Wacker Neuson telescopic loaders TH412 Repair Manual – PDF DOWNLOAD

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Wacker Neuson telescopic loaders TH412 Repair Manual – PDF DOWNLOAD

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Wacker Neuson telescopic loaders TH412 Repair Manual – PDF DOWNLOAD
Language : English
Pages :568
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TABLE OF CONTENTS:

Wacker Neuson telescopic loaders TH412 Repair Manual – PDF DOWNLOAD

Repair Manual TH412…………………………………………………………………….. 1
Repair Manual………………………………………………………………………….. 1
Content……………………………………………………………………………….. 3
Part 1 – Safety 1-1…………………………………………………………………. 3
Part 3 – Inspection, Maintenance and Troubleshooting 3-1………………………………… 3
Part 4 – Replacement and Repair 4-1…………………………………………………… 3
Part 5 – Circuit Diagrams and Technical Descriptions 5-331………………………………. 3
Part 6 – Supplier Documentation 6-1…………………………………………………… 3
Repair Manual TH412 1……………………………………………………………. 3
Repair Manual 1…………………………………………………………………. 3
Content 1………………………………………………………………………. 3
Preface 3………………………………………………………………………. 3
Safety 1……………………………………………………………………….. 3
Symbols 3………………………………………………………………………. 3
Repair work (complete vehicle) 5………………………………………………….. 3
Engine 7……………………………………………………………………….. 3
Hydraulic system 9………………………………………………………………. 3
Drive and axles 11………………………………………………………………. 3
Brake system 13…………………………………………………………………. 3
Frame and telescopic arm 15………………………………………………………. 3
Electrical system 17…………………………………………………………….. 3
Technical Data 1………………………………………………………………… 3
Technical Data 1………………………………………………………………… 3
Overview 3……………………………………………………………………… 3
Technical Data – Engine 5………………………………………………………… 3
Filling quantities 7…………………………………………………………….. 3
Tightening torques 9…………………………………………………………….. 3
Pressure values 11………………………………………………………………. 3
Flow rates 13…………………………………………………………………… 3
Safety stickers 15………………………………………………………………. 3
Test equipment 19……………………………………………………………….. 3
Special tools 23………………………………………………………………… 3
Hose log book 29………………………………………………………………… 3
Inspection, Maintenance and Troubleshooting 1………………………………………. 3
Inspections 3…………………………………………………………………… 3
Complete vehicle 5………………………………………………………………. 3
Engine 7……………………………………………………………………….. 3
Hydraulic system 17……………………………………………………………… 4
Drive and axles 49………………………………………………………………. 4
Brake system 61…………………………………………………………………. 4
Frame and load arm 65……………………………………………………………. 4
Cab 67…………………………………………………………………………. 4
Electrical system 69…………………………………………………………….. 4
Replacement and Repair 1…………………………………………………………. 4
Replacement 3…………………………………………………………………… 4
Complete vehicle 5………………………………………………………………. 4
Engine 7……………………………………………………………………….. 4
Hydraulic system 51……………………………………………………………… 4
Drive and axles 131……………………………………………………………… 5
Brake system 161………………………………………………………………… 5
Frame and load arm 173…………………………………………………………… 5
Driver platform and cab 235………………………………………………………. 6
Electrical system 289……………………………………………………………. 6
Attachments 321…………………………………………………………………. 7
Circuit Diagrams and Technical Descriptions 327…………………………………….. 7
Circuit diagrams and technical descriptions 329…………………………………….. 7
Hydraulic circuit diagrams 331……………………………………………………. 7
Wiring diagram 337………………………………………………………………. 7
Connector pin assignments / contact assignments 363…………………………………. 7
Technical description 373………………………………………………………… 7
Supplier Documentation 1…………………………………………………………. 7
Supplier documentation 3…………………………………………………………. 7
Engine operating manual (example) 5……………………………………………….. 7
Engine workshop manual (example) 7………………………………………………… 7
Displacement pump repair instruction (example) 9……………………………………. 7
Displacement engine repair instruction (example) 11…………………………………. 7
Axle workshop manual (example) 13…………………………………………………. 7
Electrical components 15…………………………………………………………. 7
Preface……………………………………………………………………………….. 9
Before you read on …………………………………………………………………. 9
