VMT 545 GR

TRACK MOTOR CAR

SERIAL NUMBER : 1145 ÷ 1154

USE AND MAINTENANCE HANDBOOK

Delivery date: February 2019 Rev.00

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VMT 545 GR TRACK MOTOR CAR .......................................................... 1145 ÷ 1154

GENERAL FEATURES
Mass when unloaded .....................................................................................................approx.15 tons
Useful load (person + tools) .............................................................................................approx.6 tons
Mass when fully loaded ..................................................................................................approx.21 tons
Fuel tank ................................................................................................................................. 430 litres
Max. speed on level track .......................................................................................... .approx. 80 km/h
Max. speed when towed ..............................................................................................approx.90 km/h
Max. gradient ................................................................................................................................. 25‰
Maximum track cant ................................................................................................................. 150 mm
Driving position (with control board).................................................................................................... 1
Coupling ........................................................................................................... Automatic coupler AAR

ENGINE TRANSMISSION
Manufacturer ............................................. Deutz Hydrostatic transmission
Nominal power ....................................... 190 kW - Hydraulic pump ............... REXROTH 145cc
Rated speed ........................................ 2300 rpm - Hydraulic motor ............... REXROTH 115cc

BRAKE RUNNING GEAR

Pneumatic brake ............................. Direct brake Wheels................................ R9 steel / UIC 812.3
......... Automatic brake (only with towed vehicle) Nominal diameter .................................. 850 mm
........................Hand / electric emergency brake Minimum returning diameter ................. 810 mm
Parking brake .............................Negative spring
Compressor......................................... SANDEN
Valve distributor (Automatic brake) ......... Wabco
Brake-cylinder ......................................... Wabco

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CONTENTS
 Safety symbols ............................................................................................................................. 6
 General safety precautions .......................................................................................................... 7
 Information on elimination of noxious substances ..................................................................... 11
 Use and conservation of the handbook ..................................................................................... 11
 Manufacturer’s liability ............................................................................................................... 12
 Risk analysis for the personnel .................................................................................................. 13
 Personnel qualifications ............................................................................................................. 14

CHAPTER I : DESCRIPTION - EQUIPMENTS…………………..…………..15

1.0 General features .................................................................................................................. 16
1.1 Technical features ............................................................................................................... 17
1.2 Performances and limit of use conditions ............................................................................ 18
1.3 Engine specifications ........................................................................................................... 19
1.4 Running gear - suspension .................................................................................................. 21
1.5 Braking system and auxiliary equipment ............................................................................. 22
1.6 Braking system check .......................................................................................................... 23
1.6.1 Direct brake ......................................................................................................................... 23
1.6.2 Automatic brake ................................................................................................................... 23
1.6.3 Parking brake ....................................................................................................................... 24
1.6.4 Emergency brake................................................................................................................. 24
1.7 Use of the braking system ................................................................................................... 25
1.7.1 Direct brake ......................................................................................................................... 25
1.7.2 Automatic brake ................................................................................................................... 25
1.7.3 Parking brake ....................................................................................................................... 25
1.8 Cabin.................................................................................................................................... 27
1.8.1 Control board ....................................................................................................................... 28
1.9 Loading platform .................................................................................................................. 30
1.10 Loading crane ...................................................................................................................... 30
1.10.1 Crane features .................................................................................................................... 30
1.10.2 Crane fittings ...................................................................................................................... 31
1.10.3 Crane controls .................................................................................................................... 32
1.10.4 Crane stabilizers controls ................................................................................................... 32
1.10.5 Hydraulic crane using conditions on lifting charge configuration ....................................... 32

CHAPTER II : OPERATION INSTRUCTIONS ……….…………….….…….33

2.0 Vehicle starting and stopping .............................................................................................. 35
2.1 Crane ................................................................................................................................... 36
2.1.1 Crane control panels ............................................................................................................ 36
2.1.2 Work operation controls ....................................................................................................... 37
2.2 Crane safety devices description ......................................................................................... 38

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2.2.1 Max working pressure valve ................................................................................................ 38
2.2.2 Overpressure valves ............................................................................................................ 38
2.2.3 Load limiting device ............................................................................................................. 39
2.2.4 Exclusion of load limiting device of EC crane ...................................................................... 40
2.2.5 Emergency stop buttons ...................................................................................................... 40
2.2.6 Block valves on hydraulic cylinders ..................................................................................... 41
2.2.7 Locking devices fo r stabilizer extensions ........................................................................... 42
2.2.8 Slewing limiting device ......................................................................................................... 43
2.2.9 Boom inclination control....................................................................................................... 44
2.2.10 Boom elevation limiting device ............................................................................................ 44
2.2.11 Emergency hand-pump ....................................................................................................... 45
2.3 Crane gauges and warning lights ........................................................................................ 46
2.3.1 Configuration indicators and headlights switch ................................................................... 46
2.3.2 Load indicator ...................................................................................................................... 46
2.4 Vehicle towing ..................................................................................................................... 47
2.4.1 Automatic brake system configuration ................................................................................. 48
2.4.2 Remove wheels block .......................................................................................................... 49
2.4.3 Restore normal conditions ................................................................................................... 49

CHAPTER III : MAINTENANCE .......................................................... 50

3.0 Run-in period ....................................................................................................................... 51
3.1 First 100 hours maintenance ............................................................................................... 51
3.2 Preventive maintenance ...................................................................................................... 52
3.2.1 Engine ................................................................................................................................. 52
3.2.2 Transmission system ........................................................................................................... 53
3.2.3 Hydraulic system ................................................................................................................. 53
3.2.4 Hydraulic crane .................................................................................................................... 54
3.2.5 Pneumatic system ............................................................................................................... 54
3.2.6 Braking system .................................................................................................................... 54
3.2.7 Wheelset .............................................................................................................................. 55
3.2.8 Electric system .................................................................................................................... 55
3.2.9 Loading platform –Side Walls .............................................................................................. 56
3.2.10 Sign plates ........................................................................................................................... 56
3.3 Filling table ........................................................................................................................... 56
3.4 Lubricants table .................................................................................................................... 57
3.5 Brake blocks clearance check .............................................................................................. 58
3.6 Brake blocks clearance regulation ....................................................................................... 58
3.7 Brake blocks replacement .................................................................................................... 59

ENCLOSURES..................................................................................... 61
A.01 Front view .............................................................................................................................. 63
A.02 Side view ............................................................................................................................... 64
A.03 Top view................................................................................................................................. 65

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A.04 Wheel ..................................................................................................................................... 66
A.05 Axle ........................................................................................................................................ 67

DIAGRAMS………………………………………………………………………….....68
B.01 Pneumatic diagrams
 Braking system diagram ................................................................................................ 70
 Horns pneumatic system .............................................................................................. 73
 Gear range selection pneumatic system ...................................................................... 75

B.02 Hydraulic circuit diagrams

 Hydrostatic transmission ............................................................................................... 77
 Hydrostatic oil radiator hydraulic system....................................................................... 79
 Crane hydraulic system ................................................................................................. 81

B.03 Electric diagram

 Nomenclature of the parts in the vehicle 24 Vdc. wiring diagram ................................. 84
 24 Vdc. vehicle wiring diagram .................................................................................... 90

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SAFETY SYMBOLS

Below symbols are used to locate the safety provisions. Important notes, instructions or warnings are
particularly clear and signaled by them. Follow with the greatest attention the instructions developed
for people and vehicle security.

This symbol reminds safety practices or warns that unsafe practices could lead to personal injury or
material damage.

This symbol indicates a potentially hazardous situation, which could lead to injury or death if proper
precautions are not taken.

This symbol denotes a real hazardous situation, which could lead in a high probability of death or
serious injury if proper precautions are not taken.

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GENERAL SAFETY PRECAUTIONS

 The track motor car is an efficient working tool that needs checks and maintenance.
 Only trained and authorized staff can operate the track motor car.
 Never use the track motor car if safety is unsure for any reason.
 Never use the track motor car if the operator is not completely aware of the vehicle controls.
 Safety does not mean following operating instructions only. Whenever working on or with the track
motor car, be aware of any potential dangers and the ways to prevent them.
 Never use the track motor car and/or its equipment for purposes they are not designed for.
 In case of damage the track motor car can be set in motion, but only if there is no potential danger
to people or objects.
 Personnel must wear individual protection devices according to safety regulations (safety helmet,
gloves, safety belt, safety trousers or trousers with protective reinforcement, boots with steel
toecaps and non-slips soles, etc.).
 Always keep the minimum clearance from rail infrastructures (tunnels, electrical power poles, etc.)
when using the crane.
 The track motor car safety is integrated to the efficiency of the installed safety systems.
 It is forbidden to modify the track motor car or the equipment and their functions.
 Keep all track motor car components clean and free. Dirty equipment controls, steps and standing
areas increase the risk of accidents.
 There are pictograms on the track motor car. It is important to learn and understand them. Clean
or replace them whenever they are damaged, missing or illegible. Contact us for new pictograms.
 Observe the local railway regulations. The operator must know about the national regulations,
standards and safety provisions for operating the track motor car.
 If the operating instructions contains regulation and safety provisions that go againts the national
laws and regulations, the national laws and regulations will have priority.
 It is forbidden to use the vehicle (and its equipment) along a railway network whose track cant is
more than 150 mm.

Before operation
 Before reaching the vehicle sides, make sure the third power rail is de-energized (if present).
 Before starting the engine, make sure the parking brake is activated and all levers are in “neutral”
position.
 Before moving the track motor car, always make sure the removable elements are set back in
position and blocked in order not to engage the gauge.
 Before moving the track motor car, always sound the warning acoustic device.
 Before moving the track motor car, always check the pressure in the pneumatic breaking system
main tanks. Pressure gauges will display the pneumatic system pressure which have to reach pre-
established setting values.

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During operation
 Never get on or off the vehicle if it is not completely stopped.
 Before reaching the vehicle sides, make sure the third power rail is de-energized.
 Whenever the track motor car is operating, nobody is allowed to stay near the working area.
 Never exceed the load capacities of the track motor car and its equipment.
 It is forbidden to leave the vehicle when loads are still hung up.
 Pay attention while travelling along double track lines and risky areas such as bridges, tunnels,
prone slopes, landslides and level crossings.

