Service Manual - Wacker Neuson

Service Manual 

Dumper 

Machine models 3001/3001 Speed 

Edition 2.0 

Language English 

Article number 1000156004

Documentation 

Description Order no. 

Operator's Manual 1000103746 

Service manual 

Spare parts catalogue 

Up to serial no. AB27168D 

Up to serial no. AD310200 

From serial no. AE310242D 

Legend 

Edition Issued 

1.0 01/2005 

1.1 05/2007 

2.0 02/2008 

1000156004 

1000138134 

1000173900 

1000183393 

Copyright – 2004 Neuson Baumaschinen GmbH, Linz-Leonding 

Printed in Austria 

All rights reserved 

No part of this publication may be reproduced, translated or used in any form or by any means – graphic, electronic 

or mechanical including photocopying, recording, taping or information storage or retrieval systems – without prior 

permission in writing from the manufacturer. 

The cover features the machine with possible optional equipment. 

Neuson Baumaschinen GmbH 

Haidfeldstr. 37 

A-4060 Linz-Leonding 

Document: SERV-HB 3001 EN 

Order no.: 1000156004 

Edition: 2.0

Table of contents 



Operation 

Important information on this service manual .......................................................... 1-1 

Identification of warnings and dangers .................................................................... 1-2 

Designated use and exemption from liability ........................................................... 1-3 

Type labels and component numbers ...................................................................... 1-4 

Description of 3001F components (overview) ......................................................... 1-6 

Description of 3001S components (overview) ......................................................... 1-7 

Control stand overview ............................................................................................ 1-8 

Instrument panel overview ....................................................................................... 1-9 

Front skip maintenance prop ................................................................................. 1-10 

Swivel skip maintenance prop ............................................................................... 1-10 

Rollbar ................................................................................................................... 1-11 

Centre pivot prop ................................................................................................... 1-11 

Locking the control levers ...................................................................................... 1-12 

Battery master switch ............................................................................................ 1-12 

Specifications 

Chassis .................................................................................................................... 2-1 

Engine ...................................................................................................................... 2-1 

Engine capacities .............................................................................................. 2-2 

Engine tightening torques .................................................................................. 2-2 

Travelling drive ........................................................................................................ 2-2 

Brakes ...................................................................................................................... 2-2 

Steering system ....................................................................................................... 2-2 

Work hydraulics ....................................................................................................... 2-3 

Skip .......................................................................................................................... 2-3 

Drive specifications .................................................................................................. 2-3 

Vibration ................................................................................................................... 2-3 

Electric system ......................................................................................................... 2-4 

Fuse box ............................................................................................................ 2-4 

Relays ................................................................................................................ 2-4 

Tyres ........................................................................................................................ 2-5 

Noise levels ............................................................................................................. 2-5 

Coolant compound table .......................................................................................... 2-5 

General tightening torques ...................................................................................... 2-6 

Tightening torques for hydraulic screw connections (dry assembly) ................. 2-6 

Tightening torques for high-resistance screw connections ................................ 2-8 

Tightening torques for Nordlock lock washers ................................................... 2-9 

Dimensions model 3001 front skip ......................................................................... 2-10 

Dimensions model 3001 swivel skip ...................................................................... 2-11 

Maintenance 

Fluids and lubricants ................................................................................................ 3-1 

Maintenance plan (overview) ................................................................................... 3-3 

Service package ...................................................................................................... 3-6 

Up to serial no. .................................................................................................. 3-6 

From serial no. AE310242D .............................................................................. 3-6 

Introduction .............................................................................................................. 3-6 

Fuel system ............................................................................................................. 3-7 

Specific safety instructions ................................................................................ 3-7 

Refuelling ........................................................................................................... 3-7 

Stationary fuel pumps ........................................................................................ 3-8 

Diesel fuel specification ..................................................................................... 3-8 

Bleeding the fuel system ................................................................................... 3-8 

Fuel prefilter with water separator ..................................................................... 3-9 

Replacing the fuel filter .................................................................................... 3-10 

SERV-HB 3001 EN - Edition 2.0 * Sh3001EN_0IVZ.fm I-1


Engine lubrication system ...................................................................................... 3-11 

Checking the oil level ....................................................................................... 3-11 

Filling up engine oil .......................................................................................... 3-12 

Changing engine oil ......................................................................................... 3-13 

Replacing the engine oil filter cartridge ............................................................ 3-14 

Cooling system ...................................................................................................... 3-15 

Specific safety instructions .............................................................................. 3-15 

Checking/filling up coolant ............................................................................... 3-16 

Draining coolant ............................................................................................... 3-17 

Air filter ................................................................................................................... 3-18 

Replacing the filter ........................................................................................... 3-19 

Functional check once a week of the dust valve ............................................. 3-19 

V-belt ...................................................................................................................... 3-20 

Checking V-belt tension ................................................................................... 3-20 

Retightening the V-belt .................................................................................... 3-21 

Hydraulic system .................................................................................................... 3-22 


Checking the hydraulic oil level ....................................................................... 3-23 

Filling up hydraulic oil ...................................................................................... 3-23 

Changing hydraulic oil ..................................................................................... 3-24 

Fouling indicator for hydraulic oil filter ............................................................. 3-24 

Replacing the hydraulic oil filter element ......................................................... 3-24 

Checking hydraulic pressure lines ................................................................... 3-25 

Lubrication points ................................................................................................... 3-26 

Tyres ...................................................................................................................... 3-27 

Inspection work ................................................................................................ 3-27 

Changing wheels .................................................................................................. 3-28 

Removing the wheels ...................................................................................... 3-28 

Fitting the wheels ............................................................................................. 3-28 

Axles ...................................................................................................................... 3-29 

Checking the oil level and filling up oil ............................................................. 3-29 

Draining oil ....................................................................................................... 3-29 

Electric system ....................................................................................................... 3-30 


Service and maintenance work at regular intervals ......................................... 3-30 

Instructions concerning specific components .................................................. 3-31 

Alternator ......................................................................................................... 3-31 

Battery ............................................................................................................. 3-32 

Battery master switch ............................................................................................. 3-33 

General maintenance work .................................................................................... 3-34 

Cleaning ........................................................................................................... 3-34 

General instructions for all areas of the machine ............................................ 3-34 

Screw connections and attachments ............................................................... 3-34 

Pivots and hinges ............................................................................................ 3-34 

Engine 

3TNV88-KNSV engine: overview ............................................................................. 4-1 

Fuel system (up to AB) ............................................................................................ 4-3 

Fuel system (starting AC) ........................................................................................ 4-4 

Checking and adjusting valve clearance ........................................................... 4-5 

Tightening order for cylinder head bolts ............................................................ 4-6 

Checking the injection nozzles ................................................................................. 4-7 

Pressure check .................................................................................................. 4-7 

Checking the nozzle jet ...................................................................................... 4-7 

Injection time ...................................................................................................... 4-8 

Adjusting engine revs ............................................................................................... 4-9 

Compression ............................................................................................................ 4-9 

I-2 SERV-HB 3001 EN - Edition 2.0 * Sh3001EN_0IVZ.fm


Checking the coolant thermostat ........................................................................... 4-10 

Checking the thermal switch ............................................................................ 4-10 

Oil pressure switch ................................................................................................ 4-11 

Checking the coolant circuit ................................................................................... 4-11 

Clutch ..................................................................................................................... 4-12 

Engine 3TNV88-BKNSV overview (from serial no. AE310242D) .......................... 4-13 

Fuel system (from serial no. AE310242D) ............................................................. 4-15 

Checking and adjusting valve clearance ......................................................... 4-16 

Tightening order for cylinder head bolts .......................................................... 4-17 

Checking the injection nozzles .............................................................................. 4-18 

Pressure check ................................................................................................ 4-18 

Checking the nozzle jet ................................................................................... 4-18 

Injection time ................................................................................................... 4-19 

Adjusting engine revs ............................................................................................ 4-20 

Automatic revs setting option (Tier 3A from AE310242D) ..................................... 4-20 

Function ........................................................................................................... 4-20 

Installation ....................................................................................................... 4-21 

Compression .......................................................................................................... 4-22 

Checking the coolant thermostat ........................................................................... 4-22 

Checking the thermal switch ............................................................................ 4-23 

Oil pressure switch ................................................................................................ 4-23 

Checking the coolant circuit ................................................................................... 4-23 

Clutch ..................................................................................................................... 4-24 

Engine trouble ........................................................................................................ 4-24 

Travelling drive 

Variable displacement pump A10VG45DA .............................................................. 5-1 

Variable displacement pump: diagram .............................................................. 5-3 

Variable displacement pump: design ................................................................. 5-4 

Travelling drive overview ................................................................................... 5-5 

Connecting plate with valves ............................................................................. 5-6 

A6VM80EZ hydraulic motor ..................................................................................... 5-7 

Travelling drive overview (up to AB) ........................................................................ 5-8 

Travelling drive overview (starting AC) .................................................................... 5-8 

Towing and transporting the machine ...................................................................... 5-9 

Safety instructions ............................................................................................. 5-9 

Towing ............................................................................................................... 5-9 

Opening the high-pressure circuit ...................................................................... 5-9 

Test instruction ...................................................................................................... 5-10 

High pressure check ........................................................................................ 5-10 

Check: boost pressure ..................................................................................... 5-11 

Check: setting pressure ................................................................................... 5-12 

Adjustment ............................................................................................................. 5-13 

Setting: control initiation .................................................................................. 5-13 

Axles 

Axle type label ......................................................................................................... 6-1 

Drain, fill and check plug .......................................................................................... 6-2 

Tightening torques ................................................................................................... 6-2 

Wheel screws .................................................................................................... 6-2 

General tightening torques ................................................................................ 6-3 

Articulated joint (up to AB) ....................................................................................... 6-4 

Articulated joint (starting AC) ................................................................................... 6-6 

Transfer gearbox (up to AD) .................................................................................... 6-8 

Transfer gearbox (from AE310242D) .................................................................... 6-10 

Semiaxles .............................................................................................................. 6-12 

Wheel hub .............................................................................................................. 6-14 

Front axle brake (up to AB) .................................................................................... 6-16 



Brake diagram ........................................................................................................ 6-17 

Front axle brake (starting AC up to AD) ................................................................. 6-20 

Front axle brake (from AE310242D) ...................................................................... 6-21 

Differential (up to AB) ............................................................................................. 6-23 

Front axle (up to AB) ........................................................................................ 6-25 

Front axle (starting AC up to AD) ..................................................................... 6-27 

Rear axle ......................................................................................................... 6-30 

Cardan shaft .......................................................................................................... 6-32 

Brakes 

Brake circuit (up to AB) ............................................................................................ 7-1 

Brake circuit (starting AC) ........................................................................................ 7-2 

Parking brake ..................................................................................................... 7-2 

Service brake ..................................................................................................... 7-4 

Steering system 

Steering circuit (up to AB) ........................................................................................ 8-1 

Steering circuit (starting AC) .................................................................................... 8-2 

Steering unit: diagram .............................................................................................. 8-3 

Function ............................................................................................................. 8-3 

Steering unit connections ......................................................................................... 8-4 

Steering unit overview .............................................................................................. 8-5 

Priority valve overview ....................................................................................... 8-5 

Priority valve (legend) ........................................................................................ 8-5 

Steering unit ....................................................................................................... 8-6 

Steering unit (legend) ........................................................................................ 8-7 

Hydraulic system 

Manual spool connections: overview ....................................................................... 9-1 

Valves – differential lock (up to AB) ......................................................................... 9-2 

Check valve ....................................................................................................... 9-2 

Dumping the skip: hydraulic diagram (up to AB) ...................................................... 9-3 

Dumping the skip: hydraulic diagram (starting AC) .................................................. 9-4 

Swivelling the skip: hydraulics diagram (up to AB) .................................................. 9-5 

Swivelling the skip: hydraulics diagram (starting AC) .............................................. 9-6 

Test instructions ....................................................................................................... 9-7 

Check: work hydraulics ...................................................................................... 9-7 

Diagram A4 (up to AB) ............................................................................................. 9-8 

Diagram legend (up to AB) ...................................................................................... 9-9 

Diagram A4 (starting AC) ....................................................................................... 9-10 

Diagram legend (starting AC) ................................................................................ 9-11 

Electric system 

Ohm's Law (current, voltage, resistance); power ................................................... 10-1 

Measuring equipment, measuring methods ........................................................... 10-1 

Relays .................................................................................................................... 10-2 

Use, mode of function ...................................................................................... 10-2 

Electric units ........................................................................................................... 10-3 

Fuse box .......................................................................................................... 10-3 

Relays .............................................................................................................. 10-3 

Control stand overview .......................................................................................... 10-4 

Instrument panel overview ..................................................................................... 10-5 

Wiring diagram (legend) ......................................................................................... 10-7 

Wiring diagram version 1 A4 .................................................................................. 10-8 

Wiring harness 1000115009 main wiring harness up to AB (legend) .................... 10-9 

Wiring harness 1000115009 main wiring harness up to AB ................................ 10-11 

Wiring harness 1000173558 main wiring harness starting AC (legend) .............. 10-12 

Wiring harness 1000173558 main wiring harness starting AC ............................ 10-14 

Wiring diagram A3 up to AB (legend) .................................................................. 10-16 

I-4 SERV-HB 3001 EN - Edition 2.0 * Sh3001EN_0IVZ.fm


Wiring diagram A3 (up to AB) .............................................................................. 10-17 

Wiring harness 1000115009 main wiring harness up to AB (legend) .................. 10-18 

Wiring harness 1000115009 main wiring harness up to AB ................................ 10-19 

Wiring harness 1000173558 main wiring harness starting AC (legend) .............. 10-20 

Wiring harness 1000173558 main wiring harness starting AC ............................ 10-21 

Wiring harness 1000115414 engine wiring harness (legend) .............................. 10-22 

Wiring harness 1000115414 engine wiring harness ............................................ 10-23 

Wiring harness 1000075039/1000079012 telltale/indicator base – ignition lock base up 

to AB (legend) ...................................................................................................... 10-24 

Wiring harness 1000075039 telltale/indicator base (up to AB) ............................ 10-25 

Wiring harness 1000173351 ignition lock base starting AC ................................ 10-26 

Light switch connector assignment ...................................................................... 10-27 

Legend and STVO wiring harness (Austrian road traffic regulations) 1000166512 (starting 

AC) ................................................................................................................ 10-28 

Extension cable (front skip) 1000166698 ............................................................ 10-29 


Index 

A 

Abbreviations ........................................................................................ 1-1 

F 

Fluids and lubricants ............................................................................. 3-1 

I 

Index 

Important information 

On this service manual ................................................................... 1-1 

Instrument panel overview .............................................1-6, 1-7, 1-8, 10-4 

M 

Maintenance 

Air filter ......................................................................................... 3-19 

Bleeding the fuel system ................................................................ 3-8 

Changing engine oil ..................................................................... 3-13 

Checking the engine oil level ....................................................... 3-11 

Checking the hydraulic oil level .................................................... 3-23 

Cleaning ....................................................................................... 3-34 

Electric system ............................................................................. 3-30 

Engine and hydraulics cooling system ......................................... 3-15 

Engine lubrication system ............................................................ 3-11 

Filling in engine oil ........................................................................ 3-12 

Filling up coolant .......................................................................... 3-16 

Filling up hydraulic oil ................................................................... 3-23 

Fluids and lubricants ...................................................................... 3-1 

Fuel system .................................................................................... 3-7 

General maintenance work .......................................................... 3-34 

Hydraulic pressure lines ............................................................... 3-25 

Hydraulic system .......................................................................... 3-22 

Instructions concerning specific components ............................... 3-31 

Maintenance plan ........................................................................... 3-3 

Pivots and hinges ......................................................................... 3-34 

Replacing the engine oil filter cartridge ........................................ 3-14 

Replacing the fuel filter ................................................................. 3-10 

Screw connections ....................................................................... 3-34 

Service and maintenance work at regular intervals ...................... 3-30 

Tyres ............................................................................................ 3-27 

V-belt ............................................................................................ 3-20 

Wheel change .............................................................................. 3-28 

O 

Operation 

Control stand overview .......................................................... 1-8, 10-4 

Description of 3001F components (overview) .........................1-6, 1-7 

Instrument panel overview ......................................1-6, 1-7, 1-8, 10-4 

P 

Putting into operation ..................................................................... 1-6, 1-7 

R 

Refuelling .............................................................................................. 3-7 

Rollbar ................................................................................................. 1-11 

S 

Safety instructions 

Identification ................................................................................... 1-2 

Specifications .................................................................2-1, 4-1, 5-1, 10-1 

Chassis .......................................................................................... 2-1 

Coolant compound table ................................................................ 2-5 

Dimensions .........................................................................2-10, 2-11 

Electric system ............................................................................... 2-4 

Engine ............................................................................................ 2-1 

Noise levels .................................................................................... 2-5 

T 

Tyres ....................................................................................................3-27 

W 

Wheel change ......................................................................................3-28 

S-1 SERV-HB 3001 EN - Edition 2.0 * Sh3001EN_0SIX.fm

Operation

Operation 

1 Operation 

1.1 Important information on this service manual 

Operation 

This service manual contains important information on how to service your machine safely, 

correctly and economically. Therefore, it aims not only at new operators, but it also serves 

as a reference for experienced ones. It helps to avoid dangerous situations and reduce 

repair costs and downtimes. Furthermore, the reliability and the service life of the machine 

will be increased by following the instructions in the service manual. 

Careful and prudent working is the best way to avoid accidents! 

Operational safety and readiness of the machine do not only depend on your skill, but also 

on maintenance and servicing of the machine. 

Insist on using original spare parts when carrying out maintenance and repair work. This 

ensures operational safety and readiness of your machine, and maintains its value. 

Your Neuson dealer will be pleased to answer any further questions regarding the 

machine or the service manual. 

Abbreviations/symbols 

• This symbol stands for a list 

Subdivision within lists or an activity. Follow the steps in the recommended sequence 

☞This symbol requires you to carry out the activity described 

➥Description of the effects or results of an activity 

n. s. = not shown 

“Option” = optional equipment 

Stated whenever controls or other components of the machine are installed as an option. 

A combination of digits, or a combination of digits and letters, e.g. 40/18 or 40/A used for 

identifying the control elements, means: 

Figure no. 40/control element no. 18 or position A in figure no. 40 

Figures carry no numbers if they are placed to the left of the text. 

SERV-HB 3001 EN – Edition 2.0 * 3001s110.fm 1-1

Operation 

1.2 Identification of warnings and dangers 

Important indications regarding the safety of the staff and the machine are identified in this 

service manual with the following terms and symbols: 

Danger! 

Failure to observe the instructions identified by this symbol can result in 

personal injury or death for the operator or other persons. 

☞Measures for avoiding danger 

Caution! 

Failure to observe the instructions identified by this symbol can result in 

damage to the machine. 

☞Measures for avoiding danger for the machine 

Important! 

This symbol identifies instructions for a more efficient and economical use of the 

machine. 

Environment! 

Failure to observe the instructions identified by this symbol can result in damage to the 

environment. The environment is in danger if environmentally hazardous material (e.g. 

waste oil) is not subject to proper use or disposal. 

1-2 SERV-HB 3001 EN – Edition 2.0 * 3001s110.fm

1.3 Designated use and exemption from liability 

The machine is intended for: 

transporting the usual bulk material and concrete on construction sites 

Operation 

Every other application is regarded as not designated for the use of the machine. 

Neuson Baumashinen GmbH will not be liable for damage resulting from use other 

than mentioned above. The user alone will bear the risk. 

Designated use also includes observing the instructions set forth in the Operator's 

Manual and observing the maintenance and service conditions. 

The safety of the machine can be negatively affected by carrying out machine 

modifications without proper authority and by using spare parts, equipment, 

attachments and optional equipment which have not been checked and released by 

Neuson Baumaschinen GmbH. Neuson Baumaschinen GmbH will not be liable for 

damage resulting from this 

Neuson Baumaschinen GmbH shall not be liable for personal injury and/or damage to 

property caused by failure to observe the safety instructions, the Operator's Manual 

and the service manual, and by the negligence of the duty to exercise due care when: 

handling 

operating 

servicing and carrying out maintenance work and 

repairing the machine. This is also applicable in those cases in which special 

attention has not been drawn to the duty to exercise due care, in the safety 

instructions, the Operator's Manuals and maintenance manuals (machine/engine). 

Read and understand the Operator's Manual and the service manual before starting 

up, servicing or repairing the machine. Observe the safety instructions! 


Operation 

1.4 Type labels and component numbers 

Fig. 1: Type label: location 

Fig. 2: Type label 

Fig. 3: Diesel engine number 

Fig. 4: Number of variable displacement pump 

Serial number 

The serial number is stamped on the machine chassis next to the right-hand side front 

tyre. It is also located on the type label. 

The type label is also located at the front right, on the chassis next to the tyre. 

Type label information 

Model: 3001 

Year: 2004 

PIN: AC 000000 

Power: 24.4 kW (32.7 hp) 

Mass: 2550 kg (5622 lbs) 

Load: 3000 kg (6614 lbs) 

Max. gross mass: --------------- 

Max. axle load: --------------- 

--------------- 

Other information – see Specifications on page 2-1 

Engine number 

The type label (arrow) is located on the valve cover (engine). 

Example: Yanmar 46557 

Hydraulic pump number 

The type label (arrow) is located on the hydraulic pump housing. 


Fig. 5: Rollbar type label 

Fig. 6: Axle type label 

Rollbar number 

The type label is located on the left on the rollbar. 

Axle number 

The type label (arrow) is located on the upper side of the axle housing. 

Operation 


Operation 

8 

1.5 Description of 3001F components (overview) 

2 

3 

9 

1-6 SERV-HB 3001 EN – Edition 2.0 * 3001s110.fm 

10 

Pos. Description 

1 Rear chassis 

2 Front chassis 

3 Articulated joint 

4 Seat 

5 Control stand 

6 Mudguard 

7 Engine cover 

8 Skip 

9 Tilt ram 

10 Steering ram 

11 Rollbar 

1 

5 

6 

11 

4 

7

19 

18 

16 

12 

1.6 Description of 3001S components (overview) 

24 

25 

17 

15 

Operation 

SERV-HB 3001 EN – Edition 2.0 * 3001s110.fm 1-7 

20 

23 


12 Rear chassis 

13 Front chassis 

14 Swivelling console 


16 Seat 

17 Control stand 

18 Mudguard 

19 Engine cover 

20 Swivel centring 

21 Skip 

22 Offset ram 

23 Tilt ram 


25 Rollbar 

13 

22 

14 

21

Operation 

1.7 Control stand overview 

38 

38 

37 

29 

34 

31 

32 

36 

30 

35 


38 

27 

26 

33 


26 Accelerator pedal 

27 Service brake 

28 Parking brake 

29 Lever – backrest adjustment 

30 Forwards-reverse control 

31 Turn indicator lever – horn 

32 Round display element 

33 Lever for horizontal seat adjustment 

34 Skip control lever 

35 Light switch 

36 Low speed switch (turtle) 

37 Footrest 

38 Handle 

28 

38 

Rollbar not included in this figure for a 

clearer graphic representation.

