Руководство по эксплуатации мерло

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  INSTRUCTION MANUAL KEEP THIS MANUAL WITH THE MACHINE AT ALL TIMES P25.6 TRANSLATION OF THE ORIGINAL INSTRUCTIONS PAN25-07 (AU) (AU) Solo 3 moduli CHASSIS M2-P256-AU-01 M3-ZM2-03 (EN) C6184487 Solo 3 moduli Solo 3 moduli…
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  PUBLICATION DATE 04/2017…
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  INDEX INTRODUCTION …………………………..1 MACHINE TECHNICAL SPECIFICATIONS …………………… 2 STICKERS WITH CONTROL DESCRIPTIONS — LEAFLETS IN THE CABIN…………3 CONTROLS AND INSTRUMENTS ……………………..4 OPERATING INSTRUCTIONS……………………….. 5 ORDINARY MAINTENANCE ……………………….6 SECURITY PERIODICAL INSPECTIONS ……………………7 ATTACHMENTS AND OPTIONAL EXTRA ……………………. 8 HYDRAULIC CIRCUITS’ DIAGRAMS …………………….

• Page 5: Table Of Contents

  WORK ENVIRONMENT …………………………… 3 FIRST COMMISSIONING OR RECOMMISSIONING AFTER A LONG SHUTDOWN …………..3 MACHINE GARAGING …………………………….. 3 TYRES ………………………………..3 ORIGINAL MERLO SPARES …………………………… 4 MACHINE SCRAPPING …………………………… 4 GUARANTEE ………………………………4 ORDINARY MAINTENANCE OPERATIONS ……………………..4 DRIVING THE MACHINE ON PUBLIC ROADS ……………………..4 SAFETY AND ACCIDENT PREVENTION MEASURES …………………….

• Page 7: General Notes

  Should the manual be damaged or made illegible in any of its parts, please order a new copy to Merlo Technical Support, by providing the identification code written in the bottom left-hand corner of the front page.

• Page 8: Work Environment

  Replace the damaged or illegible plates and/or stickers with new ones, to be ordered from the Merlo Technical Support Service.

• Page 9: Original Merlo Spares

  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 10: Safety And Accident Prevention Measures

  Merlo S.p.A. denies liability for any damage, accident or injury if the code of conduct described in the following sections of this paragraph is not applied: •…

• Page 11: 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 12: End Of Chapter

  1 — INTRODUCTION • MACHINE-PRODUCED VIBRATIONS Your machine has been designed and built in compliance with international ergonometric standards. The vibrations sent by the machine to the upper limbs of the operator’s body are irrelevant, as the machine operation does not require a lengthy contact of upper limbs with vibrating parts.

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  (P1) CONTROL PANEL KEY WORDS ……………………….5 DASHBOARD KEY WORDS (C) …………………………5 DYNAMIC LOAD CONTROL DISPLAY KEY WORDS (D) ………………….6 DIMENSIONS — P25.6…………………………….6 LOAD CHART ………………………………7 PERFORMANCE AND FEATURES ……………………….. 10 SERIAL NUMBER OF THE MACHINE ……………………….11 IDENTIFICATION AND TYPE APPROVAL PLATES ……………………
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  2 — MACHINE TECHNICAL SPECIFICATIONS EXTERNAL VIEW OF THE MACHINE KEY WORDS Please, pay attention to the identification of the machine sides, because they will be requoted in the handbook. REF. DESCRIPTION Front side Rear side Left — hand side Right — hand side REF.

• Page 15: Cab Interior Key Word

  2 — MACHINE TECHNICAL SPECIFICATIONS CAB INTERIOR KEY WORD REF. DESCRIPTION REF. DESCRIPTION Telescopic boom control joystick and Lever for air suction selection either inside/outside driving direction buttons the cab Rear windscreen-wiper switch Driving speed adjustment pedal Hydrostatic transmission or hydraulic Emergency pump for the release of the parking system oil pressure gauge brake…

• Page 16: (P) Control Panel Key Words

  2 — MACHINE TECHNICAL SPECIFICATIONS (P) CONTROL PANEL KEY WORDS REF. DESCRIPTION Red warning light for anti-tilting exclusion Working mode selector Start key Hazard lights switch (4 emergency flashing lights) Portable light socket Parking brake selector Push button for retraction of the telescopic boom if the joystick has been damaged or during maintenance operations on the overturn system Yellow warning light for hydrostatic transmission lock out Switch for the selection of the attachment type installed on the machine…

• Page 17: (P1) Control Panel Key Words

  2 — MACHINE TECHNICAL SPECIFICATIONS (P1) CONTROL PANEL KEY WORDS REF. DESCRIPTION Cab roof indicator switch Fan switch for cab heating Indicator lamp showing that button (U) on the joystick is pressed (joystick enable button) Adjustment buttons for instrument panel settings (C) DASHBOARD KEY WORDS (C) REF.

• Page 18: Dynamic Load Control Display Key Words (D)

  DYNAMIC LOAD CONTROL DISPLAY KEY WORDS (D) REF. DESCRIPTION Light bar indicating the stability percentage of the machine Display showing the operating functions of the machine P1 – P2 – P3 Selection buttons / setup P4 – P5 DIMENSIONS — P25.6 2 — 6…

• Page 19: Load Chart

  2 — MACHINE TECHNICAL SPECIFICATIONS LOAD CHART The load charts available on your machine, and shown in this manual, provide the different load capacity ranges of your machine when equipped with standard forks. The centre of gravity of the load being transported is calculated 600 mm away from the fork heel.

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  If it is necessary to replace one type of tyre with another model (included in the list of authorised tyres), first contact Merlo’s Technical Support service since replacing the tyres may also require replacement of the electronic control unit managing safety and load tables.
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  2 — MACHINE TECHNICAL SPECIFICATIONS 2 — 9…

• Page 22: Performance And Features

  2 — MACHINE TECHNICAL SPECIFICATIONS PERFORMANCE AND FEATURES The tables shown show data relative to a machine in it’s base/standard configuration. Merlo Spa reserves the right to modify or amend machines/specifications without prior notification. WEIGHT (kg) MEASUREMENT CONDITIONS • Machine in a basic configuration, without any attachments and variations •…

• Page 23: Serial Number Of The Machine

  When you either report a technical problem or place an order for spare parts, please provide Merlo Technical Support Service with both the serial number and the Sav number of your machine.

