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Wacker Kramer 4507/KT457 5007/KT507 5507/KT557 4209/KT429 5509/KT559 Telehandlers System manual- PDF DOWNLOAD
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Wacker Kramer 4507/KT457 5007/KT507 5507/KT557 4209/KT429 5509/KT559 Telehandlers System manual- PDF DOWNLOAD
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Wacker Kramer 4507/KT457 5007/KT507 5507/KT557 4209/KT429 5509/KT559 Telehandlers System manual- PDF DOWNLOAD
Language :English
Pages :1048
Downloadable : Yes
File Type : PDF
Size:53.4 MB
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TABLE OF CONTENTS:
Wacker Kramer 4507/KT457 5007/KT507 5507/KT557 4209/KT429 5509/KT559 Telehandlers System manual- PDF DOWNLOAD
System manual............................................................................................................................ 1 E Introduction....................................................................................................................... 3 E.1 Notes on system manual....................................................................................................... 4 Use of the system manual..................................................................................................... 4 Required tools and screw connections......................................................................................... 5 Procedure.................................................................................................................... 5 E.2 Safety instructions.......................................................................................................... 6 Pay particular attention to the following.................................................................................... 6 Safety symbols and signal words.............................................................................................. 6 Safety and accident prevention regulations................................................................................... 7 E.3 Symbol and abbreviations..................................................................................................... 11 Symbols...................................................................................................................... 11 Abbreviations................................................................................................................ 12 E.4 Tightening torques........................................................................................................... 15 General tightening torques................................................................................................... 15 Torque values for metric coarse-pitch thread................................................................................. 16 Torque values for metric fine-pitch thread................................................................................... 17 Tightening torques for hydraulic screw connections and climate screw fixtures with taper connections and O-rings DIN 3865.... 18 Tightening torques for hydraulic screw connections with cutting ring DIN 3861................................................ 19 Tightening torques for hydraulic screw struts SDS............................................................................ 20 Tightening torques for hydraulics rotating screw connections................................................................. 23 Tightening torques for hollow screws DIN 7643................................................................................ 23 Tightening torques for hydraulic system screw-in spuds SDE................................................................... 24 Tightening torques for brake line screw connections.......................................................................... 26 Tightening torques for worm drive hose clamps................................................................................ 26 Tightening torques for spring-loaded worm drive hose clamps.................................................................. 26 2 Engine............................................................................................................................. 27 2.1 Overview of components TCD 3.6............................................................................................... 28 Technical data............................................................................................................... 28 Type plates for TCD 3.6...................................................................................................... 29 Cylinder numbering........................................................................................................... 30 Overview of diesel engine from right TCD 3.6................................................................................. 31 Overview of diesel engine from left TCD 3.6.................................................................................. 32 2.2 Lubricant oil system TCD 3.6................................................................................................. 33 Component overview of the lubricating oil system............................................................................. 33 Lube oil circuit............................................................................................................. 34 Oil pressure control valve................................................................................................... 36 Pressure limiting valve...................................................................................................... 37 2.3 Fuel system TCD 3.6.......................................................................................................... 38 Component overview of the fuel system........................................................................................ 38 Fuel injection system........................................................................................................ 41 Injector..................................................................................................................... 42 High-pressure pump........................................................................................................... 45 Control valve Y076 (FCU)..................................................................................................... 46 Pressure relief valve for the rail (PRV)..................................................................................... 47 2.4 Cooling system TCD 3.6....................................................................................................... 48 Cooling liquid inlet......................................................................................................... 48 Thermostat overview.......................................................................................................... 50 Coolant drainage............................................................................................................. 51 2.5 Turbocharging TCD 3.6........................................................................................................ 52 Turbo-charging............................................................................................................... 52 2.6 Exhaust gas recirculation EGR TCD 3.6........................................................................................ 53 Exhaust gas recirculation cooler (EGR cooler)................................................................................ 54 Adjustment valve of the EGR exhaust gas recirculation........................................................................ 55 Reed valve of the EGR exhaust gas recirculation.............................................................................. 56 2.7 Electric components TCD 3.6.................................................................................................. 57 2.8 Overview of components TCD 4.1............................................................................................... 61 Technical data............................................................................................................... 61 Type labels diesel engine TCD 4.1............................................................................................ 62 Cylinder numbering........................................................................................................... 63 Overview of diesel engine from right TCD 4.1................................................................................. 64 Overview of diesel engine from left TCD 4.1.................................................................................. 65 2.9 Lubricant oil system TCD 4.1................................................................................................. 66 2.10 Fuel system TCD 4.1......................................................................................................... 68 Fuel injection system........................................................................................................ 70 Injector..................................................................................................................... 71 Pressure relief valve for the rail (PRV)..................................................................................... 73 Metering unit (FCU).......................................................................................................... 74 Metering unit (FCU).......................................................................................................... 75 High-pressure pump........................................................................................................... 76 Operation of the high pressure pumps......................................................................................... 77 Operation of the high pressure pumps......................................................................................... 78 2.11 Cooling circuit TCD 4.1..................................................................................................... 79 Checking the thermostat...................................................................................................... 81 Coolant drainage............................................................................................................. 82 2.12 Turbocharging TCD4.1........................................................................................................ 83 Overview of turbocharging.................................................................................................... 84 2.13 Exhaust gas recirculation EGR TCD 4.1....................................................................................... 85 Regulating unit (EGR valve) exhaust gas recirculation........................................................................ 87 Exhaust gas recirculation cooler (EGR cooler)................................................................................ 88 Reed valve of the EGR exhaust gas recirculation.............................................................................. 89 2.14 Electric components TCD 4.1................................................................................................. 90 Electric components of diesel engine......................................................................................... 91 2.15 Exhaust-gas treatment....................................................................................................... 92 General information on emissions legislation................................................................................. 92 Abbreviations................................................................................................................ 93 Explanation of terms......................................................................................................... 94 Exhaust after-treatment system EAT........................................................................................... 95 Overview of the exhaust aftertreatment....................................................................................... 96 Electrical components of exhaust aftertreatment.............................................................................. 97 Exhaust aftertreatment disconnect XM05....................................................................................... 98 CSF system setup............................................................................................................. 100 SCR catalytic converter...................................................................................................... 101 Mixing section............................................................................................................... 103 Metering unit Y141........................................................................................................... 104 Differential pressure sensor B037............................................................................................ 106 Exhaust back pressure sensor B092............................................................................................ 108 Temperature sensor B029/B030/B090............................................................................................ 