning labels. 4. Verify the battery power level and connection 5. Check of the machine to verify if there are leaks in the following components and plants: - Hydraulic system - Arm cylinders (main, secondary and telescopic arms). - Front axle oscillation locking cylinders (road and railway). - Railway truck lowering cylinders. 6. Check the level of fuel and fluids such as: - Fuel - Hydraulic oil - Engine oil - Gearbox, axle differential unit and epicyclical reduction unit - Slew drive control reduction gear oil - Battery electrolyte 7. Verify the state of the hoses (check if there are cuts, abrasions, tears, etc.) 8. Verify the state of the steel pipes (check if there are cuts, holes, cracks, etc.) 9. Verify the st ate of the chromium pl ated parts (check if the re are scorings or dents on the cyl inder rods) 10. Verify the state of the electrical cables (check if there are abrasions, loose connections, skinned wire or sheaths, etc.) 11. Verify the good working of the emergency and safety devices 12. Verify the efficiency of the machine controls and warning lamps 13. Verify the state of painting 14. Verify the good working of the lighting installation 15. Perform an idling test under all the expected working conditions 16. After the tests have been performed verify if there are leaks The machine will be delivered with the correct lubricant level in the e ngine, in the slew driv e control reduction gear, gearbox, axle differential unit and epicyclical reduction unit; moreover it will be d elivered with the oil tank completely full and the fuel tank containing enough diesel oil to start up the machine. CAUTION Before starting the machine the op erator in ch arge has to read this manual thoroughly

PAG. 36

T10000 FS

3.6.2 CHECKS AT THE START OF EACH WORKDAY Before the beginning of each workday checks what follows: 1. General check of the machine to verify if there are leaks 2. Verify the state of the hoses (check if there are cuts, abrasions, tears, etc.) 3. Verify the state of the steel pipes (check if there are cuts, holes, cracks, etc.) 4. Verify the st ate of the chromium pl ated parts (check if the re are scorings or dents on the cyl inder rods) 5. Verify the state of the electrical cables (check if there are abrasions, loose connections, skinned wire or sheaths, etc.) 6. Verify the good working of the emergency and safety devices 7. Verify the efficiency of the machine controls and warning lamps (located on the control board, on the external starting board, on the remote control and in the crane operators cab.) 8. Verify the state of painting 9. Verify the battery power level and connection 10. Verify the hydraulic oil and fuel levels. Do not use the machine if one or m ore of the a bove checks are not satisfying an d take measures to restore optimum efficiency. In particular, if one or more of the first seven checks are not satisfying call Colmar Customer Servic e (Tel. 0039 0425 932 133). 3.7 ROAD CIRCULATION If the machine is ho mologated to circulate on roads, t he manufacturer shall have to supply the documents to request t he logbook and the nu mber plate which have to be sent to the Trafic Control Authority. The logbook contains all the specifications which hav e to be observed when the machine circulates on the public highway. Strictly adhere to what specified in the machine logbook and in the highway code in force. If the machine is not homologated to circulate o n road and it is transpor ted on a tru ck, strictly adhere to the specifications given in the truck logbook a nd to all ap plicable standards, regulations and laws as regards road traffic. CAUTION Verify that the dimensio ns and weights of the whole machine comply with the laws in force as regards road traffic

T10000 FS

PAG. 37

3.8 PROTECTION AND STORAGE If the machine has to be idle for a short or a long period precautions shall be ta ken to pre serve the efficiency of the machine itself. 3.8.1 MACHINE IDLE FOR A SHORT PERIOD 1. Rest the machine in a safe position (arm in a safe position, tool rested on the ground, parking brake on, blocks on the wheels, if necessary) 2. Lock the operators cab, remove the key and keep it in a safe place. 3. Disconnect the battery. 4. Insert the slew drive control check pin. 5. Clean the machine and lubricate all units provided with lubricator. 3.8.2 MACHINE IDLE FOR A LONG PERIOD As above, moreover: 1. Change the engine oil a nd replace the filters, the slew drive control red uction gear, the gearbox, the axle differential unit and the epicyclical reduction unit oil. 2. Clean the diesel engine air filter. 3. Protect the silencer to avoid the penetration of foreign matters. 4. Spray the entire machine with protective oil. 5. Store the machine in a sheltered, well-aired, dry and without dust place, if possible, otherwise protect it against the weather with a plastic sheet. 6. Grease the battery electrodes to potect them against corrosion. 7. Recharge batteries once a month. 8. If the machine has been stored in a place which can become icy we suggest you to remo ve the batteries and keep the m in a suit able place and to sub stitute the coolant in the radiator wit h an antifreeze. 3.8.3 MACHINE RESTARTING AFTER A LONG IDLE PERIOD 1. Clean the machine carefully. 2. Remove the silencer protection. 3. Locate the batteries and check the electrolyte level and the battery power level. 4. Verify the level of the fuel, hydraulic oil, engine oil and slew drive control reductin gear oil. 5. Start the engine and let it idle for some minutes. 6. Verify the good working of the emergency and safety devices. 7. Verify the efficiency of the machine controls and warning lamps.

PAG. 38

T10000 FS

3.9 LIFTING THE MACHINE On some points on the machine, as illu strated in the figure (marked with stickers), there are holes for hooking and lifting the machine. We remind that the machine mass is approxima tely 31500 daN. (69445 lbs). Therefore great care is to be g iven to resista nce and length of the ropes to be u sed, which will have to be homologated an d suitable f or the kind of operation to be performed. During the machine lifting the slew drive co ntrol check pins shall be in.

T10000 FS

PAG. 39

3.10 REFUELING The machine is equipp ed with a le vel indicator of the fuel pla ced on the dashboard (no. 3) and a visual indicator, inside t he canopy rear left, sho wn in the photo at the side. When refueling of the fuel, use the electric pu mp dedicated for the purp ose. The pump is lo cated close to the motor, inside the canopy right. As a first step to bring the container of oil (eg tanks) to the cha rger and connect the rubber h ose supplied to the fuel intake to the quick shown. To operate the pump is sufficient to turn on the ignition by turning the ignition key to the right to position R, and press the red switch on the pump housing. Avoid prolonged drives the pump for not cau sing damage to the same. In the case of full disch arge of batteries, you must supply a tanks. WARNING: ALWAYS Open the steam exaust valve. place in the side to the quick pump before starting. WARNING: During refueling oper ations use the container supplied to collect any spilled fuel.

Fuel level gauge

Steam exaust valve

Suction quick connection

Switch pump drive

CAUTION The particular structure of this machine means t hat special care must be taken during refueling/topping up operations. To access the filling points, use exclusively steps according to the law in force. If refueling/topping up is to be carried out u sing cans, remember that the maximu m capacity of each can is 25 l. (6,6 US gal).

PAG. 40

T10000 FS

3.11 OPERATORS CAB ACCESS To enter the operators cab of the machine use the handles set to this purpose. Make use of t he special grips and steps to rise and descend from the cab. The grips a nd the step s installed on the machine are shown by the arrows in the alongside figure.

Use the stairs in the figure to climb on the machine to perform maintenance.

3.12 LOADING AND UNLOADING THE MACHINE FOR ROAD/RAIL TRANSPORTATION WARNING The T10000 FS is capable of self-lo ading and unloading from a flatbed t ruck, or from a flat wagon equipped with normal ramps. These operation s are to be carried out in a perfectly level area with the flatbed truck or flat wagon braked. To put the machine on a transport vehicle, follow these instructions: 1. The machine positioning on the transport vehicle must be done in reversing gear while a collaborator or the carrier help the operator. 2. After having positioned the machine onto the transport vehicle, activate the parking brake. This lever controls the activation of the parking brake drum on the transmission. 3. The carrier of the transport vehicle must block the machine wheels using wooden chocks and nail them to the floor on the transport vehicle 4. Insert the rotation locking pin to lock the rotating turret in a fixed position during the transport. 5. Rest the machine arm on the floor of the transport vehicle. 6. The carrier must strap the machine to the floor of the transport vehicle by using strong cables. 7. Switch off the machine engine and exit the machine only after having removed the ignition key. 8. Lock the cab door. 9. The equipment must be removed from the loader during the transport and loaded in a stable position. WARNING Check that the overall dimensions of the vehi cle plus the loa d conforms to road traffic regulations.

T10000 FS

PAG. 41

NOTE ON THE PARKING BRAKE When the machine rem ains idle for a prolonged period, the hydraulic system of the parking brake may loose pressure with a consequent automatic operation o f the cylinder which acts on the braking elements. Should the parking brake stay on when the machine is next operated, check the condition of the braking system. 3.13 SCHEMA TUBI IN PUNTA BRACCIO

Grapple rotation Open / Close grapple Piling pressure line

Grapple rotation Open / Close grapple Drainage line Piling discharge line

3.14 DIGGING BUCKET ASSEMBLY The arm is prearranged to the installation of the operation gear of the digging device which is composed by a c ylinder (A), a couple of connecting rods (B) and b y a drawrod (C). When t he equipment is not used, the system has to be put at rest with the cylinder closed. The drawrod (C) shall be supported by two short pins in order to make use of the telescopic arm. Whereas, if the machine has to work with the applied equipment, the unthrough pins must be replaced with a through pin and lock it with its B hexagon nut. A C On the arm the hydraulic cir cuit controlling the accessories is provided with a deviation valve so as to easily commute the digging bucket fee ding circuit to the accessory control cylin der feeding. To operate the digging bucket is necessary control the deviation valve with the select or Nr. 29 on the 1 2 dashboard. To install the digging bucket to the machine act as follows: 1. The bucket must be steadily positioned on even and solid ground. 2. Retract completely the digging cylinder (arrow 1 in the figure) and the telescopic arm (arrow 2). 3. Approach the arm extremity to the bucket. 4. Insert the pin 3 complet ely; fix it by means of the bolt carried in stock. 5. Operate the digging cylinder so as to be able to insert the p in 4 complet ely; fix it by means of the bolt carried in stock.
PAG. 42

4 3

T10000 FS

3.15 BUCKET ASSEMBLY To mount the bucket on the machine, contact the authorized personnel and follow the indications here below.

