Wacker Neuson 3001 Dumper Service Manual 1000156004 – PDF DOWNLOAD

Description

Wacker Neuson 3001 Dumper Service Manual 1000156004 – PDF DOWNLOAD

FILE DETAILS:

Wacker Neuson 3001 Dumper Service Manual 1000156004 – PDF DOWNLOAD

Language : English
Pages : 294
Downloadable : Yes
File Type : PDF
Size: 17.7 MB

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DESCRIPTION:

Wacker Neuson 3001 Dumper Service Manual 1000156004 – PDF DOWNLOAD

This chapter describes the controls and contains information on the function and handling of the indicator and warning lights and controls on the control stand. The pages stated in the table refer to the description of the controls.

Designated use and exemption from liability

. The machine is intended for:

TABLE OF CONTENTS:

Wacker Neuson 3001 Dumper Service Manual 1000156004 – PDF DOWNLOAD

Documentation 2
Legend 2
F 10
I 10
M 10
N 10
O 10
S 10
T 10
1 Operation 13
1 1 Notices on this service manual 13
1 2 Identification of warnings and dangers 14
1 3 Designated use and exemption from liability 15
1 4 Type labels and component numbers 16
1 5 Machine overview 18
1 6 Control stand overview 20
1 7 Overview of cabin control stand (option) 21
1 8 Instrument panel overview (Yanmar) 22
1 9 Overview of display element and switches (Perkins) 23
1 10 Parking the machine 25
1 11 Engine cover 26
1 12 Maintenance accesses (machine with optional cabin) 27
1 13 Maintenance prop 28
Front skip 28
Swivel skip 29
1 14 Center-pivot prop 29
1 15 Rollbar 30
1 16 Locking the control lever 31
1 17 Battery master switch (Yanmar, Tier III) 32
1 18 Rotating beacon (option) 32
1 19 Opening the high-pressure circuit 33
1 20 Fire extinguisher 34
2 Technical data 39
2 1 Chassis 39
2 2 Engine (Yanmar) 39
Engine capacities 40
Engine tightening torques 40
2 3 Engine (Perkins) 41
Engine capacities 41
2 4 Work hydraulics 42
2 5 Travel drive 42
2 6 Machine travel specifications 42
2 7 Brakes 43
2 8 Steering system 43
2 9 Tires 43
2 10 Skip 44
2 11 Weights 45
Transport weights 45
Operating weights 45
2 12 Coolant compound table 46
2 13 Vibration 46
2 14 Electrical system 47
Fuses and relays (up to serial no EA01931, Yanmar) 47
Fuses and relays (serial nos EA01932 to EA01950, Yanmar) 48
Additional fuses for machine with optional cabin (Yanmar) 48
Fuses and relays (Perkins) 49
2 15 Noise levels (Yanmar) 51
2 16 General tightening torques 51
Tightening torques for hydraulic threaded fittings (dry assembly) 51
Tightening torques for high-resistance threaded fittings 53
Tightening torques for Nordlock lock washers 54
2 17 Dimensions model 3001 (front skip) 55
2 18 Dimensions model 3001s (swivel skip) (option) 56
2 19 Dimensions model 3001s special skip (swivel skip) (option) 57
Tilted height 2 2 m (86 6 in) 57
2 20 Dimensions model 3001s (swivel skip) concrete mixer (option) 58
2 21 Dimensions model 3001 (front skip) cabin (option) 59
2 22 Dimensions model 3001s (swivel skip) cabin (option) 60
3 Maintenance 63
3 1 Introduction 63
3 2 Safety-relevant parts 63
3 3 Fluids and lubricants (Yanmar) 64
3 4 Fluids and lubricants (Perkins) 65
Oil grades for the diesel engine, depending on temperature (Yanmar) 66
Oil grades for the diesel engine, depending on temperature (Perkins) 66
Oil grades for the hydraulic system, depending on temperature 67
Additional oil change and filter replacement (hydraulic system) 67
Important information regarding operation with biodegradable hydraulic oil 67
3 5 Maintenance label 68
Explanation of symbols on the maintenance label 69
3 6 Maintenance plan (overview – Yanmar) 70
3 7 Maintenance plan (Perkins) 75
3 8 fuel system 79
Refueling 80
Stationary fuel pumps 81
Emptying the fuel tank 82
Draining the condensation water in the fuel tank 83
Bleeding the fuel system (Yanmar) 83
Yanmar fuel prefilter with water separator (Yanmar) 84
Replacing the fuel filter (Yanmar) 85
Fuel filter with water separator (Perkins) 86
Emptying the fuel filter (Perkins) 86
Replacing the fuel filter (Perkins) 87
Changing the fuel prefilter (Perkins) 87
3 9 Engine lubrication system 88