Crane
Transfer Condition
 Never move the vehicle in travel speed when the crane or its equipment is not in transport
position. Fix and park correctly the crane equipment.
Work Condition
 Read the crane instructions manual.
 Keep the crane in good working conditions.
 Crane must be operated by trained staff only.
 Pay attention while travelling along double track lines and risky areas such as bridges, tunnels,
prone slopes, landslides and level crossings.
 Operators must wear individual protections (safety belt, safety helmet, etc.).
 Before using the crane, deactivate the catenary (if present).
 Never use the crane near another running line without taking precautions.
 Never use the crane when the wind speed exceeds 50 km/h.
 Never use the crane with the rated capacity limit device (load moment limit) disconnected or
damaged (consult the specific manual).
 Crane can be operated only when track motor car is stopped.
 The crane (with equipment) can be operated with jacks retracted, partially or totally extended on
compact ground. Lift the maximum rated load only with jacks completely extended.
 Keep always a minimum clearance from infrastructures (tunnels, electrical power poles, etc.).
 It is strongly recommended to know in advance the weight of the hoisted load.
 Never use the crane improperly (to hoist loads at an angle, to drag/push/hammer loads, etc.).
 Before starting loading operations, always verify the state of the accessories (straps, chains,
cables, hooks).
 Always fasten well the loads to lift by means of strips (belts, chains, etc.) having equal length and
resistance.
 Make sure the hoisted load is hung or fastened to the points provided for it. If there is no specific
indication, hang the load and look for the maximum balance during the phase of hoisting. Lift it
slowly and check load at the same time.
 Always lift loads over gravity center and secure them in order to avoid slip or fall.
 As far as possible drive the load by means of ropes/belts to avoid oscillations.
 As far as possible keep the load to the ground.
 Prevent the hung loads from crashing into installations or something else.

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 Never hoist people by means of the crane.
 Every time the crane is operating, nobody is allowed to stay near the working area.
 After working, switch off the hydraulic system.

Loading Platform

Transfer Conditions
 Before moving the vehicle in travel speed, set the loading platform in transport position (internal
sideboards refolded and locked).
 Secure all loads in transport position.
Work Conditions (Vehicle Stopped)
 Operators must wear individual protections (safety belt, safety helmet, etc.).
 Never exceed the platform limit capacity.
 Only use the fitted ladders and handrails to access the platform.
 Keep all the surfaces and access ladders clean, free from oil, snow, ice or dirt.
 Place objects carefully on the floor to avoid tripping over them.
 Risk of falling exists if access helps are not employed or they are used incorrectly.
 Risk of slipping exists if fitted ladders and standing surfaces are not kept free from oil and dirt.
 Risk of tripping exists if there are object placed on the floor without care.
 Driver cannot leave the track motor car if there are people still on the loading platform
 Do not use anything to increase the height to the platform.
 Always perform operational movements with great care.
 Access the platform only when the track motor car is in safety condition.

After Operation
 At the end of every work shift, always remove the feeding key from the panel. Then turn the
battery switch to “OFF” and close and lock the access door.

Maintenance, Intervention
 Never fill the fuel tank while the engine is running.
 Fill up in a well-ventilated area.
 Do not smoke or approach live flames or sparks when filling.
 Be careful not to spill fuel while refuelling.
 Before performing every maintenance intervention, stop the engine and make sure the vehicle is
standstill and in a stable position.
 Do not touch movable parts if not sure of doing it without risk.
 Never neutralize preventive or limiting safety equipment.
 Replace any suspicious or worn pieces.
 Never change the safety mechanisms values and settings without the constructor’s permission.
 Never perform welding operations when battery–isolating lever is positioned on “ON”, it could
damage the vehicle electronic system.
 Plan inspection schedules and record all maintenance operations.

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 Use only non-corrosive, non-toxic and non-inflammable solvents to clean.
 When cleaning with compressed air jet, wear safety goggles and limit the pressure to 2 bar.
 Pay attention when cleaning electric parts (batteries, derivation cases, etc.). In this case, never
use pressurized water.

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INFORMATION ON ELIMINATION OF NOXIOUS SUBSTANCES

The oil used for the diesel engine, in the transmission, in the hydraulic installation, the liquid of the air
conditioner (if installed) and the liquid of the cooling system, have not to be disposed off but
eliminated in compliance with local laws.

USE AND CONSERVATION OF THE “OPERATION AND

MAINTENANCE” MANUAL
 The operation and maintenance manual is addressed to personnel in charge of: installation,
maintenance, revision, repairs and to all operators who work during the running of the vehicle,
especially for what concerns industrial safety.
 The information contained in the manual supplies all suggestions for proper vehicle utilization,
according to the expected planning and constructions purposed. There is also information on
features, use, maintenance, revision and solution of problems. Everything is with the observance
of the limits imposed by the manufacturer.
 The operation and maintenance manual is part of the machine and it must be kept until the
dismantling of the vehicle. In case of consultation of the manual, it must be kept in a safe place, on
board of the vehicle.
 In the event of damage of the manual, the user has to ask the manufacturer for a new copy. The
manufacturer reserves the right to modify the machine and the manuals without being obliged to
update the previous editions.
 The user is allowed to ask for information or updates that - after being released - become part of
the manual.
 In case of cession of the vehicle, the user is kindly requested to communicate the new owner’s
name to the manufacturer. Please, hand both this manual over to the new owner with the vehicle.

The data and information contained in this publication are not binding and the
manufacturer reserves the right to make alterations at any time and without prior
notice.
The information in this manual was correct at the time of going to press.

Copyright by GEISMAR
All rights reserved.

This publication may not be reproduced in whole or in part, in any form, without the
express written agreement of the COPY Right Owner.

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MANUFACTURER’S LIABILITY
The manufacturer will not be held responsible in the following cases:

 The vehicle is operated inappropriately;

 The vehicle is operated by unauthorized and/or unqualified personnel;
 Statutory legislation is not observed when using the vehicle;
 Incorrect installation;
 Power supply defects;
 Maintenance accomplished disregarding information supplied by the manufacturer;
 Alterations or interventions not authorized by the manufacturer;
 Use of non-genuine spare parts;
 Total or partial violation of the instructions contained in this manual;
 Exceptional or unpredictable events;
 Use of different lubricants, fuels and expandable materials from the ones recommended in this
manual.

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RISK ANALYSIS FOR THE PERSONNEL

It is dangerous:
 To fill up without following the indications prescribed for such liquids.
 When vehicle is operated by not trained personnel, inadequately educated or with altered physical
and mental abilities (alcohol, medicines), etc.
 To stay in or near the area where the vehicle or its equipment are at work.
 To get in or out the vehicle while is moving.
 To get out of the vehicle on the running track side.
 Not fixing the safety bar on the guardrails on the six-foot way while the vehicle is running.
 To use the vehicle when the pneumatic braking system is off-duty or inefficient.
 To use the vehicle when the parking brake is not in working condition.
 To operate the vehicle and its equipment without performing a proper maintenance cycle
according to the schedules and indications set out by this manual.
 To remove bonnets and/or protective casings, unless is for maintenance reasons.
 To transport loads which are overweighing the vehicle or its equipment capacity.
 To use the vehicle with inefficient or modified safety systems.
 To carry out maintenance operations while the vehicle is moving or with engine started up.
 To move the vehicle in travel speed when the equipment is not in transport position.
 To move the vehicle in travel speed when loads are not stable and fastened.
 When vehicle speed exceeds the maximum permitted one for the coupling used (towing vehicle).
 Moving the vehicle in traveling speed, with cabin door stopped in open position without applying
the safety barrier (chain).
 When operators do not wear devices meant for individual protection (safety helmets, gloves, etc.).
 To carry out electric connections without disconnecting the battery switch or the suitable circuit
breaker.
 To use the crane when the catenary is activated (if it is present).
 To work when the load limit device of the crane is damaged use the equipment without installing
the catenary grounding rod first (if present).
 To work when the load limit device of the crane is damaged.
 To use the crane when the speed of the wind exceeds 50 km/h.
 To stand below loads hung or within the working area of the equipment during operations.
 To smoke and/or to approach live flames or sparks to the vehicle battery.
 To work on the end platform by using ladders or any other device in order to increase the height of
the surface.
 To use the equipment when there is poor visibility.
 To use the vehicle (and its equipment) along a railway network whose cant of the track is more
than 150 mm

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PERSONNEL QUALIFICATIONS
Personnel using or operating the vehicle must be skilled and comply with the following features:

Physical
Good eyesight, hearing, coordination and capability to carry out any tasks required to use the
equipment safely.

Mental
Full understanding of the content of this manual, observation of regulations, rules and safety
precautions are required.
Work must be properly performed taking care of own safety and safety of others.

Emotional
He must be calm and able to stand up to any stress and make use of his own common sense as far as
physical and mental conditions are concerned.

Training
He must study and understand this handbook, diagrams, plans, indications and danger plates.
He must be qualified in all aspects related to the vehicle service and maintenance.
On first operation, he must know already how to use all controls in order to be ready for any
occurrence

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Chapter I

DESCRIPTION - EQUIPMENTS

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1.0 GENERAL FEATURES

The Track Motor Car VMT 545 GR is a modern and reliable vehicle specially designed to carry
passengers and material for track construction and maintenance under the climatic conditions
prevailing in Saudi Arabia (0° C / +50° C).

It includes:
 A cab for 5 passengers plus the driver;
 A loading platform;
 One 15 tm hydraulic crane;

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1.1 TECHNICAL FEATURES

Vehicle dimensions
Overall length: ................................................................................................... approx.10200 mm
Overall width ........................................................................................................ approx. 2900 mm
Height: ................................................................................................................ approx. 3800 mm
Frame length: ................................................................................................................... 8600 mm
Frame width: ..................................................................................................................... 2500 mm
Wheel base ....................................................................................................................... 4500 mm
Wheel diameter: ................................................................................................................. 850 mm
Track gauge: ..................................................................................................................... 1435 mm

Sighting distance
The control panel in the cab is positioned parallel to the track axis to give the driver an excellent
visibility when operating in each direction.