109 NOXsensor and NOX electronics B093/B094...................................................................................... 111 Urea provision............................................................................................................... 113 Urea fill level indicator H094/H095.......................................................................................... 114 Ambient temperature sensor B031.............................................................................................. 115 Sampling unit B095........................................................................................................... 116 Discharge module............................................................................................................. 118 Solenoid valve for the tank heater Y143...................................................................................... 120 2.16 Exhaust system only for EDG................................................................................................. 121 2.17 Starting the engine......................................................................................................... 122 Start diesel engine control.................................................................................................. 122 Start diesel engine activation with drive interlock.......................................................................... 123 Description of starting engine............................................................................................... 124 2.18 Diesel engine monitoring.................................................................................................... 125 2.19 Diesel engine monitoring components......................................................................................... 126 2.20 Control of EAT system....................................................................................................... 128 Urea injection............................................................................................................... 128 Description of EAT system components......................................................................................... 129 2.21 Heating circuit of EAT system............................................................................................... 130 Heating circuit of diesel engine 3.6 EAT system.............................................................................. 130 Heating circuit of diesel engine 4.1 EAT system.............................................................................. 131 Description of heating circuit components.................................................................................... 132 3 Cooling............................................................................................................................ 133 3.1 Cooling control.............................................................................................................. 134 Cooling control - standard................................................................................................... 134 Cooling control - standard + trailer brake................................................................................... 135 Control of the cooling reversing fan......................................................................................... 136 Cooling reversing fan control + trailer brake................................................................................ 137 3.2 Components of the component control.......................................................................................... 138 Cooling description - standard............................................................................................... 138 Cooling description - standard + trailer brake............................................................................... 139 Description of the cooling reversing fan..................................................................................... 140 Description of the cooling reversing fan + trailer brake..................................................................... 141 3.3 Functional description of cooling components................................................................................. 142 Fan control.................................................................................................................. 142 Fan speed.................................................................................................................... 142 Hydraulic oil temperature gauge.............................................................................................. 142 Coolant temperature display.................................................................................................. 142 Reversing operation.......................................................................................................... 143 3.4 Cooling component description................................................................................................ 144 Tandem pump 001.1............................................................................................................ 145 Fan motor II................................................................................................................. 146 Reversing valve for fan XXIII................................................................................................ 147 Fan valve, standard XXIV..................................................................................................... 148 Coolant level sensor B015.................................................................................................... 149 Fan control temperature sensor B016.......................................................................................... 149 3.5 Check / adjust cooling....................................................................................................... 150 Checking and making adjustments.............................................................................................. 150 Test report: cooling......................................................................................................... 151 Checking the diesel engine speed............................................................................................. 152 Checking / adjusting the fan speed........................................................................................... 153 4 Traveling drive.................................................................................................................... 155 4.1 Drive control................................................................................................................ 156 Control of drive system with high speed transmission (ICVD).................................................................. 156 Control of the high-speed transmission drive system P370..................................................................... 157 Description of drive control................................................................................................. 158 4.2 Function description of travelling drive..................................................................................... 160 Forward travel............................................................................................................... 160 Reverse travel............................................................................................................... 161 Boost pressure............................................................................................................... 162 Inching function............................................................................................................. 162 Low-speed control............................................................................................................ 162 Speed ranges................................................................................................................. 162 Travel speeds................................................................................................................ 163 4.3 Drive component description.................................................................................................. 164 Speed sensor B009............................................................................................................ 165 1st/2nd speed proportional valve Y002........................................................................................ 166 Proportional valves Y004/Y005................................................................................................ 168 Driving direction identification solenoid valve Y010......................................................................... 169 PCOR valve Y112 depending on the degree of utilization....................................................................... 170 4.4 Drive system with H1P and ICVD............................................................................................... 172 Overview of variable displacement pump VII (H1P089).......................................................................... 172 Overview of high-speed transmission X (ICVD)................................................................................. 174 Control cover................................................................................................................ 175 Setting the high-speed gearbox............................................................................................... 176 Stroke adjustment............................................................................................................ 178 Pressure limiting valve (PCOR) for control piston M3......................................................................... 179 Driving direction identification 058......................................................................................... 180 Scouring slide valve 059..................................................................................................... 181 Gear unit.................................................................................................................... 182 4.5 Checking / adjusting ICVD high speed gearbox................................................................................. 183 Checking and making adjustments.............................................................................................. 183 Test report: model 416-32 (i=1.18:1)......................................................................................... 185 Test report: model 416-32 (i=1.18:1)......................................................................................... 188 Test report: model 416-32 /416-38 / 416-39 (i=1.39:1)........................................................................ 190 Test report: model 416-32 /416-38 / 416-39 (i=1.39:1)........................................................................ 192 Test port fittings for high-speed gearbox.................................................................................... 194 Checking the diesel engine speed............................................................................................. 195 Checking / adjusting boost pressure.......................................................................................... 196 Checking / adjusting starting speed.......................................................................................... 197 Driving direction identification: Checking................................................................................... 198 Checking/setting the pressure cut-off (H1P089)............................................................................... 199 Check high pressure.......................................................................................................... 201 Checking / adjusting cardan shaft speed...................................................................................... 203 Checking / adjusting engine lugging, variable displacement pump VII.......................................................... 204 Checking / adjusting engine droop, high speed gearbox X...................................................................... 205 4.6 Error descriptions........................................................................................................... 206 Boost pressure not attained.................................................................................................. 206 High pressure not attained................................................................................................... 206 Starting speed............................................................................................................... 207 The vehicle does not reach the final speed................................................................................... 207 Vehicle only drives in Snail mode............................................................................................ 208 Drive has no output.......................................................................................................... 