HOOKLOADER

HYVALIFT08-S

___________________________________________________________________

User’s Manual___________________________________________________________________________

HYVALIFT 08-S

User’s Manual 1

Introductory Note

This manual applies to hookloader HYVALIFT 08-S.

Specification :

Hookheight H :

Standard H (mm)DIN 30 722 900CHEM 930CTS 1 000POL 1 190SC 1 420

1 450DIN_1570 1 570

OH

L

KX

81T

Fig. 1

TYP H STANDARD (hookheight)

X(mm)

L (mm)

O (mm)

K T (mm)

MIN./MAX. container length (mm)

08-33-S- DIN, CHEM, CTS, POL 700 3 300 225 50º 65 2 800 – 4 30008-36-S- DIN, CHEM, CTS, POL 800 3 600 225 50º 65 3 000 – 4 60008-39-S- DIN, CHEM, CTS, POL 900 3 900 225 50º 65 3 200 – 4 90008-42-S- DIN, CHEM, CTS, POL 1 000 4 200 225 50º 65 3 400 – 5 20008-45-S- DIN, CHEM, CTS, POL 1 100 4 500 225 50º 65 3 600 – 5 500

08-36-S- SC, DIN_1 570 800 3 600 225 48º 100 3 150 – 4 65008-39-S- SC, DIN_1 570 900 3 900 225 48º 100 3 150 – 4 90008-42-S- SC, DIN_1 570 1 000 4 200 225 48º 100 3 350 – 5 15008-45-S- SC, DIN_1 570 1 100 4 500 225 48º 100 3 650 – 5 40008-48-S- SC, DIN_1 570 1 200 4 800 225 48° 100 3 750 – 5 65008-51-S- SC, DIN_1 570 1 300 5 100 225 48° 100 4 150 – 6 15008-54-S- SC, DIN_1 570 1 400 5 400 225 48° 100 4 400 – 6 400

The operation instructions are applicable to the use of the HYVALIFT 08-S Hookloader. The description, operation, maintenance etc. of the carrier vehicle itself are contained in the specific documentation provided by the vehicle manufacturer.

Prior to the start of operations the user must become acquainted with the HYVALIFT 08-Scarrier as described in the manual in addition to all applicable work safety regulations.

Disregarding the manual may cause injuries, operating defects, and the cancellation of applicable warranties.

Left, Right, and Rear relates always to the direction of travel.

Only a professional may perform adjustments and work on the hydraulic system.

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User’s Manual 2

Manufacturer : TECHNAMICS B.V.Zeppelinstraat 217903 BR Hoogeveen

Phone : 00 31 - 528 - 22 98 50Fax : 00 31 - 528 - 26 62 11

All rights are reserved.

Due to continuous development of the product line all future engineering changes are reserved.

TECHNAMICS B.V.- I. issue, 2006 -

HYVALIFT 08-S

User’s Manual 3

TABLE OF CONTENTS

Introductory Note : 1

Safety Conditions : 4

A. Work Safety ………………………… 4B. Fire Safety ………………………… 6C. Travel on public roads ………………………… 6D. Liquidation of the machine at the end of its useful

life………………………… 6

1. Description of the machine : 71.1 Overall view ………………………… 71.2 Description ………………………… 71.2.1 Controls ………………………… 71.2.2 Steel Construction ………………………… 71.2.3 Hydraulics ………………………… 81.3 Model Label ………………………… 91.4 Control equipment ………………………… 101.4.1 Controls in driver’s cabin ………………………… 101.5 Specifications ………………………… 121.5.1 Specifications of 08-S System ………………………… 121.5.2 Container specifications ………………………… 13

2. System operation : 142.1 Operating and safety instructions ………………………… 142.2 Loading of the container ………………………… 152.3 Container unloading ………………………… 172.4 Tipping the container ………………………… 182.5 Loading to the trailer ………………………… 192.6 Unloading the trailer ………………………… 20

3. Instructions for the maintenance of the system : 203.1 To be done by professionals only ………………………… 203.2 Instructions for the liquidation of operating materials ………………………… 203.3 Schedules for maintenance ………………………… 203.4 Lubrication Plan ………………………… 223.5 Maintenance ………………………… 233.5.1 Checking level of hydraulic oil ………………………… 233.5.2 Suction filter replacement ………………………… 233.5.3 Replacing cartridge of return filter ………………………… 233.5.4 Replacement of hydraulic oil ………………………… 23

4. Repairs : 244.1 Table of repairs ………………………… 24

5. Warranty 26

Appendix

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User’s Manual 4

Safety Conditions :

A. Work Safety :

Before you accept the machine, check that all parts listed in the delivery slip have been received.

