Maintenance and Care

Maintenance - and 

Operation Manual 

Menzi Muck A81 version D 

Edition June 2011 – english 

Original manual

Technical modifications 

The edition of this manual refer to the date on the front page. 

Innovative improvements require technical changes on the Menzi Muck. Mutations, which are not yet integrated in 

this manual, you will find in the appendix with amendment date. 

Menzi Muck AG Maschinenfabrik Telefon +41 (0)71 727 12 12 

CH-9443 Widnau/Switzerland Fax +41 (0)71 727 12 13 

www.menzimuck.com 

info@menzimuck.com 

Page 2 www.menzimuck.com

Index 

1. General 10 

1.1 Explanation of symbols 10 

1.2 Information on the operator's manual 11 

1.3 Limitation of liability 11 

1.4 Copyright 11 

1.5 Spare parts 12 

1.6 Disposal 12 

1.7 Type plate 12 

1.8 EC-Declaration 13 

2. Safety 14 

2.1. General 14 

2.1.1 Basic requirement for safe operation 14 

2.1.2 Machine operator 14 

2.1.3 Read and understand the warning instructions 14 

2.1.4 Health 14 

2.1.5 Work clothes 14 

2.1.6 Sufficient ventilation 15 

2.1.7 Safe handling of fuel 15 

2.1.8 Emergency preparedness 15 

2.1.9 Safe handling of starter fluids 15 

2.1.10 Noise protection 15 

2.1.11 ROPS / FOPS 15 

2.1.12 Compliant disposal of waste 15 

2.2 Warning symbols 16 

2.2.1 Positions of the warning symbols 16 

2.2.2 Meaning of the warning symbols 17 

2.3 Users and their responsibilities 18 

Operation Manual Menzi Muck A81 Page 3

Index 

3. Technical Data 20 

3.1 Dimensions 20 

3.2 Weights 21 

3.3 Engine 21 

3.4 Hydraulic system 21 

3.5 Drive 22 

3.6 Set of tyres 22 

3.7 Noise emissions 22 

3.8 Forces 22 

3.9 Accessories 24 

3.9.1 Buckets 24 

3.9.2 Hydr. quick changer 24 

3.9.3 Powertilt 24 

3.9.4 Tiltrotator 24 

3.9.5 Hydr. Grappler 24 

3.9.6 Hydr. hammer 24 

4. Structure 26 

4.1 Menzi Muck A81 Mobil 26 

4.2 Menzi Muck A81 with steered hub drive 27 


Index 

5. Transport, packaging and storage 28 

5.1 Safety notes 28 

5.2 Transport by truck 28 

5.2.1 Safety notes for transport by truck 28 

5.2.2 Loading and unloading 31 

5.2.3 Release the residual pressure 34 

5.2.4 Clamp the machine 34 

5.3 Lift the machine 35 

5.3.1 Safety instructions on lifting the machine 35 

5.3.2 Transport by helicopter, crane or skyline crane 37 

5.3.3 Component mass 38 

5.4 Transport inspection 41 

5.5 Packaging 41 

5.5.1 About the packaging 41 

5.5.2 Handling packaging material 41 

5.6 Storage 41 

6. Control and Display elements 42 

6.1 Operator's workplace 42 

6.2 Main switch 42 

6.3 Display 43 

6.3.1 Ignition Lock 43 

6.3.2 Emergency shut down switch 44 

6.3.3 Speed adjustment 44 

6.3.4 Potentiometer speed 44 

6.3.5 Ventilation step switch 45 

6.3.6 Heating valve control 45 

6.3.7 Cigarette lighter 45 

6.3.8 Switch functions 46 

6.3.9 Display 48 

6.4 Joystick 54 

6.4.1 A81 Mobil 54 

6.4.2 A81 Mobil steered hubdrive 56 

6.4.3 Basic functions OK control 58 


Index 

6.5 Pedals 59 

6.5.1 Pedal assignment 59 

6.5.2 Pedal telescope "Menzi Muck" 59 

6.5.3 Pedal winch 59 

6.5.4 Pedal driving 60 

6.5.5 Large auxiliary pedal 60 

6.6 Adjusting the controls 61 

6.6.1 Adjust workplace 61 

6.6.2 Operator’s seat 62 

6.6.3 Seat belt 64 

6.6.4 Joystick 64 

6.6.5 Foot pedal adjustment 65 

6.6.6 Brightness / contrast 65 

6.6.7 Date and time 66 

6.6.8 Air vents 66 

6.7 Cab windows and door 67 

6.7.1 Upper front window 67 

6.7.2 Lower front window 67 

6.7.3 Side window 67 

6.7.4 Open and close doors 68 

6.8 Covers 69 

6.8.1 Rear cover 69 

6.8.2 Right side cover 69 

6.8.3 Left side cover 69 

6.9 Refuelling system 70 

6.9.1 Filling working diesel tank 70 

6.9.2 Filling chassis tank 71 

6.9.3 Transferring fuel to chassis tank 72 

6.10 Tilt cab 73 


Index 

7. Working with the machine 78 

7.1 Safety instructions 78 

7.1.1 Getting in and out 78 

7.1.2 Before starting the engine 78 

7.1.3 Starting the engine 79 

7.1.4 Checks before startup 80 

7.1.5 Operation of the machine 81 

7.1.6 Safe driving / movement of the machine 89 

7.1.7 Towing 91 

7.1.8 Shutting off the machine 92 

7.1.9 Warning symbols 93 

7.2 Intended use as prescribed by the manufacturer 94 

7.2.1 Work above ground 94 

7.2.2 Work in general 94 

7.2.3 Work on slopes 94 

7.2.4 Work on paved surfaces 94 

7.2.5 Work on unpaved surfaces 95 

7.2.6 Work in water 95 

7.2.7 Work with attachments 95 

7.3 Commissioning 96 

7.3.1 Preliminary check 96 

7.3.2 Daily checks 97 

7.3.3 Startup and commissioning 99 

7.4 Operating upperstructure 101 

7.4.1 Powermode 101 

7.4.1 Hoisting operation 102 

7.5 Command of chassis 104 

7.5.1 A81 Mobil / A81 Mobil steered wheel hub 104 

7.6 Driving 106 

7.6.1 A81 Mobil / A81 Mobil steered hub drive 106 

7.6.2 Driving 107 

7.6.3 Braking 108 

7.6.4 Steering 109 

7.6.5 Tow / Hide 110 

7.6.6 Mechanically decouple and couple the traction drive 111 

7.6.7 Driving positions (Swiss road traffic license) 112 

7.7 Operating the hydraulic auxiliary connections 113 

7.8 Operating the accessories 114 

7.8.1 Attaching buckets 114 

7.8.2 Tiltrotator Engcon 115 

7.8.3 Winch 116 


Index 

8. Maintenance and Care 118 

8.1 Safety instructions 118 

8.1.1 Carry out maintenance regularly 118 

8.1.2 Warning during service work 118 

8.1.3 Work equipment 119 

8.1.4 Protective guards 119 

8.1.5 Fluids and lubricants 120 

8.1.6 Actuated controls 121 

8.1.7 Machine condition 121 

8.2 Machine position for maintenance work 123 

8.3 Maintenance intervals 124 

8.4 Lubricant table 126 

8.5 Engine and air-conditioning 127 

8.5.1 Inspection cooling water 127 

8.5.2 Cleaning the radiator 128 

8.5.3 Servicing the air filter 128 

8.5.4 Engine oil and filter replacement 130 

8.5.5 Fuel filter replacement 132 

8.5.6 Cleaning the crankcase bleed pipe 133 

8.5.7 Checking and adjusting valve play 133 

8.6 Heating/Air conditioning 134 

8.6.1 Coolant 134 

8.6.2 Filling 134 

8.6.3 Cooling oil 134 

8.6.4 Repairs to the coolant circuit 134 

8.7 Gears 135 

8.7.1 Wheel hub 135 

8.7.2 Swing gear 136 

8.8 Hydraulic system 137 

8.8.1 Check hydraulic oil level 137 

8.8.2 Change / Refill hydraulic oil 138 

8.8.3 Check hydraulic oil tank cover 140 

8.8.4 Changing hydr. filter 141 

8.8.5 Installation instructions for pipe and hose lines 144 

8.8.6 Hydraulic diagrams 145 


Index 

8.9 Electric system 148 

8.9.1 Batteries 149 

8.9.2 Fuses 150 

8.9.3 Relays 152 

8.9.4 Electrical anti-rotation device 152 

8.9.5 Control module menu 153 

8.9.6 Status menu of the GLR 153 

8.9.7 Joystick diagnostic menu 155 

8.9.8 Output module diagnostic menu 155 

8.9.9 Service menu 158 

8.9.10 Service code 158 

8.9.11 Electric diagram 159 

8.10 Lubrication schedule 172 

8.10.1 Upperstructure 172 

8.10.2 Chassis 174 

8.10.3 Central lubrification 175 

8.11 General maintenance work 176 

8.11.1 Adjust telescope 176 

8.11.2 Refill windscreen fluid 177 

8.12 Tightening torque table 178 

8.13 Proof of service 179 

9. Faults and fault rectification 181 

9.1 Trouble shooting on the engine 181 

9.2 General trouble shooting on the machine 184 

10. Notes for spare part orders 187 

11. Warranty provisions 188 

12. Appendix 189 


General 

1. General 

1.1 Explanation of symbols 

Warning instructions are marked in this operator's manual by symbols. The instructions are introduced by signal 

words that indicate the level of danger. Always observe the instructions and handle them carefully to prevent accidents, 

injuries to persons and damage to property. 

Danger ! 

This symbol indicates an immediately dangerous situation that 

results in death or severe injuries if it is not avoided! 

Warning ! 

This symbol indicates a possibly dangerous situation that might 

result in death or severe injuries if it is not avoided. 

Caution ! 


result in slight or mild injuries if it is not avoided. 

Attention ! 


result in damage to property if it is not avoided. 

Note ! 

This symbol highlights useful tops and recommendations as well 

as information for efficient and troublefree operation. 


General 

1.2 Information on the operator's manual 

This operator's manual describes the safe and correct handling of the machine. Observe the stipulated 

safety instructions as well as the valid local accident-prevention regulations and general safety regulations 

that apply at the location the equipment is used. 

Before carrying out any work on or at the machine, read the operator's manual, especially the Safety 

chapter and the respective safety instructions. You must have fully read and understood everything 

you read there. These are basic instructions and suggestions pertaining to accident prevention. Faults 

during operation, inspection and maintenance may result in injuries or death. 

1.3 Limitation of liability 

All details and instructions listed in this operator's manual have been written up taking the valid standards and regulations 

into consideration, as well as the state-of-the-art and our many years of knowledge and experience. 

We have tried to provide as exhaustive information as possible on accident-prevention during operation but we 

cannot be held responsible for any missing information regarding dangers and danger sources. 

The manufacturer does not accept any liability for damages due to: 

Nonobservance of the manual 

• Non-intended of the machine 

• Improper assembly, commissioning, operation or maintenance of the machine 

• Use of the machine when safety equipment is defective or improperly installed or if safety or 

• protective devices are not in proper functioning condition 

• Non-compliance with the operating instructions regarding transportation, storage, assembly, 

• installation, commissioning, use, maintenance and equipping of the machine 

• Unauthorised modifications to the construction of the machine 

• Unauthorised modifications to the machine (for example hydraulic pressure and volume flow) 

• Insufficient monitoring of machine parts that are subject to wear and tear 

• Improperly performed repairs 

• Catastrophic damage caused by the influence of foreign objects or force majeure 

1.4 Copyright 

Treat this operator's manual confidentially. It is solely intended for persons working on and at the machine. It is forbidden 

to pass this operator's manual on to third parties without the written approval of the manufacturer. 

Note ! 

Data protection 

The content, texts, drawings, pictures and other representations 

made in this manual are copyright protected. It is forbidden to 

convey this information to third parties without the written approval 

of the manufacturer. 


General 

1.5 Spare parts 

Warning ! 

Risk of injury from incorrect spare parts 

• Incorrect or missing spare parts may result in damages, incorrect 

function or total failure of the equipment as well as 

also impairing safety. The same applies to inappropriate or 

incorrectly installed spare parts. 

• Only use original spare parts of the manufacturer. 

1.6 Disposal 

If return or disposal agreements have not been made then recycle the dismantled components 

after correctly disassembling them. 

The following materials must be disposed of separately and according to the valid regulations 

for recycling or scrapping: 

• Hydraulic and lubricating oils 

• Parts made of rubber and plastic 

• Parts made of steel, aluminium and cast iron 

1.7 Type plate 

The type plate is underneath the right side casing at the front. 

It contains the following: 

Producer's address, type of machine, chassis-No. and engine-No., year of construction 

and engine rating, total weight (without bucket) and max. permissible weight, axle load front and rear. 


General 

1.8 EC-Declaration 

1. Manufacturer: MENZI MUCK AG 

Maschinenfabrik 

Auenstrasse 7 

9443 Widnau 

Schweiz 

2. Storage of technical 

documentation: 

MENZI MUCK AG 

Maschinenfabrik 

Stefan Tagmann 

Technical departement 

Auenstrasse 7 

9443 Widnau Switzerland 

3. Description of the machine: Mobile allterrain excavator type Menzi Muck A81 

Chassis No. ........................................ 

Output P=89 [kW] @ 2000 [min -1 ] 

4. Conformity assessment: Corresponsds to 2006/42EG, annex IIA 

5. Representative sound level: 97.2 [dB(A)] 

6. Guaranteed sound level: 99.0 [dB(A)] 

7. The company Menzi Muck AG declares that the above-mentioned machine meets all in 

item 8 discribed guidelines and standards. Through subsequent changes, which does not 

correspond in consultation with the manufacturer, this declaration looses its validity. 

8. Applied guidelines and 

standards: 

Widnau, 26. may 2010 

René Bürgler 

Director 

EC-Declaration 

2006/42/EG EN ISO 13850 

EN ISO 12100-1 EN ISO 12100-2 

En 474-1 EN 474-5 


Safety 

2. Safety 

2.1. General 

This section provides an overview of the most important safety aspects for optimum protection of personnel as 

well as for safe and troublefree operation. 

Please note that the safety instructions listed here are not exhaustive and do not cover all possible dangers that 

might occur during operation. 

2.1.1 Basic requirement for safe operation 

The knowledge, ability and experience of the machine operator are of decisive importance for optimum use of the 

machine. It is therefore absolutely necessary that you acquaint yourself with all operational procedures and receive 

appropriate training. On request, Menzi Muck organises training courses in which the driver is acquainted with 

the most important requirements of the excavator. 

2.1.2 Machine operator 

The machine may only be operated by a qualified person who is up to the task both physically and mentally. The 

machine operator must be acquainted with the sources of danger and the safety measures required for safe operation. 

2.1.3 Read and understand the warning instructions 

This manual as well as the plates and stickers on the machine contain important instructions 

for safe operation. This information must be read and understood. Nonobservance may result 

in injuries or death! You must not simply ignore points that you do not understand. If you have 

any questions then your Menzi Muck distributor will be pleased to provide information. If the 

manual or a plate or a sticker is lost or damaged then you must get a replacement from your 

Menzi Muck distributor. 

2.1.4 Health 

The machine operator must be fit for the work both physically and mentally; this is one of the best protections 

against accidents. 

Warning ! 

Consuming intoxicants! 

• Can result in death or severe injuries. 

• Never operate the machine under the influence of alcohol, 

medicine or other intoxicants. 

2.1.5 Work clothes 

Only wear tight-fitting clothing. Do not wear any loose jackets and shirtsleeves or rings 

and other jewellery that can easily get caught in moving parts. Clothing that is soiled with 

oil or is torn must also be avoided. Clean shoes of grease and dirt before commencing 

work. Always wear the stipulated protective clothing such as helmet, goggles, reflective 

clothing, safety boots and ear protection. 


Safety 

2.1.6 Sufficient ventilation 

When operating in a pit, a tunnel or a trench make sure that the exhaust gases are fed to 

the outside Normally, the air is very calm in such places. Inhaling exhaust gases is extremely 

dangerous. 

Don't forget - exhaust gases can be deadly. 

2.1.7 Safe handling of fuel 

Exercise care in handling fuel: it is highly flammable. Never smoke while fuelling the machine 

and make sure that no open flame or sources of sparks are nearby. Shut down the 

motor while fuelling the machine. Only fuel outdoors. Prevent fires by making sure the 

machine is kept free of dirt and greasy residue. Always clean up spilled fuel. 

2.1.8 Emergency preparedness 

Be prepared for potential fires. Keep a first aid kit and fire extinguisher within reach at all 

times. Keep the emergency numbers for doctors, ambulance, hospital, and fire department 

available at the telephone at all times. 

2.1.9 Safe handling of starter fluids 

Starter fluids are highly flammable. When using starter fluid, keep away from sparks and 

flames. Keep starter fluid away from batteries and cables. To prevent accidental discharge 

during storage of pressurised containers, do not touch the seal cap and store the container 

in a cool, safe place. Do not burn or puncture starter fluid containers. 

2.1.10 Noise protection 

A long-lasting, high noise level can result in hearing damage or deafness. When exposed 

to loud noises, wear proper heading protection (for example, earmuffs or earplugs). 

2.1.11 ROPS / FOPS 

Never modify the ROPS / FOPS protective equipment under any circumstances. Modifications 

such as welding, drilling or cutting may weaken the structure and reduce the 

protective effect. Damaged ROPS / FOPS protective equipment can not be repaired - it 

must be replaced. 

2.1.12 Compliant disposal of waste 

If disposal does not take place according to regulations, the environment and ecological 

systems can be harmed. Drain fluids into leak-proof and sealed containers. Do not use 

food or beverage containers from which someone could mistakenly drink. Never pour 

waste on the floor, down the drain or into a body of water. Information about the correct 

recycling or disposal method is available from the locally responsible environmental protection 

office or from the dealer. 


Safety 

2.2 Warning symbols 

This segment informs you where the warning symbols are located and what they mean. You must always keep 

the warning symbols in perfect condition. Clean the warning signs when they are dirty. Replace the warning signs 

when they are broken or damaged. 

2.2.1 Positions of the warning symbols 

6 

10 

Page 16 www.menzimuck.com 

5 

1 

11 

5 

8 

9 

7 

2 

3 

4

Safety 

2.2.2 Meaning of the warning symbols 

1 • Warning 

• Read the operator's 

manual before commissioning 

and starting the 

machine. 

2 • Warning 

• Before maintenance or 

repairs, read the maintenance 

or repair instructions 

and remove 

the ignition key. 

3 • Warns of the danger 

from rotating parts such 

as fans, etc. 

• Switch off the machine 

before inspections, 

maintenance and repairs. 


from moving parts. 

• Only touch machine 

parts after they have 

completely stopped. 


of being caught by the 

attachment tool or the 

machine. 

• Keep outside of the 

work area when operating 

the machine. 

6 • Warns of the risk of 

being struck by the machine. 

• Keep outside of the 

work area when operating 

the machine. 

7 • Warns of the danger of 

the cab tipping over during 

operation. 

• Only start the motor 

once the cab is correctly 

seated in its retainer 

and is locked in place. 

8 • Warns of the risk of 

being struck by the tilted 

cab. 

• Position the cab tilt protection 

mechanism. 

9 • Warns of the risk of burning 

caused by hot water 

or oil that sprays out 

when opening the fan 

or hydraulic tank cover 

when still hot. 

• Allow the fan or the 

hydraulic tank to cool 

down before removing 

the cover. 

10 • Warns of the risk of explosion. 

• Do not keep any aerosol 

cans in the toolbox. 

11 • Indicates the danger of 

electric shock when the 

machine is operated 

near to power lines. 

• Observe sufficient safety 

clearance! 


Safety 

2.3 Users and their responsibilities 

The demands on the user vary according to the tasks that he/she wants to perform. Therefore, we distinguish between 

the following user roles: 

Owner 

The „owner“ is the contracting party with the manufacturer, or that party’s representatives. The „owner“ is entitled 

to sign legally binding contracts. He/she procures the machine and has it used for its intended application. 

Operator 

The „operator“ is an employee trained in use of the device / machine. The „operator“ operates and looks after the 

machine. 

Operating mechanic 

The „operating mechanic“ is a professional with mechanical and / or electrical vocational training. The „operating 

mechanic“ installs the device / machine, connects it and commissions it. He/she also performs service, maintenance 

and small repairs when necessary. 

Note ! 

