Sie sind auf Seite 1von 216

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 1000156004

Spare parts catalogue


Up to serial no. AB27168D 1000138134
Up to serial no. AD310200 1000173900
From serial no. AE310242D 1000183393

Legend

Edition Issued

1.0 01/2005

1.1 05/2007

2.0 02/2008

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

Table of contents

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


Table of contents

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
Specific safety instructions .............................................................................. 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
Specific safety instructions .............................................................................. 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


Table of contents

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

SERV-HB 3001 EN - Edition 2.0 * Sh3001EN_0IVZ.fm I-3


Table of contents

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


Table of contents

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 (star-
ting AC) ................................................................................................................ 10-28
Extension cable (front skip) 1000166698 ............................................................ 10-29

SERV-HB 3001 EN - Edition 2.0 * Sh3001EN_0IVZ.fm I-5


Index

Index

A T
Abbreviations ........................................................................................ 1-1 Tyres ....................................................................................................3-27
F W
Fluids and lubricants ............................................................................. 3-1 Wheel change ......................................................................................3-28
I
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

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


Operation
Operation

Operation

1 Operation
1.1 Important information on this service manual
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


Operation

1.3 Designated use and exemption from liability


The machine is intended for:
transporting the usual bulk material and concrete on construction sites
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!

SERV-HB 3001 EN Edition 2.0 * 3001s110.fm 1-3


Operation

1.4 Type labels and component numbers


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
Fig. 1: Type label: location
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: ---------------
---------------
Fig. 2: Type label Other information see Specifications on page 2-1

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

Example: Yanmar 46557

Fig. 3: Diesel engine number

Hydraulic pump number


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

Fig. 4: Number of variable displacement pump

1-4 SERV-HB 3001 EN Edition 2.0 * 3001s110.fm


Operation

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

Fig. 5: Rollbar type label

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

Fig. 6: Axle type label

SERV-HB 3001 EN Edition 2.0 * 3001s110.fm 1-5


Operation

11

9
10 4

2
3
1

1.5 Description of 3001F components (overview)


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

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


Operation

25
16 21

17

19

23
15
20

18

12 24 14

22

13

1.6 Description of 3001S components (overview)


Pos. Description
12 Rear chassis
13 Front chassis
14 Swivelling console
15 Articulated joint
16 Seat
17 Control stand
18 Mudguard
19 Engine cover
20 Swivel centring
21 Skip
22 Offset ram
23 Tilt ram
24 Steering ram
25 Rollbar

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


Operation

1.7 Control stand overview

36 30
32
35
38
31

27
26 33
28
38

37 38

29

34

38

Rollbar not included in this figure for a


clearer graphic representation.

Pos. Description
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

1-8 SERV-HB 3001 EN Edition 2.0 * 3001s110.fm


Operation

47
46 48

45 49

50
44

43
51

54

42 52

53

41 40 39

1.8 Instrument panel overview


Pos. Description
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
46 Not assigned
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)
52 Not assigned
53 Fuel level indicator
54 Low speed switch (turtle)

SERV-HB 3001 EN Edition 2.0 * 3001s110.fm 1-9


Operation

1.9 Front skip maintenance prop

Danger!
Mount the red maintenance prop before you carry out maintenance work with
E 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
A Insert pin C in guide E
D
Secure pin C with spring plug B

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

B
Fig. 7: Front skip maintenance prop

1.10 Swivel skip maintenance prop

Danger!
Mount the red maintenance prop before you carry out maintenance work with
the skip raised.

C
Mount the maintenance prop as follows:
Raise the skip
B
Remove safety pin B from pin C
Lower the skip until maintenance prop A rests on swivelling console D
A D
Mount the maintenance prop back onto the skip, in the reverse order, if it is no longer
needed!

Fig. 8: Swivel skip maintenance prop

1-10 SERV-HB 3001 EN Edition 2.0 * 3001s110.fm


Operation

1.11 Rollbar

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
A 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
Fig. 9: Rollbar

1.12 Centre pivot prop

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

The centre pivot prop connects the front and rear chassis to prevent steering movements
(via the articulated joint) when crane handling the dumper.
B
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

A
Important!
Fig. 10: Centre pivot prop
Before putting the machine into operation again, mount the centre pivot prop back
onto the front chassis again by means of pin B.

SERV-HB 3001 EN Edition 2.0 * 3001s110.fm 1-11


Operation

1.13 Locking the control levers

A
Caution!
Lock the control lever for the skip during road travel!
This avoids unintentional actuation of the skip.

B Lock as follows:
Remove split pin A from bracket B
Fold bracket B to the front
Insert split pin A in bracket B
Fig. 11: Locking the control lever
Unlock in the reverse order!

1.14 Battery master switch

Important!
Do not disconnect the battery while the engine is running.
A B
Important!
C Power supply is interrupted directly after the battery, by means of a key
Before working on the electric system

Interrupting power supply:


Fig. 12: Battery master switch
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

1-12 SERV-HB 3001 EN Edition 2.0 * 3001s110.fm


Specifications
Specifications

Specifications

2 Specifications
2.1 Chassis
Sturdy steel sheet chassis, rubber-mounted engine
2.2 Engine

Model 3001
Engine
Tier 2 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 cm (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
101.5 110.5 Nm (75 82 lbf ft)
Max. torque 105 Nm (77 lbf ft) at 1000 rpm
at 1100 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)
Standard 34.3 bar (497.5 psi) 33.3 35.3 bar (483 512 psi) at
Compression Limit 27.5 1 bar (399 15 psi) 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 0.5 0.1 bar (7 1.5 psi) 0.4 0.6 bar (6 9 psi)
pump
71 C/160 F (start)
Thermostat opening temperature 69.5 72.5 C/157.1 162.5 F
85 C/185 F (fully open)
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)
Preheater (preheating time 15 sec- Glow elements (preheating time
Starting aid
onds) 10 15 seconds)
Max. inclined position (engine no 30 in all directions
longer supplied with oil):
97/68/EC Tier 2 97/68/EC Tier 3A
Exhaust values according to
EPA Tier 2 EPA Tier 4 interim

SERV-HB 3001 EN Edition 2.0 * 3001s210.fm 2-1


Specifications

Engine capacities
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

Engine tightening torques


Tightening torques Nm/lbf ft
Cylinder-head bolt 85.3 91.1/62.9 67.2 (M10x1.25)
Connecting rod bearing screw 44.1 49.0/32.5 36.1 (M9x1)
Main bearing screw 93.2 98.1/68.7 72.4 (M12x1.5)
Flywheel screw 83.3 88.2/61.4 65.1 (M10x1.25)

2.3 Travelling drive

Variable displacement pump Model 3001


Design Axial piston pump
Displacement 45 cm/rev (2.75 cu in/rev)
Flow rate 126 l/min (33 gpm)
Max. service pressure 360 bar (5221 psi)
Boost pump (integrated in variable displacement pump)
Design Gear pump
Displacement 8.4 cm (0.5 cu in)
Charging/boost pressure 25 bar (363 psi)

2.4 Brakes

Service brake/parking brake Model 3001


Design Multiple disc brakes
Location Brake discs in front axle
Hydraulic service brake,
Effect mechanical parking brake

2.5 Steering system

Steering system Model 3001


Design Hydrostatic
Steering mode Chassis articulation steering

2-2 SERV-HB 3001 EN Edition 2.0 * 3001s210.fm


Specifications

2.6 Work hydraulics

Work hydraulics Model 3001


Hydraulic pump displacement 16.2 cm/rev (1.0 cu in/rev)
Hydraulic pump flow rate 45 l/min (12 gpm)
Control valve Sections
Max. service pressure 175 bar (2538 psi)
Secondary pressure limiting for offset 160 bar (2321 psi)
ram
Hydraulic oil cooler Standard
Hydraulic tank capacity 48 l (13 gal)
Steering system 150 bar (2176 psi)

2.7 Skip

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)

2.8 Drive specifications

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

2.9 Vibration

Vibration
Effective acceleration value for the < Trigger value
upper extremities of the body *
Effective acceleration value for the < Trigger value
body *

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

SERV-HB 3001 EN Edition 2.0 * 3001s210.fm 2-3


Specifications

2.10 Electric system

Electric system
Alternator 12 V 40 A
Starter 12 V 1.7 kW (2.3 hp)
Battery 12 V 88 Ah
Fuse box

Rated current
Fuse number Protected circuit
(A)
F10
F3 10 A Cutoff solenoid, cutoff solenoid time lag relay
F9
F8 F4 15 A Drive solenoid valves
F7 F5 10 A Horn, brake lights
F6
F5
F6 15 A Turn indicators
F4 F7 15 A High beam
F3
F8 10 A Low beam
F9 10 A Clearance light
F 10 10 A Hazard warning system
Fig. 1: Fuse box

Relays

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

K7 Switching relay
Protected circuit
no.
F1, F2 Main fuses
K6 Preheating time lag relay
K7 Start high current relay
K8 Cutoff solenoid time lag relay
F1 F2
K6 K9 Cutoff solenoid switching relay
K 10 Turn indicator relay
V2 K32 Start interlock relay
K 34 K9 K33 Low beam relay
K 33 K34 High beam relay
K 32 K 10 V2 Diodes

K8

Fig. 2: Relays

2-4 SERV-HB 3001 EN Edition 2.0 * 3001s210.fm


Specifications

2.11 Tyres

Tyre pressure
Type Tyre size Front Rear Load-bearing
bar/psi bar/psi 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

2.12 Noise levels

Sound power level 3001


Sound power level (LWA) 101 dB (A)
Sound pressure level (LPA) 85 dB (A)

Important!
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.

