Maintenance Instructions: BG 190TA-4

B A U M A S C H I N E N
Maintenance instructions
BG 190TA-4
Motor Grader
Motorgrader
Niveleuse
englisch
01/2010
Motor Grader
Motorgrader
Niveleuse
BG 190TA-4
Maintenance instructions
Wartungsanleitung
Instructions d’entretien
01/2010 HBM/NOBAS construction machine
Maintenance instructions BG
Table of Contents
Preface 1
Safety regulations 2
Drive engine 4
Daily Maintenance Procedures 4.1
Daily Maintenance Procedures - Overview 4.1.1
Crankcase Breather Tube 4.1.2
Fuel-Water Separator 4.1.3
Lubricating Oil Level 4.1.4
Coolant Level 4.1.5
Drive Belts 4.1.6
Maintenance Procedures at 250 hours or 3 months 4.2
Air Cleaner Restriction 4.2.1
Charge-Air Cooler 4.2.2
Charge-Air Piping 4.2.3
Radiator Hoses 4.2.4
Air Intake Piping 4.2.5
Fan, Cooling 4.2.6
Maintenance Procedures at 500 hours or 6 months 4.3
Cooling System 4.3.1
Fuel Filter (Spin-On Type) 4.3.2
Lubricating Oil and Filters 4.3.3
Maintenance Procedures at 1000 hours or 1 year 4.4
Cooling Fan Belt Tensioner 4.4.1
Fan Hub, Belt Driven 4.4.2
Maintenance Procedures at 2000 hours or 2 years 4.5
Cooling System 4.5.1
Cooling system 5
Checking the coolant level 5.1
External cleaning of the cooler 5.2
Air filter system 6

Air filter 6.1
Replacement, removal and insertion of the filter insert 6.1.1
Blowing-off the filter insert 6.1.2
Checking the filter insert 6.1.3
Table of Contents
Replacement of safety cartridge 6.1.4
Powershift transmission 7
Gear type 6 WG 160 7.1
Battery 8
Rear axle 9
Checking the oil levels 9.1
Exchange of oil at the rear axle 9.2
Drive shafts 9.4
Front axle (not driven) 10
Braking system 11
Parking brake 11.1
Clearance adjusting 11.1.1
Bleeding the brake 11.2
Servicing the wheel brake 11.3
Emergency release of the parking brake 11.4
Moldboard assembly 12
Lubricating the moldboard assembly 12.1
Greasing the moldboard assembly 12.2
Readjustment the blade guide 12.3
Readjustment the circle 12.4
Circle drive 12.5
Hydraulic working system 13

Checking oil level 13.1
Refilling with oil 13.2
Changing the oil 13.3
Replacement of the hydraulic filter 13.4
Replacement of the filter cartridge of the backflow filter 13.4.1
High-pressure filter cleaning 13.4.2
Replace the filter cartridge of the high-pressure filter 13.4.2.1
Equipment list for the working hydraulics circuit diagram 13.5
Equipment list for the drive hydraulics circuit diagram 13.6
Table of Contents
Articulated frame joint and articulated steering cylinder 14
Lubrication of the grading plate 15
Rear ripper 16
Changing the tyres 17
Electrical system 18
Electrical system on the machine 18.1
Electrical symbols 18.2
Lubricants, fuels, filling quantities 19
Lubricants 20
Diesel fuels 21
Long-term coolants 22
Winter operation 23
Shutting the machine down for a longer period 24
Maintenance and inspection plan 25

Maintenance instructions 1
1 Preface
Proper operation and care are important prerequisites for maintaining the serviceability of the building machine.
These maintenance instructions should always be within the machine operator’s reach.
Please read the maintenance instructions and safety rules carefully and follow them strictly. Carry out the inspections,
checks and maintenance jobs at the specified intervals. Any guarantee claims will only be recognized if all the inspec-
tions, checks and maintenance work have been carried out properly and at the specified intervals before the date of dam-
age/defect.
Be aware that regular maintenance and inspections can prevent unexpected and unnecessary downtimes.
Should troubles occur with the machine or equipment, report to the persons responsible for maintenance and repair. If a
trouble may lead to consequential damage, put the machine out of operation and remedy the trouble.
Jobs marked with this symbol in the maintenance instructions should only be done by our agents’
expert staff.
At the printing date of this manual, the building machine described herein corresponded to the state of the art. In the
interest of further development, we reserve the right to make changes to our products at any time without simultaneously
updating these maintenance instructions. For this reason, we recognize no claims arising from technical data, descrip-
tions and figures which deviate from those of the machine.
Note: The test, measuring, and diagnostic equipment mentioned in the maintenance instructions is not included in the
machine's scope of supply. Please call your authorised service representative.
1
2 Safety regulations
As to the inspections, checks and maintenance of the building machine, the safety regulations of the country in which the
machine is used and those of the trade association concerned are applicable.
The regulations specified in European standards EN 474-1 and EN 474-8 are applicable to this.
In the Federal Republic of Germany, the requirements are applicable in accordance with the material content of the "Op-
eration" section in the accident prevention regulations for "earth-moving machinery" (VBG 40).
Control equipment may only be operated from the driver’s seat or operator’s stand.
Only the steps and platforms intended for climbing and walking may be used for the purpose. Their walksafe condition
must be maintained.
Protections covering moving machine parts may only be opened after the drive has been stopped and secured against
unintentional starting.
After the maintenance or repair work, all protections must be properly closed or replaced.
Such protections are, for example: engine covers, doors, safeguards, protective gratings, panels.
The breakdown coupling may only be used for towing vehicles which are not in working order. Towing a trailer with this
coupling in road traffic is not permissible.
Keep out of the machine’s danger zone!
When the engine is running, keep also out of the frame articulation zone!
Do not stand under the lifted and unsecured grading equipment!
Before the execution of any welding work at the grader, make sure that the dynamo, the microproc-
essor and the battery are completely disconnected!
See also section 1.2 of the operation instructions for this machine; it is considered part of these
maintenance instructions.
Original HBM-NOBAS parts are especially designed for HBM-NOBAS machines.
Please note that parts and accessories not supplied by us are not tested and approved by us. The use of such products
may affect specific design characteristics of your machine negatively and, consequentially, have an adverse effect on the
active and/or passive safety. The machine manufacturer is not liable for damage caused by the use of parts and acces-
sories which are not original parts or accessories.
2
4 Drive engine
General Information
At each scheduled maintenance interval, perform all previous maintenance checks that are due for scheduled mainte-
nance.
Maintenance Schedule
Daily or Refuelling - Maintenance Check (3) Section 4.1

• Crankcase Breather Tube - Inspect
• Fuel-Water Separator - Drain
• Engine oil level - Check
• Coolant Level - Check/Correct
• Drive Belts - Check/Correct
Every 250 hours or 3 months - Maintenance Check (3) Section 4.2

