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Kramer Allrad 800 - Service Manual PDF
Table of contents
Cab overview, labels, operation
Inside of cab: overview ............................................................................................ 1-1
Instrument panel, multifunctional lever and drive lever: overview ........................... 1-2
Overview of exterior of machine .............................................................................. 1-3
Important information on this service manual .......................................................... 1-4
Models and trade names: overview ......................................................................... 1-5
Brief description of the wheel loader ........................................................................ 1-5
Hydrostatic drive ................................................................................................ 1-6
Work hydraulics and 4 wheel steering ............................................................... 1-6
Cooling system .................................................................................................. 1-6
Fields of application and using the wheel loader with an attachment ...................... 1-6
Use: attachment with certified material density ...................................................... 1-7
Regulations .............................................................................................................. 1-8
Driving licence ................................................................................................... 1-8
Licence .............................................................................................................. 1-8
Equipment ......................................................................................................... 1-8
Warranty ............................................................................................................ 1-8
Machine inspections .......................................................................................... 1-9
Documents ........................................................................................................ 1-9
Warning identification of wheel loader on public roads (option) ........................ 1-9
Type labels and component numbers .................................................................... 1-10
Serial number of frame .................................................................................... 1-10
Cab serial number ........................................................................................... 1-10
Serial number of engine .................................................................................. 1-10
Hydraulic pump serial number ......................................................................... 1-11
Hydraulic motor serial number ......................................................................... 1-11
Serial number of rear axle ............................................................................... 1-11
Serial number of front axle .............................................................................. 1-11
Warning and information labels ............................................................................. 1-12
Label on the outside of the machine ................................................................ 1-12
Label on the inside of the machine .................................................................. 1-13
Description: telltales and warning lights on the instrument panel .......................... 1-16
Drive interlock with code input (option) .................................................................. 1-19
Keyboard for entering codes: overview ........................................................... 1-19
Entering/changing the personal code .............................................................. 1-20
Enabling the drive interlock ............................................................................. 1-20
Disabling the drive interlock ............................................................................. 1-21
Taking the drive interlock out of service .......................................................... 1-22
Putting the drive interlock back into service again ........................................... 1-22
Interruption of drive interlock power ................................................................ 1-22
Drive interlock maintenance ............................................................................ 1-22
Key-based drive interlock (option) ......................................................................... 1-23
Key-based drive interlock: scope of delivery ................................................... 1-23
Coding (“training”) new ignition keys ............................................................... 1-23
Enabling (locking) the drive interlock ............................................................... 1-24
Disabling (releasing) the drive interlock ........................................................... 1-24
Deleting coded keys ........................................................................................ 1-24
Safety functions ............................................................................................... 1-24
Battery master switch (option) ............................................................................... 1-25
Interrupting power supply ................................................................................ 1-25
Switching on power supply .............................................................................. 1-25
Engine oil, hydraulic oil and fuel preheater (option) ............................................... 1-25
Putting the engine oil and hydraulic oil preheating into operation ................... 1-25
Fuel preheater operation ................................................................................. 1-25
Table of contents
I-2 Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm
Table of contents
Jump-starting the engine (external battery) ........................................................... 1-26
Safety instructions regarding external starting aids ......................................... 1-26
Providing external starting aid ......................................................................... 1-26
Manual throttle (option) .......................................................................................... 1-27
Setting the drive speed with the manual throttle .............................................. 1-27
Low-speed control (option) .................................................................................... 1-27
Selecting the drive speed ................................................................................ 1-27
Electric connection – socket (option) ..................................................................... 1-28
Reversing cooling fan (option) ............................................................................... 1-28
Working lights ........................................................................................................ 1-28
Rotating beacon (option) ........................................................................................ 1-29
Signalling system ................................................................................................... 1-29
Turn indicators ................................................................................................. 1-29
Hazard warning system ................................................................................... 1-29
Working with the automatic bucket repositioning (option) ...................................... 1-30
General information on automatic bucket repositioning ................................... 1-30
Additional control circuit for attachments (option) .................................................. 1-31
Single-action additional control circuit ............................................................. 1-31
Double-action additional control circuit (option) ............................................... 1-32
“Hose burst valve” safety feature (option) .............................................................. 1-33
Towing the machine ............................................................................................... 1-34
Safety instructions for towing away ................................................................. 1-34
Getting ready for towing ................................................................................... 1-34
Towing the machine ......................................................................................... 1-35
Specifications
Models and trade names: overview ......................................................................... 2-1
Frame ....................................................................................................................... 2-1
Engine ...................................................................................................................... 2-1
Oil/water cooling fan ................................................................................................ 2-1
Power train ............................................................................................................... 2-2
Variable displacement pump ............................................................................. 2-2
Boost pump ........................................................................................................ 2-2
Variable displacement motor ............................................................................. 2-2
Axles ........................................................................................................................ 2-3
Front axle ........................................................................................................... 2-3
Rear axle ........................................................................................................... 2-3
Brakes ...................................................................................................................... 2-3
Service brake ..................................................................................................... 2-3
Parking brake ..................................................................................................... 2-3
Steering system ....................................................................................................... 2-4
Work hydraulics ....................................................................................................... 2-4
Hydraulic pump .................................................................................................. 2-4
Control valve, suction reflux filter ....................................................................... 2-4
Lift and tilt rams, 3rd control circuit .................................................................... 2-5
Additional control circuit (option) ....................................................................... 2-5
Hydraulic pilot control (control valve) ................................................................. 2-5
Electric system ......................................................................................................... 2-6
Electric units ...................................................................................................... 2-6
Fuse box on left and right under the steering column ........................................ 2-6
Main fuse box with relays .................................................................................. 2-7
Switching relays ................................................................................................. 2-8
Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm I-3
Table of contents
Tyres ........................................................................................................................ 2-9
Weights .................................................................................................................... 2-9
Noise levels ........................................................................................................... 2-10
Vibration ................................................................................................................. 2-10
Coolant compound table ........................................................................................ 2-10
Tightening torques, conversion tables ................................................................... 2-11