43 

42 

44 

41 

45 

47 

46 48 

1.8 Instrument panel overview 


Operation 


49 

40 

53 

50 

39 Hazard warning switch 

40 Preheating start switch 

41 Hour meter 

42 Not assigned 

43 High beam telltale (blue) 

44 Preheating telltale (yellow) 

45 Telltale (red) – hydraulic oil filter 


47 Telltale (red) – alternator charge function 

48 Parking brake telltale (red) 

49 Telltale (red) – engine oil pressure 

50 Telltale (red) – coolant temperature 

51 Turn indicator telltale (green) 


53 Fuel level indicator 


52 

51 

39 

54

Operation 

1.9 Front skip maintenance prop 

E 

Fig. 7: Front skip maintenance prop 

1.10 Swivel skip maintenance prop 

A 

B 

A 

C 

C 

Fig. 8: Swivel skip maintenance prop 

B 

D 

D 

Danger! 

Mount the red maintenance prop before you carry out maintenance work with 

the skip raised. 

Mount the maintenance prop as follows: 

☞Raise the skip 

☞Remove spring plug B from pin C 

☞Remove pin C from guide D 

☞Lower the skip until the holes of guide E and maintenance prop A are aligned 

☞Insert pin C in guide E 

☞Secure pin C with spring plug B 

Mount the maintenance prop back onto the skip, in the reverse order, if it is no longer 

needed! 

Danger! 

Mount the red maintenance prop before you carry out maintenance work with 

the skip raised. 

Mount the maintenance prop as follows: 

☞Raise the skip 

☞Remove safety pin B from pin C 

☞Lower the skip until maintenance prop A rests on swivelling console D 

Mount the maintenance prop back onto the skip, in the reverse order, if it is no longer 

needed! 


1.11 Rollbar 

Fig. 9: Rollbar 

1.12 Centre pivot prop 

Fig. 10: Centre pivot prop 

A 

A 

B 

Danger! 

The rollbar is very heavy, folding it up or down is very 

Dangerous! 

☞Two persons are required for raising or lowering the rollbar. 

Caution! 

Do not fasten the seat belt when driving with the rollbar lowered! 

Folding up the rollbar: 

☞Park the machine on level ground 

☞Raise the rollbar 

☞Fasten the rollbar with lock pins A and secure them with split pins 

Lowering the rollbar: 

☞Park the machine on level ground 

☞Remove the split pins from lock pins A 

☞Remove lock pins A 

☞Slowly and carefully lower the rollbar with the help of a second person 

Danger! 

Put the red centre-pivot prop in place before loading the machine. 

Operation 

The centre pivot prop connects the front and rear chassis to prevent steering movements 

(via the articulated joint) when crane handling the dumper. 

Proceed as follows: 

☞Remove the spring plug from pin B 

☞Turn centre pivot prop A towards the rear chassis 

☞Secure centre pivot prop A with the spring plug and pin B 

Important! 

Before putting the machine into operation again, mount the centre pivot prop back 

onto the front chassis again by means of pin B. 


Operation 

1.13 Locking the control levers 

Fig. 11: Locking the control lever 

1.14 Battery master switch 

A 

A 

Fig. 12: Battery master switch 

C 

B 

B 

Lock as follows: 

Caution! 

Lock the control lever for the skip during road travel! 

☞This avoids unintentional actuation of the skip. 

☞Remove split pin A from bracket B 

☞Fold bracket B to the front 

☞Insert split pin A in bracket B 

Unlock in the reverse order! 

Important! 

Do not disconnect the battery while the engine is running. 

Important! 

Power supply is interrupted directly after the battery, by means of a key 

Interrupting power supply: 

• Before working on the electric system 

☞Turn key A of the battery master switch to position B and remove it 

Switching on power supply: 

☞Insert key A in the battery master switch 

☞Turn the key down to the notched position C 


Specifications


2 Specifications 

2.1 Chassis 

2.2 Engine 

Sturdy steel sheet chassis, rubber-mounted engine 


Engine 

Tier 2 

Model 3001 

Tier 3A 

Product Yanmar diesel engine 

Type 3TNV88-KNSV 3TNV88-BKNSV 

Design Water-cooled 4 stroke diesel engine 

No. of cylinders 3 

Fuel injection system Direct injection 

Aspiration Natural aspiration 

Cooling system Water-cooled/aspirating fan 

Lubrication system Force-feed lubrication with trochoidal pump 

Displacement 1642 cm³ (100.2 cu in) 

Nominal bore and stroke 88 x 90 mm (3.46 x 3.54") 

Output 24.4 kW (32.7 hp) at 2800 rpm 

Max. torque 

101.5 – 110.5 Nm (75 – 82 lbf ft) 

at 1100 rpm 

105 Nm (77 lbf ft) at 1000 rpm 

Max. engine speed without load 2500 ±10 rpm 

Idling speed 1100 rpm ± 50 rpm 

Valve clearance (intake = outlet) 0.15 – 0.25 mm (0.006 – 0.01") 

Injection pressure 196 – 206 bar (2843 – 2988 psi) 

Compression 

Standard 34.3 bar (497.5 psi) 

Limit 27.5 ± 1 bar (399 ± 15 psi) 

33.3 – 35.3 bar (483 – 512 psi) at 

250 rpm 

Engine oil pressure 2.9 – 3.9 bar (42 – 57 psi) 3.5 – 5.0 bar (51 – 73 psi) 

Pressure switch for engine oil 

pump 

0.5 ± 0.1 bar (7 ± 1.5 psi) 0.4 – 0.6 bar (6 – 9 psi) 

Thermostat opening temperature 

71 °C/160 °F (start) 

85 °C/185 °F (fully open) 

69.5 – 72.5 °C/157.1 – 162.5 °F 

Thermal switch 

107 – 113 °C/224.6 – 235.4 °F 

Firing order 

1 – 3 – 2 (1st cylinder on fan wheel side) 

Direction of rotation 

Counterclockwise (as seen from the flywheel) 

Starting aid 

Preheater (preheating time 15 seconds) 

Glow elements (preheating time 

10 – 15 seconds) 

Max. inclined position (engine no 

longer supplied with oil): 

30° in all directions 

Exhaust values according to 

97/68/EC Tier 2 

EPA Tier 2 

97/68/EC Tier 3A 

EPA Tier 4 interim 



Engine capacities 

Engine tightening torques 

2.3 Travelling drive 

2.4 Brakes 

2.5 Steering system 

Capacities Model 3001 

Fuel tank 

40 l (11 gal) 

Engine oil (max./min. fill) 

6.7 l/3.9 l (1.8/1.0 gal) 

Coolant (without radiator) 

2.0 l (0.5 gal) 

Radiator 

5.36 l (1.42 gal) 

Expansion tank 

0.84 l (0.22 gal) 

Overview of capacities: – see Fluids and lubricants on page 3-1 

Tightening torques 

Cylinder-head bolt 

Connecting rod bearing screw 

Main bearing screw 

Flywheel screw 

Variable displacement pump 

Design 

Displacement 

Flow rate 

Max. service pressure 

Nm/lbf ft 

85.3 – 91.1/62.9 – 67.2 (M10x1.25) 

44.1 – 49.0/32.5 – 36.1 (M9x1) 

93.2 – 98.1/68.7 – 72.4 (M12x1.5) 

83.3 – 88.2/61.4 – 65.1 (M10x1.25) 

Model 3001 

Axial piston pump 

45 cm³/rev (2.75 cu in/rev) 

126 l/min (33 gpm) 

360 bar (5221 psi) 

Boost pump (integrated in variable displacement pump) 

Design 

Gear pump 

Displacement 

8.4 cm³ (0.5 cu in) 

Charging/boost pressure 

25 bar (363 psi) 

Service brake/parking brake Model 3001 

Design Multiple disc brakes 

Location Brake discs in front axle 

Effect 

Hydraulic service brake, 

mechanical parking brake 

Steering system Model 3001 

Design Hydrostatic 

Steering mode Chassis articulation steering 


2.6 Work hydraulics 

2.7 Skip 

2.8 Drive specifications 

2.9 Vibration 

Work hydraulics 

Hydraulic pump displacement 

Hydraulic pump flow rate 

Model 3001 

16.2 cm³/rev (1.0 cu in/rev) 

45 l/min (12 gpm) 

Control valve Sections 

Max. service pressure 

Secondary pressure limiting for offset 

ram 

Hydraulic oil cooler 

Hydraulic tank capacity 


175 bar (2538 psi) 

160 bar (2321 psi) 

Standard 

48 l (13 gal) 

150 bar (2176 psi) 


Skip Model 3001 F Model 3001S 

1500 l (396 gal) struck 1300 l (343 gal) struck 

Skip capacity 

1850 l (489 gal) heaped 1750 l (462 gal) heaped 

1160 l (306 gal) liquid capacity 900 l (238 gal) liquid capacity 

Payload 

3000 kg (6614 lbs) 

Swivel angle - 180 – 217 °C (356 – 423 °F) 

Steering system Model 3001 F Model 3001S 

Drive speed I 0 – 7 km/h (0 – 4.4 mph) 

Drive speed II 0 – 22 km/h (0 – 13.7 mph) 

Articulation ± 37° 

Oscillation ± 15° 

Outside turning radius 4000 mm (157.5") 3650 mm (143.7") 

Hill climbing ability 50 % (theoretically) 

Safe authorised inclination 25 % in all drive positions left/right 

Vibration 

Effective acceleration value for the 

upper extremities of the body * 

Effective acceleration value for the 

body * 

< Trigger value 

< Trigger value 

* Measured according to 2002/44/EC. Machine and attachment operation and maintenance as per Operator's Manual. 



2.10 Electric system 

Fuse box 

Fig. 1: Fuse box 

Relays 

K7 

K 34 

K 33 

K 32 

F1 

K8 

F2 

Fig. 2: Relays 

V2 

K9 

K 10 

F10 

F9 

F8 

F7 

F6 

F5 

F4 

F3 

K6 


Alternator 

Starter 

Battery 

Fuse number 

Rated current 

(A) 

Protected circuit 

12 V 40 A 

12 V 1.7 kW (2.3 hp) 

12 V 88 Ah 

F 3 10 A – Cutoff solenoid, cutoff solenoid time lag relay 

F 4 15 A – Drive solenoid valves 

F 5 10 A – Horn, brake lights 

F 6 15 A – Turn indicators 

F 7 15 A – High beam 

F 8 10 A – Low beam 

F 9 10 A – Clearance light 

F 10 10 A – Hazard warning system 

The relays are located in the relay box under the the floor panel of the control stand 

Switching relay 

no. 


F1, F2 – Main fuses 

K 6 – Preheating time lag relay 

K7 – Start high current relay 

K 8 – Cutoff solenoid time lag relay 

K 9 – Cutoff solenoid switching relay 

K 10 – Turn indicator relay 

K32 – Start interlock relay 

K33 – Low beam relay 

K34 – High beam relay 

V2 – Diodes 


2.11 Tyres 

2.12 Noise levels 

2.13 Coolant compound table 

Type Tyre size 

Important! 

Front 

bar/psi 

Tyre pressure 

Rear 

bar/psi 


Load-bearing 

capacity 

3001 11.5/80 x 15.3 4/58 4/58 PR 10 

3001 speed 10.0/75 x 15.3 4/58 4/58 PR 8 

Sound power level 3001 

Sound power level (LWA ) 101 dB (A) 

Sound pressure level (L PA ) 85 dB (A) 

Measurement of sound power level according to EC Directive 2000/14 EC. Noise 

level at the driver's ear measured according to EC Directives 84/532/EEC, 89/514/ 

EEC and 95/27/EEC. Measurements carried out on asphalted surface. 

Outside tempera- 

Coolant 

ture Water Anticorrosion agent Antifreeze agent 

Up to °C/°F 

% by 

volume 

cm³/l 

(cu in/gal) 

% by volume % by volume 

4/39 99 

– 

-10/14 

-20/-4 

-25/-13 

79 

65 

59 

10 

2.6 

1 

20 

34 

40 

-30/-22 55 44 



2.14 General tightening torques 

Tightening torques for hydraulic screw connections (dry assembly) 

Metric hose fittings for hydraulic applications (light execution, DKOL) 

Nominal ø Outer ø Thread Wrench size 

Torque 

Nm (lbf ft) 

05 6L M12X1.5 WS 14 15 (11) 

06 8L M14X1.5 WS 17 20 (15) 

08 10L M16X1.5 WS 19 40 (30) 

10 12L M18X1.5 WS 22 50 (37) 

12 15L M22X1.5 WS 27 75 (55) 

16 18L M26X1.5 WS 32 85 (63) 

20 22L M30X2 WS 36 100 (74) 

25 28L M36X2 WS 41 180 (133) 

32 35L M45X2 WS 55 220 (162) 

Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 % 

Values determined empirically and to be applied as approximate figures. 

Metric hose fittings for hydraulic applications (heavy execution, DKOL) 

Nominal ø Outer ø Thread Wrench size 

Torque 

Nm (lbf ft) 

05 8S M16X1.5 WS 19 40 (30) 

06 10S M18X1.5 WS 22 50 (37) 

08 12S M20X1.5 WS 24 60 (44) 

10 14S M22X1.5 WS 27 75 (55) 

12 16S M24X1.5 WS 30 90 (66) 

16 20S M30X2 WS 36 100 (74) 

20 25S M36X2 WS 41 180 (133) 

25 30S M42X2 WS 50 270 (199) 

32 38S M52X2 WS 60 400 (295) 

Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 % 

Values determined empirically and to be applied as approximate figures. 



Screw connections with various seals for hydraulic applications (light execution) 

Thread 

Straight pipe fitting with thread and 

screwed plug 

Sealing 

washer 

Nm (lbf ft) 

Elastic seal 

Nm (lbf ft) 

Torque tolerance: – 10 %; countermaterial: steel/aluminium 

Torque tolerance: – 10 %; countermaterial: steel/aluminium 

O-ring 

Nm (lbf ft) 

Non-return 

valve with 

elastic seal 

Nm (lbf ft) 

Identification 

aid, outside Ø 

mm (") 

M10X1.0 9 (7) 18 (13) 15 (11) 18 (13) 10 (0.4) 

M12X1.5 20 (15) 25 (18) 25 (18) 25 (18) 12 (0.5) 

M14X1.5 35 (26) 45 (33) 35 (26) 35 (26) 14 (0.6) 

M16X1.5 45 (33) 55 (41) 40 (30) 50 (37) 16 (0.6) 

M18X1.5 55 (41) 70 (52) 45 (33) 70 (52) 18 (0.7) 

M22X1.5 65 (48) 125 (92) 60 (44) 125 (92) 22 (0.9) 

M27X2.0 90 (66) 180 (133) 100 (74) 145 (107) 27 (1.0) 

M33X2.0 150 (111) 310 (229) 160 (118) 210 (155) 33 (1.3) 

M42X2.0 240 (177) 450 (332) 210 (155) 360 (266) 42 (1.7) 

M48X2.0 290 (214) 540 (398) 260 (192) 540 (398) 48 (1.9) 

G1/8A 9 (7) 18 (13) 15 (11) 18 (13) 9.73 (0.4) 

G1/4A 35 (26) 35 (26) 30 (22) 35 (26) 13.16 (0.5) 

G3/8A 45 (33) 70 (52) 45 (33) 50 (37) 16.66 (0.7) 

G1/2A 65 (48) 90 (66) 55 (41) 65 (48) 20.96 (0.8) 

G3/4A 90 (66) 180 (133) 100 (74) 140 (103) 26.44 (1.0) 

G1A 150 (111) 310 (229) 160 (118) 190 (140) 33.25 (1.3) 

G1 1/4A 240 (177) 450 (332) 210 (155) 360 (266) 41.91 (1.6) 

G1 1/2A 290 (214) 540 (398) 360 (266) 540 (398) 47.80 (1.9) 

Screw connections with various seals for hydraulic applications (heavy execution) 

Thread 

Straight pipe fitting with thread and 

screwed plug 

Sealing 

washer 

Nm (lbf ft) 

Elastic seal 

Nm (lbf ft) 

O-ring 

Nm (lbf ft) 

Non-return 

valve with 

elastic seal 

Nm (lbf ft) 

Identification 

aid, outside Ø 

mm (") 

M12X1.5 20 (15) 35 (26) 35 (26) 35 (26) 12 (0.5) 

M14X1.5 35 (26) 55 (41) 45 (33) 45 (33) 14 (0.6) 

M16X1.5 45 (33) 70 (52) 55 (41) 55 (41) 16 (0.6) 

M18X1.5 55 (41) 90 (66) 70 (52) 70 (52) 18 (0.7) 

M20X1.5 55 (41) 125 (92) 80 (59) 100 (74) 22 (0.8) 

M22X1.5 65 (48) 135 (100) 100 (74) 125 (92) 27 (1.0) 

M27X2.0 90 (66) 180 (133) 170 (125) 135 (100) 12 (0.5) 

M33X2.0 150 (111) 310 (229) 310 (229) 210 (155) 33 (1.3) 

M42X2.0 240 (177) 450 (332) 330 (243) 360 (266) 42 (1.7) 

M48X2.0 290 (214) 540 (398) 420 (310) 540 (398) 48 (1.9) 

G1/8A 35 (26) 55 (41) 45 (33) 45 (33) 13.16 (0.5) 

G1/4A 45 (33) 80 (59) 60 (44) 60 (44) 16.66 (0.7) 

G3/8A 65 (48) 115 (85) 75 (55) 100 (74) 20.96 (0.8) 

G1/2A 90 (66) 180 (133) 170 (125) 145 (107) 26.44 (1.0) 

G3/4A 150 (111) 310 (229) 310 (229) 260 (192) 33.25 (1.3) 

G1A 240 (177) 450 (332) 330 (243) 360 (266) 41.91 (1.6) 

G1 1/4A 290 (214) 540 (398) 420 (310) 540 (398) 47.80 (1.9) 



Tightening torques for high-resistance screw connections 

With coarse-pitch thread 

Screws according to DIN 912, DIN Screws according to 

Thread 

8.8 

931, DIN 933 etc. 

10.9 12.9 8.8 

DIN 7984 

10.9 

Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) 

M5 5.5 (4) 8 (6) 10 (7) 5 (4) 7 (5) 

M6 10 (7) 14 (10) 17 (13) 8.5 (6) 12 (9) 

M8 25 (18) 35 (26) 42 (31) 20 (15) 30 (22) 

M10 45 (33) 65 (48) 80 (59) 40 (30) 59 (44) 

M12 87 (64) 110 (81) 147 (108) 69 (51) 100 (74) 

M14 135 (100) 180 (133) 230 (170) 110 (81) 160 (118) 

M16 210 (155) 275 (203) 350 (258) 170 (125) 250 (184) 

M18 280 (207) 410 (302) 480 (354) 245 (181) 345 (254) 

M20 410 (302) 570 (420) 690 (509) 340 (251) 490 (361) 

M22 550 (406) 780 (575) 930 (686) 460 (339) 660 (487) 

M24 710 (524) 1000 (738) 1190 (878) 590 (435) 840 (620) 

M27 1040 (767) 1480 (1092) 1770 (1305) 870 (642) 1250 (922) 

M30 1420 (1047) 2010 (1482) 2400 (1770) 1200 (885) 1700 (1254) 

DIN 912 – hexagon socket head cap screw; DIN 931/DIN 933 – hexagon head screw with/without shaft; 

DIN 7984 – hexagon socket head cap screw with short head 

All values subject to a friction coefficient of µ = 0.12 and are to be used as approximate figures. 

With fine-pitch thread 

Screws according to DIN 912, DIN Screws according to 

Thread 

8.8 

931, DIN 933 etc. 

10.9 12.9 8.8 

DIN 7984 

10.9 

Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) 

M8X1.0 25 (18) 37 (28) 43 (32) 22 (16) 32 (24) 

M10X1.0 50 (37) 75 (55) 88 (65) 43 (32) 65 (48) 

M10X1.25 49 (36) 71 (52) 83 (61) 42 (31) 62 (46) 

M12X1.25 87 (64) 130 (96) 150 (111) 75 (55) 110 (81) 

M12X1.5 83 (61) 125 (92) 145 (107) 72 (53) 105 (77) 

M14X1.5 135 (100) 200 (148) 235 (173) 120 (89) 175 (129) 

M16X1.5 210 (155) 310 (229) 360 (266) 180 (133) 265 (195) 

M18X1.5 315 (232) 450 (332) 530 (391) 270 (1991) 385 (284) 

M20X1.5 440 (325) 630 (465) 730 (538) 375 (277) 530 (391) 

M22X1.5 590 (435) 840 (620) 980 (723) 500 (369) 710 (524) 

M24X2.0 740 (546) 1070 (789) 1250 (922) 630 (465) 900 (664) 

M27X2.0 1100 (811) 1550 (1143) 1800 (1328) 920 (679) 1300 (959) 

M30X2.0 1500 (1106) 2150 (1586) 2500 (1844) 1300 (959) 1850 (1364) 

DIN 912 – hexagon socket head cap screw; DIN 931/DIN 933 – hexagon head screw with/without shaft; 

DIN 7984 – hexagon socket head cap screw with short head 

All values subject to a friction coefficient of µ = 0.12 and are to be used as approximate figures. 


