Edition 2.6, 10/2015 D03-05 (from WNCD0305VPAL00283) Content: Documentation Legend OPERATION Information on this service manual Identification of warnings and dangers Designated use and exemption from liability Type labels and component numbers Machine overview Control stand overview Overview of cabin control stand (option) Instrument panel overview (Yanmar) Overview of display element and switches (Perkins) Parking the machine Engine cover Maintenance accesses (machine with optional cabin) Maintenance prop Front skip Swivel skip Center-pivot prop Rollbar Locking the control lever Battery master switch up to serial number WNCD0305VPAL00283 (Yanmar) Rotating beacon (option) Opening the high-pressure circuit TECHNICAL DATA Chassis Engine (Yanmar) Engine capacities Engine tightening torques Engine (Perkins) Engine capacities Operating hydraulics Traveling drive Machine travel specifications Brakes Steering system Tires Skip Coolant compound table Vibration Electrical system Fuses and relays (up to serial no. EA01931, Yanmar) Fuses and relays (serial nos. EA01932 to EA01950, Yanmar) Additional fuses for machine with optional cabin (Yanmar) Fuses and relays (Perkins) Noise levels (Yanmar) General tightening torques Tightening torques for hydraulic threaded fittings (dry assembly) Tightening torques for high-resistance threaded fittings Tightening torques for Nordlock lock washers Dimensions model 3001 (front skip) Dimensions model 3001s (swivel skip) (option) Dimensions model 3001s special skip (swivel skip) (option) Tilted height 2.2 m (86.6 in) Dimensions model 3001 (front skip) cabin (option) Dimensions model 3001s (swivel skip) cabin (option) MAINTENANCE Introduction Safety-relevant parts Fluids and lubricants (Yanmar) Fluids and lubricants (Perkins) Oil grades for the diesel engine, depending on temperature (Yanmar) Oil grades for the diesel engine, depending on temperature (Perkins) Oil grades for the hydraulic system, depending on temperature Additional oil change and filter replacement (hydraulic system) Important information regarding operation with biodegradable hydraulic oil Maintenance label Explanation of symbols on the maintenance label Maintenance plan (overview - Yanmar) Maintenance plan (Perkins) Fuel system Refueling Stationary fuel pumps Emptying the fuel tank Draining the condensation water in the fuel tank Bleeding the fuel system (Yanmar) Yanmar fuel prefilter with water separator (Yanmar) Replacing the fuel filter (Yanmar) Fuel filter with water separator (Perkins) Emptying the fuel filter (Perkins) Replacing the fuel filter (Perkins) Changing the fuel prefilter (Perkins) Engine lubrication system Checking the engine oil level (Yanmar) Checking the engine oil level (Perkins) Adding engine oil Changing engine oil Replacing the engine-oil filter cartridge Engine and hydraulics cooling system Specific safety instructions Checking the coolant level/adding coolant Draining coolant Cleaning the radiator Air filter Replacing the filter Checking the engine air intake (Perkins) Replacing the cabin air filter V-belt Checking V-belt tension Replacing the alternator V-belt Retensioning the alternator V-belt Replacing the compressor V-belt (Perkins) Retensioning the compressor V-belt (Perkins) Replacing the crankcase breather filter Replace the fuel-burner glow plug Hydraulic system Specific safety instructions Checking the hydraulic oil level Adding hydraulic oil Changing hydraulic oil Wear indicator of hydraulic oil filter insert Replacing the hydraulic oil filter element Replace the braking system fluid Checking hydraulic pressure lines Overview of lubrication points Lubrication plan for swivel skip (option) Lubrication plan for front skip (option) Tires Inspection work Changing wheels Braking system Axles Checking the oil level and adding oil Draining oil Axle mounting Front axle Rear axle Electrical system Specific safety instructions Servicing and maintenance at regular intervals Fuses and relays Battery Battery charge condition Charging the battery Replacing the battery General maintenance Cleaning General instructions for all areas of the machine Exterior of the machine Cleaning the seat belt Inside the cabin Engine compartment Threaded fittings and attachments Pivots and hinges Preparatory work before taking out of service Maintenance if the machine is out of service for a longer period of time Putting into operation again (Yanmar) Putting into operation again (Perkins) ENGINE 3TNV88-KNSV engine (overview) Fuel system (up to AB) Fuel system (from AC) Checking and adjusting valve clearance