General tightening torques .............................................................................. 2-11
Specific tightening torques .............................................................................. 2-11
Conversion table: DIN standard – USA standard ............................................ 2-12
Payloads ................................................................................................................ 2-13
Payload with bucket ......................................................................................... 2-13
Payload with pallet forks .................................................................................. 2-13
Trailer weight/drawbar load for automatic trailer coupling (option) .................. 2-13
Dimensions with bucket ......................................................................................... 2-14
Wheel loader dimensions with pallet forks ............................................................. 2-15
Maintenance and service work
Explanation of symbols on the maintenance label ................................................... 3-1
Maintenance label .................................................................................................... 3-2
Located inside the cab on the rear window ....................................................... 3-2
Fluids and lubricants ............................................................................................... 3-3
Maintenance plan .................................................................................................... 3-4
Important information on maintenance and service work ........................................ 3-8
Important information on the maintenance plan ................................................ 3-8
Overview of repair work on separate components ............................................ 3-8
Maintenance kits ...................................................................................................... 3-8
Fuel system ............................................................................................................. 3-9
General safety instructions for refuelling ........................................................... 3-9
Diesel fuel specification ..................................................................................... 3-9
Stationary fuel pumps ........................................................................................ 3-9
Refuelling ............................................................................................................... 3-10
Bleeding the fuel system ........................................................................................ 3-10
Checking/cleaning the fuel prefilter (water separator) ........................................... 3-11
Checking/filling up the engine oil ........................................................................... 3-12
Check the engine oil ........................................................................................ 3-12
Filling up engine oil .......................................................................................... 3-12
Changing engine oil ............................................................................................... 3-13
Replacing the engine oil filter cartridge .................................................................. 3-14
Engine and hydraulics cooling system ................................................................... 3-15
Safety instructions regarding cooling system maintenance ............................. 3-15
Checking the coolant level ..................................................................................... 3-16
Draining coolant ..................................................................................................... 3-17
Cleaning the radiator fins of the oil/water radiator ................................................. 3-18
Cleaning the radiator fins with compressed air ................................................ 3-18
Cleaning the radiator fins with the reversing fan (option) ................................ 3-18
Air filter maintenance ............................................................................................. 3-19
Checking the air filter for dirt ............................................................................ 3-19
Checking the dust collector (option) ................................................................ 3-20
Replacing the air filter cartridge ....................................................................... 3-20
V-belts .................................................................................................................... 3-21
Checking V-belt tension ................................................................................... 3-21
Retightening the V-belts .................................................................................. 3-21
Hydraulic system ................................................................................................... 3-22
Specific safety instructions regarding the hydraulic system ............................ 3-22
Important information for the use of biodegradable oil .................................... 3-23
Monitoring the hydraulic oil reflux filter ............................................................ 3-23
I-4 Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm
Table of contents
Checking the hydraulic oil level .............................................................................. 3-24
Filling up hydraulic oil ............................................................................................. 3-24
Replacing hydraulic oil ........................................................................................... 3-25
Maintenance of the hydraulic oil reflux filter ........................................................... 3-26
Replacing the hydraulic oil reflux filter ............................................................. 3-26
Maintenance of the drive control line (LS) line filter ............................................... 3-26
Cleaning the line filter ...................................................................................... 3-26
Maintenance of the drive boost pressure microfilter .............................................. 3-27
Replacing the microfilter .................................................................................. 3-27
Checking hydraulic pressure lines ......................................................................... 3-28
Specific safety instructions regarding pressure line checks ............................ 3-28
Maintenance: gearbox oil ....................................................................................... 3-29
Checking/filling up the gearbox oil ................................................................... 3-29
Changing the gearbox oil ................................................................................. 3-30
Oil levels: front and rear axle differentials .............................................................. 3-31
Checking/filling up oil on the rear axle differential ........................................... 3-31
Changing oil on the rear axle differential ......................................................... 3-31
Checking/filling up oil on the front axle differential ........................................... 3-32
Changing oil on the front axle differential ........................................................ 3-32
Checking/filling up oil on the planetary drives .................................................. 3-33
Changing the oil in the planetary drives ........................................................... 3-33
Front and rear axle lubrication ............................................................................... 3-34
Lubricating the rear axle oscillation-type bearing ............................................ 3-34
Lubricating the front and rear axle planetary drive bearings ............................ 3-34
Loader unit lubrication work ................................................................................... 3-35
Lubricating the pivots on the loader unit .......................................................... 3-35
Lubricating with the central lubrication system (option) ......................................... 3-36
General functional description of the central lubrication system ...................... 3-36
Setting the lubrication and break times ............................................................ 3-37
Filling the central lubrication system ................................................................ 3-37
Attachment maintenance ....................................................................................... 3-37
Brake system maintenance .................................................................................... 3-38
Specific safety instructions regarding the brake system .................................. 3-38
Checking/filling up the brake fluid level ............................................................ 3-38
Tyre maintenance .................................................................................................. 3-39
Tyre check ....................................................................................................... 3-39
Changing wheels ............................................................................................. 3-40
Heating and ventilation system maintenance ........................................................ 3-41
General information on the heating system ..................................................... 3-41
Cleaning/replacing the fine-dust filter of the heating system ........................... 3-41
Air conditioning (option): maintenance ................................................................... 3-42
General instructions regarding the air conditioning ......................................... 3-42
Cleaning and carrying out functional and visual checks of the air conditioning .......
3-43
Electric system ....................................................................................................... 3-44
Specific safety instructions regarding the electric system ............................... 3-44
Service and maintenance work at regular intervals ......................................... 3-44
Cables, bulbs and fuses .................................................................................. 3-45
Alternator ......................................................................................................... 3-45
Checking/replacing relays and fuses ............................................................... 3-46
Main fuse box with switching relays ................................................................. 3-46
Checking/replacing the battery ........................................................................ 3-47
General maintenance work .................................................................................... 3-48
Specific safety instructions regarding cleaning ................................................ 3-48
When using washing solvents ......................................................................... 3-48
When using compressed air ............................................................................ 3-48
When using a high-pressure cleaner or steam jet ........................................... 3-48
Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm I-5
Table of contents
When using volatile and easily flammable anticorrosion agents and sprays ... 3-48
Cleaning inside the cab ................................................................................... 3-49
Cleaning the seat belt ...................................................................................... 3-49
Cleaning the exterior of the machine ............................................................... 3-49
Cleaning the engine compartment ................................................................... 3-50
Checking screw connections ........................................................................... 3-50
Checking pivots and hinges ............................................................................. 3-50
Maintenance: diesel particulate filter (option) ........................................................ 3-51
Checking the electronic filter monitoring .......................................................... 3-51
Maintenance work “Aggressive Media” (option) .................................................... 3-52