Safety………………………………………………………………………………… 13
Symbols……………………………………………………………………………….. 15
Repair work (complete vehicle)…………………………………………………………… 17
Safety regulations for repair work (complete vehicle)…………………………………… 17
Engine………………………………………………………………………………… 19
Safety regulations for work on the engine……………………………………………… 19
Hydraulic system……………………………………………………………………….. 21
Safety regulations for work on the hydraulic system…………………………………….. 21
Drive and axles………………………………………………………………………… 23
Safety regulations for work on drive and axles…………………………………………. 23
Brake system…………………………………………………………………………… 25
Safety regulations for work on the brake system………………………………………… 25
Frame and telescopic arm………………………………………………………………… 27
Safety regulations for work on frame and telescopic arm…………………………………. 27
Electrical system………………………………………………………………………. 29
Safety regulations for work on the electrical system……………………………………. 29
Technical Data…………………………………………………………………………. 31
Technical Data…………………………………………………………………………. 31
Overview………………………………………………………………………………. 33
Technical Data – Engine…………………………………………………………………. 35
Filling quantities……………………………………………………………………… 37
Tightening torques……………………………………………………………………… 39
Pressure values………………………………………………………………………… 41
Flow rates…………………………………………………………………………….. 43
Safety stickers………………………………………………………………………… 45
Test equipment…………………………………………………………………………. 49
7.1 Hydraulic test pump……………………………………………………………… 49
7.2 Flow meter……………………………………………………………………… 49
7.3 Alternator tester……………………………………………………………….. 50
7.4 Magnetic field tester……………………………………………………………. 51
7.5 Test manometer………………………………………………………………….. 51
7.6 Fuse tester set…………………………………………………………………. 52
Special tools………………………………………………………………………….. 53
8.1 Drive out and drive in drift punches………………………………………………. 53
8.2 Sealing plate (2 x)……………………………………………………………… 54
8.3 Sleeve, steering cylinder………………………………………………………… 54
8.4 Insertion tool………………………………………………………………….. 55
8.5 Pin punch………………………………………………………………………. 55
8.6 Electrical contact tool………………………………………………………….. 56
8.7 Half shells and puller…………………………………………………………… 56
8.8 Hose clamp……………………………………………………………………… 56
8.9 Tool for contact removal…………………………………………………………. 58
8.10 VLS induction switch setting gauge……………………………………………….. 58
Hose log book………………………………………………………………………….. 59
Inspection, Maintenance and Troubleshooting……………………………………………….. 61
Inspections……………………………………………………………………………. 63
Complete vehicle……………………………………………………………………….. 65
1.1 Engine test report………………………………………………………………. 65
1.2 Telescopic arm test report……………………………………………………….. 66
Engine………………………………………………………………………………… 67
2.1 Check and adjust valve clearance………………………………………………….. 67
2.2 Check exhaust system for leaks……………………………………………………. 70
2.3 Check radiator installation………………………………………………………. 71
2.4 Check radiator for leaks…………………………………………………………. 72
2.5 Engine troubleshooting…………………………………………………………… 74
Hydraulic system……………………………………………………………………….. 77
3.1 Drive hydraulics………………………………………………………………… 77
3.1.1 Checking and adjusting starting speed………………………………………… 77
3.1.2 Checking and adjusting pressure cut-off………………………………………. 78
3.1.3 Checking high pressure of the displacement pump……………………………….. 79
3.1.4 Checking supply pressure of the displacement pump……………………………… 80
3.1.5 Checking signal pressure of the displacement pump……………………………… 81
3.1.6 Adjusting travel speed……………………………………………………… 82
3.1.7 Checking and adjusting control start of the displacement engine…………………. 83
3.2 Checking steering hydraulics……………………………………………………… 86
3.3 Checking and adjusting inching……………………………………………………. 89
3.4 Working hydraulics………………………………………………………………. 90
3.4.1 Checking gear pump…………………………………………………………. 90
3.4.2 Checking function of the control valve……………………………………….. 94
3.4.3 Checking function of the throttle control…………………………………….. 94
3.4.4 Checking Vertical Lift System (VLS)………………………………………….. 95