Before starting the machine read operating instructions, mainly the sections on work safety, fire safety, travel on public roads, equipment controls, maintenance and repairs. Get acquainted with machine control elements and its overall function.

Follow the instructions of this manual as well as generally applicable work safety, health protection, fire, traffic safety, and environment protection regulations.

The machine may be operated by persons over 18 years, licensed to drive at least vehicles of Group C, properly and evidently instructed in the operation of the machine, containers and the rules of work safety.

The operation and maintenance manual must remain on hand in the carrier

The automobile carrier is operated by one person only.

For the carrier to handle containers it must be in a perfect technical condition.

The automobile container carrier may be used to handle containers of approved type only, in a good shape with undamaged safety elements.

It is not allowed to use the automobile carrier to functions other than container handling.

Should the carrier be equipped with other equipment as well, this equipment must be operated in compliance with its operating instructionsIt is not permitted to handle an overloaded container, or a container with its load unevenly distributed. The operator is responsible for the load during transport, its distribution, and his adherence to specified maximum capacity of the vehicle, the carrier, and the container.

The load that could become loose during travel must be secured against spontaneous release. If the container has gates, supports etc., the operator must check before the trip that they are locked and secured in the travel mode. Similarly, the container must be checked to be in a safe transport position.

While handling the container, it is not allowed for anybody to be near the carrier less than 4 meters on the sides and 8 meters behind it.

WARNING !!!

Prior to the start of handling the container, the operator must make sure that there is nobody within the specified area, and should sound a horn immediately before starting operations. Should the conditions require, the operator must use an instructed person for supervising the area.

The transport of people on the hookloader and/or on the loading platform is not allowed.

When operating from the side of the vehicle, do not enter underneath a lifted and unsecured container or the arm !

Do not enter underneath the lifted and unsecured container or the arm !

When handling the container, observe instructions for the operating and/or emergency brakes according to specific actions, since there is danger of spontaneous movement of the vehicle !

Containers may be handled on slopes with a maximum incline of 5 degrees.

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User’s Manual 5

It is not allowed to handle containers on a sloping, uneven or infirm terrain.

While turning or backing, be extra careful; keep good lookout, or use an instructed person.

When severe vibrations are present or an unusual sound is heard, stop immediately, stop the motor and secure it against starting. Block the wheels, and first then start looking for the cause !

WARNING !!!

In case there is a defect present during container handling, and the container remains in a position, where it cannot be safely loaded or unloaded (hydraulic loop defect), the situation must be considered an emergency, where spontaneous freeing of the container may occur. In this situation the operator must secure the carrier against spontaneous movement, prevent other persons from entering the area near the vehicle, and report the accident to the owner through a messenger. To leave the carrier unsupervised or to repair it is strictly forbidden. For the repair of an emergency condition a procedure must be established in consultation with the manufacturer. Only properly trained persons may repair the equipment.

It is not allowed to travel with the hydraulic pump turned on. The operator must check before starting the trip that the pump is off, and must not permit the position of the controls to change and switch the pump on.

Check during work that the hydraulic loop is not leaking.

When handling containers near electrical power lines, it is necessary to be extra careful, and to maintain safe distance from the lines.

Work Safety – Maintenance :

For cleaning and maintenance use suitable tools and protective means.

Adjustments, cleaning, and lubrication of the carrier may be done only while the machine is idle. The vehicle must be wedged, with brakes on.

WARNING !!!

All repairs may be done on the vehicle without the container loaded. Should repairs be done on lifted equipment, it should be secured by a support and with no container loaded.

When the hydraulic system is being repaired, it should be done so that hydraulic oil doesn’t escape and contaminates the ground.

For lubrication or cleaning of badly accessible spots use suitable means, such as service platforms.

Prior to work on hydraulic loops, release pressure in the loop. Observe that pressure loops are not removed with pressure present. Hydraulic oil that gets under the skin under high pressure causes bad injuries, in which case seek out medical help immediately.

To check tightness of the hydraulic loop use suitable means, such as paper or wood, never your hand, to avoid injury!

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User’s Manual 6

Prevent tools from falling down and injuring somebody!

Check the tightness of bolts regularly.