Anticorrosion protection applied in the factory ................................................. 3-52
Components coated with anticorrosive wax .................................................... 3-52
Measures for maintaining anticorrosive protection .......................................... 3-53
Applying the protective anticorrosion coating .................................................. 3-54
Treatment of oxidised surfaces ....................................................................... 3-54
Engine
Engine designation .................................................................................................. 4-1
Fuel specification ..................................................................................................... 4-1
Coolant specification ................................................................................................ 4-1
Engine overview (oil filter and oil radiator side) ....................................................... 4-2
Engine overview (turbocharger side) ....................................................................... 4-3
Engine overview (oil filter connection) ..................................................................... 4-4
Engine overview (drive flange side) ......................................................................... 4-5
Engine overview (drive clutch) ................................................................................. 4-6
Engine number ........................................................................................................ 4-7
Cylinder numbering, firing order .............................................................................. 4-7
Coolant system ........................................................................................................ 4-8
Cooling circuit .................................................................................................... 4-8
Lube oil system ........................................................................................................ 4-9
Lube oil circuit .................................................................................................... 4-9
Lube oil circuit diagram .......................................................................................... 4-10
Engine fuel system ................................................................................................ 4-11
Fuel system: fuel tank – engine ............................................................................. 4-12
Bleeding the fuel system ........................................................................................ 4-13
Fuel pump overview ............................................................................................... 4-14
Fuel injection system ............................................................................................. 4-15
Mounting the injection pumps ................................................................................ 4-16
Mounting coded injection pumps (88 kW diesel engine TIER III) .......................... 4-17
Replacing uncoded pumps .............................................................................. 4-17
Shims for coded injection pumps ..................................................................... 4-18
General information on valve clearance ................................................................ 4-18
Valve clearance setting with a feeler gauge (75/100 kW diesel engine TIER II) ... 4-19
Setting the valves with a protractor (88 kW diesel engine TIER III) ....................... 4-20
Setting the valve clearance (special tool: protractor) ....................................... 4-21
Special tools for protractor ..................................................................................... 4-22
Determining the cylinder-head gasket ................................................................... 4-23
Measuring piston projection ............................................................................. 4-23
Mounting the cylinder head .................................................................................... 4-24
Engine malfunctions .............................................................................................. 4-25
I-6 Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm
Table of contents
Power train
Functional despcription of drive hydraulics and electric system .............................. 5-1
Boost pressure circuit ........................................................................................ 5-1
Boost pressure relief valve ................................................................................ 5-1
Pump adjustment ............................................................................................... 5-1
Motor adjustment ............................................................................................... 5-2
Drive output regulation ....................................................................................... 5-2
Flush feature ...................................................................................................... 5-2
Locking driving direction selection ..................................................................... 5-2
Holding the signal for the forwards driving direction selection ........................... 5-2
Holding the signal for the reverse driving direction selection ............................. 5-2
Drive speed control ............................................................................................ 5-3
Inching pedal function ........................................................................................ 5-3
Calibrating the inching pedal ............................................................................. 5-3
Crawler gear potentiometer (low-speed control) ................................................ 5-3
Drive settings ..................................................................................................... 5-3
Troubleshooting (drive) ...................................................................................... 5-3
Towing the machine ................................................................................................. 5-4
Safety instructions for towing away ................................................................... 5-4
Getting ready for towing ..................................................................................... 5-4
Towing the machine ........................................................................................... 5-5
Variable displacement pump: overview ................................................................... 5-6
Overview of variable displacement pump: H1 test ports .......................................... 5-7
Overview of 20 kph hydraulic motor: test ports ........................................................ 5-8
Overview of 20 kph hydraulic motor: proportional valve .......................................... 5-9
Overview of 20 kph hydraulic motor: drive hydraulics ports ................................... 5-10
20 kph drive: diagram ............................................................................................ 5-11
20 kph drive: circuit ................................................................................................ 5-12
Test report: 20 kph power train .............................................................................. 5-13
Test and adjustment instructions for 20 kph drive ................................................. 5-14
Adjusting boost pressure ................................................................................. 5-14
Checking/adjusting high pressure .................................................................... 5-15
Checking/adjusting engine droop .................................................................... 5-16
Checking/adjusting control initiation on the hydraulic motor ............................ 5-17
Checking driving direction identification ........................................................... 5-18
Mode of function of 40 kph high speed gearbox (Ecospeed) ................................. 5-19
40 kph high speed gearbox (Ecospeed) ................................................................ 5-19
40 kph high speed gearbox overview .................................................................... 5-20
Control cover and 40 kph circuit diagram (overview) ............................................. 5-21
40 kph control cover (component parts) ................................................................ 5-22
40 kph drive circuit ................................................................................................. 5-23
Test report: 40 kph power train .............................................................................. 5-24
Test and adjustment instructions for 40 kph drive ................................................. 5-25
Adjusting boost pressure ................................................................................. 5-25
Checking/adjusting high pressure .................................................................... 5-26
Checking/adjusting engine droop .................................................................... 5-27
Checking driving direction identification ........................................................... 5-28
Checking/adjusting control initiation ................................................................ 5-29
Checking/adjusting engine droop on the high speed gearbox ......................... 5-30
Checking/adjusting cardan shaft revs on the high speed gearbox .................. 5-31
Troubleshooting diagram (40 kph) ......................................................................... 5-32
Troubleshooting diagram: boost pressure ....................................................... 5-32
Troubleshooting diagram: high pressure (HP valves) ...................................... 5-33
Troubleshooting diagram: pump engine droop, driving direction
identification, differential pressure measurement ............................................ 5-34
Checking/adjusting the differential pressure between M4 and M3 .................. 5-35
Evaluating M4 differential pressure measurement .......................................... 5-36
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Table of contents
Example: high pressure measurement M4 (0 – 40 kph) .................................. 5-37
Clean the shuttle throttle .................................................................................. 5-37
Evaluating setting pressure measurement M3 (0 – 40 kph) ............................ 5-38
Example: setting pressure measurement M3 (0 – 40 kph) .............................. 5-39
or ..................................................................................................................... 5-39
Cleaning the 40 kph pressure relief valve .............................................................. 5-40
Drive electronics Operator's Manual (SUSMIC) .................................................... 5-41
Drive electronics error table (SUSMIC) ........................................................... 5-42
Checking proportional valve (1) energisation (40 kph) .......................................... 5-43
Table for electric current values of proportional valves 0 – 40 kph ................. 5-44
Checking the proportional valves by means of current measurement ............. 5-45
Exchanging proportional valves (0 – 40 kph) ......................................................... 5-46
Interrupting the hydraulic circuit between the variable displacement pump and the hydraulic
motor (0 – 40 kph) ...................................................................................... 5-46
Separating the consumer circuit from the hydraulic drive ...................................... 5-47
Checking control pressure M4/M5 (0 – 40 kph) ..................................................... 5-48
Variable displacement pump control pressure H1 P078 ................................. 5-48
Checking the control pressure (control piston pressure) ................................. 5-48
Sealing work on the input shaft (40 kph) ............................................................... 5-49
Mounting the rotary shaft seal ............................................................................... 5-50
Removing the control cover ................................................................................... 5-51
Removing the control cover for driving direction identification ............................... 5-52