2.13 Coolant compound table

Outside tempera- Coolant


ture Water Anticorrosion agent Antifreeze agent
% by cm/l
Up to C/F % by volume % by volume
volume (cu in/gal)
4/39 99
-10/14 79 20
10
-20/-4 65 1 34
2.6
-25/-13 59 40
-30/-22 55 44

SERV-HB 3001 EN Edition 2.0 * 3001s210.fm 2-5


Specifications

2.14 General tightening torques


Tightening torques for hydraulic screw connections (dry assembly)

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


Torque
Nominal Outer Thread Wrench size
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)


Torque
Nominal Outer Thread Wrench size
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.

2-6 SERV-HB 3001 EN Edition 2.0 * 3001s210.fm


Specifications

Screw connections with various seals for hydraulic applications (light execution)
Straight pipe fitting with thread and
screwed plug Non-return
Identification
valve with
Thread Sealing aid, outside
Elastic seal O-ring elastic seal
washer mm (")
Nm (lbf ft) Nm (lbf ft) Nm (lbf ft)
Nm (lbf ft)
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)
Torque tolerance: 10 %; countermaterial: steel/aluminium

Screw connections with various seals for hydraulic applications (heavy execution)
Straight pipe fitting with thread and
screwed plug Non-return
Identification
valve with
Thread Sealing aid, outside
Elastic seal O-ring elastic seal
washer mm (")
Nm (lbf ft) Nm (lbf ft) Nm (lbf ft)
Nm (lbf ft)
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)
Torque tolerance: 10 %; countermaterial: steel/aluminium

SERV-HB 3001 EN Edition 2.0 * 3001s210.fm 2-7


Specifications

Tightening torques for high-resistance screw connections

With coarse-pitch thread


Screws according to DIN 912, DIN Screws according to
931, DIN 933 etc. DIN 7984
Thread
8.8 10.9 12.9 8.8 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 = 0.12 and are to be used as approximate figures.

With fine-pitch thread


Screws according to DIN 912, DIN Screws according to
931, DIN 933 etc. DIN 7984
Thread
8.8 10.9 12.9 8.8 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 = 0.12 and are to be used as approximate figures.

2-8 SERV-HB 3001 EN Edition 2.0 * 3001s210.fm


Specifications

Tightening torques for Nordlock lock washers

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)
Fig. 3: Nordlock dimensions 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)

Fig. 4: Nordlock

SERV-HB 3001 EN Edition 2.0 * 3001s210.fm 2-9


Specifications

2.15 Dimensions model 3001 front skip

Fig. 5: Machine dimensions (model 3001 F)

Main data Model 3001 F


Dead weight 2450 kg (5401 lbs)
Overall height 2670 mm (8'9")
Overall height with rollbar folded down 1870 mm (6'2")
Overall height without rollbar 1870 mm (6'2")
Overall width 1785 mm (5'10")
Ground clearance 280 mm (11.0")
Wheelbase 1960 mm (6'5")
Outside turning radius 4000 mm (13'1")
Hill climbing ability 50 % theoretically
Safe authorised inclination 25 % in all drive positions

2-10 SERV-HB 3001 EN Edition 2.0 * 3001s210.fm


Specifications

2.16 Dimensions model 3001 swivel skip

Fig. 6: Machine dimensions (model 3001S)

Main data Model 3001S


Dead weight 2550 kg (5622 lbs)
Overall height 2670 mm (8'9")
Overall height with rollbar folded down 1870 mm (6'2")
Overall height without rollbar 1870 mm (6'2")
Overall width 1785 mm (5'10")
Ground clearance 290 mm (11.4")
Wheelbase 1960 mm (6'5")
Outside turning radius 3950 mm (12'11")
Hill climbing ability 50 % theoretically
Safe authorised inclination 25 % in all drive positions

SERV-HB 3001 EN Edition 2.0 * 3001s210.fm 2-11


Specifications

2-12 SERV-HB 3001 EN Edition 2.0 * 3001s210.fm


Maintenance
Maintenance

Maintenance

3 Maintenance
3.1 Fluids and lubricants

Season/tem-
Component/ application Engine/machine fluid Specification Capacities1
perature
SAE10W-40 2; API: CD, CF, CF-4, CI-4 -20 C (-4 F)
Diesel engine Engine oil ACEA: E3, E4, E5 6.7 l (1.8 gal)
+40 C (104 F)
JASO: DH-1
Q8 T 55, SAE 85W-904
About 1.3 l each
Travelling drive Gearbox oil3 Q8 T 55, SAE 80W-905 Year-round
(0.3 gal)
FINA PONTONIC GLS, SAE85W-90
Hydraulic oil HVLP466
PANOLIN HLP Synth 46
Hydraulic oil tank Year-round 48 l (12.7 gal)
Biodegradable oil7 FINA BIOHYDRAN SE 46
BP BIOHYD SE-46
Roller and friction bear-
FINA Energrease L21M Year-round As required
ings8
Grease
Open gear9 BP Energrease MP-MG2 Year-round As required
(live ring gears)
Grease nipples Multipurpose grease10 FINA Energrease L21 M Year-round As required
Battery terminals Acid-proof grease11 FINA Marson L2 Year-round As required
2-D ASTM D975 94 (USA)
1-D ASTM D975 94 (USA)
EN 590 : 96 (EU)
ISO 8217 DMX (International)
Fuel tank Diesel fuel 40 l (10.6 gal)
BS 2869 A1 (GB) Summer or win-
ter diesel
depending on
BS 2869 A2 (GB) outside temper-
atures
Soft water + antifreeze ASTM D4985
Radiator Coolant Year-round 5.36 l (1.4 gal)
Distilled water + antifreeze ASTM D4985
Refrigerating agent R134a12 Year-round ~ 950 g (2.1 lbs)
122 cm (7.45 cu in)
Air conditioning Tier 2
Compressor oil Sanden SP20 Year-round
90 cm (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 MoS 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 MoS additive
11. Standard acid-proof grease
12. According to DIN 8960

SERV-HB 3001 EN Edition 2.0 * 3001s310.fm 3-1


Maintenance

Oil grades for the diesel engine, depending on temperature

Engine oil grade Ambient temperature (C)


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

SAE 10W

SAE 20W

SAE 10W-30

API CD, CF, CF-4, SAE 10W-40


CI-4
SAE 15W-40
ACEA: E3, E4, E5

JASO: DH-1 SAE 20

SAE 30

SAE 40

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

3-2 SERV-HB 3001 EN Edition 2.0 * 3001s310.fm


Maintenance

Maintenance plan/service hours (s/h)

3.2 Maintenance plan (overview)


Work description

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

(once a day)
Every 50 s/h
of the attachment manufacturer as well.

Every 250 s/h


Every 500 s/h
After 1500 s/h

Maintenance work

SERV-HB 3001 EN Edition 2.0 * 3001s311.fm


Fluid and filter changes ( ): Once a year or after 1000 s/h
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
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

3-3
3-4
Maintenance plan/service hours (s/h)

3.2 Maintenance plan (overview)


Work description
Maintenance

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

Every 50 s/h

(once a day)
of the attachment manufacturer as well.

Every 250 s/h


Every 500 s/h
After 1500 s/h

Maintenance work
Once a year or after 1000 s/h
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

SERV-HB 3001 EN Edition 2.0 * 3001s311.fm


Maintenance plan/service hours (s/h)

3.2 Maintenance plan (overview)


Work description

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

(once a day)
Every 50 s/h
of the attachment manufacturer as well.

Every 250 s/h


Every 500 s/h
After 1500 s/h

Maintenance work

SERV-HB 3001 EN Edition 2.0 * 3001s311.fm


Once a year or after 1000 s/h
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

3-5
Maintenance

Maintenance

3.3 Service package


Up to serial no.
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

From serial no. AE310242D


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
3.4 Introduction
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).

3-6 SERV-HB 3001 EN Edition 2.0 * 3001s312.fm


Maintenance

3.5 Fuel system


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

Refuelling
Filler inlet A for the fuel tank is located under the engine cover, on the right in driving
A 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
Fig. 1: Fuel filler inlet 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.

SERV-HB 3001 EN Edition 2.0 * 3001s312.fm 3-7


Maintenance

Stationary fuel pumps General


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
If refuelling from barrels cannot be avoided, note the following points (see fig. 2):
wrong 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
right Keep all refuelling containers clean at all times

Fig. 2: Refuelling from a barrel

Diesel fuel specification Use only high-grade fuels

Cetane
Grade Use
number
No. 2-D
according to For normal outside temperatures
DIN 51601
Min. 45
No. 1-D
according to For outside temperatures below 4 C (39F) or for
operation above 1500 m (4921') altitude
DIN 51601

Bleeding the fuel system


Danger!
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

3-8 SERV-HB 3001 EN Edition 2.0 * 3001s312.fm


Maintenance

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
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

Fuel prefilter with water separator


Check the fuel prefilter as follows:
On If the red indicator ring D in sight glass E rises
Off Remove and clean the housing (sight glass)
A Remove and clean filter insert B
Mount filter insert
Mount the housing (sight glass) with the maintenance display (red ring) and spring D
B
Open stop cock A

Interrupt fuel supply as follows:


Turn ball-type cock A to the OFF mark
C Fuel supply is interrupted
Turn ball-type cock A to the ON mark
Fuel supply is open again
D

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.