Mass loaded / unloaded

Unloaded vehicle mass: ............................................................................................... approx. 15 t
Useful load ...................................................................................................................... approx. 6 t
Fully loaded vehicle mass: .......................................................................................... approx. 21 t

Tanks capacites
Fuel tank .................................................................................................................................. 430 l
Auxiliary services and brakes air tank ....................................................................................... 60 l
Direct brake air tank .................................................................................................................. 60 l
Hydraulic oil tank ..................................................................................................................... 200 l

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1.2 PERFORMANCES AND LIMIT OF USE CONDITIONS

Speed
Maximum speed on level track (vehicle alone) ................................................... approx. 80 km/h
Maximum speed when towed ................................................................................ approx. 90 km/h

Running limits
Always use the vehicle in compliance with local regulations.
Minimum curve radius (depot) ............................................................................................... 108 m
Maximum gradient .................................................................................................................... 25‰

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1.3 ENGINE SPECIFICATIONS

Specifications
Model : TCD 2013 L06 2V
Manufacturer : DEUTZ
Cycle : 4 stroke Diesel engine with direct
injection system
Number of cylinders : 6 (in-line)
Turbo charging : With charge-air cooler
Electronic governor : Deutz EMR 3
Engine power (ISO 14396 IFN III) : 190 kW at 2300 rpm
Maximum torque at 1500 rpm : 1000 Nm
Max engine speed : 2300 rpm
Min. engine speed : 800 rpm
Bore : 108 mm
Stroke : 130 mm
3
Total dispacement : 7146 cm

Engine starting / electric equipment

Engine electric starter : 24 V / 4 kW
Alternator : 28 V / 80 A

Aspiration filter
Dry air filtration with double cartridge and cyclone pre-filter for dusty environment.

Exhaust pipe
The engine is fitted with an exhaust pipe with catalityc converter and silencer discharging upward the
vehicle.
Exhaust emission according to regulation UE 2004/26/CE Step 3 A and EPA non road Tier 3.

Cooling system
Liquid cooling.

Fuel circuit
It is fitted with two filtration stages (pre-filter and filter).

Oil filter
One oil filter incorporated on the engine.

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Compressed air production

The pneumatic system includes a compressor, 360 cc driven by the diesel engine.

Fuel tank
A 430 litres capacity tank is equipped with one locking cap, level indicator, internal baffle, drain plugs.

Performances
The below diagram provide the curves of power, torque and fuel consumption according to the engine
speed.

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1.4 RUNNING GEAR - SUSPENSION

Wheels
Type : Solid
Material : R9 quality steel
Specifications : UIC 812.3
Diameter : 850 mm
Minimum re-turning diameter : 810 mm
Wheel profile : UIC 510.2
Back to back wheel gauge : 1360 mm
The appendix A.04 shows the wheel drawing

Axle boxes
The axle boxes, conforming to UIC 510- 1 standard, are fitted with double range ball bearings. They
are guided by axle guards welded to the frame.

Suspension
The suspension conforming to UIC 517 is ensured by means of flat springs and rubber shock
absorbers.

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1.5 BRAKING SYSTEM

The vehicle is provided with a pneumatic braking system acting on the brake blocks (mounted in pairs
on each wheel) sending pressure to the brake cylinders (one per wheel).
The braking pneumatic system includes:

 Automatic brake: one distributor controls the air pressure going to the brake cylinders. This
distributor is controlled through the brake pipe (BP) pressure. The driver can control the pressure
inside the BP using the specific lever on the control board in the cabin;
 Direct brake: the air pressure going to the brake cylinders is controlled directly by a lever on driver
control board;
 Emergency brake: the braking action is provoked by draining the BP into the atmosphere (causing
automatic brake action). The emergency brake activators are located:
 Inside the cabin: drain valve and emergency push button;
 On vehicle frame corner: emergency push button;
 Parking brake: the parking brake system is included in the brake cylinders. A preloaded spring
inside the brake cylinder applies a braking force when there is no air pressure (a pneumatic
pressure is necessary to release the brake). The parking brake is automatically applied when
battery is isolated or control board is off (no air pressure). A manual device enables the operator to
release the parking brake mechanically for hauling the vehicle in train formation or in case of
pneumatic failure;

Note : Pictures shown in this chapter are to be considered as purely indicative and may
be different from actual vehicle.

Braking system Commands on Control Board

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1.6 BRAKING SYSTEM CHECK

Before moving the vehicle, check the braking system conditions.

Non-compliance can lead to serious danger and damage.

Perform the following operations:

 Put movable scotch blocks in front of wheels to prevent the vehicle from moving;
 Switch the control board on;
 Check that pressure in the brake tank is at least 6 bar. If pressure is insufficient, start the engine
up and wait until the minimum pressure is reached;
 Push the green reset button that turns on and activates the vehicle emergency system. The direct,
automatic and parking brakes controls are operative;
 Release all brakes by their corresponding controls:
 Push the Direct Brake lever to the top end;
 Push the Indirect Brake lever to the top end;
 Rotate the Parking Brake switch to the left;
The braking pressure inside the brake cylinders should go to 0 bar. The parking brake should be
released. Also check that the brake blocks are released.

1.6.1 Direct Brake

 Pull the lever on the control board to apply the direct brake, pressure inside brake cylinders
increases (check the pressure gauge);
 The maximum pressure is 2.8 bar;
 Check that brake blocks are applied;
 Push the lever to release the direct brake;

1.6.2 Automatic Brake

 Check that valve levers “R2” and “R8” are in service position;
 Pull the lever on control board to decrease the pressure inside Brake Pipe (BP), pressure inside
brake cylinders consequently increases (check the pressure gauge);
 The maximum pressure inside the brake pipe is 5 bar;
 The maximum pressure inside the brake cylinders is 2.8 bar (when air inside brake pipe is
completely drained);
 Check that brake blocks are applied;
 Push the lever to release the automatic brake;

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Automatic Brake Isolating Levers

1.6.3 Parking Brake

The parking brake is a negative braking system (spring-controlled); it is automatically applied when air
is drained from the brake cylinders spring chamber.
 Rotate the selector switch in braking position (to the right). Pressure in the spring chamber should
fall down to 0 bar. The selector switch light is on when pressure goes below 4.5 bar;
 Check that brake blocks are applied;
 Rotate the selector switch in brake release position (to the left). Pressure in the spring chamber
should go up to 6 bar. The selector switch light turns off;
 Check that all brake blocks are all released;
The parking brake is automatically applied every time the electric power switches off.

1.6.4 Emergency Brake

 Push one of the emergency push button (on the control board or one of the four at the frame
corner) or open R1 lever inside the cabin;
 The brake pipe pressure should fall down and, contemporarily, the pressure inside the brake
cylinders should rise to 2.8 bar. The reset button light is off;
 Check that brake blocks are applied;
 Turn and pull up the emergency push button, or close R1 valve lever;
 Push the reset button on control board;
 Brake pipe pressure should rise to 5 bar and release the brake blocks;

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VMT 545 GR

1.7 USE OF THE BRAKING SYSTEM

1.7.1 Direct Brake

Before using the direct brake, reduce the engine rpm to the minimum. The gearbox will produce a
braking effect according to the engaged ratio.
 Braking: Pull the brake lever, the pressure gauge indicates the braking pressure. Maximum
pressure is 2.8 bar.
 Brake Release: Push the brake lever.
The direct brake can be applied progressively or rapidly.

Modulate the brake action to prevent brake blocks from excessive

overheating.

1.7.2 Automatic Brake

The automatic brake is used to brake a towed vehicle. It works on

the pressure in the brake pipe (BP).
The brake system of the towed vehicle shall be consistent with the
brake installation. Brake pipes must be connected.
The automatic brake application is slower than the direct brake.

Before using the automatic brake, reduce the engine rpm to minimum. The gearbox will produce a
braking effect according to the engaged ratio.
The automatic brake can be applied progressively or rapidly.
 Braking: Pull the automatic brake lever: the brake pipe (BP) pressure should fall down. At the
same time, the pressure in the brake calipers should rise. Maximum braking pressure is 2.8
bar.
 Brake Release: Push the lever forwards: the pressure in the brake pipe (BP) should increases
with the simultaneous and progressive release of the vehicle’s brakes.

Apply the brake early in order to stop the vehicle in the right
position, with regard to the vehicle speed and the reaction time of
the brake system.
Try not to overheat the brake disks by alternating both brake
application and brake release operations.

1.7.3 Parking Brake

Activate the parking brake using the yellow selector switch (turning it clockwise); the control lights on
when the brake is applied. The pressure gauge should fall down to 0 bar.
The parking brake system acts on all wheels.
Use parking brake in case of protracted stop of the vehicle.
Release the parking brake by turning the selector anticlockwise.

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VMT 545 GR

Ref : 6449 Rev.00 26

VMT 545 GR

1.8 CABIN

General features
Overall dimensions
 Length : approx. 2200 mm
 Width : approx. 2200 mm
 Height : approx. 2108 mm
The fully enclosed cab, insulated and glazed on all its sides, is designed to carry 5 persons plus the
driver. The structure is mounted directly on the frame.

General characteristics
 Construction made of steel plates welded to the main structure made with rolled steel sections;
 Wooden floor covered with non-slip rubber material and fitted with thermal and acoustic insulation;
 Windscreens made of stratified glass ensuring perfect visibility;
 External handrails for cab access on the platform deck;
 One swiveling door, with fixed pane (giving access to the platform deck), fitted with lock(s) in two
positions (open and closed);
 Internal handrails;
 One control panel;
 One rotating driver seat, adjustable in high and distance from the control panel;
 Five upholstered seats with synthetic covering;
 Three electrical windscreen wipers with washers (two at the front and one at the rear);
 One central headlight on front top of the cab;
 Two working searchlights on the side walls of the cab;
 Roof-lights;
 Sun-visors (rolling type), on the windscreens;
 One documents box;
 Rain gutters applied to both sides of the cab roof;
 One wastebasket with ashtray;
 Two hooks for clothes;
 Hammer for emergency;
 One socket 24V DC for portable lamp;
 One fire extinguisher;

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VMT 545 GR

1.8.1 CONTROL PANEL

The control panel includes all the equipment needed to control and drive the vehicle. It is positioned
parallel to the track to give excellent visibility in both directions.
The control panel includes the instruments to control the following main functions:
 Braking;
 Engine;
 Hydrostatic transmission;
 Horns;
 Windscreen wipers and washers;
 Vehicle lighting;
 Indicating lights for crane and stabilizers in travelling position;
 Air Conditioning;

Item Description
01 Emergency push-button
02 Emergency reset push-button
03 Low pitch pneumatic horn push-button (“FA” sound)
04 High pitch pneumatic horn push-button (“MI” sound)
05 Electric horn push-button
06 Gearbox in neutral
07 Forward running push-button
08 Backward running push-button
09 Fast speed luminous push-button

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VMT 545 GR
10 Slow speed luminous push-button
11 Change of travel direction pilot-lamp
12 Traction consent pilot-lamp
13 Overspeed warning light
14 Gearbox lever
15 Direct brake lever
16 Parking brake selector
17 Automatic brake lever
18 Automatic brake isolating pilot-light
19 Safeties by-pass pilot-lamp
20 Stabilizers retracted pilot-lamp
21 Crane within gauge pilot-lamp
22 Crane activation selector
23 Oil traction manometer
24 Hydraulic oil high level warning light
25 Hydraulic oil gauge
26 Speedometer
27 Traction pump filter clogged warning light
28 Oil tank filter clogged warning light
29 Oil tank low level warning light
30 Deutz engine display
31 Engine oil low level warning light
32 Engine stopping push-button
33 Engine oil low pressure warning light
34 Diesel engine starting/preheating luminous button
35 Engine alternator not charging warning light
36 Control board feeding key
37 Working lights selector
38 Front windscreen wipers selector
39 Front windscreen washers selector
40 Rear windscreen wipers selector
41 Rear windscreen washers selector
42 Manometer: red pointer for brakes air pressure/white pointer for main pipe
Manometer: white pointer for main tank air pressure/red pointer for air pressure when
43
stationary
44 Low air pressure warning light
45 Fuel level gauge

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VMT 545 GR

1.9 LOADING PLATFORM

The loading platform is equipped with 400 mm high folding sideboards. Its flooring is made of non-slip
chequer steel plate.

