Page 1 Tel. +39 0171614111 - Fax +39 0171614100 www.merlo.com - info@merlo.com USER AND MAINTENANCE MANUAL VARIABLE REACH TRUCK TRANSLATION OF THE ORIGINAL INSTRUCTIONS PANORAMIC-02 (GB) VALID FROM SAV C422222...
Page 2 INDEX INTRODUCTION ................................1 MACHINE TECHNICAL INFORMATION ........................2 STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB ............... 3 CONTROLS AND INSTRUMENTS ..........................4 OPERATING INSTRUCTIONS............................. 5 ORDINARY MAINTENANCE ............................6 PERIODICAL SAFETY CONTROLS .......................... 7 ATTACHMENTS AND OPTIONAL EXTRA ......................... 8 HYDRAULIC CIRCUITS' DIAGRAMS .........................
Page 3: Table Of Contents
WORK ENVIRONMENT ................................. 3 FIRST COMMISSIONING OR RECOMMISSIONING AFTER A LONG SHUTDOWN ..............3 MACHINE GARAGING ................................... 4 TYRES ......................................4 ORIGINAL MERLO SPARES ................................. 4 MACHINE SCRAPPING ................................. 4 WARRANTY ....................................5 ORDINARY MAINTENANCE OPERATIONS ..........................5 INFORMATION FOR DRIVING THE MACHINE ON PUBLIC ROADS ................... 5 SAFETY AND ACCIDENT PREVENTION MEASURES .........................
Page 4: Validity Of The Manual
Should the manual be damaged or made illegible in any of its parts, please order a new copy from the Merlo Technical Assistance service, by providing the identification code written in the bottom left-hand corner of the front page.
Page 5: Work Environment
This symbol is shown on some machine plates and warns the operator that the explanations contained in the Operator manual shall be carefully read before using the control. WORK ENVIRONMENT The machines manufactured by Merlo S.p.a., are designed to be used within the following environmental temperature ranges: - minimum temperature: - 20°C - maximum temperature: + 40°C Always take the atmospheric and climatic conditions of the workplace into account.
Page 6: Machine Garaging
In this case Merlo S.p.A holds itself free from any liability, and the warranty terms on the machine shall no longer be applicable. Finally, only Merlo S.p.A has all the technical and engineering know-how which ensures maximum expertise in the maintenance if its machines.
Page 7: Warranty
It is strictly forbidden and highly dangerous to modify any machine component by changing its original structure. it is further forbidden to change the hydraulic and electric setup or modify the safety systems. Otherwise, Merlo S.p.A shall be relieved from any civil or criminal liability.
Page 8: Safety And Accident Prevention Measures
Merlo S.p.A. declines liability for any damage, accident or injury if the code of conduct described in the following sections of this paragraph is not applied: •...
Page 9: Fire Prevention Measures
Should stickers and plates be damaged or illegible, replace them with new original ones, to be ordered from Merlo Technical Support Service, and to be placed in the position shown in the Operator's Manual.
Page 10: Ce" Compliance
1 - INTRODUCTION "CE" COMPLIANCE Your machine complies with the safety requirements of the European directives (2006/42/CE) (2004/108/CE) for the protection and safety of people from potential hazards deriving from machine operation. To ensure the operator's safety, the cab is built in compliance with the following standards: ISO 3449 FALLING-OBJECT PROTECTIVE STRUCTURES (FOPS) ISO 3471 TIP-OVER PROTECTION STRUCTURES (ROPS) As it complies with the above mentioned requirements of the Safety directive, your machine is...
Page 11: End Of Section
1 - INTRODUCTION The value of uncertainty KpA is 2 dB. The operating cycle used during measurement is as follows: • LIFTING (a=0,18) • MINIMUM (b=0,58) • TRACTION (c=0,24) References a, b, c are coefficients proportional to usage time. During equipment operation, higher noise levels may be measured due to particular working conditions, the surrounding environment and additional noise sources.
Page 12 2 - MACHINE TECHNICAL INFORMATION CONTENTS CAB INTERIOR KEY WORD ................................7 (P) CONTROL PANEL KEY WORDS ............................13 DESCRIPTION OF THE COMMAND PANEL (P1) ........................14 INSTRUMENT PANEL (C) DESCRIPTION ..........................14 NOMENCLATURE FOR DYNAMIC LOAD CONTROL DISPLAY (D) ................... 15 DIMENSIONS - P37.12 PLUS ..............................
Page 13 2 - MACHINE TECHNICAL INFORMATION NOMENCLATURE MACHINE EXTERIOR Please, pay attention to the identification of the machine sides, because they will be re quoted in the manual. REF. DESCRIPTION Front side Rear side Left-hand side Right-hand side P37.12 PLUS - P40.9 PLUS REF.
Page 14 2 - MACHINE TECHNICAL INFORMATION P38.12 PLUS - P38.13 PLUS – P38.12 – P38.13 – P38.13EE REF. DESCRIPTION REF. DESCRIPTION Operator cab Fork tilt jack Engine compartment and battery compartment Crossways angle correction jacks Front axle - brake callipers - wheel reducers First boom Rear axle - brake callipers - parking brake calliper - Second boom...
Page 15 2 - MACHINE TECHNICAL INFORMATION P38.14 PLUS – P38.14 REF. DESCRIPTION REF. DESCRIPTION Operator cab Fork tilt jack Engine compartment and battery compartment Crossways angle correction jacks Front axle - brake callipers - wheel reducers First boom Rear axle - brake callipers - parking brake calliper - Second boom wheel reducers Forks...
Page 16 2 - MACHINE TECHNICAL INFORMATION P40.17 PLUS – P40.17 – P40.17EE REF. DESCRIPTION REF. DESCRIPTION Operator cab Telescopic boom lifting jack Engine and battery compartment Fork tilt jack Electronic control unit compartment Crossways angle correction jacks Rear axle - brake callipers - wheel reducers First boom Front axle - brake callipers - parking brake calliper - Second boom...
Page 17 2 - MACHINE TECHNICAL INFORMATION P60.10 - P72.10 – P60.10EE – P72.10EE REF. DESCRIPTION REF. DESCRIPTION Operator cab Telescopic boom lifting jacks Engine compartment and battery compartment Fork tilt jack Front axle - brake callipers - wheel reducers Crossways angle correction jacks Rear axle - brake callipers - parking brake calliper - First boom wheel reducers...
Page 18: Cab Interior Key Word
2 - MACHINE TECHNICAL INFORMATION CAB INTERIOR KEY WORD (only for models P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.9PLUS – P40.17PLUS – P60.10 – P72.10) 2 - 7...
Page 19 2 - MACHINE TECHNICAL INFORMATION REF. DESCRIPTION Telescopic boom control joystick Rear windscreen-wiper switch Pressure gauge for hydraulic system oil or hydrostatic transmission system Spirit level Accelerator pedal Brake pedal Steering wheel trim lock lever Air vent Gear control Drive direction selector Load chart and safety instruction holder Steering wheel Parking lights switch/ low beam lights / Direction indicators / head lights / Horn...
Page 20 2 - MACHINE TECHNICAL INFORMATION (only for models P60.10EE – P72.10EE) 2 - 9...
Page 21 2 - MACHINE TECHNICAL INFORMATION REF. DESCRIPTION Telescopic boom control joystick Rear windscreen-wiper switch Pressure gauge for hydraulic system oil or hydrostatic transmission system Spirit level Accelerator pedal Brake pedal Steering wheel trim lock lever Air vent Gear control Drive direction selector Load chart and safety instruction holder Steering wheel Parking lights switch/ low beam lights / Direction indicators / head lights / Horn...
Page 22 2 - MACHINE TECHNICAL INFORMATION (only for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE) 2 - 11...
Page 23 2 - MACHINE TECHNICAL INFORMATION REF. DESCRIPTION Telescopic boom movements command lever Telescopic boom and chassis movements command lever Rear windscreen-wiper switch Pressure gauge for hydraulic system oil or hydrostatic transmission system Spirit level Accelerator pedal Brake pedal Steering wheel trim lock lever Air vent Gear control Drive direction selector...