Prior to electric arc welding disconnect alternator and battery cables

Spare parts must comply with technical specifications issued by the manufacturer; use preferably original parts.

B. Fire Safety :

The operator must be aware of technical specifications of transported flammables.

When handling containers with flammables or other dangerous materials, it is necessary to maintain special precautions for handling and transporting dangerous matters.

When using the carrier on sites or activities with a high fire danger, it is necessary to be extra careful and to respect fire regulations valid on the site and for the specific activity.

The operator must maintain the motor area, the carrier surface and the exhaust clean, toprevent flammable oil film to form and catch fire.

The operator must make sure that transported flammables do not get in touch with exhaust pipes of the carrier.

When transporting and handling flammables, the carrier must be equipped with at least one universal fire extinguisher of approved type (it is not standard equipment of the machine).

C. Travel on public roads :

The hookloader carrier has been approved for travel on public roads in the Czech Republic by the Ministry of Transport, and the technical certificate lists applicable data accordingly.

The hookloader carrier may handle only the approved type of containers. Technical certificate of approved types of containers is supplied with the vehicle, and is part of its certificate, which the operator must have on hand during travel on public roads.

The ADR regulations must be obeyed for the transportation of dangerous materials.

D. Liquidation of the machine at the end of its useful life :

For the liquidation of the machine at the end of its usuful life follow applicable local laws and regulation.

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User’s Manual 7

1. Description of the machine :

1.1 Overall view :

56

3 47 21 879 10 11 12

Fig. 2

Legend :

1. Sliding Arm 7. Side roller

2. Main arm Frame 8. Guiding Pulleys

3. Tipping Frame 9. Hydraulic cylinder – Sliding Arm (loading, unloading)

4. Under Frame 10. Hydraulic cylinder - Main arm Frame (loading, unloading, tipping)

5. Pick-up hook 11. Hydraulic distributor

6. Drop lock 12. Container locking

1.2 Description :

HYVALIFT 08-S is fully hydraulically driven. The containers may be loaded or unloaded on a slope of up to 5° on a firm ground.

1.2.1 Controls :

HYVALIFT 08-S is controlled from the driver’s cabin. Control signals are carried by compressed air to the distributor.

The distributor is located on the left side of the vehicle. It controls the movement of two hydraulic cylinders that load, unload and tip (it. 10, Fig. 2), and the hydraulic cylinder of the telescoping sliding arm (it. 9, Fig. 2). The third section of the distributor is a spare for the control of additionally installed equipment.

Should the driver’s controls fail, the equipment may be controlled directly from the distributor.

1.2.2 Steel Construction :

The superstructure of HYVALIFT 08-S consists of four units. The rotating tipping frame (it.3 Fig. 2) is located in the under-frame (it. 4, Fig. 2) . The telescopic assembly of the sliding arm

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User’s Manual 8

and the main arm frame (it. 1, 2, Fig. 2) rotates in the tipping frame. The entire assembly is moved by two hydraulic cylinders of loading, unloading, and tipping (it. 10, Fig. 2), and one cylinder of the telescoping sliding arm (it. 9, Fig. 2).

When loading and unloading, the sliding arm and the main arm frame are active. When tipping the container, the fully extended sliding arm, the main arm frame, and the tipping frame are active. The position of the main arm frame and the tipping frame is secured by a pin at the bottom of the main arm frame. The movement of this pin is controlled by the movement of the sliding arm.

WARNING !!!

For that reason it is not allowed to manipulate the sliding arm while the container is being tilted and doesn’t rest fully on the bearing surface of the under-frame. The position between the main arm frame and tipping frame may become loose, and the entire system may be seriously damaged !

1.2.3 Hydraulics :

The hydraulic pump located on the auxiliary drive of the gearbox supplies HYVALIFT 08-Swith the needed hydraulic power.

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User’s Manual 9

1.3 Model Label :

Example :

OKRÍNEK, 290 01 PODEBRADY, TEL. 00420 / 325 / 608111

ROK VÝR.

VÝR. C.

TYP

R

CÍSLO SCHVÁLENÍ HMOTNOST (kg)M-C-1055

08-39-S

xxxx - yyyyy

2006

zzzz

Fig. 3,4

TYPE HYVALIFT 08-39-S - product typeYEAR OF MANUFACTURE 2006SERIAL NUMBER xxxx - yyyyyWEIGHT zzzz - weight of the superstructure only

Explanation of the product type nomenclature :

HYVALIFT 08-SCapacity class of the carrier (t) 08Hookloader length (dm) 33-36-39-42-45Hookloader type series S

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User’s Manual 10

1.4 Control equipment :

1.4.1 Controls in driver’s cabin :

HYVALIFT 08-S is controlled from the driver’s cabin remotely.