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  2 — MACHINE TECHNICAL SPECIFICATIONS • CAB TYPE-APPROVAL PLATE GRCF01 Metal plate GRCF01 is applied inside the cab, on the electric box cover behind the driver’s seat. This plate shows the cab type-approval data in compliance with the following international standards: — ISO 3449: Falling object protective structures (FOPS) — ISO 3471: Rollover protective structures (ROPS) For further information please refer to paragraph «EC CONFORMITY», chapter…
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  3 — STICKERS WITH CONTROL DESCRIPTIONS — LEAFLETS IN THE CABIN INDEX GENERAL REMARKS …………………………….2 INSIDE CAB STICKERS …………………………… 2 OUTSIDE CAB STICKERS …………………………..4 LEAFLETS IN THE CAB …………………………… 5 END OF CHAPTER …………………………….5 3 — 1…
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  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.
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  3 — STICKERS WITH CONTROL DESCRIPTIONS — LEAFLETS IN THE CABIN • STICKERS OF CONTROL PANEL (P) 3 — 3…
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  3 — STICKERS WITH CONTROL DESCRIPTIONS — LEAFLETS IN THE CABIN OUTSIDE CAB STICKERS 3 — 4…
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  Always keep these leaflets in good condition. Should they be damaged, replace them with new ones, to be ordered from Merlo Technical Support Service. To consult the leaflets in the cab, grab their protruding part, then lift it and rotate…
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  4 — CONTROLS AND INSTRUMENTS INDEX GENERAL VIEW OF THE CAB …………………………2 STANDARD SEAT …………………………….5 INSTRUMENT PANEL (C) DESCRIPTION ………………………. 6 CONTROL PANEL (P) DESCRIPTION ……………………….10 CONTROL PANEL (P1) DESCRIPTION ……………………….11 DYNAMIC LOAD CONTROL SYSTEM (M-CDC) ……………………. 12 ANGLE INDICATOR ON THE TELESCOPIC BOOM ……………………
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  4 — CONTROLS AND INSTRUMENTS GENERAL VIEW OF THE CAB • OPENING THE DOOR In order to open the driver’s cab door, release the lock by rotating the provided key «X» in clockwise direction, then act on handle «A» as indicated in figure (1). •…
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  4 — CONTROLS AND INSTRUMENTS • OPENING THE DOOR UPPER PART 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»…
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  4 — CONTROLS AND INSTRUMENTS • WINDSCREEN OPENING turn the lever «A» through 45° open a little the windscreen move the lever «A» in horizontal position push the windscreen forward up to the automatic stop position. • WINDSCREEN CLOSING turn the lever «A» through 45° close a little the windscreen move the lever «A»…
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  4 — CONTROLS 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 Chapter «OPTIONAL EXTRA».
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  4 — CONTROLS AND INSTRUMENTS INSTRUMENT PANEL (C) DESCRIPTION The dashboard of your machine shows the following information: — ANALOGIC REV COUNTER (61) The analogic rev counter shall be used to: control the engine running speed adjust the engine speed when using manual lever (86) (see related paragraph) carry out maintenance operation (by skilled staff) — ANALOGIC TACHOMETER (60) The analogic tachometer shall be used to control the driving speed during on-road transfers.
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  This warning light illuminates above 1,000 rpm with low engine oil pressure. In this condition stop the engine immediately and fill up oil. Start the engine again, and see if the warning light switches off. If the problem persists, please contact the Merlo Technical Support Service. Brake oil level Insufficient brake oil level.
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  4 — CONTROLS AND INSTRUMENTS — LCD DISPLAY (62) When the engine is not running display (62) is off (Fig.1). To set some functions of the LCD display use the (OK) and (C) buttons on the instrument panel (P1). The LCD display provides the operator with the following information: •…
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  4 — CONTROLS AND INSTRUMENTS • malfunction display Any malfunction detected in the machine is made known to the operator by switching on the corresponding control indicator in fields (A) of the LCD display (62). For some of these malfunctions the corresponding warning lights in the upper part of the instrument panel switch on too.
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  4 — CONTROLS AND INSTRUMENTS CONTROL PANEL (P) DESCRIPTION • WORKING MODE SELECTOR (6) On delivery this key can be found in the Operators Manual wallet, in the back of the seat. It is important to understand its use, before using this key: A) Movements enabled.
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  4 — CONTROLS AND INSTRUMENTS • SOCKET FOR TROUBLE LIGHT (11) The shown socket (11) can be used to feed a trouble light equipped with connection for electric lighter. Use a 12 V and max. 40 W lamp. • HAND BRAKE (37) With engine running: Turn the (37) selector towards right to engage hand brake (the selector lights) Turn the (37) selector towards left to release hand brake (the selector stop…
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  4 — CONTROLS AND INSTRUMENTS • HEATER (35) HEATER CONTROL KNOB (ITEM 35) increase temperature decrease temperature CAB HEATING FAN SWITCH (REF. 36) The switch has three positions: fan off fan on, at speed 1 fan on, at speed 2 CAUTION! Never place any objects behind the seat which may obstruct the air inlet of the ventilation system.
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  • NOMENCLATURE OF DISPLAY (D) When the instrument panel is switched on (ignition key (8) to the «R» position) (Fig. 1), the system displays a screen with the MERLO symbol (Fig. 2) for 3 seconds and then automatically shifts to the main screen.
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  4 — CONTROLS AND INSTRUMENTS The main screen shows the following information: REF. DESCRIPTION Percentage longitudinal stability limit Maximum liftable load in the spot where the telescopic boom is (this value depends on the attachment) Bar graph indicating the load effectively lifted in relation to the equipment installed Height of the load from the ground (expressed in metres) Distance between the external limit of the tyres (or of stabilizers, if available) (expressed in metres) Telescopic boom lift angle (expressed in degrees)
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  4 — CONTROLS AND INSTRUMENTS • ACTIVATION OF THE GRAPHIC BAR FOR CONTROL SELECTION Display (D) of the load control system is equipped with a floating bar which shows control buttons P1, P2, P3, P4 and P5. The activation of this floating bar depends on the weighing mode selected by the operator: 1) In the ‘AUTO WEIGHING’ mode (see paragraph ‘WEIGHING SCREEN’), when one of the 5 selection buttons (P1, P2, P3, P4 or P5) is pressed, the system…
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  4 — CONTROLS AND INSTRUMENTS • SELECTION OF THE DAYTIME/NIGHT MODE FOR DISPLAY ILLUMINATION (BUTTON P4) Carry out the following operations to select either the daytime or the night mode for the illumination of display (D): activate the menu bar press button (P4) to change over from the daytime mode to the night mode for the illumination of display (D) and vice versa.
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  4 — CONTROLS AND INSTRUMENTS REF. DESCRIPTION Net weight lifted by the attachment installed on the carriage (expressed in tonnes) Table showing the latest 20 weighings stored in the system, including the total weight Deletion of all weighings stored in the system. The total is set back to zero. Attachment tare Manual weighing Selection of the weighing mode: either automatic or manual…
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  4 — CONTROLS AND INSTRUMENTS 4) MANUAL WEIGHING (E) Use this control to manually weigh the load being lifted on the attachment. The data measured by the system are shown in table ‘B’, from cell number 1 to cell number 20. After 20 weighings all the values scroll up, and the next values are displayed at the bottom of the table.
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  4 — CONTROLS AND INSTRUMENTS 6) WEIGHING MODIFICATION (G) Should you need to either modify or delete one or several weighings stored in table ‘B’ you can do that using the modification function available on the WEIGHING SCREEN. Scroll the weighing screen with button (P2) until you select ‘EDIT DATA’, then press button (P3) to confirm.
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  4 — CONTROLS AND INSTRUMENTS • SELF-IDENTIFICATION OF AN ATTACHMENT (selector (204) in the AUTO position) When an attachment equipped with a self-identification sensor is installed on the carriage, you need to shift selector (204) to the «AUTO» position; in this case the system automatically determines the appropriate working chart for the machine/attachment combination, thus calculating the correct stability index, the maximum load capacity and the safe working area.
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  4 — CONTROLS 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.
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  4 — CONTROLS AND INSTRUMENTS The LOOSE MATERIAL BUCKET / 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.
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  4 — CONTROLS AND INSTRUMENTS • FRONT OVERTURN PREVENTION SYSTEM The front overturn prevention system steps in when the machine is close to its longitudinal stability limit, and locks all aggravating movements. While handling a load, the system automatically detects and processes the position of the load being lifted on the carriage, as well as the percentage stability of your machine.
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  4 — CONTROLS AND INSTRUMENTS TELESCOPIC BOOM CONTROL JOYSTICK AND SELECTION OF THE DRIVE DIRECTION (1) Your machine is equipped with a single-lever joystick (1) that allows you to control the 4 main movements of the telescopic boom, to select the drive direction (forward/reverse) of the machine and activate the second equipment hydraulic function.The controls provided on the joystick are: •…