Checking the engine oil level (Yanmar) 88
Checking the engine oil level (Perkins) 89
Adding engine oil 90
Change the engine oil 91
Replacing the engine-oil filter cartridge 92
3 10 Engine and hydraulics cooling system 93
Specific safety instructions 93
Checking the coolant level/adding coolant 94
Draining coolant 97
Cleaning the radiator 98
3 11 Air filter 99
Replacing the filter 100
Checking the engine air intake (Perkins) 101
3 12 Replacing the cabin air filter 102
3 13 V-belt 103
Checking V-belt tension 103
Replacing the alternator V-belt 104
Retensioning the alternator V-belt 104
Replacing the compressor V-belt (Perkins) 105
Retensioning the compressor V-belt (Perkins) 105
3 14 Replace the crankcase breather filter 106
3 15 Replace the fuel-burner glow plug 107
3 16 Hydraulic system 108
Specific safety instructions 108
Checking the hydraulic oil level 109
Adding hydraulic oil 110
Replace the hydraulic oil 111
Wear indicator of hydraulic oil filter insert 112
Replacing the hydraulic oil filter element 112
Replace the braking system fluid 113
Checking hydraulic pressure lines 114
3 17 Overview of lubrication points 115
Lubrication plan for swivel skip (option) 115
Lubrication plan for front skip (option) 116
Lubrication points of concrete mixer 117
3 18 Tires 117
Inspection work 117
Changing wheels 119
3 19 Braking system 120
3 20 Axles 121
Checking the oil level and adding oil 121
Draining oil 121
3 21 Axle mounting 122
Front axle 122
Rear axle 123
3 22 Electrical system 125
Specific safety instructions 125
Servicing and maintenance at regular intervals 125
Fuses and relays 125
3 23 Battery 126
Battery charge condition 126
Charging the battery 126
Replacing the battery 126
3 24 General maintenance 127
Cleaning 127
General instructions for all areas of the machine 127
On the outside of the machine 127
Cleaning the seat belt 128
Inside the cabin 128
Engine compartment 128
Threaded fittings and attachments 129
Pivots and hinges 129
3 25 Preparatory work before taking out of service 130
3 26 Maintenance when out of service for a longer period of time 130
Putting into operation again (Yanmar) 130
Putting into operation again (Perkins) 131
4 Engine 135
4 1 3TNV88-KNSV engine (overview) 135
4 2 Fuel system (up to AB) 137
4 3 Fuel system (from AC) 138
Checking and adjusting valve clearance 139
Tightening order for cylinder head bolts 140
4 4 Checking the injection nozzles 141
Pressure check 141
Checking the nozzle jet 141
Injection time 142
4 5 Adjusting engine speed 143
4 6 Compression 143
4 7 Checking the coolant thermostat 144
Checking the thermal switch 144
4 8 Oil pressure switch 145
4 9 Checking the coolant circuit 145
4 10 Clutch 146
4 11 Overview of engine 3TNV88-BKNSV (from serial no AE310242D) 147
4 12 Fuel system (from serial no AE310242D) 149
Checking and adjusting valve clearance 150
Tightening order for cylinder head bolts 151
4 13 Checking the injection nozzles 152
Pressure check 152
Checking the nozzle jet 152
Injection time 153
4 14 Adjusting engine speed 154
4 15 Compression 154
4 16 Checking the coolant thermostat 154
Checking the thermal switch 155
4 17 Oil pressure switch 155
4 18 Checking the coolant circuit 156
4 19 Clutch 156
4 20 Engine malfunctions 157
4 21 Perkins engine 403F-15T (overview) 159
4 22 Fuel system 166
4 23 Checking and adjusting valve clearance 167
4 24 Clean the diesel particulate filter 167
4 25 Checking the injection nozzles 167
4 26 Turbocharger 167
4 27 Checking/replacing the coolant thermostat 168
4 28 Checking the coolant circuit 168
4 29 Engine malfunctions 169
5 Traveling drive 173
5 1 Variable displacement pump A10VG45DA 173
Variable displacement pump: diagram 175
Variable displacement pump: design 176
Traveling drive overview 177
Connecting plate with valves 178
5 2 Hydraulic motor A6VM80EZ 179
5 3 Traveling drive overview (up to AB) 180
5 4 Traveling drive overview (from AC) 180
5 5 Towing and transporting the machine 181
Safety instructions 181
Towing 181
Opening the high-pressure circuit 181
5 6 Test instructions 182
