Service training

Safety regulations
Service training Safety while servicing and repairing

1. SHUT OFF THE MAIN POWER SWITCH BEFORE SERVICING THE HARVESTER AND
ALSO ALWAYS AT THE END OF YOUR SHIFT.

2. KEEP A MOBILE PHONE NEAR YOU WHILE YOU SERVICE THE HARVESTER
OUTSIDE THE CAB. STORE THE EMERGENCY ALARM NUMBER AS ONE OF THE
QUICK SELECT PHONE NUMBERS.

3. REMOVE THE PRESSURE FROM THE HYDRAULIC SYSTEM BEFORE BEGINNING

TO SERVICE THE HARVESTER.

4. USE CAUTION AND PATIENCE WHEN SERVICING THE HARVESTER.

5. IMMEDIATELY REPORT ANY MALFUNCTIONS IN THE HARVESTER TO YOUR

FOREMAN OR THE PERSON RESPONSIBLE FOR SERVICING.

6. THE ENGINE MUST ALWAYS BE SHUT OFF DURING SERVICING.

7. AVOID UNNECESSARY IDLING OF THE ENGINE IN ENCLOSED AREAS. MAKE

SURE THAT EXHAUST GASES ARE VENTED OUTSIDE.

8. THE ENGINE MUST BE TURNED OFF AND ALL FIRES EXTINGUISHED BEFORE
CHECKING BATTERY ACID OR FUEL LEVELS.

9. HOT RADIATOR COOLANT IS UNDER PRESSURE. OPEN THE RADIATOR CAP

SLOWLY AND WITH CAUTION.

10. AVOID SLIPPING WHILE WORKING ON THE HARVESTER. KEEP THE HARVESTER
CLEAN. WEAR RUBBER-SOLED SHOES.

11. AVOID WORKING ALONE.

12. SERVICE THE HARVESTER ACCORDING TO THE MANUFACTURER’S SERVICE

SCHEDULE.

13. CHECK FOR LEAKS, RUB MARKS AND LOOSE PARTS. REMOVE THE CAUSE OF
THE PROBLEM. REPAIR EVEN SMALL DEFECTS IMMEDIATELY.

14. IF YOU ARE NOT FAMILIAR WITH THE CONSTRUCTION OF YOUR HARVESTER,
ASK THE MANUFACTURER FOR INSTRUCTIONS BEFORE BEGINNING TO SERVICE
IT.

15. TIP THE CAB COMPLETELY SO THAT IT LEANS AGAINST THE SUPPORT BEFORE
GOING UNDER THE CAB. MAKE SURE NOBODY IS TOO NEAR THE CAB WHILE IT
IS TIPPED —> RISK OF GETTING SQUEEZED.

000
03012000 1.1
 Safety regulations
Service training Safety while servicing and repairing

16. NEVER OPEN HOSE CONNECTORS OR OTHER HYDRAULIC COMPONENTS WHILE

THEY ARE UNDER PRESSURE. ATTENTION! PRESSURE CAN REMAIN BUILT UP IN
THE HYDRAULIC SYSTEM FOR A LONG TIME.

17. WARNING! WHEN LOOKING FOR FLUID LEAKS UNDER PRESSURE, USE A PIECE
OF PAPER. NEVER USE YOUR BARE HAND.

18. BEFORE PRESSURE ADJUSTMENTS FAMILIARIZE YOURSELF WITH THE

INSTRUCTIONS IN THE BASIC MACHINE, HARVESTER HEAD AND CRANE
MANUALS.

19. BEFORE WELDING THE HARVESTER REMOVE:

- SUSMIC connectors
- BATTERY
- ACTIVE DAMPING connectors (Ergo HS16)
- ENGINE HEATER connectors
- ALTERNATOR B+ conductor
- OPTI (Ergo HS16 and Cobra HS10)
- FIRE EXTINQUISHING SYSTEM
- REMOVE THE BATTERIES BEFORE WELDING NEAR THEM
- CONNECT THE GROUND WIRE AS CLOSE AS POSSIBLE TO THE POINT BEING
WELDED

20. FILL THE PRESSURE ACCUMULATOR WITH NITROGEN. OXYGEN OR AIR MAY
EXPLODE.

21. IF YOU OPEN THE INTAKE TO INSPECT THE GLOW PLUGS, AVOID FLAMES DUE
TO THE RISK OF FIRE.

22. DO NOT MODIFY OR REPAIR THE WHEELS OF THE HARVESTER. ANYONE

MAKING MODIFICATIONS TO THE WHEELS WITHOUT PERMISSION FROM THE
MANUFACTURER ASSUMES RESPONSIBILITY FOR THE MODIFICATIONS.

23. ONLY A TIRE SPECIALIST WITH THE PROPER TRAINING AND TOOLS MAY
CHANGE OR MOUNT TIRES ON THE WHEELS OF THE HARVESTER. TIRES
MOUNTED BY ANYONE ELSE CAN POSE A SAFETY RISK.

24. DO NOT REPAIR THE TIRE WHILE IT IS MOUNTED ON THE WHEEL —> RISK OF
EXPLOSION.

25. IF THE HARVESTER HAS TO BE REPAIRED OUT IN THE FIELD, DRIVE IT TO A

LEVEL AND EVEN PLACE.

26. KEEP YOUR FEET, HANDS, HEAD AND LOOSE CLOTHING AWAY FROM
REVOLVING PARTS.

000
03012000 1.2
 Safety regulations
Service training Safety while servicing and repairing

27. DO NOT CHANGE ANY PRESSURE SETTINGS WITHOUT PERMISSION FROM THE
MANUFACTURER.

28. USE ONLY PROPER TOOLS AND APPROVED LIFTING DEVICES, REMOVE/ REPAIR
FAULTY EQUIPMENT.

29. DANGER! USE CARE WHEN REMOVING HOT FLUIDS OR OILS FROM THE
HARVESTER. HOT FLUID OR OIL CAN CAUSE SERIOUS BURNS.

30. DISPOSAL OF FLUIDS, OILS, OR OTHER HAZARDOUS WASTES:

-DO NOT POUR ON THE GROUND OR INTO WATER.
-FIND OUT HOW TO CORRECTLY DISPOSE OF THEM
-OBSERVE LOCAL ENVIRONMENTAL REGULATIONS.

31. WHEN YOU SERVICE THE SLEWING MEHCANISM AND THE BOOM, TAKE INTO
ACCOUNT THE RISK OF SQUEEZING. SHUT OFF THE MACHINE AND SUPPORT
THE BOOM TO PREVENT MOVEMENT OF THE COLUMN, THE BASE AND THE
BOOM. USE A SEPARATE LIFTING DEVICE.

32. IF THE HARVESTER HEAD BREAKS DURING FELLING, DO NOT ATTEMPT TO

REPAIR IT NEAR THE TREE WHICH HAS BEEN CUT NEARLY THROUGH OR AT THE
POSSIBLE FALLING POINT, BUT MOVE THE HARVESTER HEAD TO A SAFE PLACE.

33. NEVER DO SERVICING OR REPAIR WORK WITHIN THE RANGE OF MOTION OF THE
CUTTING EDGE OR BETWEEN THE PRUNING BLADES OR THE FEED ROLLERS
WHILE THE MACHINE IS FUNCTIONING —> DANGER TO LIFE.