• Air Cleaner Restriction - Check/Correct
• Charge Air Cooler - Check/Correct
• Charge Air Piping - Check/Correct
• Radiator Hoses - Check
• Air admission line - Check
• Cooling Fan - Check
Every 500 hours or 6 month - Maintenance Check (1, 2, 3) Section 4.3

• Engine Coolant - Antifreeze Check
• Fuel Filter, Spin-on-Type - Replace
• Lubricating Oil and Filters - Change
Every 1000 hours or 1 year - Maintenance Check (3) Section 4.4

• Cooling Fan Belt Tensioner - Check/Correct
• Fan Hub, Belt-Driven - Check/Correct
Every 2000 hours, or 2 years - Maintenance Check (2, 3) Section 4.5

• Cooling System - Drain, Flush, and Fill
(1) The lubricating oil and lubricating oil filter interval can be adjusted based on application, fuel consumption, gross
vehicle weight, and idle time. See the Oil Drain Intervals in this section.
(2) Antifreeze check interval is every oil change or 500 hours or 6 months, whichever occurs first. The operator must use
a heavy-duty year-round antifreeze that meets the chemical composition of GM6038M. The antifreeze change interval
is 2 years or 2000 hours whichever occurs first. Antifreeze is essential for freeze, overheat, and corrosion protection.
(3) Follow the manufacturer’s recommended maintenance procedures for the starter, alternator, generator, batteries,
electrical components, exhaust brake, charge air cooler, radiator, air compressor, air cleaner, freon compressor, and
fan clutch. Refer to Procedure 203-001 (Component Manufacturers) in Section M.
Oil Drain Intervals
American Petroleum Insti- European Classification Engine Rating is 260Hp [194] or less
tute Classification (API) (ACEA)
API CH-4/SJ ACEA E-5 500 hours or 6 months
4
Maintenance Record
Maintenance Record
Engine Serial No.: Engine Model:
Owner’s Name: Equipment Name/Number:
Date km [Miles], hours Actual km [Miles] Maintenance Check Per- Comments

or Time Interval or hours Check Performed formed By
4
4.1 Daily Maintenance Procedures

4.1.1 Daily Maintenance Procedures - Overview
General Information
Preventative maintenance begins with day-to-day awareness of the engine
and its system. Before starting the engine, check the oil and coolant levels.
Look for:
• Leaks
• Loose or damaged parts
• Worn or damaged belts
• Any change in engine appearance.
• Odor of fuel
Engine Operation Report

The engine must be maintained in top mechanical condition if the operator
is to get optimum satisfaction from its use. The maintenance department
needs daily running reports from the operator to make necessary adjust-
ments in the time allocated. The daily running reports also helps to make
provisions for more extensive maintenance work as the reports indicate the
necessity.
Report to the maintenance department any of the following conditions:

• Low lubricating oil pressure
• Low power
• Power increases or engine surge
• Erratic or no accelerator control or response
• Any warning lights flashing or staying on
• Abnormal water or oil temperature
• Unusual engine noise
• Excessive smoke
• Excessive use of coolant, fuel, or lubricating oil
• Any fuel, coolant, or lubricating oil leaks
• Loose or damaged parts
• Worn or damaged belts
Unusual Engine Noise

Fig. 4.1.1/1
During daily maintenance checks, listen for any unusual engine noise that
can indicate that service is required.
Fig. 4.1.1/1
4.1
4.1.2 Crankcase Breather Tube

Fig. 4.1.2/1
Maintenance Check
Inspect the breather tube for sludge, debris, or ice in the tube.
The tube must be free.
Inspect the tube more frequently in icy conditions.
The line must be laid freely, and must not be kinked.
4.1.3 Fuel-Water Separator Fig. 4.1.2/1

Drain
Warning!
Drain the water-fuel separator into a container and
dispose of in accordance with local environmental
regulations.
Drain the water and sediment from the separator daily.
Spin-on Type
Fig. 4.1.3/1
Shut off the engine.
Use your hand to open the drain valve. Turn the valve counterclockwise
approximately 3½ turns until the valve drops down 25,4mm [1in] and drain-
ing occurs.
Drain fluid from the filter bottom part until you see clear fuel flowing out.
Caution!
When closing the drain valve, do not overtighten the
valve. Overtightening can damage the threads. Fig. 4.1.3/1
To close the valve, lift the valve and turn clockwise until it is hand-tight.
4.1.4 Lubricating Oil Level

Fig. 4.1.4/1
Maintenance Check
Caution!
Never operate the engine with oil level below the L
(low) mark or above the H (high) mark. Poor engine
performance or engine damage can occur.
The engine must be level when checking the oil level to make sure the
measurement is correct.
Shut off the engine for an accurate reading.
Wait at least 15 minutes after shutting off the engine to check the oil level.
This allows time for the oil to drain into the oil pan. Fig. 4.1.4/1
For further recommendations on lubricating oil, see the maintenance speci-
fications (chapter 20).
4.1
4.1.5 Coolant Level

Fig. 4.1.5/1 to Fig. 4.1.5/3
Maintenance Check
Warning!
Do not remove a pressure cap from a hot engine.
Wait until the coolant temperature is below 50 °C
(122 °F) before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Caution! Fig. 4.1.5/1

Never use a sealing additive to stop leaks in the
cooling system. This can result in cooling system
plugging and inadequate coolant flow, causing the
engine to overheat.
The coolant level must be checked daily.
Caution!
Do not add cold coolant to a hot engine. Engine
castings can be damaged. Allow the engine to cool
to below 50 °C (122 °F) before adding coolant. Fig. 4.1.5/2
Make up coolant added to the engine must be mixed with the correct pro-
portions of antifreeze, supplemental coolant additive, and water to avoid
engine damage.
Coolant recommendations and specification details on correct mixing of

coolant can be found in Maintenance Specifications (Section 22).
Fill the cooling system with coolant to the bottom of the fill neck in the radia-
tor fill or expansion tank.
Fig. 4.1.5/3
4.1.6 Drive Belts

Fig. 4.1.6/1
Maintenance Check
Cogged Belt
Inspect the belts daily. Replace the belts if they are cracked, frayed, or
have chunks of material missing. Small cracks are acceptable.
Adjust the belts that have a glazed or shiny surface, which indicates belt
slippage. Correctly installed and tensioned belts will show even pulley and
belt wear. Fig. 4.1.6/1
Belt damage can be caused by:

• Incorrect tension
• Incorrect size or length
• Pulley misalignment
• Incorrect installation
• Severe operating environment
• Oil or grease on the belts
4.1
4.2 Maintenance Procedures at 250 hours or 3 months

4.2.1 Air Cleaner Restriction
Maintenance Check
Refer to item 6.1of the maintenance instructions.
Caution!
Never operate the engine without an air cleaner.
Intake air must be filtered to prevent dirt and debris
from entering the engine and causing premature
wear.
4.2.2 Charge-Air Cooler