Tightening order for cylinder head bolts Checking the injection nozzles Pressure check Checking the nozzle jet Injection time Adjusting engine speed Compression Checking the coolant thermostat Checking the thermal switch Oil pressure switch Checking the coolant circuit Clutch Engine 3TNV88-BKNSV overview (from serial no. AE310242D) Fuel system (from serial no. AE310242D) Checking and adjusting valve clearance Tightening order for cylinder head bolts Checking the injection nozzles Pressure check Checking the nozzle jet Injection time Adjusting engine speed Compression Checking the coolant thermostat Checking the thermal switch Oil pressure switch Checking the coolant circuit Clutch Engine malfunctions Perkins engine 403F-15T (overview) Fuel system Checking and adjusting valve clearance Clean the diesel particulate filter Checking the injection nozzles Turbocharger Checking/replacing the coolant thermostat Checking the coolant circuit Engine malfunctions TRAVELING DRIVE Variable displacement pump A10VG45DA Variable displacement pump: diagram Variable displacement pump: design Traveling drive overview Connecting plate with valves Hydraulic motor A6VM80EZ Traveling drive overview (up to AB) Traveling drive overview (from AC) Towing and transporting the machine Safety instructions Towing Opening the high-pressure circuit Test instructions High pressure check Check: boost pressure Check: setting pressure Adjustment Setting: control initiation AXLES Axle type label Drain, fill and check plug Tightening torques Wheel screws Axle mounting General tightening torques Articulated joint (up to AB) Articulated joint (from AC) Transfer gearbox (up to AD) Transfer gearbox (from AE310242D) Semiaxles Wheel hub Front axle brake (up to AB) Brake diagram Front axle brake (from AC to AD) Front axle brake (from AE310242D) Differential (up to AB) Front axle (up to AB) Front axle (from AC to AD) Front axle (from AE310242D) Rear axle Cardan shaft Front axle (Tier IV Perkins) Rear axle (Tier IV Perkins) BRAKES Brake circuit (up to AB) Brake circuit Parking brake Service brake STEERING SYSTEM Steering circuit (up to AB) Steering circuit (from AC) Steering unit: diagram Function Steering unit connections Steering unit overview Priority valve overview Priority valve (legend) Steering unit Steering unit (legend) HYDRAULIC SYSTEM Control valve Machines with front skip up to serial no. EA03236 Overview of connections Machines with front skip from serial no. EA03237 Overview of connections Valves - differential lock (up to AB) Check valve Tilting the skip: hydraulic diagram (up to AB) Tilting the skip: hydraulic diagram (from AC) Swiveling the skip: hydraulics diagram (up to AB) Swiveling the skip: hydraulics diagram (from AC) Test instructions Check: operating hydraulics Hydraulics diagram from serial no. EA01441 Hydraulics diagram Tier IV (Perkins) ELECTRICAL SYSTEM Ohms Law (current, voltage, resistance); power Measuring equipment, measuring methods Relays Use, mode of function Electric units Fuses and relays (up to serial no. EA01931, Yanmar) Fuses and relays (serial nos. EA01932 to EA01950, Yanmar) Additional fuses for machine with optional cabin (Yanmar) Fuses and relays (Perkins) Telematic Connections Functional check/diode Yanmar wiring diagram up to AB (legend) Yanmar wiring diagram (up to AB) Wiring diagram legend Tier III (from serial no. WNCD0305TPAL01054) Wiring diagram Tier III (from serial no. WNCD0305TPAL01054) Perkins wiring diagram Tier IV part 1 Perkins wiring diagram Tier IV part 2 Perkins wiring diagram Tier IV part 3 with StVO registration (Austrian road traffic regulations) Main wiring harness legend (up to AB) Main wiring harness up to AB Main wiring harness legend (from AC to serial no. WNCD0305CPAL01053) Main wiring harness (from AC to serial no. WNCD0305CPAL01053) Main wiring harness legend Tier III (from serial no. WNCD0305TPAL01054) Main wiring harness Tier III (from serial no. WNCD0305TPAL01054) Main Perkins wiring harness Tier IV (legend) Main Perkins wiring harness Tier IV Engine wiring harness legend Engine wiring harness Wiring harness legend: indicator base - starter base (up to AB) Wiring harness: indicator light base (up to AB) Wiring harness: starter base (from AC) Light switch connector assignment StVO (Austrian road traffic regulations) wiring harness from AC StVZO (Austrian road traffic regulations) wiring harness Tier IV Extension cable (front skip) Rotating beacon cable Alternator wiring harness (up to serial no. WNCD0305JPAL00636) Alternator wiring harness (from serial no. WNCD0305CPAL00637) Battery lead