Tightening torques for Nordlock lock washers 

Fig. 3: Nordlock dimensions 

Fig. 4: Nordlock 


Standard dimensions 

Thread d mm (") D mm (") T mm (") Mv Nm (lbf ft) 

M3 3.2 (0.13) 7.0 (0.28) 1.8 (0.07) 1.5 (1.1) 

M4 4.3 (0.17) 9.0 (0.35) 1.8 (0.07) 3.5 (2.6) 

M5 5.2 (0.20) 9.0 (0.35) 1.8 (0.07) 7.2 (5.3) 

M6 6.5 (0.26) 10.8 (0.43) 1.8 (0.07) 12 (8.9) 

M8 8.2 (0.32) 13.5 (0.53) 2.6 (0.10) 30 (22.1) 

M10 10.3 (0.41) 16.6 (0.65) 2.6 (0.10) 59 (43.5) 

M12 13.0 (0.51) 19.5 (0.77) 2.6 (0.10) 103 (76) 

M14 14.5 (0.57) 23.0 (0.91) 3.7 (0.15) 160 (118) 

M16 17.0 (0.67) 25.4 (1.00) 3.7 (0.15) 250 (184) 

M18 19.5 (0.77) 29.0 (1.14) 3.7 (0.15) 350 (258) 

M20 21.0 (0.83) 30.7 (1.21) 3.7 (0.15) 490 (361) 

M22 22.9 (0.90) 34.5 (1.36) 3.7 (0.15) 660 (487) 

M24 26.0 (1.02) 39.0 (1.54) 3.7 (0.15) 850 (627) 

M27 28.5 (1.12) 42.0 (1.65) 4.6 (0.18) 1220 (900) 

M30 30.5 (1.20) 47.0 (1.85) 4.6 (0.18) 1600 (1180) 

M33 33.5 (1.32) 48.5 (1.91) 4.6 (0.18) 2200 (1623) 

M36 36.6 (1.44) 56.0 (2.20) 4.6 (0.18) 2900 (2139) 

M39 39.5 (1.56) 58.5 (2.30) 4.6 (0.18) 3800 (2803) 

Dimensions with larger outside diameters (oblong bores) 

Thread d mm (") D mm (") T mm (") Mv Nm (lbf ft) 

M6 6.5 (0.26) 13.5 (0.53) 2.6 (0.10) 13 (9.6) 

M8 8.6 (0.34) 16.6 (0.65) 2.6 (0.10) 32 (23.6) 

M10 10.3 (0.41) 21.0 (0.83) 2.6 (0.10) 64 (47.2) 

M12 13.0 (0.51) 25.4 (1.00) 3.7 (0.15) 110 (81) 

M16 17.0 (0.67) 30.7 (1.21) 4.0 (0.16) 260 (192) 



2.15 Dimensions model 3001 front skip 

Fig. 5: Machine dimensions (model 3001 F) 

Main data 

Dead weight 

Overall height 

Overall height with rollbar folded down 

Overall height without rollbar 

Overall width 

Ground clearance 

Wheelbase 

Outside turning radius 

Hill climbing ability 

Safe authorised inclination 

Model 3001 F 

2450 kg (5401 lbs) 

2670 mm (8'9") 

1870 mm (6'2") 

1870 mm (6'2") 

1785 mm (5'10") 

280 mm (11.0") 

1960 mm (6'5") 

4000 mm (13'1") 

50 % theoretically 

25 % in all drive positions 


2.16 Dimensions model 3001 swivel skip 

Fig. 6: Machine dimensions (model 3001S) 

Main data 

Dead weight 

Overall height 

Overall height with rollbar folded down 

Overall height without rollbar 

Overall width 

Ground clearance 

Wheelbase 

Outside turning radius 

Hill climbing ability 

Safe authorised inclination 


Model 3001S 

2550 kg (5622 lbs) 

2670 mm (8'9") 

1870 mm (6'2") 

1870 mm (6'2") 

1785 mm (5'10") 

290 mm (11.4") 

1960 mm (6'5") 

3950 mm (12'11") 

50 % theoretically 

25 % in all drive positions 




Maintenance

Maintenance 

3 Maintenance 

3.1 Fluids and lubricants 

Component/ application Engine/machine fluid Specification 

SAE10W-40 

Diesel engine Engine oil 

2 ; API: CD, CF, CF-4, CI-4 

ACEA: E3, E4, E5 

JASO: DH-1 

Travelling drive Gearbox oil 3 

Q8 T 55, SAE 85W-904 Q8 T 55, SAE 80W-90 5 

FINA PONTONIC GLS, SAE85W-90 

Hydraulic oil HVLP466 Season/temperature 

-20 °C (-4 °F) 

+40 °C (104 °F) 

Year-round 

Maintenance 

Capacities 1 

6.7 l (1.8 gal) 

About 1.3 l each 

(0.3 gal) 

Hydraulic oil tank 

Biodegradable oil 

Year-round 48 l (12.7 gal) 

7 

PANOLIN HLP Synth 46 

FINA BIOHYDRAN SE 46 

BP BIOHYD SE-46 

Grease 

Roller and friction bearings8 

Open gear 

FINA Energrease L21M Year-round As required 

9 

(live ring gears) 

BP Energrease MP-MG2 Year-round As required 

Grease nipples Multipurpose grease10 FINA Energrease L21 M Year-round As required 

Battery terminals Acid-proof grease 11 FINA Marson L2 

2-D ASTM D975 – 94 (USA) 

1-D ASTM D975 – 94 (USA) 

EN 590 : 96 (EU) 

Year-round As required 

Fuel tank Diesel fuel 

ISO 8217 DMX (International) 

BS 2869 – A1 (GB) 

Summer or winter 

diesel 

40 l (10.6 gal) 

BS 2869 – A2 (GB) 

depending on 

outside temperatures 

Radiator Coolant 

Soft water + antifreeze ASTM D4985 

Distilled water + antifreeze ASTM D4985 

Year-round 5.36 l (1.4 gal) 

Refrigerating agent R134a 

Air conditioning 

12 Year-round ~ 950 g (2.1 lbs) 

122 cm³ (7.45 cu in) 

Compressor oil Sanden SP20 Year-round 

Tier 2 

90 cm³ (5.5 cu in) 

Tier 3A 

Washer system Cleaning agent Water + antifreeze Year-round 1.2 l (0.32 gal) 

1. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level 

2. According to DIN 51502 

3. Hypoid gearbox oil based on basic mineral oil (SAE85W-90 according to DIN 51502), (API GL-4, GL5) 

4. The Q8 T55 SAE 85W-90 gearbox oil is no longer produced. 

5. The Q8 T55 SAE 80W-90 gearbox oil is used from 10/2006 onwards. Do not mix both gearbox oils! 

6. According to DIN 51524 section 3 

7. Hydraulic ester oils (HEES) 

8. KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive 

9. KP2N-20 according to DIN 51502 EP multipurpose calcium sulphonate complex grease 

10. KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive 

11. Standard acid-proof grease 

12. According to DIN 8960 


Maintenance 

Oil grades for the diesel engine, depending on temperature 

Engine oil grade Ambient temperature (C°) 

API CD, CF, CF-4, 

CI-4 

ACEA: E3, E4, E5 

JASO: DH-1 

°C -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 

SAE 10W 

SAE 20W 

SAE 10W-30 

SAE 10W-40 

SAE 15W-40 

SAE 20 

SAE 30 

SAE 40 

°F -4 5 14 23 32 41 50 59 68 77 86 95 104 


Maintenance 

Maintenance plan/service hours (s/h) 

Once a year or after 1000 s/h 

3.2 Maintenance plan (overview) 

Authorised 

workshop 

Customer 

After 1500 s/h 

Every 500 s/h 

Every 250 s/h 

Every 50 s/h 

Maintenance work 

(once a day) 

Work description 

For service and maintenance work on the attachment, please refer to the operation and maintenance manual 

of the attachment manufacturer as well. 

Fluid and filter changes ( ): 

Carry out the following oil and filter changes (check oil levels after test run): 

• Engine oil 1 

● ● ● 

• Engine oil filter 2 

● ● ● 

• Fuel filter 3 

● ● ● 

• Air filter element ● ● 

• Coolant ● ● 

• Differential oil 4 

● ● ● 

• Semiaxle oil 4 

● ● ● 

• Transfer gearbox oil 4 

● ● ● 

• Hydraulic oil filter insert 5 

● ● ● 

• Hydraulic oil ● ● 

• Hydraulic oil tank breather ● ● 

Inspection work ( ): 

Check the following material. Refill if necessary: 

• Engine oil ● ● 

• Engine coolant ● ● 

• Hydraulic oil ● ● 

Clean water ducts 6 ● ● 

Check cooler for engine and hydraulic oil for contamination. Clean if necessary ● ● 

Maintenance 

Check cooling systems, heating and hoses for leaks and pressure (visual check) ● ● 

Air filter (damage) ● ● 

Check the air filter, clean if necessary ● ● 

Prefilter with water separator: drain water ● ● 


Maintenance 



Authorised 

workshop 

Customer 



Every 500 s/h 

Every 250 s/h 

Every 50 s/h 


(once a day) 




• Clean ● ● 

Check V-belt condition and tension ● ● 

Check V-belt condition and tension ● ● 

Check exhaust system for damage and condition ● ● 

Check valve clearance. Adjust if necessary ● ● 

Fuel injection pump ● ● 

Injection and pressure ● ● 

Check injection nozzles and valves 7 ● ● 

Empty diesel fuel tank ● ● 

Check battery electrolyte. Fill up with distilled water if necessary ● ● ● 

Tyre check (damage, air pressure, tread depth) ● ● 

Wheel nuts ● ● 

Check alternator, starter and electric connections, bearing play and function ● ● 


Preheating system, electric connections ● ● 

Pressure check of primary pressure limiting valves 8 ● ● ● 

Check piston rods for damage ● ● 

Check screws for tightness ● ● ● 

Pin lock ● ● 

Line fixtures ● ● 

Check telltales for correct function ● ● ● 

Insulating mats in engine compartment ● ● ● 

Cleanliness of access ● ● 

Adhesive labels and Operator's Manual ● ● ● 

Engine cover gas strut ● ●



Authorised 

workshop 

Customer 



Every 500 s/h 

Every 250 s/h 

Every 50 s/h 


(once a day) 




Lubrication service ( ): 

Lubricate the following assemblies/components: – see Lubrication points on page 3-26 

• Steering ram ● ● 

• Tilt ram – offset ram ● ● 

• Articulated joint ● ● 

• Swivelling console ● ● 

Functional check ( ): 

Check the function of the following assemblies/components. Rectify if necessary: 

• Lights, signalling system, acoustic warning system ● ● 

• Parking brake function ● ● 

• Steering function ● ● 

Leakage check ( ): 

Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary: 

• Visual check ● ● 

☞ Engine and hydraulic system ● ● 

☞ Cooling circuit ● ● 

☞ Travelling drive ● ● 

1. Drain engine oil the first time after 50 s/h, then every 250 s/h 

2. Replace the engine oil filter the first time after 50 s/h, then every 250 s/h 

3. Replace the fuel filter the first time after 50 s/h, then every 250 s/h 

4. Replace the oil the first time after 50 s/h, then every 1000 s/h or once a year 

5. Replace the hydraulic oil filter insert the first time after 50 s/h, then every 500 s/h 

6. Clean the water ducts every other 1000 s/h servicing 

7. Check the injection nozzles and the valves every other 1500 s/h servicing 

8. Check the first time at 50 s/h, then every 500 s/h 

Maintenance 


Maintenance 

Maintenance 

3.3 Service package 

Up to serial no. 

From serial no. AE310242D 

3.4 Introduction 

1000173798 1 3001 service package (500 s/h interval) 

1000012537 1 ➥Engine oil filter 

1000106891 1 ➥Fuel filter 

1000106892 1 ➥Water separator element 

1000069998 1 ➥Filter housing gasket 

1000064543 1 ➥Filter housing O-ring 

1000012360 1 ➥Oil drain plug gasket 

1000050807 1 ➥Filter element 

1000099475 1 ➥Air filter element (outside) 

1000099476 1 ➥Air filter element (inside) 

1000104765 1 ➥Valve cover gasket 

1000003894 3 ➥O-ring 

1000183192 1 3001 service package (500 s/h interval) 

1000001011 1 ➥Engine oil filter 

1000172001 1 ➥Fuel filter 

1000106892 1 ➥Water separator element 

1000069998 1 ➥Filter housing gasket 

1000064543 1 ➥Filter housing O-ring 

1000012360 1 ➥Oil drain plug gasket 

1000050807 1 ➥Filter element 

1000099475 1 ➥Air filter element (outside) 

1000099476 1 ➥Air filter element (inside) 

1000104765 1 ➥Valve cover gasket 

1000003894 3 ➥O-ring 

Operational readiness and the service life of machines are heavily dependent on 

maintenance. 

Before carrying out service and maintenance work, always read, understand and follow 

the instructions given in 

Chapter 2 “SAFETY INSTRUCTIONS” in the Operator's Manual 

The Operator's Manuals of the attachments. 

Secure open (engine) covers appropriately. Do not open (engine) covers on slopes or in 

strong wind. 

Dirt can be blown away and cause severe injuries when using compressed air. Always 

wear protective goggles, masks and clothing. 

Daily service and maintenance work, and maintenance according to maintenance plan 

“A” must be carried out by a specifically trained driver. All other maintenance work must 

be carried out by trained and qualified staff only. 

The maintenance plans indicate when the maintenance work mentioned below must be 

carried out (– see Maintenance plan (overview) on page 3-3). 


3.5 Fuel system 

Specific safety instructions Extreme caution is essential when handling fuel – high risk of fire! 

Refuelling 

A 

Fig. 1: Fuel filler inlet 

Maintenance 

Never carry out work on the fuel system in the vicinity of naked flames or sparks! 

Do not smoke when working on the fuel system or when refuelling! 

Before refuelling, switch off the engine and remove the ignition key! 

Do not refuel in closed rooms! 

Wipe away fuel spills immediately! 

Keep the machine clean to reduce the risk of fire! 

Filler inlet A for the fuel tank is located under the engine cover, on the right in driving 

direction. 

Danger! 

All work involving fuel carries an increased 

Danger of fire and poisoning! 

☞Do not refuel in closed rooms 

☞Never carry out work on the fuel system in the vicinity of naked flames or 

sparks 

Environment! 

Use a suitable container to collect the fuel as it drains and dispose of it in an 

environmentally friendly manner! 

Important! 

Do not run the fuel tank completely dry. Otherwise, air is drawn into the fuel 

system. This requires bleeding the fuel system 

– see Bleeding the fuel system on page 3-8. 

Important! 

Fill up the tank with the correct fuel type at the end of each working day to prevent 

the formation of condensation water in the fuel tank (condensation water damages 

the injection pump). 

Do not fill the tank completely but leave some space for the fuel to expand. 


Maintenance 

Stationary fuel pumps General 

right 

wrong 

Fig. 2: Refuelling from a barrel 

Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually contaminated. 

Even the smallest particles of dirt can cause 

Increased engine wear 

Malfunctions in the fuel system and 

Reduced effectiveness of the fuel filters 

Refuelling from barrels 

Diesel fuel specification Use only high-grade fuels 

Bleeding the fuel system 

If refuelling from barrels cannot be avoided, note the following points (see fig. 2): 

Barrels must neither be rolled nor tilted before refuelling 

Protect the suction pipe opening of the barrel pump with a fine-mesh strainer 

Immerse it down to a max. 15 cm (6") above the floor of the barrel 

Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter 

Keep all refuelling containers clean at all times 

Grade 

No. 2-D 

according to 

DIN 51601 

No. 1-D 

according to 

DIN 51601 

Danger! 

Cetane 

number 

Min. 45 

If the fuel, as it drains, comes into contact with hot engine parts or the exhaust 

system, there is an increased 

Danger of burns! 

☞Never bleed the fuel system if the engine is hot! 

Bleed the fuel system in the following cases: 

After removing and fitting the fuel filter, prefilter or the fuel lines back on again 

After running the fuel tank empty 

After running the engine again, after it has been out of service for a longer period of 

time 


Use 

For normal outside temperatures 

For outside temperatures below 4 °C (39°F) or for 

operation above 1500 m (4921') altitude

Fuel prefilter with water separator 

On 

Fig. 3: Fuel prefilter 

Off 

A 

B 

C 

D 

E 

Bleed the fuel system as follows: 

☞Fill the fuel tank 

☞Turn the ignition key to the first position 

☞Wait about 5 minutes while the fuel system bleeds itself automatically 

☞Start the engine 

Maintenance 

If the engine runs smoothly for a while, and then stops; or if it does not run smoothly: 

☞Switch off the engine 

☞Bleed the fuel system again as described above 

☞Have this checked by authorised staff if necessary 

Check the fuel prefilter as follows: 

If the red indicator ring D in sight glass E rises 

☞Remove and clean the housing (sight glass) 

☞Remove and clean filter insert B 

☞Mount filter insert 

☞Mount the housing (sight glass) with the maintenance display (red ring) and spring D 

☞Open stop cock A 

Interrupt fuel supply as follows: 

☞Turn ball-type cock A to the OFF mark 

➥Fuel supply is interrupted 

☞Turn ball-type cock A to the ON mark 

➥Fuel supply is open again 

Environment! 

Thread A is fitted with a hose. Collect the water as it drains with a suitable container and 

dispose of it in an environmentally friendly manner. 


Maintenance 

Replacing the fuel filter 

Fig. 4: Fuel filter 

A 

Danger! 

If the fuel, as it drains, comes into contact with hot engine parts or the exhaust 

system, there is an increased 


☞Never change the fuel filter if the engine is hot! 

Environment! 

Use a suitable container to collect the fuel as it drains and dispose of it in an 


Removing the fuel filter 

☞Close the fuel cock 

☞Slacken the union nut 

Caution: the filter housing contains fuel 

☞Remove filter housing A 

Mounting the fuel filter 

☞Mount all elements in the reverse order with a new filter element 

☞Open the stop cock on the water separator again 

☞Bleed the fuel system 

– see Bleeding the fuel system on page 3-8 

☞Make a test run – and check for tightness! 

☞Dispose of the old fuel filter cartridge by an ecologically safe method 


3.6 Engine lubrication system 

Checking the oil level 

max 

min 

A 

Fig. 5: Checking the oil level 

Caution! 

Maintenance 

If the engine oil level is too low or if an oil change is overdue, this can cause 

Engine damage or loss of output! 

☞Have the oil changed by an authorised workshop 

– see Maintenance plan (overview) on page 3-3 

Important! 

Check the oil level once a day. 

We recommend checking it before starting the engine. After switching off a warm 

engine, wait at least 5 minutes before checking. 


☞Proceed as follows: 

Park the machine on level ground 

Switch off the engine! 

Let the engine cool down 

Open the engine cover 

Clean the area around the oil dipstick with a lint-free cloth 

Pull out oil dipstick A 

Wipe it with a lint-free cloth 

Push it back in as far as possible 

Withdraw it and read off the oil level 

☞However if necessary, fill up oil at the latest when the oil reaches the MIN mark on the 

oil dipstick A 


Maintenance 

Filling up engine oil 

B 

OIL 

Fig. 6: Filling up engine oil 

Caution! 

Too much or incorrect engine oil can result in engine damage! For this reason: 

☞Do not add engine oil above the MAX mark of oil dipstick 5/A 

☞Use only the specified engine oil 

☞Use engine oils of the same brand and grade => never mix different oils! 

Environment! 

Use a suitable container to collect the engine oil as it drains and dispose of it in an 



Clean the area around oil filler cap B with a lint-free cloth 

Open filler cap B 

Raise oil dipstick 5/A slightly to allow any trapped air to escape 

Fill in engine oil 

Wait about 3 minutes until all the oil has run into the oil sump 

Check the oil level 

– see Checking the oil level on page 3-11 

Fill up if necessary and check the oil level again 

Close filler cap B 

Push oil dipstick A back in as far as possible 

Completely remove all oil spills from the engine 


Changing engine oil 

+ 80 °C 

+176 °F 

OIL 

Fig. 7: Optimum engine oil temperature 

Danger! 

Caution when draining hot engine oil – 

☞Wear protective gloves 

☞Use suitable tools 

Environment! 


Maintenance 

Use a suitable container to collect the engine oil as it drains and dispose of it in an 


☞Change the engine oil as follows: 


Let the engine run until it reaches its operating temperature 

(oil temperature about 80 °C/176 °F) 

Switch off the engine 

Place a container under the opening to collect the oil as it drains 

Unscrew the oil drain plug from the sump 

Completely drain the oil 

Screw the oil drain plug back on again 

Fill in engine oil 

– see chapter Filling up engine oil on page 3-12 



Start the engine and let it run briefly at low revs 


Wait a moment until all the oil has run into the oil sump 

Check the oil level again 

Fill up if necessary and check again 


Maintenance 

Replacing the engine oil filter cartridge 

A 

Fig. 8: Unscrewing the engine oil filter 

Fig. 9: Cleaning the filter head and oiling the gasket 

A 

Fig. 10: Tightening the filter cartridge 

B 

Danger! 

Caution when draining hot engine oil – 

☞Wear protective gloves 

Environment! 


Collect the drained engine oil in a suitable container. 

Dispose of used oil and filters in an environmentally friendly manner! 

☞Change the filter as follows: 


Place a suitable container underneath the oil filter to collect the oil as it drains 

Slowly slacken oil filter cartridge A using a commercially available tool 

Let the oil drain into the container 

Remove the filter cartridge once the oil is completely drained 

Make sure the thread adapter is correctly placed in the filter head 

Clean the inside of the filter head 

Apply a thin coat of fresh engine oil to rubber seal B of the new oil filter cartridge 

Tighten the new filter cartridge by hand until the gasket makes contact 

Tighten oil filter cartridge A with a commercially available tool by about a further 3/4 

of a revolution 

Make sure the oil level is correct! 


Let the engine run briefly 


Check the seal of oil filter cartridge A and retighten by hand 

Check the oil level and fill in engine oil if necessary 

Dispose of the used oil filter in an environmentally friendly manner 


3.7 Cooling system 

Maintenance 

The combined oil and water radiator is located in the engine compartment, behind the 

engine. 

The expansion tank for the coolant is screwed onto the tool box next to the oil cooler in the 

engine compartment. 

Specific safety instructions Dirt on the radiator fins reduces the cooler's heat dissipation capacity! To avoid this: 

☞Clean the outside of the radiator at regular intervals. Use oil-free compressed air 

(2 bar/29 psi max.) to clean. Maintain a certain distance to the radiator to avoid 

damage to the radiator fins. Clean the radiator from the inside to the outside with 

compressed air. Refer to the maintenance plans in the appendix for the cleaning 

intervals 

☞In dusty or dirty work conditions, clean more frequently than indicated in the 

maintenance plans 

An insufficient coolant level reduces the heat dissipation capacity as well and can lead 

to engine damage! Therefore: 

☞Check the coolant level at regular intervals. Refer to the maintenance plans in the 

appendix for the intervals 

☞If coolant must be added frequently, check the cooling system for leaks and/or 

contact your dealer! 

☞Never fill in cold water/coolant if the engine is warm! 

☞After filling the expansion tank, make a test run with the engine and check the coolant 

level again after switching off the engine 

The use of the wrong coolant can destroy the engine and the cooler. Therefore: 

☞Add enough antifreeze compound to the coolant – but never more than 50 %. If 

possible use brand-name antifreeze compounds with anticorrosion additives 

☞Observe the coolant compound table 

– see Coolant compound table on page 2-5 

☞Do not use cooler cleaning compounds if an antifreeze compound has been added to 

the coolant – otherwise this causes sludge to form, which can damage the engine 

Once you have filled the expansion tank: 

☞Test run the engine 


☞Let the engine cool down 

☞Check the coolant level again 

Environment! 