Page 24: (P) Control Panel Key Words
2 - MACHINE TECHNICAL INFORMATION (P) CONTROL PANEL KEY WORDS REF. DESCRIPTION Emergency stop push-button Anti-overturn disabling red warning lamp Operating mode selector switch Starter key Emergency lights Portable lamp socket Parking brake selector Lifting equipment load limiting device Side-tilt corrector control The selector type of equipment installed on the machine (only for models P37.12PLUS –...
Page 25: Description Of The Command Panel (P1)
2 - MACHINE TECHNICAL INFORMATION DESCRIPTION OF THE COMMAND PANEL (P1) REF. DESCRIPTION Roof flashing light switch Heating cock Fan switch for cab heating Adjustment buttons for instrument panel settings (C) INSTRUMENT PANEL (C) DESCRIPTION REF. DESCRIPTION Coolant thermometer Fuel level indicator Speedometer Tachometer Hour counter / clock LCD display...
Page 26: Nomenclature For Dynamic Load Control Display (D)
2 - MACHINE TECHNICAL INFORMATION NOMENCLATURE FOR DYNAMIC LOAD CONTROL DISPLAY (D) (only for models P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.9PLUS – P40.17PLUS – P60.10 – P72.10) REF. DESCRIPTION Light bar indicating percentage machine stability Machine operating function display P1 –...
Page 27: Dimensions - P37.12 Plus
2 - MACHINE TECHNICAL INFORMATION DIMENSIONS - P37.12 PLUS DIMENSIONS - P38.12 PLUS – P38.12 2 - 16...
Page 28: Dimensions - P38.13 Plus - P38.13 - P38.13Ee
2 - MACHINE TECHNICAL INFORMATION DIMENSIONS - P38.13 PLUS – P38.13 – P38.13EE DIMENSIONS - P38.14 PLUS – P38.14 2 - 17...
Page 29: Dimensions - P40.9 Plus
2 - MACHINE TECHNICAL INFORMATION DIMENSIONS - P40.9 PLUS DIMENSIONS – P40.17 PLUS – P40.17 – P40.17EE 2 - 18...
Page 30: Dimensions - P60.10 - P60.10Ee
2 - MACHINE TECHNICAL INFORMATION DIMENSIONS - P60.10 – P60.10EE DIMENSIONS - P72.10 – P72.10EE 2 - 19...
Page 31: Performance And Features
2 - MACHINE TECHNICAL INFORMATION PERFORMANCE AND FEATURES The present tables contain data indicating the machine's standard configuration. MERLO S.p.a. reserves the right to make changes to its range of machines without prior notice, even with regards the data declared. WEIGHT (kg) MEASUREMENT CONDITIONS •...
Page 32 2 - MACHINE TECHNICAL INFORMATION TRANSMISSION Hydrostatic with electronic control ENGINE P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.9PLUS – P40.17PLUS – P60.10 – P72.10 DEUTZ TCD 3.6 Turbo – Intercooler – water cooled Power: 74 kW – (100CV) at 2600 rpm Reduced emissions IIIB Stage / Tier IV Interim ENGINE P38.12 –...
Page 33: Load Chart
This paragraph provides instructions to consult the load charts correctly. To see all attachments, the installation of which in combination with the machine has been approved by Merlo, refer to the file of diagrams shown at the back of this manual.
Page 34 2 - MACHINE TECHNICAL INFORMATION • MACHINE WITH STABILISERS LIFTING A LOAD USE CONDITIONS TRANSPORTING A LOAD 2 - 23...
Page 35 2 - MACHINE TECHNICAL INFORMATION LIFTING A LOAD 2 - 24...
Page 36 2 - MACHINE TECHNICAL INFORMATION Metric grid Lifting angle of the telescopic boom Working area (in reference to section B) Additional information Use on rough and unprepared Filling the bucket with the boom extended is The transportation of people in the terrain is prohibited prohibited handler is prohibited...
Page 37 PERFORMANCE AND FEATURES of chapter TECHNICAL SPECIFICATIONS. In the event a type of tire needs to be replaced with another model in the list of those authorized, contact the Merlo Technical Assistance Service, since tire replacement may also require the replacement of the safety devices electronic management unit and load tables.
Page 38 2 - MACHINE TECHNICAL INFORMATION TRANSPORTING A LOAD 16. Indication of the machine moving at a speed less than 3 km/h 17. Load transportation in slow gear 18. Load transportation with partial throttle WARNING! Sudden acceleration can cause instability of the machine. 19.
Page 39: Serial Number Of The Machine
The chassis number of your machine is printed on the front right side of the chassis, and coated with a layer of black paint. When requesting assistance or spare parts, please provide Merlo Technical Support Service with both the chassis number and the Sav number of your machine.
Page 40 2 - MACHINE TECHNICAL INFORMATION • ENGINE IDENTIFICATION PLATE The engine identification plate is applied in the upper part of the engine, and provides you with engine data and specifications. Should you need information, support, or original spare parts, please provide the engine Manufacturer with the data shown on the engine identification plate.
Page 41 2 - MACHINE TECHNICAL INFORMATION TIGHTENING TORQUES FOR ISO METRIC THREADS The tightening torque "Ma" of either a screw or a nut is the moment of a force required to put the screw under a certain initial tension. The tightening torque value is used to adjust the dynamometric wrench, as well as to prevent the screw from breaking due to fatigue.
Page 42 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB CONTENTS GENERAL REMARKS ..................................2 INSIDE CAB STICKERS ................................. 2 OUTSIDE CAB STICKERS ................................7 END OF SECTION ..................................14 3 - 1...
Page 43: General Remarks
Should they be damaged or illegible, replace them with new original ones, to be ordered from Merlo Technical Support Service, and to be placed in the positions shown in the Operator's Manual.
Page 44 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB (only for models P60.10EE – P72.10EE) 3 - 3...
Page 45 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB (only for models P38.13 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE) 3 - 4...
Page 46 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB • CONTROL PANEL STICKERS (P) (only for models P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.9PLUS – P40.17PLUS – P60.10 – P72.10) 3 - 5...
Page 47 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB (only for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE – P60.10EE – P72.10EE) 3 - 6...
Page 48: Outside Cab Stickers
3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB OUTSIDE CAB STICKERS • P40.17 PLUS – P40.17 – P40.17EE 3 - 7...
Page 49 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB 3 - 8...
Page 50 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB • P38.12 PLUS – P38.13 PLUS – P38.12 – P38.13 – P38.13EE – P38.14 – P38.14PLUS 3 - 9...
Page 51 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB 3 - 10...
Page 52 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB • P37.12 PLUS – P40.9 PLUS 3 - 11...
Page 53 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB 3 - 12...
Page 54 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB • P60.10 – P72.10 – P60.10EE – P72.10EE 3 - 13...
Page 55: End Of Section
3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB END OF SECTION 3 - 14...
Page 56 4 - COMMANDS AND INSTRUMENTS CONTENTS GENERAL OVERVIEW OF THE CAB ............................2 STANDARD SEAT ..................................5 INSTRUMENT PANEL (C) DESCRIPTION ............................ 6 CONTROL PANEL (P) DESCRIPTION ............................11 DESCRIPTION OF THE COMMAND PANEL (P1) ........................15 HYDROSTATIC TRANSMISSION LOCK (90) ..........................16 DYNAMIC LOAD CONTROL SYSTEM (M-CDC) .........................
Page 57: General Overview Of The Cab
4 - COMMANDS AND INSTRUMENTS GENERAL OVERVIEW OF THE CAB • OPENING THE DOOR To open the driving cab door, release the lock by rotating the key "X" (supplied) clockwise, then act on handle "A" as indicated in the figure (1). •...
Page 58 4 - COMMANDS AND INSTRUMENTS • OPENING THE UPPER PART OF THE DOOR To open the upper part of the door, proceed as follows: rotate handle "A" upwards (direction indicated by the arrow) (fig.5) completely open the upper part of the door and hook it to the appropriate external device "B"...
Page 59 4 - COMMANDS AND INSTRUMENTS • WINDSCREEN OPENING turn the lever "A" through 45° open the windscreen slightly move the lever "A" in the horizontal position push the windscreen forward up to the automatic stop position. • WINDSCREEN CLOSING turn the lever "A" through 45° close the windscreen slightly move the lever "A"...
