01 5055L Reparacion

Service manual
Wheel loaders
Machine model 349-00/349-01

From serial no. 349 00 0001/349 01 0001
Edition 1.0
Order number 1000277645
Language [en]
Documentation Language Order no.
Service manual [en] 1000277645
Operator’s Manual [en] 1000268039
[de] 1000159213
Service Booklet [en] 1000159214
[fr] 1000159215
Spare parts catalogue, model 349-

1000274206
00
[de]/[en]/[fr]
Spare parts catalogue, model 349-
1000268040
01
Legend
Edition 1.0
Date 12/2011
Document Serv-HB 34900/01
Copyright – 2011 Kramer-Werke GmbH

Printed in Germany
All rights reserved, in particular the copyright, the right of reproduction and the right of distribution applicable worldwide.
No part of this publication may be reproduced, translated or used in any form or by any means – graphic, electronic or mechanical includ-
ing photocopying, recording, taping or information storage or retrieval systems – without prior permission in writing from the manufacturer.
No reproduction or translation of this publication, in whole or part, without the written consent of KRAMER-WERKE GmbH.
Any infringement of legal provisions, in particular of those regarding copyright protection, shall be subject to civil and criminal law prose-
cution.
KRAMER-WERKE GmbH keep abreast of the latest technical developments and constantly improve their products. For this reason, we
may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which
have already been delivered and which will not be implemented on these machines.
Technical data, dimensions and weights are given as an indication only. Responsibility for errors or omissions not accepted.
The cover features the machine with possible optional equipment.
Kramer-Werke GmbH
Wacker-Neuson-Str. 1
D-88630 Pfullendorf
Tel. 0080090209020
E-mail info@kramer.de
www.kramer.de
Table of Contents
Table of Contents
Table of Contents
1 Cab overview, use, operation
1.1 Machine outside view ........................................................................................................................................................ 1-2
1.2 Inside of cab (overview) .................................................................................................................................................... 1-3
1.3 Instrument panel, multifunctional lever, switch consoles (overview) ................................................................................. 1-4
1.4 Legal regulations regarding wheel loader operation ......................................................................................................... 1-5
1.5 Fields of application and using a machine with an attachment ......................................................................................... 1-8
2 Specifications
2.1 Models and trade names (overview) ................................................................................................................................. 2-2
2.2 Frame ................................................................................................................................................................................ 2-2
2.3 Engine ............................................................................................................................................................................... 2-2
2.4 Drive .................................................................................................................................................................................. 2-3
2.5 Front/rear axles ................................................................................................................................................................. 2-4
2.6 Brakes ............................................................................................................................................................................... 2-5
2.7 Steering system ................................................................................................................................................................ 2-5
2.8 Work hydraulics ................................................................................................................................................................. 2-6
2.9 Electrical system ............................................................................................................................................................... 2-8
2.10 Tyres ............................................................................................................................................................................... 2-11
2.11 Weights ........................................................................................................................................................................... 2-11
2.12 Noise levels ..................................................................................................................................................................... 2-12
2.13 Coolant compound table ................................................................................................................................................. 2-13
2.14 Vibrations, oscillation and acceleration value ................................................................................................................. 2-13
2.15 Tightening torques .......................................................................................................................................................... 2-14
2.16 Payloads and capacities ................................................................................................................................................. 2-15
2.17 Dimensions with bucket .................................................................................................................................................. 2-17
2.18 Dimensions with pallet forks ............................................................................................................................................ 2-18
Serv-HB 34900/01 - Ausgabe 1.0 * Serv-HB 34901_10_enIVZ2.fm I-1

Table of Contents
3 Maintenance and servicing work

3.1 Explanation of symbols on the maintenance label ........................................................................................................... 3-2
3.2 Maintenance label ............................................................................................................................................................ 3-3
3.3 Fluids and lubricants ........................................................................................................................................................ 3-4
3.4 Maintenance plan ............................................................................................................................................................. 3-5
3.5 Maintenance staff ............................................................................................................................................................. 3-9
3.6 Important information on maintenance and service work ................................................................................................. 3-9
3.7 Fuel system .................................................................................................................................................................... 3-10
3.8 Engine lubrication system .............................................................................................................................................. 3-13
3.9 Changing engine oil ........................................................................................................................................................ 3-14
3.10 Washer system tank ....................................................................................................................................................... 3-15
3.11 Changing the engine oil filter cartridge ........................................................................................................................... 3-16
3.12 Washer system tank ....................................................................................................................................................... 3-17
3.13 Engine and hydraulics cooling system ........................................................................................................................... 3-17
3.14 Air filter ........................................................................................................................................................................... 3-22
3.15 Replacing the air filter cartridge ...................................................................................................................................... 3-23
3.16 V-belt .............................................................................................................................................................................. 3-24
3.17 Hydraulic system ............................................................................................................................................................ 3-26
3.18 Checking hydraulic pressure lines .................................................................................................................................. 3-31
3.19 Replacing hydraulic oil ................................................................................................................................................... 3-32
3.20 Replacing the hydraulic oil return filter ........................................................................................................................... 3-33
3.21 Replacing the filler and breather filter ............................................................................................................................. 3-33
3.23 Lubrication work on the axles ......................................................................................................................................... 3-38
3.24 Lubrication work on the loader unit ................................................................................................................................ 3-39
3.25 Lubricating with the central lubrication system (option) .................................................................................................. 3-40
3.26 Maintenance of the brake system .................................................................................................................................. 3-42
3.27 Tyres .............................................................................................................................................................................. 3-43
3.28 Heating and ventilation system maintenance ................................................................................................................. 3-45
3.29 Maintenance of the air conditioning system (option) ...................................................................................................... 3-46
3.30 Electrical system ............................................................................................................................................................ 3-48
3.31 General cleaning and maintenance work ....................................................................................................................... 3-56
3.32 Maintenance of attachments and of the work equipment ............................................................................................... 3-58
3.33 Maintenance of the automatic trailer coupling (option) ................................................................................................... 3-59
3.34 Maintenance work “Aggressive Media” (option) ............................................................................................................. 3-60
4 Diesel engine
4.35 Diesel engine electrical system diagram .......................................................................................................................... 4-2
4.36 Diesel engine electrical diagram (legend) ........................................................................................................................ 4-3
4.37 Engine designation ........................................................................................................................................................... 4-5
4.38 Fuel specification .............................................................................................................................................................. 4-5
4.39 Coolant specification ........................................................................................................................................................ 4-5
4.40 Engine (overview) ............................................................................................................................................................. 4-6
4.41 Electric components on engine (overview) ....................................................................................................................... 4-7
4.42 Preheating system (circuit diagram) ................................................................................................................................. 4-8
4.43 Starting system (circuit diagram) ...................................................................................................................................... 4-9
4.44 Cutoff solenoid (circuit diagram) ..................................................................................................................................... 4-10
4.45 Cooling (overview) .......................................................................................................................................................... 4-11
4.46 Valve clearance .............................................................................................................................................................. 4-12
4.47 Fuel system .................................................................................................................................................................... 4-13
I-2 Serv-HB 34900/01 - Ausgabe 1.0 * Serv-HB 34901_10_enIVZ2.fm

Table of Contents
5 Power train
5.1 Drive (electrical diagram) .................................................................................................................................................. 5-2
5.2 Drive hydraulics diagram ................................................................................................................................................... 5-4
5.3 Functional description of the drive hydraulics ................................................................................................................... 5-5
5.4 Variable displacement pump test ports (20 kph) ............................................................................................................... 5-7
5.5 Valves of variable displacement pump 20 kph .................................................................................................................. 5-8
5.6 Test ports of variable displacement motor (20/30 kph) ..................................................................................................... 5-9
5.7 Variable displacement motor – solenoid valves (20/30 kph) ........................................................................................... 5-10
5.8 Inching valve overview .................................................................................................................................................... 5-11
5.9 Inching valve circuit ......................................................................................................................................................... 5-12
5.10 Inching valve diagram ..................................................................................................................................................... 5-13
5.11 Drive circuit ..................................................................................................................................................................... 5-14
5.12 Low-speed control ........................................................................................................................................................... 5-15
5.13 Drive diagram .................................................................................................................................................................. 5-16
5.14 Towing and transporting the machine ............................................................................................................................. 5-17
5.15 Test report: 20/30 kph power train .................................................................................................................................. 5-18
5.16 Adjustment instructions ................................................................................................................................................... 5-19
5.17 Adjusting boost pressure ................................................................................................................................................. 5-19
5.18 Checking the control pressure ........................................................................................................................................ 5-20
5.19 Checking the driving direction identification .................................................................................................................... 5-21
5.20 Adjusting starting engine speed ...................................................................................................................................... 5-22
5.21 Setting high pressure/drive pressure .............................................................................................................................. 5-23
5.22 Checking/adjusting the high-pressure valves .................................................................................................................. 5-24
5.23 Pressure cutoff (exploded view) ...................................................................................................................................... 5-25
5.24 Checking/setting the high pressure/characterisic curve of the pump .............................................................................. 5-26
5.25 Check engine droop ........................................................................................................................................................ 5-27
5.26 Control cartridge function ................................................................................................................................................ 5-27
5.27 Setting control initiation on the variable displacement motor .......................................................................................... 5-28
5.28 Setting the wheel speed .................................................................................................................................................. 5-29
6 Axles
6.1 Differential lock (electrical/hydraulics diagram) ................................................................................................................. 6-2
6.2 Axle type label ................................................................................................................................................................... 6-3
6.3 Tightening values (Nm) ..................................................................................................................................................... 6-4
6.4 Screw connections ............................................................................................................................................................ 6-5
6.5 Sealing work ...................................................................................................................................................................... 6-6
6.6 Sealing: planetary drive ..................................................................................................................................................... 6-7
6.7 Installing the planetary drive ........................................................................................................................................... 6-11
6.8 Sealing work: axle carrier – differential housing .............................................................................................................. 6-14
6.9 Sealing: gearbox – input flange ....................................................................................................................................... 6-15
6.10 Differential (overview) ..................................................................................................................................................... 6-17
6.11 Replacing the gear drive ................................................................................................................................................. 6-18
6.12 Differential cage with lock (overview) .............................................................................................................................. 6-24
6.13 Differential cage .............................................................................................................................................................. 6-25
6.14 Removing the differential lock ......................................................................................................................................... 6-26
6.15 Mounting the differential lock .......................................................................................................................................... 6-27
6.16 Axle carrier overview ....................................................................................................................................................... 6-28
6.17 Steering ram overview .................................................................................................................................................... 6-29
6.18 Wheel hub overview ........................................................................................................................................................ 6-30

Table of Contents
7 Brakes
7.1 Brakes (electrical/hydraulics diagram) ............................................................................................................................. 7-2
7.2 Maintenance of the brake system .................................................................................................................................... 7-3
7.3 Brake circuit ...................................................................................................................................................................... 7-4
7.4 Brake diagram .................................................................................................................................................................. 7-5
7.5 Inching valve circuit .......................................................................................................................................................... 7-6
7.6 Service brake ................................................................................................................................................................... 7-7
7.7 Adjusting the service brake .............................................................................................................................................. 7-8
7.8 Removing the brake calliper ............................................................................................................................................. 7-9
7.9 Replacing brake linings .................................................................................................................................................... 7-9
7.10 Parking brake ................................................................................................................................................................. 7-10
7.11 Adjusting the parking brake ............................................................................................................................................ 7-11
7.12 Bleeding the brake system ............................................................................................................................................. 7-12
8 Steering system
8.1 Steering system (electrical/hydraulics diagram) ............................................................................................................... 8-2
8.2 Steering circuit with final-position synchronisation ........................................................................................................... 8-3
8.3 Steering circuit with front and 4 wheel steering ................................................................................................................ 8-4
8.4 Steering system adjustment ............................................................................................................................................. 8-5
8.5 Hydraulic ports on servostat ............................................................................................................................................. 8-5
8.6 Pressure relief valve: adjustment ..................................................................................................................................... 8-5
8.7 Sealing steering rams ....................................................................................................................................................... 8-6
8.8 Checking the steering valve ............................................................................................................................................. 8-9
8.9 Checking a steering ram ................................................................................................................................................ 8-10
8.10 Overview of steering ram setting .................................................................................................................................... 8-10
8.11 How to check and set the steering rams ........................................................................................................................ 8-11
8.12 Checking the track setting (1) ......................................................................................................................................... 8-12
8.13 Correcting the track setting (2) ....................................................................................................................................... 8-12
8.14 Steering misalignment during final-position synchronisation (3) .................................................................................... 8-13
8.15 Checking steering synchronisation (4) ........................................................................................................................... 8-14

Table of Contents
9 Hydraulic system
9.1 Overall hydraulics diagram ................................................................................................................................................ 9-2
9.2 Hydraulics legend .............................................................................................................................................................. 9-3
9.3 Load stabiliser/float position (electrical diagram) .............................................................................................................. 9-6
9.4 Load stabiliser/float position (hydraulics diagram) ............................................................................................................ 9-8
9.5 Quickhitch (electrical diagram) ........................................................................................................................................ 9-10
9.6 Quickhitch (hydraulics diagram) ...................................................................................................................................... 9-12
9.7 Additional function (electrical diagram) ........................................................................................................................... 9-14
9.8 Additional function (hydraulics diagram) ......................................................................................................................... 9-16
9.9 Test report ....................................................................................................................................................................... 9-17
9.10 Work hydraulics oil supply ............................................................................................................................................... 9-18
9.11 Work hydraulics circuit .................................................................................................................................................... 9-19
9.12 Circuit: auxiliary hydraulics .............................................................................................................................................. 9-20
9.13 Load stabiliser circuit ....................................................................................................................................................... 9-21
9.14 Circuit: electrical 3rd control circuit ................................................................................................................................. 9-22
9.15 Circuit: tipping trailer ....................................................................................................................................................... 9-23
9.16 Control valve connections (overview) ............................................................................................................................. 9-24
9.17 Control valve secondary valves (overview) ..................................................................................................................... 9-25
9.18 Pressure relief valve of control valve (overview) ............................................................................................................. 9-26
9.19 Checking and setting the work hydraulics ....................................................................................................................... 9-27
9.20 Load stabiliser ................................................................................................................................................................. 9-28
9.21 Checking and adjusting the load stabiliser ...................................................................................................................... 9-29
9.22 Front/rear additional control circuit function .................................................................................................................... 9-30
9.23 Using the 3rd electrical control circuit plus the additional control circuit ......................................................................... 9-31
9.24 Valve: electrical 3rd control circuit ................................................................................................................................... 9-32
9.25 Lift ram: sealing work ...................................................................................................................................................... 9-33
9.26 Tilt ram: sealing work ...................................................................................................................................................... 9-34
9.27 Control ram (quickhitch frame): sealing work .................................................................................................................. 9-35

Table of Contents
10 Electrical system
10.1 Cab wiring harness ......................................................................................................................................................... 10-2
10.2 Cab wiring harness legend ............................................................................................................................................. 10-3
10.3 Frame wiring harness ..................................................................................................................................................... 10-8
10.4 Frame wiring harness (legend) ....................................................................................................................................... 10-9
10.5 Cab (option) wiring harness ......................................................................................................................................... 10-12
10.6 Cab (option) wiring harness legend .............................................................................................................................. 10-13
10.7 Working light, rotating beacon (electrical diagram) ...................................................................................................... 10-16
10.8 Lights (electrical diagram) ............................................................................................................................................ 10-18
10.9 Turn indicator/horn (electrical diagram) ........................................................................................................................ 10-20
10.10 Heating/air conditioning (electrical diagram) ................................................................................................................ 10-22
10.11 Seat contact switch, front socket, fuel preheater (electrical diagram) .......................................................................... 10-24
10.12 Multimedia, window heating, Telematic GPS (electrical diagram) ............................................................................... 10-26
10.13 Wiper/washer system, cigarette lighter (electrical diagram) ......................................................................................... 10-28
10.14 Wiring harness: alternator with 80 A ............................................................................................................................ 10-29
10.15 Wiring harness: alternator with 50 A ............................................................................................................................ 10-30
10.16 Additional valves wiring harness .................................................................................................................................. 10-31
10.17 Ohm’s Law (current, voltage, resistance); power ......................................................................................................... 10-32
10.18 Measuring equipment, measuring methods ................................................................................................................. 10-32
10.19 Terminal description ..................................................................................................................................................... 10-33
10.20 Colour coding of electric lines ...................................................................................................................................... 10-37
10.21 Switching relay function ................................................................................................................................................ 10-39
10.22 Electric units/light bulbs ................................................................................................................................................ 10-40
10.23 Connector description (overview) ................................................................................................................................. 10-40
10.24 Fuses ............................................................................................................................................................................ 10-41
10.25 Switch assignment on board (overview) ....................................................................................................................... 10-44
10.26 Overview of front switch assignment ............................................................................................................................ 10-45
10.27 Control lever ................................................................................................................................................................. 10-46
10.28 Joystick outputs (overview) .......................................................................................................................................... 10-47
10.29 3rd electrical control circuit (overview) ......................................................................................................................... 10-48
10.30 Auxiliary hydraulics overview ....................................................................................................................................... 10-49
10.31 Steering-column control lever S012 ............................................................................................................................. 10-50
10.32 Plug-and-socket connections of steering-column control lever .................................................................................... 10-51
10.33 Overview: cab retrofitting (wiring) ................................................................................................................................. 10-52
10.34 Retrofitting a rear 7-pole socket ................................................................................................................................... 10-54
10.35 Retrofitting a front 4-pole socket .................................................................................................................................. 10-54

Table of Contents
Cab overview, use, operation
1 Cab overview, use, operation Machine

Outside view
Inside view
1.1 Machine outside view

Pos. Description
1 Bracket for warning stripe (option)
2 Headlights with turn indicators
3 Radio aerial (option)
4 Left/right rearview mirrors
5 Front working light (option)
6 Protective FOPS screen (option)
7 4 eye hooks for removing the cab1
4 5 6 7 8 9 10 11 12 13 8 Door arrester
9 Rear left working light
3
10 Rotating beacon (option)
11 Backup warning system (option)
2
12 Numberplate bracket with light (option)
13 Rear right working light (option)
1 14
14 Engine cover lock
15 Turn indicator/brake/rear lights and reflectors
16 Rear hooks for loading/tying down the machine (left/right)
17 Quickhitch couplers for additional control circuit (option)
18 Towing gear2 or automatic trailer coupling (option)
19 Handle
20 Socket for hydraulic oil preheater (option)
21 Safety strut for loader unit
26 25 24 23 22 21 20 19 15 16 18 17 16 15
22 Wheel chock
23 Bracket for numberplate and warning stripe (option)
24 Hooks for loading/tying down the machine at front of frame (left/right)
25 Front towing gear2
26 Front-edge protection
1. Eye hooks are for removing the cab only, and may not be used for crane handling the machine.
2. Not certified as a trailer coupling and for loading or tying down the machine.
1-2 Serv-HB 34900/01 – Edition 1.0 * 34901_0110_a3_Übersicht-Bedienung.fm

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1.2 Inside of cab (overview)
Inside of cab (overview)

15
1 Sun visor
2 Front and left/right window air vents ...................................................................................................................................................
16 3 Timer – auxiliary heating programming (option) ..................................................................................................................................
4 Interior light ..........................................................................................................................................................................................
5 Radio (option)
17 6 Side window opener and lock (left/right) ..............................................................................................................................................
7 Accelerator pedal .................................................................................................................................................................................
8 Low-speed control (option) ..................................................................................................................................................................
18
36 9 Manual throttle (option) ........................................................................................................................................................................
10 Joystick and 3rd control circuit lock for road travel ..............................................................................................................................
2 19 11 Control lever (joystick) ........................................................................................................................................................................
12 Lock/unlock – arrester for open side window (left/right)......................................................................................................................
35 13 3rd control circuit control lever (quickhitch)..........................................................................................................................................
14 Fire extinguisher (option) .....................................................................................................................................................................
2 15 Hazard warning switch.........................................................................................................................................................................
16 Relay bracket – special equipment and options ..................................................................................................................................
20
17 Loudspeakers (option)
18 Rear window wiper motor ....................................................................................................................................................................
19 Arrester for open side window (left/right) .............................................................................................................................................
21 20 12 V socket
21 Board – relays and fuses (under the switch console) ..........................................................................................................................
34 22 Preheating start switch for diesel engine .............................................................................................................................................
23 Storage net for documents
22 24 Seat......................................................................................................................................................................................................
25 Document box (only for machines with canopy option)
26 Brake fluid tank (LHM) .........................................................................................................................................................................
27 Storage – first-aid kit, warning triangle, tool bag, etc.
33
28 Seat belt ...............................................................................................................................................................................................
23 29 Hook
30 Parking brake lever ..............................................................................................................................................................................
31 Fresh air filter for cab and heating .......................................................................................................................................................
32 Brake/inching pedal .............................................................................................................................................................................
32 31 12 30 29 28 27 26 19 25 17 24 33 Outside door handle with lock..............................................................................................................................................................
34 Washer system tank ............................................................................................................................................................................
35 Multifunctional lever – turn indicators, wipers, horn .............................................................................................................................
36 Front window wiper motor ...................................................................................................................................................................
Serv-HB 34900/01 – Edition 1.0 * 34901_0110_a3_Übersicht-Bedienung.fm 1-3

44 45
46 1.3 Instrument panel, multifunctional lever, switch consoles (overview)
43 47 56 57
Pos. Indicator lights on indicating instrument 68 Switch – forwards/reverse driving direction
48 37 Differential lock indicator light (green) 69 Tip switch – driving direction in neutral
42
38 Load stabiliser, hose burst valve (option) indicator light (yellow) 70 Switch – 3rd control circuit (quickhitch lock/unlock) (option)
49 39 Not assigned 71 Differential lock tip switch (option for model 349-00)
41
40 Right/left turn indicator light (green) for rear attachments/trailer Switch console (A) For more information see page
41 Right/left turn indicator light (green) 72 Lights switch (grey)
50
42 Hydraulic oil temperature indicator light (red) 73 Switch with lock (green) – switching the 3rd control circuit ON/OFF
40
(option)
43 Hydraulic oil filter indicator light (red)
51 74 Switch with lock (green) – continuous operation of 3rd control circuit
44 Diesel engine coolant temperature indicator light (red)
58 59 60 61 62 63 (option)
39 45 Alternator charge function indicator light (red)
52 75 Switch (green) – emergency lowering of loader unit with hose burst
46 Parking brake indicator light (red) valve (option)/ quickhitch lock (option)
38 53 47 Engine oil pressure indicator light (red) 76 Switch (grey) – heated rear window (option)
37 54 48 Tank gauge (fuel)
55 77 Switch (green) – front or rear additional control circuit (option)
49 Indicator light (red) – 3rd control circuit (hydraulics) Switch console (B) For more information see page
50 High beam indicator light (blue)
78 Switch (green) – load stabiliser (option)
51 Cold starter indicator light (yellow)
79 Switch (grey) – front working light (option)
52 Service interval indicator light (yellow),
80 Switch (grey) – rotating beacon (option)
53 Water separator (fuel filter) indicator light (red)
64 65 35 11 66 81 Switch (grey) – front working light (standard on left, option on right)
54 Air filter indicator light (red)
82 Not assigned
67 55 Hour meter
83 Tip switch (green) – raise/lower hydraulic tipping trailer during trailer
Heating/ventilation switch consoleFor more information see page operation (option)
68 56 Rotary switch – heating temperature
57 Rotary switch – heater fan (heating, ventilation)
70
69 Front left/right switch consoleFor more information see page
71 58 Tip switch (grey) – front socket with two circuits (option)

59 Air conditioning (option) switch (grey)
60 Switch with lock (green) – front/rear additional control circuit (option)
77 61 Drive range selection switch (blue)
62 Switch with lock (blue) – 4 wheel/front axle steering (option)
76 A 83 B
63 Indicator light (green) – front axle steering/4 wheel steering (option)
75 82 Multifunctional lever turn indicators, wipers, hornFor more informa-
tion see page
74 81 64 Horn tip switch
65 Rotary switch and tip switch – front wiper, washer pump
73 80
Control lever (joystick)For more information see page
72 79 66 Front socket tip switch (option)
67 Switch – front additional control circuit (option)
78
1-4 Serv-HB 34900/01 – Edition 1.0 * 34901_0110_a3_Übersicht-Bedienung.fm

1.4 Legal regulations regarding wheel loader operation

Principal regulations for the operating staff
• Read and understand the Operator’s Manual before putting the machine into service!
➥ Pay particular attention to the chapter on safety in the Operator’s Manual
• Be sure to observe the “Safety and Warning Instructions” labels on the wheel loader!
• Have damaged or illegible safety instructionss immediately replaced by new ones!
• Transporting accompanying persons in the cab, on the wheel loader or in/on the attach-
ments is not allowed!
• Driving or operating the wheel loader outside the operator’s compartment is not
allowed!
➥ Put the machine into operation only when seated
• Before leaving the seat, lower the loader unit completely, apply the parking brake, stop
the diesel engine and remove the ignition key!
• The wheel loader may not be used for applications with lifting gear
• As a self-propelled work machine, the wheel loader may not be used for transport
jobs on public roads!
If this machine is licensed for agriculture and forestry, the national regulations and laws
apply (see also the “Data Confirmation and Licence Certificate” of the wheel loader)!
Driving licence
Wheel loaders may be driven on public roads only if the driver has a driving licence for the
machine, as defined by national traffic regulations.
German traffic regulations require one of the following driving licences for driving the wheel
loader:
Driving licence category L (new, European Union)
• Self-propelled work machines up to 25 kph
• Tractors and agricultural or forestry machinery up to 32 kph (with trailer 25 kph)
Driving licence category C (new, European Union)
• Motor vehicles with over 3500 kg gross weight rating (with trailers up to 750 kg)
Driving licence category C1 (new, European Union)
• Motor vehicles between 3500 and 7500 kg gross weight rating (with trailers up
to 750 kg)
Driving licence category CE (new, European Union)
• Motor vehicles with over 3500 kg gross weight rating (with trailers over 750 kg)
Driving licence category T (new, European Union)
• Self-propelled work machines for agriculture and forestry up to 40 kph
• Tractors and agricultural or forestry machinery up to 60 kph
Get informed on and follow the legal regulations of your country.
Serv-HB 34900/01 – Edition 1.0 * 34901_0110_Verwendung.fm 1-5

Licence/identification
§ 3 FZV (German vehicle licensing ordinance) requires self-propelled work machines
with maximum speeds over 20 kph to be fitted with their own numberplates in accord-
ance with §8 FZV (German vehicle licensing ordinance).
§ 4b of FZV (German vehicle licensing ordinance) requires owners of self-propelled
work machines with maximum speeds below 20 kph to affix their first name, surname and
place of residence (company and registered office) in indelible print on the left side of their
machines. This does not apply to machines certified for agricultural and forestry applica-
tions.
Machine inspections
When operating the machines, the national safety regulations must be followed as well, for
instance in Germany, the regulations for accident prevention “Deutsche Prüfstelle für
Land- und Forsttechnik” (DPLF German inspection and certification body for agriculture
and forestry) and the accident prevention regulation “Fahrzeuge (vehicles)” (BGV D29 §
57 clause 1).
In Germany, legislation requires all machine operators to have all machines and equip-
ment inspected regularly (BGV A1/BetrSichV §10).
Inspections must be carried out as required, but at least once a year, by an expert and
must be documented in written form. Subsequent inspections of detected defects must be
carried out, too.
A The competent inspection authority may require the inspection report to be available at the
place where the machine is used.
☞ Affix inspection label A for evidence (see example on the left)
Fig. 1: Example: inspection label ➥ The inspection tag can be acquired from the inspection authorities
Bear in mind that all work equipment is inspected, i.e. not only the machine but also all
technical auxiliary means, tools and attachments. (Work equipment is defined as all tools,
attachments, machines or systems.)
This requirement is met, for instance, if the results are documented in a test logbook, a test
log file or in a test report; see also policy of German employers’ liability insurance associa-
tion for construction engineering “Inspection of vehicles by experts” (BGG 916).
1-6 Serv-HB 34900/01 – Edition 1.0 * 34901_0110_Verwendung.fm

Documents
German traffic regulations require to have the following documentation on board, e.g.:
• General Certification for Vehicles (Germany) or Data Confirmation (Germany), Licence
Certificate (Germany)
• Driving licence
• Test report according to BGV D29 § 57 clause 2 (safety and health regulations of
German employer’s liability insurance association)
• Operator’s Manual and supplements
On-board equipment
§ 53 StVZO (German road traffic regulations) requires the following equipment to be sup-
plied by the operator and to be fitted on the machine, for instance:
• 1 warning triangle with design certification
• 1 warning light with design certification
• 1 first-aid kit in accordance with the legal regulations of your country
Machine warning identification (option)

From 01.10.1998 onwards, § 52 clause 4.1 of StVZO German road traffic regulations
requires wheel loaders that are used on public roads for the construction and maintenance
of roads, and for the cleaning of roads or facilities, to be fitted with the red and white warn-
ing identification as per DIN 30 710 in connection with a yellow rotating beacon (option).