208 Vehicle cannot drive forwards or backwards................................................................................... 209 Check scouring slide 059..................................................................................................... 210 Check forward-reverse spool valve 058........................................................................................ 211 Check proportional controller 100............................................................................................ 213 4.7 Drive system with H1P and P370............................................................................................... 214 Hydraulic pump VII........................................................................................................... 214 Overview of hydraulic pump VII............................................................................................... 215 Overview of high-speed transmission X (P370)................................................................................. 217 Cam cover P370............................................................................................................... 218 Scouring slide valve 059..................................................................................................... 219 Gear unit.................................................................................................................... 220 4.8 Adjustment work for drive system............................................................................................. 221 Test report: model 416-34 / 416-36........................................................................................... 222 Test report: model 416-34 / 416-36........................................................................................... 225 Test report: model 416-34 / 416-36........................................................................................... 227 Test report: model 416-34 / 416-36........................................................................................... 229 Test report: model 416-32 / 416-38 / 416-39.................................................................................. 231 Test report: model 416-32 / 416-38 / 416-39.................................................................................. 234 Drive test ports............................................................................................................. 236 Checking the diesel engine speed............................................................................................. 237 Setting the boost pressure................................................................................................... 238 Adjusting starting engine speed.............................................................................................. 239 Driving direction identification: Checking................................................................................... 240 Check and adjust the pressure cut-off........................................................................................ 241 Check high pressure.......................................................................................................... 243 If the high pressure is not attained......................................................................................... 244 Checking / adjusting cardan shaft speed...................................................................................... 245 Checking / adjusting engine droop, variable displacement pump VII............................................................ 246 Checking / adjusting engine droop, high speed gearbox X...................................................................... 247 4.9 Error descriptions........................................................................................................... 248 Boost pressure not attained.................................................................................................. 248 High pressure not attained................................................................................................... 248 Starting speed............................................................................................................... 249 The vehicle does not reach the final speed................................................................................... 249 Vehicle only drives in Snail mode............................................................................................ 250 Drive has no output.......................................................................................................... 250 Vehicle cannot drive forwards or backwards................................................................................... 250 Check scouring slide 059..................................................................................................... 251 Check travel direction slide 058 (Y010)...................................................................................... 252 Check the PCOR Y112 dependent on electric degree of utilization.............................................................. 253 Check solenoid valve for speed Y002.......................................................................................... 254 6 Brakes............................................................................................................................. 255 6.1 Brake control................................................................................................................ 256 Control of the vehicle brake................................................................................................. 256 Control of the parking brake................................................................................................. 257 Description of brake control................................................................................................. 258 Description of parking brake control......................................................................................... 259 Control of hydraulic trailer brake........................................................................................... 260 Description of the hydraulic trailer brake actuation......................................................................... 261 6.2 Trailer compressed air brake control......................................................................................... 262 Compressed air brake control................................................................................................. 262 Electric compressed air braking system control............................................................................... 263 Compressed air brake diagram................................................................................................. 264 Compressed air brake description............................................................................................. 265 6.3 Functional description of the braking system components...................................................................... 266 Service brake................................................................................................................ 266 Brake/inching pedal (service brake).......................................................................................... 268 Parking brake................................................................................................................ 270 Hydraulic trailer brake...................................................................................................... 273 Compressed-air braking system................................................................................................ 276 6.4 Description of brake system elements......................................................................................... 281 Tandem pump 001.1............................................................................................................ 282 Pressure accumulator charge valve XIX........................................................................................ 283 Brake valve XVIII with inching potentiometer R002............................................................................ 284 Hydraulic trailer brake valve 140............................................................................................ 285 Pressure accumulator 142 (R1, R2)............................................................................................ 292 Valve block 162 (only for hydraulic trailer brakes).......................................................................... 294 Power brake sensor B051...................................................................................................... 295 Proportional valve trailer brake Y113........................................................................................ 296 Solenoid valve of the trailer brake Y115..................................................................................... 297 Brake light switching relay K030............................................................................................. 298 Relay K055................................................................................................................... 299 Inching position encoder R002................................................................................................ 300 Button S065 parking brake.................................................................................................... 301 6.5 Element description for the compressed air system............................................................................ 302 Compressor P500.............................................................................................................. 302 Pressure regulator 510....................................................................................................... 303 Air reservoir 520............................................................................................................ 305 Automatic drainage valve..................................................................................................... 306 Pressure reducing valve P530................................................................................................. 307 Solenoid valve for compressed-air brake, parking brake signal Y049........................................................... 309 Solenoid valve, compressed-air brake advancement Y050........................................................................ 310 Non-return valve P560........................................................................................................ 312 Trailer control valve P570................................................................................................... 313 Trailer control valve P571................................................................................................... 314 Compressed air brake system sensor B052...................................................................................... 315 Push button switch for the compressed air brake S208......................................................................... 316 Touch button for compressed air brake S209................................................................................... 317 6.6 Braking system test logs..................................................................................................... 318 Checking and making adjustments.............................................................................................. 318 Test report: service brake................................................................................................... 320 Checking the diesel engine speed............................................................................................. 321 Check the accumulator pressure............................................................................................... 322 Checking / adjusting pilot control pressure.................................................................................. 323 Check the brake pressure of the front axle service brake..................................................................... 324 Brake pressure for the rear axle service brake............................................................................... 325 Test the brake pressure for the parking brake................................................................................ 326 6.7 Trailer brake test log....................................................................................................... 327 Hydraulic trailer brake...................................................................................................... 327 Connections for trailer brake................................................................................................ 328 6.8 Compressed air brake system test log......................................................................................... 329 Compressed-air brake......................................................................................................... 329 Check service brake.......................................................................................................... 