Page 60: Standard Seat
4 - COMMANDS AND INSTRUMENTS STANDARD SEAT The instructions for the proper use of the driver's seat, described in this paragraph, refer to the standard model mounted on your machine. If your machine is equipped with a seat different from the standard one, please refer to the relevant instructions in the "OPTIONAL EXTRAS"...
Page 61: Instrument Panel (C) Description
4 - COMMANDS AND INSTRUMENTS INSTRUMENT PANEL (C) DESCRIPTION The instrument panel on your machine shows the following information: - ANALOGUE TACHOMETER (61) The analogue tachometer is used to: check the engine usage speed adjust the engine speed when using the manual lever (86) (see the relevant paragraph) allow specialised personnel to perform maintenance operations - ANALOGUE TACHOMETER (60) The analogue tachometer is used to check the drive speed on roads.
Page 62 This indicator light switches on when the engine is running at more than 1000 rpm and the engine oil pressure is low. In these conditions, stop the engine immediately and top up the oil level. Start the engine again and make sure the indicator light switches off. If the problem persists, contact Merlo Technical Assistance service. Brake oil level Insufficient brake oil.
Page 63 4 - COMMANDS AND INSTRUMENTS - LCD DISPLAY (62) When the engine is off, the display (62) is disabled. To set some functions of the LCD display it is necessary to use the (OK) and (C) keys on the control panel (P1). The LCD display provides the operator with the following information: •...
Page 64 4 - COMMANDS AND INSTRUMENTS • indication of operating faults Any faults with the machine are signalled to the operator by the lighting up of the relative indicator lights in the specific fields (A) of the LCD display (62). Some faults also light up, at the same time, the corresponding indicator light at the top of the instrument panel.
Page 65 Radio field interference or too distant from purchase of a remote control unit) machine Steady Control joystick fault (available with purchase Contact Merlo Technical Assistance Service of single-lever joystick) Flashing Machine lock following activation of satellite anti-theft device (available with purchase of...
Page 66: Control Panel (P) Description
4 - COMMANDS AND INSTRUMENTS CONTROL PANEL (P) DESCRIPTION • EMERGENCY PUSH BUTTON (4) These can be used to stop the diesel engine with subsequent disconnection of the controls. Before starting the engine again, the button has to be reset rotating it in direction of the arrow.
Page 67 4 - COMMANDS AND INSTRUMENTS • IGNITION KEY (8) engine off dash board lights on spark plug heating For models with DEUTZ ENGINE, the management of the glow plugs is automatically managed by the electronic control unit For models with KUBOTA ENGINE, the management of the glow plugs is controlled manually by the operator with the key (8) in position "H"...
Page 68 4 - COMMANDS AND INSTRUMENTS LOAD LIMITER FOR LIFTING ATTACHMENTS (43) (valid for models P37.12PLUS - P38.12PLUS - P38.13PLUS - P38.14PLUS - P40.9PLUS - P40.17PLUS - P60.10 - P72.10) Lifting attachments (fitted with a hook) having a lower maximum capacity than the capacity of the machine are fitted with a load limiting system designed to protect the attachment when performing lifts/hoists with the machine boom.
Page 69 4 - COMMANDS AND INSTRUMENTS LOAD LIMITER FOR LIFTING ATTACHMENTS (43) (valid for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE – P60.10EE – P72.10EE) Lifting attachments (fitted with a hook) having a lower maximum capacity than the capacity of the machine are fitted with a load limiting system designed to protect the attachment when performing lifts/hoists with the machine boom.
Page 70: Description Of The Command Panel (P1)
4 - COMMANDS AND INSTRUMENTS • CROSSWAYS TILT CORRECTOR COMMAND (61) ROCKER SWITCH (61) clockwise chassis levelling anticlockwise chassis levelling WARNING! Make sure that machine is correctly levelled before attempting any lifting operations. Load handling on uneven surfaces is permitted by using frame levelling device to level the machine chassis to the proper position.
Page 71: Hydrostatic Transmission Lock (90)
• DISPLAY NOMENCLATURE (D) When the instrument panel is switched on (starter key (8) in position "R") (FIg.1), the system displays a screen for 3 seconds with the MERLO logo (Fig.2) and then automatically opens the main screen. 4 - 16...
Page 72 4 - COMMANDS AND INSTRUMENTS The main screen displays the following information: REF. DESCRIPTION Percentage longitudinal stability limit Maximum liftable load, in the point where the telescopic boom is located, in relation to the attachment Graphics bar indicating the load effectively lifted in relation to the attachment mounted Height of load from ground (in metres) Distance of load from external limit of tyres (or stabilisers, if present) (in metres) Telescopic boom lifting angle (in degrees)
Page 73 4 - COMMANDS AND INSTRUMENTS • ACTIVATING THE COMMAND SELECTION GRAPHIC BAR The display (D) of the load control system is equipped with a disappearing graphics bar which shows the functions of command buttons P1 - P2 - P3 - P4 - P5.
Page 74 4 - COMMANDS AND INSTRUMENTS • DISPLAY DAY/NIGHT BRIGHTNESS MODE SELECTION (BUTTON P4) To set day or night display (D) brightness mode, perform the following operations: activate the menu graphic bar press button (P4) to switch between day and night brightness mode for the display (D). The system signals the operator that the setting has been made by showing window "1"...
Page 75 4 - COMMANDS AND INSTRUMENTS REF. DESCRIPTION Net weight lifted by the attachment mounted on the carriage (in tonnes) Table summarising the last 20 weighing operations stored indicating total lifted weight Cancel all stored weighing operations. The total weight is reset. Attachment tare Manual weighing Selecting the weighing mode: automatic or manual...
Page 76 4 - COMMANDS AND INSTRUMENTS 4) MANUAL WEIGHING (E) Use this command to weigh the load lifted by the attachment manually. The data measured by the system is displayed in Table "B" starting from box n. 1 through to box n. 20. When there are more than 20 weighing operations, all values scroll upwards and more recent figures will always be displayed at the bottom of the table.
Page 77 4 - COMMANDS AND INSTRUMENTS 6) MODIFYING WEIGHTS (G) If one or more weights stored in Table "B" have to be modified or cancelled, this can be done using the modification function on the WEIGHING SCREEN. To do this, move around the weighing screen using button (P2) and select the item "EDIT DATA";...
Page 78 4 - COMMANDS AND INSTRUMENTS • AUTO-IDENTIFICATION OF AN ATTACHMENT (selector switch (204) positioned on AUTO) When an attachment fitted with an auto-identification sensor is installed on the carriage, the selector switch (204) must be placed in the "AUTO" position; in this case, the system automatically calculates the work chart for the machine + attachment combination to define the correct index of stability, maximum capacity and the safe working area.
Page 79 4 - COMMANDS AND INSTRUMENTS The attachment installed on your machine was correctly identified by the system, but the corresponding image is not available in the database. Make sure that selector (204) is turned to the AUTO position The attachment installed on your machine is either not equipped with a self-identification sensor, or it was not automatically identified by the system due to a system failure or malfunctioning.
Page 80 4 - COMMANDS AND INSTRUMENTS The BULK LOADER / REHANDLING BUCKET / DIGGING BUCKET attachment, installed on the machine, was correctly identified by the system. The CARRIAGE-MOUNTED WINCH attachment installed on the machine was correctly identified by the system. The PUSHING BLADE attachment installed on the machine was correctly identified by the system.
Page 81: Front Anti-Tip-Over Control
4 - COMMANDS AND INSTRUMENTS • FRONT ANTI-TIP-OVER CONTROL The front anti-tip-over control device steps in when the machine is close to its longitudinal stability limit, and locks all aggravating movements. During handling operations, the system automatically detects and processes the position of the lifted load and the machine's stability percentage.
Page 82: Joystick (1)
4 - COMMANDS AND INSTRUMENTS FRONT ANTI-TIP-OVER CONTROL (only for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE – P60.10EE – P72.10EE) The front anti-tip-over control device steps in when the machine is close to its longitudinal stability limit, and locks all aggravating movements.