34. WHILE SERVICING OR REPAIRING THE HARVESTER HEAD, MAKE ABSOLUTELY

SURE THAT NO-ONE CAN START UP THE MACHINE. -> IF THE MACHINE STARTS
UP, THE BLADES AND ROLLERS ARE CLOSED, THE CUTTING BLADES RETURN TO
THEIR HOME POSITION AND THE WHOLE HARVESTER HEAD TURNS INTO A
HORIZONTAL POSITION. —> DANGER TO LIFE.

MANUAL CONTROL:
EACH DIRECTION VALVE HAS A PRECONTROL SOLENOID, WHICH CAN BE USED
TO CONTROL THE DIRECTION VALVE MANUALLY BY PRESSING THE SPINDLE AT
THE END OF THE VALVE.

35. AVOID USING MANUAL CONTROL WHILE REPAIRING THE HARVESTER HEAD
AND TROUBLESHOOTING. IF YOU HAVE TO USE MANUAL CONTROL, USE
SPECIAL CAUTION.

ATTENTION!!
DO NOT USE MANUAL CONTROL FOR TILTING THE HARVESTER HEAD OR
OPERATING THE ROTATOR, EXCEPT WHEN ADJUSTING ROTATOR PRESSURE,
WHEN THE HYDRAULIC HOSES HAVE BEEN PLUGGED.
000
03012000 1.3
 Safety regulations
Service training Safety while servicing and repairing

MAKE SURE YOU ARE WORKING ON THE RIGHT VALVE. MAKE SURE THE FEED
ROLLERS ARE NOT ROLLING AND THE PRUNING BLADES AND CUTTING BLADE
ARE NOT MOVING.

36. WHEN YOU TEST THE CUTTING FUNCTION, KEEP THE HARVESTER HEAD IN A
HORIZONTAL POSITION. DO NOT ALLOW ANYBODY TO BE ON THE CUTTING
LINE, BECAUSE THE CHAIN MAY BREAK AND CAUSE INJURIES. KEEP THE
HARVESTER HEAD AS CLOSE TO THE GROUND AS POSSIBLE.

37. NEVER LIFT THE HARVESTER HEAD NEAR THE CAB WINDOW TO DO A TEST CUT.

38. WHEN YOU SERVICE OR REPAIR THE MACHINE INSIDE, ALWAYS DO THE TEST
CUTS WITHOUT A CHAIN.

39. CLEAN AND INSPECT ESPECIALLY THE LIMIT SWITCHES, THE BLADE DISK, THE
CHAIN, THE PRUNING BLADES, THE HYDRAULIC HOSE PROTECTORS AND
OTHER IMPORTANT COMPONENTS.

40. ALWAYS USE PROTECTIVES GLOVES WHEN YOU WORK ON THE CHAIN.

41. DO NOT CLIMB ON THE GRAPPLE OR STAY BETWEEN THE GRABBLE OR THE
PRUNING BLADES.

42. DO NOT DISCONNECT THE AIR CONDITIONERS TUBES, BECAUSE THEY CONTAIN
PRESSURIZED REFRIGERANT. —> THE AIR CONDITIONER MUST ALWAYS BE
SERVICED BY AUTHORIZED SERVICE PERSONNEL.

43. FILL THE AIR CONDITIONER AND COMPRESSOR WITH THE REFRIGERANT/OIL
RECOMMENDED BY THE MANUFACTURER, AND DO NOT MIX DIFFERENT
REFRIGERANTS/OILS.

44. USE PROTECTIVE GLASSES WHILE SERVICING/REPAIRING THE MACHINE.

45. DO NOT WORK UNDER THE MACHINE OR BETWEEN THE FRONT CHASSIS AND
THE REAR FRAME WHILE THE ENGINE IS RUNNING. —> DANGER TO LIFE.

000
03012000 1.4
Service training Technical data
Weight 15400 kg Tyres Crane
Weight, total Front 600x34 Ponsse HN125
Rear 600x26.5 Outreach 2.4-10 m
Pull force (gross) 27 kN
Dimensions Hydraulic system
Lifting moment (gross) 190 kNm
Width 2640 mm Separate hydraulic circuits for Turning angle 280º
Lenght 7540 mm harvester head and crane Tilting angle of base 30º
Height 3740 mm Harvester Control: EHC, individually
Transport height 3740 mm head pumps 130 and 45 cm³ adjustable motions.
Ground clearance Crane pump 130 cm³
front 610 mm Volume of
Harvester head
hydraulic oil tank 360 l
Ponsse H53, H60 or H73
Performance Electric system
Tractive force 160 kN Voltage 24 V
Driving speed Gear 1 = 0-8 km/h Batteries 2 x 130 Ah Lights
Gear 2 = 0-27 km/h Generator 120 Ah 19 working lights

Engine Brake system

CAT 3116 TA Standart equipment
Drive brake:
Power 157 kW front and rear hydraulic multi-disc - Ponsse Opti or Ponsse 1000
Torque 815 Nm / 1450 rpm brakes. measuring device
Exhaust gas turbine type Parking brake: - Odometer
supercharger spring-loaded - Pressure gauge
Fuel tank capacity 230 l Loading brake: - Engine heater
affects both front and rear brakes - Radio / casette player
Transmission - Tool set
- Seat heater
- Hydrostatic-mechanical Bogies
- Barrel pump
transmission Front: Swing axle equipped with - 2 power extinguishers
- Two speed ranges forward and planetary gear and differential lock - Ultraviolet screens in the cabin
reverce Rear: Boggie equipped with
- Electronic drive automation planetary gear and differential lock Options
- Rear drive is disengageable
- Differential lock:mechanical on Cabin - Fire extinguisher system
each axle - Tracks and chains
Tilts off, fulfils safety standard ISO - 700 mm tyres
3471. Windows polycarbonate. Air-
suspended and fully adjustable
seat. Air conditioning.

2
1. Machine type plate inside the cab and
on the side of the toolchest. 4
1
2. Crane type plate (3 pcs).
2
3. Machine serial number punched on the
3740

frame (opposite side e.g. 16008).