Use a suitable container to collect the coolant as it drains and dispose of it in an 



Maintenance 

Checking/filling up coolant 

FULL 

LOW 

Fig. 11: Expansion tank for coolant 

A 

Danger! 

Never open the coolant tank and never drain coolant if the engine is warm 

since the cooling system is under high pressure– 


☞Wait at least 15 minutes after switching off the engine! 

☞Wear protective gloves and clothing 

☞Open filler cap B to the first notch and release the pressure 

☞Make sure the coolant temperature is sufficiently low so you can touch the 

radiator plug with your hands 

Danger! 

Antifreeze is flammable and poisonous – 

Danger of accidents! 

☞Keep away from flames 

☞Avoid eye contact with antifreeze 

• If antifreeze comes into contact with the eyes: 

➥Immediately rinse with clean water and seek medical assistance 

Checking the coolant level 



Switch off the engine! 

Remove the key and carry it with you 

Let the engine and the coolant cool down 

Open the engine cover 

Check the coolant level on the transparent coolant tank A and on the radiator Fig. 11 

☞If the coolant level is below the LOW seam or if there is no coolant at the radiator's 

filler inlet: 

Fill up coolant (use only coolants of the same brand and grade => do not mix different 

coolants!) 

Important! 

Check the coolant level once a day. 

We recommend checking it before starting the engine. 


Fig. 12: Radiator 

Draining coolant 

B 

Filling up coolant 

After the engine has cooled down: 

☞Release overpressure in the radiator 

☞Carefully open the cap to the first notch and fully release the pressure 

☞Open filler cap B 

Maintenance 

☞Fill up coolant up to the lower edge of the filler inlet (radiator); use coolants of the same 

brand and grade => never mix different coolants! 

☞Close filler cap B 

☞Start the engine and let it warm up for about 5 – 10 minutes 


☞Remove the key and carry it with you 


☞Check the coolant level again 

➥The coolant level must be between the LOW and FULL tank seams 

☞If necessary, fill up coolant and repeat the procedure until the coolant level remains 

constant 

Important! 

Check the antifreeze every year before the cold season sets in! 

Danger! 

Never open the coolant tank and never drain coolant if the engine is warm 

since the cooling system is under high pressure– 


☞Wait at least 10 minutes after switching off the engine! 

☞Wear protective gloves and clothing 

☞Open filler cap 12/B to the first notch and release the pressure 

After the engine has cooled down: 

☞Release overpressure in the radiator 

☞Open the cap to the first notch and fully release the pressure 

☞Open filler cap 12/B 

☞Slacken the lower radiator hose and drain the coolant in a container 

☞Retighten the radiator hose 

☞Fill up the radiator with suitable coolant 

– see Fluids and lubricants on page 3-1 

☞Check the coolant level 

– see Checking the coolant level on page 3-16 


Maintenance 

3.8 Air filter 

A 

Fig. 13: Indicator for air filter contamination 

B 

Caution! 

The filter cartridge will be damaged if it is washed or brushed out! 

Bear in mind the following to avoid premature engine wear! 

☞Do not clean the filter cartridge 

☞Replace the filter cartridge when the telltale comes on 

☞Never reuse a damaged filter cartridge 

☞Ensure cleanliness when replacing the filter cartridge! 

Control element A on the air filter monitors the filter cartridge. 

☞Replace filter B if: 

Control element A indicates air filter contamination 

According to the maintenance plan 

Important! 

For applications in especially dusty environment, replace or clean the air filter 

more frequently. 

Caution! 

Filter cartridges degrade prematurely when in service in acidic air for longer 

periods of time. This risk is present for example in acid production facilities, 

steel and aluminium mills, chemical plants and other nonferrous-metal plants. 

☞Replace filter B after 50 service hours at the latest! 

General instructions for air filter maintenance: 

Store filters in their original packaging and in a dry place 

Do not knock the filter against other objects as you install it 

Check air filter attachments, air intake hoses and air filters for damage, and 

immediately repair or replace if necessary 

Check the screws at the induction manifold and the clamps for tightness 


Replacing the filter 

D 

Fig. 14: Removing the lower housing section 

Fig. 15: Removing the filter element 

Functional check once a week of the dust valve 

Fig. 16: Air filter – dust valve 

E 

F 

B 

F 

Replace filter A as follows: 


☞Apply the parking brake 



☞Open the engine cover 

☞Remove dirt and dust from the air filter and the area around the air filter 

☞Fold both bow clips D on lower housing section E to the outside 

☞Remove lower housing section E 

☞Unscrew wing nut F 

☞Carefully remove filter B with slightly turning movements 

☞Make sure all dirt (dust) inside the air filter housing has been removed 

☞Clean the parts with a clean lint-free cloth, do not use compressed air 

☞Check the air filter cartridges for damage, only install intact filters 

☞Carefully insert the new filter B in the air filter housing 

☞Position lower housing section E (make sure it is properly seated) 

☞Close both bow clips D 

Maintenance 

The air filter is located in the engine compartment, on the right side of the machine 



Apply the parking brake 

Squeeze the discharge slot of dust valve F 

Remove hardened dust by compressing the upper area of the valve 

☞Clean the discharge slot if necessary 


Maintenance 

3.9 V-belt 

Checking V-belt tension 

1 

Fig. 17: Checking V-belt tension 

Danger! 

Only check or retighten/replace the V-belt when the engine is switched off – 

Danger of personal injury! 

☞Switch off the engine before carrying out inspection work in the engine 

compartment! 

☞Disconnect the battery or the battery master switch 


Check the V-belt once a day, and retighten if necessary! 

Retighten new V-belts after about 15 minutes of running time. 

Check as follows: 



☞Disconnect the battery or the battery master switch 



☞Carefully check V-belt 1 for damage, cracks or cuts 

☞Replace the V-belt if it touches the base of the V-belt groove or the discs of the pulley 

If the V-belt is damaged: 

☞Have the V-belt replaced by authorised staff 

☞Press with your thumb to check the deflection of the V-belt between the crankshaft 

disc and the fan wheel position C. 

A new V-belt should have a deflection of 6 to 8 mm (0.2" – 0.3"), a used V-belt (after 

about 5 minutes running time) should have a deflection of 7 to 9 mm (0.3" – 0.35") 

☞Retighten the V-belt if necessary 


Retightening the V-belt 

2 

Fig. 18: Retightening the V-belt 

3 

A 

Caution! 

Maintenance 

Overtightening the V-belt can damage the V-belt, the V-belt guide and the 

water pump bearing. 

Avoid contact of oil, grease or similar substances with the V-belt. 

☞Check V-belt tension 

– see Checking V-belt tension on page 3-20 

Retighten as follows: 



☞Remove the battery master switch 



☞Slacken fastening screws 2 of alternator 3 

☞Use a suitable tool to push the alternator in the direction of arrow A until reaching the 

correct V-belt tension (fig. 18) 

☞Keep the alternator in this position, and at the same time retighten fastening screws 2 

☞Check V-belt tension again and adjust it if necessary 

☞Connect the battery or the battery master switch 

☞Close the engine cover 


Maintenance 

Maintenance 

3.10 Hydraulic system 

Specific safety instructions 

Release the pressure in all lines carrying hydraulic oil prior to any maintenance and 

repair work. To do this: 

Lower all hydraulically controlled attachments to the ground 

Move all control levers of the hydraulic control valves several times 

Hydraulic oil escaping under high pressure can penetrate the skin and cause serious 

injuries. Always consult a doctor immediately even if the wound seems insignificant – 

otherwise serious infections could set in! 

If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has 

penetrated the hydraulic system. This can cause damage to the hydraulic pump! 

Oil or fuel flowing out of high pressure lines can cause fire or malfunctions, and severe 

injuries or damage to property. Interrupt work immediately if slack nuts or damaged 

hoses and lines are detected. 

☞Contact your Neuson dealer immediately 

Replace the hose or line if one of the problems mentioned below is detected. 

☞Damaged or leaky hydraulic seals. 

☞Worn or torn shells or uncovered reinforcement branches. 

☞Expanded shells in several positions. 

☞Entangled or crushed movable parts. 

☞Foreign bodies jammed or stuck in protective layers. 

Caution! 

Contaminated hydraulic oil, lack of oil or wrong hydraulic oil – 

Danger of severe damage to the hydraulic system! 

☞Take care to avoid contamination when working! 

☞Always fill in hydraulic oil by means of a strainer or the reflux filter! 

☞Only use authorised oils of the same type 

– see Fluids and lubricants on page 3-1 

☞Always fill up hydraulic oil before the level gets too low 

– see Filling up hydraulic oil on page 3-23 

☞If the hydraulic system is filled with biodegradable oil, then only use 

biodegradable oil of the same type for filling up – observe the sticker on the 

hydraulic oil tank! 

☞Contact customer service if the hydraulic system filter is contaminated with 

metal chippings. Otherwise, follow-on damage can result! 

Environment! 

Collect drained hydraulic oil and biodegradable oil in a suitable container! Dispose of 

drained oil and used filters by an ecologically safe method. Always contact the relevant 

authorities or commercial establishments in charge of oil disposal before disposing of 

biodegradable oil. 


Checking the hydraulic oil level 

A 

Fig. 19: Oil level indicator on the hydraulic oil tank 

Filling up hydraulic oil 

Fig. 20: Hydraulic oil tank 

B 



Retract all hydraulic rams 

☞Fully dump in the skip 


Sight glass A is located under the right-hand side mudguard 

Check the oil level on sight glass A 

The oil level must be at the FULL level 

• A gauge element in sight glass A indicates the oil level 

If the oil level is lower 

Fill up hydraulic oil 

The oil level varies according to the machine's operating temperature: 

1 

Machine condition Temperature Oil level 

Before putting into Between 10 and 30 °C LOW mark 

operation 

(50 and 86 °F) 

Normal operation Between 50 and 90 °C 

(122 and 194 °F) 

FULL mark 

Important! 

Maintenance 

Measure the oil level of the hydraulic system only after the machine reaches its 

operating temperature. 

Danger! 

Removing the filler plug can cause oil to escape – 


☞Carefully unscrew the plug to slowly reduce the pressure inside the tank. 

Do not fill up the hydraulic oil unless the engine is switched off. Otherwise, hydraulic oil will 

overflow at the filler opening on the hydraulic tank. 

☞Fill up as follows: 


Retract all hydraulic rams 


Clean the area around filler inlet B with a cloth 

Open filler inlet B 

With the filter insert in place: 

Fill up hydraulic oil 

Check the hydraulic oil level on sight glass A 

Fill up if necessary and check again 

Firmly tighten plug B 


Maintenance 

Changing hydraulic oil 

Fouling indicator for hydraulic oil filter 

45 

Fig. 21: Fouling indicator for hydraulic oil filter 

Replacing the hydraulic oil filter element 

Fig. 23: Hydraulic reflux filter 

1 

2 

3 

Important! 

Only change the hydraulic oil if it is warm (about 50 °C/122 °F). Lower the skip in 

centre position before draining the oil (dumper in straight-ahead position). 

☞Open the drain plug to let the oil drain into a container 

☞Check the hydraulic oil tank for contamination and clean if necessary 

☞Replace the filter according to the maintenance specifications 

☞Screw the drain plug back in correctly 

☞Fill in clean hydraulic oil through the strainer 

– see Filling up hydraulic oil on page 3-23 

☞Close the hydraulic oil tank correctly 

☞Let the machine run at idling speed without load for some minutes 

A red telltale on the instrument panel monitors the filter. 

Replace the filter: 

If the telltale comes on when the hydraulic oil is at operating temperature 

According to the maintenance interval 

In cold weather the telltale can come on immediately when the engine is started. This is 

caused by increased oil viscosity. In this case: 

☞Let the engine run at idling speed for about 2 minutes 



☞Open cover 1 by about 2 turns and wait until the oil level in the filter housing drops to 

the oil level in the hydraulic oil tank 

☞Open the cover completely and remove it 

☞Pull filler pipe 2 upwards with a slightly turning movement, together with filter element 3 

☞Remove the filter element from the filler pipe and dispose of it 

☞Slide the filler pipe onto the new filter element and insert it in the filter 

☞Tighten the cover by hand 


Checking hydraulic pressure lines Specific safety instructions 

Fig. 24: Flexible line 

Danger! 

Maintenance 

Caution when checking hydraulic lines, especially when searching for leaks. 

Hydraulic oil escaping under high pressure can penetrate the skin and cause 

serious injuries. 

Danger of personal injury! 

☞Always consult a doctor immediately, even if the wound seems insignificant 

– otherwise serious infections could set in! 

☞Always observe the following instructions: 

• Retighten leaking screwed fittings and hose connections only when the 

system is not under pressure; i.e. release the pressure before working 

on pressurised lines! 

• Never weld or solder damaged or leaking pressure lines and screw 

connections. Replace damaged parts with new ones! 

• Never search for leaks with your bare hands, but wear protective gloves! 

• Use paper or wood to check for minor leaks. Never use an unprotected 

light or naked flame! 

• Have damaged flexible lines replaced by authorised workshops only! 

Leaks and damaged pressure lines must be immediately repaired or replaced by an 

authorised workshop or after-sales staff. This not only increases the operating safety of 

your machine but also helps to protect the environment. 

Replace hydraulic hoses every 6 years from the date of manufacture, even if they do 

not seem to be damaged. 

In this respect, we recommend that you observe all the relevant safety regulations for 

hydraulic lines, as well as the safety regulations regarding accident prevention and 

occupational health and safety in your country. Also observe DIN 20066, part 5. 

The article number and the date of manufacture are marked on the clamping section of 

each hose connection. 


Maintenance 

3.11 Lubrication points 

3001 front skip 

3001 swivel skip 

Fold down the red maintenance prop before you carry out maintenance work with the skip 

dumped out. 


3.12 Tyres 

Fig. 25: Tyres 

Inspection work 

Tyre wear can vary according to work and ground conditions. 

Danger! 

Improper tyre repairs – 


Maintenance 

☞All repair work on tyres and rims may only be carried out by authorised 

workshops. 

☞We recommend checking the tyres for wear and the wheel nuts for tightness once a 

day. 

☞Park the machine on firm and level ground to check and carry out maintenance. 

Important! 

Checking the tyres at regular intervals increases operational safety and the service 

life of the tyres, and reduces machine downtimes. Please refer to Chapter “Tyres” 

on page 2-5 for the authorised tyre types and the correct tyre pressures. 

Important! 

Replace tyres with new ones after 6 years (irrespective of wear) and dispose of 

them correctly. After this period, the rubber no longer has its full capability due to 

various chemical and physical processes. 

☞Carry out the following maintenance work once a day: 

Visual check of the tyre condition 

Check the tyre pressure 

Tyre and rim (outside and inside) for damage 

Check for wear 

Remove foreign bodies from the tyre tread 

Remove traces of oil and grease from the tyres 


Maintenance 

3.13 Changing wheels 

Danger! 

Use of wrong tyres or wheels – 


☞Use only wheels and tyres authorised for your machine 

– see Tyres on page 2-5 

☞Check the wheel nuts for tightness after every wheel or tyre change 

Caution! 

Removing the wheels ☞Proceed as follows: 

The wheels are heavy and can damage the threads on the wheel studs if they 

are handled incorrectly! 

☞Use suitable assembly tools, such as covering sleeves for the studs, a jack 

etc. 

Park the machine on level and firm ground and prevent it from rolling away 

Slightly loosen the wheel nuts of the wheel you want to remove 

Place a jack under the chassis, making sure it is standing firmly 

Raise the side from which you want to remove the tyre 

Check the machine is standing firmly 

Completely remove the wheel nuts 

Remove the wheel 

Fitting the wheels ☞Proceed as follows: 

Place the wheel onto the wheel studs 

Tighten all wheel nuts part-way 

Lower the raised side 

Tighten the wheel nuts to the prescribed tightening torque (135 Nm/100 lbf ft) 

– see General tightening torques on page 2-6 

Important! 

Subsequent to changing wheels check the wheel nuts for tightness after 

10 service hours – tighten if necessary! 

Important! 

Refer to the table in chapter “Specifications” for the authorised tyre types and the 

correct tyre pressures. A label affixed ex works also contains the prescribed tyre 

pressures. Regular inspection of the tyres. 

• Improves operating safety 

• Increases the service life of the tyres 

• Reduces machine downtimes 


3.14 Axles 

Checking the oil level and filling up oil 

A 

Fig. 26: Checking the oil level 

Draining oil 

Danger! 

Maintenance 

Some components of the machine and the oil are still very hot after switching 

off the machine – 


☞Wait until the engine has cooled down before taking up work. 

☞Slowly open filler plug A to release the pressure inside. 

☞Park the machine on firm and horizontal ground 

☞Place the machine so that filler plug A is at the left 

☞Remove the ignition key 

☞Unscrew screws A 

➥The oil must be level with opening A 

➥If the oil level is lower, 

☞Fill in oil through opening A until it flows out slightly 

☞Screw screws A back in again 

☞Move the machine a few metres 

☞Park the machine on firm and horizontal ground 

☞Place the machine so that filler plug A is at the bottom 

☞Remove the ignition key 

☞Unscrew screws A 

➥The oil now flows out of opening A 

☞Use a suitable container to collect the oil as it drains 

Environment! 

Collect the oil with a suitable container and dispose of it in an environmentally friendly 

manner. 


Maintenance 

3.15 Electric system 

Specific safety instructions 

The battery contains sulphuric acid! This acid must not be allowed to come into contact 

with the skin, the eyes, clothing or the machine. 

Therefore when recharging or working near the battery: 

☞Always wear goggles and protective clothing with long sleeves 

If acid is spilt: 

Service and maintenance work at regular intervals 

☞Thoroughly rinse all affected surfaces immediately with plenty of water 

☞Thoroughly wash any part of the body touched by the acid immediately with plenty of 

water and seek medical attention at once! 

Especially when charging batteries, as well as during normal operation of batteries, an 

oxyhydrogen mixture is formed in the battery cells – danger of explosion! 

Do not attempt to jump-start the machine if the battery is frozen or if the acid level is 

low. The battery can rupture or explode! 

☞Replace the battery immediately 

Avoid naked flames and sparks and do not smoke in the vicinity of open battery cells – 

otherwise the gas produced during normal battery operation can ignite! 

Use only 12 V power sources. Higher voltages will damage the electric components 

When connecting the battery leads, make sure the poles +/– are not inverted, otherwise 

sensitive electric components will be damaged 

Do not interrupt voltage-carrying circuits at the battery terminals because of the danger 

of sparking! 

Never place tools or other conductive articles on the battery – danger of short circuit! 

Disconnect the negative (–) battery terminal from the battery before starting repair work 

on the electric system 

Dispose of used batteries properly 

Before driving the machine 

☞Check every time before driving the machine: 

Is the light system OK? 

Is the signalling and warning system OK? 

Every week 

☞Check once a week: 

Electric fuses 

– see Fuse box on page 2-4 

Cable and earth connections 

Battery charge condition 

– see Battery on page 3-32 

Condition of battery terminals 


Instructions concerning specific components 

Alternator Always observe the following instructions: 

Maintenance 

Cables, bulbs and fuses 

Always observe the following instructions: 

Defective components of the electric system must always be replaced by an authorised 

expert. Bulbs and fuses may be changed by unqualified persons. 

When carrying out maintenance work on the electric system, pay particular attention to 

ensuring good contact in leads and fuses. 

Blown fuses indicate overloading or short circuits. The electric system must therefore 

be checked before installing the new fuse. 

Only use fuses with the specified load capacity (amperage) 

– see Fuse box on page 2-4 

Only test run the engine with the battery connected 

When connecting the battery, make sure the poles (+/–) are not inverted 

Always disconnect the battery before carrying out welding work or connecting a quick 

battery charger 

Replace defective charge telltales immediately 

– see Instrument panel overview on page 1-9 


Maintenance 

Battery 

+ 

Fig. 27: Battery 

A 

- 

Danger! 

Battery acid is highly caustic! 

Danger of caustic injury! 

Therefore when recharging and/or working near the battery: 

☞Always wear goggles and protective clothing with long sleeves 

If acid is spilt: 

☞Thoroughly rinse all affected surfaces immediately with plenty of water 

☞Thoroughly wash any part of the body touched by the acid immediately with 

plenty of water and seek medical attention at once! 

Especially when charging batteries, as well as during normal operation of 

batteries, an oxyhydrogen mixture is formed in the battery cells – 

Danger of explosion! 

☞Avoid naked lights and sparks in the vicinity of the battery and do not 

smoke! 

☞Do not attempt to jump-start the machine if the battery is frozen or if the 

acid level is low. The battery can rupture or explode! 

• Replace the battery immediately 

☞Always disconnect the negative terminal (–) from the battery before starting 

repair work on the electric system! 

Battery A is located underneath the engine cover. The battery is “maintenance-free”. 

However have the battery checked at regular intervals to make sure the electrolyte level is 

between the MIN and MAX marks. 

Checking the battery requires it to be removed and must be carried out by an authorised 

workshop. 

Always follow the specific battery safety instructions! 

Important! 



3.16 Battery master switch 

A 

Fig. 28: Battery master switch 

C 

B 

Important! 


Important! 

Power supply is interrupted directly after the battery, by means of a key 

Interrupting power supply: 

• Before working on the electric system 

☞Turn key A of the battery master switch to position B and remove it 

Switching on power supply: 

☞Insert key A in the battery master switch 

☞Turn the key down to the notched position C 

Maintenance 


Maintenance 

3.17 General maintenance work 

Cleaning Cleaning the machine is divided into 2 separate areas: 

General instructions for all areas of the machine 

Screw connections and attachments 

Pivots and hinges 

Exterior of the machine 

Engine compartment 

The wrong choice of cleaning equipment and agents can impair the operating safety of the 

machine on the one hand, and on the other undermine the health of the persons in charge 

of cleaning the machine. It is therefore essential to observe the following instructions. 

When using washing solvents 

Ensure adequate room ventilation 

Wear suitable protective clothing 

Do not use flammable liquids, such as petrol or diesel 

When using compressed air 

Work carefully 

Wear goggles and protective clothing 

Do not aim the compressed air at the skin or at other people 

Do not use compressed air for cleaning your clothing 

When using a high-pressure cleaner or steam jet 

Electric components and damping material must be covered and not directly exposed 

to the jet 

Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc. 

Protect the following components from moisture: 

Engine 

Electric components such as the alternator etc. 

Control devices and seals 

Air intake filters etc. 

When using volatile and easily flammable anticorrosion agents and sprays: 

Ensure adequate room ventilation 

Do not use unprotected lights or naked flames 

Do not smoke! 