Page 83: Main Distributor Lever (1-2)
4 - COMMANDS AND INSTRUMENTS MAIN DISTRIBUTOR LEVER (1-2) (only for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE) These machines are equipped with two control levers with which it is possible to perform the following movements: 1) LIFTING/LOWER OF THE TELESCOPIC BOOM 2) UPWARD/DOWNWARD ROTATION OF THE FORKS 3) EXTENSION/RETRACTION OF THE TELESCOPIC BOOM...
Page 84: Hydraulic Or Hydrostatic System Pressure Gauge (12)
"HYDRAULIC SYSTEM OIL PRESSURE" in the chapter "SECURITY PERIODICAL INSPECTIONS". In case of anomalies in the hydrostatic transmission system, please refer directly to the Merlo Service Centre for further information. PEDALS (14-15-27) ACCELERATOR PEDAL (14) operate the pedal to increase or decrease the diesel engine rpm.
Page 85: Gearbox (19)
4 - COMMANDS AND INSTRUMENTS GEARBOX (19) The machine gearbox has two forward gears and two reverse gears which can be selected through selector switch (19), located on the steering column. Press button (P1) to downshift Press button (P2) to upshift Press and hold button (P1) for more than 5 seconds to select the neutral gear.
Page 86: Lights And Horn On/Off Lever (24)
4 - COMMANDS AND INSTRUMENTS LIGHTS AND HORN ON/OFF LEVER (24) Lever (24), located beside the steering wheel, allows you to switch the lights on your machine on/off, and to operate the horn. To carry out these operations, the ignition key (8) needs to be in position "R". Should the ignition key (8) be in position "0", the operation of lever (24) is disabled.
Page 87: Selecting Steering Mode (29)
4 - COMMANDS AND INSTRUMENTS • SELECTING STEERING MODE (29) The machine relies on a system which allows the operator to choose among 3 steering modes: A) Four wheel coordinated steering Use this mode to obtain a narrower steering angle. B) Front axle steering mode Use this mode when travelling on public roads.
Page 88: Stabiliser Command Switches (135)
4 - COMMANDS AND INSTRUMENTS STABILISER COMMAND SWITCHES (135) (only for P38.12 PLUS – P38.13 PLUS – P38.14 PLUS – P40.17 PLUS – P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE) The machine is equipped with a stabilising system consisting of 2 ground supports.
Page 89 5 - OPERATING INSTRUCTIONS CONTENTS INTRODUCTION .................................... 2 GENERAL INFORMATION ................................2 STANDARD FORKS ASSEMBLY ..............................2 STANDARD FORKS DISASSEMBLY ............................. 3 RULES FOR LOAD TRANSPORT ..............................3 MACHINE OPERATING AREA ............................... 3 HOW TO HANDLE A LOAD ................................4 INSTRUCTIONS FOR STARTING YOUR MACHINE ........................
Page 90: Introduction
Merlo S.p.A., is installed carrying a second operator on-board the machine is absolutely prohibited.
Page 91: Standard Forks Disassembly
Merlo S.p.A. or your local dealer for additional solutions which may suit your needs.
Page 92: How To Handle A Load
• MANOEUVRING A CIRCULAR-SHAPED LOAD For handling circular shaped loads (barrels, cans etc.) installation of the appropriate attachment, provided and type-approved by Merlo S.p.a., on the machine carriage is necessary. In order to ascertain the attachment best suited to the type of circular load to be handled, contact the nearest dealer.
Page 93 "N". WARNING! Manoeuvring loads suspended on cables, chains, slings or other is prohibited if the machine is not equipped with the Merlo attachment specific to such use (hook on forks, hook on carriage, crane boom, fly jib etc...) When using compatible and type-approved Merlo attachments, always refer to the relevant load chart present in the holder provided in the cab.
Page 94: Instructions For Starting Your Machine
INSTRUCTIONS FOR STARTING YOUR MACHINE WARNING! Before starting to drive your MERLO machine all the information and safety instructions in this paragraph need to have been read and understood. It is particularly important to have a good knowledge of the positioning and functioning of all controls.
Page 95 5 - OPERATING INSTRUCTIONS • GENERAL CHECKS BEFORE STARTING THE ENGINE NOTE! A P40.17PLUS was taken to list the parts to be checked. The same instructions apply to all models included in this manual. Carry out the following checks every day (before using the vehicle): keep all machine parts in due order and clean inspect the exterior of the machine to check that no screws or bolts are loose or missing and that there are no leakages of hydraulic oil...
Page 96 5 - OPERATING INSTRUCTIONS • CHECKS WITH THE IGNITION KEY (8) IN POSITION "R" Turn the ignition key (8) to position "R" and carry out the following checks: warning light panel (figure 7) correct operation of all control switches (figure 8) front lights and direction indicators (figure 9) rear lights and direction indicators (figure 10) hazard warning lights...
Page 97 5 - OPERATING INSTRUCTIONS • CONTROL PANEL ACTIVATION To switch on the machine control panel turn the ignition key (8) to "R". At this point all the lights and indicators on the instrument panel come on for a short time (GENERAL CHECK function) and then only these indicators remain on: 44 - battery charger indicator light 45 - engine oil pressure indicator light...
Page 98 • 133 - water in the diesel fuel indicator light • 206 - cable failure indicator light • 207 - MERLO SERVICE indicator light • 208 - steering system low pressure indicator light For all the information on the general CHECK CONTROL indicator lights see the instructions in the table "INDICATOR LIGHTS ON THE INSTRUMENT PANEL"...
Page 99: Instructions For Driving Your Machine On The Road
5 - OPERATING INSTRUCTIONS INSTRUCTIONS FOR DRIVING YOUR MACHINE ON THE ROAD WARNING! Observe the laws in force. The circulation of the machine on public roads is permitted only with the attachments foreseen and indicated in the road traffic documents. Lock the working tools with the special mechanical stops and install any prescribed protective devices.
Page 100 5 - OPERATING INSTRUCTIONS • MAXIMUM INCLINE WITH LOAD ON FORKS Ensure that the proper steering mode has been selected. Retract the boom fully. Raise the boom, rotate the carriage backwards (not to the stop) so that the load is approximately 50 cm from the ground Carry the load using the slow gear.
Page 101 5 - OPERATING INSTRUCTIONS Release the parking brake following these instructions: Turn the ignition key to position R. Turn selector (37) to the left. Act on the emergency pump (28) in order to open the brake calliper (the selector 37 stop lightening). If it is not possible to disable the hand brake, go on as described in the chapter "FAILURE - CAUSES - REMEDIES"...
Page 102: Instructions For The Correct Use Of The Machine In The Vicinity Of Electricity Power Supply Lines
5 - OPERATING INSTRUCTIONS • TRANSPORTATION OF THE MACHINE Load and unload the machine on a firm and level surface. Ensure that the brakes of the truck and trailer are engaged. Use a ramp or loading platform. The ramp must be strong, shallow angle and correct height. Drive the machine onto the ramp.
Page 103 INTRODUCTION .................................... 2 SAFETY INFORMATION AND GENERAL RULES ........................2 ENVIRONMENTAL INFORMATION ............................... 2 INFORMATION ON ORIGINAL MERLO SPARE PARTS ....................... 2 MAINTENANCE INFORMATION ..............................2 FUEL AND LUBRICANTS ................................3 SCHEDULED MAINTENANCE DURING THE MACHINE'S RUNNING-IN PERIOD ..............6 COVERS ......................................
Page 104: Introduction
WARNING! Maintenance operations on Merlo machines must be carried out using original and approved spare parts only. If non original spare parts are used, Merlo shall be waived of any liability and all machine guarantee terms shall be deemed void.
Page 105: Fuel And Lubricants
6 - ORDINARY MAINTENANCE use either a ladder or an access platform - compliant with the law in force - if you need to carry out maintenance operations on the machine at a height exceeding 1.50 m from the ground. if you need to carry out maintenance operations underneath the machine, use either a pit or an auto lift with appropriate characteristics.
Page 106 6 - ORDINARY MAINTENANCE • ANTI FREEZE Refer to the relative engine workshop manual. • OILS CHART FOR USE OF THE MACHINE IN NORMAL TEMPERATURES (0°C, + 40°C) WARNING! The oil to be used for the replacement or top up can be chosen between the products indicated by the manufacturer or between others available on the market;...