4. Harvester head serial number punched

on the frame of the harvester head
(e.g. 033).
3

1960 1700
The manufacturer reserves the right to
make technical changes. 7545
000
11012000 2.1
 Main components
Service training
1. Engine: CATERPILLAR 3116 TA
2. Pumpgear: SAUER 160-3
3. Drive hydraulic pump: SAUER 90L100
4. Crane pump: REXROTH 130
5. Cooling circuit pump: SAUER 38
6. Drive hydraulic motor: SAUER 51V160
7. Transfear gear: NAF PO27
00061
11012000
8. Propeller shafts
9. Rear bogie: CLARK-HURT 151/60
10. Front axle: CLARK-HURT 176/223
11. Harvester head small pump: REXROTH 71/45
12. Harvester head large pump: REXROTH 130/115
13. Steering cylinders
14. Hydraulic oil cooler
15. Engine cooler
2.2
Service training

Gauges and switches

1. Horn
2. Blinker
3. Windscreen washer
4. Wiper
5. Hazard swich
6. Drive light switch
7. Signal light, battery charging
8. Signal light, long beam
9. Parking brake switch
10. Engine stop
11. Fan

00062
11012000 3.1
Service training

Gauges and switches

1. Speed range selector

Note! Stop the machine while changing the
speed range.
2. Horn
3. Ignition switch
4. Rear drive release switch
Note! Stop the machine while releasing
the rear drive.
5. Color marking switch
6. Color marking pressure gauge
7. Color marking pressure adjusting
8. Manual AV control
9. Current switch for AV manual control
10. On/Off-switch for AV
11. Emergency stop
12. Fuel filling pump signal light
13. Cigarette lighter
00062
11012000 3.2
 Service training

Gauges and switches

24 26 41 39 29
23 4 27
28 30 32 33 19 17 37
31 34 35 22 36 38

42
7
5

6 2
1 3 45
44 9 11 12 14 16 43 40
25 8 10 21 13 15 18 20

1. Mile meter 24. Frame lock switch

2. Cabin heater fan regulator 25. A/C fan speed switch
3. Windscreen wiper frequency 26. Crane switch
potentiometer 27. Radio / cassette player
4. Harvester head switch 28. Battery charging signal light
5. Windscreen wiper 29. Hydraulic oil low level signal light
6. Stop-switch 30. Working brake signal light
7. Windscreen washer 31. Hydraulic oil pressure filter signal light
8. Worklights, front 32. Fuel low level signal light
9. Worklights, rear 33. Hydraulic oil return filter signal light
10. Worklights, left 34. Parking brake signal light
11. Worklights, right 35. Drive direction signal light
12. Engine RPM 36. Cabin light switch
13. Fuel gauge 37. Seat heater switch
14. Engine oil pressure gauge 38. Parking brake switch
15. Hour gauge 39. Glow plug pre-heating switch
16. Engine temperature gauge 40. Drive speed adjusting potentio meter
17. Drive hydraulic charge (Alpha offset)
pressure signal light 41. Constant RPM ON/OFF -switch
18. Voltage gauge 42. Central lubrication switch (optional)
19. Hydraulic oil pressure filter 43. Constant RPM adjusting potentiometer
signal light 44. Air conditioner ON/OFF -switch
20. Hydraulic oil temperature gauge 45. Air conditioner thermostat
21. Work light, crane
22. Brake accumulator, charging signal light
23. Differential lock switch

00062
11012000 3.3
Service training

Placing of the fuses

Cabin fuses

AF1
AF2
AF3
AF4
AF5

A, B, C = after the ignition switch

D = before the ignition switch
AF = automatic fuse

00064
11012000 4.1
Service training

Fuses
Automatic fuse

Automatic fuse
15A
20A

Voltage

00064
11012000 4.2
Service training

Placing of the fuses

Fuses in relaycards

Nokia 6081, 3A

Mobira 720, 7.5 A

Benefon Forte, 7.5 A

1. Relay card
2. Measuring unit fuse, 15A
3. Length-sensor fuse 1A (H53, H73)
4. Empty
5. Phone fuses

00064
11012000 4.3
Service training

Placing of the fuses

Outside of the cabin

1. Mainswitch
2. Fuses
3. Fuses (optional)
4. Main fuses 2x80 A.
5. Emergency steering motor fuses 2x80 A
6. Socket

2.1 3.1
2.2 3.2
2.3 3.3
2.4 3.4

2.1 Voltage reducer 7.5A 3.1 Hydraulic oil fill up pump, 25 A

Radio, heater clock 3.2 Empty
2.2 Opti, 10 A 3.3 Fire extinguisher system,
2.3 Worklight, after the mainswitch, 10 A
(under cabin), 10 A 3.4 Fire extinguisher system,
2.4 Vacum pump, 10 A before the mainswitch, 10 A
00064
11012000 4.4
Service training

Fuses
Outside of the cabin

1. Heater 20A
2. Heater 15A
3. Start motor’s control 20 A
4. Charging 7,5 A

00064
11012000 4.5
Service training Relays
Cabin, relays in relay cards,
Ponsse Opti or Ponsse 1000

relay card´s top side

RELAY CARD 5
board
RELAY CARD 4 connector
J2
RELAY CARD 3

RELAY CARD 2
board
RELAY CARD 1 connector
J1

Relay cards in cabin. Relays have same position in all relay cards.

Relay card 1 Relay card 2 Relay card 3 (IPS) Relay card 3 (Knutsson)
Relay 1 Crane, work lights Work lights, front Right joy-stick Feed voltage sorting
Relay 2 Crane, work lights Work lights on top of
valvebank, front Left joy-stick Voltage input
Relay 3 Work lights on Work lights, rear
roof, left Seat sensor Seat sensor
Relay 4 Work lights on roof, Feeding forward /
Low beam right steering right Free
Relay 5 Work lights in side case, Feeding reverse /
High beam right steering left Free
Relay 6 Work lights in Work lights, rear * Restrain of starting * Restrain of starting
sidecase, left

Relay card 4 Relay card 5

Relay 1 * Start motor relay Susmic current * Relays are not in use after january 1999
(Susmic requires acknowledgement of neutral
Relay 2 Motor stop Emergency steering position before allowing driving.
solenoid relay
Relay 3 Brake charging Gas pedal selection
valve according to seat position
Relay 4 Fuel pump Slow-down speed

Relay 5 Urea pump Frame lock valve

Relay 6 Empty Frame lock valve /
working brake valve

00064
11012000 4.6
Service training Relays
Cabin, relays in relay cards,
Optinet-IPS
relay card´s top side

RELAY CARD 5 board

connector
RELAY CARD 4 J2

RELAY CARD 3

RELAY CARD 2 board

connector
RELAY CARD 1 J1

Relay cards in cabin. Relays have same position in all relay cards.

Relay card 1 Relay card 2 Relay card 3 (IPS)

Relay 1 Crane, work lights Work lights, front Right joy-stick
Relay 2 Crane, work lights Work lights front, valve
block Left joy-stick
Relay 3 Work lights on Work lights, rear
roof, left Seat sensor
Relay 4 Work lights on roof, Feeding forward /
Low beam right steering right
Relay 5 Work lights in side case, Feeding reverse /
High beam right steering left
Relay 6 Work lights in Work lights on roof, rear Grounding of IPS-grips
sidecase, left

Relay card 4 Relay card 5

Relay 1 Free Susmic current

Relay 2 Engine stop Emergency steering

solenoid control
Relay 3 Brake charging Gas pedal selection
valve
Relay 4 Fuel pump Speed range

Relay 5 Urea pump Frame lock valve

Relay 6 Free Working brake valve

00064
11012000 4.7
Service training

Relays
Cabin, relays outside of the relay cards

A
ME

B
K2 K1 MF

K1 = Option, kun pohjan alla tuuletus

K2 = Blinkers
MF = Relay for measuring units, central processing unit´s voltage inlet.
MF-relay (fet-side)
ME = Relay for measuring units, central processing unit´s voltage inlet.
(If there is Optinet, there is no ME-relay)
A = Main current relay
B = Air condition unit relay

00064
11012000 4.8
Service training

Relays

Relay 11: Fuel valve relay. (If the machine is equipped

with central fire extinguisher.)