Control cover for driving direction identification (overview) ................................... 5-53
Control cover for flush valve (overview) ................................................................. 5-54
Stroke adjustment for wheel revs (overview) ......................................................... 5-55
Control valve overview ........................................................................................... 5-56
Proportional adjustment overview .......................................................................... 5-57
Axles
Front/rear axle type labels ....................................................................................... 6-1
Front axle screw connections .................................................................................. 6-2
Rear axle screw connections ................................................................................... 6-3
Front axle drain, fill and inspection plug .................................................................. 6-4
Rear axle drain, fill and inspection plug ................................................................... 6-5
Front axle tightening torques (Nm) .......................................................................... 6-6
Other front axle tightening torques (Nm) ........................................................... 6-7
Rear axle tightening torques (Nm) ........................................................................... 6-8
Other rear axle tightening torques (Nm) ............................................................ 6-9
Sealing the front axle differential ........................................................................... 6-10
Sealing the rear axle differential ............................................................................ 6-11
Sealing the planetary drive, front/rear axle joint housing ....................................... 6-12
Sealing work: front axle support ............................................................................ 6-17
Sealing work: rear axle support ............................................................................. 6-20
Removing the front axle brake (sealing work) ....................................................... 6-22
Mounting the front axle brake after the sealing work ....................................... 6-25
Sealing the front/rear differential lock cylinder ....................................................... 6-29
Front/rear differential lock: overview ................................................................ 6-30
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Table of contents
Brakes
Brake circuit ............................................................................................................. 7-1
Brake diagram ................................................................................................... 7-2
Service brake function ............................................................................................. 7-3
Parking brake function ............................................................................................. 7-3
Bleeding the brake system ....................................................................................... 7-3
Bleeding the master brake cylinder ................................................................... 7-3
Bleeding the parking brake ................................................................................ 7-4
Bleeding the service brake ................................................................................ 7-4
Service brake: checking wear .................................................................................. 7-5
Brake discs: basic and wear dimensions ................................................................. 7-6
Front axle parking brake: overview .......................................................................... 7-7
Brake discs enabled .......................................................................................... 7-7
Brake discs disabled (released) ......................................................................... 7-7
Steering
Steering valve positions ........................................................................................... 8-1
Complete steering circuit ......................................................................................... 8-2
Front axle and 4 wheel steering circuit diagram ..................................................... 8-3
4 wheel and diagonal (crab) steering circuit ............................................................ 8-4
4 wheel and diagonal steering (crab steering) diagram ........................................... 8-5
Steering system adjustment ..................................................................................... 8-6
Checking the steering rams ............................................................................... 8-6
Checking the steering valve ............................................................................... 8-7
Checking the check block ........................................................................................ 8-8
Front/rear axle steering ram ..................................................................................... 8-9
Hydraulic system
Test report ................................................................................................................ 9-1
Oil supply: work hydraulics with variable displacement pump ................................. 9-2
Work hydraulics/pump pressure test port ................................................................ 9-3
Variable displacement pump (hydraulic pump): circuit diagram .............................. 9-4
Variable displacement pump .................................................................................... 9-5
How the pressure controller (variable displacement pump) works .................... 9-5
How the flow regulator (variable displacement pump) works ............................ 9-6
How the output regulator (variable displacement pump) works ......................... 9-6
Checking and setting the work hydraulics ................................................................ 9-7
Setting the pressure controller (variable displacement pump) ........................... 9-7
Control valve (primary pressure): settings ......................................................... 9-7
Setting the flow regulator (variable displacement pump) ................................... 9-8
Control valve: overview ............................................................................................ 9-9
Overview of standard pilot valve unit ..................................................................... 9-10
Standard pilot control circuit ................................................................................... 9-11
Valve block connections: overview ........................................................................ 9-12
Hose burst valve circuit with load stabiliser ........................................................... 9-13
Work hydraulics circuit ........................................................................................... 9-14
Front and rear additional control circuit (single action) .......................................... 9-15
Front additional control circuit (double-acting) ....................................................... 9-16
Bucket repositioning circuit .................................................................................... 9-17
Pilot valve unit connections (overview) .................................................................. 9-18
Load stabiliser ........................................................................................................ 9-19
Load stabiliser: description .............................................................................. 9-19
Checking and setting the load stabiliser .......................................................... 9-20
Mounting position of load stabiliser changeover valve .................................... 9-20
Load stabiliser diagram .................................................................................... 9-21
Hydraulics diagram ............................................................................................... 9-22
Options: hydraulic diagram ................................................................................... 9-23
Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm I-9
Table of contents
Electric system
List of electric components .................................................................................... 10-1
Ohm's Law (current, voltage, resistance); power ................................................. 10-10
Measuring equipment, measuring methods ......................................................... 10-10
Multifunction measuring device ..................................................................... 10-10
Test device with acoustic and optical signal output ....................................... 10-10
Measuring methods – multifunction measuring device .................................. 10-11
Terminal description ............................................................................................ 10-12
Cable colour coding ............................................................................................. 10-16
Fuses, relays ....................................................................................................... 10-17
Fuse box on left and right of steering column ................................................ 10-17
Main fuse box with relays .............................................................................. 10-18
Switching relays ............................................................................................. 10-19
Steering electronics up to serial no. 34502 0138 ................................................. 10-20
Steering electronics from serial no. 34502 0139 ................................................. 10-21
Wiring harness – new steering electronics (frame side) ...................................... 10-22
Hold electronics with proportional technology ..................................................... 10-23
Wiring harness (joystick) ...................................................................................... 10-23
Proportional electronics ....................................................................................... 10-24
Proportional controls: overview and connections ................................................ 10-25
Instrument panel switches (overview) .................................................................. 10-26
Retrofitting a rotating beacon ............................................................................... 10-27
Retrofitting the backup warning system ............................................................... 10-27
Retrofitting 2 front working lights ......................................................................... 10-28
Retrofitting 2 front working lights and 1 or 2 rear working lights .......................... 10-28
Retrofitting a rear 7 pole socket ........................................................................... 10-29
Retrofitting a front 4 pole socket .......................................................................... 10-30
Instrument panel, fuse box: assembly and routing plan ...................................... 10-32
Wiring diagram 1000127711: legend ................................................................... 10-33
Wiring harness 1000126355: legend ................................................................... 10-35
Cab wiring harness 1000126355 ........................................................................ 10-36
Drive electronics (Susmic) plug (overview) .......................................................... 10-37
Armrest wiring harness 1000126681 .................................................................. 10-38
Engine/frame wiring harness 1000160435 (legend) ........................................... 10-39
Engine/frame wiring harness 1000160435 ......................................................... 10-40
Proportional amplifier 1000127179 ..................................................................... 10-41
Wiring harness for load stabiliser retrofitting 1000142468 (option) ..................... 10-42
Numberplate light wiring harness 1000126998 (option) ...................................... 10-43
High speed cable 1000130515 (option) ............................................................... 10-44