Dimensions
 Length (including hydraulic crane) ........................................................................ approx. 3750 mm
 Width ...................................................................................................................... approx. 2500 mm
 Height of floor above rail level ............................................................................... approx. 1120 mm
The loading platform can be reached from the rear side of the cabin using the platform deck.
The deck includes:
 Footboard made of non-slip chequer steel plate;
 Two access staircases (one on each side);
 Safety handrails;
 Safety chain (on each side).

The operators working have to wear individual protections (gloves,

helmet etc.)
Pay the maximum attention when you work near a double track
area.
Never work on the platform by using ladders or any other device to
increase the height of the surface.

1.10 LOADING CRANE

The vehicle is equipped with a 15,69 t.m hydraulic crane mounted at the far end of the platform. The
jibs are parallel to the track axis in travel position to optimise the driver’s visibility.

1.10.1 Crane features

Make ................................................................................................................ AMCO VEBA
Model ............................................................................................................... 817 1S
Lifting capacity ................................................................................................. 15,69 t.m
Maximum hydraulic outreach: (with one hydraulic extension):
Horizontal ......................................................................................................... approx. 6.23 m
Vertical ............................................................................................................. approx. 9.5 m
Slewing angle .................................................................................................. 387°
Slewing moment .............................................................................................. 2 150 daNm
Design standard .............................................................................................. EN 12999

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VMT 545 GR

1.10.2 Crane fittings

The crane is equipped with:
 Emergency hand operated pump;
 Double arm with one hydraulic extension;
 Hook;
 Radio remote control system;
 Slewing gear with one drive unit;

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VMT 545 GR
 All hydraulic cylinders double acting type;
 Load holding valves on slewing rim and all cylinders;
 High pressure filter;
 Manual bilateral commands;
 Hydraulic stabilizers jacks with hydraulic outriggers (on both sides);
 Electronic control of lifting capacity and range management system;
 Height limiting device;
 Mechanical rotation limiting device;
 Hydraulic tank fitted with filter and level gauge (under vehicle frame);
 Electric check of stabilizers jacks, outriggers and crane in transport position;
 One worklight 24 V DC – 100 W with protective grating mounted on the outer boom;
 Plates of working diagrams and safety instructions on each side of the crane;
 Earth bonding of all components.

1.10.3 Crane controls

The radio remote control panel includes controls and checks for:
 Movements of hydraulic crane;
 Emergency stop;
 Horn.
All crane movements are performed smoothly and proportionally.

1.10.4 Crane stabilizers controls

Hydraulic stabilizer jacks and hydraulic outriggers control levers are fitted on each side of the vehicle
close to the corresponding supporting legs.

1.10.5 Hydraulic crane using conditions on lifting charge configuration

The crane lifting capacities have two stage functions: max capacity or reduced capacity, depending on
the slewing angle, the position of stabilizer jacks and outriggers movement.
Max lifting capacity is obtained with the following conditions:
a) All around 360° at maximum cant, when:
 Vehicle is stopped and braked;
 Stabilizer jacks are on the ground (or at least at the same crane working side);
 Stabilizers outriggers are fully extended (or at least at the same crane working side)
b) Crane boom inside the two sectors in vehicle axis at maximum cant, when:
 Stabilizer jacks are in stowing position;
 Stabilizer outriggers are retracted;
Reduced lifting capacity is obtained with the following condition:
Crane boom outside the two sectors in vehicle axis at maximum cant, when:
 Stabilizer jacks are in stowing position;
 Stabilizer outriggers are retracted;

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VMT 545 GR

Chapter II

OPERATING INSTRUCTIONS

Ref : 6449 Rev.00 33

VMT 545 GR

36

07

08
17
09
16
10

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VMT 545 GR

2.0 VEHICLE STARING AND STOPPING

The vehicle starting and stopping procedure for driving is explained here as follow:
 Turn lever to connect the battery-switch;
 Act on feeding key « 36 » to power on the control board;
 With engine on, wait until pressure in the pneumatic reservoirs reaches 8 bar. Pressure must
always be at 6 bar minimum when operating with the VMT 545 vehicle;
 With engine idling, select and engage the fast/slow range of speed. This action is confirmed by
corresponding luminous button « 09 »/« 10 » lighting on;
 Select running direction using relevant push-button « 07 » for forward running or « 08 » for
backward running;
 Act on selector « 16 » to disengage parking brake;
 Use specific lever « 17 » to fill up the main pipe and disengage the automatic brake;
 Disengage the direct brake;
 Increase engine rpms to reach the required speed;
 When speed has overcome 0 Km/h it will be necessary to operate on the driver safety device
pedal according to the following settings:
 Not pressed for longer than 30seconds.
 Not released for longer than 5 seconds.
If above timing is not observed, an alarm buzzer will go off and the vehicle emergency action will
start right after.
 To reduce speed, act on the direct brake if vehicle is operating by itself, or on the indirect brake if
vehicle is towing another trailer. Rpm’s should be decreased to the minimum to stop the VMT 545
GR track motor car;
 Shut down the engine by turning back to “0” position the main control board feeding key;
 Disconnect the battery-switch.

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VMT 545 GR

2.1 CRANE
Activate the crane by using selector « 22 » on the vehicle control board.

22

2.1.1 Crane control panels

The machine is equipped with two control panels located above the operation controls on the right and
left sides of the crane.

Item Description
« A » Starting key If ON, it enables the crane controls.
st
It unblocks the machine when the 1 boom cylinder is locked at the end of
« B » Reset button the stroke without load.
« C » Alimentation
If this is on, the electric system is enabled.
pilot light (POWER)
« D » Electric
system malfunction If this is on, the electric system is not working correctly.
light
« E » Emergency
It stops all crane controls.
stop button
« F » Time counter It displays the crane total working hours

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VMT 545 GR

Use the “RESET” button only in case of need or emergency.

Push the “RESET” button to control every crane operation to restore the ordinary conditions.
The controls are efficient for a maximum of 3 seconds.
If the problem persists, the controls become inefficient for another 30 seconds. Then it’s possible to
push the “RESET” button again.

2.1.2 Work operation controls

Item Description
MST Stabilizer legs control

MG1 Slewing control

MG2 1st boom control
MG3 2nd boom control
MG4 Hydraulic extensions control

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VMT 545 GR

2.2 CRANE SAFETY DEVICES DESCRIPTION

2.2.1 Max working pressure valve

The purpose of the max working pressure valve is to limit the pump pressure to control the main valve:
so the working pressure of all hydraulic cylinders is limited.The max working pressure valve on the
main control valve operates when into the activated cylinder the pressure reaches the max setting
value: the valve diverts the oil to return line, stopping in this way the load moving.

2.2.2 Overpressure valves

nd
The overpressure valves (overcenter) are fitted on the 1st boom and 2 boom cylinders.
Their purpose is to block or lower the load if pressure into the cylinders reaches the setting value.
So the crane is kept safe.
OVERPRESSURE VALVE ON THE 1st BOOM CYLINDER
This valve operates as antishock valve or as load limiter if the load limiting device does not operate.

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VMT 545 GR
OVERPRESSURE VALVE ON THE 2nd BOOM CYLINDER
If the crane hoists the rated load with fully extended 2nd boom and extensions cylinders, this safety
valve lowers automatically the 2nd boom until the crane reaches the safety configuration.

2.2.3 Load limiting device

The purpose of the load limiting device is to protect the crane structure and/or safeguard the machine
stability. It works by coming into operation when the moment given by the load on the hook, exceeds
the setting maximum value.
This type of load limiting device constantly analyses the load value.
When the load limiting device comes into operation all crane movements are disabled except those
that don’t increase the moment due to the load.

When the lifting cylinder stem is completely out, if one insists with
the manoeuvre to have it extracted, the limiting device
intervenes even if the crane is not loaded. To unblock the crane
press the reset push-button on the control board and close the
lifting cylinder little by little.

Ref : 6449 Rev.00 39

VMT 545 GR

2.2.4 Exclusion of load limiting device of EC crane

The load limiting device can be excluded by the operator only if it

breaks down, or it can be done by the installer during crane load
tests.

Below procedure has to be performed to bring the crane back to its rest position ONLY.
EXCLUSION OF LOAD LIMITING DEVICE FOR NO RDC CRANE
Break the A screw seal then tighten the A screw to cut out the load limiting device.

You must restore the normal safety conditions at an authorised

workshop.

2.2.5 Emergency stop buttons

The crane is equipped with red emergency buttons placed on the control boards.
In case of danger or emergency, the crane movements can be blocked immediately by pressing one
of these stop buttons.

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VMT 545 GR
When an emergency stop button is pressed, the oil in the power circuit is diverted to the return line by
a solenoid valve.
To restore the normal operating conditions, turn the button head until release is engaged and button
returns to its normal position.

Before restoring the crane normal operating conditions, always

check that the issues which prompted the use of the emergency
button no longer exist and that safety is guaranteed again.

CHECKING THE RIGHT WORKING OF THE EMERGENCY STOP BUTTON

Operate with a joystick und push the emergency stop button: the crane movement must stop
immediately and all crane controls must be forbidden.

If you find some faults, you must block immediately the crane
operations.

2.2.6 Block valves on hydraulic cylinders

These seals allow to hold the load in the reached position in case of hoses failure and in absence of
motive power, they prevent all movements caused by accidental operation of the control levers.