1.5 Fields of application and using a machine with an attachment

Important notice, use of attachments
The attachments will decide in the first place how the machine is used.
Caution!
In order to avoid damage to the machine, mounting attachments from other
manufacturers is only allowed if they correspond to the description in chapter
“Operation”. The following table lists the certified attachments with the possible
applications!
Please refer to the General Certification for Vehicles (Germany) or the data confirma-
tion (Germany) for information on the authorised attachments and the specific require-
ments!
Attachments listed neither in the General Certification for Vehicles (Germany) nor in the
Data confirmation (Germany) require a Separate Certification for Vehicles (Germany)
made out by the competent authority!
German road traffic regulations prohibit driving on public roads with an attachment if the
distance between the front edge of the bucket and the centre of the steering wheel is over
3500 mm in transport position.
Overview of certified attachments

ISO 7546
Wheel Part no. Dimensions capacity
Description of attachment Use
loader (model) mm (in) struck/heaped
m3
1650 (64.96) with teeth
1000275101
349-00 1650 (64.96) without 0.35/0.55 Loosening, picking up, transport-
1000275244
teeth ing and loading loose or solid
Bucket (normal material)
1650 (64.96) with teeth material (material density  p =
1000260472 1.8 t/m³)
349-01 1650 (64.96) without 0.55/0.65
10002613571
teeth
Picking up, transporting and load-
Bucket 349-00 1850 (72.83) without
1000266449 0.65/0.8 ing very lightweight material
(lightweight material) 349-01 teeth
(material density  p = 1.3 t/m³)
Picking up, transporting and load-
Bucket 349-00 1850 (72.83) without
1000266582 0.9/1.1 ing very lightweight material
(superlightweight material) 349-01 teeth
(material density  p = 0.9 t/m³)
1650 (64.96) with teeth Grading, removing and scraping
1000260700
349-00 1650 (64.96) without vegetation, for example; picking
1000260527
teeth up and evenly spreading material;
Multipurpose bucket2 0.4/0.5
1650 (64.96) with teeth grabbing bulky material; loading
1000275259 trucks (material density  p = 1.8 t/
349-01 1650 (64.96) without
1000275273 m³)
teeth
349-00 Picking up and transporting pallets
Pallet forks2, 3 1000237357 1000 (39.37) –
349-01 and stacked material
1. With screwed-on blade
2. See the Operator’s Manual of the attachment for putting the attachment into operation and using it
3. Not authorised for use on public roads (Federal Republic of Germany)

Type labels and component numbers

Explanation of “Book” symbol
The “Book” symbol on the signs and type labels indicates that the Operator’s Manual
contains more detailed information and explanations.
Fig. 2: Explanation of “Book” symbol
Serial number
The serial number A is stamped on the machine frame (next to the mudguard attachment,
at the front right). It is also located on the type label B.
The CE mark on the type label means that the machine meets the requirements of the
A Machine Directive (2006/42 EC) and that the conformity procedure has been carried out.
Example: type label
1 Machine designation Wheel loader (650)
2 Serial no. 349 01 0020
3 Machine model 349
4 Output (kW) 35 (46.94 hp)
1 5 Machine model/version 349-01
2 6 Dead weight (kg) 3800 (8377.4 lbs.)
3 4 5 7 Transport weight (kg) –
6 7
8 Gross weight rating (kg) 4500 (9920.6 lbs.)
8 9
10 11 9 Maximum payload (kg) –
10 Front gross axle weight rating (kg) 3200 (7054.7 lbs.)
12 13
14 15 11 Rear gross axle weight rating (kg) 3200 (7054.7 lbs.)
16 17 12 Gross unbraked trailer weight rating (kg) 1 –
Fig. 3: Type label: location
13 Gross braked trailer weight rating1 –

overrun brake (kg)
14 Gross braked trailer weight rating1 (kg) –
overrun brake (1 axle)
15 Gross trailer weight rating1 (kg) –
(compressed-air brake)
16 Check number of EU approval See also the General Certification for
for machines with agricultural or forestry Vehicles (Germany) or the data confir-
licence mation (Germany)
17 Year of construction 2012
Other information – see chapter 2 “Specifications” on page 2-1
1. The trailer coupling option is only for machines with agricultural or forestry registration

Cab number
The type label (arrow) is located in the cab, on the top right frame member.
Fig. 4: Cab type label
Engine number
The type label (arrow) is located on the cylinder-head cover (engine).
• Example:Yanmar 46557
Fig. 5: Diesel engine number
Variable displacement pump number

The type label (arrow) is located on the variable displacement pump housing (flanged on
the diesel engine).
Fig. 6: Hydraulic pump type label

Variable displacement motor number

Seen on lower side of machine.
The type label (arrow) is located on the housing of the variable displacement motor (rear
axle).
Fig. 7: Variable displacement motor type label
Number of transfer gearbox

The type label (arrow) is located on the housing of the transfer gearbox (rear axle).
Fig. 8: Gearbox type label
Front or rear axle number

The type label is located on the axle support (arrow).
➥ Rear axle (on the left in driving direction)
Fig. 9: Rear axle and gearbox type label

Notes:

Specifications
2 Specifications
Specifications
2.1 Models and trade names (overview)

Wheel loader model Trade name
349-00 550
349-01 650
2.2 Frame
Sturdy steel sheet frame, rubber-mounted engine
2.3 Engine
Wheel loader models 349-00/349-01
Product Yanmar
Type 4TNV 88 (BKNKR)
Design Water-cooled 4 stroke diesel engine
Number of cylinders 4
Displacement 2190 cm³
Nominal bore and stroke 88 x 90 mm
35 kW
Output (kW) as per ISO
at 2800 rpm
Max. torque 136.3 Nm at 1680 rpm
Max. engine speed without load 2995 rpm
Idling speed 1100 rpm
Specific fuel consumption 266 g/kWh
Fuel injection system Direct injection
Firing order 1–3– 4–2
Glow plug
preheating time
Starting aid
above 0 °C about 10 – 15 seconds
below 0 °C about 15 – 30 seconds
30° in all directions
Max. inclined position (engine no longer
Observe the tilting limit1 (20° laterally) of the
supplied with oil):
machine!
Exhaust values according to 97/68 KA * 2004/26 EC
1. Loader unit in transport position
2-2 Serv-HB 34900/01 – Edition 1.0 * 34901_0210_Technische Daten.fm

Specifications
2.4 Drive
Variable displacement pump
Automotive, infinitely variable hydrostatic axial-piston gear-
Design
box
Displacement 0 – 40 cm ³/rev
Max. operating pressure 460 bar
Starting engine speed 1250 – 1350 rpm at 50 bar HP
Speed-sensitive, hydraulic displacement adjustment with
Control
pressure cutoff
Driving direction Electrohydraulic control
Inching Inching valve via brake/inching pedal
Pushing power 26.0 kN1/28 kN2
Boost pump integrated in variable displacement pump
Design Internal gear pump
Displacement 11.6 cm³/rev
Charging/boost pressure 25 – 30 bar at 2800 rpm
1. Model 349-00 with tyres 10.5-18

2. Model 349-01 with tyres 12.0-18
Serv-HB 34900/01 – Edition 1.0 * 34901_0210_Technische Daten.fm 2-3

Specifications
2.5 Front/rear axles

Front axle
Planetary steering and drive axle, rigid screw connection
Design
with frame
Traction is evenly distributed to all 4 wheels by means of
Differential lock1 (100 %)
the cardan shaft
King-pin inclination 7°
Camber 1.5°
Steering angle 38°
Toe-in 0 mm
Track width2 1262 mm (49.7 in)
1. Option for model 349-00

2. Standard tyres 10.5-18 (model 349-00)
Standard tyres 12.0-18 (model 349-01)
Rear axle
Design Oscillating axle carrier suspension on frame
Differential lock None
King-pin inclination 7°
Camber 1.5°
Oscillation  8°
Steering angle 38°
Toe-in 0 mm
1
Track width 1262 mm (49.7 in)
1. Standard tyres 10.5-18 (model 349-00)

Standard tyres 12.0-18 (model 349-01)

Specifications
2.6 Brakes
Service brake
Design Foot-operated hydrostatic disc brake
Location Input shaft – front axle input
Effect On both axles via cardan shaft
Parking brake
Design Manual mechanical disc brake
Location Input shaft – front axle input
2.7 Steering system

Hydrostatic 4 wheel steering with emergency steering fea-
Design
tures
Steering mode 4 wheel steering/front axle steering (option)
Hydraulic pump, steering unit with priority valve, one steering
Assemblies ram per axle, automatic synchronisation in final positions (left
and right)
Displacement (servostat) 60 cm³/rev / steering wheel rotation
Steering pressure 180 bar (2560 psi)
Hydraulic pump (gear
20 cm3/rev (1.22 cu. in./rev)
pump) displacement

Specifications
2.8 Work hydraulics

Hydraulic pump, control valve, hydraulic oil tank
Hydraulic pump Gear pump
20 cm3/rev  56 l/min (1.22 cu. in./rev 14.8 gal/min)
Displacement
at 2800rpm
Max. operating pressure1 235 bar (3345 psi)
Operation: raise/lower with joystick,
Control valve (3-fold) Operation: 3rd control circuit with control lever or
switch on joystick (option)
Return suction filter 0.5 bar (711 psi) pre-tension
Hydraulic oil tank About 58 l (15.33 gal)
1. Measured at control valve test port
Protection: lift, tilt and quickhitch rams

20 cm3/rev  56 l/min (1.22 cu. in./rev 14.8 gal/min)
Hydraulic pump
at 2800rpm
Max. operating pressure1 235 bar (3345 psi)
Tilt ram Rod side 260 bar (3698 psi)
Secondary protection: Base side 120 bar (1707 psi)
Lift ram None on rod side
Secondary protection: Base side 260 bar (3698 psi)
Quickhitch ram
260 bar (3698 psi)
Secondary protection:
1. Measured at control valve test port

Specifications
Lift and tilt ram speed

20 cm3/rev  56 l/min (1.22 cu. in./rev 14.8 gal/
Hydraulic pump min)
at 2800rpm
Raise 4.8 sec
Lift ram
Lower 3.2 sec
Dump in 2.1 sec
Tilt ram
Dump out 2.0 sec
Usable consumer pressure at additional control circuit (option)
Notice !
The specified flow rates are available at the front or rear quick couplers!

Tandem hydraulic pump
Rpm / litres / bar
20 + 14 cm3/rev Function
(rpm / gal / psi)
(1.22 + 0.85 cu. in./rev)
Rear additional control circuit 2800/38/180
(tipping trailer connection) Solenoid valve with electric (2800/10/2560)
actuation via 3rd control circuit 2800/38/180
(2800/9.25/2560)
Front additional control circuit Solenoid valve with electric
(on left of loader unit with exter- actuation with additional con-
nal return) 2800/90/160
trol: 3rd control circuit via
(2800/23.77/2275)
locked control lever or switch
on joystick

Specifications
2.9 Electrical system

Electric units/light bulbs
Description Output
Alternator 12 V 55 A/12 V 80 A (option)
Starter 12 V 2.3 kW
Battery 12 V 74 Ah 680 A
Light bulb – high beam (left/right) 12 V 55 W/H3
Light bulb – low beam (left/right) 12 V 55 W/H7
Light bulb – side marker light (left/right) 12 V 4 W
Light bulb – front and rear turn indicators
12 V 21 W
(left/right)
Light bulb – brake/rear lights (left/right) 12 V 21/5W
Light bulb – working light 12 V 55 W/H3
Light bulb – rotating beacon 12 V 55 W/H1
Light bulb – interior light 12 V 10 W
Checking/replacing the main fuse box and the switching relays

The main fuse box is located in the engine compartment (on the left on the rear wall)
K005 K009 F026 F027
Rated cur-
Fuse Protected circuit
rent (A)
F025 40 A Cutoff solenoid relay
F026 40 A Start high current relay
F027 100 A Main fuse
F028 40 A High-power connection
F025 F028 Relay no. Protected circuit

Fig. 10: Main fuse box
K005 Preheating high current relay
K009 Start high current relay

Specifications
Fuse assignment
Rated cur-
No. Symbol Protected circuit
rent (A)
F001 7.5 High beam (left)
F002 7.5 High beam (right)
F003 5 Side marker light (left)
F004 5 Side marker light (right)
Interior light, glow control unit, hazard warning
F005 10
lamp
F006 15 Front working light, rotating beacon
F007 25 Low/high beam
F008 7.5 Low beam (left)
F7 F6 F5 F4 F3 F2 F1 F009 7.5 Low beam (right)

Cutoff solenoid, indicating instrument,
F010 5
fuel pump
F16 F15 F14 F13 F12 F11 F10 F9 F8
F011 15 Front/rear wiper, horn
F24 F23 F22 F21 F20 F19 F18 F17 F012 7.5 Solenoid valves, load stabiliser
Backup warning system, joystick,
Fig. 11: Fuse assignment F013 7.5
drive solenoid valve
Window heating, air-suspension seat,
F014 25
quickhitch lock
F015 7.5 Turn indicators, brake lights
F016 5 Radio, safe load indicator
F017 10 Front socket
F018 15 Heating fan, air conditioning (option)
Solenoid valve for differential lock and steer-
F019 5
ing modes
Solenoid valve, additional control circuit and
F020 15
air conditioning fan
F021 1 Telematic (option)
F023 15 Rear working lights
F024 15 12 V socket (cigarette lighter)

Specifications
Switching relay assignment on board

The relays are located under the fuse board.
K010 K018
K017 Switching
Protected circuit
relay no.
K003 K001 High current relay
K004 K003 Reverse driving switching relay
K004 Forwards driving switching relay
K016
K010 Switching relay – turn indicators
K027
K016 Not assigned
K023 K017 Switching relay for unlocking the quickhitch (option)
K018 Switching relay for locking the quickhitch (option)
K001
K023 Switching relay for wiper
Fig. 12: Relays on board K027 Step-by-step relay for window heating (option)
Switching relay assignment on bracket

The relays are located under the trim of the control lever console.
B018 K025 K073 K002 K070 K047
Switching
Protected circuit
relay no.
B018 Buzzer
K002 Power supply high current relay
K021 Differential lock switching relay
K021 K030 K053 K075
K025 Intermittent-wipe switching relay
K030 Brake lights
Fig. 13: Relay bracket
K047 Switching relay for rear working light
K053 Air conditioning fan (option)
K070 Switching relay (diesel engine runs)
K073 Switching relay for seat contact switch (option)
K075 Switching relay for additional control circuit (option)

Specifications
2.10 Tyres
Tyres
Tyre pressure
Wheel rims
(bar/psi)
Tyre size1
Wheel offset
Front Rear size
(mm/in)
10.5-182 MPT 10PR 126 G 2.5 2.0
3
12.0-18 NHS 12PR 145 A6 (36 psi) (29 psi)
38
12.0/75-184 12PR TR11 9x18
3.0 2.5 (0.15 in)
TBL 123A8
(43 psi) (36 psi)
325/70 R18 MPT AC70G TL125G
365/70 R18 EM-01 135 B
2.5 2.0 25
335/80 R18 151A2/139B XZSL 11x18
(36 psi) (29 psi) (0.1 in)
340/80 R 18 550 143A8/138D
1. Increase front tyre pressure by 0.5 bar (7.11 psi) during pallet forks operation!
2. Standard tyres for model 349-00/not allowed for “30 kpm high speed” option (18.65 mph)
3. Standard tyres for model 349-01/not allowed for “30 kpm high speed” option (18.65 mph)
4. Not allowed for “30 kph high speed” option
2.11 Weights
Wheel loader model 349-00 349-01
Kerb weight1 with canopy 3450 kg (7606 lbs.) –
Kerb weight1 with cab 3600 kg (7936 lbs.) 3800 kg (8377.4 lbs.)
Gross weight rating 4500 kg (9920.6 lbs.)
Front axle weight rating
3200 kg (7054.7 lbs.)
Rear axle weight rating
1. With standard bucket, without driver and full fuel tank

Specifications
2.12 Noise levels

Noise levels (self-propelled work machines)
Measured value 100.3 dB
Guaranteed value 101 dB
Driver-perceived noise level
79 dB
(cab)
82 dB
(canopy)
Notice!
Measurement of sound power level according to Directives 2000/14 EC, ISO
6395: 1995 and EN ISO 3711: 1995.
Noise levels (agricultural and forestry tractors)

Measured value
73 dB
(stationary)
Measured value
74 dB
(moving)
86 dB
(cab)
83 dB
(canopy)
Notice!
Measurement of sound power level according to Directives 2009/76 EC /
2009/63 EC.

Specifications
2.13 Coolant compound table

Outside temperature Water1 Antifreeze 2
Up to °C (°F) % by volume % by volume
4 °C (39.2 °F) 99 –
−10 °C (14 °F) 79 20
−20 °C (−4 °F) 65 34
−25 °C (−13 °F) 59 40
−35 °C (−31 °F) 55 45
−42 °C (−43 °F) 50 50
1. Water quality at 20 °C (−4 °F) = 6.5 – 8.5 ph/overall hardness 3 – 20 °dGH

2. Antifreeze concentrate −90 °C (−130 °F)
2.14 Vibrations, oscillation and acceleration value

Vibration1
Overall vibration value for upper m
< 2.5 ----- (< 8.2 feet/s²)
extremities of the body s2
Maximum effective value of m

< 0.5 ----2- (< 1.64 feet/s²)
weighted acceleration for body s
1. The driver/operator must be informed of the risks if the vibration values are higher than those indicated (Directive 78/764/EEC)

Specifications
2.15 Tightening torques

General tightening torques
Screw dimen- Tightening torques1

sions 8.8 10.9 12.9
M4 3 Nm (2.2 lbf ft) 4 Nm (2.9 lbf ft) 5 Nm (3.7 lbf ft)
M5 5.5 Nm (4.1 lbf ft) 8 Nm (5.9 lbf ft) 10 Nm (7.4 lbf ft)
M8 23 Nm (17 lbf ft) 34 Nm (25 lbf ft) 40 Nm (29.5 lbf ft)
M14 125 Nm (92.1 lbf ft) 185 Nm (136 lbf ft) 220 Nm (162 lbf ft)
M16 195 Nm (144 lbf ft) 290 Nm (214 lbf ft) 340 Nm (250 lbf ft)
1450 Nm 1700 Nm
M27 1000 Nm (737 lbf ft)
(1069 lbf ft) (1253 lbf ft)
1950 Nm 2300 Nm
M30 1350 Nm (995 lbf ft)
(1437 lbf ft) (1695 lbf ft)
1. These values are valid for screws with untreated, non-lubricated surfaces.
Specific tightening torques

Description Torque
Wheel nut 390 ±10 Nm (287.6±7 lbf ft)

Specifications
2.16 Payloads and capacities

Loader unit with bucket
Bucket Wheel loader model 349-00 Wheel loader model 349-01
1
Bucket capacity ,
heaped, as per 0.55 m³ (1.95 cu. ft.) 0.65 m³ (2.3 cu. ft.)
ISO 7546
Tipping load 1980 kg (4365 lbs.) 2340 kg (5159 lbs.)
Payload2 990 kg (2182 lbs.) 1170 kg (2579 lbs.)
Breakout force:
32.5 kN (23.97 lbf ft)
lift ram
Breakout force:
28 kN (20.65 lbf ft)
tilt ram
Scraping depth 3 −55 mm (−0.22 in)
1. With standard bucket

2. Loader unit in horizontal position
3. With tyres 12.0-18
Loader unit with pallet forks

Loader unit in horizon-
tal position, 500 mm
Wheel loader model 349-00 Wheel loader model 349-01
(19.68 in) load dis-
tance
Payload1
1600 kg (3527 lbs.) 1750 kg (3858 lbs.)
safety factor 1.25
Payload1
1200 kg (2645 lbs.) 1310 kg (2888 lbs.)
safety factor 1.67
Transport position:
movable payload1 1850 kg (4078 lbs.) 2000 kg (4009 lbs.)
safety factor 1.25
Transport position:
movable payload1 1380 kg (3042 lbs.) 1500 kg (3307 lbs.)
safety factor 1.67
1. Applies to pallet forks 1000237357 only (see load diagram)

Specifications
Trailer weight/drawbar load: trailer couplings (option)

Tractors and agricul-
tural or forestry
Gross trailer weight rating1 Gross drawbar load rating
machinery Directive
2003/37 EC
Trailer without brakes 750 kg (1653 lbs.)
Trailer with brakes (1
braked axle) 150 kg (331 lbs.)
3500 kg (7716 lbs.)
Trailer with brakes (all
axles braked)
Ball2 2500 kg (5511 lbs.) 150 kg (331 lbs.)
For the control mark, refer to the machine documentation and the type label on the
trailer coupling
Towing gear (not the
Only certified for towing the machine
trailer coupling)
1. Bucket certified for travel on public roads must be fitted during trailer operation
2. For further indications, see the type label – D-value of ball coupling  17.5

Specifications
2.17 Dimensions with bucket
d
b
a
1700
2390
2470
2590
f 250
280
1780 1850 1320 1262

4950 1650
Fig. 14: Machine dimensions with bucket

– Overall length1, 2 4950 mm (194.9 in)
– Overall width1 1650 mm (64.9 in)
3, 4, 5
– Overall height with cab 2390 mm (94 in)
– Overall height with protective FOPS screen3, 5 2470 mm (97.24 in)
– Overall height, upper edge of engine cover3, 5 1700 mm (67 in)
– Ground clearance in transport position of loader unit 250 mm (9.85 in)
3, 5
– Ground clearance 280 mm (11 in)
a Pin height3, 5 3050 mm (121 in)
b Load-over height3, 5 2900 mm (114.7 in)
c Dump height3, 5 2330 mm (91.7 in)
1
d Dump reach 300 mm (11.8 in)
e Dump-out angle1 42°
f Dump-in angle1 45°
– Front/rear track width3 1262 mm (49.7 in)
– Wheelbase (front/rear axles) 1850 mm (72.8 in)
Turning radius between kerbs3 2700 mm (106.3 in)
–
Between walls1 3550 mm (139.7 in)
1. With standard bucket

2. With towing gear
3. With tyres 12.0-18
4. With rotating beacon + 200 mm (+7.9 in)
5. With tyres 10.5-18 (−10 mm) (−0.39 in)/with tyres 325/70 R18 (−10 mm) (−0.39 in)/
with tyres 365/70 R18 (+10 mm) (+0.39 in)/with tyres 335/80 R18 (+30 mm) (+1.81 in)/
with tyres 340/80 R 18 (+25 mm) (+0.98 in)

Specifications
2.18 Dimensions with pallet forks
d
a
b
c
Fig. 15: Machine dimensions with pallet forks

a Pin height1, 2 3050 mm (194.9 in)
b Pallet height1, 2 2830 mm (111.4 in)
c Dump-in angle in transport position (250 mm) 15°
d Dump-out angle 30°
Turning radius with pallet forks
– 3820 mm (150.4 in)
(horizontal fork arms in transport position)
1. Measured with pallet forks order no. 1000237357 (1000 mm) and tyres 12.0-18
2. With tyres 10.5-18 (−10 mm) (−0.39 in)/with tyres 325/70 R18 (−10 mm) (−0.39 in)/
with tyres 365/70 R18 (+10 mm) (+0.39 in)/with tyres 335/80 R18 (+30 mm) (+1.81 in)/
with tyres 340/80 R 18 (+25 mm) (+0.98 in)

Maintenance and servicing work
3 Maintenance and servicing work

3.1 Explanation of symbols on the maintenance label
Symbol Explanation
Before starting maintenance work, follow the safety instructions in the Operator’s Manual!
Before starting maintenance work, read the “Maintenance” chapter in the Operator’s Manual!
Carry out a functional check of the light system!
Check tyres for damage, pressure and tread depth!
Carry out a functional check and synchronise the steering system!
Carry out a functional check of the brake system!
Check hydraulic oil level. Fill up if necessary!
Check engine oil level. Fill up if necessary!
Compress the dust valve
Check radiator for engine coolant and hydraulic oil for contamination. Clean if necessary!
Check condition and initial tension of V-belt. Retighten or replace if necessary!
Leakage check:
Check for tightness, leaks and chafing: pipes, flexible lines and screw connections. Rectify if necessary!
Leakage check:
Check the fuel/water separator. Drain water if necessary!
Lubrication service:
Lubricate the assemblies concerned!
3-2 Serv-HB 34900/01 – Edition 1.0 * 34901_0330_Wartung.fm

3.2 Maintenance label

Affixed on right-hand window
Serv-HB 34900/01 – Edition 1.0 * 34901_0330_Wartung.fm 3-3

3.3 Fluids and lubricants

Season/temper-
Component/application Engine/machine fluid1 SAE grade Specification Capacities 2
ature
10W-40; EO1040B4
Diesel engine Engine oil3 with oil filter 15W-40; EO1540B4 Year-round About 7.5 l (2 gal)
5
5W-30
Gearbox 20 kph (30 kph option) 0.3 l (0.08 gal)
7
Front or rear axle differentials 3.0 l (0.8 gal) each
Left or right-hand planetary Gearbox oil6 SAE 90 LS (hypoid gear oil) Year-round
drives, 0.5 l (0.13 gal) each
front or rear axles7
HVLPD 46 Year-round
Hydraulic oil8
HVLPD 325 – About 58 l9
Hydraulic system/oil tank
AVILUB Syntofluid 46 (15.32 gal)
Biodegradable oil Year-round
PANOLIN HLP Synth 46
Grease nipples
Lithium-saponified brand-name
Multipurpose grease
grease MPG-A4
loader unit/axles Year-round As required
Battery terminals Acid-proof grease SP-B4
Aggressive media (option) Anticorrosion protection Anticorit BW 36610
DIN 51628/DIN EN 590 (EU) Year-round About 60 l
Fuel system, fuel tank Diesel fuel11, 12
ASTM D975-94 (USA) −40 °C (−58 °F) (15.85 gal)
Brake system Brake fluid13 Agip LHM/Shell LHM – 0.5 l (0.13 gal)
About 0.85 kg
Air conditioning (option)14 Refrigerant R 134a –
(1.9 lbs.)
Water
Radiator – engine and hydrau- 15, 16 Year-round 3.0 l (0.8 gal)
Antifreeze PROCAR Kühlerschutz Extra
lics −28 °C (−18.4 °F) Antifreeze
4.0 l (1.1 gal)
Water
Year-round 0.5 l (0.13 gal)
Washer system Cleaning agent16 Water + antifreeze
−20 °C (−4 °F) Antifreeze
1.0 l (0.26 gal)
1. Bear in mind the safety data sheet when using engine/machine fluids
2. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
3. Specification: MIL-L-2104C; API CD/CE/CH4; CCMC-D4
4. Abbreviation for lubricants (Hauptverband der Deutschen Bauindustrie e. V. – German construction engineering association)
5. Used in Scandinavian countries only
6. Specification: API GL 5 MIL-L-2105 D
7. Capacity indications for each axle or planetary drive
8. DIN 51 524/ISO 11158-HM
9. After an oil change, fill up to the middle of the sight glass (complete new fill of hydraulic system about 75 l/19.8 gal)
10. Specification: TI 8030-015/K 19/MIL-C-16 173 C-Grade 4
11. In order to avoid engine damage, add only additives to the diesel fuel that have been certified by Yanmar!
12. If fuels are used that do not comply with the indicated standards, warranty rights shall not apply in case of diesel engine damage
13. In order to avoid brake system failure, use only LHM brake fluids.
14. Maintenance work must be carried out by trained technical staff only
15. Factory fill – antifreeze concentrate −60 °C (−76 °F)
For complete refill, see manufacturer indications on the packaging
16. Have the coolant replaced every 2 years by an authorised workshop

3.4 Maintenance plan

Important notice on the maintenance plan
For service and maintenance work on the attachment, please refer to the Operator’s and
maintenance manual of the attachment manufacturer as well.
Have maintenance work, the Delivery Inspection, the 1st Inspection at 100 s/h and the 2nd
Inspection every 500 and 1500 s/h (once a year) carried out by an authorised workshop,
otherwise warranty claims will not be acknowledged.
Maintenance plan overview
Work-
Operator/driver Workshop
shop
Maintenance work
2nd Inspection1
1st Inspection1
every 1500 s/h

every 500 s/h
(once a day)
Every 20 s/h
once a year
Work description inspection
at 100 s/h
Delivery
“A”
“B”
“C”
Oil and filter changes, fan bearing ( )
• Change the engine oil ● ● ●
• Replace the engine oil filter ● ● ●
• Replace fuel filter, fuel prefilter ● ● ●
• Replace the2 air filter insert ● ●
3
• Replace the safety cartridge of the air filter insert ●
• Gearbox oil in rear axle gearbox ● ●
• Gearbox oil in differential (front and rear axles) ● ●
• Gearbox oil in left and right-hand planetary drives (front and
● ●
rear axles)
• Replace the hydraulic oil4 ●
• Replace the hydraulic oil filter insert ● ●
• Replace the hydraulic oil tank breather filter 3 ●
5
• Replace the fine-dust filter of the heating ● ●
Inspection work ( ):
• Check engine oil level ● ●
• Check hydraulic oil level ● ● ● ● ●
6
• Check coolant level ● ● ● ● ●
• Check gearbox oil level in front and rear axle differential ● ● ● ●
• Check gearbox oil level in gearbox ● ● ● ●
• Check gearbox oil level in front and rear axle, left and right
● ● ● ●
planetary drives
• Check brake fluid (LHM) level6 ● ● ● ● ●
7
• Check water/oil cooler for dirt and clean if necessary ● ● ● ●
• When using biodegradable oil: drain the condensation water
● ●
in the hydraulic oil tank 4
• Clean dust valve on air filter housing 2 ● ● ● ● ●
Serv-HB 34900/01 – Edition 1.0 * 34901_0340_Wartungsplan.fm 3-5

Work-
shop
Maintenance work
2nd Inspection1
1st Inspection1
every 1500 s/h

every 500 s/h
(once a day)
Every 20 s/h
once a year
Work description
inspection
at 100 s/h
Delivery
“A”
“B”
“C”
• Check condition and pre-tension of V-belts. Retighten or
● ● ● ● ●
replace if necessary
• Drain the water in the fuel/water separator ● ● ● ●
• Check valve clearance (engine management). Set if neces-
● ● ●
sary
• Check battery charge condition. Charge if necessary8 ● ● ●
• Clean the fine-dust filter of the heating system (replace every
● ● ●
500 s/h)
• Check and set service and parking brake pads9. Replace if
● ● ●
necessary
• Tyre check (damage, air pressure, tread depth) ● ● ● ● ●
9
• Check condition of trailer couplings (option). Replace if
● ● ● ●
necessary
• Aggressive media (option): check anticorrosion protection,
● ● ● ●
renew if necessary 10
Check screws and nuts or screw connections for tightness on the following assemblies/components. Retighten if necessary
• Engine and engine bearing ● ● ●
• Steering system9 ● ● ●
• Hydraulic system ● ● ●
• Loader unit (pin locking) ● ● ●
• Axle mounting, axle suspension ● ● ●
• Counterweight (attachment) ● ● ●
• Fastening screws of cardan shafts ● ● ●
• Fastening screws of cab ● ● ●
• Wheel nuts ● ● ● ●
• Fastening screws of trailer coupling (option) ● ● ● ●
• Electrical system: check electric and earth connections,
● ● ● ●
chafing on wiring harness, battery terminals
3-6 Serv-HB 34900/01 – Edition 1.0 * 34901_0340_Wartungsplan.fm

Work-
shop
Maintenance work
2nd Inspection1
1st Inspection1
every 1500 s/h

every 500 s/h
(once a day)
Every 20 s/h
once a year
Work description
inspection
at 100 s/h
Delivery
“A”
“B”
“C”
Lubrication ( ):11 (Note: lubricate more frequently when in heavy-duty operation!)
• Hinges, joints (e.g. door arresters) ● ● ● ●
• Rear axle oscillating bearing ● ● ● ● ●
• Front and rear axle planetary drive bearings (left and right) ● ● ● ● ●
• Trailer coupling – joint (option) ● ● ● ● ●
Loader unit – see Lubrication work on the loader unit on page 3-39
• Lift frame bearing ● ● ● ● ●
• Tilt rod bearing ● ● ● ● ●
• Tilt lever bearing ● ● ● ● ●
• Lift ram bearing ● ● ● ● ●
• Tilt ram bearing ● ● ● ● ●
• Quickhitch: bearing on lift frame ● ● ● ● ●
Functional check ( ):
• Service and parking brake ● ● ● ● ●
9
• Steering system synchronous position of wheels ● ● ● ● ●
• Electrical system – lights, indicator lights, signalling system,
● ● ● ● ●
washer system
• Air conditioning (option) ● ● ● ● ●
9
• Trailer couplings (option) ● ● ● ● ●
• Drive interlock (option) ● ● ● ● ●
• Seat adjustment, seat belt ● ● ● ● ●
• Lock – control lever (joystick) and 3rd control circuit (road
● ● ● ● ●
travel)
• Loader unit load stabiliser (option) ● ● ● ● ●
• Front and rear additional control circuits (option) ● ● ● ● ●
Serv-HB 34900/01 – Edition 1.0 * 34901_0340_Wartungsplan.fm 3-7

Work-
shop
Maintenance work
2nd Inspection1
1st Inspection1
every 1500 s/h

every 500 s/h
(once a day)
Every 20 s/h
once a year
Work description
inspection
at 100 s/h
Delivery
“A”
“B”
“C”
Leakage check ( ): Check for tightness, leaks and chafing: pipes, flexible lines and screw connections. Have rectified by an author-
ised workshop if necessary.
• Air intake line12 (air filter – engine) ● ● ● ● ●
• Engine lubrication (engine – filter) ● ● ● ● ●
13
• Fuel lines ● ● ● ● ●
• Cooling system (engine – hydraulic oil) ● ● ● ● ●
9
• Steering system (flexible lines and steering rams) ● ● ● ● ●
• Hydraulic system (flexible lines14 and rams) ● ● ● ● ●
9
• Brake system (flexible lines and cylinders) ● ● ● ● ●
• Air conditioning system (option) – flexible lines, condenser,
● ● ● ● ●
dehumidifier
1. Have the 1st Inspection at 100 service hours and the 2nd Inspection at 500 service hours carried out by an authorised workshop otherwise warranty claims will not be acknowledged
2. Replace filter insert at least every 12 months or 1500 s/h.
3. When working in an acidic environment, replace the filter every 300 s/h!
4. When using biodegradable oil: drain the condensation water in the hydraulic oil tank every 500 s/h, in any case before the cold season.
5. Depending on operation and dust conditions, it may be necessary to replace the fine-dust filter more frequently
6. Replace every 2 years
7. Clean radiator more frequently depending on operation and dust conditions.
8. Make a note of the date the battery is charged
9. Safety part! All maintenance and repair work must be carried out by an authorised workshop
10. See maintenance instructions for aggressive media, order no. 1000108296
11. Observe the manufacturer’s indications for lubrication of the attachment!
12. In order to avoid engine damage, have air intake lines with cracks and chafe marks immediately replaced by an authorised workshop
13. Replace flexible fuel leak oil lines every 2 years (plastic lines)
14. Replace flexible lines every 6 years (DIN 20066 part 5)
3-8 Serv-HB 34900/01 – Edition 1.0 * 34901_0340_Wartungsplan.fm

3.5 Maintenance staff

Operational readiness and the service life of the machine are heavily dependent on main-
tenance.
• Daily and weekly service and maintenance work must be carried out by a specifically
trained driver
• Maintenance work that is not described in the Operator’s Manual must be carried out
only by the trained and qualified staff of an authorised workshop.
• The manufacturer shall not be liable for damage or personal injury caused by failure to
observe a specific manual!
• Please contact your dealer if you require more information on maintenance work.
Notice!
Refer to the maintenance plan for the maintenance work
– see Maintenance plan on page 3-5.
Insist on using original spare parts for repairs.
The machine’s permits, certifications, registrations, etc., may be withdrawn if
machine parts/components with a prescribed condition or quality, or machine
parts/components that can put persons at risk during operation, are subse-
quently modified or exchanged.
3.6 Important information on maintenance and service work
Notice!
Refer to the maintenance plan for the maintenance work.
• – see Maintenance plan on page 3-5
Before carrying out service and maintenance work, always ensure that:
• the machine is parked on level and firm ground and that it cannot roll away under its
own weight.
• the engine is stopped and the ignition key removed.
• the cable on the negative terminal (−) of the battery is disconnected before starting
welding or repair work on the electrical system!
• the key is removed if the machine is equipped with the “Battery master switch” option.
• the maintenance and safety instructions in the Operator’s Manuals of the attachments
are observed.
Danger!
Do not carry out assembly and maintenance work if the loader unit is raised
and not secured – danger of crushing and injury!
☞ Secure the loader unit with an appropriate prop or support to prevent it from
being lowered unintentionally
☞ Stop the engine and remove the ignition key
☞ Apply the parking brake

3.7 Fuel system

Safety instructions for refuelling
• Extreme caution is essential when handling fuel – high risk of fire!
• Never carry out work on the fuel system in the vicinity of naked flames or sparks!
• Do not smoke when working on the fuel system or when refuelling!
• Before refuelling, stop the engine and remove the ignition key!
• Do not refuel in closed rooms!
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner! Keep the machine clean to reduce the risk of
fire and wipe away fuel spills immediately!
Diesel fuel specification
Caution!
In order to avoid engine damage, use only the diesel fuel specified in the table!
• If other fuels are used, warranty rights shall not apply in case of diesel
engine damage (guarantee)!
• When adding additives to the diesel fuel, use only the ones authorised by
YANMAR
• Please contact your dealer if you require more information on fuel
Cetane
Specification Use (°C)
number
DIN 51628/DIN EN 590 (EU),

Min. 49 Up to -44 °C outside temperature
ASTM D975-94 (USA)
EN 14214 (biodiesel) Min. 51 Up to -20 °C outside temperature
Stationary fuel pumps

Important notice
Wrong ✗ Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually contaminated.
Even small dirt particles cause increased engine wear and fuel system malfunctions, and
reduce fuel filter effectiveness.
Refuelling from barrels
If refuelling from barrels cannot be avoided, note the following points:
Right ✓ • Barrels must neither be rolled nor tilted before refuelling
• Protect the suction pipe opening of the barrel pump with a fine-mesh strainer
Fig. 16: Refuelling from a barrel • Immerse it down to a max. 15 cm above the floor of the barrel
• Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter
• Keep all refuelling containers clean at all times

Refuelling
Fuel tank filler inlet A is located on the right-hand side of the machine (cab access).
Danger!
Danger of fire and suffocation!
☞ Do not refuel in closed rooms!
☞ Proceed as follows before filling up the fuel tank:

A • Lower the loader unit to the ground
• Stop the diesel engine and remove the ignition key
Fig. 17: Fuel filler inlet
• Apply the parking brake
• Clean the area around the filler opening before opening the filler cap
• Open the filler cap and fill the fuel tank through the filling screen
Notice!
Fuel may be drained and the fuel tank may be cleaned only by an authorised
workshop!
Bleeding the fuel system
Notice!
If the fuel tank has been run empty, or after having carried out maintenance work
on the fuel system (filter replacement, water separator cleaned), the fuel system
bleeds itself automatically when starting the engine!
Checking/cleaning the water separator

Drain the condensation water every 50 s/h (service hours)
Drain the condensation water in the additional fuel filter at the latest if indicator light 1 on
the indicating instrument comes on.
1 ☞ Proceed as follows:
• Lower the loader unit to the ground
A
B • Place a container to collect the fuel
• Open drain cock A on the additional fuel filter and drain the condensation water
• Close drain cock A
Fig. 18: Bleeding the fuel system • Start the diesel engine and check the additional fuel filter for leaks
Notice!
Have the additional fuel filter A (cartridge) replaced by an authorised workshop
every 500 s/h!

