6001H Service Manual Tier III DUMPER

Service Manual
Dumper
Machine models 6001/6001 H

Edition 2.0
Language English
Item no. 1000163656
Documentation
Description Order no.
Operator's Manual 1000113720
Service Manual 1000163656
Spare parts list: Up to serial no. AA60080D 1000113932
Up to serial no. AB60997D 1000130920
From serial no. AD60001D 1000182752
Legend
Edition Issued
1.0 03/2006
2.0 03/2008
Copyright 2008 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 6001 EN
Order no.: 1000163656
Edition: 2.0
Table of contents
Table of contents
Table of contents
Safety Information ............................................................................................................ 0
Safety Symbols Found in this Manual ..................................................................... 0-1
Warranty .................................................................................................................. 0-1
Designated Use and Exemption from Liability ......................................................... 0-1
General Conduct and Safety Instructions ................................................................ 0-2
Conditions for use .............................................................................................. 0-2
User training and knowledge ............................................................................. 0-2
Preparing for use ............................................................................................... 0-3
Modifications and spare parts ............................................................................ 0-3
Staff Qualifications and Basic Responsibilities ........................................................ 0-3
User/owner responsibility .................................................................................. 0-3
Repair person qualifications .............................................................................. 0-3
Safety instructions Regarding Operation ................................................................. 0-4
Preparing for use ............................................................................................... 0-4
Startup and shutdown ........................................................................................ 0-4
Work area awareness ........................................................................................ 0-4
Danger area awareness .................................................................................... 0-5
Operating the machine ...................................................................................... 0-5
Carrying passengers ......................................................................................... 0-5
Carrying passengers ......................................................................................... 0-5
Mechanical integrity ........................................................................................... 0-6
Driving on public roads ...................................................................................... 0-6
Trailering and Transport .......................................................................................... 0-6
Trailers ............................................................................................................... 0-6
Transport ........................................................................................................... 0-6
Temperature Range ................................................................................................. 0-7
Safety Guidelines for Maintenance .......................................................................... 0-7
General maintenance notes .............................................................................. 0-7
Personal safety measures ................................................................................. 0-7
Preparing for maintenance and repair work ...................................................... 0-8
Performing maintenance and repairs ................................................................ 0-8
Special Hazards ....................................................................................................... 0-9
Battery ............................................................................................................... 0-9
Tracks (Track dumpers) .................................................................................. 0-9
Electric energy ................................................................................................... 0-9
Hydraulics .......................................................................................................... 0-9
Noise ............................................................................................................... 0-10
MSDS .............................................................................................................. 0-10
Tires (Wheel dumpers) .................................................................................... 0-10
Safety Guidelines while using Internal Combustion Engines ................................. 0-10
Guidelines for running the engine .................................................................... 0-10
Guidelines for fueling the engine ..................................................................... 0-11
Operation ........................................................................................................................... 1
Important information on this Service Manual ......................................................... 1-1
Type labels and component numbers ...................................................................... 1-2
Machine overview .................................................................................................... 1-5
Operating equipment overview ................................................................................ 1-7
Operating equipment (legend) ........................................................................... 1-7
Operating equipment (legend) ........................................................................... 1-8
Control stand ........................................................................................................... 1-9
Instrument panel .................................................................................................... 1-12
Dumper without cab (up to AB60997D) ........................................................... 1-12
Dumper with cab (option) up serial number AB60997D .................................. 1-13
Dumper without/with cab (option) from serial number AD60001D .................. 1-14
SERV-HB 6001 EN - Edition 2.0 * Sh6001En_0IVZ.fm T-1

Table of contents
Maintenance prop .................................................................................................. 1-15

Front skip maintenance prop ........................................................................... 1-15
Swivel skip maintenance prop ......................................................................... 1-16
Centre pivot prop ................................................................................................... 1-16
Specifications....................................................................................................................2
Chassis .................................................................................................................... 2-1
Engine ...................................................................................................................... 2-1
Engine capacities ............................................................................................... 2-2
Engine tightening torques .................................................................................. 2-2
Travelling drive ......................................................................................................... 2-2
Brakes ...................................................................................................................... 2-2
Steering system ....................................................................................................... 2-3
Work hydraulics ....................................................................................................... 2-3
Loader unit ............................................................................................................... 2-3
Drive specifications .................................................................................................. 2-3
Vibration ................................................................................................................... 2-3
Electric system ......................................................................................................... 2-4
Up to serial no. AB60997D ................................................................................ 2-4
From serial no. AD60001D ................................................................................ 2-5
Tyres ........................................................................................................................ 2-6
Noise levels .............................................................................................................. 2-6
Coolant compound table .......................................................................................... 2-7
General tightening torques ....................................................................................... 2-7
Tightening torques for hydraulic screw connections (dry assembly) ................. 2-7
Tightening torques for high-resistance screw connections ................................ 2-9
Tightening torques for Nordlock lock washers ................................................. 2-10
Dimensions model 6001 (up to AB60997D) ........................................................... 2-11
Dimensions model 6001 HF (Hydrostat/front tip) ................................................... 2-12
Dimensions model 6001 HF (Hydrostat/front tip) with cab ..................................... 2-13
Dimensions model 6001 HS (Hydrostat/swivel) ..................................................... 2-14
Dimensions model 6001 HS (Hydrostat/swivel) with cab ....................................... 2-15
Maintenance ......................................................................................................................3
Engine/machine fluids and lubricants (up to AB60997D) ......................................... 3-1
Maintenance plan (overview) ................................................................................... 3-3
Service package ...................................................................................................... 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 (up to serial no. AB60997D) ........................ 3-9
Replacing the fuel filter .................................................................................... 3-10
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 ............................................................................................... 3-18
T-2 SERV-HB 6001 EN - Edition 2.0 * Sh6001En_0IVZ.fm

Table of contents
Air filter ................................................................................................................... 3-19

Weekly check of air filter for dirt ...................................................................... 3-19
Replacing the filter ........................................................................................... 3-20
Functional check once a week of the dust valve ............................................. 3-21
V-belt ..................................................................................................................... 3-21
Checking V-belt tension ................................................................................... 3-21
Retightening the V-belt .................................................................................... 3-22
Gearbox lubrication system (up to AB60997D) ..................................................... 3-24
Checking the oil level ....................................................................................... 3-24
Filling up gearbox oil ........................................................................................ 3-25
Changing gearbox oil ....................................................................................... 3-26
Replacing the gearbox oil filter cartridge ......................................................... 3-27
Hydraulic system ................................................................................................... 3-28
Checking the hydraulic oil level ....................................................................... 3-29
Filling up hydraulic oil ...................................................................................... 3-29
Changing hydraulic oil ..................................................................................... 3-30
Monitoring the hydraulic oil reflux filter ............................................................ 3-30
Replacing the hydraulic oil reflux filter ............................................................. 3-30
Checking hydraulic pressure lines ................................................................... 3-31
Lubrication points ................................................................................................... 3-32
Tyre maintenance and checks ............................................................................... 3-33
Checks once a day .......................................................................................... 3-33
Checks once a week ....................................................................................... 3-33
Changing wheels .................................................................................................. 3-34
Removing the wheels ...................................................................................... 3-34
Fitting the wheels ............................................................................................. 3-34
Axles ...................................................................................................................... 3-35
Checking the oil level and filling up oil ............................................................. 3-35
Draining oil ....................................................................................................... 3-35
Electric system ....................................................................................................... 3-36
Service and maintenance work at regular intervals ......................................... 3-36
Instructions concerning specific components .................................................. 3-37
Alternator ......................................................................................................... 3-37
Battery ................................................................................................................... 3-38
General maintenance work .................................................................................... 3-40
Cleaning .......................................................................................................... 3-40
General instructions for all areas of the machine ............................................ 3-40
Exterior of the machine .................................................................................... 3-41
Engine compartment ....................................................................................... 3-41
Screw connections and attachments ............................................................... 3-41
Pivots and hinges ............................................................................................ 3-41
Engine ................................................................................................................................ 4
Engine overview 1104 C-44 ..................................................................................... 4-1
Engine overview 1104 C-44T .................................................................................. 4-3
Fuel system ............................................................................................................. 4-5
Checking and adjusting valve clearance ........................................................... 4-6
Tightening order for cylinder head bolts ............................................................ 4-7
Checking the injection nozzles ................................................................................ 4-8
Pressure check .................................................................................................. 4-8
Checking the nozzle jet ..................................................................................... 4-9
Injection time ..................................................................................................... 4-9
Adjusting engine revs ............................................................................................ 4-10
Compression .......................................................................................................... 4-10
Checking the coolant thermostat ........................................................................... 4-11

Table of contents
Checking the thermal switch ............................................................................ 4-11

Oil pressure switch ................................................................................................. 4-12
Checking the coolant circuit ................................................................................... 4-12
TD 2011 L04 W engine overview (from serial no. AD60001D) .............................. 4-13
Fuel system ............................................................................................................ 4-16
Checking and adjusting valve clearance ................................................................ 4-17
Checking and adjusting the fuel injectors .............................................................. 4-18
Adjusting engine revs ............................................................................................. 4-20
Compression pressure ........................................................................................... 4-21
Removing/mounting the cylinder head ................................................................... 4-22
Intake/exhaust manifold ................................................................................... 4-25
Replacing the injection pump/setting fuel injection time ........................................ 4-25
Oil pressure switch ................................................................................................. 4-29
Engine trouble ........................................................................................................ 4-30
Travelling drive..................................................................................................................5
Torque converter gearbox SS620 (from serial no. AA60004D to AB60997D) ......... 5-1
Section SS 600 .................................................................................................. 5-5
Torque converter gearbox PS750 (opt) from serial no. AB60078D to AB60997D ... 5-6
Section PS 750 ................................................................................................ 5-10
Oil level check on torque converter gearbox ................................................... 5-11
Cardan shaft .......................................................................................................... 5-11
Transfer gearbox (from serial no. AA60004D to AB60997D) ................................. 5-12
Travelling drive diagram (up to serial no. AB60997D) ........................................... 5-14
Test instructions SS620 ......................................................................................... 5-15
Check: converter pressure ............................................................................... 5-15
Check: main pressure ...................................................................................... 5-16
Check: clutch pressure (forwards & reverse) ................................................... 5-17
Check: oil cooler flow capacity (in neutral position) ......................................... 5-18
Test instructions PS750 ......................................................................................... 5-19
Checking converter pressure (up to AB60997D) ............................................. 5-19
Checking main pressure (up to AB60997D) .................................................... 5-20
Check: oil cooler flow capacity (in neutral position) up to AB60997D .............. 5-21
Hydrostat (from serial no. AD60001D) ................................................................... 5-22
Automotive driving ........................................................................................... 5-22
Closed circuit with inching valve ...................................................................... 5-22
Variant ............................................................................................................. 5-22
Variable displacement motor A6VM160HA2U1 ..................................................... 5-23
High-pressure-sensitive regulation .................................................................. 5-23
Travelling drive overview ................................................................................. 5-24
Hydraulic diagram ............................................................................................ 5-24
Replacing external components (hydraulic motor) ................................................. 5-25
Replacing the rotary shaft lip seal .................................................................... 5-26
Replacing seals ............................................................................................... 5-27
Control unit ...................................................................................................... 5-27
Sealing the cover ............................................................................................. 5-29
Hydraulic motor settings ........................................................................................ 5-31
Checking control initiation ................................................................................ 5-31
Checking the settings ...................................................................................... 5-32
Variable displacement pump A4VG71DA1D8 (from serial no. AD60001D) ........... 5-33
Variable displacement pump: diagram ............................................................ 5-35
Variable displacement pump: diagram ............................................................ 5-36
Power train overview ....................................................................................... 5-37
Connecting plate with valves ........................................................................... 5-38
Inching valve .......................................................................................................... 5-39
Inching ............................................................................................................. 5-39
Replacing components (hydraulic pump) ............................................................... 5-40

Table of contents
Replacing the rotary shaft lip seal ................................................................... 5-40

Seals ................................................................................................................ 5-41
Auxiliary (boost) pump ..................................................................................... 5-44
Replacing the inching valve ............................................................................. 5-44
Towing ................................................................................................................... 5-46
Opening the high-pressure circuit .................................................................... 5-46
Axles .................................................................................................................................. 6
Axle type label ......................................................................................................... 6-1
Drain, filler and check plug ...................................................................................... 6-2
Transfer gearbox ............................................................................................... 6-3
Tightening torques ................................................................................................... 6-4
Wheel screws .................................................................................................... 6-4
General tightening torques (Nm) ....................................................................... 6-4
Cardan shaft ............................................................................................................ 6-5
Transfer gearbox (up to serial no. AB60997D) ........................................................ 6-6
Semiaxles (up to serial no. AB60997D) ................................................................... 6-8
Wheel hub .............................................................................................................. 6-12
Brakes (up to serial no. AB60997D) ...................................................................... 6-16
Differential (up to serial no. AB60997D) ................................................................ 6-22
Drive housing (from serial no. AD60001D) ............................................................ 6-24
Semiaxles (from serial no. AD60001D) ................................................................. 6-26
Rear axle ......................................................................................................... 6-28
Brakes (from serial no. AD60001D) ....................................................................... 6-30
Differential (from serial no. AD60001D) ................................................................. 6-32
Removing the double cardan shaft (rear axle) ....................................................... 6-33
Assembling the joint housing (rear axle) ................................................................ 6-34
Removing the rear axle planetary drive ................................................................. 6-36
Mounting the rear axle planetary drive .................................................................. 6-39
Special tools .......................................................................................................... 6-43
Brakes ................................................................................................................................ 7
Brake circuit (up to serial no. AB60997D) ................................................................ 7-1
Brake circuit (from serial no. AD60001D) ................................................................ 7-2
Service brake ..................................................................................................... 7-2
Steering system ................................................................................................................ 8
Steering circuit ......................................................................................................... 8-1
Steering unit: diagram .............................................................................................. 8-3
Function ............................................................................................................. 8-4
Steering unit connections ........................................................................................ 8-4
Exploded view of steering unit (up to serial no. AB60997D) .................................... 8-6
Priority valve overview ....................................................................................... 8-6
Priority valve (legend) ........................................................................................ 8-6
Hydraulic system .............................................................................................................. 9
Gear pump ............................................................................................................... 9-1
Manual spool connections: overview ....................................................................... 9-2
Swivel skip spool (up to serial no. AB60997D) .................................................. 9-2
Swivel skip spool (from serial no. AD60001D) .................................................. 9-3
Front skip spool (up to serial no. AB60997D) .................................................... 9-4
Front skip spool (from serial no. AD60001D) .................................................... 9-5
Dumping the skip: hydraulic diagram ....................................................................... 9-6

Table of contents

Swivelling the skip (option): hydraulics diagram ...................................................... 9-8
Test instructions ..................................................................................................... 9-10
Checking the work hydraulics on a swivel skip machine ................................. 9-10
Checking the work hydraulics on a front skip machine .................................... 9-11
A4 diagram (up to serial no. AB60997D) ............................................................... 9-12
Diagram (up to AB60997D): legend ................................................................. 9-13
A4 diagram (from serial no. AD60001D) ................................................................ 9-14
Diagram (from AD60001D): legend ................................................................. 9-15
A3 hydraulics diagram (up to serial no. AB60997D) .............................................. 9-16
A3 hydraulics diagram (from serial no. AD60001D) ............................................... 9-17
Electric system................................................................................................................10
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
Up to serial no. AB60997D .............................................................................. 10-3
From serial no. AD60001D .............................................................................. 10-4
Fuse box .......................................................................................................... 10-4
Relays .............................................................................................................. 10-4
Operating equipment overview .............................................................................. 10-5
Operating equipment (legend) ......................................................................... 10-5
Operating equipment (legend) ......................................................................... 10-6
Dumper with cab (option) from serial number AD60001D ............................... 10-7
Wiring diagram legend (up to AB60997D) ............................................................. 10-9
Wiring diagram version 1 A4 (up to AB60997D) .................................................. 10-10
Wiring diagram legend (from AD60001D) ............................................................ 10-11
A4 wiring diagram (from AD60001D) ................................................................... 10-12
Wiring harness legend 1000129021: main wiring harness (up to AB60997D) .... 10-13
Wiring harness 1000129021: main wiring harness (up to AB60997D) ................ 10-14
Wiring harness legend 1000174363: main wiring harness (from AD60001D) ..... 10-15
Wiring harness 1000182212: main wiring harness (from AD60001D) ................. 10-17
Wiring harness 1000115003 main wiring harness with Powershift option (legend) .......
10-18
Wiring harness 1000115003 main wiring harness with Powershift option ........... 10-19
Wiring harness legend 1000115817: additional Powershift electrics ................... 10-20
Shift positions ................................................................................................ 10-20
Wiring harness 1000115817: additional Powershift electrics ............................... 10-21
A3 wiring diagram legend (up to AB60997D) ....................................................... 10-25
A3 wiring diagram (up to AB60997D) .................................................................. 10-26
Wiring diagram legend (from AD60001D) ............................................................ 10-27
A4 wiring diagram (from AD60001D) ................................................................... 10-28
Wiring harness legend 1000115817: additional Powershift electrics ................... 10-29
Shift positions ................................................................................................ 10-29
Wiring harness 1000115817: additional Powershift electrics ............................... 10-30
Wiring harness legend 1000115003: main wiring harness (up to AB60997D) .... 10-31
Wiring harness 1000115003: main wiring harness (up to AB60997D) ................ 10-32
Wiring harness legend 1000182212: main wiring harness (from AD60001D) ..... 10-33
Wiring harness 1000182212: main wiring harness (from AD60001D) ................. 10-35
Wiring harness 1000115003 main wiring harness with Powershift option (legend) .......
10-36
Wiring harness 1000115003 main wiring harness (Powershift option) ................ 10-37

Table of contents
Wiring harness 1000115002 engine wiring harness (legend) .............................. 10-38

Wiring harness 1000115002 engine wiring harness ............................................ 10-39
Wiring harness legend 1000075039/1000115017 telltale/indicator base ignition lock
base ..................................................................................................................... 10-40
Wiring harness 1000075039 telltale/indicator base ............................................. 10-41
Wiring harness 1000115017 ignition lock base ................................................... 10-42
Wiring harness legend 1000115006: STVO (Austrian road traffic regulations) wiring
harness (up to AB60997D) .................................................................................. 10-43
Wiring harness 1000115006: STVO (Austrian road traffic regulations) wiring harness
(up to AB60997D) ................................................................................................ 10-44
Wiring harness legend 1000174957: STVO (Austrian road traffic regulations) wiring
harness (from AD60001D) ................................................................................... 10-45
Wiring harness: STVO (Austrian road traffic regulations) wiring harness 1000174957
(from AD60001D) ................................................................................................. 10-46

Index
Index
A S
Abbreviations ............................................................................. 1-1 Specifications .................................................... 2-1, 4-1, 5-1, 10-1
Air filter .................................................................................... 3-19 Chassis ................................................................................2-1
F Coolant compound table .....................................................2-7
Dimensions ...............................................................2-11, 2-12
Fluids and lubricants .................................................................. 3-1
Electric system ....................................................................2-4
I Engine .................................................................................2-1
Important information Noise levels .........................................................................2-6
On this service manual ........................................................1-1 T
Instrument panel overview .........................................................1-5
Travelling drive
M A4VG56 hydraulic pump
Maintenance Replacing components 5-40
Bleeding the fuel system .....................................................3-8 Hydraulic motor A6VM
Checking hydraulic pressure lines .....................................3-31 Settings
Checking the engine oil level .............................................3-11 Control initiation 5-31
Checking the gearbox oil level ..........................................3-24 Inching valve .....................................................................5-39
Checking the hydraulic oil level .........................................3-29 Tyre maintenance ....................................................................3-33
Cleaning ............................................................................ 3-40 W
Electric system .................................................................. 3-36
Wheel change ..........................................................................3-34
Engine and hydraulics cooling system .............................. 3-15
Engine lubrication system .................................................3-11
Filling in engine oil ............................................................. 3-12
Filling in gearbox oil ........................................................... 3-25
Filling up coolant ............................................................... 3-16
Filling up hydraulic oil ........................................................3-29
Fluids and lubricants ...........................................................3-1
Fuel system ......................................................................... 3-7
General maintenance work ...............................................3-40
Hydraulic system ............................................................... 3-28
Instructions concerning specific components .................... 3-37
Maintenance plan ................................................................ 3-3
Pivots and hinges .............................................................. 3-41
Replacing the gearbox oil filter cartridge ........................... 3-27
Screw connections ............................................................ 3-41
Service and maintenance work at regular intervals ........... 3-36
Tyre maintenance .............................................................. 3-33
V-belt ................................................................................. 3-21
Wheel change ................................................................... 3-34
O
Operation
Control stand ....................................................................... 1-9
Control stand overview .............................. 1-7, 1-8, 10-5, 10-6
Dumpers with cab (option) for 6001/9001 machines with serial
numbers AB ..., and 10001 machines with serial
numbers AA ... ...............................1-13, 1-14, 10-7
Instrument panel ................................................................ 1-12
Dumpers without cab 1-12
Instrument panel overview ..................................................1-5
R
Refuelling ................................................................................... 3-7
I-1 SERV-HB 6001 EN - Edition 2.0 * Sh6001En_0SIX.fm

Safety Information
0 Safety Information
0.1 Safety Symbols Found in this Manual
This is the safety alert symbol. It is used to alert you to potential personal hazards.
Obey all safety messages that follow this symbol to avoid injury or death.
NOTICE: indicates a hazardous situation which, if not avoided, could result in

property damage.
Note: Contains additional information important to a procedure.
Important
Important identifies an instruction that, when followed, provides 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, such as
waste oil, is not subject to proper use or disposal.
0.2 Warranty
Warranty claims can be brought forward to your Wacker Neuson dealer only. This
requires, among other things, following the instructions in this Service Manual.
0.3 Designated Use and Exemption from Liability

In accordance with its designated use, the machine may be used ONLY for moving
earth, gravel, coarse gravel or ballast and rubble. It may also be used for working with
the attachments mentioned in the Fields of Application chapter.
No other applications are designated for the use of the machine. Wacker Neuson 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 this Service
Manual and observing the maintenance schedule.
Machine safety 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
Wacker Neuson. Wacker Neuson will not be liable for damage resulting from
unapproved parts or unauthorized modifications.
SERV-HB 6001 EN Edition 2.0 * 6001s100.fm 0-1

Safety Information
Wacker Neuson shall not be liable for personal injury and/or damage to property
caused by failure to observe the safety instructions on labels and in this Service
Manual, and by the negligence of the duty to exercise due care when:
handling the machine
operating the machine
servicing the machine and carrying out maintenance work
repairing the machine
This is also applicable when special attention has not been drawn to the duty to
exercise due care.
Read and understand this Service Manual before starting up, servicing or repairing the
machine. Observe all safety instructions.
The machine may NOT be used for transport jobs on public roads!
0.4 General Conduct and Safety Instructions

Conditions for use
The machine has been designed and built in accordance with state-of-the-art standards
and recognized safety regulations. Nevertheless, its use can constitute a risk to life and
limb of the user or of third parties, or cause damage to the machine and to other
material property.
Read and follow this Service Manual and other manuals that accompany the machine.
The machine must only be used in accordance with its designated use and the
instructions set forth in this Service Manual.
The machine must only be used by safety-conscious persons who are fully aware of the
risks involved in operating the machine.
The machine must only be used when it is in technically perfect condition. Any
mechanical dysfunctions, especially those affecting the safety of the machine, must be
repaired immediately.
The user/owner commits himself to operate and keep the machine in perfect condition
and, if necessary or required by law, to require the operating or servicing persons to
wear protective clothing and safety equipment
User training and knowledge

Always keep this Service Manual and other manuals that accompany the machine on
hand in their storage bin at the place of use of the machine. Immediately replace an
incomplete or illegible Service Manual.
All persons working on or with the machine must read and understand the safety
information in this Manual before beginning work. This applies especially to persons
working only occasionally on the machine, such as performing set-up or maintenance
tasks.
Follow, and instruct the operator in, legal and other mandatory regulations relevant to
accident prevention and environmental protection.These may include handling
hazardous substances, issuing and/or wearing personal protective equipment, or
obeying traffic regulations.
The user/owner must regularly ensure that all persons entrusted with operation or
maintenance of the machine are working in compliance with this Service Manual and
are aware of the risks and safety factors of the machine.
0-2 SERV-HB 6001 EN Edition 2.0 * * 6001s100.fm

Safety Information
Preparing for use

Before starting up the machine, ALWAYS inspect the machine to make sure that it is
ready for safe work and road operation.
Wear close-fitting work clothes that do not hinder movement. Tie back long hair and
remove all jewelry (including rings).
Modifications and spare parts

NEVER make any modifications, additions or conversions to the machine and its
superstructures (for example, cab, etc.), or the machines attachments, without the
approval of Wacker Neuson! Such modifications may affect safety and/or machine
performance. This also applies to the installation and adjustment of safety devices and
valves, as well as to welding work on load-bearing elements.
Spare parts must comply with the technical requirements specified by Wacker Neuson.
Contact your Wacker Neuson dealer for assistance.
0.5 Staff Qualifications and Basic Responsibilities
User/owner responsibility
Only allow trained and experienced individuals to drive, maintain, or repair the
machine. NEVER let unauthorized or underaged persons drive or work with the
machine.
Clearly and unequivocally define the individual responsibilities of the staff for operation,
maintenance, and repair.
Define the machine operators responsibilities on the job site and for observing traffic
regulations. Give the operator the authority to refuse instructions by third parties that
are contrary to safety.
Do not allow persons to be trained or instructed by anyone other than an experienced
person. Also, NEVER allow persons taking part in a general training course to work on
or with the machine without being permanently supervised by an experienced person.
Repair person qualifications

Work on the electric system and equipment, on the undercarriage and the steering and
brake systems may be carried out only by skilled individuals who have been specially
trained for such work.
Work on the hydraulic system of the machine must be carried out only by staff with
special knowledge and experience in hydraulic equipment.