Be sure that the grab has the CE mark. The gripping equipment must be on flat and compacted ground on a stable position.

Approach the second arm extremity to the equipment.

Switch off the engine and lock the cab door. Connect the two parts with the fitted pin by hammering it in for all its length.

Fasten the pin with the standard bolt.

WARNING If the hydraulic hose s were connected in t he inverted order, the man euvers would be invert ed too. Before working with the equip ment, check the correct motion direction. Connect the hydraulic hoses taking care to gather and throw the spilled hydraulic oil away as prescribed by the regulations in force. DANGER Shock and crush danger: pay attention durin g lifting and transport o perations, be sure that there are no persons in danger of grab fall.

T10000 FS

PAG. 43

4 USE OF THE MACHINE

4.1 ENGINE START-UP Turn the switch key t o H position to start t he starter (position 11 on dashboard). As soon as the engine h been started let the switch key back to R position. NOTE: Before repeating the start ing, make sure that both engine and starter are off. To retry starting the unit is still necessary to wait at least 6 seconds 4.2 ENGINE STOP To stop the machine diesel engine let the engine idle and tur n the switch key counter clockwise to position 0. 4.3 COLD STARTING Before starting the machine, let the pump idle for 15 minutes with diesel engine at mean rpm. 4.4 MACHINE ELECTRICAL SYSTEM To feed t he machine electrical system it is necessary to actuate the battery disconnect ing device located in front of the batteries, by rotating it of 90. If this device is not brought into action, t he electrical circuit cannot be fed by th e batteries and no kind of machine operation will be possible. To bring t he battery disconne cting device into action turn the lever of 90 counter clockwise until it protrudes of approximately 2 cm. (1). To bring th e battery disconnect ing device out of action turn the lever of 90 clockwise until it retracts of approximately 2 cm. (1). When the battery disconnecting de vice is brought into action both the pilot lights in the operators cab control panel and the voltage red warning light on the starting board shall be ON (on ly if the swi tch key is in R position).

R H

PAG. 44

T10000 FS

4.5 SLEW DRIVE CONTROL CHECK PIN During the transport of the mac hine insert the check pins placed to lo ck the rotat ing turret in a fixed position. The lower fixed locator shall corr espond to the mobile upper one. During the working steps lift the check pins.

4.6 DRIVING PLACE A miscroswitch placed under the drivers seat in the operators cab inhibits the machine horizon tal traveling motion. The operator shall perfo rm the horizontal traveling motion from his seat (it is the weight of the operator on the seat which gives the consent to the controls thanks to a microswitch placed under the operators seat). CAUTION The machine can ONLY be operated with the operator seated in the control position. 4.6.1 SAFETY PUSH BUTTONS To enable maneuvers, press the pushbutton on the top of the handle. Releasing the pushbutton will halt the maneuver immediately. DANGER Before carrying out an y operation, block acce ss to the working area with barrie rs making sure that there are no persons within the range of operation of the machi ne. Range of operation means a distance of at least 10 m. (33 ft). 4.6.2 STEERING WHEEL The vehicle is steered using the steering wheel. CAUTION The operator must check that the rotating tur ret is posit ioned correctly for forwa rd travel, i.e., t hat the ope rator is fa cing towards the steering axle when sitting in the driving seat facing forward. If the operator is facing in th e opposite direction, this means that the turret is rotated 180 relative to t he direction of forward travel. In this condition steering is inverted, i.e. tu rning the steering wheel to the right will cause the vehicle to turn to the left and vice versa. 4.6.3 STEERING WHEEL ADJUSTMENT LEVER Using the lever, located under the steering wheel to the side, the angle of the steering wheel can be adjusted as desired.
PAG. 45

T10000 FS

4.6.4 OPERATOR SEAT ADJUSTMENT CAUTION To prevent damage to the drivers back, the seat must be adjusted f or the drivers weight before use and before every change of driver. CAUTION To prevent injury, no objects shou ld be placed within the moving are a of the driver seat. CAUTION To eliminate any risk of accident, the sett ings must be checked to ensure they are correctly engaged before the vehicle is driven.

CAUTION Adjustments must not be made while driving. CAUTION When the b ackrest upholstery has been removed, the backrest frame must be supported, for example held in place, before the backrest adjuster is operated. If you fail to do so, there is a danger that the backrest frame may jerk forward and cause injury. CAUTION If you make any chan ges to the standard seat it may n o longer m eet the safety standards to which it is tested. Functions may be impaired, threatening your safety CAUTION Seatbelts must be fa stened before driving.The seatbelts must be rep laced after an accident.Where seatbelts are fitted to the driver seat, the seat and seat mounting must be checked additionally by specialist personnel after an accident has occurred.
4.6.4.1 WEIGHT ADJUSTMENT

The seat is adjusted for the drivers weight by turning the weight adjuster lever with the s eat empty. The set weight can be read from t he indicator. To prevent damage to the drivers back, the seat must be adjusted for the drivers weight before use and before every change of driver

PAG. 46

T10000 FS

4.6.4.2

HEIGHT ADJUSTMENT

The seat h eight can be adjusted with several settings. Raise the dr iver seat t o the required height until it audibly latches into place. When the seat is raised above the highest setting (end stop) it drops back down to the lowest position.

4.6.4.3

SEAT PAN ANGLE ADJUSTMENT

The angle of the seat pan can be individually adjusted. To adjust the angle of the seat pan, lift the L/H handle (see arrow). By e xerting pressure on or off the seat pan it can be mo ved to the desired angle position.

4.6.4.4

SEAT DEPTH ADJUSTMENT

The depth of the seat pan can be individually adjusted. To adjust the depth of th e seat cushion, lift the R/H handle (see arrow). By moving the seat cushion backwards or forwards the desired seating position can be reached.

T10000 FS

PAG. 47

4.6.4.5

FORE/AFT ADJUSTMENT CONTROL CARRIER EQUIPMENT

WITH

The fore/aft adjustment is re leased by lifting the locking lever. The locking lever must latch into the de-sired position. It should not be possible to mo ve the driver seat into another position when it is locked.

4.6.4.6

HEADREST

The headrest can be individually adjusted for height by pulling it upward over the vario us increments up the end stop. By pushing forew ord or rearward the angle of the he adrest can be adjusted individually. To remove the headrest, pull it over the end stop.
4.6.4.7

LUMBAR SUPPORT

By turning the adjustment knob to t he left or rig ht, both the height and curvature of the backr est cushion can be individually adjusted. This increases both the seating comfort and the performance of the driver.

4.6.4.8

BACKREST ADJUSTMENT

The backrest is adjust ed using the locking le ver (arrow). The locking lever must latch into the de-sired position. It should not be possible to mo ve the backrest into another position when it is locked.

PAG. 48

T10000 FS

4.6.4.9

ARMRESTS

The inclination of the armrests can be modified by turning the adjustment knob (arrow).

4.6.5 FORWARD/REVERSE PEDAL With the turret rotated so that the cab is fa cing towards the steering axle: push the left pedal A towards to engage forward gear push the right pedal A towards to engage reverse The pedal will have th e opposite effect if the turret is rotated 180 relative to the previous position. NOTE: do not change the directio n of travel until the machine has come to a complete stop. 4.6.6 SERVICE BRAKE PEDAL Press pedal B to brake hydraulically all four wheels of the machine and pneumatically the to wing wheels.

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4.6.7 GEARBOX SELECTOR The gears are let in by operating the selecto r C (selector Nr. 18 on dashboard). To operate the gearb ox selector the opera tor should brake the machine for 5 seconds. There are three light: yellow, blue and white that identify the three gears. NOTE: gear change is performed hydraulically; it is therefore necessary to change gear with the engine running at idling speed and then wait a f ew seconds before operating the f orward/reverse travel pedal to be absolutely sure that t he operation has been performed. 4.6.8 PARKING BRAKE BUTTON Operating the button D (button Nr. 17 on dashboard) applies/releases the parking brake located on the transmission and t he air parking brake on the tow. NOTE: When the machine stands idle for a lo ng time, the hydraulic circuit controlling the handbrake may lose pressure with consequ ent automatic operation of the spring cylinder which acts on t he braking elements. Should you find that the parking brake stays on when you subsequently start t he machine and release the brake lever, check the condition of the brake system. 4.6.9 THROTTLE SELECTOR The selector E (Nr. 12 on the dash board) adjusts the diesel engine speed. Move the switch counterclockwise to decrease the rpm and clockwise to increase the rpm. NOTE: The movements of slew drive control and arm ascent/descent are controlled by the handles. These controls are proportional. This means t hat they allow the operator to modify the control intensity from 0 to the maximum without solution of continuity. The operator has to partialize th ese controls in relation to the boom length and to the load weight. The more t he capacity limit is approached, the lower the operation speed of each movement must be. The speed of the move ments just described can be controlled in relation to t he number of revs of the diesel engine an d to the strokes given to the handles (the higher is the engine rate when the handle stroke is the same or the higher is the handle stroke when the engine rate is the sa me, the higher is the move ment speed. In case t he diesel engine is at low rates and many mo vements are made at the same time, it could be switched off.