Fig. 4.2.2/1
Maintenance Check
Inspect the charge-air cooler (CAC) for dirt and debris blocking the fins.
Check for cracks, holes, or other damage. If damage is found, refer to the
vehicle, vessel, or equipment manufacturer.
Fig. 4.2.2/1
4.2.3 Charge-Air Piping

Fig. 4.2.3/1
Maintenance Check
Inspect the charge-air piping and hoses for leaks, holes, cracks, or loose
connections. Tighten the hose clamps if necessary.
Fig. 4.2.3/1
4.2.4 Radiator Hoses

Fig. 4.2.4/1
Maintenance Check
Check all hoses for cracks, cuts, or collapsing.
Note: The silicone engine coolant hose will exhibit swelling due to the elas-
ticity of the hose.
Fig. 4.2.4/1
4.2
4.2.5 Air Intake Piping

Fig. 4.2.5/1
Maintenance Check
Visually inspect the intake piping daily for wear points and damage to piping,
loose clamps, or punctures that can damage the engine.
Replace damaged pipes, and tighten loose clamps, as necessary, to pre-

vent the air system from leaking.
Torque Value: 8 Nm [72 in-lb] Fig. 4.2.5/1
Check for corrosion under the clamps and hoses of the intake system pip-
ing. Corrosion can allow corrosive products and dirt to enter the intake sys-
tem. Disassemble and clean, as required.
4.2.6 Fan, Cooling

Fig. 4.2.6/1 to Fig. 4.2.6/3
Inspect for Reuse

Warning!
Do not rotate the engine by pulling or prying on the
fan. The fan blade(s) can be damaged and cause the
fan to fail and cause personal injury or property
damage. Use the accessory drive shaft or the crank-
shaft barring tool to rotate the crankshaft.
Fig. 4.2.6/1
Warning!
Do not straighten a bent fan blade or continue to use
a damaged fan. A bent or damaged fan blade can
fail during operation and cause personal injury or
property damage.
Replace a damaged fan by a new fan with the same part number. Any other
change or modification to the fan requires a prior authorization by the manu-
facturer to be covered by warranty.
The tightening torque for the hexagon bolt is 40 Nm. Fig. 4.2.6/2
Fig. 4.2.6/3
4.2
4.3 Maintenance Procedures at 500 hours or 6 months

4.3.1 Cooling System
Maintenance Check - coolant

Refer to item 22 of the maintenance instructions.
4.3.2 Fuel Filter (Spin-On Type)
Remove
Fig. 4.3.2/1
Remove the spin-on fuel filter with fuel filter wrench.
Fig. 4.3.2/1
Install
Fig. 4.3.2/2
Note: Do not prefill the fuel filter.
Caution!
Do not pre-fill the on-engine fuel filter with fuel. The
system must be primed after the fuel filter is in-
stalled. Pre-filling the fuel filter can result in debris
entering the fuel system and damaging fuel system
components. Fig. 4.3.2/2
Lubricate the o-ring seal with clean lubricating oil.
Caution!
Mechanical overtightening will distort the threads,
filter element seal, or filter can.
Use the correct fuel filter (see spare parts catalogue, page 25.001).
Install the filter on the filter head. Tighten the filter until the gasket contacts
the filter head surface.
After making contact, tighten the fuel filter by another ¾ turn.
Torque Value: 34 Nm [25 ft-lb]
Prime fuel system after fuel filter installation.
Prime
Fig. 4.3.2/3
Warning!
The fuel pump high-pressure fuel lines and fuel rail
contain very high-pressure fuel. Never loosen any
fittings while the engine is running. Personal injury
and property damage can result.
Use the installed filling device to fill the engine. Typically, a priming pump is
installed at or near the prefilter. Use lever movements (hand pump) to fill the Fig. 4.3.2/3
low pressure system.
4.3
Note: It is not necessary to vent air from the high pressure system before
starting the engine.
Note: It is not necessary to pre-fill the on-engine fuel filter.
Operate the engine and check for leaks.
4.3.3 Lubricating Oil and Filters
Drain Fig. 4.3.2/3

Fig. 4.3.3/1 and Fig. 4.3.3/2
Warning!
Some state and federal agencies have determined
that used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
environmental regulations.
Warning!
Fig. 4.3.3/1
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.
Change the lubricating oil and filter(s) at the specified oil change interval.
See the Maintenance Schedule to find the correct change interval for your
application.
Note: The engine requires a tank with a capacity of not less than 18 litres of
lubricating oil.
Operate the engine until the water temperature reaches 60 °C (140 °F).
Fig. 4.3.3/2
Shut off the engine.
Remove the oil drain plug. Drain the oil immediately to be sure all the oil
and suspended contaminants are removed from the engine.
Remove
Fig. 4.3.3/3
Clean the area around the lubricating oil filter head.
Use the oil filter wrench to remove the filter.
Clean the gasket surface of the filter head.
Note: The o-ring can stick on the filter head. Make sure it is removed be-
fore installing the new filter. Fig. 4.3.3/3
4.3
Install
Fig. 4.3.3/4 to Fig. 4.3.3/6
Use the correct oil filter (refer to page 25.001 of the parts manual).
Caution!
The lack of lubrication during the delay until the filter
is pumped full of oil at start- up can damage the
engine.
Note: Do not prefill the oil filter. Fig. 4.3.3/4
Note: Be careful that no debris is poured into the filter. If using an oil supply
with a metallic or plastic seal under the cap, be careful to peel the
seal back. Puncturing the seal with a knife or sharp object can create
debris in the oil container.
Caution!
Mechanical overtightening of filter can distort the
threads or damage the filter element seal.
Den Install the filter on the oil filter head. Tighten the filter until the gasket Fig. 4.3.3/5
contacts the filter head surface.
Tighten ¾ to 1 turn after gasket makes contact with the filter head.
Fig. 4.3.3/6
Fill
Fig. 4.3.3/7
Fill the engine with clean lubricating oil to the proper level (H).
Note: Total system capacity assumes lubricating oil pan plus lubricating oil
filter.
Idle the engine to inspect for leaks at the drain plug and, if replaced, the oil
filter seal.
Fig. 4.3.3/7
Stop the engine, and wait approx. 5 minutes.
Check the level again.
If necessary, top up oil until the top level mark (H) at the dip stick is
reached.
4.3
4.4 Maintenance Procedures at 1000 hours or 1 year