Item Description
V1 1st boom articulation cylinder

V2 2nd boom articulation cylinder

V3 Hydraulic extensions cylinder
V4 Stabilizers cylinders
V5 Slewing cylinders

Ref : 6449 Rev.00 41

VMT 545 GR

2.2.7 Locking devices for stabilizer extensions

SEMIAUTOMATIC ROD LOCK WITH LEVER
Its purpose is to automatically lock the stabilizer rods in their fully closed position, when the lever is
turned toward the basement end.

AUTOMATIC ROD LOCKS WITH SPRING (NOT-AA CRANE)

Its purpose is to automatically lock the stabilizer rods in their fully closed position.

Failure to lock the retracted rods correctly when transporting the

machine may cause damage to property and injury to people.

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VMT 545 GR

2.2.8 Slewing limiting device

The crane is equipped with an adjustable rotation limiting device.

The mechanic limiting device consists of two metal blocks fixed on the crane base: its purpose is to
limit the column rotation angle. These blocks can be fixed in different positions in order to obtain
different working areas:
 No limitation of rotation;
 Sector 180° at controls side;
 Sector 180° at opposite controls side;
 Rotation locked in the direction of crane rest position on the flatcar;

The limiting blocks must be locked on the crane base by padlock.

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VMT 545 GR

2.2.9 Boom inclination control

The crane is equipped with a boom inclination control device: this device signals if the crane position
is suitable to operate with moving vehicle (boom under the horizontal line).

2.2.10 Boom elevation limiting device

The crane is equipped with an adjustable boom elevation limiting device.

Ref : 6449 Rev.00 44

VMT 545 GR
The elevation limiting device consists of a drain valve, operated by the actuating rod when the 1st
boom inclination angle exceeds the setting value.

The maximum elevation angle can be changed shifting the end of stroke
of the rod, after opening the padlock.

2.2.11 Emergency hand-pump

The crane is equipped with a emergency handpump, that allows to move the crane even without
driving power and power supply.

The emergency pump can be used only when the driving power fails
and only to close the crane in rest position, without lifting any load.
In this case the operator has to be helped by an assistant to activate the
pump.

If the crane is powered, the pump is always active when the emergency stop button is not pushed.
If the crane is not powered, in order to use the pump, it’s necessary to bypass the electrovalve YVH2:
unseal the valve, push and turn 90° the knurled knob.

Ref : 6449 Rev.00 45

VMT 545 GR

You must restore the normal operating conditions of the electrovalve

YVH2 at an authorised workshop.

2.3 CRANE GAUGES AND WARNING LIGHTS

2.3.1 Configuration indicators and headlights switch

Near the control panel there is a check control with warning lights indicating the crane configuration.

Item Description
Green: stabilizer beams locked in folded position
S1 LIGHT
Red: stabilizer beams not folded
Green: crane in rest position
S2 LIGHT Red: crane not in rest position
Green: crane suitable to operate with
moving vehicle
S3 LIGHT
Red: crane not suitable to operate with
moving vehicle
Blue: work headlights ON
F SWITCH
Not lighted: work headlights OFF

2.3.2 Load indicator

On the control boards there are load indicators pressure gauges showing the 1st boom cylinder
pressure.
Yellow sector: the crane has reached 90% of max lifting capacity.Red sector: the crane has reached
the max lifting capacity (100%).

Ref : 6449 Rev.00 46

VMT 545 GR

2.4 VEHICLE TOWING

Towing the track motor car by another vehicle involves some operations to be performed to assimilate
it as a conventional towed vehicle, or rather “set up in vehicle configuration”. These operations mainly
consist in disengaging the transmission and isolating the brake control group.

If possible, set the vehicle on horizontal track for this procedure.

The following procedure is mandatory for towing the track motor car.

Isolate the Vehicle

 Block wheels with movable scotch blocks and apply parking brake;
 Lock all movable equipment into rest position;
 Verify that control board is switched off, also set the battery-switch off;
 Mechanically disengage the transmission following this procedure:
 Remove safety plug « R » and disengage transmission by pushing the Joystick forward
following below detailed procedure. SUCH PROCEDURE MUST BE PERFORMED WITH
OPEN DISCONNECTOR.

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VMT 545 GR
 Check that emergency lever « R1 » inside cabin is not activated;
 Isolate Automatic Brake: turn valve lever « R2 » into “OFF” position;
 Release Direct Brake: push the direct brake lever till top position;
 Release air from services and braking reservoirs using corresponding levers « R3 » and « R4 »;
 Release parking brake: release manually the internal spring with the special screw on each brake
cylinder;
 Check that all brake blocks are released;

Couple the Tractor Vehicle

 Use the lever on the headstock side to unlock the couplers;
 Open manually the couplers on both headstock;
 Move the towing vehicle slowly toward the power car until the two couplers are inserted and
locked properly;

Move the tractor vehicle car carefully at reduced speed.

Nobody can stand close to the coupling area.

2.4.1 Automatic brake system configuration

Motor Car using Automatic Brake System
 Check that valve lever « R8 » is NOT in “OFF” position;
 Connect the brake pipe hoses on both headstocks;
 Open the brake pipe stop valves on the headstocks;

Use this configuration only if the towing vehicle has a compatible

automatic brake system.
Proceed with a braking test to verify the correct and simultaneous
working of the indirect brake system on both vehicles.

Motor Car Not Using Automatic Brake System – Through Brake Pipe
 Put valve lever “R8” in “OFF” position;
 Connect the brake pipe hoses on both headstock;
 Open the brake pipe stop valves on the headstock;

The track motor car is not braked, but enables the brake action on
the connected vehicles.

Motor Car Not Using Automatic Brake System – Brake Pipe Disconnected
 Put valve lever “R8” into “OFF” position;

In this transport configuration, the vehicle is considered as a non-

braked mass. It is necessary to consider it for the convoy brake
performance calculation.
The motor car should be positioned at the tail of the convoy.

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VMT 545 GR
2.4.2 Remove wheels block
Remove all blocks previously inserted on the wheels.
Now the vehicle is ready for towing.

2.4.3 Restore normal conditions

At the end of the work, bring back the vehicle in normal running condition:
 Block the vehicle with scotch blocks at wheels level;
 If applicable, close the brake pipe stop valve facing the headstock then disconnect the brake pipe
half-couplings and put their heads onto their supports;
 Put valve levers « R2 » and « R8 » on position “ON”;
 Remove the special cylinders on all cylinders brake to restore parking brake;
 Switch on the battery- witch;
 Feed the panel by using ignition-key;
 Start the engine and wait for the air reservoirs to be filled again with air;
 The vehicle is ready for operation;
 Remove the scotch block before moving;

Ref : 6449 Rev.00 49

VMT 545 GR

Chapter III

MAINTENANCE

Ref : 6449 Rev.00 50

VMT 545 GR

Maintenance operations are excluded from the warranty and remain

at the customer’s expense and responsability.

3.0 RUN-IN PERIOD (First 150-200 Hours)

 Do not use the vehicle at its maximum performance; do not overload the engine.
 After each cold start, idle the engine for few minutes.
 Check for leaks of engine oil, engine coolant, hydraulic system and air leaks.

3.1 FIRST 100 HOURS MAINTENANCE

Table for first 100 Hours Maintenance

Device Activity
Check the concentration of the coolant liquid additive.
Engine Check the tension of the pulley belt.
Check bolts, screws tightness and engine mounting.

Change the oil.

Hydrodynamic
Change the oil cartridge.
Transmission
Check for leaks.

Change the oil.

Hydraulic System Change the oil cartridge.
Check for leaks.

Pneumatic system Check for leaks.

Grease the four axle boxes.

Driving axles and wheel
Replace the oil in the axle reduction gear case.
arrangement
Check for leaks.

Grease the mechanical parts.

Braking system
Check the brake blocks. Replace if necessary.

Electric system Check batteries state of charge and their electrolyte level.

Generating Set Check bolts and screws tightness.

Crane Grease all mechanical components and check bolts tightness.

Always refer to the relevant maintenance booklet.

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VMT 545 GR

3.2 PREVENTIVE MAINTENANCE

For all maintenance, repair, inspections and part replacements

engine shall be stopped and parking brake applied.
When replacing parts, use exclusively genuine spare parts.

Ask an authorization from manufacturer about interventions that are

not included in the ordinary maintenance.

Never perform any welding operations when the batteries isolating

switch lever is positioned on “ON”, it can damage the vehicle
electronic system.

The engine and hydraulic system waste oil, the air conditioner fluid,
the engine coolant and any kind of waste shall be disposed
respecting national laws and regulations.

3.2.1 Engine
All maintenance concerning the engine can be performed inside the engine compartment. Panels can
be removed to have an easy access to the parts.

Before greasing or changing oil and filter cartridges, always clean

the component and surrounding parts.

Always refer to the engine manual for its maintenance operations.

Table for Engine Maintenance

Hours Activity Measure
Lubricating oil level (if necessary top up)
10 (daily) Check Engine tightness (visual inspection for leaks)
Suction air filter
125 Check Battery and battery cable connections
Cooling System
250 Check
V-belts (retension if necessary)
Lubricating oil (at least once a year)
Oil filter cartridge
500 Replace
Bypass oil filer
Filter bowl on hydr. bowler

750 Check Alternator

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VMT 545 GR
Hours Activity Measure
Valve clearance (readjust if necessary)
Check
Fastenings
1000 Fuel filter cartridge
Replace
Valve set (crankcase breather)
Clean Fuel prefilter
300 Check Injectors (clean if necessary)

3.2.2 Transmission system

Always refer to the components manual for the maintenance

operations.

Transmission System Maintenance table

Hours Activity Measure
Oil level, this operation (made this operation with oil temperature between
10 (daily) Check 82° – 92° C).
If necessary top up.
50 Check Oil filter clogging. Replace if necessary
125 Clean Cooling System on engine
250 Grease Cardan Shafts
500 Replace Oil filter cartridge
Grease Tension bar
1000
Replace Transmission oil
Bolts and screws tightness
2000 Check Flex hoses state
Cardan shafts state

3.2.3 Hydraulic system

Hydraulic System Maintenance table
Hours Activity Measure
50 Check Oil level on tank. Top up if necessary.
125 Clean Cooling radiator
Hydraulic oil
Replace
Oil filter cartridge
200
Clean Oil tank
Check Flex hoses and fittings. Replace if necessary

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VMT 545 GR
3.2.4 Hydraulic crane

Always refer to the components manual for the maintenance

operations.