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RAILWAY AXLE LOCKING SELECTOR SWITCH When the selector switch Nr. 9 on the dashboard is in pos. 1, the locking cylinders o f the swinging front railway axle F rise/descend. When the railway axle is locked the red lamp Nr. 7 lights on, when the axle is unlocked the green lamp Nr. 8 lights on. When the axle is locked the traslation is inhibited. During the raceway digging or du ring lifting, the swinging axle shall be locked whereas in case of unloaded motions on road, the axle must fre ely swing. NOTE: the swinging railway a xle locking sha ll be performed on an even track; the machine must be horizontal (i.e. the arm must be parallel to the running direction). 4.6.11 ROAD AXLE LOCKING LEVER Operate the lever G (Nr. 14 on the dashboard) to raise/lower the locking cylinders of the swinging front road axle. During the raceway processing or during lifting, the swinging axle must be locked. In case of idle road horizontal traveling motions, the swinging axle must be unlocked.

4.6.10

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4.6.12 TELESCOPIC COUNTERWEIGHT LEVER Operate the lever G (Nr. 17 on the dashboard) to position the telescopic counterweight. The warning light Nr. 17 is switched on if the telescopic counterweight has not b een completely retracted. NOTE: The safety profile of the machine shall be observed when the ma chine is wor king on a track letting the lock in to avoid that the telescopic counterweight comes o ut. To let th e lock in retract completely the counterweight and insert the two check pins (one on each side as you can see in t he figure). The lock co nsists of tw o plates, co nnected to t he mobile part of the conte rweight, inserted on a slit on the crossbeam of the fixed part of the frame and on which a pin will then be inserted.

DANGER When the machine has to work on an highrail, the telescopic counter completely retracted to avoid that the machine may overturn.

weight shall be

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4.6.13 TELESCOPIC ARM CONTROL LEVER Turn the selector switch 31 placed on the right armrest to 0 position and operate the lever 32 on the left armrest to use the telescopic arm L. 4.6.14 RAILWAY TRUCK LEVER Turn the selector swich 31 placed on the right armrest to 1 position and operat e the lever 32 shown in t he figure to position the rise and the descent of the rear railway truck L. Turn the selector switch 31 placed on the right armrest to 2 position and operat e the lever 32 shown in t he figure to position the rise and the descent of the front railway truck N. Before lowering the rail way trucks m ake sure that the wheels of the steering road axle are alined. After having positioned the machine on the track lock the steering arm by means of the cock placed under the bashboard (see picture below).

1 0 2

1 0 2

1 0 2

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4.6.15 LEFT HANDLE The left-hand handle serves to rotate the turret and raise/lower the arm. The manoeuvres effected are the following: O Slew to the right O Slew to the left P Raise arm P Lower arm 4.6.16 RIGHT HANDLE The right-hand handle serves to op en/close bucket and rotate the turret and raise/lower the arm. The manoeuvres effected are the following: Q Raise boom Q Lower boom R Open bucket R Close bucket

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4.6.17 DIGGING MECHANISM To operate the digging mechanism rotate the selector N. 29 on the dashbosrd in position 1 and use the bucket opening/closing control by means of the right handle.

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4.6.18 PILING LINE 250 l 280 Bar To operate the piling hydraulic line 250 Liters and 280 Bar turn the selector Nr. 30.

PILING LINE 250 L - 280 Bar

4.6.19 CAMERA SYSTEM The machine is provided with two cameras, one that fits to t he right side and one fit to the counterweight to see the rear area to the machine. The images f ilmed by the cameras are displayed simultaneously on the monitor installed in the cab. When starting the machine the monitor turns on automatically. The cameras are also equipped with infrared illuminators that allow vision in low light conditions CAUTION All the devices for vision must be active and regulated for the complete visibility around the machine.

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4.7 AIR- CONDITIONING (OPTIONAL)

Heating: To operate the heater, turn on the diesel engine. The heating of the a ir will be effective only after a few minutes from when the unit. Adjust the f an speed a nd air temperature thro ugh the control panel visible in the picture.

Air-conditioning: To operate the air conditioner, turn on the diesel engine loader and run t he air conditioning compressor by pressing the A / C. Adjust the fan speed and air temperature through the control panel visible in the picture.
4.8 CONVOY AIR BRAKES For the convoy towing connect the bar of towing to the hook of the convoy and connect the flexible tubes, placed in proximity of the undercarriage, to the air brakes circuit. T he rapid couplings on t he left (female coupling, on e in front and one on the rear of the machine) are for the convoy parking brake also t he rapid co uplings on t he right (male coupling, one in front a nd one on t he rear of t he machine) are for the convoy service brakes. Moreover connect the electrical plug placed under the railway lights. The pneumatic circu it pressure gauge is placed under the instrument panel. CAUTION The maximum speed of towing of the convoy does not have to exceed the 5 km/h. The maximum weight of the towed convoy does not have to exceed 60 ton. CAUTION The connection and the disconnection of the convoy to the loader must be carried out with loader refrained and diesel engine off.

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4.9 SAFETY DEVICES The machine features a number of safety devices which are essential for protecting the health of the operator and those working in the immediate vicinity of the vehicle.

CAUTION It is absolutely forbidden to tamper with the safety devices.

CAUTION The dangers which can not be eliminated by safety measures adopted b y manufacturer may derive from the incorrect op eration of the machine or the failure, by the user, to heed the safety guidelines described in this manual. 4.9.1 CYLINDER SHUT-OFF VALVE This specific type of v alve, with b alanced stop and lower ing control functions, is insen sitive to backpressure and discharge. It is fitted on the ra ms of the lifting arm, t he front arm and the telescopic extension, and allows the loads described in the load tables to be hoisted in full safety. FUNCTIONS OF THIS TYPE OF VALVE STOP: controls the loa d, stopping it from being lowered even if one of the pipes which delivers pressurized oil to the devices breaks. LOWERING CONTROL: this function controls the flow of oil and allows the load, e ven if at the limit, to be lowered gradually. OVER-CENTER: this specific function acts when the set valve pressure is exceeded due to overloading, and draws oil through the valve itself, lowering the load very slowly to the ground and avoiding the frame overload. 4.9.2 OPERATORS SEAT SAFETY A microswitch on the operators seat reveals t he presence of the dr iver. The microswitch controls a solenoid valve which en ables the servo control circuit and allows the operator to manouver the loading machine. The solenoid valve can be manually reset to avoid possible stops of th e machine caused by th e device malfunction.

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5 EMERGENCY
5.1 MACHINE TOWING 5.1.1 PRELIMINARY REMARKS: In order to carry out the towing of the machine (in case of breakdown on road or on track lin e), do as follows: 1. If possible, turn on the diesel engine in order to proceed with the n ecessary maneuvers, on the contrary use the emergency pump. 2. Bring the machine in shift position (on road or track line) and in gouge (on case using the emergency pump), blocking the turret rotation, inserting the due pivot. 3. Unlock the road and railway axle stabilzers. 4. If the diesel engine doesnt work, do not operate the brake pedal. Several power-off brakings cause the exhaustion of the hydraulic power in the brake circuit. 5. During the towing phase, the pre sence of an operator on board of the machine is necessary in oder to be able to steer and brake when needed. CAUTION When towing a disabled machine, it is absolutely forbidden to exceed 3 Km/h. (2 mph)

MACHINE TOWING IN ROAD MODE When the machine is in its road mode, and as a result of a failure the diesel eng ine cannot be restarted, the machine shall be t owed following these instructions. To unlock the parking brake unscr ew the solenoid vave incated on the right. In this way the gearbox is not engaged and is possible to towing the machine.

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MACHINE TOWING IN RAIL MODE When the machine is in its rail mode, and as a result of a failure the diesel engine cannot be restarted, the machine shall be towed following these instructions: 1. Lift up slow ly the railway axles, so that the railway weels will not b e in contact with the road pneumatics. To do this it is necessary to operate the axles position ing lever: the machines weight will make them lift without needing to turn on th e engine. The panel needs in any way to be turned on. If this is not possible, lift the railway axles using the emergency pump. 2. The control of the swinging railwa y axle must be unlocked. Do not operate the brake pedal. In case the swinging axle is locked , open the valve on the swinging axle. 3. In order to unlock the brakes remove the two compensator bolts from the rear of the brake caliper by turning anti-clockwise. a. Install the Manual Retractor plate by reinstalling items the compensator bolts through the retractor plate. b. Tighten the retractor bolt until th e brake pads are released from the disc and the wheel becomes free to Brake pad wear compensator bolt move. c. Repeat the procedure for all four rail brakes CAUTION: The hydraulic oil which flows out sh all be collected and disposed of a ccording to the law in force. 4. Use a rigid drawbar and a towing vehicle having a carrying capacity suit able for the mass of the loading machine. 5. Take the machine in a suitable place to repair it (yard, workshop, etc), but in anyway clear the road as soon as possible.

Manual reactor plate Manual reactor bolt 5.2 SAFETY SOLENOID VALVE The solenoid valves for the machine movement consent can be isolated only in case of emergency. The solenoid valves allow the machine manouvering only when the o perator is seated on th e cab seat and push th e push butt ond under handles head . The solen oid valves (see figure) are located rear the drivers cab. In case of solenoid valve fault or of emergency manoeuvers, the solenoid valves can be isolated by completely screwing the knob s shown in the figure by the arrows A and B. A The seat solenoid valve isolator ( arrow B) allows the machine horizontal traveling motion even when B the operator is not seated on the cab seat. The handle solenoid valve isolator (arrow A) allows the slew drive control, the main and the arm motions and the bucket motion even when the operator dont push th e push buttons under the handles head.
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5.3 MACHINE MOVEMENTS SOLENOID VALVE Under the operators seat there are 6 solenoid valves that can be excluded in case of emergency.