Fig. 3: Fuel prefilter

SERV-HB 3001 EN Edition 2.0 * 3001s312.fm 3-9


Maintenance

Replacing the fuel filter


Danger!
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 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
environmentally friendly manner!

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
A Open the stop cock on the water separator again
Bleed the fuel system
see Bleeding the fuel system on page 3-8
Fig. 4: Fuel filter
Make a test run and check for tightness!
Dispose of the old fuel filter cartridge by an ecologically safe method

3-10 SERV-HB 3001 EN Edition 2.0 * 3001s312.fm


Maintenance

3.6 Engine lubrication system

Caution!
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

Checking the oil level


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.

Checking the oil level


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
A Wipe it with a lint-free cloth
max
min
Push it back in as far as possible
Withdraw it and read off the oil level
Fig. 5: Checking the oil level However if necessary, fill up oil at the latest when the oil reaches the MIN mark on the
oil dipstick A

SERV-HB 3001 EN Edition 2.0 * 3001s312.fm 3-11


Maintenance

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
environmentally friendly manner!

Proceed as follows:
B OIL
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
Fig. 6: Filling up engine oil
Completely remove all oil spills from the engine

3-12 SERV-HB 3001 EN Edition 2.0 * 3001s312.fm


Maintenance

Changing engine oil

Danger!
Caution when draining hot engine oil
Danger of burns!
+ 80 C
+176 F Wear protective gloves
Use suitable tools

OIL
Fig. 7: Optimum engine oil temperature
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in an
environmentally friendly manner!

Change the engine oil as follows:


Park the machine on level ground
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
Checking the oil level
Completely remove all oil spills from the engine
Start the engine and let it run briefly at low revs
Switch off the engine
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

SERV-HB 3001 EN Edition 2.0 * 3001s312.fm 3-13


Maintenance

Replacing the engine oil filter cartridge

Danger!
Caution when draining hot engine oil
Danger of burns!
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:


Switch off the engine
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
A 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

Fig. 8: Unscrewing the engine oil filter

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

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

Tighten oil filter cartridge A with a commercially available tool by about a further 3/4
of a revolution
A Make sure the oil level is correct!
Completely remove all oil spills from the engine
Let the engine run briefly
Switch off the engine
Check the seal of oil filter cartridge A and retighten by hand
Check the oil level and fill in engine oil if necessary
Fig. 10: Tightening the filter cartridge
Dispose of the used oil filter in an environmentally friendly manner

3-14 SERV-HB 3001 EN Edition 2.0 * 3001s312.fm


Maintenance

3.7 Cooling system


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
Switch off 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
environmentally friendly manner!

SERV-HB 3001 EN Edition 2.0 * 3001s312.fm 3-15


Maintenance

Checking/filling up coolant

Danger!
Never open the coolant tank and never drain coolant if the engine is warm
since the cooling system is under high pressure
Danger of burns!
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

Proceed as follows:
Park the machine on level ground
Switch off the engine!
A 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:
FULL Fill up coolant (use only coolants of the same brand and grade => do not mix different
coolants!)

LOW
Important!
Check the coolant level once a day.
Fig. 11: Expansion tank for coolant We recommend checking it before starting the engine.

3-16 SERV-HB 3001 EN Edition 2.0 * 3001s312.fm


Maintenance

Filling up coolant
After the engine has cooled down:
Release overpressure in the radiator
B Carefully open the cap to the first notch and fully release the pressure
Open filler cap B
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
Switch off the engine
Fig. 12: Radiator Remove the key and carry it with you
Let the engine cool down
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!

Draining coolant
Danger!
Never open the coolant tank and never drain coolant if the engine is warm
since the cooling system is under high pressure
Danger of burns!
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

SERV-HB 3001 EN Edition 2.0 * 3001s312.fm 3-17


Maintenance

3.8 Air filter

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
A According to the maintenance plan

Important!
For applications in especially dusty environment, replace or clean the air filter
more frequently.

Caution!
B 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
Fig. 13: Indicator for air filter contamination
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

3-18 SERV-HB 3001 EN Edition 2.0 * 3001s312.fm


Maintenance

Replacing the filter


Replace filter A as follows:
D Switch off the engine
Apply the parking brake
Remove the key and carry it with you
E Let the engine cool down
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
Fig. 14: Removing the lower housing section Remove lower housing section E
Unscrew wing nut F
Carefully remove filter B with slightly turning movements
B
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)
F
Fig. 15: Removing the filter element
Close both bow clips D

Functional check once a week of the dust valve


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

Proceed as follows:
Switch off the engine
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
F

Fig. 16: Air filter dust valve

SERV-HB 3001 EN Edition 2.0 * 3001s312.fm 3-19


Maintenance

3.9 V-belt

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
Let the engine cool down

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


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

Checking V-belt tension


Check as follows:
1 Switch off the engine
Remove the key and carry it with you
Disconnect the battery or the battery master switch
Let the engine cool down
Open the engine cover
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
Fig. 17: Checking V-belt tension
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

3-20 SERV-HB 3001 EN Edition 2.0 * 3001s312.fm


Maintenance

Retightening the V-belt

Caution!
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:
Switch off the engine
2 Remove the key and carry it with you
Remove the battery master switch
Let the engine cool down
Open the engine cover
A Slacken fastening screws 2 of alternator 3
Use a suitable tool to push the alternator in the direction of arrow A until reaching the
3
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
Fig. 18: Retightening the V-belt

SERV-HB 3001 EN Edition 2.0 * 3001s312.fm 3-21


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.

3-22 SERV-HB 3001 EN Edition 2.0 * 3001s313.fm


Maintenance

Checking the hydraulic oil level


Proceed as follows:
Park the machine on level ground
Retract all hydraulic rams
A
Fully dump in the skip
Switch off the engine
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
Fig. 19: Oil level indicator on the hydraulic oil tank 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:

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 FULL mark
(122 and 194 F)

Important!
Measure the oil level of the hydraulic system only after the machine reaches its
operating temperature.
1

Filling up hydraulic oil


Danger!
Removing the filler plug can cause oil to escape
Danger of accidents!
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:
Park the machine on level ground
B
Retract all hydraulic rams
Switch off the engine
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
Fig. 20: Hydraulic oil tank

SERV-HB 3001 EN Edition 2.0 * 3001s313.fm 3-23


Maintenance

Changing hydraulic oil

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

Fouling indicator for hydraulic oil filter


A red telltale on the instrument panel monitors the filter.
45 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
Fig. 21: Fouling indicator for hydraulic oil filter

Replacing the hydraulic oil filter element


Proceed as follows:
1 Switch off the engine
Open cover 1 by about 2 turns and wait until the oil level in the filter housing drops to
2
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
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

Fig. 23: Hydraulic reflux filter

3-24 SERV-HB 3001 EN Edition 2.0 * 3001s313.fm


Maintenance

Checking hydraulic pressure lines Specific safety instructions

Danger!
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.

Fig. 24: Flexible line

SERV-HB 3001 EN Edition 2.0 * 3001s313.fm 3-25


Maintenance

3.11 Lubrication points


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

3001 front skip

3001 swivel skip

3-26 SERV-HB 3001 EN Edition 2.0 * 3001s313.fm


Maintenance

3.12 Tyres
Tyre wear can vary according to work and ground conditions.

Danger!
Improper tyre repairs
Danger of accidents!
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.
Fig. 25: Tyres
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.

Inspection work
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

SERV-HB 3001 EN Edition 2.0 * 3001s313.fm 3-27


Maintenance

3.13 Changing wheels

Danger!
Use of wrong tyres or wheels
Danger of accidents!
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!
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.

Removing the wheels Proceed as follows:


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

3-28 SERV-HB 3001 EN Edition 2.0 * 3001s313.fm


Maintenance

3.14 Axles

Danger!
Some components of the machine and the oil are still very hot after switching
off the machine
Danger of burns!
Wait until the engine has cooled down before taking up work.
Slowly open filler plug A to release the pressure inside.

Checking the oil level and filling up oil


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
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

Fig. 26: Checking the oil level

Draining oil
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.

SERV-HB 3001 EN Edition 2.0 * 3001s313.fm 3-29


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:
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

Service and maintenance work at regular intervals

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

3-30 SERV-HB 3001 EN Edition 2.0 * 3001s313.fm


Maintenance

Instructions concerning specific components


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

Alternator Always observe the following instructions:


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

SERV-HB 3001 EN Edition 2.0 * 3001s313.fm 3-31


Maintenance

Battery

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!
A
Do not disconnect the battery while the engine is running.

Fig. 27: Battery

3-32 SERV-HB 3001 EN Edition 2.0 * 3001s313.fm


Maintenance

3.16 Battery master switch

Important!
Do not disconnect the battery while the engine is running.
A B
Important!
C Power supply is interrupted directly after the battery, by means of a key
Before working on the electric system

Interrupting power supply:


Fig. 28: Battery master switch
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

SERV-HB 3001 EN Edition 2.0 * 3001s313.fm 3-33


Maintenance

3.17 General maintenance work


Cleaning Cleaning the machine is divided into 2 separate areas:
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.