4.4.1 Cooling Fan Belt Tensioner
Fig. 4.4.1/1 to Fig. 4.4.1/5
Maintenance Check
With the engine turned off, check that neither the top nor bottom tensioner
arm stop is touching the cast boss on the tensioner body. If either of the
stops is touching a boss, the alternator belt must be replaced. Check to
make certain the correct belt part number is being used if either condition
exists.
Fig. 4.4.1/1
Warning!
When using a steam cleaner, wear safety glasses or
a face shield, as well as protective clothing. Hot
steam can cause serious personal injury.
Warning!
Wear safety glasses or a face shield, as well as
protective clothing, to prevent personal injury when
using a steam cleaner or high-pressure water.
Fig. 4.4.1/2
Check the tensioner pulley and body for cracks. If any cracks are noticed,
the tensioner must be replaced. Please ask your service representative.
Check the tensioner for dirt buildup. If this condition exists, the tensioner
must be removed and steam cleaned.
With the cooling fan belt removed, check that the bottom tensioner arm stop
is in contact with the bottom tensioner arm stop boss on the tensioner body.
If these two are not touching, the tensioner must be replaced.
Fig. 4.4.1/3
Inspect the tensioner for evidence of the pivoting tensioner arm contacting
the stationary circular base. If there is evidence of these two areas touching,
the pivot tube bushing has failed and the tensioner must be replaced.
Fig. 4.4.1/4
The worn tensioner that has play in it or a belt that “walks” off its pulley
possibly indicates pulley misalignment.
Note: Maximum pulley misalignment is 3 degrees.
This measurement can be taken with a straightedge and an inclinometer.

Install the belt
Fig. 4.4.1/5
4.4
4.4.2 Fan Hub, Belt Driven

Fig. 4.4.2/1 and Fig. 4.4.2/2
Maintenance Check
Remove the drive belt.
Fig. 4.4.2/1
Note: The fan hub must rotate without any wobble or excessive end play.
Fan Hub End Play

mm in
0.15 MAX 0.006
Fig. 4.4.2/2
4.5 Maintenance Procedures at 2000 hours or 2 years

4.5.1 Cooling System
Drain
Fig. 4.5.1/1 to Fig. 4.5.1/3
Warning!
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50 °C
(122 °F) before removing the pressure cap. Heated Fig. 4.5.1/1
coolant spray or steam can cause personal injury.
Warning!
Coolant is toxic. Keep away from children and pets.
If not reused, dispose of in accordance with local
environmental regulations.
Drain the cooling system by opening the drain valve on the radiator and
removing the plug in the bottom of the water inlet. A drain pan with a capac-
ity of 19 liters will be adequate in most applications.
Fig. 4.5.1/2
Check for damaged hoses and loose or damaged hose clamps. Replace as
required. Check the radiator for leaks, damage, and buildup of dirt. Clean
and replace as required.
Fig. 4.5.1/3
4.4
4.5
Flush
Fig. 4.5.1/4 to Fig. 4.5.1/7
Caution!
The system must be filled properly to prevent air
locks. During filling, air must be vented from the
engine coolant passages. Wait 2 to 3 minutes to
allow air to be vented; then add mixture to bring the
level to the top.
Note: Adequate venting is provided for a fill rate of 19 liters/minute. Fig. 4.5.1/4
Caution!
Do not install the radiator cap. The engine is to be
operated without the cap for this process.
Fill the system with a mixture of sodium carbonate and water (or a commer-
cially available equivalent).
Note: Use 0.5 kg of sodium carbonate for every 23 liters of water.
Warning! Fig. 4.5.1/5

Coolant is toxic. Keep away from children and pets.
Dispose of in accordance with local environmental
regulations.
Operate the engine for 5 minutes with the coolant temperature above 80 °C
(176 °F).
Shut the engine off, and drain the cooling system.
Fill the cooling system with good- quality water.

Fig. 4.5.1/6
Note: Be sure to vent the engine for complete filling.
Note: Do not install the radiator cap.
Operate the engine for 5 minutes with the coolant temperature above 80 °C
(176 °F).
Shut the engine off, and drain the cooling system.
Note: If the water being drained is still dirty, the system must be flushed
again until the water is clean. Fig. 4.5.1/7
4.5
Fill
Fig. 4.5.1/8 to Fig. 4.5.1/10
Caution!
The system must be filled properly to prevent air
locks. During filling, air must be vented from the
engine coolant passages. Wait 2 to 3 minutes to
allow air to be vented; then add mixture to bring the
level to the top.
The system has a design fill rate of 19 liters per minute. Fig. 4.5.1/8
Caution!
Never use water alone for coolant. Damage from
corrosion can be the result of using water alone for
coolant.
Use a mixture of 50-percent water and 50-percent ethylene glycol or propyl-

ene glycol antifreeze to fill the cooling system. Refer to the cooling system
specifications in Section 19 for system capacity.
Fig. 4.5.1/9
Install the pressure cap. Operate the engine until it reaches a temperature
of 80 °C (176 °F) and check for coolant leaks.
Check the coolant level again to make certain the system is full of coolant or
that the coolant level has risen to the hot level in the recovery bottle on the
system, if so equipped.
Fig. 4.5.1/10
4.5
5 Cooling system
5.1 Checking the coolant level
Fig. 5.1/1
Put down the engine horizontally, and turn off the engine. Slowly unscrew
and remove the balance tank cover (D).
When the engine is cold, the coolant level should be at the lower end of the
filler neck (water must be always visible). If required, top up coolant mix.
Let the engine run in low idle run for 2-3 minutes, afterwards. The control
valve of the heating and ventilation system must be opened during this
running (adjust to ”hot”). Check the coolant level once more, and add water, Fig. 5.1/1
if required.
Note: The cooling system is filled with a long-term coolant for temperatures
up to -37 °C (-35 °F). It consists of a mixture of water, anti-freeze,
and anti-corrosion agents. The little losses by evaporation can be
balanced with clean, soft water.
Be careful when opening the cover lid (D)!

Danger of burning if the machine is hot!
When the machine is hot, loosen the balance tank cover only to its first
catch, and release the overpressure. Afterwards screw off the cover lid and
take it off.
Check the overpressure and underpressure valve of the cover lid. Replace
any damaged or defective cover.
The cooling system should be checked before the beginning of the cold
season, and should have a frost resistance of up to -37 °C (-35 °F). If lower
temperatures are expected the portion of the anti-freeze has to be in-
creased.
Note: At min. 80 °C (176 °F), the cooling system runs in the small circuit.
The thermostat opening is in an order of 88°C (190°F). The complete
opening is reached at 96 °C (205 °F). The heating system is con-
nected to the small circuit.
5.2 External cleaning of the cooler

Fig. 5.2/1
Open the rear grid designed as a door.