331 Check the hand brake......................................................................................................... 332 Test push-button............................................................................................................. 333 Leak test.................................................................................................................... 334 Check the break function..................................................................................................... 335 7 Steering system.................................................................................................................... 336 7.1 Steering system actuation.................................................................................................... 337 Overview of Steering Control................................................................................................. 337 Description of steering components........................................................................................... 338 7.2 Function description: steering system........................................................................................ 339 Steering system oil supply................................................................................................... 339 Emergency steering function.................................................................................................. 339 Steering mode valve with check block XXVII................................................................................... 339 Steering electronics......................................................................................................... 339 Synchronize the steering system after a repair............................................................................... 340 Bleeding the steering system................................................................................................. 341 7.3 Description of steering components........................................................................................... 342 Double gear pump 001.1....................................................................................................... 343 Hydrostatic steering system IV............................................................................................... 344 Steering mode valve with check block XXVII................................................................................... 346 Steering sensors B004 and B005............................................................................................... 349 Switch S022 steering mode switch............................................................................................. 350 Switch S022 steering mode switch (4 steering modes).......................................................................... 352 Push button switch for steering pressure S217................................................................................ 354 7.4 Check / adjust steering system............................................................................................... 355 Checking and making adjustments.............................................................................................. 355 Test report: steering system................................................................................................. 356 Checking the diesel engine speed............................................................................................. 357 Inspecting and adjusting the steering pressure............................................................................... 358 8 Hydraulics......................................................................................................................... 359 8.1 Lifting cylinder / load stabilizer actuation................................................................................. 360 Overview of electrical control............................................................................................... 360 Overview of hydraulic control................................................................................................ 361 Description of lifting cylinder with load stabiliser......................................................................... 362 8.2 Control of the overload control.............................................................................................. 364 Overview of electrical control............................................................................................... 364 Overview of hydraulic control................................................................................................ 365 Description of the overload control.......................................................................................... 366 8.3 Tilt ram control............................................................................................................. 368 Overview of electrical control............................................................................................... 368 Overview of hydraulic control................................................................................................ 369 Description of tilt ram...................................................................................................... 370 8.4 Bucket repositioning control................................................................................................. 371 Overview of electrical control............................................................................................... 371 Overview of hydraulic control................................................................................................ 372 Description of bucket retraction............................................................................................. 373 8.5 3rd control circuit (control)................................................................................................ 374 Overview of electrical control............................................................................................... 374 Overview of hydraulic control................................................................................................ 375 Description of 3rd control circuit........................................................................................... 376 8.6 Control of the 3rd control circuit with changeover valve..................................................................... 377 Overview of electrical control............................................................................................... 377 Overview of hydraulic control................................................................................................ 378 Description of 3rd control circuit, changeover valve......................................................................... 379 8.7 Tipper control............................................................................................................... 381 Overview of electrical / hydraulic control................................................................................... 381 Description of tipping trailer............................................................................................... 382 8.8 Control of the tipper/auto-hitch............................................................................................. 383 Overview of electrical control............................................................................................... 383 Overview of hydraulic control................................................................................................ 384 Description of the tipper/auto-hitch......................................................................................... 385 8.9 Adjust the sensor plate sensor S137.......................................................................................... 386 Overview of autohitch 092.................................................................................................... 387 Adjusting the sensor plate................................................................................................... 388 The sensor plate cannot be adjusted.......................................................................................... 389 8.10 Rear additional control circuit actuation................................................................................... 391 Overview of electrical/ hydraulic control.................................................................................... 391 Description of rear additional control circuit............................................................................... 392 8.11 Actuation of additional control circuit, large, front....................................................................... 393 Overview of electrical/ hydraulic control.................................................................................... 393 Description of additional control circuit, large, front...................................................................... 394 8.12 Control of the leveling/oscillating-axle interlock model 416-36............................................................. 395 Overview of electrical/ hydraulic control.................................................................................... 395 Description of leveling / oscillating-axle interlock......................................................................... 396 8.13 Control of the leveling and tipper model 416-36............................................................................. 397 Overview of electrical control............................................................................................... 397 Overview of hydraulic control................................................................................................ 398 Description of the leveling and tipper....................................................................................... 399 8.14 Control of the leveling, tipper, hitch model 416-36......................................................................... 400 Overview of electrical control............................................................................................... 400 Overview of hydraulic control................................................................................................ 401 Description of the leveling, tipper, hitch................................................................................... 402 8.15 Hydraulics component description............................................................................................ 404 Tandem pump 001.1............................................................................................................ 405 Boost pressure filter 015.................................................................................................... 406 Reflux filter 026............................................................................................................ 407 Hydraulic oil cooler 027..................................................................................................... 408 Pressure accumulator 077 and 080............................................................................................. 409 Suction valve for tipping compensation cylinder 082.......................................................................... 412 Tilt ram hose burst valve 088................................................................................................ 413 Hose burst valve level cylinder 088.......................................................................................... 415 Hose burst valve for push-out ram 090........................................................................................ 417 Quickhitch lock valve block 117.............................................................................................. 418 Changeover valve for tipper/leveling 131..................................................................................... 419 Changeover valve of 4th service 133.......................................................................................... 420 Relief valve 134............................................................................................................. 422 Valve block pressureless circulation 143..................................................................................... 423 Bleed valve load stabilizer 144.............................................................................................. 424 Valve block 162 (only for hydraulic trailer brakes).......................................................................... 425 Pilot control valve 163...................................................................................................... 427 Variable displacement pump for work hydraulics I............................................................................. 428 Valve block V................................................................................................................ 431 Hydraulic control unit XIII.................................................................................................. 433 Connections of hydraulic control unit XIII model: 416-32-34-38............................................................... 