Cab overview, labels, operation
Inside of cab: overview ............................................................................................ 1-1
Instrument panel, multifunctional lever and drive lever: overview ........................... 1-2
Overview of exterior of machine .............................................................................. 1-3
Important information on this service manual .......................................................... 1-4
Models and trade names: overview ......................................................................... 1-5
Brief description of the wheel loader ........................................................................ 1-5
Hydrostatic drive ................................................................................................ 1-6
Work hydraulics and 4 wheel steering ............................................................... 1-6
Cooling system .................................................................................................. 1-6
Fields of application and using the wheel loader with an attachment ...................... 1-6
Use: attachment with certified material density ...................................................... 1-7
Regulations .............................................................................................................. 1-8
Driving licence ................................................................................................... 1-8
Licence .............................................................................................................. 1-8
Equipment ......................................................................................................... 1-8
Warranty ............................................................................................................ 1-8
Machine inspections .......................................................................................... 1-9
Documents ........................................................................................................ 1-9
Warning identification of wheel loader on public roads (option) ........................ 1-9
Type labels and component numbers .................................................................... 1-10
Serial number of frame .................................................................................... 1-10
Cab serial number ........................................................................................... 1-10
Serial number of engine .................................................................................. 1-10
Hydraulic pump serial number ......................................................................... 1-11
Hydraulic motor serial number ......................................................................... 1-11
Serial number of rear axle ............................................................................... 1-11
Serial number of front axle .............................................................................. 1-11
Warning and information labels ............................................................................. 1-12
Label on the outside of the machine ................................................................ 1-12
Label on the inside of the machine .................................................................. 1-13
Description: telltales and warning lights on the instrument panel .......................... 1-16
Drive interlock with code input (option) .................................................................. 1-19
Keyboard for entering codes: overview ........................................................... 1-19
Entering/changing the personal code .............................................................. 1-20
Enabling the drive interlock ............................................................................. 1-20
Disabling the drive interlock ............................................................................. 1-21
Taking the drive interlock out of service .......................................................... 1-22
Putting the drive interlock back into service again ........................................... 1-22
Interruption of drive interlock power ................................................................ 1-22
Drive interlock maintenance ............................................................................ 1-22
Key-based drive interlock (option) ......................................................................... 1-23
Key-based drive interlock: scope of delivery ................................................... 1-23
Coding (“training”) new ignition keys ............................................................... 1-23
Enabling (locking) the drive interlock ............................................................... 1-24
Disabling (releasing) the drive interlock ........................................................... 1-24
Deleting coded keys ........................................................................................ 1-24
Safety functions ............................................................................................... 1-24
Battery master switch (option) ............................................................................... 1-25
Interrupting power supply ................................................................................ 1-25
Switching on power supply .............................................................................. 1-25
Engine oil, hydraulic oil and fuel preheater (option) ............................................... 1-25
Putting the engine oil and hydraulic oil preheating into operation ................... 1-25
Fuel preheater operation ................................................................................. 1-25
Table of contents
I-2 Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm
Table of contents
Jump-starting the engine (external battery) ........................................................... 1-26
Safety instructions regarding external starting aids ......................................... 1-26
Providing external starting aid ......................................................................... 1-26
Manual throttle (option) .......................................................................................... 1-27
Setting the drive speed with the manual throttle .............................................. 1-27
Low-speed control (option) .................................................................................... 1-27
Selecting the drive speed ................................................................................ 1-27
Electric connection – socket (option) ..................................................................... 1-28
Reversing cooling fan (option) ............................................................................... 1-28
Working lights ........................................................................................................ 1-28
Rotating beacon (option) ........................................................................................ 1-29
Signalling system ................................................................................................... 1-29
Turn indicators ................................................................................................. 1-29
Hazard warning system ................................................................................... 1-29
Working with the automatic bucket repositioning (option) ...................................... 1-30
General information on automatic bucket repositioning ................................... 1-30
Additional control circuit for attachments (option) .................................................. 1-31
Single-action additional control circuit ............................................................. 1-31
Double-action additional control circuit (option) ............................................... 1-32
“Hose burst valve” safety feature (option) .............................................................. 1-33
Towing the machine ............................................................................................... 1-34
Safety instructions for towing away ................................................................. 1-34
Getting ready for towing ................................................................................... 1-34
Towing the machine ......................................................................................... 1-35
Specifications
Models and trade names: overview ......................................................................... 2-1
Frame ....................................................................................................................... 2-1
Engine ...................................................................................................................... 2-1
Oil/water cooling fan ................................................................................................ 2-1
Power train ............................................................................................................... 2-2
Variable displacement pump ............................................................................. 2-2
Boost pump ........................................................................................................ 2-2
Variable displacement motor ............................................................................. 2-2
Axles ........................................................................................................................ 2-3
Front axle ........................................................................................................... 2-3
Rear axle ........................................................................................................... 2-3
Brakes ...................................................................................................................... 2-3
Service brake ..................................................................................................... 2-3
Parking brake ..................................................................................................... 2-3
Steering system ....................................................................................................... 2-4
Work hydraulics ....................................................................................................... 2-4
Hydraulic pump .................................................................................................. 2-4
Control valve, suction reflux filter ....................................................................... 2-4
Lift and tilt rams, 3rd control circuit .................................................................... 2-5
Additional control circuit (option) ....................................................................... 2-5
Hydraulic pilot control (control valve) ................................................................. 2-5
Electric system ......................................................................................................... 2-6
Electric units ...................................................................................................... 2-6
Fuse box on left and right under the steering column ........................................ 2-6
Main fuse box with relays .................................................................................. 2-7
Switching relays ................................................................................................. 2-8
Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm I-3
Table of contents
Tyres ........................................................................................................................ 2-9
Weights .................................................................................................................... 2-9
Noise levels ........................................................................................................... 2-10
Vibration ................................................................................................................. 2-10
Coolant compound table ........................................................................................ 2-10
Tightening torques, conversion tables ................................................................... 2-11
General tightening torques .............................................................................. 2-11