The cooler contaminated on its outside can be cleaned by a water jet or by
compressed air.
The water or are should be sprayed or blown against the blow direction of
the fan through the cooler.
Note: The cleaning with water can only be carried out when the engine has
cooled down. Do not spray against the insulation material.
Fig. 5.2/1
5
5.1
5.2
6 Air filter system

Fig. 6/1 and Fig. 6/2
The air filter is a combined air filter with an integrated filter-element (1) and
a safety cartridge. The rough dust is discharged through the dust discharge
valve (S), almost free of maintenance. The discharge slot of the valve must
be checked for cleanness daily. Remove possible dust accumulations; move
the valve slightly for that purpose. The rubber piece must be always well
seated and lay on the bottom.
6.1 Air filter

Fig. 6.1/1
The more the air filter insert is contaminated the higher becomes the under-
pressure in the suction line. If the extend of the contamination of the air filter
insert becomes so high that the pressure drops below the permissible un- Fig. 6/1
derpressure the warning lamp (2) in the cabin shines, and requests for the
cleaning of the filter insert. To control the underpressure, an underpressure
switch is installed in the suction line. It is adjusted to the permissible limit of
underpressure.
The filter element has be cleaned. However, it has to be replaced not later
than after the 6th cleaning or after 2,000 operating hours, at the latest. The
control light expires to start the engine, after the cleaning of the filter ele-
ment.
Notwithstanding the indication by the control lamps, the filter insert should
be checked for its state from time to time. A damaged or deformed filter
insert must be replaced immediately. The safety filter is replaced after every
3rd cleaning of the filter insert.
The filter element must not be cleaned! Fig. 6/2
The maintenance of the air filter shall only be carried out with the engine
switched off. The functioning of the indicator lamp in the cabin to check the
filter must be checked every day, by operating the control switch (42). When
the switch is operated, the control lamp (2) must shine.
6.1.1 Replacement, removal and insertion of the filter insert

The air filter is opened by a locking system (toggle fasteners A). Remove
the air filter casing component after opening the toggle fasteners.
The filter element (1) and safety cartridge (2) can now be removed, and
cleaned or exchanged.
Check the seal and its seating face in the filter casing. Fig. 6.1/1
Check the seal on the filter cover.
The filter insert and the safety cartridge are fitted in the reverse order to
their disassembly.
6
6.1
6.1.2 Blowing-off the filter insert

Fig. 6/6
The dry cleaning can be carried out with compressed air up to a maximum
pressure of 6 bar (87 Psi).
For this, the air nozzle is moved up and down at a minimum distance of
approx. 3 cm (1.2 in.) from the paper.
Fig. 6/6
The cleaning is made from the inside to the outside.
The cleaning is finished as soon as no dust is discharged any more.
CAUTION! Do not clean the filter insert by hitting it.
6.1.3 Checking the filter insert

Fig. 6/7
The filter paper is checked by a glow bulb which is inserted into the filter
insert. The smallest damage can be seen by a light beam.
If the filter paper or the gasket are damaged the filter insert has to be re-
placed by a new one.
Fig. 6/7
6.1.4 Replacement of the safety cartridge

Fig. 6/8
The safety cartridge is replaced after every 3rd cleaning of the filter insert.
The safety cartridge must not be cleaned!
Note: The filter has to be replaced with the engine being switch off only! A Fig. 6/8
contaminated safety filter indicates a damaged filter insert.
Check the new safety filter (1) for damages by using a lamp.
Check the gasket (2) of the safety filter and its contact surface in the filter
casing.
The installation is carried in reciprocal order.
6.1
7 Powershift transmission
7.1 Gear type 6 WG 160
Fig. 7.1/1 shows the schematic structure of the Ergopower gear.
For all activities at the gears, urgently comply with the prescribed safety regulations acc. to § 6 of
the Regulation on the Prevention of Accidents at Propulsion Units.
For example, the machine must be secured by wedges against rolling away, and articulated vehi-
cles additionally against unintended turning (frame lockage).
At the following operations, the ignition must be switched off and the control unit plug must be pulled off from Electronics:
At any kind of electrical operations on the vehicle.
At welding operations on the vehicle.
At insulation tests on the electrical system.
Installation scheme 6 WG-160

1 = Oil dipstick
2 = Power take-off
3 = Electro hydraulic control
4 = Output
5 = Converter bell
6 = Oil drain
7 = Parking brake
Fig. 7.1/1
Checking the oil level
The oil level check must be carried out as follows:

• Oil level check (weekly)
• At horizontally standing vehicle
Fig. 7.1/2
• Transmission in Neutral position “N”
• In the cold start phase, the engine must be running about 2 - 3 minutes at idling speed, and the marking on the oil
dipstick must then be lying above the cold start mark “COLD MIN” (see Fig. 7.1/2)
• At operating temperature of the transmission (about 80 – 90 °C (176 – 194 °F))
• For diesel engine idle speed.
• Loosen oil dipstick by counterclock rotation, remove and clean it
• Insert oil dipstick slowly into the oil level tube until contacts is obtained, and pull it out again.
• On the oil dipstick, the oil level must be lying in the zone “HOT” (see fig. 7.1/2)
• Insert the oil dipstick again, and tighten it by clockwise rotation.
If the oil level has dropped in operating temperature condition below the “HOT” Zone, it is absolutely necessary to replen-
ish oil according to approved oil grades (refer to item 21). An oil level above the “HOT” marking, is leading to a too high
oil temperature.
7
7.1
Oil change
Oil change and filter replacement interval:

• First oil change after 100 operating hours in application.
• Every further oil change after 1000 operating hours in application, however at least once a year!
• At every oil change, the Fine filter (pressure filter) has to be replaced.
The oil change must be carried out as follows:

• Park the vehicle at a horizontal position, and open the oil drain plug to drain used oil while the gearbox is still at operat-
ing temperature (approx. 50 °C (122 °F). Unscrew the closing screw at the cooler top side to allow the cooler to drain.
• Clean the oil drain plug with magnetic insert and the sealing surface on the housing, and install it along with new O-ring
again.
• Fill in oil (about 34 litres). The indicated value is a guide value. Binding is in any case the marking on the oil dipstick!
• Start the engine - idling speed
• Transmission in Neutral position “N”
• Top up oil up to the marking “COLD - MIN”
• Brake the vehicle, and allow the gearbox to heat up. Turn off the all-wheel drive (front axle), press the foot brake (de-
celerate the vehicle), and change into 6th gear.
• When operating temperature is reached (50 °C (122 °F)), change to all gears.
• On the oil dipstick, the oil level must be lying in the Zone “HOT”
• Insert the oil dipstick again and tighten it by clockwise rotation
At the initial filling of the transmission has to be considered that the oil cooler, the pressure filter as well as the pipes must
get filled with oil. According to these cavities, the oil capacity to be filled in is greater than at the later oil fillings in the
course of the usual maintenance service.
It is imperative to pay attention to absolute cleanliness of oil and filter.