Hydraulic Crane Maintenance table

Hours Activity Measure
10 (daily) Check Leaking on hydraulic system
Suction and pressure pump connections
100 Check
Main valve fittings tightening
Test Load limiting device
500 Grease All the rotating and sliding parts of crane
Check Sliding pads wear
1000 Check Bolts and screws tightness

3.2.5 Pneumatic system

Pneumatic system Maintenance table

Hours Activity Measure
Drain Condensate on the main tanks (open valve R3 and R4)
10 (daily)
Check Condensate drain valve functioning.
Filter inside condensate drain valve
500 Clean Main filter silencer
Sand ejectors
1000 Replace Main filter cartridge
Hoses states. Replace if necessary.
Check
2000 Compressor state
Clean Sandboxes

3.2.6 Braking system

Braking system Maintenance table

Hours Activity Measure
10 (daily) Check Brake test
125 Check Brake block clearance. Correct if necessary.
250 Check Brake block state. Replace if necessary.
1000 Grease Brake linkage

Ref : 6449 Rev.00 54

VMT 545 GR
3.2.7 Wheelset

Wheelset Maintenance table

Hours Activity Measure
125 Check Oil level inside crown and pinion case. Add if necessary.
Check Oil leaks in the two crowns and pinion cases.
500
Grease The 4 axle boxes.
Replace Oil in the 2 crowns and pinion cases.
1000 Check Wheel profile and diameter. If necessary, re-turn the wheels.
Grease Axle guides
Axles guide clearance
2000 Check
Bolt and screws clearance

3.2.8 Electric system

Electric system Maintenance table

Hours Activity Measure
Acoustic and electric horns
10 (daily) Check Running and working lights
Fuses state
Batteries state and connection cables
125 Check
Batteries liquid level. Top up if necessary
500 Check Windscreen wipers state. Replace if necessary
1000 Check Control board indicators. Replace if necessary.
End switches. Replace if necessary
2000 Check
Wiring. Replace if necessary.

Ref : 6449 Rev.00 55

VMT 545 GR

3.2.9 Loading platform – Side Walls

Grease hinge, pins and support sidewalls every 500 hours.

3.2.10 Sign plates

Clean all plates every 125 hours and replace if needed.

3.3 FILLING TABLE

PART Q.ty TYPE NOTE

BP VANELLUS Always consider the upper mark on the

Engine (Oil)
MULTIFLEET 15W 40 gauge.

Engine Tank For fuel quantity consult the specific

430 l DIESEL FUEL
(Fuel) manual.

Check oil level qhen crane is in transport

Hydraulic Tank 200 l BP BARTRAN HV46
position.

Hydrodynamic CASTROL AGRI TRANS

Transmission PLUS 10W 30

As
Axle Boxes MULTIS EP3 Grease by using a brush.
needed

Axle Reduction BP ENERGEAR

2X7l
Gear HYPO 80W 90

Windscreen
2 X 5,5 l WATER + DETERGENT
washer tank

As
Batteries DISTILLED WATER
needed

Sandboxes 4 x 25 l TRACK SAND

Grease all nipples (for pump), equipment,

As
Crane Greasing MULTIS EP3 joints, and extensions. Consult the specific
needed
manual.

General As
MULTIS EP3 All lubricators (for pump), equipment.
Greasing needed

Quantities given in the table are those required for the periodic changes; however, with every filling
operation, it is advised to check that level corresponds to the marks on the various indicators/checking
devices.
Before proceeding with refilling operation, always stop the engine
and park the vehicle.

Ref : 6449 Rev.00 56

 VMT 545 GR

3.4 LUBRICANTS TABLE

KPL
BP AGIP CASTROL ESSO MOBIL SHELL TOTAL PANOLINE
(Q8)
Rubie
Diesel Sigma Ultron T 850 Delvac Rimula
Vanellus Tir
Engine Oil - Super Enduron Turbo SAE XHP Ultra
Multifleet 8500
New TFE 10W- 10W-40 Diesel 10W- Extra 10W-
10W-40 10W-
Generation 40 5W-40 40 10W-40 40
40
BP
Unirlo Rubia
Diesel Vanellus Sigma Delvac Rimula
Tection Diesel T 500 XT
Engine Oil - Multigrad Turbo MX X 15W-
15W-40 15W- 15W40 15W-
Standard e 15W- 15W-40 15W-40 40
40 40
40
Hydraulic
Tellus
Oil Bartran Hyspin Univis Haend DTE 15 Equivis
Arnica 46 Oil ST HLP UNI 46
Mineral HV 46 AWHM 46 N 46 el 46 M ZS 46
46
White

Hydraulic
Oil Autran ATF Donax Fluide ATF MULTI
ATF II D TQD ATF D Auto 14
Mineral MBX 220 TA ATX 21996
Red
BP
Essolu
Vanellus Diesel Agri Trans Delvac
Speed be T 400 Rimula Rubia S
Monogr Sigma S Plus Hydraul
Gear HYD 10W X 10W 10W
ade 10W20 10W30 ic 10W
10W
10W
Gear Mobilu Spirax
Energea Transmis SUPER
Rotra MP EPX 80W- Oil GX T 55be HD HD
Axle Gear r Hypo sion TM DUTY 80W-
80W90 90 80W- 80W-9080W- 80W-
80W-90 80W-90 90
90 90 90
Chassi
Graisse
Standard Graisse Ronex Rembrant s Retinax Multis RP
universe GR LP 2
Grease universelle MP 2 Grease WB 2 2
lle
LBZ
Axle box Graisse GR Unirex Rembrant Mobilux Retinax Multis
Piroplex 2 HT GREASE 3
Grease MR MU/EP 3 N3 EP 3 EP 3 WB 3 EP 3

Ref : 6449 Rev.00 57

VMT 545 GR

3.5 BRAKE BLOCKS CLEARANCE CHECK

After releasing the braking system, the brake blocks should be close to the wheels without blocking
them. Clearance between wheels and brake shoes is minimum 5 mm and maximum 40 mm.

The following instructions are for brake blocks check and adjustment:
 Use movable scotch blocks to avoid any movements of the vehicle;
 Release the emergency brake;
 Release the direct brake;
 Release the automatic brake;
 Release the parking brake;
 Check that brake blocks are free to move;
 Push one of the brake blocks against the wheel and measure the clearance on the opposite side.
The measure should not exceed 40 mm;
 If clearance is higher than the indicated value, regulate the brake block;
 Repeat this operation on all wheels.

3.6 BRAKE BLOCKS CLEARANCE REGULATION

There are two ways to regulate brake block on the same wheel. The rod connecting the brake shoes
on the wheel has two different systems at each end for distance regulation.
On one end (A), we have a drilled plate for positioning the rod on the brake shoe holder.
To change the regulation, proceed with the following operation:
 Remove cotter pin from the blocking pin;
 Remove blocking pin from the setting hole;
 Move the brake shoe holder to choose another setting hole;
 Put back the blocking pin;
 Check again the brake block clearance;
 Put a new cotter pin for safety;
This first regulation depends mainly on the distance between the setting holes.
For a more precise regulation, operate on the other end (B):
 Remove cotter pin from blocking pin 1;
 Remove blocking pin;
 Unscrew blocking nut 3;
 Take regulating plate 2 out of the brake shoe holder;
 Screw or unscrew regulating plate 2 to obtain the required spacing;
 Put the regulating plate back inside the brake shoe holder;
 Put blocking pin back;
 Check again the brake block clearance;
 Put a new cotter pin for safety;
 Repeat the steps on all wheels;

Ref : 6449 Rev.00 58

VMT 545 GR

After the brake block clearance regulation, apply parking brake and remove the scotch blocks from
wheels.

3.7 BRAKE BLOCKS REPLACEMENT

Replace brake blocks when wear exceeds 15 mm. Proceed with the following operations:
 Use movable scotch blocks to avoid any movements of the vehicle;
 Release the emergency brake;
 Release the direct brake;
 Release the automatic brake;
 Release the parking brake;
 Check that brake blocks are free to move;
 Remove the blocking pin on the brake shoe holder;
 Remove the blocking key on brake block;
 Replace the worn brake block with a new one;
 Replace the blocking key to former position;
 If necessary, regulate the clearance between 5 and 10 mm;
 Apply and release (automatic or direct) to verify the assembly;
 Check again the brake block clearance;
 Apply the parking brake and remove scotch blocks from wheels;

Ref : 6449 Rev.00 59

VMT 545 GR

Ref : 6449 Rev.00 60

VMT 545 GR

ENCLOSURES

Ref : 6449 Rev.00 61

VMT 545 GR

Plans
A.01 Front view
A.02 Top view
A.03 Side view
A.04 Wheel
A.05 Front axle

Ref : 6449 Rev.00 62

VMT 545 GR

A.01 Front view

Ref : 6449 Rev.00 63

VMT 545 GR

A.02 Side view

Ref : 6449 Rev.00 64

VMT 545 GR

A.03 Top view

Ref : 6449 Rev.00 65

 VMT 545 GR

A.04 Wheel

Ref : 6449 Rev.00 66

VMT 545 GR

A.05 Axle

67
Ref : 6449 Rev.00
VMT 545 GR

DIAGRAMS

Ref : 6449 Rev.00 68

VMT 545 GR

DIAGRAMS
Pneumatic circuit diagrams
 Braking system diagram
 Horns pneumatic system
 Gear range selection pneumatic system

Hydraulic circuit diagrams

 Hydrostatic transmission hydraulic system diagram
 Hydrostatic oil radiator hydraulic system diagram
 Crane hydraulic system diagram

Electric circuit diagram

 Nomenclature of the parts in the vehicle 24 Vdc. wiring diagram
 24 Vdc. vehicle wiring diagram

Ref : 6449 Rev.00 69

VMT 545 GR

057.007.613.00
076.007.605.00 e1

Ref : 6449 Rev.00 70

VMT 545 GR

Braking system diagram (Dwg N° 076.007.605.00 e1)