Specific tightening torques .............................................................................. 2-11
Conversion table: DIN standard – USA standard ............................................ 2-12
Payloads ................................................................................................................ 2-13
Payload with bucket ......................................................................................... 2-13
Payload with pallet forks .................................................................................. 2-13
Trailer weight/drawbar load for automatic trailer coupling (option) .................. 2-13
Dimensions with bucket ......................................................................................... 2-14
Wheel loader dimensions with pallet forks ............................................................. 2-15
Maintenance and service work
Explanation of symbols on the maintenance label ................................................... 3-1
Maintenance label .................................................................................................... 3-2
Located inside the cab on the rear window ....................................................... 3-2
Fluids and lubricants ............................................................................................... 3-3
Maintenance plan .................................................................................................... 3-4
Important information on maintenance and service work ........................................ 3-8
Important information on the maintenance plan ................................................ 3-8
Overview of repair work on separate components ............................................ 3-8
Maintenance kits ...................................................................................................... 3-8
Fuel system ............................................................................................................. 3-9
General safety instructions for refuelling ........................................................... 3-9
Diesel fuel specification ..................................................................................... 3-9
Stationary fuel pumps ........................................................................................ 3-9
Refuelling ............................................................................................................... 3-10
Bleeding the fuel system ........................................................................................ 3-10
Checking/cleaning the fuel prefilter (water separator) ........................................... 3-11
Checking/filling up the engine oil ........................................................................... 3-12
Check the engine oil ........................................................................................ 3-12
Filling up engine oil .......................................................................................... 3-12
Changing engine oil ............................................................................................... 3-13
Replacing the engine oil filter cartridge .................................................................. 3-14
Engine and hydraulics cooling system ................................................................... 3-15
Safety instructions regarding cooling system maintenance ............................. 3-15
Checking the coolant level ..................................................................................... 3-16
Draining coolant ..................................................................................................... 3-17
Cleaning the radiator fins of the oil/water radiator ................................................. 3-18
Cleaning the radiator fins with compressed air ................................................ 3-18
Cleaning the radiator fins with the reversing fan (option) ................................ 3-18
Air filter maintenance ............................................................................................. 3-19
Checking the air filter for dirt ............................................................................ 3-19
Checking the dust collector (option) ................................................................ 3-20
Replacing the air filter cartridge ....................................................................... 3-20
V-belts .................................................................................................................... 3-21
Checking V-belt tension ................................................................................... 3-21
Retightening the V-belts .................................................................................. 3-21
Hydraulic system ................................................................................................... 3-22
Specific safety instructions regarding the hydraulic system ............................ 3-22
Important information for the use of biodegradable oil .................................... 3-23
Monitoring the hydraulic oil reflux filter ............................................................ 3-23
I-4 Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm
Table of contents
Checking the hydraulic oil level .............................................................................. 3-24
Filling up hydraulic oil ............................................................................................. 3-24
Replacing hydraulic oil ........................................................................................... 3-25
Maintenance of the hydraulic oil reflux filter ........................................................... 3-26
Replacing the hydraulic oil reflux filter ............................................................. 3-26
Maintenance of the drive control line (LS) line filter ............................................... 3-26
Cleaning the line filter ...................................................................................... 3-26
Maintenance of the drive boost pressure microfilter .............................................. 3-27
Replacing the microfilter .................................................................................. 3-27
Checking hydraulic pressure lines ......................................................................... 3-28
Specific safety instructions regarding pressure line checks ............................ 3-28
Maintenance: gearbox oil ....................................................................................... 3-29
Checking/filling up the gearbox oil ................................................................... 3-29
Changing the gearbox oil ................................................................................. 3-30
Oil levels: front and rear axle differentials .............................................................. 3-31
Checking/filling up oil on the rear axle differential ........................................... 3-31
Changing oil on the rear axle differential ......................................................... 3-31
Checking/filling up oil on the front axle differential ........................................... 3-32
Changing oil on the front axle differential ........................................................ 3-32
Checking/filling up oil on the planetary drives .................................................. 3-33
Changing the oil in the planetary drives ........................................................... 3-33
Front and rear axle lubrication ............................................................................... 3-34
Lubricating the rear axle oscillation-type bearing ............................................ 3-34
Lubricating the front and rear axle planetary drive bearings ............................ 3-34
Loader unit lubrication work ................................................................................... 3-35
Lubricating the pivots on the loader unit .......................................................... 3-35
Lubricating with the central lubrication system (option) ......................................... 3-36
General functional description of the central lubrication system ...................... 3-36
Setting the lubrication and break times ............................................................ 3-37
Filling the central lubrication system ................................................................ 3-37
Attachment maintenance ....................................................................................... 3-37
Brake system maintenance .................................................................................... 3-38
Specific safety instructions regarding the brake system .................................. 3-38
Checking/filling up the brake fluid level ............................................................ 3-38
Tyre maintenance .................................................................................................. 3-39
Tyre check ....................................................................................................... 3-39
Changing wheels ............................................................................................. 3-40
Heating and ventilation system maintenance ........................................................ 3-41
General information on the heating system ..................................................... 3-41
Cleaning/replacing the fine-dust filter of the heating system ........................... 3-41
Air conditioning (option): maintenance ................................................................... 3-42
General instructions regarding the air conditioning ......................................... 3-42
Cleaning and carrying out functional and visual checks of the air conditioning .......
3-43
Electric system ....................................................................................................... 3-44
Specific safety instructions regarding the electric system ............................... 3-44
Service and maintenance work at regular intervals ......................................... 3-44
Cables, bulbs and fuses .................................................................................. 3-45
Alternator ......................................................................................................... 3-45
Checking/replacing relays and fuses ............................................................... 3-46
Main fuse box with switching relays ................................................................. 3-46
Checking/replacing the battery ........................................................................ 3-47
General maintenance work .................................................................................... 3-48
Specific safety instructions regarding cleaning ................................................ 3-48
When using washing solvents ......................................................................... 3-48
When using compressed air ............................................................................ 3-48
When using a high-pressure cleaner or steam jet ........................................... 3-48
Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm I-5
Table of contents
When using volatile and easily flammable anticorrosion agents and sprays ... 3-48
Cleaning inside the cab ................................................................................... 3-49
Cleaning the seat belt ...................................................................................... 3-49
Cleaning the exterior of the machine ............................................................... 3-49
Cleaning the engine compartment ................................................................... 3-50
Checking screw connections ........................................................................... 3-50
Checking pivots and hinges ............................................................................. 3-50
Maintenance: diesel particulate filter (option) ........................................................ 3-51
Checking the electronic filter monitoring .......................................................... 3-51
Maintenance work “Aggressive Media” (option) .................................................... 3-52
Anticorrosion protection applied in the factory ................................................. 3-52