Use approved oil grades only!
At every oil change it will recommend, to start the automatic calibration of the shifting elements (AEB).
Filter replacement
At the replacement of the filter in the main oil stream, pay attention that no dirt or oil sludge can penetrate into the circuit.
Besides, the parking brake has to be covered, resp. protected from oil wetting.
At the mounting of the filter, any exertion of force has to be avoided.
The filter pressure regulating valve (bypass valve) has a filter plugging switch warning the driver when the fine filter is
clogged. The fine filter must be replaced when the error code (BA) lights up in the display.
Replace the filter cartridge with every oil change.
The mounting of the filter must be carried out as follows:

• Do not top up the filter
• Cover the gasket with a small amount of oil.
• Screw the filter in until contact with the sealing surface is obtained and tighten it now by hand about 1/3 to ½ turn.
Handling the filter

Handle the filter with care when mounting, transporting or storing it. Defective filters must not be used!
7.1
Oil temperature
Fig. 7.1/3
The oil temperature in the gearbox sump is monitored by a temperature

sensor in the electrohydraulic controller. An operating temperature of be-
tween 60 and 90 °C (140 - 194 °F) must not be exceeded in the sump. The
gearbox oil temperature icon will light up on the display (D) whenever an
excessive gearbox temperature is reached (see chapter 1.4.6). A higher
temperature will not be reached unless a fault occurs in the machine, or
unless the machine is driven in an inexpert manner.
Whenever an error is displayed (see chapter 1.4), stop the vehicle, check
for any outside oil loss, and have the engine run at a rotational speed of
1200 - 1500 rpm at the neutral gear position.
Fig. 7.1/3
Then, the temperature should fall quickly to normal values (within 2 or 3

minutes, approximately). If a normal temperature is not reached, there is a
fault which needs to be corrected before operations can be resumed.
7.1
8 Battery
Fig. 8/1
Please also observe section 18 on the "Electric System".

The batteries are located at the rear part of the frame, to the left and right of
the frame knuckle joint. There is easy access to the batteries after the fixing
nuts of the protective hood have been loosened and the hood has been
removed.
The batteries are maintenance-free acc. to DIN 43539-5.
Keep batteries clean and dry. Lubricate the clamp terminals with acid-free
grease.
Checking of the acid level

Clean the batteries so that no dirt can reach into the cells after the plugs
Fig. 8/1
have been opened.
The level of the acid shall be at the acid-level mark or 15 mm (0.6 in.)
above the upper edge of the plates.
Use distilled water for topping up. Do not use so-called improving agents.
Checking of the charging state

A fully charged battery has a density of 1.28 kg/l (10.68 lb/USgal) at 20 °C
(68 °F), in tropical regions 1.23 kg/l (10.26 lb/USgal) with pure sulphuric
acid for accumulators (acc. to VDE 0510). An insufficient charging state of
the batteries requires a re-charging, as they do not ensure the starting of
the engine, and can freeze at strong frost. The seating of the pole terminals
must be straight, and they have to be coated with pole grease.
Caution:
Acid! Danger of burning! Danger of explosion! Do not
use a naked flame, generate sparks or smoke in the
near of it!
Do not place conducting items (tools) on the batter-
ies.
Be sure to set the master switch to "Off" before start-

ing any welding work.
Pull off the plug from the microcontroller (front axle) and from the power
shift transmission control unit.
The plugs are located in the dashboard inside the driver's cab.
Pull off all contacts from the generator. During reinstallation, be sure to use
the correct connection sequence.
8
9 Rear axle
Do not connect the (-) pole to the rear axle during any welding work carried
out on the machine.
No welding is allowed at the rear axle!
9.1 Oil level checks

Checking the oil level in the axle transmission
Fig. 9/1
Park the machine in a horizontal position. Stop the engine. Slowly unscrew
the checking screw (K).
The oil level should be at the bottom rim of the inspection hole. Top up oil if
required.
Fig. 9/1
Checking the oil level in the tandems

Fig. 9/2
The oil level is shown at the inspection hole (K). The oil level should fill half
the inspection hole. Top up oil if required.
Fig. 9/2
Checking the oil level in the wheel hubs (planetary gear set)
Fig. 9/3
Move the machine such that the wheel hub to a be checked is in a position
where the closing screw (K) is horizontal. The oil level should be at the
bottom rim of the borehole. Top up oil if required.
Fig. 9/3
9
9.1
9.2 Oil change at the rear axle

Always change the oil while it is warm. To do so, park the machine at a
horizontal position. Do not allow any oil to drain into the soil. Always use
containers to catch all oil. Replace the drain plug seal rings for every oil
change.
Oil entering the soil will destroy human habitat.
Axle transmission oil change

Fig. 9/4
Fig. 9/4 and Fig. 9.2/1
Unscrew drain plug (A) and fill plug (E), and drain oil to a container. Close
the drain plug (A), and fill in oil. Check the oil level, and close the oil plug.
Greasing the ball slewing ring

Reminder: The ball slewing ring has 2 separate chambers for lubrication.
Chamber 1 is a ball track, and chamber 2 is the antechamber
with a protective grease fill.
The ball track (chamber 1) is already filled with grease. This is a so called Fig. 9.2/1
"lifetime" grease fill, and does not need to be refilled.
The antechamber (chamber 2) must be regreased periodically using stan-
dard grease.
• Clean the areas around grease fitting (n° 90) and discharge screws (n° 92)
4x per ball slewing ring, and remove the black closing plugs.
• Open the closing screw n° II, and fill in grease through grease fitting (I)
using a hand grease gun until grease comes out by about an inch at the
closing screw (II).
• Then open the closing screw (IV), and fill in grease through grease fitting
(III) using a hand grease gun until grease comes out by about an inch at
the closing screw (IV).
• Close the opening again with closing screw and closing plug.
Plug
chamber 1
chamber 2
plug
Fig. 9/5 Fig. 9/6
9.2
Tandem oil change

Unscrew the oil filler hole (E) cover, and unscrew the two oil drain plugs (A).
Drain oil into a container. Close the drain plugs (A), and fill in oil until the
level fills half the inspection hole (Fig. 9/2). Close the fill hole.
Fig. 9/7
Fig. 9/8
Wheel hub oil change (planetary gear set)

Fig. 9/3, Fig. 9/9 and Fig. 9/10
To drain oil, park the machine such that the oil drain plug (A) of the corre-
sponding wheel is at the lowest position. Unscrew the drain plugs (A) and
(B). Drain oil into a container. Close the drain ports (A) and (B). The torque
used to tighten the drain plugs (A) and (B) is 45+5 Nm.
Fig. 9/9
Fig. 9/10
9.2
Oil drain plug (A) is checking screw (K).