Safety Information
0.6 Safety instructions Regarding Operation

Preparing for use
Keep the machine clean. This reduces the risk of fire hazards (such as from
combustible materials like rags), and reduces the risk of injury or operational accidents
that can be caused by dirt build-up on the drive pedals or footholds.
Observe all safety, warning, and informational signs and labels on the machine.
Start and operate the machine from the seat only.
The operator must sit in the seat, fasten and tighten the seat belt before putting the
machine into operation.
Always adjust the seating position before starting work. Never change the seat position
when driving or working!
Make sure that all safety devices are properly installed and functional before starting
work.
Before putting the machine/attachment into operation (startup/moving), make sure that
no one in the immediate vicinity will be at risk.
Startup and shutdown

Carry out startup and shutdown procedures according to this Service Manual.
Observe all indicator lights.
Do not use starting fluid (for example, ether) especially in those cases in which a heater
plug (intake air pre-heating) is used at the same time.
Make sure the drive levers, the signaling and the light systems are functional before
operating the machine, and also before restarting after an interruption of work.
6001 Dumper: Make sure that the service brake and the parking brake are functional
before operating the machine, and also after a work interruption. The drive must be
switched off if the parking brake is applied
Fold up the control lever base before releasing the seat belt in order to avoid
unintentional operation.
Work area awareness

Familiarize yourself with the surroundings and circumstances of the work site before
beginning work. Be aware of:
obstacles in the working and traveling area
the soil bearing capacity
any necessary barriers separating the work site from public roads
Always keep at a safe distance from the edges of building pits and slopes.
Look out for the following when working in buildings or in enclosed areas:
height of the ceiling/clearances
width of entrances
maximum load of ceilings and floors
sufficient room ventilationdanger of carbon monoxide poisoning!
Observe the danger area. See Danger area awareness.
Always use the rearview mirror.
Always switch on the work lights in conditions of poor visibility and after dark. However,
make sure that users of public roads will not be temporarily blinded by the work lights.
Provide additional lighting of the work area if the lights of the machine are not sufficient
for carrying out work safely.

Safety Information
Danger area awareness

The danger area is the area in which persons are in danger due to the movements of
the machine, work equipment, additional equipment, or material.
The danger area also includes the area affected by falling material, equipment or
construction debris. The danger area must be extended by 0.5 m (20 inches) in the
immediate vicinity of buildings, scaffolds, or other elements of construction.
Seal off the danger area if it is not possible to keep a safe distance. Stop work
immediately if persons do not leave the danger area in spite of warnings!
Operating the machine

Never operate the machine if you are standing on the ground.
Operate the machine ONLY when you are seated and you have fastened your seat
belt. Switch off the engine before releasing the seat belt.
On sloping terrain, adapt your drive speed to the prevailing ground conditions.
Never get on or off a moving machine, and Never jump off the machine.
Carrying passengers
Always adapt your drive speed to the road and ground conditions, and to the visibility
conditions. Ask for help in navigating difficult passages or obstacles. To avoid tipping
the dumper, drive appropriately and slowly as conditions dictate. This applies in
particular to rough terrain, the edges of trenches, curves and emergency braking. Use
only the low speed range when driving off-road (see the turtle indicator on the
instrument panel).
6001 Dumper: Proceed with extreme care when driving on slopes. The dumper can be
driven on firm ground in all positions on slopes up to 25%.
Make sure the engine cover is closed and locked before starting the dumper.
Apply the parking brake when parking the machine. If possible, do not park the dumper
on slopes. If this cannot be avoided, use wheel chocks, etc. Lower the skip before
leaving the dumper. Apply the parking brake only in an emergency when driving the
machine.
Keep the base plate of the skip in a clean condition so that the material is easily
dumped out of the skip. Load only material that can be easily dumped out.
Never drive too close to the edges of unsecured pits, precipices, etc. The pressure of
the wheels on the ground can cause the edge to give way.
Never dump material into trenches where people are working. If the driver cannot see
into the trench, he or she must be guided by someone who can see into the trench.
Always make sure the brakes are in perfect condition.
Carrying passengers
Apart from the driver, do not allow anyone to ride on the machine.
Never lift, lower, or carry persons in the work equipment or attachments.
Never install a man basket or a working platform to the machine.

Safety Information
Mechanical integrity
Take the necessary precautions to make sure the machine is used only when in a safe
and reliable state.
Operate the machine ONLY if all protective and safety-oriented devices (ROPS,
removable safety devices, soundproofing elements, mufflers, etc.) are in place and fully
functional.
Check the machine at least once a day/per work shift for visible damage and defects.
Report any changes, including changes in the machines working behavior, to your
supervisor immediately!
If the machine is behaving unpredictably, stop the machine immediately, lock it, and
report the malfunction to the competent authority/person. Safety-relevant damage or
malfunctions of the machine must be rectified immediately.
Driving on public roads

When driving on public roads, ways and places, observe all applicable traffic
regulations. If necessary, make sure beforehand that the machine is in compliance with
these regulations.
When crossing underpasses, gates, bridges and tunnels, or when passing under
overhead lines, make sure the clearance height and width are sufficient.
0.7 Trailering and Transport
Trailers
Even though the dumper is equipped with towing gear, it is not a tractor and may not be
used as such in difficult terrain.
If the dumper is used on construction sites for towing trailers, weight the skip with 25%
of the payload. However, do not exceed the dumpers maximum payload with the
combination of towed equipment and the weight in the skip!
Secure the towing pin of the towing gear with a split pin.
Counterweights affect handling and the machines steering capability.
Use special care when coupling trailers, and couple them with the specially required
devices only.
Always secure trailers against unintentional movement.
If optional equipment such as a trailer is installed, make sure that all lights and
associated indicator lamps are installed and functional.
Transport
The machine must be towed, loaded, and transported only in accordance with
procedures described in this Service Manual.
For towing the machine, observe the prescribed transport position, admissible speed,
and itinerary.
Make sure that the vehicle transporting the machine has a sufficient capacity and
payload.
Safely secure the machine on the transporting vehicle. Use the specified tie-down
points.

Safety Information
0.8 Temperature Range

The machine may only be used between a maximum +45C (113F) and
minimum -15C (5F). Contact your Wacker Neuson dealer if you intend to use the
machine in other temperature ranges. Store the machine in a dry place at room
temperature (about 15C, or 59F). Observing these temperature ranges will help to
prolong the machines service life.
0.9 Safety Guidelines for Maintenance
General maintenance notes

Adhere to prescribed intervals or those specified in this Service Manual for routine
checks/inspections and maintenance work.
For inspection and maintenance work, ensure that all tools and workshop equipment
are adapted to the task that must be performed.
Replace hydraulic hoses within stipulated and appropriate intervals even if no safety-
relevant defects have been detected.
Make sure all consumables and replaced parts are disposed of safely and with
minimum environmental impact.
Always tighten any screws, electrical connections, or hose connections that may have
been loosened during maintenance.
Upon completion of the maintenance and repair work, immediately refit and check any
safety devices removed for set-up or maintenance purposes.
Personal safety measures

Brief the staff and the driver before beginning maintenance or repair work. Appoint
someone to supervise the activities.
Always work in groups of two. Both persons must be trained on the machineone
person must be seated on the seat and maintain visual contact with the other person.
Observe the specific safety instructions in the Maintenance section of this Service
Manual.
Always keep a safe distance from all rotating and moving parts, for example, fan
blades, V-belt drives, PTO shaft drives, fans, etc.
Before starting work on machine parts dangerous to life and limb (bruising, cutting),
always ensure safe blocking/support of these areas.
Apply special care when working on the fuel system due to the increased danger of fire.
Engine block and muffler system become very hot during operation and require cool-
down time after machine is shut off. Avoid contact with hot parts. Wait for the machine
to cool before touching components.
Retainer pins can fly out or splinter when struck with force. Avoid striking the pins
during operation, repair, or maintenance.
Do not use starting fluid (for example, ether), especially in those cases in which a
heater plug (intake air pre-heating) is used at the same time.

Safety Information
Preparing for maintenance and repair work

Prior to carrying out repair and maintenance work, always attach a warning label such
as Repair workdo not start machine! to the control elements as a precautionary
measure.
Observe the startup and shutdown procedures set forth in this Service Manual. This
applies to any work concerning the operation, conversion or adjustment of the machine
and its safety-oriented devices, or any work related to inspection and maintenance.
Prior to carrying out assembly work on the machine, make sure no movable parts will
roll away or start moving.
Carry out maintenance work ONLY if:
the machine is positioned on firm and level ground
secured against unintentional movement
all hydraulically movable attachments and working equipment have been lowered to the
ground
if the engine is switched off
if the ignition key has been removed
the pressure accumulator is empty
Carry out maintenance work beneath a raised machine, attachments or additional
equipment ONLY if a safe and secure support has been provided. The use of hydraulic
rams or jacks as the sole method of support does NOT sufficiently secure raised
machines or equipment/attachments!
Performing maintenance and repairs

Observe the adjustment, maintenance and inspection activities and intervals set forth in
this Service Manual, including information on the replacement of parts and partial
equipment. These activities must be carried out only by qualified personnel.
Disconnect the negative battery terminal when working on the electrical system.
Do not allow the machine to be serviced, repaired, or test-driven by unauthorized staff.
If maintenance with the engine running cannot be avoided, lower the skip and apply the
parking brake.
Wear a safety harness when performing elevated maintenance work. Keep all handles,
steps, handrails, platforms, landings, and ladders free from dirt, snow and ice.
Always use specially designed or otherwise safety-oriented ladders and working
platforms to carry out overhead assembly work. NEVER use machine parts or
attachments/superstructures as a climbing aid!
Do not use the work equipment as lifting platforms for persons.
In accordance with this Service Manual and instructions for the respective assembly,
release the pressure in all system sections and pressure lines (hydraulic system)
before carrying out any maintenance work.

Safety Information
0.10 Special Hazards
Battery
In case of a frozen battery or of an insufficient electrolyte level, do not try starting the
machine with battery jumper cables. The battery can burst or explode.
Batteries contain caustic sulphuric acid. When handling the battery, observe the
specific safety instructions and regulations relative to accident prevention.
A volatile oxyhydrogen mixture forms in batteries during normal operation and
especially when charging. Always wear gloves and eye protection when working with
batteries.
Starting the machine with a battery jumper cable can be dangerous if carried out
improperly. Observe the safety instructions regarding the battery.
Tracks (Track dumpers)

Repair work on the tracks must be carried out only by trained technical staff or by an
authorized workshop.
Defective tracks reduce the machines operational safety. Therefore, check the tracks
regularly for cracks, cuts or other damage.
Check track tension at regular intervals.
Electric energy
Use only original fuses with the specified current rating.
In case of electrical system malfunctions, switch off the machine immediately,
disconnect the battery (by using the battery master switch), and carry out
troubleshooting procedures.
When working with the machine, maintain a safe distance from overhead electric lines!
If work must be carried out close to overhead lines, the equipment and attachments
must be kept well away from them.
If the machine comes into contact with a live wire:
Immediately drive the machine out of the danger area.
Warn others against approaching and touching the machine.
Do not leave the machine until the line that has been touched or damaged has been
safely de-energized!
Make sure that work on the electric system is carried out only by a technician with
appropriate training, in accordance with applicable electrical engineering codes.
Inspect and check the electrical equipment of the machine at regular intervals. Defects
such as loose connections or scorched cables must be repaired immediately.
Observe the operating voltage of the machine/attachments.
Always remove the grounding strap from the battery when working on the electric
system.
Hydraulics
Check all lines, hoses, and screwed connections regularly for leaks and obvious
damage. Repair any damage and leaks immediately. Splashed oil can cause injury and
fire!

Safety Information
Noise
Close all sound baffles during operation.
Wear ear protection. This is especially important when performing hammer operations
or working in enclosed areas.
MSDS
When handling oil, grease, and other chemical substances such as battery electrolyte
or hydraulic fluid, observe the product-related safety regulations (Material Safety Data
Sheet: MSDS).
Tires (Wheel dumpers)

Repair work on the tires must be carried out only by trained technical staff or by an
authorized workshop.
Defective tires reduce the machines operational safety. Therefore, check the tires
regularly for cracks, cuts or other damage.
Check the tire pressure at regular intervals.
0.11 Safety Guidelines while using Internal Combustion Engines
Internal combustion engines present special hazards during operation and

fueling. Failure to follow the warnings and safety guidelines could result in
severe injury or death.
Read and follow the warning instructions in the engine owners manual and
the safety guidelines below.
Guidelines for running the engine

Keep the area around muffler pipe free of flammable materials.
Check the fuel lines and the fuel tank for leaks and cracks before starting the engine.
Do not run the machine if fuel leaks are present or the fuel lines are loose.
Never run the machine indoors or in an enclosed area such as a deep trench unless
adequate ventilation, through such items as muffler fans or hoses, is provided. Muffler
gas from the engine contains poisonous carbon monoxide gas; exposure to carbon
monoxide can cause loss of consciousness and may lead to death.
Never smoke while operating the machine.
Never run the engine near open flames.
Never touch the engine or muffler while the engine is on or immediately after it has
been turned off.
Never operate a machine when its fuel cap is loose or missing.
Never remove the radiator cap when the engine is running or hot. The radiator fluid is
hot and under pressure, and may cause severe burns!

Safety Information
Guidelines for fueling the engine

Clean up any spilled fuel immediately.
Refill the fuel tank in a well-ventilated area.
Replace the fuel tank cap after refueling.
Never smoke when refueling the engine.
Never refuel a hot or running engine.
Never refuel the engine near an open flame.

Safety Information

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. After you will have read this Service Manual,
your knowledge will help you avoid danger and reduce repair costs and downtimes. You
will thereby increase the reliability and the service life of the machine.
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 the dumper, 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.
1-1 SERV-HB 6001 EN Edition 2.0 * 6001s110.fm

Operation
1.2 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 located on the engine cover (6001 without cab) or at the front right on the
front chassis (6001 with cab).
Fig. 1: Type label without cab
Type label information
Model: 6001
Year: 2004
PIN: AD00000D
Power: 64.6 kW (86.6 hp)
Fig. 1: Type label with cab Mass: 4240 kg (9348 lbs)
Load: 6000 kg (13228 lbs)
Max. gross mass: ---------------
Max. axle load: ---------------
---------------
Other information see Specifications on page 2-1
Fig. 1: Type label
Engine number
The type label (arrow) is located on the valve cover (engine).
Example: Perkins 1104C-44T
Fig. 2: Perkins diesel engine type label up to serial

number AB60997D
Example: Deutz TD 2011 L04
Fig. 2: Deutz diesel engine type label from serial number

AD60001D

Operation
Number of torque converter gearbox

The type label is located on the mounting base of the forwards/reverse drive changeover
valve.
Fig. 3: Number of torque converter gearbox
Rollbar type label

The type label is located on the right on the rollbar.
Fig. 4: Rollbar type label

Cab (option) type label
The type label is located in the cab on the left on the cab frame.
Fig. 5: Cab (option) type label

Axle type label
The type label (arrow) is located on the upper side of the axle housing.
Fig. 6: Axle type label

Operation
Spool number
The type label (arrow) is located on the spool housing.
Front skip spool type label (up to AB60997D)
Fig. 7: Swivel skip spool type label Spool type label (from AD60001D)
Hydraulic pump type label (from serial no. AD60001D)
Fig. 8: Hydraulic pump type label (from AD60001D)
Hydraulic motor type label (from serial no. AD60001D)
Fig. 9: Hydraulic motor type label (from AD60001D)

Operation
1.3 Machine overview

11
10
2
4
1 9
7 Model 6001F
10
11
6
5 3
4 12
13
8 14
1 9
7 Model 6001S

Operation
10
6
15
9
13
5
3
12
14
4 7
8
1
Model 6001 with cab (option)
Pos. Description
1 Rear chassis
2 Front chassis
3 Tilt ram
4 King link
5 Seat
6 Control stand
7 Mudguard
8 Engine cover
9 Steering ram
10 Skip
11 Rollbar (machines without cab)
12 Swivelling console (option)
13 Slewing ram (option)
14 Slewing centre position (option)
15 Cab (option)

Operation
1.4 Operating equipment overview

Operating equipment 6001 (up to AB60997D)
6 7 8 9 14 15 16 17 10 11 12 13
1st row of telltales 2nd row of telltales 3rd row of telltales
21 20
4
5
25
23 3
22 1
24
2
18
19
Operating equipment (legend)

Pos. Description Pos. Description
1 Accelerator pedal 14 Spare fuel telltale
2 Parking brake 15 Not assigned
3 Ignition lock 16 Converter oil pressure telltale
Forwards-reverse control (optional with 4 drive ranges)
4 Up/down: slow/fast 17 Low-speed telltale
Forwards/backwards: forwards/reverse
5 Turn indicator switch horn light switch 18 Lever for horizontal seat adjustment
6 Alternator charge telltale 19 Skip control lever
7 Engine oil pressure telltale 20 Hour meter
8 Parking brake telltale 21 Fuel level indicator
9 Engine temperature telltale 22 Brake pedal
10 High beam telltale 23 Clutch pedal
Shift lever (functions can be selected on forwards-reverse control
11 Converter oil temperature telltale 24 as an option)
12 Preheating telltale 25 Footrest
13 Turn indicator telltale

Operation
Operating equipment 6001 Powershift (option) up to serial no. AB60997D
6 7 8 9 14 15 16 17 10 11 12 13
21 20
5
4
23
3
1
22
2
18
19

1 Accelerator pedal 13 Turn indicator telltale
2 Parking brake 14 Spare fuel telltale
3 Ignition lock 15 Not assigned
Forwards-reverse control with 4 drive ranges
4 Up/down: slow/fast 16 Converter oil pressure telltale
5 Turn indicator switch horn light switch 17 Low-speed telltale
6 Alternator charge telltale 18 Bar for horizontal seat adjustment
7 Engine oil pressure telltale 19 Skip control lever
8 Parking brake telltale 20 Hour meter
9 Engine temperature telltale 21 Fuel level indicator
10 High beam telltale 22 Brake pedal
11 Converter oil temperature telltale 23 Footrest
12 Preheating telltale

Operation
1.5 Control stand

22 17
21
28 20
28
23 19
28
18
16
28
Model 6001
21 17
20
28
28
22
23 19
28
18
16
28
Model 6001 (Swiss version)

Operation
26 22
29
27 27
21
20
17
18
19
28 28
23
16
16
30 30
24 25
Model 6001 with cab (option) up to AB60997D

26
29 22
27
27
21
20
17
18
19
28 28
23
16
16
30 30
24 25
Model 6001 Hydrostat with cab (option) from AD60001D

Operation
Pos. Description
16 Seat
17 Steering wheel
18 Parking brake
19 Lever for horizontal seat adjustment
20 Forwards-reverse control
21 Turn indicator horn lights
22 Indicator
23 Skip control lever
24 Drinks holder (machines with cab)
25 Washer fluid tank (machines with cab)
26 Air vent (machines with cab)
27 Rearview mirror (option)
28 Handle
29 Storage compartment (machines with cab)
30 Door arrester (machines with cab)

Operation
1.6 Instrument panel

Dumper without cab (up to AB60997D)
13 5 4 14
8 7
6 9
1 3
2 10
11 12
15 16
1/2
GRE
0 4/4 I
II III
HOURS
0
UNIDECK UNIDECK
Pos. Description
1 Air filter telltale (red)
2 High beam telltale (blue)
3 Preheating telltale (yellow)
4 Hydraulic oil filter telltale (red)
5 Converter oil temperature telltale (red)
6 Telltale (red) alternator charge function
7 Parking brake telltale (red)
8 Engine oil pressure telltale (red)
9 Coolant temperature telltale (red)
10 Turn indicator telltale (green)
11 Fuel gauge
12 Hour meter
13 Low fuel level telltale (red)
14 Low speed (turtle) telltale (red)
15 Ignition lock
16 Hazard warning switch

Operation
Dumper with cab (option) up serial number AB60997D
6 8 7 9 13 5 4 14
2 1 3 10 17 18 19
1/2
GRE
0 4/4
HOURS
UNIDECK UNIDECK
11 12 15 16
II III
I
0
Pos. Description
1 Air filter telltale (red)
2 High beam telltale (blue)
3 Preheating telltale (yellow)
4 Hydraulic oil filter telltale (red)
5 Converter oil temperature telltale (red)
6 Telltale (red) alternator charge function
7 Parking brake telltale (red)
8 Engine oil pressure telltale (red)
9 Coolant temperature telltale (red)
10 Turn indicator telltale (green)
11 Fuel gauge
12 Hour meter
13 Low fuel level telltale (red)
14 Low speed (turtle) telltale (red)
15 Ignition lock
16 Hazard warning switch
17 Wiper switch
18 Fan switch
19 Air conditioning switch (option)

Operation
Dumper without/with cab (option) from serial number AD60001D

6
5 7
8 14
4
9
3
2 10
1 20
11
12
15 16
Switches 17, 18, 19 installed additionally only with cab option.

II III
I
0
17 18 19 13

1 Air filter telltale (red) 2 High beam telltale (blue)
3 Preheating telltale (yellow) 4 Hydraulic oil filter telltale (red)
5 Converter oil temperature telltale (red) 6 Telltale (red) alternator charge function
7 Parking brake telltale (red) 8 Engine oil pressure telltale (red)
9 Coolant temperature telltale (red) 10 Turn indicator telltale (green)
11 Fuel gauge 12 Hour meter
13 Working light switch 14 Low speed switch (turtle)
15 Ignition lock 16 Hazard warning switch
17 Wiper switch 18 Fan switch
19 Air conditioning switch (option) 20 Not assigned

Operation
1.7 Maintenance prop

Front skip maintenance prop
Fold down the red maintenance prop before you carry out maintenance work
A B with the skip raised.
C
Proceed as follows:
Raise the skip.
Remove split pin A out of lock pin B.
Pull out lock pin B.
Hold maintenance prop C.
C Fold down maintenance prop C.
B
D Stay clear of the danger area under the skip.
The skip must be lowered a little.
A Lower the skip until maintenance prop C fits into bracket D.

Fasten maintenance prop C in bracket D with lock pin B.
Fig. 10: Front skip maintenance prop
Insert split pin A in lock pin B.
Important
Fasten maintenance prop C on the skip again (in the reverse order) once
maintenance work is over.

Operation
Swivel skip maintenance prop
Mount the red maintenance prop before you carry out maintenance work with
the skip raised.
B
C Proceed as follows:
Raise the skip.
Remove split pin A out of lock pin B.
A Fold down maintenance prop C.
Lower the skip until maintenance prop C rests on the swivelling console.
Important
C Fasten maintenance prop C on the skip again (in the reverse order) once
maintenance work is over.
Fig. 11: Swivel skip maintenance prop
1.8 Centre pivot prop

B
A
Secure the steering ram with the red centre pivot prop when crane handling
the machine.
Fig. 12: Centre pivot prop
The centre pivot prop secures the steering ram to prevent steering movements (via the
articulated joint) when crane handling the dumper.
A Proceed as follows:
Remove the spring plug from pin B.
Rotate centre pivot prop A towards rear chassis C.
Secure centre pivot prop A with the spring plug on pin B.
C
Important
A
Before putting the machine into operation again, mount the centre pivot prop
onto the front chassis again by means of pin B.

Operation

Specifications
Specifications
Specifications
2 Specifications
2.1 Chassis
Sturdy steel sheet chassis, rubber-mounted engine
2.2 Engine
Models 6001, 6001 F Models 6001 H, 6001 HF

Engine
Tier 2 Tier 3A
Product Perkins diesel engine Deutz
Type 1104 C-44 TD 2011 L04 W
Water-cooled 4 stroke diesel Water-cooled 4 stroke
Design engine turbocharged diesel engine
No. of cylinders 4
Fuel injection system Direct injection
Aspiration Natural aspiration Turbocharger
Cooling system Water-cooled
Force-feed lubrication with
Lubrication system Forced feed lubrication
trochoidal pump
Displacement 4400 cm (269 cu in) 3619 cm (221 cu in)
Nominal bore and stroke 105 x 127 mm (4.13 x 5") 96 x 125 mm (3.8 x 4.9")
61.5 kW (82.5 hp) 5 % at 2200
Output 64.6 kW (86.6 hp) at 2600 rpm
rpm
Max. torque 308 Nm (227 lbf ft) at 1200 rpm 257 Nm (190 lbf ft) at 1600 rpm
Max. engine speed 2350 rpm 25 rpm 2660 rpm 25 rpm
without load
Idling speed ~ 1000 rpm 25 rpm ~ 900 rpm 25 rpm
Valve clearance (intake/ 0.2/0.45 mm (0.008"/ 0.018") 0.3 0.5 mm (0.01 0.02")
outlet)
Injection pressure 290 +8/-0 bar (4206 +116/-0 psi) 210+8 bar (3046+116 psi)
Compression 21 35 bar (305 508 psi) 25 30 bar (363 435 psi)
1.4 bar/20 psi (at 900 rpm)
Engine oil pressure 3.0 bar (44 psi)1 2.2 bar/32 psi (at 1800 rpm)
3 bar/44 psi (at 2800 rpm max.)
Pressure switch for engine 0.6 0.15 bar (8.7 2.2 psi) 0.5 bar (7.25 psi)
oil pump
Thermostat opening 79 C/174 F (start) ~ 93 C (~ 199 F)
temperature 93 C/199 F (fully open)
Thermal switch 110 3 C (230 37 F) 113 C (235 F)
Firing order 1 3 4 2 (1st cylinder on fan side)
Counterclockwise
Direction of rotation (as seen from the flywheel)
Starting aid Glow plugs
Max. inclined position
(engine no longer supplied 35 in all directions 30 in all directions
with oil):
Exhaust values according 97/68/EC tier 2 Tier 3
to EPA tier 2, ECE R24
1. At operating temperature and maximum revs

Specifications
Specifications
Engine capacities Model 6001

Capacities
Tier 2 (Perkins) Tier 3 (Deutz)
Fuel tank 70 l (18.5 gal)
Engine oil (max.) 10 l (2.6 gal) 8.5 l (2.2 gal)/10 l (2.6 gal)
Coolant (without radiator) 2.7 l (0.7 gal)
Radiator 5.36 l (1.42 gal) 10 l (2.6 gal)
Expansion tank 0.5 l (0.13 gal) 1.2 l (0.3 gal)
Overview of capacities: see Engine/machine fluids and lubricants (up to AB60997D) on

page 3-1
Engine tightening torques Model 6001
Tightening torques
Cylinder-head bolt 50 Nm (37 lbf ft) 30 Nm (22 lbf ft)
1st pass 100 Nm (74 lbf ft) + 225 (short screws) 80 Nm (59 lbf ft)
2nd pass 100 Nm (74 lbf ft) + 270 (long screws) 160 Nm (118 lbf ft) + 90
30 Nm (22 lbf ft)
Connecting rod bearing 70 Nm (52 lbf ft) + 120 1st retightening angle: +60
screw
2nd retightening angle: +60
50 Nm (37 lbf ft)
Main bearing screw 245 Nm (181 lbf ft) 1st retightening angle: +60
30 Nm (22 lbf ft)
Flywheel screw (front) 115 Nm (85 lbf ft) 1st retightening angle: +60
2.3 Travelling drive 6001 6001 Powershift 6001 H

Torque converter gearbox
Type Hydrostatic drive
ITL SS620 ITL PS750
2WD torque converter 2WD torque converter
Design gearbox with gearbox with Automotive control
electrohydraulic control electrohydraulic control
Automatic (manual
Shift Manual Electric
optional)
Speeds 4 forwards and reverse 4 forwards and reverse 2 forwards and 2 reverse
Transmission ratio Up to 6.55:1 Up to 7.17:1
Transfer gearbox
Type ITL ITL DANA
Transmission ratio 1:1 1:1 1:2.28
Cardan shafts
Flange type DANA 1480 Yoke DANA 1480 Yoke DANA 1410 Yoke
2.4 Brakes Model 6001 Tier 2 (Perkins) Tier 3 (Deutz)

Hydraulic pedal-operated wet dual- Hydraulic pedal-operated wet single-
Service Design circuit brake circuit brake
brake
Location Brake discs in either axle Brake discs in front axle
Disc brake with brake effect on transfer Brake effect on front axle via eccentric
gearbox shaft
Parking brake
Brake effect on either axle via cardan Additional brake effect on rear axle via
shaft cardan shaft

Specifications
2.5 Steering system

Steering Model 6001
system Tier 2 Tier 3 (Deutz)
Design Hydrostatic chassis articulation steering with emergency steering features
Steering
Chassis articulation steering
mode
2.6 Work hydraulics

Model 6001
Work hydraulics
Tier 2 Tier 3 (Deutz)
Gear pump displacement 25 cm/rev (1.5 cu in/rev) 22 cm/rev (1.3 cu in/rev)
Gear pump flow rate 55 l/min (14.5 gpm) 57 l/min (15 gpm)
Max. service pressure 220 bar (3191 psi)
Optional secondary protection
160 bar (2321 psi) 150 bar (2176 psi)
offset ram
Hydraulic tank capacity 70 l (18.5 gal)
Steering system 150 bar (2176 psi)
2.7 Loader unit

Loader unit Models 6001 & 6001 F
2400 l (634 gal) struck
Skip capacity 3200 l (845 gal) heaped
1880 l (497 gal) liquid capacity
Payload 6000 kg (13228 lbs)
Angle of rotation 180 217 (6001 S only)
2.8 Drive specifications

6001 6001F 6001 H 6001 HF
Hydrostat
Drive speed I 0 4.5 km/h (0 2.8 mph) 0 5 km/h (0 3.1 mph)
Drive speed II 0 7 km/h (0 4.3 mph) 0 25 km/h (0 15.5 mph)
Drive speed III 0 14 km/h (0 8.7 mph) -
Drive speed IV 0 27 km/h (0 16.8 mph) -
Articulation 33
Oscillation 13
5200 mm 5500 mm 5200 mm 5500 mm
Outside turning radius
(17'1") (18'1") (17'1") (18'1")
Hill climbing ability 50 %
Safe authorised
25 % in all drive positions
inclination
2.9 Vibration
Vibration
Effective acceleration value for the upper extremities of the body
< Trigger value
*
Effective acceleration value for the body * < Trigger value
* Measured according to 2002/44/EC. Machine and attachment operation and maintenance as per Operator's Manual.

