F400 series

CONTENTS

Chapter 1

INTRODUCTION 1.1

- Foreword
1.2
- Important information
1.3
 By-passing the electric system
1.4
- After sales service
1.5
 Service
1.5
 Spare parts
1.5
 Warranty
1.5
 Responsibility
1.5
 Transport
1.6
- Vehicle identification
1.7
 Model Chapter 2
1.7
SAFETY
 Chassis number 2.1
1.7
- Basic safety remarks
 Manufacturer's plate
2.4
1.8
-Safety
Lifting of the operator
capacity plate and of bystanders
1.8 2.15
- Lubricants - hygiene and safety instructions
2.21
- Behaviour in emergency cases
2.24
- Security systems of the "C.V.S. Reach Stacker"
2.26
Chapter 3

DRIVER'S CAB 3.1

- Cab 3.2
 Doors
3.2
 Emergency exit
3.3
 Controls and main parts (cab interior)
3.4
 Front left controls panel
3.5
 Digital display [HTD Version]
3.6
 Digital display [VIEW Version]
3.7
 Front right controls panel
Page 0.1
3.8
 Side right controls panel [Standard]
3.9
 F400 series
CONTENTS

Chapter 4

VEHICLE'S CONTROLS 4.1

- Driver's seat
4.2
- Pneumatic driver's seat
4.3
- Seat belts
4.4
 Additional seat
4.4
- Steering wheel adjustment
4.5
- Right side controls panel position adjustment
4.6
- Controls panel position adjustment (vehicle with steering control levers)
4.7
- Steering control levers [Option]
4.8
- Main switch [Standard]
4.9
- Emergency engine cut-off
4.9
- Button Switch [Option]
4.10
- Parking brake operation
4.11
- External lights control stalk
4.12
- Window washer/wiper controls
4.13
- Heater and blower
4.14
- Auxiliary heater "AIRTRONIC" [Option]
4.15
- Electronic Climate System E.C.S
4.17
- “HTD” digital display
4.20
- “VIEW” digital display
4.21
- Cab movement (manual control)
4.22
- Cab movement (hydraulic control)
4.23
- Cab lifting (if fitted)
4.24
- Work and signal lights controls
4.26
Page 0.2
- "Optional" controls
4.30
 F400 series
CONTENTS

Chapter 5

VEHICLE'S OPERATION 5.1

- Introduction
5.2
- First operation hours - Running-in
5.3
- Checks before starting
5.4
- Engine
5.5
 Ignition [Standard with key]
5.5
 Ignition [Optional with button]
5.6
 Pre-heater system
5.7
 Engine stop
5.7
- Use of the vehicle
5.8
 Moving off
5.8
 Stopping the vehicle
5.9
 Gearbox selector lever
5.10
 Autoshift transmission
5.11
 During the drive
5.12
* Optional signal devices
5.14
 Parking brake
5.15
* drive axle "KESSLER"
5.16
* Emergency brake release drive axle "KESSLER"
5.16
* Drive axle "AxleTech" “MERITOR”
5.17
* Emergency brake release drive axle "AxleTech" "MERITOR"
5.17
 Use of the “declutch” pedal
5.18
* “Brake and Declutch” hydraulic compensation circuit
5.18
 “Joy-stick" control lever [Standard version]
5.19
 Twistlock-Automatic Operation ON/OFF (Rotation)
5.21
 “Hydro-Pos” system
5.22
 Spreader extension/retraction r (20' – 40')
5.23
 Spreader extension/retraction (20’ – 40’) Override Page 0.3
5.24
 Spreader [Pile Slope] control
 F400 series
CONTENTS