Replacing the fuel filter

B
Danger!
If the fuel, as it drains, comes into contact with hot engine parts or the exhaust
system, there is an increased
A Danger of burns!
☞ Never change the fuel filter if the engine is hot!
Fig. 19: Fuel filter position

Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner!
Change fuel filter 19/A as follows:

☞ Pinch off fuel feed line 19/B with a suitable tool
☞ Thoroughly clean the outside surfaces of fuel filter 19/A
☞ Slacken and unscrew fuel filter cartridge using a commercially available tool
☞ Collect the fuel as it drains
☞ Clean the sealing surface of the filter carrier if it is fouled
☞ Lightly oil the rubber gasket of the new filter cartridge or apply a thin coat of clean diesel
fuel to it
☞ Screw on the cartridge by hand until the gasket makes contact
☞ Tighten the fuel filter cartridge by turning it a further half revolution
☞ Remove the tool which has been used to pinch off the fuel feed line 19/B
☞ Make a test run – and check for tightness!
Fig. 20: Unscrewing the fuel filter ☞ Dispose of the old fuel filter cartridge by an ecologically safe method

3.8 Engine lubrication system

Safety instructions regarding inspections and maintenance work on the engine
Danger!
Danger of burns! Do not carry out maintenance work on a hot engine!
☞ Bear the warning label in mind
☞ Wear protective gloves and clothing during maintenance work
Fig. 21: Label: hot surface
After switching off the engine, wait at least 10 minutes before checking the oil level!
• Check the engine oil level every 10 service hours or once a day before starting work!
• Do not check the oil level if the engine is running!
Checking the engine oil level
Caution!
If the engine oil level is too low or if an oil change is overdue, this can cause
engine damage or loss of output!
☞ Have an authorised workshop carry out the 1st oil change at 100 service
hours, then every 500 service hours
☞ Check the engine oil as follows:

max
• Park the machine on level ground
• Stop the engine and switch off the ignition
min
• Remove the ignition key

• Apply the parking brake and open the engine cover
A • Pull out oil dipstick A and wipe it with a lint-free cloth
• Push the oil dipstick back in as far as possible and pull it back out again
• Read off the oil level
• Fill up the oil when the oil reaches the MIN mark on oil dipstick A
– see Filling up engine oil on page 3-14
Fig. 22: Checking the oil level

Filling up engine oil
Caution!
Too much or incorrect engine oil can result in engine damage!
☞ Do not add engine oil above the MAX mark of the oil dipstick A
B ☞ Use only the specified engine oil – see Fluids and lubricants on page 3-4
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in
an environmentally friendly manner!
max
min
☞ Fill up the engine oil as follows:
• Clean the area around oil filler cap B with a lint-free cloth
• Open filler cap B
A • Pull out oil dipstick A and wipe it with a lint-free cloth
• Fill in engine oil
• Wait a moment until all the oil has run into the oil sump
• Check the oil level with oil dipstick A – see Checking the engine oil level on page 3-
Fig. 23: Filling up engine oil 13
• Fill up oil if necessary and check the oil level again
Close filler cap B and completely remove
all oil spills from the engine
3.9 Changing engine oil
Danger!
Caution when draining hot oil:
Danger of burns!
☞ Wear protective gloves!
☞ Use suitable tools, e.g. for unscrewing the oil drain plug 1!
☞ Change the oil as follows:

☞ Park the machine on level ground
• Let the engine run until it reaches operating temperature (oil temperature about
80 °C)
• Stop the engine
+ 80 °C ☞ Place container for collecting the oil under the engine

➥ (minimum capacity: 12 l)
☞ Open oil drain plug 1
• Completely drain the oil
OIL
1 ☞ Screw in oil drain plug 1 and fill in engine oil
Fig.
Fig.24:
24: Checking
Checkingthe
theoiloillevel
level
• See “Engine/machine fluids” for the oil type and capacities

☞ Start the engine and let it run briefly at low speed

☞ Stop the engine
• Wait a moment until all the oil has run into the oil sump
☞ Check the oil level again
• Fill up if necessary and check again
☞ Completely remove all oil spills from the engine
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in
3.10 Washer system tank

Refilling washer fluid
Tank filler inlet 1 is located in the cab to the left of the seat.
1 Notice!
MAX Fill with clean tap water only!
Add a suitable cleaning agent if required.
MIN In winter: add antifreeze for washer systems to the water. Refer to the antifreeze
instructions for further information on concentrations.
Fig. 25: Tank for washer system

3.11 Changing the engine oil filter cartridge

OIL
Danger!
A B C Hot engine oil –
Danger of burns!
☞ Wear protective gloves
Environment!
Use a suitable container to collect the engine oil as it drains. Dispose of used
Fig. 26: Oil dipstick, oil filter, filler cap oil and filters in an environmentally friendly manner!
Change the oil filter as follows:

☞ Stop the engine
☞ Place a suitable container under the oil filter
B ☞ Unscrew oil filter cartridge B using a commercially available oil filter wrench
Fig. 27: Unscrewing the engine oil filter
☞ Clean the inside of the filter head

☞ Apply a thin coat of engine oil to seal D of the new oil filter cartridge
D ☞ Screw oil filter cartridge B until the filter contacts the sealing surface of the filter head
Fig. 28: Cleaning the filter head
☞ Tighten oil filter cartridge B by hand by about a further half revolution

☞ Check engine oil level (oil dipstick fig. 26/A)
☞ Let the engine run briefly
B ☞ Stop the engine
☞ Check oil filter cartridge B for leakage, tighten by hand if necessary
☞ Check the engine oil level, refill engine oil if necessary (fig. 26/C)
☞ Completely remove all oil spills from the engine
Fig. 29: Tightening the engine oil filter
☞ Dispose of used oil filter cartridges in an environmentally friendly manner

3.12 Washer system tank

Refilling washer fluid
Tank filler inlet 1 is located in the cab to the left of the seat.
1 Notice!
MAX Fill with clean tap water only!
Add a suitable cleaning agent if required.
MIN In winter: add antifreeze for washer systems to the water. Refer to the antifreeze
instructions for further information on concentrations.
Fig. 30: Tank for washer system
3.13 Engine and hydraulics cooling system

Safety instructions regarding cooling system maintenance
The combined water/oil cooler is located in the engine compartment. It cools both the die-
sel engine and the hydraulic oil of the drive and work hydraulics.
Danger!
The cooling system is hot and under high pressure! Never open the coolant
tank or drain coolant if the diesel engine is hot!
☞ Wait at least 10 minutes after stopping the diesel engine, then open the
Fig. 31: Label: hot surface filler cap to the first notch and release the pressure – see Filling up coolant
on page 3-20
☞ Wear protective gloves and clothing
Danger!
Danger of swallowing antifreeze when handling it!
☞ Seek medical attention immediately if antifreeze has been swallowed
☞ Keep antifreeze out of reach of children
Information on inspection and cleaning work on the cooling system

Dirt on the radiator fins reduces the radiator’s heat dissipation capacity!
• Check the radiator once a day for dirt and clean it if necessary. Refer to the mainte-
nance plan for the intervals
• In dusty or dirty work conditions, clean more frequently than indicated in the mainte-
nance plan
• An insufficient coolant level reduces the heat dissipation capacity and can lead to
engine damage!
• Check the coolant level at regular intervals. Refer to the maintenance plan for the
intervals – see Maintenance plan overview on page 3-5
• If the coolant must be replace frequently, have the cooling system checked for leaks by
an authorised workshop!

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

• After filling the expansion tank, make a test run with the engine and check the coolant
level again after stopping the engine
• Add enough antifreeze to the coolant.
• Use brand-name antifreeze compounds with anticorrosion additives – see Fluids and
lubricants on page 3-4
• Do not use radiator cleaning compounds if an antifreeze compound has been added to
the coolant – otherwise this causes sludge to form that can damage the engine
Environment!
Use a suitable container to collect the coolant as it drains and dispose of it in

Temperature gauge: diesel engine coolant

Indicator light 44 on the indicating instrument (with acoustic warning) monitors the cooling
44 system.
Caution!
Engine temperature should be between 80 and 105 °C.
☞ If indicator light 44 comes on and an acoustic warning sounds (105 °C)
• Let the diesel engine run briefly without any load at idling speed until the
acoustic warning does not sound any more
• Stop the diesel engine and check the coolant level
Fig. 32: Temperature gauge • Clean the radiator fins
Checking the coolant level
Notice!
Check the coolant level every 10 s/h (service hours) or once a day.
Check before starting the diesel engine
☞ Checking the coolant level

• Lower the loader unit
A • Stop the diesel engine and remove the ignition key
FULL • Open the engine cover
LOW • Check the coolant level in the transparent tank A
If the coolant level is below seam LOW of the expansion tank:
• Fill up coolant – see Filling up coolant on page 3-20
Fig. 33: Expansion tank for coolant

Filling up coolant
Danger!
A The cooling system is hot and under high pressure!

Never open the coolant tank or drain coolant if the diesel engine is hot!
☞ Wait at least 10 minutes after stopping the diesel engine!
FULL
☞ Wear protective gloves and clothing
LOW
☞ Open filler cap B to the first notch and release the pressure
☞ Fill up coolant as follows:

A • Stop the diesel engine and remove the ignition key
Z • Apply the parking brake
• Open the engine cover
• Open the filler cap towards A up to the first notch
• Release the pressure
• Open the filler cap fully
• Fill in coolant up to the lower edge of the filler inlet (radiator)
➥ Use antifreeze compounds with anticorrosion additives – see Fluids and lubri-
Fig. 34: Filling up coolant
cants on page 3-4
• Close the radiator with the filler cap by turning it towards Z
• Start the diesel engine and let it warm up for about 5 – 10 minutes
• Open the heating circuit fully for this
• Stop the diesel engine and check the coolant level again
➥ The coolant level must be between LOW and FULL on the tank
• If necessary, fill up coolant and repeat the procedure until the coolant level remains
constant
Notice!
Check the cooling system and the heating circuit for leaks!
• Have leaks immediately repaired by an authorised workshop

Cleaning the radiator fins
Danger!
Maintenance work on a hot diesel engine and radiator carries a danger of
burns!
☞ Wait at least 10 minutes after stopping the diesel engine until the cooling
system has cooled down!
☞ Wear protective goggles, gloves and clothing!
Caution!
Dirt on the radiator fins reduces the radiator’s heat dissipation capacity and
can cause damage to the diesel engine and the hydraulic system!
☞ Check and clean the outside of the radiator once a day.
Clean the radiator more frequently in dusty or dirty work conditions
☞ Clean the radiator as follows:

• Lower the loader unit fully
• Stop the diesel engine and switch off ignition
• Remove the key and let the diesel engine cool down
• Clean the radiator fins by blowing compressed air from either side of the radiator
• Remove dirt in the intake area of the radiator
Fig. 35: Cleaning the radiator

Caution!
In order to ensure the radiator’s cooling capacity, do not damage the radiator
fins as you clean them with a compressed-air gun!

3.14 Air filter

Checking the air filter for dirt
54
Caution!
The filter housing is fitted with a discharge slot E for removing the dust.
Bear in mind the following to avoid premature engine wear!
☞ Do not wash, brush or clean the filter cartridge with compressed air
☞ Replace the filter cartridge when indicator light 54 comes on
☞ Never reuse a damaged filter cartridge
☞ Ensure cleanliness when replacing the filter cartridge!
☞ Do not clean the safety cartridge – replace it every third time maintenance
E is carried out on the filter!
☞ Checking the dust valve

• Stop the engine
E • Apply the parking brake
D • Remove the ignition key and switch off the battery master switch (option) if necessary
F • Squeeze the discharge slot of dust valve E
• Remove hardened dust by compressing the upper area of the valve
Fig. 36: Air filter with safety cartridge
• Clean the discharge slot if necessary
Notice!
Replace the air filter cartridge as soon as indicator light 54 on the indicating instru-
ment comes on – see Replacing the air filter cartridge on page 3-23
• At the latest after 1500 service hours (however once a year)
Caution!
Filter cartridges degrade prematurely when in service in acidic air for longer
periods of time!
☞ Replace filter cartridge D and safety cartridge F at the latest after 500 ser-
vice hours!
☞ – see Replacing the air filter cartridge on page 3-23

3.15 Replacing the air filter cartridge

☞ Change the filter cartridge as follows:
H • Park the machine on level ground
• Lower the loader unit fully
G
K • Stop the diesel engine and switch off ignition
• Fold both bow hooks G on the air filter to the outside, off the notch of the upper
housing section H
Fig. 37: Removing 307b0700.ai
the lower housing section
• Remove the lower housing section K
• Carefully pull out filter cartridge D with slightly turning movements
• In addition, every 3rd time the filter is replaced, carefully remove the safety cartridge
F with slightly turning movements
H D
Caution!
Before inserting the new filter, ensure that all dirt (dust) inside the upper and
307b0710.ai lower housing sections has been removed!
• Carefully insert new safety cartridge F into the upper housing section H
• Carefully insert new filter cartridge D into the upper housing section H
• Cleaning the dust valve – see Checking the air filter for dirt on page 3-22
• Position lower housing section K (ensure that it is properly seated)
• Fold and close both bow hooks G on the notch of the upper housing section H
Fig. 38: Removing the filter element

3.16 V-belt
Checking/retightening the V-belt on the fan wheel
Danger!
Danger of personal injury! Caution, turning parts!
Only check or retighten/replace the V-belt when the engine is stopped!
About 10 mm ☞ Stop the engine before carrying out inspection work in the engine compart-
ment!
Caution!
1 Cracked and stretched V-belts cause engine damage!
☞ Have the V-belt replaced by an authorised workshop every 2 years at the
latest
B
Check the V-belt once a day or every 10 service hours, and retighten if necessary.
Retighten new V-belts after about 15 minutes of running time.
☞ Check the V-belt as follows
2
Fig. 39: Checking V-belt tension/retightening the V-belt • Lower the loader unit fully
• Switch off the battery master switch (option)
• Carefully inspect the V-belt for damage
➥ Have a damaged V-belt replaced by authorised staff
• Press with your thumb to check whether the V-belt can be deflected between the
pulleys by no more than about 10 mm
• Retighten the V-belt if necessary
☞ Retighten the V-belt as follows
• Slacken fastening screws 1 on the clamping collar of the alternator
• Slacken fastening screws 2 at the bottom of the alternator
• Use a suitable tool to push the alternator in the direction of arrow B until the correct
V-belt tension is obtained
• Keep the alternator in this position, and at the same time retighten fastening screws 1
on the clamping collar
• Tighten fastening screws 2 at the bottom of the alternator
• Start the engine
• Check V-belt tension after about 15 minutes

Checking/retightening the V-belt (compressor of optional air conditioning)
1 2
Danger!
A Danger of personal injury! Caution, turning parts!
Only check or retighten/replace the V-belt when the engine is stopped!
About 10 mm ☞ Stop the engine before carrying out inspection work in the engine compart-
ment!
Fig. 40: Air conditioning V-belt Notice!

Have the V-belt replaced by an authorised workshop every 2 years at the latest!
☞ Check the V-belt as follows

• Stop the engine
• Switch off ignition and remove the ignition key
• Switch off the battery master switch (option)
• Remove V-belt guard A
• Carefully inspect the V-belt for damage
➥ Have a damaged V-belt replaced by authorised staff
• Press with your thumb to check whether the V-belt can be deflected between the
pulleys by no more than about 10 mm
• Retighten the V-belt if necessary
• Mount V-belt guard A
☞ Retighten the V-belt as follows
• Slightly slacken fastening screw 1
• Turn hexagon nut 2 on the clamping screw to the right until the correct V-belt tension
on the compressor is reached
• Tighten fastening screw 1
• Check V-belt tension after about 15 minutes
• Mount V-belt guard A

3.17 Hydraulic system

Safety instructions regarding maintenance of the hydraulic system
Danger!
Danger of burns! Do not carry out maintenance work on a hot engine and
hydraulic system!
☞ Wait at least 10 minutes after stopping the engine
Danger!
Hydraulic oil escaping under high pressure can penetrate the skin and cause
serious injuries.
☞ Always consult a doctor immediately even if the wound seems insignificant
– otherwise serious infections could set in!
Before starting maintenance work on the hydraulic system, bear in mind the following
instructions:
• Lower the loader unit to the ground.
• Lower all hydraulically controlled attachments to the ground.
• Stop the diesel engine and remove the ignition key.
• Switch off the battery master switch (option)!
• Use the parking brake to park the machine safely and to prevent it from rolling away!
• After stopping the diesel engine, release the pressure in the hydraulic system. To do
this: move all control levers of the hydraulic control valves repeatedly!
• Wear protective clothes during maintenance work.
• Always fill in hydraulic oil before the level gets too low.
• Always fill in hydraulic oil using the filling screen. – see Filling up hydraulic oil on
page 3-29!
• Only use authorised oils of the same type – see Fluids and lubricants on page 3-4.
• If the hydraulic system is filled with biodegradable oil, then only use biodegradable oil of
the same type for filling up – observe the sticker on the hydraulic oil tank!
• Immediately contact an authorised workshop if the filter insert is contaminated with
metal chippings, otherwise follow-on damage can result!
• Collect drained hydraulic oil and biodegradable oil in a suitable container!
• Dispose of drained oil and used filters by an ecologically safe method.

Monitoring the hydraulic oil and the return filter

Two indicator lights on the indicating instrument monitor the return filter (dirt) and the oil
42 43 temperature
• Indicator light 42 – oil temperature
• Indicator light – return filter flow (dirt)
Caution!
Indicator light 43 on the indicating instrument comes on if the flow resistance in
the return filter is too high!
☞ The filter element is dirty and must be replaced by an authorised workshop
Fig. 41: Preheating start switch The indicator light 42 on the indicating instrument comes on if the operating
temperature of the hydraulic oil is too high!
☞ Check the hydraulic oil level (not enough oil in the tank)
☞ The filter element or the hydraulic oil is dirty and must be replaced by an
authorised workshop
Notice!
Indicator light 42 on the indicating instrument can come on in cold weather imme-
diately after starting the engine. This is caused by increased oil viscosity. In this
case:
• Set engine speed so that the indicator light goes out
• Bear in mind the instructions concerning warmup

Checking the hydraulic oil level
Danger!
Danger of burns! Do not carry out maintenance work on a hot engine and
hydraulic system!
☞ Check the oil as follows:

• Retract all hydraulic rams
• Stop the engine and remove the ignition key
• Check the oil level in sight glass B
B ☞ If the oil level is visible in the lower half of the oil level sight glass
➥ OK
Fig. 42: Oil level sight glass on the hydraulic oil tank
☞ If the oil level is not visible in the oil level sight glass (not enough oil)
➥ Fill up the hydraulic oil
Notice!
If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has
penetrated the hydraulic system.
Have the hydraulic system immediately checked by an authorised workshop!

Filling up hydraulic oil
Notice!
Do not fill up the hydraulic oil unless the engine is stopped. Otherwise, hydraulic oil
will run out of the filler opening on the hydraulic tank.
☞ Fill up hydraulic oil as follows:

A • Park the machine on level ground
• Stop the engine
• Clean the area around the filler and breather filter B with a cloth
B • Place a container to collect the oil as it drains
• Open breather filter A by hand
• Fill up hydraulic oil with the filter insert in place
Fig. 43: Filler cap for hydraulic oil tank ➥ Use only authorised oils – see Fluids and lubricants on page 3-4
• Check the hydraulic oil level in sight glass B
• Fill up oil if necessary and check again
• Firmly close breather filter B by hand
Caution!
Any excess quantity of hydraulic oil in the tank escapes via the breather as
soon as the temperature rises!
If the oil level is no longer visible in the upper half of the oil level sight glass
☞ Drain he hydraulic oil.

Important notices on the use of biodegradable oil

• Use only the biodegradable hydraulic fluids which have been tested and approved by
Kramer-Werke GmbH – see Fluids and lubricants on page 3-4. Always contact Kramer-
Werke GmbH for the use of other products which have not been recommended. In
addition, ask the oil supplier for a written declaration of guarantee. This guarantee is
applicable to damage occurring on the hydraulic components, which can be proved to
be due to the hydraulic fluid
• Use only biodegradable oil of the same type for filling up. In order to avoid misunder-
standings, a label providing clear information is located on the hydraulic oil tank (next to
the filler inlet) regarding the type of oil currently used! Replace missing labels! The joint
use of two different biodegradable oils can affect the quality of one of the oil types.
Therefore, ensure that the remaining amount of initial hydraulic fluid in the hydraulic
system does not exceed 8 % when changing biodegradable oil (manufacturer indica-
tions)
• Do not fill up with mineral oil – the content of mineral oil should not exceed 2 % in order
to avoid foaming problems and to ensure biological degradability
• When running the machine with biodegradable oil, the same oil and filter replacement
intervals are valid as for mineral oil – see maintenance plans in the appendix
• Have the condensation water in the hydraulic oil tank drained by an authorised
workshop every 500 service hours, in any case before the cold season. The water
content must not exceed 0.1 % by weight
• The instructions in this Service Manual concerning environmental protection are also
valid for the use of biodegradable oil
• If additional hydraulic attachments are mounted or operated, use the same type of
biodegradable oil for these attachments to avoid mixtures in the hydraulic system
Notice!
Subsequent change from mineral oil to biodegradable oil must be carried out
by an authorised workshop or by your dealer!

3.18 Checking hydraulic pressure lines

Safety instructions regarding pressure line checks
Danger!
Caution when checking hydraulic lines, especially when searching for leaks
Hydraulic oil escaping under high pressure can penetrate the skin and cause
serious injuries.
☞ Always consult a doctor immediately, even if the wound seems insignificant
– otherwise serious infections could set in!
☞ Always observe the following instructions:
• Retighten leaking screwed fittings and hose connections only when the
system is not under pressure; i.e. release the pressure before working
on pressurised lines!
• Never weld or solder damaged or leaking pressure lines and screw con-
nections. Replace damaged parts with new ones!
• Never search for leaks with your bare hands, but wear protective gloves!
• Have damaged flexible lines replaced by authorised workshops only!
The entrepreneur/owner of the machine must ensure that flexible lines are replaced in
appropriate intervals, even if no safety-relevant defects can been detected on the flexible
line.
Flexible lines must be inspected by an expert (competent person) before the first commis-
sioning, and then at least once a year for safe working condition.
• Leakages and damaged pressure lines must be immediately repaired or replaced by an
4 Q/11 authorised workshop or after-sales staff.
This not only increases the operating safety of your machine but also helps to protect
the environment
• Replace hydraulic hoses every 6 years after the date of manufacture, even if they do
not seem to be damaged
In this respect, we recommend that you observe all the relevant safety regulations for
Fig. 44: Hydraulic hose identification hydraulic lines, as well as the safety regulations regarding accident prevention and occu-
pational health and safety in your country. Also observe DIN 20066, part 5.
The date of manufacture (month or quarter and year) is indicated on the flexible line.
Example:
The indication “4 Q/11” means manufactured in the 4th quarter of 2011.

3.19 Replacing hydraulic oil
Danger!
Caution when draining hot hydraulic oil and removing the filter element –
Danger of burns!
☞ Use a drain coupling with a sufficiently long hose
☞ Proceed as follows:
• Lower the loader unit completely. To do this:
C D push the lever forwards
• Tilt in the bucket completely. To do this:
push the lever to the left
• Stop the engine
• Unscrew filler and breather filter B
• Place a suitable container to collect the oil as it drains, with a minimum capacity of 40
l
• Remove cap C of the drain valve
• Screw drain coupling D with a sufficiently long hose onto the drain valve
➥ Ensure that the end of the hose is in container used for collecting the oil
➥ The drain valve opens and the oil drains into the container
B
• Remove the filter insert of the filler and breather filter B
• Reinsert the clean filter insert
• Rinse the hydraulic oil tank with a little hydraulic oil
• Unscrew the drain coupling from the drain valve
• Screw on cap C of the drain valve
• Replace the hydraulic oil return filter
A • Fill in fresh hydraulic oil up to the middle of oil level sight glass A
• Screw on the new filler and breather filter B
Fig. 45: Drain valve with cap
With the engine running at low speed:
• Fully extend and retract the lift and tilt rams on the loader unit
• Turn the steering wheel to the left and right several times, from lock to lock
• Retract all the hydraulic rams again
• Stop the engine
• Check the hydraulic oil level and fill up if necessary

3.20 Replacing the hydraulic oil return filter

A red indicator light 43 in the instrument panel monitors the filter. Replace the filter:
43
• If teltale 43 comes on when the hydraulic oil is at operating temperature
• At the latest after 1500 service hours (once a year)
In cold weather indicator light 43 can come on immediately after starting the engine. This is
caused by increased oil viscosity. In this case:
☞ Let the engine run at idling speed for about 2 minutes
Changing the filter insert

Fig. 46: Hydraulic oil return filter indicator light ☞ Proceed as follows:
• Stop the engine.

E B
• Open breather filter/cap B.
• Unscrew cap E by about 2 turns and wait for the oil level in the filter housing to drop
to the level in the hydraulic oil tank
2 • Remove cap E completely
• Pull out filler pipe F with filter element G, turning them slightly
• Pull filter element G off filler pipe F and dispose of the filter element
• Check that flat gasket H on the filter cap and O-ring I on the filler pipe are in perfect
307b0770.ai condition
• Fit new O-rings if the old ones are damaged
Fig. 47: Return filter – breather filter
• Slide filler pipe F onto a new filter element G and insert the assembly into the filter
• Tighten cap E by hand (tightening torque 20 Nm)
E • Tighten cap/breather filter B by hand
H
• Carry out a test run of the hydraulic system
F I With the engine stopped:
2 • Check the hydraulic oil filter for leakage
G
307b0760.ai
Fig. 48: Return suction filter
3.21 Replacing the filler and breather filter

Replace breather filter B for the hydraulic oil tank every 1500 service hours or at least
B once a year.
• Unscrew breather filter B
• Remove retaining chain J on lower section K of the filter
K 307b0780.ai
• Attach retaining chain J on lower section K of the new breather filter B
• Screw in the new breather filter B
J
L
Fig. 49: Securing the filler and breather filter

3.22 Gearboxes and axles

Maintenance of these components is limited to checking the oil levels and to changing the
oil at the prescribed intervals
➥ See the maintenance plan
Authorised oil types
➥ See “Engine/machine fluids”
Notice!
Only use new sealing rings for oil filler and drain plugs. Drain oil only after running the
machine for a longer period of time!
Rear axle transfer gearbox
Fig. 50: Rear axle transfer gearbox

C
Checking the oil level

• Park the machine on level ground when the gearbox is at operating temperature
• Clean and unscrew plug B on transfer gearbox A
If the oil level is below the opening or if the oil level cannot be seen at all:
• Fill up the oil
If the oil level is correct:
• Tighten plug B with a new sealing ring to make an oil-tight seal
Filling up the oil

• Fill in oil until it runs out of the filler opening
If the oil level in the gearbox remains constant:

Changing the oil
Danger!
Careful when draining hot gearbox oil –
Danger of burns!
☞ Use suitable tools, e.g. for unscrewing the oil drain plug
• Place a sufficiently large container under the transfer gearbox to collect the oil
• Unscrew plug C on transfer gearbox A
A • Completely drain the old gearbox oil
• Tighten plug C with a new sealing ring to make an oil-tight seal
B • Fill in oil until it runs out of the filler opening
If the oil level in the gearbox remains constant:
After carrying out a test run:
• Check the oil level again after about 5 minutes, and fill up if necessary
C
Fig. 51: Rear axle transfer gearbox

Front and rear axle differentials
Environment!
Use a suitable container to collect the gearbox oil as it drains and dispose of it in an envi-
ronmentally friendly manner!
Notice!
Only use new sealing rings for oil filler and drain plugs. Drain oil only after running the
machine for a longer period of time! See “Engine/machine fluids” for the authorised oil
types and capacities.
Checking the oil level

B • Park the machine on level ground
• Clean and unscrew plug B
If the oil level is below the opening or if the oil level cannot be seen at all:
• Fill up the oil
If the oil level is correct:
C • Tighten plug B with a new sealing ring to make an oil-tight seal
Fig. 52: Checking the oil level on the rear axle
Filling up the oil
B ☞ Proceed as follows:
C
Changing the oil
Fig. 53: Checking the oil level on the front axle
• Park the machine on level ground when it is at operating temperature
• Place a container under plug C to collect the oil
• Clean and unscrew plug C
• Completely drain the old oil
• Tighten plug C with a new sealing ring to make an oil-tight seal

Front and rear axle planetary drives

Check the oil level as follows:
☞ Park the machine on level ground
☞ Turn plug E and oil level mark F to a horizontal position
H 2
G F ☞ Clean and unscrew plug E
If the oil level is below opening G or if the oil level cannot be seen at all:
E ☞ Fill up the oil
☞ Tighten plug E with a new sealing ring H to make an oil-tight seal
Fig. 54: Checking the oil level in the planetary drive
Filling up the oil
☞ Clean and unscrew plug E
☞ Fill in fresh oil up to oil level mark F (overflow)
Changing the oil

☞ Park the machine on level ground when it is at operating temperature
☞ Place a container to collect the oil
☞ Turn plug E to the topmost position
☞ Clean and unscrew plug E
☞ Turn plug E to the lowest position
☞ Completely drain the old oil
☞ Fill in fresh oil up to oil level mark F (overflow)

3.23 Lubrication work on the axles
Caution!
In order to avoid damage to the lubrication points, use only lithium-saponified
brand-name grease!
Lubricating the rear axle
Notice!
The machine has an oscillation-type rear axle. Lubricate the bearing every 20 ser-
vice hours at the latest.
A
☞ Lubricate the oscillation-type bearing as follows:
Fig. 55: Grease nipples for oscillation-type bearing
• Lubricate grease nipple A of the oscillation-type bearing
Lubricating the front and rear axle planetary drive bearings

☞ Lubricate the planetary drive bearing as follows:
B • Lubricate grease nipples B (2 x) on each planetary drive bearing
Fig. 56: Grease nipples on planetary drive bearings

3.24 Lubrication work on the loader unit

Safety instructions regarding lubrication work on the loader unit
• Park the wheel loader on level ground
• Apply the parking brake and secure the machine with wheel chocks
• Raise the loader unit so you can lubricate it comfortably from the ground
Caution!
In order to avoid damage to the lubrication points, use only lithium-saponified
brand-name grease!
Lubricating the loader unit, lift, tilt and lock rams

☞ Lubricate the following lubrication points on the loader unit of the machine:
C
• Lubricate grease nipple C of the tilt ram bearing on the frame every 10 service hours.
Lubricate more frequently when in heavy-duty operation
• Lubricate grease nipple D of the loader unit bearing every 10 service hours. Lubricate
D more frequently when in heavy-duty operation
• Lubricate grease nipple E on the lift ram bearing on the frame every 20 service hours
Fig. 57: Lubrication points on frame
• Lubricate grease nipple F of the tilt rod bearing every 10 service hours. Lubricate
more frequently when in heavy-duty operation
F • Lubricate grease nipple G of the tilt ram bearing every 20 service hours
• Lubricate grease nipple H of the lift ram bearing every 20 service hours. Lubricate
L G more frequently when in heavy-duty operation
• Lubricate grease nipple I of the tilt lever bearing every 10 service hours. Lubricate
• Lubricate grease nipples K of the quickhitch bearing every 10 service hours.
Lubricate more frequently when in heavy-duty operation
• Lubricate grease nipples L of the tilt lever bearing every 10 service hours. Lubricate
K I H
Fig. 58: Lubrication points for lift and tilt ram bearings

3.25 Lubricating with the central lubrication system (option)

Functional description of the central lubrication system
The central lubrication system allows you to lubricate all lubrication points of the wheel
loader in one single step.
• The LED on the central lubrication system comes on for 1.5 seconds upon switching on
ignition to indicate functional readiness of the controls (switch-on check). It stays lit
during the entire lubrication procedure.
• The integrated electronic control unit has a data memory for saving the times that have
been set or that have elapsed. The time is taken and saved if ignition is switched off
during lubrication or during a break. The remaining lubrication time or break time is
read from the memory upon switching ignition on again, and lubrication is resumed
where it was interrupted.
Lubrication time control

• Break and lubrication times can be set with the time-dependent control of the central
lubrication system. Break times are the periods between two lubrication times.
Notice!
Pressing the tip switch A on the side of the pump starts intermediate lubrication at
any given time if ignition is switched on. This also serves as a functional check.
• The pump then immediately starts with a lubrication cycle. The lubrication or
break time that has elapsed so far or that has been saved is reset and starts
A over again.
• A lubrication system malfunction can also be reset by pressing the intermediate
Fig. 59: Filling the central lubrication system lubrication switch, and the pump restarts lubrication.
Repair work
Repair work on the central lubrication system may be carried out only by authorised work-
shops!