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  «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) ACCELERATOR PEDAL (14) Operate the pedal to increase or decrease the diesel engine rpm.
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  4 — CONTROLS AND INSTRUMENTS FORWARD / REVERSE DRIVE SELECTOR (20) The drive direction (forward/reverse) of the machine can be selected in two ways: 1) by pressing the buttons (F,N,R) located on the joystick (1) (see paragraph «TELESCOPIC BOOM AND DRIVE DIRECTION CONTROL JOYSTICK» in this chapter) 2) by pressing the buttons (F,N,R) on the drive selector (20) located next to the steering column…
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  4 — CONTROLS AND INSTRUMENTS LIGHTS AND HORN ON/OFF LEVER (24) Lever (24), placed beside the steering wheel, allows you to switch on/off the lights on your machine, and to operate the horn. To do so, engine start key (8) needs to be in position «R».
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  4 — CONTROLS AND INSTRUMENTS STEERING MODE (29) The machine is fitted with a system which allows the operator to select one of three steering modes: A) Steering with corrected turn angle Use this mode to obtain a narrower steering angle. B) Front axle steering Use this mode when executing transfers on public roads.
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  4 — CONTROLS AND INSTRUMENTS LATERAL AND LONGITUDINAL SLOPE INDICATORS 2 slope indicators are available on your machine: • lateral slope indicator (A) is available on the windscreen • longitudinal slope indicator (B) is available on the right window Each indicator is provided with 2 scales: •…
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  5 — OPERATING INSTRUCTIONS INDEX INTRODUCTION ……………………………… 2 GENERAL INFORMATION …………………………..2 RULES FOR LOAD TRANSPORT …………………………2 MACHINE OPERATING AREA …………………………. 2 HOW TO HANDLE A LOAD …………………………..3 INSTRUCTIONS FOR STARTING YOUR MACHINE ……………………5 INSTRUCTIONS FOR DRIVING YOUR MACHINE ON THE ROAD ……………….. 10 INSTRUCTIONS FOR A CORRECT MACHINE USE IN THE VICINITY OF ELECTRICITY POWER SUPPLY LINES ….
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  Merlo S.p.A. or your local dealer for additional solutions which may suit your needs.
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  • MANOEUVRING A CIRCULAR-SHAPED LOAD For handling circular shaped loads (barrels, cans etc.) installation of the appropriate attachment, provided and homolgated by Merlo S.p.a., on the machine carriage is necessary. In order to find out the attachment best suited to the type of circular load to be handled, contact the nearest dealer.
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  Manoeuvring loads suspended on cables, chains, slings or other is prohibited if the machine is not equipped with the Merlo attachment specific to such a use (hook on forks, hook on carriage, crane boom, fly jib etc…) When using compatible and homolgated Merlo attachments always refer to the relevant load chart present in the holder provided in the cab.
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  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 the controls.
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  5 — OPERATING INSTRUCTIONS • GENERAL CHECKS BEFORE STARTING THE ENGINE 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 at the end to check that no screws or bolts are loose or missing and that there are no leakages of hydraulic oil roof rotating flashing beacon (figure 1) water level in the radiator (figure 2)
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  5 — OPERATING INSTRUCTIONS • CHECKS WITH THE IGNITION KEY (8) IN POSITION «R» Turn the start key (8) in «R» position and carry out the following checks: lamp panel (figure 7) correct run of all control switches (figure front lights and turn indicators (figure 9) rear lights and turn indicators (figure 10) emergency lights…
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  5 — OPERATING INSTRUCTIONS • TURNING ON THE INSTRUMENT PANEL Per accendere il quadro di comando della macchina ruotare la chiave d’avviamento (8) in posizione «R». All the warning lights and indicators on the instrument panel illuminate for a short time (GENERAL CHECK function), then all but the following switch off: 44 — battery charge warning light 45 — engine oil pressure warning light…
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  • 133 — water in the diesel oil warning light • 206 — break in the ropes warning light • 207 — MERLO SERVICE reminder warning light • 208 — low steering system pressure warning light For further information about the warning lights involved in the GENERAL CHECK please refer to the instructions provided in table «WARNING LIGHTS AND INDICATORS ON THE INSTRUMENT PANEL», paragraph «DESCRIPTION OF THE…
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  5 — OPERATING INSTRUCTIONS INSTRUCTIONS FOR DRIVING YOUR MACHINE ON THE ROAD WARNING! Observe the laws in force. The circulation on public road of the machine is allowed only in compliance and fittings reported in the road circulation documents. Lock the working tools with the special locking devices and install any prescribed protective devices.
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  5 — OPERATING INSTRUCTIONS • TOWING OF THE MACHINE The vehicle can be towed only if it is not possible to act differently. If possible, it is advisable to use the suitable aid equipment. Keep in mind that the towing force must be, at least, 1500 kg (3310 lb) GENERAL INSTRUCTIONS FOR MACHINE TOW to tow the machine use the coupling points available for this purpose…
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  5 — OPERATING INSTRUCTIONS Once you have identified the pressure relief valve you need to bypass, proceed as follows: loosen check nut «2» (with a 13 mm wrench) which locks in place the dowel of the pressure relief valve you need to bypass (depending on the direction in which you need to tow your machine).
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  5 — OPERATING INSTRUCTIONS • TRANSPORTING OF THE MACHINE Load and unload the machine on a firm and level surface. Ensure that truck and trailer are braked. Use a ramp or loading deck. Ramp must be strong enough, have a low angle, and correct height. Drive the machine into the ramp squarely.
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  5 — OPERATING INSTRUCTIONS VISIBILITY The truck is fitted with visibility aids which operator must avail himself/herself of in order to safely operate the truck and the handling of loads. Such visibility aids are: — left-side rear-view mirror — right-side rear-view mirror MAIN SAFETY RULES…
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  5 — OPERATING INSTRUCTIONS LEFT-SIDE REAR-VIEW MIRROR The adjuster should: — turn the mirror support to the locked position; — once in the locked position, not disturb the mirror support through the rest of the procedure; — rotate the mirror about its axis of rotation following the instructions from the operator in the cab The operator in the cab should: — sit correctly at the driving position;…
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  5 — OPERATING INSTRUCTIONS SUSPENDED LOADS WARNING! When handling a suspended load with the boom raised at an angle so as to have the upper face of the forks at a height of about 2200mm ± 50 mm from the ground, the rear part of the truck and the boom position may reduce visibility to the rear and right-side of the truck.
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  5 — OPERATING INSTRUCTIONS EXTERNAL LONGITUDINAL STABILITY INDICATORS An indicator light is available on the roof of your machine. Its three lamps (green, amber and red) show the stability conditions shown on display (D). This information helps the operator who is standing outside the machine to show the other operator (who is sitting in the driver’s cab) the necessary manoeuvres for load handling (see figure 1 for the correct position of the operator outside the machine).
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  INDEX INTRODUCTION ……………………………… 2 SAFETY INFORMATION AND GENERAL RULES ……………………2 ENVIRONMENTAL INFORMATION …………………………. 2 INFORMATION ON ORIGINAL MERLO SPARES ……………………. 2 MAINTENANCE INFORMATION …………………………2 MECHANICAL RETAINER FOR THE LIFT CYLINDER ……………………. 3 FUEL AND LUBRICANTS …………………………..3 SCHEDULED MAINTENANCE DURING THE MACHINE BREAK IN PERIOD …………….6 COVERS ………………………………..
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  It is strictly forbidden and highly dangerous to change any machine component by modifying its original structure. It is also forbidden to change the hydraulic and electric settings or to alter the safety systems. Otherwise, Merlo S.p.a shall be waived of any liability and guarantee claim.
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  6 — ORDINARY MAINTENANCE if you need to carry out maintenance operations underneath the machine, use either a pit or an auto lift having proper features. For the total weight of the machine please refer to the identification plate applied on the outside of the cab. if you need to raise the telescopic boom to carry out maintenance operations, equip the working area with external supports which can support the telescopic boom and prevent it from being lowered accidentally.
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  6 — ORDINARY MAINTENANCE — FUEL TANK FILLING Refuel with diesel at the end of each working day. To carry out a correct refuelling procedure, follow these instructions: Carefully clean the area of the fuel cap. Remove the fuel cap «T» by releasing its lock with the provided key. Insert the diesel fuel into the tank by making sure not to fill it up to its brim, as it is necessary to leave some free space to accomodate for fuel expansion.
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  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, always use these products only, which shall be ordered from Merlo Technical Support Service.