TURRET ROTATION BRAKE SOLENOID VALVE EV11

TURRET ROTATION SOLENOID VALVES EV12 EV13

BOOM LIMITATOR ARM LIMITATOR SOLENOID VALVE SOLENOID VALVE EV14 EV15

CAUTION In normal working conditions the solenoid valve shall be cut in, as it is a safety devic e provided by the law in force concerning the safety of the machine. The solenoid valve shall be isolated only in case of fault or for em ergency maneuvers. Colmar Technik S.r.l. accepts no liability for any damage and/or accident arising from the imprudent or wrong maneuvering.

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5.4 EMERGENCY PUMP Should the machine be jammed be cause of a diesel engine failure, the manual pump allows operation of some emergency movements. The movements are allowed by the emergency pump only if the batteries are charged. If the b atteries are discharged, the safety device shall be isolated by completely screwing the handwheels placed on the seat and on the handle solenoid valves (see the preceding paragraph). To perform the manoeuvers switch the control panel on by turning the ignition key to position R, then give the consent signal to the safety device placed on the seat by seating on the drivers seat. The pump ( see figure) shall be op erated by an operators assistant who sets on the lev er under the drivers seat and allows him to operate the machine i.e. to lift the jib, to rotate the turret, to open and close the bucket. To manoeuvre the machine, move the handles as if the diesel engine were started, paying attention to press the safety push buttons placed on the handle head. The movements allowed by the emer gency pump are the slew drive control, the motion of the boom, of the arm and of the bucket. Turn the lever A -se e figure- to rotate the tu rret or to move the arm, turn the valve towards the outside of the machine to move the boom or the bucket.

WARNING In the following operations, the operator can be in potential danger. To minimize accident risks, it is necessary not to panic, to maintain calm and to follow carefully the several phases to overcome the emergency 5.5 FIRE In case of f ire, inside t he cab there is a CO 2 fire extinguisher to b e used according to the relative regulations in force. In case of fire of the machine or tha t the machine is near a f ire, get immediately out of the cab, give the warning and contact the fire men.

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5.6 EMERGENCY EXIT In case the cab door is blocked or an emergency exit is ne cessary, it is possible to get out o f the cab through the sliding windows on the cab sides or by breaking the glasses with the hammer installed inside the cab. DANGER Should the cab door entry be locked or an exit way on the rail be necessary, do not get out on the side open to traffic. 5.7 OPERATORS EXTRACTION FROM THE CAB IN CASE OF ILLNESS In case the operator is ill and it is impossible for him to get out from the cab by himself, it is necessary to intervene immediately following these phases: 1. Join the cab with stable and safe structures or, if it is impossible to operate in safe conditions, contact the medical or emergency personnel. 2. Open the cab door. 3. Lift the ope rator from the seat an d extract him from the cab paying attention n ot to worse n his conditions. In case of doubt or serious illness, contact the medical personnel. 4. Rest the operator on the ground and follow the most important directions of first aid. 5. If not already done, contact the medical personnel. DANGER If the machine arm or the machine itself is near or in contact with electrical cable, before approaching the machine arrange to have the voltage switched off by the company who manages the electric line. 5.8 PNEUMATIC BRAKE SOLENOID VALVE In case of solenoid valve fault or of emergency manoeuvers, the pneumati parking brake solenoid valves can be isolated by completely screwing the screw A (shown in the picture) a nd rotating the lever behind.

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5.9 EMERGENCY PUSH BUTTON On the machine are in stalled two emergency push buttons, to be used only in case of emergency, that block all the comma nds of the machine without stoppin g the motor, which is br ought to 1200 rpm. To re-enable the contr ols, turn the head of th e button clo ckwise and release it and then restart the engine. These emergency buttons are red with a yellow background and are positioned e xternally to the two sides of the turret.

Emergency push button on the left side of the machine 5.10 WEATHER CONDITIONS

Emergency push button on the right side of the machine

In case of bad weather conditions, storms, lightning storms or high win ds do not use the mac hine. It is recalled that the machine must always be left in safe conditions and with arm resting on the ground. In the case in which the machine is struck by lightning, if possible, to su pport the load arm to th e ground and wait for rescue.

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6 TROUBLESHOOTING
Problem Cause Hydraulic oil level in the tank is to low. The machine, with diesel engine powered-on, does not run Wrong assembly of hydraulic pump. Engine/pump coupling not correct. Distributor pressure relief valve jammed or worn. Worn pump. Hydraulic oil pre heating device not warmed up (optional) Hydraulic oil viscosity is too high. Hydraulic oil level in the tank is too low. Suction pipe clogged or crushed. A flange on the suction pipe lets air in. Too low hydraulic oil level in the tank. Dirty or clogged exchanger. Electric fan protection fuse fault. Little cooling water in the radiator. Electric fan / solenoid valve fault. The pressure relief valve on the distributor related to the ci rcuit section showing the probl em is n ot calibrated or its shutter is open due to impurities. Worn pump. Oil slip bet ween the two cylinder chambers with consequent non-lifting of the load. Loosen piston/rod connection. Pressure relief valve on the dist ributor jammed or worn. Jammed cursor. Slips inside the distributor. Elements with worn ga skets show signs of oil leaks. Cursor return springs worn. Insufficient pilot pressure. High hydraulic oil temperature. No tension to the pilot solenoid valve. Worn cylinder seals. Leaks at rotary coupling. Worn feed pump. Power steering unit worn. Solution Top up with hydraulic oil of the sa me type. Check assembly. Check assembly. Disassemble and clea n the pre ssure relief valve or replace. Replace pump. Wait until the hydraulic oil is wa rmed up Use recommended hydraulic oil Top up with hydraulic oil of the sa me type. Check duct for integrity Check seals and replace gasket. Top up with hydraulic oil of the same type. Clean exchanger fins and/or check for internal obstructions. Replace fuse. Add cooling water in the radiator. Replace electric fan / solenoid valve. Recalibrate the valve. Disa ssemble and clean the valve, then assem ble with new metal packings. Replace valve. Replace pump Replace the cylinder gaskets. Check rod/piston connection. Disassemble and clean or replace the pressure relief valve. Replace distributor element. Replace distributor element. Replace gaskets. Replace return springs. Check servo control circuit. Check conditions of heat exchanger. Check tension. Renew seals. Renew seals. Renew the pump. Renew the power steering unit.

Noisy pump

Extreme hydraulic oil heating

Slow operation of some hydraulic functions Irregular operation of the oil-hydraulic cylinder

Irregular operation of the distributor.

Irregular steering

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Problem

Irregular slew drive control

Irregular operation of machine in travel mode

Hydraulic oil inside the components Servo controls are not working Solenoid valves are not working

Cause The pressure relief valve on the distributor jammed or worn. Pressure relief valve on the distributor too low calibrated. Antishock valve jammed or dirty. Flow control valve not calibrated. Motor pinion-crown gear too much slack. Worn slew ring. Worn reduction gear. Pressure relief valve on directional control valve stuck or worn. Seals on rotary coupling worn. Pump worn. Travel motor worn. Gearbox components worn. Gear not engaged. Travel control valve stuck or worn. Parking brake on. Pressure relief valve on directional control valve set too low. Oil seal on pumps/motors out of seat owing to high pressure in the casing. Low pilot pressure Faulty servo control Faulty solenoid valve Faulty electrical connections No tension

Solution Disassemble and clea n the pre ssure relief valve or replace. Calibrate the valve. Replace the valve. Calibrate the valve. Replace the motor. Replace. Replace. Remove and clean the pressure relief valve or renew if necessary. Renew seals Fit new pump. Fit new motor. Renew worn parts. Renew worn parts. Renew the valve. Release the brake. Set valve to correct pressure. Check hydraulic circuit and replace worn pump/motor. Check hydraulic circuit Replace Replace Check electric circuit Check hydraulic system

7 SCRAPPING AND DISPOSAL

When the machine has reached the end of its service life, the owner shall arrange for the scrapping and disposal of the machine itself in a ccordance with the applicable regulations and by means of authorised disposal contractors for the different components. We also remind that all used oil, b atteries, rubber hoses, tyres and an y other machine parts requiring separate disposal shall always be d isposed of in accordance with applicable regula tions by authorised contractors.