Relay 12: Cabin- / engine heater relay

00064
11012000 4.9
Service training

Sensors

1. Engine oil pressure sensor.

2. Engine oil pressure signal light sensor.
3. Engine temperature sensor (buzzer/signal light)
4. RPM-sensor

00064
11012000 4.10
Service training

Sensors

1. Emergency steering sensor, 120 bar

2. Hydraulic oil pressure filter sensor (blocked filter), 2,5 bar
3. Hydraulic oil temperature sensor
4. Hydraulic oil level sensor
6. Hydraulic oil return filter sensor, 1,2 bar
7. Fuel gauge sensor
8. Parking brake sensor, 20 bar
9. Brake circuit, pressure relief sensor, 120-160 bar
10. Brake charging sensor, 90 bar
11. Differential lock sensor, 20 bar
12. Cabin levelling solenoid valve

00064
11012000 4.11
Service training

Sensors

Drive hydraulic motor

1. Charge pressure sensor, minimum 10 bar

00064
11012000 4.12
Service training

Explanations of markings and

abbreviations of the electric
diagrams

Connectors marking
X = Connector
XH = Harting-connector
XK = Card connector
XPKL = Base machine connector
N = Female pole
U = Male pole

For example
X50-1 = Connector nr. 50, pole nr. 1
XK5-J2-3 = Relay card nr. 5, connector nr. J2, pole nr. 3

Abbreviation markings
F = Fuse
FAut = Automatic fuse
M = Motor
S = Switch

For example
FC1 = Fuse in row C of the fuse panel nr. 1

00064
11012000 4.13
 Electric diagrams
Service training

Reading of the wiring diagram

Pos Function Location Place

A Voltage - before the main switch A1- A19
B Voltage - after the main switch A1 - A19
B32 Sensor - fuel tank upper level I - 16 fuel tank
C Voltage - from the main switch B1 - B19
E02 Cabin light H-16 cabin
E03 Stop solenoid I- 15 engine
E41 Fuel pump signal light H - 17 switches in rear panel
F08 Fuse - battery charging I- 13 engine
F1M Fuse - main current 80 A C-11 underneath the cabin
F2M Fuse - main current 80 A A-12 underneath the cabin
F3M Fuse - main current 80 A B-18 underneath the cabin
F4M Fuse - main current 80 A B-18 underneath the cabin
F5M Fuse - fuel pump CAT I - 10 engine
FA2 Fuse - charger´s indication light H-13 fuse box
FB5 Fuse - engine stop solenoid B-15 fuse box
FB6 Fuse - fire extingquisher solenoid B-15 fuse box

00065
11012000 4.14
 Electric diagrams
Service training

Reading of the wiring diagram

Pos Function Location Place

FB8 Fuse - re-start D-15 fuse box
FC2 Fuse, engine start C -12 fuse box
FC8 Fuse - stump spray system B - 16 fuse box
FD5 Fuse - fuel pump/radio/cabin light B - 17 fuse box
FD7 Fuse - ignition switch C- 12 fuse box
G01 Battery G - 10 front frame
G01 Alternator I - 13
G02 Battery H - 10 front frame
H01 Signal light - alternator (front) G - 12 signal light
H02 Signal light - alternator (rear) F - 13 gauges
K01 Relay - main current H - 11 relay card
K06 Relay - solenoid´s control solenoid I - 12 engine
...
M01 Engine - relay card´s fan (2 pcs) H - 11 front box
...
M14 Engine - CAT fuel pump I - 10 engine

Manuf.no . . . . . .10322 - 11/17/1998 YL00490

00065
11012000 4.15
Service training
Reading of the wiring diagram

Pos Function Position Place

K01 Relay, main current H - 11 relaycard

M01 Motor, relaycard fan 2 pcs H - 11 front box
M14 Motor, CAT fuel pump I - 10 engine

00065
11012000 4.16
Service training Reading of the wiring diagram
10 11 12 13 14 15

00065
11012000 4.17
Service training Function of the alarm buzzer

00065
11012000 4.18
Service training

Functions related to seat sensor

00065
11012000 4.19
Service training Crane control

00065
11012000 4.20
Service training Susmic 20

00065
11012000 4.21
 AV-active suspension
Service training

REG

INC

GYR
POT

LV

00065
11012000 4.22
Service training

Speed adjusting unit of the crane

1. ICL -joy-stick
3. Signal lights of the functions
4. IPS 302 control unit
5. Universal gauge
6. Pre-control valve
7. Starting point adjustment screw (min-adjusting)
8. Max. speed adjusting screw (max. angle adjusting)
9. Directional valve (F150 or K170)
10. ERROR -light (red)
11. ERROR RESET
12. Frequency correction
13. Current ON -signal light
14. Delay adjustment, so called “ramp adjusting”
- do not adjust rotator and crapple movements
- other movements can be adjusted approx.
1/4 round

00066
11012000 5.1
Service training

Crane movement speed

adjusting

Crane movement speed adjusting by IPS 302

central unit

3. Signallight for function

7. Starting point adjusting screw (min. speed)
8. Max. speed adjusting screws (max. speed)
14. Delay adjusting, “ramp”
Recommendated adjustings:
- Crane swing
- Crane lifting, if “ramps” need to
be used.

00066
11012000 5.2
Service training

ICL - JOY-STICKS
Cleaning and service

Cleaning, checking the ten-

sion of the glide tip and check-
ing the condition of the poten-
tiometers.

1. Snapring
2. Potentiometer
3. Conductor
4. Slide bar
5. Cover

00066
11012000 5.3
Service training Block 1, drive hydraulic

1. Block 1, assembly plate M1 = Work pressure A

2. Gear range M2 = Work pressure B
3. Rear drive M3/P = Charge pressure
4. Parking brake M3/M = Minimum pressure
5. Hydraulic stair M4/P = Hydraulic stair
6. Drive hydraulic motor M4/M = Maximum pressure
7. Drive hydraulic pump M5/P = Servo pressure
8. Pressure accumulator M7 = Internal regulating pressure
M8 = Internal regulating pressure
00067
11012000 6.1
 FEED PRESSURE, ENGINE RUNNING,
10 bar D2.0 MACHINE STATIONARY

"B" 0 "A"

FEED PRESSURE, 28 +/- 1

M5 M4 M3 / P X1 X2
RETURN PRESSURE
(CONTAINER PRESSURE)

L2 M6 M4 / P M3 / P
M1 A A M2

M9
M5
M2
L1 S B B M2

L1
M7 X1 M8
 FORWARD DRIVE, DRIVE PRESSURE under 370 bar
10 D2.0 DRIVE PRESSURE, M4 under 370 bar
bar
FEED PRESSURE 28 +/- 1 bar /
"B" 0 "A" FLUSH PRESSURE 26 bar
SERVO PRESSURE
M5 M4 M3/P X1 X2
RETURN PRESSURE / CONTAINER PRESSURE
ADJUSTMENT PRESSURE

L2 M6 M4/P M3/P
M1 A A M2

M9
M5
M2
L1 S B B M2

L1
M7 X1 M8
 FORWARD DRIVE, DRIVE PRESSURE over 370 bar
Engine running, machine stationary, rear wheel drive-,
fast range switched on, drive direction in neutral
10 D2.0 DRIVE PRESSURE, M4 370 - 425 bar
bar
FEED PRESSURE, 28 +/- 1 bar
"B 0 "A RETURN PRESSURE
" "
M5 M4 M3/P X1 X2
SERVO PRESSURE
ADJUSTMENT PRESSURE