To top up oil, park the machine to have the checking screw (K) in a horizon-
tal position.
Unscrew oil plug (E) and checking screw (K).
Fill oil into the fill hole (E) until the oil level reaches the bottom edge of the
checking screw (K).
Close oil plug (E) and checking screw (K) (use a torque of 45+5 Nm).
Clean the area around the closing screws before

unscrewing these screws.
9.4 Drive shafts
The drive unit must be in its rest position before working on the drive
shaft(s). Stop the engine, block the grader to prevent it from rolling away, Fig. 9/3
and prevent any restart of the drive unit by unauthorized third persons.
Lubricate the joints as per lubrication chart during both installation and ser-
vicing. Relubrication is sufficient when fresh grease is flowing out at the
gaskets.
Use only lithium soap grease of consistency grade 2 without MoS2 additives
for relubricating the drive shafts.
The sliding sections should only be greased during installation. No further

lubrication is needed after this.
Do not relubricate the sliding section unless the sliding section is pushed
together!
Fig. 9/9
Clean every grease fitting before greasing, and apply grease slowly using a
grease gun.
When greasing, check the tight fit of screws and connecting flanges.
Drive shaft between engine and Ergopower transmission

Fig. 9.4/1
- 2 greasing points -
Drive shaft between powershift transmission and rear axle differential
Lubrication is as for the drive shaft between engine and powershift trans-
mission.
Fig. 9.4/1
- 2 greasing points -
9.2
9.4
10 Front axle (not driven)

Fig. 10/1
The following points are to be greased at the intervals shown in the maintenance plan:
King pins (1) - 4 lubrication points
Axle (2) - 2 lubrication points
Tipping cylinder (3) - 2 lubrication points
Axles (4) - 4 lubrication points
Clean the lubricating nipple thoroughly before regreasing.
Wheel bearings
The grease level in the grease compartment of the wheel bearing must be checked after the number of operating hours
shown in the maintenance plan, but in any case at least every two years. The covers must be unscrewed to do this. The
grease compartment must be about 2/3 full with grease. The grease must be topped up as and when necessary.
When checking the grease fill in the wheel bearings, you should also check the wheel bearing clearance (tapered roller
bearing), and readjust this clearance as follows. Tighten the tapered roller bearings with the slotted round nut against one
another until no further rotation by hand is possible. Turn back the slotted round nut until the hub can be rotated freely
(approx. 1/12 turn), and lock using a tab washer. Lock using both the 2nd slotted round nut and Loctite 648. Check
whether the hub runs without stoppage and without tilting clearance.
The wheel bearing must be readjusted when the front axle is lifted, i.e. when the wheels do not touch the ground.
lubrication point (1)
Fig. 10/1
10
11 Braking system
Fig. 11/1
The diagram of the operating brake system is shown in fig. 11/1. There is no specific maintenance obligation for the brak-
ing system.
Keep the whole system clean, and check it for leaks in compliance with the inspection schedule.
Four measuring points are provided for check

measurements:
M1 = Storage pressure
M3 = Service brake pressure
M4 = Service brake pressure
M5 = Parking brake release pressure
Location of measuring points:

M1 = Right-hand control block output
M3 = Right-hand inside rear frame part
(in the tandem rocker area)
M4 = Right-hand inside rear frame part
(in the tandem rocker area)
M5 = Cab floor at the accumulator; connection
BR3
Measured values: rear

M1 = Filled accumulators 24 bars
during storage loading (short time)
123 - 150 bar
M3 = 90 - 5 bar front fuel tank
M4 = 90 - 5 bar Fig. 11/1
M5 = 123 - 150 bar
The complete brake valve will need to be changed when a fault occurs in the brake system.
The repair or modification of braking valves by unauthorised personnel is not permitted.
Irrespective of the brake pressure, priority is given to a pressure setting which achieves the specified deceleration rate of
at least 5m/s².
Caution!
Maintenance and repair activities at the braking system shall be carried out by a specialist only, the
safety regulations must be complied with.
The tanks of the braking system are exposed to high pressure.
Before lines are disconnected or before any other work at the hydraulic brake, the pressure in the
pedal braking system must be reduced by pressing the brake pedal for 15 times, at least, with the
engine turned off.
11
11.1 Parking brake
The parking brake is maintenance-free. It has to be checked for the wear of the brake lining in accordance with the main-
tenance and inspection schedule. The brake needs to be adjusted when the air gap is greater than 1.5 mm. Replace the
brake lining if no further adjustment is possible.
11.1.1 Clearance adjusting

Fig. 11.1.1/1
1. Insert a setting gauge on both sides between the brake lining carrier and brake disc and hold them in position.
Note! The thickness of the setting gauge must be adjusted to the desired air gap.
Clearance in mm Setting gauge in

mm
min. 0,5 0,25
Nominal clearance 1,0 0,50
max. 1,5 0,75
2. Turn the adjusting screw (2) in a clockwise direction until the two setting gauges are clamped between the brake lining
carriers and the brake disc.
3. Hold the adjusting screw (2) in position and lock using the locknut (1).
Caution!
The application pressure for clamping the setting gauges must be selected so that both gauges can
be removed using a small amount of force after locking in position.
4. Release the locknut (4) and then turn the setting screw (3) in a clockwise direction until the end surface of the setting
screw (3) is in contact with the surface provided for setting.
5. Hold the setting screw (3) in position and lock using the locknut (4).
6. Remove the setting gauges from both sides of the brake disc.
Note! The fitting procedure for the brake and the setting of the desired air gap is now complete. The brake is ready for
use.
7. Turn the screw cap (5) in a clockwise direction and tighten hand-tight.
Note! The brake should be actuated and released several times to check that it is functioning properly.
1 Locknut (SW 24)

2 Setting screw (SW 8)
3 Adjusting screw (SW 6)
4 Counter nut (SW 13)
5 Screw cap
6 Pressure bolt
7 Guiding bolt
8 Bleeding screw (SW 11)
9 Piston
Fig. 11.1.1/1
11.1
11.2 Bleeding the brake

Fig. 11.2/1
Start bleeding at the left rear brake of the tandem axle. Continue with the right rear brake,
then the left front brake and finally the right front brake.
Push a tube onto the nipple (N) beside the pipe connection and dip the tube into a container
which is filled to half its capacity with hydraulic oil (see the consumable and lubricant table).
Unscrew the breather plug, actuate the brake pedal and hold it in this position until the plug
has been screwed in again. Continue the process until no air bubbles can be seen any more
in the container. Two persons are required to bleed the brake.
Attention!
The braking system is a high-pressure system! Fig. 11.2/1
11.2
11.3 Servicing the wheel brake
The wet multidisk brakes installed in the wheel hubs are almost free of wear, and require no maintenance apart from the
checking of the different wheel brakes.
However you should take the following facts into due consideration:
1. If the checking of the oil level at the wheel hub indicates a possibly rising oil level, this is caused by a leak of the hy-
draulically operated multidisk brake.
2. Unusual sounds in the wheel hubs during braking indicate possibly damaged brake disks.
In these cases, consult the after-sales service facilities.
Check wear on multi-plates