434 Secondary valves, model: 416-32-34-38........................................................................................ 435 Connections of hydraulic control unit XIII model: 416-26/29.................................................................. 436 Secondary valves model: 416-26/29............................................................................................ 437 Connections for hydraulic control unit XII................................................................................... 438 Hose burst valve with load stabilizer XIV.................................................................................... 439 Pressure accumulator charge valve XIX........................................................................................ 441 Hydraulic tank XX............................................................................................................ 442 Intake filter................................................................................................................ 443 8.16 Check / adjust work hydraulics.............................................................................................. 444 Checking and making adjustments.............................................................................................. 444 Test report for work hydraulics: Model 416-32-34-38.......................................................................... 445 Test report for work hydraulics: Model 416-22-24-26-28-29.................................................................... 447 Checking the diesel engine speed............................................................................................. 450 Checking/adjusting the circuit pressure...................................................................................... 451 Checking / adjusting the working pressure.................................................................................... 452 Checking / adjusting the pressure regulator of the variable displacement pump I.............................................. 453 Check the LS pressure........................................................................................................ 454 Checking / adjusting pilot control pressure.................................................................................. 455 8.17 Checking secondary valves................................................................................................... 456 Check secondary valves, model: 416-32-34-38.................................................................................. 456 Removing the secondary valves................................................................................................ 457 Tightening torques – hydraulic control unit XIII............................................................................. 458 8.18 Hydraulic diagrams.......................................................................................................... 459 Hydraulic diagram for work hydraulics........................................................................................ 460 Drive system with high speed transmission (ICVD)............................................................................. 464 Drive system with high speed transmission (P370)............................................................................. 467 Hydraulic circuit diagram for brake.......................................................................................... 470 Hydraulic trailer brake hydraulic diagram.................................................................................... 471 Hydraulic circuit diagram for steering....................................................................................... 474 9 Electrical system.................................................................................................................. 477 9.1 CAN signals component overview............................................................................................... 478 Description of CAN signals................................................................................................... 479 9.2 Inputs/outputs for traction electronics N001................................................................................. 480 Inputs/outputs for traction electronics N001................................................................................. 481 9.3 Frame controller N004 inputs / outputs....................................................................................... 488 Controller N004 for frame inputs/outputs..................................................................................... 489 9.4 Inputs/outputs for diesel engine electronics N005............................................................................ 493 Overview of inputs/outputs for diesel engine electronics N005 plug XE01...................................................... 493 Overview of inputs/outputs for diesel engine electronics N005 plug XE02...................................................... 494 Pin assignment for diesel engine electronics N005............................................................................ 495 Pin assignment for plug XE01................................................................................................. 497 Pin assignment for plug XE02................................................................................................. 502 9.5 Controller N015 for cab inputs/outputs....................................................................................... 506 Controller N015 for cab inputs/outputs....................................................................................... 507 9.6 Inputs/outputs for additional controller N016................................................................................ 511 Inputs/outputs for additional controller N016................................................................................ 512 9.7 Telematic module N018 inputs/outputs......................................................................................... 516 Telematic module N018 inputs/outputs......................................................................................... 517 9.8 Drive interlock N021 inputs/outputs.......................................................................................... 519 Drive interlock N021 inputs/outputs.......................................................................................... 520 9.9 Oil volume setting N023 inputs/outputs....................................................................................... 523 Oil volume setting N023 inputs/outputs....................................................................................... 524 9.10 Inputs/outputs for steering electronics D001................................................................................ 526 Component description of steering electronics D001........................................................................... 527 Pin assignment for steering electronics D001................................................................................. 528 Description of joystick D002................................................................................................. 530 9.11 Display P014 inputs/outputs................................................................................................. 532 Display P014 inputs/outputs.................................................................................................. 533 9.12 Fuses, relay................................................................................................................ 537 Fuse assignment for printed circuit board N033............................................................................... 537 Relay assignment for printed circuit board N033.............................................................................. 540 Main fuse box N025 (engine compartment)...................................................................................... 541 Relay in the main fuse box N025.............................................................................................. 542 Additional relay............................................................................................................. 543 9.13 Safe load indicator in the display P014..................................................................................... 544 Safe load indicator A........................................................................................................ 544 9.14 Calibrating the safe load indicator......................................................................................... 547 Zero point calibration....................................................................................................... 547 Calibrating the 100% point (version 1)....................................................................................... 549 Calibrating the 100% point (version 2)....................................................................................... 551 9.15 Basic setting of the travel sensor B028..................................................................................... 552 Setting the angle of rotation sensor R023.................................................................................... 554 9.16 Camera (front).............................................................................................................. 555 Front camera overview........................................................................................................ 555 Display mode................................................................................................................. 558 Menu CAM/mode................................................................................................................ 558 9.17 Rear camera................................................................................................................. 569 Rear camera overview......................................................................................................... 569 9.18 Functional descriptions of electric components.............................................................................. 572 Speed sensor B009............................................................................................................ 574 Speed sensor B010............................................................................................................ 575 Light warning buzzer B018.................................................................................................... 576 Angle of rotation sensor for automatic bucket reverse B028................................................................... 577 Load sensor – safe load indicator B066....................................................................................... 579 Relay K003, K016, K023....................................................................................................... 580 Relay K029, K088, K092....................................................................................................... 581 Relay K093, K125, K126....................................................................................................... 582 Relay K127, K128, K129....................................................................................................... 583 High current relay preheating K005........................................................................................... 585 High current relay preheating K007........................................................................................... 586 Turn indicator relay K010.................................................................................................... 587 Load stabilizer switching relay K022......................................................................................... 588 Battery isolator relay K141.................................................................................................. 589 Low-speed control of crawler gear R003....................................................................................... 590 Accelerator pedal R011....................................................................................................... 591 Manual throttle R012......................................................................................................... 592 Angle of rotation sensor R023................................................................................................ 593 Setting the angle of rotation sensor R023.................................................................................... 594 Leveling potentiometer R036.................................................................................................. 595 Pre-heating start switch S001................................................................................................ 596 Steering column switch S012.................................................................................................. 598 Light switch S014............................................................................................................ 600 Oscillating-axle interlock switch S024....................................................................................... 