Assembly and startup 

Expert personnel from the manufacturer should be assigned for 

assembly and startup. Please contact the manufacturer or his representative 

for this. 


Safety 


Technical Data 

3. Technical Data 

3.1 Dimensions 

C 

D 

E 

A 

F 

G 

J 

I 


H 

Menzi Muck A81 mobil T1.8 

A Max. Excavation depth (with adjusted chassis) mm / inch 5650 / 18'6" 

B Max. Excavation depth (chassis horizontally) mm / inch 5220 / 17'1" 

C Max. Excavation height (with adjusted chassis) mm / inch 9350 / 30'8" 

D Max. Excavation height (chassis horizontally) mm / inch 6860 / 22'6" 

E Max. Discharge height (with adjusted chassis) mm / inch 6810 / 22'4" 

F Max. Discharge height (chassis horizontally) mm / inch 4780 / 15'8" 

G Max. Jib Range mm / inch 8180 / 26'10" 

H Smallest svivelling radius mm / inch 2770 / 9'1" 

I Dipper length mm / inch 1800 / 5'11" 

J Positioning range stabilizers mm / inch 2780 / 9'1" 

K Positioning range hub drive mm / inch 1790 / 5'10" 

L Transport height mm / inch 2530 / 8'3" 

a Minimum width hub drive (transport width) mm / inch 2230 / 7'4" 

b Max. positioning width hub drive mm / inch 4450 / 14'7" 

c Max. positioning width stabilizers mm / inch 6100 / 20' 

d Chassis length mm / inch 5400 / 17'8" 

Measurements depend on type of tyre and accessories. 

K 

L 

B 

c 

d 

a 

b


3.2 Weights 

Type A81 Mobil 

Weight without accessories (kg) 8500 

3.3 Engine 

Model John - Deere 4 - cylinder Diesel engine 

Type 4045HF285 

Emissions 97/68 stage 3a / CARB TIER 3 

Displacement 4500 cm3 / 275 cuinch 

Regulated output according to ISO 3046 89 kW (120 PS) @ 1850 rpm 

Battery 2 x 12V / 815CCA 

Operating voltage 24 volts 

Alternator 45 A / 100 A 

Starter 7.2 kW 

Diesel tank upperstructure approx. 135 l / 35.7 US-gall. 

Diesel tank chassis approx. 220 l / 58 US-gall. 

Engine oil approx. 15 l / 3.9 US-gall. 

3.4 Hydraulic system 

Pumps 2 x swash plate axial pistons 

Working pump 215 l/min / 56.8 US-gall./min. 

Working pressure 280 bars 

Drive pump 110 l/min / 29.1 US-gall./min. 

Working pressure 400 bars 

Working hydraulic system Social Load Sensing 

Hydraulikoelkühler Serie with temperatur regulated ventilator 

Hydrauliktank (Systemfüllung) approx. 200 l / 52.8 US-gall. 

Hydraulic oil cooler return filter, 10 Micron 

Rotation 360° endless 

Swing torque 40000 Nm gross 

Swing speed up to 10 rpm 

Stop brake swivelling Spring brake in the hydraulic engine 

Auxiliary connections 5 

Control circuit 1 (proportional) max. 160 l/min / 42.3 US-gall./min. 

Control circuit 2 (digital) max. 80 l/min / 21.1 US-gall./min. 

Control circuit 3 (digital, option) max. 40 l/min / 10.6 US-gall./min. 

Control circuit 4 (option hydr. quick changer) max. 60 bars 

Winch connection chassis (option) max. 100 l/min / 26.4 US-gall./min. 


3.5 Drive 


Speed A81 Mobil * up to 8 km/h / 5 mph 

Speed A81 Mobil 2 stage * up to 12.5 km/h / 7.8 mph 

Climbing ability * up to 40 % on reinforced roads 

Operating brake hydrostatic 

Stop brake Spring brake in drive gear 

* depending on wheel dimension 

3.6 Set of tyres 

Wheel dimension Diameter / Width in mm in inch Air pressure in bar in psi 

500/60-22.5 1200 / 500 4' / 1'8" 6.5 94.3 

600/50-22.5/16Ply 1130 / 600 3'8" / 2' 4.5 65.3 

12.5/60-15 20Ply 720 / 275 2'4" / 11" 9.0 130.6 

3.00-15 18Ply 820 / 300 2'8" / 1' 9.0 130.6 

3.7 Noise emissions 

Sound power level (LWA) 101 dB 

Sound pressure level (LPA) (LPA) 77 dB 

Plausibility declaration in accordance with EU Standard 2000/14/EG, Appendix VI 

3.8 Forces 

Boom T1.8 

Ripping force 52000 N / 11690 lbf 

Breakout force 66000 N / 14837 lbf 

Lifting force see table 



Lifting force diagram A81 T1.8 

The stresses in the diagram are maximum values which exceed 75% of the tip load. These values may not be exceeded 

when using lifting gear (crane operation). 

Stoppers, auxiliary lifting devices and shovels must be subtracted from the rated load in order to determine the net 

lifting power . 

Deviations of +/- 10% are possible. 

7 

6 

5 

4 

3 

2 

1 

0 

-1 

-2 

-3 

50kN 

60kN 

-3 -2 -1 0 1 2 3 4 5 6 7 8 

40kN 

30kN 

20kN 

Operation Manual Menzi Muck A81 Page 23 

kN 

100 

90 

80 

70 

60 

50 

40 

30 

20 

10 

0 

-10


3.9 Accessories 

3.9.1 Buckets 

Width in Type Capacity in 

(ISO/DIN 7451) 

Weight in 

mm liters US-gall. kg lb 

400 Standard bucket 170 44.9 211 465.2 




1300 Grading bucket rigid 540 142.7 360 793.7 

1500 Grading bucket rigid 680 179.6 420 925.9 

1400 Grading bucket with swivelling cylindre 590 155.9 615 1355.8 

3.9.2 Hydr. quick changer 

Type Weight in kg in lb 

Hydr. quick changer A81 160 352.7 

3.9.3 Powertilt 


Powertilt PTA9 330 727.5 

3.9.4 Tiltrotator 


Tiltrotator EC 15 > 340 > 749.6 

3.9.5 Hydr. Grappler 


Universal grappler UG 12 710 1565.3 

Universal grappler UG 15 840 1851.9 

Demolition grappler UG 12 710 1565.3 

Demolition grappler UG 15 885 1951.1 

3.9.6 Hydr. hammer 


Hydr. hammer RHB 306 BA 540 

Hydr. hammer RHB 313-V BA 975 




Structure 

4. Structure 

4.1 Menzi Muck A81 Mobil 

1. Bucket 

2. Bucket cylinder 

3. Hose pipe 

4. Telescope arm / cylinder 

5. Dipper 

6. Dipper cylinder 

7. Cab 

8. Headlight - rear 

9. Muffler / Particulate filter 

10. Fearing - rear 

11. Stabilizer cylinder - rear 

12. Revolving head 

13. Stabilizer - rear 

14. Adjustment cylinder 

15. Hub drive 

16. Hub engine 

17. Swivel base 

18. Steering wheel 

19. Pad 

20. Telescopic stabilizer / 

Shearing cylinder 

21. Stabilizer - front 

22. Stabilizer cylinder - front 

23. Fearing - right 

24. Diesel tank 

25. Boom cylinder 

26. Boom 

27. Headlight - front 

28. Operator's seat 

29. Fearing - left 

30. Center part 

31. Chassis 

32. Reserve tank 

33. Swivel cylinder 


13 

9 

10 

11 

12 

Direction of travel 

8 

14 

15 

7 

33 

6 

17 

16 

5 

18 

4 

32 

3 

26 

25 

24 

23 

22 

2 

27 

1 

Direction of work 

21 

31 

20 

28 

19 

29 

30

Structure 

4.2 Menzi Muck A81 with steered hub drive 

1. Bucket 

2. Bucket cylinder 

3. Hose pipe 

4. Telescope arm / cylinder 

5. Dipper 

6. Dipper cylinder 

7. Cab 

8. Headlight - rear 

9. Muffler / Particulate filter 

10. Fearing - rear 

11. Stabilizer cylinder - rear 

12. Revolving head 

13. Steering cylinder - rear 

14. Stabilizer - rear 

15. Axle pivot - rear 

16. Adjustment cylinder 

17. Hub drive 

18. Hub engine - rear 

19. Swivel base 

20. Steering wheel 

21. Pad 

22. Telescopic stabilizer / 

Shearing cylinder 

23. Stabilizer - front 

24. Stabilizer cylinder - front 

25. Fearing - right 

26. Diesel tank 

27. Boom cylinder 

28. Boom 

29. Headlight - front 


31. Fearing - left 

32. Center part 

33. Chassis 

34. Reserve tank 

35. Swivel cylinder 

9 

10 

11 

12 

13 

14 

16 

Direction of travel 

8 

17 

7 

6 

19 

Direction of work 


4 

3 

27 

26 

25 

20 

15 21 

37 

18 

5 

36 

29 

28 

2 

24 

30 

35 

1 

23 

31 

34 

22 

32 

33

Transport, packaging and storage 

5. Transport, packaging and storage 

5.1 Safety notes 

Warning ! 

Incorrect or faulty road traffic equipment 


• Assemble the road traffic equipment complaint to specifications 

of Menzi Muck AG completely and correctly. 

Note ! 

Transport on public roads 

• Observe the road regulations when transporting. 

• Driving the machine on public roads always requires additional 

fittings/measures (optional road traffic license) 

• For longer distances, we recommend that the machine be 

transported using a suitably large vehicle with loading bridge 

and adequate bearing capacity. 

• Only use transport vehicles that are in perfect working order 

and licensed for road traffic. 

5.2 Transport by truck 

5.2.1 Safety notes for transport by truck 

Warning ! 

Slipping or tilting when loading and unloading 


• Load the machine on as even a surface as possible. 

Warning ! 

Overload to loading ramp 

• Might break, thereby resulting in death or severe injuries. 

• Make sure that the loading ramps have suitable lengths, 

widths, bearing capacities and inclines. 



Warning ! 

Loading ramps slip off the loading bridge 


• Anchor the loading ramps on the transport vehicle to prevent 

the ramps from slipping. 

Warning ! 

Incorrectly positioned loading ramp 


• Take into consideration the different treads of the front and 

back wheels and position the ramps accordingly. 

Warning ! 

Transport vehicle rolls away 


• When loading, engage the parking brake of the transport vehicle 

and place dry wedges under the wheels. 

Warning ! 

Icy loading area 


• Free the ramps and the loading area of the truck from ice, 

snow and other slippery material. 

Warning ! 

High speed when loading 


• Never load the machine at a high loading speed onto the 

transport vehicle. 

Warning ! 

Fast movement of boom when loading 


• Adjust the moving speed of the boom to the circumstances 

when loading and unloading. 



Warning ! 

Fast rotational speed of upper structure when loading 


• Rotate the upper structure slowly when loading and unloading 

and without any jerky movements. 

Warning ! 

Sluggish movement when machine is cold 


• Allow the machine to heat up before loading and unloading 

in cold conditions. 

Attention ! 


• Can result in damage to property. 



Note ! 

After loading 

• Lower the machine and the excavator arm into the loading 

area of the transport vehicle. 

• Switch the machine off after loading and release the residual 

pressure from the hydraulic system. 

• The hydraulic brake valves of the drive are activating on releasing 

the throttle and control lever. 

• Lock the cab and remove the ignition key. 

Warning ! 

Unintended, autonomous movement of the machine during 

transport 


• after loading, place blocks under the wheels of the machine 

and then secure it onto the loading area. 



Attention ! 

Incorrect clamping of machine 


• Only clamp the machine at suitable locations. 

Warning ! 

Overshoot of permitted overall height during transport 


• Measure the overall height and correct as required. 

5.2.2 Loading and unloading 

This example illustrates how a standard model Menzi Muck is loaded. 

Warning ! 

Unintended operation due to insufficient knowledge 


• Only load without ramps when you are acquainted and proficient 

with the machine. 

Basic adjustment of the chassis 

1. Close the left and right drive 

wheel supports fully. 

2. Position the steering wheel supports 

so that the drive wheels are 

parallel to the machine. 

3. Lift the excavator chassis approx. 

15 cm from the ground. 

4. Fully retract the telescopic feet. 

15 cm 



Worksteps for loading 

1. Place the machine compliant to 

the figure on the right straight 

behind the truck at a distance of 

approx. 1m. 

2. Place the boom at a distance of at 

least 1m from the edge of the platform 

onto the loading bridge. 

3. Lower the boom until the drive 

wheels are at the same height as 

the loading bridge. 

4. Retract the boom until the machine 

moves forward and the drive 

wheels reach the loading bridge. 

5. Lift the boom so that the drive 

wheels stand on the loading 

bridge. 

6. As soon as the boom is on the 

lading bridge, lift the boom and 

retract the dipper. 



7. Swivel the upper structure by 180° 

(pull up boom and dipper when 

swivelling). 

8. Position the excavator arm between 

the front support and then 

place on the ground 

9. Lower the boom and at the same 

time slightly extend the dipper 

so that the complete excavator is 

lifted to the height of the loading 

bridge. 

10. Extend the excavator arm including 

the telescope and at the 

same time activate the travelling 

gear until the machine is completely 

on the loading bridge. 

11. Before the excavator arm is lifted, 

make sure that the steering wheels 

are fully on the loading bridge. 

12. Move the machine to the required 

position using the hub engine. 

13. Lower the excavator arm onto the 

loading area. 

14. Switch off the motor. 

15. Release the residual pressure 

from the hydraulic system. 

The procedure for unloading is the reverse of that of loading. 



5.2.3 Release the residual pressure 

For a certain time, some of the components of the hydraulic system remain pressurised after switching off the motor. 

To release the residual pressure from the hydraulic system, proceed as follows: 

1. Turn the ignition key up to the first stop to activate the electric system of the excavator (control lamps and display 

light up) without starting the motor. 

2. Fold down the arm rest of the driver's seat. 

3. Depressurise the hydraulic system using the joystick and the pedals. 

5.2.4 Clamp the machine 

1. Align the upper structure parallel to the truck. 

2. Lock the cab and remove the ignition key. 

3. After loading, place blocks under the excavator wheels 

and then secure it on the loading area against slipping, 

tilting and moving off independently. Only clamp the 

machine at suitable locations (Pos. 1+2). Be careful 

with the hydraulic line guides and the movable guards. 

4. Check the overall height and correct as required. 

Mounting eyes 

Front stabilizers 

Rear stabilizers 


max. 4m 

1 

Rear stabilizers directed 

2


5.3 Lift the machine 

5.3.1 Safety instructions on lifting the machine 

Warning ! 

Accidents during transport 


• The company transporting the machine is responsible for the 

necessary, operationally safe means of attachment that ensure 

safe and secure transport. 

Warning ! 

Load lifting equipment is too weak 


• Only use load lifting equipment with sufficient lifting power. 

Warning ! 

Insufficient means of attachment 


• Only use means of attachment that can sustain the load and 

is of suitable length. 

Warning ! 

Additional persons on machine 


• Never move the machine when additional people are on it. 

Warning ! 

Loads moving to and for 


• Use additional guide ropes and retaining ropes. 



Attention ! 

Fuels and lubricants escape into bodies of water and 

into the soil 

• Can result in damage to property and to the environment. 

• Catch oil, fuel and lubricants in suitable containers and dispose 

of them correctly. 

Attention ! 

Dirt in and on the machine 


• Work cleanly and clean soiled components. 

Note ! 

Assembly and disassembly of components 

• Menzi Muck AG expressly refuses to accept liability for damage 

caused by incorrect 

• disassembly and assembly of components and the use of 

contaminated fluids and lubricants. 



5.3.2 Transport by helicopter, crane or skyline crane 

If it is to be transported by helicopter, crane or skyline crane, secure the machine as shown in Figure. Fix the machine 

at the marked locations with rope. Make sure that no obstacles or persons remain around the machine. 

Note ! 

Weight of machine 

You can look up the weight of the machine in the "Technical data" 

chapter. These specifications may vary depending on the fittings 

and accessories! 


Cab 


5.3.3 Component mass 

The machine can be disassembled if the available lifting gear and lifting tackle is not of sufficient load-bearing 

strength to lift the machine as a complete unit. The weights of the individual components are listed below. 

Pos. Part Weight (kg/lbf) 

1 Cab 600 / 1323 

2 Headlight arrangement 1 90 / 198 

3 Headlight arrangement 2 20 / 44 

Center part 


1 Center part cpl. without hydraulic and 

diesel oil 

2400 / 5291 

2 Center part steel structure 900 / 1984 

3 Slewing ring and swing gear incl. 

swing engine 

200 / 441 

4 Diesel engine cpl. with distribution 

gear and hydraulic pumps incl. Powerline 

pumps 

810 / 1786 

5 Cooler cpl. incl. ventilator 120 / 265 

6 Hydraulic oil tank 90 / 198 

7 Fearing cpl. 90 / 198 

Hydr. oil depending on level 200 / 441 


1 

3 

3 

1 

5 

2 

2 

7 

4 

6

Chassis 



1 Chassis cpl. incl. oil distributor 1250 / 2756 

2 Chassis 810 / 1786 

3 2x Swivel base 230 / 507 

4 2x Stabilizer cylinder 100 / 220 

5 2x Swivel cylinder 100 / 220 

Stabilizers rear 


1 2x Stabilizers rear cpl. 

incl. wheel 500/50-22.5 

1450 / 3197 

2 2x Revolving head 240 / 529 

3 2x Adjustment cylinder 100 / 220 

4 2x Stabilizers interior 130 / 287 

5 2x Stabilizers exterior 150 / 331 

6 2x Pivots 130 / 287 

7 2x Hub drives kpl. 170 / 375 

8 2x Wheels 500/50-22.5 

350 / 772 

2x Wheels 600/50-22.5 

440 / 970 

Stabilizers front 


1 2x Stabilizers front kpl. 1050 / 2315 

2 2x Stabilizer cylinders front 100 / 220 

3 2x Stabilizers - outside beam 300 / 662 

4 2x Stabilizers - inner beam 140 / 309 

5 2x Rupper pads 85 / 187 

6 2x Steels pads 120 / 265 

7 2x Hub 65 / 143 

8 2x Wheels 300-15 kpl. 

185 / 408 

2x Wheels 12.5/60-15 

165 / 364 

1 

1 

1 

2 

6 

2 

3 

5 


4 

4 

2 

3 

3 

6 

5 

8 

5 

7 8 

4 

7


Rear stabilization 4RL 


1 2x Stabilizers 4x4 Plus 4RL cpl. 

incl. wheel 500/50-22.5 

1700 / 3748 

2 2x Pivots 240 / 529 

3 2x Steering cylinders 100 / 220 

4 2x Revolving heads 230 / 507 

5 2x Adjustment cylinders 100 / 220 

6 2x Stabilizers 360 / 794 

7 2x Hub drives 190 / 419 

8 2x Wheels 500/50-22.5 

350 / 772 

2x Wheels 600/50-22.5 

440 / 970 

Boom 


1 Boom cpl. without bucket 1750 / 3858 

2 Bucket cylinder 105 / 232 

3 Dipper / telescopic arm cpl. with telescope, 

arm brace and push rod 

1080 / 2381 

4 Dipper cylinder 110 / 243 

5 Rear boom 310 / 683 

6 Boom cylinder 120 / 265 

7 400 Standard bucket 

211 / 465 

600 Standard bucket 

271 / 597 


330 / 728 


390 / 860 

1250 Grading bucket 

360 / 794 

1400 Grading swiveling bucket 615 / 1356 


1 

1 

3 

4 5 

2 

3 

7 

6 

2 

6 

4 

7 8 

5


5.4 Transport inspection 

On receipt of the goods, make an immediate check of completeness and for any damages incurred during transport. 

Note ! 

Defects 

If defects occur or the delivery is not complete then make an immediate 

claim with the carrier or the sender. 

5.5 Packaging 

5.5.1 About the packaging 

The machine or the single packages have been packaged according to the expected transport conditions. The 

packaging should protect the machine or its single components from transport damages, corrosion, and ageing 

until it/they are used or installed, and should also keep it complete. 

5.5.2 Handling packaging material 

If no agreement on return of goods has been made for the packaging then separate the materials according to 

their types and sizes and recycle or reuse accordingly. 

Attention ! 

Incorrect disposal of packaging material 

• Can result in damage to property and to the environment. 

• Separate the packaging materials according to their types 

and sizes and recycle. 