Lever no.1 controls main hydraulic cylinder – loading, unloading, and tipping.Lever no.2 controls hydraulic cylinder of the sliding arm

B

A

1 2Fig. 5

LeverDirection Function Position of Sliding Arm

lever no. 2 A Sliding arm - retractedlever no. 2 B Sliding arm - extended

lever no. 1 A Unloading Retractedlever no. 1 B Loading Retracted

lever no. 1 A Tipping up Extendedlever no. 1 B Tipping down Extended

Should the driver’s controls fail, the equipment may be controlled directly from the distributor.This control ist necessary rate as only for emergency !

In case to use emergency control of hookloader (directly with levers on distributor) are out of operation all items of security system hydraulic circuit hookloader !

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User’s Manual 11

Icons and functions of the remote controller

MOVE THE SLIDING ARMmode – container unloading.

POSITIONING OF THE SLIDING ARMto basic positionmode – container loading

FOLDING THE MAIN ARM FRAMEmode – container unloading, tilting of containers (discharging contents)

POSITIONING MAIN ARM FRAMEto basic positionMode: folding the container back into its transport position

Table of functions

Press button- function

Locking of container Sliding arm position

loading the container

unlocked ► locked retracted ► extended

unloading the container

locked ► unlocked extended ► retracted

unloading

tipping container

locked ► unlocked

locked

extended ► retracted ► tilted

extended ► tilted

loading

tipping container

unlocked ► locked

locked

tilted ► retracted ► extended

tilted ►basic

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User’s Manual 12

1.5 Specifications :

1.5.1 Specifications of the 08-S System :

Lifting and tipping capacity (kg) 8 000Hookheight H (mm) 900 - 930 - 1 000 - 1 190

(mm) * 1 420/1 450 – 1 570Overall height of the system (H= 900 - 1 190 mm) (mm) 1 240 - 1 270 - 1 340 - 1 530Overall height of the system (H= 1 420/1 450 – 1570 mm) (mm) * 1 770/1 790 – 1 910Overall width of the system (mm) 1 505Tipping angle (H= 900 - 1 190 mm) (°) 50Tipping angle (H= 1 420/1 450 - 1 570 mm) (°) 48Hookloader - height (mm) 225Max. pressure (MPa) 35Volume of the equalizing tank (l) 50Maximum transversal slop when tipping (°) 5°Maximum longitudinal slope when loading or unloading (°) 5°

08-33-SSliding Arm - horizontal elevation (mm) 700Overall length of the system (H= 900/930 - 1 190 mm) (mm) 3 579System weight incl. operating fluids (H= 900/930) (kg) 1 077System weight incl. operating fluids (H= 1 000) (kg) 1 079System weight incl. operating fluids (H= 1 190) (kg) 1 085Nominal working pressure (MPa) 19,3Min./max. container length (mm) 2 800 – 4 300

08-36-SSliding Arm - horizontal elevation (mm) 800Overall length of the system (H= 900/930 - 1 190 mm) (mm) 3 829Overall length of the system (H= 1 420/1450 – 1 570) (mm) 3 866System weight incl. operating fluids (H= 900/930) (kg) 1 114System weight incl. operating fluids (H= 1 000) (kg) 1 117System weight incl. operating fluids (H= 1 190) (kg) 1 123System weight incl. operating fluids (H= 1 420/1450 – 1 570) (kg) 1 162Nominal working pressure (H= 900 - 1 190 mm) (MPa) 20,2Nominal working pressure (H= 1 420/1 450 - 1 570 mm) (MPa) 11,7 / 13,8Min./max. container length (mm) 3 000 – 4 600

08-39-SSliding Arm - horizontal elevation (mm) 900Overall length of the system (H= 900/930 - 1 000 mm) (mm) 4 111Overall length of the system (H= 1 420/1450 – 1 570) (mm) 4 166System weight incl. operating fluids (H= 900/930) (kg) 1 150System weight incl. operating fluids (H= 1 000) (kg) 1 153System weight incl. operating fluids (H= 1 420/1450 – 1 570) (kg) 1 197Nominal working pressure (H= 900 - 1 190 mm) (MPa) 20,9Nominal working pressure (H= 1 420/1 450 - 1 570 mm) (MPa) 11,6 / 14,9Min./max. container length (mm) 3 200 – 4 900