601 3rd control circuit continuous operation S033................................................................................ 603 Switch (touch button) quickhitch lock S040................................................................................... 605 Load stabilizer switch S044.................................................................................................. 606 Push button switch for the load stabilizer S045.............................................................................. 607 Tilt cylinder lock switch S047............................................................................................... 608 Front additional control circuit S056........................................................................................ 609 Reversing fan button S064.................................................................................................... 610 Parking brake button S065.................................................................................................... 611 Switch for additional control circuit in rear S069........................................................................... 612 Switch (touch button) tipper S070............................................................................................ 615 Switch (touch button) hydraulic shut-off S084................................................................................ 617 Joystick shutdown switch S085 (lock for long-haul travel).................................................................... 618 Plunger switch S103 (four-wheel cut-off)..................................................................................... 619 Seat contact switch S104..................................................................................................... 620 Limit switch S116............................................................................................................ 622 Regeneration of the diesel particulate filter S119........................................................................... 623 Switch S123 seat belt contact switch (option)................................................................................ 624 Lower mode switch S125....................................................................................................... 625 Pressure relief switch S127.................................................................................................. 630 Axle cut-off button S130..................................................................................................... 631 Switch (touch button) autohitch S131......................................................................................... 632 Sensor plate switch S137..................................................................................................... 635 9.19 Diagrams.................................................................................................................... 636 Notes on working with electrical diagrams.................................................................................... 636 Circuit diagram 3.6 engine ................................................................................................. 637 1 | cover sheet.......................................................................................................... 637 2 | contents............................................................................................................. 638 3 | contents............................................................................................................. 639 4 | contents............................................................................................................. 640 5 | contents............................................................................................................. 641 6 | 3. Control circuit................................................................................................... 642 7 | 3. Control circuit // Pressure relief................................................................................ 643 8 | 3. Control circuit // Unlock......................................................................................... 644 9 | Axle cut-off......................................................................................................... 645 10 | Working lights...................................................................................................... 646 11 | Working lights Telescopic boom...................................................................................... 647 12 | illumination........................................................................................................ 648 13 | illumination Instrument panel light................................................................................. 649 14 | Turn indicators..................................................................................................... 650 15 | brake............................................................................................................... 651 16 | brake Trailer hydraulic............................................................................................. 652 17 | brake compr. Air.................................................................................................... 653 18 | CAN Exhaust-gas treatment........................................................................................... 654 19 | CAN Work hydraulics................................................................................................. 655 20 | CAN diagnostics Diesel engine....................................................................................... 656 21 | CAN Vehicle diagnostics............................................................................................. 657 22 | Diesel engine starter/Preheating system............................................................................. 658 23 | Diesel engine EAT I................................................................................................. 659 24 | Diesel engine EAT II................................................................................................ 660 25 | Diesel engine EAT III............................................................................................... 661 26 | Diesel engine EAT IV................................................................................................ 662 27 | Diesel engine Fuel injectors........................................................................................ 663 28 | Diesel engine alternator............................................................................................ 664 29 | Diesel engine Sensors I Engine side................................................................................. 665 30 | Diesel engine Sensors II Engine side................................................................................ 666 31 | Diesel engine Sensors III Engine side............................................................................... 667 32 | Diesel engine Control valve......................................................................................... 668 33 | Diesel engine electronics overview.................................................................................. 669 34 | Differential lock................................................................................................... 670 35 | Display USB connection.............................................................................................. 671 36 | Display - overview.................................................................................................. 672 37 | Tilt in / Tilt out.................................................................................................. 673 38 | Travelling drive valve.............................................................................................. 674 39 | Travelling drive.................................................................................................... 675 40 | Operator seat....................................................................................................... 676 41 | Front power outlet 4pol............................................................................................. 677 42 | Accelerator pedal................................................................................................... 678 43 | H1 pump overview.................................................................................................... 679 44 | Manual throttle/Creep gear potentiometer............................................................................ 680 45 | Main board (fuses & Relay).......................................................................................... 681 46 | main Fuse box....................................................................................................... 682 47 | Raise / Lower....................................................................................................... 683 48 | Rear wiper, Side wiper.............................................................................................. 684 49 | heating / Air conditioning.......................................................................................... 685 50 | Autohitch trailer coupling / Tipping trailer........................................................................ 686 51 | Inching pedal....................................................................................................... 687 52 | Joystick............................................................................................................ 688 53 | Cabin Control valve................................................................................................. 689 54 | Tipping trailer..................................................................................................... 690 55 | Fuel preheater...................................................................................................... 691 56 | Cooling............................................................................................................. 692 57 | Load stabilizer..................................................................................................... 693 58 | Steering system..................................................................................................... 694 59 | Steering system - overview.......................................................................................... 695 60 | Earth-CBW........................................................................................................... 696 61 | Earth-EBW........................................................................................................... 697 62 | Earth-FRW........................................................................................................... 698 63 | Multimedia.......................................................................................................... 699 64 | Frame levelling..................................................................................................... 700 65 | Frame electronics overview.......................................................................................... 701 66 | Frame electronics overview.......................................................................................... 702 67 | Oscillating-axle interlock.......................................................................................... 703 68 | Rotating beacon..................................................................................................... 704 69 | Reversing warning system/-Lights.................................................................................... 705 70 | Bucket repositioning................................................................................................ 706 71 | Window heating / Mirror adjustment.................................................................................. 707 72 | Lock for road travel................................................................................................ 708 73 | telematic- module................................................................................................... 709 74 | Boom function....................................................................................................... 710 75 | Switch valve........................................................................................................ 711 76 | Safe load indicator................................................................................................. 712 77 | Controls............................................................................................................ 713 78 | Supply Display / Jog dial / Camera.................................................................................. 714 79 | Supply terminal 15.................................................................................................. 715 80 | Supply Motor........................................................................................................ 716 81 | Supply switch / button.............................................................................................. 