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8 MAINTENANCE
CAUTION Maintenance must be exclusively carried ou t by Colma r Customer Engineerin g Service or by qualified personnel. 8.1 FOREWORD To obtain the best performance from the machine and the maximum service life from its components, the use and maintenance instructions must be followed scrupulously by all maintenance personnel. We recommend that users read this section thor oughly and consult it whenever a problem arises on the machine. As the machine is freq uently used in contact with water, sand and e arth, etc., r egular lubrication is extremely important in order to obtain the long est possible service life from the machine and to keep operating costs to a minimum. For further information please contact the Colmar service department:

COLMAR Service (Tel. 0039 0425 932 133)

8.2 GENERAL MAINTENANCE PROCEDURE Routine maintenance includes all the information necessary for conservation of the machine. the good working a nd the

Maintenance should always be performed by the same engineer who not only has to kno w the machine deeply but also what described in the following pages. Check the lubricant level when th e machine is cooled down and positioned on even floor. Be fore checking the levels, carefully clean the areas to be inspected to avoid the penetration o f foreign matters. Should the level n eed to be topped up, use clean receivers and make sure that no foreign matters enters the lubricant. Change the engine oil when the machine is warmed up to facilitate the dripping. Before injecting new grease in the lubricators by means of the grease gun pump, remove carefully old paint, dirt, etc. from the lubricator and pump until the old grease has completely dripped out. Refer to the use and maintenance manual of the diesel engine for special maintenance operations of the engine itself. Always use suitable strippers, wrenches and tools in order not to d amage the pieces dur ing disassembling and reassembling operations. Use copper hammers or wooden mallets to release firmly adhering parts. Distinctly separate the parts of the different gr oups and p artially screw the nuts with their pins or studs. Clean the parts using brushes or cloth s then wash them with cleansing so lution and re move the remaining impurities with compressed air. Carefully wash the pie ces or use compressed air jet after grinding or using abra sive means, an d make sure that any abrasive powder has been removed. Make sure that all pieces are clean, then lubricate before reassembling them. Pay greatest attention to safety rings and split pins: re breakage.
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place immediately if they show signs of

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8.3 MAINTENANCE CHART The routine maintenance stated in the following chart shall be performed after the machine has worked for the number of hours stated in the left column (see hour meter on the control panel). Approximately 10 hours correspond to a workday, 50 hours to a week, 250 hours to a month and 2000 hours to a year. The column chapter refers to the specific cha pter of this manual in which the mentioned ope ration is described. The entry manual refers to the diesel engine manual.
Working hours

Operation Check fuel level Check engine oil level Check hydraulic oil level Greasing pins Check hydraulic system filter cartridges Check electrolyte level in batteries Check bolt tightening Check pipe fittings tightening Pinion/slew ring greasing Telescopic arm pins and sliding blocks greasing Telescopic counterweight sliding blocks greasing Universal joints and steering axle a rticulated joints greasing. Check hydraulic system slips Check diesel engine air filter Check slew drive control reduction gear oil level Check axle differential unit oil level Check epicyclical reduction unit oil level Check gearbox oil level First change of hydraulic oil filter cartridge First change of diesel engine oil filter cartridge Clean magnetic rod Hydraulic oil topping up, if necessary External cleaning of the hydraulic circuit heat exchanger Check diesel engine belts tension Change diesel engine oil Replace hydraulic oil filter cartridge Replace diesel engine air filter cartridge Replace diesel engine oil filter cartridge Replace fuel filter cartridge Check the thickness of telescopic arm sliding blocks Check the thickness of telescopic counterweight sliding blocks Clean filter on diesel oil pump Change slew drive control reduction gear oil Change axle differential unit oil Change epicyclical reduction unit oil Change gearbox oil Change hydraulic oil and clean tank

Chapter 8.9.3 8.8.4 8.7.1 8.9.1 8.14 8.10 8.8.3 8.7.1 8.7.1 8.7.1 8.7.1 8.8 8.9.2 8.13 8.21 8.22 8.23 8.8.4 8.9.1 8.8.5 8.8.4 8.18 Manual 8.9.3 8.9.1 8.9.2 8.9.3 8.9.4 8.11 8.12 Manual 8.13 8.21 8.22 8.23 8.8.4

Lubricant Classification SAE 10W30 Classification ISO HV 46 Consistency NLGI 2

10

50

Consistency NLGI 2 Consistency NLGI 2 Consistency NLGI 2 Consistency NLGI 2

100

Viscosity class ISO VG 150 Viscosity class ISO VG 150 Viscosity class ISO VG 150 Viscosity class ISO VG 150

Classification ISO HV 46

250

Classification SAE 10W30

500

1000 2000 or after the first year

NOTE: The lubricants in the right column of the chart refer to norma l weather conditions. In case o f especially rigorous weather conditions sing le out the suit able lubricant in the charts of the following pages.
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Viscosity class ISO VG 150 Viscosity class ISO VG 150 Viscosity class ISO VG 150 Viscosity class ISO VG 150 Classification ISO HV 46

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8.4 HYDRAULIC OIL CHART Only use good-quality hydraulic oil complying with the specifications of the following chart. The properties of the hydraulic oil suggested fo r common use shall comply with API-CC or MR-L-2104 and MR-L-4615. The characteristics of the hydraulic oil suggested for common use shall be VG 46. However Colmar suggest the use of HV hydraulic oil.
ISO Viscosity Class HLP (HM), HV

VG 22

VG 32

VG 32

VG 46

VG 46

VG 68

VG 68

VG 100

HLP

HV

HLP

HV

HLP

HV

HLP

HLP

AGIP

ARNICA 32

OSO 32 VITAM GF 32 VITAM DE 32 AVILUB RSL 32 ENERGOL HLP 32 ENERGOL HLP D 32 HYSPIN AWS 32

ARNICA 46

OSO 46 VITAM GF 46 VITAM DE 46 AVILUB RSL 46 ENERGOL HLP 46 ENERGOL HLP D 46 HYSPIN AWS 46

ARNICA 68

OSO 68

OSO 1000 VITAM GF 100 AVILUB RSL 100 ENERGOL HLP 100 HYSPIN AWS 100

ARAL

VITAM GF 22 AVILUB RSL 22 ENERGOL HLP 22 ENERGOL HLP D 22 HYSPIN AWS 22

VITAM HF 32 AVILUB HVI 32 ENERGOL SHF 32 HYSPIN AWH 22

VITAM HF 46 AVILUB HVI 46 ENERGOL SHF 46 HYSPIN AWH 46 /

/ AVILUB HVI 68

VITAM GF 68 AVILUB RSL 68 ENERGOL HLP 68 ENERGOL HLP D 68 HYSPIN AWS 68

AVIA

BP

CASTROL

HYSPIN AWH 68

CHEVRON

EP HIDR. OIL EP HIDR. OIL EP HIDR. OIL 22 32 HV 32 NUTO H 22 UNIVIS J 32 HYDRAN HV 22 NUTO H 32

EP HIDR. OIL EP HIDR. OIL EP HIDR. OIL EP HIDR. OIL 46 68 HV 68 100 NUTO H 46 UNIVIS N 56 HYDRAN HV 68 NUTO H 68 NUTO H 100

ESSO

UNIVIS N56 HYDRAN HV 46

FINA

HYDRAN 22

HYDRAN 32

HYDRAN 46

HYDRAN 68

HYDRAN 100

FUCHS

RENOLIN MR RENOLIN MR 5 520 RENOLIN B 5 DTE 22 TELEX HVLP 22 TELLUS OEL 22 RANDO OIL HD A-22 ETC 20 DTE 13

RENOLIN MR RENOLIN MR RENOLIN MR 10 15 RENOLIN B 1030 RENOLIN B 10 15 DTE 24 HIDR. OIL HLPD 32 TELEX HVLP 32 TELLUS OEL 32 RANDO OIL HD A-32 ETC 25 DTE 15 DTE 25 HIDR. OIL HLPD 46 TELEX HVLP 46 TELLUS OEL 46 RANDO IL HD B-46 ETC 30

RENOLIN MR RENOLIN MR 30 20 RENOLIN B RENOLIN B 30 20 DTE 26 HIDR. OIL HLPD 68 TELEX HVLP 68 TELLUS OEL 68 RANDO OIL HD C-68 ETC 35 DTE 27 TELEX HVLP 100 TELLUS OEL 10 RANDO OIL HD E-100 /

MOBIL

DTE 16

REPSOL

TELEX HV 32 TELLUS OEL T 32 RANDO OIL HD AZ32 /

TELEX HV 46 TELLUS OEL T 46 /

TELEX HV 68 TELLUS OEL T 68 RANDO OIL HD CZ68 /

SHELL

TEXACO VALVOLINE

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8.5 LUBRICATING OIL CHART Only use good-quality lubricating oil complying with the specifications of the chart. The reduction gears are oil-lubricated. The characteristics of t he lubricant suggested for common use sha ll be EP (extreme pressure) an d viscosity ISO VG 150 (11 - 13 E at 50C).
Room temperature Viscosity ISO VG Viscosity E / 50C AGIP BP CASTROL CHEVRON ESSO FINA IP MOBIL REPSOL SHELL TOTAL ELF - 20C + 5C 100 7,3 BLASIA 100 ENERGOL GR HP 100 ALPHA SP 100 NL GEAR CAMPOUND 100 SPARTAN EP 100 GIRAN 100 MELLANA 100 / TAURO 100 OMALA EP 100 CARTER EP 100 + 5C +40C 150 10,8 12,5 BLASIA 150 ENERGOL GR HP 150 ALPHA SP 150 NL GEAR CAMPOUND 150 SPARTAN EP 150 GIRAN 150 MELLANA 150 MOBILGEAR 629 TAURO 150 OMALA EP 150 CARTER EP 150 + 30C + 65C 220 15 18 BLASIA 220 ENERGOL GR HP 220 ALPHA SP 220 NL GEAR CAMPOUND 220 SPARTAN EP 220 GIRAN 220 MELLANA 220 MOBILGEAR 630 TAURO 220 OMALA EP 220 CARTER EP 220 + 40C + 65C 320 22 26 BLASIA 320 ENERGOL GR HP 320 ALPHA SP 320 NL GEAR CAMPOUND 320 SPARTAN EP 320 GIRAN 320 MELLANA 320 MOBILGEAR 632 TAURO 320 OMALA EP 320 CARTER EP 320

REDUCTELF SP 100 REDUCTELF SP 150 REDUCTELF SP 220 REDUCTELF SP 320

8.6 ENGINE OIL CHART The diesel engine lubricating oil shall be chosen according to the chart here on the right. Only use good-q uality lubricating oil complying with the specificat ions of this chart. Verify you are always using lubricating oil having the right degree of viscosity according to the engine operative room temperature (see the chart lower line). The lubricating oil shall comply wit h API CF4 or ACEA E2 specifications in standard loading conditions and wit h API CG4 or ACEA E3 in high loading conditions. NOTE: If t he machine is equipped with hydraulic oil preheating device, the engine oil shall be changed with running-in oil for rigorous climate. The first change of the -30 running-in oil shall be performed aft er the -22 first twenty operating h ours with 0 W30 or 0W40 viscosity class oil.