All screw connections must be checked regularly for tightness, even if they are not listed in 

the maintenance schedules. 

Retighten loose connections immediately. Contact an authorised workshop if necessary. 

Lubricate all mechanical pivots on the machine (such as hinges and joints) and fittings at 

regular intervals even if they are not listed in the lubrication plan. 


Engine

4 Engine 

4.1 3TNV88-KNSV engine: overview 

Flywheel 

Engine 

Oil drain plug 

Engine 

Fuel injection pump 

Engine oil filter 

Oil dipstick 

Oil pressure switch 

Oil filler neck 


Engine 

Tightening bracket 

Fan blade 

Water pump 



V-belt 

Alternator 

Exhaust manifold 

Starter

4.2 Fuel system (up to AB) 

Injection nozzles 

Injection line 


Reflux to tank 

Engine 


Feed 

Fuel filter 

with stop cock 

Water separator 


Fuel pump

Engine 

4.3 Fuel system (starting AC) 


1 Water separator 

12 Fuel filter 

13 Fuel pump 


Checking and adjusting valve clearance 

normal abnormal 

Fig. 1: Valve cap wear 

A 

Fig. 2: Valve clearance 

Fig. 3: Setting valve clearance 

Fig. 4: Put the valve cover gasket in place 

B 

C 

☞Standard setting of valve clearance is possible: 

➥On a cold engine 

☞Remove the valve cover 

Engine 

☞Turn the engine until the cylinder reaches the top dead centre of the compression 

cycle. 

☞Check the valve cap for abnormal wear 

☞Check valve clearance 2/A with a feeler gauge 

➥Valve clearance: 0.15 – 0.25 mm (0.006 – 0.01”) 

☞Adjust valve clearance by turning set screw 2/B. 


☞Tighten locknut 2/C. 

➥Check the setting again with the feeler gauge. 

☞Repeat the procedure for each cylinder 

☞Place the valve cover gasket 

☞Mount the valve cover 


Engine 

Tightening order for cylinder head bolts 

☞Mount the cylinder-head bolts 

➥Tightening torques: 

1st pass 41.1 – 46.9 Nm (30.31 – 34.59 lbf ft) 

2nd pass 85.3 – 91.1 Nm (62.91 – 67.19 lbf ft) 

Flywheel 

Caution! 

Bear in the mind the order for tightening the cylinder-head bolts! 

☞See figure 

Oil the threads and the contact surfaces of the cylinder-head bolts before mounting them! 

☞Order for removing the cylinder-head bolts 

Flywheel 

Important! 

Always carry out work on the cylinder head on a cold engine! 


Fan 

Fan

4.4 Checking the injection nozzles 

Pressure check 

Fig. 5: Nozzle tester 

Leak oil line 

Checking the nozzle jet 

Fig. 6: Nozzle jet 

Normal atomisation 

Bad atomisation 

Upper nozzle 

screw fitting Spacers 

☞Remove the injection line and the injection nozzle 

☞Connect the injection nozzle with the high pressure line of the nozzle tester 

Engine 

☞Slowly increase pressure until the nozzle ejects fuel and read the pressure off the 

pressure gauge 

☞If the injection pressure is too low, replace the spacer in the nozzle by a thicker one. 

If the pressure is too high, replace the spacer by a thinner one. 

➥Injection pressure: 196 – 206 bar (2843 – 2988 psi) 

Spacer thickness of 0.1 mm (0.004") corresponds to modification by 19 bar (276 psi) 

Compression 

spring 

Pressure spring centring 

Compression 

spring seat 

Nozzle needle 

☞Remove the injection lines and the injection nozzles 

Nozzle body 


☞Quickly create pressure until the nozzle ejects fuel (ejection 3 – 4 times) 

Lower nozzle 

screw fitting 

☞Hold a white sheet of paper about 30 cm (12") away from the nozzle and let the nozzle 

eject fuel 

☞The nozzle jet must create a circle on the paper 

☞Check the nozzle for drips after it has ejected fuel 

☞Create a pressure of about 20 bar (290 psi) below injection pressure and check 

whether fuel escapes from the nozzle 


Engine 

Injection time Checking injection time 

Fig. 7: Drip tube 


☞Turn the engine clockwise with the crankshaft (as seen from the radiator) up to the top 

dead centre of the first cylinder and check whether both cams show upwards to the left 

and right 

☞Remove the rubber covers from the flywheel housing and check whether the mark on 

the belt pulley is aligned with the 0 mark on the scale 

☞Unscrew the injection line of the first cylinder and replace it by the drip tube (place a 

container to collect the fuel (Fig. 7) 

☞Rotate the engine 1.5 revolutions until it is 40° before top dead centre in the 

compression stroke 

☞Slowly keep on turning the engine (degree by degree) until dripping stops 

Do not turn back if you have turned too much! 

☞The point at which the dripping stops is the start of delivery (injection time) of the fuel 

injection pump 

➥You can now read the value (in degrees before top dead centre) off the belt pulley 

Setting injection time 

☞If injection time should no longer be correct, you can adjust it by rotating the fuel 


☞Mark the initial position on the pump and wheel case housing before setting the fuel 


☞Remove all injection lines before rotating the injection pump, and slacken the 4 flange 

screws by about half a revolution 

☞Rotate the pump in the required direction, and tighten one of the screws before you 

check the setting 

➥Rotated towards the engine: earlier injection time 

➥Rotated away from the engine: later injection time 

☞Bend each of the injection lines before you mount them so they are not subject to 

tension once they are mounted 

Mark on belt 

pulley 

Engraved scale 

Pulley 


Mark on pump and wheel case 

housing 

Flange screws (oblong slots for rotating the pump) 


4.5 Adjusting engine revs 

B 

Fig. 8: Adjusting engine revs 

4.6 Compression 

Fig. 9: Compression 

A 

Important! 

Maximum engine revs are sealed in the factory and may not be modified! 

Adjust engine revs without load! 

☞Run the diesel engine until it reaches operating temperature 

Engine 

☞Check idling speed A and maximum revs B with all attachment functions in neutral 

➥Idling speed 1000 ± 25 rpm 

➥Max. revs: 3000 ± 25 rpm 

☞Adjust if engine revs differ 

– see Setting injection time on page 4-8 


☞Set the fuel injection pump to zero delivery (remove the plug for the cutoff solenoid) 

☞Turn the engine 

☞Mount the compression gauge on the cylinder you want to measure 

☞Turn the engine with the starter and read the pressure off the pressure gauge 

➥Standard 34.3 bar (497 psi) 

➥Limit 27.5 bar (399 psi) 


Engine 

4.7 Checking the coolant thermostat 

Housing cover 

Thermostat 

Seal 

Housing 


Fig. 10: Coolant thermostat 

Thermometer 


Checking the thermal switch 

Thermometer 

Fig. 11: Checking the thermal switch 

Test prods 

☞Remove the thermostat 

➥The thermostat is located on the water pump 

– see 3TNV88-KNSV engine: overview on page 4-1 

☞Warm up the thermostat in a container with water 

☞Check whether the thermostat opens at the specified temperature (check with a 

temperature gauge) 

➥Thermostat opening temperature: begins at 71 °C (160 °F), 

fully open at 85 °C (185 °F) 

☞Remove the thermal switch 

☞Warm up the thermal switch in a container with antifreeze or oil 

☞Measure the resistance of the thermal switch as shown by means of an ohmmeter. 

➥The switch must allow the coolant to pass at a temperature of 107 – 113 °C 

(224.6 – 235.4 °F) 


4.8 Oil pressure switch 

Measurement 

prod 

Fig. 12: Oil pressure switch 

4.9 Checking the coolant circuit 

Fig. 13: Checking the radiator for leaks 

Radiator cap 

Fig. 14: Checking the radiator cap 

Engine 

☞Remove the cable connection from the oil pressure switch (in the area of the cutoff 

solenoid) 

☞Start the engine, check for correct idling speed 

☞Measure the resistance of the oil pressure switch as shown by means of an ohmmeter. 

➥Oil pressure switch OK: infinite resistance 

➥The oil pressure switch is defective if the oil can pass 

Leakage check 

☞Fill up the radiator completely 

☞Mount an adapter on the radiator as shown 

☞Increase the pressure in the cooling system by means of a hand pump to about 1 bar 

(15 psi) 

➥Check the lines and the connections for leaks if the pressure drops at the pressure 

gauge 

Checking the radiator cap 

☞Remove the radiator cap and mount it onto the adapter as shown 

☞Increase the pressure to about 1 bar/15 psi (stamped onto the radiator cap) with the 

hand pump 

➥The radiator cap must open 


Engine 

4.10 Clutch 

Fig. 15: Fastening the clutch 

Fastening material: 

3 off ISK M12 x 20 – DIN 912 

3 off M12 Schnorr washers 

Screw M12x20-DIN 912 

Schnorr washer M12 

Tightening torque: 

86 Nm/63 lbf ft (glue with 

medium-strength Loctite) 

➥Fasten the clutch by gluing the screws with Loctite and then tightening them 

to 86 Nm (63 lbf ft). 


4.11 Engine 3TNV88-BKNSV overview (from serial no. AE310242D) 

Air intake 

Sheathed-element 

heater plugs 

Engine 


Engine 

SERV-HB 3001 EN – Edition 2.0 * 3001s420_Tier 3.fm 4-13 


Fuel filter 

Engine oil filter 

Oil dipstick 

Oil pressure switch

Engine 

Valve cover 

Exhaust manifold 

Water pump 

4-14 SERV-HB 3001 EN – Edition 2.0 * 3001s420_Tier 3.fm 

Starter 

Tightening bracket 

Fan blade 

Alternator 

V-belt

4.12 Fuel system (from serial no. AE310242D) 

Sintered metal filter 

Fuel radiator 

Filler inlet 

Reflux 

Tank 

Feed line 

Engine 


Water separator 



Fuel filter 

Fuel pump

Engine 

Checking and adjusting valve clearance 

normal abnormal 

Fig. 16: Valve cap wear 

A 

Fig. 17: Valve clearance 

Fig. 18: Setting valve clearance 

Fig. 19: Put the valve cover gasket in place 

B 

C 

☞Standard setting of valve clearance is possible: 

➥On a cold engine 


☞Turn the engine until the cylinder reaches the top dead centre of the compression 

cycle. 

☞Check the valve cap for abnormal wear 

☞Check valve clearance 2/A with a feeler gauge 


☞Adjust valve clearance by turning set screw 2/B. 


☞Tighten locknut 2/C. 

➥Check the setting again with the feeler gauge. 

☞Repeat the procedure for each cylinder 

☞Place the valve cover gasket 

☞Mount the valve cover 

4-16 SERV-HB 3001 EN – Edition 2.0 * 3001s420_Tier 3.fm

Tightening order for cylinder head bolts 

☞Mount the cylinder-head bolts 

➥Tightening torques: 

1st pass 42.6 – 45.5 Nm (31.4 – 33.6 lbf ft) 

2nd pass 85.3 – 91.1 Nm (62.9 – 67.2 lbf ft) 

Flywheel 

Caution! 

Bear in the mind the order for tightening the cylinder-head bolts! 

☞See figure 

Engine 

Oil the threads and the contact surfaces of the cylinder-head bolts before mounting them! 

☞Order for removing the cylinder-head bolts 

Flywheel 

Important! 

Always carry out work on the cylinder head on a cold engine! 


Fan 

Fan

Engine 

4.13 Checking the injection nozzles 

Pressure check 

Fig. 20: Nozzle tester 

Leak oil line 

Checking the nozzle jet 

Fig. 21: Nozzle jet 

Normal atomisation 

Bad atomisation 

Upper nozzle 

screw fitting Spacers 

☞Remove the injection line and the injection nozzle 


☞Slowly increase pressure until the nozzle ejects fuel and read the pressure off the 

pressure gauge 

☞If the injection pressure is too low, replace the spacer in the nozzle by a thicker one. If 

the pressure is too high, replace the spacer by a thinner one. 

➥Injection pressure: 196 – 206 bar (2843 – 2988 psi) 

Spacer thickness of 0.1 mm (0.004") corresponds to modification by 19 bar (276 psi) 

Compression 

spring 

Pressure spring centring 

Compression 

spring seat 

Nozzle needle 


Nozzle body 


☞Quickly create pressure until the nozzle ejects fuel (ejection 3 – 4 times) 

Lower nozzle 

screw fitting 

☞Hold a white sheet of paper about 30 cm (12") away from the nozzle and let the nozzle 

eject fuel 

☞The nozzle jet must create a circle on the paper 

☞Check the nozzle for drips after it has ejected fuel 

☞Create a pressure of about 20 bar (290 psi) below injection pressure and check 

whether fuel escapes from the nozzle 


Injection time Checking injection time 

Fig. 22: Drip tube 


Engine 

☞Turn the engine clockwise with the crankshaft (as seen from the radiator) up to the top 

dead centre of the first cylinder and check whether both cams show upwards to the left 

and right 

☞Remove the rubber covers from the flywheel housing and check whether the mark on 

the belt pulley is aligned with the 0 mark on the scale 

☞Unscrew the injection line of the first cylinder and replace it by the drip tube (place a 

container to collect the fuel (Fig. 22) 

☞Rotate the engine 1.5 revolutions until it is 40° before top dead centre in the 

compression stroke 

☞Slowly keep on turning the engine (degree by degree) until dripping stops 

Do not turn back if you have turned too much! 

☞The point at which the dripping stops is the start of delivery (injection time) of the fuel 


➥You can now read the value (in degrees before top dead centre) off the belt pulley 

Setting injection time 

☞If injection time should no longer be correct, you can adjust it by rotating the fuel 


☞Mark the initial position on the pump and wheel case housing before setting the fuel 


☞Remove all injection lines before rotating the injection pump, and slacken the 4 flange 

screws by about half a revolution 

☞Rotate the pump in the required direction, and tighten one of the screws before you 

check the setting 

➥Rotated towards the engine: earlier injection time 

➥Rotated away from the engine: later injection time 

☞Bend each of the injection lines before you mount them so they are not subject to 

tension once they are mounted 

Mark on belt 

pulley 

Engraved scale 

Pulley 


Mark on pump and wheel case 

housing 

Flange screws (oblong slots for rotating the pump) 

SERV-HB 3001 EN – Edition 2.0 * 3001s420_Tier 3.fm 4-19

Engine 

4.14 Adjusting engine revs 

B 

Fig. 23: Adjusting engine revs 

Important! 

Maximum engine revs are sealed in the factory and may not be modified! 

Adjust engine revs without load! 

☞Run the diesel engine until it reaches operating temperature 

☞Check idling speed A and maximum revs B with all attachment functions in neutral 

➥Idling speed 1000 ± 25 rpm 

➥Max. revs: 2590 ± 25 rpm 

☞Adjust if engine revs differ 

– see Setting injection time on page 4-19 

4.15 Automatic revs setting option (Tier 3A from AE310242D) 

Function 

A 

A 

The required diesel engine revs are mechanically adjusted by means of a cable pull and 

the manual throttle lever. The automatic revs setting is enabled via switch A on the control 

stand. 

If the automatic revs setting is enabled and the machine does not carry out any work 

movements for about 5 seconds, the diesel engine is set to idling speed by means of the 

hydraulic ram and the controls (= directional valve and time lag relay). As soon as a work 

operation is carried out again, the engine is reset to the engine speed that has been set 

previously. 


Installation 

Engine 

If the automatic revs setting is not enabled, engine speed is not lowered automatically. 

This is then carried out mechanically with the cable pull and the manual throttle lever. 

Revs control retrofit kit 1 


Engine 

4.16 Compression 

Fig. 24: Compression 


☞Set the fuel injection pump to zero delivery (remove the plug for the cutoff solenoid) 

☞Turn the engine 

4.17 Checking the coolant thermostat 

Housing cover 

Thermostat 

Seal 

Housing 


Fig. 25: Coolant thermostat 

Thermometer 


☞Mount the compression gauge on the cylinder you want to measure 

☞Turn the engine with the starter and read the pressure off the pressure gauge 

➥Standard: 33.3 – 35.3 bar (483 – 512 psi) at 250 rpm 

➥Limit: 26.5 – 28.5 bar (384 – 413 psi) at 250 rpm 

☞Remove the thermostat 

➥The thermostat is located on the water pump 

– see Engine 3TNV88-BKNSV overview (from serial no. AE310242D) on page 4-13 

☞Warm up the thermostat in a container with water 

☞Check whether the thermostat opens at the specified temperature (check with a 

temperature gauge) 

➥Thermostat opening temperature: 69.5 – 72.5 °C (157.1 – 162.5 °F) 


Checking the thermal switch 

Thermometer 

Fig. 26: Checking the thermal switch 

4.18 Oil pressure switch 

Measurement 

prod 

Fig. 27: Oil pressure switch 

4.19 Checking the coolant circuit 

Fig. 28: Checking the radiator for leaks 

Radiator cap 

Fig. 29: Checking the radiator cap 

Test prods 

☞Remove the thermal switch 

☞Warm up the thermal switch in a container with antifreeze or oil 

Engine 

☞Measure the resistance of the thermal switch as shown by means of an ohmmeter. 

➥The switch must allow the coolant to pass at a temperature of 107 – 113 °C 

(224.6 – 235.4 °F) 

☞Remove the cable connection from the oil pressure switch (in the area of the cutoff 

solenoid) 

☞Start the engine, check for correct idling speed 

☞Measure the resistance of the oil pressure switch as shown by means of an ohmmeter. 

➥Oil pressure switch OK: infinite resistance 

➥The oil pressure switch is defective if the oil can pass 

Leakage check 

☞Fill up the radiator completely 

☞Mount an adapter on the radiator as shown 

☞Increase the pressure in the cooling system by means of a hand pump to about 1 bar 

(15 psi) 

➥Check the lines and the connections for leaks if the pressure drops at the pressure 

gauge 

Checking the radiator cap 

☞Remove the radiator cap and mount it onto the adapter as shown 

☞Increase the pressure to about 1 bar/15 psi (stamped onto the radiator cap) with the 

hand pump 

➥The radiator cap must open 


Engine 

4.20 Clutch 

4.21 Engine trouble 

Fig. 30: Fastening the clutch 

Engine does not start or is not easy to start 

Fastening material: 

3 off ISK M12 x 20 – DIN 912 

3 off M12 Schnorr washers 

Screw M12x20-DIN 912 

Schnorr washer M12 

Tightening torque: 

86 Nm/63 lbf ft (glue with 

medium-strength Loctite) 

➥Fasten the clutch by gluing the screws with Loctite and then tightening them 

to 86 Nm (63 lbf ft). 

Problem Possible causes 

Wrong SAE grade of engine lubrication oil 

Fuel grade does not comply with specifications 

Defective or flat battery 

Loose or oxidised cable connections in starter circuit 

Defective starter, or pinion does not engage 

Wrong valve clearance 

Defective fuel injector 

Defective starting relay 

Defective glow plug 

Defective solenoid switch 

Cutoff solenoid does not attract 

Cutoff solenoid without current 

High pressure created immediately in the hydraulic system 


Engine starts, but does not run smoothly or faultless 

Engine overheats. Temperature warning system responds 

Insufficient engine output 

Engine does not run on all cylinders 

Insufficient or no engine oil pressure 

Engine oil consumption too high 

Engine smoke 

Problem Possible causes 

Blue 

White 

Black 



Injection line leaks 


Oil level too low 

Oil level too high 

Dirty air filter 

Dirty oil cooler fins 

Defective fan, torn or loose V-belt 

Resistance in cooling system too high, flow capacity too low 

Defective thermostat 





Defective air filter maintenance switch or gauge 






Oil level too low 

Machine inclination too high (max. 25°) 

Wrong SAE grade of engine lubrication oil 





Engine oil combustion (defective cylinder-head gasket) 

Engine starting temperature too low 




Coolant combustion (defective cylinder-head gasket) 


Defective air filter maintenance switch or gauge 



Engine 


Engine 


Travelling drive


5 Travelling drive 

5.1 Variable displacement pump A10VG45DA 

1 


1 X2 pressure in control piston 

2 X1 pressure in control piston 

3 Boost pressure – G 

4 High pressure Mb 



4 

2 

3


6 

8 

5 


5 Control cartridge 

6 Inching valve 

7 High-pressure valve 

8 High pressure Ma 


7

Variable displacement pump: diagram 

1 

Description: 

A10 VG 

➥Axial-piston machine, swash plate design, adjustable, closed circuit 

45 

➥Displacement volume Vg max in cm³ 

DA 

➥Hydraulic adjustment, speed-sensitive 


The A10VG pump is a variable displacement pump in axial-piston swash plate design. The 

volume flow is proportional to the drive revs and can be infinitely adjusted to the 

displacement volume. The volume flow increases from 0 to maximum value the higher the 

deflection. The feed flow changes as soon as the swash plate goes out of line through the 

zero position, i.e. the flow direction changes. 

The pump is fitted with two pressure limiting valves, pressure cutoff, control cartridge with 

hydraulic inching valve, boost pressure valve and a forwards/reverse solenoid valve. 

9 

2 3 

5 6 7 8 


1 Solenoid (a reverse; b forwards) 

2 Control cartridge 

3 Boost pump 

4 Work pump 

5 Servo cylinder 

6 HP valve 

7 Boost pressure valve 

8 Pressure cutoff 



4


Variable displacement pump: design 

6 

9 

15 

12 

7 

9 2 

17 16 5 10 


13 

8 

11 



2 Hydraulic adjustment 

3 Connecting plate with valves 

4 Internal gear pump 


6 Set cartridge 

7 Pump housing 

8 Articulated pin 

9 Screw plug 

10 Screw plug 

11 Screw plug 

12 Double tear-off plug 

13 Parallel pin 

14 O-ring 

15 Nozzle 

16 Nozzle 

17 Set element 

1 

14 

3 4

Travelling drive overview 

14 

4 

10 

13 12 

9 

5 

8 

7 

11 

3 



2 Cradle 

3 Sliding block 

4 Drive shaft 

5 Wire 

6 Articulated pin 

7 Wire 

8 Roller 

9 Pair of bearing pins 

10 Cylindrical roller bearing 

11 Cage pair 

12 Circlip 

13 Circlip 

14 Rotary shaft lip seal 



2 

6 

1


Connecting plate with valves 

5 

4 

2 

13 

9 

7 

3 


1 Pressure limiting valve 

2 Pressure limiting valve 

3 Cutoff valve 


5 Screw plug 

6 Screw plug 


8 O-ring 

9 Screw plug 

10 Nozzle 

11 HP valve 

12 HP valve 

13 Screw plug 


8 

4 

2 

1 

11 

12 

10 

6

5.2 A6VM80EZ hydraulic motor 

2 

3 

1 

5 


1 Leak fluid/oil drain 

2 Switching magnet slow/fast 

3 MA pump port 

4 MB pump port 

5 Maximum flow rate limit -> fast 

6 Minimum flow rate limit -> slow 



6 

4


5.3 Travelling drive overview (up to AB) 

Diesel engine 

Rated speed 

Forwards driving function: 

Flow-through direction of variable displacement pump from A to B 

Reverse driving function: 

5.4 Travelling drive overview (starting AC) 

Diesel engine 

B 

A 

Service brake 

Differential lock 

Flow-through direction of variable displacement pump from B to A 


Hydraulic motor 


B 


A

5.5 Towing and transporting the machine 

Safety instructions 

Towing 


The machine may only be towed using suitable towing equipment (towing bar or cable) 

in connection with suitable towing facilities, such as a towing coupling, hooks and eyes! 