General instructions for all areas of the machine

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!
Screw connections and attachments
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.

Pivots and hinges


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.

3-34 SERV-HB 3001 EN Edition 2.0 * 3001s313.fm


Engine
Engine

Engine

4 Engine
4.1 3TNV88-KNSV engine: overview

Oil filler neck

Fuel injection pump

Engine oil filter

Oil dipstick

Oil pressure switch

Oil drain plug


Flywheel

SERV-HB 3001 EN Edition 2.0 * 3001s410.fm 4-1


Engine

Oil filler neck Alternator

Water pump

Tightening bracket

Starter

Fan blade Exhaust manifold

V-belt

4-2 SERV-HB 3001 EN Edition 2.0 * 3001s410.fm


4.2

SERV-HB 3001 EN Edition 2.0 * 3001s410.fm


Injection nozzles
Fuel system (up to AB)

Injection line

Fuel injection pump


Reflux to tank

Feed

Fuel filter
with stop cock

Fuel pump Water separator


with stop cock
Engine

4-3
Engine

4.3 Fuel system (starting AC)


Water separator
Description

Fuel pump
Fuel filter
Pos.

12
13
1

4-4 SERV-HB 3001 EN Edition 2.0 * 3001s410.fm


Engine

Checking and adjusting valve clearance


Standard setting of valve clearance is possible:
On a cold engine

Remove the valve cover


Turn the engine until the cylinder reaches the top dead centre of the compression
cycle.

Check the valve cap for abnormal wear

normal abnormal
Fig. 1: Valve cap wear

Check valve clearance 2/A with a feeler gauge


B C
Valve clearance: 0.15 0.25 mm (0.006 0.01)
A

Fig. 2: Valve clearance

Adjust valve clearance by turning set screw 2/B.


Valve clearance: 0.15 0.25 mm (0.006 0.01)
Tighten locknut 2/C.
Check the setting again with the feeler gauge.

Repeat the procedure for each cylinder

Fig. 3: Setting valve clearance

Place the valve cover gasket

Mount the valve cover

Fig. 4: Put the valve cover gasket in place

SERV-HB 3001 EN Edition 2.0 * 3001s410.fm 4-5


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)

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

Flywheel Fan

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

Order for removing the cylinder-head bolts

Flywheel Fan

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

4-6 SERV-HB 3001 EN Edition 2.0 * 3001s410.fm


Engine

4.4 Checking the injection nozzles


Pressure check
Remove the injection line and the injection nozzle
Connect the injection nozzle with the high pressure line of the nozzle tester
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)

Fig. 5: Nozzle tester Spacer thickness of 0.1 mm (0.004") corresponds to modification by 19 bar (276 psi)

Upper nozzle Lower nozzle


Leak oil line screw fitting Spacers Pressure spring centring Nozzle needle screw fitting
Compression Compression
spring spring seat Nozzle body

Checking the nozzle jet


Remove the injection lines and the injection nozzles
Connect the injection nozzle with the high pressure line of the nozzle tester
Quickly create pressure until the nozzle ejects fuel (ejection 3 4 times)
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
Normal atomisation whether fuel escapes from the nozzle

Bad atomisation
Fig. 6: Nozzle jet

SERV-HB 3001 EN Edition 2.0 * 3001s410.fm 4-7


Engine

Injection time Checking injection time


Remove the valve cover
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
Fig. 7: Drip tube
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
injection pump
Mark the initial position on the pump and wheel case housing before setting the fuel
injection pump
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

Engraved scale
Pulley

Mark on belt
pulley Direction of rotation

Mark on pump and wheel case


housing

Flange screws (oblong slots for rotating the pump)

4-8 SERV-HB 3001 EN Edition 2.0 * 3001s410.fm


Engine

4.5 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
B
Idling speed 1000 25 rpm
Max. revs: 3000 25 rpm
A
Adjust if engine revs differ
see Setting injection time on page 4-8

Fig. 8: Adjusting engine revs

4.6 Compression
Remove the injection lines and the injection nozzles
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)
Fig. 9: Compression

SERV-HB 3001 EN Edition 2.0 * 3001s410.fm 4-9


Engine

4.7 Checking the coolant thermostat


Remove the thermostat
The thermostat is located on the water pump
see 3TNV88-KNSV engine: overview on page 4-1
Housing cover

Thermostat

Seal

Housing

Thermal switch

Fig. 10: Coolant thermostat

Warm up the thermostat in a container with water


Thermometer
Check whether the thermostat opens at the specified temperature (check with a
Thermal switch temperature gauge)
Thermostat opening temperature: begins at 71 C (160 F),
fully open at 85 C (185 F)

Checking the thermal switch


Remove the thermal switch
Thermometer
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)

Test prods

Fig. 11: Checking the thermal switch

4-10 SERV-HB 3001 EN Edition 2.0 * 3001s410.fm


Engine

4.8 Oil pressure switch


Remove the cable connection from the oil pressure switch (in the area of the cutoff
solenoid)
Measurement Start the engine, check for correct idling speed
prod 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

Fig. 12: Oil pressure switch

4.9 Checking the coolant circuit


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
Fig. 13: Checking the radiator for leaks

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
Radiator cap

Fig. 14: Checking the radiator cap

SERV-HB 3001 EN Edition 2.0 * 3001s410.fm 4-11


Engine

4.10 Clutch

Screw M12x20-DIN 912


Schnorr washer M12
Tightening torque:
86 Nm/63 lbf ft (glue with
medium-strength Loctite)

Fig. 15: Fastening the clutch

Fastening material:
3 off ISK M12 x 20 DIN 912
3 off M12 Schnorr washers
Fasten the clutch by gluing the screws with Loctite and then tightening them
to 86 Nm (63 lbf ft).

4-12 SERV-HB 3001 EN Edition 2.0 * 3001s410.fm


Air intake

Sheathed-element
heater plugs

SERV-HB 3001 EN Edition 2.0 * 3001s420_Tier 3.fm


Engine

Oil filler neck

Fuel injection pump

Fuel filter
4.11 Engine 3TNV88-BKNSV overview (from serial no. AE310242D)

Engine oil filter

Oil dipstick

Oil pressure switch


Engine

4-13
4-14
Engine

Valve cover

Exhaust manifold

Water pump

Starter

Fan blade Tightening bracket

Alternator

V-belt

SERV-HB 3001 EN Edition 2.0 * 3001s420_Tier 3.fm


Sintered metal filter

Fuel radiator

Filler inlet

SERV-HB 3001 EN Edition 2.0 * 3001s420_Tier 3.fm


Tank Reflux

Feed line
4.12 Fuel system (from serial no. AE310242D)

Water separator
with stop cock

Fuel injection pump

Fuel filter
Fuel pump
Engine

4-15
Engine

Checking and adjusting valve clearance


Standard setting of valve clearance is possible:
On a cold engine

Remove the valve cover


Turn the engine until the cylinder reaches the top dead centre of the compression
cycle.

Check the valve cap for abnormal wear

normal abnormal
Fig. 16: Valve cap wear

Check valve clearance 2/A with a feeler gauge


B C
Valve clearance: 0.15 0.25 mm (0.006 0.01)
A

Fig. 17: Valve clearance

Adjust valve clearance by turning set screw 2/B.


Valve clearance: 0.15 0.25 mm (0.006 0.01)
Tighten locknut 2/C.
Check the setting again with the feeler gauge.

Repeat the procedure for each cylinder

Fig. 18: Setting valve clearance

Place the valve cover gasket

Mount the valve cover

Fig. 19: Put the valve cover gasket in place

4-16 SERV-HB 3001 EN Edition 2.0 * 3001s420_Tier 3.fm


Engine

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)

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

Flywheel Fan

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

Order for removing the cylinder-head bolts

Flywheel Fan

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

SERV-HB 3001 EN Edition 2.0 * 3001s420_Tier 3.fm 4-17


Engine

4.13 Checking the injection nozzles


Pressure check
Remove the injection line and the injection nozzle
Connect the injection nozzle with the high pressure line of the nozzle tester
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)

Fig. 20: Nozzle tester Spacer thickness of 0.1 mm (0.004") corresponds to modification by 19 bar (276 psi)

Upper nozzle Lower nozzle


Leak oil line screw fitting Spacers Pressure spring centring Nozzle needle screw fitting
Compression Compression
spring spring seat Nozzle body

Checking the nozzle jet


Remove the injection lines and the injection nozzles
Connect the injection nozzle with the high pressure line of the nozzle tester
Quickly create pressure until the nozzle ejects fuel (ejection 3 4 times)
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
Normal atomisation whether fuel escapes from the nozzle

Bad atomisation
Fig. 21: Nozzle jet

4-18 SERV-HB 3001 EN Edition 2.0 * 3001s420_Tier 3.fm


Engine

Injection time Checking injection time


Remove the valve cover
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
injection pump
Fig. 22: Drip tube
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
injection pump
Mark the initial position on the pump and wheel case housing before setting the fuel
injection pump
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

Engraved scale
Pulley

Mark on belt
pulley Direction of rotation

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

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

A 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
Fig. 23: Adjusting engine revs see Setting injection time on page 4-19

4.15 Automatic revs setting option (Tier 3A from AE310242D)

Function
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
A operation is carried out again, the engine is reset to the engine speed that has been set
previously.