-20 -4

-10 14

0 32

10 50

20 68

30 86

40 104

50 C 122 F

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8.7 LUBRICATING GREASE CHART Only use good-quality lubricating grease having consistency NL GI 2 and complying with the specifications of the following chart. In case of especially rigorous weather conditions we suggest the use of a special low-temperature grease. AGIP ARAL BP CASTROL ELF ESSO IP MOBIL REPSOL SHELL VALVOLINE 8.8 GREASING According to the maintenance char t, all elements provided with lubricat or shall be greased with NLGI 2 consistency grease (see chart 8.7). If the machine is used in heavy-duty conditions, grease the elements more frequently. The lubricators are identified by colored dust protective caps and are generally located on the articulated joints. Slew ring toothing greasing: Before greasing the loading crane slew ring toothing, remove by means of a spatula the old grease which gathers on the rims of the pinion gear and of the s lew ring toothing, then smear the sl ew ring toothing with new grease by means of a spatula or a brush. After having greased the slew ring toothing rotate sometimes the turret to distribute t he new gre ase on the whole toothing circumference. GR MU EP 2 ARALUB HPL 2 GREASE LTX - EP 2 SPHEEROL EPL 2 EPEXA 2 BEACON EP 2 ATHESIA EP GREASE 2 MOBILUX EP 2 GRASA LITICA EP 2 ALVANIA GREASE 2 VALVOLINE LB 2

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Jack and articulated joint greasing: Inject the new grease with a suit able grease gun pump till t he old gre ase has been completely discharged. The lubricators are identified by colored dust protective caps Before injecting the new grease accurately remove from the lubricator old paint, dirt, etc. The lubricators are p laced on the articulated joints of the jib cylinders (lifting of 1 an d 2 jib and of telescopic arm) and of the bucket and of the railway truck cylinders. In the figure on the right you can see the lubricators of the railway truck cylinders. Steering axle articulated joint greasing: Inject the new grease with a suit able grease gun and pump until the old grease has been completely discharged. The lubricators are identified by coloured dust protective caps. Before injecting the new grease accurately remove from the lubricator old paint, dirt, etc. The lubricators are placed on the steering axle levers articulated joints and on the wheel hub.

Propeller shaft greasing: Inject the new grease with a suit able grease gun and pump until the old grease has been completely discharged. The lubricators are identified by coloured dust protective caps. Before injecting the new grease accurately remove from the lubricator old paint, dirt, etc. The lubricators are p laced on the articulated joints of both car dan propeller shafts, on the differ ential gear side and on the gearbox side.

Telescopic arm greasing: Before greasing the telescopic arm extension, remove by means of a spatula the old grease which gathers on the rims of t he jib itself, then smear the jib extension with new grease by means of a spatula or a brush. After having greased the sliding blocks, draw the jib extension in and out many times t o distribute the new grease on the whole length of the sliding blocks guide.

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Telescopic counterweight sliding blocks greasing: Before greasing the telescopic counterw eight sliding blocks, remove by means o f a spatula the old grease which gathers on the rims of the blocks itself, then smear the jib extension with new grease by means of a spatula or a brush. After having greased th e sliding blocks, draw the counterweight extension in and out many times to distribute the new grea se on the whole length of the sliding blocks guide.

8.9 HYDRAULIC SYSTEM 8.9.1 HYDRAULIC CYLINDERS Check the seal of the h ose fittings and make sure that the bushing pins an d the ball joints have been greased. As regards extraordin ary maintenance all seals have to be replaced when operating anomalies develop as a result o f excessive wear generating the hydraulic cylinder anomalous working.

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8.9.2 CRANE ROTATING JOINTS The rotating joint needs extraordinary maintenance only when the internal gaskets are worn. Check regularly the sea l between t he pipe unions and the rotating joint and verify the tightening of the supporting brackets bolts.

8.9.3 HYDRAULIC SYSTEM Check the pipe seals and tighten fittings at the first sign of leakage. This operation is especially important at the beginning of the machine service life when oil leaks may develop as a result of vibrations and parts bedding in. The figures on the right are only illustrative. Check the seal of all hydraulic pipes.

8.9.4 HYDRAULIC OIL Check the o il level in the tank, in according to the maintenance chart, by means of the level ga uge shown by the arrow in the figure. The level g auge can b e seen fro m the cab rear seat or when the telescopic co unterweight is retracted. If the oil level is near the MIN marking, refill with the oil suggested in the 8.4 chart. In case of a constant hydraulic oil loss, check the seals of the cylinders and of the hydraulic system. Change the hydraulic, in according to the maintenance chart, and clean the tank internally. To change the hydraulic oil remove the tank filing cap (see ar row 2 in the following figure), remove the cap placed under the tank and collect the oil in a suitable container. Change the hydraulic oil when the machine is completely cooled. As the hydraulic actua tors contain plenty of oil, check and change the oil when the cylinders have all been completely closed. The hydraulic oil shall b e disposed of according to the law in force. For the maintenance intervals see attached maintenance plan issue 7.

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8.9.5 MAGNETIC ROD Inside the machine oil tank a magnetic rod (arrow 1 in figure) h ave been in stalled to catch the fer rous impurities in the plant. Clean the magnetic rods in according to the maintenance chart, and clean the tank internally. To remove the rod unscrew the nut installed askew on the oil tank side, take out the ro d, clean it with a wiping cloth and put it back in its seat. For the maintenance intervals see attached maintenance plan issue 7. 8.10 FILTERS

2 1

8.10.1 HYDRAULIC OIL FILTER Oil filters (arrows 2 in previous figure) must be regularly checked as clogge d filters red uce the machines performance and can also lead to the collapse of the filter element with the conse quent contamination of the hydraulic system and serious damage to the hydraulic components. IMPORTANT: At the beginning of the machine service life filters must be replaced more frequently. Hydraulic system filters should be replaced in according to the maintenance chart. Shorter intervals between filter rep lacements will be scheduled, if the machine works in very dusty areas. IMPORTANT: the above mentioned filter rep lacement shall be repeate d from the beginning whenever hydraulic system components are replaced as the result of serious f aults, such as seizure of pumps, motors or cylinders, which cause big quantities of impurities to enter the hydraulic system. For the maintenance intervals see attached maintenance plan issue 7. 8.10.2 DIESEL ENGINE AIR FILTER To check the diesel engine air filte r loosen the knob (1) and remove the filter cover. Pull out th e filter cart ridge, shake it with your hand and blow compressed air on it. Also remove any dust particles fr om the cartridge outside covering. Press periodically the rubber cap (2) to let go out the dust which gather s inside th e filter. Follow the instruction s of the diese l engine manual. The air filter shall be ch ecked and replaced in according to the maintenance chart. Shorter intervals between filter chan ges will be scheduled, if the machine works in very dusty areas. When the a ir filter is clogged the warning light Nr. 26 on the op erators cab control panel lights on. The filter has to be cleaned or replaced. For the maintenance intervals see attached maintenance plan issue 7.

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8.10.3 DIESEL ENGINE OIL LEVEL AND DIESEL ENGINE OIL FILTER Check the e ngine oil, in according to the maintenance cha rt, by mean s of the d ipstick (arrow 1). The level must be included between the MIN and MAX markings. If the oil level is near the MIN marking, refill with the oil suggested in the 8.6 chart. The engine oil shall be changed in according to the maintenance chart. Change the oil when the engine is warmed up. Unscrew the cap on the oil pan. Remove the filling cap (arrow 2) to let the oil freely flow. Screw the oil pan cap a gain and pour new oil through the filling ca p until the oil lev er reaches t he MAX marking on the staff. Screw the filling cap again, start the engine for 5 minutes then stop it. Check the oil level and top up if necessary.

At the beginning of the machine service life the diesel engine oil filter must be replaced more frequently. Diesel engine oil filters should be replaced in according to the maintenance chart. Shorter intervals between filter rep lacements will be scheduled, if the machine works in very dusty areas. The engine oil shall be disposed of according to the law in force. For the maintenance intervals see attached maintenance plan issue7. 8.10.4 DIESEL ENGINE FUEL FILTER The fuel filters (arrow 1) shall be replaced in according to the maintenance chart. Turn off the cock placed under the gas oil tank, unscrew the filter cartridges located on the engine block and replace them with new ones of the same type. Turn the cock on and remove the air from the plant. As different kinds of cartridges can be installed, follow the instructions of the diesel engine manual.
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For the maintenance intervals see attached maintenance plan issue 7. 8.10.5 DIESEL ENGINE WATER SEPARATION FILTER To eliminate any cond ensation in the fuel, u nscrew the cap placed under filter 2 and c ollect the condensate in a container. Since the condensate contains traces of diesel fuel to provide discard it according to local regulations. The presence of water in the fuel pre-filter will be signaled by the indicator 23 on the dashboard. To replace the pre filter close the fuel tap unscrew the cartridge and replace it with one of the same type. Re-open the fuel valve and bleed the system. To bleed the system, turn the black knob on top of the pre-filter, remove and manually pump. For the maintenance intervals see attached maintenance plan issue7.