5.6 Storage 

The machine should be stored protected from the effects of weather when decommissioned for longer periods. 

Attention ! 

Weather effects such as rain, snow, ice, hail or direct 

sunlight 


• When not in use, keep the machine protected from effects of 

the weather. 

Note ! 

Manufacturer's instructions 

Under certain circumstances there might be storage instructions 

on the attachments above and beyond the requirements listed 

here. Observe these accordingly. 


Control and Display elements 

6. Control and Display elements 

6.1 Operator's workplace 

1. Loudspeaker left 


3. Storage compartment 

4. Rear console 

5. Multi-Joystick left 

6. Seat belts 

7. Cab security lock 

8. Cab security bolt 

20 

9. Air vent - leg area at left 

19 

10. Air vent - front screen at left 

11. Foot pedal for telescope 

12. Foot pedal for winch 

13. Foot pedal for driving 

18 

14. Foot pedal for auxiliary connection line (large) 

15. Air vent - leg area at right 

16. Air vent - front screen at right 

17. Ash tray 

17 

18. Console (right) 

19. Warning buzzer 

16 

20. Air vent - front side window 

21. Display unit 

15 

22. Multi-Joystick right 

23. Fuse box cover 

24. Air vent - right 

25. Document compartment 

26. Console (roof) 

27. Loudspeaker right 

28. Radio 

14 

6.2 Main switch 

The main switch (1) is located at the rear to the right of the engine 

support. The diagram shows the main switch in the OFF position. 

Rotate the main switch clockwise to switch it on. If the machine is 

not to be used for a prolonged period, switch it off so that the batteries 

are disconnected from all consumers. 

Attention ! 


21 

13 

12 

22 

28 27 26 

23 24 25 

Switching on the main switch during work 


• Before you switch on the main switch, make sure that nobody 

is working on the electrical system. 

11 10 

1 

9 

8 

7 

6 

1 

5 

2 

3 

4


6.3 Display 

1 

8 5 6 1 

8 

9 

4 3 2 7 

1. Ignition Lock 

2. Emergency shut down switch 

3. Potentiometer for engine speed adjustment 

4. Potentiometer speed 

5. Level switch ventilation 

6. Regulation heating 

7. Cigarette lighter 24V 

8. Switches (functions see table) 

9. Display 

6.3.1 Ignition Lock 

0. The ignition lock is in idle position in the position in the drawing 

(Pos. 0). 

1. Turn the ignition key clockwise up to the first stop (Pos. 1) to 

switch on the ignition. The display goes on and the control 

lamps appear on the display unit. 

2. Turn the ignition key to Pos. 2 and the engine starts. Keep the 

ignition key turned until the Diesel engine starts. Then immediately 

let go of the ignition key. It automatically jumps back to the 

ignition position. If the engine is to be turned off then turn the 

ignition key back to its starting position. 


0 

8 

1 

2


6.3.2 Emergency shut down switch 

The Emergency shut down switch (4) shuts the machine down immediately 

in an emergency situation. The Emergency shut down switch must be 

reset before the machine can be restarted. Do this by turning it clockwise. 

Danger ! 

Start of machine after an emergency shutdown when the 

danger has not yet been remedied 

• Results in death or severe injuries. 

• Make sure that nobody can be endangered by restarting the 

machine. 

6.3.3 Speed adjustment 

The DYGSY, together with the engine’s ECU, is responsible for adjusting 

the engine speed, and thus the control of the injection device, 

ensuring economical and efficient operation. For heavy loads, the 

ECU equalises the pressure of the diesel engine, making possible a 

higher capacity. 

While the engine is running, the engine speed can be set variably 

between upper and lower idle speeds by turning the potentiometer 

on the instrument panel clockwise or counter-clockwise. The speed 

can be read on the display. The maximum permissible speeds are 

limited electronically. 

6.3.4 Potentiometer speed 

The engine speed can be set variably between upper and lower 

speeds by turning the potentiometer. The maximum final speed increases 

by rotating the potentiometer clockwise. 

Note ! 

Potentiometer speed 

If the required speed for the travelling gear is not reached then 

check to make sure the potentiometer of the travelling gear is not 

set to the minimum speed. 



6.3.5 Ventilation step switch 

Using this rotary switch, you can variably regulate the vent air volume 

entering the cab from the air vents. The fan is switched off in the 

diagram. Turn the rotary switch clockwise to increase the air volume 

in steps. 

6.3.6 Heating valve control 

Using this rotary switch, you can variably regulate the vent temperature 

entering the cab from the air vents. The heating valve is switched 

off in the diagram. Turn the rotary switch clockwise to increase 

the air temperature in steps. 

6.3.7 Cigarette lighter 

The cigarette lighter is used to light cigarettes. If you remove the lighter 

then you can use the socket to supply a voltage of 24 VDC with a maximum 

of 10A. Various accessories such as, e.g. a charging unit for mobile 

telephones, can be supplied by this connection. 

Attention ! 

24 VDC voltage 


• Only connect consumers with a voltage of 24 VDC. 



6.3.8 Switch functions 

Warning ! 

Enabling a switch when you are unsure of its function 


• Before you enable a switch, make sure that you are able to 

execute the function in question 

Warning indicator unit 

You can switch on the warning indicator 

unit with this switch. 

Parking light 

You can switch on the parking light with 

this switch. 

Front working headlamps 

You can switch on the front working headlamps 

with this switch. 

Side working headlamps 

You can switch on the side roof headlamps 


Windscreen wiper 

You can switch on the windscreen wiper 


1 step = intermittent 

2 step = constant operation 


Direction indicator 

You can switch on the direction indicator 

with this switch. Move the switch upwards 

and the right direction indicator flashes; 

move it downwards and the left direction 

indicator flashes. 

Dim light 

You can switch on the dim light with this 

switch. 

Rear working headlamps 

You can switch on the rear working headlamps 


Panorama indicator lamp 

You can switch on the panorama indicator 

lamp with this switch. 

Wiper system 

You can switch on the windscreen wiper 

system with this switch as long as the button 

remains pressed.


Circulated air ventilation 

You can switch the ventilation to circulated 

air with this switch. 

Fine mode 

You can switch on the fine mode with this 

switch. 

Steering 

You can switch on the steering with this 

switch. 

1 step = switch off bucket 

2 step = switch off boom 

Overload warning device 

You can switch on the overload warning 

device with this switch. 

Stroke limiter 

You can switch on the stroke limiter with 

this switch. 

Turn tilt rotator 

You can switch on the tilt rotator with this 

switch. 

Attachment 

You can switch on the attachment with this 

switch. 

Air-conditioning unit 

You can switch on air-conditioning unit with 

this switch. 

Drive stage fast-slow 

You can switch over from slow to fast 

wheel drive with this switch. 

Central lubrication 

You can switch on the central lubrication 


Hydr. quick changer 

You can switch on the hydraulic quick 

changer with this switch. 

To activate it you must press the safety bar 

on the switch. 

Electric cable winch 

You can switch on the electric cable winch 

control with this switch. 

Hydraulic breaker 

You can switch on the hydraulic breaker 

(hammer) with this switch. 



6.3.9 Display 

Note ! 

Main switch during operation 

When operating the display unit, never rotate the main batter 

switch to "off; this could result in errors in the software. 

Note ! 

Display after shut off 

When shutting off with the ignition key, the display remains switched 

on for approx. 10s and then switches off automatically. 

Note ! 

Contrast and brightness 

If the contrast and brightness are adjusted so extremely that the 

display is no longer visible, restore the default settings by turning 

the engine off, then on again (after turning the ignition key back 

from „off,“ wait approx. 15 seconds. 

Note ! 

Date and time 

If the battery is disconnected or the main switch switched off (for 

example, during welding), the clock and date stand still. 

Afterwards, the date and time must be corrected. 

Design 

The display is separated into two areas. There is the user area 

and the secure service area. The latter is only accessible to 

service technicians of MENZI MUCK AG.The following menus 

are accessible to the user and inform the driver of the operating 

status of the machine: 

• Main menu 

• Menu for setting the clock 

• Menu for setting brightness and contrast 

• Menu for setting Powerline 

• Detail menu 

• Service and diagnostic menu (see maintenance !) 

Additional menus are available to MENZI MUCK assembly 

personnel after entering the password. This area will not be 

discussed further in this manual. 



Keyword index 

DIGSY Display + control 

DIGSY Compact DCE Control (built into the midsection, to the rear, lower right) 

CGMT Display (built into the console) 

ECU Engine electronics of the John Deere engine 

CEB 16/21 electronic maximum load control (GLR) 

ICN-V control integrated into chassis 

CR2011 auxiliary module 

Commissioning 

The DIGSY control unit and display starts up in the „ignition on“ 

position. After a short time, the start-up screen appears. Afterwards, 

the control automatically loads the main menu. 

Main menu design 

In this screen, all important data are presented in overview form: 

· Tank display 

· Speed display (rpm) 

· Clock 

· Operating hours 

· Operating displays (see 5.2.8) 

· Cooling water temperature 

· Hydraulic oil temperature 

· Status displays 

· Powerline setting 

· Buttons and Corresponding menu fields 



User controls 

A set of keys is located beneath the display (F1 - F6). Above these 

keys, symbols indicate which menu or command is activated 

by pressing the key. 

Example main menu: 

F1 Detail menu 

F2 Powerline setting (not activ) 

F3 Day/night switch. The screen colours are inverted and the 

keys are lit up. 

F4 Brightness / contrast setting 

F5 Date / time setting 

F6 Confirmations of the message windows and other messages 

Main displays 

Using bar graphs and a graphical speed display, the driver is 

continuously informed of the most important operating status details, 

all at once. 

1 Tank display 

2 Cooling water temperature 

3 Hydraulic oil temperature 

4 Powerline setting 

5 Numerical display of rpm 

6 Graphical display of rpm 

7 Operating hours 

8 Clock 

Operation and status display 

Note ! 

Symbols 

The operation and status display symbols only appear when they 

are active. 

Note ! 


Note for machines with central lubrication: after filling the grease 

container, this must be confirmed using the central lubrication 

control. To do so, please read the operating manual for the central 

lubrication control. 


6 8 

1 5 2 3 7 4


Diesel tank is at reserve 

Warning on 

< 30 l x x x Re- 

Warning off 

Supply pressure filter (the left image) 

> 40 l 

start 

Supply pressure filter dirty x x x 60s 

Warning lamp engine 

Limit 


Symbol blinks 

Timed buzzer 

Permanent buzzer 

Can be acknowledged 

Repeats after .... 

x x x 60s 

Engine stop 

Attention: Stop engine immediatly! x x x 60s 

Fault lamp GLR 

x x x 60s 

Water temperature 

Warning on 

> 103°C x x x 60s 

Warning off 

Hydraulic oil temperature 

< 100°C 

Warning on 

> 85°C x x x 30s 

Warning off 

Drive level 

< 80°C 

2. Level activ x 


Central lubrication activ x 

Over load warning 

System activ and overloading condition x x 

Battery voltage 

Alarm: Voltage is out of toleranced range 31V x x 60s


Pre-heating Diesel engine 

x 

Diesel engine air intake filte 

Alarm: Filter dirty x x x 60s 

CAN Bus faulty (left image) 

No connection between ECU-Engine / GLR/RC4-4/20 x 

Engine oil pressure 

Alarm: Pressure too low x x x 60s 

Coolant level too low 

Alarm: Level toot low x x x 60s 

Hydraulic return filter 

Alarm: Filter dirty x x x 60s 

Central lubrication level (right image) 

Alarm: Level too low x 

Overpressure central lubrication (blinks) 

Pressure in central lubrication to high 

Maintenance due 

Deletion only with maintance code ! x 

CAN Bus faulty (right image) 

No connection between joystick / chassis comand x x x 60s 

Left-turn signal 

Signal on x 

Working headlights 

Headlights on x 

Right-turn signal 

Signal on x 


Limit 

Symbol blinks 

x 

Timed buzzer 

Permanent buzzer 

Can be acknowledged 

Repeats after ....


Detail menu 

The detail menu can be reached from the main menu by pressing 

the F1 key. Find in this menu detailed information about value of 

the machine. There are also saved information about condition of 

the machine. 

1 Date 

2 Time 

3 Hours meter per day (reset by F5) 

4 Current battery load 

5 Maintenance is overdue in X hours 

6 Tank capacity in litre 

7 Current consumption per hour 

8 Consumption on the average per hour (reset by F4) 

9 Current hydraulic oil temperature 

10 Maximum measured hydraulic oil temperature (reset by F3) 

11 Curren temperature of cooling water 

12 Maximum measured temperature of cooling water 

(reset by F3) 

Return to the main menu by F1 

Note ! 

Tank capacity 

Tank capacity is correct when the chassis is horizontal. If it isn't, 

there may be a difference to the display. 

Note ! 

Reset values 

By F4 the maximum of cooling water and hydraulic oil temperature 

can be reseted together. So you will loose both values. 

Adjust brightness, contrast, date and time 

The description of how to adjust the brightness, contrast, date and time is contained in Chapter "Adjusting the 

controls". 


4 

5 

9 

10 

11 

12 

6 

7 

8 

1 

2 

3


6.4 Joystick 

6.4.1 A81 Mobil 

19 

3 

27 

28 

29 

17 

18 

23 

1 

24 

2 

15 

20 

26 

4 

13 

14 

Left 


16 

11 

9 

10 

25 

12 

7 

22 

21 

5 

6 

8 

1. Dipper - out 

2. Stiel - in 

3. Swivelling - left 

4. Swivelling - right 

5. Grappler of tiltrotatorgreifer - open * 

6. Grappler of tiltrotatorgreifer - close * 

7. Tiltrotator swivelling - left * 

8. Tiltrotator swivelling - right * 

9. Stabilizator rear left - up 

10. Stabilizator rear left - down 

11. Stabilizator rear left - outwards 

12. Stabilizator rear left - inwards 

13. Stabilizator front left - up 

14. Stabilizator front left - down 

15. Stabilizator front left - outwards 

16. Stabilizator front left - inwards 

17. Telescopic stabilizer left - out 

18. Telescopic stabilizer left - in 

19. reserve 

20. reserve 

21. Additional hydr. circuit 80 l/min 


23. reserve 

24. Horn 

25. Winch - cable in * 

26. Winch - cable out * 

27. reserve 

28. Interval windshield wiper 

29. reserve 

* optional


1. Boom - down 

2. Boom - up 

3. Bucket - close 

4. Bucket - open 

5. Grappler - open * 

6. Grappler - close * 

7. Tiltrotator - turning anticlockwise * 

8. Tiltrotator - turning clockwise * 

9. Stabilizator rear right - up 

10. Stabilizator rear right - down 

11. Stabilizator rear right - inwards 

12. Stabilizator rear right - outwards 

13. Stabilizator front right - up 

14. Stabilizator front right - down 

15. Stabilizator front right - inwards 

16. Stabilizator front right - outwards 

17. Telescopic stabilizer right - out 

18. Telescopic stabilizer right - in 

19. reserve 

20. reserve 

21. Additional hydr. circuit 40 l/min * 


23. Powermode 

24. reserve 

25. Hydr. quick changer - open * 

26. Reset idling speed 

27. Commutation from bucket to stabilisator direction 

28. Hydr. freewheel * 

29. reserve 

* optional 

7 

5 

6 

21 

22 

11 

8 

25 

9 

10 

12 


15 

13 

14 

Right 

3 

26 

16 

19 

24 

2 

23 

1 

17 

18 

4 

28 

29 

27 

20


6.4.2 A81 Mobil steered hubdrive 

19 

3 

27 

28 

29 

17 

18 

23 

1 

24 

2 

15 

20 

26 

4 

13 

14 

Left 


16 

11 

9 

10 

25 

12 

7 

22 

21 

5 

6 

8 


2. Dipper - in 



5. Grappler of tiltrotatorgreifer - open * 

6. Grappler of tiltrotatorgreifer - close * 

7. Tiltrotator swivelling - left * 

8. Tiltrotator swivelling - right * 

9. Stabilizator rear left - up 

10. Stabilizator rear left - down 

11. Stabilizator rear left - outwards 

12. Stabilizator rear left - inwards 

13. Stabilizator front left - up 

14. Stabilizator front left - down 

15. Stabilizator front left - outwards 

16. Stabilizator front left - inwards 

17. Telescopic stabilizer left - out 

18. Telescopic stabilizer left - in 

19. Hub drive left - outwards 

20. Hub drive left - inwards 



23. reserve 

24. Horn 

25. Winch - cable in * 

26. Winch - cable out * 

27. Commutation - Stabilizers to direction of pivots 

28. Interval windshield wiper 

29. reserve 

* optional



2. Boom - up 



5. Grappler - open * 

6. Grappler - close * 

7. Tiltrotator - turning anticlockwise * 

8. Tiltrotator - turning clockwise * 

9. Stabilizator rear right - up 

10. Stabilizator rear right - down 

11. Stabilizator rear right - inwards 

12. Stabilizator rear right - outwards 

13. Stabilizator front right - up 

14. Stabilizator front right - down 

15. Stabilizator front right - inwards 

16. Stabilizator front right - outwards 

17. Telescopic stabilizer right - out 

18. Telescopic stabilizer right - in 

19. Hub drive right - inwards 

20. Hub drive right - outwards 



23. Powermode 

24. reserve 

25. Hydr. quick changer - open * 

26. Reset idling speed 

27. Commutation from bucket to stabilisator direction 

28. Hydr. freewheel * 

29. reserve 

* optional 

7 

5 

6 

21 

22 

11 

8 

25 

9 

10 

12 


15 

13 

Right 

14 

3 

26 

16 

19 

24 

2 

23 

1 

17 

18 

4 

28 

29 

27 

20


6.4.3 Basic functions OK control 

Optionally the basic functions of the joystick are available with an OK control. Joystick assignment of the single 

switches is the same as described on the previous pages. 

3 

1 

2 


2. Dipper - in 



4 

Left 



2. Boom - up 



Right 

3 

2 

1 

4


6.5 Pedals 

6.5.1 Pedal assignment 

The "Menzi Muck" pedal assignment is installed as standard. However, 

the "Special" pedal assignment can also be installed. 

"Menzi Muck" 

pedal assignment 

1. Telescopic arm 

2. Winch * 

3. Driving 

4. Large hydraulic auxiliary 

connection 

* optional 

6.5.2 Pedal telescope "Menzi Muck" 

1. Extending telescope 

2. Rectracting telescope 

6.5.3 Pedal winch 

1. Retract rope 

2. Pull out rope 

"Special" 

pedal assignment 

1. Large hydraulic auxiliary 

connection 

2. Winch * 

3. Driving 

4. Telescopic arm 

1 

2 3 4 


1 

1 

2 

2


6.5.4 Pedal driving 

With this pedal you can activate the drive. The description refers to 

the direction of the machine. 

1. Driving forward 

2. Driving backward 

6.5.5 Large auxiliary pedal 

The adjacent diagram shows the "Menzi Muck" pedal assignment. 

You can enable the auxiliary consumers proportionally with this 

pedal. 


1 

2


6.6 Adjusting the controls 

6.6.1 Adjust workplace 

To use the possibilities provided by the machine and to make your work as comfortable as possible, it is important 

to be acquainted with the adjustments for the seat and the controls. Instructions on the correct adjustment of your 

workplace are contained in the explanations listed below. 

Healthy posture during work is extremely important for fatigue-free operation. Additionally, correct posture can 

have a positive effect on your health. 

4 

3 

2 

1. The neck should be stretched and more or less vertical. Avoid postures in which your body is tilted forwards 

and the neck is bent back. 

2. Elbows should not be far from the body and arms should be supported as much as possible. If the armrest is 

too high then this can push up the shoulders, resulting in cramps. 

3. Avoid extreme wrist and finger joint position when operating the joystick. 

4. Angles of the hip and knees should be about the same and should be between 90-110°. A large knee angle 

with a small hip angle has negative effects on the spine. 

5. The thighs should be supported as much as possible. 

5 

1 


4

Klepp 


6.6.2 Operator’s seat 

The comfortable operator’s seat makes possible a fatigue-free operation of the machine. Several adjustment 

possibilities ensures an optimal adaptation to the operator. For superior ergononomics the control levers are integrated 

into the seat. The left control lever can be folded back in order to make boarding and disembarking from 

cabin easier. 

Warning ! 

Incorrect seating position 

• Can result in severe injuries. 

• Check and adjust the position of the seat before commencing 

work and every time the driver is changed. 