Setting the lubrication and break times

Break times and lubrication times are set with the notched switches (S and P) in the win-
Break time dow of the controls.
☞ Adjust as follows:
Lubrication time • Remove the red frame on the protective motor housing of the pump with a flat screw-
driver to set the time
• Slacken the four cross-slotted screws and remove the transparent cover
• Set the break time P and the lubrication time S with a flat screwdriver
Lubrication times (S):
➥ 1 to 16 minutes (16 notches, 1 minute each)
➥ 2 to 32 minutes (16 notches, 2 minutes each)
Break time (P):
S P L ➥ 0.5 to 8 h (16 notches, 0.5 h each)
LED (L)
➥ (B) lubrication system in operation
B
➥ (A) lubrication under progress: 0.5 seconds LED ON/0.5 seconds LED OFF
A • Install the transparent cover (window) once the settings are carried out
Fig. 60: Setting the lubrication times
Caution!
Water can penetrate into the controls and damage them if the cover is not
fitted and closed correctly!
Filling the central lubrication system

The lubrication system is filled via conical grease nipple 1 or a fill coupling with a manual or
pneumatic grease gun.
1
Caution!
Use only commercially available greases up to NLGI-Kl. 2 to avoid damage to
the lubrication system and the lubrication points!
☞ – see Fluids and lubricants on page 3-4
Fig. 61: Filling the central lubrication system

3.26 Maintenance of the brake system

Specific safety instructions regarding the brake system
Brakes are crucial to safety. Incorrect maintenance can cause brake failure.
All repair work on the brakes may be carried out only by trained staff of an author-
ised workshop.
An exception to this is the following work which must be carried out by the driver/
operator:
• Daily check of the level in the brake fluid tank
• Daily check of the brake lines
Danger!
Defective brake lines or hoses carry a danger of accidents!
☞ Have defective brake lines or hoses immediately replaced by an authorised
workshop
Checking/filling up the brake fluid level

The brake-fluid tank is located inside the cab to the left of the seat.
A Danger!
Danger of accidents! An incorrect brake fluid grade or an insufficient brake
fluid level can impair the safety of the brake system.
• Check the brake fluid in the tank at regular intervals
MI X
MA
N
• Fill up brake fluid up to the upper edge of the sight glass

• The brake fluid must comply with the SAE specification (LHM)–
see Fluids and lubricants on page 3-4
• The brake fluid must be replaced every 2 years by an authorised work-
Fig. 62: Brake fluid level in the tank
shop
• If the brake system loses too much brake fluid, have the brake system
checked by an authorised workshop
☞ If the level is below the upper edge of the sight glass:

• Clean the area around the opening with a clean cloth
• Open tank cover A
• Fill up brake fluid up to the upper edge of the sight glass MAX
➥ – see Fluids and lubricants on page 3-4
• Close tank cover A

3.27 Tyres
Daily tyre checks
Danger!
All repair work on tyres and rims may only be carried out by authorised
workshops.
Notice!
Regular checks for damage and of the tyre pressure increase operational safety
and the service life of the tyres, and reduce the machine’s downtimes.
☞ Check the tyres as follows:

• Check the tyre pressure with a measuring instrument
• Refer to the label (on the front window) or in the Operator’s Manual
• Check the tyres and the rims – also on the inside – for cracks, ageing and tread
Fig. 63: Tyre table
thickness
• Remove foreign bodies from the tyre tread
• Remove traces of oil and grease from the tyres

Wheel change
Danger!
In order to avoid danger of accidents, use only wheels and tyres that have
been released for the machine – see chapter 3 “Tyres” on page 3-43, the label
on the front window, the General Certification for Vehicles (Germany) or the
Data Confirmation (Germany) of the machine.
Caution!
The threads on the wheel bolts can be damaged when mounting the heavy
wheels!
☞ Use suitable assembly tools, such as covering sleeves for the studs, a jack
etc.
Danger!
An incorrectly raised machine can tip over – danger of crushing and injury!
☞ Use only jacks that have been certified for the machine
☞ After raising the machine, install additional safety elements (trestles)
☞ Seal off the work area and ensure constant supervision of the machine
☞ Remove the wheels as follows:

• Place the machine on firm and level ground
• Lower the loader unit to the ground
• Prevent the machine from rolling away (wheel chocks)
• Loosen the wheel nuts a little of the wheel you want to remove
• Install a jack (certified for the machine) under the axle body ensuring stability
• Check the safe position of the jack and raise the machine
• Install trestles to ensure safety
• Completely remove the wheel nuts
• Remove the wheel
☞ Mount the wheels as follows:
• Fit the covering sleeves to the wheel bolts
• Place the wheel onto the wheel bolts
• Tighten all wheel nuts part-way
• Lower the raised axle and remove the jack
• Tighten the wheel nuts to the prescribed tightening torque

3.28 Heating and ventilation system maintenance

Important notice on the heating system
The heating system of the machine is equipped with a fine-dust filter.
• Clean the fine-dust filter every 20 service hours, however replace it every 500 service
hours at the latest.
Danger!
Health hazard! In order to be able to comply with the required safety
measures regarding occupational safety and health, defective or dirty fine-dust
filters must be replaced by new ones!
Cleaning the dust filter of the heating system

The dust filter is located in the leg room at the left behind the instrument panel trim.
☞ Clean the filter as follows:
• Remove the fastening screws on the left-hand side of the trim A (allen key 3 mm)
• Pull away trim A a little
A • Pull out dust filter B and check it for damage
• Knock the dust filter on a plate on either side, or blow compressed air from the inside
to the outside to clean the filter, or wash it with water and allow to dry
➥ Replace or clean the filter more frequently if the machine is used in severe dust
conditions
• Insert dust filter B (ensure that it is seated properly)
• Install trim A
Notice!
Replace the fine-dust filter every 500 s/h (service hours) by a new one.
Fig. 64: Replacing the dust filter of the heating system

3.29 Maintenance of the air conditioning system (option)

Safety instructions regarding the air conditioning
Functional and visual checks must be carried out by the driver/user!
Maintenance and repair work may only be carried out by the trained staff of an
authorised workshop.
• Careful when carrying out maintenance and repair work – sharp-edged fins on the
condensor and the heat exchanger
• Wear protective equipment (protective gloves and goggles) during maintenance and
repair work
• Lines and hoses containing refrigerants and cooling fluids are under pressure and can
be hot
• Avoid touching parts containing refrigerants
• Do not carry out maintenance work unless the heating and air conditioning systems are
switched off
• Bear in mind the pertinent regulations relevant to accident prevention, other generally
acknowledged regulations regarding safety and occupational medicine
Daily functional and visual checks of the air conditioning
Danger!
Danger of personal injury! Do not carry out maintenance work when the
engine is running!
☞ Stop the engine and switch off the ignition
☞ Carry out a daily visual check as follows:

• Stop the engine
• Check the heating and coolant lines for damage
• Check the hoses for tightness, leaks and chafing
• Check the electric connections for correct condition and tightness
• Check V-belt tension and if necessary, retighten the V-belt – see Checking/retight-
ening the V-belt (compressor of optional air conditioning) on page 3-25
Notice!
The air conditioning system must be checked and serviced twice a year by trained
staff in an authorised workshop!
For the first fill, see the air conditioning label inside the cab on the door.

Cleaning the heat exchanger (condenser)

☞ Clean as follows:
• Stop the engine
• Remove cover A from the protective screen
• Clean heat exchanger C with a water jet (do not use a high-pressure cleaner or
compressed air)
Caution!
A
Do not damage the fins as you clean the heat exchanger!
B
• Clean the air intake area
• Install cover A
C Notice!
Have the air conditioning system checked twice a year by trained staff in an
authorised workshop!
Replace dehumidifier B every 2 years!
Fig. 65: Air conditioning: heat exchanger, dehumidifier

3.30 Electrical system

Important notice
Maintenance and repair work on the electrical system (including the battery) may be
performed only by trained staff and/or authorised workshops!
Safety instructions regarding the electrical system and the battery

The battery contains sulphuric acid! This acid must not be allowed to come into contact
with the skin, the eyes, clothing or the machine. Therefore when recharging or working
near the battery, always wear goggles and protective clothing with long sleeves
If acid is spilt:
• Thoroughly wash any part of the body touched by the acid immediately with plenty of
water and seek medical attention at once
• Immediately rinse acid splashes in the eyes with clear water for several minutes! Then
seek medical attention at once
• Immediately neutralise acid splashes on skin or clothing with an acid neutraliser or
soap, and rinse with plenty of water
• Immediately seek medical attention if acid has been swallowed
• Thoroughly rinse all affected surfaces immediately with plenty of water
Battery maintenance – danger of explosion!
• Avoid naked flames and sparks and do not smoke in the vicinity of open battery cells,
otherwise gas can ignite
• When charging batteries, as well as during normal operation of batteries, an oxyhy-
drogen mixture is formed in the battery cells
• Do not attempt to jump-start the machine if the battery is frozen or if the acid level is
low. The battery can rupture or explode
• Disconnect the negative (−) battery terminal from the battery before starting repair work
on the electrical system
Jump-starting
• Use only 12 V power sources. Higher voltages will damage the electric components
• When connecting the battery leads, ensure that the poles +/- are not inverted,
otherwise sensitive electric components will be damaged
• Danger of sparking! Do not interrupt voltage-carrying circuits at the battery terminals
• Never place tools or other conductive articles on the battery – danger of short circuit!
Putting the machine out of operation
• Remove the battery, store it in a dry and frost-free place
• If the machine is put out of operation for extended periods, charge the battery every 2
months or use a battery charge maintainer
• Always charge the battery when storing it. The sulphation of the electrodes causes
lasting damage! A flat battery must be recharged as soon as possible
Before putting the machine into operation
• Charge the battery and clean the terminals before installing it
Disposal of old battery
• For safe transport to a recycling point, place the protective cap on the positive terminal
of the old battery and dispose of if properly

Checking the battery

The battery is low in maintenance and no fluid needs to be refilled under normal operating
conditions.
However have the battery checked at regular intervals to ensure that the electrolyte level is
between the MIN and MAX marks.
Danger!
When charging batteries, as well as during normal operation of batteries, an
oxyhydrogen mixture is formed in the battery cells with danger of explosions or
causticisation!
☞ Therefore when recharging and/or working near the battery:
• Always wear goggles and protective clothing with long sleeves
• Open the caps of the battery openings by half a revolution before
recharging the battery
• Avoid naked lights and sparks in the vicinity of the battery and do not
smoke!
• Always disconnect the negative terminal (−) from the battery before
starting repair work on the electrical system!
• Switch off the battery master switch (option) and remove the key
☞ If acid is spilt:
• Thoroughly rinse all affected surfaces immediately with plenty of water
• Thoroughly wash any part of the body touched by the acid immediately
with plenty of water and seek medical attention at once in case of injury!

Replacing the battery

The battery is located in the engine compartment in front of the radiator.
☞ Replace the battery as follows:
A • Lower the loader unit to the ground
• Remove the key from the battery master switch (option)
• Remove fastening nut A from the battery cover
B
• Remove the battery cover
Caution!
- + In order to avoid short circuits when disconnecting or connecting the battery

leads, always bear in mind the order for connecting the leads under all circum-
stances!
Disconnecting the battery leads

• First disconnect the negative terminal (−) lead, then the positive terminal (+) lead
• Remove battery fixture B
• Replace the battery with a new one
Fig. 66: Battery
• Mount battery fixture B
Connecting the battery leads
• First connect the positive terminal (+) lead, then the negative terminal (−) lead
• Install the positive terminal (+) cover
• Install the battery cover
• Mount fastening nut A
Inspection and maintenance work on the electrical system at regular intervals

☞ Daily checks before operating the machine
• Light system
• Signalling and warning systems
• Ignition lock
☞ Weekly checks
• Electric fuses – replace defective fuses by new ones with the specified amperage
only
• Charge condition of battery – see Checking the battery on page 3-49
Notice!
Defective relays must be checked and replaced by an authorised workshop only!

Checking the alternator

Observe the following under all circumstances:
• Only test run the diesel engine with the battery connected
• When connecting the battery, ensure that the poles (+/-) are not inverted
• Replace defective charge indicator lights immediately
Caution!
In order to avoid voltage damage on the alternator, always disconnect the
battery leads from the battery terminals before carrying out welding work or
connecting a quick battery charger!
Checking/replacing fuses on the board

The fuses are located under cover A on the right on the control lever console.
For fuse assignment information, see label B on cover A
☞ Checking/replacing fuses
A • Lower the loader unit
• Stop the diesel engine
• Remove cover A and the defective fuses or relays from the relay bracket, and replace
B them by new ones
• Check the correct function of the electrical system
Caution!
Blown fuses indicate overloading or short circuits!
☞ Have the electrical system checked by an authorised workshop before
inserting a new fuse!
• In order to avoid damage to the electrical system, use only fuses and
relays of the specified load capacity (amperage) – see chapter 2 “Switch-
ing relay assignment on board” on page 2-10
Fig. 67: Fuses

Fuse assignment
The board with the fuses is located under the cover in the switch console on the right on
the instrument panel.
Rated cur-
rent (A)
F005 10
lamp
F009 7.5 Low beam (right)
F010 5
fuel pump
F012 7.5 Solenoid valves, load stabiliser
F013 7.5
drive solenoid valve
F014 25
quickhitch lock
F019 5
ing modes
F020 15

Checking/replacing relays on the board and the bracket

The relays are mounted on the board (fuses) and a bracket.
• C => relays on board (under the fuses)
• D => relays on bracket
☞ Checking/replacing relays
C • Lower the loader unit
B
• Remove instrument panel B from the trim
• Replace the defective relay by a new one
• Mount instrument panel B on the trim
D
Fig. 68: Relays

K010 K018
K017 Switching
Protected circuit
relay no.
K016
K027
K016 Not assigned
K023 K017 Switching relay for unlocking the quickhitch (option)
K001
K023 Switching relay for wiper
Fig. 69: Relays on board K027 Step-by-step relay for window heating (option)


B018 K025 K073 K002 K070 K047
Switching
Protected circuit
relay no.
B018 Buzzer
K021 K030 K053 K075 K021 Differential lock switching relay
Fig. 70: Relay bracket K030 Brake lights


The main fuse box is located in the engine compartment on the left on the rear wall
K005 K009 F026 F027
☞ Checking/replacing fuses and switching relays
• Remove the key from the battery master switch A (option) or disconnect the negative
lead (−) from the battery
• Remove the cover from the fuse box and replace defective fuses or relays
F025 F028
Fig. 71: Main fuse box
Caution!
Blown fuses indicate overloading or short circuits!
☞ Have the electrical system checked by an authorised workshop before
inserting a new fuse!
• In order to avoid damage to the electrical system, use only fuses and
relays of the specified load capacity (amperage) – see chapter 2 “Fuse
assignment” on page 2-9
Rated cur-
rent (A)
Relay no. Protected circuit

Electric units
Description Output
Alternator 14 V/55 A
Starter 12 V/2.3 kW
Battery 12 V 74 Ah

3.31 General cleaning and maintenance work

Safety instructions regarding general cleaning work
Cleaning the machine is divided into 3 separate areas:
• Inside the cab
• Exterior of the machine
• Engine compartment
The wrong choice of cleaning equipment and agents can impair the operating safety of the
machine on the one hand, and on the other undermine the health of the persons in charge
of cleaning the machine. Therefore always observe the following instructions.
Cleaning with washing solvents

• Ensure adequate room ventilation
• Wear suitable protective clothing
• Do not use flammable liquids, such as petrol or diesel
Cleaning with compressed air

• Work carefully
• Wear goggles and protective clothing
• Do not aim the compressed air at the skin or at other people
• Do not use compressed air for cleaning your clothing
Cleaning with a high-pressure cleaner or steam jet

• Electric components and damping material must be covered and not directly exposed
to the jet
• Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.
• Cover the piston rods of the hydraulic rams (the scraper is not water-tight, and water in
the guide bushing causes corrosion and damage to the piston rod)
• Cover electric parts, such as the alternator, the ignition lock, the turn indicator and light
switches, the relays etc.
• Cover the controls and seals
• Cover the air-intake filter etc.
Cleaning with volatile and flammable anticorrosion agents and sprays

• Ensure adequate room ventilation
• Do not use unprotected lights or naked flames
• Do not smoke!

Cleaning inside the cab
Caution!
Never use high-pressure cleaners, steam jets or high-pressure water to clean
inside the cab.
☞ Water under high pressure can penetrate into the electrical system, cause
short circuits, damage seals and disable the controls!
We recommend using the following aids to clean the cab:

• Broom
• Vacuum cleaner
• Damp cloth
• Bristle brush
• Water with mild soap solution
Cleaning the seat belt

• Clean the seat belt (which remains fitted in the machine) only with a mild soap solution;
do not use chemical agents as they can destroy the fabric!
Cleaning the exterior of the machine

The following articles are generally suitable:
• High-pressure cleaner
• Steam jet
Cleaning the engine compartment
Danger!
Caution, turning parts! Do not carry out maintenance work on a hot engine!
Caution!
The engine must be cold before cleaning it with a water or steam jet
☞ Do not point the jet directly at the electric sensors such as the oil pressure
switch.
• The humidity penetrating any such sensors causes them to fail and leads
to engine damage!

Checking screw connections

All screw connections must be checked regularly, even if they are not listed in the mainte-
nance plans.
Tighten loose connections immediately. Refer to chapter “Specifications” for the tightening
torques.
Checking pivots and hinges

All mechanical pivot points on the machine (e.g. door hinges, joints) and fittings (e.g. door
arresters) must be lubricated regularly, even if they are not listed in the lubrication plan.
3.32 Maintenance of attachments and of the work equipment

Correct maintenance and service is absolutely necessary for smooth and continuous oper-
ation, and for an increased service life of the attachments. Observe the lubrication and
maintenance instructions in the Operator’s Manuals of the attachments!

3.33 Maintenance of the automatic trailer coupling (option)

Cleaning and lubricating the trailer coupling
Caution!
Ensure that the coupling pin is engaged in the trailer coupling before cleaning
with high-pressure equipment!
☞ Apply a little more grease to the coupling pin and the base ring once clean-
ing is over
• Apply tough water-proof grease (EP3) to the coupling pin, the base ring and the
drawbar eye after heavy use and before putting the coupling into operation
• Apply tough waterproof grease (EP3) to the lower bearing of the coupling jaw
• Apply grease to the grease nipple on the joint
Check the trailer coupling for wear
A 3.0 mm
Danger!
Danger of accidents in case of worn coupling pins, too much play in the
bearing or a worn base ring!
36.5 mm ☞ Check the trailer coupling once a day for wear and play
☞ Apply grease to the base ring
2.5 mm
B
☞ Have a defective trailer coupling replaced by a new one
36.5 mm
☞ Check the bearing and longitudinal play A of the coupling head
C • Move the uncoupled coupling head with force in driving direction
☞ Checking the height-wise play of the coupling head
• Open the coupling
2.5 mm • Move the coupling head up and down with a suitable tool (mounting lever)
D ➥ Play A in the centre axis of the coupling head = max. 3 mm
E ☞ Check the coupling pin C/D
• Measure wear by means of a slide gauge on the thickest section of the coupling pin C
7 mm
➥ Diameter C may not drop below 36.5 mm

➥ Height-wise play B max. 2.5 mm
• Check pin play D in the base ring and thickness E of the base ring
Fig. 72: Rockinger trailer coupling
➥ Pin play D max. 2.5 mm
➥ Thickness E of base ring min. 7 mm
Caution!
Repair work on the trailer coupling must be carried out by an authorised
workshop only!

3.34 Maintenance work “Aggressive Media” (option)

Your machine is specially protected against corrosion for work in aggressive media (e.g. a
saline environment).
However, this anticorrosion protection is affected by external factors e.g. dirt, cleaning etc.
This is why it only has ongoing effect if checked at regular intervals and renewed or reap-
plied as required.
If no anticorrosion protection is applied to your machine, for instance for work in a saline
environment, we recommend retrofitting your machine with the “Aggressive Media” option
by your sales partner.
Anticorrosion protection applied in the factory

The following anticorrosive wax has been used in the factory:
Designation: ANTICORIT BW 366
Manufacturer: FUCHS MINERALOELWERKE GmbH/Mannheim (Germany)
Complies with specification:TI 8030-015/K 19
MIL-C-16 173 C – grade 4
Components coated with anticorrosive wax
Component Remarks
Before applying the wax:
• Apply contact spray to contact surfaces and
connect the plug-and-socket connections
All electric plug-and-socket, earthing
again
and crimp connections
• Apply a particularly thick anticorrosion layer
to the connecting parts of the fuel level
transmitter
Except:
• Piston rods (chromium coating)
• Cab, cab bearings
• Engine cover, engine mounting
All parts of the machine, e.g. • Air filter
Axles, gearbox, trim panels, servicing • Counterweight
lids, loader unit, quickhitch • Fastening surfaces for mounting parts on
frame
• Radiator and insulating mats
• Mudguards, rubber and plastic parts
• Light elements
Flange surfaces E.g. axles, engine and cab bearing:
• Seal gaps with anticorrosion wax after
assembly
3-60 Serv-HB 34900/01 – Edition 1.0 * Aggressive Medien.fm

Measures for maintaining anticorrosive protection

Safety instructions
• When handling chemical substances of any kind, such as solvents, wax etc., observe
the specific product-related safety regulations (safety data sheet)!
• When using volatile and easily flammable anticorrosive agents and solvents:
• Ensure adequate room ventilation!
• Do not use unprotected lights or naked flames!
• Do not smoke!
• Corrosion on electric connections or components can lead to dangerous operating
malfunctions. Therefore check the electric functions of the machine with special care.
Immediately put the machine out of operation if you detect any defects and have
defects rectified immediately.
• Carry out work on the electrical system only with the battery disconnected and the
engine stopped!
Cleaning
• If the machine is used in corrosive environment over a longer period of time, we
recommend removing the floor mat in the cab to avoid collecting corrosive humidity.
• Thoroughly clean machines that are put out of operation over a longer period of time.
• Clean the machine at least once a week. In particular, remove corrosive deposits (such
as salt crusts) as fast as possible.
• Clean the machine with cold running water preferably.
Caution!
Contrary to the instructions given in Chapter “General maintenance work” in
the Operator’s Manual of the machine, neither clean the machine with a bristle
brush nor with a steam jet or a high-pressure cleaner. Otherwise the
anticorrosive protection will be heavily affected.
☞ If cleaning the machine with these means cannot be avoided, check the
wax coating very carefully and have it renewed or reapplied as required.
If you replace components, check whether they are classified as in Compo-
nents coated with anticorrosive wax on page 3-60 and whether they are
subject to special treatment before assembly.
Serv-HB 34900/01 – Edition 1.0 * Aggressive Medien.fm 3-61

Applying the protective anticorrosion coating

Bear in mind the following instructions as you apply the anticorrosive wax:
Caution!
Carefully cover all fastening surfaces and elements to which the anticor-
rosive protection may not be applied – see Components coated with
anticorrosive wax on page 3-60
• ANTICORIT BW 366 can be applied with a brush, by means of immersion or with all
commercially available spray guns.
• ANTICORIT BW 366 protective coating can be removed with petrol, RENOCLEAN E/K
or FUCHS MULTICLEAN as required.
• ANTICORIT BW 366 spots are difficult to remove on clothing.
• Affix a “Wet paint!” or a similar sign to newly coated machines.
Treatment of oxidised surfaces

If in spite of all precautionary measures some components should be affected by corrosion
(oxidised), proceed as follows depending on the affected component:
Electric connections
☞ Remove the remaining protective wax in the oxidised area with petrol, RENOCLEAN E/
K or FUCHS MULTICLEAN
☞ Treat all affected parts with an oxide solvent, such as KONTAKT 60
☞ Rinse the area with e.g. KONTAKT WL
☞ Treat the contact surfaces of the connection with e.g. KONTAKTSPRAY WD 40
☞ Establish the connection
☞ Apply/spray anticorrosion wax onto the electric connection from all sides
Sheet-metal parts
☞ Remove the remaining protective wax in the oxidised area with petrol, RENOCLEAN E/
K or FUCHS MULTICLEAN
☞ Remove all remaining corrosion and paint coating from the affected area down to the
bare material, otherwise the paint coating will not adhere properly!
☞ Clean the affected part with a cleaning solvent
☞ Apply a 2-component prime coating to the affected area and then a 2-component paint
coating
☞ Preserve the area with anticorrosion wax
3-62 Serv-HB 34900/01 – Edition 1.0 * Aggressive Medien.fm

Diesel engine
4 Diesel engine Diagram

Electrical system
Diesel engine
Diesel engine
4.35 Diesel engine electrical system diagram
4-2 Serv-HB 34900/01 – Edition 1.0 * 34901_0401_Dieselmotor_el_a3.fm

Diesel engine
Diesel engine
4.36 Diesel engine electrical diagram (legend)
Diesel engine electrical diagram (legend)

B001 Fuel indicator
B018 Engine temperature buzzer
F Fuses
G001 Alternator
G002 Battery
H002 Preheating indicator light
H003 Diesel engine temperature indicator light
H004 Engine oil pressure indicator light
H005 Alternator charge indicator light
H006 Air filter indicator light
H018 Parking brake indicator light
K008 Time lag relay 1s cutoff solenoid
K009 Cutoff solenoid switching relay
K018 Switching relay (lock)
K075 Switching relay for continuous operation of 3rd control circuit
M001 Starter
M009 Fuel pump
P001 Hour meter
P002 Fuel gauge
R001 Preheating system
S001 Preheating start switch
S002 Engine oil pressure switch
S003 Diesel engine temperature switch
S004 Air filter pressure switch
S008 Battery master switch (OPTION)
S011 Parking brake switch
S033 Continuous operation of 3rd control circuit
S124 Start repeat interlock limit switch
V Diodes
X015 1-pole disconnect (seat contact switch)
X021 1-pole connector (start repeat interlock for additional control circuit)
XA01 15-pole connection (indicating instrument)
Serv-HB 34900/01 – Edition 1.0 * 34901_0401_a4_Dieselmotor_Legende_el.fm 4-3

Diesel engine
Diesel engine electrical diagram (legend)

XP01 18-pole board connection
XR01 1-pole High-Power connection
XR02 21-pole disconnect (cab-engine/frame)
Y001 Cutoff solenoid
4-4 Serv-HB 34900/01 – Edition 1.0 * 34901_0401_a4_Dieselmotor_Legende_el.fm

Diesel engine
Diesel engine
4.37 Engine designation

Wheel loader model Trade name
349-00 550
349-01 650
4.38 Fuel specification

Fuel specification Country
No. 2-D, no. 1-D, ASTM D975-94 USA
DIN EN 590 European Union
ISO 8217 DMX International
BS 2869-A1 or A2 United Kingdom
GB252 China
4.39 Coolant specification

Specification Country
ASTM D6210, D4985 USA
SAE J814C, J1941, J1034 or J2036 International
Serv-HB 34900/01 – Edition 1.0 * 34901_0401_Motor.fm 4-5

4-6
50 Nm Spacers
Diesel engine
86 Nm
4.40 Engine (overview)
Fuel filter
Elastic clutch
Oil pressure
Spacers switch
Spacers
Engine oil filter
50 Nm
Spacers Oil drain valve (not
installed)
Serv-HB 34900/01 – Edition 1.0 * 34901_0401_Motor.fm

Diesel engine
4.41 Electric components on engine (overview)
Alternator 12 V/55 A
Alternator 12 V/80 A (option)
Glow elements
S002 oil pressure switch Y001 cutoff solenoid S003 temperature sensor
Coolant

Diesel engine
4.42 Preheating system (circuit diagram)
F – fuses
G002 – battery
H002 – preheating indicator light
K005 – preheating high current relay
R001 – glow elements
S001 – ignition lock
XA01 – 15-pole connection (indicating instrument)
XA02 – 10-pole connection (indicating instrument)
XP01 – 18-pole connection (board)
XP04 – 18-pole connection (board)
4-8 Serv-HB 34900/01 – Edition 1.0 * 34901_0401_Motor.fm

Diesel engine
4.43 Starting system (circuit diagram)
F000 – fuses
G001 – alternator
G002 – alternator
H013 – parking brake indicator light
K001 – power supply high current relay
K007 – high current relay for starting (start repeat interlock; as soon as the alternator turns,
the relay does not switch any more)
K018 – switching relay (lock)
K075 – switching relay for continuous operation of 3rd control circuit
M001 – starter
M002 – fuel pump
S001 – ignition lock
S011 – parking brake switch
S033 – continuous operation of 3rd control circuit
S124 – start repeat interlock mechanical control valve 3rd control circuit
XP – board connection
XR – cab/frame disconnect

Diesel engine
4.44 Cutoff solenoid (circuit diagram)
F – fuses
G002 – battery
K001 – power supply high current relay
K008 – time-lag relay for 1 sec. for pickup winding of cutoff solenoid
K009 – cutoff solenoid switching relay
M009 – fuel pump
XP – board connection

Thermostat
– opens at 72 °C
– open at 83 °C

4.45 Cooling (overview)
Hydraulic oil cooling
Engine cooling
(water)
Adjust air guide plate
Fan blade must no touch the
dirt ring
Radiator cap (0.9 bar)
Expansion tank
Coolant
4-11
Diesel engine
Diesel engine
4.46 Valve clearance
Firing order
1–3–4–2
Locknut
Valve clearance 0.15 – 0.20 mm Set screw
Rocker arm

B001 fuel indicator
Injection nozzle 4.47 Fuel system

Cutoff solenoid
Water separator
Fuel filter
Electric feed pump
4-13
Diesel engine
Diesel engine
Notes:

Power train
5 Power train Drive (electrical diagram)

Power train
5.1 Drive (electrical diagram)
Description:
B003 Backup warning system
H016 Forwards driving indicator light
H017 Reverse driving indicator light
K003 Reverse driving switching relay
S021 1st/2nd speed switch
S034 Forwards driving tip switch
S035 Reverse driving tip switch
S066 Neutral tip switch
X012 1-pole connection – driving direction identification
XJ01 12-pole joystick connection
XJ05 Joystick connection
Y002 1st/2nd speed solenoid valve
Y004 Reverse driving solenoid valve
Y005 Forwards driving solenoid valve
Y010 Driving direction identification solenoid valve
5-2 Serv-HB 34900/01 – Edition 1.0 * 34901_0510_Fahrantrieb_el_a3.fm

Power train
Drive hydraulics diagram Drive hydraulics diagram

Power train
5.2 Drive hydraulics diagram
Description:
I Pump unit PFC
VII Drive hydraulics variable displacement pump
VIII Drive hydraulics variable displacement motor
A Consumer port
B Consumer port
To the brake (inching valve) C Consumer port

M Test port
T Tank port
X Control signal
016 Non-return valve

025 Tank
026 Return filter
027 Oil cooler
035 Drive pump
037 Drive boost-pressure relief valve
040 Multifunctional valve, reverse (drive)
041 Multifunctional valve, forwards (drive)
050 Drive swivel-angle control cylinder
054 Drive variable displacement motor
To the differential lock
To the pilot control of the 3rd control cir- 055 Hydraulic ram (drive)
cuit (option) 058 (driving direction valve)
104 (S5) fouling indicator
107 Hydraulic oil dirt pressure switch
Y002 1st/2nd speed solenoid valve

Y004 Reverse driving solenoid valve
Y005 Forwards driving solenoid valve
Y010 Driving direction identification solenoid valve
5-4 Serv-HB 34900/01 – Edition 1.0 * 34901_0510_Fahrantrieb_hy_a3.fm

Power train
Power train
5.3 Functional description of the drive hydraulics

Drive settings
A range of settings can be carried out if drive output is not optimal. Carrying out all the
measurements, one after another, as specified in the test report is absolutely necessary to
this effect.
The test and adjustment instructions are indicated by the page numbers in the test report.
Follow the instructions carefully. The rated values in the test report are decisive for the
adjustments which must not fall short of or exceed the values.
Notice! File the completed test report for later evidence!
Troubleshooting (drive)
Follow the exact steps shown in the diagram for carrying out troubleshooting on the drive.
Each step is described separately. All measured values must be entered in the test report.
Notice!
➥ A completed test report must be included in any warranty claim brought forward
➥ Warranty claims cannot be processed without a test report
Oil supply via boost pump (001)

The boost pump (001) supplies oil for a range of functions:
• Drive with boost pressure
• Differential lock
• Electrical 3rd control circuit (option)
Boost-pressure circuit
The oil pumped by the boost pump (001) creates a boost pressure against the boost pres-
sure relief valve (037). Depending on the spring setting in the valve (037), the oil flow is put
under initial stress and then released to the tank.
Boost pressure is applied to the servo adjustment valve (Y005 and Y004). The high-pres-
sure valves supply the closed circuit with oil
Boost-pressure relief valve

The pressure setting can be corrected with washers at the boost-pressure relief valve
(037).
Pump adjustment
The spool in the servo adjustment valve is moved out of the neutral position, in either
direction by means of the solenoid coils (Y004, Y005). Depending on the driving direction,
pressure is applied to one side of the servo cylinder (050), and the other side is connected
with the tank by means of the return. The servo cylinder (050) swivels the variable dis-
placement pump (VII). In doing so, the magnetic force of the solenoid coils (Y004/Y005)
acts against the spring tension of the spool. There is no mechanical feedback of the swivel
angle to the servo adjustment valve (non feedback system). The swivel angle is set
according to the control pressure.
Serv-HB 34900/01 – Edition 1.0 * 34901_0510_Funktionsbeschreibung_Fahrhydr.fm 5-5

Power train
Adjustment of variable displacement motor

The engine has maximum capacity in its base position. In doing so, a high torque is cre-
ated. The motor is adjusted to minimum capacity via high pressure. The higher the diesel
engine speed, the higher the control pressure. Drive speed is controlled in the first range
by the pump. The control pressure sets the motor to minimum capacity in accordance with
the drive requirements. In doing so, a small torque is created at high engine speed
Flush feature
The high-pressure side in the high-pressure circuit switches the shuttle valve (scouring
slide valve 059) in the variable displacement motor (drive hydraulics VIII). In doing so, a
larger amount of oil is replaced in the closed oil circuit.
Inching pedal function

The (brake) inching pedal reduces the control pressure of drive speed regulation.
5-6 Serv-HB 34900/01 – Edition 1.0 * 34901_0510_Funktionsbeschreibung_Fahrhydr.fm

Power train
Power train
5.4 Variable displacement pump test ports (20 kph)
Solenoid valve Y004 = forwards driving (green/violet cable colour)

Solenoid valve Y005 = reverse driving (white/violet cable colour)
Test port Test port

High pressure/reverse Control pressure
X2
Y005
X1
HP/forwards driving
HP/reverse driving
Test port Test port

Boost pressure High pressure/forwards
Serv-HB 34900/01 – Edition 1.0 * 34901_0510_Fahrantrieb.fm 5-7

Power train
5.5 Valves of variable displacement pump 20 kph
High-pressure cartridges Transposition plug Mechanical zero position Pressure cutoff

(towing function)
Boost pressure valve Control cartridge High-pressure cartridges

(starting engine (towing function)
speed)
5-8 Serv-HB 34900/01 – Edition 1.0 * 34901_0510_Fahrantrieb.fm

Power train
5.6 Test ports of variable displacement motor (20/30 kph)
Variable displacement motor 20 kph A6VM 60 DA

Variable displacement motor 30 kph AA6 VM 60 DA
Scouring slide
valve 30 kph
Control initiation
test port
Y 10 solenoid valve
Driving direction iden-
tification
Test port for driving
direction identification Forwards energised
Cable colour WH/VT
Control initiation set screw allen Y 2 solenoid valve 1st –

key 3 / w/f 10 2nd speed
1st speed energised
Cable colour YE/GY

Power train
5.7 Variable displacement motor – solenoid valves (20/30 kph)
Variable displacement motor 20 kph A6VM 60 DA

Variable displacement motor 30 kph AA6 VM 60 DA
Control pressure line 1st/2nd speed
Leak oil line
Set screw for speed/cardan shaft

speed
Y 10 solenoid valve Y 2 solenoid valve 1st –

Driving direction identification 2nd speed
Forwards energised 1st speed energised
Cable colour WH/VT Cable colour YE/GY

Power train
5.8 Inching valve overview

P – control pressure
Bleeder valve for brake system
Y – control line (master brake cylinder)
venting/bleeding the piston

T – return line
Description of inching valve

Actuating the brake pedal applies pressure to the inching valve and the service
brake.
The machine is first braked by means of the hydraulic drive, and then with the
service brake.
Functional description
Actuating the master brake cylinder applies brake pressure to port Y of the inch-
ing valve, which in turn controls the control spool in the inching valve and estab-
lishes a connection between port P and port T.
The control pressure of the variable displacement pump is reduced, and hence
the flow rate of the variable displacement pump is reduced.
The machine slows down. At the same time, the brakes become active, propor-
tionally to the brake pressure.
Danger!
The inching valve is a safety component! Do not carry out any

modifications!