Page 107 Vegetal (Repco brake group) IMPORTANT! "ROLOIL SPECIAL-MERLO" greases have been designed and manufactured especially for Merlo machines. Therefore, to ensure maximum reliability and efficiency of your machine, use these products only, which can be ordered from Merlo Technical Assistance Service.
Page 108: Scheduled Maintenance During The Machine's Running-In Period
6 - ORDINARY MAINTENANCE IMPORTANT! Your machine can operate at top efficiently only if clean lubricants are used. Before mounting the pivot pins in the joints that mount plastic bushings, a film of "ESSO CAZAR K2" grease must be applied to the latter to avoid oxidation.
Page 109 6 - ORDINARY MAINTENANCE • SCHEDULED MAINTENANCE AFTER THE FIRST 10 HOURS NUTS AND BOLTS OF THE DRIVE COMPONENTS Tighten the screws "V" of the universal joint coupling flanges to a torque of 11.7 kgm (115 Nm) (8 screws for each of the two universal joints).
Page 110 6 - ORDINARY MAINTENANCE NUTS AND BOLTS FASTENING THE AXLES THE FRAME FRONT BRIDGE (A) Torque (13,5 Kgm) the crossways tilt corrector securing screws of the jacks (8 screws for each of the two jacks) Torque (70 Kgm) the horizontal long- life tie-rods clamping nuts (2 nuts for each of the four tie-rods) REAR AXLE (P)
Page 111: Covers
6 - ORDINARY MAINTENANCE COVERS Before carrying out some ordinary maintenance operations on your machine, you are required to either remove or open the following covers: - COVER 1 COVER 1 is located in the front-central part of the machine chassis and contains certain components of the front differential, front universal joint, braking system and Long-life tie-rods.
Page 112 6 - ORDINARY MAINTENANCE - COVER 6 COVER 6 is located in front of the cab and houses the machine electronic control unit. Proceed as follows to remove COVER 6: - open the lock using the specific key provided - slide protective cover in the direction shown by the arrow To re-close the cover, proceed as follows: - fit the cover in its seat - push the cover fully into place...
Page 113: Engine Compartment - Nomenclature
6 - ORDINARY MAINTENANCE ENGINE COMPARTMENT - NOMENCLATURE Pay particular attention to the position of the engine compartment components mentioned in this paragraph, because they will be mentioned again and described in the MAINTENANCE paragraphs. • (P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.17PLUS – P40.9PLUS – P60.10 – P72.10) DEUTZ 74 kW (100CV) 1) Diesel engine 2) Hydrostatic transmission oil level small tank...
Page 114: Merlo Periodic Maintenance Schedule
EVERY 1000 HOURS OR 12 MONTHS in relation to machine use conditions. • Always use original spare parts approved by Merlo S.p.a. For information on maintenance times and interventions to carry out on diesel engines always refer to the engine manual supplied as standard with the machine.
Page 115 6 - ORDINARY MAINTENANCE PERIODIC MAINTENANCE SCHEDULE COMPONENT * EVERY 10 HOURS OPERATION Hydraulic oil Check level and top up Hydrostatic transmission oil Check level and top up Engine cooling system Check level and top up Tyres and wheel bolts Inspect Safety belts Inspect...
Page 116: Every 10 Hours Or Daily
6 - ORDINARY MAINTENANCE EVERY 10 HOURS OR DAILY • HYDRAULIC OIL To check the hydraulic oil level it is necessary to: place the machine on a perfectly even ground lower and retract the telescopic boom completely switch off the Diesel engine use indicator "A"...
Page 117: Every 50 Hours Or Weekly
6 - ORDINARY MAINTENANCE • TYRES AND STUDS BOLTS Check that the wheel studs are tightened and the tyres are properly inflated. Inspect tires for damages or excessive wear daily. • SAFETY BELTS Check the presence, function and the good condition of safety belt. WARNING! Do not use the machine on site if the safety belt is not in efficient working condition.
Page 118 Check the tightening (550 Nm) of the wheel locking stud bolts (B). WARNING! The tyres which can be used on the machine are those indicated in the Merlo List and/or in the machine registration document (if provided). • CAB VENTILATION SYSTEM FILTER To check its cartridge, follow the instructions below: Unscrew fastening screws "V"...
Page 119 6 - ORDINARY MAINTENANCE • BATTERY WARNING! Before working on the battery, carefully read the instructions in chapter "ELECTRICAL SYSTEM". Keep the battery and its compartment clean and the terminals covered with Vaseline grease to avoid corrosion. Disconnect negative (-) terminal cable before you charge the battery or work on the electrical system.
Page 120 "GENERAL MAINTENANCE" apply a layer of specific Merlo grease on the telescopic boom, as described in paragraph "OUTER SLIDING PADS OF THE TELESCOPIC BOOM"...
Page 121: Every 500 Hours Or Every 6 Months
6 - ORDINARY MAINTENANCE • GREASING THE QUICK UNCOUPLING PLUNGER OF THE ATTACHMENTS Periodically grease the quick uncoupling plunger of the attachments to ease sliding and prevents rust from forming inside the cylinder chamber. To perform this operation correctly, please follow the instructions below: lower the telescopic boom stop the machine apply 30 ml of specific grease (see paragraph "FUELS AND LUBRICANTS")
Page 122 6 - ORDINARY MAINTENANCE • FRONT AND REAR DIFFERENTIAL OIL Carry out the following operations to check the oil of the front and rear differentials: remove the cap "A" on the front bridge "A" as well as on the rear bridge "P"...
Page 123 6 - ORDINARY MAINTENANCE • FUEL TANK Carry out the following operations to discharge any water or sediment from the fuel tank: Place an appropriately sized container underneath discharge cap "A" loosen discharge cap "A" using an appropriate hexagonal wrench. discharge the water and sediments contained in the tank.
Page 124 3 - visual inspection of inner sliding pads to check for any breaks 4 - visual inspection of inner sliding pads to check for any burrs or large shavings (plastic powder is accepted). Should any of the above conditions occur, please contact Merlo Technical Assistance Service. • SCREWS AND BOLTS Check tightness.
Page 125 Merlo Technical Assistance service replacing the filter, connecting the pipelines and securing the retainer clamps "B"...
Page 126: Every 1000 Hours Or Every 12 Months
6 - ORDINARY MAINTENANCE EVERY 1000 HOURS OR EVERY 12 MONTHS • ARTICULATED JOINTS Check the play on the articulated joints of the indicated components. If the play is more than 1 mm, replace the related bushings. Lubricate the articulated joints of the indicated components that are equipped with greaser. A) Wheel reduction hubs - B) Front axle - C) Rear axle - D) Boom - E) Carriage - F) Fork jack G) Lifting jack - H) Offset jack - L) Stabilisers (if fitted to the machine) NOTE! A P40.17PLUS has been selected to explain this maintenance operation.
Page 127 6 - ORDINARY MAINTENANCE • BOOM SLIDING PADS (EXTERNAL) Fully extend the telescopic boom Carefully clean the boom sliding surface, removing the residual grease Using a cotton wad, evenly spread a thin layer of grease (see paragraph "FUELS AND LUBRICANTS") over the entire boom sliding surface Carry out a few boom extension and retraction cycles so as to evenly distribute the product.
Page 128: Every 1500 Hours Or Every 18 Months
6 - ORDINARY MAINTENANCE EVERY 1500 HOURS OR EVERY 18 MONTHS • HYDROSTATIC TRANSMISSION SYSTEM Replace the oil from the hydrostatic transmission system Radiator Tank Hydrostatic pump Hydrostatic motor Hydrostatic transmission filter Hand pump The total capacity of the system is 12 litres WARNING! Use only hydrostatic oil shown in paragraph FUEL AND LUBRICANTS ..
Page 129 6 - ORDINARY MAINTENANCE • HYDRAULIC OIL To correctly change the hydraulic oil, do as follows: Fully retract and lower the telescopic boom Stop the machine diesel engine Remove filling cap "B" Extract and clean the magnets Remove discharge cap "C" and empty the hydraulic oil into an appropriate container Close the discharge cap "C"...
Page 130 6 - ORDINARY MAINTENANCE • FRONT AND REAR DIFFERENTIALS OIL To correctly change the differential oil, do as follows: Stop the machine diesel engine work on one differential at a time remove the filler cap "A" remove the discharge cap "B" and collect the differential oil in an appropriate container close the discharge cap "B"...