Chapter 6

MAINTENANCE 6.1

- Maintenance instructions
6.2
- Spare parts
6.3
- General maintenance information
6.4
- General safety rules
6.5
- During maintenance
6.7
- Hygienic safety rules
6.8
- Engine
6.11
 Lubrication
6.13
* Oil
6.14
* filter 6.15
* Oil cleaner (if fitted)
6.16
 Timing system
6.18
 Injection
6.18
 Drive belts
6.19
 Cooling fan
6.20
- Air intake system
6.21
 Turbocharger
6.21
 Air cleaner
6.22
* Cyclone precleaner
6.25
* Crankcase ventilation valve (if fitted)
6.25
- Fuel system
6.26
 Engine fuel filter and water/fuel separator
6.26
 Bleeding of the fuel system [SCANIA engines]
6.28
 Bleeding of the fuel system [CUMMINS engines; Type: “QSM11 and QSL9”]
6.29
 Bleeding of the fuel system [CUMMINS engine; Type: “QSB 6.7”]
6.30
 Bleeding of the fuel system [VOLVO engines]
6.31
 Water/fuel separator [SCANIA engines]
Page 0.4
6.32
 Water/fuel separator [CUMMINS engines]
6.33
 F400 series
CONTENTS

Chapter 6 (cont’d)

- Tyres and wheels

6.55
 Tyre check
6.55
 Wheel changing
6.56
 Tyre specifications
6.59
 Inflating pressure
6.59
- Boom 6.60
 Sliding shoes adjustment
6.62
- Cab sliding system
6.63
 Hydraulic brake (with hydraulic movement)
6.63
- Lifting cab (if fitted)
6.64
 Chains
6.65
* Lubrication
6.65
* Tensioner adjustment
6.66
* Inspection
6.67
* Cleaning
6.69
- Hydraulic system
6.70
 Hydraulic oil tank
6.70
 Air/Oil heat exchanger
6.73
 Braking system
6.74
* Filters
6.74
* Accumulator
6.75
* Brake pedal adjustment
6.75
 Hydraulic system for brake and declutch pedal compensation
6.76
 Hydraulic cylinders
6.77
- Air conditioning system
6.78
- Towing hook
6.79
- Counterweights
6.79
- Lubrication
6.80 Page 0.5
 Manual lubrication
6.80
 F400 series
CONTENTS

Chapter 6 (cont’d)

 Fuses [in the cab]

6.96
 Fuses [in "QGS Box"]
6.98
 Fuses and remote switches [in "QGS Box"]
6.100
 Location of electrical and electronic equipment
6.101

 Main electric cabinet "QGS Box"

6.102
* Emergency stop 6.105
 Relay
6.106
 Jumpers
6.107
 Diodes
6.108
 Connectors
6.109
 Control units and boards
6.110
- Cab 6.111
- General care and checkes
6.112
- Tool kit
6.114
- Tightening torque tables
6.115

Page 0.6
 F400 series
CONTENTS

Chapter 7

LUBRICATION 7.1
- Fuel, fluids and lubricants chart
7.2
 Specifications of fuel, fluids and lubricants
7.2
 "NOTES" 7.3
- Maintenance charts
7.5
 First maintenance steps
7.5
 Maintenance intervals
7.6
- Lubrication points of Reach Stacker [Standard]
7.10
 Reach Stacker with Lifting Side Cab
7.11 Chapter 8

FIGURES AND DIAGRAMS

8.1
- Introduction
8.1
- Figures:
 Identification plates (standard vehicle) .............................................. Draw. 600164
8.2
 Dimensions "F479" (with Spreader) ................................................. Draw. 598059
8.3

- System diagrams :
 Hydraulic system Steering, Lifting, Outriggers “F470 – F480 series”
- Version “Rexroth – Oil Control” .................................................................................... Draw. 611673
 Hydraulic system Emergency ................................................................................................ Draw. 1340
 Hydraulic system Optionals ................................................................................................... Draw. 596863
 Hydraulic system Brakes ....................................................................................................... Draw. 596886
 Hydraulic system Dumping
- Version “Standard” ....................................................................................................... Draw. 609988

 Wiring diagram – " F400 series" (Version "WURTH") ........................................................ Draw. 621786
* Electronic board "QGS"....................................................................................................... Draw. 601106

Page 0.7
 F400 series
CONTENTS

Chapter 9

SPECIFICATIONS 9.1
- Introduction
9.1
- Technical data of the vehicle in standard execution
9.2

Chapter 10

MAINTENANCE REPORTS 10.1

- Introduction
10.1
 Maintenance reports
10.2

ATTACHMENTS
- “VIEW” Multipurpose CAN display manual (if fitted)

- “DANA – APC200” Transmission

 Calibration manual
 Users’ manual

- Spreader and/or Piggy-Back

Page 0.8