Specifications
2.10 Electric system

Up to serial no. AB60997D
Fuse box in instrument panel
Fuse number Rated current (A) Protected circuit

Driving direction
4 8 1 10 A Hazard warning system 30
11
2 10 A Clearance lights, numberplate lights
3 7
3 10 A Low beam
10
4 15 A High beam
2 6
5 Not assigned
9
6 10 A Travelling drive
1 5
7 10 A Fuel pump, cutoff solenoid
8 Not assigned
Fig. 1: Fuse box 9 Not assigned
10 7.5 A Horn, brake lights
11 10 Turn indicators, telltale, fuel level indicator
Relays
F2 The relays are located in the relay box in the engine compartment, to the right of the seat.
K7 K 7.1 K 10 F1
Switching relay no. Protected circuit
F1 Main fuse
F2 Main fuse
K7 Starting relay
D1
K 7.1 Start interlock
K 10 Turn indicator relay

Fig. 2: Relays
D1 Diode box

Specifications
From serial no. AD60001D
Electric system
Alternator 12 V 55 A
Starter 12 V 2.3 kW (3.1 hp)
Battery 12 V 100 Ah
Fuse box
The fuse box is located on the right-hand side of the machine behind the maintenance flap
F11 above the access.
F10
Fuse Rated current (A) Protected circuit
F9
F4 10 A Preheating
F8
F5 15 A Drive solenoid valves
F7
F6 10 A Horn, brake lights
F6
F7 15 A Turn indicators
F5
F8 15 A High beam
F4
F9 10 A Low beam
Fig. 3: Fuse box F 10 10 A Clearance light
F 11 10 A Hazard warning system

Specifications
Relays
F1 F2 F3 The relays are located in the relay box under the the floor panel of the control stand.
K 31 Switching relay no. Protected circuit

K 32 F 1, F2, F3 Main fuses (50 A)
K 29 K 33
K 34
K 10 K 29 Preheating relay
K 35
K 30 Deutz preheating time relay
K 31 Low beam relay
K 32 Preheating telltale relay
K 33 High beam relay
K 34 Parking brake telltale relay
K 35 Start interlock relay
K 30
Fig. 4: Relays
2.11 Tyres
Tyre pressure
Tyre size Load-bearing
Front Rear
capacity
405/70-20 14 Ply 3.25 bar (47 psi) 3.25 bar (47 psi) PR 14
2.12 Noise levels

Sound power level 6001
Sound power level (LWA) 102 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.

Specifications
2.13 Coolant compound table

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

Tightening torques for hydraulic screw connections (dry assembly)
Metric hose fittings for hydraulic applications (light execution, DKOL)

Torque Nm
Nominal Outer Thread Wrench size
(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 Nm
Nominal Outer Thread Wrench size
(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

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
Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) mm (")
M10X1.0 9 (7) 18 (13) 15 (11) 18 (13) 10 (0.4)
M12X1.5 20 (15) 25 (18) 25 (18) 25 (18) 12 (0.5)
M14X1.5 35 (26) 45 (33) 35 (26) 35 (26) 14 (0.6)
M16X1.5 45 (33) 55 (41) 40 (30) 50 (37) 16 (0.6)
M18X1.5 55 (41) 70 (52) 45 (33) 70 (52) 18 (0.7)
M22X1.5 65 (48) 125 (92) 60 (44) 125 (92) 22 (0.9)
M27X2.0 90 (66) 180 (133) 100 (74) 145 (107) 27 (1.0)
M33X2.0 150 (111) 310 (229) 160 (118) 210 (155) 33 (1.3)
M42X2.0 240 (177) 450 (332) 210 (155) 360 (266) 42 (1.7)
M48X2.0 290 (214) 540 (398) 260 (192) 540 (398) 48 (1.9)
G1/8A 9 (7) 18 (13) 15 (11) 18 (13) 9.73 (0.4)
G1/4A 35 (26) 35 (26) 30 (22) 35 (26) 13.16 (0.5)
G3/8A 45 (33) 70 (52) 45 (33) 50 (37) 16.66 (0.7)
G1/2A 65 (48) 90 (66) 55 (41) 65 (48) 20.96 (0.8)
G3/4A 90 (66) 180 (133) 100 (74) 140 (103) 26.44 (1.0)
G1A 150 (111) 310 (229) 160 (118) 190 (140) 33.25 (1.3)
G1 1/4A 240 (177) 450 (332) 210 (155) 360 (266) 41.91 (1.6)
G1 1/2A 290 (214) 540 (398) 360 (266) 540 (398) 47.80 (1.9)
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
Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) mm ( " )
M12X1.5 20 (15) 35 (26) 35 (26) 35 (26) 12 (0.5)
M14X1.5 35 (26) 55 (41) 45 (33) 45 (33) 14 (0.6)
M16X1.5 45 (33) 70 (52) 55 (41) 55 (41) 16 (0.6)
M18X1.5 55 (41) 90 (66) 70 (52) 70 (52) 18 (0.7)
M20X1.5 55 (41) 125 (92) 80 (59) 100 (74) 22 (0.8)
M22X1.5 65 (48) 135 (100) 100 (74) 125 (92) 27 (1.0)
M27X2.0 90 (66) 180 (133) 170 (125) 135 (100) 12 (0.5)
M33X2.0 150 (111) 310 (229) 310 (229) 210 (155) 33 (1.3)
M42X2.0 240 (177) 450 (332) 330 (243) 360 (266) 42 (1.7)
M48X2.0 290 (214) 540 (398) 420 (310) 540 (398) 48 (1.9)
G1/8A 35 (26) 55 (41) 45 (33) 45 (33) 13.16 (0.5)
G1/4A 45 (33) 80 (59) 60 (44) 60 (44) 16.66 (0.7)
G3/8A 65 (48) 115 (85) 75 (55) 100 (74) 20.96 (0.8)
G1/2A 90 (66) 180 (133) 170 (125) 145 (107) 26.44 (1.0)
G3/4A 150 (111) 310 (229) 310 (229) 260 (192) 33.25 (1.3)
G1A 240 (177) 450 (332) 330 (243) 360 (266) 41.91 (1.6)
G1 1/4A 290 (214) 540 (398) 420 (310) 540 (398) 47.80 (1.9)
Torque tolerance: 10 %; countermaterial: steel/aluminium

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.

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. 5: 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. 6: Nordlock

Specifications
2.15 Dimensions model 6001 (up to AB60997D)
Fig. 7: Machine dimensions (model 6001)
Main data Model 6001 Model 6001 F

Dead weight 4320 kg (9524 lbs) 4100 kg (9039 lbs)
Overall height 3045 mm (10") 3050 mm (10")
Overall height with rollbar folded down 2240 mm (7'4") 2250 mm (7'5")
Overall height without rollbar 2240 mm (7'4") 2250 mm (7'5")
Overall width 2255 mm (7'5") 2330 mm (7'8")
Ground clearance 380 mm (1'3")
Wheelbase 2485 mm (8'2")
Outside turning radius 5200 mm (17'1") 5500 mm (18'1")
Hill climbing ability 50 % theoretically
Safe authorised inclination 25 % in all drive positions

Specifications
2.16 Dimensions model 6001 HF (Hydrostat/front tip)
Fig. 8: Machine dimensions (model 6001 F)
Main data Model 6001HF

Dead weight 4120 kg (9083 lbs)
Overall height 3080 mm (10'1")
Overall height with rollbar folded down 2300 mm (7'6")
Overall height without rollbar 2300 mm (7'6")
Overall width 2330 mm (7'8")
Outside turning radius 5500 mm (18'1")

Specifications
2.17 Dimensions model 6001 HF (Hydrostat/front tip) with cab
Fig. 9: Machine dimensions (model 6001 F)
Main data Model 6001HF

Overall height with dumped-out skip 2550 mm (8'4")

Specifications
2.18 Dimensions model 6001 HS (Hydrostat/swivel)
Fig. 10: Machine dimensions (model 6001S)
Main data Model 6001HS

Overall height with dumped-out skip 3660 mm (12'1")
Overall height without rollbar 2300 mm (7'6")

Specifications
2.19 Dimensions model 6001 HS (Hydrostat/swivel) with cab
Fig. 11: Machine dimensions (model 6001S with cab)
Main data Model 6001HS

Overall height with dumped-out skip 3670 mm (12")

Maintenance
Maintenance
Maintenance
3 Maintenance
3.1 Engine/machine fluids and lubricants (up to AB60997D)
Component/ Engine/machine Season/
Specification Capacities1
application fluid temperature
-15 C/5F
Diesel engine Engine oil DUPLEX CDX 15W-40 10 l (2.6 gal)
+40 C/104 F
HVLP462
Hydraulic oil tank Hydraulic oil Year-round 70 l (18.5 gal)
Fina Hydrav TSX 46
-25 C/-13 F
All lubrication points BP Energrease L 21 M As required
+40 C/104 F
Acid-proof
Battery terminals FINA Marson L2 Year-round As required
grease3
No. 2-D, DIN 51601 grade Over 4C/39F
Fuel tank Diesel fuel 70 l (18.5 gal)
No. 1-D, DIN 51601 grade Below 4C/39F
Radiator Coolant Water + antifreeze; SP-C Year-round 8.5 l (2.2 gal)
API Gl5-LS A-M IL2105B oil classification
Fuchs Titan Gear LS 85W90 initial fill
Shell Spirax HD 85W90 7.9 l (2.1 gal)
Axles Gearbox oil Year-round
Mobil1 SAE 75W90 LS front and rear
Castrol LSC SAE 90
BP Energear Lim Slip 90 SAE 80W90
Transfer gearbox Gearbox oil EP 90 gear oil Year-round 1 l (0.27 gal)
Torque converter gearbox Gearbox oil Austromatic F Year-round 15 l (4 gal)
1. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
2. According to DIN 51524 section 3
3. Standard acid-proof grease
5. First replacement after 100 service hours
From AD60001D
Component/ Engine/machine Season/
Specification Capacities1 (l / gal)
application fluid temperature
-15C/5F
Diesel engine Engine oil API CD, CF, CF-4, CI-4 10 (2.6)
+45C/113F
Hydraulic oil HVLP462
PANOLIN HLP Synth 46
Hydraulic oil tank Year-round 70 (18.5)
Biodegradable oil3 FINA BIOHYDRAN SE 46
BP BIOHYD SE-46
All lubrication points FINA Energrease L21M Year-round As required
Battery terminals Acid-proof grease4 FINA Marson L2 Year-round As required
No. 2-D, DIN 51601 grade Above 4C/39F
Fuel tank Diesel fuel 70 (18.5)
No. 1-D, DIN 51601 grade Below 4C/39F
Radiator Coolant Water + antifreeze; SP-C Year-round 8.5 (2.2)
Front axle Rear axle
Differential 7.9 (2.1) 5.6 (1.5)
Semiaxle Once a year or 0.85 (0.22) 0.9 (0.24)
Axles Gearbox oil SAE85W90LS
Transfer every 1000 hours5
0.9 (0.24)
gearbox
1. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
1. Capacities indicated are no system fills
2. According to DIN 51524 section 3
3. Hydraulic ester oils (HEES)
4. Standard acid-proof grease
5. First replacement after 50 service hours

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
SAE 10W-40
API CD, CF, CF-4,
CI-4
SAE 15W-40
SAE1 E3, E4, E5

SAE 20
SAE 30
SAE 40
F -4 5 14 23 32 41 50 59 68 77 86 95 104
1. According to DIN 51511

3-3
Maintenance plan/service hours (s/h)
3.2 Maintenance plan (overview)
Maintenance
Work description
For service and maintenance work on the attachment, please refer to the operation and maintenance manual
Maintenance
Customer
workshop
Authorised
of the attachment manufacturer as well.
(once a day)
after 1000 s/h
Every 250 s/h

Every 500 s/h
(once a week)
After 1500 s/h
Once a year or
Maintenance work
Maintenance work
After the first 50 s/h
Fluid and filter changes ( ):
Carry out the following oil and filter changes (check oil levels after test run):
Engine oil 1
Engine oil filter 2
Fuel filter 3
Air filter element
Coolant
Hydraulic oil filter insert 4
Hydraulic oil
Hydraulic oil tank breather
Gearbox oil5
Inspection work ( ):
Check the following material. Refill if necessary:
Engine oil
Engine coolant
Hydraulic oil
Clean the water ducts6
Check cooler for engine and hydraulic oil for dirt. 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
Clean
Adjust the V-belt
1. Replace the engine oil the first time after 50 s/h, then every 250 s/h or once a year
2. Replace the engine oil filter the first time after 50 s/h, then every 250 s/h or once a year
3. Replace the fuel filter the first time after 50 s/h, then every 250 s/h or once a year
4. Replace the hydraulic oil filter insert the first time after 50 s/h, then every 500 s/h or once a year
5. Replace the gearbox oil the first time after 500 s/h, then every 1000 s/h or once a year
6. Clean the water ducts every other 1000 s/h servicing
SERV-HB 6001 EN Edition 2.0 * 6001s311.fm

Work description
Customer
workshop
Authorised
(once a day)
after 1000 s/h
Every 250 s/h

Every 500 s/h
(once a week)
After 1500 s/h
Once a year or
Maintenance work
Maintenance work
Check V-belt condition and tension

Check toothed belt and change it after 3000 s/h or after max. 5 years
Check exhaust system for damage and condition
Maintenance
Check valve clearance. Adjust if necessary 1

Fuel injection pump
Injection and pressure
Check injection nozzles and valves 2
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 3
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
1. Check (and adjust as required) valve clearance the first time after 50 s/h, then every 1000 s/h
2. Check injection nozzles and valves every second time 1500 s/h servicing is carried out.
3. First check at 50 s/h, then every 500 s/h
Maintenance
3-4
3-5
Work description
Maintenance
Customer
workshop
Authorised
(once a day)
after 1000 s/h
Every 250 s/h

Every 500 s/h
(once a week)
After 1500 s/h
Once a year or
Maintenance work
Maintenance work
Lubrication service ( ):
Lubricate the following assemblies/components: see Lubrication points on page 3-32
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

Maintenance
Maintenance
3.3 Service package

1000129350 1 Service package 6001

1000000259 1 Engine oil filter (filter suitable for 500 h interval)
1000004556 1 Fuel filter cartridge
1000129349 1 Water separator element
1000113383 1 Air filter element (outside)
1000113384 1 Air filter element (inside)
1000115598 1 Filter element
1000123922 1 Pilot filter insert
1000130606 1 Valve cover gasket
1000130795 1 Sealing kit
1000103020 3 O-ring
1000181993 1 Service package 6001

1000108955 1 Engine oil filter (filter suitable for 500 h interval)
1000108956 1 Fuel filter
1000109037 1 Valve cover gasket
1000050807 1 Filter element
1000108916 1 Oil drain plug sealing ring
1000113383 1 Air filter element (outside)
1000113384 1 Air filter element (inside)
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 0 SAFETY INFORMATION in the Service 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 the maintenance plan
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).

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 behind the right-hand side servicing lid.
A
All work involving fuel carries an increased
Danger of fire and poisoning!
Do not refuel in closed rooms.
Fig. 1: Refuelling 6001 (without cab) Never carry out work on the fuel system in the vicinity of naked flames or
Up to AB60997D (with cab)
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
A 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
Fig. 1: Refuelling 6001 Hydrostat (without cab) From
AB60001D (with cab) some space for the fuel to expand.

Maintenance
Stationary fuel pumps General

Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually dirty.
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.
Keep all refuelling containers clean at all times.
right
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
No. 1-D according to Min. 45
For outside temperatures below 4 C (39F) or
DIN 51601 for operation above 1500 m (4921') altitude
Bleeding the fuel system
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:

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.
Bleed the fuel system as follows:
Fill up 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.

Maintenance
Fuel prefilter with water separator (up to serial no. AB60997D)

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.
Open stop cock A.
B
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

Maintenance
Replacing the fuel filter
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

Place a suitable container under the filter.
Unscrew screw A.
The fuel runs out of the filter housing.
Empty the filter housing completely.
Remove filter housing B.
Replace the fuel filter.
B
A
Mounting the fuel filter

Mount all elements in the reverse order with a new filter element.
Bleed the fuel system see Bleeding the fuel system on page 3-8.
Make a test run and check for tightness.
B Dispose of the old fuel filter cartridge by an ecologically safe method.
Fig. 4: Fuel filter (Deutz diesel engine)

Maintenance
3.6 Engine lubrication system
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.
Proceed as follows:
Park the machine on level ground.
Let the engine cool down.
Open the engine cover.
A Clean the area around the oil dipstick with a lint-free cloth.
Pull out oil dipstick A.
Fig. 5: Oil level check (up to AB60997D) Wipe it with a lint-free cloth.
Push oil dipstick A back in as far as possible.
max Withdraw it and read off the oil level.
min
A
However if necessary, fill up oil at the latest when the oil reaches the MIN mark on the
oil dipstick A.
Fig. 5: Oil level check 6001 Hydrostat (from AD60001D)
max
min
A
Fig. 5: Oil level check 6001 (with cab)

Maintenance
Filling up engine oil
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 Clean the area around oil filler cap B with a lint-free cloth.
OIL Open filler cap B.
Raise oil dipstick 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.
Completely remove all oil spills from the engine.
Close filler cap B.
Fig. 6: Filling up engine oil (up to AB60997D)
B
OIL
Fig. 6: Filling up engine oil 6001 Hydrostat (from

AD60001D)
B
OIL
Fig. 6: Filling up engine oil 6001 (with cab)

Maintenance
Changing engine oil
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:

Let the engine run until it reaches its operating temperature (oil temperature
about 80C / 176 F).
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 Filling up engine oil on page 3-12.
Check the oil level.
Start the engine and let it run briefly at low revs.
Wait a moment until all the oil has run into the oil sump.
Check the oil level again.
Fill up if necessary and check again.

Maintenance
Replacing the engine oil filter cartridge

The oil filter is located on the engine next to the oil dipstick.
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:

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.
Let the engine run briefly.
Check the seal of oil filter cartridge A and retighten by hand.
Check the oil level and fill in engine oil if necessary.
Fig. 10: Tightening the filter cartridge
Dispose of the used oil filter in an environmentally friendly manner.

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 to the left of the oil cooler in the engine
compartment.

Dirt on the radiator fins reduces the cooler's heat dissipation capacity. To avoid dirt:
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, test run 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 2-7.
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.
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.

Maintenance
Checking/filling up coolant
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.
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 the eyes with clean water and seek medical
assistance.

Maintenance
Checking the coolant level
A Proceed as follows:
FULL Remove the key and carry it with you.
Let the engine and the coolant cool down.
LOW
Check the coolant level in the transparent expansion tank A.
Fig. 11: Coolant expansion tank (up to AB60997D)
(from AD60001D) If the coolant level is below the LOW seam or if there is no coolant at the radiator's
filler inlet:
Fill up coolant (use only coolants of the same brand and grade => do not mix different
FULL coolants).
LOW
Important
Check the coolant level once a day. We recommend checking it before starting
A the engine.
Fig. 11: Coolant expansion tank (6001 Hydrostat) Filling up coolant

A After the engine has cooled down:
Release overpressure in the radiator.
Carefully open the cap to the first notch and fully release the pressure.
FULL
Open filler cap B.
LOW
Fill up coolant up to the lower edge of the filler inlet (radiator) and of the expansion tank
(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
Fig. 11: Coolant expansion tank 6001 (with cab) Remove the key and carry it with you.
Check the coolant level again.
B 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.
Fig. 11: Filler cap 6001 (with cab)

Maintenance
Draining coolant
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 11/B to the first notch and fully 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 11/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 Engine/machine fluids and lubricants (up
to AB60997D) on page 3-1.
Check the coolant level see Checking the coolant level on page 3-17.

Maintenance
3.8 Air filter
The filter cartridge is 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.
General maintenance of air filters:

Store filters in their original packaging and in a dry place.
Do not knock the filter against other objects as you install it.
Check air filter attachments, air intake hoses and air filters for damage, and
immediately repair or replace if necessary.
Check the screws at the induction manifold and the clamps for tightness.
Check the function of the dust valve, replace if necessary.
Weekly check of air filter for dirt

Maintenance display A on the filter housing monitors the filter cartridge.
A Replace the filter cartridge:
If the red mark in window B of maintenance display A can be seen (check with the
engine running only).
Press reset button C after you have cleaned or replaced the air filter.
After 500 service hours or in the case of dirt pile-up.
C
A
B
Fig. 12: Air filter fouling indicator

Maintenance
Replacing the filter

Replace the filter as follows:
E Switch off the engine.
Remove the key and carry it with you.
D Open the engine cover.
Remove dirt and dust from the air filter and the area around the air filter.
Fold all 3 bow clips D on lower housing section E to the outside.
Remove lower housing section E.
Carefully remove outside filter B with slightly turning movements.
Make sure all dirt (dust) inside the upper and lower housing sections has been
F removed.
Clean the parts with a clean lint-free cloth, do not use compressed air.
Fig. 13: Removing/installing the lower housing section
Check the air filter cartridges for damage, only install intact filters.
Carefully insert new filter element B in the upper housing section.
Position lower housing section E (make sure it is properly seated).
Close bow clips D.
Replace the inside filter as follows:

Remove dirt and dust from the air filter and the area around the air filter.
Fold all 3 bow clips D on lower housing section E to the outside.
B Remove lower housing section E.
Carefully remove outside filter B with slightly turning movements.
Fig. 14: Removing/installing the filter element Carefully remove inside filter C.
Cover the air supply at the end of the filter with a clean lint-free cloth to prevent dust
from entering the engine.
Make sure all dirt (dust) inside the upper housing section and dust valve F the has been
removed.
B Clean the parts with a clean lint-free cloth, do not use compressed air.
Remove the cloth from the air supply.
Check the air filter cartridges for damage, only install intact filters.
C Carefully insert the new inside filter C in the inner housing section.
Insert outside filter B in the upper housing section.
Position the lower housing section E.
Fig. 13: Removing/installing the inside filter element Close bow clips D.
Important
Make sure dust valve F shows downwards once it is installed.

Maintenance
Functional check once a week of the dust valve

The air filter is located in the engine compartment, on the left side of the machine.
Proceed as follows:
Apply the parking brake.
Squeeze the discharge slot of dust valve F.
Remove hardened dust by squeezing the upper area of the valve.
F
Clean the discharge slot if necessary.
Fig. 14: Air filter dust valve
3.9 V-belt
Only check or retighten/replace the V-belt when the engine is switched off
Danger of personal injury!
Switch off the engine before carrying out inspection work in the engine
compartment.
Disconnect the battery or the battery master switch.
Check the V-belt once a day, and retighten if necessary!

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

Check as follows:
1 Switch off the engine.
Disconnect the battery or the battery master switch.
Carefully check V-belt 1 for damage, cracks or cuts.
Replace the V-belt if it touches the base of the V-belt groove or the discs of the
pulley.
If the V-belt is damaged:
Fig. 15: Checking V-belt tension Have the V-belt replaced by authorised staff.
Press with your thumb to check the deflection of the V-belt between the crankshaft
disc and the fan wheel position C. A new V-belt should have a deflection of 6 to
8 mm (0.2" 0.3"), a used V-belt (after about 5 minutes running time) should have a
deflection of 7 to 9 mm (0.3" 0.35")
Retighten the V-belt if necessary.