Page 131: General Maintenance
6 - ORDINARY MAINTENANCE GENERAL MAINTENANCE • INTRODUCTION This chapter describes all the general maintenance operations to be performed on the machine based on its actual operating conditions, without following any particular schedule. WARNING! Carefully read the instructions in chapter ORDINARY MAINTENANCE before carrying out the following operations.
Page 132 6 - ORDINARY MAINTENANCE connect an overhead crane "C" to the head of the telescopic boom (as shown in the photo) in such a way as to lift the second boom bringing it into contact with the first boom. It is also possible to rest the carriage on the ground on a perfectly flat plate, small-sized and positioned centrally with respect to the boom, and then to lower the telescopic boom in such a way as to raise the second boom bringing it into contact with the first.
Page 133 6 - ORDINARY MAINTENANCE • BRAKE SYSTEM BLEED Bleeding consists in eliminating the air inside the system. This operation must be performed each time hydraulic parts of the system are disassembled. Carry out the operations needed to bleed the brake system on both axles and just on the callipers that have the special screw "A"...
Page 134 6 - ORDINARY MAINTENANCE • ENGINE COOLING SYSTEM For coolant replacement operations. Contact an Authorised Workshop. • ENGINE OIL Periodically check the engine oil as follows: position the machine on a level surface and turn off the diesel engine wait a few minutes to allow the engine to cool and drain the engine oil inside the sump check the oil lever by extracting the...
Page 135 6 - ORDINARY MAINTENANCE • WINDSCREEN WASHER LIQUID TANK Fill tank "A" situated inside the cab with the specific liquid available on the market. • GEAR BOX OIL BLEEDING TANK The gearbox oil breather small tank is located inside the engine compartment and is maintenance-free.
Page 136: Trouble Shooting
Should your machine not work correctly, please refer to the following table, so as to identify and eliminate the cause of the problem. The operator is allowed to carry out just some operations, while the most complex ones shall be carried out by Merlo Technical Assistance service.
Page 137: End Of Section
Indicator light selector (A) on "1" = emergency function engaged (the selector is ON). WARNING! Never remove the cover of the box, this should only and exclusively be carried out by personnel from the technical assistance service of MERLO S.p.A. END OF SECTION 6 - 35...
Page 139 7 - PERIODIC SAFETY INSPECTIONS CONTENTS PERIODIC INSPECTION RECORD SHEET ..........................2 SOUND-VISUAL ALARMS AND MOVEMENT BLOCKING OF THE ANTI-OVERTURN SYSTEM ..........6 STEERING OPERATING MODES ..............................7 PLATES AND INSTRUCTIONS ..............................7 STABILISERS COMMAND LOCK ..............................7 CROSSWAYS LEVELLING "TILTING" COMMANDS LOCK ......................7 USE AND MAINTENANCE INSTRUCTIONS MANUAL .........................
Page 140: Periodic Inspection Record Sheet
7 - PERIODIC SAFETY INSPECTIONS PERIODIC INSPECTION RECORD SHEET The following card must be reproduced (i.e. photocopied) and used to record the inspections to be carried out following the periods as reported in the table. If the box between the line and the column is not highlighted, inspection is not necessary. The operations hereafter listed must be carried out following the deadlines in working hours or in months, whichever come first.
Page 141 7 - PERIODIC SAFETY INSPECTIONS (P38.12 - P38.12 PLUS - P38.13 - P38.13 PLUS - P38.14 - P38.14 PLUS – P38.13EE) TYPE OF MACHINE CHASSIS NUMBER NAME OF CONTROLLER PERIOD IN HOURS / MONTHS Every Every Every FUNCTION TO BE CHECKED 250 hours or 2 months 500 hours or 6 months 1000 hours or 1 year...
Page 142 7 - PERIODIC SAFETY INSPECTIONS (P40.9 PLUS - P60.10 - P72.10 – P60.10EE – P72.10EE) TYPE OF MACHINE CHASSIS NUMBER NAME OF CONTROLLER PERIOD IN HOURS / MONTHS Every Every Every FUNCTION TO BE CHECKED 250 hours or 2 months 500 hours or 6 months 1000 hours or 1 year Restoratio...
Page 143 7 - PERIODIC SAFETY INSPECTIONS (P40.17 – P40.17PLUS – P40.17EE) TYPE OF MACHINE CHASSIS NUMBER NAME OF CONTROLLER PERIOD IN HOURS / MONTHS Every Every Every FUNCTION TO BE CHECKED 250 hours or 2 months 500 hours or 6 months 1000 hours or 1 year Control Restoration...
Page 144: Sound-Visual Alarms And Movement Blocking Of The Anti-Overturn System
The test is successfully passed only if - when carrying put the above mentioned operations - the anti-overturn system works correctly on both sides of the rear axle. If even one of the two anti-overturn control systems does not work correctly, do not use the machine and contact the Technical Assistance Service of Merlo S.p.A. 7 - 6...
Page 145: Steering Operating Modes
Check on the gauge in the cab that the pressure is between 205 and 215 Bar. WARNING! If the gauge indicates a pressure value different from that expected, please ask for assistance from qualified Merlo Service personnel. When the checking of the pressure is ended, disconnect the small hose from the pump and rearrange it in the engine compartment.
Page 146: Jack Locking Valves
Lock the cab and wait approx. 30'. Repeat the measurement. The difference between the two measurements must not be over 25 mm, in case the difference is over 25 mm contact the MERLO service centre. PARKING BRAKE Start the engine and engage 2nd gear.
Page 147: Control Of The Chains For The Extension And Retraction Of The Boom
7 - PERIODIC SAFETY INSPECTIONS CONTROL OF THE CHAINS FOR THE EXTENSION AND RETRACTION OF THE BOOM (only for models P40.17 – P40.17PLUS – P40.17EE) INSPECTION OF CHAINS a) chains inside the boom To check the integrity and the state of wear of chains "A", as well as their correct fitting on combs "B", extend the telescopic boom completely and perform the inspection through the slots on the second and third boom (fig.1), third and fourth boom (fig.2).
Page 148 7 - PERIODIC SAFETY INSPECTIONS b) chains outside the boom To check the integrity and the wear level of chains "A", of pulleys "B" and their correct fitting on combs "C", the telescopic boom of the machine must be placed parallel to the ground and the inspection carried out: X –...
Page 149 7 - PERIODIC SAFETY INSPECTIONS Re-assemble the springs on the pins, proceeding as follows: Insert the spring (D) then screw in the threaded bar (E). Insert on the threaded bar, in the following order: the retainer nut (H) of the spring, the washer (F) and the nut (G).
Page 150 7 - PERIODIC SAFETY INSPECTIONS INSPECTION OF THE TELESCOPIC BOOM CHAIN STRETCHING WITH SLIDE RULE "R" It is advisable to perform the following operations every 1,000 operating hours. This check shall not replace the compulsory inspections of the chain status in compliance with national provisions and regulations.
Page 151: End Of Section
7 - PERIODIC SAFETY INSPECTIONS place rule "R" into contact with the chain, so that the v-shaped notch can be inserted into a chain link pin; perform this operation with side "R2" of the rule facing the operator (fig. 3) starting from the v-shaped notch, count the number "B"...
Page 152 CONTROL OF HYDRAULICALLY FUNCTIONING ATTACHMENTS ..................... 5 DISMANTLING OF ATTACHMENTS WITH QUICK COUPLING ....................5 ATTACHMENTS COMPATIBLE WITH VEHICLES MANUFACTURED BY MERLO S.p.A............6 VARIANTS AND ACCESSORIES..............................19 GENERAL INSTRUCTIONS FOR THE USE OF THE MACHINE APPROVED AS ITALIAN OPERATIVE ........19 REAR DIFFERENTIAL LOCKING ..............................
Page 153 8 - ATTACHMENTS AND OPTIONAL EXTRA JOYSTICK (5 FUNCTIONS) ................................. 29 MULTI-FUNCTION CONTROL JOYSTICK ........................... 30 GRAMMER EXTRA-COMFORT PNEUMATIC SEAT ........................31 TYRE SEAT ....................................32 CYCLONE PRE-FILTER ................................32 A/C SYSTEM ....................................33 FAULTS WITH DIRECTION INDICATORS ON AGRICULTURAL TRAILERS ................33 END OF SECTION ..................................