Power train
5.9 Inching valve circuit
Bleeder valve for brake Variable displacement pump control

system line
Caution!
When measuring output with the

brakes, return must be closed on
either side (inching valve and
return line)
P from the brake Ventilation and bleeding

Inching valve
From the hydraulic pump To tank
From the variable displacement motor
Serv-HB 34900/01 – Edition 1.0 * 34901_0510_Fahrantrieb.fm

5.10 Inching valve diagram
Brake calliper
valve
Pressure relief
Brake cylinder
Brake pedal
S 9 brake light switch
Brake fluid tank

Power train
5-13
5-14
Power train
Control initia-
tion test port
5.11 Drive circuit
Suction line Return suc-

tion filter
Leak oil
T
Radiator
outlet
Non-return valve
T2 2 bar Hydraulic oil
radiator
Radiator Engine coolant

intake radiator

Variable displacement pump control pressure
5.12 Low-speed control

Low-speed control cable pull
Low-speed control valve
Tank line
Control pressure
Hydraulic oil tank

Power train
5-15
5-16
Control cartridge
Solenoid valve 1st – 2nd speed
Pressure controller
Directional valve ➥ 1st speed energised
Power train
Control initiation setting
Forwards/reverse To the inching ➥ 2nd speed de-energised
valve
To the inching To the priority valve
5.13 Drive diagram

Work hydraulics
steering
Oil-to-water-cooler
Pressure switch
Vent filter
Control initiation Return

HP valves Boost suction
test port
pump
Servo cylinder Boost pressure valve
Pressure cutoff Driving direction identification
➥ Reverse driving de-
energised
➥ Forwards driving energised
Valve 2.0 bar

(small oil circuit)

Power train
5.14 Towing and transporting the machine

Safety instructions
• The machine may only be towed using suitable towing equipment (towing bar or cable)
in connection with suitable towing gear, such as a towing coupling, hooks and eyes!
• Move off slowly!
Ensure that no-one is dangerously close to the towing bar
• The machine may only be towed with a cable if the service brakes and steering are fully
operational!
Getting ready for towing
C B
Danger!
A
Turning the steering wheel requires greater effort if the diesel engine breaks
down. Take this into account especially when towing the machine!
☞ Use a towing bar!
A
B
Caution!
The hydrostatic power train can be damaged when towing the machine!
C
☞ Stop the engine!
☞ Short-circuit the hydraulic circuit before towing (see below)
Fig. 1: 20 kph hydraulic pump
☞ Do not tow the machine for more than 100 meters and do not tow it faster
than 3 – 4 kph!
D
F ☞ Tow away the machine as follows:
• Fit an adequately sized towing bar to the towing gear
20 kph hydraulic pump
☞ Switch over the HP pressure relief valves A on the hydraulic pump. To do this:
E • Slacken hexagon lock nuts B on both HP valves A
• Screw in hexagon socket head screws C on both HP valves A until they are flush with
lock nuts B
• Secure hexagon socket head screws C on both HP valves A with lock nuts B
Fig. 2: 30 kph hydraulic pump (option) 30 kph hydraulic pump (option)
☞ Mount hose D between test ports E and F
➥ The hose is included in the tool kit
☞ If possible, run the engine at idling speed when towing the machine
Once towing is over ...
☞ ... reset the HP valves A on the 20 kph hydraulic pump! To this effect, unscrew each of
hexagon socket screws C as far as they will go and secure them with locknuts B, or
☞ Remove hose D in the case of the 30 kph hydraulic pump

Power train
5.15 Test report: 20/30 kph power train

Model: Prod. no. variable displace- Prod. no. variable displace- Serial no.
ment pump ment motor
____________________ ___________________
____________________ ____________________
Variable displacement pump settings
Test conditions: Oil temperature (rated): 50 – 60 °C
See Test features: Actua

page: Notes: l
value:
Lower idling speed with- 1075 – 1125 rpm
Measured on crankshaft
out air conditioning
Upper idling speed with- 2970 – 3020 rpm

Measured on crankshaft
out air conditioning
5-19 Boost pressure Max. engine speed 25 – 30 bar
5-20 Control pressure Max. engine speed About 25 – 30 bar

Min. engine speed About 5 bar
5-21 Driving direction identifi- Same pressure

Measured in forwards and reverse
cation increase as for high
driving
pressure
5-22 Starting engine speed Measured on crankshaft 1250 – 1350 rpm
5-23 High pressure 450 – 460 bar

2nd speed braked max. engine speed
Drive pressure
5-26 Hydraulic resistance curve Over 340 bar

2nd speed braked at 2200 rpm
– high pressure
5-27 Engine droop HP/forwards driving 220 – 240 bar 2480 – 2520 rpm
Hydraulic motor settings (variable displacement motor)
5-28 Control initiation 2nd speed after braking 240 – 260 bar
5-29 Wheel revs 20 kph 12.0/75-18 12PR TR11T

12-16.5 10PR SK-02 TBL
110 – 120 rpm
12.0.18 T86 Stab. 12PR TL
325/70 R18 MPT AC70G TL
5-29 Wheel revs 20 kph 365/70 R18 EM01

12.5-18 MPT04
100 – 110
335/80 R18 XZSL
340/80 R18 Multiuse 550
5-29 Wheel revs 30 kph 12.0/75-18 12PR TR11T

12-16.5 10PR SK-02 TBL
165 – 180
12.0.18 T86 Stab. 12PR TL
325/70 R18 MPT AC70G TL
5-29 Wheel revs 30 kph 365/70 R18 EM01 150 – 165

12.5-18 MPT04
335/80 R18 XZSL
340/80 R18 Multiuse 550

Power train
5.16 Adjustment instructions
Notice!
Run the machine warm before taking the measurement so the hydraulic system
reaches its optimum operating temperature of 60 °C!
Brake the machine with the service brake when taking the measurement. Conse-
quently, unscrew the brake-inching line from the hydraulic pump and fit a dummy
cover! Only set the valves if the pressure has been released!
Tools required for setting the drive

• High pressure gauge (600 bar, 2 off)
• Pressure gauge (60 bar, 2 off)
• Tachometer
5.17 Adjusting boost pressure
Boost pressure valve Boost-pressure test port
Notice!
The boost pressure can only be set by means of washers in the boost pres-
sure valve
Check as follows:
☞ Connect 60 bar pressure gauge
☞ Start the diesel engine, no driving direction
☞ At max. engine speed 25 – 35 bar
☞ Remove the complete valve if boost pressure is too low
☞ Set the pressure to 25 – 35 bar by adding or removing washers

Power train
5.18 Checking the control pressure
Control pressure test port
Inching valve/variable displacement motor control line
Control cartridge
Orifice diameter? mm
Check as follows:
☞ Connect 60 bar pressure gauge
☞ Jack up the machine
☞ Select a driving direction
➥ Control pressure at idling speed about 5.5 – 7.5 bar
➥ Control pressure at full speed about 25 – 30 bar
➥ If the control pressure is not reached:
☞ Close the control line to the inching valve/variable displacement motor
➥ No control pressure = check inching valve and the variable displacement motor
➥ Control pressure = check the control cartridge for dirt and smooth running

Power train
5.19 Checking the driving direction identification
Test connection for driving

direction identification
Test port for high pres- Test port for high pres-
sure reverse driving sure forwards driving
Check as follows:
☞ Switch off ignition
☞ Connect a pressure gauge to forwards and reverse driving high pressure test port
☞ Connect a pressure gauge to the driving direction identification test port
☞ Start the diesel engine and select the forwards driving direction
☞ Low engine speed
➥ The forwards driving test port and the driving direction identification must have the
same pressure
☞ Carry out the same measurement in reverse
Solenoid valve for driving ➥ If there is no high pressure at the driving direction identification test port, check
direction identification (for- energisation or the forwards-reverse spool valve
wards driving energised)
☞ Remove the forwards-reverse spool valve

☞ Check the forwards-reverse spool valve for smooth running

Power train
5.20 Adjusting starting engine speed
Control cartridge
Check as follows:
☞ Switch off ignition
☞ Connect the tachometer
☞ Increase the diesel engine speed until the wheels start turning
➥ The starting speed is reached when the wheels start turning
Set the starting speed on the control cartridge:
Screw in the control cartridge w/f 13 / allen key 4
➥ Later start (higher diesel engine speed)
Unscrew the control cartridge w/f 13 / allen key 4
Earlier start (lower diesel engine speed)

Power train
5.21 Setting high pressure/drive pressure
Pressure cutoff
Test port for high pressure forwards

driving
Connect pressure gauge (600 bar)
High-pressure valve forwards driving
Notice!
The pressure cutoff corresponds to the hydraulic pressure measured at the for-
wards and reverse driving HP test ports
Check as follows:
☞ Select the 2nd drive range
☞ Drive the machine against “hydraulic resistance” (wheels not allowed to spin at full
thrust)
☞ Read off the pressure on the forwards driving HP gauge
Set the pressure at the pressure cutoff (w/f 13 – allen key 4)
☞ Screw in the pressure cutoff
➥ Pressure increase
☞ Unscrew the pressure cutoff
➥ Pressure reduction

Power train
5.22 Checking/adjusting the high-pressure valves

Pressure cutoff Check as follows:
☞ Connect the forwards – reverse driving high pressure gauges
☞ Turn in the pressure cut-off valve completely
Drive the machine against a hydraulic resistance (the wheels must not turn)
☞ Read the pressure gauge
➥ Pressure must be 490 – 510 bar
High-pressure valve forwards driving
Adusting the high-pressure valve

Slacken hexagon
☞ Unscrew the high-pressure cartridge (wrench size 32)
socket screw 3
☞ Clamp the valve insert at the spring seat
Clamp at the ☞ Slacken hexagon socket screw 3
spring seat ☞ Turn the screw (wrench size 8) on the opposite side to the right (pressure increase)
➥ 1 turn corresponds to about 40 bar
Set w/f 8 here
☞ To check the pressure, install the valve again and repeat the pressure test
1 turn corresponds
to about 40 bar If the pressure is not adusted correctly, re-adjust the pressure cutoff again.
302S2214.ai
Remove valve completely
(wrench size 32)

Power train
5.23 Pressure cutoff (exploded view)
Sleeve can be pulled out of the

variable displacement pump
34001s22_10.eps

Power train
5.24 Checking/setting the high pressure/characterisic curve of the pump

Transposition plug
Caution!
We recommend you to contact Kramer customer service before modifying the

hydraulic resistance curve!
Notice!
Test port for high Transposition screw is set to 9 o’clock (position indicated by slot in the screw)!
pressure forwards Correct the hydraulic resistance curve as required by turning the transposition
driving screw!
Check as follows:
Control line ☞ Close the control line on the inching valve (disable inching)
☞ Slowly increase the engine speed and drive against a hydraulic resistance (the wheels
must not turn)
➥ At 2200 rpm, high pressure (forwards) must be:
➥ Over 340 bar
The brake system does not have to be bled after connecting the control line
Inching valve
Example:
Hydraulic resistance ☞ Set the transposition screw to 12 o’clock:
curve
➥ Hydraulic resistance curve becomes flatter (= machine reacts more smoothly)
set on test rig
☞ Set the transposition screw to 6 o’clock:
(bar) 6 o’clock Hydraulic resistance curve becomes steeper (= machine reacts more abruptly)
500
450
9 o’clock
400
300
12
200
100
Control pressure
1000 1500 2000 2500

Speed [rpm]

Power train
5.25 Check engine droop

Control cartridge Check as follows:
☞ Close the control line on the inching valve (disable inching)
☞ Forwards driving direction, select 1st speed
☞ Run the diesel engine to full speed
☞ Brake the machine to 220 – 240 bar high pressure at full diesel engine speed
➥ Droop speed 2480 – 2520 rpm
Test port for high pressure If the engine droop is excessive:
forwards driving ☞ Check the diesel engine
☞ Check the control cartridge
5.26 Control cartridge function
X1
x1 X2
x2
Pump setting
Pumpenverstellkolben
b a Direction valve
Fahrtrichtungsventil
Control pressure
p sp = p 2
Control valve Drive range pis-

Regelventil
p3
ton
Stufenkolben
Orifice
Blende 3 Accelerator pedal
p1.Q1 Gaspedal
Set screw (starting

Stellzapfen für
speed) Vorspannung
Pressure
Druckfeder spring
(Inch-Hebel)
Diesel engine
Boost pump

Power train
5.27 Setting control initiation on the variable displacement motor

Test port for high pressure forwards driving
Control initiation test port
Adjust control initiation w/f 10 – allen key 3

- Screw in = pressure increase
- Unscrew = pressure reduction
Check as follows:
☞ Connect a 600 bar high-pressure gauge on HP forwards driving and on the control pis-
ton of the variable displacement motor
Control line ☞ Close the control line on the inching valve (disable inching)
☞ Forwards driving direction, select 2nd speed
☞ Slowly brake the machine with the service brake
➥ Pressure gauge (forwards driving high pressure) and control piston pressure rise
evenly
➥ Control initiation starts as soon as the pressure in the control piston drops
Adjustment
☞ Screw in the set screw = pressure increase
Inching valve ☞ Unscrew the set screw = pressure reduction

Power train
5.28 Setting the wheel speed

Check as follows:
Label (measure-
See the test report for the adjustment values
ment point)
☞ Forwards driving direction, select 2nd speed
☞ Read off the wheel speed with a tachometer
Speed is adjusted at the variable displacement motor
☞ Unscrew the set screw
➥ Wheel speed is increased
☞ Screw in the set screw
➥ Wheel speed is reduced
Set screw for wheel speed

Power train
Notes:

Axles
6 Axles Differential lock (electrical/hydraulics diagram)

Axles
6.1 Differential lock (electrical/hydraulics diagram)
Description:
F Fuses
H012 Differential lock indicator light
K030 Brake lights switching relay
S009 Brake light switch
S025 Differential lock tip switch
V Diodes
XA01 15-pole indicating instrument
XA02 10-pole indicating instrument
Y009 Differential lock solenoid valve
063 Differential lock

A Consumer connection (P connection)
B Consumer port
C Consumer connection (T connection)
6-2 Serv-HB 34900/01 – Edition 1.0 * 34901_0600_Differenzialsperre_el_hy_a3.fm

Axles
Axles
6.2 Axle type label
Type label contains all axle data

Wheel loader model: 349-00/01 (550/650)
➥ Axle type: front axle 26.09/rear axle 26.09 M+TB
➥ Axle type: front axle 26.09 M/rear axle 26.09 M+TB
Axle type label
Axle type Carraro serial no.
Carraro no. Customer no. Transmission ratio
Input shaft speed Differential type
Serv-HB 34900/01 – Edition 1.0 * 34901_0610_Achsen.fm 6-3

Axles
6.3 Tightening values (Nm)
6-4 Serv-HB 34900/01 – Edition 1.0 * 34901_0610_Achsen.fm

Axles
6.4 Screw connections
Loctite 270 or
Superbond 331
Wheel bolts glued in wheel
hub
Loctite 542 or
Superbond 321

Axles
6.5 Sealing work

Input flange – front axle
3
4
5
Replacing the rotary shaft seal

• Remove the cardan shaft
• Remove brake calliper 2
• Remove brake disc 1
• Remove circlip 5 with suitable tools
• Remove flange 4 from the input shaft with an extractor
• Replace rotary shaft seal 3 with a new one
• Assembly in the reverse order

Axles
6.6 Sealing: planetary drive
Rotary shaft lip seal
Cassette seal
Taper roller bearing
Final drive carrier

Internal-geared wheel
Wheel hub
Screw lock

Axles
☞ Drain the oil

• Open the drain plug
• Remove the drain plug and drain the oil
• Remove fastening screws 1
Environment!
Use a suitable container to collect the oil as it drains and dispose of it in an
environmentally friendly manner!
1
☞ Remove cover 2
☞ Remove the O-ring from the wheel hub
2 Danger!
Careful when removing the planetary drive –

Danger of personal injury!
☞ Use a strap or cable to secure the planetary drive onto a lifting tackle or
other lifting gear to avoid damage or personal injury
☞ Mount the eyebolt for lifting the planetary drive

☞ Remove screws 3 the top and the bottom of the bearing pin
☞ Carefully remove the planetary drive with the double cardan shaft from the axle carrier
☞ Remove the circlip

☞ Remove the spacer washer and the screw lock

Axles
☞ Extract double cardan shaft 4 from planetary drive 5

4
5
☞ Remove the screws from internal-geared wheel 6

6
☞ Remove the internal-geared wheel by applying pressure with pressure screws 7

7 • Screw in two of the screws that have been removed into the extraction bore
☞ Remove wheel hub 8 from final drive carrier 9

9
8

Axles
☞ Remove the old rotary shaft lip seal 10 from the final drive carrier
10
☞ Remove the old cassette seal 11 from the final drive carrier
11
☞ Remove rotary shaft lip seal 12 from the axle tube with an inside extractor
12

Axles
6.7 Installing the planetary drive

☞ Apply a sealing compound to the outside sealing surface of the rotary shaft lip seal
☞ Mount the rotary shaft lip seal with an adapter
☞ Apply a thin coat of grease inside the rotary shaft lip seal
☞ The mounting position of the new cassette seal must be free of oil and grease
• Do not apply any grease inside the cassette seal
☞ The cassette seal must be mounted with a precise-fit adapter
☞ Apply a thin coat of grease inside the rotary shaft lip seal
☞ Check the double cardan shaft for damage

☞ Insert the double cardan shaft in the axle tube

Axles
☞ Carefully put the double cardan shaft through the planetary carrier
☞ Fasten the final drive carrier with the upper bearing pin, then mount the lower bearing
pin
➥ The planetary drive bearing must be mounted without any tolerance
☞ Tightening torque 120 Nm
☞ Mount the taper roller bearing for the wheel hub

• Apply oil to the taper roller bearing
☞ Put the wheel hub on the taper roller bearing mounted previously
☞ Then mount the thrust bearing
☞ Apply oil to the taper roller bearing
• No measurement is required
☞ Before mounting the internal-geared wheel, parallel pins 13 on the internal-geared

13 wheel must be flush with the housing
☞ In order to be able to fasten the internal-geared wheel, make both parallel pins 13 pro-
trude about 2 mm
☞ Fasten the internal-geared wheel on the final drive carrier with 2 screws

Axles
☞ Mount parallel pins 14 crosswise with a soft mandrel

14
☞ Tighten the fastening screws crosswise

• Use Loctite 270 screw lock
14
➥ You must be able to turn the wheel hub
☞ Insert screw lock 15

15 ☞ Insert spacer ring 16
16 ☞ Pull the double cardan shaft to the front and mount circlip 17
• Push back the double cardan shafts and ensure that circlip 17 is positioned correctly
17 in the groove
☞ Mount the cover and mount fastening screws 18

18 ☞ Fill gearbox oil into the planetary drive
• Refer to chapter “Maintenance (engine/machine fluids)” for the oil type and capacities

Axles
6.8 Sealing work: axle carrier – differential housing
Axle carrier housing
O-ring
Drain plug
Axle carrier housing
Differential housing O-ring
34001e2301.eps
Danger!
Careful when removing the axle carrier housing –

Danger of personal injury!
☞ Place the axle on a suitable support to safely strut the differential and axle
carrier after separating them.
☞ Mark the axle carrier

20
☞ Drain the gearbox oil
14
☞ Remove the fastening screws
☞ Remove the axle half with lifting gear
• The differential can be removed (front and rear axles) to the right as seen onto
the flange
☞ Apply a thin coat of grease to the new sealing ring 20 before mounting it
19 ☞ Tighten fastening screws 19 to 169 Nm
• Refer to chapter “Maintenance (engine/machine fluids)” for the oil and the capacities

Axles
6.9 Sealing: gearbox – input flange
1 4
2 5 7
3 6 8
17 25 24 23 16 15
34101e2602.eps
19 20
14 13 12 11 10 9
22 18 21
1 Bearing 15 Breather
2 Gear 16 Flange
3 Bearing 17 Plug
4 Screw plug 18 Screw
5 Housing 19 Plug
6 Pin 20 Shaft
7 Nut 21 Bearing
8 Stud bolt 22 Sealing ring
9 Screw 23 O-ring
10 Screw plug 24 Flange
11 Sealing ring 25 Screw
12 Circlip
13 Bearing
14 Gear

Axles
Preparatory work for removing and sealing the flanged shaft of the intermediate
gearbox
☞ Drain the gearbox oil from the differential and the intermediate gearbox
☞ Remove the cardan shaft
☞ Remove the variable displacement motor
☞ Remove intermediate gearbox 1 from the differential housing

1
☞ Remove circlip 2
☞ Press out input shaft 3 in the direction of the arrow
2
3
☞ Remove rotary shaft lip seal 4
☞ Mount the new rotary shaft lip seal with an adapter
3
4 • Apply a thin coat of grease inside the rotary shaft lip seal
• Clean all sealing surfaces and apply a sealant to them
☞ Install circlip 2
☞ Mount the intermediate gearbox onto the differential housing
☞ Tightening torque 70 Nm (screws)
☞ Tightening torque 77 Nm (nuts)
☞ Mount the variable displacement motor
☞ Mount the cardan shaft

Axles
6.10 Differential (overview)
Shims for bearing pressure of taper Differential cage Shims for bearing pressure of taper
roller bearings and backlash roller bearings and backlash
Crown wheel
Spacer Input bevel gear
Slotted nut
Adjustment bushing
Rotary shaft lip seal (squeeze bushing)

Axles
6.11 Replacing the gear drive

• Remove the axle
• Remove the track rods
• Remove both axle halves
☞ Remove the differential cage from the differential housing
• Remove the input bevel gear
☞ Remove and replace all taper roller bearings

Axles
Proceed as follows for the exact adjustment of the gear drive:

Spacer ☞ The stamped dimension V on the input bevel gear is used for the calculation of the
spacer
☞ Measure the thickness of the old spacer
• E. g. dimension V (+ 0.05) is subtracted from the thickness of the old spacer with 0.05
V mm
• E. g. dimension V (− 0.05) is added to the thickness of the old spacer with 0.05 mm
Caution!
If the differential housing is replaced, this calculation for the spacer cannot be
used. Please get in touch with your Kramer service in this case.
☞ Place the spacer with the nose showing downwards

Spacer
☞ Mount the taper roller bearing
☞ Insert spacer washer 1

1 2 ☞ Insert squeeze bushing 2
☞ Insert spacer washer 1
☞ Mount the bearing shells in the differential housing

• Ensure that the bearing shells of the taper roller bearings are not mixed up
☞ Apply a thin coat of oil to the taper roller bearing
☞ Mount the input shaft in the differential housing

Axles
☞ Tighten the bearing of the input bevel gear

• Check bearing pre-tension: you must be able to feel a resistance at the shaft
The rolling moment is 3.5 – 5.2 daN
☞ Secure the slotted nut on the shaft

1
Dimension A Measuring the differential

☞ Measure the axle half from the collar to the contact surface
• Measure the left and right-hand axle halves
• Make a note of dimension A
Dimension B ☞ Measure the axle half from the collar to the bearing bore
• Measure the left and right-hand axle halves
• Make a note of dimension B

Axles
☞ Measure the width of the differential housing

• Make a note of dimension C
Dimension C
☞ Measure the differential cage

Dimension D • Make a note of dimension D
Size S of spacer Dimension D Size S of spacer
Determining dimension S
B left B right
A left + A right = X
B left + B right = X1
C − (X + X1) = XC
XC − D = 2S
2S : 2 = S setting dimension
for left and right-hand axle
halves
A left A right
Dimension C

Axles
☞ Insert dimension S shims

Dimension S • Insert dimension S shims in the left and right-hand axle halves
☞ Insert the differential cage in the differential housing

☞ Mount both axle halves without the planetary drives
☞ Determine the backlash by means of a dial gauge
• Backlash 0.15 mm – 0.30 mm
Not enough backlash

• Move the differential cage to the right towards A
A A
• Reduce the spacer on the right-hand bearing of the differential cage and add the
difference to the left-hand bearing
Too much backlash
• Move the differential cage to the left towards A
• Reduce the spacer on the left-hand bearing of the differential cage and add the
difference to the right-hand bearing
B B
☞ Remove the right-hand axle half as seen onto the flange

☞ Remove the differential cage
☞ Apply oil to the tooth flanks
☞ Insert the differential cage in the differential housing
☞ Mount the axle half again

Axles
Checking the contact pattern of the gear drive

• Contact pattern not OK since the input shaft engages too far outside on the tooth flank
☞ Move the input shaft inwards towards the tooth flank by means of a thicker spacer
• Contact pattern not OK since the input shaft engages too far inside on the tooth flank
☞ Move the input shaft outwards towards the tooth flank by means of a thinner spacer
• Contact pattern OK since the input shaft engages exactly at the centre of the tooth flank
The rolling moment is 5.0 − 5.9 daN

Axles
6.12 Differential cage with lock (overview)
Seals
Shift fork
Shift cylinder
Seal
Springs
Differential cage

Axles
6.13 Differential cage

☞ Slacken the fastening screws
• Component parts of differential cage

• During assembly ensure that a good coat of grease is applied to all thrust washers
and bearing bushings
• Shift sleeve and lock pin

• Tightening torque 95 Nm

Axles
6.14 Removing the differential lock

☞ Slacken the fastening screws

Circlip
☞ Unscrew the cover on the opposite side

☞ Remove the guide sleeve and the spring
☞ Remove the shaft from the shift fork

Axles
6.15 Mounting the differential lock

☞ Insert the shaft into the differential housing through the shift fork
☞ Mount new sealing rings on the shift cylinder
☞ Mount the guide sleeve and the spring on the opposite side

Axles
6.16 Axle carrier overview
5 7 8 9
6
10 8 11 5 6
18
12
19
1
13
14
15
4
3 16
18
2
17
34001e2300.iso
1 Cpl front axle 13 Bushing

2 Bow 14 Bushing
3 Washer 15 Circlip
4 Hexagon nut 16 Bearing
5 Axle carrier 17 Wave spring washer
6 Screw plug 18 Screw
7 Breather 19 Spacer washer
8 O-ring
9 Differential housing
10 Screw plug
11 Plug
12 Wave spring washer

Axles
6.17 Steering ram overview
10 9 8 11 7
16 R
L 4 3 2 1 7
18 12 13 14 15 19
20
5
34101e2302.eps
6
17 2
1 Conical grease nipple 11 Screw
2 Screw 12 Sealing ring
3 Bearing pin 13 Bushing
4 Planetary carrier 14 Stop bolt
5 Nut 15 Hexagon nut
6 Bearing pin 16 Planetary carrier
7 Swivel head 17 Conical grease nipple
8 Screw connection 18 Piston rod
9 Sealing ring 19 Piston
10 Steering ram 20 Sealing kit

Axles
6.18 Wheel hub overview
19 18 17 5 6 2
1
17 12 18 19
2
3
16
15
4
20
10 9 8 7
11
30100e2640.eps
21 22 23
34101e2304.eps
14 13
1 Sealing ring 13 Sealing ring
2 Bearing 14 Screw plug
3 Housing 15 Screw
4 Stud bolt 16 Planetary carrier
5 Gear 17 Washer
6 Circlip 18 Needle bearing
7 O-ring 19 Pressure disc
8 Ring 20 Double cardan shaft
9 Gear 21 Washer
10 Bushing 22 Washer
11 Screw 23 Circlip
12 Gear

Brakes
7 Brakes Brakes (electrical/hydraulics diagram)

Brakes
7.1 Brakes (electrical/hydraulics diagram)
Description:
F Fuses
H018 Parking brake indicator light
H020 Brake lights
H021 Brake lights
S009 Brake light switch
XX02 7-pole rear socket
VI Master brake cylinder with brake servo
029 Expansion tank
030 Master brake cylinder (sensor)
031 Service brake hydraulic ram
P Pressure supply (hydraulic pump)
T Tank return line
Y Control line
Front axle Front axle
7-2 Serv-HB 34900/01 – Edition 1.0 * 34901_0700_Bremse_el_hy_a3.fm

Brakes
Brakes
7.2 Maintenance of the brake system

Specific safety instructions regarding the brake system
Brakes are crucial to safety. Incorrect maintenance can cause brake failure.
All repair work on the brakes must be carried out by trained staff.
An exception to this is the following work which must be carried out by the driver/
operator:
• Daily check of the level in the brake fluid tank
• Daily check of the brake lines
Fig. 1: Brake fluid label
Danger!
Defective brake lines or hoses carry a danger of accidents!

☞ Damaged brake lines or hoses must immediately be replaced by an author-
ised workshop
Checking/filling up the brake fluid level

The brake-fluid tank is located inside the cab to the left of the seat.
Danger!
A
Danger of accidents! An incorrect brake fluid grade or an insufficient brake
fluid level can impair the safety of the brake system.
☞ Check the brake fluid in the tank at regular intervals
MI AX
☞ Fill up brake fluid up to the upper edge of the sight glass

M
N
☞ The brake fluid must comply with the SAE specification (LHM)
☞ The brake fluid must be replaced every 2 years by an authorised workshop
Fig. 2: Brake fluid level in the tank ☞ If the brake system loses too much brake fluid, have the brake system
checked by an authorised workshop
☞ If the level is below the upper edge of the sight glass:

• Clean the area around the opening with a clean cloth
• Open tank cover A
• Fill up brake fluid up to the upper edge of the sight glass MAX
• Close tank cover A
Serv-HB 34900/01 – Edition 1.0 * 34901_0710_Bremse.fm 7-3

7-4
7.3
Brakes
Pressure line to brake 2 mm clearance to pedal Brake-fluid tank
calliper • Agip LHM Super
Shell LHM
Brake circuit
Master brake cylinder
Brake light switch (S 16) Control pressure line
Pressure relief valve 8

bar
Inching valve Inching up to 8 bar
Serv-HB 34900/01 – Edition 1.0 * 34901_0710_Bremse.fm

Brakes
7.4 Brake diagram
Inching valve
Brake pedal
To tank
Master brake cylinder
Ventilation and bleeding
Brake light switch
Pressure relief
valve 8 bar
Brake-fluid tank
Control pressure line • Agip LHM Super
• Shell LHM
Bleeder valve for

brake system Brake (front axle)
Service brake/inching valve function

A force (F) is applied to the displacement piston with the service brake. Moving the dis-
placement piston directs the brake fluid towards the pressure relief valve (up to 8 bar) and
towards the inching valve. Brake pressure is applied to the brake calliper at 8 bar.
Actuating the master brake cylinder applies control pressure to port Y of the inching valve,
which in turn controls the control spool in the inching valve and establishes a connection
between ports P and T.
The control pressure in the servo piston (variable displacement pump) is reduced, and
hence the flow rate of the drive hydraulics is reduced.