Maintenance
Retightening the V-belt
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
2 V-belt.
Check V-belt tension see Checking V-belt tension on page 3-21.
A
Fig. 16: Retightening the V-belt
Up to AB60997D
Retighten as follows:
Fold the control lever base up.
Disconnect the battery or the battery master switch 1.
Slacken fastening screws 2 of alternator 3.
Use a suitable tool to push the alternator in the direction of arrow A until reaching the
correct V-belt tension (fig. 16).
1 Keep the alternator in this position, and at the same time retighten fastening
screws 2.
Fig. 16: Retightening the V-belt

Check V-belt tension again and adjust it if necessary.
Connect the battery or the battery master switch 1.
Close the engine cover.

Maintenance
From AD60001D
Retighten as follows:
Remove the key and carry it with you
Disconnect the battery or the battery master switch A.
Slacken fastening screws 1, 2 and 3 of alternator 4.
Fig. 17: Retightening the V-belt Use a suitable tool to adjust the alternator in the direction of the arrow by turning
screw 3 until reaching the correct V-belt tension (fig. 17).
Keep the alternator in this position, and retighten fastening screws 1, 2 and 3.
Connect the battery or the battery master switch A.
A B
Fig. 17: Retightening the V-belt: with cab

Hydrostat without cab
A
B
Replacing the V-belt
Replace as follows:
C Switch off the engine.
Remove the key and carry it with you
Disconnect the battery or the battery master switch A.
Slacken fastening screws 1, 2 and 3 of alternator 4.
Use a suitable tool to adjust the alternator in the direction of the arrow by turning
screw 3.
Remove V-belt 5 and install a new V-belt.
Adjust alternator 4 in the opposite direction of the arrow by turning screw 3 until
reaching the correct V-belt tension.
Keep alternator 4 in this position, and retighten fastening screws 1, 2 and 3.
Fig. 17: Replacing the V-belt
Connect the battery or the battery master switch A.

Maintenance
3.10 Gearbox lubrication system (up to AB60997D)
If the gearbox oil level is too low or if an oil change is overdue, this can cause
Damage to the gearbox.
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 the oil level before
putting the machine into operation. After switching off the machine, wait at
MAX MIN least 5 minutes before checking.
A
Proceed as follows:
Fig. 18: Oil level check (machines without cab)
Let the gearbox cool down.
Open the engine cover or servicing lid B (cab option).
Clean the area around the oil dipstick with a lint-free cloth.
Wipe it with a lint-free cloth.
Withdraw oil dipstick A and read off the oil level.
B
However if necessary, fill up oil at the latest when the oil reaches the MIN mark on the
oil dipstick A.
MAX MIN
Fig. 18: Oil level check (machines with cab)

Maintenance
Filling up gearbox oil
OIL
A
Too much or incorrect gearbox oil can result in increased viscosity and
gearbox damage! For this reason:
Do not add gearbox oil above the MAX mark of oil dipstick 18/A.
Use only the specified gearbox oil.
Fig. 19: Oil dipstick and filler cap (machines without cab)
Environment
Use a suitable container to collect the gearbox oil as it drains and dispose of it
in an environmentally friendly manner.
Proceed as follows:
Open servicing lid B (cab option).
B
Clean the area around oil dipstick A with a lint-free cloth.
A Fill in gearbox oil.
OIL Wait about 3 minutes until all the oil has run into the oil sump.
Check the oil level.
Fill up if necessary and check the oil level again.
Completely remove all oil spills from the engine compartment.
Close servicing lid B (cab option).
Fig. 19: Oil dipstick and filler cap (machines with cab)

Maintenance
Changing gearbox oil
Caution when draining hot gearbox oil

Danger of burns!
+ 80 C
+176 F Wear protective gloves.
Use suitable tools.
OIL
Fig. 20: Optimum engine oil temperature
Environment
Use a suitable container to collect the gearbox oil as it drains and dispose of it
in an environmentally friendly manner.
Change the gearbox oil as follows:

Let the engine run until it reaches its operating temperature
(oil temperature about 80 C/179 F).
Place a container under the opening to collect the oil as it drains.
Unscrew the oil drain plug on the lower side of the gearbox.
Completely drain the oil.
Screw the oil drain plug back on again.
Fill in gearbox oil see Filling up gearbox oil on page 3-25.
Start the engine and let it run briefly at low revs.
Wait a moment until all the oil has run into the oil sump.
Check the oil level again.

Maintenance
Replacing the gearbox oil filter cartridge

The oil filter is located under the base plate on the right side of the gearbox.
Caution when draining hot gearbox oil

Danger of burns!
Wear protective gloves.
Environment
Collect the drained gearbox oil in a suitable container. Dispose of used oil and
filters in an environmentally friendly manner.
Change the filter as follows:

Place a suitable container underneath the oil filter to collect the oil as it drains.
Slowly slacken oil filter cartridge A using a commercially available tool.
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. 21: Unscrewing the gearbox oil filter

Clean the inside of the filter head.
Apply a thin coat of fresh gearbox oil to rubber seal B of the new oil filter cartridge.
Tighten the new filter cartridge by hand until the gasket makes contact.
Fig. 22: 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 gearbox oil level is correct.
Let the engine run briefly.
Check the seal of oil filter cartridge A and retighten by hand.
Check the oil level and add gearbox oil if necessary.
Fig. 23: Tightening the filter cartridge
Dispose of the used oil filter in an environmentally friendly manner.

Maintenance
Maintenance
3.11 Hydraulic system

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. Therefore always consult a doctor immediately, even in the case of minor
wounds 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 and/or damaged
hoses and lines are detected.
Contact your Neuson dealer immediately.
Replace the pipe line if one of the following problems 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.
Dirty hydraulic oil, lack of oil or wrong hydraulic oil

Danger of severe damage to the hydraulic system!
Take care to avoid dirt 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 Engine/machine fluids and
lubricants (up to AB60997D) on page 3-1.
Always fill up hydraulic oil before the level gets too low see Filling up
hydraulic oil on page 3-29.
If the hydraulic system is filled with biodegradable oil, then only use
biodegradable oil of the same type observe the sticker on the hydraulic oil
tank.
Contact customer service if the hydraulic system filter is dirty and contains
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. Contact
the relevant authorities or commercial establishments in charge of oil disposal
before disposing of biodegradable oil.

Maintenance
Checking the hydraulic oil level

Proceed as follows:
A Retract all hydraulic rams.
Fully dump in the skip.
Sight glass A is located on the left-hand side of the dumper, above the mudguard.
Check the oil level on sight glass A.
The oil level must be at the FULL level.
Fig. 24: Oil level gauge A gauge element in sight glass A indicates the oil level.
If the oil level is lower:
Fill up hydraulic oil.
Important
Measure the oil level of the hydraulic system only after the machine reaches its
operating temperature.
1
Filling up hydraulic oil

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:
B
Retract all hydraulic rams.
Clean the area around filler inlet B with a cloth.
Open filler inlet B.
With the filter insert in place:
Fill up hydraulic oil.
Check the hydraulic oil level on sight glass A.
Fig. 25: Filling up hydraulic oil (6001 Hydrostat)
Firmly close filler inlet B.
Fig. 25: Filling up hydraulic oil 6001 (with cab)

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 dirt 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 3-29.
Close the hydraulic oil tank correctly.
Let the machine run at idling speed without load for some minutes.
Monitoring the hydraulic oil reflux filter

The red telltale on the instrument panel monitors the hydraulic oil reflux filter.
Replace the filter:
If the telltale comes on when the hydraulic oil is at operating temperature.
Fig. 26: Telltale for hydraulic oil reflux line 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.
Replacing the hydraulic oil reflux filter

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. 27: Hydraulic oil reflux filter

Maintenance
Checking hydraulic pressure lines

Caution when checking hydraulic pressure lines, especially when searching for
leaks. 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.
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. 28: Flexible line

Maintenance
3.12 Lubrication points

Fold down the red maintenance prop before you carry out maintenance work with the skip
raised
see Dumper without/with cab (option) from serial number AD60001D on page 1-14.
Front skip
Swivel skip
Apply multipurpose lithium grease with an MoS additive to all lubrication points indicated.

Maintenance
3.13 Tyre maintenance and checks
Improper tyre repairs

All repair work on tyres and rims may only be carried out by authorised
workshops.
Important
Please refer to ( see Tyres on page 2-6) 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
Checks once a day

Carry out the following maintenance work once a day:
Check tyre pressure.
Check tyres and rims for damage (cracks, ageing etc.) also on the inside.
Remove foreign bodies from the tyre tread.
Remove traces of oil and grease from the tyres.
Checks once a week

Carry out the following maintenance work once a week:
Check tyres for wear and measure tread depth.

Maintenance
3.14 Changing wheels
Use of wrong tyres or wheels

Only use the authorised wheels and tyres for your machine see
chapter 2.10 Tyres on page 2-5.
Check the wheel nuts for tightness after every wheel or tyre change.
Fig. 29: Tyres
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

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 axle body, making sure it is standing firmly.
Raise the side of the axle from which you want to remove the wheel.
Check the dumper is standing firmly.
Completely remove the wheel nuts.
Remove the wheel
Fitting the wheels

Place the wheel onto the wheel studs.
Tighten all wheel nuts part-way.
Lower the raised axle.
Tighten the wheel nuts to the prescribed torque of 490 Nm (361 lbf ft).
Important
After changing wheels check the wheel nuts for tightness after 10 service
hours. Retighten the wheel nuts if necessary!

Maintenance
3.15 Axles
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. 30: 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.
Unscrew screws A.
The oil now flows out of opening A.
Use a suitable container to collect the oil as it drains.
Environment
Collect the oil with a suitable container and dispose of it in an environmentally
friendly manner.

Maintenance
3.16 Electric system

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 sulphuric acid immediately with
plenty of water and seek medical attention at once.
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 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 2-5
Cable and earth connections
Battery charge condition see Battery on page 3-38
Condition of battery terminals

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 2-5
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.

Maintenance
3.17 Battery
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:
Fig. 31: Battery (6001 Hydrostat)
Thoroughly rinse all affected surfaces immediately with plenty of water.
Thoroughly wash any part of the body touched by the sulphuric acid
+ immediately with plenty of water and seek medical attention at once.
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.
- Disconnect the negative terminal () from the battery before starting repair
A work on the electric system.
Battery A is located underneath the servicing lid, to the left of the steps. The battery is
located at the rear right under the engine cover in the case of the 6001 Hydrostat. The
1
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
Never disconnect the battery while the engine is running.
Fig. 31: Battery 6001

Maintenance
Important
The power supply is interrupted directly at the battery by removing the battery
terminal clamp.
A
Before working on the electric system
Interrupting power supply:

Fold away rubber cover A and slacken the battery clamp with a spanner. Remove the
clamp from the + terminal.
Fig. 32: Battery
Switching on power supply:
Fit the clamp onto the positive (+) terminal and tighten it with a spanner. Fit rubber
cover A back over the terminal to avoid dirt.
Starting aid:
Place the jump-starting vehicle so that there is only a short distance between the
1 batteries. Open the access to the batteries.
The access is located to the left of the steps.
Remove the four fastening screws 1.
Remove the battery servicing lid.
Take the battery jump cable.
Fold away rubber cover A and connect the positive (+) terminals by means of the red
clamps.
Fig. 33: Battery access
Do not clamp the negative (-) cable onto the negative (-) terminal of the flat
battery, but onto a sheet-metal part away from the battery.
Clamp the negative (-) cable onto the negative (-) terminal of the battery of the jump-
starting vehicle.
The engine speed of the jump-starting vehicle can be raised slightly to improve
alternator output (press the accelerator pedal/throttle slightly).
Try starting the machine with the flat battery.
Once the engine has started, first remove the clamp on the sheet-metal part away from
the battery. Never remove one of the clamps on the batteries first (danger of explosion
due to electrolytic gas). Careful when touching the sheet metal of the clamps. It can be
hot due to high electric currents.
Remove the remaining clamps.
Store away the battery jump cable, close the battery accesses again.

Maintenance
3.18 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, and 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.

Maintenance
Exterior of the machine
Cleaning the machine can cause engine damage.

Protect the engine against humidity.
The following articles are generally suitable for cleaning:

High-pressure cleaner
Steam jet
Engine compartment
Clean the engine at engine standstill only

Switch off the engine before cleaning.
When cleaning the engine with a water jet or steam

The engine must be cold and
do not point the jet directly at electric sensors such as the oil pressure
switch.
The humidity penetrating any such sensors causes them to fail and leads to
engine damage.
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.

Engine
Engine
Engine
4 Engine
4.1 Engine overview 1104 C-44

Engine
12
11
5 10
Pos. Description
1 1 V-belt
2 V-grooved pulley
3 Oil filter
4 Oil dipstick
5 V-grooved pulley
6 Starter
7 Alternator
8 Tightening bracket
9 V-grooved pulley
10 Pipe
11 Fan wheel
12 Coolant thermostat

Engine
4.2 Engine overview 1104 C-44T
13

Engine
12
9
11
6
4
5 10
Pos. Description
1 V-belt
1 2 V-grooved pulley
3 Oil filter
4 Oil dipstick
5 V-grooved pulley
6 Starter
7 Alternator
8 Tightening bracket
9 V-grooved pulley
10 Pipe
11 Fan wheel
12 Coolant thermostat
13 Turbocharger

Engine
4.3 Fuel system
Pos. Description
1 Atomiser
2 Leak oil line
3 Power supply for fuel pump
4 Fuel pump
5 Fuel filter
6 Fuel injection pump

Engine
Checking and adjusting valve clearance
Danger of (fatal!) injuries if the engine starts unexpectedly.

In order to prevent the engine from starting unexpectedly, move the ignition
switch to the OFF position, place a sign Do not actuate/start on the
ignition switch, and remove the electric connection on the stop solenoid coil
from the fuel injection pump and wrap tape around it.
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: 0.20 mm (0.008")
A
Fig. 2: Valve clearance
Open locknut 2/C and turn set screw 2/B to adjust the valve clearance on a cylinder.
Valve clearance: 0.20 mm (0.008")
Tighten locknut 2/C to 27 Nm (20 lbf ft).
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

Engine
Tightening order for cylinder head bolts

Mount the cylinder-head bolts
Tightening torques:
1st pass: 50 Nm (37 lbf ft)
2nd pass: 100 Nm (74 lbf ft) + 225 with short screws or 270 with long screws
Bear in the mind the order for tightening the cylinder-head bolts.
See figure
Fan Flywheel
Oil the threads and the contact surfaces of the cylinder-head bolts before mounting them.
Important
Always carry out work on the cylinder head on a cold engine.

Engine
4.4 Checking the injection nozzles

Pressure check
Remove injection lines 2.
Remove fastening screw 3.
Remove clamp 4 from the fuel injector.
Remove the fuel injector from the cylinder head.
Remove and discard O-ring 5 from the fuel injector.
Remove and discard washer 6 from the cylinder head.
Connect the injection nozzle with the high pressure line of the nozzle tester.
Fig. 4: 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: 290 +8/-0 bar (4206 +116/-0 psi)
Check the setting again after modifying the spacers.
Fit a new O-ring and washer again before mounting the injection nozzle.
Install in the reverse order.
Tighten fastening screw 3 to 27 Nm (20 lbf ft).
1
2 Pos. Description
2 3 4
1 Fuel injector
7
2 Fuel hose
3 Fastening screw
4 Clamp
5 O-ring
5
6 Washer
7 Alignment pin
6
Upper nozzle Lower nozzle

Leak oil line screw fitting Spacers Pressure spring centring Nozzle needle screw fitting
Compression Compression
spring spring seat Nozzle body
Injection nozzle (exploded view)

Engine
Checking the nozzle jet

Remove injection lines 2.
Remove fastening screw 3.
Remove clamp 4 from the fuel injector.
Remove the fuel injector from the cylinder head.
Remove and discard O-ring 5 from the fuel injector.
Remove and discard washer 6 from the cylinder head.
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
Normal atomisation eject fuel.
The nozzle jet must create a circle on the paper.
Check the nozzle for drips after it has ejected fuel.
Create a pressure of about 20 bar (290 psi) below injection pressure and check
whether fuel escapes from the nozzle.
Bad atomisation
Fig. 5: Nozzle jet
Injection time
Can be set only by Perkins dealers.

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.

B A 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: 2350 25 rpm
Set with the screws shown in fig. 6 if values differ from those indicated above.
Fig. 6: 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 B).
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.
Compression: 21 - 35 bar (305 - 508 psi)
Fig. 7: Compression

Engine
4.7 Checking the coolant thermostat

Remove the thermostat.
Position of thermostat
see Engine overview 1104 C-44 on page 4-1
see Engine overview 1104 C-44T on page 4-3
Fig. 8: 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 79 C (174 F), fully open at 93 C
(199 F)
Checking the thermal switch

Remove the thermal switch.
Fig. 9: Thermal switch

Warm up the thermal switch in a container with antifreeze or oil.
Thermometer 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 100 3 C
(212 37 F).
Test prods
Fig. 10: Checking the thermal switch

Engine
4.8 Oil pressure switch

Remove the cable connection from the oil pressure switch (on the oil filter head and
intake manifold).
Measurement Start the engine, check for correct idling speed.
prods 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. 11: Oil pressure switch
4.9 Checking the coolant circuit

Leakage check
Fill up the radiator completely.
Mount an adapter on the expansion tank as shown.
Increase the pressure in the cooling system by means of a hand pump to about 1 bar
(14.5 psi).
Check the lines and the connections for leaks if the pressure drops at the pressure
gauge.
Fig. 12: Checking the expansion tank for leaks
Check the expansion tank/radiator cap
Remove the expansion tank/radiator cap and mount it onto the adapter as shown.
Increase the pressure by means of a hand pump to about 1 bar (14.5 psi).
The expansion tank/radiator cap must open.
Expansion tank/radiator cap
Fig. 13: Check the expansion tank/radiator cap

4-13
Valve cover
Engine
Fuel injectors
Engine
Separate injection
pump
Oil filler neck
Thermostat
Oil dipstick
Flywheel Oil pressure switch
Oil pressure sensor

4.10 TD 2011 L04 W engine overview (from serial no. AD60001D)
Fuel feed
Fuel filter pump
Oil pressure valve

Engine oil cooler
Oil drain plug
Engine oil filter

Valve cover
Alternator
Charge-air line

Exhaust manifold
Exhaust
turbocharger
Intake manifold
V-belt
Starter
Water pump
Engine
4-14
Engine
Fuel injectors Fuel injection line (identical Leak oil from pump Feed line from filter to
(no leak oil) for cylinders 1 4) injection pumps
Engine oil filter Fuel filter Fuel feed pump without manual Cutoff solenoid
lever (maintenance-free)

Fuel injector Fuel filler inlet 4.11 Fuel system

Separate injection Tank
pump
Injection line
Ve
n t
Oil dipstick
Fue
Fuel filter l rad
i ato
Fuel reflux line from r
injection nozzles
S uc
ti o n
line
Engine
4-16
Engine
4.12 Checking and adjusting valve clearance

Standard setting of valve clearance is possible:
On a cold engine, or on a warm engine after it has cooled down for at least 0.5 h.
Oil temperature: ~ 80 C (~ 176 F)
Important
Increase valve clearance by 0.1 mm (0.004") every time the cylinder-head
gasket is replaced. Set the standard valve clearance after 1000 s/h.
Fig. 1: Turn the engine
With the cylinder-head cover removed

Turn the engine until the valves on cylinder no. 1 overlap.
Important
Valve overlapping means that the exhaust valve is not closed yet and the
intake valve starts to open. Both push rods cannot be rotated.
Fig. 2: Valve overlapping
Set valve clearance on the cylinder with a feeler gauge.

Inlet valve clearance: 0.3 mm (0.01")
Exhaust valve clearance:0.5 mm (0.02")
Tighten the locknut.
Tightening torque: 20 2 Nm (14.75 1.5 lbf ft)
Check the setting again with the feeler gauge.
Fig. 3: Setting valve clearance
Put the gasket in place
Fig. 4: Place the valve cover gasket

Engine
Slide the new rubber hoses onto the overflow line and fuel injectors as far as they will
go.
Install the valve cover and the overflow line.
Tighten the screws.
Tightening torque: 8.5 Nm (6.3 lbf ft)
Fig. 5: Mounting the valve cover
4.13 Checking and adjusting the fuel injectors
Important
Ensure utmost cleanliness when working on the fuel injection system. Use only
pure calibrating oil as per ISO 4113 or clean diesel fuel for checking the fuel
injectors.
Keep your hands away from the nozzle jet. Otherwise the fuel penetrates
deeply into your flesh and can cause blood poisoning.
Mount the fuel injector onto the nozzle tester
Fig. 6: Compression
Checking opening pressure
Slowly press down the lever of the nozzle tester with the pressure gauge switched on.
The opening pressure is the pressure at which the needle remains or suddenly drops.
Opening pressure for new setting: 210 + 8 bar (3046 + 116 psi)
Adjusting opening pressure

Unscrew the union nut.
Remove all parts.
Order in which the parts are removed:

1. Union nut
2. Fuel injector
3. Intermediate piece
4. Thrust pin
5. Tension spring
6. Shim
Fig. 7: Fuel injector

Engine
The pressure is set by selecting the correct shim.

Thicker shim = higher opening pressure
Thinner shim = lower opening pressure
Re-assemble the fuel injector.
Tighten the union nut.
Tightening torque: 45 5 Nm (33.2 0.7 lbf ft)
Check the injection nozzle again with the nozzle tester.
Checking for leaks
Dry the nozzle holder and the fuel injector with air.
Slowly press down the manual lever of the nozzle tester until reaching
about 20 bar (about 290 psi) less than the opening pressure read before.
The fuel injector is tight if there are no drops within 10 seconds.
If there is a drop, dismantle and clean the fuel injector. Replace the injection nozzle if this
does not lead to any satisfactory results.
No rework is allowed!
Clatter check and spray pattern

Switch of the pressure gauge of the nozzle tester.
Checking clatter allows you to audibly check whether the nozzle needle moves freely and
easily in the nozzle body. New fuel injectors have a different clatter behaviour with regard
to used fuel injectors.
Wear in the area of the needle seat causes clatter behaviour to degrade. Replace an
injection nozzle by a new one if it does not clatter in spite of having been cleaned.
At rapid lever activity, a used fuel injector must clatter audibly and eject the fuel in a fine
spray. The injection pattern can differ significantly from that of a new injection nozzle.
Fig. 8: Compression

Engine
4.14 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.
A Idling speed 900 25 rpm
Max. revs: 2660 25 rpm
Adjust according to Fig. 9 if values differ.
Fig. 9: Adjusting engine revs

Engine
4.15 Compression pressure

Checking and adjusting
Remove the ignition key and carry it with you.
The fuel injectors have been removed, the valve clearance has been checked.
Remove the connector from the cutoff solenoid.
Use a special tool (so-called Connecting piece) with a special seal.
Put a clamping clip in place.
Tighten the screw.
Screw on an adapter for the connecting piece if necessary.
Connect the compression pressure tester.

Turn the engine with the starter.
Compression pressure: 25 - 30 bar (363 - 435 psi)
The compression pressure depends on the starting revs during measurement and on the
geographical altitude, see Fig. 10.
This is why threshold values cannot be exactly specified.
We recommend regarding the compression pressure measurement only as a comparative
measurement of all cylinders of one single engine. In case of deviations of over 15 %,
remove the affected cylinder unit to determine the cause.
Plug the connector back onto the cutoff solenoid.
Important
Mount and tighten the fuel injectors with new special seals.
Tightening torque: 21 Nm (15.5 lbf ft)
Mount and tighten the fuel injection lines.
Tightening torque: 25 2.5 Nm (18.4 1.8 lbf ft)
Slide the new rubber hoses onto the overflow line and fuel injectors as far as they will go.
Fig. 10: Compression Mount the overflow line.

Engine
4.16 Removing/mounting the cylinder head

Determine the cylinder-head gasket mark (see circle).
Piston projection (mm/") Mark (notch)

0.530 0.690 / 0.021 - 0.027 1 notch
0.691 0.760 / 0.027 - 0.03 2 notches
0.761 0.830 / 0.03 - 0.033 3 notches
Fig. 11: Determining the cylinder-head gasket

Disconnect the battery.
Clean the engine.
Interrupt fuel supply.
Remove the intake/exhaust manifold.
Remove the valve cover.
Fig. 12: Removing the valve cover
Remove the rocker arm brackets.
Brackets must be re-installed in the same positions.
Fig. 13: Removing the rocker arm bracket
Remove the valve tappets.
Tappets must be re-installed in exactly the same positions.
Fig. 14: Removing the valve tappets

Engine
Slacken the cylinder-head bolts, bear in mind the order in which they are removed.
Carefully raise the cylinder head off the engine block.
Fig. 15: Removing the cylinder head
Make sure no straight pins are missing.
Fig. 16: Straight pins
Remove the old cylinder-head gasket.

Place the new cylinder-head gasket.
The sealing surfaces of the cylinder-head gasket must be oil-free.
Fig. 17: Putting the cylinder-head gasket in place
Use new cylinder-head bolts.

Check the length of the cylinder-head bolts:
150 0.8 mm (5.9" 0.03").
Mount the cylinder head.
Apply a thin coat of oil to the cylinder-head bolts.
Fig. 18: Putting the cylinder-head gasket in place

Engine
Mount the cylinder-head bolts

Tightening torques:
1st pass 30 Nm (22 lbf ft)
2nd pass 80 Nm (59 lbf ft)
3rd pass 160 Nm (118 lbf ft)
Retightening angle: 90
8 6 4 5 9 Bear in the mind the order for tightening the cylinder-head bolts.
Manifold side See figure
10 3 1 2 7
Fig. 19: Mounting the cylinder-head bolts
Insert the push rods in exactly the same positions as they were installed before.
Fig. 20: Inserting the push rods
Insert the rocker arm bracket in the same order as it has been removed and align it with
the push rods.
Set valve clearance.
Fig. 21: Mounting the rocker arm bracket
Place the valve cover gasket.