4-20 SERV-HB 3001 EN Edition 2.0 * 3001s420_Tier 3.fm


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.

Installation

Revs control retrofit kit 11

SERV-HB 3001 EN Edition 2.0 * 3001s420_Tier 3.fm 4-21


Engine

4.16 Compression
Remove the injection lines and the injection nozzles
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: 33.3 35.3 bar (483 512 psi) at 250 rpm
Limit: 26.5 28.5 bar (384 413 psi) at 250 rpm
Fig. 24: Compression

4.17 Checking the coolant thermostat


Remove the thermostat
The thermostat is located on the water pump
see Engine 3TNV88-BKNSV overview (from serial no. AE310242D) on page 4-13
Housing cover

Thermostat

Seal

Housing

Thermal switch

Fig. 25: Coolant thermostat

Warm up the thermostat in a container with water


Thermometer
Check whether the thermostat opens at the specified temperature (check with a
Thermal switch temperature gauge)
Thermostat opening temperature: 69.5 72.5 C (157.1 162.5 F)

4-22 SERV-HB 3001 EN Edition 2.0 * 3001s420_Tier 3.fm


Engine

Checking the thermal switch


Remove the thermal switch
Thermometer
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)

Test prods

Fig. 26: Checking the thermal switch

4.18 Oil pressure switch


Remove the cable connection from the oil pressure switch (in the area of the cutoff
solenoid)
Measurement Start the engine, check for correct idling speed
prod 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

Fig. 27: Oil pressure switch

4.19 Checking the coolant circuit


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
Fig. 28: Checking the radiator for leaks

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
Radiator cap

Fig. 29: Checking the radiator cap

SERV-HB 3001 EN Edition 2.0 * 3001s420_Tier 3.fm 4-23


Engine

4.20 Clutch

Screw M12x20-DIN 912


Schnorr washer M12
Tightening torque:
86 Nm/63 lbf ft (glue with
medium-strength Loctite)

Fig. 30: Fastening the clutch

Fastening material:
3 off ISK M12 x 20 DIN 912
3 off M12 Schnorr washers
Fasten the clutch by gluing the screws with Loctite and then tightening them
to 86 Nm (63 lbf ft).

4.21 Engine trouble

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
Engine does not start or is not easy to start 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

4-24 SERV-HB 3001 EN Edition 2.0 * 3001s420_Tier 3.fm


Engine

Problem Possible causes


Fuel grade does not comply with specifications
Wrong valve clearance
Engine starts, but does not run smoothly or faultless
Injection line leaks
Defective fuel injector
Oil level too low
Oil level too high
Dirty air filter
Dirty oil cooler fins
Engine overheats. Temperature warning system responds
Defective fan, torn or loose V-belt
Resistance in cooling system too high, flow capacity too low
Defective thermostat
Defective fuel injector
Oil level too high
Fuel grade does not comply with specifications
Dirty air filter
Insufficient engine output Defective air filter maintenance switch or gauge
Wrong valve clearance
Injection line leaks
Defective fuel injector
Injection line leaks
Engine does not run on all cylinders
Defective fuel injector
Oil level too low
Insufficient or no engine oil pressure Machine inclination too high (max. 25)
Wrong SAE grade of engine lubrication oil
Oil level too high
Engine oil consumption too high
Machine inclination too high (max. 25)
Oil level too high
Blue Machine inclination too high (max. 20)
Engine oil combustion (defective cylinder-head gasket)
Engine starting temperature too low
Fuel grade does not comply with specifications
White Wrong valve clearance
Engine smoke
Defective fuel injector
Coolant combustion (defective cylinder-head gasket)
Dirty air filter
Defective air filter maintenance switch or gauge
Black
Wrong valve clearance
Defective fuel injector

SERV-HB 3001 EN Edition 2.0 * 3001s420_Tier 3.fm 4-25


Engine

4-26 SERV-HB 3001 EN Edition 2.0 * 3001s420_Tier 3.fm


Travelling drive
Travelling drive
Travelling drive

5 Travelling drive
5.1 Variable displacement pump A10VG45DA

2
1

Pos. Description
1 X2 pressure in control piston
2 X1 pressure in control piston
3 Boost pressure G
4 High pressure Mb

SERV-HB 3001 EN Edition 2.0 * 3001s510.fm 5-1


Travelling drive

6
7

Pos. Description
5 Control cartridge
6 Inching valve
7 High-pressure valve
8 High pressure Ma

5-2 SERV-HB 3001 EN Edition 2.0 * 3001s510.fm


Travelling drive

Description:
A10 VG
Axial-piston machine, swash plate design, adjustable, closed circuit
45
Displacement volume Vg max in cm
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.

Variable displacement pump: diagram

9
2 3 4
1

5 6 7 8

Pos. Description
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
9 Inching valve

SERV-HB 3001 EN Edition 2.0 * 3001s510.fm 5-3


Travelling drive

Variable displacement pump: design

12 7 13 9 2 17 16 5 10
6 15

8 11 1 14 3 4

Pos. Description
1 Travelling drive
2 Hydraulic adjustment
3 Connecting plate with valves
4 Internal gear pump
5 Inching valve
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

5-4 SERV-HB 3001 EN Edition 2.0 * 3001s510.fm


Travelling drive

Travelling drive overview

13 12 7 3 6 1

14

10 9 5 8 11 2

Pos. Description
1 Travelling drive
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

SERV-HB 3001 EN Edition 2.0 * 3001s510.fm 5-5


Travelling drive

Connecting plate with valves

3
13
5
2 8
10
4 9

7 6
2
11

1
12

Pos. Description
1 Pressure limiting valve
2 Pressure limiting valve
3 Cutoff valve
4 Double tear-off plug
5 Screw plug
6 Screw plug
7 Double tear-off plug
8 O-ring
9 Screw plug
10 Nozzle
11 HP valve
12 HP valve
13 Screw plug

5-6 SERV-HB 3001 EN Edition 2.0 * 3001s510.fm


Travelling drive

5.2 A6VM80EZ hydraulic motor


5

3 4

Pos. Description
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

SERV-HB 3001 EN Edition 2.0 * 3001s510.fm 5-7


Travelling drive

5.3 Travelling drive overview (up to AB)


Service brake

Diesel engine Hydraulic motor

Rated speed

Differential lock

Forwards driving function:


Flow-through direction of variable displacement pump from A to B

Reverse driving function:


Flow-through direction of variable displacement pump from B to A

5.4 Travelling drive overview (starting AC)

Service brake

Hydraulic motor
B
Diesel engine

5-8 SERV-HB 3001 EN Edition 2.0 * 3001s510.fm


Travelling drive

5.5 Towing and transporting the machine


Safety instructions
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!

Towing

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.

Proceed as follows:
2 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

1 Caution!
Screwing in any further damages the valve.

Fig. 1: High-pressure circuit screw 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).

SERV-HB 3001 EN Edition 2.0 * 3001s510.fm 5-9


Travelling drive

5.6 Test instruction


High pressure check
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

Fig. 2: Parking brake switch (starting AC)

5-10 SERV-HB 3001 EN Edition 2.0 * 3001s510.fm


Travelling drive

Check: boost pressure


Tools required:
Pressure gauge 50 bar/725 psi

Boost pressure test port

Check boost pressure as follows:


Switch off the ignition
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

SERV-HB 3001 EN Edition 2.0 * 3001s510.fm 5-11


Travelling drive

Check: setting pressure Tools required:


Pressure gauge 50 bar/725 psi

X2 X1

Setting pressure test ports X1 and X2

Check the setting pressure as follows:


Switch off the ignition
Connect a pressure gauge to X1 or X2
Start the diesel engine
The pump starts to swivel at about 12 bar/174 psi and the dumper moves
Maximum pressure is about 25 bar/363 psi

5-12 SERV-HB 3001 EN Edition 2.0 * 3001s510.fm


Travelling drive

5.7 Adjustment
Setting: control initiation Tools required:
2 x pressure gauges 600 bar/8702 psi

Setting pressure test ports X1 and X2

Adjust control initiation as follows


Switch off the ignition
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
Start the diesel engine
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!

SERV-HB 3001 EN Edition 2.0 * 3001s510.fm 5-13


Travelling drive

5-14 SERV-HB 3001 EN Edition 2.0 * 3001s510.fm


Axles
Axles

Axles

6 Axles
6.1 Axle type label

Type label contains all axle data

Axle type label

Axle manufacturer

Type and model


designation. Serial number

Lubricant

Manufacturer's address

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-1


Axles

6.2 Drain, fill and check plug

Pos Description
1 Fill plug
2 Drain plug
3 Checking the oil level

6.3 Tightening torques


Wheel screws
Wheel nut Thread Tightening torque

300 350 Nm
With taper M18X1.5
221 258 lbf ft

Important!
Check the wheel nuts for tightness every 50 service hours!