Brakes
7.5 Inching valve circuit
Bleeder valve for brake

system Control line to variable displacement pump
From the master brake cylinder
Caution!
When measuring output with the

Ventilation and bleeding brakes, return must be closed on
To the brake calliper
either side (inching valve and
return line)
7-6 Serv-HB 34900/01 – Edition 1.0 * 34901_0710_Bremse.fm

Brakes
7.6 Service brake

Important information on the brake system
Caution!
For reasons of safety, the brake/inching valve and the brake calliper
may be dismantled and repaired by authorised specialist staff only.
Otherwise replace these parts completely.
In order to avoid destroying the seals in the brake system, use Agip LHM
Super or Shell LHM brake fluid.
☞ Ensure that old brake fluid in the bleed equipment is fully replaced by the
brake fluid specified above – no mixtures!
Brake calliper maintenance
Caution!
Ensure that under all circumstances that no grease with metallic components
is used for maintenance work (e.g. copper paste)
☞ Use only PLASTILUBE or similar lubricants
Notice!
In connection with copper and salt water, aluminium-alloy brake callipers turn into
galvanic elements producing electric tension. This in turn produces corrosion, and
the components “seize”.

Brakes
7.7 Adjusting the service brake
3
4
Brake light switch
Adjusting the service brake

☞ Completely remove linkage 1 from the master brake cylinder and connect it with revers-
ing lever 2
☞ Connect linkage 3 with reversing lever 2 and brake pedal 4
• No sealing kit is available for the master brake cylinder for safety reasons

Brakes
7.8 Removing the brake calliper

☞ Unscrew the brake line
☞ Unscrew the brake calliper from the axle
☞ The fastening screws are slackened through the mounting bores in the brake disc
☞ Connect the brake line
Mounting bores ☞ Mount the brake calliper
☞ Then bleed the brake system
7.9 Replacing brake linings

☞ Push back the left and right-hand brake pistons
☞ Remove safety pins 1 and remove the brake linings
☞ Insert the new brake linings
☞ Mount safety pins 1 ensuring that the springs are under the safety pins
➥ Mount safety pins 1 centrally
☞ Press the brake pedal several times until you can feel the brake pressure
☞ Check the brake fluid in the brake-fluid tank
Safety pins

7-10
Brakes
7.10 Parking brake

Parking brake Service brake Reversing lever
Parking brake lever
Parking brake switch with starting interlock S11

Parking brake switch (S 16 indicator light on instrument panel)
☞ If the indicator light comes on:
➥ The power train is switched off
Parking brake lever ➥ Diesel engine cannot be started
Parking brake

7.11 Adjusting the parking brake
Cable colours
➥ Red
➥ Blue
➥ Yellow
0.5 mm 0.5 mm
☞ Adjust brake lever A ➥ Red
• Adjust the set screw until the brake lining is
0.5 mm away from the brake disc
Caution!
Adjust the parking brake if lever travel

A A is over 30° (4 – 5 notches). Do not
adjust the parking brake on the fork
heads of the Bowden cable.
7-11
Brakes
Brakes
7.12 Bleeding the brake system
Caution!
Use only Agip LHM Super or Shell LHM brake fluid!
☞ Always ensure that the brake-fluid tank is full when bleeding (use bleed equipment)
• (on the left in the cab)
☞ Connect the bleed hose onto the bleeder valve of the inching valve
☞ Press the brake pedal, open the bleeder valve (wrench size 8) on the inching valve as
you do so
☞ The bleeder valve on the inching valve must close before the brake pedal returns to
the initial position.
☞ Repeat the procedure (press the brake pedal) until there are no more bubbles at the
bleed hose
Bleeder valve of
inching valve
☞ Connect a bleed hose to bleeder valve 1 of the brake calliper

1 ☞ Press the brake pedal, open bleeder valves 1 (wrench size 8) on the brake calliper as
you do so
☞ Bleeder valve 1 on the brake calliper must close before the brake pedal returns to the
Bleeder valves of
initial position.
brake calliper
☞ Repeat the procedure (press the brake pedal) until there are no more bubbles at the
bleed hose
☞ Then repeat the procedure for bleeder valve 2
2

Steering system
8 Steering system Steering system (electrical/hydraulics diagram)

Steering system
8.1 Steering system (electrical/hydraulics diagram)
Description:
F Fuses
H013 4 wheel steering indicator light
H014 Front axle steering indicator light
S022 Steering mode switch
Y006 Front axle steering solenoid valve
Y007 4 wheel steering solenoid valve
IV Steering system valve block
Pressure supply from the pump
008 Priority valve (CF)
018 Front axle steering ram
019 Rear axle steering ram
020 Pressure relief valve
To the work hydraulics
021 Rotary spool valve
024 Steering system non-return valve
103 (Y06/07) 4/2 directional valve for steering system
A Consumer port
B Consumer port
CF “Orbitrol” port
Without steering-mode valve (4 wheel steering)
EF Valve unit port
L Left
LS Load-Sensing port
M Test port
P Pressure supply port (pump)
R Right
T Tank port
With steering-mode valve
Front axle Rear axle
8-2 Serv-HB 34900/01 – Edition 1.0 * 34901_0801_Lenkung_el_hy_a3.fm

LS
Steering system
LS line
Serv-HB 34900/01 – Edition 1.0 * 34901_0810_Lenkung.fm

L
Front axle
R
P
B1
A1
B2
A2 Steering ram with final
position synchronisation
Rear axle
Test port and P line to steering
system
8.2 Steering circuit with final-position synchronisation
P
Priority valve
CF
Tank
8-3
Steering system
8-4
Steering system
Steering system
LS line
LS
Front axle
Test port and P line to steering

Check block system
Valve 0.5 and 10.0 bar
8.3 Steering circuit with front and 4 wheel steering
Y006 Y007 Rear axle

A P
P
CF
Front axle/4 wheel steer- Priority valve
ing valve
Steering ram with final

To tank
position synchronisation
Serv-HB 34900/01 – Edition 1.0 * 34901_0810_Lenkung.fm

Steering system
8.4 Steering system adjustment

Function
Steering is carried out by means of 2 steering rams. Both steering rams are connected
together on one side of the chamber, the steering valve and the check block are located in
between. Each of these components has a certain amount of leakage which means
hydraulic oil escapes between the front and rear steering rams. This oil is no longer replen-
ished while steering since pressure is applied to only one side of the front or rear steering
ram when steering to the left or right. This is why synchronising several times a day is nor-
mal, depending on the use the machine is put to.
8.5 Hydraulic ports on servostat
P = pressure Hydraulic pump => priority

valve => servostat
LS = priority valve
L => servostat
T
L = left servostat
=> rear axle steering ram
R = right servostat
LS => front axle steering ram
T = servostat return
=> hydraulic oil tank
P R
8.6 Pressure relief valve: adjustment

Adjusting screw for steering pressure Proceed as follows:
☞ Remove the leg room cover
☞ Slacken the servostat (4 screws M10) and slide downwards
☞ Adjust the steering pressure with an allen key
➥ 180 – 190 bar
Secondary valve
Serv-HB 34900/01 – Edition 1.0 * 34901_0810_Lenkung.fm 8-5

Steering system
8.7 Sealing steering rams
3
34001e2303,eps
7
8
2
6
1 2
1
• Remove lock nut 1 on track rod joint 2
• Remove track rod joint 2 from the planetary carrier
• Determine the setting value between the end of the piston rod and the track rod joint
➥ e.g. determine the revolutions as you remove track rod joint 2
• Remove track rod joint 2 from piston rod 3
• Remove threaded pipe fitting 4
• Remove the complete steering ram from the axle carrier
➥ 3 screws 5
• Fasten the steering ram in a vice with aluminium clamps
• Remove circlip 6
• Slide guide bushing 7 to the inside
• Remove circlip 8
• Pull out piston rod 3 with guide bushing 7
• Replace the seals and cuffs 9
• Assembly in the reverse order
8-6 Serv-HB 34900/01 – Edition 1.0 * 34901_0810_Lenkung.fm

Steering system
Steering ram: replacing the seals

☞ Fasten the steering ram in a vice with aluminium clamps
☞ Remove circlip A
A
Fig. 3: Circlip
☞ Slide the guide bushing into the ram cylinder
Fig. 4: Guide bushing
☞ Remove circlip B
B
➥ Bear in mind the installation position as you remove the piston rod
➥ The wrench surface of the piston rod is opposite the screw surface of the ram
cylinder
☞ Pull out piston rod with guide bushing
Fig. 5: Circlip 2

Steering system
☞ Seal C is a rubber seal of the guide bushing

D
☞ D are the guide bands of the piston rods
C ☞ Piston rod seal E
E ➥ Piston rod seal must be warmed up in hot water before installing it
Fig. 6: Seals
☞ Insert piston rod seal F with the raised part to the rear in the guide bushing
☞ Insert scraper G with the raised part to the front in the guide bushing
➥ Apply oil liberally to the parts of the steering ram before assembly
Notice!
Bear in mind the installation position of piston rod 3
☞ Assemble the steering ram in the reverse order

G F
Fig. 7: Seals

Steering system
8.8 Checking the steering valve
Y006 front axle steering B Y007 4 wheel steering

WH/BK P WH/RD
☞ Check procedure
• Use the screw connection to screw the solenoid valves and the connecting plate
together, bear in mind the position. Port P
• Check the solenoid valve of the electric controls, then move to position A.
• Fill the solenoid valves with hydraulic oil and close ports A and T with plugs
• P connect the port with the manual pump
• Port B to test tube
☞ Test:
• Increase pressure to 160 bar with the manual pump. Once the transparent hose is
bled, clock the time with a stopwatch. Keep the pressure constant at 160 bar for 1
minute.
☞ Evaluation
• Direct reading off the test tube (ml)
• Enter the result in the test report
☞ Test criterion
• Kramer value 14 cm³/min with cold oil

Steering system
8.9 Checking a steering ram

• Apply pressure to the steering ram in centre position, i.e. block one side with a sleeve.
• Remove the hydraulic lines. The connecting piece to the manual pump must have a
micro port and a stop cock
• Raise pressure to 150 bar; pressure is allowed to drop to about 20 bar in 10 minutes
• Then carry out a low-pressure test at 10 bar; no pressure drop in the process!
8.10 Overview of steering ram setting

Readjust the steering system when carrying out repair work on the axles or in case of com-
plaints:
• After replacing/repairing the track rods or the track-rod ends C
• After carrying out repair work on the joint housings or stop screws E
• After carrying out repair work on the steering ram, e.g. replacing the piston rod or ram
cylinder.
The steering requires no setting in case of sealing work during which locknut B on
track-rod end C has not been slackened.
A / Contact surface for fork spanner Steering ram Track rod

D / Joint Joint housing
B / Locknut
C / Track-rod end
E / Stop screw
Necessary tools
1 measuring staff, about 3 m
1 track measurement rod
1 screw connection
Standard tools

Steering system
8.11 How to check and set the steering rams

The diagram shows how to follow the separate steps.
1. Check track setting

Specified value = 0 (max. 1 mm toe-in)?
No
2. Correct track setting

OK Specified value = 0 (max. 1 mm toe-in)?
3. Set the steering angle or steering

stop!
4. Check synchronisation
Identical resistance on either side of the steering wheel? No
5. Set synchronisation
OK Centre the piston rod (bypass)
1. Check track setting

Specified value = 0 (max. 1 mm toe-in)? No
OK 6. Test run END

Steering system
8.12 Checking the track setting (1)

Check the track as follows:
A ☞ Jack up the machine and prop it safely. Ensure that there is enough space for steering
at the full steering angles for the front and rear axles.
Front axle ☞ Set the steering to straight ahead. Check with the measuring staff
☞ Determine dimension A and dimension B. To this effect, measure with the track
B measurement rod on the inside on the rim flange at the centre of the wheel
➥ Rated dimension B – A = 0, max. + 1 mm
Measuring
Rim flange ➥ I.e. dimension A may be a max. 1 mm smaller than dimension B on the same axle
Caution!
A Check and set the tracks of front and rear axles separately!
The front and rear axle dimensions can differ slightly due to production
Rear axle tolerances.
8.13 Correcting the track setting (2)
A / Contact surface for fork spanner
C / Track-rod end B / Locknut
If the track setting does not correspond to the specified value 0 (max. 1 mm toe-in), set
the track as follows:
☞ Slacken locknut B on either side
☞ Slightly and evenly screw in or unscrew the threaded rod in track-rod end C on either
side.
➥ Ensure that dimension X is identical on either side.
☞ Check the track setting again
☞ Repeat this procedure until the track setting corresponds to the specified value.
☞ Counter locknut B
☞ Check dimension X again on either side of the steering ram

Steering system
8.14 Steering misalignment during final-position synchronisation (3)
If the steering system goes out of line during road travel, then check both the steer-
ing rams and the steering mode valve.
If the steering system goes out of line when manoeuvring, then adjust the steering
again.
Notice!
Outlay for adjustment work cannot be settled on a warranty basis, since

this is not a technical but a handling error.
Adjustment work
☞ Safely jack up the machine at the front and rear
Stop bolt ☞ Connect a 250 bar pressure gauge to the steering system test port
B ☞ Remove the flexible lines from the rear steering ram and connect them together
☞ Fully screw in stop screw B on the opposite side of the steering ram
A ➥ Slowly and gently turn the steering wheel to the steering limit so that the steering
pressure at the limit is about 80 – 120 bar.
➥ The full pressure at the steering ram is reached if the steering wheel is turned faster.
Stop screw on
steering ram side ➥ It is also important to not just rely on the pressure gauge but to turn the steering
wheel gently
☞ By unscrewing stop screw A (steering ram side) progressively, you can modify the
pressure from 80 to 120 bar, and it should be increased to about 140 – 150.
A B ☞ This work step must be carried out on the left and right
Stop bolt
A B

Steering system
8.15 Checking steering synchronisation (4)

The axles are synchronised by means of a bypass in the final positions of the steering
rams. In the final position of the piston, oil flows from one side of the cylinder to the other.
Bypass
In the axle that reaches the steering limit first, the oil flows through a bypass in the steering
ram and on to the other side if the wheels do not run synchronously.
If the steering wheel is turned further, the steering ram of the other axle moves on as far as
it will go. The wheels on the inside curve have the same steering angle in this case. The
wheels (or the axles) are hence synchronous.
R However, this only works optimally if the bypass position with regard to the left and right of
the piston (and with regard to the front and rear axles) is symmetrical in the limit positions.
L This is the case if the same resistance can be felt at the steering limits on the left and right
when evenly turning the steering wheel at the same speed.
➥ The force required to turn the steering wheel at the limit stops on the left and right must
be identical.

Hydraulic system
9 Hydraulic system Overall hydraulics diagram

Hydraulic system
9.1 Overall hydraulics diagram
9-2 Serv-HB 34900/01 – Edition 1.0 * 34901_0940_Hydraulik_a3.fm

Hydraulic system
Hydraulic system
9.2 Hydraulics legend

Description Description Description
I Pump unit PFC 069 Load retaining valve (secondary protection) R Right
IV Steering system valve block 072 Load retaining valve (secondary protection) T Tank port
VI Master brake cylinder with brake servo 073 Load retaining valve (secondary protection) X Control signal
VII Drive hydraulics variable displacement pump 077 Pressure accumulator
VIII Drive hydraulics variable displacement motor 078 Pilot pressure insert S063 Float position limit switch
XII Solenoid valve pilot control unit 079 Load stabiliser pressure relief valve Y002 1st/2nd speed solenoid valve
XIII Valve block (control valves) 080 Load stabiliser pressure accumulator Y004 Reverse driving solenoid valve
XIV Load stabiliser 081 Release valve Y005 Forwards driving solenoid valve
XV Lift ram load safety valve (with hose burst valve) 083 Throttle non-return valve Y006 Front axle steering solenoid valve
XVI Additional control circuit valve unit 084 Hose burst valve pilot spool Y007 4 wheel steering solenoid valve
085 Lift ram Y009 Differential lock solenoid valve
008 Priority valve (CF) 091 3rd additional control circuit hydraulic ram Y010 Driving direction identification solenoid valve
016 Non-return valve 094 4th additional control circuit valve block Y011 Increased pump output solenoid valve
018 Front axle steering ram 099 Load retaining valve (secondary pressure limiting) lift ram piston side Y012 Increased pump output solenoid valve
019 Rear axle steering ram 103 (Y06/07) 4/2 directional valve for steering system Y016 “Lock” solenoid valve
020 Pressure relief valve 104 (S5) fouling indicator Y017 “Unlock” solenoid valve
021 Rotary spool valve 107 Hydraulic oil dirt pressure switch Y020 Load stabiliser solenoid valve
024 Steering system non-return valve 110 (Y16) proportional valve/pressure reducing valve (lock) Y021 Load stabiliser solenoid valve
025 Tank 111 (Y17) proportional valve/pressure reducing valve (unlock) Y022 Hose burst valve solenoid
026 Return filter 126 (Y44) 3/2 directional valve (tipping trailer) Y025 Quickhitch lock solenoid valve
027 Oil cooler 127 (Y45) 3/2 directional valve (tipping trailer) Y044 Raise tipping trailer solenoid valve
028 Vent filter Y045 Lower tipping trailer solenoid valve
029 Expansion tank A Consumer port Y080 Solenoid valve for 4th control circuit with additional functions
030 Master brake cylinder (sensor) ACC Accumulator port Y081 Solenoid valve for 4th control circuit with additional functions
031 Service brake hydraulic ram AGV Attachment port
035 Drive pump B Consumer port
037 Drive pressure relief valve – boost pressure C Consumer port
040 Multifunctional valve, reverse (drive) CF “Orbitrol” port
041 Multifunctional valve, forwards (drive) EF Valve unit port
050 Drive swivel-angle control cylinder F Base side connection
054 Drive variable displacement motor KST Tipping trailer port
055 Hydraulic ram (drive) L Left
058 (driving direction valve) L Leak oil port
063 Differential lock LS Load-Sensing port
067 3rd additional control circuit control valve M Test port
068 Lift ram control valve P Pressure supply port (pump)
Serv-HB 34900/01 – Edition 1.0 * 34901_0940_Hydraulik_Legende_a3.fm 9-3

Hydraulic system
9-4 Serv-HB 34900/01 – Edition 1.0 * 34901_0940_Hydraulik_Legende_a3.fm

Hydraulic system
jLoad stabiliser/float position (electrical diagram) Load stabiliser/float position (electrical diagram)
Hydraulic system
9.3 Load stabiliser/float position (electrical diagram)
Description:
F Fuses
G001 Alternator
H010 Hose burst valve indicator light
S040 Quickhitch lock tip switch
S044 Load stabiliser switch
S063 Float position limit switch
V Diodes
X013 2-pole connector (additional control circuit)
X018 1-pole connection (float position)
Y020 Load stabiliser solenoid valve
Y022 Hose burst valve solenoid
Y025 Quickhitch lock solenoid valve
9-6 Serv-HB 34900/01 – Edition 1.0 * 34901_0900_Laststabilisator_Schwimmstellung_el_a3.fm

Hydraulic system
Load stabiliser/float position (hydraulics diagram) Load stabiliser/float position (hydraulics diagram)
Hydraulic system
9.4 Load stabiliser/float position (hydraulics diagram)
Description:
XIII Valve block (control valves)
XIV Load stabiliser
XV Lift ram load safety valve (with hose burst valve)
A Consumer port
ACC Accumulator port
B Consumer port
F Base side connection
T Tank port
X Control signal
068 Lift ram control valve
069 Load retaining valve (secondary protection)
078 Pilot pressure insert
079 Load stabiliser pressure relief valve
080 Load stabiliser pressure accumulator
081 Release valve
083 Throttle non-return valve
084 Hose burst valve pilot spool
085 Lift ram
099 Load retaining valve (secondary pressure limiting) lift ram piston side
S063 Float position limit switch
Y022 Hose burst valve solenoid
9-8 Serv-HB 34900/01 – Edition 1.0 * 34901_0900_Laststabilisator_Schwimmstellung_hy_a3.fm

Hydraulic system
Quickhitch (electrical diagram) Quickhitch (electrical diagram)

Hydraulic system
9.5 Quickhitch (electrical diagram)
Description:
F Fuses
H010 Hose burst valve indicator light
H011 3rd control circuit indicator light
K017 Switching relay (unlock)
Switching relay for continuous operation of 3rd control cir-
K075
cuit
S001 Preheating start switch
S030 “Unlock” tip switch
S031 “Lock” tip switch
S032 3rd control circuit switch
S033 Continuous operation of 3rd control circuit
S040 Quickhitch lock tip switch
S124 Start repeat interlock limit switch
V Diodes
X013 2-pole additional control circuit connector
1-pole connector (start repeat interlock for additional control
X021
circuit)
XA02 6-pole connection (safe load indicator)
XJ04 4-pole joystick connection (Deutsch DTM)
Y016 “Lock” solenoid valve
Y017 “Unlock” solenoid valve
9-10 Serv-HB 34900/01 – Edition 1.0 * 34901_0900_Schnellwechselplatte_el_a3.fm

Hydraulic system
Quickhitch (hydraulics diagram) Quickhitch (hydraulics diagram)

Hydraulic system
9.6 Quickhitch (hydraulics diagram)
Description:
XII Solenoid valve pilot control unit
016 Non-return valve
067 3rd additional control circuit control valve
077 Pressure accumulator
091 3rd additional control circuit hydraulic ram
110 (Y16) proportional valve/pressure reducing valve (lock)
111 (Y17) proportional valve/pressure reducing valve (unlock)
A Consumer port
B Consumer port
T Tank port
Y016 “Lock” solenoid valve
Y017 “Unlock” solenoid valve
Electrically pilot-controlled
valve control
Valve control with lever
9-12 Serv-HB 34900/01 – Edition 1.0 * 34901_0900_Schnellwechselplatte_hy_a3.fm

Hydraulic system
Additional function (electrical diagram) Additional function (electrical diagram)

Hydraulic system
9.7 Additional function (electrical diagram)
Description:
F Fuses
K045 Additional function switching relay
K046 Additional function switching relay
S056 Additional control circuit switch (release)
S069 Additional control circuit switch
S070 Switch for raising/lowering the tipping trailer
S101 Control lever tip switch for additional function
S102 Plunger switch for front ball-type cock
S103 Plunger switch for rear ball-type cock
S117 Control lever tip switch for additional function
V Diodes
1-pole connector – additional control circuit + tipping trailer
X009
(natural-coloured)
X010 1-pole connector – tipping trailer only (red)
1-pole connector (additional control circuit and tipping
X011
trailer/Autohitch)
X013 2-pole connector (additional control circuit)
X014 2-pole disconnect (joystick)
1-pole connector (start repeat interlock for additional control
X021
circuit)
X022 1-pole connector (additional control circuit only)
XJ04 4-pole joystick connection (Deutsch DTM)
XR03 11-pole disconnect (additional control circuit)
Tipping trailer only --> X010 and X011 connected Y011 Increased pump output solenoid valve
--> Y044 raises the tipping trailer
Y012 Increased pump output solenoid valve
--> Y045 lowers the tipping trailer
Additional control circuit + tipping trailer --> X009 and X011 Y044 Raise tipping trailer solenoid valve
connected
Y045 Lower tipping trailer solenoid valve
--> Y012 raises the tipping trailer
--> Y045 lowers the tipping trailer Solenoid valve for additional control circuit with additional
Y080
--> Connect X021.1 to X021 function
Additional control circuit only --> X022 connected
Solenoid valve for additional control circuit with additional
Y081
function
9-14 Serv-HB 34900/01 – Edition 1.0 * 34901_0900_Zusatzfunktionen_el_a3.fm

Hydraulic system
Additional function (hydraulics diagram) Additional function (hydraulics diagram)

Hydraulic system
9.8 Additional function (hydraulics diagram)
Additional function (tipping trailer only) Additional function (additional control circuit and tipping trailer)
Description:
I Pump unit PFC
XVI Additional control circuit valve unit
020 Pressure relief valve
025 Tank
026 Return filter
027 Oil cooler
028 Vent filter
067 3rd additional control circuit control valve
S102
S103
091 3rd additional control circuit hydraulic ram
094 4th additional control circuit valve block
126 (Y44) 3/2 directional valve (tipping trailer)
127 (Y45) 3/2 directional valve (tipping trailer)
A Consumer port
AGV Attachment port
3rd control circuit valve actuation either with
lever or electrically pilot-controlled KST Tipping trailer port
L Leak oil port
M Test port
T Tank port
S102 Plunger switch for front ball-type cock
S103 Plunger switch for rear ball-type cock
Y044 Raise tipping trailer solenoid valve
Y045 Lower tipping trailer solenoid valve
Solenoid valve for 4th control circuit with additional func-
Y080
tions
Solenoid valve for 4th control circuit with additional func-
Y081
tions
9-16 Serv-HB 34900/01 – Edition 1.0 * 34901_0900_Zusatzfunktionen_hy_a3.fm

Hydraulic system
Hydraulic system
9.9 Test report
Nomi-
See nal
Test features: Notes: Nominal value
page: value:
(rpm)
Min. idling speed Measured on crankshaft 1075 – 1125 rpm
Max. idling speed Measured on crankshaft 2970 – 3020 rpm
Main pressure of work hydrau- Max. engine

235 – 245 bar
lics speed
Secondary pressure
Minimum idling speed 260 bar
Lift ram
Secondary pressure
Minimum idling speed 115 – 135 bar
Tilt ram (dump out)
Secondary pressure
Tilt ram (dump in)
9-27
Secondary pressure
3rd control circuit
Steering pressure Max. engine speed 180 – 190 bar
T oil = 50 °C Lift ram max. 12 mm

Loader unit lowering
P cylinder = 100 bar t = 10 min Tilt ram max. 16 mm
Load stabiliser Minimum idling speed 240 bar
Displacement for front and rear

At full throttle About 37 l/min front/rear
additional control circuit
Displacement for additional con-

9-29 At full throttle About 82 l/min
trol circuit and 3rd control circuit
Serv-HB 34900/01 – Edition 1.0 * 34901_0910_Hydraulikanlage.fm 9-17

Hydraulic system
9.10 Work hydraulics oil supply
P
Priority valve
Work hydraulics
and steering sys-
EF tem test port
Pressure line
Gear pump 54 l/
min
Suction line
Return line
9-18 Serv-HB 34900/01 – Edition 1.0 * 34901_0910_Hydraulikanlage.fm

Hydraulic system
9.11 Work hydraulics circuit
B2
B1
A2
A1
Control valve
Tilt ram Lift ram

Hydraulic system
9.12 Circuit: auxiliary hydraulics
Return suction filter
Suction line
Gear pump 54 l/
min
Lock B3
Gear pump 38 l/
min
Front socket Test port 210 bar
Y012
Y080/81
Leak oil
Y011
Pressure relief valve 210 bar

Main current Front/rear changeover tap
return
Additional func-
tion 20 l/min High flow rate

A1
B1
9.13 Load stabiliser circuit
Serv-HB 34900/01 – Edition 1.0 * 34901_0910_Hydraulikanlage.fm

Lift ram
Release valve
Y021 A
Pressure accu- T
Pilot pressure
mulator
F insert 120 bar
Y020
Pressure relief valve
240 bar
ACC
9-21
Hydraulic system
Hydraulic system
9.14 Circuit: electrical 3rd control circuit
Pressure accumulator
Non-return valve
Y017 Pilot control cap of 3rd control circuit
B Y016
A T
P
Boost pressure

Hydraulic system
9.15 Circuit: tipping trailer
Tipping trailer connection

Y045
Y044
Tipping trailer valve

A
P
T
Gear pump 38 l/
min

Hydraulic system
9.16 Control valve connections (overview)
A1 A2 A3
Load retaining valves
B1 B2 B3
A1 – raise B1 – lower
A2 – dump in B2 – dump out
A3 – unlock B3 – lock
P – pressure line from priority valve
T – tank line to return filter

Hydraulic system
9.17 Control valve secondary valves (overview)
A1 A2 A3
P
B1 B2 B3
A1 – secondary valve 260 bar (red) lift ram base side

A2 – secondary valve 120 bar (white) tilt ram base side
A3 – secondary valve 260 bar (red) left (unlock)
B1 – no secondary valve installed

B2 – secondary valve 260 bar (red) tilt ram rod side
B3 – secondary valve 260 bar (red) right (lock)

Hydraulic system
9.18 Pressure relief valve of control valve (overview)
Pilot pressure insert for internal return line of Set screw for pressure relief
spool valves 18 – 22 bar valve 230 bar
Description of pilot pressure insert

For an optimal fill in the return lines of the rams, an initial stress of 18 – 22 bar is applied to
the return lines. This means that the rams can be positioned precisely even in difficult con-
ditions.

Hydraulic system
9.19 Checking and setting the work hydraulics

Setting the control valve main pressure relief valve
☞ Open the maintenance opening under the joystick (allen key 3)
Hexagon socket screw
Test port
☞ Connect a 600 bar pressure gauge
Work hydraulics test port
Measurement
☞ Start the diesel engine and set max. engine speed
☞ Lower the loader unit completely applying pressure to it
➥ The measured value is equal to pump pressure
Adjustment
☞ Unscrew the cap (wrench size 13)
☞ Screw in the high-pressure valve
☞ Unscrew the high-pressure valve
➥ Pressure reduction
Specified value is 235 – 245 bar at full throttle
Main pressure relief valve

Hydraulic system
9.20 Load stabiliser

Load stabiliser description
During machine operation, a pilot pressure insert always applies a pressure of 120 bar to
the load stabiliser (pressure accumulator). This prevents the loader unit from sagging as
the load stabiliser is switched on.
The entire system is protected by a pressure relief valve (240 bar).
Danger!
Work on the hydraulic circuit of the load stabiliser – danger of injury!

☞ Lower the loader unit fully
☞ Stop the diesel engine and remove the ignition key
☞ Release the pressure in the system by means of the “Relief valve”
Release valve
Y020
Y021
F A
Pressure relief valve

T 240 bar
Pilot pressure
ACC insert 120 bar

Hydraulic system
9.21 Checking and adjusting the load stabiliser

Tools: pressure gauge 600 bar
Oil temperature: 50 °C
Measurement
☞ Connect a pressure gauge
☞ Start the engine and let it run at low speed
☞ Switch the load stabiliser to continuous operation
☞ Raise the loader unit as far as it will go
➥ Specified value must be 240 bar
Work hydraulics test port
Adjustment
☞ Open the plug (wrench size 8) on the pressure relief valve
☞ Screw in the hexagon socket screw (allen key 3/16) on the pressure relief valve
☞ Unscrew the hexagon socket screw (allen key 3/16) on the pressure relief valve on the
changeover valve (wrench size 3/16)
Pressure relief valve ➥ Pressure reduction
240 bar

Hydraulic system
9.22 Front/rear additional control circuit function

Distributing block for high quantities and changeover to rear tipping trailer
S117
Y081
S101
Y080
Y011
Y012
• Y11 and Y12 are for the summation of the 3rd control circuit + additional pump 80 l/min
• Y81 and Y80 changeover for small couplings about 20 l/min (double-acting)
☞ Switching on the front additional control circuit 80 l/min (large couplings P and T)
• Turn on switch 1 and turn switch 2 to MAX
☞ Switching on the front additional control circuit 80 l/min (large couplings P and T)
T P plus additional control circuit (small couplings) double-acting
• Turn on switch 1 and turn switch 2 to MAX
• For the double-action additional function (small couplings 3 and 4), press switches
3 4 S117 and S101
☞ Switching on the front additional control circuit about 38 l/min (large couplings)
• Turn on switch 1 and turn switch 2 to MIN
• For the double-action additional function (small couplings 3 and 4), press switches
S117 and S101
☞ Switching on the tipping trailer function
• Switch off switch 1
• Press tip switch 5 for the tipping trailer upwards or downwards

Hydraulic system
9.23 Using the 3rd electrical control circuit plus the additional control circuit
☞ Switching on the 3rd control circuit plus the additional control circuit (small flow
rate)
• Press switch 3 and actuate the 3rd control circuit with switch (S030 or S031)
• Turn on switch 1 and turn switch 2 to MIN
3 2
S030
S031
Y017
Y016
Y011

Hydraulic system
9.24 Valve: electrical 3rd control circuit

• Unlock switch S030
• Lock switch S031
• P – boost pressure
• 1 – switch for S030 and S031 function
• 2 – switch for continuous operation S031
1 2
S030
S031
P
Y016 Y017
T
A B
Pressure accumulator
for pressure relief of 3rd
control circuit
Non-return valve

Hydraulic system
9.25 Lift ram: sealing work
Seals (included in sealing kit) Securing screw 10 Nm
Joint bearing 34300s910_11.iso
Ram head 400 Nm Piston 700 Nm
Disassembly/assembly
☞ Unscrew ram head with special key
☞ Pull out piston rod
☞ Remove securing screw from piston
☞ Unscrew piston from piston rod
☞ Replace complete sealing kit
➥ Sealing kit includes all seals, sleeves and threaded pins
➥ Calibrate the piston seal when replacing it
☞ Assembly in the reverse order
➥ Bear in mind the tightening torques
Notice!
Special tools required for sealing the ram!

Hydraulic system
9.26 Tilt ram: sealing work
Seals (included in sealing kit) Securing screw 10 Nm
Joint bearing 34300s910_12.iso
Ram head 400 Nm Piston 700 Nm
☞ Unscrew ram head with special key
☞ Pull out piston rod
☞ Remove securing screw from piston
☞ Unscrew piston from piston rod
☞ Replace complete sealing kit
➥ Sealing kit includes all seals, sleeves and threaded pins
➥ Calibrate the piston seal when replacing it
➥ Bear in mind the tightening torques
Notice!

Hydraulic system
9.27 Control ram (quickhitch frame): sealing work
Piston seal
Rod seal
Circlip
Seal between ram cylinder and guide 36eh3610.iso
bushing
☞ Release the pressure in the quickhitch ram control circuit
☞ Drive out the piston with an impact extractor M 8
☞ Renew the seal between piston rod and guide bushing
➥ Replace complete sealing kit
Notice!