Mount the valve cover
Fig. 22: Mounting the valve cover

Engine
Intake/exhaust manifold
Mount the new gaskets.
Mount the intake/exhaust manifold.
Tightening torque
Intake manifold: 21 Nm (15.5 lbf ft)
Exhaust manifold: 55 Nm (40.5 lbf ft)
Open the fuel supply.
Fig. 23: Intake manifold gaskets
4.17 Replacing the injection pump/setting fuel injection time

Interrupt fuel supply.
Clean the area around the injection pump.
Remove the fuel injection line.
Remove the injection pump.
Unscrew the crankcase screw plug.
Fig. 24: Crankcase screw plug
Move the control rack to centre position.

Screw in the adjusting pin for the control rack into the crankcase as far as it will go.
Adjusting pin
Fig. 25: Setting the control rack
Turn the camshaft until the tappet stroke of a specific cylinder is at the bottom dead
centre (BDC).
Fig. 26: Camshaft

Engine
Install the injection pump tappets.
Important
Use a flexible magnetic lifter.
Fig. 27: Mounting the tappets
Determine the compensation gasket.
Fig. 28: Determining the compensation gasket
Measure depth A (fig. 28) from the crankcase contact surface to the spring seat
contact surface on the tappet.
Fig. 29: Measuring the spring contact surface on the tap-
Fitting dimension X of injection pump = 60 mm (2.36").
Important
The fitting dimension X is used for calculating the compensation gasket and
cannot be measured on an injection pump that has been removed.
Determine the difference between fitting dimension X and depth A.

Example:
Fitting dimension X = 60.00 mm (2.36")
Fig. 30: Injection pump fitting dimension - depth A = 59.35 mm (2.34")
= difference = 0.65 mm (0.02")

Engine
Select a compensation gasket according to the table and the mark.

L
Difference determined (mm/") Mark size (mm/")

Up to 0.4 / up to 0.016 9.0 / 0.35
0.401 0.5 / 0.016 - 0.02 12.0 / 0.47
0.501 0.6 / 0.02 - 0.024 15.0 / 0.59
0.601 0.7 / 0.024 - 0.028 18.0 / 0.71
0.701 0.8 / 0.028 - 0.031 21.0 / 0.83
0.801 0.9 / 0.031 - 0.035 24.0 / 0.94
0.901 1.0 / 0.035 - 0.039 27.0/ 1.06
Fig. 31: Compensation gaskets
Place a matching compensation gasket.
Important
Bear in mind the installation position.
Fig. 32: Placing the compensation gaskets
Remove the plug pin from the injection pump.
Fig. 33: Plug pin

Engine
Before mounting the injection pump, make sure lock wire X has locked into place into
the control-sleeve lever.
X
Fig. 34: Lock wire
Mount the injection pump.

Press down the injection pump centrically as far as it will go.
Tighten the nuts.
Fig. 35: Mounting the injection pump
Pull out the lock wire.
Fig. 36: Pulling out the lock wire
Close the hole with the plug pin.
Fig. 37: Hole with plug pin
Remove the adjusting pin for the control rack.
Fig. 38: Control rack adjusting pin

Engine
Tighten the screw plug with a new copper sealing ring.

Fig. 39: Screw plug
4.18 Oil pressure switch

Remove the cable connection from the oil pressure switch.
Start the engine, check for correct idling speed.
Measurement Measure the resistance of the oil pressure switch as shown by means of an ohmmeter.
prods
Oil pressure switch OK: infinite resistance.
The oil pressure switch is defective if the oil can pass.
Fig. 40: Oil pressure switch

Engine
4.19 Engine trouble
Problem Possible causes

Parking brake not applied
Steering-column control lever not in neutral
Engine starting temperature too low
Wrong SAE grade of engine lubrication oil
Fuel grade does not comply with specifications
Engine does not start or is not easy to start Defective or flat battery
Loose or oxidised cable connections in starter circuit
Defective starter, or pinion does not engage
Wrong valve clearance
Defective fuel injector
Defective cutoff solenoid
Engine starts, but does not run smoothly or faultless
Injection line leaks
Oil level too low
Oil level too high
Dirty air filter
Defective air filter maintenance switch/air filter maintenance display
Engine overheats. Temperature warning system
Dirty oil cooler fins
responds
Defective fan, torn or loose V-belt
Cooling air heats up
Resistance in cooling system too high, flow capacity too low
Oil level too high
Dirty air filter
Insufficient engine output Defective air filter maintenance switch/air filter maintenance display
Engine does not run on all cylinders Defective fuel injection pump

Engine
Problem Possible causes

Oil level too low
Insufficient or no engine oil pressure Engine inclination too high
Wrong SAE grade of engine lubrication oil
Leak in radiator hoses (cooling system)
Oil cooler leaks
Engine oil consumption too high Oil level too high
Worn/defective oil scraper rings
Engine inclination too high
Oil level too high
Blue
Engine inclination too high
Engine starting temperature too low
White Wrong valve clearance
Engine smoke Defective fuel injector
Defective cylinder-head gasket
Dirty air filter
Defective air filter maintenance switch/air filter maintenance display
Black

Travelling drive
Travelling drive
Travelling drive
Travelling drive
5 Travelling drive
5.1 Torque converter gearbox SS620 (from serial no. AA60004D to AB60997D)
Description:
SS620 synchromesh gearbox
SS
Synchro shuttle
Output:
Rated output: 75 kW (100 hp)
Maximum input revs: 3000 rpm
Maximum torque on the converter housing: 700 Nm (516 lbf ft)
Maximum ratio: 6.55:1
Control lever shift
4 forwards speed ranges, 4 reverse speed ranges

Travelling drive
Pos. Description
1 Outgoing line to oil cooler
2 Checking the oil level
3 Gearbox oil filter
4 Brake system tank (hydraulic oil SHF 46 do not fill in brake fluid!)

Travelling drive
7
9
5
8 10
Pos. Description
5 Parking brake
6 Gear shift
7 Forwards/reverse driving direction valve
8 Oil cooler feed line
9 Main pressure measuring point
10 Gearbox ventilation
Fig. 1: Gearbox position

Travelling drive
11
Pos. Description
11 Main pressure shunt
Fig. 2: Gearbox position

Travelling drive
Section SS 600
Path of power transmission + transmission ratio
Speed 1 2 3 4
Standard forwards transmission

31/31 x 44/15 x 36/19 31/31 x 40/22 x 36/19 31/31 x 31/30 x 36/19 31/31
ratio
Standard reverse transmission
22/22 x 44/15 x 36/19 22/22 x 40/22 x 36/19 22/22 x 31/10 x 36/19 22/22
ratio
Transmission ratio 5.558 3.445 1.834 1.00
High forwards transmission ratio 31/31 x 44/15 x 38/17 31/31 x 40/22 x 38/17 31/31 x 28/33 x 38/17 31/31
High reverse transmission ratio 22/22 x 44/15 x 38/17 22/22 x 40/22 x 38/17 22/22 x 28/33 x 38/17 22/22

Travelling drive
5.2 Torque converter gearbox PS750 (opt) from serial no. AB60078D to AB60997D
Description:
PS750 Synchromesh gearbox
PS
Powershift
750
750 Nm (553 lbf ft) torque
Output:
Rated output: 86 kW (115 hp)
Maximum input revs: 3000 rpm
Maximum torque on the converter housing: 750 Nm (553 lbf ft)
Maximum ratio: 7.17:1
Speed controller shift on steering wheel
4 forwards speed ranges, 4 reverse speed ranges

Travelling drive
2
1
Pos. Description
1 Oil line to oil cooler
3 Gearbox oil filter
4 Brake system tank (hydraulic oil SHF 46 do not fill in brake fluid!)

Travelling drive
6
7
Pos. Description
5 Forwards pressure shunt
6 Main shaft/countershaft pressure shunt
7 Reverse pressure shunt
8 Main pressure measuring point

Travelling drive
10
Pos. Description
9 Oil cooler feed line
10 Outgoing line to oil cooler

Travelling drive
Section PS 750
Path of power transmission + transmission ratio
Speed 1 2 3 4
Standard forwards
39/22 x 40/31 x 45/18 31/31 x 40/31 x 45/18 39/22 31/31
transmission ratio
Standard reverse 43/43 x 39/22 x 40 /31 x 45/
43/43 x 31/31 x 40/31 x 45/18 43/43 x 39/22 43/43
transmission ratio 18
Small forwards
39/22 x 40/31 x 46/16 31/31 x 40/31 x 46/16 39/22 31/31
transmission ratio
Small reverse
43/43 x 39/22 x 40/31 x 46/16 43/43 x 31/31 x 40/31 x 46/16 43/43 x 39/22 43/43
transmission ratio
Extra small forwards
39/22 x 40/31 x 47/15 31/31 x 40/31 x 47/15 39/22 31/31
transmission ratio
Extra small reverse
43/43 x 39/22 x 40/31 x 47/15 43/43 x 31/31 x 40/31 x 47/15 43/43 x 39/22 43/43
transmission ratio

Travelling drive
Oil level check on torque converter gearbox
Pos. Description
1 Oil dipstick
1 Filling in/filling up oil
5.3 Cardan shaft
Screws 3 are tightened to a torque of 61 81 Nm (82 109 lbf ft).
Pos. Description
1 Cardan shaft
2 Coupling
3 Fastening screws

Travelling drive
5.4 Transfer gearbox (from serial no. AA60004D to AB60997D)
9
10
18
2
12 17
14
11
15
7
4 1
6
7
1
8
5
15
13 7
11
9 12
10
11 12 10
16 19
17

Travelling drive
Pos. Description Tightening torque

1 Housing
2 Housing
3 Spline shaft
4 Spline shaft
5 Gear
6 Gear
7 Ball bearing
8 Ball bearing
9 Slide ring
10 Shaft flange
11 Hexagon nut 250 270 Nm (184 199 lbf ft)
12 Washer
13 Hexagon head screw 52 58 Nm (38 43 lbf ft)
14 Sealing ring
15 Pin
16 Sealing ring
17 Hexagon head screw 52 58 Nm (38 43 lbf ft)
18 Loctite
19 Type label

Travelling drive
5.5 Travelling drive diagram (up to serial no. AB60997D)
1
6
4 5
3
Pos. Description
1 Front axle
2 Rear axle
3 Diesel engine
4 Torque converter gearbox
5 Transfer gearbox
6 Master brake cylinder
Forwards/reverse drive function:
The driving direction is selected with the forwards-reverse drive selector on the steering
wheel and is changed accordingly in the torque converter gearbox.

Travelling drive
5.6 Test instructions SS620

Check: converter pressure
Tools required:
Pressure gauge 10 bar (145 psi)
Converter intake/pressure limiting valve test port
Check converter pressure as follows:

Switch off ignition
Connect the pressure gauge.
Start the diesel engine and move the drive lever to neutral position.
Converter pressure (in neutral position) bar/psi

Intake pressure at 50 C/122 F and 1000 rpm 2.4 3.4 / 34.8 - 49.3
Outlet pressure at 50 C/122 F and 1000 rpm 1.0 1.7 / 14.5 - 24.7
Outlet pressure at 50 C/122 F and 2000 rpm 2.0 / 29.0 max.
Maximum pressure of torque converter intake and pressure limiting valve 6.5/94.3

Travelling drive
Check: main pressure

Tools required:
Pressure gauge 16 bar/232 psi
Main pressure test port
Check main pressure as follows:

Switch off ignition
Main pressure (in neutral position) bar/psi

At 50 C/122 F and 1000 rpm 9.3 10.3 / 134.9 - 149.4
At 50 C/122 F and 2000 rpm 10.7 11.7 / 155.2 - 169.7
At 50 C/122 F and maximum revs (3000 rpm) 11.0 12.4 / 159.5 - 179.8
At 100 C/212 F and 1000 rpm 9.3 10.3 / 134.9 - 149.4
At 100 C/212 F and 2000 rpm 9.3 10.3 / 134.9 - 149.4

Travelling drive
Check: clutch pressure (forwards & reverse)

Tools required:
Clutch pressure test port
Check clutch pressure as follows:

Switch off ignition
Forwards clutch pressure port A
Reverse clutch pressure port B
Start the diesel engine and move the drive lever to forwards or reverse.
Clutch pressure (forwards or reverse) bar/psi

At 50 C/122 F and 1000 rpm 8.3 9.0 / 120.4 - 130.5
At 50 C/122 F and 2000 rpm 9.0 10.0 / 130.5 - 145.0
At 100 C/212 F and 1000 rpm 8.3 9.0 / 120.4 - 130.5
At 100 C/212 F and 2000 rpm 8.3 9.0 / 120.4 - 130.5

Travelling drive
Check: oil cooler flow capacity (in neutral position)

Tools required:
Flow meter 35 l/min / 9.2 gpm minimum
Oil line port to oil cooler
Check flow capacity as follows:

Switch off ignition
Connect the flow meter.
Flow capacity (in neutral position) l/min/gpm

At 50 C/122 F and 1000 rpm 10.4 13.6 / 2.7 - 3.6
At 50 C/122 F and 2000 rpm 14.5 20.0 / 3.8 - 5.3
At 100 C/212 F and 1000 rpm 10.2 12.5 / 2.7 - 3.3
At 100 C/212 F and 2000 rpm 22.7 26.1 / 6.0 - 6.9

Travelling drive
5.7 Test instructions PS750

Checking converter pressure (up to AB60997D)
Ensure utmost cleanliness of all measuring points, measuring 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 10 bar (145 psi)
Converter intake valve/pressure limiting valve test port
Check converter pressure as follows:

Switch off ignition
Start the diesel engine and move the drive lever to neutral.
Converter pressure (in neutral position) bar/psi

Maximum pressure of torque converter intake valve and torque converter
6.5/94.3
pressure limiting valve

Travelling drive
Checking main pressure (up to AB60997D)

Tools required:
Main pressure test port
Check main pressure as follows:

Switch off ignition
Main pressure (in neutral position) bar/psi

At 50 C/122 F and 1000 rpm 9.0 10.0 / 130.5 - 145.0
At 50 C/122 F and 2000 rpm 9.7 11.0 / 140.7 - 159.5

Travelling drive
Check: oil cooler flow capacity (in neutral position) up to AB60997D

Tools required:
Flow meter 35 l/min / 9.2 gpm minimum
Oil line port to oil cooler
Check flow capacity as follows:

Switch off ignition
Connect the flow meter.
Flow capacity (in neutral position) l/min/gpm

At 50 C/122 F and 1000 rpm 10.4 13.6 / 2.7 - 3.6
At 50 C/122 F and 2000 rpm 14.5 20.0 / 3.8 - 5.3

Travelling drive
5.8 Hydrostat (from serial no. AD60001D)

Automotive driving
Engine revs are increased as the accelerator pedal is pressed.
An increase of engine revs results in an increase of pump revs. Since the boost pump
is integrated in the drive pump, its volumetric flow increases as well.
The volumetric flow of the boost pump is measured by the speed-sensitive control valve
integrated in the drive pump.
The higher the volumetric flow from the boost pump through the speed-sensitive control
valve, the more the pump swivels, which thereby supplies a higher volumetric flow.
Drive speed is increased due to the higher engine revs and the larger swivel angle of
the hydraulic pump.
The driving direction is selected with the driving direction lever by means of an
integrated directional valve.
Fuel-saving potential
The hydrostatic drive has its full tractive power including at low diesel engine revs.
Easy handling
Driving the machine is easy for the driver since all he has to do is select the driving
direction with the drive lever and set the drive speed as required with the accelerator
pedal.
Hydrostatic braking
Reducing the diesel engine revs brakes the machine hydrostatically with no intervention of
the mechanical brake.
Closed circuit with inching valve

Inching function
Brake pedal The inching function supports the service brake by reducing the wear on the brake linings.
Only the hydrostatic drive brakes via the inching function when braking smoothly. Both the
Brakes hydrostatic drive and the service brake brake when braking with more force. The control
unit of the pump is connected with the circuit of the service brake. An increasing pressure
in the brake system causes the control pressure to drop and the hydraulic pump to swivel
back.
Variant
Speed-sensitive pump combined with a high-pressure-sensitive variable
displacement motor
When combining the speed-sensitive pump with a high-pressure-sensitive variable
displacement motor, handling can be adjusted not only with the pump but also with the
motor as a function of high pressure. If the pump is fully swivelled, the capacity of the
motor can be reduced in addition, and hence the drive revs can be increased. This allows
for a higher machine speed and hence for a larger converter range of the speed-sensitive
regulation.

Travelling drive
5.9 Variable displacement motor A6VM160HA2U1

High-pressure-sensitive regulation
High-pressure-sensitive regulation adjusts the capacity as a function of service pressure
(high pressure). The adjusting device measures the internal service pressure on ports A or
B of the hydraulic motor (no control line required) and when the specified pressure value
adjusted on the regulator is reached, this adjusting device swivels from minimum capacity
Vg min to maximum capacity Vg max. With high-pressure-sensitive regulation, control
initiation is carried out at Vg min (minimum torque, maximum revs) and control end at Vg
max (maximum torque, minimum revs).
Electric full maximum control of specified pressure value setting

An electric signal is emitted to a switching magnet which in turn switches high-pressure-
sensitive regulation to full maximum control. In the case of full maximum control, the
variable displacement motor swivels to its maximum swivel angle.
4
5
6
1
Pos. Description
1 Maximum flow rate limit -> slow
2 Minimum flow rate limit -> fast
3 Switching magnet slow/fast
4 MA pump port
5 MB pump port
6 Leak fluid/oil drain

Travelling drive
Travelling drive overview

Service brake
Hydraulic motor
71
B
Diesel engine
Front axle Rear axle

A
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
Hydraulic diagram
Pos. Description
A,B Work ports
G Closed
T1, T2 Leak oil ports
U Closed
Vgmax Max. capacity
Vgmin Min. capacity

Travelling drive
5.10 Replacing external components (hydraulic motor)
Output shaft Qmin limit

Cover, scouring slide valve Cover
Connecting plate
Rotary shaft lip seal
Travelling drive
Control unit
Control unit

Travelling drive
Replacing the rotary shaft lip seal

Cover drive shaft d with tape to avoid damage to rotary shaft lip seal b.
Remove circlip a and washer c.
Screw the sheet-metal screws into the holes of rotary shaft lip seal b filled with rubber.
Extract the rotary shaft lip seal with pliers.
Apply a thin coat of grease to the new rotary shaft lip seal between the sealing lip and
the dust lip to prevent it from running dry.
Press rotary shaft lip seal b as far as it will go with assembly sleeve e.
Limit
Insert washer c.
Insert circlip a so that it engages in the groove.
Remove the tape from drive shaft d.
Result

Travelling drive
Replacing seals
Measure and make a note of measure X of sealing nut a for further assembly.
Remove the sealing nut.
Screw in sealing nut a.

Block set screw b as you tighten the sealing nut.
Check measure X after assembly.
Control unit
Slackening the set screw

Measure and make a note of measure x of set screw a for further assembly.
Unscrew set screw until set sleeve b makes contact with the control unit housing c.

Travelling drive
Replacing the control unit
Description
a High pressure small control piston side
b Setting pressure
c High pressure A/B
d Prop ring
e O-ring
f Non-return valve
Tighten the new control unit.

Bear in mind the parallel pin (placed loosely in the guide of the set screw).
Screw in the set screw up to measure x.
Check measure x after assembly.
Important
Check control initiation after assembling the control unit see Checking
control initiation on page 5-31.

Travelling drive
Sealing the cover
Description
a Cover
b Flush valve
c O-ring
d Throttle stud
Unscrew the cover.

Replace the O-rings.
Check and replace O-rings c.

Travelling drive
O-ring
Description
c O-ring
e Control oil feed
f High/low pressure
g Leak oil
H Control piston
Cover
Description
a Cover
c O-ring
e Control oil feed
I Throttle stud

Travelling drive
5.11 Hydraulic motor settings
Important
Run the machine warm before taking the measurement so the hydraulic
system reaches its optimum operating temperature of about 60 C/140 F.
Checking control initiation
Description
a Control initiation set screw
b Vg min
G Service pressure
M1 Setting pressure
c Throttle orifice
X Full maximum control port

Travelling drive
Checking the settings

Control initiation of Vg max Vg min:
Jack up the machine.
Start the diesel engine.
Make sure pressure gauges are connected to measuring points G (M14x1.5) and M1
(M14x1.5) of the hydraulic motor.
Move the driving direction lever forwards to Forwards and downwards (Qmin) = high
speed range.
Press the accelerator pedal fully to maximum revs.
Brake the drive continually with the service brake.
If the service brake is fully pressed and the wheels are still turning, pull the parking
brake in addition until the wheels are at a standstill.
Slowly increase the service pressure until the control initiation pressure is applied to
measuring port G
Observe the pressure at measuring port M1:
1/2 the service pressure
Control initiation: readjust the setting pressure with the set screw
Important
Clockwise rotation earlier control initiation.
Counterclockwise rotation later control initiation.

Travelling drive
5.12 Variable displacement pump A4VG71DA1D8 (from serial no. AD60001D)
8
7
10
Pos. Description
7 X2 setting pressure (plug) M12x1
8 X1 (plug) M12x1
9 Boost pressure G M10x1
10 High pressure Mb M12x1

Travelling drive
11
12
13
14
Pos. Description
11 Boost pressure set screw
12 Inching valve
13 High pressure control valve
14 High pressure Ma

Travelling drive
Description:
A4 VG
Axial-piston machine, swash plate design, adjustable, closed circuit
71
Displacement volume Vgmax in cm
DA
Hydraulic adjustment, speed-sensitive
The A4VG 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
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

Travelling drive
Variable displacement pump: diagram
13 14 7 11 2 20 19 5 12
11
11
18
12
10
11
15 8 1 3 4
10 9
16
17
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 Screw plug
13 Double tear-off plug
14 Parallel pin
15 Screw plug
16 Eccentric screw
17 Lock nut
18 Nozzle
19 Nozzle
20 Set element

Travelling drive
Power train overview
17 9 5 8 2 15 16 23 1
20
20
21 10 3
6
24
19
7 14 11 18 4 12 13
Pos. Description
1 Cylinder with check plate
2 Piston
3 Belleville spring washer
4 Cradle
5 Slide ring
6 Articulated pin
7 Wire
8 Articulated pin
9 Wire
10 Washer
11 Roller
12 Retaining plate
13 Retaining butt
14 Pair of bearing pins
15 Spacer washer
16 Compression spring
17 Cylindrical roller bearing
18 Cage pair
19 Circlip
20 Circlip
21 Rotary shaft lip seal
22 Circlip
23 Washer
24 Circlip

Travelling drive
Connecting plate with valves
12
11
10 4
9
13
2 10
6 5
8 7 15 14 9
Pos. Description
1 Pressure limiting valve
2 Pressure limiting valve
3 Cutoff valve
4 Connecting plate
5 Bearing bushing
6 Hexagon socket screw
7 Parallel pin
8 O-ring
10 Screw plug
11 O-ring
12 Screw plug
14 Bush
15 Bearing bushing

Travelling drive
5.13 Inching valve
Pos. Description
1 Directional valve 12V
2 Inching facility
11 Seal
42 4 cheese-head screws M6x70-8.8 10.4 Nm
43 Cheese-head screw M6x45-8.8 10.4 Nm
45 O-ring
Inching
The inching function is used for braking the machine hydraulically before actuating the
mechanical service brake. This reduces the wear on the service brake and also makes it
possible to drive the machine slowly at full revs and output of the diesel engine. This
output can then be used for other purposes, such as for the work hydraulics in the
excavator.
The hydraulic inching valve is used in connection with a fixed-setting speed-sensitive
control valve. The control pressure can be reduced as required irrespective of the diesel
engine revs. The valve is controlled hydraulically via the pump's Z port.

Travelling drive
5.14 Replacing components (hydraulic pump)

Replacing the rotary shaft lip seal
Replace the rotary shaft lip seal as follows:
Cover drive shaft c with tape to avoid damage to rotary shaft lip seal b.
Remove circlip a.
Screw the sheet-metal screws into the holes of rotary shaft lip seal b filled with rubber.
Extract the rotary shaft lip seal with pliers.
Apply a thin coat of grease to the rotary shaft lip seal between the sealing lip and the
dust lip.
Press in the rotary shaft lip seal as far as it will go.
Insert circlip a so that it engages in the groove.
Remove the tape from drive shaft c.

Travelling drive
Seals
Description
a Left-hand side cover
b Right-hand side cover
c O-ring
d Set screw
e Locknut
f Fastening screws
Replacing the seals on the control piston covers

Either side of the control piston is covered by a different cover. Replacing the seals for
either cover is therefore carried out differently.
Remove fastening screws f of the left-hand side cover a.
Turn cover a and carefully slacken it by applying slight blows with a rubber hammer.
Remove the old O-ring c.

Check groove h and housing g for wear and dirt.
Insert the new O-ring.
Screw the left-hand side cover back on.
Mark the position of the right-hand side cover b to make sure it is re-installed in the
correct position after the seal has been replaced.
Measure and make a note of measure X of locknut e for further assembly.

Travelling drive
Remove locknut e.
Hold set screw d to prevent it from turning.
Extract the cover by screwing in the set screw.
Remove both O-rings c.

Check grooves i and housing j for wear and dirt.
Apply tape to the thread to avoid damage to the O-ring.

Slide the small O-ring up to the groove.
Insert the large O-ring.

Remove the tape.
Screw the cover back on.
Screw in locknut e by hand.
Block set screw d whilst tightening the locknut.
Check measure X after assembly.

Travelling drive
Replacing the pressure cutoff seals
Make a note of measure X of the sealing nut

for further assembly.
Remove sealing nut a and screw plug b.
Remove O-ring c.
Insert the new O-ring c.
Tighten screw plug b.
Tightening torque: 35 Nm (25.8 lbf ft).
Mount the new sealing nut a.
Adjust the measure X you have made a note
of.
Tighten sealing nut a to
25 Nm (18.4 lbf ft).
Replacing the control valve seal

Unscrew control valve a.
Apply tape to the thread to avoid damage to the O-ring.
Slide on the new O-ring.

Remove the tape.
Screw in the control valve.
Tightening torque: 50 Nm (36.9 lbf ft).

Travelling drive
Auxiliary (boost) pump

Mark the position of cover a to make sure it is re-installed in the correct position after
the seal has been replaced.
Remove fastening screws b.
Remove the cover as shown.
Mark the position of the auxiliary pump provided that the old one is used again.
Remove the auxiliary pump (complete replacement only).
Check the components of the auxiliary pump for wear and dirt.
Insert two new O-rings or sealing rings c.
Insert the (new) auxiliary pump.