717 82 | Supply Controllers.................................................................................................. 718 83 | Front camera........................................................................................................ 719 84 | Immobiliser......................................................................................................... 720 85 | Immobiliser - overview.............................................................................................. 721 86 | Front wiper motor / Horn............................................................................................ 722 87 | Central lubrication system.......................................................................................... 723 88 | 12 V power outlet................................................................................................... 724 89 | Addition-Screen Front camera - overview............................................................................. 725 90 | Additional control circuit rear..................................................................................... 726 91 | Additional control circuit Front.................................................................................... 727 92 | itemregister........................................................................................................ 728 93 | itemregister........................................................................................................ 729 94 | itemregister........................................................................................................ 730 95 | itemregister........................................................................................................ 731 96 | itemregister........................................................................................................ 732 97 | itemregister........................................................................................................ 733 98 | itemregister........................................................................................................ 734 99 | itemregister........................................................................................................ 735 100 | itemregister....................................................................................................... 736 101 | itemregister....................................................................................................... 737 102 | itemregister....................................................................................................... 738 103 | itemregister....................................................................................................... 739 104 | itemregister....................................................................................................... 740 105 | itemregister....................................................................................................... 741 106 | itemregister....................................................................................................... 742 107 | itemregister....................................................................................................... 743 108 | itemregister....................................................................................................... 744 109 | itemregister....................................................................................................... 745 110 | itemregister....................................................................................................... 746 111 | itemregister....................................................................................................... 747 112 | itemregister....................................................................................................... 748 113 | itemregister....................................................................................................... 749 114 | itemregister....................................................................................................... 750 115 | itemregister....................................................................................................... 751 116 | itemregister....................................................................................................... 752 117 | itemregister....................................................................................................... 753 Circuit diagram 4.1 engine .................................................................................................. 754 1 | cover sheet.......................................................................................................... 754 2 | contents............................................................................................................. 755 3 | contents............................................................................................................. 756 4 | contents............................................................................................................. 757 5 | contents............................................................................................................. 758 6 | 3. Control circuit................................................................................................... 759 7 | 3. Control circuit // Pressure relief................................................................................ 760 8 | 3. Control circuit // Unlock......................................................................................... 761 9 | Axle cut-off......................................................................................................... 762 10 | Working lights...................................................................................................... 763 11 | Working lights Telescopic boom...................................................................................... 764 12 | illumination........................................................................................................ 765 13 | illumination Instrument panel light................................................................................. 766 14 | Turn indicators..................................................................................................... 767 15 | brake............................................................................................................... 768 16 | brake Trailer hydraulic............................................................................................. 769 17 | brake compr. Air.................................................................................................... 770 18 | CAN Exhaust-gas treatment........................................................................................... 771 19 | CAN Work hydraulics................................................................................................. 772 20 | CAN diagnostics Diesel engine....................................................................................... 773 21 | CAN Vehicle diagnostics............................................................................................. 774 22 | Diesel engine starter/Preheating system............................................................................. 775 23 | Diesel engine EAT I................................................................................................. 776 24 | Diesel engine EAT II................................................................................................ 777 25 | Diesel engine EAT III............................................................................................... 778 26 | Diesel engine EAT IV................................................................................................ 779 27 | Diesel engine Fuel injectors........................................................................................ 780 28 | Diesel engine alternator............................................................................................ 781 29 | Diesel engine Sensors I Engine side................................................................................. 782 30 | Diesel engine Sensors II Engine side................................................................................ 783 31 | Diesel engine Sensors III Engine side............................................................................... 784 32 | Diesel engine Control valve......................................................................................... 785 33 | Diesel engine electronics overview.................................................................................. 786 34 | Differential lock................................................................................................... 787 35 | Display USB connection.............................................................................................. 788 36 | Display - overview.................................................................................................. 789 37 | Tilt in / Tilt out.................................................................................................. 790 38 | Travelling drive valve.............................................................................................. 791 39 | Travelling drive.................................................................................................... 792 40 | Operator seat....................................................................................................... 793 41 | Front power outlet 4pol............................................................................................. 794 42 | Accelerator pedal................................................................................................... 795 43 | H1 pump overview.................................................................................................... 796 44 | Manual throttle/Creep gear potentiometer............................................................................ 797 45 | Main board (fuses & Relay).......................................................................................... 798 46 | main Fuse box....................................................................................................... 799 47 | Raise / Lower....................................................................................................... 800 48 | Rear wiper, Side wiper.............................................................................................. 801 49 | heating / Air conditioning.......................................................................................... 802 50 | Autohitch trailer coupling / Tipping trailer........................................................................ 803 51 | Inching pedal....................................................................................................... 804 52 | Joystick............................................................................................................ 805 53 | Cabin Control valve................................................................................................. 806 54 | Tipping trailer..................................................................................................... 807 55 | Fuel preheater...................................................................................................... 808 56 | Cooling............................................................................................................. 809 57 | Load stabilizer..................................................................................................... 810 58 | Steering system..................................................................................................... 811 59 | Steering system - overview.......................................................................................... 812 60 | Earth-CBW........................................................................................................... 813 61 | Earth-EBW........................................................................................................... 814 62 | Earth-FRW........................................................................................................... 815 63 | Multimedia.......................................................................................................... 816 64 | Frame levelling..................................................................................................... 817 65 | Frame electronics overview.......................................................................................... 818 66 | Frame electronics overview.......................................................................................... 819 67 | Oscillating-axle interlock.......................................................................................... 820 68 | Rotating beacon..................................................................................................... 821 69 | Reversing warning system/-Lights.................................................................................... 