3.4.5 VLS electronics – plug-in connector test instruction…………………………… 97
3.4.6 Checking function of the rear hydraulics………………………………………102
3.5 Hydraulic system troubleshooting…………………………………………………..103
Drive and axles…………………………………………………………………………109
4.1 Differential lock………………………………………………………………..109
4.1.1 Engageable differential lock, checking………………………………………..109
4.1.2 Checking automatic differential lock………………………………………….110
4.2 Checking and adjusting steering……………………………………………………112
4.3 Checking water filling of the wheels……………………………………………….116
4.4 Troubleshooting on the drive………………………………………………………118
Brake system……………………………………………………………………………121
5.1 Checking and adjusting brake………………………………………………………121
Frame and load arm………………………………………………………………………125
6.1 Telescopic arm troubleshooting…………………………………………………….125
xdCab………………………………………………………………………………….127
7.1 Checking heater………………………………………………………………….127
7.2 Troubleshooting in the cab………………………………………………………..128
Electrical system……………………………………………………………………….129
8.1 Checking alternator………………………………………………………………129
8.2 Checking starter motor……………………………………………………………130
8.3 Checking temperature sensor……………………………………………………….131
8.4 Checking tank sensor……………………………………………………………..132
8.5 Calibrating load display………………………………………………………….132
8.6 Troubleshooting on the electrical system……………………………………………137
Replacement and Repair…………………………………………………………………..139
Replacement…………………………………………………………………………….141
Complete vehicle………………………………………………………………………..143
9.1 Helpful tips…………………………………………………………………….143
9.2 Replacing protective stickers……………………………………………………..143
Engine…………………………………………………………………………………145
10.1 Engine…………………………………………………………………………145
10.1.1 Replacing cover and holder………………………………………………….145
10.1.2 Removing engine……………………………………………………………146
10.1.3 Preparing engine for installation……………………………………………151
10.1.4 Installing engine………………………………………………………….154
10.1.5 Replacing hydro bearings……………………………………………………158
10.1.6 Replacing coupling flange…………………………………………………..159
10.1.7 Cleaning engine (after tipping over of the loader)…………………………….159
10.2 Radiator……………………………………………………………………….161
10.2.1 Replacing expansion reservoir……………………………………………….161
10.2.2 Replacing holder for expansion reservoir……………………………………..162
10.2.3 Removing radiator………………………………………………………….163
10.2.4 Replacing fan cowling………………………………………………………165
10.2.5 Installing radiator………………………………………………………..166
10.2.6 Replacing fan impeller and spacer……………………………………………169
10.3 Air filter unit…………………………………………………………………170
10.3.1 Replacing hoses……………………………………………………………170
10.3.2 Replacing complete air filter……………………………………………….171
10.4 Fuel System…………………………………………………………………….172
10.4.1 Replacing complete fuel filter………………………………………………172
10.4.2 Replacing fuel pump………………………………………………………..174
10.4.3 Replacing fuel lines……………………………………………………….175
10.4.4 Replacing fuel filler hose………………………………………………….176
10.4.5 Tank lock emergency opening…………………………………………………177
10.4.6 Replacing breather filter for fuel tank………………………………………178
10.4.7 Replacing ventilation hose for fuel tank……………………………………..179
10.4.8 Replacing fuel tank………………………………………………………..180
10.4.9 Replacing Bowden cable of the accelerator actuation……………………………182
10.5 Exhaust system………………………………………………………………….184
10.5.1 Replacing tail pipe………………………………………………………..184
10.5.2 Replacing exhaust silencer………………………………………………….184
10.5.3 Replacing holder…………………………………………………………..185
10.5.4 Replacing flame pipe……………………………………………………….186
10.5.5 Replacing flexible pipe…………………………………………………….187
Hydraulic system………………………………………………………………………..189
11.1 Complete vehicle………………………………………………………………..189
11.1.1 Depressurising hydraulic system……………………………………………..189
11.1.2 Seal hydraulic cylinder…………………………………………………….189
11.1.3 Replacing bearing on the hydraulic cylinder…………………………………..193
11.2 Drive hydraulics………………………………………………………………..194
11.2.1 Replacing displacement pump…………………………………………………194