Components coated with anticorrosive wax .................................................... 3-52
Measures for maintaining anticorrosive protection .......................................... 3-53
Applying the protective anticorrosion coating .................................................. 3-54
Treatment of oxidised surfaces ....................................................................... 3-54
Engine
Engine designation .................................................................................................. 4-1
Fuel specification ..................................................................................................... 4-1
Coolant specification ................................................................................................ 4-1
Engine overview (oil filter and oil radiator side) ....................................................... 4-2
Engine overview (turbocharger side) ....................................................................... 4-3
Engine overview (oil filter connection) ..................................................................... 4-4
Engine overview (drive flange side) ......................................................................... 4-5
Engine overview (drive clutch) ................................................................................. 4-6
Engine number ........................................................................................................ 4-7
Cylinder numbering, firing order .............................................................................. 4-7
Coolant system ........................................................................................................ 4-8
Cooling circuit .................................................................................................... 4-8
Lube oil system ........................................................................................................ 4-9
Lube oil circuit .................................................................................................... 4-9
Lube oil circuit diagram .......................................................................................... 4-10
Engine fuel system ................................................................................................ 4-11
Fuel system: fuel tank – engine ............................................................................. 4-12
Bleeding the fuel system ........................................................................................ 4-13
Fuel pump overview ............................................................................................... 4-14
Fuel injection system ............................................................................................. 4-15
Mounting the injection pumps ................................................................................ 4-16
Mounting coded injection pumps (88 kW diesel engine TIER III) .......................... 4-17
Replacing uncoded pumps .............................................................................. 4-17
Shims for coded injection pumps ..................................................................... 4-18
General information on valve clearance ................................................................ 4-18
Valve clearance setting with a feeler gauge (75/100 kW diesel engine TIER II) ... 4-19
Setting the valves with a protractor (88 kW diesel engine TIER III) ....................... 4-20
Setting the valve clearance (special tool: protractor) ....................................... 4-21
Special tools for protractor ..................................................................................... 4-22
Determining the cylinder-head gasket ................................................................... 4-23
Measuring piston projection ............................................................................. 4-23
Mounting the cylinder head .................................................................................... 4-24
Engine malfunctions .............................................................................................. 4-25
I-6 Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm
Table of contents
Power train
Functional despcription of drive hydraulics and electric system .............................. 5-1
Boost pressure circuit ........................................................................................ 5-1
Boost pressure relief valve ................................................................................ 5-1
Pump adjustment ............................................................................................... 5-1
Motor adjustment ............................................................................................... 5-2
Drive output regulation ....................................................................................... 5-2
Flush feature ...................................................................................................... 5-2
Locking driving direction selection ..................................................................... 5-2
Holding the signal for the forwards driving direction selection ........................... 5-2
Holding the signal for the reverse driving direction selection ............................. 5-2
Drive speed control ............................................................................................ 5-3
Inching pedal function ........................................................................................ 5-3
Calibrating the inching pedal ............................................................................. 5-3
Crawler gear potentiometer (low-speed control) ................................................ 5-3
Drive settings ..................................................................................................... 5-3
Troubleshooting (drive) ...................................................................................... 5-3
Towing the machine ................................................................................................. 5-4
Safety instructions for towing away ................................................................... 5-4
Getting ready for towing ..................................................................................... 5-4
Towing the machine ........................................................................................... 5-5
Variable displacement pump: overview ................................................................... 5-6
Overview of variable displacement pump: H1 test ports .......................................... 5-7
Overview of 20 kph hydraulic motor: test ports ........................................................ 5-8
Overview of 20 kph hydraulic motor: proportional valve .......................................... 5-9
Overview of 20 kph hydraulic motor: drive hydraulics ports ................................... 5-10
20 kph drive: diagram ............................................................................................ 5-11
20 kph drive: circuit ................................................................................................ 5-12
Test report: 20 kph power train .............................................................................. 5-13
Test and adjustment instructions for 20 kph drive ................................................. 5-14
Adjusting boost pressure ................................................................................. 5-14
Checking/adjusting high pressure .................................................................... 5-15
Checking/adjusting engine droop .................................................................... 5-16
Checking/adjusting control initiation on the hydraulic motor ............................ 5-17
Checking driving direction identification ........................................................... 5-18
Mode of function of 40 kph high speed gearbox (Ecospeed) ................................. 5-19
40 kph high speed gearbox (Ecospeed) ................................................................ 5-19
40 kph high speed gearbox overview .................................................................... 5-20
Control cover and 40 kph circuit diagram (overview) ............................................. 5-21
40 kph control cover (component parts) ................................................................ 5-22
40 kph drive circuit ................................................................................................. 5-23
Test report: 40 kph power train .............................................................................. 5-24
Test and adjustment instructions for 40 kph drive ................................................. 5-25
Adjusting boost pressure ................................................................................. 5-25
Checking/adjusting high pressure .................................................................... 5-26
Checking/adjusting engine droop .................................................................... 5-27
Checking driving direction identification ........................................................... 5-28
Checking/adjusting control initiation ................................................................ 5-29
Checking/adjusting engine droop on the high speed gearbox ......................... 5-30
Checking/adjusting cardan shaft revs on the high speed gearbox .................. 5-31
Troubleshooting diagram (40 kph) ......................................................................... 5-32
Troubleshooting diagram: boost pressure ....................................................... 5-32
Troubleshooting diagram: high pressure (HP valves) ...................................... 5-33
Troubleshooting diagram: pump engine droop, driving direction
identification, differential pressure measurement ............................................ 5-34
Checking/adjusting the differential pressure between M4 and M3 .................. 5-35
Evaluating M4 differential pressure measurement .......................................... 5-36
Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm I-7
Table of contents
Example: high pressure measurement M4 (0 – 40 kph) .................................. 5-37
Clean the shuttle throttle .................................................................................. 5-37
Evaluating setting pressure measurement M3 (0 – 40 kph) ............................ 5-38
Example: setting pressure measurement M3 (0 – 40 kph) .............................. 5-39
or ..................................................................................................................... 5-39
Cleaning the 40 kph pressure relief valve .............................................................. 5-40
Drive electronics Operator's Manual (SUSMIC) .................................................... 5-41
Drive electronics error table (SUSMIC) ........................................................... 5-42
Checking proportional valve (1) energisation (40 kph) .......................................... 5-43
Table for electric current values of proportional valves 0 – 40 kph ................. 5-44
Checking the proportional valves by means of current measurement ............. 5-45
Exchanging proportional valves (0 – 40 kph) ......................................................... 5-46
Interrupting the hydraulic circuit between the variable displacement pump and the hydraulic
motor (0 – 40 kph) ...................................................................................... 5-46
Separating the consumer circuit from the hydraulic drive ...................................... 5-47
Checking control pressure M4/M5 (0 – 40 kph) ..................................................... 5-48
Variable displacement pump control pressure H1 P078 ................................. 5-48
Checking the control pressure (control piston pressure) ................................. 5-48
Sealing work on the input shaft (40 kph) ............................................................... 5-49
Mounting the rotary shaft seal ............................................................................... 5-50
Removing the control cover ................................................................................... 5-51
Removing the control cover for driving direction identification ............................... 5-52
Control cover for driving direction identification (overview) ................................... 5-53