822 70 | Bucket repositioning................................................................................................ 823 71 | Window heating / Mirror adjustment.................................................................................. 824 72 | Lock for road travel................................................................................................ 825 73 | telematic- module................................................................................................... 826 74 | Boom function....................................................................................................... 827 75 | Switch valve........................................................................................................ 828 76 | Safe load indicator................................................................................................. 829 77 | Controls............................................................................................................ 830 78 | Supply Display / Jog dial / Camera.................................................................................. 831 79 | Supply terminal 15.................................................................................................. 832 80 | Supply Motor........................................................................................................ 833 81 | Supply switch / button.............................................................................................. 834 82 | Supply Controllers.................................................................................................. 835 83 | Front camera........................................................................................................ 836 84 | Immobiliser......................................................................................................... 837 85 | Immobiliser - overview.............................................................................................. 838 86 | Front wiper motor / Horn............................................................................................ 839 87 | Central lubrication system.......................................................................................... 840 88 | 12 V power outlet................................................................................................... 841 89 | Addition-Screen Front camera - overview............................................................................. 842 90 | Additional control circuit rear..................................................................................... 843 91 | Additional control circuit Front.................................................................................... 844 92 | itemregister........................................................................................................ 845 93 | itemregister........................................................................................................ 846 94 | itemregister........................................................................................................ 847 95 | itemregister........................................................................................................ 848 96 | itemregister........................................................................................................ 849 97 | itemregister........................................................................................................ 850 98 | itemregister........................................................................................................ 851 99 | itemregister........................................................................................................ 852 100 | itemregister....................................................................................................... 853 101 | itemregister....................................................................................................... 854 102 | itemregister....................................................................................................... 855 103 | itemregister....................................................................................................... 856 104 | itemregister....................................................................................................... 857 105 | itemregister....................................................................................................... 858 106 | itemregister....................................................................................................... 859 107 | itemregister....................................................................................................... 860 108 | itemregister....................................................................................................... 861 109 | itemregister....................................................................................................... 862 110 | itemregister....................................................................................................... 863 111 | itemregister....................................................................................................... 864 112 | itemregister....................................................................................................... 865 113 | itemregister....................................................................................................... 866 114 | itemregister....................................................................................................... 867 115 | itemregister....................................................................................................... 868 116 | itemregister....................................................................................................... 869 117 | itemregister....................................................................................................... 870 15 Heating/air conditioning.......................................................................................................... 871 15.1 Control of heating, air conditioning........................................................................................ 872 Electrical control........................................................................................................... 872 Air-conditioning system circuit.............................................................................................. 873 Component description for heating, air conditioning.......................................................................... 874 Air-conditioning system component............................................................................................ 875 15.2 Safety instructions for the air-conditioning system......................................................................... 876 Personal Protective Equipment................................................................................................ 876 Service personnel competence................................................................................................. 876 Safety instructions.......................................................................................................... 876 Function description of heating, ventilation and air conditioning system..................................................... 877 Blower M004.................................................................................................................. 880 Heating switch S015.......................................................................................................... 881 Push button switch for the dryer S052........................................................................................ 882 Air conditioning system temperature switch S054.............................................................................. 883 Air conditioning compressor Y031............................................................................................. 884 Dryer........................................................................................................................ 886 Evaporator with expansion valve.............................................................................................. 887 Condenser.................................................................................................................... 888 19 Installation position............................................................................................................. 889 19.1 Hydraulics.................................................................................................................. 890 Installation position of hydraulics.......................................................................................... 890 19.2 Installation position of electrical system, cab............................................................................. 914 Installation position of electrical system, cab.............................................................................. 914 19.3 Installation position of electrical system, frame........................................................................... 954 Installation position of electrical system, frame............................................................................ 954 19.4 Installation position of engine bay electrics engine 3.6.................................................................... 987 Installation position of engine bay electrics engine 3.6..................................................................... 987 19.5 Installation position of engine bay electrics engine 4.1....................................................................1003 Installation position of engine bay electrics engine 4.1.....................................................................1003 19.6 Installation position of the compressed air system..........................................................................1020 Installation position of the compressed air..................................................................................1020 20 Switch............................................................................................................................1022 20.1 Switch assignment with symbols and installation location....................................................................1023 22 Error codes.......................................................................................................................1029 22.1 Error code list.............................................................................................................1030 Vehicle electronics..........................................................................................................1030 Error code status............................................................................................................1031 Description of the error list................................................................................................1032 Additional information from the error memory.................................................................................1035 23 Central lubrication system........................................................................................................1038 23.1 Central lubrication system..................................................................................................1039 Integrated electronic control S-EP 4.........................................................................................1042 Time control.................................................................................................................1043 Progressive distributor MX-F.................................................................................................1045
DESCRIPTION:
Wacker Kramer 4507/KT457 5007/KT507 5507/KT557 4209/KT429 5509/KT559 Telehandlers System manual- PDF DOWNLOAD
Notes on system manual
Use of the system manual
- This system manual should help you better understand the way in which the individual machine modules operate. The method by which modules are to be controlled will be depicted schematically and individual component descriptions will be provided. This will be followed by a functional description of the respective module.
- Electrical diagrams will be depicted for the various modules at the end of the chapter on hydraulics and electrical systems. These will be of use when identifying functional faults.
- The experiences of our factory personnel and service technicians are summarized in this system manual. Following repairs to or replacement of components, test logs must be used to ensure proper operation and that the components have been set up correctly.
- The most important machine components are accompanied by a depiction of the installation position to ensure it can be easily located in the event of a fault. Any errors displayed can be rectified using the error code lists.
- For reasons of safety and security, always compare the specified values and capacities with the latest Operator’s Manual of the respective machine. Deviations of images are possible
Information
Careful and prudent working is the best way to avoid accidents!
Questions? Email us: [email protected]
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.M