High pressure check 182
Check: boost pressure 183
Check: setting pressure 183
5 7 Adjustment 184
Setting: control initiation 184
6 Axles 187
6 1 Axle type label 187
6 2 Drain, fill and check plug 188
6 3 Tightening torques 188
Wheel screws 188
Axle mounting 189
General tightening torques 189
6 4 Articulated joint (up to AB) 191
6 5 Articulated joint (from AC) 193
6 6 Transfer gearbox (up to AD) 195
6 7 Transfer gearbox (from AE310242D) 197
6 8 Semiaxles 199
6 9 Wheel hub 201
6 10 Front axle brake (up to AB) 203
6 11 Brake diagram 204
6 12 Front axle brake (from AC to AD) 207
6 13 Front axle brake (from AE310242D) 208
6 14 Differential (up to AB) 210
Front axle (up to AB) 212
Front axle (from AC to AD) 214
Front axle (from AE310242D) 215
Rear axle 217
6 15 Cardan shaft 218
6 16 Front axle (Tier IV Perkins) 219
6 17 Rear axle (Tier IV Perkins) 220
7 Brakes 223
7 1 Brake circuit (up to AB) 223
7 2 Brake circuit 224
Parking brake 224
Service brake 226
8 Steering system 229
8 1 Steering circuit (up to AB) 229
8 2 Steering circuit (from AC) 230
8 3 Steering unit: diagram 231
Function 231
8 4 Steering unit connections 232
8 5 Steering unit overview 233
Priority valve overview 233
Priority valve (legend) 233
Steering unit 234
Steering unit (legend) 235
9 Hydraulic system 239
9 1 Control valve 239
Machines with front skip up to serial no EA03236 239
Overview of connections 239
Machines with front skip from serial no EA03237 240
Overview of connections 240
9 2 Valves – differential lock (up to AB) 241
Check valve 241
9 3 Tilting the skip: hydraulic diagram (up to AB) 242
9 4 Tilting the skip: hydraulic diagram (from AC) 243
9 5 Swiveling the skip: hydraulics diagram (up to AB) 244
9 6 Swiveling the skip: hydraulics diagram (from AC) 245
9 7 Test instructions 246
Check: operating hydraulics 246
9 8 Hydraulics diagram from serial no EA01441 0
9 9 Hydraulics diagram Tier IV (Perkins) 0
10 Electrical system 253
10 1 Ohmic law (current, voltage, resistance); Power 253
10 2 Measuring equipment, measuring methods 253
10 3 Relays 254
Use, mode of function 254
10 4 Electric units 255
Fuses and relays (up to serial no EA01931, Yanmar) 255
Fuses and relays (serial nos EA01932 to EA01950, Yanmar) 256
Additional fuses for machine with optional cabin (Yanmar) 256
Fuses and relays (Perkins) 257
10 5 Telematic 259
Connections 259
Functional check/diode 259
10 6 Yanmar wiring diagram up to AB (legend) 0
10 7 Yanmar wiring diagram (up to AB) 0
10 8 Wiring diagram legend Tier III (from serial no WNCD0305TPAL01054) 0
10 9 Wiring diagram Tier III (from serial no WNCD0305TPAL01054) 0
10 10 Perkins wiring diagram Tier IV part 1 0
10 11 Perkins wiring diagram Tier IV part 2 0
10 12 Perkins wiring diagram Tier IV part 3 with StVO registration (Austrian road traffic regulations) 0
10 13 Main wiring harness legend (up to AB) 0
10 14 Main wiring harness up to AB 0
10 15 Main wiring harness legend (from AC to serial no WNCD0305CPAL01053) 0
10 16 Main wiring harness (from AC to serial no WNCD0305CPAL01053) 0
10 17 Main wiring harness legend Tier III (from serial no WNCD0305TPAL01054) 0
10 18 Main wiring harness Tier III (from serial no WNCD0305TPAL01054) 0
10 19 Main Perkins wiring harness Tier IV (legend) 0
10 20 Main Perkins wiring harness Tier IV 0
10 21 Engine wiring harness legend 0
10 22 Engine wiring harness 0
10 23 Wiring harness legend: indicator base – starter base (up to AB) 0
10 24 Wiring harness: indicator light base (up to AB) 0
10 25 Wiring harness: starter base (from AC) 0
10 26 Light switch connector assignment 0
10 27 StVO (Austrian road traffic regulations) wiring harness from AC 0
10 28 StVZO (Austrian road traffic regulations) wiring harness Tier IV 0
10 29 Extension cable (front skip) 0
10 30 Rotating beacon cable 0
10 31 Alternator wiring harness (up to serial no WNCD0305JPAL00636) 0
10 32 Alternator wiring harness (from serial no WNCD0305CPAL00637) 0
10 33 Battery lead 0

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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