Make sure the chamfered side d is mounted towards cover a.
The auxiliary pump is supplied with plugs e. They are pressed into their holes during
assembly onto the connecting plate.
Screw cover a back on.
Bear in mind the marks made previously.
Replacing the inching valve
Pole tube
tightening torque: 19 Nm (14 lbf ft)
Tightening torque:
5+1 Nm (3.7+0.7 lbf ft) ws 26

Travelling drive
Remove fastening screws a.

a
Remove inching valve b as shown.
Remove O-ring c and flat seal e.

Check sealing surfaces d for damage and dirt.
Replace the inching valve if necessary (complete replacement only).
Insert a new O-ring and a new flat seal e.

Insert the (new) inching valve.
Centre seal e with two fastening screws a.
Install the inching valve.
Tighten all four fastening screws a to half the torque.
Insert the fifth screw f and tighten.

Tightening torque: 10.4 Nm (7.7 lbf ft).
Tighten the other four screws a crosswise to the specified torque.

Travelling drive
5.15 Towing
The dumper is equipped with towing gear at the rear and a towing lug at the
front. Only this equipment may be used for towing. Open the high-pressure
circuit before towing the machine.
Opening the high-pressure circuit

There are two HP pressure limiting valves on the pump under the floor panel, one on the
2
upper left and the other on lower left.
Proceed as follows:
1 Mark the exact position of both high pressure limiting valves.
Slacken locknut ws 14 (part 2) and unscrew it to the end of the screw.
Screw in the screw with allen key ws 4 (part 1) until you can feel a firmer resistance.
Then screw in a further half revolution.
Both high pressure limiting valves must be open.
Fig. 3: Opening the high-pressure circuit Screwing in any further damages the valve.
Retighten the locknut.

You can now slowly tow the machine (max. 2 kph/1.2 mph) over a short distance
(max. 1 km/0.62 miles).
Then put the valves back into operation again. Proceed in the reverse order to do this
(unscrew the screw as far as it will go).

Travelling drive

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

Axles
6.2 Drain, filler and check plug
Tightening torque
Pos. Description
Nm/lbf ft
1 Fill plug 52 58/38 43
2 Drain plug 52 58/38 43

Axles
Transfer gearbox
Pos Description
1 Fill plug/oil level check

Axles
6.3 Tightening torques

Wheel screws
Wheel nut Thread Tightening torque
500 550 Nm/

With taper M18X1.5
369 406 lbf ft
Important
Check the wheel nuts for tightness every 50 service hours.
General tightening torques (Nm)
Thread
+Loctite +Loctite +Loctite
Thread Normal Normal Normal
270 270 270
size
8.8 10.9 12.9
M6x1 9.5-10.5 10.5-11.5 14.3-15.7 15.2-16.8 16.2-17.8 18.1-20.0
M8X1.25 23.8-26.2 25.6-28.4 34.2-37.8 36.7-40.5 39.0-43.0 43.7-48.3
M10X1.5 48-53 52-58 68-75 73-81 80-88 88-97
M12X1.7
82-91 90-100 116-128 126-139 139-153 152-168
5
M14x2 129-143 143-158 182-202 200-221 221-244 238-263
M16x2 200-221 219-242 283-312 309-341 337-373 371-410
M18x2.5 276-305 299-331 390-431 428-473 466-515 509-562
M20x2.5 390-431 428-473 553-611 603-667 660-730 722-798
M22x2.5 523-578 575-635 746-824 817-903 893-987 974-1076
M24x3 675-746 732-809 950-1050 1040-1150 1140-1260 1240-1370
M27x3 998-1103 1088-1202 1411-1559 1539-1701 1710-1890 1838-2032
M30x3.5 1378-1523 1473-1628 1914-2115 2085-2305 2280-2520 2494-2757
M8x1 25.7-28.3 27.5-30.5 36.2-39.8 40.0-44.0 42.8-47.2 47.5-52.5

M10X1.2
49.4-54.6 55.2-61.0 71.5-78.5 78.0-86.0 86.0-94.0 93.0-103.0
5
M12X1.2
90-100 98-109 128-142 139-154 152-168 166-184
5
M12X1.5 86-95 94-104 120-132 133-147 143-158 159-175
M14X1.5 143-158 157-173 200-222 219-242 238-263 261-289
M16X1.5 214-236 233-257 302-334 333-368 361-399 394-436
M18X1.5 312-345 342-378 442-489 485-536 527-583 580-641
M20X1.5 437-483 475-525 613-677 674-745 736-814 808-893
M22X1.5 581-642 637-704 822-908 903-998 998-1103 1078-1191
M24x2 741-819 808-893 1045-1155 1140-1260 1235-1365 1363-1507
M27x2 1083-1197 1178-1302 1520-1680 1672-1848 1834-2027 2000-2210
M30X2 1511-1670 1648-1822 2138-2363 2332-2577 2565-2835 2788-3082

Axles
6.4 Cardan shaft
Screws 3 are tightened to a torque of 61 81 Nm (82 109 lbf ft).
Pos. Description
1 Cardan shaft
2 Coupling
3 Fastening screws

Axles
6.5 Transfer gearbox (up to serial no. AB60997D)
9
10
18
2
12 17
14
11
15
7
4 1
6
7
1
8
5
15
13 7
11
9 12
10
11 12 10
16 19
17 20

Axles

1 Housing
2 Housing
3 Spline shaft
4 Spline shaft
5 Gear
6 Gear
7 Ball bearing
8 Ball bearing
9 Slide ring
10 Shaft flange
11 Hexagon nut 260 280 Nm/192 207 lbf ft
12 Washer
13 Hexagon head screw 48 53 Nm/35 39 lbf ft
14 Sealing ring
15 Pin
16 Sealing ring
17 Hexagon head screw 48 53 Nm/35 39 lbf ft
18 Loctite
19 Type label
20 Type label

Axles
6.6 Semiaxles (up to serial no. AB60997D)

Front axle

Axles

1 Axle housing
2 Screw 200/280 Nm (147.5/206.5 lbf ft)
3 Plug 52 58 Nm (38 43 lbf ft)
4 Plug 52 58 Nm (38 43 lbf ft)
5 Spacer ring
6 Sealing ring
7 Ball bearing
8 Wheel bolt
9 Wheel hub
10 O-ring
11 Axle shaft
12 Tab washer
13 Stud 90 100 Nm (66 74 lbf ft)
14 Nut 90 100 Nm (66 74 lbf ft)
15 Wheel nut 500 550 Nm (369 406 lbf ft)
16 Countersunk screw 40 50 Nm (29.5 37 lbf ft)
17 Planetary housing

Axles
Rear axle

Axles

1 Axle housing
2 Axle housing
3 Hexagon head screw 200/283 Nm (147.5/209 lbf ft)
4 O-ring
5 Plug
6 Breather
7 Screw 200/283 Nm (147.5/209 lbf ft)
8 Ring
9 Sealing ring
10 Bearing
11 Wheel bolt
12 Wheel nut 500 550 Nm (369 406 lbf ft)
13 Wheel hub
14 O-ring
15 Centering ring
16 Stud 90 100 Nm (66 74 lbf ft)
17 Nut 90 100 Nm (66 74 lbf ft)
18 Tab washer
20 Plug 52 58 Nm (38 43 lbf ft)
22 Axle shaft

Axles
6.7 Wheel hub

Front axle
10 5
12
11
7
3
4
8 2
9
1

Axles
1 Plug 52 58 Nm (38 43 lbf ft)
2 Sealing ring
3 Sealing ring
4 Bearing
5 Wheel bolt
6 Wheel hub
7 Wheel hub
8 Axle shaft
9 Tab washer
10 Stud 90 100 Nm (66 74 lbf ft)
11 Nut 90 100 Nm (66 74 lbf ft)
12 Countersunk screw 45 50 Nm (33 37 lbf ft)

Axles
Rear axle
4
8
12
9 5
6
7
1
13
2
10 11

Axles
1 Sealing ring
2 Sealing ring
3 Bearing
4 Wheel bolt
5 Wheel hub
6 O-ring
7 Centering ring
8 Stud 90 100 Nm (66 74 lbf ft)
9 Nut 90 100 Nm (66 74 lbf ft)
10 Tab washer
11 Plug 52 58 Nm (38 43 lbf ft)
13 Axle shaft

Axles
6.8 Brakes (up to serial no. AB60997D)

Front axle

Axles
Brake diagram
6
1
4 8
3
2
9
5
6

Axles

1 Brake disc set
2 Screw 10 15 Nm/7 11 lbf ft
3 Sleeve
4 Piston
5 Tension spring
6 Sealing kit
7 Pin
8 Plug
9 Bleed screw

Axles
Rear axle

Axles
Brake diagram
19
14
13
15
16
20
21
11
15
9
10
12
17
18
22
4
8
2
7
6
23
1

Axles

1 Brake disc set
2 Intermediate bushing
3 Ball
4 Tension spring
5 Spacer ring
6 Circlip
7 Shim ring
8 Counterdisc
9 Clamping sleeve
10 Antiextrusion ring
11 O-ring
12 Piston
13 O-ring
16 O-ring
17 Tension spring
18 Piston
19 Stud bolt 8 10 Nm/6 7 lbf ft
20 Bleed screw 3 5 Nm/2 4 lbf ft
21 Plug
22 Sealing ring

Axles
6.9 Differential (up to serial no. AB60997D)

Axles

1 Nut 260 300 Nm/192 221 lbf ft
2 O-ring
3 Flange
4 Protective plate
5 Sealing ring
6 Spacer ring
7 Bearing
8 Set of rings
9 Spacer ring
10 Shim ring
11 Crown wheel pair
12 Shim ring
13 Taper roller bearing
14 Screw 78 86 Nm/57.5 63 lbf ft
15 Differential housing
16 Ball
18 Circlip
19 Circlip
20 Circlip
21 Spacer ring
22 Bearing
23 Shim ring
24 Circlip
25 Differential set
26 Washer set

Axles
6.10 Drive housing (from serial no. AD60001D)

Axles
Pos. Description
1 Hexagon head screw
2 Spring lock washer
3 Cover
4 Ball bearing
5 Housing
6 Gear
7 Input shaft
8 Ball bearing
9 Cover
10 Breather
12 Stud
13 O-ring
14 Gear
15 Flange
16 Hexagon head screw
18 Cover
19 Sealing ring
20 Set screw
21 Spacer ring
22 Plug
23 Sheet metal
24 Magnet filter plug
25 Cover
26 O-ring
27 Cheese-head screw
28 Screw
29 Shaft
30 Nut
31 Nut

Axles
6.11 Semiaxles (from serial no. AD60001D)

Front axle

Axles

1 Axle housing
2 Axle shaft
3 Screw 200/280 Nm (147.5/206.5 lbf ft)
4 Plug 52 58 Nm (38 43 lbf ft)
5 Plug 52 58 Nm (38 43 lbf ft)
6 Sealing ring
7 Sealing ring
8 Bearing
9 Wheel bolt
10 Spherical collar nut 490 Nm (361 lbf ft)
11 Circlip
12 Wheel hub
13 Internal-geared wheel support
14 Circlip
15 Circlip
16 Planetary gear
17 Bearing
18 O-ring
19 Stud 90 100 Nm (66 74 lbf ft)
22 Thrust washer
23 Nut 90 100 Nm (66 74 lbf ft)

Axles
Rear axle

Axles

1 Axle housing
2 Screw 200/283 Nm (147.5/209 lbf ft)
3 Breather
4 Plug
5 O-ring
6 Ring
7 Sealing ring
8 Bearing
9 Wheel bolt
10 Spherical collar nut 490 Nm (361 lbf ft)
11 Circlip
12 Centering ring
13 Internal-geared wheel support
14 Tab washer
15 Circlip
16 Planetary gear
17 Bearing
18 Plug 52 58 Nm (38 43 lbf ft)
19 Axle shaft
22 Thrust washer
23 Nut 90 100 Nm (66 74 lbf ft)
24 Stud 90 100 Nm (66 74 lbf ft)
25 Screw plug
26 O-ring
27 Wheel hub

Axles
6.12 Brakes (from serial no. AD60001D)

Axles

1 Left-hand side lever
2 Right-hand side lever
3 Plug
4 Cheese-head screw
5 O-ring
7 Stud bolt
8 Nut
9 O-ring
10 Lever
11 Spacer ring
12 Countersunk screw
13 Counterdisc
15 Spring
16 Brake disc
17 Sealing kit
18 O-ring
19 Pin
20 Drain plug
21 Tension spring
22 Thrust pin
23 Piston
24 Piston

Axles
6.13 Differential (from serial no. AD60001D)

Axles

2 Screw
3 Screw
4 Crown wheel pair
6 Nut 260 300 Nm/192 221 lbf ft
7 Shaft nut
8 Sealing ring
9 Spacer ring
10 O-ring
11 Nut
12 Cheese-head screw
13 Flange
14 Differential
6.14 Removing the double cardan shaft (rear axle)

Remove retaining ring 7 of bearing 8.
7
Remove bearing 8 with an extractor.

Remove the piston ring with a suitable tool.

Axles
6.15 Assembling the joint housing (rear axle)

Use tool T3 to mount piston ring 9 in flange 10.
Check the direction of assembly carefully.
9
10
Use tool T4 to mount bearing 8 in flange 10.
8
10
Mount retaining ring 7 on bearing 8.

7
10
Insert flange 10 in double cardan shaft 29.
29
10
Mount retaining ring 6 on bearing 8.

Axles
Insert the double cardan shaft and screw down the upper and lower pins.
Tightening torque: 15 20 Nm (11 15 lbf ft)
Make sure the tip of the pin is centred correctly on the double cardan shaft with the
bushing.
Screw down the nuts to fasten the pins and tighten them with a torque wrench.
Tightening torque: 60 70 Nm (44 52 lbf ft)
Apply grease to the upper bushing 7, the lower spherical bushing 10 and to the holes of
the arm.
Use tools T3 and T4 to this effect.
T3
T4
Place the lower pivot pin 47 under a press and mount cover A.
Mount sealing rings 43 on pivot pins 47.

Check the direction of the sealing rings.

Axles
6.16 Removing the rear axle planetary drive

Remove oil level plug 1.
Drain the oil into a suitable container.
1
Unscrew fastening screws 3 from the cover of the planetary carrier.
Remove cover 4 of the planetary carrier with a screwdriver.

Insert the screwdriver alternately in the grooves provided to this effect and raise
slightly.
4
Remove the complete cover 4.
4
Slacken fastening nuts 5 of retaining flange 8.
5
8
Remove safety flange 7.

Axles
Remove retaining flange 11 via the studs by means of an extractor.

11
Apply a pressure of at least 7 bar (102 psi) on the brakes to block the brake discs in this
position.
Pull out wheel hub 15 by means of two levers.
15
Remove the outer bearing 13.
13
Pull out wheel hub 15.
15
Remove the inner bearing 17.

17

Axles
Remove rings 10.
Remove planetary gears 10 with an extractor.
10
Bear in mind the direction of assembly of the planetary gears.
10
Remove ring 12 from rim 11.
12
11
8 Remove retaining flange 8.
17 Expel the outer discs of bearings 13/17 through hub holes 15 with a Rawlplug.
Expel alternately to avoid deformations.
13
Remove ring 18.

18 Make a note of the order of assembly.

Axles
6.17 Mounting the rear axle planetary drive
Oil side
LOCTITE 242
Tightening
torque:
255 285 Nm/
188 210 lbf ft

Axles
Bear in mind the direction of ring 18.

18
Outer side
Oil side
Apply a sealing compound for removable seals to the outside surface of ring 18.
18
Mount ring 18 in the hub.
T33 To this effect, apply slight blows with a rubber hammer and tool T33 along the
circumference.
T33
Oil side Outer side
Insert planetary gears 10 in the cover with tool T11.

Carefully check the position.
T11
Down
10
Fasten planetary gears 10 with retaining rings 9.
9
10

Axles
Position the ring of inside bearing 17.

17 Bear in mind the position of the disc.
Position the upper part of tool T9.

Firmly press the rings into wheel hub 15.
T9
15
Position the ring of outside bearing 13.

Bear in mind the position of the disc.
13
Mount inside bearing 17.
17
Mount wheel hub 15.
Mount outside bearing 13.
13

Axles
Mount the complete retaining flange 11.

11
Down
Use a rubber hammer to insert flange 11 as far as it will go.
11
Apply alternate blows crosswise.
Apply Tecnolube Seal 101 grease to the surface of safety flange 7 making contact with
retaining flange 8.
8 7 Mount safety flange 7.
Apply Loctite 242 to the studs.

Mount nuts 5.
Tighten nuts 5 alternately and crosswise.

5 Initial tightening torque: 120 Nm (88.5 lbf ft).
Final tightening torque: 255 285 Nm (188 210 lbf ft)
Check the torque (10 30 Nm/7 22 lbf ft) as the hub turns.
14 Assembly is made easier by applying grease to O-ring 14.
15
Mount wheel hub 15.

Check the condition and the position of the O-ring.
4
Tighten cover 4 of the planetary carrier with screws 3.
3 Tightening torque of screws: 40 50 Nm (29.5 37 lbf ft)

Axles
6.18 Special tools

Special tools for axles can be ordered as a tool kit from Neuson Baumaschinen GmbH
quoting article number 1000185089.

Brakes
Brakes
Brakes
7 Brakes
7.1 Brake circuit (up to serial no. AB60997D)
Hydraulic pedal-operated dual-circuit brake with wet disc brakes in either axle.
Front axle
Rear axle
Master brake cylinder

Brakes
7.2 Brake circuit (from serial no. AD60001D)

Service brake
Hydraulic pedal-operated single-circuit brake with wet disc brakes in front axle.
Master brake cylinder

Front axle
Variable displacement
pump

Brakes

Steering system
Steering system
Steering system
8 Steering system
8.1 Steering circuit
R
Steering unit
Steering ram
T
P
Pump port
Leak oil line
Spool

Steering system

Steering unit
Right
P
T
Steering ram
Left
Pump port
Leak oil line

Steering system
8.2 Steering unit: diagram

5
4
3
1
4 Left
3 2
Right
Pos. Description
1 Pilot valve for load signal
2 Shock valves
3 Steering ram anticavitation valves
4 Non-return valve
5 Priority valve (only up to serial no. AB60997D)

Steering system
Function
Both shock valves 2 protect the Left and Right 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).
Valid only up to serial no. AB60997D:

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.
8.3 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

Steering system
EF
T L
P R/CF
Port
P Pump line
T Leak oil line
EF Control valve pressure line
L Steering ram bottom side
R/CF Steering ram rod side

Steering system
8.4 Exploded view of steering unit (up to serial no. AB60997D)

Priority valve overview
Priority valve (legend)
Pos. Description
1 Plug 50 10 Nm/37 7 lbf ft
2 Spring 7 bar/101.5 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 lbf ft
9 Type label
10 Type label rivets
11 Fastening screws 65 5 Nm/48 4 lbf ft
12 O-ring

Steering system

Hydraulic system
Hydraulic system
Hydraulic system
9 Hydraulic system
9.1 Gear pump
B3
2
Pos. Description
1 Suction line
2 Pressure line

Hydraulic system
9.2 Manual spool connections: overview

Swivel skip spool (up to serial no. AB60997D)
5
1
2 6
3 7
4 8
Pos. Description
1 Secondary pressure limiting valves (swivel) 160 bar (2321 psi)
2 Port: swivel to the right
3 Tank line
4 Port: swivel to the left
5 Primary pressure limiting valve 220 bar (3191 psi)
6 Tilt ram rod side connection
7 Supplied via steering unit
8 Tilt ram bottom side connection

Hydraulic system
Swivel skip spool (from serial no. AD60001D)
9
13
10
14
11
15
12
Pos. Description
9 Port: swivel to the right
16 10 Tank line
11 Port: swivel to the left
16 Secondary pressure limiting valves (swivel) 150 bar (2176 psi)

Hydraulic system
Front skip spool (up to serial no. AB60997D)
1
3
2
4
Pos. Description T1
2 Tank line

Hydraulic system
Front skip spool (from serial no. AD60001D)
2
4
Pos. Description
2 Tank line

Hydraulic system
9.3 Dumping the skip: hydraulic diagram

LEFT
RIGHT
Steering ram
1 2
Tilt ram
Pos. Description
1 Manual spool, front skip version
2 Steering valve

Hydraulic system
LEFT
RIGHT
Steering ram
Tilt ram
Deutz diesel
engine 2011

Hydraulic system
9.4 Swivelling the skip (option): hydraulics diagram

LEFT
RIGHT
Steering ram
2
1
Offset ram
Pos. Description
1 Manual spool, front and swivel skip version
2 Steering valve

Hydraulic system
LEFT
RIGHT
Steering ram
Offset ram
Deutz diesel
engine 2011

Hydraulic system
9.5 Test instructions

Checking the work hydraulics on a swivel skip machine
Tools required:
1 x pressure gauge 250 bar (3626 psi)
Up to AB60997D Work hydraulics measuring point From AD60001D
Check the work hydraulics pressure as follows:

A Move the drive lever to neutral.
Connect the 250 bar (3626 psi) pressure gauge to the test port.
Raise the skip with the control lever.
Pressure at 1500 rpm: about 220 bar (3191 psi)
The pressure can be set with primary 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 (up to AB60997D).
Pressure at 1000 rpm: about 150 bar/2176 psi (from AD60001D).
The pressure can be set with secondary valves B.
Turn the steering wheel as far as it will go.
Fig. 1: Control lever valves for swivel skip (up to Pressure must be about 160 bar (2321 psi) or 150 bar (2176 psi).
AB60997D)
Secondary pressure limiting valves (from
AD60001D)
Important
The pressure of the steering system cannot be adjusted.
B

Hydraulic system
Checking the work hydraulics on a front skip machine

Tools required:
1 x pressure gauge 250 bar (3626 psi)
A
Up to AB60997D Work hydraulics measuring point From AD60001D
Check the work hydraulics pressure as follows:

Move the drive lever to neutral.
Connect the 250 bar (3626 psi) pressure gauge to the test port.
A
Raise the skip with the control lever.
Pressure at 1500 rpm: about 220 bar (3191 psi)
The pressure can be set with primary pressure valve A.
Important
Fig. 2: Control lever valves for front skip
The pressure of the steering system cannot be adjusted.

Hydraulic system
9.6 A4 diagram (up to serial no. AB60997D)
9
Swivel skip option
10
8
8
9
3
12
6
13
4
11
2
1
7

Hydraulic system
Diagram (up to AB60997D): legend
Pos. Description
1 Diesel engine
2 Gear pump
3 Primary pressure limiting valve
4 Service brake
5 Vent filter
6 Steering unit
7 Priority valve (steering system)
8 Manual spool
9 Tilt ram
10 Offset ram
11 Radiator
12 Steering ram
13 Combined filter

Hydraulic system
9.7 A4 diagram (from serial no. AD60001D)

Swivel skip option
8
9
Hydraulic motor
Transfer
gearbox
Rear
axle
7
Front
axle
4
10
11
Hydraulic pump
LEFT RIGHT
5
6
12
1
2

Hydraulic system
Diagram (from AD60001D): legend
Pos. Description
1 Diesel engine
2 Gear pump
4 Service brake
5 Vent filter
6 Steering unit
7 Manual spool
8 Tilt ram
9 Offset ram
10 Radiator
11 Steering ram
12 Combined filter

Hydraulic system
Hydraulic system
9.8 A3 hydraulics diagram (up to serial no. AB60997D)
7 Pos. Description
6 1 Diesel engine
2 Gear pump
3 Primary pressure limiting
valve
12 Swivel skip option 4 Service brake
5 Vent filter
8 6 Steering unit
3 7 Priority valve (steering sys-
8 tem)
8 Manual spool
9 Tilt ram
10 Offset ram
11 Radiator
12 Steering ram
13 Combined filter
9
1 2
11
13
10
5
SERV-HB 6001 EN Edition 2.0* 6001s911.fm 9-16

Hydraulic system
9.9 A3 hydraulics diagram (from serial no. AD60001D)

6 4
LEFT
11
9
3 7
RIGHT
Hydraulic pump
Front Rear
1
axle axle
2 Transfer
gearbox
Hydraulic motor
Pos. Description
1 Diesel engine
10 2 Gear pump
4 Service brake
5 Vent filter
6 Steering unit
7 Manual spool
12 5 8 Tilt ram
9 Offset ram
10 Radiator
11 Steering ram
12 Combined filter

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), observe AC/DC basic
setting.
AC = alternating current/alternating voltage
DC = direct current/direct voltage
Test device with acoustic and optical signal output
Continuity test in de-energised machine electric system and of wiring harnesses

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):
red cable in V socket;
connect in parallel to consumer
Measuring resistance (ignition switched off):
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 30 86 = Start of coil (control line)
85 = End of coil (earth)
30 = Input (load line)
87 = Make-contact switch output (load line)
87 a= Break-contact switch output (load line)
85 87 87a
Fig. 1: Terminal description on relay

Electric system
10.4 Electric units

Fuse box in instrument panel
Fuse number Rated current (A) Protected circuit

Driving direction
4 8 1 10 A Hazard warning system 30
11
2 10 A Clearance lights, numberplate lights
3 7
3 10 A Low beam
10
4 15 A High beam
2 6
5 Not assigned
9
6 10 A Travelling drive
1 5
7 10 A Fuel pump, cutoff solenoid
8 Not assigned
Fig. 2: Fuse box 9 Not assigned
10 7.5 A Horn, brake lights
11 10 Turn indicators, telltale, fuel level indicator
Relays
K7 K 7.1 F2 The relays are located in the relay box in the engine compartment, to the right of the seat.
K 10 F1
Switching relay
Protected circuit
no.
F1 Main fuse
F2 Main fuse
D1 K7 Starting relay
K 7.1 Start interlock
Fig. 3: Relays K 10 Turn indicator relay
D1 Diode box

Electric system
Electric system
Alternator 12 V 55 A
Starter 12 V 2.3 kW (3.1 hp)
Battery 12 V 100 Ah
Fuse box
The fuse box is located on the right-hand side of the machine above the access.
F11
Fuse Rated current (A) Protected circuit
F10
F4 10 A Preheating
F9
F5 15 A Drive solenoid valves
F8
F6 10 A Horn, brake lights
F7
F7 15 A Turn indicators
F6
F8 15 A High beam
F5
F9 10 A Low beam
F4
F 10 10 A Clearance light
Fig. 4: Fuse box
F 11 10 A Hazard warning system
Relays
F1 F2 F3 The relays are located in the relay box under the the floor panel of the control stand.
K 31 Switching relay no. Protected circuit