11.2.2 Replacing shaft sealing ring of the displacement pump………………………….198
11.2.3 Replacing displacement engine……………………………………………….199
11.3 Steering hydraulics……………………………………………………………..200
11.3.1 Cleaning priority valve…………………………………………………….200
11.3.2 Replacing priority valve……………………………………………………201
11.3.3 Replacing orbital steering unit……………………………………………..202
11.3.4 Replacing pulsation damper………………………………………………….204
11.4 Brake hydraulics………………………………………………………………..205
11.4.1 Inching device (brake)……………………………………………………..205
11.5 Working hydraulics (gear pump, valves)…………………………………………….206
11.5.1 Replacing gear pump………………………………………………………..206
11.5.2 Sealing gear pump………………………………………………………….207
11.5.3 Removing control valve……………………………………………………..209
11.5.4 Sealing control valve………………………………………………………210
11.5.5 Installing control valve……………………………………………………216
11.5.6 Retrofitting latch on the control valve………………………………………217
11.5.7 Replacing overload cut-out valve…………………………………………….218
11.5.8 Replacing 3/2 directional control valve (high speed)…………………………..219
11.5.9 Replacing 3/2 directional control valve (differential lock)…………………….220
11.5.10 Replacing pressure limiter valve on the compensating cylinder (comfort control)….221
11.5.11 Replacing throttle valve (lifting frame)…………………………………….222
11.5.12 Replacing 6/2 directional control valve (VLS)………………………………..223
11.6 Working hydraulics (fan motor, gear pump)………………………………………….224
11.6.1 Replacing fan motor………………………………………………………..224
11.6.2 Replacing gear pump for cooling……………………………………………..225
11.7 Working hydraulics (hydraulic cylinders)…………………………………………..227
11.7.1 Replacing lift cylinder…………………………………………………….227
11.7.2 Replacing compensating cylinder……………………………………………..229
11.7.3 Replacing tilt cylinder…………………………………………………….232
11.7.4 Replacing extension cylinder………………………………………………..234
11.7.5 Replacing lowering brake valve………………………………………………237
11.7.6 Replacing valve cartridge on the lowering brake valve………………………….238
11.7.7 Lowering brake valve for emergency lowering…………………………………..239
11.8 Additional hydraulics, rear hydraulics and hydraulic locking…………………………241
11.8.1 Replacing hydraulic motor (power take-off shaft) (option)………………………241
11.8.2 Sealing hydraulic locking…………………………………………………..243
11.8.3 Replacing locking cylinder (Euro mounting)……………………………………244
11.8.4 Replacing cylinder (three-point rear mounting)………………………………..245
11.8.5 Replacing control valve for rear hydraulics (option)…………………………..246
11.8.6 Replacing switching valve (mechanical) (three-way valve) of the rear hydraulics…..248
11.8.7 Replacing switching valve of the rear hydraulics………………………………248
11.8.8 Replacing solenoid valve (comfort control)……………………………………249
11.8.9 Replacing solenoid valve (fourth control circuit)……………………………..250
11.8.10 Replacing 2/2 directional control valve (two-hand operation)…………………..251
11.8.11 Replacing solenoid valve (High Flow)………………………………………..252
11.8.12 Replacing hydraulic couplings (lifting frame)………………………………..253
11.8.13 Replacing hydraulic couplings (fourth control circuit)………………………..254
11.8.14 Replacing hydraulic plug-in couplings (High Flow)…………………………….255
11.8.15 Replacing hydraulic quick release couplings (rear hydraulics)………………….256
11.8.16 Replacing hydraulic plug-in couplings (three-point mounting)…………………..257
11.9 Tank, filter and hydraulic lines………………………………………………….258
11.9.1 Replacing hydraulic oil tank………………………………………………..258
11.9.2 Return filter, complete, replacing…………………………………………..260
11.9.3 Replacing hydraulic oil preheater (option)……………………………………262
11.9.4 Replacing hydraulic line……………………………………………………262
11.9.5 Replacing hydraulic line (tilt cylinder)……………………………………..263
11.9.6 Replacing hydraulic pipe……………………………………………………265
11.9.7 Replacing manifold…………………………………………………………266
Drive and axles…………………………………………………………………………269
12.1 Replacing propeller shaft………………………………………………………..269
12.2 Front axle……………………………………………………………………..271