6-2 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

General tightening torques


Thread
+Loctite
Normal +Loctite 270 Normal Normal +Loctite 270
Thread 270
size 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
M6x1
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
M8X1.25
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
M10X1.5
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
M12X1.75
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
M14x2
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
M16x2
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
M18x2.5
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
M20x2.5
288 318 316 349 408 451 445 492 487 538 533 589
523 578 575 635 746 824 817 903 893 987 974 1076
M22x2.5
386 426 424 468 550 608 603 666 659 728 718 794
675 746 732 809 950 1050 1040 1150 1140 1260 1240 1370
M24x3
498 550 540 597 701 774 767 848 841 929 915 1010
998 1103 1088 1202 1411 1559 1539 1701 1710 1890 1838 2032
M27x3
736 814 802 887 1041 1150 1135 1255 1261 1394 1356 1499
1378 1523 1473 1628 1914 2115 2085 2305 2280 2520 2494 2757
M30x3.5
1016 1123 1086 1201 1412 1560 1538 1700 1682 1859 1839 2033
25.7 28.3 27.5 30.5 36.2 39.8 40 44 42.8 47.2 47.5 52.5
M8x1
19 20.9 20.3 22.5 26.7 29.4 29.5 32.5 31.6 34.8 35 38.7
49.4 54.6 55.2 61 71.5 78.5 78 86 86 94 93 103
M10X1.25
36.4 40.3 40.7 45 52.7 57.9 57.5 63.4 63.4 69.3 68.6 76
90 100 98 109 128 142 139 154 152 168 166 184
M12X1.25
66.4 73.8 72.3 80.4 94.4 105 102.5 114 112.1 123.9 122.4 135.7
86 95 94 104 120 132 133 147 143 158 159 175
M12X1.5
63.4 70 69.3 76.7 88.5 97.4 98.1 108.4 105 117 117.3 129
143 158 157 173 200 222 219 242 238 263 261 289
M14X1.5
105 117 116 128 148 164 161 178 176 194 193 213
214 236 233 257 302 334 333 368 361 399 394 436
M16X1.5
158 174 172 190 223 246.3 245.6 271 266 294 291 322
312 345 342 378 442 489 485 536 527 583 580 641
M18X1.5
230 254 252 279 326 361 358 395 389 430 428 473
437 483 475 525 613 677 674 745 736 814 808 893
M20X1.5
322 356 350 387 452 499 497 549 543 600 596 659
581 642 637 704 822 908 903 998 998 1103 1078 1191
M22X1.5
429 474 470 519 606 670 666 736 736 814 795 878
741 819 808 893 1045 1155 1140 1260 1235 1365 1363 1507
M24x2
547 604 596 659 771 852 841 929 911 1007 1005 1112
1083 1197 1178 1302 1520 1680 1672 1848 1834 2027 2000 2210
M27x2
799 883 869 960 1121 1239 1233 1363 1353 1495 1475 1630
1511 1670 1648 1822 2138 2363 2332 2577 2565 2835 2788 3082
M30X2
1114 1232 1216 1344 1577 1743 1720 1901 1892 2091 2056 2273

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-3


Axles

6.4 Articulated joint (up to AB)

6-4 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

17
2

7 4 1

6
5

14 15 16

17

14 15 16

Pos. Description
1 Articulated joint
2 Spacer washer
3 Bush
4 Spacer washer
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

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-5


Axles

6.5 Articulated joint (starting AC)

6-6 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

Pos. Description
1 Articulated joint
2 Thrust washer
3 Thrust washer
4 Bush
5 Supporting washer
6 Tab washer
7 Slotted nut
8 Articulated joint pin
9 Bush
10 Spacer washer
11 Pin gasket
12 Countersunk screw
13 Washer
14 Articulated joint pin
15 Hexagon head screw
16 Schnorr lock
17 Washer
18 Grease nipples
19 Protective cap
20 Steering ram pin
21 Washer
22 Schnorr lock
23 Hexagon head screw

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-7


Axles

6.6 Transfer gearbox (up to AD)

6-8 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

Pos. Description
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
10 Hexagon head screw
11 Plug
12 Sealing ring
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
27 Cheese-head screw
28 O-ring
29 Sheet metal
30 Hexagon head screw
31 Flange
32 O-ring
33 Centering ring

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-9


Axles

6.7 Transfer gearbox (from AE310242D)

6-10 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

Pos. Description
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

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-11


Axles

6.8 Semiaxles

6-12 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

Pos. Description
1 Axle housing
2 Screw
3 Breather
4 Plug
5 O-ring
6 Ring
7 Sealing 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
19 Thrust washer
20 Screw
21 Planetary housing
22 Thrust washer
23 Nut
24 Stud
25 Ring
26 Wheel hub
27 Axle shaft
28 Axle housing
29 Hexagon head screw

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-13


Axles

6.9 Wheel hub

3
7

16 12
15 10 11

2
5

14

13

6 8 9 1
4

6-14 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

Pos. Description
1 Ring
2 Sealing ring
3 Wheel bolt
4 Plug
5 Bearing
6 Circlip
7 Ring gear
8 Internal-geared wheel support
9 Tab washer
10 Circlip
11 Thrust washer
12 Planetary housing
13 Thrust washer
14 Hexagon nut
15 Ring
16 Wheel hub

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-15


Axles

6.10 Front axle brake (up to AB)

Hydraulic differential lock


with brake lever

6-16 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

6.11 Brake diagram

16
7 9 19

5
15

14

18 13 11

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-17


Axles

Pos. Description
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
13 Antiextrusion ring
14 Circlip
15 Tension spring
16 Antiextrusion ring
17 O-ring
18 Tension spring
19 Piston
20 Cheese-head screw
21 Intermediate bushing
22 O-ring
23 Bearing
24 Brake lever
25 Spacer ring
26 Nut
27 Piston
28 O-ring
29 Screw
30 Antiextrusion ring
31 Lever
32 Countersunk screw
33 Spacer ring
34 Intermediate bushing
35 O-ring
36 O-ring
37 Screw
38 Sealing ring
39 Plug
40 Bleed screw
41 Stud bolt
42 Plug
43 O-ring

6-18 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

Differential discs Spring

Semiaxle

Differential carrier
Spring

Brake discs Axle housing

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.

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-19


Axles

6.12 Front axle brake (starting AC up to AD)

6-20 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

6.13 Front axle brake (from AE310242D)

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-21


Axles

Pos. Description (starting AC up to AD) Pos. Description (from AE310242D)


1 Brake disc 1 Countersunk screw
2 Counterdisc 2 Shim
3 Intermediate bushing 3 Lever
4 Ball 4 Cheese head screw
5 Spacer ring 5 Intermediate bushing
6 Shim ring 6 Thread bolt
7 Counterdisc 7 Nut
8 Clamping sleeve 8 O-ring
9 Piston 9 O-ring
10 O-ring 10 Plug
11 Antiextrusion ring 11 Drain screw
12 O-ring 12 Lever left
13 Antiextrusion ring 13 Lever right
14 Circlip 14 Pin
15 Tension spring 15 Sleeve
16 Antiextrusion ring 16 Pressure plate
17 O-ring 17 Screw
18 Tension spring 18 Spring
19 Piston 19 Screw
20 Cheese-head screw 20 Spring
21 Intermediate bushing 21 O-ring
22 O-ring 22 Ring
23 Bearing 23 O-ring
24 Brake lever 24 O-ring
25 O-ring 25 Ring
26 Nut 26 Clamping sleeve
27 Stud bolt 27 Friction plate
28 Bleed screw 28 Friction plate
29 Screw
30 Plug
31 Lever
32 Countersunk screw
33 Spacer ring
34 Intermediate bushing
35 O-ring
36 O-ring
37 Screw
38 Sealing ring

6-22 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

6.14 Differential (up to AB)

Spring
Spring

Semiaxle

Axle housing
Brake discs
Differential housing
Differential discs

Differential

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-23


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.

6-24 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

Front axle (up to AB)

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-25


Axles

Pos. Description
1 Nut
2 Flange
3 Sealing ring
4 Bearing
5 Spacer ring
6 O-ring
7 Protective plate
8 Spacer ring
9 Set of rings
10 Shim ring
11 Crown wheel pair
12 Screw
13 Shim ring
14 Taper roller bearing
15 Differential housing
16 Thrust washer
17 Compensating shaft gear
18 Bevel gear
19 Thrust washer
20 Pin
21 Pin
22 Pin
23 Cross piece
24 Compensating shaft gear
25 Ball
26 Ring
27 Circlip
28 Clutch disc
29 Ring
30 Bearing
31 Circlip
32 Bearing
33 Clutch disc
34 Intermediate bushing
35 Bearing
36 Spacer ring
37 Circlip
38 Shim ring
39 Circlip

6-26 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

Front axle (starting AC up to AD)

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-27


Axles

Front axle (from AE310242D)

6-28 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

Pos. Description (starting AC up to AD) Pos. Description (from AE310242D)


1 Nut 1 Screw
2 Flange 2 Washer
3 Bearing 3 O-ring
4 Sealing ring 4 Flange
5 Spacer ring 5 Protection plate
6 Shim ring 6 Seal ring
7 Set of rings 7 Bearing
8 Spacer ring 8 Shim
9 Crown wheel pair 9 Taper roller bearing
10 Screw 10 Shaft nut
11 Shim ring 11 Bevel gear pair
12 Taper roller bearing 12 Lock plate
13 Differential housing 13 Hex screw
14 Thrust washer 14 Cheese head screw
15 Compensating shaft gear 15 Screw
16 Bevel gear 16 Differential axle
17 Thrust washer
18 Pin
19 Pin
20 Pin
21 Cross piece
22 Compensating shaft gear
23 Thrust washer
24 Clutch disc
25 Clutch disc
26 Bearing
27 Circlip
28 Bearing
29 Shim ring
30 Circlip
31 O-ring
32 Protective plate

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-29


Axles

Rear axle

6-30 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Axles

Pos. Description
1 Shim ring
2 Taper roller bearing
3 Screw
4 Differential housing
5 Thrust washer
6 Compensating shaft gear
7 Thrust washer
8 Bevel gear
9 Pin
10 Pin
11 Pin
12 Cross piece
13 Cover
14 Hexagon head screw
15 Bevel gear and crown wheel pair

SERV-HB 3001 EN Edition 2.0 * 3001s610.fm 6-31


Axles

6.15 Cardan shaft

18

Screws A are tightened to a torque of 38 Nm (28 lbf ft).

