CTS PRO 04-S CTS PRO 06-S CTS PRO 08-S

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HOOKLOADER

CTS PRO 04-S

CTS PRO 06-S

CTS PRO 08-S

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User’s Manual 1

Introductory Note

This manual applies to hookloader CTS PRO 04-S, CTS PRO 06-S a CTS PRO 08-S.

Explanation of the product type nomenclature :

Example :

Type CTS PRO 08-37-S-DIN

Capacity class of the carrier (t) 08

Hookloader length (dm) 37

Hookloader type series S

Standard DIN

Hookloader CTS PRO 04.06.08-S is being produced in the following versions :

Hookheight H : Standard H (mm) DIN 30 722-3 900 CHEM 930 CTS 1 000 POL 1 190 Fig. 1 TYP H STANDARD (hookheight) X (mm) L (mm) O (mm) K (°) T (mm)

MIN./MAX. container length (m)

04.06.08-33-S- DIN, CHEM, CTS, POL 700 3 300 220 58 53 2,8 / 3,7-3,8 / 4,3 04.06.08-37-S- DIN, CHEM, CTS, POL 900 3 700 220 53 53 3,2 / 4,2-4,5 / 4,6 04.06.08-41-S- DIN, CHEM, CTS, POL 900 4 100 220 53 53 3,4 / 4,7 / 5,2 04.06.08-45-S- DIN, CHEM, CTS, POL 1 100 4 500 220 49 53 3,6 / 5,2 / 5,5

The operation instructions are applicable to the use of the CTS PRO 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 CTS PRO carrier 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.

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User’s Manual 2 Manufacturer : CTS-servis, a. s. Okřínek 53 290 01 Poděbrady tel. : 00420 325 608111 fax : 00420 325 653097, - 81 E-mail : info@cts-servis.cz http : //www.cts-servis.cz

All rights are reserved.

Due to continuous development of the product line all future engineering changes are reserved.     CTS-servis, a. s. OKŘÍNEK - I. issue, 2011 -

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User’s Manual 3 TABLE OF CONTENTS Introductory Note : 1 Safety Conditions : 4 A. Work Safety ……… 4 B. Fire Safety ……… 6

C. Travel on public roads ……… 6

D. Liquidation of the machine at the end of its useful life ……… 6

1. Description of the machine : 7 1.1 Overall view ……… 7

1.2 Mechanism description of hookloader ……… 8

1.3 Description ……… 10 1.3.1 Controls ……… 10 1.3.2 Steel Construction ……… 10 1.3.3 Hydraulics ……… 11 1.4 Model Label ……… 11 1.5 Control equipment ……… 12

1.5.1 Controls in driver’s cabin ……… 12

1.6 Specifications of hookloaders ……… 14

1.7 Container specifications ……… 16

2. System operation : 16 2.1 Operating and safety instructions ……… 16

2.2 Loading of the container ……… 17

2.3 Container unloading ……… 19

2.4 Tipping the container ……… 21

2.5 Loading to the trailer ……… 22

2.6 Unloading the trailer ……… 23

2.7 Failure of the in-cab controller ……… 23

3. Instructions for the maintenance of the system : 23

3.1 To be done by professionals only ……… 23

3.2 Instructions for the liquidation of operating materials ……… 23

3.3 Schedules for maintenance ……… 24

3.4 Lubrication Plan ……… 26

3.5 Maintenance ……… 27

3.5.1 Checking level of hydraulic oil ……… 27

3.5.2 Suction filter replacement ……… 27

3.5.3 Replacing cartridge of return filter ……… 27

3.5.4 Replacement of hydraulic oil ……… 27

4. Repairs : 28 4.1 Table of repairs ……… 28

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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 instructions

It 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 !

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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, to prevent 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 : 1111 4 44 4 2222 3333 5555 6666 7777 7777 7777 8888 9999 10 10 1010 10 11 11 11 11 12 12 12 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 container locking

6. Drop lock 12. Passive container locking

B

A

Fig. 3

Controller in the cabin of the vehicle:

The mechanism is controlled with a controller located in the cabin (fig.3). Control signals are transferred from the cabin in the hydraulic distributor via compressed air, possibly via an electrical signal.

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User’s Manual 8

Fig. 4

Hydraulic oil tank:

The hydraulic oil tank (fig. no. 4) is equipped with a check filter, suction filter, filler with air filter and standard oil gauge.

Fig. 5

Hydraulic pump:

The hydraulic pump (fig. no. 5) is driven by a PTO on the vehicle’s gearbox. This way the pump provides sufficient pressure for the system to function. Transmission is achieved via a direct pump installation or via the drive shaft.