12.2.1 Removing front axle………………………………………………………..271
12.2.2 Preparing new front axle for the installation…………………………………273
12.2.3 Installing front axle………………………………………………………274
12.2.4 Sealing front axle…………………………………………………………277
12.3 Rear axle………………………………………………………………………282
12.3.1 Removing rear axle…………………………………………………………282
12.3.2 Installing rear axle……………………………………………………….285
12.3.3 Sealing rear axle………………………………………………………….289
12.4 Steering cylinder……………………………………………………………….292
12.4.1 Removing steering cylinder………………………………………………….292
12.4.2 Sealing steering cylinder…………………………………………………..293
12.4.3 Installing steering cylinder………………………………………………..296
Brake system……………………………………………………………………………299
13.1 Service brake…………………………………………………………………..299
13.1.1 Replacing brake disc……………………………………………………….299
13.1.2 Replacing brake pads……………………………………………………….300
13.1.3 Replacing brake lever………………………………………………………301
13.1.4 Replacing brake pedal………………………………………………………302
13.1.5 Replacing sliding bearings………………………………………………….304
13.2 Parking brake…………………………………………………………………..308
13.2.1 Replacing operating lever of the parking brake………………………………..308
Frame and load arm………………………………………………………………………311
14.1 Frame………………………………………………………………………….311
14.1.1 Replacing front mudguard……………………………………………………311
14.1.2 Replacing rear view mirror………………………………………………….311
14.1.3 Rear view mirror, complete, replacing………………………………………..312
14.1.4 Replacing engine cover……………………………………………………..312
14.1.5 Replacing retaining cable…………………………………………………..314
14.1.6 Replacing locking mechanism and handle of the engine cover……………………..315
14.1.7 Engine cover emergency unlocking…………………………………………….316
14.1.8 Replacing floor pan………………………………………………………..317
14.1.9 Replacing registration plate holder (option)………………………………….318
14.1.10 Removing and attaching rear panelling……………………………………….318
14.1.11 Replacing rear weight……………………………………………………..319
14.1.12 Replacing cover plate for frame…………………………………………….322
14.1.13 Replacing cover plate on engine sump………………………………………..322
14.1.14 Removing engine sump………………………………………………………323
14.1.15 Attaching engine sump……………………………………………………..326
14.1.16 Replacing remote lubrication system…………………………………………329
14.2 Holder…………………………………………………………………………330
14.2.1 Replacing holder for tail lights (option)…………………………………….330
14.2.2 Replacing holder for rear view mirror………………………………………..331
14.2.3 Replacing holder for mudguard……………………………………………….332
14.2.4 Replacing holder for locking bolt (mechanical)………………………………..332
14.2.5 Replacing holder for air filter……………………………………………..333
14.2.6 Replacing holder for fan……………………………………………………334
14.2.7 Replacing holder for fuel filter…………………………………………….335
14.3 Tool holder…………………………………………………………………….336
14.3.1 Replacing locating pin……………………………………………………..336
14.3.2 Replacing tool holder………………………………………………………336
14.3.3 Replacing locking bolt (Euro mounting)……………………………………….337
14.3.4 Replacing locking mechanism of the tool holder (US)……………………………338
14.4 Telescopic arm………………………………………………………………….339
14.4.1 Replacing guide rail……………………………………………………….339
14.4.2 Replacing protective cover………………………………………………….341
14.4.3 Replacing tipping bar………………………………………………………343
14.4.4 Replacing bearings of the tipping bar………………………………………..343
14.4.5 Replacing tilting lever…………………………………………………….344
14.4.6 Replacing bearings of the tilting lever………………………………………345
14.4.7 Removing inner tube………………………………………………………..346
14.4.8 Installing inner tube………………………………………………………350
14.4.9 Replacing sliding plate of the inner tube…………………………………….353
14.4.10 Replacing sliding plates of the outer tube…………………………………..353
14.4.11 Removing telescopic arm, complete…………………………………………..355
14.4.12 Attaching telescopic arm, complete………………………………………….358
14.4.13 Replacing front bearing……………………………………………………361
14.4.14 Replacing rear bearing…………………………………………………….362
14.5 Replacing trailer coupling (option)……………………………………………….363