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  6 — ORDINARY MAINTENANCE IMPORTANT! Your machine can operate at top efficienty only if clean lubrificant are used. Use clean containers to handle all lubricants. When replacing plastic bushes, always smear pivot pins with grease «ESSO CAZAR K2» thus to avoid oxidation. SCHEDULED MAINTENANCE DURING THE MACHINE BREAK IN PERIOD •…
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  6 — ORDINARY MAINTENANCE TYRES AND WHEEL COLUMNS Check the tyre pressure with a a pressure gauge and, if needed, inflate them through valve «A». The correct tyre inflation pressure is indicated on the sticker on the inside of the wheel rim.
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  6 — ORDINARY MAINTENANCE REAR BRIDGE (P) Tighten to a torque of 45 Kgm (440 Nm) (325 lbft) the 6 «V2» screws which fasten the rear bridge to the frame. To better understand the position of the «V2» screws which fasten the front (A) and rear (P) bridge to the frame, refer to the drawing below: •…
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  6 — ORDINARY MAINTENANCE COVERS Before carrying out some routine maintenance operations on your machine, you are required to either remove or open the following covers: — COVER 1 Inside COVER 1, which is placed next to the fuel tank, there are some components of the front differential, of the front Cardan joint, and of the braking system.
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  6 — ORDINARY MAINTENANCE — COVER 6 Inside COVER 6, which is placed behind the driver’s cab, there are the return filter and the filling cap of the hydraulic system. To remove COVER 6, use a proper spanner to unscrew the 3 screws shown in the picture. — COVER 7 Inside COVER 7, which is placed behind the driver’s seat, there is the electrical box where the fuses, the relays and the electronic boards of the machine can be found.
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  6 — ORDINARY MAINTENANCE GREASING POINTS ON YOUR MACHINE This paragraph shows all the greasing points on your machine that feature a greasing nipple. Some of these points (marked with symbol *) are described in the planned maintenance schedule, because they require more detailed explanations. For the kind of grease to be used, please refer to paragraph «FUELS AND LUBRICANTS»…
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  6 — ORDINARY MAINTENANCE 6 — 12…
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  • Always use original spare parts approved by Merlo S.p.a. • To know the times and the maintenance jobs to be done on the diesel engine, always refer to the engine manual supplied with the machine.
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  6 — ORDINARY MAINTENANCE PERIODIC MAINTENANCE SCHEDALE ITEM * EVERY 10 HOURS DESCRIPTION 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…
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  6 — ORDINARY MAINTENANCE DAILY OR EVERY 10 HOURS • 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 check indicator «A»…
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  6 — ORDINARY MAINTENANCE • SAFETY BELTS Check the presence, function and the good condition of safety belt «A». IMPORTANT! Do not use the machine on site if the safety belt is not in efficient working condition. EVERY 50 HOURS OR WEEKLY •…
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  Check studs (B), tighten to 28 Kgm (280 Nm). 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 cartrdidge, follow the instructions below: Unscrew fastening screws «V»…
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  6 — ORDINARY MAINTENANCE • BATTERY WARNING ! Read carefully the instructions in the chapter «ELECTRIC SYSTEM» before carrying out any intervention on the battery. Keep battery and its compartment clean and terminals covered with vaselin grease to avoid corrosion. Disconnect negative (-) terminal cable before you charge battery or act on electrical system.
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  «GENERAL MAINTENANCE» apply a layer of boom-specific grease by Merlo, as described in paragraph «OUTER SLIDING PADS OF THE TELESCOPIC BOOM» Should the problem persist, please contact Merlo Technical Support Service for a repair.
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  6 — ORDINARY MAINTENANCE • GREASING THE PLUNGER FOR QUICK UNCOUPLING OF ATTACHMENTS Periodically grease the plunger for quick uncoupling of attachments; grease makes it easier for plunger «A» to slide, 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 engine…
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  6 — ORDINARY MAINTENANCE • FRONT AND REAR DIFFERENTIALS OIL Carry out the following operations to properly check the oil of the front and rear differentials: FRONT AXLE (3) Remove cap (A) Check that differential oil reaches up to the hole edge. If needed, fill up with specific oil (see the «OIL TABLE»…
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  6 — ORDINARY MAINTENANCE • UNIVERSAL JOINTS Lubricate every 200 hours when used under heavy conditions. FRONT AXLE Universal joints between gear box and differentials : Front universal joint Rear universal joint Grease points shown in picture: splines crosses • FUEL TANK Carry out the following operations to discharge any water or sediment from the fuel tank:…
• Page 101
  6 — ORDINARY MAINTENANCE • HYDRAULIC OIL FILTER ON RETURN LINE Hydraulic oil return filter «A» is located in the CARTER 6 To carry out the replacement procedure, please follow the instructions below: unscrew the 4 screws «V» which fasten the filter cap remove the cap assembly and its gasket «G»…
• Page 102
  Inspect the inside of the filter and make sure that the net is in good conditions and contains no cloggings. Otherwise, request a spare net to the Merlo Technical Support Service and replace the old net. Mount back the filter by connecting the conduits and inserting the fastening bands «B».
• Page 103
  6 — ORDINARY MAINTENANCE EVERY 1000 HOURS OR EVERY 12 MONTHS • ARTICULATED JOINTS Check the existing 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 which do not have a greaser. A) Wheel reducers — B) Front bridge — C) Rear bridge — D) Boom — E) Carriage — F) Fork jack G) Lifting jack — H) Compensation jack WARNING!
• Page 104
  6 — ORDINARY MAINTENANCE • BOOM SLIDING PADS (EXTERNAL) Fully extract the telescopic boom Carefully clean the boom sliding surface, taking away the residual grease With the help of a cotton wad, evenly spread a thin layer of grease (see chapter «FUELS AND LUBRICANTS) on the entire boom sliding surface Carry out a few boom extraction and retraction cycles, so as to evenly distribute the product.
• Page 105
  6 — ORDINARY MAINTENANCE EVERY 1500 HOURS • HYDROSTATIC TRANSMISSION OIL To properly carry out the hydrostatic transmission oil replacement, follow the instructions below: Radiator Tank Hydrostatic pump Fuel electro-pump Hydrostatic transmission filter Hand pump The overall system capacity is 12 l. WARNING! Only use the hydrostatic oil shown in the OIL TABLE of chapter STICKERS WITH…
• Page 106
  6 — ORDINARY MAINTENANCE After filling the system, bleed air from it by following the instructions below: turn starting key (8) to «ON» position for max. 10 seconds. wait 2 minutes to bleed air completely from the system. repeat the machine start procedure for two times reconnect electrical contacts (F) and start the engine, letting it idle for about 5 minutes with the vehicle standing still.
• Page 107
  6 — ORDINARY MAINTENANCE • FRONT AND REAR DIFFERENTIALS OIL To properly carry out the differential oil replacement, follow the instructions below: Stop the machine diesel engine Operate on one differential at a time Remove filling cap «A» Remove discharge cap «B» and collect the differential oil into an appropriate container Close back discharge cap «B»…
• Page 108
  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 sticking to any rigorous schedule. WARNING! Before carrying out the following, please, carefully read the instructions in the chapter ORDINARY MAINTENANCE.
• Page 109
  To use the machine in maximum safety conditions, always use the supplied pressurised cap. If this is lost or damaged, contact Merlo Technical Support Service and request it as a spare part. remove clamp «C» and disconnect duct «D» from the radiator remove drain plug «E»…
• Page 110
  6 — ORDINARY MAINTENANCE The system total capacity is 6,2 litres. CLEANING OF THE RADITOR CORE Should you need, clean the radiating mass using a jet of water at a maximum pressure of 30 bar or using compressed air and directing the jet in the directio of arrow «3»…
• Page 111
  6 — ORDINARY MAINTENANCE • BRAKE PEDAL ADJUSTMENT It is necessary to adjust slack if the brake pedal is moving excessively; in order to solve the problem, carry out the following operations: loosen nut «A». either screw or unscrew dowel screw «B» depending on the kind of adjustment you want to perform, so that a maximum allowance of 1 mm can be obtained lock nut «A»…
• Page 112
  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 Support Service.
• Page 113
  6 — ORDINARY MAINTENANCE • HOW TO START ENGINE WHEN BATTERY IS DOWN CAUTION! Before working on the battery, carefully read the instructions found in paragraph «BATTERY» and in chapter «ELECTRIC SYSTEM». Check polarity before connecting the cables. Avoid contact between the two cables. Should you start the engine with the battery down, act as follows: 1) Take an emergency battery having the same characteristics and two cables.
• Page 115
  7 — SECURITY PERIODICAL INSPECTIONS INDEX PERIODICAL INSPECTIONS REGISTRATION CARD ……………………2 AUDIBLE-VISUAL ALARM AND BLOCKING OF THE MOVEMENTS OF THE ROLL-OVER PROTECTION SYSTEM ….3 STEERING MODES OPERATION …………………………3 PLATES AND INSTRUCTIONS …………………………3 INSTRUCTION HANDBOOK FOR OPERATING AND MAINTENANCE ………………3 POWER STEERING PRESSURE CALIBRATION …………………….
• Page 116
  7 — SECURITY PERIODICAL INSPECTIONS PERIODICAL INSPECTIONS REGISTRATION CARD 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. In case the cell between the line and the column is not highlighted, the inspection is not necessary.
• Page 117
  7 — SECURITY PERIODICAL INSPECTIONS AUDIBLE-VISUAL ALARM AND BLOCKING OF THE MOVEMENTS OF THE ROLL-OVER PROTECTION SYSTEM ATTENTION! We recommend using a load of about 2/3 of the maximum load for the test. 1) Work on flat, solid ground 2) Align the wheels with the frame. 3) Install the forks on the machine.