1. Longitudinal adjustment of seat including armrest 

2. Adjusting weight to driver 

3. Height adjustment 

4. Longitudinal adjustment of upper seat section 

5. Tilt adjustment of backrest 

6. Adjustment of backrest 

7. Tilt and height adjustment of armrest 


5 

4 

3 

7 

2 1 

6

Grammer 


A Grammer driver seat can also be fitted on request (optional). 

1. Tilt adjustment of backrest 

2. Longitudinal adjustment of upper seat section 

3. Longitudinal resilience 

4. Tilt adjustment of seat cushion 

5. Height adjustment 

6. Adjusting weight to driver 

7. Longitudinal adjustment of seat including armrest 

8. Longitudinal adjustment of seat cushion 

9. Lower and upper adjustment of backrest 

10. Seat heating on - off 

11. Tilt and height adjustment of armrest 

8 

7 

6 

11 


5 

10 

4 

3 

2 

9 

1


6.6.3 Seat belt 

Warning ! 

Not wearing the seat belt 


• Fasten your seatbelts always firmly when operating the machine. 

Warning ! 

Defective parts on seat belt 


• Check seat belt and its attachment parts before each use for 

wear and defective parts. Replace defective parts with new 

ones. 

1. Make sure that seat belt is not twisted and 

insert the buckle until it clicks into the buckle. 

2. Adjust strap length, so that it firmly applies. 

Pull lightly on the belt to ensure that it's tight. 

3. For loosen the belt press the enter button on 

the buckle. 

6.6.4 Joystick 

The joysticks can be rotated so that they fit perfectly in operators 

hands: 

1. Push back the sleeve. 

2. Loosen the top clamp screw. 

3. Rotate the joystick in desired position. 

4. Tighten the clamp screw. 

5. Pull down the sleeves. 


1 

5 

2 

4


6.6.5 Foot pedal adjustment 

For increased comfort, the foot pedals can be set individually for 

each driver. Tilt can be set separately for each foot pedal using the 

rocker (1). 

Loosen the screws (2) to adjust the height and inclination of the entire 

attachment within its adjustment range to meet the requirements 

of the driver. 

Once the setting has been adjusted, the screws (2) must be tightened 

in order to prevent the attachment being adjusted inadvertently. 

6.6.6 Brightness / contrast 

This menu is reached by pressing the F4 key in the main menu. 

1 Adjusting the display brightness: F4 reduces and F5 increases 

the brightness level. The contrast setting screen is reached by 

F6 in the main menu. 

2. Adjusting the display contrast: F4 reduces and F5 increases the 

contrast level. The brightness setting can be reached F6. The 

main menu can be reached again by pressing the F1 key. 

Note ! 

Brightness and contrast 

If the contrast and brightness are adjusted so extremely that the 

display is no longer visible, restore the default settings by turning 

the engine off, then on again (after turning the ignition key back 

from „off,“ wait approx. 15 seconds). 

Note ! 

Faster adjusting of contrast 

Holding down the F4 or F5 key adjusts the contrast or brightness 

more quickly than pressing the key repeatedly. 

1 


2


6.6.7 Date and time 

This menu is reached by pressing the F5 key in the main menu or 

detail menu. 

1. Setting the clock 

F4 sets the hour back, F5 sets advances the hour 

F6 minute setting 

F4 sets the minute display back, F5 advances the minutes 

F6 date setting 

2 Setting the date 

F4 sets the day back, F5 advances the day. 

F6 month setting 

F4 sets the month back, F5 advances the month. 

F6 year setting 

F4 sets the year back, F5 advances the year. 

F6 back to clock setting 

The main menu or detail menu can be reached again by pressing 

the F1 key. 

Note ! 

Faster settings 

Holding down the F4 or F5 key adjusts the date or time 

more quickly than pressing the key repeatedly. 

Note ! 

Time and date 

If the battery is removed or the main switch switched off, the 

clock and date stand still. Afterwards, the date and time must be 

corrected. 

6.6.8 Air vents 

The air circulating in the driver’s cab can be controlled using the 

built-in air vents. The air flowing out of the heating/air conditioning 

system can be directed as required by turning or opening/closing 

the individual vents. 

1 Front air vent for demisting/defrosting the windscreen 

2 Footwell air vent 

3 Right-hand air vent 

4 Rear air vent 


1 

2 

3 

4 

1 

2


6.7 Cab windows and door 

6.7.1 Upper front window 

Open: Rotate the lock of the front window clockwise by 90°. You 

can now open the front window. 

Close: Close the top window and turn the lock to fix it in place. 

6.7.2 Lower front window 

You can remove the lower front window without tools to clean the 

cab. 

Open: Hold onto the front window and release the two star grip nuts 

anticlockwise. You can then lift up the lower window from its frame. 

Close: Place the front window in its lower frame. Then mount the 

star grip nuts clockwise. 

6.7.3 Side window 

Open: Fold open the lock of the side window. You can now open 

the window and fix it with the fastening lever. 

Close: Turn up the fastening lever and close the side window. Then 

fold the lock downwards. 



6.7.4 Open and close doors 

Opening from the outside: 

Open the door locks by turning the ignition key. Then actuate the 

lock and open the door. You can lock the door in place after opening 

by 180°. 

Attention ! 

Door not locked in place 


• Check whether the door is correctly locked in place either in 

open or closed position. 

Opening from the inside: 

Press the actuating level downwards and open the doors. 

Close: Turn the locking switch anticlockwise to release the doors 

from their fasteners. Then close the doors. 

You can lock the doors with the ignition key. 



6.8 Covers 

6.8.1 Rear cover 

Open: Open the rear cover lock by turning the ignition key. Then 

actuate the lock and open the rear cover. It is kept open by gas 

pressure springs. 

Close: Fold the rear cover downwards until it engages into the lock. 

The rear cover can be locked using the ignition key. 

6.8.2 Right side cover 

Open: Open the right side cover lock by turning the ignition key. 

Then actuate the lock and open the right side cover. It is kept open 

by gas pressure springs. 

Close: Fold the right side cover downwards until it engages into the 

lock. You can lock the right side cover with the ignition key. 

6.8.3 Left side cover 

Open: First open the rear cover as shown in the above diagram. The 

lift the unlocking button to open the side cover. It jumps open, but 

is held by the safety chain. You can now unhook the snaphook from 

the safety chain and lift away the cover. 

Close: Lift eh side cover in its attachment and hook on the safety 

chain. Now press the left side cover into the lock. Close the rear cover. 



6.9 Refuelling system 

The standard refuelling system used to fill the diesel tank in the 

upper vehicle section and the reserve tank located in the chassis. 

The system can be reached and operated easily by the operator 

by opening the right engine cover. 

6.9.1 Filling working diesel tank 

In the basic position the suction hose is stored rolled-up on the 

diesel tankand sealed off against the penetration of dirt at one end 

with an cover. 

1. Pull suction hose off cover 

2. Guide suction hose into new Diesel 

3. Set switchover cock to vertical position 

4. Activate electric filling pump by the switch 

5. Monitor fill level of diesel tank with attached oil level eye 


1 

3 

5 

4 

2


6.9.2 Filling chassis tank 

1. Pull out filling hose from the running board 

2. Remove plugs 

Attention ! 

Escaping fuel 


• Position the machine so that the chassis tank cover 

is at the highest position. 

3. Open the chassis tank cover. 

Note ! 

Chassis tank cover 

The chassis tank cover rotates freely when closed. Unlock 

the cover with the key 

4. Attach filling hose to the chassis tank. 

5. Set switchover cock to horizontal position. 

6. Refuel as described above. 

7. Make a visual check of the filling level of the chassis tank at the 

filling nozzle. 

3 


1 

4 

7 

2 

5


6.9.3 Transferring fuel to chassis tank 

1. Position upper vehicle section so that the chassis tank can be 

reached with the suction hose. 

2. Unscrew the cover from the suction hose. 

Attention ! 

Escaping fuel 


• Position the machine so that the chassis tank cover 

is at the highest position. 

3. Unlock the chassis tank cover and open the tank cover. If the 

chassis tank cover rotates freely then it is closed. 

Note ! 

Chassis tank cover 

The chassis tank cover rotates freely when closed. Unlock 

the cover with the key. 

4. Insert suction hose in chassis tank. 

5. Set switchover cock to vertical position. 

6. Refuel as described above. 


3 

4 

2 

5 

6


6.10 Tilt cab 

Warning ! 

Cab door not secured 


• Close or lock doors in place before tilting the cab. 

Attention ! 


• Can result in breakage to cab door or other damage to property. 


Warning ! 

Non-secured cab 


• After tilting, immediately position the lock for the cab. 

Attention ! 

Boom in raised position when tilting the cab 

• Can break the front window. 

• Lower the boom before tilting the cab. 



Kabine kippen: 

1. Place the machine on an even surface. Stretch the dipper 

and lower the boom. 

2. Pull forward the cab release lever. 

3. Pull forward the top lever to unlock the cab. 

4. Open the rear cover as described in the "Covers" chapter. 

5. Plug the cab tilting lever into the hydraulic hand pump. 

6. Switch the valve actuating lever to the right. 

7. Pump until the cab is fully tilted. 

8. Position the cab fastening mechanism. 


2 

3 

8 

7 

7 

6 

5


Securing the cab when working under the cabin 

Secure the cab by additional means when you perform maintenance and repair work on the tilt cylinder or the mechanical 

cab tilt protection mechanism. The cab must always be secured by two means. 

Danger ! 

Working under the cab with insufficient cab tilt 

protection 

• This may lead to death or serious injuries. 

• Make absolutely sure the cab is always secured against tilting 

by two means when you perform maintenance or repair work. 

There are 5 different ways to secure the cab: 

Secure by tilt cylinder and cab tilt protection mechanism 

Secure by tilt cylinder and additional support 


1 

2 

1 

2


Secure by tilt cylinder and crane 

Secure by cab tilt protection mechanism and additional support 

Secure by cab tilt protection mechanism and crane 


4 

5 

3 

3 

5 

4

Lower the cab: 


Warning ! 

Careless lowering of the cab 


• Make sure there is no-one is the danger zone before lowering 

the cab 

1. Pull the cab fastening mechanism downwards. 

2. Slowly switch the valve actuating lever to the left until the cab 

is fully lowered. Switch the valve actuating lever back to the 

right. 

3. Close the rear cover as described in the "Covers" chapter. 

4. Pull back the top lever to lock the cab. 

5. Pull back the lower lever to secure the cab fastening mechanism. 


5 

4 

1 

2

Working with the machine 

7. Working with the machine 

7.1 Safety instructions 

Warning ! 

Untrained operating personnel 


• Appropriate training is required before using the machine. 

7.1.1 Getting in and out 

Warning ! 

Getting in and out 


• To get in or out, always hold the steps and handle with both 

hands and get in and out of the machine with your face pointed 

towards it in such a way that you always hold onto at 

least three points. 

• Never touch the control lever when getting in and out. 

• Never try to get in or out of the machine when it is moving. 

• Never jump out of the machine. 

• Never get in or out of the machine when you are holding 

tools or other objects in your hands. 

7.1.2 Before starting the engine 

Warning ! 

Staff or other persons are in the vicinity of the machine 


• Make sure that staff and other persons move away from the 

machine and its work area 

Warning ! 

Defective control 


• Put the control level into neutral position before starting the 

engine. 



Warning ! 

Damaged parts on safety belt 


• Each time before starting up, check the safety belt and its 

fastenings for wear and defects. Replace damaged parts with 

new parts. 

Warning ! 

Not wearing a safety belt 


• Before starting the engine, always fasten the safety belt. 

Warning ! 

Incorrect seating position 


• Check and adjust the position of the seat before commencing 

work and every time the driver is changed. 

7.1.3 Starting the engine 

Warning ! 

Short-circuiting to start the engine 


• Always start the engine from the driver's seat in the order presented 

in this operator's manual. 

Warning ! 

Nonobservance of instructions 


• If the ignition lock or any other control is labelled "do not activate" 

then doe not leave the engine on or actuate the control. 

Attention ! 

Short-circuiting of different voltages 


• Never short-circuit different voltages.. 



7.1.4 Checks before startup 

Warning ! 

Staff and other persons 


• Make sure that staff and other persons move away from the 

machine and its work area. 

Warning ! 

Defective warning equipment 


• Check correct function of the warning equipment. 

Warning ! 

Dirty windows and door windows 


• Make sure that all windows and door windows are clean. 

Warning ! 

Defective machine 


• Move the machine outdoors on an open space and check 

that all controls and protective devices are in perfect working 

order. 

Warning ! 





Attention ! 







Warning ! 

Open doors and windows 


• Do not forget to close all doors and windows before commencing 

work. 

7.1.5 Operation of the machine 

Warning ! 

Careless worksteps 


• Carry out all worksteps with the appropriate care. 

Attention ! 

Careless worksteps 

• Can result in damage to property 

• Carry out all worksteps with the appropriate care. 

Warning ! 

Random actuation of controls 


• Do not move the controls to and for randomly. 

Attention ! 

Random actuation of controls 


• Do not move the controls to and for randomly. 

Warning ! 

Insufficient care and attention 


• You must not read, drink or allow yourself to be distracted during 

operation. If you have to concentrate on something else 

then stop operating the machine. 



Warning ! 

Not operating the machine from the workplace 


• Only operate the machine from the driver's seat. Never try to 

operate the machine in a standing position or from outside 

the machine. 

Warning ! 

Electric shock from overhead line 

• Can result in death or severe injuries 

• Under no circumstances must the boom ever approach or 

touch electrical lines. Check the clearance height above the 

machine as well as the area around it.When working under 

overhead lines, observe a minimum clearance of 3m, plus 10 

cm for every 100 volts for lines more than 50000 volts. Pay 

careful attention to local and governmental requirements, as 

these might require even greater clearances. Treat all lines as 

if they are live. 

Danger ! 

Touching an electrical line 

• Results in death or severe injuries. 

• If you touch electrical line, remain in the machine until the 

boom has been removed from the line or the power on the 

line has been switched off. Do not allow any other person on 

or at the machine! 

• If you need to leave the machine then jump away from it as 

far as possible and never, ever climb down it! You must never 

touch the machine and the ground at the same time. 

Warning ! 

Loaded bucket in a suspended position 


• When stopping operation or leaving the machine, the bucket 

must never remain in a suspended position under load. Always 

first place the bucket on the ground. 



Warning ! 

Carrying along persons on equipment 


• Never attempt to lift other persons onto the attachment or the 

bucket because the machine has only been designed to excavate 

and move material and not to lift persons. 

Warning ! 

Collision when swivelling 


• Before swivelling with the machine, make sure that there is 

nobody within its swivel radius. 

Attention ! 

Collision when swivelling 


• Before swivelling with the machine, make sure that there are 

no obstacles within its swivel radius. 

Warning ! 

Swivelling away above persons 


• Before swivelling with the machine, make sure that the boom 

is not swivelled over persons. Pay special attention to persons 

in a ditch or a pit because you might not be able to see 

them. Always observe the hand signals of the signaller to 

avoid such dangerous situations. 



Warning ! 

Falling objects when loading trucks 


• When possible, load the truck from the rear. Never move the 

bucket over the cab of the truck. Emptying the bucket form 

a great height is always dangerous. Make sure that the truck 

driver is not sitting in the cab when emptying the bucket and 

that he is not on or near the loading area. 

Attention ! 

Falling objects when loading trucks 


• When possible, load the truck from the rear. Never move the 

bucket above the cab of the truck. Emptying the bucket form 

a great height is always dangerous. 

Warning ! 

Tilting of machine during a hoisting operation 


• Loads may only be moved with activated overload warning 

device. 

• Adjustment of overload warning device corresponds to the 

highest possible stability of the machine, 

• i.e. swivel bases and wheels must be brought to their widest 

position and the hydraulic telescopic feet must be fully extended. 

• The chassis should be placed as low as possible. 

• The excavator must be placed on an even and paved ground. 

• Otherwise, the operator must taken adequate precautions. 

Attention ! 

Collisions with hydraulic cylinders 


• Prevent collisions with hydraulic cylinders. When near cylinders, 

carry out all movements slowly. 



Warning ! 

Missing, incorrect or incomprehensible hand signals 


• Only use hand signals that have been carefully agreed upon 

and that are known to all staff. Only ever one person should 

coordinate the work as signaller. 

Warning ! 

Unauthorised persons on the machine 

• May result in death or severe injuries. 

• Only the excavator operator is allowed on the machine during 

operation. Never allow unauthorised persons onto the machine 

or allow them to drive in it. 

Warning ! 

Careless bucket movements 


• If the bucket is full, and especially when the bucket is very 

near to the cab, always carry out arm and boom movements 

slowly 

Attention ! 

Banging the bucket against pit walls 


• Make sure that the bucket does not bang against the pit wall 

when swivelling it during excavation work. 

Attention ! 

Lateral movement when levelling with the bucket 


• When levelling, do not move the bucket laterally to and fro. 



Attention ! 

Extending and retracting the cylinders at full speed 


• Move the cylinders at reduced speed to their limit positions. 

Warning ! 

If there is an overload to the cylinders then the secondary 

safeguards open and the loads can no longer be controlled 


• Do not use the machine for work that exceeds its performance 

specifications. 

Warning ! 

Tilting or stalling of the machine in water 


• Before driving the machine into water, measure the depth of 

the water and check the water bed for dangerous locations. 

Attention ! 

Exceeding the permitted water depth 


• The machine may be immersed in water up to the top edge 

of the swivel base. If possible, keep the chassis casing above 

water. Generally, as few components as possible should be 

immersed in water. Parts that have been exposed to water for 

a longer time must be subsequently lubricated until the grease 

exits from the bearings. For additional information, refer to 

the Maintenance chapter. 



Warning ! 

Missing or faulty ROPS (Roll Over Protective Structure) 


• Always wear the safety belt when working with the machine. 

Never try to jump out of the cab when the machine tilts over. 

Warning ! 

Missing or faulty FOPS (Falling Object Protective Structure) 


• When working above overhangs or when objects can fall 

onto the machine, you should fit the machine with a FOPS 

(Falling Object Protective Structure)-approved roof protection. 

The FOPS roof protection is an optional extra. Please 

request advice from your Menzi Muck distributor. 

Warning ! 

Bad soil conditions 


• Before commencing work, make sure that the underground is 

sufficiently firm to prevent the machine from slipping or tilting 

over. 

Warning ! 

Machine tilts due to heavy loads 


• If using a large and heavy attachment, keep the working radius 

as small as possible and carry out the work movements 

slowly. 

Note ! 

Emergency exit 

If the machine tilts over and the cab door is blocked then you can 

exit from the front or side window. 



Warning ! 

Change in load 


• Position the machine as wide and deep as possible. Carry 

out movements slowly and carefully. 

Warning ! 

Oversized attachments 


• When selecting attachments, pay attention to their weights, 

sizes and power requirements. 

Warning ! 

Lifting objects that are too heavy 


• Keep to the bearing load specifications of the manufacturer. 

Take into account the range of application of the machine. 

Warning ! 

Means of attachment is too weak or is defective 


• Make sure that the bearing capacity of the bands, chains, 

ropes, eyes and hooks used is sufficient and that these parts 

have been correctly placed and are in perfect working order 

before lifting material with the machine. 

Warning ! 

No lifting coordinator 


• When lifting objects with the machine, a person should be 

assigned for supervision and coordination of the single working 

processes. During his work, this person must observe 

the machine operator, the machine, the staff and the surroundings. 

He must also be acquainted with the possible dangers 

and the correct approach and he must also have the necessary 

ability to judge the situation and must be alert. 



7.1.6 Safe driving / movement of the machine 

Warning ! 

Unclear driving direction 


• Before actuating the driving pedal, check the direction of the 

upper structure in relation to the chassis. If the upper structure 

is not in the driving direction then the machine drives in the 

opposite direction. 

Warning ! 

Low visibility 


• When driving, always be aware of possible obstacles above 

and near to the machine. If there is no clear visibility from the 

driver's seat then only drive with a pilot to guide you. 

Warning ! 

Loss of control on slopes and inclines 


• When driving down slopes, keep the attachment approx. 200 

to 300 mm above the ground. If the machine starts to slip or 

topple then immediately place the attachment on the ground 

to stop (brake). Do not drive down slopes backwards. 

Warning ! 

Speed is too high on slopes and inclines 


• When driving down steep slopes, adjust the speed so that 

the Diesel engine can stop the machine. If necessary, switch 

to the slow drive level. 