14.6 Rear three-point linkage (option)…………………………………………………364
14.6.1 Replacing upper link……………………………………………………….364
14.6.2 Replacing linkage draw bar………………………………………………….364
14.6.3 Replacing lower link……………………………………………………….365
14.6.4 Replacing rear three-point linkage…………………………………………..366
14.6.5 Replacing rear three-point linkage mounting…………………………………..367
14.6.6 Replacing mounting for upper link……………………………………………369
14.6.7 Removing and attaching complete rear three-point linkage……………………….369
14.6.8 Replacing power take-off shaft protection…………………………………….371
Driver platform and cab………………………………………………………………….373
15.1 Attachments…………………………………………………………………….373
15.1.1 Replacing FOPS protection grille (option)…………………………………….373
15.1.2 Replacing rear view mirror………………………………………………….374
15.1.3 Replacing holder for spot lamps (option)……………………………………..374
15.1.4 Replacing holder for rotating beacon (option)…………………………………375
15.2 Window panes and doors…………………………………………………………..376
15.2.1 Replacing windscreen wiper blade…………………………………………….376
15.2.2 Replacing windscreen wiper arm………………………………………………377
15.2.3 Replacing windscreen washer liquid reservoir………………………………….378
15.2.4 Replacing glued-in window glass……………………………………………..379
15.2.5 Replacing opening mechanism for the rear window……………………………….381
15.2.6 Replacing rear window………………………………………………………382
15.2.7 Replacing stay…………………………………………………………….383
15.2.8 Replacing rubber buffer…………………………………………………….384
15.2.9 Replacing locking handle……………………………………………………386
15.2.10 Replacing door glass………………………………………………………387
15.2.11 Replacing locking device…………………………………………………..389
15.2.12 Replacing locking bolt…………………………………………………….390
15.2.13 Replacing door locking mechanism……………………………………………390
15.2.14 Replacing door handle……………………………………………………..391
15.2.15 Replacing retaining strap………………………………………………….391
15.2.16 Replacing cab door………………………………………………………..392
15.3 Seat…………………………………………………………………………..394
15.3.1 Replacing driver seat………………………………………………………394
15.3.2 Safety belt, complete, replacing…………………………………………….396
15.3.3 Replacing seat rails……………………………………………………….396
15.4 Interior panelling………………………………………………………………397
15.4.1 Replacing floor mat………………………………………………………..397
15.4.2 Detaching and fastening instrument panel……………………………………..397
15.4.3 Replacing instrument panel………………………………………………….398
15.4.4 Replacing front panelling…………………………………………………..399
15.4.5 Replacing side panelling……………………………………………………400
15.4.6 Replacing rear panelling……………………………………………………401
15.4.7 Replacing roof lining………………………………………………………402
15.4.8 Replacing blind……………………………………………………………403
15.5 Operating lever…………………………………………………………………403
15.5.1 Replacing multifunction lever……………………………………………….403
15.5.2 Replacing cross controller………………………………………………….405
15.5.3 Replacing operating lever for additional hydraulics……………………………405
15.5.4 Replacing switching rod…………………………………………………….406
15.5.5 Replacing locking lever for working hydraulics………………………………..408
15.5.6 Replacing throttle hand lever……………………………………………….409
15.5.7 Replacing manual inching (option)……………………………………………410
15.6 Frame………………………………………………………………………….412
15.6.1 Cab, complete, removing…………………………………………………….412
15.6.2 Cab, complete, attaching……………………………………………………417
15.6.3 Replacing documents box (option)…………………………………………….420
15.7 Steering column…………………………………………………………………421
15.7.1 Replacing steering wheel knob……………………………………………….421
15.7.2 Replacing steering wheel……………………………………………………422
15.7.3 Replacing steering column…………………………………………………..423
15.8 Heater…………………………………………………………………………424
15.8.1 Replacing cab heater……………………………………………………….424
15.8.2 Replacing shut-off valve……………………………………………………425
Electrical system……………………………………………………………………….427
16.1 Alternator, battery and motors……………………………………………………427
16.1.1 Replacing alternator……………………………………………………….427
16.1.2 Replacing starter………………………………………………………….428
16.1.3 Replacing windscreen wiper motor…………………………………………….430