Move off slowly! Make sure no-one is dangerously close to the towing bar! 

The machine may only be towed with a cable if the service brakes and steering are fully 

operational! 

Caution! 

The hydrostatic drive can be damaged when towing the machine! 

☞Switch off the engine! 

☞Open the high-pressure circuit on the pump 

☞Release the hydraulic parking brakes on both wheel motors 

☞Do not tow the machine for more than 1 km (0.62 miles) and no faster than 

2 kph (1.2 mph)! 

Opening the high-pressure circuit There are two HP pressure limiting valves on the pump under the floor panel, one on the 

upper left and the other on lower left. 

Fig. 1: High-pressure circuit screw 

2 

1 


☞Slacken locknut ws 14 (part 1) and unscrew it to the end of the screw 

☞Screw in the screw with allen key ws 4 (part 2) until you can feel a firmer resistance 

☞Then screw in a further half revolution 

Caution! 

Screwing in any further damages the valve. 

☞Retighten the locknut 

☞Slowly tow the machine (max. 2 kph/1.2 mph) over a short distance 

(max. 1 km/0.62 miles) 

☞Then reset the valves. Proceed in the reverse order to do this 

(unscrew the screw as far as it will go). 



5.6 Test instruction 

High pressure check 

Fig. 2: Parking brake switch (starting AC) 

Ensure utmost cleanliness of all measuring points and ports, micro measuring lines 

and pressure gauges that are connected for checking pressure => even the 

slightest traces of dirt, e.g. a grain of sand, can impair tightness and cause leaks! 

Tools required: 

Pressure gauge 600 bar/8702 psi 

Test port HP Parking brake switch (up to AB) 

Check high pressure as follows: 

☞Switch off the ignition 

☞Up to AB: disconnect or remove the parking brake switch to make sure there is no 

contact by applying the parking brake 

☞Starting AC: disconnect or remove the parking brake lever to make sure there is no 

contact by applying the parking brake 

☞Connect the pressure gauge 

☞Start the diesel engine and move the drive lever to forwards speed range 

☞Drive the machine against hydraulic resistance 

➥Do not allow the wheels to spin 

☞Read the pressure gauge 

➥High pressure must be about 360 bar/5221 psi 

Important! 

It is not possible to adjust the high pressure valves 


Check: boost pressure 



Boost pressure test port 

Check boost pressure as follows: 


☞Remove flexible line A from the differential circuit 

☞Connect the pressure gauge 

☞Start the diesel engine 

➥Boost pressure: about 5 bar/72.5 psi at idling speed 

➥Boost pressure at full revs about 25 bar/363 psi 



A


Check: setting pressure Tools required: 

X2 


Setting pressure test ports X1 and X2 

Check the setting pressure as follows: 


☞Connect a pressure gauge to X1 or X2 


☞The pump starts to swivel at about 12 bar/174 psi and the dumper moves 

➥Maximum pressure is about 25 bar/363 psi 


X1

5.7 Adjustment 

Setting: control initiation Tools required: 

2 x pressure gauges 600 bar/8702 psi 

A 

Setting pressure test ports X1 and X2 

Adjust control initiation as follows 


☞Connect the pressure gauge to ports G and M1 

☞Drive the machine against a hydraulic resistance 

Brake the machine firmly 


Disconnect or remove the parking brake switch to make sure there is no contact by 

applying the parking brake 

Shift to road-travel speed 


☞Slowly increase the service pressure (shown on the pressure gauge on port G) 

☞The pressure gauge on port M1 indicates the setting pressure 

➥Service pressure x 0.5 = setting pressure 

☞Readjust the setting pressure until reaching control initiation with set screw A 

Important! 

Clockwise rotation: earlier control initiation! 

Counterclockwise rotation: later control initiation! 




Axles

6 Axles 

6.1 Axle type label 

Axle manufacturer 

Type and model 

designation. 

Manufacturer's address 

Axles 

Type label contains all axle data 

Axle type label 

Serial number 

Lubricant 

Axles 


Axles 

6.2 Drain, fill and check plug 

6.3 Tightening torques 

Wheel screws 

Pos Description 

1 Fill plug 

2 Drain plug 

3 Checking the oil level 

Wheel nut Thread Tightening torque 

With taper M18X1.5 

Important! 

300 – 350 Nm 

221 – 258 lbf ft 

Check the wheel nuts for tightness every 50 service hours! 


General tightening torques 

Thread 

size 

M6x1 

M8X1.25 

M10X1.5 

M12X1.75 

M14x2 

M16x2 

M18x2.5 

M20x2.5 

M22x2.5 

M24x3 

M27x3 

M30x3.5 

Axles 

Normal +Loctite 270 

Thread 

Normal 

+Loctite 

270 

Normal +Loctite 270 

8.8 10.9 12.9 

Nm (lbf ft) 

9.5 – 10.5 10.5 – 11.5 14.3 – 15.7 15.2 – 16.8 16.2 – 17.8 18.1 – 20.0 

7 – 7.7 7.7 – 8.5 10.5 – 11.6 11.2 – 12.4 11.9 – 13.1 13.3 – 14.8 

23.8 – 26.2 25.6 – 28.4 34.2 – 37.8 36.7 – 40.5 39.0 – 43.0 43.7 – 48.3 

17.6 – 19 18.9 – 20.9 25.2 – 27.9 27.1 – 29.9 28.8 – 31.7 32.2 – 35.6 

48 – 53 52 – 58 68 – 75 73 – 81 80 – 88 88 – 97 

35 – 39 38 – 43 50.2 – 55.3 53.8 – 59.7 59 – 64.9 64.9 – 71.5 

82 – 91 90 – 100 116 – 128 126 – 139 139 – 153 152 – 168 

60.5 – 67.1 66.4 – 73.8 85.6 – 94.4 92.9 – 102.5 102.5 – 112.8 112.1 – 123.9 

129 – 143 143 – 158 182 – 202 200 – 221 221 – 244 238 – 263 

95.1 – 105 105 – 117 134.2 – 149 148 – 163 163 – 180 176 – 194 

200 – 221 219 – 242 283 – 312 309 – 341 337 – 373 371 – 410 

148 – 163 161 – 178 209 – 230 228 – 251.5 249 – 275 274 – 302 

276 – 305 299 – 331 390 – 431 428 – 473 466 – 515 509 – 562 

203.5 – 225 220.5 – 244 288 – 318 316 – 349 344 – 380 375 – 415 

390 – 431 428 – 473 553 – 611 603 – 667 660 – 730 722 – 798 

288 – 318 316 – 349 408 – 451 445 – 492 487 – 538 533 – 589 

523 – 578 575 – 635 746 – 824 817 – 903 893 – 987 974 – 1076 

386 – 426 424 – 468 550 – 608 603 – 666 659 – 728 718 – 794 

675 – 746 732 – 809 950 – 1050 1040 – 1150 1140 – 1260 1240 – 1370 

498 – 550 540 – 597 701 – 774 767 – 848 841 – 929 915 – 1010 

998 – 1103 1088 – 1202 1411 – 1559 1539 – 1701 1710 – 1890 1838 – 2032 

736 – 814 802 – 887 1041 – 1150 1135 – 1255 1261 – 1394 1356 – 1499 

1378 – 1523 

1016 – 1123 

1473 – 1628 

1086 – 1201 

1914 – 2115 

1412 – 1560 

2085 – 2305 

1538 – 1700 

2280 – 2520 

1682 – 1859 

M8x1 

25.7 – 28.3 

19 – 20.9 

27.5 – 30.5 

20.3 – 22.5 

36.2 – 39.8 

26.7 – 29.4 

40 – 44 

29.5 – 32.5 

42.8 – 47.2 

31.6 – 34.8 

M10X1.25 

49.4 – 54.6 

36.4 – 40.3 

55.2 – 61 

40.7 – 45 

71.5 – 78.5 

52.7 – 57.9 

78 – 86 

57.5 – 63.4 

86 – 94 

63.4 – 69.3 

M12X1.25 

90 – 100 

66.4 – 73.8 

98 – 109 

72.3 – 80.4 

128 – 142 

94.4 – 105 

139 – 154 

102.5 – 114 

152 – 168 

112.1 – 123.9 

M12X1.5 

86 – 95 

63.4 – 70 

94 – 104 

69.3 – 76.7 

120 – 132 

88.5 – 97.4 

133 – 147 

98.1 – 108.4 

143 – 158 

105 – 117 

M14X1.5 

143 – 158 

105 – 117 

157 – 173 

116 – 128 

200 – 222 

148 – 164 

219 – 242 

161 – 178 

238 – 263 

176 – 194 

M16X1.5 

214 – 236 

158 – 174 

233 – 257 

172 – 190 

302 – 334 

223 – 246.3 

333 – 368 

245.6 – 271 

361 – 399 

266 – 294 

M18X1.5 

312 – 345 

230 – 254 

342 – 378 

252 – 279 

442 – 489 

326 – 361 

485 – 536 

358 – 395 

527 – 583 

389 – 430 

M20X1.5 

437 – 483 

322 – 356 

475 – 525 

350 – 387 

613 – 677 

452 – 499 

674 – 745 

497 – 549 

736 – 814 

543 – 600 

M22X1.5 

581 – 642 

429 – 474 

637 – 704 

470 – 519 

822 – 908 

606 – 670 

903 – 998 

666 – 736 

998 – 1103 

736 – 814 

M24x2 

741 – 819 

547 – 604 

808 – 893 

596 – 659 

1045 – 1155 

771 – 852 

1140 – 1260 

841 – 929 

1235 – 1365 

911 – 1007 

M27x2 

1083 – 1197 

799 – 883 

1178 – 1302 

869 – 960 

1520 – 1680 

1121 – 1239 

1672 – 1848 

1233 – 1363 

1834 – 2027 

1353 – 1495 

M30X2 

1511 – 1670 

1114 – 1232 

1648 – 1822 

1216 – 1344 

2138 – 2363 

1577 – 1743 

2332 – 2577 

1720 – 1901 

2565 – 2835 

1892 – 2091 

2494 – 2757 

1839 – 2033 

47.5 – 52.5 

35 – 38.7 

93 – 103 

68.6 – 76 

166 – 184 

122.4 – 135.7 

159 – 175 

117.3 – 129 

261 – 289 

193 – 213 

394 – 436 

291 – 322 

580 – 641 

428 – 473 

808 – 893 

596 – 659 

1078 – 1191 

795 – 878 

1363 – 1507 

1005 – 1112 

2000 – 2210 

1475 – 1630 

2788 – 3082 

2056 – 2273 


Axles 

6.4 Articulated joint (up to AB) 


7 

6 

5 

4 

3 

2 

4 

Axles 


1 



2 Spacer washer 

3 Bush 


5 Supporting washer 

6 Tab washer 

7 Slotted nut 

8 Grease nipples 

9 Protective cap 

10 Articulated joint pin 

11 Hexagon head screw 

12 Schnorr lock 

13 Washer 

14 Spacer washer 2 mm (0.08") 

15 Spacer washer 2.5 mm (0.1") 

16 Spacer washer 3 mm (0.12") 

17 Bush 

17 

17 

14 

15 

14 

16 

15 

16

Axles 

6.5 Articulated joint (starting AC) 




2 Thrust washer 


4 Bush 

5 Supporting washer 

6 Tab washer 

7 Slotted nut 


9 Bush 


11 Pin gasket 

12 Countersunk screw 

13 Washer 




17 Washer 

18 Grease nipples 

19 Protective cap 

20 Steering ram pin 

21 Washer 



Axles 


Axles 

6.6 Transfer gearbox (up to AD) 



1 O-ring 

2 Shim ring 

3 Bearing 

4 Sealing ring 

5 Screw 

6 Spacer ring 

7 Set of rings 

8 Gear 

9 Spring lock washer 


11 Plug 


13 Protective plate 

14 O-ring 

15 Washer 

16 Screw 

17 Cover 

18 Gear 

19 Circlip 

20 Grooved ball bearing 

21 Circlip 

22 Housing 

23 Pin 

24 Breather 

25 Cheese-head screw 

26 Cover 


28 O-ring 

29 Sheet metal 


31 Flange 

32 O-ring 

33 Centering ring 

Axles 


Axles 

6.7 Transfer gearbox (from AE310242D) 



1 Flange 

2 O-ring 

3 Bearing 

4 Seal ring 

5 Screw 

6 Shim 

7 Hex screw 

8 Gear 

9 Spring washer 

10 Hex screw 

11 Plug 

12 Seal ring 

13 Plate 

14 O - ring 

15 Washer 

16 Screw 

17 Cover 

18 Gear 

19 Lock ring 

20 Ball bearing 

21 Lock ring 

22 Housing 

23 Pin 

24 Breather 

25 Cheese head screw 

26 Cover 

27 Cover 

28 O - ring 

29 Plate 

30 Centering ring 

Axles 


Axles 

6.8 Semiaxles 



1 Axle housing 

2 Screw 

3 Breather 

4 Plug 

5 O-ring 

6 Ring 


8 Wheel bolt 

9 Spherical collar nut 

10 Bearing 

11 Circlip 

12 Ring gear 

13 Internal-geared wheel support 

14 Tab washer 

15 Circlip 

16 Pin 

17 Planetary gear 

18 Needle cage 


20 Screw 

21 Planetary housing 


23 Nut 

24 Stud 

25 Ring 

26 Wheel hub 

27 Axle shaft 

28 Axle housing 


Axles 


Axles 

6.9 Wheel hub 

2 

16 

5 


15 

10 

11 

3 

6 8 9 1 

7 

12 

4 

14 

13


1 Ring 


3 Wheel bolt 

4 Plug 

5 Bearing 

6 Circlip 

7 Ring gear 

8 Internal-geared wheel support 

9 Tab washer 

10 Circlip 


12 Planetary housing 


14 Hexagon nut 

15 Ring 

16 Wheel hub 

Axles 


Axles 

6.10 Front axle brake (up to AB) 

Hydraulic differential lock 

with brake lever 


6.11 Brake diagram 

2 

1 

6 

5 

15 

3 

14 

7 9 19 

16 

18 13 11 

Axles 


Axles 


1 Brake disc 

2 Counterdisc 

3 Intermediate bushing 

4 Ball 

5 Spacer ring 

6 Shim ring 

7 Counterdisc 

8 Clamping sleeve 

9 Piston 

10 O-ring 

11 Antiextrusion ring 

12 O-ring 


14 Circlip 

15 Tension spring 


17 O-ring 


19 Piston 



22 O-ring 

23 Bearing 

24 Brake lever 

25 Spacer ring 

26 Nut 

27 Piston 

28 O-ring 

29 Screw 


31 Lever 




35 O-ring 

36 O-ring 

37 Screw 


39 Plug 

40 Bleed screw 

41 Stud bolt 

42 Plug 

43 O-ring 


Differential discs 

Differential carrier 

Semiaxle 

Brake discs Axle housing 

Spring 

Spring 

Axles 

The service brake is actuated hydraulically by applying pressure through feed hole A (max. 

pressure 80 bar/1160 psi). 

The brake piston acts both on the differential discs and on the the brake discs. The 

differential is locked with a slight shift by means of the preloaded elastic intermediate part, 

with regard to the closure of the disc play of the brake system. This creates a brake effect 

between the differential housing (which forms a unit with the stub shafts that are already 

locked) and the axle body. This system of locking the differential lock ensures an even 

distribution of the braking effect on both stub shafts. 


Axles 

6.12 Front axle brake (starting AC up to AD) 


6.13 Front axle brake (from AE310242D) 

Axles 


Axles 

Pos. Description (starting AC up to AD) 

1 Brake disc 

2 Counterdisc 


4 Ball 

5 Spacer ring 

6 Shim ring 

7 Counterdisc 


9 Piston 

10 O-ring 


12 O-ring 


14 Circlip 



17 O-ring 


19 Piston 



22 O-ring 

23 Bearing 

24 Brake lever 

25 O-ring 

26 Nut 

27 Stud bolt 

28 Bleed screw 

29 Screw 

30 Plug 

31 Lever 




35 O-ring 

36 O-ring 

37 Screw 


Pos. Description (from AE310242D) 


2 Shim 

3 Lever 



6 Thread bolt 

7 Nut 

8 O-ring 

9 O-ring 

10 Plug 

11 Drain screw 

12 Lever left 

13 Lever right 

14 Pin 

15 Sleeve 

16 Pressure plate 

17 Screw 

18 Spring 

19 Screw 

20 Spring 

21 O-ring 

22 Ring 

23 O-ring 

24 O-ring 

25 Ring 


27 Friction plate 

28 Friction plate 


6.14 Differential (up to AB) 

Spring 

Differential discs 

Semiaxle 

Differential 

Axles 


Differential housing 

Spring 

Brake discs Axle housing

Axles 

The 100 % differential lock is actuated hydraulically by supplying a continous pressure (15 

bar/218 psi min. – 25 bar/363 psi max.) via feed hole B. Compacting the clutch discs with 

the center piston locks the differential, and the differential housing forms one unit with one 

of the stub shafts. The differential is fully locked. 

As soon as the pressure is released, the stroke of the planetary carrier removes the clutch 

discs and the lock is disabled. 

Unless locked hydraulically, the differential is preloaded under normal circumstances. This 

improves traction considerably in extreme off-road conditions. 


Front axle (up to AB) 

Axles 


Axles 


1 Nut 

2 Flange 


4 Bearing 

5 Spacer ring 

6 O-ring 


8 Spacer ring 


10 Shim ring 

11 Crown wheel pair 

12 Screw 

13 Shim ring 

14 Taper roller bearing 

15 Differential housing 


17 Compensating shaft gear 

18 Bevel gear 


20 Pin 

21 Pin 

22 Pin 

23 Cross piece 


25 Ball 

26 Ring 

27 Circlip 

28 Clutch disc 

29 Ring 

30 Bearing 

31 Circlip 

32 Bearing 



35 Bearing 


37 Circlip 

38 Shim ring 

39 Circlip 


Front axle (starting AC up to AD) 

Axles 


Axles 

Front axle (from AE310242D) 


Pos. Description (starting AC up to AD) 

1 Nut 

2 Flange 

3 Bearing 


5 Spacer ring 

6 Shim ring 


8 Spacer ring 

9 Crown wheel pair 

10 Screw 

11 Shim ring 





16 Bevel gear 


18 Pin 

19 Pin 

20 Pin 






26 Bearing 

27 Circlip 

28 Bearing 

29 Shim ring 

30 Circlip 

31 O-ring 


Pos. Description (from AE310242D) 

1 Screw 

2 Washer 

3 O-ring 

4 Flange 

5 Protection plate 

6 Seal ring 

7 Bearing 

8 Shim 


10 Shaft nut 

11 Bevel gear pair 

12 Lock plate 

13 Hex screw 


15 Screw 

16 Differential axle 

Axles 


Axles 

Rear axle 



1 Shim ring 


3 Screw 





8 Bevel gear 

9 Pin 

10 Pin 

11 Pin 


13 Cover 


15 Bevel gear and crown wheel pair 

Axles 


Axles 

6.15 Cardan shaft 

Screws A are tightened to a torque of 38 Nm (28 lbf ft). 


18

Brakes

7 Brakes 

7.1 Brake circuit (up to AB) 

Master brake cylinder 

Brakes 

Hydrostatic automotive travelling drive, service brake effect on front axle via master brake 

cylinder. 


Front axle 

Inching valve 

Variable displacement 

pump

Brakes 

7.2 Brake circuit (starting AC) 

Parking brake 



1 Parking brake lever 



4 Hexagon nut 

5 Fork joint 

6 Hexagon nut 

7 Traction bar 


9 Hexagon nut 

10 Joint 

11 Bush 

12 Washer 


14 Bellows 

15 Bowden cable 

16 Microswitch 


18 Spring lock washer 

19 Washer 

20 Parking brake switch plate 

21 Bowden cable bracket 


23 Nord-Lock washer 

24 Fork joint 




28 Washer 

29 Compression spring 


Brakes 


Brakes 


Swivel skip 

Front skip 

Master brake cylinder 

Front axle 


Inching valve 

Variable displacement 

pump

Steering system

8 Steering system 

8.1 Steering circuit (up to AB) 

Steering unit 

Spool 



Leak oil line 

Steering ram 

Gear pump


8.2 Steering circuit (starting AC) 

Steering unit 

T 

CF 

L 

P 


Steering ram 


Manual spool

8.3 Steering unit: diagram 

5 

P 

4 

1 


1 Pilot valve for load signal 

2 Shock valves 

3 Steering ram anticavitation valves 

4 Non-return valve 

5 Priority valve 


Function Both shock valves 2 protect the L and R connections to the steering ram. The oil is 

directed to the other side via the anticavitation valve 3 as soon as one of the shock valves 

responds. These anticavitation valves 3 also allow for resuction of leak oil from the tank. 

The steering unit runs as a manual pump in the case of a defective pump. The oil is 

reaspirated from the leak oil line via the anticavitation valve. In doing so, non-return valve 4 

avoids air being aspirated via pump port P. In normal operation, this same valve prevents 

high external steering forces from affecting the steering wheel (shocks). 

Using a priority valve is necessary given the fact that the steering system and the work 

hydraulics are supplied with oil by the same pump. This valve ensures the steering unit is 

supplied with oil first. In the process, the valve is controlled by the load signal of the 

steering unit. The entire oil volume of the pump is available for the work hydraulics if no 

steering movements are carried out. 