Hydraulic system
Notes:

Electrical system
10 Electrical system Cab wiring harness

Electrical system
10.1 Cab wiring harness
Indicating instrument Indicating instrument Board connection

Telematic (XE90) (XA01) (XA02) (XP 02/04/06/05)
Loudspeakers (X006)
Earth connection 1
Front wiper (M002)

Radio (X006)
Front socket (S027) Air conditioning (S051)
Steering-column Power socket

control lever (XL01/ (E015)
02))
Additional control circuit (S013)
Heating (X001)
Hazard warning
switch (S019)
Connecting points 3
Front axle Thermostat (X017)

steering indi-
cator light Fan (S015) Preheating start
1st/2nd speed (H014) Connecting points 5
Steering (S022) switch (S001)
(S021)
4 wheel steering indicator light (H013)

Washer pumps (M005)
Rear left working light (E008)
Front left working light (E009)

Numberplate light (E016)
Left-hand loudspeaker Connecting points 4

Joystick (XJ05/01/02/03/04) Additional control circuit (X014)
Rotating beacon (H028)

Backup warning system
(B003)
Parking brake switch
Rear right working light (S011)
(E007)
Right-hand loudspeaker (B011)
Interior light (E014)

Rear wiper (M003)
Connecting points 1
Front right working light Frame/cab disconnect (XR02)
(E010) Air-suspension seat (X008)
Connecting points 2
Connecting points 6
10-2 Serv-HB 34900/01 – Edition 1.0 * 34901_1011_1000260126-1_02_E_Kabine_frei_a3.fm

Electrical system
Electrical system
10.2 Cab wiring harness legend

From To Colour From To Colour
1 XR02 (1) 21-pole connector (cab/frame disconnect) K047 (86) working light switching relay YE XL02 (1) 6-pole connector (steering-column control lever connec-
36 S019 (6/terminal L) hazard warning switch BK/WH
tion)
2 K047 (85) working light switching relay Earthing point I BK
37 S019 (6/terminal L) hazard warning switch XP05 (2) 22-pole connector (board connection) BK/WH
3 F023 (G) fuse K047 (30) working light switching relay VT/YE
38 S019 (3/terminal 30) hazard warning switch XP05 (17) 22-pole connector (board connection) RD/GN
4 K047 (87) working light switching relay Connecting point 1 VT/YE
XL01 (5) 8-pole connector (steering-column control lever connec-
5 Connecting point 1 E007 rear working light VT/YE 39 XP05 (11) 22-pole connector (board connection) BN/YE
tion)
6 Connecting point 1 E008 rear working light VT/YE 41 XP02 (10) 14-pole connector (board connection) S011 (1) parking brake switch BN
7 XP06 (14) 14-pole connector (board connection) Connecting point 2 VT/WH 42 XP02 (6) 14-pole connector (board connection) S011 (3) parking brake switch BN/VT
8 Connecting point 2 E009 front working light VT/WH 43 S011 (2) parking brake switch Earthing point I BK
9 Connecting point 2 E010 front working light BK 44 XP04 (10) 18-pole connector (board connection) XA01 (9/H018) 15-pole indicating instrument connection BN
10 E007 rear working light Earthing point I BK 45 XP05 (10) 22-pole connector (board connection) Connecting point 3 RD/BK
11 E008 rear working light Earthing point I BK 46 Connecting point 3 XA01 (1/mirror adjustment) 15-pole indicating instrument connection RD/BK
12 E009 front working light Earthing point I BK 47 Connecting point 3 B018 (15 +) buzzer (engine temperature) RD/BK
13 E010 front working light Earthing point I BK 48 S001 (2/terminal 30) preheating start switch XP04 (6) 18-pole connector (board connection) RD/WH
14 XP04 (3) 18-pole connector (board connection) Connecting point 6 GY/BK 49 S001 (8/terminal 19) preheating start switch XP04 (9) 18-pole connector (board connection) RD/GY
15 XP04 (3) 18-pole connector (board connection) S073 (10) steering system switch GY/BK 51 S001 (5/terminal 15) preheating start switch XP04 (2) 18-pole connector (board connection) YE/WH
16 S073 (10) steering system switch 1-pole plug and socket connection GY/BK 52 S001 (5/terminal 15) preheating start switch K002 (86) high current relay (power supply) YE/WH
17 XP04 (4) 18-pole connector (board connection) XJ02 1-pole joystick connection GY/BK 53 K002 (85) high current relay (power supply) Earthing point I BK
18 XP04 (4) 18-pole connector (board connection) S051 (10) air conditioning switch GY/BK 54 XR01 1-pole High-Power connection K002 (30) high current relay (power supply) RD
19 S051 (10) air conditioning switch 1-pole plug and socket connection GY/BK 55 K002 (87) high current relay (power supply) F017 (1) fuse BU
20 XP04 (1) 18-pole connector (board connection) XA01 (15/H001) 15-pole indicating instrument connection WH/BK 56 XP04 (11) 18-pole connector (board connection) XA01 (13/H002) 15-pole indicating instrument connection BU/GY
21 XP04 (7) 18-pole connector (board connection) XA01 (2/lights) 15-pole indicating instrument connection GY/RD 57 XP04 (5) 18-pole connector (board connection) Connecting point 5 BU
22 XA01 (5) 15-pole indicating instrument connection Earthing point I BK 58 XP04 (12) 18-pole connector (board connection) XA01 (4/P002) 15-pole indicating instrument connection VT/BU
23 E016 numberplate light Earthing point I BK 59 XP04 (15) 18-pole connector (board connection) XA01 (7/H003) 15-pole indicating instrument connection BU/WH
XL02 (5) 6-pole connector (steering-column control lever connec- 60 XP04 (15) 18-pole connector (board connection) B018 (31 -) buzzer (engine temperature) BU/WH
24 XP05 (6) 22-pole connector (board connection) YE
tion)
61 XP04 (14) 18-pole connector (board connection) XA01 (10/H004) 15-pole indicating instrument connection BU/GN
25 XP05 (8) 22-pole connector (board connection) WH 62 XR02 (2) 21-pole connector (cab/engine disconnect) XA02 (3/H006) 10-pole indicating instrument connection YE/BU
tion)
XL01 (8) 8-pole connector (steering-column control lever connec- 63 XP05 (16) 22-pole connector (board connection) S021 (5) 1st/2nd speed switch RD/BU
26 XP05 (13) 22-pole connector (board connection) GY/GN
tion) 64 XP05 (16) 22-pole connector (board connection) XJ01 (1) 4-pole joystick connection RD/BU
XL02 (4) 6-pole connector (steering-column control lever connec- 66 XJ03 (B) 3-pole joystick connection K030 (30) brake lights switching relay GY
27 XP05 (14) 22-pole connector (board connection) YE/WH
tion) 67 K021 (85) switching relay (differential lock) Earthing point I BK
28 XP02 (14) 14-pole connector (board connection) S019 (1/terminal 15) hazard warning switch RD/YE 68 F019 (C) fuse K021 (30) switching relay (differential lock) RD/WH
29 XP02 (5) 14-pole connector (board connection) S019 (4/terminal 49) hazard warning switch BK/RD 69 K021 (87) switching relay (differential lock) XR02 (3) 21-pole connector (cab/engine disconnect) GY/GN
30 XP02 (3) 14-pole connector (board connection) S019 (5/terminal 49a) hazard warning switch WH/RD 70 K021 (87) switching relay (differential lock) XA02 (4/H012) 10-pole indicating instrument connection GY/GN
XL02 (3) 6-pole connector (steering-column control lever connec- 71 S021 (9) 1st/2nd speed switch Earthing point I BK
31 XP02 (1) 14-pole connector (board connection) WH/RD
tion)
72 S021 (10) 1st/2nd speed switch S021 (1) 1st/2nd speed switch YE/GY
32 XP02 (7) 14-pole connector (board connection) XA01 (11/H022) 15-pole indicating instrument connection WH/GN
73 S021 (7) 1st/2nd speed switch XP02 (4) 14-pole connector (board connection) GY/YE
33 XP04 (18) 18-pole connector (board connection) XA01 (3/H023) 15-pole indicating instrument connection BK/BU
74 S021 (7) 1st/2nd speed switch S021 (B) 1st/2nd speed switch GY/YE
34 S019 (7/terminal R) hazard warning switch BK/GN 75 XP02 (2) 14-pole connector (board connection) XJ01 (4) 4-pole joystick connection GN/VT
tion)
35 S019 (7/terminal R) hazard warning switch XP05 (3) 22-pole connector (board connection) BK/GN 76 XP02 (12) 14-pole connector (board connection) XJ01 (3) 4-pole joystick connection WH/VT
Serv-HB 34900/01 – Edition 1.0 * 34901_1012_Kabine_Legende_a3.fm 10-3

Electrical system

77 XJ01 (2) 4-pole joystick connection Earthing point I BK 117 X006 (8) 8-pole connector (radio power supply) Earthing point I BK
78 X008 6-pole (5) connection (air-suspension seat) X008 6-pole (4) connection (air-suspension seat) RD/WH 118 X007 (1) 8-pole connector (loudspeakers) B011 loudspeaker (right) BN/GN
79 X008 6-pole (5) connection (air-suspension seat) Earth connection 1 BK 119 X007 (2) 8-pole connector (loudspeakers) B011 loudspeaker (right) BK
80 F017 (A) fuse S027 (3) front socket switch BK/YE 120 X007 (7) 8-pole connector (loudspeakers) B012 loudspeaker (left) BN/YE
81 S027 (7) front socket switch XR02 (5) 21-pole connector (cab/engine disconnect) RD/YE 121 X007 (8) 8-pole connector (loudspeakers) B012 loudspeaker (left) BK
82 S027 (7) front socket switch S027 (B) front socket switch RD/YE 122 XP06 (4) 14-pole connector (roof) H028 rotating beacon GN
83 S027 (1) front socket switch XR02 (6) 21-pole connector (cab/engine disconnect) YE/RD 123 H028 rotating beacon Earthing point I BK
84 S027 (1) front socket switch S027 (10) front socket switch YE/RD 124 XP06 (8) 14-pole connector (roof) E014 interior light GY/GN
85 S027 (9) front socket switch Earthing point I BK 125 E014 interior light Earthing point I BK
86 F018 (B) fuse X019 1-pole connector RD/GN 126 XP06 (2) 14-pole connector (roof) X005 1-pole connector RD/YE
87 S015 (L) heater switch X001 (2) 4-pole fan connection WH 127 XP02 (11) 14-pole connector (board connection) XJ04 (1) 4-pole connector (joystick connection) BU/YE
88 S015 (M) heater switch X001 (4) 4-pole fan connection RD 128 XP02 (9) 14-pole connector (board connection) XJ04 (2) 4-pole connector (joystick connection) BU/RD
89 S015 (H) heater switch X001 (3) 4-pole fan connection RD/GN 129 XP04 (8) 18-pole connector (board connection) V028 (cathode −) diode BK/VT
90 X001 (1) 4-pole fan connection Earthing point I BK 130 XP04 (17) 18-pole connector (board connection) XA01 (12/H008) 15-pole indicating instrument connection YE/GN
91 S015 (C) heater switch S051 (5) air conditioning switch GN/BN 131 XP04 (13) 18-pole connector (board connection) XA01 (6/H007) 15-pole indicating instrument connection BU/YE
92 S051 (1) air conditioning switch S054 air conditioning temperature switch GN/BN 132 XR02 (13) 21-pole connector (cab/engine disconnect) XA02 (9) 10-pole indicating instrument connection RD/BU
93 S051 (1) air conditioning switch S051 (B) air conditioning switch GN/BN 133 XP05 (14) 22-pole connector (board connection) Connecting point 4 GN/WH
94 S054 air conditioning temperature switch XR02 (7) 21-pole connector (cab/engine disconnect) GN/BN XL01 (1) 8-pole connector (steering-column control lever connec-
134 Connecting point 4 GN/WH
95 S051 (9) air conditioning switch Earth connection 1 BK tion)
97 K070 (85) switching relay (diesel engine runs) Earthing point I BK 135 Connecting point 4 X003/M003 rear wiper motor GN/WH
98 XR02 (12) 21-pole connector (cab/engine disconnect) K070 (30) switching relay (diesel engine runs) WH/GN 136 Connecting point 4 K025 (4/terminal 15) intermittent wipe relay GN/WH
99 K070 (87) switching relay (diesel engine runs) V020 (anode) diode WH/BU 137 XP05 (14) 22-pole connector (board connection) XP05 (15) 22-pole connector (board connection) GN/WH
100 XP05 (7) 22-pole connector (board connection) V021 (anode) diode WH/BN XL01 (4) 8-pole connector (steering-column control lever connec-
138 XP05 (4) 22-pole connector (board connection) GN/BK
tion)
101 V021 (anode) diode XR02 (10) 21-pole connector (cab/engine disconnect) WH/BN
102 V020 (cathode) diode V021 (cathode) WH/BU 139 XP05 (9) 22-pole connector (board connection) WH/BU
tion)
103 V020 (cathode) diode XA02 (5) 10-pole indicating instrument connection WH/BU XL01 (6) 8-pole connector (steering-column control lever connec-
140 XP05 (1) 22-pole connector (board connection) BU/GN
104 V020 (cathode) diode XR02 (11) 21-pole connector (cab/engine disconnect) WH/BU tion)
105 XR02 (11) 21-pole connector (cab/engine disconnect) X018 1-pole plug and socket connection WH/BU XL01 (7) 8-pole connector (steering-column control lever
141 K025 (2/terminal I) intermittent wipe relay RD
106 F019 (C) fuse S073 (5) crab steering switch RD/WH connection)
107 S073 (7) crab steering switch XR02 (15) 21-pole connector (cab/engine disconnect) WH/RD 142 XP06 (1) 14-pole connector (roof) K025 (6/terminal S) intermittent wipe relay GN/BK
108 S073 (7) crab steering switch H013 4 wheel steering indicator light WH/RD 143 X002 (1) (M002) front wiper motor K025 (5/terminal 31b) intermittent wipe relay BN/BK
109 S073 (1) crab steering switch XR02 (16) 21-pole connector (cab/engine disconnect) WH/BK 144 K025 (1/terminal 31) intermittent wipe relay Earthing point I BK
110 S073 (1) crab steering switch H035 crab steering indicator light WH/BK 145 XP06 (3) 14-pole connector (roof) K025 (3/terminal 86) intermittent wipe relay BU/GN
111 S073 (9) crab steering switch Earthing point I BK 146 XP06 (3) 14-pole connector (roof) X004/M005 wipe/wash pump BU/GN
112 H013 4 wheel steering indicator light Earthing point I BK 147 X004/M005 wipe/wash pump Earthing point I BK
113 H035 crab steering indicator light Earthing point I BK 148 X003/M003 rear wiper motor Earthing point I BK
114 XP05 (20) 22-pole connector (board connection) X006 (7) 8-pole connector (radio power supply) BN/VT 149 X002 (6) (M002) front wiper motor Earthing point I BK
115 XP06 (13) 14-pole connector (roof) X006 (4) 8-pole connector (radio power supply) RD/WH 150 XP06 (12) 14-pole connector (roof) X002 (3) (M002) front wiper motor GN
116 XP04 (7) 18-pole connector (board connection) X006 (6) 8-pole connector (radio power supply) GY/RD 151 XP06 (6) 14-pole connector (roof) X002 (2) (M002) front wiper motor BK/BU
152 F024 (H) fuse E015 cigarette lighter RD/BK
10-4 Serv-HB 34900/01 – Edition 1.0 * 34901_1012_Kabine_Legende_a3.fm

Electrical system

153 E015 cigarette lighter Earthing point I BK 186 XR02 (19) 21-pole connector (cab/engine disconnect) V026 (anode +) diode RD
154 XP05 (18) 22-pole connector (board connection) 1-pole plug and socket connection RD 187 V026 (cathode −) diode V027 (cathode −) diode RD/GY
155 XP05 (21) 22-pole connector (board connection) 1-pole plug and socket connection RD/WH 188 V027 (cathode) diode K030 (86) brake lights switching relay RD/GY
156 XJ04 (5) 4-pole connector (joystick connection) X014 2-pole connector (joystick disconnect) BN/GN 189 V027 (anode +) diode K030 (87) brake lights switching relay RD/GN
157 XJ04 (6) 4-pole connector (joystick connection) X014 2-pole connector (joystick disconnect) BN/WH 190 K030 (87) brake lights switching relay K021 (86) switching relay (differential lock) RD/GN
158 F020 (D) fuse X013 (I) 2-pole connector (additional control circuit) BK/WH 191 K030 (85) brake lights switching relay Earthing point I BK
159 Earthing point I Earthing point II BK 192 XP02 (10) 14-pole connector (board connection) XJ05 joystick connection BN
160 F024 (8) fuse Cable lug (+) BK 193 XP04 (8) 18-pole connector (board connection) XR02 (20) 21-pole connector (cab/engine disconnect) BK/VT
161 XR02 (4) 21-pole connector (cab/engine disconnect) B003 backup warning system GN/VT 194 V028 (anode +) diode XA01 (14/H011) 15-pole indicating instrument connection BK/VT
162 B003 backup warning system Earthing point I BK 195 XP02 (9) 14-pole connector (board connection) X013 (II) 2-pole connector (additional control circuit) BU/RD
163 XP05 (21) 22-pole connector (board connection) XR02 (14) 21-pole connector (cab/engine disconnect) RD/WH
165 X019 1-pole connector S015 (B) heater switch RD/GN
166 Earthing point I XE90 (1) Telematic connection (earth) BK
167 Connecting point 5 XA01 (8/H005) 15-pole indicating instrument connection BU
168 Connecting point 5 K070 (86) switching relay (diesel engine runs) BU
169 Connecting point 5 XE90 (5) Telematic connection (D+) BU
170 F021 (E) fuse XE90 (6) Telematic connection (terminal 15) RD/WH
171 F022 (F) fuse XE90 (12) Telematic connection (terminal 30) RD
172 S001 (7/terminal 50a) preheating start switch K075 (30) 3rd control circuit switching relay (start repeat interlock) BU/BK
K075 (87a) 3rd control circuit switching relay (start repeat
173 X021 1-pole connector BU/BK
interlock)
174 X021 1-pole connector XP04 (16) 18-pole connector (board connection) BU/BK
175 XR02 (18) 21-pole connector (cab/engine disconnect) K075 (86) 3rd control circuit switching relay (start repeat interlock) VT
176 S124 (A) start repeat interlock limit switch K075 (86) 3rd control circuit switching relay (start repeat interlock) VT
177 Connecting point 3 S124 (B) start repeat interlock limit switch RD/BK
K075 (85) 3rd control circuit switching relay (start repeat
178 Earthing point I BK
interlock)
179 S051 (B) air conditioning switch K053 (86) switching relay for air conditioning fan GN/BN
180 K053 (86) switching relay for air conditioning fan Earthing point I BK
181 F020 (D) fuse K053 (30) switching relay for air conditioning fan BK/WH
182 K053 (87) switching relay for air conditioning fan XR02 (17) 21-pole connector (cab/engine disconnect) WH
183 Connecting point 6 E016 numberplate light GY/BK
184 Connecting point 6 E016 numberplate light GY/BK
185 E016 numberplate light Earthing point I BK
Serv-HB 34900/01 – Edition 1.0 * 34901_1012_Kabine_Legende_a3.fm 10-5

Electrical system
10-6 Serv-HB 34900/01 – Edition 1.0 * 34901_1012_Kabine_Legende_a3.fm

Electrical system
Frame wiring harness Frame wiring harness

Electrical system
10.3 Frame wiring harness
Starting relay (K007) Alternator (G001)

Board connection (XP01/03)
Driving direction identification (XP12.2)
Air conditioning fan (M013)

Fuel preheater Coolant temperature
Load stabiliser (Y020/021) (X020) switch (S003)
Air conditioning pressure switch (S052)
Lock (Y016)
Air filter pressure
Earth switch (S004) Pressure switch for
Starter (M001) hydraulic return
Headlights (right)
S005
Fuel level sensor (B001)
Engine oil pres-
Unlock (Y017) sure switch Preheating (R001)
(S002)
Cutoff solenoid (Y001)

Connecting point 3 Connecting point 1 Reverse (Y004)
Front socket (XX01)
Connecting point 2 Engine earth Forwards (Y005)

Brake light switch (S009) Hydraulic oil temper- Rear socket (XX02)
Headlights (left) ature switch (S006)
4 wheel steering (Y007)
Front axle steering (Y006)

Compressor (Y031)
Horn (B002)
Fuse 100A
Rear left light (E004/H021/H027)
Fuel pump (M009)

1st/2nd speed (Y002)
Hose burst valve (Y022) Driving direction identification (Y010)

Fuse 40A
Quickhitch lock (Y025)
10-8 Serv-HB 34900/01 – Edition 1.0 * 34901_1013_1000260127-1_02_E_Rahmen_frei_a3.fm

Electrical system
Electrical system
10.4 Frame wiring harness (legend)

From To Colour
From To Colour
36 F027 fuse F026 fuse RD
1 XP01 (16) 18-pole connector (board connection) XR02 (1) 21-pole connector (cab/frame disconnect) YE
2 XP03 (2) 22-pole connector (board connection) E001 connection (front right side marker light) GY/RD
38 F025 fuse K005 (30) preheating high current relay RD
3 XP03 (3) 22-pole connector (board connection) E002 connection (rear right light) GY/RD
39 K005 (87) preheating high current relay R001 preheating system BU
4 XP03 (4) 22-pole connector (board connection) XX01 (58R) front socket connection GY/RD
40 F025 fuse K009 (30) cutoff solenoid switching relay RD
5 XP03 (5) 22-pole connector (board connection) XX02 (58R) rear socket connection GY/RD
41 K009 (87) cutoff solenoid switching relay Y001 cutoff solenoid RD/BK
6 XP03 (6) 22-pole connector (board connection) E003 connection (front left side marker light) GY/BK
42 F026 fuse K007 (A) start high current relay RD
7 XP03 (8) 22-pole connector (board connection) E004 connection (rear left light) GY/BK
43 K007 (B) start high current relay M001 starter RD/BK
8 XP03 (9) 22-pole connector (board connection) XX01 (58L) front socket connection GY/BK
44 F028 fuse XR01 1-pole High-Power connection RD
9 XP03 (10) 22-pole connector (board connection) XX02 (58L) rear socket connection GY/BK
45 XP01 (11) 18-pole connector (board connection) K005 (86) preheating high current relay BU/GY
10 XP03 (13) 22-pole connector (board connection) E005 (56a) high beam connection (right) WH
46 K005 (85) preheating high current relay Earth connection BK
11 XP03 (11) 22-pole connector (board connection) E005 (56b) low beam connection (right) YE
47 XP01 (3) 18-pole connector (board connection) K007 (E) start high current relay BU/GY
12 XP03 (15) 22-pole connector (board connection) E006 (56a) high beam connection (left) WH/BK
48 K007 (G) start high current relay V001 (anode) BN
13 XP03 (21) 22-pole connector (board connection) E006 (56b) low beam connection (left) YE/BK
49 V001 (cathode) XP01 (13) 18-pole connector (board connection) BN
14 E001 front right side marker light Earth connection BK
50 K007 (H) start high current relay 3-pole connector (C) alternator P YE
15 E002 rear right light Earth connection BK
51 XP01 (5) 18-pole connector (board connection) X015 1-pole connector BK/WH
16 E003 front left side marker light Earth connection BK
52 X015 1-pole connector Connecting point 2 BK/WH
17 E004 rear left light Earth connection BK
53 Connecting point 2 K007 (C) start high current relay BK/WH
18 XX01 (31) front socket Earth connection BK
54 Connecting point 2 3-pole connector (B) alternator terminal 15 BK/WH
19 XX02 (31) rear socket Earth connection BK
55 Connecting point 2 K008 (86) time-lag relay 1s cutoff solenoid BK/WH
20 XP03 (7) 22-pole connector (board connection) B002 2-pole connector (horn) BN/YE
56 Connecting point 2 Y001 cutoff solenoid BK/WH
21 B002 2-pole connector (horn) Earth connection BK
57 Connecting point 2 M009 fuel pump BK/WH
22 XP03 (12) 22-pole connector (board connection) H024 front right turn indicator BK/GN
58 M009 fuel pump Earth connection BK
23 XP03 (16) 22-pole connector (board connection) H025 rear right turn indicator BK/GN
59 Y001 cutoff solenoid Earth connection BK
24 XP03 (19) 22-pole connector (board connection) H026 front left turn indicator BK/WH
60 K008 (85) time-lag relay 1s cutoff solenoid Earth connection BK
25 XP03 (17) 22-pole connector (board connection) H027 rear left turn indicator BK/WH
61 K008 (87) time-lag relay 1s cutoff solenoid K009 (86) cutoff solenoid switching relay RD/WH
26 XP03 (14) 22-pole connector (board connection) XX02 (4/R) rear socket BK/GN
62 K008 time-lag relay 1s cutoff solenoid K009 (85) cutoff solenoid switching relay YE
27 XP03 (22) 22-pole connector (board connection) XX02 (1/L) rear socket BK/WH
63 XP01 (15) 18-pole connector (board connection) 3-pole connector (A) alternator D+ BU
28 XP03 (1) 22-pole connector (board connection) S009 brake light switch RD/YE
65 Engine earth connection Earth connection BK
29 S009 brake light switch Connecting point 1 RD
66 XP01 (9) 18-pole connector (board connection) S002 engine oil pressure switch BU/GN
30 Connecting point 1 H021 brake lights RD
67 XP01 (7) 18-pole connector (board connection) S003 diesel engine temperature switch BU/WH
31 Connecting point 1 H020 brake lights RD
68 XP01 (12) 18-pole connector (board connection) B001 (2) fuel indicator VT/BU
32 Connecting point 1 XX02 (6/54) rear socket connection RD
69 B001 (1) fuel indicator Earth connection BK
33 Battery connection F027 fuse RD
70 XR02 (2) 21-pole connector (cab/engine disconnect) S004 air filter pressure switch YE/BU
34 F027 fuse 1-pole Power connection RD
71 S004 air filter pressure switch Earth connection BK
72 XR02 (3) 21-pole connector (cab/engine disconnect) Y009 (2) differential lock solenoid valve GY/GN
Serv-HB 34900/01 – Edition 1.0 * 34901_1014_Rahmen_Legende_a3.fm 10-9

Electrical system

73 Y009 (1) differential lock solenoid valve Earth connection BK 109 XP01 (8) 18-pole connector (board connection) S006 temperature switch (hydraulic oil) YE/GN
74 XP01 (4) 18-pole connector (board connection) Connecting point 3 GN/VT 110 XP01 (5) 18-pole connector (board connection) S006 temperature switch (hydraulic oil) BK/WH
75 Connecting point 3 Y004 (2) forwards driving solenoid valve GN/VT 111 XR02 (13) 21-pole connector (cab/engine disconnect) S058 (3) water separator switch RD/BU
76 Connecting point 3 X012.1 driving direction identification GN/VT 112 XR02 (14) 21-pole connector (cab/engine disconnect) S058 (2) water separator switch RD/WH
77 Connecting point 3 XR02 (4) 21-pole connector (cab/engine disconnect) GN/VT 113 S058 (1) water separator switch Earth connection BK
78 XP01 (14) 18-pole connector (board connection) Y005 (2) reverse driving solenoid valve GN/VT 114 XR02 (17) 21-pole connector (cab/engine disconnect) M013 2-pole connector (air conditioning fan) WH
79 XP01 (14) 18-pole connector (board connection) X012.2 driving direction identification GN/VT 115 M013 2-pole connector (air conditioning fan) Earth connection BK
80 X012.0 driving direction identification Y010 (2) driving direction identification solenoid valve GN/VT 116 XP01 (1) 18-pole connector (board connection) XR02 (18) 21-pole connector (cab/engine disconnect) VT
81 Y010 (1) driving direction identification solenoid valve Earth connection BK 117 Connecting point 2 X020 1-pole fuel preheater connector BK/WH
82 Y005 (1) reverse driving solenoid valve Earth connection BK 118 Connecting point 1 XR02 (19) 21-pole connector (cab/engine disconnect) RD
83 Y004 (1) forwards driving solenoid valve Earth connection BK
84 XP01 (6) 18-pole connector (board connection) Y002 (2) 1st/2nd speed solenoid valve YE/GY
85 Y002 (1) 1st/2nd speed solenoid valve Earth connection BK
86 XR02 (5) 21-pole connector (cab/engine disconnect) XX01 (54) front socket connection RD/YE
87 XR02 (6) 21-pole connector (cab/engine disconnect) XX01 (54G) front socket connection YE/RD
88 XR02 (7) 21-pole connector (cab/engine disconnect) S052 (1) air conditioning pressure switch GN/BN
89 S052 (3) air conditioning pressure switch Y031 magnetic clutch (compressor) GN/BN
90 XR02 (10) 21-pole connector (cab/engine disconnect) Y025 (2) solenoid valve (quickhitch lock) WH/BN
91 Y025 (1) solenoid valve (quickhitch lock) Earth connection BK
92 XR02 (11) 21-pole connector (cab/engine disconnect) Y022 (2) hose burst valve solenoid valve WH/BU
93 Y022 (1) hose burst valve solenoid valve Earth connection BK
94 XR02 (12) 21-pole connector (cab/engine disconnect) XP01 (17) 18-pole connector (board connection) WH/GN
95 XP01 (18) 18-pole connector (board connection) Y020 (2) load stabiliser solenoid valve WH/GN
96 XP01 (18) 18-pole connector (board connection) Y021 (2) load stabiliser solenoid valve WH/GN
97 Y020 (2) load stabiliser solenoid valve Earth connection BK
98 Y021 (1) load stabiliser solenoid valve Earth connection BK
99 XR02 (15) 21-pole connector (cab/engine disconnect) Y007 (2) 4 wheel steering solenoid valve WH/RD
100 Y007 (1) 4 wheel steering solenoid valve Earth connection BK
101 XR02 (16) 21-pole connector (cab/engine disconnect) Y006 (2) front axle steering solenoid valve WH/BK
102 Y006 (1) front axle steering solenoid valve Earth connection BK
103 XP01 (1) 18-pole connector (board connection) Y016 (2) lock solenoid valve VT
104 XR02 (20) 21-pole connector (cab/engine disconnect) Y016 (1) lock solenoid valve BK/VT
105 XP01 (2) 18-pole connector (board connection) Y017 (2) unlock solenoid valve OG
106 XR02 (20) 21-pole connector (cab/engine disconnect) Y017 (1) unlock solenoid valve BK/VT
107 XP01 (10) 18-pole connector (board connection) S005 hydraulic oil pressure switch BU/YE
108 S005 hydraulic oil pressure switch Earth connection BK
10-10 Serv-HB 34900/01 – Edition 1.0 * 34901_1014_Rahmen_Legende_a3.fm

Electrical system
Cab (option) wiring harness Cab (option) wiring harness

Electrical system
10.5 Cab (option) wiring harness
Additional control circuit relay (K045/046) Raise/lower (S070) Additional control circuit
Power supply for additional (S069)
control circuit (X013)
Joystick disconnect (X014)
Changeover switch additional control

circuit/tipping trailer (S056)
Tipping trailer X010 and X011 connected
Earth
Additional control circuit and tipping
trailer
X009 and X011 connected
Connecting point 1 Connecting point 2

Instrument panel light
Frame/cab disconnect (XR03)
10-12 Serv-HB 34900/01 – Edition 1.0 * 34901_1015_1000262644_Opt.Kabine_frei_a3.fm

Electrical system
Electrical system
10.6 Cab (option) wiring harness legend

From To Colour
X013 1-pole connector Power supply of additional control
1 Connecting point 1 BK/WH
circuit
2 Connecting point 1 S056 (5) additional control circuit switch BK/WH
3 Connecting point 1 X010 1-pole connector – tipping trailer only (red) BK/WH
4 Connecting point 1 S063 2-pole connector BK/WH
5 S056 (1) additional control circuit switch S069 (3) additional control circuit switch WH
6 S069 (1) additional control circuit switch S069 (10) additional control circuit switch WH/RD
7 S069 (1) additional control circuit switch V023 (cathode) diode WH/RD
8 V023 (cathode) diode Connecting point 2 Pink
9 Connecting point 2 K045 (30) switching relay for additional function Pink
10 Connecting point 2 K046 (30) switching relay for additional function Pink
11 V023 (cathode) diode V024 (cathode) diode Pink
12 Connecting point 2 XR03 (3) 9-pole connector (additional control circuit disconnect) Pink
XR03 (3) 9-pole connector (additional control circuit dis-
13 XR03 (4) 9-pole connector (additional control circuit disconnect) Pink
connect)
14 Connecting point 2 S070 (7) tip switch for raising/lowering tipping trailer Pink
15 S070 (7) tip switch for raising/lowering tipping trailer S070 (B) tip switch for raising/lowering tipping trailer Pink
16 S070 (1) tip switch for raising/lowering tipping trailer S070 (10) tip switch for raising/lowering tipping trailer BN/YE
17 S070 (1) tip switch for raising/lowering tipping trailer XR03 (6) 9-pole connector (additional control circuit disconnect) BN/YE
18 S069 (7) additional control circuit switch S069 (B) additional control circuit switch WH/GY
19 S069 (7) additional control circuit switch V024 (anode) diode WH/GY
20 V024 (anode) diode XR03 (5) 9-pole connector (additional control circuit disconnect) WH/GY
21 S056 (7) additional control circuit switch X009 1-pole connector (additional control circuit and tipping trailer) BK/RD
X011 1-pole connector (additional control circuit and tip-
22 S070 (3) tip switch for raising/lowering tipping trailer BK/WH
ping trailer)
23 X014 2-pole connector (joystick disconnect) K045 (86) switching relay for additional function BN/GN
24 X014 2-pole connector (joystick disconnect) K046 (86) switching relay for additional function BN/WH
25 K045 (87) switching relay for additional function XR03 (1) 9-pole connector (additional control circuit disconnect) GN
26 K046 (87) switching relay for additional function XR03 (2) 9-pole connector (additional control circuit disconnect) WH
27 S063 2-pole connector V022 (anode) diode WH/BK
28 V022 (cathode) diode X018 1-pole connector WH/BU
29 1-pole instrument light connector S056 (10) additional control circuit switch GY/RD
30 1-pole instrument light connector 1-pole instrument light connector GY/RD
31 K045 (85) switching relay for additional function Earth connection BK
32 K046 (85) switching relay for additional function Earth connection BK
33 S056 (9) additional control circuit switch Earth connection BK
Serv-HB 34900/01 – Edition 1.0 * 34901_1016_1000262644_Legende_Opt.Kabine_a3.fm 10-13