16.2 Switches and sensors…………………………………………………………….431
16.2.1 Replacing battery disconnector………………………………………………431
16.2.2 Replacing ignition lock…………………………………………………….432
16.2.3 Replacing oil pressure switch on the engine…………………………………..433
16.2.4 Replacing engine temperature switch………………………………………….434
16.2.5 Replacing brake switch……………………………………………………..435
16.2.6 Replacing steering column switch…………………………………………….436
16.2.7 Replacing switches in the cab……………………………………………….436
16.2.8 Adjusting proximity switch………………………………………………….437
16.2.9 Replacing proximity switch………………………………………………….438
16.2.10 Adjusting VLS initiator……………………………………………………439
16.2.11 Replacing VLS initiator……………………………………………………440
16.2.12 Replacing tank sensor……………………………………………………..441
16.3 Relays, coils and fuses………………………………………………………….442
16.3.1 Replacing relays…………………………………………………………..442
16.3.2 Replacing stop solenoid…………………………………………………….443
16.3.3 Replacing coil and core on solenoid valves……………………………………444
16.3.4 Replacing solenoid valve of the variable displacement pump……………………..445
16.3.5 Replacing coil and core on the variable displacement pump………………………446
16.3.6 Replacing control unit……………………………………………………..447
16.3.7 Replacing fuse block……………………………………………………….448
16.4 Indicator lamps, warning buzzer and instruments…………………………………….449
16.4.1 Replacing instrument cluster………………………………………………..449
16.4.2 Replacing load display……………………………………………………..449
16.4.3 Replacing horn…………………………………………………………….450
16.4.4 Replacing warning buzzer (option)……………………………………………451
16.4.5 Replacing power socket (12 V)……………………………………………….451
16.5 Lighting equipment………………………………………………………………452
16.5.1 Completely replacing headlight with flasher unit………………………………452
16.5.2 Replacing complete tail light……………………………………………….453
16.5.3 Replacing work light……………………………………………………….453
16.5.4 Replacing number plate light (option)………………………………………..454
16.5.5 Replacing rotating beacon (option)…………………………………………..455
16.5.6 Replacing cab light………………………………………………………..456
16.6 Additional electrical equipment…………………………………………………..456
16.6.1 Replacing 7-pole power socket……………………………………………….456
16.6.2 Replacing 3-pole power socket (option)……………………………………….457
Attachments…………………………………………………………………………….459
17.1 Replacing ripping tooth of the earth bucket………………………………………..459
17.2 Replacing locking device of the pallet fork………………………………………..459
17.3 Replacing tines of the silage fork………………………………………………..460
17.4 Replacing hydraulic cylinder of the silage fork…………………………………….461
17.5 Replacing hydraulic cylinder of the multi-purpose bucket…………………………….462
17.6 Replacing valve of the multi-purpose bucket………………………………………..463
Circuit Diagrams and Technical Descriptions………………………………………………..465
Circuit diagrams and technical descriptions………………………………………………..467
Hydraulic circuit diagrams……………………………………………………………….469
Wiring diagram………………………………………………………………………….475
Connector pin assignments / contact assignments…………………………………………….501
20.1 Connector pin assignments………………………………………………………..502
20.2 Contact assignments……………………………………………………………..509
Technical description……………………………………………………………………511
21.1 Engine…………………………………………………………………………511
21.2 Hydraulics……………………………………………………………………..512
21.3 Drive and axles…………………………………………………………………515
Supplier Documentation…………………………………………………………………..519
Supplier documentation…………………………………………………………………..521
Engine operating manual (example)…………………………………………………………523
Engine workshop manual (example)………………………………………………………….525
Displacement pump repair instruction (example)……………………………………………..527
Displacement engine repair instruction (example)……………………………………………529
Axle workshop manual (example)……………………………………………………………531
Electrical components……………………………………………………………………533
Wiring diagram from serial no. 3014175…………………………………………………….545

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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