3 

3 

2


8.4 Steering unit connections 

Port 

P Pump line 

T Leak oil line 

EF Control valve pressure line 

L Steering ram bottom side 

R/CF Steering ram rod side 


8.5 Steering unit overview 

Priority valve overview 

Priority valve (legend) 



1 Plug 50 ± 10 Nm/37 ± 7.4 lbf ft 

2 Spring 7 bar/102 psi 

3 O-ring 

4 Nozzle diameter 1 mm/0.04" 

5 Housing 

6 Piston 

7 Nozzle diameter 0.8 mm/0.03" 

8 Plug with O-ring 50 ± 10 Nm/37 ± 7.4 lbf ft 

9 Type label 

10 Type label rivets 

11 Fastening screws 65 ± 5 Nm/48 ± 3.7 lbf ft 

12 O-ring 



Steering unit 

1 

2 

3 

4 

11 

12 

5 

10 

6 

7 

13 

14 

8 

9 

18 

17 


15 

19 

20 

16 

21 

26 

22 

23 

24 

25

Steering unit (legend) 



1 Shock valve 200 – 220 bar/2901 – 3191 psi 

2 Valve housing 

3 Shock valve 200 – 220 bar/2901 – 3191 psi 

4 Dust seal 

5 Pilot valve 140 – 145 bar/2031 – 2103 psi 

6 Housing for pilot valve 

7 Plug 


9 Threaded bushing 

10 O-ring 


12 Bushing with pin 

13 Bearing 

14 Ring 

15 Piston housing 

16 Set of springs 

17 Safety pin 

18 Cardan shaft 

19 O-ring 

20 Distributor plate 

21 Gear set 

22 O-ring 

23 Terminal plate 

24 Washer 

25 Screw with pin 30 ± 6 Nm/22 ± 4.4 lbf ft 

26 Screw 30 ± 6 Nm/22 ± 4.4 lbf ft 




Hydraulic system


9 Hydraulic system 

9.1 Manual spool connections: overview 

8 

7 

6 

1 

8 

B 3 

T1 


1 Port: swivel to the left 

2 Tilt ram bottom side connection 

3 Tilt ram rod side connection 

4 Supplied via steering unit 

5 Primary pressure limiting valve 175 bar/2538 psi 

6 Tank line 

7 Port: swivel to the right 

8 Secondary pressure limiting valves (swivel) 160 bar/2321 psi 



5 

3 

4 

2


9.2 Valves – differential lock (up to AB) 

Check valve As soon as the differential lock is actuated, the boost pressure of 30 bar (435 psi) closes 

the disc package of the axle. Upon releasing the differential lock, the disc package opens 

again and the hydraulic oil returns to the hydraulic oil tank. 

2 

3 

1 


1 Hydraulic pump port 

2 Axle port 

3 Hydraulic oil tank port 

Important! 

There is no more differential lock starting series AC! 


9.3 Dumping the skip: hydraulic diagram (up to AB) 

Diesel engine 

1 


1 Manual spool 

2 Steering valve 


Steering ram 


2 

Right Left 

Tilt ram


9.4 Dumping the skip: hydraulic diagram (starting AC) 

Diesel 

engine 

Right Left 

Steering ram 

Tilt ram 


9.5 Swivelling the skip: hydraulics diagram (up to AB) 

Diesel engine 

1 



2 Steering valve 


Steering ram 

Offset ram 


2 

Right Left


9.6 Swivelling the skip: hydraulics diagram (starting AC) 

Diesel 

engine 

Right Left 

Steering ram 

Offset ram 


9.7 Test instructions 

Check: work hydraulics 

B 

A 

Fig. 1: Control lever valves 


1 x pressure gauge 200 bar (2901 psi) 

Work hydraulics measuring point 

Check the work hydraulics pressure as follows: 

☞Move the drive lever to neutral 

☞Apply the parking brake 

☞Connect the 200 bar (2901 psi) pressure gauge to the test port 


☞Raise the skip with the control lever 

➥Pressure at 2000 rpm: about 175 bar (2538 psi) 

➥The pressure can be set with service pressure valve A 


☞Swivel the skip with the control lever as far as it will go, then swivel it to the other side 

➥Pressure at 1000 rpm: about 160 bar (2321 psi) 

➥The pressure can be set with secondary valves B 

☞Turn the steering wheel as far as it will go 

➥Pressure must be about 150 bar (2176 psi) 

Important! 

The pressure of the steering system cannot be adjusted 



9.8 Diagram A4 (up to AB) 

8 

9 

6 

14 

11 

10 

5 

16 

12 


19 

4 

1 

2 

3 

15 

7 

17 

18 

13

9.9 Diagram legend (up to AB) 


1 Diesel engine 

2 Hydraulic pump 

3 Flush valve 

4 Hydraulic motor 



7 Vent filter 

8 Hydrostatic steering 

9 Priority valve (steering system) 


11 Offset ram 

12 Tilt ram 

13 Radiator 


15 Combined filter 

16 Non-return valve 1 bar/14.5 psi 

17 Rear axle 

18 Front axle 

19 Differential lock 




9.10 Diagram A4 (starting AC) 

8 

6 

11 

10 

14 

9 

5 

16 

12 


1 

3 

2 

4 

15 

17 

18 

7 

13

9.11 Diagram legend (starting AC) 




3 Flush valve 




7 Vent filter 


9 Road travel lights option 


11 Offset ram 

12 Tilt ram 

13 Radiator 



16 Non-return valve 2 bar/29 psi 

17 Rear axle 

18 Front axle 





Hydraulics diagram A3 (up to AB) 

7 

2 


16 

9 

5 

1 

8 

15 

14 

13 

6 

19 

3 

18 





3 Flush valve 

4 Work pump 



7 Vent filter 


9 Priority valve (steering system) 


11 Tilt ram 

12 Offset ram 

13 Radiator 




17 Rear axle 

18 Front axle 

19 Differential lock 


10 

17 

11 

4 

12


Hydraulics diagram A3 (starting AC) 

7 

16 

1 

2 

5 

8 

15 

14 

13 

3 

6 




3 Flush valve 




7 Vent filter 


9 Road travel lights option 


11 Offset ram 

12 Tilt ram 

13 Radiator 




17 Rear axle 

18 Front axle 


18 

9 

17 

10 

11 

4 

12

Electric system


10 Electric system 

10.1 Ohm's Law (current, voltage, resistance); power 

It describes the interrelation between current, voltage and resistance. 

Current “I” – Ampere (A) 

Voltage “U” – Volt (V) 

Resistance “R” – Ohm (Ω) 

Mnemonic: 

Output 

Power “P” – Watt (W) 

U 

R I 

P = U x I = R x I² = U²/R 

10.2 Measuring equipment, measuring methods 


Multifunction measuring device 

Measurements of values (U, R, I, f) 

Continuity test 

Diode test 

Calculate the measuring range using known data (P, U, R, I) and set before measuring! 

Observe AC/DC basic setting. 

➥AC = alternating current/voltage; 

➥DC = direct current/voltage 

Test device with acoustic and optical signal output 

Continuity test in de-energised machine electric system and of wiring harnesses 



10.3 Relays 

Measuring methods – multifunction measuring device 

Measuring current (ignition switched on): 

Black cable in COM socket (earth), 

red cable in A socket or mA socket; connect in series to consumer. 

Measuring voltage (ignition switched on): 


red cable in V socket; 

connect in parallel to consumer. 

Measuring resistance (ignition switched off): 


red cable in Ω socket; 

connect in parallel to consumer (see measuring voltage). 

Test lamp 

The test lamp is used to test lines and functions with the ignition switched on. 

Line test (testing voltage): 

Connect test lamp between test point (live cable) and machine earth or between test point 

(earth line) and a live cable. 

Functional check (testing current): 

Connect test lamp between a connection on the consumer to be tested and the connection 

line. 

Use, mode of function Relays are used for switching electric loads (high currents) whereby the control power of 

the relay coil is relatively low. Relays can therefore be controlled by microelectronics or 

microswitches (e.g. touchpad keyboards, sensors). The switch contacts can be makecontact, 

break-contact or changeover switches. These undertake the actual switching 

function. 

86 30 

85 87 87a 

Fig. 1: Terminal description on relay 

Zero-centre relay 

86 = Start of coil (control line) 

85 = End of coil (earth) 

30 = Input (load line) 

87 = Make-contact switch output (load line) 

87 a= Break-contact switch output (load line) 


10.4 Electric units 

Fuse box 

Fig. 2: Fuse box 

Relays 

K 34 

K 33 

K 32 

F1 

F2 

Fig. 3: Relays 

V2 

K9 

K 10 

F10 

F9 

F8 

F7 

F6 

F5 

F4 

F3 

K6 


Alternator 12 V 40 A 

Starter 12 V 1.7 kW (2.3 hp) 

Battery 12 V 88 Ah 


Fuse number 

Rated current 

(A) 


F 3 10 A – Cutoff solenoid, cutoff solenoid time lag relay 

F 4 15 A – Drive solenoid valves 

F 5 10 A – Horn, brake lights 

F 6 15 A – Turn indicators 

F 7 15 A – High beam 

F 8 10 A – Low beam 

F 9 10 A – Clearance light 

F 10 10 A – Hazard warning system 

The relays are located in the relay box under the the floor panel of the control stand 

K7 Switching relay no. Protected circuit 

K8 

F1, F2 – Main fuses 

K 6 – Preheating time lag relay 

K7 – Start high current relay 

K 8 – Cutoff solenoid time lag relay 

K 9 – Cutoff solenoid switching relay 

K 10 – Turn indicator relay 

K32 – Start interlock relay 

K33 – Low beam relay 

K34 – High beam relay 

V2 – Diodes 



10.5 Control stand overview 

13 

13 

12 

4 

9 

6 

7 

11 

5 

10 


13 


1 Accelerator pedal 


3 Parking brake 

4 Lever – backrest adjustment 

5 Forwards-reverse control 

6 Turn indicator lever – horn 

7 Round display element 

8 Lever for horizontal seat adjustment 

9 Skip control lever 

10 Light switch 


12 Footrest 

13 Handle 

2 

1 

8 

3 

13 

Rollbar not included in this figure for a 

clearer graphic representation.

18 

17 

19 

16 

20 

22 

21 23 

10.6 Instrument panel overview 



24 

15 

28 

25 


14 Hazard warning switch 

15 Preheating start switch 

16 Hour meter 


18 High beam telltale (blue) 

19 Preheating telltale (yellow) 

20 Telltale (red) – hydraulic oil filter 


22 Telltale (red) – alternator charge function 

23 Parking brake telltale (red) 

24 Telltale (red) – engine oil pressure 

25 Telltale (red) – coolant temperature 

26 Turn indicator telltale (green) 


28 Fuel level indicator 


27 

26 

14 

29




Wiring diagram: overview

10.7 Wiring diagram (legend) 


No. Description Section No. Description Section 

B1 Fuel-level sensor F10 H20 Brake lights F6 

B2 Horn C6 H22 Machine turn indicator telltale B1 

B14 Warning buzzer B13 H24 Turn indicators (right) F7 

D1 Diode box B9 H26 Turn indicators (left) F7 

E1 Parking light F8 H30 Reversing light F8 

E5 Low beam F7 H35 Fuel telltale A1 

E6 High beam F7 K6 Preheating time lag relay C14 

F1 Main fuse D14 K7 Start high current relay D12 

F2 Main fuse D14 K7.1 Start interlock relay B12 

F3 Hazard warning system A4 K8 Pull contact time lag relay C13 

F4 Parking light E5 K9 Pull contact high current relay D13 

F5 Low beam E5 K10 Turn indicator relay E2-3 

F6 High beam E5-6 K29 1st/2nd speed relay D9 

F7 Spare A13 M1 Starter F14 

F8 Drive valves A7 M9 Fuel pump B11 

F9 Warning buzzer, relay A13-14 P1 Hour meter A1 

F10 Spare A8 P2 Fuel level indication C1 

F11 Cutoff solenoid, fuel feed pump A11 R1 Glow plug E15 

F12 Horn, brake lights A6 S1 Preheating start switch A2-3 

F13 Displays, turn indicators A5 S2 Engine oil pressure switch F12 

G1 Alternator F11 S3 Engine temperature switch F12 

G2 Battery F14-15 S5 Hydraulic oil pressure switch F11 

H1 High beam telltale B1 S8 Battery master switch F14 

H2 Preheating telltale B1 S9 Brake light switch C7 

H3 Engine temperature telltale B1 S10 Hydraulic parking brake switch B6 

H4 Engine oil pressure telltale B1 S11 Parking brake switch B7 

H5 Alternator charge function telltale B1 S12 Right-hand side steering-column control lever D1 

H6 Air filter telltale B1 S13 Left-hand side steering-column control lever F0-1 

H7 Hydraulic oil filter telltale B1 S19 Hazard warning switch E1 

H8 Hydraulic oil temperature telltale C1 Y1 Cutoff solenoid F13 

H16 Low-speed telltale C1 Y4 Reverse driving solenoid valve F9-10 

H18 Parking brake telltale A1 Y5 Forwards driving solenoid valve F9 



10.8 Wiring diagram version 1 A4 


10.9 Wiring harness 1000115009 main wiring harness up to AB (legend) 


No. From Up to Description Colour mm 2 No. From Up to Description Colour mm 2 

1 X1 F7 wht/blk 1 33 M9 GND Earth blk 1 

2 X1 K7 Starting motor 50 wht 2.5 33A M9 S10 Earth blk 1 

3 X1 GND Earth blk 2.5 34 S1 K7.1 Start wht 1 

5 X1 K9 Cutoff solenoid pick-up contact wht/red 2.5 34A K6 K7.1 Start wht 1 

6 X1 F11 Holding contact cutoff solenoid blu/blk 1.5 35 S1 F9 +12 V/15 blu 2.5 

7 X2 D1 Forwards driving brn/wht 1 35A S1 X7/1 +12 V/15 blu 2.5 

7A X2 X7/2 Forwards driving brn/wht 1 36 S1 F13 +12 V/15 blu 2.5 

8 X2 X8 Reverse driving gry/blk 1 37 X6 S11 Parking brake yel/red 1 

8A X2 X7/2 Reverse driving gry/blk 1 37A X6 S10 Parking brake yel/red 1 

8B D1 X8 Reverse driving gry/blk 1 38 X6 K6 Preheating telltale brn/blk 1 

9 X2 K29 Fast driving vio/grn 1 39 X6 D1 Charge telltale pkn/yel 1 

10 X2 X6 Empty tank pkn/wht 1 40 X8 F6 High beam grn 1 

11 X2 X6 Fuel level indicator vio 1 41 X7/1 F6 High beam grn 1 

12 X2 D1 Fouled hydraulic oil filter org/wht 1 42 X7/1 X6 High beam telltale grn 1 

12A X2 X6 Fouled hydraulic oil filter org/wht 1 43 X6 K10 Turn indicator telltale ltblu/grn 1 

13 X2 D1 Engine temperature grn/blk 1 44 X6 X7/2 Low-speed telltale vio/wht/vio 1 

13A X2 X6 Engine temperature grn/blk 1 44A X6 K29 Slow driving vio/wht/vio 1 

14 X2 D1 Charge telltale pkn 1 45 X7/1 F5 Low beam gry/blk 1 

15 X2 F11 Alternator excitation ltblu/red 1 46 X8 F5 Low beam gry 1 

15A X2 M9 Feed pump ltblu/red 1 32A X7/1 B2 Horn org 1 

16 X2 X6 Engine oil pressure wht 1 33 X8 F4 Parking light yel/blk 1 

17 X2 D1 Hydraulic oil temperature wht/blk/wht 1 47 X7/1 B2 Horn org 1 

17A X2 X6 Hydraulic oil temperature wht/blk/wht 1 48 X8 F4 Parking light yel/blk 1 

18 X2 D1 Dirty air filter gry/blk/gry 1 49 X7/2 S11 +12 V drive gry/blk 1 

18A X2 X6 Dirty air filter gry/blk/gry 1 50 S11 K29 +12 V drive org/blu 1 

19 X3 F1 +12 V/30 red 6 51 F8 K29 +12 V drive org/blu 1 

20 X3 F2 +12 V/30 red 6 51A F8 X7/2 +12 V drive org/blu 1 

21 X3 S1 Preheating system brn 4 52 X8 S9 Brake lights red 1 

21A S1 S1 Preheating system brn 2.5 53 F12 B2 +12 V horn, brake lights org/blk 1 

21B X3 K6 Preheating system brn 1 54 B2 S9 +12 V horn, brake lights org/blk 1 

22 X2 K7 Revs signal blu/blk 1 55 X8 GND Earth blk 1.5 

23 X7/1 X6 Parking light yel/blk 1 56 K29 GND Earth blk 1 

23A X7/1 F4 Parking light yel/blk 1 56A K29 K7 Earth blk 1 

24 X7/1 GND Earth blk 1 57 S11 GND Earth blk 1 

24A X7/1 X6 Earth blk 1 58 K8 GND Earth blk 1 

24B X6 X6 Earth blk 1 58A K8 K6 Earth blk 1 

25 S19 F13 +12 V/15 turn indicators/displays blu/red 1 59 B14 F9 +12 V relay ltblu/blk 1 

25A S19 X6 +12 V/15 turn indicators/displays blu/red 1 59A B14 K8 +12 V relay ltblu/blk 1 



No. From Up to Description Colour mm 

26 S19 X8 Right-hand side turn indicators ltblu 1 59B K7 K8 +12 V relay ltblu/blk 1 

26A S19 X7/1 Right-hand side turn indicators ltblu 1 60 K8 K9 Cutoff solenoid timer yel 1 