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User’s Manual 13

08-42-SSliding Arm - horizontal elevation (mm) 1 000Overall length of the system (H= 900 - 1 000 mm) (mm) 4 411Overall length of the system (H= 1 420/1450 – 1 570) (mm) 4 466System weight incl. operating fluids (H= 900) (kg) 1 190System weight incl. operating fluids (H= 1 000) (kg) 1 193System weight incl. operating fluids (H= 1 420/1450 – 1 570) (kg) 1 240Nominal working pressure (H= 900 - 1 000 mm) (MPa) 21,6Nominal working pressure (H= 1 420/1 450 mm) (MPa) 11,6 / 16,1Nominal working pressure (H= 1 570 mm) (MPa) 11,5 / 16,1Min./max. container length (mm) 3 400 – 5 200

08-45-SSliding Arm - horizontal elevation (mm) 1 100Overall length of the system (H= 900 - 1 000 mm) (mm) 4 680Overall length of the system (H= 1 420/1450 – 1 570) (mm) 4 766System weight incl. operating fluids (H= 900) (kg) 1 229System weight incl. operating fluids (H= 1 000) (kg) 1 232System weight incl. operating fluids (H= 1 420/1450 – 1 570) (kg) 1 282Nominal working pressure (H= 900 - 1 000 mm) (MPa) 22,2Nominal working pressure (H= 1 420/1 450 mm) (MPa) 11,7 / 17,3Nominal working pressure (H= 1 570 mm) (MPa) 11,6 / 17,3Min./max. container length (mm) 3 600 – 5 500

08-48-SSliding Arm - horizontal elevation (mm) 1 200Overall length of the system (mm) 5 066System weight incl. operating fluids (H= 1 420/1450 – 1 570) (kg) 1 332Nominal working pressure (H= 1 420/1 450 mm) (MPa) 11,9 / 18,5Nominal working pressure (H= 1 570 mm) (MPa) 11,7 / 18,5Min./max. délky kontejnerů (mm) 3 750 – 5 650

08-51-SSliding Arm - horizontal elevation (mm) 1 300Overall length of the system (mm) 5 365System weight incl. operating fluids (H= 1 420/1450 – 1 570) (kg) 1 372Nominal working pressure (H= 1 420/1 450 mm) (MPa) 12,1 / 19,7Nominal working pressure (H= 1 570 mm) (MPa) 11,2 / 19,7Min./max. container length (mm) 4 150 – 6 150

08-54-SSliding Arm - horizontal elevation (mm) 1 400Overall length of the system (mm) 5 665System weight incl. operating fluids (H= 1 420/1450 – 1 570) (kg) 1 412Nominal working pressure (H= 1 420/1 450 mm) (MPa) 11,7 / 20,8Nominal working pressure (H= 1 570 mm) (MPa) 11,4 / 20,8Min./max. container length (mm) 4 400 – 6 400

1.5.2 Container specifications :

Elevation of the pick-up hook (mm) 900 - 930 -1 000 - 1 190 - 1 420 / 1 450 - 1570

Other specifications according DIN 30 722-3, C.H.E.M. /T.S.13/, CTS, POL, SC, DIN 30 722-1

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User’s Manual 14

2. System operation :

2.1 Operating and safety instructions :

Loading or unloading the container :

The vehicle and the container are placed on a firm horizontal surface of sufficient capacity.

When loading, unloading or tipping while the container is hanging in the pick-up hook of the sliding arm, it is not permited to handle the sliding arm lest it is severely damaged.

The total weight of the vehicle cannot be exceeded – see the technical certificate of the vehicle.

Damaged Containers :

Damaged containers may not be used, since they could affect the safety of the handling system or other participants of traffic on the road.

By damage we consider :

tears in steel plating or welding, deformed or damaged locking elements.

Travel :

People may not be transported in the container. The load must be secured against spontaneous movement. Cistern-type containers must be secured by additional elements.

Dangerous loads :

When handling or transporting dangerous loads, regulations for storing, handling and transporting dangerous loads (ADR) must be observed.

Dangerous areas :

The vicinity of the carrier, where people may be hit by the load or the equipment, is considered a dangerous area.

Load safety :

Loads, such as sand, paper, sawdust, which the air stream may disperse during transport must be protected by tarps.