Item Description
01 Air filter on Deutz Diesel engine

02 Compressor (installed on Deutz engine)

03 Metal flexible connection pipe

04 Cooling pipe

05 Water separator

06 Automatic drain valve

07 Air dryer

08 Air dryer cartridge

09 Air dryer tank

10 Direct brake manual valve

11 Manual drain valve

12 Main pneumatic tank

13 Selecting valve

14 Parking brake pressure gauge

15 Emergency brake valve

16 Automatic brake lever

17 Pressure gauge

18 Automatic brake electro-magnetic valve

19 Automatic brake relays valve

20 Automatic brake isolating valve

21 Pressure switch for air pressure in brake reservoir

23 Automatic brake distributor valve

24 Pressure regulating valve

25 Automatic brake pneumatic tank

26 Main pipe pneumatic half-couplings

27 Headstock stop valve

28 Silencer plug

29 Strangler 1.5 mm

Ref : 6449 Rev.00 71

VMT 545 GR

Item Description
30 Silencer

31 Pressure switch change of direction forbidden

32 Brake cylinder

33 Parking brake electro-magnetic valve

34 Pressure limiting valve

35 Pressure switch parking brake testing

36 Check valve

37 Anti-compound valve

38 Brake cylinders isolating valve

Ref : 6449 Rev.00 72

VMT 545 GR

076.007.603.00 e2

Ref : 6449 Rev.00 73

VMT 545 GR

Horns pneumatic system diagram (Dwg N° 076.007.603.00 e2)

Item Description
02 Electro-magnetic valve

03 Acoustic warning device (High pitch)

04 Acoustic warning device (Low pitch)

Ref : 6449 Rev.00 74

VMT 545 GR

076.007.606.00 e1

Ref : 6449 Rev.00 75

VMT 545 GR

Gear range selection pneumatic system diagram (Dwg N°

076.007.606.00 e1)

Item Description
01 Gear range changing cylinder
02 Electro-magnetic valve
03 Air filter plug

Ref : 6449 76
Rev.00
VMT 545 GR

076.015.601.00 e2
C 1/3
Ref : 6449 Rev.00 77
VMT 545 GR

Hydrostatic transmission hydraulic system diagram (Dwg N°

076.015.601.00 e2 )

Item Description
01 200 Lt Capacity oil tank
02 Complete oil filter
03 Oil level indicator
04 Lever indicator magnetic switch
05 120°C transmitter (M16X1.5)
06 Thermo-contact (M14X1.5)
07 Thermo-contact (M14X1.5)
08 Pressure gauge 1/8” gas (1.2 bar)
09 Non-return valve (2bar)
10 Oil radiator double circuit
11 Block
12 Pump
13 Hydraulic motor
14 Mooring block for braking
15 Cartridge
16 Non-return valve S20A3 1"G opening at 3 bar
17 Manometer rear connection
18 Manometer connection

Ref : 6449 Rev.00 78

VMT 545 GR

076.016.602.00 e1

Ref : 6449 Rev.00 79

VMT 545 GR

Hydrostatic oil radiator hydraulic system diagram (Dwg N°

076.016.602.00 e1)

Item Description
01 Hydrauilc pump
02 Manometer pressure gauge
03 Pressure regulating valve
04 Oil flow control valve
05 Base plate ½”
06 Oil cooling down electro-magnetic valve
07 Oil radiator ventilation hydraulic motor
08 Check valve

Ref : 6449 Rev.00 80

VMT 545 GR

076.016.603.00 e1

Ref : 6449 Rev.00 81

VMT 545 GR

Crane hydraulic system diagram (Dwg N°076.016.603.00 e1)

Item Description
01 Casappa Formula series pump

02 Hand pump

03 Regulating valve

04 Manometer connection

05 Base plate ½”

06 Electro-magnetic valve 24V.

07 Check valve ½”

08 Feed-through connection

09 Electro-magnetic valve 24V.

10 Switch

11 Return collecting block

12 Stabilizers controls distributor

13 Stabilizers stop valve

14 Stabilizers jack rod

15 Stabilizers cylinder
nd
16 2 boom extension cylinder

17 Extension valve
nd
18 2 boom cylinder
nd
19 2 boom valve
st
20 1 boom cylinder
st
21 1 boom valve

22 Safety valve

23 Slewing cylinder

24 Load limiting manometer

25 Load limiting valve

26 Crane movement locking slider cylinder

27 Feed-through connection

28 Crane controls distributor

29 Feed-through connection

Ref : 6449 Rev.00 82

VMT 545 GR
Item Description
30 Stabilizers rod blocking valve

31 Stabilizing cylinders block

32 Safety valve

33 Unidirectional valve

34 Valve

Ref : 6449 Rev.00 83

VMT 545 GR

Nomenclature of the parts in the vehicle 24 Vdc. Wiring diagram

of (Dwg n°076.012.503.00e1)

Symbol Page Description

1BOX.9B 1 Master fuse box
1FU.8B 1 Master fuse
1G.8D 1 Generator
1GB.2B 1 12 V - 220Ah battery
1GB.4C 1 12 V - 220Ah battery
1HL.18B 1 Preheating led
1KA.10E 1 Alternator relay
1KM.13E 1 Feeding Line “15” relay
1KM.17E 1 Diesel engine start relay
1M.6D 1 Starting motor
1QF.13A 1 General switch magneto-thermal circuit breaker
1QF.14A 1 Line “15” protection
1QF.17A 1 Diesel engine start line magneto-thermal circuit breaker
1QS.2D 1 Battery switch
1SA.13C 1 Control panel feeding key
1SH.17B 1 Diesel start push-button
2KM.10C 2 Control unit power supply relay
2QF.3A 2 EMR control unit magneto-thermal circuit breaker
2QF.9A 2 EMR control unit magneto-thermal circuit breaker
2R.15B 2 Can end resistance
2S.5C 2 Diesel engine air filter
2S.6C 2 Liquid level in fuel pre-filter
2SB.3C 2 Engine stopping push-button
EMR 2 Electric motor control unit
2SL.7C 2 Coolant low level
3BL.17E 3 Fuel level transmitter
3HA.2C 3 Coolant low level buzzer
3HA.4D 3 Engine oil low level buzzer
3HL.3C 3 Coolant low level warning light
3HL.4D 3 Engine oil low pressure warning light
3HL.15C 3 Generator warning light
3PL.17C 3 Fuel level indicator
3QF.10A 3 Display power supply magneto-thermal circuit breaker
3QF.15A 3 Control board signals power supply magneto-thermal circuit breaker
3R.4C 3 Resistor
3R.6D 3 Resistor
3R.9E 3 Can end resistance

Ref : 6449 Rev.00 84

VMT 545 GR
Symbol Page Description
EMS 3 EMS display
4HL.6C 4 Hydraulic oil filter clogged led
4HL.8E 4 Hydraulic oil low level warning light
4HL.15E 4 Hydraulic oil high temperature warning light
4KA.10E 4 Hydraulic oil low level relay
4KA.12E 4 Radiator hydraulic oil activation relay
4KA.17E 4 Hydraulic oil high temperature relay
4PT.11C 4 Hydraulic oil temperature indicator
CP9 4 Hydraulic oil filter clogged connector (pump)
P4 4 Hydraulic oil low level sensor
P5 4 Hydraulic oil temperature transmitter
P6 4 Hydraulic oil temperature thermostat
P7 4 Hydraulic oil high temperature thermostat
P8 4 Hydraulic oil filter clogged
P9 4 Hydraulic oil filter clogged (pump)
YVH6 4 Radiator hydraulic oil activation electro-magnetic valve
5HL.20E 5 Crane system activated warning light
5KA.15E 5 Crane selecting relay
5KA.17E 5 Crane selecting relay
5QF.3A 5 Air conditioning evaporator magneto-thermal circuit breaker
5QF.4A 5 Air conditioning condenser magneto-thermal circuit breaker
5QF.6A 5 Air conditioner magneto-thermal circuit breaker
5QF.7A 5 Air conditioner magneto-thermal circuit breaker
5QF.10A 5 Crane power supply magneto-thermal circuit breaker
5QF.14A 5 Crane signals power supply magneto-thermal circuit breaker
5SA.14C 5 Crane selector switch
YVH7 5 Crane general electro-magnetic valve
6HL.3D 6 Parking brake engaged led
6HL.7C 6 Automatic braking isolating valve led
6HL.10C 6 Air in the reservoirs not sufficient led
6HL.14C 6 Gearbox in neutral led
6HL.17C 6 Cardan shaft not moving led
6KA.5E 6 Parking brake warning relay
6S.7D 6 Automatic brake isolating valve limit switch
7CSQ.3D 7 Speed sensor connector
P1 6 Air not sufficient in the reservoirs pressure-switch
P3 6 Parking brake pressure-switch
7CSQ.11D 7 Speed sensor connector
7QF.16B 7 Air conditioning condenser magneto-thermal circuit breaker
7R.4C 7 Pull-up resistance
7R.11C 7 Pull-up resistance

Ref : 6449 Rev.00 85

VMT 545 GR
Symbol Page Description
7SQ.3D 7 Speed sensor
7SQ.11D 7 Speed sensor
7TH.6C 7 Tachymeter
9BOX.8C 9 By-pass key connector block
9HL.3E 9 Safeties by-pass warning light
9SA.3C 9 Safeties by-pass selector
11HL.14C 11 Crane retracted configuration led
11HL.16C 11 Stabilizers retracted led
11KA.3E 11 Crane retracted configuration relay
11KA.9E 11 Stabilizers retracted relay
12KA.7E 12 Parking brake OFF relay
12SA.7B 12 Parking brake selector
YVP1 12 Parking brake electro-magnetic valve
YVP2 12 Braking electro-magnetic valve
13BOX.3B 13 By-pass key connector block
13BOX.3C 13 By-pass key connector block
13BOX.3D 13 By-pass key connector block
13BOX.3E 13 By-pass key connector block
13HL.15C 13 Emergency system active led
13KA.11E 13 Emergency system relay
13KA.12E 13 Emergency system relay
13QF.12A 13 Emergency line magneto-thermal circuit breaker
13S.6D 13 Cabin emergency lever limit switch
13SB.2B 13 Emergency push button on vehicle frame (front left)
13SB.2C 13 Emergency push button on vehicle frame (front right)
13SB.2D 13 Emergency push button on vehicle frame (rear right)
13SB.2E 13 Emergency push button on vehicle frame (rear left)
13SB.6C 13 Emergency push button on control board
13SB.12D 13 Emergency reset push-button
14HL.3E 14 Forward running direction engaged warning light
14HL.5E 14 Backward running direction engaged warning light
14KA.7E 14 Running lights relay (front white)
14KA.9E 14 Running lights relay (front red)
14KA.11E 14 Running lights relay (rear white)
14KA.13E 14 Running lights relay (rear red)
14KA.15E 14 Running lights relay (front central)
14KA.17E 14 Running lights relay (rear central)
15HL.3E 15 Front white running light
15HL.5E 15 Front white running light
15HL.9E 15 Front red running light
15HL.11E 15 Front red running light
15HL.17E 15 Front central light