6-32 SERV-HB 3001 EN Edition 2.0 * 3001s610.fm


Brakes
Brakes

7 Brakes
7.1 Brake circuit (up to AB)
Hydrostatic automotive travelling drive, service brake effect on front axle via master brake
cylinder.

Front axle

Variable displacement
pump
Master brake cylinder

Inching valve

SERV-HB 3001 EN Edition 2.0 * 3001s710.fm 7-1


Brakes

7.2 Brake circuit (starting AC)


Parking brake

7-2 SERV-HB 3001 EN Edition 2.0 * 3001s710.fm


Brakes

Pos. Description
1 Parking brake lever
2 Hexagon head screw
3 Schnorr lock
4 Hexagon nut
5 Fork joint
6 Hexagon nut
7 Traction bar
8 Hexagon head screw
9 Hexagon nut
10 Joint
11 Bush
12 Washer
13 Hexagon head screw
14 Bellows
15 Bowden cable
16 Microswitch
17 Cheese-head screw
18 Spring lock washer
19 Washer
20 Parking brake switch plate
21 Bowden cable bracket
22 Hexagon head screw
23 Nord-Lock washer
24 Fork joint
25 Hexagon head screw
26 Hexagon nut
27 Hexagon nut
28 Washer
29 Compression spring
30 Tension spring

SERV-HB 3001 EN Edition 2.0 * 3001s710.fm 7-3


7-4
Brakes

Service brake

Swivel skip
Master brake cylinder Front skip

Front axle

Inching valve

Variable displacement
pump

SERV-HB 3001 EN Edition 2.0 * 3001s710.fm


Steering system
Steering system

8 Steering system
8.1 Steering circuit (up to AB)

Steering ram
Steering unit

Gear pump
Leak oil line
Spool

SERV-HB 3001 EN Edition 2.0 * 3001s810.fm 8-1


Steering system

8.2 Steering circuit (starting AC)

Steering ram
Steering unit

CF
L
T
P

Hydraulic motor

Manual spool

8-2 SERV-HB 3001 EN Edition 2.0 * 3001s810.fm


Steering system

8.3 Steering unit: diagram

3
5

1
2

Pos. Description
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.

SERV-HB 3001 EN Edition 2.0 * 3001s810.fm 8-3


Steering system

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

8-4 SERV-HB 3001 EN Edition 2.0 * 3001s810.fm


Steering system

8.5 Steering unit overview


Priority valve overview

Priority valve (legend)


Pos. Description
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

SERV-HB 3001 EN Edition 2.0 * 3001s810.fm 8-5


Steering system

Steering unit

17

26

14 16

13 25
12
11

10

24

9 15
23
8

4
2
3 22

7
6
1

21

5
20

19

18

8-6 SERV-HB 3001 EN Edition 2.0 * 3001s810.fm


Steering system

Steering unit (legend)


Pos. Description
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
8 Non-return valve
9 Threaded bushing
10 O-ring
11 Non-return valve
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

SERV-HB 3001 EN Edition 2.0 * 3001s810.fm 8-7


Steering system

8-8 SERV-HB 3001 EN Edition 2.0 * 3001s810.fm


Hydraulic system
Hydraulic system
Hydraulic system

9 Hydraulic system
9.1 Manual spool connections: overview

B3
5
8

7 3

6 4

1 2

T1
Pos. Description
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

SERV-HB 3001 EN Edition 2.0 * 3001s910.fm 9-1


Hydraulic system

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.

3
2

Pos. Description
1 Hydraulic pump port
2 Axle port
3 Hydraulic oil tank port

Important!
There is no more differential lock starting series AC!

9-2 SERV-HB 3001 EN Edition 2.0 * 3001s910.fm


Hydraulic system

9.3 Dumping the skip: hydraulic diagram (up to AB)

Left
Pos. Description
1 Manual spool
2 Steering valve
Steering ram

Right
2
Tilt ram

Diesel engine

SERV-HB 3001 EN Edition 2.0 * 3001s910.fm 9-3


Hydraulic system

9.4 Dumping the skip: hydraulic diagram (starting AC)

Left
Steering ram

Right

Tilt ram

Diesel
engine

9-4 SERV-HB 3001 EN Edition 2.0 * 3001s910.fm


Hydraulic system

9.5 Swivelling the skip: hydraulics diagram (up to AB)

Left
Pos. Description
1 Manual spool
2 Steering valve
Steering ram

Right
2
Offset ram

Diesel engine

SERV-HB 3001 EN Edition 2.0 * 3001s910.fm 9-5


Hydraulic system

9.6 Swivelling the skip: hydraulics diagram (starting AC)

Left
Offset ram

Steering ram

Right

Diesel
engine

9-6 SERV-HB 3001 EN Edition 2.0 * 3001s910.fm


Hydraulic system

9.7 Test instructions


Check: work hydraulics
Tools required:
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
A
Connect the 200 bar (2901 psi) pressure gauge to the test port
Start the diesel engine
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
B
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
Fig. 1: Control lever valves

SERV-HB 3001 EN Edition 2.0 * 3001s910.fm 9-7


Hydraulic system

9.8 Diagram A4 (up to AB)

12
4

11

10

17

18
3
19

14
13

15

9 5 16 2

1
7

9-8 SERV-HB 3001 EN Edition 2.0 * 3001s910.fm


Hydraulic system

9.9 Diagram legend (up to AB)

Pos. Description
1 Diesel engine
2 Hydraulic pump
3 Flush valve
4 Hydraulic motor
5 Inching valve
6 Service brake
7 Vent filter
8 Hydrostatic steering
9 Priority valve (steering system)
10 Manual spool
11 Offset ram
12 Tilt ram
13 Radiator
14 Steering ram
15 Combined filter
16 Non-return valve 1 bar/14.5 psi
17 Rear axle
18 Front axle
19 Differential lock

SERV-HB 3001 EN Edition 2.0 * 3001s910.fm 9-9


Hydraulic system

9.10 Diagram A4 (starting AC)


12

11

10

9
17

18

14 13

15

5
2
1
16
7

9-10 SERV-HB 3001 EN Edition 2.0 * 3001s910.fm


Hydraulic system

9.11 Diagram legend (starting AC)

Pos. Description
1 Diesel engine
2 Hydraulic pump
3 Flush valve
4 Hydraulic motor
5 Inching valve
6 Service brake
7 Vent filter
8 Hydrostatic steering
9 Road travel lights option
10 Manual spool
11 Offset ram
12 Tilt ram
13 Radiator
14 Steering ram
15 Combined filter
16 Non-return valve 2 bar/29 psi
17 Rear axle
18 Front axle

SERV-HB 3001 EN Edition 2.0 * 3001s910.fm 9-11


Hydraulic system

9-12 SERV-HB 3001 EN Edition 2.0 * 3001s910.fm


Hydraulic system

Hydraulic system
Hydraulics diagram A3 (up to AB)

8
Pos. Description
9
6 1 Diesel engine
14 2 Hydraulic pump
3 Flush valve
4 Work pump
11
5 Hydraulic pump
6 Service brake
7 Vent filter
8 Hydrostatic steering
10 9 Priority valve (steering system)
10 Manual spool
11 Tilt ram
12 Offset ram
13 Radiator
14 Steering ram
15 Combined filter
5 16 Non-return valve 2 bar/29 psi
17 Rear axle
18 Front axle
19 Differential lock
16

12
1

19

2
3

18 17
7

15

13

SERV-HB 3001 EN Edition 2.0 * 3001s911.fm 9-13


Hydraulic system

Hydraulics diagram A3 (starting AC)

8
6

9
11
14

10

5
12

16

3
Pos. Description
1 Diesel engine
1 2 Hydraulic pump
4 3 Flush valve
4 Hydraulic motor
5 Inching valve
6 Service brake
7 Vent filter
8 Hydrostatic steering
2 9 Road travel lights option
10 Manual spool
11 Offset ram
12 Tilt ram
13 Radiator
18 17
14 Steering ram
7 15 Combined filter
16 Non-return valve 2 bar/29 psi
15
17 Rear axle
18 Front axle
13

9-14 SERV-HB 3001 EN Edition 2.0 * 3001s911.fm


Electric system
Electric system

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 ()

Mnemonic: U
R I
Output
Power P Watt (W)

P = U x I = R x I = U/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

SERV-HB 3001 EN Edition 2.0 * 3001s1010.fm 10-1


Electric system

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):
Black cable in COM socket (earth),
red cable in V socket;
connect in parallel to consumer.
Measuring resistance (ignition switched off):
Black cable in COM socket (earth),
red cable in 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.