Page 154: Attachment Identification Plate
The attachment is designed and built following Merlo specifications. In order to avoid accidents and to ensure good performance, the attachment must not be changed from that approved by Merlo S.p.A. and it must not be used for any purpose other than that for which it is intended by design.
Page 155: Assembly Of Attachments With Quick-Coupling
Merlo that is equipped with the same coupling system. read and make sure to understand all the instructions regarding the attachment you purchased, which are provided either in the following paragraphs or in the attached manual.
Page 156: Control Of Hydraulically Functioning Attachments
Merlo that is equipped with the same coupling system. read and make sure to understand all the instructions regarding the attachment you purchased, which are provided either in the following paragraphs or in the attached manual.
Page 157: Attachments Compatible With Vehicles Manufactured By Merlo S.p.a
Never force the attachment on to the ground to carry out uncoupling. ATTACHMENTS COMPATIBLE WITH VEHICLES MANUFACTURED BY MERLO S.p.A. The attachments described in this paragraph are those available at the time the manual was published. For increased safety, before using any type of attachment, always check all of the relevant data given in the type-approval charts applied to the attachment.
Page 158 8 - ATTACHMENTS AND OPTIONAL EXTRA • CARRIAGE WITH FLOATING FORKS To install this attachment on the carriage, carry out the same operations described paragraph "INSTALLATION QUICK-COUPLING ATTACHMENTS" in this chapter. Install this attachment on the carriage if the digging angle with the carriage in a folded position is required to be 5°...
Page 159 8 - ATTACHMENTS AND OPTIONAL EXTRA WARNING! Always check to ensure that the forks are correctly secured on the carriage so as to prevent any lateral sliding possible escape. Fitting this attachment demands a reduction in the useful loads in the diagram equal to the weight of the FEM carriage.
Page 160 WARNING! (BUCKET, 4 X 1 BUCKET): the excavation or loading of loose material using the machine with extended boom, may cause serious damage to the boom itself; MERLO S.p.A. strongly recommends not to perform such operation and will not be held responsible for any damage arising from this use.
Page 161 8 - ATTACHMENTS AND OPTIONAL EXTRA • RE-HANDLING BUCKET Assemble the attachment on the carriage as described in the paragraph INSTALLATION OF QUICK-COUPLING ATTACHMENTS in this chapter and use it with the auxiliary controls in the cab as described in the paragraph CONTROL OF HYDRAULICALLY FUNCTIONING ATTACHMENTS.
Page 162 8 - ATTACHMENTS AND OPTIONAL EXTRA • MULTIPURPOSE BUCKET WITH GRAB Assemble the attachment on the carriage as described in the paragraph INSTALLATION OF QUICK-COUPLING ATTACHMENTS in this chapter and use it with the auxiliary controls in the cab as described in the paragraph CONTROL OF HYDRAULICALLY FUNCTIONING ATTACHMENTS.
Page 163 8 - ATTACHMENTS AND OPTIONAL EXTRA • FLY-JIB WITH WINCH Light weight trestle structure, highly rigid under load. A shape bent forward permits to reach an operating height as high as that of the machine combined with the jib height, keeping the hook clear of the machine. High-resistance anti- spin rope complete with pulley and rope guide at the jib end (A1300).
Page 164 8 - ATTACHMENTS AND OPTIONAL EXTRA • FLY JIB Light weight trestle structure, highly rigid under load. A shape bent forward permits to reach an operating height as high as that of the machine combined with the jib height, keeping the hook clear of the machine. Safety hook slewing over 360°.
Page 165 8 - ATTACHMENTS AND OPTIONAL EXTRA • CONCRETE SKIP (500 l) - Weight: 255 kg - Door opening: Manual (A1400) or Hydraulic (A1410) - Max capacity: 500 l (700 l) - Weight: 275 kg - Door opening: Manual (A1420) or Hydraulic (A1430) - Max capacity: 700 l To assemble the concrete skip on the machine proceed as follows: Insert the forks into the appropriate locations...
Page 166 8 - ATTACHMENTS AND OPTIONAL EXTRA ATTACHMENT MAINTENANCE Lubricate the concrete unloading flap operating cylinder "M" every 50 working hours, on the lubrication points shown (ref. 1) • CONCRETE MIXER For attachment assembly, operating and maintenance instructions, refer to the relevant manual.
Page 167 8 - ATTACHMENTS AND OPTIONAL EXTRA • MANURE FORK WITH CLAW Assemble the attachment on the carriage described paragraph INSTALLATION QUICK-COUPLING ATTACHMENTS in this chapter and use it with the auxiliary controls in the cab as described paragraph CONTROL HYDRAULICALLY FUNCTIONING ATTACHMENTS.
Page 168 8 - ATTACHMENTS AND OPTIONAL EXTRA • HAY BALE FORK WITH SLIDING GUARD Fork suitable for loading one or two bales on top of each other, with height- adjustable, hydraulically operated upper guard. height adjustment means that this equipment is ideal for stacking bales up to the roof where the height of the last load is variable.
Page 169 8 - ATTACHMENTS AND OPTIONAL EXTRA • BALE GRIPPER Assemble the attachment on the carriage as described in the paragraph INSTALLATION OF QUICK-COUPLING ATTACHMENTS in this chapter and use it with the auxiliary controls in the cab as described in the paragraph CONTROL OF HYDRAULICALLY FUNCTIONING ATTACHMENTS.
Page 170: Variants And Accessories
Before using any accessory mentioned in the present chapter, it is necessary to read and fully understand the instructions on its operation. If the installation or operation of the accessory is not entirely clear, please contact your dealership or Merlo Technical Support Service.
Page 171 8 - ATTACHMENTS AND OPTIONAL EXTRA PERMITTED LOAD ON TYRES PER TECHNICALLY PERMISSIBLE MASS (kg) AXLE (kg) MACHINE TOTAL FRONT REAR FRONT REAR P37.12 PLUS 8900 5000 5000 5000 5000 P38.12 / PLUS 8900 5000 5000 5000 5000 P38.13 / PLUS / EE 9050 5000 5000...
Page 172: Rear Differential Locking
8 - ATTACHMENTS AND OPTIONAL EXTRA REAR DIFFERENTIAL LOCKING Operated using button (A): button pressed lock engaged button released lock disengaged When warning light (88) is ON, it indicates that the differential lock is engaged. IMPORTANT! Do not operate the steering with differential lock engaged on tarmac or compact surfaces.
Page 173: Rear Hydraulic Outlet
8 - ATTACHMENTS AND OPTIONAL EXTRA REAR HYDRAULIC OUTLET The provision for mixing bucket control may be of 2 types depending on the distributor fitted to the machine: - if the machine is fitted with levers, the mixing bucket is operated using control lever (2) (configuration 1) - if the machine is fitted with a joystick, the mixing bucket is operated using the joystick (1) (configuration 2) The 2 options available are analysed separately below;...
Page 174: Rear Wheel Centring Indicator On The Machine Axis
8 - ATTACHMENTS AND OPTIONAL EXTRA REAR HYDRAULIC OUTLET To understand the operation of the rear hydraulic connection, refer to the following instructions: selector "S" on "0": the rear hydraulic connections are deactivated and the functions of the joystick (1) are those described in chapter "COMMANDS AND INSTRUMENTS"...
Page 175: Fixed Building Site Tow Hook
8 - ATTACHMENTS AND OPTIONAL EXTRA FIXED BUILDING SITE TOW HOOK Mount the fixed tow hook (A) for building sites if: it is necessary to tow the vehicle on public roads (see also paragraph "MACHINE TOWING" in chapter "OPERATING INSTRUCTIONS") it is necessary to tow trailers or other equipment within a building site.
Page 176: Provision For Mixing Bucket Control
8 - ATTACHMENTS AND OPTIONAL EXTRA PROVISION FOR MIXING BUCKET CONTROL The provision for mixing bucket control may be of 2 types depending on the distributor fitted to the machine: - if the machine is fitted with levers, the mixing bucket is operated using control lever (2) (configuration 1) - if the machine is fitted with a joystick, the mixing bucket is operated using the joystick (1) (configuration 2) The 2 options available are analysed separately below;...