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8.11 DIESEL BELTS Check, according to the schedule shown in t he table maintenance, wear and tension the timing belt engine, shown in the picture on the side. To check the belt tension must be previously removed the protective cover. For the maintenance intervals see attached maintenance plan issue 7.

8.12 GENERAL MECHANICS The mechanical part s that rotate r eciprocally must be periodically ch ecked and lubricated. It is also necessary to check the bolted connections for loosened bolts. To this purpose it shall be verified: the slew ring flanging both as to the frame and as to the rotating turret (see arrow in the figure) the turret rotating joint supporting bracket connection any other bolt, above all those of the components subject to vibrations and movements. 8.13 TELESCOPIC ARM SLIDING BLOCKS Check periodically the t hickness of the telesco pic arm extension sliding block of the loading crane. The min. thi ckness shall not be lower than 5 mm. Should the thickness of the sliding b locks be lower than 5 mm., they must be replaced. To replace the telescopi c arm sliding blocks act as follows: 1. Remove the cylinder connection p in from the rod side. 2. Remove the setscrew (see arrows in the figure) on the arm fixed section. 3. Withdraw the extractable part. 4. Replace the four sliding blocks. 5. Reassemble the jib extension.

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8.14 TELESCOPIC COUNTERWEIGHT SLIDING BLOCKS Check periodically the t hickness of the telesco pic counterweight sliding block of the loading cra ne. The min. thi ckness shall not be lower than 5 mm. Should the thickness of the sliding b locks be lower than 5 mm., they must be replaced. To replace the telescopic counterweight sliding blocks act as follows: 1. Remove the cylinder connection p in from the rod side. 2. Remove the setscrews (see arrows in the figure) on the frame fixed section. 3. Withdraw the extractable part an d support it with a suitable lifting equipment. 4. Replace the four sliding blocks. 5. Reassemble all components. 8.15 SLEW DRIVE CONTROL REDUCTION GEAR Check the oil level in the slew drive control reduction gear, in a ccording to th e maintenance chart, by unscrewing the plug 1 an d verifying if the oil is visible. Top up the oil leve l with the oil suggested in the 8.5 chart, if necessary. The exhausted lubricating oil must be disposed of according to the law in force. For the maintenance intervals see attached maintenance plan issue 7.

8.16 BATTERIES Batteries are installed in the air filter housing, before the diesel engine. The electrolyte level of each cell shall be of about 6 mm. above the edge of the battery plate. If necessary, add distilled water up to the r ight level. IMPORTANT: Check the electrolyte level only when the engine has stopped. Do not use naked lights to light the cells up, as batteries contain explosive gas. Before replacing the cell caps, make sure th ey are clean. If the temperature is below 0C, start the engine for some minutes after the level topping up. In case the battery ha s to be removed, first
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disconnect the negative pole () and then the positive pole (+); to re store it f irst connect the positive pole (+) and then the negative pole (). Unscrew the metallic bracket to remove the battery. Clean periodically cla mps joints and grease them with antioxidant. 8.17 SERVICE BRAKE The braking system does not require special maintenance except the replacement of the worn pads.

See document NAJH038 Type 9b for service rail wheel braking system operation and maintenance.
8.18 PARKING BRAKE As far as th e parking b rake located at the en d of gearbox is concerned, t he play between the shoes and the dr um does not need to be adjust ed; however, the activation position of the negat ive cylinder does need to be adjusted. This adjustment is performed b y adjusting the threaded fork which connects the rod of the spring ram to the b rake lever. Turning the fork adjusts the position of t he connector in respect to the brake lever. The parking b rake is released by the pressure supplied by the opposing hydraulic circuit. When the supply circuit is under pressure, the parking brake is relea sed: in t his condition the pressure switch in the circuit keeps t he light, on the instrument panel, switched off.

See document NAJH038 Type 9b for parking rail wheel braking system operation and maintenance.

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8.19 FUSES The fuse carrier is placed on the control panel side in the operators cab an d in the rear bonnet on the left side of the machine. To approach the fuse s just remove the sa fety plastic cover and, if necessary, replace the bur ntout fuse. In case of short circuit do not rep lace any fu se before having verified the reasons and having repaired the fault. Other two fuses are installed near the diesel engine.

Fuses placet in the rear bonnet on the left side of the machine 1. Position light Movement buzzer. stop light Counterweight limit switch (10A) 2. Passing lights (15A) 3. Engine ECU (25A) 4. Boom working lamps (10A) 5. Klaxon (7.5A) 6. Air conditioning compressor (10A) 7. Magnet ridger Hammer (10A) 8. Fuel pump (15A) 9. Dashboard feeding (7.5A) 10. Cab feeding (20A) 11. Air conditioning fans (15A) 12. High limit switch (5A) 13. Camcorder (5A) 14. Clacson feeling and parking brake (7.5A) 15. Engine ECU (7.5A) 16. Ignition key feeding (10A) 17. Electric board feeding (50A) 18. Machine ECU feeling (30A) 19. Limiting device feeding (10A)

Fuses placed on the enginel 1. Start engine (30A) 2. Spark plug (60A)

1. 2. 3. 4. 5. 6. 7.

Fuses placed on the cab Cab headlight (10A) Cab headlight (10A) Boom working lamps (10A) Rear headlight (10A) Rotating lamp (10A) Windscreen wiper (10A) Optional

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8.20 HEAT EXCHANGER Clean the heat exchanger periodically by means of a compressed air jet or wash with water. IMPORTANT: Do not use products containing even little quantities of oily substances as they facilitate dust adhesion which damages the heat exchange. Clean the heat exchanger whenever it gets dirty with oil, grease, gas oil or oily or fatty substances. 8.21 TYRES Check periodically bolt tightening an d the pressure of the tyres The recommended pre ssure shall be checked by means of the valves shown by the arrow B in the figure and shall be of 10 bar (MICHELIN XZM 9.0020 160A5). Check the inflation pressure and the tyre tread wear. During the nut tightening (see arrow A in the figu re on the hub circumference) the load shall not have to weigh on the wheels. To avoid that, raise t he wheels from the ground by means of the railway trucks and operate the parking brake. The nut torque wrench setting is 55 daNm. Replace the damaged or excessively worn out tyres. 8.22 RAILWAY TRUCKS To control t he pressure of the ra ilway wheels on the rubber wheels, control the tension rod by means of the register you can see in the figure. The adjustment is necessary to avoid tire sliding on the iron wheels, should the tires be worn out. To control the iron wh eel pressure, unscrew the ring nut A and unscrew the ring nut B of some turns (a turn is equivalent to a tension rod elongation of 9 mm.). We suggest you to try until there is no slippage between the rubber and the tires. Tighten the ring nut A when th e pressure is sufficient to avoid any sliding. The tension rod length shall be adjusted when the railway trucks are raised. After replacement of th e tires, restore the original pressure (when the tires are new, the tension rod length is 450 mm). NOTE: an excessive pressure of the iron wheels on the rubber wheels may cause the early wearing of the latter.