Electrical system
10-14 Serv-HB 34900/01 – Edition 1.0 * 34901_1016_1000262644_Legende_Opt.Kabine_a3.fm

Electrical system
Working light, rotating beacon (electrical diagram) Working light, rotating beacon (electrical diagram)
Electrical system
10.7 Working light, rotating beacon (electrical diagram)
Description:
E007 Rear working light
E008 Rear working light
E009 Front working light
E010 Front working light
F Fuses
H028 Rotating beacon
K047 Working light switching relay
S016 Working light switch
S017 Working light switch
S018 Rotating beacon switch
10-16 Serv-HB 34900/01 – Edition 1.0 * 34901_1000_Arbeitsscheinw_Rundumkennl_el_a3.fm

Electrical system
Lights (electrical diagram) Lights (electrical diagram)

Electrical system
10.8 Lights (electrical diagram)
Description:
E001 Front right side marker light
E002 Rear right light
E003 Front left side marker light
E004 Rear left light
E005 High, low beam (right)
E006 High, low beam (left)
E014 Interior light
E016 Numberplate light (OPTION)
F Fuses
H001 High beam indicator light
S012 Steering-column control lever (left)
S014 Light switch
XL01 8-pole connection (steering-column control lever)
XX01 Front socket
XX02 Rear socket
10-18 Serv-HB 34900/01 – Edition 1.0 * 34901_1000_Beleuchtung_el_a3.fm

Electrical system
Turn indicator/horn (electrical diagram) Turn indicator/horn (electrical diagram)

Electrical system
10.9 Turn indicator/horn (electrical diagram)
Description:
B002 Horn
F Fuses
H022 Machine turn indicator light
H023 Rear attachment turn indicator light
H024 Front right turn indicator
H025 Rear right turn indicator
H026 Front left turn indicator
H027 Rear left turn indicator
K010 Turn indicator relay
S019 Hazard warning switch
XX02 7-pole rear socket
10-20 Serv-HB 34900/01 – Edition 1.0 * 34901_1000_Blinklicht_Horn_el_a3.fm

Electrical system
Heating/air conditioning (electrical diagram) Heating/air conditioning (electrical diagram)

Electrical system
10.10 Heating/air conditioning (electrical diagram)
Description:
F Fuses
K053 Fan switching relay
K072 Auxiliary heating relay
M004 Fan
M013 Fan
M014 Auxiliary heating
P009 Auxiliary heating indicating instrument
S015 Heating switch
S051 Air conditioning switch
S052 Air conditioning pressure switch
S054 Air conditioning temperature switch
X001 4-pole connection (heater fan)
X019 1-pole connector
X020 1-pole connector
X022 8-pole connection (auxiliary heating)
XA03 18-pole board connection
Y031 Electro-magnetic clutch – compressor
10-22 Serv-HB 34900/01 – Edition 1.0 * 34901_1000_Heizung_Klima_el_a3.fm

Electrical system
Seat contact switch, front socket, fuel preheater (electrical diagram) Seat contact switch, front socket, fuel preheater (electrical diagram)
Electrical system
10.11 Seat contact switch, front socket, fuel preheater (electrical diagram)
Description:
F Fuses
G001 Alternator
K031 Fuel preheater switching relay
K073 Seat contact time-lag relay
M010 Air-suspension seat
R009 Fuel preheater
S027 Front socket switch
S104 Seat contact switch
X008 2-pole connection (air-suspension seat)
X015 1-pole seat contact switch disconnect (engine stop)
X016 1-pole seat contact switch disconnect (neutral)
X020 1-pole connection (fuel preheater)
XP05 22-pole connection
XX01 7-pole front socket
Seat contact switch Seat Front socket Fuel preheater

Front socket
10-24 Serv-HB 34900/01 – Edition 1.0 * 34901_1000_Sitzk_Fahrers_Fronts_Krafts_el_a3.fm

Electrical system
Multimedia, window heating, Multimedia, window heating,

Telematic tracking (electrical diagram) Telematic tracking (electrical diagram)
Electrical system
10.12 Multimedia, window heating, Telematic GPS (electrical diagram)
Description:
A001 Radio
A002 Telematic module
B011 Loudspeaker
B012 Loudspeaker
F Fuses
G001 Alternator
H007 Hydraulic oil filter indicator light
H008 Hydraulic oil temperature indicator light
H033 Water separator indicator light
K027 Time lag relay 5 min
R006 Window heating
S005 Hydraulic oil pressure switch
S006 Hydraulic oil temperature switch
S058 Water separator switch
S059 Rear window heating tip switch
W001 Aerial
X005 1-pole disconnect (window heating)
X006 8-pole connection (radio power supply)
X007 8-pole connection (radio loudspeakers)
XE90 12-pole Telematic connection
XP05 22-pole power supply connector
Multimedia Window heating Telematic Monitoring
10-26 Serv-HB 34900/01 – Edition 1.0 * 34901_1000_Sitzk_Multim_Scheibenh_Telem_Überw_el_a3.fm

Electrical system
Wiper/washer system, cigarette lighter (electrical diagram) Wiper/washer system, cigarette lighter (electrical diagram)
Electrical system
10.13 Wiper/washer system, cigarette lighter (electrical diagram)
Description:
E015 Cigarette lighter
F Fuses
G002 Battery
K023 Switching relay – wiper (1st speed)
K025 Intermittent-wipe relay
M002 Front wiper motor
M003 Rear wiper motor
M005 Washer pump
V Diodes
X002 6-pole front wiper connection
X003 2-pole rear wiper connection
X004 2-pole washer pump connection
XR01 1-pole High-Power connection
Wipe/wash Cigarette lighter
10-28 Serv-HB 34900/01 – Edition 1.0 * 34901_1000_Wisch_Zigaretten_el_a3.fm

Electrical system
Electrical system
10.14Wiring harness: alternator with 80 A
Alternator
Alternator D+
From To Colour
1 3-pole connector (A) D+ G001 2-pole connector (D+) BU
2 3-pole connector (B) terminal 15 G001 2-pole connector (terminal 15) BK/WH
3 3-pole connector (C) P G001 2-pole connector (P) YE
4 Starter cable lug Alternator cable lug B+ RD
Serv-HB 34900/01 – Edition 1.0 * 34901_1017_Lichtma_Kabelbaum.fm 10-29

Electrical system
Electrical system
10.15Wiring harness: alternator with 50 A
Alternator
Alternator D+
From To Colour
1 3-pole connector (A) D+ G001 3-pole connector (1) BU
2 3-pole connector (B) terminal 15 G001 3-pole connector (2) BK/WH
3 3-pole connector (C) P G001 3-pole connector (3) YE
4 Starter cable lug Alternator cable lug B+ RD
10-30 Serv-HB 34900/01 – Edition 1.0 * 34901_1018_1000263148_50A_Lichtma_Kabelbaum.fm

Electrical system
Electrical system
10.16Additional valves wiring harness

Raise tipping trailer (Y044) Lower tipping trailer (Y045)
Frame/cab discon-
nect XR03
From To Colour
1 XR03 (1) 9-pole additional control circuit Y080 (2) additional control circuit GN
2 XR03 (2) 9-pole additional control circuit Y081 (2) additional control circuit WH
3 XR03 (3) 9-pole additional control circuit Y012 (2) increased pump output Pink
4 XR03 (4) 9-pole additional control circuit Y044 (2) raise tipping trailer Pink
5 XR03 (5) 9-pole additional control circuit Y011 (2) increased pump output WH/GY
6 XR03 (6) 9-pole additional control circuit Y045 (2) raise tipping trailer BN/YE
7 Y080 (1) additional control circuit Earth connection BK
8 Y081 (1) additional control circuit Earth connection BK
9 Y012 (1) increased pump output Earth connection BK
10 Y044 (1) raise tipping trailer Earth connection BK
11 Y011 (1) increased pump output Earth connection BK
12 Y045 (1) raise tipping trailer Earth connection BK
Earth
Additional function Additional function

(Y080) (Y081)
Increased pump out- Increased pump output (Y012)

put (Y011)
Serv-HB 34900/01 – Edition 1.0 * 34901_1019_1000262645_Kabelbaum_Zusatzventile.fm 10-31

Electrical system
Electrical system
10.17Ohm’s Law (current, voltage, resistance); power

It describes the interrelation between current, voltage and resistance.
Current “I” – Ampere (A)

Voltage “U” – Volt (V)
Resistance “R” – Ohm ()
! Mnemonic: R
U
I
Power
Power "P" – Watt (W)
P = U x I = R x I² = U²/R
10.18Measuring equipment, measuring methods

Multifunction measuring device
• Measurements of values (U, R, I, f)
• Diode test
Calculate measuring range using known data (P, U, R, I) and set before measuring!
Observe AC/DC basic setting.
➥ AC = alternating current/voltage;
➥ DC = direct current/voltage
Test device with acoustic and optical signal output
• Continuity test in de-energised machine electrical system and of wiring harnesses.
Measuring methods – multifunction measuring device
• Measuring current (ignition switched on):
• Black cable in COM socket (earth),
• red cable in A socket or mA socket; connect in series to consumer.
• Measuring voltage (ignition switched on):
• red cable in V socket;
• connect in parallel to consumer.
• Measuring resistance (ignition switched off):
• red cable in socket;
• connect in parallel to consumer (see measuring voltage).
10-32 Serv-HB 34900/01 – Edition 1.0 * 34901_1010_Elektrik.fm

Electrical system
10.19Terminal description
Terminal descriptions and cable descriptions are not identical because equipment with dif-
ferent terminal descriptions can be connected to both ends of a cable.
If there are not enough terminal descriptions (multiple connectors), the terminals are
marked with continuous number or letter codes without any standardised function assign-
ment.
Terminal Meaning
Ignition coil, ignition distributor
1 Low voltage
Ignition distributor with two separate electric circuits
1a
to ignition contact breaker I
1b
to ignition contact breaker II
Short-circuit terminal
2
(magneto ignition)
Ignition coil, ignition distributor
4
High voltage
Ignition distributor with two separate electric circuits
4a from ignition coil I, terminal 4
4b from ignition coil II, terminal 4
15 Switched plus behind battery (output ignition [drive] switch)
15a Output at dropping resistor to ignition coil and starter
Preheating start switch
17 Start
19 Preheating
Battery
30 Input from + battery terminal, direct
12/24 V battery changeover relay
30a Input from + terminal of battery II
Return line to battery
31 Minus terminal or earth, direct
Return line to battery
31b Minus terminal or earth, via switch or relay (switched negative)
12/24 V battery changeover relay
31a Return line to minus terminal of battery II
31c Return line to minus terminal of battery I
Electric motors
32 Return line1)
33 Main terminal connection1)
33a Self-parking switch-off
33b Shunt field
33f For second lower drive range
33g For third lower drive range
33h For fourth lower drive range
33L Counterclockwise rotation
33R Clockwise rotation
Serv-HB 34900/01 – Edition 1.0 * 34901_1010_Elektrik.fm 10-33

Electrical system
Terminal Meaning
Starter
45 Separate starter relay, output; Starter, input (main current)
Two-starter parallel operation
Starting relay for engagement current
45a Output starter I,
Input starters I and II
45b Output starter II
48 Terminal on starter and on start-repeating relay (to monitor starting)
Turn indicator unit (pulse generator)
49 Input
49a Output
49b Output, 2nd turn indicator circuit
49c Output, 3rd turn indicator circuit
Starter
50 Starter control (direct)
Battery changeover relay
50a Output for starter control
Starter control
50b with parallel operation of 2 starters with sequential control
Starting relay for sequential control of the engagement current during parallel
operation of 2 starters
50c
Input at starting relay for starter I
50d
Input at starting relay for starter II
Start locking relay
50e Input
50f Output
Start repeat relay
50g Input
50 h Output
AC alternator
51 Direct current voltage at rectifier
51e Direct current voltage at rectifier with choke coil for daytime driving
Trailer signals
52 Signals from trailer to towing machine
53 Wiper motor, input (+)
53a Wiper (+), self-parking switch-off
53b Wiper (shunt winding)
53c Electric window washer pump
53e Wiper (brake winding)
53i Wiper motor with permanent magnet and third brush (for higher speed)
Trailer signal
54 For lamp combinations and trailer plug connections
Brake lights
54g Pneumatic valve for additional retarding brake, electromagnetically actuated
55 Fog lights

Electrical system
Terminal Meaning
56 Headlight
56a High beam and high beam indicator light
56b Low beam
56d Headlight flasher contact
57 Side marker light for motorcycles (also for cars, trucks etc. in other countries)
57a Parking light
57L Parking light, left
57R Parking light, right
Side marker, rear, numberplate and instrument panel lights
58
Rear light changeover for single-axle tractors
58b
Trailer plug-and-receptacle assembly for single-conductor rear light cable with
58c
fuse in trailer
58d
Variable-intensity instrument panel lights, side marker and rear light
58L
Left
58R
Right, numberplate light
AC alternator (magneto alternator)
59 Alternating voltage, output, rectifier, input
59a Charging armature, output
59b Rear light armature, output
59c Brake light armature, output
61 Alternator charge indicator light
Tone sequence control device
71 Input
71a Output to horns 1 + 2 low
71b Output to horns 1 + 2 high
72 Alarm switch (rotating beacon)
75 Radio, cigarette lighter
76 Loudspeaker
77 Door valve control
Switches (break contact and changeover switches)

Input
81
1st output, break side
81a
2nd output, break side
81b
Make-contact switch
Input
82
1st output
82a
2nd output
82b
1st input
82z
2nd input
82y
Multiple position switch
Input
83
Output, position 1
83a
Output, position 2
83b
Output, left-hand position
83L
Output, right-hand position
83R

Electrical system
Terminal Meaning
Current relay
84 84a 84b
Input, actuator and relay contact
84a
Output, actuator
84b
Output, relay contact 84
Switching relay – output, actuator (end of winding negative or earth)

Input, actuator
Start of winding
85
Start of winding or 1st winding
86
Winding tap or 2nd winding
86a
86 87a 88a 87a 88a 87a 88a
86b 88b
85 87 88 87 87
Relay contact for break and changeover contacts

87
Input
87a
1st output (break side)
87b
2nd output
87c
3rd output
87z
1st input
87y
2nd input
87x
3rd input
Relay contact for make-contact
88 Input
Relay point for make-contact and changeover contacts (make side)
88a 1st output
88b 2nd output
88c 3rd output
Relay contact for make-contact
88z 1st input
88y 2nd input
88x 3rd input
Alternator and governor

B+ Battery positive
B- Battery negative
D+ Dynamo positive
D- Dynamo negative
DF Dynamo field
DF 1 Dynamo field 1
DF 2 Dynamo field 2
U, V, W Three-phase alternator – three-phase terminals
Turn indicators (turn indicator unit)
First indicator light
C
Main terminal connection for separate indicator circuits actuated by the turn
C0
indicator switch
C2
Second indicator light
C3
Third indicator light (e.g. when towing two trailers)
L
Turn indicators (left)
R
Turn indicators (right)

Electrical system
10.20Colour coding of electric lines

The cables are colour-coded according to DIN 72551 Part 4. Refer to the 21 pin cab/frame
interface or the explanation in the wiring harness drawings for other colours not listed in
this DIN standard.
Extract from DIN 72551, sheet 4
Line Identification
Basic colour
From To colour
Ignition coil I Ignition distributor (low-voltage ignition lead) Green -
Ignition coil II Ignition distributor (low-voltage ignition lead) Green Red
Battery Starter Black -
Battery Earth (if bare earth lead is not used) Black -
Starter Alternator Red -
Starter Control panel (30) Red -
Light switch (30) Ignition switch (30) Red -
Control panel (30) or light switch (30) Fuse Red -
Fuse Hand lamp, radio, clock etc. Red -
Heater plug and starter switch; heater-plug indi-
Control panel (15/54) Black -
cator light
Heater plug and starter switch; heater-plug indi-
Glow plugs Black -
cator light
Ignition switch (15/54) Ignition coil Black -
Ignition switch or control panel (54/15/61a) Indicator lights Black -
Control panel or ignition switch (15/54) Fuse Black -
Fuse box Brake light Black Red
Fuse box Turn indicator switch Black White-green
Turn indicator switch Turn indicators (left) Black White
Turn indicator switch Turn indicators (right) Black Green
Indicator light Turn indicators Light blue -
Fuse Cigarette lighter Black -
Fuse Heated window Black Yellow-red
Fuse 1st horn Black Yellow
Fuse 2nd and 3rd horn Black Yellow-light blue
Horns 1-pole horn pushbutton (earth) Brown -
Fuse Wipers Black Purple
Terminal 61 of alternator or reverse current cut-
Battery charge indicator light Light blue -
out
Fuse High beam indicator light Light blue White
Oil pressure gauge (indicator) Oil pressure switch Light blue Green
Fuel level indicator Fuel tank Light blue Black
Tyre-pressure warning device Tyre-pressure drop indicator Light blue Yellow
Control panel bzw. Lichtschalter Low beam switch White Black

Electrical system
Line Identification
Basic colour
From To colour
Low beam switch (a) Fuse White -
Fuse Main headlight, left White -
Fuse Main headlight, right White -
Low beam switch (b) Fuse Yellow -
Fuse Low beam, left Yellow -
Fuse Low beam, right Yellow -
Control panel or light switch (58) Fuse Grey -
Fuse Rear light, side light and side marker lights left Grey Black
Fuse Numberplate light (combined with rear left light) Grey Black
Fuse Rear light, side light and side marker lights, right Grey Red
Numberplate light (combined with rear right
Fuse Grey Red
light)
Fuse Numberplate light (only if special line is laid) Grey -
Fuse Dome light Red -
Control panel (57) Fuse Grey Green
Control panel bzw. Lichtschalter Instrument panel light Grey Red
All consumers except the battery earth lead if
Earth Brown -
the use of bare lines is not possible
Battery changeover switch (50)/starter pushbut-
Starter Black -
ton or heater plug and starter switch

Electrical system
Other colour codes (identical to IEC 757)
Abbreviation Abbreviation
Colour
Old New
Black sw BK
Brown br BN
Red rt RD
Orange or OG
Yellow ge YE
Green gn GN
Blue bl BU
Violet vi VT
Grey gr GY
White ws WH
Pink rs PK
Gold - GD
Turquoise tk TQ
Silver - SR
10.21Switching relay function

Use, mode of function
Relays are used for switching electric loads (high currents) whereby the control power of
the relay coil is relatively low. Relays can therefore be controlled by micro electronics or
micro switches (e.g. touchpad keyboards, sensors). The switch contacts can be make-
contact, break-contact or changeover switches. These undertake the actual switching
function.
Terminal description on relay
Zero-centre relay
86 = Start of coil (control line)
85 = End of coil (earth)
30 = Input (load line)
87 = Make-contact switch output (load line)
87 a= Break-contact switch output (load line)

Electrical system
10.22Electric units/light bulbs

Description Power
Alternator 12 V 55 A/12 V 80 A (option)
Starter 12 V 2.3 kW (12 V 3.1 hp)
Battery 12 V 74 Ah 680 A
Light bulb – high beam (left/right) 12 V 55 W/H3
Light bulb – low beam (left/right) 12 V 55 W/H7
Light bulb – side marker light (left/right) 12 V 4 W
Light bulb – front and rear turn indicators
12 V 21 W
(left/right)
Light bulb – brake/rear lights (left/right) 12 V 21/5W
Light bulb – working light 12 V 55 W/H3
Light bulb – rotating beacon 12 V 55 W/H1
Light bulb – interior light 12 V 10 W
10.23Connector description (overview)
Assignment Description
X000 General connector
XP00 Board connector
XL00 Steering-column control lever connector
XA00 Indicating instrument connector
XE00 Electronics connector
XS00 Armrest (control lever base) disconnect connector
XR00 Cab/frame disconnect connector
XJ00 Joystick (control lever) connector
XD00 Cab/roof disconnect connector
XX00 Sockets

Electrical system
10.24Fuses
Fuse assignment
Rated cur-
rent (A)
F005 10
lamp
F009 7.5 Low beam (right)
F7 F6 F5 F4 F3 F2 F1
F010 5
fuel pump
F16 F15 F14 F13 F12 F11 F10 F9 F8
F24 F23 F22 F21 F20 F19 F18 F17 F012 7.5 Solenoid valves, load stabiliser
F013 7.5
Fig. 1: Fuse assignment drive solenoid valve
F014 25
quickhitch lock
F019 5
ing modes
F020 15

Electrical system

K010 K018
K017 Switching
Protected circuit
relay no.
K016
K027 K016 Not assigned
K017 Switching relay for unlocking the quickhitch (option)
K023
K001 K023 Switching relay for wiper
K027 Step-by-step relay for window heating (option)
Fig. 2: Relays on board

B018 K025 K073 K002 K070 K047
Switching
Protected circuit
relay no.
B018 Buzzer
K021 K030 K053 K075
K030 Brake lights
Fig. 3: Relay bracket

Electrical system

The main fuse box is located in the engine compartment (on the left on the rear wall)
K005 K009 F026 F027
Rated cur-
rent (A)
Relay no. Protected circuit

F025 F028
Fig. 4: Main fuse box K005 Preheating high current relay

Electrical system
10.25Switch assignment on board (overview)
1 2 3 4 5 6
7 8 9 10 11 12
Caution!
Mount the switches as shown and affix symbols on them to

avoid damage due to malfunctions!
☞ Remove the dummy cover
☞ Insert the switch (tip switch) in the board
Switch posi-
1 2 3 4 5 6
tion
Abbreviation S 014 S 032 S 033 S 040 S 059 S069
Switch order no. 1000051958 1000101016 1000116427 1000051971 1000051971 1000133788
Symbol order no. 1000268826 – – 1000183934 1000052372 1000269427
Continuous
Electrical 3rd operation of Rear window Large/small oil
Function Light switch Quickhitch lock
control circuit 3rd control cir- heating quantity
cuit
Switch position 7 8 9 10 11 12
Abbreviation S 044 S016 S 018 S 017 – S070
Switch order no. 1000051962 1000051959 1000051959 1000051959 – 1000181773
Symbol order no. 1000185520 1000096654 1000052356 1000052361 – 1000183935
Raises/lowers
Front working Rotating bea- Rear working
Function Load stabiliser – the tipping
light con lights
trailer

Electrical system
10.26Overview of front switch assignment
1 2 3 4 5 6
Caution!
Mount the switches as shown and affix symbols on them to

avoid damage due to malfunctions!
☞ Remove the dummy cover
☞ Insert the switch (tip switch) in the board
Switch posi-
1 2 3 4 5 6
tion
Abbreviation S 056 S 027 S 051 S 021 S 073 H13/14
Switch order no. 1000183943 1000133738 1000051959 1000051962 1000183941
Symbol order no. – 1000257066 1000098305 1000183961 1000250154 1000030174
Activates the
Front/rear Air condition- Front axle Front/4 wheel steer-
Function 4th control Hare/turtle
socket ing steering ing indicator light
circuit
Switch posi-
7
tion
Abbreviation S 019
Switch order no. 1000027198
Symbol order no. –
Hazard warning
Function
switch

Electrical system
10.27Control lever
Description:
S117
S117 Tip switch additional function connection (red 13) Y081
Tip switch additional function connection (blue 12)
S034 S101 S101
Y080
S034 Forwards driving tip switch Y005
S035 S035 Reverse driving tip switch Y004
S66
S066 Neutral tip switch
Description:
S025 Differential lock tip switch Y009
S030 Unlock tip switch Y017
S031 Lock tip switch Y016
S030
S031
S025 Joystick cable assignment (description)
XJ 4-pole Deutsch connector Colour
1 Input +12 V RD
2 Earth input BN
3 Output +12 V forwards Y005 GN
4 Output +12 V reverse Y004 BK/GN
XJ 6-pole Deutsch connector OK
1 Unlock output Y017 BU
2 Lock output Y016 GY
3 Free
4 Not assigned YE
Output additional control circuit with additional function
5 BK/RD
Y081
Output additional control circuit with additional function
6 WH
Y080
XJ 3-pole Deutsch connector
B Output differential lock tip switch Y009 BK
XJ 1-pole plug and socket connection
1 Lights +12 V BK/BU

Electrical system
10.28Joystick outputs (overview)
S117
YE
S034 S101 BK/GN
93 WH
S035
S66
GY BU
BK
BN RD BK/GN GN
XJ03 XJ01 XJ04
GY
X X
1 2 3 4 1 2 5 6 BU/RD
GN/VT
RD/BU
WH/VT
BN/GN
XP05
Relay K30 (30)
brake light XP05
16 XP02
12
2
11 9
BU/YE BU/RD
To plug and socket

connection X014 2-
pole
To plug and socket connection X003
From K045 (87) to X003 (1) GN to Y080 K045 relay (86)
From K046 (87) to X003 (2) WH to Y081 BN/GN
K045 K046
K046 relay (86)
BU/RD
Y080 Y081

Electrical system
10.293rd electrical control circuit (overview)
S032 S033
0 0
1 1
K075 start repeat interlock

on terminal 50
Y016 lock Y017 unlock

Electrical system
10.30Auxiliary hydraulics overview
S056 S069 S070

0 2 2
1 1 1

Electrical system
10.31Steering-column control lever S012
Description: cable assignment of steering-column control lever con-

Colour
nector
6 pole Steering-column control lever connection
1 L – front and rear left turn indicators BK/WH
2 R – front and rear right turn indicators BK/GN
3 49a – K10 (c) turn indicator relay BK/WH
4 15 – terminal 30 (constant current) RD
5 56b – right and left low beam YE
6 56a – right and left high beam WH
8 pole Steering-column control lever connection
1 15 – K023 (87) wiper speed 1 BK
2 Free Free
3 53 – K023 (86) wiper speed 1 (signal) BK/VT
4 31B – K025 (S) intermittent wipe relay BN/BK
5 H – horn BK/YE
6 53c – wipe/wash pump VT/YE
7 J – K025 (I) intermittent wipe relay BK/RD
8 56 – S014 (1) light switch WH/BK

Electrical system
10.32Plug-and-socket connections of steering-column control lever

Steering-column control lever connection Steering-column control lever connection
seen from above seen from above
XL01 XL02
Description: cable assignment of steering-column control lever connector Colour

6 pole Steering-column control lever connection XL02
1 To XP05 (2) to XP03 (19) turn indicator H026/H027 front and rear left BK/WH
2 To XP05 (3) to XP03 (12) turn indicator H024/H025 front and rear right BK/GN
3 To XP02 (3) to K10 (c) turn indicator relay WH/RD
4 To XP05 (14) to terminal 30 (constant current) GN/WH
5 To XP05 (6) to XP03 (11, 13) to right and left low beam E005/E006 YE
6 To XP05 (8) to XP03 (13, 15) to right and left high beam E005/E006 WH
8 pole Steering-column control lever connection XL01
1 To XP05 (15) to K023 (87) wiper speed 1 GN/WH
2 Free Free
3 To XP05 (9) to K023 (86) wiper speed 1 (signal) WH/BU
4 To XP05(4) to K025 (S) intermittent wipe relay GN/BK
5 To XP05 (11) to horn BN/YE
6 To XP05 (1) to XP06 (3) to wipe/wash pump BU/GN
7 To K025 (I) intermittent wipe relay RD
8 To XP05 (13) to S014 (1) light switch GY/GN

Electrical system
10.33Overview: cab retrofitting (wiring)

Rotating beacon
Rear working light Rear working light
Numberplate light
Backup warning system Window heating
Retrofitting a rotating beacon H028 (wiring)

• The wiring harness is installed at the rear right on the C pillar
• Mount rotating beacon H028
• Pull the cable out of opening 1 in the cab roof
• Cable colour GN (green) for power
• Bk (black) for earth
1 ☞ Insert switch S018 with the symbol in slot 9 in the board (see board switch assignment)
☞ Check the correct function of the electrical system
Retrofitting a backup warning system 3 (wiring)

• Install backup warning system 3
3 • Cable colour GN/VT (green/violet) for power
2 ☞ Check the correct function of the electrical system
Retrofitting a numberplate light 4 (wiring)

4 • Install numberplate light 4
• Pull the cable out of the opening in the cab roof
• Cable colour GY/BK (grey/black) for power

Electrical system
Retrofitting a rear working light 5 (wiring)

6
• Install the rear working light 5
• Cable colour VT/YE (violet/yellow) for power
Bk (black) for earth
5 ☞ Insert switch S017 with the symbol in slot 10 in the board (see board switch assign-
ment)
☞ Insert the switching relay in the additional base
K047
Retrofitting a front working light (wiring)

• Mount the front working light
• Pull the cable out of the opening in the cab roof
• Cable colour VT/WH (violet/white) for power
Bk (black) for earth
☞ Insert switch S016 with the symbol in slot 8 in the board (see board switch assignment)

Electrical system
10.34Retrofitting a rear 7-pole socket

☞ Connect the 6-core cable A according the PIN assignment plan
PIN assignment plan XX01
A
Pin Function Cable colour
1 L BK/WH
3 31 BK
4 R BK/GN
5 58R GY/RD
6 54 RD
7 58L GY/BK
- - -
10.35Retrofitting a front 4-pole socket

PIN assignment plan XX02
Function Cable colour
31 BK
58L GY/BK
58R GY/RD
54 RD/YE
54g YE/RD

KRAMER-WERKE GmbH keep abreast of the latest technical developments and constantly
improve their products. For this reason, we may from time to time need to make changes to
diagrams and descriptions in this documentation which do not reflect products which have
already been delivered and which will not be implemented on these machines.
Technical data, dimensions and weights are given as an indication only. Responsibility for
errors or omissions not accepted.
No reproduction or translation of this publication, in whole or part, without the written con-
sent of KRAMER-WERKE GmbH.
All rights under the provision of the Copyright Act are reserved.
Kramer-Werke GmbH
D-88630 Pfullendorf
Germany
Kramer-Werke GmbH
D-88630 Pfullendorf
Tel.: 0080090209020
E-mail info@kramer.de
www.kramer.de
Order no. 1000277645

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Service manual

Machine model 349-00/349-01

Service manual [en] 1000277645

Operator’s Manual [en] 1000268039

Service Booklet [en] 1000159214

Spare parts catalogue, model 349-

Document Serv-HB 34900/01

Copyright – 2011 Kramer-Werke GmbH

Serv-HB 34900/01 - Ausgabe 1.0 * Serv-HB 34901_10_enIVZ2.fm I-1

3 Maintenance and servicing work

I-2 Serv-HB 34900/01 - Ausgabe 1.0 * Serv-HB 34901_10_enIVZ2.fm

Serv-HB 34900/01 - Ausgabe 1.0 * Serv-HB 34901_10_enIVZ2.fm I-3

I-4 Serv-HB 34900/01 - Ausgabe 1.0 * Serv-HB 34901_10_enIVZ2.fm

Serv-HB 34900/01 - Ausgabe 1.0 * Serv-HB 34901_10_enIVZ2.fm I-5

I-6 Serv-HB 34900/01 - Ausgabe 1.0 * Serv-HB 34901_10_enIVZ2.fm

1 Cab overview, use, operation Machine

1.1 Machine outside view

1-2 Serv-HB 34900/01 – Edition 1.0 * 34901_0110_a3_Übersicht-Bedienung.fm

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1.2 Inside of cab (overview)

Inside of cab (overview)

Serv-HB 34900/01 – Edition 1.0 * 34901_0110_a3_Übersicht-Bedienung.fm 1-3

71 58 Tip switch (grey) – front socket with two circuits (option)

1-4 Serv-HB 34900/01 – Edition 1.0 * 34901_0110_a3_Übersicht-Bedienung.fm

Cab overview, use, operation

1.4 Legal regulations regarding wheel loader operation

Serv-HB 34900/01 – Edition 1.0 * 34901_0110_Verwendung.fm 1-5

1-6 Serv-HB 34900/01 – Edition 1.0 * 34901_0110_Verwendung.fm

Machine warning identification (option)

Serv-HB 34900/01 – Edition 1.0 * 34901_0110_Verwendung.fm 1-7

1.5 Fields of application and using a machine with an attachment

Overview of certified attachments

1-8 Serv-HB 34900/01 – Edition 1.0 * 34901_0110_Verwendung.fm

Type labels and component numbers

Fig. 2: Explanation of “Book” symbol

13 Gross braked trailer weight rating1 –

Serv-HB 34900/01 – Edition 1.0 * 34901_0110_Verwendung.fm 1-9

Fig. 4: Cab type label

Fig. 5: Diesel engine number

Variable displacement pump number

Fig. 6: Hydraulic pump type label

1-10 Serv-HB 34900/01 – Edition 1.0 * 34901_0110_Verwendung.fm

Variable displacement motor number

Fig. 7: Variable displacement motor type label

Number of transfer gearbox

Fig. 8: Gearbox type label

Front or rear axle number

Fig. 9: Rear axle and gearbox type label

Serv-HB 34900/01 – Edition 1.0 * 34901_0110_Verwendung.fm 1-11

1-12 Serv-HB 34900/01 – Edition 1.0 * 34901_0110_Verwendung.fm

2.1 Models and trade names (overview)

1. Loader unit in transport position

2-2 Serv-HB 34900/01 – Edition 1.0 * 34901_0210_Technische Daten.fm

1. Model 349-00 with tyres 10.5-18

Serv-HB 34900/01 – Edition 1.0 * 34901_0210_Technische Daten.fm 2-3

2.5 Front/rear axles

1. Option for model 349-00

1. Standard tyres 10.5-18 (model 349-00)

2-4 Serv-HB 34900/01 – Edition 1.0 * 34901_0210_Technische Daten.fm

2.7 Steering system

Serv-HB 34900/01 – Edition 1.0 * 34901_0210_Technische Daten.fm 2-5

2.8 Work hydraulics

1. Measured at control valve test port

Protection: lift, tilt and quickhitch rams