K 32 F 1, F2, F3 Main fuses (50 A)
K 29 K 33
K 34
K 10 K 29 Preheating relay
K 35
K 30 Deutz preheating time relay
K 31 Low beam relay
K 32 Preheating telltale relay
K 33 High beam relay
K 34 Parking brake telltale relay
K 35 Start interlock relay
K 30
Fig. 5: Relays

Electric system
10.5 Operating equipment overview

Operating equipment 6001 (up to AB60997D)
6 7 8 9 14 15 16 17 10 11 12 13
21 20
4
5
25
23 3
22 1
24
2
18
19

1 Accelerator pedal 14 Spare fuel telltale
2 Parking brake 15 Not assigned
3 Ignition lock 16 Converter oil pressure telltale
Forwards-reverse control (optional with 4 drive ranges)
4 Up/down: slow/fast 17 Low-speed telltale
5 Turn indicator switch horn light switch 18 Lever for horizontal seat adjustment
6 Alternator charge telltale 19 Skip control lever
7 Engine oil pressure telltale 20 Hour meter
8 Parking brake telltale 21 Fuel level indicator
9 Engine temperature telltale 22 Brake pedal
10 High beam telltale 23 Clutch pedal
Shift lever (functions can be selected on forwards-reverse control
11 Converter oil temperature telltale 24 as an option)
12 Preheating telltale 25 Footrest
13 Turn indicator telltale

Electric system
Operating equipment 6001 Powershift (option) up to serial no. AB60997D
6 7 8 9 14 15 16 17 10 11 12 13
21 20
5
4
23
3
1
22
2
18
19

1 Accelerator pedal 13 Turn indicator telltale
2 Parking brake 14 Spare fuel telltale
3 Ignition lock 15 Not assigned
Forwards-reverse control with 4 drive ranges
4 Up/down: slow/fast 16 Converter oil pressure telltale
5 Turn indicator switch horn light switch 17 Low-speed telltale
6 Alternator charge telltale 18 Bar for horizontal seat adjustment
7 Engine oil pressure telltale 19 Skip control lever
8 Parking brake telltale 20 Hour meter
9 Engine temperature telltale 21 Fuel level indicator
10 High beam telltale 22 Brake pedal
11 Converter oil temperature telltale 23 Footrest
12 Preheating telltale

Electric system
Dumper with cab (option) from serial number AD60001D

6
5 7
8 14
4
9
3
2 10
1 20
11
12
15 16
II III
I
0
17 18 19 13

1 Air filter telltale (red) 2 High beam telltale (blue)
3 Preheating telltale (yellow) 4 Hydraulic oil filter telltale (red)
5 Converter oil temperature telltale (red) 6 Telltale (red) alternator charge function
7 Parking brake telltale (red) 8 Engine oil pressure telltale (red)
9 Coolant temperature telltale (red) 10 Turn indicator telltale (green)
11 Fuel gauge 12 Hour meter
13 Working light switch 14 Low speed switch (turtle)
15 Ignition lock 16 Hazard warning switch
17 Wiper switch 18 Fan switch
19 Air conditioning switch (option) 20 Not assigned

Electric system
Electric system
Wiring diagram: overview

10.6 Wiring diagram legend (up to AB60997D)
10-9
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
Electric system
D1 Diode box B9 H26 Turn indicators (left) F7

E1 Parking light F8 H30 Reversing light F8
E5 Low beam F7 H35 Fuel telltale A1
E6 High beam F7 K5 Preheating high current relay E14
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 K10 Turn indicator relay E2-3
F4 Parking light E5 M1 Starter F14
F5 Low beam E5 M9 Fuel pump B11
F6 High beam E5-6 P1 Hour meter A1
F7 Spare A13 P2 Fuel level indication C1
F8 Drive valves A7 R1 Glow plug E15
F9 Warning buzzer, relay A13-14 S1 Preheating start switch A2-3
F10 Spare A8 S2 Engine oil pressure switch F12
F11 Cutoff solenoid, fuel feed pump A11 S3 Engine temperature switch F12
F12 Horn, brake lights A6 S5 Hydraulic oil pressure switch F11
F13 Displays, turn indicators A5 S6 Hydraulic oil temperature switch F13
G1 Alternator F11 S8 Battery master switch F14
G2 Battery F14-15 S9 Brake light switch C7
H1 High beam telltale B1 S10 Hydraulic parking brake switch B6
H2 Preheating telltale B1 S11 Parking brake switch B7
H3 Engine temperature telltale B1 S11.1 Clutch B1
H4 Engine oil pressure telltale B1 S12 Left-hand side steering-column control lever D1
H5 Alternator charge function telltale B1 S13 Right-hand side steering-column control lever F0-1
H6 Air filter telltale B1 S19 Hazard warning switch E1
H7 Hydraulic oil filter telltale B1 Y1 Cutoff solenoid F13
H8 Hydraulic oil temperature telltale C1 Y4 Reverse driving solenoid valve F9-10
H16 Low-speed telltale C1 Y5 Forwards driving solenoid valve F9
H18 Parking brake telltale A1

Electric system
10.7 Wiring diagram version 1 A4 (up to AB60997D)

10.8 Wiring diagram legend (from AD60001D)
10-11
B1 Fuel-level sensor F5 H20 Brake lights F10
B2 Horn B10 H24 Turn indicators (left) F7
Electric system
B3 Backup warning system D6 H26 Turn indicators (right) E7

B4 Engine temperature F4 H28 Rotating beacon B13
B6 Engine oil pressure F3 H30 Reversing light D6
B7 Preheating solenoid valve F3 K10 Turn indicator relay F14
B8 Preheating solenoid valve F2 K29 Preheating relay B1
B9 Parking brake B6 K30 Deutz preheating time relay D1
B10 Starter E3 K31 Low beam relay B13
B11 Cigarette lighter E3 K32 Preheating telltale relay C1
B14 Diode box D3 K33 High beam relay B12
E1 Parking light F8 K34 Parking brake telltale relay A6
E5 Low beam F7 K35 Start interlock relay A5
E6 High beam F7 M Starter F1
F1 Main fuse D0 S1 Preheating start switch A1-2
F2 Main fuse D1 S5 Hydraulic oil pressure switch F4
F3 Main fuse D0 S10 Brake light switch B9
F4 Preheating A4 S11 Low speed switch B7
F5 Drive solenoid valves A7 S12 Drive switch C/D 7-8
F6 Horn/brake lights A7 S13 Lights switch D12-14
F7 Turn indicators A14 S19 Hazard warning switch F12-13
F8 High beam A12 Y1 Low speed solenoid valve B7
F9 Low beam A13 Y2 Forwards solenoid valve (pump) F6
F10 Position lights D8 Y3 Reverse driving solenoid valve F6-7
F11 Hazard warning system A15 Y4 Forwards solenoid valve F7
G1 Alternator F2 Y5 Cutoff solenoid B8
G2 Battery F0

Electric system
10.9 A4 wiring diagram (from AD60001D)

10.10 Wiring harness legend 1000129021: main wiring harness (up to AB60997D)
10-13
Cable no. From PIN Up to PIN Colour mm Cable no. From PIN Up to PIN Colour mm
1 X1 1 Fuse F3 WHT/BLK 1 35 X5 5 Fuse F5 BLU 2.5
2 X1 2 R1 30 WHT 1.5 35A X5 5 X7/2 2 BLU/BLK/BLU 1
3 X1 3 GND 1 BLK 1.5 36 X5 6 Fuse F9 BLU 2.5
4 X1 4 Fuse F5 RED/BLK 1.5 37 X6 2 X12 3 YEL/RED 1
Electric system
7 X2 1 D1 7 BRN/WHT 1 37A X6 2 SH1 YEL/RED 1

7A X2 1 X7/2 1 BRN/WHT 1 38 X6 5 F2 2 BRN/BLK 1
8 X2 2 X8 7 GRY/BLK 1 39 X6 8 D1 5 PKN/YEL 1
8A X2 2 X7/2 3 GRY/BLK 1 40 X6 9 X6 12 BLK 1
10 X2 4 X6 1 VIO/WHT 1 42 X6 13 X7/1 9 GRN 1
11 X2 5 X6 7 VIO 1 43 X6 15 K3 2 LTBLU/GRN 1
13 X2 8 D1 3 GRN/BLK 1 45 X7/1 2 Fuse F12 GRY/BLK 1
13A X2 8 X6 4 GRN/BLK 1 46 X7/1 7 SH2 1 ORG 1
14 X2 9 D1 4 PKN 1 47 X7/1 8 GND 1 BLK 1
15 X2 10 X5 6 LTBLU/RED 1 48 X7/1 9 Fuse F13 GRN/BLK 1
16 X2 11 X6 6 WHT 1 49 X7/2 4 X12 2 GRY/RED 1
17 X2 12 D1 9 WHT/BLK 1 50 X8 1 SH 3 RED 1
17A X2 12 X6 16 WHT/BLK/WHT 1 51 X8 4 Fuse F12 GRY 1
18 X2 13 X6 3 GRY/BLK/GRY 1 52 X8 5 Fuse F13 GRN 1
19 X3 1 F1 1 RED 2.5 53 X8 6 Fuse F11 YEL/BLK 1
20 X3 2 F1 1 RED 2.5 54 X8 7 D1 12 GRY/BLK 1
21 X3 3 F2 1 BRN 2.5 55 X8 8 GND 1 BLK 1.5
22 X4 1 X7/1 3 YEL 1 56 X12 1 X13 2 VIO 1
24 X4 3 X7/1 8 BLK 1 57 X12 4 GND 2 BLK 1
24A X4 3 X6 12 BLK 1 65 D1 8 Warning buzzer 1 GRY/YEL 1
25 X4 4 Fuse F9 BLU/RED 1 66 D1 11 R2 6 PKN/YEL 1
25A X4 4 X6 11 BLU/RED 1 67 D1 13 R2 4 BRN/GRN 1
26 X4 5 X8 3 LTBLU 1 69 R1 86 R2 5 WHT/GRN 1
26A X4 5 X7/1 1 LTBLU 1 70 R1 85 GND 2 BLK 1
27 X4 6 X8 2 BLU 1 74 Fuse F6 Fuse F10 RED 1
27A X4 6 X7/1 6 BLU 1 75 Fuse F8 SH3 2 ORG/BLK 1
28 X4 7 K3 6 BLU/BLK 1 76 Fuse F9 Warning buzzer 2 BLU/RED 1
28A X4 7 X7/1 5 BLU/BLK 1 77 SH1 1 GND 2 BLK 1
29 X4 8 K3 4 BLU/YEL 1 78 SH2 1 SH 3 2 ORG/BLK 1
30 X4 9 Fuse F10 RED/YEL 1 104 Fuse F5 Fuse F4 BLU 1.5
31 X5 1 R1 87 RED 1.5 105 Fuse F4 Fuse F3 BLU 1.5
31A X5 1 F1 2 RED 2.5 106 Fuse F3 Fuse F7 BLU 1.5
32 X5 2 Fuse F10 RED 1 107 Fuse F7 Fuse F8 BLU 1.5
33 X5 3 F2 2 BRN 2.5 109 Fuse F4 X13 1 ORG/BLU 1
34 X5 4 R2 2 WHT 4

10.11 Wiring harness 1000129021: main wiring harness (up to AB60997D)

Electric system
10-14
10.12 Wiring harness legend 1000174363: main wiring harness (from AD60001D)
10-15
1 M1 F1 12 V/30 red 10 73 X8 2 K33 high beam 87 grn/red 1
3 M1 A4 12V/30 red 6 75 S19 3 F11 turn indicators 12 V/30 8 red 1
4 M1 F2 12 V/30 red 10 76 S19 1 F7 turn indicators 12 V/30 D blu 1
5 B10 A1 starter wht/red 2.5 77 S19 4 K10 turn indicators + 31 blu/wht 1
Electric system
6 F3 S1 12V/30 1 red 6 78 X7/1 5 S19 turn indicators COM 5 blu/yel 1

7 F1 F11 12V/30 H red 4 79 S19 5 K10 turn indicators COM T blu/yel 1
8 K30 30 F2 12 V/30 red 4 80 K10 15 X10 turn indicator telltale 15 gry/red 1
9 M1 F3 12V/30 red 4 81 X7/1 1 S19 right-hand side turn indicators 7 gry/grn 1
10 S1 5 F4 12V/15 1 blu 4 82 S19 7 X8 right-hand side turn indicators 8 gry/grn 1
11 S1 6 F9 12V/15 6 blu 4 86 X7/1 6 S19 left-hand side turn indicators 6 gry/yel 1
12 B10 B11 wht/red 2.5 87 S19 6 X8 left-hand side turn indicators 7 gry/yel 1
14 S1 3 K30 preheating 50 brn 4 90 F6 C B2 left-hand side turn indicators gry/yel 1
15 S1 4 S1 preheating 8 brn 4 91 B2 S9 12V brakes/horn org/blk 1
17 F4 A X10 12 V/15 indicating instrument/relays 1 blu 1 92 X7/1 7 B2 12V brakes/horn org/blk 1
20 F4 A K30 cutoff solenoid/fuel feed pump 15 blu/red 1 93 K29 30 F3 12V brakes/horn red 6
21 F4 A Y5 fuel feed pump 2 blu/red 1 94 S11 1 S11 parking brake 9 blk/red 1
26 K29 87 B7 preheating brn 6 95 S11 5 Y1 parking brake 1 blk/red 1
27 K30 H B8 brn 6 97 S9 X8 brake lights 6 red/blk 1
28 X10 8 B5 alternator charge function telltale pnk 1 100 K34 87 X10 parking brake telltale 9 red/wht 1
29 B14 5 X10 alternator charge function telltale 8 pnk 1 101 K32 87 X10 preheating telltale 12 gry/red 1
30 B14 6 B6 engine oil pressure wht/grn 1 102 K30 TK K32 start interlock 86 wht/blk 1
31 B14 1 X10 engine oil pressure 10 wht/grn 1 103 K29 86 K30 start interlock R wht/grn 1
32 B14 9 B4 engine temperature blk/grn 1 104 F8 E H28 rotating beacon vio 1
33 B14 4 X10 engine temperature 14 blk/grn 1 105 K35 87 A1 horn wht/blk 1
34 S5 X10 hydraulic oil filter 6 org/wht 1 110 K32 85 K10 earth 53s blk 1
35 B1 X10 fuel sensor 4 vio/blk 1 111 K34 30 K34 earth 85 blk 1
39 K35 30 S1 starter 7 wht/blk 1 112 K34 86 B9 earth blk 1
40 K32 30 K32 starter 86 wht/blk 1 113 K32 85 K30 L wht/red 1
42 S9 B9 12V drive gry 1 114 K30 TK K30 15 blu/red 1
43 X7/2 2 S11 12V drive 1 gry 1 115 K29 85 K30 earth 31 blk 1
44 X7/2 2 F5 12V drive B gry 1 116 K29 85 K35 earth 85 blk 1
45 Y2 1 Y4 1 117 Y1 2 GND earth 2 blk 1
47 X7/2 4 B9 drive gry/blu 1 118 K24 85 K35 earth 85 blk 1
48 X7/2 1 Y2 forwards driving 1 brn/wht 1 119 X8 4 GND earth 2 blk 1
50 X7/2 3 X8 reversing light 5 gry/blk 1 120 GND 2 B3 earth blk 1
51 X7/2 3 B3 reverse driving gry/blk 1 121 B3 H30 earth blk 1
52 X8 5 Y3 reverse driving 1 gry/blk 1 122 H30 GND earth 2 blk 1
54 B3 H30 reversing light gry/blk 1 123 X7/1 8 X10 earth 5 blk 1
55 X7/1 3 S1 12 V/15 lights 5 blu 1 124 X7/1 8 S11 earth 10 blk 1

56 F10 G X7/1 clearance light 4 yel/blk 1 125 S11 10 GND earth 2 blk 1
57 X7/1 4 X10 clearance light 2 yel/blk 1 128 S5 GND earth 1 blk 1
58 X8 1 F10 clearance light 7 yel/blk 1 130 Y5 1 GND earth 1 blk 1
60 K31 30 F9 clearance light F yel/red 1 131 K31 85 K33 earth 85 blk 1
66 X7/1 2 K31 low beam 86 yel 1 132 B1 GND earth 1 blk 1
67 X7/1 9 X10 high beam telltale 11 grn 1 133 K31 85 GND earth 2 blk 1
68 X7/1 9 K33 high beam 86 grn 1 134 Y3 2 GND earth 1 blk 1
69 K34 86 K35 low beam 86 wht/blk 1 135 Y2 2 Y3 earth 2 blk 1
70 X8 3 K31 low beam 87 yel/red 1 136 Y4 2 Y2 earth 2 blk 1

72 F8 E K33 high beam 30 grn/red 1 139 K33 85 K30 earth 31 blk 1
Electric system
10-16
10.13 Wiring harness 1000182212: main wiring harness (from AD60001D)
10-17
Electric system

10.14 Wiring harness 1000115003 main wiring harness with Powershift option (legend)
1 X1 1 F7 1 WHT/BLK 1 31 S1 1 F1 2 RED 6
2 X1 2 K7 87 WHT 2.5 31A F3 1 F1 2 RED 2.5
3 X1 3 GND BLK 2.5 31B F3 1 F10 2 RED 2.5
6 X1 6 F11 2 BLU/BLK 1.5 32 K7 30 F2 2 RED 4
7 X2 1 D1 7 BRN/WHT 1 33 S10 GND BLK
7A X2 1 X7/2 1 BRN/WHT 1 34 S1 7 K7.1 30 WHT 1
8 X2 2 X8 7 GRY/BLK 1 35 S1 5 F9 2 BLU 2.5
8A X2 2 X7/2 3 GRY/BLK 1 35A S1 5 X7/1 3 BLU 2.5

8B D1 12 X8 7 GRY/BLK 1 36 S1 6 F13 1 BLU 2.5
10 X2 4 X6 1 PKN/WHT 1 37 X6 2 S11 3 YEL/RED 1
11 X2 5 X6 7 VIO 1 37A X6 2 S10 YEL/RED 1
12 X2 6 D1 1 ORG/WHT 1 38 X6 5 S1 8 BRN/BLK 1
12A X2 6 X6 3 ORG/WHT 1 39 X6 8 D1 5 PKN/YEL 1
13 X2 8 D1 3 GRN/BLK 1 40 X8 5 F6 2 GRN 1
13A X2 8 X6 4 GRN/BLK 1 41 X7/1 9 F6 1 GRN 1
14 X2 9 D1 4 PKN 1 42 X7/1 9 X6 13 GRN 1
15 X2 10 F11 2 LTBLU/RED 1 43 X6 15 K10 R LTBLU/GRN 1
16 X2 11 X6 6 WHT 1 45 X7/1 2 F5 1 GRY/BLK 1
17 X2 12 D1 9 WHT/BLK 1 46 X8 4 F5 2 GRY 1
17A X2 12 X6 16 WHT/BLK/WHT 1 47 X7/1 7 B2 1 ORG 1
18 X2 13 D1 10 GRY/BLK/GRY 1 48 X8 6 F4 1 YEL/BLK 1
18A X2 13 X6 14 GRY/BLK/GRY 1 49 X7/2 4 S11 2 GRY/RED 1
19 X3 1 F1 1 RED 6 50 S11 1 S11/1 2 ORG/BLU 1
20 X3 2 F2 1 RED 6 51 F8 1 S11/1 1 BLU 1
21 X3 3 S1 4 BRN 1.5 51A F8 1 X7/2 2 BLU 1
21A S1 3 S1 9 BRN 1.5 52 X8 1 S9 RED 1
23 X7/1 4 X6 10 YEL/BLK 1 53 F12 2 B2 ORG/BLK 1
23A X7/1 4 F4 2 YEL/BLK 1 54 B2 S9 ORG/BLK 1
24 X7/1 8 GND 8 BLK 1 55 X8 8 GND BLK 1.5
24A X7/1 8 X6 12 BLK 1 56 K7 86 GND BLK 1
24B X6 9 X6 12 BLK 1 57 S11 4 GND BLK 1
25 S19 1 F13 2 BLU/RED 1 59 B14 F9 1 LTBLU/BLK 1
25A S19 1 X6 11 BLU/RED 1 62 K7 85 K7.1 87a WHT/GRN 1
26 S19 7 X8 3 LTBLU 1 64 D1 8 B14 GRY/YEL 1
26A S19 7 X7/1 1 LTBLU 1 65 D1 11 K7.1 85 PKN/YEL 1
27 S19 6 X8 2 BLU 1 66 D1 13 K7.1 86 BRN/GRN 1
27A S19 6 X7/1 6 BLU 1 67 F9 2 F8 2 BLU 2.5
28 S19 5 K10 C BLU/BLK 1 68 F7 2 F8 2 BLU 2.5
28A S19 5 X7/1 5 BLU/BLK 1 69 F7 2 F11 1 BLU 2.5
29 S19 4 K10 + BLU/YEL 1 70 F12 1 F11 1 BLU 2.5
30 S19 3 F3 2 RED/YEL 1 71 F12 1 F13 1 BLU 2.5
Electric system
10-18
10.15 Wiring harness 1000115003 main wiring harness with Powershift option
10-19
Electric system

10.16 Wiring harness legend 1000115817: additional Powershift electrics
No. Description
F6 Supply voltage from fuse F6
GND Earth
K41 Forwards drive relay
K42 Reverse drive relay 1
K44 Relay Y43/Y44
K45 Relay Y45/Y46

K46 Relay Y41/42
K47 Valve release relay
S12 Lights (steering-column control lever)
S13 Drive (steering-column control lever)
S14 Lights switch
X7.1 Lights connector (steering-column control lever)
X7.2 Wiring harness connector (drive)
X7.3 Steering-column control lever connector (drive)
Y41 1st and 2nd speed valve
Y42 3rd and 4th speed valve
Y43 2nd and 4th speed valve (reverse)
Y44 1st and 3rd speed valve (reverse)
Y45 2nd and 4th speed valve (forwards)
Y46 1st and 3rd speed valve (forwards)
Shift positions
Forwards K41 K42 K43 K46 Y42 Y41 K44 Y44 Y43 K45 Y46 Y45
1 X X X X
2 X X X X X X
3 X X X
4 X X X X X
Reverse K41 K42 K43 K46 Y42 Y41 K44 Y44 Y43 K45 Y46 Y45
1 X X X X X
2 X X X X X X X
3 X X X X
4 X X X X X X
Electric system
10-20
Electric system
10.17 Wiring harness 1000115817: additional Powershift electrics

Electric system
Electric system
Wiring harnesses: overview
SERV-HB 6001 EN Edition2.0* 6001s1012.fm 10-24

Electric system
10.6 A3 wiring diagram legend (up to AB60997D)

B1 Fuel-level sensor F10 H35 Fuel telltale A1
B2 Horn C6 K6 Preheating time lag relay C14
B14 Warning buzzer B13 K7 Start high current relay D12
D1 Diode box B9 K7.1 Start interlock relay B12
E1 Parking light F8 K8 Pull contact time lag relay C13
E5 Low beam F7 K9 Pull contact high current relay D13
E6 High beam F7 K10 Turn indicator relay E2-3
F1 Main fuse D14 K29 1st/2nd speed relay D9
F2 Main fuse D14 M1 Starter F14
F3 Hazard warning system A4 M9 Fuel pump B11
F4 Parking light E5 P1 Hour meter A1
F5 Low beam E5 P2 Fuel level indication C1
F6 High beam E5-6 R1 Glow plug E15
F7 Spare A13 S1 Preheating start switch A2-3
F8 Drive valves A7 S2 Engine oil pressure switch F12
F9 Warning buzzer, relay A13-14 S3 Engine temperature switch F12
F10 Spare A8 S5 Hydraulic oil pressure switch F11
F11 Cutoff solenoid, fuel feed pump A11 S8 Battery master switch F14
F12 Horn, brake lights A6 S9 Brake light switch C7
F13 Displays, turn indicators A5 S10 Hydraulic parking brake switch B6
G1 Alternator F11 S11 Parking brake switch B7
G2 Battery F14-15 S12 Left-hand side steering-column control lever D1
H1 High beam telltale B1 S13 Right-hand side steering-column control F0-1
H2 Preheating telltale B1 lever
H3 Engine temperature telltale B1 S19 Hazard warning switch E1
H4 Engine oil pressure telltale B1 Y1 Cutoff solenoid F13
H5 Alternator charge function telltale B1 Y4 Reverse driving solenoid valve F9-10
H6 Air filter telltale B1 Y5 Forwards driving solenoid valve F9
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
Wiring diagram (legend)
H26 Turn indicators (left) F7
H30 Reversing light F8
10-25 SERV-HB 6001 EN

Electric system
10.7 A3 wiring diagram (up to AB60997D)

Electric system
10.8 Wiring diagram legend (from AD60001D)

B1 Fuel-level sensor F5
B2 Horn B10 H20 Brake lights F10
B3 Backup warning system D6 H24 Turn indicators (left) F7
B4 Engine temperature F4 H26 Turn indicators (right) E7
B6 Engine oil pressure F3 H28 Rotating beacon B13
B7 Preheating solenoid valve F3 H30 Reversing light D6
B8 Preheating solenoid valve F2 K10 Turn indicator relay F14
B9 Parking brake B6 K29 Preheating relay B1
B10 Starter E3 K30 Deutz preheating time relay D1
B11 Cigarette lighter E3 K31 Low beam relay B13
B14 Diode box D3 K32 Preheating telltale relay C1
E1 Parking light F8 K33 High beam relay B12
E5 Low beam F7 K34 Parking brake telltale relay A6
E6 High beam F7 K35 Start interlock relay A5
F1 Main fuse D0 M Starter F1
F2 Main fuse D1 S1 Preheating start switch A1-2
F3 Main fuse D0 S5 Hydraulic oil pressure switch F4
F4 Preheating A4 S10 Brake light switch B9
F5 Drive solenoid valves A7 S11 Low speed switch B7
F6 Horn/brake lights A7 S12 Drive switch C/D 7-8
F7 Turn indicators A14 S13 Lights switch D12-14
F8 High beam A12 S19 Hazard warning switch F12-13
F9 Low beam A13 Y1 Low speed solenoid valve B7
F10 Position lights D8 Y2 Forwards solenoid valve (pump) F6
F11 Hazard warning system A15 Y3 Reverse driving solenoid valve F6-7
G1 Alternator F2 Y4 Forwards solenoid valve F7
G2 Battery F0 Y5 Cutoff solenoid B8
10-27 SERV-HB 6001 EN