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8.23 AXLE DIFFERENTIAL UNIT Check the oil level in t he axle differential unit , in according to the maintenance chart, by unscrewing the plug 1 and verifying if th e oil is visible in the hole. Top up the oil level with the oil suggested in the 8.5 chart, if nece ssary. Change the axle differential unit oil in the reduction gear, in according to the maintenance chart, by unscrewing the plug 2 a nd let flow t he exhausted oil by unscr ewing the plug 1. Scr ew the plu g 2 again after some minutes and add new oil through the plug 1 u ntil the height of the hole 1 has bee n reached. The exhausted lubrica ting oil must be disposed of according to the law in force. For the maintenance intervals see attached maintenance plan issue 7. 8.24 EPICYCLICAL REDUCTION UNIT Check the oil level in the epicyclical reduction unit, in according to the maintenance chart, by unscrewing the plug A and verifying if the oil is visible in the hole. Top up the oil level with the oil suggested in the 8.5 chart, if necessary. Change the epicyclical reduction unit oil in t he reduction gear, in a ccording to th e maintenance chart, by un screwing the plug B a nd let flow the exhausted oil by unscrewing the plug A. Screw the plug B again after some minutes and add new oil through the plug A until the height of the hole A has been reached. The exhausted lubricating oil must be disposed of according to the law in force. For the maintenance intervals see attached maintenance plan issue 7. 8.25 GEARBOX Check the gearbox oil, in according to the maintenance chart, verifying if the oil is visible in the hole. Th e level must be include d between the MIN and MAX markings. Top up the oil level with the oil sugg ested in the 8.5 chart, if necessary. Change the epicyclical reduction unit oil in t he reduction gear, in a ccording to th e maintenance chart, by un screwing the plug B a nd let flow the exhausted oil by unscrewing the plug A. Screw the plug B again after some minutes and add new oil through the plug A until the height of the hole A has been reached. The exhausted lubricating oil must be disposed of according to the law in force. For the maintenance intervals see attached maintenance plan issue 7.
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8.26 WINDSCREEN WASHER TANK La vaschetta del liquid o lavavetri posizionata allesterno della cabina nel lato interno. Periodicamente riempire la vaschetta con liquid o adatto alle temperature ambientali in cui opera la macchina. The windscreen washer tank is located outside the cab on the internal side of the machine. Periodically fill the ta nk with suitable liquid at ambient temperatures in which the machine operates. 8.27 WASHING OF THE MACHINE Perform external washing machine using a jet of high pressure water. Do not wash the inside of the machine and wash the inside of the bonnet. 8.28 CONTROL OF PRESSURE AND VALVE SETTING CAUTION The valve setting stated in this chapter sh all be performed only by authori zed workshops or by qualified personnel of Colma r Technik S .r.l., prior consent of t he company. 1 Slew drive control circuit Measuring socket 1 on pressure check unit. Double-stage pressure relief valve on the distributor. The pressure relief valve is a double-stage one and theref ore it is ne cessary to perform two pressure readings. To perform t he reading of the first stage move the bucket cylinders to the end of t he stroke. Max. allowed value: 280 bar [4060 p.s.i.]. To perform the reading of the second stage move the cylinder of the boom to the end of the stroke. Max. allowed value: 350 bar [5075 p.s.i.]. 2 Lifting circuit Measuring socket 2 on pressure check unit. Double-stage pressure relief valve on the distributor. The pressure relief valve is a double-stage one and theref ore it is ne cessary to perform two pressure readings. 3 Hydraulic power steering circuit Measuring socket 3 on pressure check unit. Attach the pressure gauge to the corre sponding measuring socket and turn the steering wheel until the steering cylinder reaches the end of the stroke. Max a llowed value: 140 bar [2030 p.s.i.]. 4 Auxiliary circuit Measuring socket 4 on the pressure check unit. Pressure relief val ve on the distributor. Place the manometer on its measuring socket and operate the cylinders of the road swinging lock or tho se of the telescopic counterweight to the end of the stroke. Max allowed value: 200 bar [2030 p.s.i.]. 5 Servocontrol circuit Measuring socket 5 on the pressure check unit. Connect the mano meter to the measuring so cket and read the pressure value on the manometer. Max allowed value: 30 bar [435 p.s.i.]. 6 Cooling circuit Measuring socket 6 on pressure check unit. Place the manometer on its measuring socket, start the hydraulic engine which operates the fan of the air-oil heat exchanger. Max allowed value: 50 bar [2030 p.s.i.]. To perform the reading of the first stage move the cylinders of the telescopic arm or of the railway trucks to the end of the stroke. Max. allowed value: 280 bar [4060 p.s.i.]. To perform the reading of the second stage move the cylind er of the ar m to the end of the stro ke. Max. allowed value: 350 bar [5075 p.s.i.].
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8.29 CONTROL OF PRESSURE AND VALVE SETTING CAUTION The valve setting stated in this chapter shall be perf ormed only by authorized workshops or by qualified personn el of Colmar Technik S .r.l., prior consent of t he company. The here described measurements shall be made with a manometer of at least 400 bar (5800 p.s.i.) fullscale and complete with a rubber hose with 16x2 female quick coupling. identifies pressure tubes in the hydraulic plan herewith enclosed. The symbol NOTE: To perform the pressure measurement the diesel engine shall be at peak rpm (2300 rev/min.). NOTE: If the settings value on the valves are not corrects, contact Service Colmar.

3 2 1

4 5

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Pressure relief and movement control valve on slew drive motor This valve has two adjusters for settin g the pressure in both delivery lines. With the bo om resting on the grou nd, rotate t he turret in either direction and, in this condition, read the feed pressure. Turn the corresponding adjuster to obtain a valve cracking pressu re of 240 bar (3480 p.s.i.) Repeat the operation for the oth er direction of rotation, this time using the other adjuster to set the maximum pressure in the second delivery line.

Pressure relief, movement control and braking valve on the hydraulic travel motor This valve serves to protect th e travel motor against pressure surges and to provi de flow control between the motor inlet and outlet, and eff ect hydraulic deceleration when the hydraulic motor feed stops. The valve i s equipped with 4 adjusters, two for adjustment of the pressure relief valves, two for the braking valves. To set the pressure relief valves, you must first increase the setting of the direction al control valve to one brin ging the pr essure up t o 360 bar ( 5220 p.s.i.), then, select 2n d gear and, keeping the machine braked, set the valve pressure to 340 bar (4930 p.s.i.). At this pressure there should be oil blow-by through the pressure relief valves. Reverse the direction of rotation of the hydraulic motor and proceed t o set the pr essure of th e other delivery line of the hydraulic travel motor. This done, reset the directional control valve to the normal value of 300 bar (4350 p.s.i.). To set the braking valve , run the ma chine at the ma ximum speed and on releasing t he travel pedal, the machine should come to a gentle stop. The op eration is to be performed for both forward and reverse travel. NOTE: to adjust the braking valves, clo se the adjuster to obtain gent ler braking and open it to obtain sharper braking. CAUTION If the high pressure valve setting values do no t correspond to the above mentio ned ones, apply to Colmar Technik S.r.l. after-sales service.

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8.30 CYLINDER LIFTING SPEED CONTROL The jib lifting speed is affected by th e weight which is carried by the jib. If the weigh t is heavy, the sinking speed may be very high. The jib sinking speed can be contr olled using the controls of the piloted locking valves installed on the rod side of the main and arm cylinders. On the boom cylinders there are two piloted locking valves (one of these can be seen in the figure), whereas on the arm cylinder there is a valve only. Operating the control of the locking valve, the speed can be controlled by limiting the oil flow during the jib descent. To control the oil flow u nscrew the lock nut (see arrow A) wi th a wrench Nr. 10 and screw the a djusting screw (see arrow B) with a socket head screw wrench. Screw (or unscrew if the descent speed has to be increased) turn at a time, then check how the machine works as the valve is very sensitive. A sensitive adjustment (and therefore a restricted speed of descent) assures very sensitive motions. CAUTION The piloted locking valves of b oth the jib cylinders shall be equally calibrated to avoid anomalous overstress of the machine steel structure. 8.31 CONVOY PNEUMATIC VALVE CONTROL The pneumatic bra ke circuit is provided of a pressure control valve. In order to anticipate/ delay the convoy bra king rotate the ring nut shown in the picture.

8.32 BRAKE VALVE Connect the manometer to the mea suring socket, push the brake pedal and read the pressure value on the manometer. Max allowed value: 30 bar [435 p.s.i.]. There are two measuring sockets, one for front brakes and one for rear brakes. In order to adjust the pressure, remove the nut on the rear of the valve and use the register inside.

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9 HYDRAULIC SYSTEM
9.1 COMPONENT LIST 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Diesel engine Variable displacement double piston pump Brakes auxiliary gear pump Double gear pump Pump displacment control valve Valve Valve Steering unit Steering cylinder Hydraulic oil filter Tank breather Heat exchanger Auxiliary block valve Dual cross over relief valve Quick coupling Lock valve Road axle locking pressure switch Road axle locking cylinders Telescopic counterweight cylinders Three way flow regulator with priority way Emergency hand pump Three vay valve Pressure check Servo Brake unit Pressure switch Pressure switch Accumulator Pressure reduce valve Service rail brakes Road Brakes Parking brake cylinder Main control block Pressure reducer valve Safety valve Boom cylinders Directional valve Diverter valve Safety valve Excavating backhoe bucket cylinder Check valves block Travel motor Travel valve Arm cylinder Safety valve 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 Turret rotation motor Relief valve Solenoid valves control block Parking rial brakes Servocontrols valve Valve Traslation pressure switch Traslation pressure switch Left joystick Right joystick Travel pedal Solenoid valves block Dead man solenoid valve Seat solenoid valve Front/rear trolley solenoid valve Gear box solenoid valve Telescopic solenoid valve Parking brake solenoid valve Rail axle locking cyclinders solenoid valve Rail axle pressurswitches Accumulator Speed gear cylinder Selector valve Accumulator Parking brake solenoid valve Directional valve Telescopic arm/trolley directional valve Front/rear trolley directional valve Telescopic arm cylinder Dual safety valve Lock valve Rear trolley cylinders Lock valve Front trolley cylinders Check valve Rail axle locking cyclinders Block valve Block valve Check valve Check valve Hydraulic rotating coupling Selector valve Check valve

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INTENTIONALLY LEFT BLANC

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9.2 HYDRAULIC PLAN

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10 ELECTRIC SYSTEM

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ANNOTATION

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Headquarters Via Nazionale Adriatica n.539/593 45031 ARQUA POLESINE (RO) ITALY Tel. +39 0425 93 21 33 ( Int.4 ) Fax +39 0425 46 50 52

www.colmarspa.com colmarspa@colmarspa.com Export Sales Department: export@colmarspa.com

AU S AU TR S T A LI BE A RI A L B U GIU M L CA GA NA R IA CH DA I S O NA U DE TH NM KO FI RE N AR A F R LA N K AN D GE CE R J A MA N P GR AN Y E IN EC DO E IR NE E S IT LA N IA AL D LA Y T M VIA AL A M OR YS I HO OC A C L NE LA N O W D NO Z RW EA L RO AY AN M D RU AN S S IA SI N IA S L GAP O O S P VE N R E AI I UN N A IT ED U. S KI S O .A. NG UT DO SW H M A E TA DE ME RI IW N CA TH AN A TU ILA R K ND EY

COLMAR S.p.a.
3790 Commerce Ct., Suite 100 Wheatfield, New York 14120 1-800-537-5204 Ph. 716 - 693 - 9877 Fax 716 - 693 - 9869

COLMAR USA, Inc. U.S.A.

www.colmarequipment.com info@colmarequipment.com sales@colmarequipment.com service@colmarequipment.com

Unit 10, Wheel Forge Way Ashburton Park Ashburton Road West, Trafford Park Manchester M17 1EH Ph. 0161 848 8902 Fax 0161 848 8903

COLMAR UK Ltd U.K.

115088 Moscow, Yuzhnoportovaya ul.7 Ph. +7 495 778-1376 Fax +7 495 648-3470 info@ooocolmar.ru

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www.colmarspa.com

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