Ref : 6449 Rev.00 86

VMT 545 GR
Symbol Page Description
15QF.3A 15 Front running lights magneto-thermal circuit breaker
15QF.17A 15 Front central running lights magneto-thermal circuit breaker
XSC 15 Connector
16HL.3E 16 Rear white running light
16HL.5E 16 Rear white running light
16HL.9E 16 Rear red running light
16HL.11E 16 Rear red running light
16QF.3A 16 Rear running light magneto-thermal circuit breaker
17HL.4E 17 Manometer lighting
17HL.5E 17 Manometer lighting
17HL.7E 17 Control board lighting
17HL.9E 17 Control board lighting
17HL.11E 17 Cabin lights ceiling-light fixture
17QF.9A 17 Control board lighting magneto-thermal circuit breaker
17QF.11A 17 Cabin lighting magneto-thermal circuit breaker
17QF.16A 17 24Vdc socket magneto-thermal circuit breaker
17X.16C 17 Cigar lighter – 24 Vdc
18M.4E 18 Front windscreen wiper motor
18M.5E 18 Front windscreen wiper motor
18M.7E 18 Front windscreen washer motor
18M.8E 18 Front windscreen washer motor
18M.11E 18 Rear windscreen wiper motor
18M.14E 18 Rear windscreen washer motor
18QF.4A 18 Front windscreen wiper and washer motors magneto-thermal circuit breaker
18QF.11A 18 Rear windscreen wiper and washer motors magneto-thermal circuit breaker
18SA.4C 18 Front windscreen wipers control selector
18SA.11C 18 Rear windscreen wipers control selector
18SB.7C 18 Front windscreen washer push button
18SB.14C 18 Rear windscreen washer push button
19HL.3D 19 Working light on cab
19HL.5D 19 Working light on cab
19HL.7D 19 Working lights on cabin side selector warning light
19QF.3A 19 Working lights magneto-thermal circuit breaker
19SA.3C 19 Working lights on cabin side selector
20KA.10E 20 Emergency horn relay
20M.16E 20 Emergency horn electro-compressor
20QF.5A 20 Pneumatic horns electro-magnetic valves magneto-thermal circuit breaker
20QF.16A 20 Emergency electric horn magneto-thermal circuit breaker
20SB.5D 20 High pitch “MI” horn push button
20SB.7D 20 Low pitch “FA” horn push button
20SB.10D 20 Emergency acoustic warning device control push-button

Ref : 6449 Rev.00 87

VMT 545 GR
Symbol Page Description
YVP5 20 Front high pitch horn electro-magnetic valve
YVP6 20 Front low pitch horn electro-magnetic valve
F01 22 Fuse
F02 22 Fuse
F03 22 Fuse
F04 22 Fuse
F05 22 Fuse
E03 23 Rear central light
25HA.17D 25 Driver safety device buzzer
25QF.4A 25 Electronic card magneto-thermal circuit breaker
25SB.18D 25 Driver safety device pedal
25UE.7B 25 I/O Module
25UE.14B 25 I/O Module
25XS.7D 25 CAN male connector
25XS.8D 25 CAN “Y” connector
25XS.9C 25 CAN female connector
25XS.9D 25 CAN male connector
25XS.9E 25 CAN “Y” connector
25XS.10E 25 CAN female connector
26R.4D 26 Diesel engine accelerator potentiometer
26S.10D 26 Engaged transmission limit switch
26S.12D 26 Disengaged transmission limit switch
26SH.6D 26 Low speed engaging push-button
26SH.8D 26 Fast speed engaging push-button
26SH.14D 26 Forward running gear engaging push-button
26SH.16D 26 Backward running gear engaging push-button
P2 27 Traction cut-off pressure switch
28HL.16E 28 Traction consent led
28KA.14E 28 Gearbox in neutral relay
28KA.18E 28 Cardan shaft not moving warning relay
CYVH1 28 Backward running electro-magnetic valve connector (pump)
CYVH2 28 Forward running electro-magnetic valve connector (pump)
CYVH5 28 Forward/Backward running electro-magnetic valve connector (engine)
YVH1 28 Backward running electro-magnetic valve (pump)
YVH2 28 Forward running electro-magnetic valve (pump)
YVH5 28 Forward/Backward running electro-magnetic valve (engine)
YVP3 28 Fast speed gear electro-magnetic valve
YVP4 28 Low speed gear electro-magnetic valve
29HL.12E 29 Overspeed led
29KA.8E 29 Emergency action relay
30HL.10E 30 Low speed engaged warning light
30HL.12E 30 Fast speed engaged warning light

Ref : 6449 Rev.00 88

VMT 545 GR
Symbol Page Description
30KA.14E 30 Forward running relay
30KA.16E 30 Backward running relay
YVH3 30 Pump braking electro-magnetic valve (mooring)
YVH4 30 Pump braking electro-magnetic valve (mooring)

Ref : 6449 Rev.00 89

VMT 545 GR

24 Vdc. Vehicle wiring diagram (Dwg. 076.012.503.00e1)

Ref : 6449 Rev.00 90

Rev.00
 1QF.13A 1QF.14A 1QF.17A

1FU.8B 1BOX.9B
1KM.17E

1GB.2B 1GB.4C 1KM.13E

1SH.17B 1HL.18B

1QS.2D 1SA.13C

1KA.10E

1QS.2D 1M.6D 1G.8D

1KA.10E 1KM.13E
1KM.17E

Rev.00
 2QF.3A 2QF.9A

2R.15B

2SL.7C

2SB.3C 2S.5C 2S.6C 2KM.10C

EMR

Rev.00
 3QF.15A
3QF.10A

3HA.2C
3HL.3C
3R.4C

DEUTZ
EMS DISPLAY 3PL.17C
3HL.15C

EMS

3HA.4D
3HL.4D
3R.6D

3R.9E

3BL.17E

Rev.00
 P6

4PT.11C
4HL.4C 4HL.6C P4
4KA.12E
P7

4KA.12E

P9
4HL.15E 4KA.17E
P5
P8 4HL.8E 4KA.10E YVH6

CP9

Rev.00
 5QF.3A 5QF.4A 5QF.6A 5QF.7A 5QF.10A 5QF.14A

5SA.14C

5KA.15E

28KA.18E
13KA.12E

5KA.15E 5KA.17E 5HL.20E

YVH7

Rev.00
 P3 6HL.7C 6HL.10C 6HL.14C 6HL.17C

6HL.3D 6KA.5E 6S.7D P1

28KA.14E 28KA.18E

Rev.00
 7QF.16B

7TH.6C
7R.4C 7R.11C

7SQ.3D 7SQ.11D

7CSQ.3D 7CSQ.11D

Rev.00
Rev.00
 9BOX.8C

9SA.3C

9HL.3E

Rev.00
 1KA.10E

Rev.00
 11HL.14C 11HL.16C

11KA.3E 11KA.9E

11KA.3E 11KA.9E

Rev.00
 12SA.7B
12SA.7B 12KA.7E 13KA.12E

12KA.7E

5KA.17E

12KA.7E YVP1 YVP2

Rev.00
 13QF.12A

13SB.2B 13BOX.3B

13SB.2C 13BOX.3C

13SB.12D 13HL.15C
13KA.12E
13SB.6C

13SB.2D 13BOX.3D

13KA.11E
13S.6D

13SB.2E 13BOX.3E
13KA.11E 13KA.12E
13KA.12E

Rev.00
 30KA.14E 30KA.16E

14HL.3E 14HL.5E 14KA.7E 14KA.9E 14KA.11E 14KA.13E 14KA.15E 14KA.17E

Rev.00
 15QF.3A 15QF.17A

14KA.7E 14KA.9E 14KA.15E

15HL.3E 15HL.5E 15HL.9E 15HL.11E

15HL.17E

XSC

Rev.00
 16QF.3A

14KA.11E 14KA.13E 14KA.17E

16HL.3E 16HL.5E 16HL.9E 16HL.11E

Rev.00
 17QF.9A 17QF.11A 17QF.16A

17X.16C

17HL.7E 17HL.9E

17HL.4E 17HL.5E

17HL.11E

Rev.00
 18QF.4A 18QF.11A

18SA.4C 18SB.7C 18SA.11C 18SB.14C

18M.4E 18M.5E 18M.7E 18M.8E 18M.11E 18M.14E

Rev.00
 19QF.3A

19SA.3C

19HL.7D

19HL.3D 19HL.5D

Rev.00
 20QF.5A 20QF.16A

20SB.5D 20SB.7D 20SB.10D

20KA.10E

YVP5 YVP6 20KA.10E 20M.16E

Rev.00
Rev.00
 -

Rev.00
Rev.00
 71

Rev.00
 25QF.4A

25UE.7B 25UE.14B

20 10 47 29 46 28 01 19 37 42 6C 7B 1B 1C 8A 7A 5B

25.1 25.1

25.4
25XS.9C

25XS.7D 25HA.17D

25.5
2.13

2.12
25XS.8D 25SB.18D

25XS.9D 25XS.10E
2.13 25.2

2.12 25.3

25XS.9E

Rev.00
 55 36 54 35 53 34 52 33

26.4

26.5
26.1

26.2

26.3

26.6

26.7

26.8
26R.4D 26SH.6D 26SH.8D 26S.10D 26S.12D 26SH.14D 26SH.16D
5KA.17E

2.15

2.14

25.1 25.1

Rev.00
 24 41 23 40 22 39 21 38
27.1

27.2

27.3
27.6

11KA.3E 4KA.10E
27.7

27.10
P2
13KA.12E 1SA.13C

27.9
4KA.17E

27.11
11KA.9E

6KA.5E

27.8

25.1 25.1

Rev.00
 18 17 16 15 14 13 12 11

28.3

28.4

28.5
28.1

28.2

13KA.11E 13KA.11E

28.6

28.7

28.8
28.10
28.9

YVP4 YVP3 YVH2 YVH1 YVH5

28KA.14E 28HL.16E 28KA.18E

CYVH2 CYVH1 CYVH5

Rev.00
 02 25 03 43

29.2

29.4
29.1

29.3
29KA.8E 29HL.12E

Rev.00
 04 05 06 07 08 09
30.1

30.2

30.3

30.4

30.5

30.6
YVH3 YVH4
30HL.10E 30HL.12E 30KA.14E 30KA.16E

Rev.00
Rev.00
Rev.00
Rev.00
Rev.00
Rev.00
Rev.00
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