27 S19 X8 Left-hand side turn indicators blu 1 61 K8 K9 Cutoff solenoid timer wht/red 1 

27A S19 X7/1 Left-hand side turn indicators blu 1 62 K7 K7.1 Start wht/grn 1 

28 S19 K10 Turn indicators blu/blk 1 64 D1 B14 Warning buzzer gry/yel 1 

28A S19 X7/1 Turn indicators blu/blk 1 65 D1 K7.1 Start interlock pkn/yel 1 

29 S19 K10 Turn indicators +12 V blu/yel 1 66 D1 K7.1 Start interlock brn/grn 1 

30 S19 F3 +12 V/30 turn indicators red/yel 1 67 F9 F8 +12 V/15 blu 2.5 

31 S1 F1 +12 V/30 red 6 68 F7 F8 +12 V/15 blu 2.5 

31A F3 F1 +12 V/30 red 2.5 69 F7 F11 +12 V/15 blu 2.5 

31B F3 F10 +12 V/30 red 2.5 70 F12 F11 +12 V/15 blu 2.5 

32 K9 F2 +12 V/30 red 4 71 F12 F11 +12 V/15 blu 2.5 

32A K7 F2 +12 V/30 red 4 

2 No. From Up to Description Colour mm 2 


10.10 Wiring harness 1000115009 main wiring harness up to AB 

Warning buzzer 



Fuses


10.11 Wiring harness 1000173558 main wiring harness starting AC (legend) 


1 G1.1 M1.1 12 V/30 red 10 57 X10.2 X7/1.4 Position lights yel/blk 1 

2 M1.1 F1 12 V/30 red 4 58 X8.1 F9.7 Position lights yel/blk 1 

3 M1.1 F1 12 V/30 red 4 66 X7/1.2 K33.86 Low beam yel 1 

4 G1.1 F2 12 V/30 red 4 67 X10.11 X7/1.9 High beam telltale grn 1 

5 G1.1 F2 12 V/30 red 4 68 X7/1.9 K34.86 High beam grn 1 

6 S1.1 F1.2 12 V/30 red 6 69 F8.6 K33.30 Low beam yel/red 1 

7 F10 H F1.2 12 V/30 red 4 70 X8.3 K33.87 Low beam yel/red 1 

8 F2.2 K9.30 12 V/30 red 4 72 F7.5 K34.30 High beam grn/red 1 

9 K7 A F2.2 12 V/30 red 4 73 X8.2 K34.87 High beam grn/red 1 

10 S1.5 F4.2 12 V/15 blu 4 75 S19.3 F10.8 Turn indicators 12 V/30 red 1 

11 S1.6 F7.5 12 V/15 blu 4 76 S19.1 F6.4 Turn indicators 12 V/15 blu 1 

12 K7 B M1 Starter wht/red 2.5 77 S19.4 K10+ Turn indicators + blu/wht 1 

13 Y1.1 K9.87 Cutoff solenoid pick-up contact wht 4 78 X7/1.5 S19.5 Turn indicators COM blu/yel 1 

14 S1.3 R1 Preheating brn 4 79 S19.5 K10 C Turn indicators COM blu/yel 1 

15 S1.4 S1.8 Preheating brn 4 80 X10.15 K10 P Turn indicator telltale gry/red 1 

16 S1.9 K6 Preheating brn 1 81 X7/1.1 S19.7 Right-hand side turn indicators gry/grn 1 

17 X10.1 F3.1 12 V/15 indicating instrument/relays blu 1 82 S19.7 X8.8 Right-hand side turn indicators gry/grn 1 

20 F3.1 V1 Cutoff solenoid/fuel feed pump blu/red 1 86 X7/1.6 S19.6 Left-hand side turn indicators gry/yel 1 

21 M9 V1 Fuel pump blu/red 1 87 S19.6 X8.7 Left-hand side turn indicators gry/yel 1 

22 Y1.2 M9 Holding contact cutoff solenoid blu/red 1 91 S9 F5.3 12 V brakes/horn org/blk 1 

23 F3.1 K8 Cutoff solenoid timer blu/red 1 92 B2 S9 12 V brakes/horn org/blk 1 

24 K7.1 K8 12 V/15 starting relay blu/red 1 96 Y2.1 S21.5 High speed brn/blk 1 

25 G1.2 2 F3.1 12 V/15 indicating instrument/relays blu 1 97 X8.6 S9 Brake lights red/blk 1 

26 K8 K9.86 Cutoff solenoid relay blu/blk 1 99 K7.5 S11 Parking brake telltale red/wht 1 

27 K8 K9.85 Cutoff solenoid relay pnk/blk 1 100 X10.9 S11 Parking brake telltale red/wht 1 

28 B14.5 G1.2 1 Charge telltale pnk 1 101 X10.12 K6 Preheating telltale gry/red 1 

29 X10.8 B14.5 Charge telltale pnk 1 102 V2.3 K32.86 Start interlock wht/red 1 

30 B14.6 S2 Engine oil pressure wht/grn 1 104 H28 F7.5 Rotating beacon vio 1 

31 X10.10 B14.1 Engine oil pressure wht/grn 1 105 B2 X7/1.7 Horn org 1 

32 B14.9 S3 Engine temperature blk/grn 1 110 K8 K6 Earth blk 1 

33 X10.14 B14.4 Engine temperature blk/grn 1 111 V1 K6 Earth blk 1 

34 X10.6 S5 Hydraulic oil filter org/wht 1 112 V1 K34.85 Earth blk 1 

35 X10.4 B1 Fuel sensor vio/blk 1 113 K33.85 K34.85 Earth blk 1 

36 K7.6 G1.2 3 Revs signal blk/blu 1 114 K33.85 K32.85 Earth blk 1 

39 S1.7 K6 Starter wht/blk 1 115 K10.31 K32.85 Earth blk 1 

40 K32.30 K6 Starter wht/blk 1 116 K10.31 GND Earth blk 1 

41 K7.3 K32.87a Starter wht/blk 1 117 Y2.2 GND Earth blk 1 


No. From Up to Description Colour mm 

42 S11 F4.2 12 V drive gry 1 118 GND S11 Earth blk 1 

43 S11 X7/2.2 12 V drive gry 1 119 X8.4 GND Earth blk 1.5 

44 S21.1 X7/2.2 12 V drive gry 1 120 B3 GND Earth blk 1 

45 S21.1 S21.9 12 V drive gry 1 121 H30 B3 Earth blk 1 

47 X7/2.4 S11 Drive gry/blu 1 124 X10.5 X7/1.8 Earth blk 1 

48 X7/2.1 V2.1 Forwards driving brn/wht 1 125 S21.10 X7/1.8 Earth blk 1 

49 Y5.1 V2.1 Forwards driving brn/wht 1 126 S21.10 GND Earth blk 1 

50 X7/2.3 X8.5 Reversing light gry/blk 1 127 GND GND2 Earth blk 2.5 

51 X7/2.3 V2.2 Reverse driving gry/blk 1 128 S5 GND2 Earth blk 1 

52 Y4.1 V2.2 Reverse driving gry/blk 1 129 Y4.2 GND2 Earth blk 1 

53 B3 V2.2 Backup warning system gry/blk 1 130 Y5.2 GND2 Earth blk 1 

54 H30 B3 Reversing light gry/blk 1 131 GND2 M9 Earth blk 1 

55 X7/1.3 S1.5 12 V/15 lights blu 1.5 132 B1 M9 Earth blk 1 

56 X7/1.4 F9 G Position lights yel/blk 1 133 GND2 Y1.3 Earth blk 1 

2 No. From Up to Description Colour mm 2 




10.12 Wiring harness 1000173558 main wiring harness starting AC 



Wiring harnesses: overview 




10.7 Wiring diagram A3 up to AB (legend) 

No. Description Section 

B1 Fuel-level sensor F10 

B2 Horn C6 

B14 Warning buzzer B13 

D1 Diode box B9 

E1 Parking light F8 

E5 Low beam F7 

E6 High beam F7 

F1 Main fuse D14 

F2 Main fuse D14 

F3 Hazard warning system A4 

F4 Parking light E5 

F5 Low beam E5 

F6 High beam E5-6 

F7 Spare A13 

F8 Drive valves A7 

F9 Warning buzzer, relay A13-14 

F10 Spare A8 

F11 Cutoff solenoid, fuel feed pump A11 

F12 Horn, brake lights A6 

F13 Displays, turn indicators A5 

G1 Alternator F11 

G2 Battery F14-15 

H1 High beam telltale B1 

H2 Preheating telltale B1 

H3 Engine temperature telltale B1 

H4 Engine oil pressure telltale B1 

H5 Alternator charge function telltale B1 

H6 Air filter telltale B1 

H7 Hydraulic oil filter telltale B1 

H8 Hydraulic oil temperature telltale C1 

H16 Low-speed telltale C1 

H18 Parking brake telltale A1 

H20 Brake lights F6 

H22 Machine turn indicator telltale B1 

H24 Turn indicators (right) F7 

H26 Turn indicators (left) F7 

H30 Reversing light F8 

H35 Fuel telltale A1 

No. Description Section 

K6 Preheating time lag relay C14 

K7 Start high current relay D12 

K7.1 Start interlock relay B12 

K8 Pull contact time lag relay C13 

K9 Pull contact high current relay D13 

K10 Turn indicator relay E2-3 

K29 1st/2nd speed relay D9 

M1 Starter F14 

M9 Fuel pump B11 

P1 Hour meter A1 

P2 Fuel level indication C1 

R1 Glow plug E15 

S1 Preheating start switch A2-3 

S2 Engine oil pressure switch F12 

S3 Engine temperature switch F12 

S5 Hydraulic oil pressure switch F11 

S8 Battery master switch F14 

S9 Brake light switch C7 

S10 Hydraulic parking brake switch B6 

S11 Parking brake switch B7 

S12 Right-hand side steering-column control lever D1 

S13 Left-hand side steering-column control lever F0-1 

S19 Hazard warning switch E1 

Y1 Cutoff solenoid F13 

Y4 Reverse driving solenoid valve F9-10 

Y5 Forwards driving solenoid valve F9 

Wiring diagram (legend) 


10.8 Wiring diagram A3 (up to AB) 




10.9 Wiring harness 1000115009 main wiring harness up to AB (legend) 

No. From Up to Description Colour mm 2 

No. From Up to Description Colour mm 2 

1 X1 F7 wht/blk 1 32A K7 F2 +12 V/30 red 4 

2 X1 K7 Starting motor 50 wht 2.5 33 M9 GND Earth blk 1 

3 X1 GND Earth blk 2.5 33A M9 S10 Earth blk 1 

5 X1 K9 Cutoff solenoid pick-up contact wht/red 2.5 34 S1 K7.1 Start wht 1 

6 X1 F11 Holding contact cutoff solenoid blu/blk 1.5 34A K6 K7.1 Start wht 1 

7 X2 D1 Forwards driving brn/wht 1 35 S1 F9 +12 V/15 blu 2.5 

7A X2 X7/2 Forwards driving brn/wht 1 35A S1 X7/1 +12 V/15 blu 2.5 

8 X2 X8 Reverse driving gry/blk 1 36 S1 F13 +12 V/15 blu 2.5 

8A X2 X7/2 Reverse driving gry/blk 1 37 X6 S11 Parking brake yel/red 1 

8B D1 X8 Reverse driving gry/blk 1 37A X6 S10 Parking brake yel/red 1 

9 X2 K29 Fast driving vio/grn 1 38 X6 K6 Preheating telltale brn/blk 1 

10 X2 X6 Empty tank pkn/wht 1 39 X6 D1 Charge telltale pkn/yel 1 

11 X2 X6 Fuel level indicator vio 1 40 X8 F6 High beam grn 1 

12 X2 D1 Fouled hydraulic oil filter org/wht 1 41 X7/1 F6 High beam grn 1 

12A X2 X6 Fouled hydraulic oil filter org/wht 1 42 X7/1 X6 High beam telltale grn 1 

13 X2 D1 Engine temperature grn/blk 1 43 X6 K10 Turn indicator telltale ltblu/grn 1 

13A X2 X6 Engine temperature grn/blk 1 44 X6 X7/2 Low-speed telltale vio/wht/vio 1 

14 X2 D1 Charge telltale pkn 1 44A X6 K29 Slow driving vio/wht/vio 1 

15 X2 F11 Alternator excitation ltblu/red 1 45 X7/1 F5 Low beam gry/blk 1 

15A X2 M9 Feed pump ltblu/red 1 46 X8 F5 Low beam gry 1 

16 X2 X6 Engine oil pressure wht 1 47 X7/1 B2 Horn org 1 

17 X2 D1 Hydraulic oil temperature wht/blk/wht 1 48 X8 F4 Parking light yel/blk 1 

17A X2 X6 Hydraulic oil temperature wht/blk/wht 1 49 X7/2 S11 +12 V drive gry/blk 1 

18 X2 D1 Dirty air filter gry/blk/gry 1 50 S11 K29 +12 V drive org/blu 1 

18A X2 X6 Dirty air filter gry/blk/gry 1 51 F8 K29 +12 V drive org/blu 1 

19 X3 F1 +12 V/30 red 6 51A F8 X7/2 +12 V drive org/blu 1 

20 X3 F2 +12 V/30 red 6 52 X8 S9 Brake lights red 1 

21 X3 S1 Preheating system brn 4 53 F12 B2 +12 V horn, brake lights org/blk 1 

21A S1 S1 Preheating system brn 2.5 54 B2 S9 +12 V horn, brake lights org/blk 1 

21B X3 K6 Preheating system brn 1 55 X8 GND Earth blk 1.5 

22 X2 K7 Revs signal blu/blk 1 56 K29 GND Earth blk 1 

23 X7/1 X6 Parking light yel/blk 1 56A K29 K7 Earth blk 1 

23A X7/1 F4 Parking light yel/blk 1 57 S11 GND Earth blk 1 

24 X7/1 GND Earth blk 1 58 K8 GND Earth blk 1 

24A X7/1 X6 Earth blk 1 58A K8 K6 Earth blk 1 

24B X6 X6 Earth blk 1 59 B14 F9 +12 V relay ltblu/blk 1 

25 S19 F13 +12 V/15 turn indicators/displays blu/red 1 59A B14 K8 +12 V relay ltblu/blk 1 

25A S19 X6 +12 V/15 turn indicators/displays blu/red 1 59B K7 K8 +12 V relay ltblu/blk 1 

26 S19 X8 Right-hand side turn indicators ltblu 1 60 K8 K9 Cutoff solenoid timer yel 1 

26A S19 X7/1 Right-hand side turn indicators ltblu 1 61 K8 K9 Cutoff solenoid timer wht/red 1 

27 S19 X8 Left-hand side turn indicators blu 1 62 K7 K7.1 Start wht/grn 1 

27A S19 X7/1 Left-hand side turn indicators blu 1 64 D1 B14 Warning buzzer gry/yel 1 

28 S19 K10 Turn indicators blu/blk 1 65 D1 K7.1 Start interlock pkn/yel 1 

28A S19 X7/1 Turn indicators blu/blk 1 66 D1 K7.1 Start interlock brn/grn 1 

29 S19 K10 Turn indicators +12 V blu/yel 1 67 F9 F8 +12 V/15 blu 2.5 

30 S19 F3 +12 V/30 turn indicators red/yel 1 68 F7 F8 +12 V/15 blu 2.5 

31 S1 F1 +12 V/30 red 6 69 F7 F11 +12 V/15 blu 2.5 

31A F3 F1 +12 V/30 red 2.5 70 F12 F11 +12 V/15 blu 2.5 

31B F3 F10 +12 V/30 red 2.5 71 F12 F11 +12 V/15 blu 2.5 

32 K9 F2 +12 V/30 red 4 


10.10 Wiring harness 1000115009 main wiring harness up to AB 

Fuses 


Warning buzzer 



10.11 Wiring harness 1000173558 main wiring harness starting AC (legend) 


1 G1.1 M1.1 12 V/30 red 10 57 X10.2 X7/1.4 Position lights yel/blk 1 

2 M1.1 F1 12 V/30 red 4 58 X8.1 F9.7 Position lights yel/blk 1 

3 M1.1 F1 12 V/30 red 4 66 X7/1.2 K33.86 Low beam yel 1 

4 G1.1 F2 12 V/30 red 4 67 X10.11 X7/1.9 High beam telltale grn 1 

5 G1.1 F2 12 V/30 red 4 68 X7/1.9 K34.86 High beam grn 1 

6 S1.1 F1.2 12 V/30 red 6 69 F8.6 K33.30 Low beam yel/red 1 

7 F10 H F1.2 12 V/30 red 4 70 X8.3 K33.87 Low beam yel/red 1 

8 F2.2 K9.30 12 V/30 red 4 72 F7.5 K34.30 High beam grn/red 1 

9 K7 A F2.2 12 V/30 red 4 73 X8.2 K34.87 High beam grn/red 1 

10 S1.5 F4.2 12 V/15 blu 4 75 S19.3 F10.8 Turn indicators 12 V/30 red 1 

11 S1.6 F7.5 12 V/15 blu 4 76 S19.1 F6.4 Turn indicators 12 V/15 blu 1 

12 K7 B M1 Starter wht/red 2.5 77 S19.4 K10+ Turn indicators + blu/wht 1 

13 Y1.1 K9.87 Cutoff solenoid pick-up contact wht 4 78 X7/1.5 S19.5 Turn indicators COM blu/yel 1 

14 S1.3 R1 Preheating brn 4 79 S19.5 K10 C Turn indicators COM blu/yel 1 

15 S1.4 S1.8 Preheating brn 4 80 X10.15 K10 P Turn indicator telltale gry/red 1 

16 S1.9 K6 Preheating brn 1 81 X7/1.1 S19.7 Right-hand side turn indicators gry/grn 1 

17 X10.1 F3.1 12 V/15 indicating instrument/relays blu 1 82 S19.7 X8.8 Right-hand side turn indicators gry/grn 1 

20 F3.1 V1 Cutoff solenoid/fuel feed pump blu/red 1 86 X7/1.6 S19.6 Left-hand side turn indicators gry/yel 1 

21 M9 V1 Fuel pump blu/red 1 87 S19.6 X8.7 Left-hand side turn indicators gry/yel 1 

22 Y1.2 M9 Holding contact cutoff solenoid blu/red 1 91 S9 F5.3 12 V brakes/horn org/blk 1 

23 F3.1 K8 Cutoff solenoid timer blu/red 1 92 B2 S9 12 V brakes/horn org/blk 1 

24 K7.1 K8 12 V/15 starting relay blu/red 1 96 Y2.1 S21.5 High speed brn/blk 1 

25 G1.2 2 F3.1 12 V/15 indicating instrument/relays blu 1 97 X8.6 S9 Brake lights red/blk 1 

26 K8 K9.86 Cutoff solenoid relay blu/blk 1 99 K7.5 S11 Parking brake telltale red/wht 1 

27 K8 K9.85 Cutoff solenoid relay pnk/blk 1 100 X10.9 S11 Parking brake telltale red/wht 1 

28 B14.5 G1.2 1 Charge telltale pnk 1 101 X10.12 K6 Preheating telltale gry/red 1 

29 X10.8 B14.5 Charge telltale pnk 1 102 V2.3 K32.86 Start interlock wht/red 1 

30 B14.6 S2 Engine oil pressure wht/grn 1 104 H28 F7.5 Rotating beacon vio 1 

31 X10.10 B14.1 Engine oil pressure wht/grn 1 105 B2 X7/1.7 Horn org 1 

32 B14.9 S3 Engine temperature blk/grn 1 110 K8 K6 Earth blk 1 

33 X10.14 B14.4 Engine temperature blk/grn 1 111 V1 K6 Earth blk 1 

34 X10.6 S5 Hydraulic oil filter org/wht 1 112 V1 K34.85 Earth blk 1 

35 X10.4 B1 Fuel sensor vio/blk 1 113 K33.85 K34.85 Earth blk 1 

36 K7.6 G1.2 3 Revs signal blk/blu 1 114 K33.85 K32.85 Earth blk 1 

39 S1.7 K6 Starter wht/blk 1 115 K10.31 K32.85 Earth blk 1 

40 K32.30 K6 Starter wht/blk 1 116 K10.31 GND Earth blk 1 

41 K7.3 K32.87a Starter wht/blk 1 117 Y2.2 GND Earth blk 1 

42 S11 F4.2 12 V drive gry 1 118 GND S11 Earth blk 1 

43 S11 X7/2.2 12 V drive gry 1 119 X8.4 GND Earth blk 1.5 

44 S21.1 X7/2.2 12 V drive gry 1 120 B3 GND Earth blk 1 

45 S21.1 S21.9 12 V drive gry 1 121 H30 B3 Earth blk 1 

47 X7/2.4 S11 Drive gry/blu 1 124 X10.5 X7/1.8 Earth blk 1 

48 X7/2.1 V2.1 Forwards driving brn/wht 1 125 S21.10 X7/1.8 Earth blk 1 

49 Y5.1 V2.1 Forwards driving brn/wht 1 126 S21.10 GND Earth blk 1 

50 X7/2.3 X8.5 Reversing light gry/blk 1 127 GND GND2 Earth blk 2.5 

51 X7/2.3 V2.2 Reverse driving gry/blk 1 128 S5 GND2 Earth blk 1 

52 Y4.1 V2.2 Reverse driving gry/blk 1 129 Y4.2 GND2 Earth blk 1 

53 B3 V2.2 Backup warning system gry/blk 1 130 Y5.2 GND2 Earth blk 1 

54 H30 B3 Reversing light gry/blk 1 131 GND2 M9 Earth blk 1 

55 X7/1.3 S1.5 12 V/15 lights blu 1.5 132 B1 M9 Earth blk 1 

56 X7/1.4 F9 G Position lights yel/blk 1 133 GND2 Y1.3 Earth blk 1 


10.12 Wiring harness 1000173558 main wiring harness starting AC 




10.13 Wiring harness 1000115414 engine wiring harness (legend) 

No. From Up to Colour mm² 

2 M1 X1 Starting motor 50 wht 2.5 

3 GND X1 Earth blk 2.5 

5 Y1 X1 Cutoff solenoid pick-up contact wht/red 2.5 

6 Y1 X1 Holding contact cutoff solenoid blu/blk 1.5 

7 Y5 X2 Forwards driving brn/wht 1 

8 Y4 X2 Reverse driving gry/blk 1 

9 Y3 X2 Fast driving vio/grn 1 

10 B1 X2 Empty tank pkn/wht 1 

11 B1 X2 Fuel level indicator vio 1 

12 S5 X2 Fouled hydraulic oil filter org/wht 1 

13 S3 X2 Engine temperature grn/blk 1 

14 G1 X2 Charge telltale pkn 1 

15 G1 X2 Alternator excitation ltblu/red 1 

16 S2 X2 Engine oil pressure wht 1 

19 M1 X3 +12 V/30 red 6 

20 M1 X3 +12 V/30 red 6 

21 R1 X3 Preheating system brn 4 

22 G1 X2 Revs signal blu/blk 1 

73 G1 M1 +12 V/30 red 2.5 

74 G1 M1 +12 V/30 red 2.5 

75 Y5 GND Earth blk 1 



79 Y1 GND Earth blk 1.5 

80 S5 GND Earth blk 1 

81 B1 GND Earth blk 1 


10.14 Wiring harness 1000115414 engine wiring harness 




10.15 Wiring harness 1000075039/1000079012 telltale/indicator base – ignition lock base up to AB (legend) 

No. From Up to Colour mm² 

10 X6 Telltales pkn/wht 320 

37 X6 Telltales yel/red 320 

12 X6 Telltales org/wht 320 

13 X6 Telltales grn/blk 320 

38 X6 Telltales brn/blk 320 

16 X6 Service hours wht 380 

11 X6 Fuel level indicator vio 380 

39 X6 Telltales pkn/yel 320 

33 X6 Telltales brn/blk 320 

40 X6 Service hours yel/blk 380 

40A X6 Fuel level indicator yel/blk 380 

25 X6 Fuel level indicator red 320 

25B X6 Telltales red 320 

41 X6 Service hours blk 380 

41B X6 Fuel level indicator blk 380 

42 X6 Telltales grn 320 

18 X6 Telltales gry/blk/gry 320 

43 X6 Telltales ltblu/grn/ltblu 320 

18 X6 Telltales wht/blk/wht 320 

44 X6 Telltales vio/wht/vio 320 

88 Service hours Service hours blk 110 

89 Service hours Telltales wht 360 

90 Fuel level indicator Fuel level indicator blk 110 

91 Fuel level indicator Telltales blk 360 

92 Telltales Telltales blk 110 

93 Telltales Telltales blk 110 

94 Telltales Telltales red 110 







33 X5 Ignition lock brn 340 

32 X5 Ignition lock red 340 

31 X5 Ignition lock red 340 

36 X5 Ignition lock blu 340 

36B X5 X4 yel 110 

35 X5 Ignition lock blu 340 

34 X5 Ignition lock wht 340 

25 X4 Hazard warning lights blu/red 340 

26 X4 Hazard warning lights ltblu 340 

27 X4 Hazard warning lights blu 340 

28 X4 Hazard warning lights blu/blk 340 

29 X4 Hazard warning lights blu/yel 340 

30 X4 Hazard warning lights red/yel 340 


10.16 Wiring harness 1000075039 telltale/indicator base (up to AB) 

Service hours 



Service hours 

Telltales 

Fuel level 

indicator 

Fuel level 

indicator


10.17 Wiring harness 1000173351 ignition lock base starting AC 


10.18 Light switch connector assignment 

1 

2 

3 

4 

Article no.: 1000099402 (= 

without connector) 

Lights 

5 

7 

1 

2 

3 

4 

5 

Driving direction 

Article no.: 1000094922 Article no.: 1000095321 



6 

7 

8 

9 

Connector article no.: 1000094922 

Pos. no. Colour Function 

1 Blue – black Forwards 

2 Red + (15) 

3 Blue Reverse 

4 White + (15) 

5 Green Fast 

7 Yellow Slow 

Connector article no.: 1000095321 

Pos. no. Colour Function 

1 Blue – black Right-hand side turn indicators 

2 Grey Low beam 

3 Brown + (15) 

4 Yellow Parking light 

5 Orange Turn indicator relay 

6 Blue Left-hand side turn indicators 

7 White Horn (earth contact) 

8 Black Earth 

9 Green High beam


10.19 Legend and STVO wiring harness (Austrian road traffic regulations) 1000166512 (starting AC) 

No. From Up to Colour mm 2 

26 X8.7 X11-1.4 blu 1 

26 B X8.7 X10.5 blu 1 

27 X8.8 X11-2.4 blu 1 

27 B X8.8 X9.5 blu 1 

50 X8.6 X11-1.1 gry/blk 1 

51 X8.3 X9.2 Grey 1 

51 A3 X8.3 X10.2 Grey 1 

52 X8.2 X9.3 grn 1 

52 A3 X8.2 X10.3 grn 1 

53 X8.1 X11-1.2 yel/blk 1 

No. From Up to Colour mm 2 

53 A3 X8.1 X9.4 yel/blk 1 

53 B X8.1 X10.4 yel/blk 1 

54 X8.5 X11-1.3 red 1 

55 X8.4 X9.6 blk 1 

55 A3 X8.4 X10.6 blk 1 

55 B X8.4 X11-1.5 blk 1 

81 X11-1.1 X11-2.1 gry/blk 1 

82 X11-1.2 X11-2.2 yel/blk 1 

83 X11-1.3 X11-2.3 red 1 

84 X11-1.5 X11-2.5 blk 1 


10.20 Extension cable (front skip) 1000166698 

Black 

yellow/black 

blue 

grey 

green 





Neuson Limited 

Crown Business Park 

Dukestown, Tredegar 

Gwent South Wales NP22 4EF 

United Kingdom 

Telephone +44 (0) 1495 723083 

Fax +44 (0) 1495 713941 

E-mail ukoffice@neuson.com 

www.neusonkramer.com 

Neuson Baumaschinen GmbH 

Haidfeldstr. 37 

A-4060 Linz/Leonding 

Telephone +43 (0) 732/90590-0 

Fax +43 (0) 732/90590-0 

E-mail: office@neuson.com 

www.neusonkramer.com

Service Manual - Wacker Neuson

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