• Page 118
  Check on the gauge in the cab that the pressure is between 205 and 215 Bar. WARNING ! In case the gauge indicates a pressure value different from the forecasted one, please ask for assistance from qualified Merlo Service personnel.
• Page 119
  7 — SECURITY PERIODICAL INSPECTIONS SPIRIT LEVEL CALIBRATION Check the correct calibration of the spirit level machine dashboard. Position a spirit level «A» of a minimum length of 400 mm (as illustrated). level the machine using the relative devices mounted on the machine (stabilizers, tilting or suspension type).
• Page 121
  8 — ATTACHMENTS AND OPTIONAL EXTRA INDEX GENERAL INSTRUCTIONS FOR THE USE OF THE MACHINE AS AN AGRICULTURAL TRACTOR (ONLY FOR 25.6) ………………………………… 2 LOCKING OF THE FRONT AND REAR DIFFERENTIAL ELEMENT ………………… 4 INDICATOR OF REAR WHEEL CENTERING ON THE MACHINE AXIS ………………4 SUPPORT BRACKET FOR THE TRAILER SERVICE BRAKE LEVER ………………
• Page 122
  Before using any accessory mentioned in the present chapter, it is necessary to read and fully understand the instructions on its operation. If the accessory installation or operation is not entirely clear, please contact your dealership or Merlo Technical Support Service.
• Page 123
  AXLE (kg) MACHINE TOTAL FRONT REAR FRONT REAR P25.6 6400 3200 3200 3200 3200 • TABLE FOR THE DETERMINATION OF MAXIMUM PERMISSIBLE LIMITS FOR TOWED MASSES Please refer to the table below for maximum permissible limits for towed masses, for the determination of the maximum vertical load on the rear tow hook, as well as on the available braking systems for trailers.
• Page 124
  8 — ATTACHMENTS AND OPTIONAL EXTRA LOCKING OF THE FRONT AND REAR DIFFERENTIAL ELEMENT It operates by using the button ref. A: button pressed differential lock engaged button released differential lock free the warning light lit (ref. 88) indicates that the differential lock is engaged. IMPORTANT! On hard surfaces do not operate steering with differential lock engaged.
• Page 125
  8 — ATTACHMENTS AND OPTIONAL EXTRA REAR TOW HOOK (4 TONS) Use the fixed tow hook 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 wihin a building site. In this case, the maximum towable weight must be less than 4000 kg.
• Page 126
  (about ten minutes), so as to prevent the oil in the machine hydraulic system from overheating. MERLO S.p.A. is not responsible for the use of attachments not produced by them or whose assembly on the base vehicle has not been explicitly approved.
• Page 127
  8 — ATTACHMENTS AND OPTIONAL EXTRA REAR SERVICE LINE Move lever (X) in position «A» or «B» in order to use the relative rear service line. NOTE! The maximum working pressure of the rear service line is 210 bar. WARNING! The hydraulic system of the rear service line is not equipped with valves or seals suitable to keep lifted loads (for example a dumb body).
• Page 128
  8 — ATTACHMENTS AND OPTIONAL EXTRA COLD CLIMATE OIL This oil table replaces and supersedes the one found in chapter «STICKERS WITH CONTROL DESCRIPTIONS — LEAFLETS IN THE CABIN». HOT CLIMATE OIL This oil table replaces and supersedes the one found in chapter «STICKERS WITH CONTROL DESCRIPTIONS — LEAFLETS IN THE CABIN».
• Page 129
  8 — ATTACHMENTS AND OPTIONAL EXTRA HYDRAULIC BRAKING SYSTEM Please follow these instruction to correctly use the hydraulic braking system when towing agricultural trailers: • connection of the trailer braking system Insert the start key (8) into the panel Start the diesel engine Connect the trailer to the tractor tow hook Connect the electric socket (see related paragraph in this chapter) Connect the hydraulic brake outlet coming from the trailer to socket «A»…
• Page 130
  8 — ATTACHMENTS AND OPTIONAL EXTRA JOYSTICK (4 FUNCTION) Your machine is equipped with a single-lever joystick (1) that allows you to control the 4 main movements of the machine during operation: 1) RAISING / LOWERING OF THE TELESCOPIC BOOM 2) UPWARD / DOWNWARD ROTATION OF THE FORKS 3) EXTENSION / RETRACTION OF THE TELESCOPIC BOOM 4) OPERATION OF ATTACHMENTS FITTED ON THE CARRIAGE…
• Page 131
  8 — ATTACHMENTS AND OPTIONAL EXTRA JOYSTICK (5 FUNCTION) Your machine is equipped with a single-lever joystick (1) that allows you to control the 5 main movements of the machine during operation: 1) RAISING / LOWERING OF THE TELESCOPIC BOOM 2) UPWARD / DOWNWARD ROTATION OF THE FORKS 3) EXTENSION / RETRACTION OF THE TELESCOPIC BOOM 4) OPERATION OF ATTACHMENTS FITTED ON THE CARRIAGE (AUX)
• Page 132
  8 — ATTACHMENTS AND OPTIONAL EXTRA JOYSTICK (5 FUNCTION) WITH SELECTION OF THE DRIVE DIRECTION Your machine is equipped with a single-lever joystick (1) that allows you to control the 5 main movements of the telescopic boom and to select the drive direction (forward/reverse) of the machine.
• Page 133
  8 — ATTACHMENTS AND OPTIONAL EXTRA — SELECTION OF THE DRIVE DIRECTION (FORWARD / NEUTRAL / REVERSE) The joystick (1) mounts buttons for selection of the drive direction (forward / neutral /reverse). • Button F: forward drive selection When forward drive is selected, the indicator light (LF) located next to the steering column is steadily illuminated. •…
• Page 134
  8 — ATTACHMENTS AND OPTIONAL EXTRA EXTRA-COMFORT PNEUMATIC SEAT GRAMMER The pneumatic seat Grammer is installed in place of the standard one. Therefore, the following instructions replace those found in chapter «CABIN» 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 135
  8 — ATTACHMENTS AND OPTIONAL EXTRA PNEUMATIC 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 outwards the hand lever «M».
• Page 136
  8 — ATTACHMENTS AND OPTIONAL EXTRA CONDITIONER To properly cool the temperature of the driver’s cabin, follow these instructions. Open all the cabin air vents After a long stop under the sun, let air into the driver’s cabin by leaving all windows open for a few minutes and bringing ventilation control (36) on the second speed (for further information, refer to paragraph «HEATING»…
• Page 137
  9 — HYDRAULIC CIRCUITS’ DIAGRAMS INDEX HYDROSTATIC TRANSMISSION CIRCUIT ……………………… 2 HYDRAULIC SYSTEM…………………………….4 END OF CHAPTER …………………………….5 9 — 1…
• Page 138
  9 — HYDRAULIC CIRCUITS’ DIAGRAMS HYDROSTATIC TRANSMISSION CIRCUIT 9 — 2…
• Page 139
  9 — HYDRAULIC CIRCUITS’ DIAGRAMS REFERENCE DESCRIPTION Diesel engine Tank for hydrostatic oil Hydrostatic pump, variable delivery type Heat exchanger Hydrostatic motor, variable displacement Filter carrying block Bypass Rams for differential-lock (OPTIONAL) Servo/brake (OPTIONAL) Cartridge filter Themal contact Pressure tube Parking brake caliper Emergency pump Solenoid valve block…
• Page 140
  9 — HYDRAULIC CIRCUITS’ DIAGRAMS HYDRAULIC SYSTEM 9 — 4…
• Page 141
  9 — HYDRAULIC CIRCUITS’ DIAGRAMS REFERENCE DESCRIPTION Intake filter Return filter Pump Diesel engine Volume recovery valve Priority valve Hydraulic power steering Steering control valve Steering cylinders Pressure gauge Main control valve Lock valve for the boom extension cylinder Lift cylinder Boom extension cylinder Forks/compensation valve Compensation cylinder…
• Page 143
  10 — ELECTRICAL SYSTEM INDEX GENERAL FEATURES …………………………….. 2 BATTERY ………………………………… 2 FUSES ………………………………..4 END OF CHAPTER …………………………….5 10 — 1…
• Page 144
  10 — ELECTRICAL SYSTEM GENERAL FEATURES Your telescopic handler is equipped with a 12 volt electrical equipment with the negative pole grounded. BATTERY The battery of your machine is placed inside engine compartment and it is equipped with a manual cut-off switch that keeps it charged when the machine is not set in motion for a prolonged period of time.
• Page 145
  10 — ELECTRICAL SYSTEM MANUAL BATTERY CUT-OFF SWITCH For greater safety, or when the machine is not set in motion for a prolonged period of time, it is possible to remove power from the electrical equipment of the machine via the manual battery cut-off switch. 1) Follow the instructions below to operate the battery cut-off switch: — turn battery cut-off switch «D»…
• Page 146
  10 — ELECTRICAL SYSTEM FUSES Electrical circuits are protected by fuses, situated in the panel «7» inside the cabin, and inside the engine compartment. If a fuse is blown, find what cause it to blow before replacing it with a new one having the same characteristics. In the following part of the paragraph the several fuses of the standard machine are described.
• Page 147
  10 — ELECTRICAL SYSTEM Fan in the cab Cab-mounted rear work lights Cab-mounted front work lights Cigar lighter, direct power supply from the battery cut-out switch Engine stop solenoid valves Power supply to the platform with simplified controls (available as an option) 7,4A Front left and rear right parking lights Power supply to optional accessories…
• Page 149
  M2-P256-AU-01…
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  M2-P256-AU-01…
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  M2-P256-AU-01…
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  M2-P256-AU-01…
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  M2-P256-AU-01…
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  M2-P256-AU-01…
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  M2-P256-AU-01…
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  M2-P256-AU-01…
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  M2-P256-AU-01…
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  M2-P256-AU-01…
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  M2-P256-AU-01…
• Page 160
  M2-P256-AU-01…
• Page 161
  M2-P256-AU-01…
• Page 163
  MODULE ATTACHMENTS FOR MERLO ZM2 CARRIAGE…
• Page 165
  The APPROVED ATTACHMENTS for this machine are exclusively the TREEMME attachments for which MERLO has supplied the load chart for the machine / attachment combination in the CHART DOSSIER CONTAINER (2) in the cab and in MODULE 2 — CHART DOSSIER.
• Page 167
  INDEX MODULE 3 FORKS ATTACHMENTS CONTENT OF THE EC DECLARATION OF CONFORMITY ………………….5 EC DECLARATION OF CONFORMITY OF THE CABLES …………………… 5 OPERATION OF THE QUICK-COUPLING CYLINDER (P) ………………….. 7 MECHANICAL COUPLING …………………………..8 HYDRAULIC CONNECTION …………………………… 9 ELECTRICAL CONNECTION …………………………… 9 ATTACHMENT CONTROL …………………………..
• Page 168
  MODULE 3 INDEX FLY JIB [A1200B | A1210B | A1230B] ……………………….52 FLY JIB WITH WINCH [A1300B | A1310B | A1330B | A1215B] ………………..55 CARRIAGE-MOUNTED WINCH LIFT/SW [A2765] ……………………58…