L2 M6 M4/P M3/P
M1 A A M2

M9
M5
M2
L1 S B B M2

L1
M7 X1 M8
 FORWARD DRIVE, DRIVE PRESSURE over 425 bar
DRIVE PRESSURE > 425 bar
PRESSURE IN PUMP’S REGULATOR’S PRESSURE
10 bar D2.0
FEED PRESSURE, 28 +/- 1 bar
"B" 0 "A"
SERVO PRESSURE
RETURN PRESSURE
M5 M4 M3 / P X1 X2

ADJUSTMENT PRESSURE

L2 M6 M4 / P M3 / P
M1 A A M2

M9
M5
M2
L1 S B B M2

L1
M7 X1 M8
Service training

Block 2 and 3, cabin levelling and

harvester head hydraulic

1. Small pump valve

2. Large pump valve
3. Frame lock valve
4. Charging valve
5. Working brake valve
6. Differential lock valve
7. Optional equipment

MP1 = Large pump

MP2 = Small pump
MP3 = Frame lock
MP4 = Charging
MP5 = Charging
MP6 = Working brake
MP7 = Differential lock

00067
11012000 6.2
 Crane hydraulics
Service training

1. Lifting
2. Pilar
3. Telescope
MP1 = Pump pressure 4. Crane swing
MP2 = Load pressure 5. Base tilt
00067 MP3 = Crane swing brake 6. Machine steering
11012000 6.3
Service training

Hydraulic oil cooling circuit Cabin tilting pump

/ 3-pass.

MP1=Cooling circuit pressure

00067
11012000 6.4
Service training

Brake air-bleeding
Service / brake pedal valve air

1. Start the engine and engage the parking brake.

Air -bleeding by screw nr. 5.

2. Take off the cable coupling of the working brake

solenoid valve and engage the parking brake.
Press the front brake pedal severaltimes, air-
bleeding by screw nr. 5.

00068
12012000 7.1
Service training

Brake air-bleeding
Parking brake

Start the engine, release the parking brake. Air-bleeding

by opening hose connector nr. 1 (bogie axle and front axle).

00068
12012000 7.2
Service training

Brake air-bleeding
Working brake air-bleeding

Start the engine, engage the parking brake. Air-bleeding

by screws 2 and 3 (bogie axle and front axle).

00068
12012000 7.3
Service training

Brake adjustings and checkings

Brake disc clearance adjusting

1. Open the locking nr. 1 and 2.

2. Start the engine, disengage working brake and parking
brake, turn the screw nr. 3 counter clockwise by 8 Nm
force, all the way until the limiter.
3. Turn the screw nr. 3 clockwise 3 rounds and re-install
the locking (1 and 2)

00068
12012000 7.4
Service training

Brake adjustings and checkings

Checking the brake disc weariness

1. Open the plug nr. 1.

2. Engage the working brake.
3. Measure the clearance between the brake discs by feeler
gauge. If the clearance is below 4,5 mm, change the discs.

00068
12012000 7.5
Service training

Adjusting of the brake charging

sensor

Set Mode / Enter

Display

Adjusting Text in Value

display

SPI SPI 160 bar

RPI rPI 160 bar

DSI dSI 0s
DRI drI 0s
OUT Hno

DSI dAP 125 s

Mode / Enter --> selection of function and reset-button

Set --> changing of settings-button
Set and mode / enter --> opening / locking of the sensor
at same time

00068
12012000 7.6
Service training

Adjusting of the brake charging

sensor
B
C

A = Measuring point
B = Max. pressure
C = Min. pressure

00068
12012000 7.7
Service training

Manual releasing of the parking

brake

1. Open the lock nut nr. 1 and turn the screw nr. 2 clock-
wise until it stops. Brake is now released.
2. Brake is functional again when screw nr. 2 is opened
to measure 47 mm and locked by nut nr. 1.

00068
12012000 7.8
 Working brake electrics
Service training

00069
12012000 7.11
 Working brake electrics
Service training

00069
12012000 7.12
Service training

Working brake hydraulic

00068
12012000 7.10
Service training Parking brake electrics

00069
12012000 7.14
Service training Parking brake hydraulic

M1 = Work pressure A
1. Block 1, assembly plate M2 = Work pressure B
2. Gear box, 15-35 bar M3/P = Charge pressure
3. Rear drive, 15-45 bar M3/M = Minimum pressure
4. Parking brake, 15-35 bar M4/P = Hydraulic steps
5. Hydraulic steps M4/M = Maximum pressure
6. Drive hydraulic motor M5/P = Servo pressure
7. Drive hydraulic pump M7 = Internal regulator pressure
00069
12012000
8. Pressure accumalator 0,7 l / 30 bar M8 = Internal regulator pressure 7.15
Service training

Parking brake hydraulic

00068
12012000 7.9
Service training

Adjusting instructions
REXROTH 130 CRANE PUMP

Adjust of the starting pressure

1. Hook up the pressure gauge to check point MP1

2. Adjust the pressure by screw nr. 3 up to 30 bar.

00070
12012000 8.1
Service training

Adjusting instructions
REXROTH 130 CRANE PUMP

Adjusting of the high pressure

1. Hook up the pressure gauge to check point MP1.

2. Switch on the crane control switch. While adjusting

the pressure pull in the crane telescope.

3. Adjust the pressure by screw (nr. 2) to 190 bar.

00070
12012000 8.2
Service training

Adjusting instructions
REXROTH 71/45 HARVESTER HEAD PUMP (SMALL PUMP)

Starting pressure adjusting screw

High pressure adjusting screw

Starting pressure adjusting

1. Close the taps of the harvester head hydraulic oil

hoses. (Located in crane pilar).

2. Hook up the pressure gauge to check point MP1.

3. Adjust the pressure by screw (nr. 2) up to 30 bar.

00070
12012000 8.3
Service training

Adjusting instructions
REXROTH 71/45 HARVESTER HEAD PUMP (SMALL PUMP)

Starting pressure adjusting screw

High pressure adjusting screw

High pressure adjusting

1. Close the taps of the harvester head hydraulic oil

hoses. (Located in crane pilar).

2. Hook up the pressure gauge to check point MP1.

3. Activate harvester head.

4. Press fast feeding button and adjust the pressure by

screw nr. 3 to 190 bar.

00070
12012000 8.4
Service training

Adjusting instructions
REXROTH 130/115 HARVESTER HEAD PUMP (LARGE PUMP)

Starting pressure adjusting

1. Close the taps of the harvester head hydraulic oil

hoses. (Located in crane pilar).

2. Hook up the pressure gauge to check point MP1.

3. Switch off cabin levelling, switch nr. 11.

4. Adjust the pressure by screw nr. 3 to 35 bar.

00070
12012000 8.5
Service training

Adjusting instructions
REXROTH 130/115 HARVESTER HEAD PUMP (LARGE PUMP)

High pressure adjusting

1. Close the taps of the harvester head hydraulic oil

hoses. (Located in crane pilar).