Page 177: Rear Electrical Connection
8 - ATTACHMENTS AND OPTIONAL EXTRA REAR ELECTRICAL CONNECTION For the electrical connection of the direction indicators and all the lights of the towed equipment use "A" socket. For the electric connection (according to ISO 1724-80) consult the enclosed electric diagram. CAR RADIO The radio is installed in the compartment under the left glove box.
Page 178: Fitting Active Hydro-Pneumatic Suspensions For Panoramic
(indicator light 56 OFF). If these safety conditions are not upheld, the led does not come ON and the suspension is not activated. In the event of system faults, contact Merlo Technical Assistance service. WARNING!! If, when turning selector switch "S"...
Page 179 8 - ATTACHMENTS AND OPTIONAL EXTRA JOYSTICK (4 FUNCTIONS) 4 main movements can be performed with this joystick (2 movements controlled by the lever of the joystick and 2 movements controlled by wheels R1 and R2). 1) LIFTING/LOWER OF THE TELESCOPIC BOOM 2) UPWARD/DOWNWARD ROTATION OF THE FORKS 3) EXTENSION/RETRACTION OF THE TELESCOPIC BOOM 4) COMMAND FOR ATTACHMENTS INSTALLED ON THE CARRIAGE...
Page 180: Joystick (5 Functions)
8 - ATTACHMENTS AND OPTIONAL EXTRA JOYSTICK (5 FUNCTIONS) 5 main movements can be performed with this joystick (2 movements controlled by the lever of the joystick and 3 movements controlled by wheels R1, R2 and R3).: 1) LIFTING/LOWER OF THE TELESCOPIC BOOM 2) UPWARD/DOWNWARD ROTATION OF THE FORKS 3) EXTENSION/RETRACTION OF THE TELESCOPIC BOOM 4) COMMAND FOR ATTACHMENTS INSTALLED ON THE CARRIAGE (AUX)
Page 181: Multi-Function Control Joystick
8 - ATTACHMENTS AND OPTIONAL EXTRA MULTI-FUNCTION CONTROL JOYSTICK Thanks to this accessory, your machine is fitted with an electro-mechanical single- lever joystick for performing 8 hydraulic functions • Position A: lift telescopic boom • Position B: lower telescopic boom •...
Page 182: Grammer Extra-Comfort Pneumatic Seat
8 - ATTACHMENTS AND OPTIONAL EXTRA GRAMMER EXTRA-COMFORT PNEUMATIC SEAT The pneumatic seat Grammer is installed in place of the standard one. Therefore, the following instructions replace those found in chapter "CAB" of the present operator manual. WARNING! It is forbidden and it is extremely dangerous to adjust the driver's seat while the vehicle is moving. Position the driver's seat so that the driver can easily reach the vehicle controls.
Page 183: Tyre Seat
8 - ATTACHMENTS AND OPTIONAL EXTRA TYRE SEAT SEAT SHIFT (1): Lift lever "S" upwards, slide the seat forwards or backwards to obtain the required position and release the lever. HEIGHT ADJUSTMENT (2): The seat height can be adjusted by means of the hand lever "M", placed on the front side of the seat frame. To lower the seat, pull the hand lever "M"...
Page 184: A/C System
8 - ATTACHMENTS AND OPTIONAL EXTRA A/C SYSTEM To cool your cab correctly, follow the advice below: open all the air vents in the cab after a prolonged stay in the sun it is necessary to air the cab by opening all the windows for a few minutes and putting the ventilation control (36) on the second speed (for further information see the section "HEATING"...
Page 186 9 - HYDRAULIC CIRCUIT DIAGRAMS CONTENTS HYDROSTATIC TRANSMISSION DIAGRAM ..........................2 HYDRAULIC SYSTEM DIAGRAM ..............................6 END OF SECTION ..................................11 9 - 1...
Page 187 9 - HYDRAULIC CIRCUIT DIAGRAMS HYDROSTATIC TRANSMISSION DIAGRAM (valid for models P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.17PLUS – P60.10 – P72.10) 9 - 2...
Page 188 9 - HYDRAULIC CIRCUIT DIAGRAMS REFERENCE DESCRIPTION Diesel engine Hydrostatic oil tank Variable delivery hydrostatic pump Heat exchanger Variable displacement hydrostatic engine Throttle Speed selection rams Filter-holder block Bypass Rams for differential-lock (OPTIONAL) Servobrake Cartridge filter Thermal contact Pressure connection Parking brake calliper Emergency pump Solenoid valve block...
Page 189 9 - HYDRAULIC CIRCUIT DIAGRAMS (valid for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE – P60.10EE – P72.10EE) 9 - 4...
Page 190 9 - HYDRAULIC CIRCUIT DIAGRAMS REFERENCE DESCRIPTION Diesel engine Hydrostatic oil tank Variable delivery hydrostatic pump Heat exchanger Variable displacement hydrostatic engine Throttle Speed selection rams Filter-holder block Bypass Rams for differential-lock (OPTIONAL) Servobrake Cartridge filter Thermal contact Pressure connection Parking brake calliper Emergency pump Solenoid valve block...
Page 191 9 - HYDRAULIC CIRCUIT DIAGRAMS HYDRAULIC SYSTEM DIAGRAM (valid for models P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.17PLUS) 9 - 6...
Page 192 9 - HYDRAULIC CIRCUIT DIAGRAMS REFERENCE DESCRIPTION Inlet filter Return filter Variable delivery pump ENGINE Volume recovery valve Power steering unit Steering distributor Steering jack Pressure gauge Main distributor Extension jack lock valve Lifting jack Throttle ø1mm Extension jack Chassis side movement jack Fork / compensation (offset) valve Compensation (offset) jack Fork jack lock valve...
Page 193 9 - HYDRAULIC CIRCUIT DIAGRAMS (valid for models P37.12 PLUS – P40.9 PLUS – P60.10 – P72.10 – P60.10EE – P72.10EE) 9 - 8...
Page 194 9 - HYDRAULIC CIRCUIT DIAGRAMS REFERENCE DESCRIPTION Inlet filter Return filter Variable delivery pump Diesel engine Volume recovery valve Power steering unit Steering distributor Steering jacks Pressure gauge Main distributor Extension jack lock valve Lifting jack Throttle ø 1 mm Extension jack Side movement jack Fork / compensation (offset) valve...
Page 195 9 - HYDRAULIC CIRCUIT DIAGRAMS (valid for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE) 9 - 10...
Page 196 9 - HYDRAULIC CIRCUIT DIAGRAMS REFERENCE DESCRIPTION Inlet filter Return filter Variable delivery pump Diesel engine Volume recovery valve Power steering unit Steering distributor Steering jacks Pressure gauge Main distributor Extension jack lock valve Lifting jack Throttle ø 1 mm Extension jack Side movement jack Fork / compensation (offset) valve...
Page 197 10 - ELECTRICAL SYSTEM CONTENTS GENERAL FEATURES ................................... 2 BATTERY ....................................... 2 FUSES ......................................3 END OF SECTION ..................................4 10 - 1...
Page 198: General Features
10 - ELECTRICAL SYSTEM GENERAL FEATURES Your telescopic handler is equipped with a 12 volt electrical system with the negative pole grounded. BATTERY The battery on your machine is located inside the engine compartment. NOMENCLATURE OF THE BATTERY COMPARTMENT: (+) Positive pole (-) Negative pole The main features of the battery are listed below: •...
Page 199: Fuses
10 - ELECTRICAL SYSTEM FUSES Electrical circuits are protected by fuses and relays located in the ENGINE COMPARTMENT and COVER "7" in the cab (see paragraph COVERS in section "ORDINARY MAINTENANCE"). If a fuse blows, first find the cause and then replace it with a new one with the same features.
Page 200: End Of Section
10 - ELECTRICAL SYSTEM • FUSES IN ENGINE COMPARTMENT The fuses and relays located in the engine compartment are protected by cover (A). Remove cover (A) by unscrewing screws “V” with the hex wrench indicated. DEUTZ 74 kW (100CV) ENGINE 1) Glow plug relay 2) Fuel pump relay 3) Fuel pump fuse (20A)