• Page 169: Forks

  FORKS SECTION 1 MODULE 3 VISUALLY verify that the locking devices (B) of the forks [Figure 4] are properly lowered to prevent the possible accidental release of the WARNING! fork: otherwise, act on the locking device (B) from the outside and move it manually to the RISK OF ACCIDENTS! locking position.

• Page 170: D E — I N S T A L L A T I On

  MODULE 3 SECTION 1 FORKS Lift the locking device (B) of each fork [Figure 6] in the vertical position. WARNING! RISK OF ACCIDENTS! DO NOT request the help of another operator for the unhooking or release of the forks. Drive the machine into the unhooking point of the forks, with the boom fully retracted and lowered and the carriage upright.

• Page 171: F O R K S L I St

  FORKS SECTION 1 MODULE 3 REF. A0300 A0301 A0303 A0304 SERIAL No. 050939 050941 050940 050942 WEIGHT CAPACITY 1750 3860 2250 4970 1750 3860 2250 4970 1200 1200 1200 1200 1327 1331 1327 1331 1750 x 500 2250 x 500 1750 x 500 2250 x 500…

• Page 173: Attachments

  Via Passatore, 2/a — 12010 S. Defendente di Cervasca (CN) — IT declares that the TREEMME interchangeable attachment: Type Trade name A—- Serial number to be installed on the following machines if indicated in their guidelines: MERLO VARIABLE-REACH TRUCK MERLO ROUGH-TERRAIN VARIABLE-REACH Type TRUCK MERLO ROUGH-TERRAIN SLEWING VARIABLE-REACH TRUCK Model interface MERLO ZM— complies with all the applicable provisions of Directive 2006/42/CE.

• Page 174: A T T A C H M E N T I D E N T I F I C A T I On

  MODULE 3 SECTION 2 ATTACHMENTS EVERY 50 OPERATING HOURS Remove the attachment Switch off the engine of the machine. Grease the pins fitted with grease nipples. WARNING! RISK OF ACCIDENTS! Before every usage: Before lifting an attachment, make sure that the lifting attachments used are in good working Clean the attachment.

• Page 175: I N S T A L L A T I On

  ATTACHMENTS SECTION 2 MODULE 3 (If installed) Press and hold button (315) (refer to al MODULE 1  SECTION 3  POSITION OF CAB COMMANDSP1 AND P2 PANEL COMMANDS). WARNING! Use the joystick command (1) to send the flow of RISK OF ACCIDENTS! oil to the hydraulic connector [A] (refer to During the installation of an attachment, make…

• Page 176: Mechanical Coupling

  MODULE 3 SECTION 2 ATTACHMENTS Retract the quick coupling piston (P) as described in the previous paragraph. WARNING   Turn carriage upwards until attachment rests on the carriage. GENERAL INFORMATION. The following images are given as an example in order to illustrate the installation operations for a generic TREEMME attachment with a quick- coupling device.

• Page 177: Hydraulic Connection

  ATTACHMENTS SECTION 2 MODULE 3 See MODULE 1  SECTION 3  JOYSTICK. Any other hydraulic movements will be described in the user instructions for the specific attachment. To allow hydraulic movements of the attachment: Connect the hydraulic pipeline (C) (indicated by the specific clamp) from the Attachments to the hydraulic connector [A].

• Page 178: D E — I N S T A L L A T I On

  MODULE 3 SECTION 2 ATTACHMENTS WARNING! WARNING! RISK OF ACCIDENTAL MOVEMENTS! Before releasing the parking brake pedal (15), RISK OF ACCIDENTS! make sure that the parking brake (37) is engaged. During the de-installation of an attachment, make sure that there are no people within the machine’s radius of action.

• Page 179
  ATTACHMENTS SECTION 2 MODULE 3 If necessary slightly lower the boom further to free the attachment. WARNING   RELEASING THE ATTACHMENT. Release the command of the quick-coupling IT IS NOT POSSIBLE to withdraw the quick- cylinder (P) on the joystick (1). coupling cylinder (P) if the hydraulic pipeline (C) Retract the boom.

• Page 180: A T T A C H M E N T S F O R F I X E D L O A Ds

  MODULE 3 SECTION 2 ATTACHMENTS For instructions on installing the attachment, refer WARNING! to MODULE 3  SECTION 2  INSTALLING THE ATTACHMENT. RISK OF ACCIDENTS! DO NOT HANDLE suspended loads with For instructions on the use of the attachment refer attachments for fixed loads.