2. Hook up the pressure gauge to check point MP1.

3. Activate harvester head.

4. Adjust the pressure by screw nr. 2 to 225 bar.

00070
12012000 8.6
Service training

Pressure adjustings

CRANE SWING BRAKE

Adjust of the crane swing brake

1. Hook up the pressure gauge to check point nr. 1.

2. Switch on the crane control.
3. Activate telescope IN-function.
4. Open the lock nut of the adjusting screw nr. 2 and adjust the
pressure to 100 bar.

00071
12012000 8.9
Service training

Adjusting instructions
VALVE BLOCKS

Front axle

Front frame

Block nr. 2 Block nr. 3

7. Directional valve, small pump 18. Cover plate

8. Directional valve, large pump 19. Directional valve, differential lock
9. Directional valve, frame lock 20. Pressure reducing valve,
10. Pressure reducing valve, frame differential lock
lock 21. Check point, differential lock
11. Check valve, frame lock pressure
12. Adjusting screw and pressure 22. Adjusting screw and pressure
reducing valve, frame lock reducing valve, differential lock
13. Check point, frame lock 23. Directional valve, working brake
14. Directional valve, brake charging 24. Pressure reducing valve,
15. Pressure reducing valve, brake working brake
charging 25. Check point, working brake
16. Adjusting screw, brake circuit pressure
pressure 26. Adjusting screw and pressure
17. Check point, brake circuit reducing valve, working brake
pressure 28. Check point, brake circuit
00071
12012000 8.10
Service training

Adjusting instructions
VALVE BLOCKS, PRESSURE ADJUSTINGS

Front axle

Front frame

Frame lock pressure adjusting (valve nr. 10)

1. Hook up the pressure gauge to check point nr. 13.

2. Close the taps of the harvester head hydraulic oil hoses.
3. Activate harvester head.
4. Open the lock nut nr. 12 and adjust the pressure to 175 bar.

Brake circuit pressure adjusting (valve nr. 15)

1. Hook up the pressure gauge to check point nr. 17.

2. Close the taps of the harvester head hydraulic oil hoses.
3. Activate harvester head.
4. Open the lock nut nr. 16 and adjust the pressure to 190 bar.

00071
12012000 8.11
Service training

Adjusting instructions
VALVE BLOCKS, PRESSURE ADJUSTINGS

Front axle

Front frame

Differential lock pressure adjusting (valve nr. 20)

1. Hook up the pressure gauge to check point nr. 21.

2. Open the lock nut of the screw nr. 22 and adjust the pressure
to 30 bar.

00071
12012000 8.12
Service training

Adjusting instructions
VALVE BLOCKS, PRESSURE ADJUSTINGS

Front axle

Front frame

Working brake pressure adjusting (valve nr. 24)

1. Hook up the pressure gauge to check point nr. 25.

2. Open the lock nut nr. 26 and adjust the pressure to
60 bar.

00071
12012000 8.13
Service training

Pressure adjustings

K170 VALVE

- Air bleeding of the valve bank

- MR-adjustings

00071
12012000 8.8
Service training

Pressure values
1. SAUER DRIVE HYDRAULIC Note
Max. pressure 425 bar
Charge pressure 28 bar
Flushing pressure 26 bar
Pressure-cutting valve 370 bar
Motive pressure 200 bar
2. CRANE PUMP
VOAC 110 Starting pressure 30 bar
Max. pressure 190 bar
REXROTH 130 Starting pressure 30 bar
Max. pressure 190 bar
3. HARVESTER HEAD PUMP
REXROTH 95 Starting pressure 35 bar
Max. pressure 220-240 bar
REXROTH 130/115 Starting pressure 35 bar limited
Max. pressure 220-240 bar
REXROTH 71/45 Starting pressure 30 bar limited
Max. pressure 190 bar
4. TYRE PRESSURES
NOKIA
Front 600/65-34 2 bar
Front 700/55-34 2 bar
Rear 600/55-26,5 3,7/liquid bar
Rear 700/50-26,5 3,5/liquid bar
TRELLEBORG
Front 600/65-34 2,4 bar
Front 700/55-34 1,9 bar
Rear 600/55-26,5 2,0/liquid bar
Rear 700/50-26,5 2,0/liquid bar
5. FRAME LOCK 175 bar
6. DIFFERENTIAL LOCK 30 bar
7. WORKING BRAKE 60 bar
8. CRANE SWING BRAKE 100 bar
9. BRAKE CIRCUIT 190 bar
10. PARKING BRAKE (see charge
pressure)
11. SERVICE BRAKE (pedalforce) max 80 bar
12. ELECTRIC SYSTEM
(charging voltage) 26 V +3/-0V

00070
12012000 8.7
Service training

Drive hydraulic pressure

adjustments

1. Spare driving unit

2. Drive direction selector
3. Drive speed potentiometer
4. Connector no. 4 (loose cable with connector)

Connect connector no. 83 to the back-up unit connec-

tor.

5. Gas motor for injection pump

6. Cable coupling

Disconnect the step motor electrical connector no. 6 and

lock the gas lever to maintain 1500 rpm.
00072
12012000 9.1
Service training

Drive hydraulic pressure

adjustments

1. Pressure adjusting, forward

2. Pressure adjusting, reverse
3. Check point, charge / flushing pressure
4. Check point, pressure cutting valve
5. Check point, driving forward
6. Check point, driving reverse
7. Pressure adjusting, pressure-cutting valve
8. Pressure adjusting, charge pressure
9. Pressure adjusting, motive pressure
10. Pressure adjusting, flushing valve
11. Manual control for pressure-cutting valve adjusting

00072
12012000 9.2
Service training

Drive hydraulic pressure

adjustments
STARTING PRESSURE ADJUSTING

Tools needed when

adjusting the pressure-
cutting valve pressure,
27 and 13 mm

9.

Push the back-up unit’s drive direction selector forward and turn the
potentiometer until the pressure at measurement point no. 5 rises to
200 bar.
Push the back-up unit’s drive direction selector back. The pressure
at measurement point 5 in step (+/- 100 bar).

5. Check point, 200±10 bar, drive pressure, forward

6. Check point, 200±10 bar, drive pressure, reverse
9. Adjusting screw (underneath the pump)

00072
12012000 9.8
Service training

Drive hydraulic pressure

adjustments

CHARGE PRESSURE 28±1 bar

Tools needed when

adjusting the pressure-
cutting valve pressure,
27 and 13 mm

Direction switch with the free

3. Check point
8. Adjusting screw

00072
12012000 9.3
Service training

Drive hydraulic pressure

adjustments
FLUSHING PRESSURE 25-26 bar (2-3 bar below charge pressure)

Tools needed when

adjusting the pressure-
cutting valve pressure,
27 and 13 mm

Press the drive direction switch

of the back-up unit and turn
back-up unit’s potentiometer to
the maximum.

3. Check point 10
10. Adjusting screw

00072
12012000 9.4
Service training

Drive hydraulic pressure

adjustments
DRIVE PRESSURE, FORWARD 425 bar

Push the back-up unit’s drive direction forward

and turn potentiometer to maximum.