Electric system
10.9 A4 wiring diagram (from AD60001D)

Electric system
10.10 Wiring harness legend 1000115817: additional Powershift electrics
No. Description
F6 Supply voltage from fuse F6
GND Earth
K41 Forwards drive relay
K44 Relay Y43/Y44
K45 Relay Y45/Y46
K46 Relay Y41/42
K47 Valve release relay
S12 Lights (steering-column control lever)
S13 Drive (steering-column control lever)
S14 Lights switch
X7.1 Lights connector (steering-column control lever)
X7.2 Wiring harness connector (drive)
X7.3 Steering-column control lever connector (drive)
Y41 1st and 2nd speed valve
Y42 3rd and 4th speed valve
Y43 2nd and 4th speed valve (reverse)
Y44 1st and 3rd speed valve (reverse)
Y45 2nd and 4th speed valve (forwards)
Y46 1st and 3rd speed valve (forwards)
Shift positions
Forwards K41 K42 K43 K46 Y42 Y41 K44 Y44 Y43 K45 Y46 Y45
1 X X X X
2 X X X X X X
3 X X X
4 X X X X X
Reverse K41 K42 K43 K46 Y42 Y41 K44 Y44 Y43 K45 Y46 Y45
1 X X X X X
2 X X X X X X X
3 X X X X
4 X X X X X X
10-29 SERV-HB 6001 EN

Electric system
10.11 Wiring harness 1000115817: additional Powershift electrics

Electric system
10.12 Wiring harness legend 1000115003: main wiring harness (up to AB60997D)
1 X1 1 Fuse F3 WHT/BLK 1 35 X5 5 Fuse F5 BLU 2.5
2 X1 2 R1 30 WHT 1.5 35A X5 5 X7/2 2 BLU/BLK/BLU 1
3 X1 3 GND 1 BLK 1.5 36 X5 6 Fuse F9 BLU 2.5
4 X1 4 Fuse F5 RED/BLK 1.5 37 X6 2 X12 3 YEL/RED 1
7 X2 1 D1 7 BRN/WHT 1 37A X6 2 SH1 YEL/RED 1
7A X2 1 X7/2 1 BRN/WHT 1 38 X6 5 F2 2 BRN/BLK 1
8 X2 2 X8 7 GRY/BLK 1 39 X6 8 D1 5 PKN/YEL 1
8A X2 2 X7/2 3 GRY/BLK 1 40 X6 9 X6 12 BLK 1
10 X2 4 X6 1 VIO/WHT 1 42 X6 13 X7/1 9 GRN 1
11 X2 5 X6 7 VIO 1 43 X6 15 K3 2 LTBLU/GRN 1
13 X2 8 D1 3 GRN/BLK 1 45 X7/1 2 Fuse F12 GRY/BLK 1
13A X2 8 X6 4 GRN/BLK 1 46 X7/1 7 SH2 1 ORG 1
14 X2 9 D1 4 PKN 1 47 X7/1 8 GND 1 BLK 1
15 X2 10 X5 6 LTBLU/RED 1 48 X7/1 9 Fuse F13 GRN/BLK 1
16 X2 11 X6 6 WHT 1 49 X7/2 4 X12 2 GRY/RED 1
17 X2 12 D1 9 WHT/BLK 1 50 X8 1 SH 3 RED 1
17A X2 12 X6 16 WHT/BLK/WHT 1 51 X8 4 Fuse F12 GRY 1
18 X2 13 X6 3 GRY/BLK/GRY 1 52 X8 5 Fuse F13 GRN 1
19 X3 1 F1 1 RED 2.5 53 X8 6 Fuse F11 YEL/BLK 1
20 X3 2 F1 1 RED 2.5 54 X8 7 D1 12 GRY/BLK 1
21 X3 3 F2 1 BRN 2.5 55 X8 8 GND 1 BLK 1.5
22 X4 1 X7/1 3 YEL 1 56 X12 1 X13 2 VIO 1
24 X4 3 X7/1 8 BLK 1 57 X12 4 GND 2 BLK 1
24A X4 3 X6 12 BLK 1 65 D1 8 Warning buzzer 1 GRY/YEL 1
25 X4 4 Fuse F9 BLU/RED 1 66 D1 11 R2 6 PKN/YEL 1
25A X4 4 X6 11 BLU/RED 1 67 D1 13 R2 4 BRN/GRN 1
26 X4 5 X8 3 LTBLU 1 69 R1 86 R2 5 WHT/GRN 1
26A X4 5 X7/1 1 LTBLU 1 70 R1 85 GND 2 BLK 1
27 X4 6 X8 2 BLU 1 74 Fuse F6 Fuse F10 RED 1
27A X4 6 X7/1 6 BLU 1 75 Fuse F8 SH3 2 ORG/BLK 1
28 X4 7 K3 6 BLU/BLK 1 76 Fuse F9 Warning buzzer 2 BLU/RED 1
28A X4 7 X7/1 5 BLU/BLK 1 77 SH1 1 GND 2 BLK 1
29 X4 8 K3 4 BLU/YEL 1 78 SH2 1 SH 3 2 ORG/BLK 1
30 X4 9 Fuse F10 RED/YEL 1 104 Fuse F5 Fuse F4 BLU 1.5
31 X5 1 R1 87 RED 1.5 105 Fuse F4 Fuse F3 BLU 1.5
32 X5 2 Fuse F10 RED 1 107 Fuse F7 Fuse F8 BLU 1.5
33 X5 3 F2 2 BRN 2.5 109 Fuse F4 X13 1 ORG/BLU 1
34 X5 4 R2 2 WHT 4
10-31 SERV-HB 6001 EN

Electric system
10.13 Wiring harness 1000115003: main wiring harness (up to AB60997D)

Electric system
10.14 Wiring harness legend 1000182212: main wiring harness (from AD60001D)
1 M1 F1 12 V/30 red 10 73 X8 2 K33 high beam 87 grn/red 1
3 M1 A4 12V/30 red 6 75 S19 3 F11 turn indicators 12 V/ 8 red 1
30
4 M1 F2 12 V/30 red 10 76 S19 1 F7 turn indicators 12 V/30 D blu 1
5 B10 A1 starter wht/red 2.5 77 S19 4 K10 turn indicators + 31 blu/wht 1
6 F3 S1 12V/30 1 red 6 78 X7/1 5 S19 turn indicators COM 5 blu/yel 1
7 F1 F11 12V/30 H red 4 79 S19 5 K10 turn indicators COM T blu/yel 1
8 K30 30 F2 12 V/30 red 4 80 K10 15 X10 turn indicator telltale 15 gry/red 1
9 M1 F3 12V/30 red 4 81 X7/1 1 S19 right-hand side turn 7 gry/grn 1
indicators
10 S1 5 F4 12V/15 1 blu 4 82 S19 7 X8 right-hand side turn 8 gry/grn 1
indicators
11 S1 6 F9 12V/15 6 blu 4 86 X7/1 6 S19 left-hand side turn 6 gry/yel 1
indicators
12 B10 B11 wht/red 2.5 87 S19 6 X8 left-hand side turn indi- 7 gry/yel 1
cators
14 S1 3 K30 preheating 50 brn 4 90 F6 C B2 left-hand side turn indi- gry/yel 1
cators
15 S1 4 S1 preheating 8 brn 4 91 B2 S9 12V brakes/horn org/blk 1
17 F4 A X10 12 V/15 indicating instrument/relays 1 blu 1 92 X7/1 7 B2 12V brakes/horn org/blk 1
20 F4 A K30 cutoff solenoid/fuel feed pump 15 blu/red 1 93 K29 30 F3 12V brakes/horn red 6
21 F4 A Y5 fuel feed pump 2 blu/red 1 94 S11 1 S11 parking brake 9 blk/red 1
26 K29 87 B7 preheating brn 6 95 S11 5 Y1 parking brake 1 blk/red 1
27 K30 H B8 brn 6 97 S9 X8 brake lights 6 red/blk 1
28 X10 8 B5 alternator charge function telltale pnk 1 100 K34 87 X10 parking brake telltale 9 red/wht 1
29 B14 5 X10 alternator charge function telltale 8 pnk 1 101 K32 87 X10 preheating telltale 12 gry/red 1
30 B14 6 B6 engine oil pressure wht/grn 1 102 K30 TK K32 start interlock 86 wht/blk 1
31 B14 1 X10 engine oil pressure 10 wht/grn 1 103 K29 86 K30 start interlock R wht/grn 1
32 B14 9 B4 engine temperature blk/grn 1 104 F8 E H28 rotating beacon vio 1
33 B14 4 X10 engine temperature 14 blk/grn 1 105 K35 87 A1 horn wht/blk 1
34 S5 X10 hydraulic oil filter 6 org/wht 1 110 K32 85 K10 earth 53s blk 1
35 B1 X10 fuel sensor 4 vio/blk 1 111 K34 30 K34 earth 85 blk 1
39 K35 30 S1 starter 7 wht/blk 1 112 K34 86 B9 earth blk 1
40 K32 30 K32 starter 86 wht/blk 1 113 K32 85 K30 L wht/red 1
42 S9 B9 12V drive gry 1 114 K30 TK K30 15 blu/red 1
43 X7/2 2 S11 12V drive 1 gry 1 115 K29 85 K30 earth 31 blk 1
44 X7/2 2 F5 12V drive B gry 1 116 K29 85 K35 earth 85 blk 1
10-33 SERV-HB 6001 EN

Electric system
45 Y2 1 Y4 1 117 Y1 2 GND earth 2 blk 1
47 X7/2 4 B9 drive gry/blu 1 118 K24 85 K35 earth 85 blk 1
48 X7/2 1 Y2 forwards driving 1 brn/wht 1 119 X8 4 GND earth 2 blk 1
50 X7/2 3 X8 reversing light 5 gry/blk 1 120 GND 2 B3 earth blk 1
51 X7/2 3 B3 reverse driving gry/blk 1 121 B3 H30 earth blk 1
52 X8 5 Y3 reverse driving 1 gry/blk 1 122 H30 GND earth 2 blk 1
54 B3 H30 reversing light gry/blk 1 123 X7/1 8 X10 earth 5 blk 1
55 X7/1 3 S1 12 V/15 lights 5 blu 1 124 X7/1 8 S11 earth 10 blk 1
56 F10 G X7/1 clearance light 4 yel/blk 1 125 S11 10 GND earth 2 blk 1
57 X7/1 4 X10 clearance light 2 yel/blk 1 128 S5 GND earth 1 blk 1
58 X8 1 F10 clearance light 7 yel/blk 1 130 Y5 1 GND earth 1 blk 1
60 K31 30 F9 clearance light F yel/red 1 131 K31 85 K33 earth 85 blk 1
66 X7/1 2 K31 low beam 86 yel 1 132 B1 GND earth 1 blk 1
67 X7/1 9 X10 high beam telltale 11 grn 1 133 K31 85 GND earth 2 blk 1
68 X7/1 9 K33 high beam 86 grn 1 134 Y3 2 GND earth 1 blk 1
69 K34 86 K35 low beam 86 wht/blk 1 135 Y2 2 Y3 earth 2 blk 1
70 X8 3 K31 low beam 87 yel/red 1 136 Y4 2 Y2 earth 2 blk 1
72 F8 E K33 high beam 30 grn/red 1 139 K33 85 K30 earth 31 blk 1

Electric system
10.15 Wiring harness 1000182212: main wiring harness (from AD60001D)
10-35 SERV-HB 6001 EN

Electric system
10.16 Wiring harness 1000115003 main wiring harness with Powershift option (legend)
1 X1 1 F7 1 WHT/BLK 1 31 S1 1 F1 2 RED 6
2 X1 2 K7 87 WHT 2.5 31A F3 1 F1 2 RED 2.5
3 X1 3 GND BLK 2.5 31B F3 1 F10 2 RED 2.5
6 X1 6 F11 2 BLU/BLK 1.5 32 K7 30 F2 2 RED 4
7 X2 1 D1 7 BRN/WHT 1 33 S10 GND BLK
7A X2 1 X7/2 1 BRN/WHT 1 34 S1 7 K7.1 30 WHT 1
8 X2 2 X8 7 GRY/BLK 1 35 S1 5 F9 2 BLU 2.5
8A X2 2 X7/2 3 GRY/BLK 1 35A S1 5 X7/1 3 BLU 2.5
8B D1 12 X8 7 GRY/BLK 1 36 S1 6 F13 1 BLU 2.5
10 X2 4 X6 1 PKN/WHT 1 37 X6 2 S11 3 YEL/RED 1
11 X2 5 X6 7 VIO 1 37A X6 2 S10 YEL/RED 1
12 X2 6 D1 1 ORG/WHT 1 38 X6 5 S1 8 BRN/BLK 1
12A X2 6 X6 3 ORG/WHT 1 39 X6 8 D1 5 PKN/YEL 1
13 X2 8 D1 3 GRN/BLK 1 40 X8 5 F6 2 GRN 1
13A X2 8 X6 4 GRN/BLK 1 41 X7/1 9 F6 1 GRN 1
14 X2 9 D1 4 PKN 1 42 X7/1 9 X6 13 GRN 1
15 X2 10 F11 2 LTBLU/RED 1 43 X6 15 K10 R LTBLU/GRN 1
16 X2 11 X6 6 WHT 1 45 X7/1 2 F5 1 GRY/BLK 1
17 X2 12 D1 9 WHT/BLK 1 46 X8 4 F5 2 GRY 1
17A X2 12 X6 16 WHT/BLK/WHT 1 47 X7/1 7 B2 1 ORG 1
18 X2 13 D1 10 GRY/BLK/GRY 1 48 X8 6 F4 1 YEL/BLK 1
18A X2 13 X6 14 GRY/BLK/GRY 1 49 X7/2 4 S11 2 GRY/RED 1
19 X3 1 F1 1 RED 6 50 S11 1 S11/1 2 ORG/BLU 1
20 X3 2 F2 1 RED 6 51 F8 1 S11/1 1 BLU 1
21 X3 3 S1 4 BRN 1.5 51A F8 1 X7/2 2 BLU 1
21A S1 3 S1 9 BRN 1.5 52 X8 1 S9 RED 1
23 X7/1 4 X6 10 YEL/BLK 1 53 F12 2 B2 ORG/BLK 1
23A X7/1 4 F4 2 YEL/BLK 1 54 B2 S9 ORG/BLK 1
24 X7/1 8 GND 8 BLK 1 55 X8 8 GND BLK 1.5
24A X7/1 8 X6 12 BLK 1 56 K7 86 GND BLK 1
24B X6 9 X6 12 BLK 1 57 S11 4 GND BLK 1
25 S19 1 F13 2 BLU/RED 1 59 B14 F9 1 LTBLU/BLK 1
25A S19 1 X6 11 BLU/RED 1 62 K7 85 K7.1 87a WHT/GRN 1
26 S19 7 X8 3 LTBLU 1 64 D1 8 B14 GRY/YEL 1
26A S19 7 X7/1 1 LTBLU 1 65 D1 11 K7.1 85 PKN/YEL 1
27 S19 6 X8 2 BLU 1 66 D1 13 K7.1 86 BRN/GRN 1
27A S19 6 X7/1 6 BLU 1 67 F9 2 F8 2 BLU 2.5
28 S19 5 K10 C BLU/BLK 1 68 F7 2 F8 2 BLU 2.5
28A S19 5 X7/1 5 BLU/BLK 1 69 F7 2 F11 1 BLU 2.5
29 S19 4 K10 + BLU/YEL 1 70 F12 1 F11 1 BLU 2.5
30 S19 3 F3 2 RED/YEL 1 71 F12 1 F13 1 BLU 2.5

Electric system
10.17 Wiring harness 1000115003 main wiring harness (Powershift option)
10-37 SERV-HB 6001 EN

Electric system
10.18 Wiring harness 1000115002 engine wiring harness (legend)
Cable no. From PIN Up to PIN Colour mm

3 X1 3 Cable lug GND BLK 1.5
2 X1 2 X75 WHT 1.5
4 X1 4 X74 RED/BLK 1.5
5 Y5 1 X74 RED/BLK 1.5
7 X2 1 Y3 1 BRN/WHT 1
8 X2 2 Y2 1 GRY/BLK 1
10 X2 4 X71 VIO/WHT 1
11 X2 5 X71 VIO 1
13 X2 8 Y6 1 GRN/BLK 1
14 X2 9 X73 1 PKN 1
16 X2 11 Y4 1 WHT 1
17 X2 12 X72 WHT/BLK 1
18 X2 13 Y1 1 GRY/BLK 1
19 X3 1 X76 RED 2.5
20 X3 2 X76 RED 2.5
21 X3 3 X70 BRN 2.5
86 X76 X73 RED 2.5
87 X76 X73 RED 2.5
101 Cable lug GND Y1 2 BLK 1
107 Cable lug GND X72 2 BLK 1
108 Cable lug GND X71 BLK 1

Electric system
10.19 Wiring harness 1000115002 engine wiring harness
10-39 SERV-HB 6001 EN

Electric system
10.20 Wiring harness legend 1000075039/1000115017 telltale/indicator base ignition lock base
10 X6 1 Instrument panel PKN/WHT 1
37 X6 2 Instrument panel YEL/RED 1
12 X6 3 Instrument panel ORG/WHT 1
13 X6 4 Instrument panel GRN/BLK 1
38 X6 5 Instrument panel BRN/BLK 1
16 X6 6 Service hours WHT 1
11 X6 7 Fuel level indicator VIO 1
39 X6 8 Instrument panel PKN/YEL 1
33 X6 9 Instrument panel BRN/BLK 1
40 X6 10 Service hours YEL/BLK 1
40A X6 10 Fuel level indicator YEL/BLK 1
25 X6 11 Fuel level indicator RED 1
25B X6 11 Instrument panel RED 1
41 X6 12 Service hours BLK 1
41B X6 12 Fuel level indicator BLK 1
42 X6 13 Instrument panel GRN 1
18 X6 14 Instrument panel GRY/BLK/GRY 1
43 X6 15 Instrument panel LTBLU/GRN/LTBLU 1
18 X6 16 Instrument panel WHT/BLK/WHT 1
44 X6 17 Instrument panel VIO/WHT/VIO 1
88 Service hours Service hours BLK 1
89 Service hours Instrument panel WHT 1
90 Fuel level indicator Fuel level indicator BLK 1
91 Fuel level indicator Instrument panel BLK 1
92 Instrument panel Instrument panel BLK 1
93 Instrument panel Instrument panel BLK 1
94 Instrument panel Instrument panel RED 1
33 X5 1 Ignition lock BRN 2.5
32 X5 2 Ignition lock RED 2.5
31 X5 3 Ignition lock RED 2.5
36 X5 4 Ignition lock BLU 2.5
36B X5 4 X4 YEL 1
35 X5 5 Ignition lock BLU 2.5
34 X5 6 Ignition lock WHT 1.5
25 X4 4 Hazard warning lights BLU/RED 1
26 X4 5 Hazard warning lights LTBLU 1
27 X4 6 Hazard warning lights BLU 1
28 X4 7 Hazard warning lights BLU/BLK 1
29 X4 8 Hazard warning lights BLU/YEL 1
30 X4 9 Hazard warning lights RED/YEL 1

Electric system
10.21 Wiring harness 1000075039 telltale/indicator base
10-41 SERV-HB 6001 EN

Electric system
10.22 Wiring harness 1000115017 ignition lock base

Electric system
10.23 Wiring harness legend 1000115006: STVO (Austrian road traffic regulations) wiring harness (up to AB60997D)

50 X8 1 X11-1 1 RED 1
27 X8 2 X11-2 4 BLU 1
27B X8 2 X10-1 3 BLU 1
26 X8 3 X11-1 4 LTBLU 1
26B X8 3 X10-1 3 LTBLU 1
51 X8 4 X9-1 1 GRY 1
51A X8 4 X9-2 1 GRY 1
52 X8 5 X9-1 3 GRN 1
52A X8 5 X9-2 3 GRN 1
53 X8 6 X11-1 2 YEL/BLK 1
53A X8 6 X10-1 1 YEL/BLK 1
53B X8 6 X10-2 1 YEL/BLK 1
54 X8 7 X11-1 3 GRY/BLK 1
55 X8 8 X9-1 2 BLK 1
55A X8 8 X9-2 2 BLK 1
55B X8 8 X11-1 5 BLK 1
79 X9-1 2 X10-1 2 BLK 1
80 X9-2 2 X10-2 2 BLK 1
81 X11-1 1 X11-2 1 RED 1
82 X11-1 2 X11-2 2 YEL/BLK 1
83 X11-1 3 X11-2 3 GRY/BLK 1
84 X11-1 5 X11-2 5 BLK 1
50 X11 1 Flat plug sleeve RED 1
53 X11 2 Flat plug sleeve YEL/BLK 1
53C X11 2 Flat plug sleeve YEL/BLK 1
54 X11 3 Flat plug sleeve GRY/BLK 1
27 X11 4 Flat plug sleeve BLU 1
55 X11 5 Flat plug sleeve BLK 1
55C X11 5 Flat plug sleeve BLK 1
85 Flat plug sleeve Flat plug sleeve BLK 1
55 X9 1 Wire sleeve BLK 1
51 X9 2 Wire sleeve GRY 1
52 X9 3 Wire sleeve GRN 1
79 X10 1 Flat plug sleeve BLK 1
53A X10 2 Flat plug sleeve YEL/BLK 1
27B X10 3 Flat plug sleeve BLU 1
10-43 SERV-HB 6001 EN

Electric system
10.24 Wiring harness 1000115006: STVO (Austrian road traffic regulations) wiring harness (up to AB60997D)

Electric system
10.25 Wiring harness legend 1000174957: STVO (Austrian road traffic regulations) wiring harness (from AD60001D)
101 X8 6 X11a 1 red 1
102 X8 6 X11b 1 red 1
103 X8 8 X11b 4 blu 1
104 X8 8 X9 5 blu 1
105 X8 7 X10 5 ltblu/gry 1
106 X8 7 X11a 4 ltblu/gry 1
107 X8 3 X9 2 gry 1
108 X8 3 X10 2 gry 1
109 X8 2 X9 3 grn 1
110 X8 2 X10 3 grn 1
111 X8 1 X11a 2 yel/blk 1
112 X8 1 X11b 2 yel/blk 1
113 X8 1 X9 4 yel/blk 1
114 X8 1 X10 4 yel/blk 1
115 X8 5 X11a 3 gry/blk 1
116 X8 5 X11b 3 gry/blk
117 X8 4 X11a 5 blk 1
118 X8 4 X11b 5 blk 1
119 X8 4 X9 1 blk 1
120 X8 4 X10 1 blk 1
10-45 SERV-HB 6001 EN

Electric system
10.26 Wiring harness: STVO (Austrian road traffic regulations) wiring harness 1000174957 (from AD60001D)

Electric system
10-47 SERV-HB 6001 EN

Neuson Limited
Crown Business Park
Tredegar
Gwent South Wales NP22 4EF
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) 732/90590-200
E-mail: office@neuson.com
www.neusonkramer.com

6001H Service Manual Tier III DUMPER

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Service Manual

Machine models 6001/6001 H

Description Order no.

Operator's Manual 1000113720

Service Manual 1000163656

Spare parts list: Up to serial no. AA60080D 1000113932

Up to serial no. AB60997D 1000130920

From serial no. AD60001D 1000182752

Copyright 2008 Neuson Baumaschinen GmbH, Linz-Leonding

Neuson Baumaschinen GmbH

SERV-HB 6001 EN - Edition 2.0 * Sh6001En_0IVZ.fm T-1

Maintenance prop .................................................................................................. 1-15

T-2 SERV-HB 6001 EN - Edition 2.0 * Sh6001En_0IVZ.fm

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

SERV-HB 6001 EN - Edition 2.0 * Sh6001En_0IVZ.fm T-3

Checking the thermal switch ............................................................................ 4-11

T-4 SERV-HB 6001 EN - Edition 2.0 * Sh6001En_0IVZ.fm

Replacing the rotary shaft lip seal ................................................................... 5-40

SERV-HB 6001 EN - Edition 2.0 * Sh6001En_0IVZ.fm T-5

Up to serial no. AB60997D ................................................................................ 9-6

T-6 SERV-HB 6001 EN - Edition 2.0 * Sh6001En_0IVZ.fm

Wiring harness 1000115002 engine wiring harness (legend) .............................. 10-38

SERV-HB 6001 EN - Edition 2.0 * Sh6001En_0IVZ.fm T-7

I-1 SERV-HB 6001 EN - Edition 2.0 * Sh6001En_0SIX.fm

NOTICE: indicates a hazardous situation which, if not avoided, could result in

Note: Contains additional information important to a procedure.

0.3 Designated Use and Exemption from Liability

SERV-HB 6001 EN Edition 2.0 * 6001s100.fm 0-1

0.4 General Conduct and Safety Instructions

User training and knowledge

0-2 SERV-HB 6001 EN Edition 2.0 * * 6001s100.fm

Preparing for use

Modifications and spare parts

0.5 Staff Qualifications and Basic Responsibilities

Repair person qualifications

SERV-HB 6001 EN Edition 2.0 * 6001s100.fm 0-3

0.6 Safety instructions Regarding Operation

Startup and shutdown

Work area awareness

0-4 SERV-HB 6001 EN Edition 2.0 * * 6001s100.fm

Danger area awareness

Operating the machine

SERV-HB 6001 EN Edition 2.0 * 6001s100.fm 0-5

Driving on public roads

0.7 Trailering and Transport

0-6 SERV-HB 6001 EN Edition 2.0 * * 6001s100.fm

0.8 Temperature Range

0.9 Safety Guidelines for Maintenance

General maintenance notes

Personal safety measures

SERV-HB 6001 EN Edition 2.0 * 6001s100.fm 0-7

Preparing for maintenance and repair work

Performing maintenance and repairs

0-8 SERV-HB 6001 EN Edition 2.0 * * 6001s100.fm

0.10 Special Hazards

Tracks (Track dumpers)

SERV-HB 6001 EN Edition 2.0 * 6001s100.fm 0-9

Tires (Wheel dumpers)

0.11 Safety Guidelines while using Internal Combustion Engines

Internal combustion engines present special hazards during operation and

Guidelines for running the engine

0-10 SERV-HB 6001 EN Edition 2.0 * * 6001s100.fm

Guidelines for fueling the engine

SERV-HB 6001 EN Edition 2.0 * 6001s100.fm 0-11