Warning ! 

Bridges with insufficient bearing loads 


• Observe the bearing loads of bridges. 



Warning ! 

Driving on public roads 


• When driving on public roads, the machine must be fitted 

with the optional equipment for road traffic licensing. Observe 

the local regulations for the use of public roads 

Warning ! 

Nonobservance of prescribed dimensions when driving on 

the road 


• Strictly adhere to the permitted dimensions when driving on 

public roads. 

Note ! 

Driver's license on public roads 

A category F driver's license at minimum is required to drive on 

public roads. Local regulations on driving vehicles on public 

roads also apply. 

Warning ! 

Coarse surfaces 


• Drive slowly when driving on coarse surfaces or surfaces covered 

in split and stones. 


7.1.7 Towing 


Warning ! 

Insufficient markings on vehicle when towing 


• When towing on public roads, attach suitable markings on 

the machine compliant to the local regulations. 

Warning ! 

Exceeding the speed limit when towing 


• The speed must be adapted to suit the conditions, although 

must not exceed 20 km/h. 

Warning ! 

Incorrect use of towing lug 


• The towing hook is intended for pulling lighter objects. Never 

use the towing hook to pull the machine. Keep the towing 

angle as low as possible. The towing rope must not be at an 

angle of more than 30 to the horizontal. 

Attention ! 

Do not disengage the hydraulic engine when towing 


• If you have to tow the vehicle due to an accident then the 

hydraulic engine must disconnected from the transmission 

using the built-in mechanical switch-off device. This prevents 

the hydraulic engine from overspeeding and the resulting 

damage. 

Warning ! 

Improper rescue of the machine 


• If the machine gets stuck in soft soil and is no longer able to 

free itself then connect a cable to the rear support and carefully 

pull out the machine with a towing vehicle. 



7.1.8 Shutting off the machine 

Warning ! 

Shutting off the machine at unsuitable locations 


• Never shut off the machine at or over a slope whose soil 

could slip or at the edge of an excavation site whose walls 

could collapse. If the machine has to be shut off and unattended 

for more than just a moment then you should always 

shut it off at a suitable distance from the danger zone. 

• When possible, the machine should be shut off on even and 

firm ground. 

Warning ! 

Improper shut off of the machine in open tracts 


• If you shut off the machine on a slope then always press the 

bucket with its teeth firmly into the ground and block the machine. 

Warning ! 

Improper shut off of the machine on roads 


• If he machine is shut off at or on a road then take the necessary 

safety precautions (barrier, warning lights, warning 

signs). 

Warning ! 

Improper securing of the machine 


• Before leaving the machine, always lower the attachment to 

the ground and switch off the engine. 

• Switch off the ignition and remove the ignition key. Lock 

doors and windows. 



7.1.9 Warning symbols 

Various warning symbols are attached to the machine; these must be observed for your safety. 

Warning ! 

Not understanding warning symbols 


• Observe the warning symbols. Take time to become acquainted 

with these safety instructions. 

Warning ! 

Missing or illegible warning symbols 


• Make sure that all safety instructions are on the machine and 

are legible. If text and symbols on plates is no longer legible 

due to scratches or dirt then wash the plates in question or 

replace them with new ones. Use a clean cloth and soap 

suds to wash the plates. Cleaning agent, benzene and other 

such substances must not be used. 

Note ! 

Replacing warning symbols 

Damaged, missing or illegible plates must be immediately replaced 

with new ones. If a part to which a plate is attached is 

replaced by a new part then make sure that an appropriate plate 

is also attached to the new part. Replacement plates are available 

from the manufacturer. 



7.2 Intended use as prescribed by the manufacturer 

The machine has been designed and constructed solely for the intended use 

described herein: 

7.2.1 Work above ground 

Only use the machine for work in the open. Special additional equipment is 

needed for working underground. 

7.2.2 Work in general 

Always position the machine supports as wide as possible. Maximum stability 

can thereby be achieved. Only lift loads that do not impair the stability of 

the machine. Always move the boom, the attachment and/or the load within 

a swivel radius as small as possible. 

7.2.3 Work on slopes 

Always position the machine supports as wide as possible. Keep the machine 

incline as low as possible. Never risk an incline that could endanger the 

stability of the machine. Only work on slopes when you are acquainted with 

the machine. 

7.2.4 Work on paved surfaces 

When working on paved surfaces make sure that the surface is not damaged. 

If necessary, mount the rubber pads. 



7.2.5 Work on unpaved surfaces 

There is an increased danger when working on unpaved surfaces. Before 

commencing work, make sure that the surface can take the load. Hummus, 

gravel, stones, shale etc., have extremely varied characteristics that 

requires a great deal of experience on the part of the machine operator. If in 

doubt use suitable auxiliary equipment such as, e.g. cable winch, to secure 

the machine. 

7.2.6 Work in water 

Work in water may only be carried out with the greatest of care. You can 

often not see the floor under the water, so the surface must be scanned 

carefully and exactly. Only work in water when you are acquainted with the 

machine. Only immerse the machine in water at maximum to top edge of 

swivel bases. 

7.2.7 Work with attachments 

Only install attachments intended and suitable for the size of the machine. 

Oversized attachment impair performance and safety. Observe the additional 

instructions of the manufacturer of the attachment. 



7.3 Commissioning 

This segment contains important information on the correct use of the machine. even if you already have experience 

in handling construction machines and equipment of this type, we strongly recommend you read this segment. 

7.3.1 Preliminary check 

Note ! 

Warning symbols 

Make sure that all warning symbols on the machine are intact 

and clean. If necessary, replace them when they are damaged. 

Warning ! 

Loose fastening devices 


• Check all connections, bolts, bushings etc. for tight seating 

and perfect condition. 

Warning ! 

Missing or defective protective equipment 


• Make sure that all safety and protection equipment is installed 

and functioning correctly. 

Warning ! 

Maintenance work when the machine is running 


• Checks, lubrication work, maintenance work or adjustments 

may only be carried out when the engine is switched off. 

The machine must be parked on a level and secure location, 

the chassis and the excavator arm must be placed on the 

ground. 

Warning ! 

Obstacles at the workplace 


• Do not take any heavy objects (bolts, tools, replacement material, 

etc.) into the cab. These block you from operating the 

controls. 



7.3.2 Daily checks 

Warning ! 

The complete description of these checks is contained in the Maintenance 

and Care chapter. 

Position of machine during maintenance work 

Engine oil level 

Insufficient protection of eyes from foreign bodies 


• Always wear goggles to protect your eyes from foreign bodies. 

Attention ! 

Incorrect position of machine during maintenance work 


• Park the machine horizontally as shown in the diagram for 

maintenance and checks. (Place machine in a horizontal 

position, lower to ground, set supports straight, extend and 

lower boom). 

Hydraulic oil level 

Open the rear cover to check the hydraulic oil level. The oil level must be 

between the two marks on the oil level eye. The optimum hydraulic oil level 

is marked by an arrow next to the gauge. 

To check the engine oil level, open the rear cover and pull the out the engine 

dipstick. The oil level must be within the hatched area on the dipstick. 



Level of cooling liquid 

Open the rear cover to check the level of the cooling liquid. The cooling liquid 

must completely fill the level eye in the cooler. Additionally, the level in 

the expansion cylinder is continually monitored and displayed on the display. 

Warning ! 

Hot cooling water and escaping vapour 


• The cooling circuit is pressurised when the engine is warm. 

Only open the cover of the expansion tank after the machine 

has cooled down. 

Cleaning the radiator 

Clean the radiator periodically to free it from dirt. Regular maintenance is especially 

essential when working in extremely dusty environments 

and damp weather. Clean the radiator daily if required. 

Attention ! 

Cleaning with high-pressure devices 


• When using high-pressure cleaning devices, make sure that 

the radiator is not damaged by excessive water pressure. 

Make sure that the cooling fins are not bent or damaged. 

Open the rear cover to check the clean the radiator. Fold open the air-conditioner 

cooler and leave it open. Clean the cooler with compressed air (max. 

7 bar). 



7.3.3 Startup and commissioning 

The machine may only be started after carrying out the work described in 

the "Daily checks" chapter. 

Warning ! 

Starting up in a closed room 


• Install a prescribed ventilation system before starting up the 

machine in a closed room. Make sure there is good ventilation. 

Starting the Diesel engine 

The described worksteps must be carried out by the operator from the cab. 

1. Insert ignition key and turn to Position 1 to activate and start the electronic 

components . 

2. Set the speed potentiometer to the minimum engine speed. 

3. Turn the ignition key further to the stop and keep it turned until the Diesel 

engine starts. Then immediately release it, leaving it in position. 

Attention ! 

Prolonged actuation of the starter 


• Do not actuate the starter for more than 30 seconds. Otherwise 

it might overheat. If the engine does not start on the first 

attempt then wait at least 2 minutes before making another 

attempt. If the machine has not started after 4 attempts then 

refer to the instructions in the "Fault and remedy" segment 

Checks and protective measures when the engine is running 

Attention ! 

Control lamps lighting 


• Make sure that no control lamp lights up on the display. 


1 

3 

2


Attention ! 

A full load when the engine and hydraulic system are 

cold 


• Operate the engine without a load for 1 - 2 minutes after startup 

or at a maximum speed of 1200 rpm. Increase this period 

by 2 - 4 minutes if the engine is operated below freezing 

point. The engine and the hydraulic system are thereby heated 

up slightly, thereby reducing wear to the engine. 

Warning ! 

Defective armrest switch 


• Check the armrest switch on the left armrest by: pulling up 

the left armrest (1) - moving the right joystick (2) to the left 

and the right. These or any other operations must not cause 

anything to move. 

Shut off the Diesel engine 

Attention ! 

Immediately shutting off the engine after a full load 


• Before shutting off the engine, which has been operated 

• under a workload, allow it to run for at least 2 minutes at 

1000 - 1200 rpm until hot engine parts cool down. 

After the engine rundown time: 

1. Set the speed potentiometer anticlockwise to the minimum engine speed. 

2. Turn the ignition key anticlockwise to Position 0 and then remove the ignition 

key. 


2 

2 

1 

1


7.4 Operating upperstructure 

8 

9 

7 

3 

9 

7.4.1 Powermode 

10 

10 

1 

1 

2 

2 

Left 

With the right button shown on the right joystick, you can enable the power 

mode for 5s. The working pressure and so the force is increased during this 

time. 

4 

5 

6 

3 

4 

Right 


7 

5 

6 

right 

8


7.4.1 Hoisting operation 

Working regulations for hoisting operation in the EC and Switzerland 

Lifting and moving loads with a hook up device, eg rope or chain is called hoisting operation. Dislocation of pieces, 

pipes or machines can be such a hoisting operation. 

Warning ! 

Overload warning device switched off 

• Can result in tilting of the machine and thereby to death or 

severe injuries. 

• Switch on the overload warning device during hoisting operations. 

Warning ! 

Insufficient stability 

• Can result in tilting of the machine and thereby to death or 

severe injuries. 

• Keep the centre of gravity of the machine as low as possible 

and fully extend the support. 

Stability in the sector range at ISO 10567 



Hoisting operation 

Switch on the overload warning device with the switch on the right is you 

want to move a load within the load range 

An acoustic and visual signal (19 warns you if the load is too heavy to be 

liftedIf a warning is issued then the load must be lowered to the bottom immediately 

(danger of tilting). 

Note ! 

Liability 

The manufacturer refuses to accept any liability for damage resulting 

form nonobservance of 

operating instructions or if the customer carries out changes to 

the overload warning device. 1 

Load diagram T1.8 

Requirements: Even and paved location, stabilizers and wheels to max. width, 

stabilizers extendend, chassis as low as possible. 

7 

6 

5 

4 

3 

2 

1 

0 

-1 

-2 

-3 

-3 -2 -1 0 1 2 3 4 5 6 7 8 


kN 

100 

90 

80 

70 

60 

50 

40 

30 

20 

10 

0 

-10


7.5 Command of chassis 

7.5.1 A81 Mobil / A81 Mobil steered wheel hub 

L 

5 

6 

11 

9 

10 

3 

1 

3 4 

12 

2 

1L 

2L 

1 

2 

7 

7 

4 

8 


5 

6 

Left 

8 

11 

9 

10 

12 

23 

21 

22 

19 

24 

19 

17 

18 

Right 

20 

20 

15 

14 

13L 

14L 

15 

23 

13 

13 

14 

21 

22 

16 

24 

17 

18 

16


Steerable wheel position 

The steerable wheels can be attached to the bases in three different positions. 

1./2. Rig positions for drive mode 

3. Rig position for moving the steerable wheel in rough terrain 

Warning ! 

Steerable wheels have no brakes 


• Work may only be performed in such a fashion as to prevent 

the machine from rolling away via the steerable 

• wheels 

Pad position 

The pads help to support the machine and anchor it in rough terrain. They 

are available in two different versions. 

The steel pads can be attached as the standard pads for terrain use. They 

can be positioned in two different positions: 

1. Perfect contour 

2. Improvement of ground clearance 

3. Position with rubber pad 

The rubber pads can be attached when there is a risk of damage to the 

ground underneath, e.g. on public roads or concrete / paved surfaces. To do 

so, the steel pads must be raised and the rubber pads attached to the available 

rig position of the steel pads. 

Warning ! 

Unsecured pad 


• The pad bolts must be secured from falling out using the securing 

blocks.. 


3 

2 

2 

1 

1 

3


7.6 Driving 

7.6.1 A81 Mobil / A81 Mobil steered hub drive 

li 


re 

V 

R 

V 

R 

li 

Right 

li 

re 

re

7.6.2 Driving 


Note ! 

Driving 

Before you leave, adjust the wheels so that they are in direction 

of travel. 

Accelerator pedal 

Select the driving direction with the accelerator pedal. Adjust to required 

speed using the proportional accelerator pedal. 

Warning ! 

Unclear driving direction 


• Before actuating the accelerator pedal, check the direction 

of the upper structure in relation to the chassis. If the upper 

structure is not in the driving direction then the machine 

drives in the opposite direction. 

Drive stage fast-slow 

Select between fast and slow drive stages using the drive stage step switch. 

Warning ! 

Excessive speed 


• Adjust the speed to the conditions. 

Maximum speed limitation 

Select the maximum speed with the traction drive potentiometer. 

Turning clockwise increases the maximum possible speed. 

Turning anticlockwise decreases the maximum possible speed. 

Note ! 

Travelling gear potentiometer 

If you cannot reach the required speed for the travelling gear then 

check to make sure the potentiometer of the travelling gear is not 

set to the minimum speed. 


V 

R


7.6.3 Braking 

If the Menzi Muck is to be brought to a standstill, allow the accelerator pedal 

to return to its centre position. If this deceleration is inadequate, locknuts 

can be used to shorten the brake path (by controlling the pedal in the opposite 

direction). 

Warning ! 

Speed is too high on slopes and inclines 


• When driving down steep slopes, adjust the speed so that 

the Diesel engine can stop the machine. If necessary, switch 

to the slow drive level. 

Warning ! 

Loss of control on slopes and inclines 


• When driving down slopes, keep the attachment approx. 200 

to 300 mm above the ground. If the machine starts to slip or 

topple then immediately place the attachment on the ground 

to stop (brake). Do not drive down slopes backwards. 


V 

R


7.6.4 Steering 

Switch over between bucket / steering 

Select the following functions with the bucket / steering switch:: 

1. Step = bucket switched off, steering and automatic driving enabled 

2. Step = boom switched off, steering and automatic driving enabled 

Steering with the joystick 

Select the steering direction with the joystick. Adjust to the required steering 

speed and turning radius using the proportional joystick. 

Warning ! 

Incorrect steering direction 


• Make sure that the upper structure is in the driving direction. 

Steering movements that are initiated when the upper structure 

is not facing the direction of travel are counteracted. 

Switch over bucket function temporarily to stabilizer or pivot steering 

Select the button (1) on the right joystick to enable stabilizer or pivot steering. 

The bucket function is re-enabled as soon as you release the button. 

Temporarily switchover from stabilzer steering to pivot steering 

Select the button (2) on the left joystick to temporarily switch over from stabilizer 

steering to pivot steering. Stabilizer steering is re-enabled as soon as 

you release the button. 

Right 


2 

li 

1 

Right 

Left 

re


7.6.5 Tow / Hide 

When being towed, the hydraulic engine must be disconnected from the 

transmission using the built-in mechanical switch-off device to prevent overspeeding 

of the hydraulic engine and the resulting damage. 

Warning ! 

Machine not stopped, towing without a towing rod 


• Always use a towing rod when towing. 

Warning ! 

Warning ! 


Zugfahrzeug 

Insufficient markings on vehicle when towing 


• When towing on public roads, attach suitable markings on 

the machine compliant to the local regulations. 

Exceeding the speed limit when towing 


• The speed must be adapted to suit the conditions, although 

must not exceed 20 km/h.


7.6.6 Mechanically decouple and couple the traction drive 

Warning ! 

Machine is not stopped after decoupling the drive 

mechanisms 


• Secure the machine against rolling off. Support the boom on 

the ground and place dry wedges underneath it. 

Trasmital drive mechanism 

Decoupling: 

• Free the wheel from the base by lifting it. 

• Using a hexagon socket screw key, turn the bolting device in the direction 

of the arrow as far as it will go. 

Coupling: 


• Using a hexagon socket screw key, turn the bolting device in the direction 

opposite the arrow. Slowly turn the wheel while doing so. As soon 

as resistance is felt, the gearwheels catch in the transmission, and you 

can now easily screw in the bolting device as far as it will go (approx. 6 

rotations) 

Reggiana drive mechanism 

Decoupling: 


• Release the screws and remove the top plate. 

• Turn the top plate inwards and mount the screw. 

Coupling: 


• Release the screw and remove the top plate. 

• Turn the top plate outwards and mount the screw. When doing so, turn 

the wheel slowly so that the teeth can grip in. 



7.6.7 Driving positions (Swiss road traffic license) 

Warning ! 

A81 Mobil T1.8 

Nonobservance of prescribed dimensions when driving on 

the road 


• Strictly adhere to the permitted dimensions when driving on 

public roads 

Note ! 

Position of vehicle when driving on roads 

Arrows are stuck onto the moving parts of the machine to help 

you easily adjust the driving direction. 



7.7 Operating the hydraulic auxiliary connections 

12 

2 

14 13 

1 

7 

8 

Left 

4 

9 

5 

6 

3 

6 

5 

13 

Pos. Denomination Flow rate Pressure Type of connection 

l/min US-gall/min bar psi 

Right 

1 Electric connection * - - Quick connect, female 

2 Leak oil connection arm - 0.5 - 2 7.2 - 29 Quick connect, female 1/2" 

3 Quick changer connection - 30 435 Quick connect, female Flat-Face 1/4" 

4 Quick changer connection - 30 435 Quick connect, male Flat-Face 1/4" 

5 Auxiliary connection 160 42.26 280 4061 Quick connect, male Roflex 1/2" 

6 Auxiliary connection 160 42.26 280 4061 Quick connect, female Roflex 1/2" 

7 Auxiliary connection 80 21.13 280 4061 Quick connect, male Flat-Face 1/4" 

8 Auxiliary connection 80 21.13 280 4061 Quick connect, female Flat-Face 1/4" 

9 Hammer return line - 2-10 29 - 145 Quick connect, male MD-019-2 1" 

10 Retract rope of winch 100 26.42 280 4061 Quick connect, male Roflex 1/2" 

11 Pullout rope of winch 100 26.42 280 4061 Quick connect, female Roflex 1/2" 

12 Leak oil connection winch - 0.5-2 7.2 - 29 Quick connect, male 1/2" 

* operation depends on accessories 

The connections vary for special equipements (forest, etc.). 

10 

14 

11 


7 

8 

3/4 

13 

15 

14


7.8 Operating the accessories 

The instructions listed here should be understood as additional information to the operating instructions of the 

respective attachment. The instructions describe only those functions required for the MENZI MUCK attachments. 

Further instructions are contained in the operating instructions of the attachment. Before using the machine for the 

first time, the operator must familiarise himself with its equipment to enable reliable, economical and above all safe 

use of the extensive range of machine functions. 

Warning ! 

Nonobservance of the attachment operating instructions 


• Please refer to the attachment operating instructions and observe 

the regulations. 

Attention ! 

Incorrect coupling of attachments 


• Make sure that the attachments are locked correctly and the 

quick couplers are connected correctly. 