10.3 Relays
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 make-
contact, break-contact or changeover switches. These undertake the actual switching
function.

Zero-centre relay
86 = Start of coil (control line)
86 30
85 = End of coil (earth)
30 = Input (load line)
87 = Make-contact switch output (load line)
87 a= Break-contact switch output (load line)
85 87 87a

Fig. 1: Terminal description on relay

10-2 SERV-HB 3001 EN Edition 2.0 * 3001s1010.fm


Electric system

10.4 Electric units

Electric system
Alternator 12 V 40 A
Starter 12 V 1.7 kW (2.3 hp)
Battery 12 V 88 Ah
Fuse box

Rated cur-
Fuse number Protected circuit
rent (A)
F10
F3 10 A Cutoff solenoid, cutoff solenoid time lag relay
F9
F8 F4 15 A Drive solenoid valves
F7 F5 10 A Horn, brake lights
F6
F5
F6 15 A Turn indicators
F4 F7 15 A High beam
F3
F8 10 A Low beam
F9 10 A Clearance light
F 10 10 A Hazard warning system
Fig. 2: Fuse box

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

K7 Switching relay no. Protected circuit


F1, F2 Main fuses
K6 Preheating time lag relay
K7 Start high current relay
K8 Cutoff solenoid time lag relay
K9 Cutoff solenoid switching relay
F1 F2
K6
K 10 Turn indicator relay
K32 Start interlock relay
V2
K33 Low beam relay
K 34 K9
K34 High beam relay
K 33
V2 Diodes
K 32 K 10

K8

Fig. 3: Relays

SERV-HB 3001 EN Edition 2.0 * 3001s1010.fm 10-3


Electric system

10.5 Control stand overview

11 5
7
10
13
6

2
1 8
3
13

12 13

13

Rollbar not included in this figure for a


clearer graphic representation.

Pos. Description
1 Accelerator pedal
2 Service brake
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
11 Low speed switch (turtle)
12 Footrest
13 Handle

10-4 SERV-HB 3001 EN Edition 2.0 * 3001s1010.fm


Electric system

22
21 23

20 24

25
19

18
26

29

17 27

28

16 15 14

10.6 Instrument panel overview


Pos. Description
14 Hazard warning switch
15 Preheating start switch
16 Hour meter
17 Not assigned
18 High beam telltale (blue)
19 Preheating telltale (yellow)
20 Telltale (red) hydraulic oil filter
21 Not assigned
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)
27 Not assigned
28 Fuel level indicator
29 Low speed switch (turtle)

SERV-HB 3001 EN Edition 2.0 * 3001s1010.fm 10-5


Electric system

Wiring diagram: overview


Electric system

10-6 SERV-HB 3001 EN Edition 2.0 * 3001s1011.fm


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

SERV-HB 3001 EN Edition 2.0 * 3001s1011.fm


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
Electric system

10-7
Electric system
10.8 Wiring diagram version 1 A4

10-8 SERV-HB 3001 EN Edition 2.0 * 3001s1011.fm


10.9 Wiring harness 1000115009 main wiring harness up to AB (legend)
No. From Up to Description Colour mm2 No. From Up to Description Colour mm2
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

SERV-HB 3001 EN Edition 2.0 * 3001s1011.fm


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
Electric system

10-9
No. From Up to Description Colour mm2 No. From Up to Description Colour mm2

10-10
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
Electric system

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

SERV-HB 3001 EN Edition 2.0 * 3001s1011.fm


10.10 Wiring harness 1000115009 main wiring harness up to AB

SERV-HB 3001 EN Edition 2.0 * 3001s1011.fm


Warning buzzer

Fuses
Electric system

10-11
10.11 Wiring harness 1000173558 main wiring harness starting AC (legend)

10-12
No. From Up to Description Colour mm2 No. From Up to Description Colour mm2
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
Electric system

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

SERV-HB 3001 EN Edition 2.0 * 3001s1011.fm


No. From Up to Description Colour mm2 No. From Up to Description Colour mm2
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

SERV-HB 3001 EN Edition 2.0 * 3001s1011.fm


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
Electric system

10-13
Electric system
10.12 Wiring harness 1000173558 main wiring harness starting AC

10-14 SERV-HB 3001 EN Edition 2.0 * 3001s1011.fm


Electric system

Electric system

Wiring harnesses: overview

SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm 10-15


Electric system

10.7 Wiring diagram A3 up to AB (legend)


No. Description Section No. Description Section
B1 Fuel-level sensor F10 K6 Preheating time lag relay C14
B2 Horn C6 K7 Start high current relay D12
B14 Warning buzzer B13 K7.1 Start interlock relay B12
D1 Diode box B9 K8 Pull contact time lag relay C13
E1 Parking light F8 K9 Pull contact high current relay D13
E5 Low beam F7 K10 Turn indicator relay E2-3
E6 High beam F7 K29 1st/2nd speed relay D9
F1 Main fuse D14 M1 Starter F14
F2 Main fuse D14 M9 Fuel pump B11
F3 Hazard warning system A4 P1 Hour meter A1
F4 Parking light E5 P2 Fuel level indication C1
F5 Low beam E5 R1 Glow plug E15
F6 High beam E5-6 S1 Preheating start switch A2-3
F7 Spare A13 S2 Engine oil pressure switch F12
F8 Drive valves A7 S3 Engine temperature switch F12
F9 Warning buzzer, relay A13-14 S5 Hydraulic oil pressure switch F11
F10 Spare A8 S8 Battery master switch F14
F11 Cutoff solenoid, fuel feed pump A11 S9 Brake light switch C7
F12 Horn, brake lights A6 S10 Hydraulic parking brake switch B6
F13 Displays, turn indicators A5 S11 Parking brake switch B7
G1 Alternator F11 S12 Right-hand side steering-column control lever D1
G2 Battery F14-15 S13 Left-hand side steering-column control lever F0-1
H1 High beam telltale B1 S19 Hazard warning switch E1
H2 Preheating telltale B1 Y1 Cutoff solenoid F13
H3 Engine temperature telltale B1 Y4 Reverse driving solenoid valve F9-10
H4 Engine oil pressure telltale B1 Y5 Forwards driving solenoid valve F9
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 Wiring diagram (legend)
H35 Fuel telltale A1

10-16 SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm


Electric system
10.8 Wiring diagram A3 (up to AB)

SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm 10-17


Electric system

10.9 Wiring harness 1000115009 main wiring harness up to AB (legend)

No. From Up to Description Colour mm2 No. From Up to Description Colour mm2
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

10-18 SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm


Electric system
10.10 Wiring harness 1000115009 main wiring harness up to AB

Warning buzzer

Fuses

SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm 10-19


Electric system

10.11 Wiring harness 1000173558 main wiring harness starting AC (legend)

No. From Up to Description Colour mm2 No. From Up to Description Colour mm2
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

10-20 SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm


Electric system
10.12 Wiring harness 1000173558 main wiring harness starting AC

SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm 10-21


Electric system

10.13 Wiring harness 1000115414 engine wiring harness (legend)

No. From Up to Colour mm


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
76 Y4 GND Earth blk 1
77 Y3 GND Earth blk 1
79 Y1 GND Earth blk 1.5
80 S5 GND Earth blk 1
81 B1 GND Earth blk 1

10-22 SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm


Electric system
10.14 Wiring harness 1000115414 engine wiring harness

SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm 10-23


Electric system

10.15 Wiring harness 1000075039/1000079012 telltale/indicator base ignition lock base up to AB (legend)

No. From Up to Colour mm


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
95 Telltales Telltales red 110
96 Telltales Telltales red 110
97 Telltales Telltales red 110
98 Telltales Telltales red 110
99 Telltales Telltales red 110
100 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

10-24 SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm


Electric system
10.16 Wiring harness 1000075039 telltale/indicator base (up to AB)

Service hours

Telltales

Fuel level
indicator

Service hours Fuel level


indicator

SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm 10-25


Electric system

10.17 Wiring harness 1000173351 ignition lock base starting AC

10-26 SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm


Electric system
10.18 Light switch connector assignment

Connector article no.: 1000094922


Article no.: 1000099402 (= Pos. no. Colour Function
without connector) 1 Blue black Forwards
2 Red + (15)
Driving direction 3 Blue Reverse
4 White + (15)
5 Green Fast
7 Yellow Slow
Connector article no.: 1000095321
Lights 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)
6 8 Black Earth
1 9 Green High beam

1 5 7
2

2
3

3
4 8

4 7 5 9

Article no.: 1000094922 Article no.: 1000095321

SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm 10-27


Electric system

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

No. From Up to Colour mm2


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 mm2


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

10-28 SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm


Electric system
10.20 Extension cable (front skip) 1000166698

Black
yellow/black
blue
grey
green

SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm 10-29


Electric system

10-30 SERV-HB 3001 EN Edition 2.0 * 3001s1012.fm


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