Building debris, larger stones, concrete blocks, etc. must be loaded in a way that would not permit them to fall off.

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User’s Manual 15

2.2 Loading of the container :

WARNING !!!

It is not allowed to be staying in the dangerous area near the vehicle or the container.

1. Back up to the container with at least 1 meter distance left free; the vehicle and the container must be in line.

2. Switch on the auxiliary drive of the pump and adjust proper RPMs (see vehicle operating instructions).

3. Slide lever no. 2 towards „A“ and the sliding arm (it. 1, Fig. 2) to the end position.

4. Slide lever no. 1 towards „A“ and tip the telescopic assembly of the sliding arm and the main arm frame (it.1, 2, Fig. 2) backwards into the loading position.

5. Level the sliding arm so that the bottom edge of the pick-up hook (it. 5, Fig. 2) is level with the upper edge of the container hook.

6. Back up the vehicle to make the pick-up hook (it. 5, Fig. 2) of the sliding arm fall into the hook of the container (Fig. 6).

7. Place the gear to neutral.

8. Slide lever no. 1 towards „B“, the container starts lifting and pulling on to the vehicle. Release the brake and the vehicle starts backing up.

9. Correct the position of the vehicle by the steering wheel and the brake to make the skids of the container settle on the rollers of guiding pulleys (Fig. 7). In this way the container will continue to settle down safely on the under-frame of the system (Fig. 8). The telescopic assembly of the sliding arm and the main arm frame settles down in the basic position in the under-frame.

10. Slide lever no. 2 towards „B“ and telescope the sliding arm forward to end position (Fig. 9).

11. Adjust RPMs to idle.

12. Turn off auxiliary drive and by sliding the controller’s levers to limit positions release the pressure in the hydraulic loop.

13. Secure the load against involuntary movement (see Chapter. 2.1).

Fig. 6 Fig. 7

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User’s Manual 16

Fig. 8 Fig. 9

WARNING !!!

During the operation be careful that the face of the container does not collide with the rear end of the carrier (the hook for the trailer, frame, etc.)

WARNING !!!

The sliding arm (it.1, Fig. 2) must be in fully extended position during travel.

WARNING !!!

During transport the container must always be LOCKED to the system !

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User’s Manual 17

2.3 Container unloading :

WARNING !!!

It is not allowed to be staying in the dangerous area near the vehicle or the container.

1. Back up to the unloading place, leave enough space for depositing the container.

2. Switch on the auxiliary drive of the pump, adjust proper RPMs of the motor (see vehicle instructions).

3. Slide lever no. 2 towards „A“ and the sliding arm to end position (Fig. 10).

4. Slide lever no. 1 towards „A“ and tip the telescopic assembly of the sliding arm and the main arm frame (it.1, 2) backwards. When the rear end of the container settles down to ground release parking brake. The unloading may be corrected continually using the operating brake (Fig. 11).

5. Lay down the container. Adjust the front member so that the low edge of the pick-up hook is level with the upper hook of the container (Fig. 12). Thereafter unhook the container.

6. Move the vehicle forward so that the pick-up-hook slides out of the container hook.

7. Slide lever no.1 towards „B“ and tip the telescopic assembly of the sliding arm and the main arm frame into the basic position in the under-frame.

8. Return the articulated mast to its front basic position.

9. Adjust RPMs to idle.

10. Switch off auxiliary drive and by sliding controller levers into limit positions release residual pressure in the hydraulic loop.

Fig. 10 Fig. 11

Fig. 12 Fig. 13

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User’s Manual 18

WARNING !!!

During the operation be careful that the face of the container does not collide with the rear end of the carrier (the hook for the trailer, frame, etc.)

2.4 Tipping the container :

WARNING !!!

It is not allowed to remain in the dangerous area of the vehicle and the container!

In the tilting mode the container must be LOCKED to the tipping frame of the system.

1. Back up to the place of dumping.

2. Set the parking brake.

3. Open the gate (face) of the container carefully and secure (watch for falling out contents).

4. Switch on auxiliary drive, adjust proper RPMs (see vehicle instructions).

5. Slide lever no. 1 towards „A“ and the telescopic assembly of the sliding arm and the off-loading frame connected to the tipping frame starts tipping up. The tipping angle is limited by the lift of the hydraulic cylinders (Fig. 14).