7.8.1 Attaching buckets 

1. Set bucket down on flat surface. 

2. Remove locking pins (A). 

3. Rotate the bucket to relieve the pin (B). 

4. Remove the pin (B). 

5. Lower the bucket onto the floor. 

6. Move the boom to relieve pin the (C). 

7. Remove the pin (C). 

Fit the bucket in the reverse sequence. 


B 

A 

C


7.8.2 Tiltrotator Engcon 

Left 

5 = Auxiliary grappler - open 

6 = Auxiliary grappler - close 

9a = Activate hydr. quick changer 

9b = Open hydr. quick changer 

Warning ! 

1 

3 

2 

4 

Incorrect locking of quick changer 


• When closing the quick changer, perform a function of the 

tilt rotator under pressure to ensure that the quick changer is 

securely closed. Lock the quick changer as described in the 

Engcon operator's manual. 

1 

2 

4 

3 

8 

7 

9b 

7 

9a 

Right 


5 

6 

9b 

8

7.8.3 Winch 


E 

Optional model: 

Electrically operated cable winch 

A 


A 

E 

The cable winch functions are 

activated on the joystick 

A E 

Left



Maintenance and Care 

8. Maintenance and Care 

8.1 Safety instructions 

8.1.1 Carry out maintenance regularly 

Warning ! 

Untrained service personnel 


• All maintenance work described here may only be carried out 

by trained service personnel. 

Warning ! 

Carelessly executed maintenance work 


• Carry out maintenance work with the utmost of care. 

Warning ! 

Ignition key is inserted during maintenance work 


• Remove the ignition key and keep it in a safe place. 

Attention ! 

Incorrect positioning of machine 


• Before all maintenance work, place the machine and its 

equipment on the ground and shut off the Diesel engine. 

8.1.2 Warning during service work 

Warning ! 

Incorrectly marked machine 


• When carrying out work, mark the machine as follows: "Maintenance 

work - Machine must not be started". 



8.1.3 Work equipment 

Warning ! 

• Escaping fuels and lubricants 


• Always wear goggles and protective clothing. 

8.1.4 Protective guards 

Warning ! 

Opening protective guards during operation 


• Only open the protective guards after the drive has stopped. 

Warning ! 

Rotating and moving parts 


• Keep sufficient distance from rotating and moving parts. 

Warning ! 

Non-secured cab 


• After tilting, immediately position the lock for the cab. 

Warning ! 




Attention ! 


• Can result in breakage to cab door or other damage to property. 




8.1.5 Fluids and lubricants 

Warning ! 

Cigarette ends, flames or other heat sources 

• can result in fires or explosions there thereby in death or severe 

injuries. 

• Keep fuel, lubricant and the like away from cigarettes, flames 

or other heat sources. 

Warning ! 

Hot coolant 


• Never open the coolant cover when the machine is running 

or is hot. 

Warning ! 

Hot engine 


• Keep sufficient distance from hot components. 

Warning ! 

Hydraulics still under pressure 


• Before maintenance work, depressurise the working and 

driving hydraulics by pressing the controls with the engine 

stopped. 

Warning ! 

Vapours during welding or heating 


• Remove paint or surface coating before welding or heating. 

Warning ! 

Insufficiently secured machine 


• Secure the machine using fasteners that are adequately 

strong and that are of adequate size. 



8.1.6 Actuated controls 

Warning ! 

Actuated controls 


• Put the control level into neutral position before starting the 

engine. 

8.1.7 Machine condition 

Warning ! 

Defective machine parts 


• Replace defective or worn machine parts immediately. 

Attention ! 

Defective machine parts 

• Can result in additional damage to property. 

• Replace defective or worn machine parts immediately. 

Warning ! 

Leaky locations at the machine 


• Remedy noticeable leaky locations immediately. 

Attention ! 

Leaky locations at the machine 

• Can result in additional damage to property or even in fire. 

• Remedy noticeable untight locations immediately and clean 

soiled parts. 



Warning ! 

Dirty machine 


• Clean the machine thoroughly after using for a longer period, 

or as required, . 

Attention ! 

Dirty machine 

• Can result in damage to property or in premature ageing. 

• Clean the machine thoroughly after using for a longer period, 

or as required, . 

Warning ! 







Attention ! 

Welding work at the machine 


1. Set the ignition key to 0 

2. Switch off the main switch. 

3. Connect the minus terminal to the batters. 

4. Connect the earth terminal directly next the part to be welded 

(observe perfect contact). 



8.2 Machine position for maintenance work 

Attention ! 

Incorrect position of machine during maintenance work 


• Park the machine horizontally as shown in the diagram below 

for maintenance and checks. (Place machine in a horizontal 

position, lower to ground, set supports straight, extend and 

lower boom). 



8.3 Maintenance intervals 

every 8 h / daily 


every 50 h / weekly 

1st ervice 50-100 h 

Intervalls Spezifications Technical data 

every 500 h 

every 1000 h / jearly 

every 2000 h 

Engine - Cooler 

Engine oil SAE 15W-40/SAE 10W-40 15 128 

Engine oil filter 877005 128 

Fuel filter l 877135/877136/126248 130 

Air filter 126638 148 

Air filter safety element 126639 126 

Valve play of intake valve 0.31-0.38 126 

Valve play of outlet valve 0.41-0.48 131 

Radiator 131 

Radiator fluid 

Belt tightener and belt 

24 125 

Crankshaft casing bleed pipe 

Tightness, engine-cooler 

Gears 

131 

Drive mechanism SAE 75W90 API-GL-4/5 2.5 133 

Swing gear 

Tightness, driving gear 

Hydraulic system 

SAE 75W90 API-GL-4/5 2.5 134 

Hydraulic oil Panolin HLP46 o. Synth 46 200 135 

Hydraulic return filter 125215 139 

Hydraulic pressure filter l 855004 140 

Hydraulic partial flow filter 

Working hydraulics pressures 

Driving hydraulics pressures 

125014 141 

Hydraulic tank cover pressure 200747 0.5 138 

Condition of hydraulic lines 142 

Condition of hydraulic hoses 

Tightness of hydraulic system 

142 

l = change = clean = grease = control = regulate 

as required 

Specifications 

Capacities in l 

Setting standards in mm 

Pressure in bar 

see page


Elektrical system 

every 8 h / daily 

every 50 h / weekly 

1st ervice 50-100 h 

Intervalls Spezifications Technical data 

every 500 h 

every 1000 h / jearly 

every 2000 h 

Battery Maintenance free 147 

Battery and earth cable 147 

Light and signalling system 

Control and warning equipment 

Electrical turning distributor 150 

General setup 

Air filter in suction channel 199370 132 

Air conditioner coolant R134a 132 

Windscreen fluid 2 175 

Chassis lubrication points EP-2 NLGI Nr.2 172 

Upper structure lubrication points EP-2 NLGI Nr.2 170 

Rotating assembly internal gearing EP-2 NLGI Nr.2 171 

Hub wheel air pressure 4.5-6.5 22 

Steering wheel air pressure 9 22 

Steering wheel bearing 172 

Telescopic arm 174 

Screw connections 

Weld connections 

Steel structure 

All functions 

l = change = clean = grease = control = regulate 

Note ! 

Hydraulic oil change interval 

Take a sample of the oil after 2000 h and have it analysed. If the 

result is OK then the hydraulic oil can be used for another 500 

hours. Carry out another analysis after another 500 hours. 

as required 

Specifications 


Capacities in l 

Setting standards in mm 

Pressure in bar 

see page


8.4 Lubricant table 

Application Type Viscosity Quality Temperatures 

Capacities 

l/US-gall. 

Diesel engine with Diesel engine oil SAE 10W/40 Panolin Diesel Synth > 25°C - 40°C 15 / 3.96 

particulate filter 

EU-4 10W/40 

Diesel engine Diesel engine oil SAE 15W40 

ACEA E4 - E7 

>20°C - 50°C 15 / 3.96 

SAE 10W40 

API CI-4/CI4-PLUS 

API CC/CD/CE 

> 25°C - 40°C 

Hydraulic system Hydraulic oil ISO VG 46 factory-filled with 

Panolin HLP46 oder 

Synth46 (Bio) 

200 / 52.8 

Diesel tank Diesel CFPP Klasse B 

DIN-EN 590 

> 0°C 

Upper structure: 

CFPP Klasse D 

max. 5% Biodiesel > -10°C 

130 / 34.3 

CFPP Klasse E 

> -15°C 

Chassis: 

CFPP Klasse F 

> -20°C 

200 / 52.8 

Cooler Coolant ASTM D6210 > -37°C 24 / 6.34 

Transmission oil SAE 75W90 API-GL-4/5 0.9-2.5 liters 

Swing gear Transmission oil SAE 75W90 API-GL-4/5 2.5 liters 

Lubricants Lithium-based grease NLHI 2 EP-2 aply as necessary 

Note ! 

Operating manual by the manufacurer of engine 

For more details, refer to the operating manual provided by the 

manufacturer of the engine. 

Note ! 

Diesel 

Cetane number 45 or higher. A cetane number of over 50 is preferred, 

especially at temperatures of below -20°C or elevations 

of over 1500 m above see level. Filtering capability limit (CFPP) 

below the anticipated minimum temperature OR turbidity point at 

least 5°C below the anticipated minimum temperature. The maximum 

permissible biodiesel concentration is a 5% mixture (also 

known as B5) with crude oil diesel fuel. 

Attention ! 

Incorrect Diesel fuel 


• Raw-pressed vegetable oils, regardless of the concentration, 

may never be used in the fuel in John Deere engines. 



8.5 Engine and air-conditioning 

This Operating Manual contains no detailed information on servicing, starting 

or maintaining the diesel motor. It provides only auxiliary, important and 

machine-related data. Please refer to the engine manufacturer’s Operating 

Manual for detailed information. 

8.5.1 Inspection cooling water 

The coolant level must be checked every day prior to beginning work. 

This is easily done by opening the right casing. The level in the cooling unit 

must completely fill the gauge. Additionally, the level in the expansion cylinder 

is continually monitored and displayed on the display. If the display lights 

up during operation, the coolant is low and must be replenished immediately. 

Warning ! 

Hot cooling water and escaping vapour 


• The cooling circuit is pressurised when the engine is warm. 

Only open the cover of the expansion tank after the machine 

has cooled down. 

Refill coolant 

1. Allow the machine to cool down and then tilt the cab. 

2. Open the coolant cover by rotating it counterclockwise. 

3. Half-fill the expansion tank with coolant. The coolant (-37°C) is comprised 

of water and antifreeze. 

4. Close the expansion tank with the coolant cover by rotating it clockwise. 

5. Lower the cab. 

Cooling water quality 

The cooling water quality you used has a significant influence on the efficiency 

and life span of the cooling system. Basically, a mix of maximum 40- 60% 

anti-freeze should be used. 



8.5.2 Cleaning the radiator 

Clean the radiator periodically to free it from dirt. Regular maintenance is especially 

essential when working in extremely dusty environments and damp 

weather. Clean the radiator daily if required. 

Attention ! 

Cleaning with high-pressure devices 


• When using high-pressure cleaning devices, make sure that 

the radiator is not damaged by excessive water pressure. 

Make sure that the cooling fins are not bent or damaged. 

Open the rear cover to check the clean the radiator. Fold open the air-conditioner 

cooler and leave it open. Clean the cooler with compressed air (max. 

7 bar). 

8.5.3 Servicing the air filter 

The interval for servicing the air filter unit depends on the dust concentration 

in the air and on the speed of the engine. Ideally the filter cartridges are only 

cleaned or replaced when the service switch is activated (no later than the 

ordered hours). However, every time on starting up the engine it should be 

briefly brought up to its maximum speed, and then it should be observed 

whether the lamp lights up, and thus the functioning of the monitoring system 

is checked. 



Mainetnance of air filter: 

1. Open the rear cover. 

2. Open the quick acting closure and dismount the air filter maintenance 

panel by lifting it out. 

3. Open the locking clips of the air filter. 

4. Pace the cyclone cover and dirt hose to the sideClean the cyclone cover 

with compressed air. 

5. Dismount the filter insert and clean it with compressed air (max. 2 bar). 

6. Check the safety filter insert for soiling. If soiling is detected then the filter 

elements must be replaced. 

Attention ! 

Cleaning the safety filter insert 

• Can result in damage to the engine. 

• Only remove the safety filter insert when it has to be replaced. 

It must not be cleaned. Normally, the safety filter 

insert only needs to be replaced when there is a hole in the 

filter insert. 

7. Mount all components in reverse order. 


3 

3 

4 

2 

5 

6


8.5.4 Engine oil and filter replacement 

Replace the engine oil and its filter compliant to the maintenance schedule. 

1. Allow the engine to run for 5 minutes to warm up the engine oil. 

2. Switch off the engine. 


4. Dismantle the lower engine plate by undoing the screws and lifting it off. 

5. Place a suitable vessel below the drain. 

6. Unscrew the drain seal to allow the engine oil to flow off. 

7. Unscrew the engine oil filter with a suitable filter key. 

8. Dispose of the engine oil filter. 

9. Wipe the sealing surfaces on the filter head using a clean cloth. 

10. Make sure that the dust seal on the filter head is correctly located in the 

slots and is not damaged. 

11. Apply new engine oil to the seals ad the grooves of the engine filter. 


11 

10 

4 

7 

9 

6 

9 

11


12. Screw on the engine oil filter by hand until it is flush with the dust seal. 

Note ! 

Only tighten the engine oil filter manually 

Tighten only by hand. Only use the filter key for removal. 

13. Screw on the drain seal and tighten it to the specified torque. 

Note ! 

Tighten the drain seal to the specified torque 

Tighten Drain seal with copper washer 70 Nm, drain seal with Oring 

50 Nm). 

14. Fill the engine crankshaft housing up to the marking with the specified 

motor oil through the oil fill seal on the engine side. 

Note ! 

Ensure sufficient lubrication of engine parts 

Rotate the engine for 30 seconds without allowing it to start (trigger 

ermegency stop). 

15. Check the amount of engine oil filled with the dipstick. 

16. Top up as necessary. 

17. Start the engine and check for any leaks. 

18. Switch off the engine and wait 10 minutes. 

19. Check the oil level on the dipstick, It should be within the hatched area. 

20. Mount the lower engine plate and close the rear cover. 


15 

19 

19 

20 

12 

14 

16 

13


8.5.5 Fuel filter replacement 


2. Clean around the fuel filter thoroughly.. 

3. Release and remove the holder of the line filter. 

4. Mount the new line filter and tighten the holder. 

5. Unplug the water sensor. 

6. Loosen the drain seals and drain the fluid into a suitable container. 

Note ! 

Release securing ring 

Raise slightly when rotating the securing ring to allow it to be turned 

more easily over the catch. 

7. Turn the securing ring 1/4 rotation counterclockwise and remove the filter 

insert. 

8. Remove and empty the water collector. 

9. Clean the filter base and the water collector. 

10. Mount the new filter inserts with the securing ring. Turn the securing ring 

clockwise 1/3 of a rotation until a clicking noise is heard indicating that it 

has engaged. Make sure that the filter inserts are correctly aligned and 

firmly seated on the base. 

11. Mount of the engine oil filter. 

12. Plug in the plug of the water sensor. 

13. Bleed the fuel system as described on the next page. 

Note ! 

Correctly position fuel filter 

Straighten the fuel filters so that the slots and the mounting boss 

line up. 


10 

4 

6 

7 

3 

4 

3 

8 

6 

10 

11 

7


Bleeding the fuel system 

Attention ! 

Fuel contamination 

• Can result in damage to the engine. 

• Do not open fuel lines to bleed the fuel system. 

1. Release the bleed screw on the fuel filter base by turning it twice fully anticlockwise. 

2. Actuate the fuel pump feed lever until fuel escapes from the bleed 

screw. 

3. Tighten the bleed screw clockwise. Continue to actuate the fuel feed 

pump until there is no noticeable pump effect. 

4. Switch on the engine and check the fuel system for leaks. 

5. If the engine does not start, repeat steps 1-4. 

Drain off condensation at the fuel filter 

Condensate water can be drained from both the preliminary fuel filter and 

the fuel filter. This is normally done during a service and filter change.If engine 

performance starts to drop, check to make sure there is no water in the 

filters. 

1. Provide a suitable vessel.. 

2. The bleed valve can be undone by turning anticlockwise. 

2 

3. As soon as only fuel runs out, the bleed valve can be reclosed. 3 

2 

3 

8.5.6 Cleaning the crankcase bleed pipe 

1. Remove the crankcase bleed pipe 

2. Clean it. 

3. Fit the bleed pipe. Make sure that the O-ring is correctly seated in the 

rocker cover of the elbow adapter. 

4. Tighten the hose clamp. 

8.5.7 Checking and adjusting valve play 

The valve play must be adjusted and re-adjusted after 2000 operating hours. 

Lower machine in a horizontal position onto the chassis. The rear, side and 

engine covers must be removed to enable work to be carried out unhindered.Please 

refer to the John Deere Operating Manual for further details. 


1 

2


8.6 Heating/Air conditioning 

With few exceptions, the heating and air conditioning system does not require 

any maintenance. To ensure the fault-free operation and maximum performance 

of the system, depending on dust concentration levels, the intake 

air must be flushed out of the air channel in the intake port at least every 500 

operating hours. The intake air flow will be reduced dramatically if the filter 

elements are excessively dirty, considerably affecting heating and cooling 

performance. The filter element is easy to maintain and can be accessed 

from the left-hand side of the machine by removing the intake port. 

1. Tilt the cab. 

2. Remove the intake port. 

3. Clean the air filter with compressed air and the filter housing with a soft 

cloth. 

4. Mount the intake port. 


8.6.1 Coolant 

The air conditioning system coolant circuit contains approx. 750 g of coolant. The manufacturer designation of 

the coolant used, which is a tetra-fluoro-ethane compound, is R134a. Unlike the compounds used in the past, like 

R12, which were composed of fluorine, chlorine, carbon and hydrogen, this coolant meets the conditions and requirements 

of a modern environmentally-friendly coolant. However, guidelines governing the use of such coolants, 

which are designed to protect health and the environment, must be observed. 

8.6.2 Filling 

The system is filled before leaving the factory. Special equipment and expert knowledge are required to fill the system 

correctly. We recommend that the fill level is checked every 2 years by a specialist operator or a Menzi Muck 

Service Centre or service engineer. 

8.6.3 Cooling oil 

In this case too, the system is filled to the correct level before leaving the factory. Do not open any couplings on 

the compressor to avoid the risk of coolant leaking. The correct fill level or residual amount of compressor oil is 

checked by Menzi Muck engineers during servicing. However, should you need to top up the compressor oil, you 

should only use PAG diester oils. The oil used must be able to combine with the coolant in order that even system 

components which are separate from the compressor, in particular the expansion valve and binary pressure 

switch, can be lubricated. 

8.6.4 Repairs to the coolant circuit 

Should repairs need to be made to the coolant circuit, please contact one of our Service Centres or a specialist 

operator in your area. You should never make modifications to or carry out repairs on the coolant circuit. If the 

coolant heats up, as is the case during soldering and welding, it decomposes and produces extremely poisonous 

gases and vapours. Decomposition products are also very aggressive. 


2 

4 

1 

5 

3


8.7 Gears 

8.7.1 Wheel hub 

The rear wheels are driven by two (four) hydrostatic wheel-hub drives filled with gear oil. The wheel-hub drives are 

equipped with an automatic parking brake that also runs in an oil bath. The brake is adjustment and maintenancefree. 

Oil level check: daily check for leaks and level check after 500 operating hours. 

Oil replacement: every 1000 operating hours or annually. 

1. Align the wheel as shown in the corresponding diagram to the left. 

2. Provide a suitable catch container. 

3. Remove the plug(s). 

4. Allow the gear oil to drain completely. 

5. Mount the plug(s). 

6. Align the wheel as shown in the corresponding diagram to the right. 

7. Fill gear oil at the top plug (A) until it runs up to the level plug (B). 

8. Mount the plug(s). 

Capacities wheel hub 

Machine Type Capacities in l 

A81 Mobil 2-stage Trasmital 606W2B 2.5 

A81 Mobil Trasmital 606W2 1.4 

A81 Mobil 2-stage Reggiana RRWD1601DB 1.8 

A81 Mobil Reggiana RRWD800DB 0.9 

Attention ! 

Fast-filling the gear oil 

• Can result in damage to the drive mechanism. 

• Fill the gear oil slowly to avoid bubbles. This prevents incorrect 

measurements. 