1.2 Mechanism description of hookloader :

Fig. 6

Sliding arm :

The sliding arm (fig. no. 6) consists of a double welded steel construction. Telescopic location of the sliding arm into the main arm frame is carried out via plastic sliding prisms, which decrease deterioration of active areas to a minimum. When the sliding arm moves forward, the main arm frame automatically connects to the tipping frame, and function of tilting the container can be easily completed without control of another button. When the sliding arm is inserted completely, the main arm frame automatically disconnects from the tipping frame, so the function of stacking the container can be completed immediately. The sliding arm hook is equipped with a safety lock.

Fig. 7

Main arm frame :

The main arm frame (fig. no. 7) is welded from high quality steel of high breaking strain. Two hydraulic cylinders are placed in such way that it provides optimal force transmission into the main construction of the main arm frame. On the bottom part of the main arm frame, there is a large quadrangular safety profile inserted on a firm lead which connects the main arm frame to the rear member during the tilting of the container.

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User’s Manual 9

Fig. 8

Tipping frame :

The tipping frame (fig. no. 8) is welded from high quality steel of high breaking strain. It

consists of two welded profiles

interconnected by the profile partition. The turning points are supported by high quality sliding plastic material. The tipping frame is equipped with a front profile, which automatically connects to the safety profile in the main arm frame during the tilting process.

Under frame :

The under frame (fig. no. 9) consists of a specially welded steel profile, which is placed on the vehicle’s undercarriage. Turning points of the tipping frame and rear pulley are separated from each other, which is beneficial for the tilting output and stability. The under frame is also equipped with steel rollers, which decrease the fraction resistance to a minimum when pulling the container.

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User’s Manual 10

1.3 Description :

CTS PRO is fully hydraulically driven. The containers may be loaded or unloaded on a slope of up to 5° on a firm ground.

1.3.1 Controls :

CTS PRO 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.

Such operation should be considered emergency!

!

When using the emergency controls (directly from the distributor using the levers), the safety system of the hydraulic circuitry is disabled !

WARNING !!!

Improper manipulation may lead to injury of the operator, or to damage to the mechanism !

1.3.2 Steel Construction :

The superstructure of CTS PRO 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 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 !

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User’s Manual 11

1.3.3 Hydraulics :

The hydraulic pump located on the auxiliary drive of the gearbox supplies CTS PRO with the needed hydraulic power.

1.4 Model Label :

Example :

OKRÍNEK 53, 290 01 PODEBRADY, TEL. 00420 / 325 / 608111 ROK VÝR.

VÝR. C. TYP

R

CÍSLO SCHVÁLENÍ M-C-1055 HMOTNOST (kg) CTS PRO 08-37-S-CTS

xxxx - yyyyy

2010

zzzz

Fig. 10

TYPE CTS PRO 08-37-S - product type YEAR OF MANUFACTURE 2010

SERIAL NUMBER xxxx - yyyyy

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User’s Manual 12

1.5 Control equipment :

1.5.1 Controls in driver’s cabin :

CTS PRO 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 2

Fig. 11

Lever Direction Function Position of Sliding Arm Lever No. 2 ⇑⇑⇑⇑_A Sliding arm - retracted

Lever No. 2 ⇓⇓⇓⇓_B Sliding arm - extended

Lever No. 1 ⇑⇑⇑⇑_A Unloading Retracted

Lever No. 1 ⇓⇓⇓⇓_B Loading Retracted

Lever No. 1 ⇑⇑⇑⇑_A Tipping up Extended

Lever No. 1 ⇓⇓⇓⇓_B Tipping down Extended

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

Such operation should be considered emergency!

!

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User’s Manual 13

Icons and functions of the remote controller

MOVE THE SLIDING ARM

mode – container unloading.

POSITIONING OF THE SLIDING ARM to basic position

mode – container loading

FOLDING THE MAIN ARM FRAME

mode – container unloading, tilting of containers (discharging contents)