6. Slide lever no.1 towards „B“ until the container settles on the under-frame.

7. Adjust RPMs to idle.

8. Switch off the auxiliary drive and by moving the controller levers to extreme positions release residual pressure in the hydraulic loop.

9. Close and lock the gate (front) of the container.

Fig. 14

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User’s Manual 19

2.5 Loading to the trailer :

To load the container on the trailer the container must be loaded first on the vehicle (see Chapter 2.2).

1. Back up the loaded vehicle to the rear of the trailer about ½ meter from it. The vehicle must be lined up with the trailer (fig. 15).

2. Shift to neutral and set parking brake.

3. Switch on the auxiliary drive of the pump, adjust proper RPMs of the motor (see vehicle instructions).

4. Slide lever no. 2 towards „A“ and the sliding arm to its end position. The pulleys of the container must settle on the guiding rails of the trailer (Fig. 15).

5. Slide lever no.1 towards „A“ and the telescopic assembly of the sliding arm and the off-loading frame tips backwards; the container rolls on the rails of the trailer until end stop.

6. Line up the vehicle to the trailer if necessary.

7. Release parking and operating brakes to let the vehicle move forward. The container settles on the trailer.

8. Adjust the sliding arm so that the bottom edge of the pick up hook is in line with the upper edge of the container hook.

9. Move the vehicle forward until the pick-up hook slides from the container hook.

10. Slide lever no. 1 towards „B“ and tip the telescopic assembly of the sliding arm and the off-loading frame to the basic position in the under-frame.

11. Slide lever no. 2 towards „B“ and extend the sliding arm to its front-end position.

12. Adjust RPMs to idle.

13. Switch off the auxiliary drive and by moving the controller levers to extreme positions release residual pressure in the hydraulic loop.

14. Secure the container and the load against an unwanted move (see operation instructions of the vehicle and the trailer).

Fig. 15

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User’s Manual 20

2.6 Unloading the trailer :

1. Release travel lock of the container on the trailer (see operation instructions of the vehicle and the trailer).

2. Back up to the loaded trailer up to ½ m away. The trailer must be lined up with the vehicle.

3. Move the container onto the vehicle (see Chapter 2.2).

3. Instructions for the maintenance of the system :

To limit the number of defects and to extend the life of the machine regular and thorough maintenance is necessary.

During maintenance it is absolutely necessary to observe cleanliness, particularly when working on the hydraulic system.

Before opening the buffer tank, the vicinity of the filling throat must be cleaned thoroughly. Clean pressure nipples and replace damaged ones before starting lubrication. Hydraulic fluid may be filled only through a sieve in the throat. The drained hydraulic oil must be filtered before reuse through a 10 um filter. The cartridge of the return filter may not be cleaned, but must be replaced with a new one. The maintenance interval must be shortened, if the vehicle is to be operated under severe

conditions, such as building sites with extreme pollution.

3.1 To be done by professionals only :

Removal of hydraulic valves, cylinders and the distributor. Disassembly of hydraulic valves, cylinders, and the distributor. Adjustment of all hydraulic valves.

3.2 Instructions for the liquidation of operating materials :

Operating materials to be liquidated according to applicable national laws and related notices.

3.3 Schedules for maintenance :

Visual Inspection daily weekly monthly annually

of hydraulic fluid level x

of damage to return filter x

of mechanical damage to hydraulic pipes and hoses

x

of air hoses to the distributor for mechanical damage

x

of leakage in the distributor and joints in the hydraulic loop

x

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Visual Inspection daily weekly monthly annually

of bolts and screws for tightness (fenders, hydraulic tank, etc.)

x

of suspension of all sections in the hydraulic loop

x

of mechanical damage to the steel structure

x

Replacements of daily weekly monthly annually

intake filter cartridge with hydraulic oil x 1/

return filter cartridge x

Lubrication of daily weekly monthly annually

lubrication points – pressure nipples x

Cleaning daily weekly monthly annually

rough cleaning x

thorough cleaning x

cleaning of corrosion x

surface finish touch up x

Inspection of daily weekly monthly annually

screw joints for tightness x

control levers of the distributor and controls in the cabin

x

1) Additional maintenance during the first run and after major repairs

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3.4 Lubrication Plan :

Recommended lubrication grease : SLOVNAFT BRATISLAVA : A 00Recommended lubrication spray : WURTH HSS 2000 or BERNER HLS 500

The list of suitable lubrication greases of other manufacturers is in the appendix to operation instructions HYVALIFT 08-S has locations that have to be lubricated marked as follows (Fig. 16) :

Lubrication spot – use grease nipples(schedule specified in Chapter 3.3)

Lubrication spot – spraying surfaces of the sliding arm (schedule specified in Chapter 3.3)

L+R

L+R L+R

L+R

Fig. 16

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3.5 Maintenance :

3.5.1 Checking level of hydraulic oil :

Recommended hydraulic oil : ESSO NUTO H 32

List of suitable hydraulic oils of other manufacturers appears in the appendix to maintenance instructions

When checking levels of hydraulic oil all hydraulic cylinders must be retracted.