• Page 181
  ATTACHMENTS SECTION 2 MODULE 3 EXTRA-WIDE FORK CARRIAGE WITH STANDARD FORKS [A0100] MERLO CODE A0100 1895 1790 Weight To install the standard forks refer to MODULE 3  SECTION 1  FORKS .
• Page 182
  MODULE 3 SECTION 2 ATTACHMENTS FEM ZM2 CARRIAGE WITH FEM III FORKS [A0200 | A0201 | A0210 | A0211] MERLO CODE A0200 A0201 A0210 A0211 1500 1500 2000 2000 9.10 Weight…
• Page 183
  Lift the safety pin (A) of the forks. Manually insert the forks in the required position on the carriage. Insert the safety pin (A) in one of the grooves used to lock the fork’s position. MERLO CODE A0500 1200 1290 Weight…
• Page 184
  MODULE 3 SECTION 2 ATTACHMENTS CARRIAGE WITH FLOATING STANDARD FORKS [A0291 | A0292] MERLO CODE A0291 A0292 1200 1200 1560 1565 1200 1300 1200 1200 Weight Capacity* 4000 8820 4000 8820 * of the attachment, not of the individual fork.
• Page 185
  SECTION 2 MODULE 3 CARRIAGE WITH FLOATING FORKS FOR RUNNING ON ROAD [A0291A | A0292A] The reference sales codes have a specific suffix (for example A, B, C, etc.) not shown in the chart. MERLO CODE A0291A A0292A 1200 1200…
• Page 186
  MODULE 3 SECTION 2 ATTACHMENTS WARNING   Rotate the carriage forward until the protective grid is no longer resting on the forks. PRE-ARRANGEMENT FOR RUNNING ON THE ROAD. lower and extend the telescopic boom slightly so as to position the grid and the forks as All operations described in the following illustrated.
• Page 187
  ATTACHMENTS SECTION 2 MODULE 3 Raise the machine’s telescopic boom slightly in order to aid the subsequent assembly operations Insert the front protection for circulation on the road (5) by hooking it to the protective grid of the forks by means of the appropriate lateral spring latches (6).
• Page 188
  MODULE 3 SECTION 2 ATTACHMENTS CARRIAGE WITH SLIM FLOATING FORKS [A0293 | A0294] MERLO CODE A0293 A0294 1200 1200 1545 1550 1180 1280 1200 1200 Weight Capacity* 1500 3310 1500 3310 * of the attachment, not of the individual fork.
• Page 189
  ATTACHMENTS SECTION 2 MODULE 3 TRAVELLING LIFT ON STANDARD CARRIAGE [A0281 | A0282] MERLO CODE A0281 A0282 1355 1355 1250 1250 Weight Capacity* 4000 8820 4000 8820 * of the attachment, not of the individual fork…

• Page 190: Loaders

  MODULE 3 SECTION 2 ATTACHMENTS LOAD CHARTS. For instructions on installing the attachment, refer A specific machine’s load chart indicates the to MODULE 3  SECTION 2  INSTALLING THE machine’s maximum work area with reference ATTACHMENT. to the specific weight of the material loaded. WARNING …

• Page 191
  ATTACHMENTS SECTION 2 MODULE 3 WARNING! RISK OF ACCIDENTS! DO NOT USE the anchor point on the second extension of the machine’s boom to lift a load. Remove the loader and place it on the ground. (OPERATOR 2) Pull the two handles (M) on the support outwards and turn them downwards.
• Page 192
  MODULE 3 SECTION 2 ATTACHMENTS BUCKET LOAD CHARTS The following information is provided in addition to the information in MODULE 2. 21) Bucket loader work area filled to max available capacity with material having the specific weight indicated in column (24). 22) Bucket loader work area with load indicated in the corresponding column (23).
• Page 193
  ATTACHMENTS SECTION 2 MODULE 3 TABLE OF MATERIAL DENSITIES FOR USING BUCKET LOADERS MATERIALS WITH DENSITY 0 — 900 (kg/m CORK LIGNITE SAWDUST POWDERED MILK SNOW SOAP TOBACCO BENTONITE VEGETAL CARBON SUGAR OATS GLUE DRY PEAT BUTTER ZINC OXIDE COTTON BRAN SOLID URBAN WASTE COTTON SEEDS…
• Page 194
  MODULE 3 SECTION 2 ATTACHMENTS DIGGING BUCKET [A0699 | A0700 | A0701 | A0706] MERLO CODE A0699 A0700 A0701 A0706 1840 2000 2240 2440 1100 1100 1100 1020 1020 1020 Weight Load capacity 1000…
• Page 195
  ATTACHMENTS SECTION 2 MODULE 3 REHANDLING BUCKET [A0710 | A0712 | A0715] MERLO CODE A0710 A0715 A0712 2240 2240 2400 1330 1245 1330 1140 1060 1140 Weight Load capacity 1250 1250 1350…
• Page 196
  MODULE 3 SECTION 2 ATTACHMENTS BULK MATERIAL BUCKET [A0713 | A0714 | A0716 | A0720 | A0780 | A0782 ] MERLO CODE A0716 A0713 A0714 A0720 A0780 A0782 1840 2000 2240 2400 2400 2500 1600 1590 1600 1600 1760 1935…
• Page 197
  ATTACHMENTS SECTION 2 MODULE 3 4×1 MULTI-FUNCTION LOADER [A0800 | A0810 | A0820 | A0860 | A0870] MERLO CODE A0800 A0810 A0820 A0860 A0870 2305 1905 2305 2585 2305 1595 1020 1030 1030 1110 1675 1245 1195 Weight 1587 1389…
• Page 198
  MODULE 3 SECTION 2 ATTACHMENTS MULTIPURPOSE BUCKET WITH GRAB [A0836* | A0838* | A0840* | A0841* | A0843*] MERLO CODE A0836 A0838 A0840 A0841 A0843 1840 2400 2240 2000 2400 1165 1255 1260 1260 1440 1550 1725 1635 1635 1910…

• Page 199: Forks With Tines

  ATTACHMENTS SECTION 2 MODULE 3 For instructions on installing the attachment, refer to MODULE 3  SECTION 2  INSTALLING THE ATTACHMENT. For instructions on the use of the attachment refer to MODULE 1  SECTION 3  JOYSTICK. WARNING! RISK OF PUNCTURES! With the boom retracted DO NOT SLANT the carriage excessively downwards: the tips may…

• Page 200
  MODULE 3 SECTION 2 ATTACHMENTS MANURE FORK WITH GRAPPLE [A2300 | A2301 ] MERLO CODE A2300 A2301 2280 1945 1285 1275 1755 1755 1380 1380 Weight 1280 1142 Capacity* 1200 2645 1000 2205 * of the attachment, not of the individual tip.
• Page 201
  TINES WITH SLIDING GUARD [A2231 | A2232 | A2233 | A2234] MERLO CODE A2331 | A2332 | A2333 | A2334 1390 1035 | 1235 | 1415 | 1415 41 | 49 | 56 | 56 840 | 1040 | 1200 | 1200…
• Page 202
  MODULE 3 SECTION 2 ATTACHMENTS 2/3 FOLDABLE TINES BALE FORK WITH HYDRAULIC SLIDING PROTECTION [A2340] MERLO CODE A2340 1720 1320 ÷ 1900 52 ÷ 75 1040 1570 1190 Weight Capacity* 1500 3310 * of the attachment, not of the individual tip.
• Page 203
  ATTACHMENTS SECTION 2 MODULE 3 3 FOLDABLE TINES BALE FORK WITH GRAB (02320) MERLO CODE A2320 1195 1865 ÷ 2790 73 ÷ 110 1040 1170 2575 Weight Capacity* 1500 3310 * of the attachment, not of the individual tip. After loading the material, lower the grab to lock on the attachment.

• Page 204: Grippers

  MODULE 3 SECTION 2 ATTACHMENTS WARNING! For instructions on installing the attachment, refer RISK OF ACCIDENTS! to MODULE 3  SECTION 2  INSTALLING THE DO NOT HANDLE a load having a diameter ATTACHMENT. larger than the max. diameter (ø D) indicated in For instructions on the use of the attachment refer TECHNICAL INFORMATION…

• Page 205
  ATTACHMENTS SECTION 2 MODULE 3 DOUBLE LOG GRIPPER [A2200] MERLO CODE A2220 1215 1420 1345 1890 1710 ØE 150 ÷ 1000 6 ÷ 39 Weight 1300 Capacity* 7000 15440…
• Page 206
  MODULE 3 SECTION 2 ATTACHMENTS BALE GRIPPER [A2400 | A2401 | A2402 | A2403 | A2405 | A2406 | A2407 | A2408 | A2409 | A2411 | A2412 | A2413] MERLO A2400 A2403 A2401 A2411 A2409 A2412 CODE A2407 A2413…
• Page 207
  ATTACHMENTS SECTION 2 MODULE 3 BARREL GRIPPER [A2210] MERLO CODE A2210 600 — 700 24 ÷ 28 Weight Capacity 1325…

• Page 208: Other Attachments

  MODULE 3 SECTION 2 ATTACHMENTS MATERIAL HANDLER [A1900] MERLO CODE A1900 1200 1320 Weight Capacity 1000 2210 For instructions on installing the attachment, refer to MODULE 3  SECTION 2  INSTALLING THE ATTACHMENT. For instructions on the use of the attachment refer to MODULE 1  SECTION 3  JOYSTICK.