Wheel hub Trasmital 

Drain oil 

Wheel hub Reggiana 

7A/B 

Filling and control 

oil 


3 

5 

3 

5 

Drain oil 

3 

3 

3 

1 

1 

6 

6 

7B 

7A 

Filling and control 

oil


8.7.2 Swing gear 

A hydromotor and a multiple disc brake are mounted on the swing gear. The hydromotor powers the swing gear 

which has the function of reducing the hydromotor speed to attain the necessary swing torque to allow the upper 

structure to rotate. The upper structure will be braked from the swinging motion over the swing gear and the 

hydromotor and held by the automatically braking multiple-plate brake. The swing gear has two planetary gear 

stages. 

Oil level check: daily check for leaks and level check after 500 operating hours. 

Oil replacement: every 1000 operating hours or annually. 


2. Remove the panel underneath the radiator. 


4. Remove the locking screw cap. 

5. Allow the gear oil to drain completely. 

6. Mount the locking screw cap. 

7. Fill in the prescribed amount of gear oil at the measuring plug or the 

drain hose. 

8. Check the level on the dipstick. 

9. Mount the panel underneath the radiator. 


Capacity swing gear: 2.5 liters 

Attention ! 

Fast-filling the gear oil 

• Can result in damage to the swivel gear. 

• Fill the gear oil slowly to avoid bubbles. This prevents incorrect 

measurements. 


4 

6 

7 

2 

9 

7 

8


8.8 Hydraulic system 

Attention ! 

Mixing hydraulic oils 

• Can result in damage to the hydraulic components. 

• Always fill in the same amount of hydraulic oil. Never mix mineral 

hydraulic oil with biological hydraulic oil. 

Attention ! 

Incorrect oil-type replacement 


• When replacing the oil type, first drain off all hydraulic oil 

and rinse the system. 

Attention ! 

Starting the engine when changing oil 


• Never start the engine if there is no hydraulic oil, or too little, 

in the tank. 

8.8.1 Check hydraulic oil level 

Open the rear cover to check the hydraulic oil level. The oil level must be 

between the two marks on the gauge. 

The optimum hydraulic oil level is marked by an arrow next to the gauge. 

Attention ! 

Incorrect position of machine during hydraulic oil 

check 

• Can result in incorrect hydraulic oil level with concomitant 

damage to the hydraulic components. 

• Shut off the machine as described at the beginning of this 

chapter. 



8.8.2 Change / Refill hydraulic oil 

Warning ! 

Hot hydraulic oil 


• The hydraulic system is pressurised. Only work on the hydraulic 

system after the hydraulic oil has cooled down 

Attention ! 

Surroundings dirty when working on hydraulic oil 

system 


• Make sure the area is clean when working on the hydraulics 

system. 

Note ! 

Hydraulic oil change interval 

Take a sample of the oil after 2000 h and have it analysed. If the 

result is OK then the hydraulic oil can be used for another 500 

hours. Carry out another analysis after another 500 hours. 

Note ! 

Change hydraulic oil after major damage to the hydraulic 

system 

Change the hydraulic oil and rinse the system after major damage 

to the hydraulic components. 

Oil change: Every 2000 operating hours or depending on the result of the 

analysis. 

1 Shut off the machine as described at the beginning of this chapter. 

2. Tilt the cab and open the rear cover. 

3. Dismantle the lower pump plate by undoing the screws and lifting it off. 



2


5. Loosen the hydraulic connections. 

6. Allow all hydraulic oil to flow out. 

7. Clean the hydraulic oil tank with clean hydraulic oil. 

8. Mount the hydraulic connections. 

Attention ! 

Unfiltered hydraulic oil 


• Only fill with filtered hydraulic oil. 

9. Fill in the prescribed amount of gear oil at the filling nozzle. 

10. Check the level on the gauge. The optimum hydraulic oil level is marked 

by an arrow next to the gauge. 

11. Mount the lower pump plate and close the rear cover. 


11 

7 

5 

8 

9 

10


8.8.3 Check hydraulic oil tank cover 

Warning ! 





The hydraulic tank cover regulates the prestress of approx. 0.5 bar in the 

hydraulic system. 

1. Start the machine and allow it to run for 2 minutes. 

2. Switch off the machine. 


4. Unscrew the hydraulic tank cover. You should hear a hissing noise; 

otherwise, the control valve in the tank cover is not functioning correctly. 

5. If you do not hear a hissing noise then replace the hydraulic tank cover. 



4


8.8.4 Changing hydr. filter 

Warning ! 





Filter replacement: Every 1000 operating hours, annually or when the filter 

control lamp lights up. 

Attention ! 

Verschmutzter Rücklauffilter 

• Kann zu Sachschäden an Hydraulikkomponenten führen, da 

das Hydrauliköl ungefiltert über das Bypassventil in den Hydrauliktank 

fliessen kann. 

• Wechseln Sie den Rücklauffilter spätestens nach 1000 

Betriebsstunden, einmal jährlich oder wenn die Filterkontrollleuchte 

aufleuchtet. 


2. Clean the area around the filter thoroughly so no dirt gets into the hydraulic 

system. 

3. Unscrew the screws on the filter cover 

4. Lift off the filter cover. 

5. Take the filter element and the dirt trap tray together out of the filter 

housing. 

6. Remove the filter element from the dirt trap tray and dispose of it. 

7. Clean the dirt trap tray. 

8. Check all O-rings for damages. 

9. Mount the filter element into the dirt trap tray. 

10. Install the filter element and the dirt trap tray together into the filter 

housing. 

11. Lubricate the O-ring on the filter cover with a little hydraulic oil. 

12. Mount the filter cover. 

13. Faster the filter cover with screws. 

14. Check level of hydraulic oil. 


6 

9 

7 


2 

13 

3 

11 

12 

4 

5 

10


Replace the supply pressure filter 

Filter replacement: Every 1000 operating hours, annually or when the filter 

control lamp lights up. 

Attention ! 

Soiled supply pressure filter 


• Replace the supply pressure filter at the latest after 1000 

operating hours, once annually or when the filter control 

lamp lights up. 


2. Dismantle the lower pump plate by undoing the screws and lifting it 

off. 



system. 

5. Unscrew the filter anticlockwise to loosen it. 

6. Remove the filter element and dispose of it correctly. 

7. Clean the filter housing. 

8. Tighten the filter housing by hand. 


13. Mount the lower pump plate and close the rear cover. 


2 

13 

8 

5


Replace partial flow filter 

Filter replacement: every 500 operating hours or annually. 

1. Open the left cover. 


3. Remove the partial flow filter from the hydraulic tank. 

4. Place a suitable vessel below the partial flow filter. 


system. 

6. Remove the three screws on the filter cover. 

7. Carefully remove the filter cover. 

8. Remove the filter element and dispose of it correctly. 

9. Clean the filter housing. 

10. Check the O-ring on the filter cover for damages and coat it with a little 

hydraulic oil. 

11. Mount the filter element in the right flow direction in the filter housing 

(red thread as in the diagram). 

12. Mount the filter cover. 

13. Faster the screws on the filter cover. 

14. Mount the partial flow filter on the hydraulic tank. 



17. Close the left cover. 


13 

7 

12 

6 

10 

6 

13 

13 

6 

3 

14 

11 

8


8.8.5 Installation instructions for pipe and hose lines 

The individual components of Hydraulic units are connected together by pipes and moving components by hoses. 

It is imperative that the following steps be carried out prior to disconnecting hose couplings and fittings or before 

replacing hoses and pipes: 

1. The boom assembly is to be placed on the ground. 

2. The machine (chassis) is to be placed on level ground. 

3. Shut down engine and activate ignition. The hydraulic system has to be made zero-pressure by activating the 

control lever and opening the hydraulic tank screw-cap (hydraulic tank is pretensioned). 

4. Suitable containers must be positioned to collect the oil 

Warning ! 

Escaping fuels and lubricants 


• Always wear goggles and protective clothing. 

Possible causes for faulty seals on fittings are: 

1. Fitting is loose. 

2. Fitting is deformed. 

3. Fitting or line is damaged. 

4. Sealing element (seal, edge, seal edge ring, O-ring) is damaged. 

5. Connecting seal surface (flange fitting) not working freely. 

Each time the compression nut is undone it must be retightened without using excessive force. 

With correctly jointed and mounted lines and fittings, retighten the compression nut if there is a leak. If the leak 

persists, the fitting must be opened and examined to see if it is deformed, cracked, or if the pipes are misaligned 

or show signs of grooving. If the seal can not be achieved after the apparent fault has been remedied the fitting 

must be replaced. 



8.8.6 Hydraulic diagrams 







8.9 Electric system 

Attention ! 

24 VDC voltage 


• Only connect consumers with a voltage of 24 VDC. 

Attention ! 

Jump-starting with batteries disconnected 


• Only connect a jump-started when the batteries are connected 

and tightened in place 

Attention ! 

Welding work at the machine 

Can result in damage to property. 

1. Set the ignition key to 0 

2. Switch off the main switch. 

3. Connect the minus terminal to the batters. 

4. Remove all plug connections from electronic devices. 

5. Connect the earth terminal directly next the part to be welded 

(observe perfect contact). 


1 

2


8.9.1 Batteries 

Attention ! 

Loose battery poles 


• Always connect the battery poles tightly. Never loosen battery 

poles when the machine is in operation. 

Attention ! 

Missing or incorrectly installed battery cover 


• Always mount the battery cover after working on the battery 

poles. 

Maintenance-free batteries are installed in Menzi Muck. Check the battery 

poles for tight seating and corrosion every 500 operating hours. Grease the 

battery poles with high-quality grease. 

Disconnect batteries 

1. Open the right cover. 

2. First loosen the minus pole. 

3. Now loosen the plus pole. 

Connect the batteries 

1. First connect the plus pole. 

2. Now connect the minus pole. 

3. Close the right cover. 


2 

3

8.9.2 Fuses 


Main fuse (70 A) 

The main fuse for protecting the electrical components is located below the 

rear cover to the left on the hydraulic oil tank mounting. 

ECU fuse (3 A) 

The engine manufacturer equips the Engine Control Unit (ECU) with an 

uninterrupted power supply. This supply is guaranteed by a fuse below the 

alternator. 

Fuse particulate filter (3 A) 

Optionally, a particulate filter is available. The supply is protected by a fuse 

behind the dash. 

General fuses 

The fuse box is in the cab under the cover right from the operator. 

Attention ! 

Wrong fuses 


• Only use fuses with the prescribed amp ratings. 



No. Functions Ampère (A) 

1 Warning lights, High speed gear, winch, Finemode, Reserve valves 15 

2 Diesel filling pump, operator's seat 20 

3 Turning light, Radio 15 

4 Intervall wiper system, central lubrication system 15 

5 Instrument lighting, Pilot control filter, D+ alternative 7.5 

Recirculating air valve switch 15 

6 A / C compressor coupling, Electric fan 15 

Air-conditioning unit USA 30 

7 Steering Linde CEB 16/21 7.5 

8 Heater fan gages 1 - 3 10 

9 Joystick supply left / right 1 

10 DIGSY Compact 10 

11 ECU 10 

12 Display, driving foot pedal 2 

13 ICN-V-modul, auxiliary moduls CR2011 15 

14 Armrest switch 2 

15 Warning lights, cab's roof 15 

16 Cigarette lighter 20 

17 reserve 

18 Front and rear working headlights above 15 

19 reserve 

20 Headlight low beam, road license Germany 20 

21 Connection 30 on display (CGM) and DIGSY Compact 3 

22 Parking light left 5 

23 Parking light right 5 

24 reserve 

25 reserve 

26 Power mode, solenoid valve 15 

27 Brake relay control circuit, relay release valve 15 

28 Steering switchover 10 


8.9.3 Relays 


The relays are in the cab under the panel to the right of the operator. 

No. Function 

E1 Armrest switch 

E2 A / C compresor coupling 

E3 Electric fan 

E4 Front working headlights above 

E5 reserve 

E6 Rear working headlights 

E7 Road approval, Germany 

E8 Traction drive brake valve 

E9 Traction drive release valve 

E10 Flasher 

E11 Interval wiper 

The starter and pre-glow relays are mounted directly at the engine in the 

rear of the engine room. 

E11 Starter relay 

E12 Pre-glow relay 

8.9.4 Electrical anti-rotation device 

When working in water there is an increased danger of condensation forming 

in the electrical anti-rotation device. Open the electrical rotary distributor 

and replace the airtight bag. 


E12 

E13 

E11


8.9.5 Control module menu 

F1 in the basic menu opens the detail menu. F2 in the detail menu 

opens the control module menu. The active control modules can 

be checked in this view, hence enabling a more accurate diagnostics 

runs.This view is also the basis for the status menu described 

below. If a control module is actively connected to the CANBUS, 

the module is ticked. If the module is inactive or not fitted, an exclamation 

mark appears! 

1. Display unit CGMT 

2. Digsy Compact DCE 

3. ICN-V, left board control 

4. ICN-V, right board control 

5. Auxiliary module 1 (tilt rotator application) 

6. Auxiliary module 2 

7. Control GLR 

8. ECU control, John Deere engine electronics 

9. Left joystick 

10. Right joystick 

F1 returns to the control module menu and pressing F1 repeatedly 

to the basic menu. 

8.9.6 Status menu of the GLR 

Starting from the control module menu, F3 opens the status menu. 

1. Memory index organises the errors according to the affected 

component. 

If errors are displayed in the status menu, they must be read off 

and noted down so that they are available for the trouble shooting 

operation at a later time. Restarting the machine (ignition on/off) 

restarts the program and an error that has occurred once may disappear. 

The error list will clear when after a restart! 

F1 returns the user to the control module menu and pressing F1 

repeatedly to the basic menu. 

7 8 9 10 


1 

1 

2 3 4 5 6

Errorcodes 

Memory index 


Error code 

(255 = no error)) 

Error type 

(affected part) 


Working hydraulics 

0 12 Accelerator nein nein accelerator potentiometer defective 

short circuit on otentiometer to GND or +24V 

Neutral switch defective 

0 130 Accelerator ja nein Press accelerator during the start 

1 Limiter potentiometer V max no diagnostic possible 

2 Diesel speed potentiometer no diagnostic possible 

3 3 Drive solenoid forwards interrupt / short circuit to +24V 

3 4 Drive solenoid backwards short circuit to GND 

4 3 Drive solenoid backwards interrupt / short circuit to +24V 

4 4 Drive solenoid forwards short circuit nach GND 

7 4 Diesel speed sensor Sensor impuls to low 

7 8 Diesel speed sensor Sensor short circuit or interrupt 

10 3 Battery voltage Voltage > 30V 

10 4 Battery voltage Voltage < 20V 

11 3 Supply voltage to sensors + 

ja nein Voltage > 8.5V 

Potentiometer 

short circuit to +24V 

11 4 Supply voltage to sensors + 

ja nein Voltage < 7.5V 

Potentiometer 

short circuit to GND 

12 12 Brake solenoid nein nein On: short circuit to GND or interrupt 

Off: short circuit to +24V 

13 12 Solenoid VD3 short circuit / interrupt 

14 12 Drive solenoid forwards nein nein short circuit / interrupt 

16 12 Release valve nein nein On: short circuit to GND or interrupt 

Off: short circuit to +24V 

17 12 Drive solenoid back nein nein short circuit / interrupt 

18 12 High pressure gear (Powermode) short circuit to +24V at "on" 

interrupt at "off" 

23 12 Free wheel (Option) short circuit to +24V at "on" 

interrupt at "off" 

24 13 EEPROM ja nein Wrong version number 

25 13 CAN - Bus CAN circuit defective / DCE or ECU off 

26 0/1/2 Control security relay nein Security relay defective 

26 137 Control security relay nein Fault detected by security software 

26 12 Control security relay nein Control defective 

27 Div. Control security relay nein Input function / Input security software 

Driving active 

Trouble shooting


Note ! 

Safety controller 

If when driving in „normal“ mode the safety controller is active 

and „driving“ is switched off, the 

vehicle will brake over a ramp to prevent it from stopping too 

quickly. 

8.9.7 Joystick diagnostic menu 

Starting from the control module menu, F5 opens the joystick diagnostic 

menu. This menu allows the user to check whether each 

individual switch on the joystick transmits the signal to the machine 

control Canbus. The cause of any error occurring is then easy 

to detect. The joystick and mounted switches are shown symbolically 

by circles. If a switch is active, the circle is black inside. See 

chapter joystick for more information. 



8.9.8 Output module diagnostic menu 

When this menu is used, the engine must be off, the ignition turned 

to on and the armrest moved to the working position 

Starting from the control module menu, F6 opens the output 

module diagnostic menu. This menu allows the user to check 

whether each individual output is switched to the Digsy Compact, 

ICN-V and CR2011. The cause of any error occurring is then easy 

to detect. 





Functions output modules 

DCE A81 Mobil A81 Mobil steered hub drive 

1 Alarm beeper x x 

2 Electric winch x x 

3 

4 Reserve Joystick button R3 x x 

5 

6 

Bucket - steering switchover valve x x 

7 Reserve Joystick button R4 x x 

8 Electric winch x x 

9 Solenoid valve LS support x x 

10 Windscreen wiper interval x x 

11 Horn x x 

12 Martin quick coupler x x 

13 Auxiliary hydraulic connection 80 l/min x x 

14 Auxiliary hydraulic connection 80 l/min x x 

15 3. circuit 40 L/min x x 

16 3. circuit 40 L/min x x 

ICN-V stabilisation, left side 

1 Front stabilizator left, in x x 

2 

3 

4 

Front stabilizator left, out x x 

5 Rear steered wheel, inwards x 

6 

7 

Rear steered wheel, outwards x 

8 Free wheel x x 

9 Telescopic stabilizer left, out x x 

10 Telescopic stabilizer left, in x x 

11 Front stabilzer left, down x x 

12 Front stabilzer left, up x x 

13 Rear wheel left, down x x 

14 Rear wheel left, up x x 

15 Rear wheel left, out x x 

16 Rear wheel left, in x x 



ICN-V stabilisation, right side Mobil A81 Mobil steered hub drive 

1 Front stabilizator right, in x x 

2 Front stabilizator right, out x x 

3 

4 

5 Rear steered wheel, inwards x 

6 

7 

Rear steered wheel, outwards x 

8 2. gear x x 

9 Telescopic stabilizer right, out x x 

10 Telescopic stabilizer right, in x x 

11 Front stabilzer right, down x x 

12 Front stabilzer right, up x x 

13 Rear wheel right, down x x 

14 Rear wheel right, up x x 

15 Rear wheel right, out x x 

16 Rear wheel right, in x x 

CR2011 option modul ID4 

Rototilt Felling head Naarva Grip 

1 Grab open Guillotine Grab closed 

2 Grab close Rotator left 

3 Tilt left Tilt up 

4 Tilt right Loading Grab closed 

5 Open auxiliary Grab Loading Grab open 

6 Close auxiliary Grab Tilt down 

7 Turn totator to left Rotator to right 

8 Turn rotator to right Retaining Grab open 



8.9.9 Service menu 

F1 in the basic menu opens the detail menu. From the detail menu, 

pressing F2 twice opens this menu. Here, the firmware and software 

version of the individual control components can be read off. 

1. Firmware version of the display (CGMT) 

2. Software version of the display (CGMT) 

3. Firmware version of DIGSY Compact (CPU side) 

4. Firmware version of DIGSY Compact (I/O side) 

5. Software version of DIGSY Compact 

6. Option code 

7. Software version of GLR (CEB 16/21) 

8. Parameter block of GLR (CEB 16/21) 

8.9.10 Service code 

The service symbol appears in the display when a service is due. 

To clear the symbol, F2 must be pressed again in the service 

menu so that the input field (1) for the service code appears. Pressing 

F3 opens an identical input field, although the service code 

below is not accepted. 

1. Service code 518300 input field. 

Pressing F4 or F5 increases and decreases the number respectively. 

Once the first digit has been entered, pressing F6 moves 

the cursor to the next digit.This process is repeated until all the 

code’s digits have been entered.During the process, the digit with 

a black background flashes. If the input range of 1-9 is over or underrun, 

an „E“ appears. In this case, input must occur in the opposite 

direction. If the correct code is confirmed, „OK“ will appear 

and the service symbol in the main screen is cleared. 

In the detail menu, the user can now control how many more 

hours can be worked and when the next service will fall due. 

When the code is entered, the service interval increases to the 

next service and the service symbol is cleared. 