POSITIONING MAIN ARM FRAME

to basic position

Mode: 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 14

1.6 Specifications :

Mechanism capacities

CTS PRO 04-S : Lifting and tipping capacity (kg) 4 900

Common technical data for all version of the mechanism

Hookheight H (mm) 900 - 930 - 1 000 - 1 190

Overall height of the system (mm) 1 260 - 1 290 - 1 360 - 1 550

Overall width of the system (mm) 1 505

Height of the container above the vehicle frame (mm) 220

Max. pressure (MPa) 28

Volume of the equalizing tank (mm) 40

Maximum transversal slop when tipping (°) 5°

Maximum longitudinal slope when loading or unloading (°) 5°

Different technical data for the individual versions CTS PRO 04-33-S

Sliding Arm - horizontal elevation (mm) 700

Tipping angle (°) 58

System weight without operating fluids (kg) 717

Min./Optim./Max. container length (m) 2,8 / 3,7-3,8 / 4,3

CTS PRO 04-37-S

CTS PRO 04-41-S

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User’s Manual 15

CTS PRO 06-33-S

CTS PRO 06-37-S

CTS PRO 06-41-S

Min./Optim./Max. container length (m) 3,4 / 4,7 / 5,2

CTS PRO 06-45-S

Sliding Arm - horizontal elevation (mm) 1 100

CTS PRO 08-33-S

CTS PRO 08-37-S

CTS PRO 08-41-S

CTS PRO 08-45-S

Sliding Arm - horizontal elevation (mm) 1 100

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User’s Manual 16

1.7 Container specifications :

Elevation of the pick-up hook (mm) 900 - 930 -1 000 - 1 190

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

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 17

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. Fully discharge air from bellows of the chassis pneumatic suspension **. 3. Switch on the auxiliary drive of the pump and adjust proper RPMs (see

vehicle operating instructions).

4. Unlock the container – i.e. make sure that the hydraulic active container locking is open *. Always hold the control lever of the active locking in the end positions for 1-2 seconds in order to ensure full unlocking.

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

6. 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.

7. 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.

8. 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. 12).

9. Place the gear to neutral.

10. 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.

11. 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. 13). In this way the container will continue to settle down safely on the under-frame of the system (Fig. 14). The telescopic assembly of the sliding arm and the main arm frame settles down in the basic position in the under-frame.

12. Slide lever no. 2 towards „B“ and telescope the sliding arm forward to end position (Fig. 15).

13. Lock the container – i.e. make sure that the hydraulic active container locking * is engaged. Always hold the control lever of the active locking in the end positions for 1-2 seconds in order to ensure full locking.

14. Adjust RPMs to idle.

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

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

* if the mechanism is equipped accordingly ** if the chassis is equipped accordingly

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User’s Manual 18

Fig. 12 Fig. 13

Fig. 14 Fig. 15

WARNING !!!

Fully discharge air from bellows of the pneumatic suspension prior to beginning any manipulation with the container (if the chassis is equipped accordingly).

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 !!!

During transportation, container must be always secured to the mechanism with passive or active locking system.

WARNING !!!

During transportation, container must be always secured to the mechanism in a suitable position with respect to axle loading and with respect to permitted overall dimensions of the vehicle!

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User’s Manual 19

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. Fully discharge air from bellows of the chassis pneumatic suspension **. 3. Switch on the auxiliary drive of the pump, adjust proper RPMs of the

motor (see vehicle instructions).

5. Slide lever no. 2 towards „A“ and the sliding arm to end position (Fig. 16).

6. 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. 17).

7. 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. 18). Thereafter unhook the container.

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

9. 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. 10. Return the articulated mast to its front basic position.

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

* if the mechanism is equipped accordingly ** if the chassis is equipped accordingly

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User’s Manual 20

Fig. 18 Fig. 19

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.)

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User’s Manual 21

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 frameof the system.

WARNING !!!

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. Fully discharge air from bellows of the chassis pneumatic suspension **. 5. Switch on auxiliary drive, adjust proper RPMs (see vehicle instructions).

Slidig arm must be extended !

6. In the tilting mode the container must be LOCKED to the tipping frameof the system.

7. 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. 20).

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

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

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

** if the chassis is equipped accordingly

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User’s Manual 22

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).

WARNING !!!

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. 21).

2. Shift to neutral and set parking brake.

3. Fully discharge air from bellows of the chassis pneumatic suspension **. 4. Switch on the auxiliary drive of the pump, adjust proper RPMs of the

motor (see vehicle instructions).

6. 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. 21).

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

8. 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.

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

10. 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.

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

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

position.

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

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

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User’s Manual 23

Fig. 21

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).

2.7 Failure of the in-cab controller :

In case of a failure of the in-cab controller, the hookloader CTS PRO 04.06.08-S can be controlled directly from the distributor using control levers. The method of operation is analogical to that from driver´s cab.

!

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.

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User’s Manual 24

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

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

Lubrication of sliding surfaced of the sliding arm

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User’s Manual 25

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

Check - Manipulation daily weekly monthly annually

After lubricating sliding surfaces of the front member, manipulate the mechanism in the extent of unloading and loading (even without container), i.e. 1 cycle.

x

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User’s Manual 26

3.4 Lubrication Plan :

Recommended lubrication grease : G00G-20 DIN 51 502

Recommended lubrication spray : WURTH HSS 2000 / BERNER HLS 500

The list of suitable lubrication greases of other manufacturers is in the appendix to operation instructions

CTS PRO has locations that have to be lubricated marked as follows (Fig. 22) :

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)

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User’s Manual 27

3.5 Maintenance :

3.5.1 Checking level of hydraulic oil :

Recommended hydraulic oil : DIN 51 524/III HVLP 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.

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User’s Manual 28

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.

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User’s Manual 29

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