The level of hydraulic oil should be visible in the inspection window.

3.5.2 Suction filter replacement :

1. Remove suction filter body.2. Remove O-ring.3. Unscrew old suction filter.4. Screw on new suction filter.5. Insert O-ring, lightly greased.6. Install suction filter body.

3.5.3 Replacing cartridge of return filter :

1. Unscrew upper cover of return filter.2. Remove O-ring.3. Remove old cartridge of return filter.4. Insert new cartridge of return filter.5. Insert O-ring, lightly greased.6. Insert and screw on upper cover of return filter.

3.5.4 Replacement of hydraulic oil :

Hydraulic oil may be replaced only at operating temperature of the hydraulic system

1. Make ready a catch basin of at least 60 l.2. Open filling and venting throat.3. Unscrew drain plug and catch draining fluid in the catch basin.4. Screw in draining plug.5. Fill with recommended hydraulic oil.

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4. Repairs :

4.1 Table of repairs :

Defect Cause Remedy

Controls in driver’s cabin and the distributor not functioning.

Auxiliary drive not engaged. Engage auxiliary drive.

Hydraulic hose pump to distributor blocked.

Position hose correctly.

Suction tube or hose blocked. Position suction hose correctly.

The main safety valve of the input to distributor dirty – not closing.

Clean and adjust main safety valve.

Faulty hydraulic pump. Correct function of hydraulic pump.

Controls in driver’s cabin dead – distributor OK

Insufficient pressure in air loop.

See vehicle instruction manual.

Sliding Arm dead Hydraulic hoses blocked. Position hydraulic hoses properly.

Hydraulic cylinder of front member extraction.

Check hydraulic cylinder of extraction.

Main hydraulic cylinders operate unevenly

Hydraulic hoses blocked, squeezed, hydraulic loop soiled.

Check hydraulic loop.

Faulty hydraulic cylinder. Check hydraulic cylinder.

The handling element doesn’t hold load.

Faulty hydraulic cylinder. Check hydraulic cylinder.

Loaded container cannot be lifted.

Container overloaded. Relieve load in container.

Main safety valve in the input section of the distributor soiled or incorrectly adjusted.

Clean and adjust main safety valve.

Free play in hydraulic pump too large.

Repair hydraulic pump.

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Defect Cause Remedy

Noises in hydraulic system

Hydraulic hoses blocked or squeezed

Position suction hoses properly

Low level of hydraulic oil Add hydraulic oil

Defective hydraulic pump Repair hydraulic pump

Foam in buffer tank. Hydraulic pump sucks air Replace seal around the shaft of the hydraulic pump

Air enters suction hose Tighten screws

Suction hose is porous Replace suction hose.

Hydraulic oil leaks from tank vents

Level of hydraulic oil too high. Drain hydraulic oil to prescribed level

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5. Warranty :

TECHNAMICS B.V. warrants the product for ..... months after sale to the first owner, and ..... months after sale to authorized dealer. The manufacturer warrants the construction, applied material, fabrication and function of the machine.

Appendix :

LIST OF SUITABLE HYDRAULIC OILS OF OTHER MANUFACTURERS:

OMV : OMV hyd HLP 32OMV hyd HLP-M 32

ARAL : ARAL VITAM HF 32ARAL VITAM HF 46

ESSO : UNIVIS N 32NUTO H 32

SHELL : TELLUS 32TELLUS T 32

MOGUL : MOGUL HV 32

VALVOLINE : VALVOLINE ULTRAMAX HLPVALVOLINE ULTRAMAX HVLP

LIST OF SUITABLE GREASES OF OTHER MANUFACTURERS

OMV : DURAPLEX EP 2, SIGNUM

ARAL : ARAL multipurpose grease H

ESSO : ESSO BEACON EP 2

SHELL : SHELL RETINAX MS

MOGUL : MOGUL A 00