• Page 209
  ATTACHMENTS SECTION 2 MODULE 3 CONCRETE MIXING BUCKET [A1400 | A1410 | A1420 | A1430] MERLO CODE A1400 — A1410 A1420 — A1430 1035 1035 1470 1470 1250 1450 1300 1300 Weight Capacity 1250 2755 1750 3858 Load capacity…
• Page 210
  MODULE 3 SECTION 2 ATTACHMENTS To install the attachment on the carriage, insert For the controls of this attachment, refer to the STANDARD FORKS in the specific seats (A) for MODULE 1 SECTION 3  JOYSTICK. side installation or (B) for front installation. Bucket with manual aperture Use the lever (L) to open and close the material unloading hatch.
• Page 211
  ATTACHMENTS SECTION 2 MODULE 3 MIXING BUCKET [A1565 | A1570 | A1571 | A1580 | A1581 | A1582 | A1583] MERLO CODE A1565 A1570 | A1571 A1580 | A1581 1270 1720 67.7 2230 1500 1500 1500 1140 ÷ 1400 45 ÷ 55 1140 ÷…
• Page 212
  MODULE 3 SECTION 2 ATTACHMENTS For instructions on installing the attachment, refer Use the bucket as a loader by moving slowly to MODULE 3  SECTION 2  INSTALLING THE forward with the machine to load the material. ATTACHMENT. Tilt the bucket upwards to retain the material loaded and obtain automatic front guard For instructions on the use of the attachment refer closure.
• Page 213
  ATTACHMENTS SECTION 2 MODULE 3 Loading the bucket manually WARNING   WARNING! MAXIMUM BUCKET CAPACITY. Maximum capacity is reached with the carriage RISK OF ACCIDENTS! in a vertical position, when the material reaches DO NOT EXCEED the maximum capacity. the edge of the bucket (ref.
• Page 214
  MODULE 3 SECTION 2 ATTACHMENTS Re-connect the bracket (1) and check the lock WARNING   and function of the spring (3). RISK OF DAMAGE TO THE CHUTE. DO NOT OPERATE front guard aperture when the chute is in the transport position. Unloading chute disassembly Unloading concrete Release the bracket (1).
• Page 215
  ATTACHMENTS SECTION 2 MODULE 3 Maintenance every 10 hours Unloading chute extension To wash the inside of the bucket with the propeller Insert the bracket (A) of the extension unit into moving, keep the front guard closed. pin (B) on the unloading chute. To wash the inside of the bucket with the front guard raised, the engine must be OFF.

• Page 216: A T T A C H M E N T S F O R S U S P E N D E D L O A Ds

  MODULE 3 SECTION 2 ATTACHMENTS For instructions on installing the attachment, refer to MODULE 3  SECTION 2  INSTALLING THE ATTACHMENT. For instructions on the use of the attachment refer to MODULE 1  SECTION 3  JOYSTICK. If the machine is equipped with load limiter, refer to MODULE 1 …

• Page 217: Carriage-Mounted Hook [A1000]

  ATTACHMENTS SECTION 2 MODULE 3 MERLO CODE A1000 Weight Capacity 4500 9900 PRECAUTION WARNING! RISK OF ACCIDENTS! RISK OF ACCIDENTS! Always operate with the attachment levelled. Before using the attachment, refer the load chart to identify the maximum capacity of the…

• Page 218: Lifting Boom [A1118B]

  MODULE 3 SECTION 2 ATTACHMENTS MERLO CODE A1118B 1485 1335 1030 Weight Capacity 2200 4850 PRECAUTION RISK OF ACCIDENTS! Always operate with the attachment levelled.

• Page 219: Telescopic Lifting Boom [A1123B]

  ATTACHMENTS SECTION 2 MODULE 3 TELESCOPIC LIFTING BOOM [A1123B] MERLO CODE A1123B 1580 1445 1160 Weight Capacity 1500 3310 PRECAUTION RISK OF ACCIDENTS! Always operate with the attachment levelled.

• Page 220
  MODULE 3 SECTION 2 ATTACHMENTS MERLO CODE A1200B A1210B A1230B 3470 2115 3470 3225 1910 3225 Weight Capacity 1320 1500 3310 PRECAUTION RISK OF ACCIDENTS! DO NOT USE the attachment with the carriage rotated downwards.
• Page 221
  ATTACHMENTS SECTION 2 MODULE 3 TRANSPORTING ATTACHMENT CIRCULATION ON PUBLIC ROADS WARNING   POSITIONING THE FLY JIB. Positioning the fly jib in the housing on the RH side of the machine requires two operators and additional lifting attachment. With the assistance of a second operator, Pull the pin (T) and turn the front support (A) position the fly jib on the bar (A) of the rear outwards [figure 1].
• Page 222
  MODULE 3 SECTION 2 ATTACHMENTS Turn the fly jib inwards and position the specific retainer (B) on the front support (T). Insert the screw (R) and lock the position with the cotter (S) [figure 5]. To open the engine compartment with the fly jib positioned [figure 6], remove the front fasteners [figure 5], pull the pin (P) [figure 1] and rotate the fly jib outwards.
• Page 223
  ATTACHMENTS SECTION 2 MODULE 3 MERLO CODE A1300B A1310B A1330B A1215B 3645 2230 3645 1660 1000 1000 3535 1975 3535 1550 Ø cable Weight Capacity 1320 1500 3310 2000 4400 Max hook travel 98’5’’ 98’5’’ 98’5’’ 98’5’’ m/min ft/min m/min…
• Page 224
  MODULE 3 SECTION 2 ATTACHMENTS TRANSPORTING ATTACHMENT WARNING   CIRCULATION ON PUBLIC ROADS UNINSTALLING THE ATTACHMENT. Refer to the information provided for the fly jib. Before uninstalling the attachment, place the hook in the rest position. PRELIMINARY OPERATIONS A1310 | A1320 Remove the hook from the rest position and carefully place it in the work position.
• Page 225
  ATTACHMENTS SECTION 2 MODULE 3 MAINTENANCE EVERY 50 HOURS Block pulley Grease the pin indicated. Hoist: grease nipples 1 and 2. Cable drive pulley: Grease the pin indicated. Limit switch: Grease the screw.
• Page 226
  MODULE 3 SECTION 2 ATTACHMENTS MERLO CODE A2765 1105 Ø cable Weight Capacity 4000 8800 Cable length 187’ Hook travel 98’5’’ m/min ft/min Hook speed N° cable winches…
• Page 227
  ATTACHMENTS SECTION 2 MODULE 3 TRANSPORTING ATTACHMENT WARNING   CIRCULATION ON PUBLIC ROADS (only ROTO models) UNINSTALLING THE ATTACHMENT. Before removing the attachment, place the WARNING   block (B) in the rest position and lock it with the specific yoke (A).
• Page 228
  MODULE 3 SECTION 2 ATTACHMENTS Handle the machine’s boom in order to MAINTENANCE suspend the lifting accessory with the free end Every 50 hours of operation grease: at the specific lifting point of the attachment (refer to MODULE 3 SECTION 2  LIFTING. A) The block pin.
• Page 229
  WARNING! RISK OF ACCIDENTS! DO NOT LIFT people if the machine is not pre-set and equipped with an overhead work platform approved by Merlo. Check: G) Reducer oil level. The level indicator must be completely submerged. H) Cable guide block wear.
• Page 230
  MODULE 3 SECTION 2 ATTACHMENTS…
• Page 231
  ATTACHMENTS FOR MERLO ZM2 CARRIAGE…

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