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