1. Adjusting screw
5. Check point

00072
12012000 9.5
Service training

Drive hydraulic pressure

adjustments
DRIVE PRESSURE, REVERSE 425 bar

Push the back-up unit’s direction selector back

and turn the potentiometer to maximum.

2. Adjusting screw
6. Check point

00072
12012000 9.6
Service training

Drive hydraulic pressure

adjustments
PRESSURE-CUTTING VALVE

Tools needed when

adjusting the pressure-
cutting valve pressure,
27 and 13 mm

A. Lock the manual control lever no. 11 to its upper position.

B. Push the back-up unit’s drive direction selector forward and turn
potentiometer until pressure at measurement point 5 rises to 370
bar. At the same time the pressure at measurement point no. 4
should drop quickly to 100bar.

4. Check point, pressure-cutting valve > 100 bar

below pressure-cutting valve
5. Check point, 370 bar, drive pressure, forward
6. Check point, 370 bar, drive pressure, reverse
7. Adjusting screw
11. Manual control lever, motor servo valve

00072
12012000 9.7
 10.1

SCHEDULED MAINTENANCE HS10, HS16,

NEW MACHINE
Service training
Crane and harvester head: See also the crane and the harvester head service manuals.
I = Inspect or check VI = Visual inspection G = Greasing
R = Replace T = Tightening
C = Clean A = Adjustment
Section Maintenance
N:o Item of interval (hours)
owner´s
manual 50 200 1000

1. ENGINE (See also the engine service manual)

1.1 Oil or fluid leaks, repair VI VI VI
1.2 Engine mounts VI VI VI
1.3 Oil pressure and charging I I I
1.4 Checking the idle speed VI VI VI
1.5 Thermometer function I I I
1.6 Engine shut off device I I I
1.7 Engine oil and filter R R R
1.8 Air filter C
1.9 Water separator C C C
1.10 Coolant level I I I
1.11 V-belt tightness, condition I I I
1.12 Valves A A
1.13 Sealing of intake manifold and exhaust outlet VI VI VI
1.14 Fuel filter for engine / cabin heater filter R
1.15 Engine fuel filter R R
2. FRONT AXLE (HS16) 5, 8
2.1 Differential gear oil I R R
2.2 Planetary gear oil I R R
2.3 Possible leaks VI VI VI
2.4 Mounting bolts VI I, T I, T
3. BOGIES 5, 8
3.1 Differential gear oil I R R
3.2 Planetary gear oil I R R
3.3 Bogie casing oil I R R
3.4 Possible leaks I I I
3.5 Lubrication oil in bogie rocker G G G
3.6 Rear bogie underpan I
3.7 Mounting bolts VI I, T I, T
4. TRANSMISSION 5, 8
4.1 Oil R R R
4.2 Mounting bolts VI I, T T
5. PUMP SPLITTER GEARBOX 5, 8
5.1 Oil R R R
5.2 Mounting bolts VI I, T I, T

WHITE - END USER RED - DEALER BLUE - PONSSE OYJ

 10.2

SCHEDULED MAINTENANCE HS10, HS16,

NEW MACHINE
Service training
Crane and harvester head: See also the crane and the harvester head service manuals.
I = Inspect or check VI = Visual inspection G = Greasing
R = Replace T = Tightening
C = Clean A = Adjustment
Section Maintenance
N:o Item of interval (hours)
owner´s
manual 50 200 1000

6. FILTERS AND HYDRAULIC OIL

6.1 Hydraulic oil 8 I I R
6.2 Hydraulic oil return filter (2 pcs) R R R
6.3 Crane circuit pressure filter R R
6.4 Drive transmission intake filter R
6.5 Drive transmission feed-pressure filter R R R
6.6 Signal pressure filter to the valve K 170 R R R
6.7 Hydraulic system breather I I R
6.8 Cooling circuit pressure filter R R
6.9 Active suspension pressure filter (HS16) R R
6.10 Harvester circuit pressure filter R R
6.11 2-block pressure filter R R
7. COOLING SYSTEM 8
7.1 Coolant I I I
7.2 Possible leaks VI VI VI
7.3 Screening grid C C C

8. EMERGENCY STEERING UNIT

8.1 Function I I I
9. MOUNTINGS
9.1 Propeller shaft mounting bolts I, T I, T I, T
9.2 Frame lock housing mounting VI I, T I, T
9.3 Frame lock cylinder block mounting VI I, T I, T
9.4 Frame lock stud mounting VI I, T I, T
9.5 Drive transmission pump mounting VI I, T I, T
9.6 Drive transmission motor mounting VI I, T I, T
9.7 Working hydraulic pumps mountings VI I, T I, T
9.8 Underpans mounting VI I, T I, T
10. CENTRAL JOINT
10.1 Horizontal bearings VI T, G T, G
10.2 Vertical bearings (HS10) VI VI VI
10.3 Vertical bearings, bolts (HS16) VI I, T I, T
11. HEATER AND AIR CONDITIONER 5
11.1 Coarse and fine filter C, R
11.2 Fine filter in cabin C, R

WHITE - END USER RED - DEALER BLUE - PONSSE OYJ

 10.3

SCHEDULED MAINTENANCE HS10, HS16,

NEW MACHINE
Service training
Crane and harvester head: See also the crane and the harvester head service manuals.
I = Inspect or check VI = Visual inspection G = Greasing
R = Replace T = Tightening
C = Clean A = Adjustment
Section Maintenance
N:o Item of interval (hours)
owner´s
manual 50 200 1000

12. WHEELS 6
12.1 Mounting bolts I, T I, T I, T
12.2 Tire pressures VI I I
13. PRESSURES 7
13.1 Drive transmission pressures I I
13.2 Transmission, parking brake and I I
rear drive release pressure
13.3 Pressures of the harvester big and small pump I I
13.4 Grane pump pressures I I
13.5 Differential lock pressures I I
13.6 Framelock pressure I I
13.7 Crane slewing brake pressure I I
13.8 Valve console pilot operation pressure I I
14. BRAKES 5, 7
14.1 Brake circuit pressure I I
14.2 Driving brake pressure I I
14.3 Brake charging pressure I I
14.4 Parking brake pressure I I
14.5 Working brake pressure I I
14.6 Crane slewing brake pressure I I
14.7 Brake disk (backflash) I, A
15. ATTENTION

15.1 Please, check that all labels are in good condition I

and in right places. If not, change them.
15.2 Greasings, according to the owner´s manual

Notes:

Place and date:

Signature of service dealer Signature of client

WHITE - END USER RED - DEALER BLUE - PONSSE OYJ

 10.4

SCHEDULED MAINTENANCE
Service training HS10, HS16
See also the crane and the harvester head service manuals.