Once the code has been correctly entered, pressing F2 again 

clears the service code input field.F1 in the basic menu re-opens 

the basic menu. 

Note ! 

Adjust service interval 

You can enter the code for the service interval several times in 

succession until max. 999 hours is exceeded in the display. After 

this the code is no longer accepted. 


1 

2 

7 

8 

1 

3 

5 

4 

6


8.9.11 Electric diagram 



























8.10 Lubrication schedule 

8.10.1 Upperstructure Lubrication interval 8h or daily 



Slewing ring Lubrication interval 50h or weekly 

Oil duct boom Lubrication interval 8h or daily 



8.10.2 Chassis 

Chassis Mobil 


Lubrication interval 50h or weekly


Steered wheels Lubrication interval 50h or weekly 

8.10.3 Central lubrification Lubrication control 8h or daily 



8.11 General maintenance work 

8.11.1 Adjust telescope 

Readjusting the front side 

1. Extend the telescope up to the red marking on the inner tube. 

2. Loosen the fixing screws. 

3. Turn the adjusting screws evenly in clockwise direction until there is no 

more play. 

4. Tighten the fixing screws. 

5. Check the selected setting by extending and retracting the telescope. 

Note ! 

Readjusting at side 

Make sure that the adjusting screws are not overtightened and 

that you do not adjust the telescope too far from the middle. 

Readjusting at front top and bottom 

Adjust telescope play at the front top and bottom using spacers. 

1. Dismount the collar. 

2. Dismount the front holding screw. 

3. Set the play with the spacers. 

4. Mount the front holding screw. 

5. Mount the collar. 

Note ! 

Holding pins 

Make sure that the holding pins are at least 2 mm shorter than 

the wearing plate. They are used to fix, and not to adjust the telescope. 

Readjusting at rear 

1. Extend the telescope by approx. 100 mm and place it on the ground 

to relieve it. 

2. Dismount the rear cover plate. 

3. Dismount the holding plate. 

4. Set the play with the spacers. 

5. Mount the holding plate. 

6. Mount the rear cover plate. 


5 

1 

4 

4 

3 

3 

2 

4 

3 

4 

2 

3 

2 

2 

3 

4 

4 

5 

3 

5 

2 

6


8.11.2 Refill windscreen fluid 

1. Open the right cover. 

2. Open the lock cover of the windscreen fluid container. 

3. Fill with suitable windscreen fluid (if there is a risk of frost, then fill with 

frost-proof windscreen fluid 

4. Close the lock cover of the windscreen fluid container. 

5. Close the right cover. 



8.12 Tightening torque table 

Note ! 

Threads and contact surface 

Threads and contact surface of the screw head must be oiled or 

lubricated. 

Torque Condition Strength class 

8.8 10.9 12.9 

M5 Oiled, lubricated 

Torque in Nm 

4.6 6.8 7.9 

dry, glued 5.5 8.1 9.5 

M6 Oiled, lubricated 8 11.7 13.7 

dry, glued 9.5 14 16.4 

M8 Oiled, lubricated 19.3 28.3 33.4 

dry, glued 23 34 40 

M10 Oiled, lubricated 39 57 66 


M10x1.25 Oiled, lubricated 41 60 70 



dry, glued 80 117 137 

M12x1.5 Oiled, lubricated 69 101 117 

dry, glued 84 123 144 


dry, glued 127 186 218 


dry, glued 194 285 333 


dry, glued 265 390 460 


dry, glued 390 560 650 


dry, glued 530 750 880 


dry, glued 675 960 1120 


dry, glued 1000 1400 1650 


dry, glued 1350 1900 2250 



8.13 Proof of service 

Operating hours Remarks / Deviations Date, Signature of mechanician 

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Operating hours Remarks / Deviations Date, Signature of mechanician 

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Faults and fault rectification 

9. Faults and fault rectification 

9.1 Trouble shooting on the engine 

Fault Cause Remedy 

Engine turns over, but will No fuel. Check fuel in tank. 

not start. 

Fuse 3A on alternator defective. Replace the fuse.. 

Exhaust blocked. Clear exhaust clogging. 

Fuel filter clogged or full of water. Replace fuel filter or drain off water from the filter. 

Engine difficult to start or will 

not start. 

Fuel not reaching the injection pump or air in 

the fuel system. 

Check fuel flow at feed pump or bleed fuel system. 

Injection pump or nozzles damaged. Have repair or replacement carried out by approved workshop. 

No fuel. Check fuel. 

Hydraulic system runs up block. Switch off hydraulic consumers. 

Air in fuel line. Vent fuel line. 

Cold starter defective. Check pre-glow relay and coil. 

Low starter motor speed. See „Starter motor is slow to turn over“. 

Incorrect viscosity of engine oil used. Use the correct viscosity of oil. 

Incorrect fuel type. Contact fuel supplier, use correct fuel type for operating conditions. 

Water, dirt or air in the fuel system. Drain, flush, fill and bleed system. 

Fuel filter clogged. Replace filter insert. 

Electronic fuel injection nozzles clogged or Have injection nozzles checked by approved workshop or engi- 

damaged. 

ne dealer. 

Problems with electronic fuel system. Contact the John Deere dealer or approved workshop. 

Motor knocks. Engine oil level below minimum. Top up engine crankshaft oil. 

Low coolant temperature. Remove thermostat and check. 

Engine overheated. See „Engine overheats“. 

Engine cold. Incorrect or defective thermostat. Remove thermostat and 

check. 

Engine runs erratically or Low coolant temperature. Remove thermostat and check. 

stalls frequently. 

Fuel filter clogged. Replace fuel filter insert. 

Water, dirt or air in the fuel system. Drain, flush, fill and bleed system. 

Engine temperature below 

normal. 

Injection nozzles clogged or damaged. Have injection nozzles checked by approved workshop or engine 

dealer. 

Problems with electronic fuel system. Contact the John Deere dealer or approved workshop. 

Thermostat defective. Remove thermostat and check. 

Temperature display or sensor defector. Check display, sensor and connections. 



Impaired performance. Engine overload. Reduce load. 

Air intake clogged. Repair air filter. 

Fuel filter clogged. Replace filter inserts. 

Incorrect fuel type. Use the correct fuel type. 

Engine overheated. See "engine overheated" 

Engine temperature below normal. Remove thermostat and check. 

Incorrect valve play. Contact approved workshop or engine dealer 

Injection nozzles clogged or damaged. Contact approved workshop or engine dealer 

Incorrect injection pump setting. Contact approved workshop or engine dealer 

Problems with electronic fuel system. Contact approved workshop or engine dealer 

Turbocharger inoperable. Contact approved workshop or engine dealer 

Exhaust manifold seal not right. Contact approved workshop or engine dealer 

Fuel hose blocked. Clean or replace fuel hose 

Top running speed too low. Engine cold. Run engine to normal operating temperature. 

Emergency gas active. Deactivate emergency gas. 

Oil pressure low. Oil level low. Top up oil. 

Incorrect engine oil. Drain crankcase and fill with the correct viscosity and quality 

of oil. 

High oil consumption. Incorrect viscosity of engine oil used. Use the correct viscosity of oil. 

Oil leak present. Check for leaks in the lines, seals and drain plugs. 

Crankcase vent pipe clogged. Clean vent pipe. 

Turbocharger defective. Contact approved workshop or engine dealer 

Incorrect fuel type. Use the correct fuel 

Engine emits white smoke. Engine temperature low. Run engine to normal operating temperature. 


Electronic fuel injection nozzles defective. Contact approved workshop or engine dealer 

Water in the fuel. Drain filter and replace. 

Cylinder head seal defective. Replace cylinder head seal. 

Motor emits black or grey Engine overload. Reduce load. 

smoke. 

Coolant level below minimum. Fill radiator to correct level, check radiator and hoses for loose 

connections and leaks. 

Radiator clogged. Clean radiator. 

Radiator fan turns too slow Check speed and if too low disconnect electric cable from the 

fan control (full speed). 

Ribbed V-belt stretched, torn or belt tensioner Check automatic belt tensioner and examine stretched belt. 

defective. 

Replace if necessary . 

Engine oil level below minimum. Check oil level. Top up oil as required. 



Engine overheats. Cooling system needs flushing. Flush cooling system. 


Temperature display or sensor defector. Check coolant temperature with thermometer and replace as 

necessary. 

Incorrect quality fuel. Use suitable fuel. 

Incorrect fuel type. Use the correct fuel type. 

Air filter clogged or dirty. Repair air filter. 

Engine overload. Reduce load. 

Incorrect valve play. Contact approved workshop or engine dealer 

Electronic fuel injection nozzles dirty. Contact approved workshop or engine dealer 

Problem with electronic fuel system. Contact approved workshop or engine dealer 

Excess fuel consumption. Turbocharger defective. Contact approved workshop or engine dealer 

Engine temperature low. Check thermostat. 

Excessive electrical consumption by accessories. 

Remove accessory or fit a higher output generator. 

Excess idling. Increase engine speed to compensate for any excessive electrical 

load. 

Bad electrical connections at battery, earth 

cable, starter or generator. 

Check and clean as required. 

Battery defective. Check battery, replace as required. 

Rotary current generator defective. Check rotary current generator, replace as required. 

Loose or corroded battery connections. Clean battery connections and tighten. 

Electrical system inadequa- Batteries worn. Contact approved workshop or engine dealer 

tely charged. 

Ribbed V-belt stretched or belt tensioner defective. 

Adjust belt setting or replace belt. 


Battery defective. Check battery, replace as required. 


Batteries will not charge. Loose or corroded battery connections. Clean battery connections and tighten. 

Batteries worn. Contact approved workshop or engine dealer 

Ribbed V-belt stretched or belt tensioner defective. 

Adjust belt setting or replace belt. 


Starter motor will not turn Loose or corroded battery connections. Clean loose connections and tighten. 

over. 

Battery power low. Contact approved workshop or engine dealer 

Starter motor current relay defective. Contact approved workshop or engine dealer 

Main system fuse burned out. Replace fuse. 

Starter motor defective . Check starter motor, replace as required. 

Starter motor turns over too Battery power low. Contact approved workshop or engine dealer 

slowly 

Incorrect viscosity of engine oil used. Use the correct viscosity of oil. 

Loose or corroded battery connections. Clean loose connections and tighten. 

Entire electrical system in- Main switch turned off. Turn on main switch. 

operable. 

Damaged battery connection Clean battery connections and tighten. 

Worn batteries. Contact approved workshop or engine dealer 

Main fuse burned out. Replace fuse. 



9.2 General trouble shooting on the machine 

Entire machine will not move. Diesel engine will not run. Start diesel engine. In the event of a fault, see „Trouble Shooting 

Engine“. 

Armrest not closed. Close armrest. 

Armrest switch inoperable. Check armrest switch, replace as required. 

Main fuse / fuses burned out. Check fuses and replace. 

No or insufficient hydraulic oil in the system. Top up hydraulic oil. Vent pumps. 

No pilot pressure. Clean supply pressure filter. 

Diesel engine speed too low Increase speed. When machine is cold or in emergency gas 

mode, max. speed is 1450 rpm. 

No LS pressure. Measure LS pressure. Check LS pressure lost. 

Traction drive inoperable Fully retract traction drive fine control. Run up fine control. 

Fuse burned out. Replace fuse. 

Control inoperable. Read off fault from display; check connections, replace any 

defective parts. 

Leak in system. Fix leak. 

Brakes do not disengage. Inadequate brake pressure, check BR solenoid valve and power 

supply to the support block. 

Wheel gear uncoupled. Couple wheel gear. 

Traction drive pump does not swivel out. Check release solenoid at traction drive pump. 

Support will not move. Fuse burned out. Replace fuse. 

CAN bus inoperable. Read off fault from display; check connections, replace any 

defective parts. 

LS solenoid valve on support block will not 

switch. 

Check solenoid valve and power supply. 

Certain solenoid valves on support block will 

not switch. 

Check solenoid valve and power supply. 

No LS pressure. Measure LS pressure. Rectify LS pressure lost. 

Bucket will not move. Steering switch to steering. Set steering switch to bucket position. (Switch off) 

Changeover valve piston jams (clogged). Remove changeover valve, strip down and clean. 

Changeover valve corroded. Replace changeover valve. 

Steering inoperable. Steering switch off Turn on steering switch. 

Changeover valve will not switch. See „Changeover valve will not switch“. 

Changeover valve corroede. Replace changeover valve. 

Fuse burned out. Replace fuse. 



Boom will not move. Steering switch turned on. Turn off steering switch. 

Shut-down valve will not switch Check shut-down valve. 

No pilot pressure. Clean supply pressure filter. 

Changeover valve will not Electric solenoid valve will not switch. Check electric solenoid valve and ensure power supply 

switch. 

Valve piston jams (clogged). Remove changeover valve, strip down and clean. 

Valve corroded. Replace valve. 

Working pressure too low. Leak in system. Fix leak. 

Working pump oil level too low. Ensure oil supply. 

Working pump sucks in air. Check intake line for leaks. 

No LS signal Measure LS pressure. Rectify LS pressure lost. 

Working pump does not swivel out. Check power supply at working pump; disconnect cable from 

pump control (pure hydraulic control). 

Pressure limiting valve will not close. Remove pressure limiting valve, replace if necessary. 

Machine slow to move. Pilot pressure too low. Clean supply pressure filter. 

No LS signal Measure LS pressure. Rectify LS pressure lost. 

Hydraulic oil temperature Radiator clogged. Clean radiator. 

gets too warm. 

Hydraulic oil too low. Top up hydraulic oil. 

Radiator fan turns too slow Check speed and if too low disconnect electric cable from the 


Excessive consumption, possibly from additional 

equipment. 

Reduce consumption. 

Incorrect operation. Adapt operation. 

Temperature sensor or cable defective. Check temperature sensor cable and replace temperature sensor. 

Machine performance drops. Machine overheats. Reduce load, clean radiator and check cooling liquids. 

Engine output too low. See Trouble Shooting, Engine „Impaired performance“. 

Machine not serviced. Carry out maintenance. 

Incorrect settings. Have settings checked and adjusted by a specialist dealer. 

Certain components worn. Replace worn components. 

No message in display. Power supply interrupted. Replace fuse, check connection. 



Charge indicator lamp illu- Cable not connected to rotary current gene- Check cable connection 

minated.rator. 

Cable to rotary current generator charge indicator 

lamp has shorted or cable broken. 

Rectify short circuit on line. 

Rotary current generator defective. Check rotary current generator and repair or replace as necessary. 

General faults on the electri- No contact between connection pins and batte- Clean oxidation from pins and terminals, tighten terminal 

cal equipment. 

ry terminals. 

screws; coat pins and terminals with anti-corrosion lubricant. 

Flashing / warning lamp unit Glow plug defective. Replace glow plug. 

inoperable. 

Power supply interrupted. Check fuse and power supply. 

Flasher unit failed. Replace flasher unit. 

Light unit inoperable. Glow plug defective. Replace glow plug. 

Power supply interrupted. Check fuse and power supply. 

Horn inoperable. Power supply interrupted. Check fuse and power supply. 

Horn failed. Replace horn. 

Windscreen wiper unit inope- Power supply interrupted. Check fuse and power supply. 

rable. 

Windscreen wiper motor failed. Replace windscreen wiper motor. 

Windscreen washer pump failed. Replace windscreen wash water pump. 

No windscreen wash water. Top up windscreen wash water. 

Windscreen wash water line interrupted. Replace windscreen wash water line. 

Heating output inadequate. Heating water valve partially closed. Open heating water valve. 

Vent filter clogged. Clean and/or replace vent filter. 

Heater blower does not work. Fresh air blower not switched on. Switch on blower. 

Power supply to heater blower interrupted Check fuse / power supply. 

Heater blower failed or blocked. Remove foreign bodies or replace blower. 

Air-conditioning system does Fresh air blower not switched on. Switch on blower. 

not work. 

Power supply to blower interrupted. Check fuse / power supply. 

Air-conditioning compressor does not work. Fuse / power supply for 

Ribbed V-belt inadequately tensioned or torn. Check ribbed V-belt, tighten if necessary. 

Coolant level too low Top up coolant. 

Inadequate cooling effect of Air-conditioning fan clogged. Blow off air-conditioning fan. 

air-conditioning system. Radiator fan turns too slow Check speed and if too low disconnect electric cable from the 


Heating valve fully opened. Set heating valve to cold 

Intake air too warm. Switch to circulating air mode 

Vent filter clogged. Clean and/or replace vent filter. 

Vaporiser iced up. Have cause rectified. 

Coolant level too low. Top up coolant. 

Windows steam up. Condensation outlet clogged. Clean drain lines. 

Pneumatic spring does not Compressed air compressor does not work. Check fuse / power supply, eventually replace compressed air 

adjust. 

compressor. 


Notes for spare part orders 

10. Notes for spare part orders 

Warning ! 







Use only original Menzi Muck spare parts. 

For every order, specify the complete part number, name and quantity of the required parts. 

For every order, specify the type and production number of the machine (type plate). 

Note ! 

The buyer is responsible for any incorrect deliveries as the result 

of incomplete ordering information. 

Note ! 

Prepare telephone orders carefully. In order to avoid inconvenient 

enquiries and possible incorrect deliveries, an order must contain 

precise listings of address, postcode, shipment method, and destination, 

and these must be easily legible. 

Example of order: 

No. of chassis: No. of engine: 

No. of assembly Assembly Denomination of part No. of part Quantity 

9107024200 Dipper rear Bushing 207354 2 


Warranty provisions 

11. Warranty provisions 

MENZI MUCK AG provides a war ranty on all MENZI products within the framework of the guarantee agreement. If defects cove- 

red by the warranty are found to exist, the purchaser must inform the vendor without delay, either in writing or by telephone. 

The vendor’s warranty obligation is confined to the repair or replace ment of the defective part which is found to fall under the 

warranty and is acknowledged as a war ranty claim after examination by MENZI MUCK AG. 

Parts will be repaired or replaced during the warranty period in the vendor’s workshops or at service centres specifically autho- 

rised by MENZI MUCK AG. 

The user undertakes to arrange for the regular maintenance work stated hereinafter in the operating manual (operating instructions) 

to be performed by the contractual workshop or by a service centre authorised by MENZI MUCK AG. The maintenance 

and service schedule as specified by MENZI MUCK AG must be observed without exception. 

This maintenance work is regarded as normal servicing and will be performed at the expense of the purchaser and under the 

purchaser’s responsibility. 

Exclusion of warranty claims: 

a) The warranty shall become void in the event of incorrect use, negli gence, conversion of the machine, accident 

or failure to perform regu lar maintenance work, and in the event of the use of equipment or attachments 

which have not been approved by MENZI MUCK AG. The warranty shall also become void if service or repair 

work is performed by anyone that has not expressly been authorised by MENZI MUCK AG. 

b) The following parts are not co vered by the warranty provisions: 

- Parts subject to normal wear and tear, e.g. oils and lubricants, filters, injection components, fuel pumps, lines, 

hydraulic ho ses, bolts and bushings, V-belts, electrical components and electrical units of the engine, fans. 

- Parts which come into contact with the ground.- Parts which are damaged by external influ ences, e.g. gasket 

sets, lines, hoses, electrical cable har nesses and connections; da mage by chemical products, falling branches, 

soil, stones etc. Screws, nuts or couplings which work loose because of vibration or are damaged by 

excessive tightening. 

c) Problems which may be caused in the fuel circuit by the presence of water and other impurities in the injection 

pump, nozzles and feed pump. 

d) Compensation for down times suffered by the purchaser as a result of breakdowns or loss of use. 

e) Incurred transport and salvage costs in the event of breakdowns are not covered by the warranty. 

f) Problems in the engine cooling system and engine air intake caused by dirty radiators and filters and their 

consequential damage are not covered by the warranty. 

Our warranty extends only to the replacement of parts recognized by us to be defective and does not cover dispatch and pakkaging 

costs, which shall be charged to the purchaser in all cases. 

The warranty liability shall not be accepted until the defective parts have been inspected by MENZI MUCK AG or by an expert 

seconded by MENZI MUCK AG. 

Every warranty claim which proves to be deliberately false shall automatically cause all further warranty claims to lapse. 

These terms of warranty apply between the dealer, the customer and MENZI MUCK AG. Any other verbal or written agreement 

provided by the dealer to a customer is hereby declared null and void. In special cases, the written agreement of MENZI MUCK 

AG shall be required. 


Appendix 

12. Appendix

Maintenance and Care

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