Control cover for flush valve (overview) ................................................................. 5-54
Stroke adjustment for wheel revs (overview) ......................................................... 5-55
Control valve overview ........................................................................................... 5-56
Proportional adjustment overview .......................................................................... 5-57
Axles
Front/rear axle type labels ....................................................................................... 6-1
Front axle screw connections .................................................................................. 6-2
Rear axle screw connections ................................................................................... 6-3
Front axle drain, fill and inspection plug .................................................................. 6-4
Rear axle drain, fill and inspection plug ................................................................... 6-5
Front axle tightening torques (Nm) .......................................................................... 6-6
Other front axle tightening torques (Nm) ........................................................... 6-7
Rear axle tightening torques (Nm) ........................................................................... 6-8
Other rear axle tightening torques (Nm) ............................................................ 6-9
Sealing the front axle differential ........................................................................... 6-10
Sealing the rear axle differential ............................................................................ 6-11
Sealing the planetary drive, front/rear axle joint housing ....................................... 6-12
Sealing work: front axle support ............................................................................ 6-17
Sealing work: rear axle support ............................................................................. 6-20
Removing the front axle brake (sealing work) ....................................................... 6-22
Mounting the front axle brake after the sealing work ....................................... 6-25
Sealing the front/rear differential lock cylinder ....................................................... 6-29
Front/rear differential lock: overview ................................................................ 6-30
I-8 Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm
Table of contents
Brakes
Brake circuit ............................................................................................................. 7-1
Brake diagram ................................................................................................... 7-2
Service brake function ............................................................................................. 7-3
Parking brake function ............................................................................................. 7-3
Bleeding the brake system ....................................................................................... 7-3
Bleeding the master brake cylinder ................................................................... 7-3
Bleeding the parking brake ................................................................................ 7-4
Bleeding the service brake ................................................................................ 7-4
Service brake: checking wear .................................................................................. 7-5
Brake discs: basic and wear dimensions ................................................................. 7-6
Front axle parking brake: overview .......................................................................... 7-7
Brake discs enabled .......................................................................................... 7-7
Brake discs disabled (released) ......................................................................... 7-7
Steering
Steering valve positions ........................................................................................... 8-1
Complete steering circuit ......................................................................................... 8-2
Front axle and 4 wheel steering circuit diagram ..................................................... 8-3
4 wheel and diagonal (crab) steering circuit ............................................................ 8-4
4 wheel and diagonal steering (crab steering) diagram ........................................... 8-5
Steering system adjustment ..................................................................................... 8-6
Checking the steering rams ............................................................................... 8-6
Checking the steering valve ............................................................................... 8-7
Checking the check block ........................................................................................ 8-8
Front/rear axle steering ram ..................................................................................... 8-9
Hydraulic system
Test report ................................................................................................................ 9-1
Oil supply: work hydraulics with variable displacement pump ................................. 9-2
Work hydraulics/pump pressure test port ................................................................ 9-3
Variable displacement pump (hydraulic pump): circuit diagram .............................. 9-4
Variable displacement pump .................................................................................... 9-5
How the pressure controller (variable displacement pump) works .................... 9-5
How the flow regulator (variable displacement pump) works ............................ 9-6
How the output regulator (variable displacement pump) works ......................... 9-6
Checking and setting the work hydraulics ................................................................ 9-7
Setting the pressure controller (variable displacement pump) ........................... 9-7
Control valve (primary pressure): settings ......................................................... 9-7
Setting the flow regulator (variable displacement pump) ................................... 9-8
Control valve: overview ............................................................................................ 9-9
Overview of standard pilot valve unit ..................................................................... 9-10
Standard pilot control circuit ................................................................................... 9-11
Valve block connections: overview ........................................................................ 9-12
Hose burst valve circuit with load stabiliser ........................................................... 9-13
Work hydraulics circuit ........................................................................................... 9-14
Front and rear additional control circuit (single action) .......................................... 9-15
Front additional control circuit (double-acting) ....................................................... 9-16
Bucket repositioning circuit .................................................................................... 9-17
Pilot valve unit connections (overview) .................................................................. 9-18
Load stabiliser ........................................................................................................ 9-19
Load stabiliser: description .............................................................................. 9-19
Checking and setting the load stabiliser .......................................................... 9-20
Mounting position of load stabiliser changeover valve .................................... 9-20
Load stabiliser diagram .................................................................................... 9-21
Hydraulics diagram ............................................................................................... 9-22
Options: hydraulic diagram ................................................................................... 9-23
Serv-HB 34502 EN - Ausgabe 1.0 * 34502s10_deIVZ.fm I-9
Table of contents
Electric system
List of electric components .................................................................................... 10-1
Ohm's Law (current, voltage, resistance); power ................................................. 10-10
Measuring equipment, measuring methods ......................................................... 10-10
Multifunction measuring device ..................................................................... 10-10
Test device with acoustic and optical signal output ....................................... 10-10
Measuring methods – multifunction measuring device .................................. 10-11
Terminal description ............................................................................................ 10-12
Cable colour coding ............................................................................................. 10-16
Fuses, relays ....................................................................................................... 10-17
Fuse box on left and right of steering column ................................................ 10-17
Main fuse box with relays .............................................................................. 10-18
Switching relays ............................................................................................. 10-19
Steering electronics up to serial no. 34502 0138 ................................................. 10-20
Steering electronics from serial no. 34502 0139 ................................................. 10-21
Wiring harness – new steering electronics (frame side) ...................................... 10-22
Hold electronics with proportional technology ..................................................... 10-23
Wiring harness (joystick) ...................................................................................... 10-23
Proportional electronics ....................................................................................... 10-24
Proportional controls: overview and connections ................................................ 10-25
Instrument panel switches (overview) .................................................................. 10-26
Retrofitting a rotating beacon ............................................................................... 10-27
Retrofitting the backup warning system ............................................................... 10-27
Retrofitting 2 front working lights ......................................................................... 10-28
Retrofitting 2 front working lights and 1 or 2 rear working lights .......................... 10-28
Retrofitting a rear 7 pole socket ........................................................................... 10-29
Retrofitting a front 4 pole socket .......................................................................... 10-30
Instrument panel, fuse box: assembly and routing plan ...................................... 10-32
Wiring diagram 1000127711: legend ................................................................... 10-33
Wiring harness 1000126355: legend ................................................................... 10-35
Cab wiring harness 1000126355 ........................................................................ 10-36
Drive electronics (Susmic) plug (overview) .......................................................... 10-37
Armrest wiring harness 1000126681 .................................................................. 10-38
Engine/frame wiring harness 1000160435 (legend) ........................................... 10-39
Engine/frame wiring harness 1000160435 ......................................................... 10-40
Proportional amplifier 1000127179 ..................................................................... 10-41
Wiring harness for load stabiliser retrofitting 1000142468 (option) ..................... 10-42
Numberplate light wiring harness 1000126998 (option) ...................................... 10-43
High speed cable 1000130515 (option) ............................................................... 10-44
You can see :
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