I = Inspect or check VI = Visual inspection G = Greasing

R = Replace T = Tighten
C = Clean A = Adjustment

Nr. Item Maintenance interval (hours)

10 50 250 500 1500 3000

1. ENGINE (See also the engine service manual)

1.1 Oil or fluid leaks, repair VI
1.2 Engine mounts VI
1.3 Oil pressure and charging VI
1.4 Checking the idle speed VI
1.5 Thermometer function VI
1.6 Engine shut off device VI
1.7 Engine oil and filter VI R
1.8 Air filter C R
1.9 Water separator C
1.10 Coolant level VI R
1.11 V-belt tihgtness, condition VI R
1.12 Valves A
1.13 Fuel filter for engine / cabin heater filter R
1.14 Engine fuel filter R

2. FRONT AXLE (HS16)

2.1 Differential gear oil R
2.2 Planetary gear oil R
2.3 Possible leaks VI
2.4 Mounting bolts I, T
3. BOGIES
3.1 Differential gear oil I R
3.2 Planetary gear oil I R
3.3 Bogie casing oil I R
3.4 Possible leaks VI
3.5 Lubrication oil in bogie rocker G
3.6 Rear bogie underpan I, T
3.7 Mounting bolts I, T
4. TRANSMISSION
4.1 Oil I R
4.2 Mounting bolts I, T
5. PUMP SPLITTER GEAR BOX
5.1 Oil VI R
5.2 Mounting bolts I, T
 10.5

SCHEDULED MAINTENANCE
Service training HS10, HS16
See also the crane and the harvester head service manuals.

I = Inspect or check VI = Visual inspection G = Greasing

R = Replace T = Tighten
C = Clean A = Adjustment

Nr. .
Item Maintenance interval (hours)
10 50 250 500 1500 3000

6. FILTERS AND HYDRAULIC OIL

6.1 Hydraulic oil VI R
6.2 Hydraulic oil return filter (2 pcs) R
6.3 Crane circuit pressure filter R
6.4 Drive transmission intake filter R
6.5 Drive transmission feed-pressure filter R
6.6 Signal pressure filter to the valve K 170 R
6.7 Hydraulic system breather R
6.8 Cooling circuit pressure filter R
6.9 Active suspension pressure filter (HS16) R
6.10 Harvester circuit pressure filter R
6.11 2-block pressure filter R
7. COOLING SYSTEM
7.1 Possible leaks VI
7.2 Screening grid C
7.3 Freezing point I
8. EMERGENCY STEERING UNIT
8.1 Function I

9. MOUNTINGS
9.1 Propeller shaft mounting bolts I
9.2 Frame lock housing mounting bolts I
9.3 Frame lock cylinder block mounting I
9.4 Frame lock stud mounting I R
9.5 Drive transmission pump mounting I
9.6 Drive transmission motor mounting I
9.7 Working hydraulic pumps mountings I
9.8 Underpans mounting I
10. CENTRAL JOINT
10.1 Horizontal bearings G I, T
10.2 Vertical bearings (HS10) G VI
10.3 Vertical bearings (HS16) G I, T

11. HEATER AND AIR CONDITIONER

11.1 Heater and air conditioner I
11.2 Filters R
11.3 Function I
11.4 Cooler C
 10.6

SCHEDULED MAINTENANCE
Service training HS10, HS16
See also the crane and the harvester head service manuals.

I = Inspect or check VI = Visual inspection G = Greasing

R = Replace T = Tighten
C = Clean A = Adjustment

Nr. Item Maintenance interval (hours)

10 50 250 500 1500 3000

12. WHEELS
12.1 Mounting bolts I, T
12.2 Tire pressures VI I

13. PRESSURES
13.1 Drive transmission pressures I
13.2 Transmission, parking brake and
rear drive release pressure I
13.3 Pressures of the harvester big and small pump I
13.4 Crane pump pressures I
13.5 Differential lock pressures I
13.6 Framelock pressure I
13.7 Crane slewing brake pressure I
13.8 Valve console pilot operation pressure I

14. BRAKES
14.1 Brake circuit pressure I
14.2 Driving brake pressure I
14.3 Brake charging pressure I
14.4 Parking brake pressure I
14.5 Working brake pressure I
14.6 Crane slewing brake pressure I
14.7 Brake disk (backflash) I
15. ELECTRIC EQUIPMENT
15.1 Electric equipment VI
15.2 Lights VI
15.3 Crane control levels C
15.4 Function of indicator and warning lights VI
16. ATTENTION
16.1 Washing the machine C
16.2 Fuel tank C
16.3 Hose connections VI
16.4 Condition of labels VI
16.5 Greasing, according to the owner’s manual
Service training
Greasing points
00073
12012000 10.7
Service training
Greasing points
00073
12012000 10.8
Service training

Greasing points

Service
schedule /
hours

Ref Nipples Object 10 50 300

1 1 Right-hand tilt cylinder top side R
2 1 Right-hand tilt cylinder lower side R
3 1 Support bearing of the front axle oscillation front side R
4 1 Support bearing of the front axle oscillation rear side R
5 1 Left-hand tilt cylinder top side R
6 1 Left-hand tilt cylinder lower side R
7 6 Propeller shaft joints R
8 4 Propeller shaft glide bushing R
9 2 Pivot joint vertical bearing lower/upper side R
10 2 Frame lock right / left side R
11 2 Pivot joint horizontal bearing R
12 2 Base tilt cylinder lower side R
13 2 Base tilt cylinder top side R
14 4 Steering cylinder bearing R
15 16 Rear bogie swing bearing R
16 2 Crane base R
17 2 Propeller shaft support bearing R
18 2 Door hinges R

00073
12012000 10.9
Service training
Filters

00073
12012000 10.10
Service training

Filters

Nr. Filter Qty Note!

1 Engine oil filter 1 CAT1R0739
2 Engine oil filter 1+1 0055198
0055200*
0055199*
3 Fuel filter 1 CAT1R0751
4 Hydraulic oil return filter 2 0040393
0040295
5 Signal pressure filter for valve bank 1 0014434
0036673*
6 Hydraulic oil tank breather 1 0009756
7 Hydraulic oil suction filter 1 0011529
8
9 Cabin air filter 1 0038142
10 Hydraulic oil pressure filter for crane circuit 1 0009077
0012956*
11 Hydraulic oil pressure filter for harvester head 1 0009077
0012956*
12 Block 2 pressure filter 1 0014431
0036673*

13 Charge pressure filter 1 0019541

14 Cooling circuit pressure filter 1 0009078

0055233*
15 A/c air filter 1 0038149
16 Fuel pre-filter/water separator 1 CAT1272308
CAT1174089*
17 Cabin levelling pressure filter 1 0009078
0055232*
18 Screen for radiator and cooler 180087
19 Engine heater filter 0055076
20 Compressor filter 0009756

00073
12012000 10.11
Service training

Engine

1. Oil drain
2. Oil filling
3. Oil filter
4. Dipstick

00073
12012000 10.12
Service training

Pump gear

1. Oil filling
2. Oil drain
3. Breather
4. Oil level
5. Oil drain

00073
12012000 10.13
Service training

Gear box

1. Oil filling / breather

2. Dipstick
3. Oil drain
4. Oil level
5. 1-gear pressure inlet
6. 2-gear pressure inlet
7. Cylinder head nut
8. Rear drive release inlet
9. Air bleeding screw
10. Splash oil removing

00073
12012000 10.14
Service training

Differentials

1. Oil drain
2. Oil filling / oil level
3. Oil level in differential

00073
12012000 10.15
Service training

Bogies

1. Oil drain
2. Oil filling / oil level
3. Oil level in bogie
4. Oil drain

00073
12012000 10.16
Service training

Planet gears

Oil drain

Oil filling / oil level

00073
12012000 10.17