Fig. 11.3/1
• Turn the wheel hub so that the aperture of the residual oil drain plug (52) comes to a standstill in the top half (above the
oil level)
• Bring the multi-plate block into the braked state and check in the braked position.
• Remove the residual oil drain plug (52).
• Measure from the flat surface for the seal of the screw-plug (52 to the test lug of the third outer multi-plate with the
caliper gauge. (Specified dimensions for new multi-plates 45,7 ± 0.55 mm)
(Intervention dimensions for worn multi-plates 43 - 0.5 mm)
The replacement of multiple braking disks shall be carried out by authorised personnel.
De-airing the braking system afterwards, and carry out braking tests.
Check multi-plate wear:

Check in braked state
New multi-plates =±45,7

Worn multi-plates =43-0,5
Fig. 11.3/1
11.3
11.4 Emergency release of the parking brake

Fig. 11.4/1
In the event of a failure in pressure supply the parking brake can be released mechanically in the following way:
1. Secure the vehicle against rolling away.

2. Rotate the screw cap in a counter-clockwise direction and unscrew it.
3. Release the locknut (1) and unscrew it back to the end of the setting screw (2).
4. Rotate the setting screw (2) in a clockwise direction until the brake disc is completely free.
For emergency release a torque of min. 70 Nm is required on the setting screw (2)!
5. Screw on the locknut (1) up to contact with the piston and apply a slight locking force to the setting screw (2).
6. Screw on the screw cap in a clockwise direction by a few threads. (dirt ingress protection)
In this condition the vehicle has no parking brake facility and thus must be protected from rolling
away by different means. The brake must be adjusted before re-commissioning.
1 Locknut (SW 24)

2 Setting screw (SW 8)
S Peg spanner
G Ring spanner
Fig. 11.4/1
11.4
12 Moldboard assembly
All sliding points and joints of the moldboard assembly shall always be well
lubricated. Lubricate whenever necessary.
Before lubricating, clean the nipples and sliding faces to be greased carefully.
Lubricate until grease emerges from the gap points.
12.1 Lubricating the moldboard assembly

Fig. 12.1/1
Press grease into the nipples for the swing bearings of the lifting and swivelling
cylinders in the forks, the fork
Fig. 12.1/1
bearings in the bridge, the piston rod heads of the hydraulic cylinders, and the
sliding face of the swivel bridge.
- 13 lubricating nipples -
Fig. 12.1/2
Lubricate the ball of the drawbar of the moldboard assembly.
Fig. 12.1/2
Fig. 12.1/3
Grease the blade tilt cylinder bearing through the grease fittings.
Fig. 12.1/3
12
12.1
12.2 Greasing the blade system (guided in babbitt bearings)

Fig. 12.2/1 and Fig. 12.2/2
Apply lubricating grease to the sliding surfaces at the slewing ring top
and bottom sides, to the ring's gear teeth, and to the blade guide rails.
Clean the sliding surface before greasing.
Basically, you should grease the front of the

crowd management, environmental conditions
must be observed!
For example, when using the grader on a sandy
bottom, the grease is not recommended.
Fig. 12.2/1
12.3 Readjusting the blade guide
Fig. 12.3/1
The blade is guided by guide supports (1) using top (2) and bottom (3)
holders. Wear plates (4) are located in the holders. Replace them if they
are worn out.
Horizontal readjustment of the moldboard guide

Unscrew the locking screws (5) and the check nuts of the adjusting
screws (6). Use the adjusting screws (6) to pull back the fastening (2,
3), and minimize the clearance (approx. 1 mm) until the blade slides
without jamming. Tighten the locking screws (5), and lock the adjusting
screw (6).
Vertical readjustment of the moldboard guide Fig. 12.2/2

Use shims B1 to B4 in the fastenings (2, 3) to compensate any vertical
clearance.
Proceed as follows to compensate the vertical clearance:
If readjustment is required, remove the number of shims B1 to B4 from
the top fastenings as required to compensate the backlash. Place the
shims in the fastenings at the top, and secure them with the locking
screws (5).
Do not throw away the shims. They will be

needed for further readjustments.
If all shims are used up, the wear angles (4 - Figure 12.3/1) must be
replaced.
Note: Wear plates will not be worn out evenly because the fastenings
are subjected to different loads. To achieve roughly equal wear,
measure wear plate thickness after every third readjustment, and Fig. 12.3/1
change the wear plates, placing thicker wear plates in the hold-
ers of thinner wear plates.
Before replacing wear plates, support the blade on a piece of
squared timber in order to relieve the load from the guide.
12.2
12.3
12.4 Slewing ring readjustment (guided in babbitt bearings)

Fig. 12.4/1 to Fig. 12.4/3
The slewing ring (D) bottom side slides on 4 pads (P), and the slewing
ring top side slides against set-on slide segments (G) of the draw beam.
The pads (P) can be adjusted both horizontally and vertically.
Horizontal readjustment, circle centring

Loosen the lock nut (3) of the adjusting screw (1). Slacken the holding
screw (4). Use screw (1) to shift claw (P) toward the external diameter
until the air gap to the contact point lies between 0.5 and about 1.5 mm.
In the readjustment process, it is advisable to clamp sheet metal strips Fig. 12.4/1
(thickness: 1.5 mm, i.e. like the air gap; 2 strips are needed for each
claw) as spacers between the circle and claw.
When all claws are adjusted, tighten the holding screws (4). Then tighten
the adjusting screws (1) and lock them with the nuts (3).
Remove the spacers.
The distance of the claw from the circle diameter

shall be equal around the entire circumference,
i.e. the claw must not be canted.
Check that the teeth mesh easily round the

complete circumference.
The teeth of the pinion must not touch the
Fig. 12.4/2
bottom part of the slewing rim (H).
Vertical readjustment of the circle

The vertical readjustment of the circle should always be followed by a
horizontal readjustment. Put the moldboard on the ground. Loosen the
adjusting screw (1) and the holding screws (4) of the first claw (P). Take
out spacer 2. Screw-fasten the claw again. Proceed in the same way
with the other claws. Then adjust the circle horizontally as described
above.
Note: Adjust the circle when the drawbar is in horizontal position. Clean
the sliding faces before adjustment. Regrease the sliding faces af-
ter the readjustment and make a test run. With the drawbar in Fig. 12.4/3
horizontal position and correct adjustment, the hydraulic pressure
required to turn the circle is approx. 6 MPa (870 psi).
12.5 Circle drive

Oil level check, oil change
Fig. 12.5/1
Unscrew the control plug (K).

The oil level should be at the lower edge of the control bore.
Top up oil if needed.
To change the oil, drain the old oil by opening the drain bore (A). Fill the
drive with new oil through the filler neck (K).
Fig. 12.5/1
12.4
12.5
13 Hydraulic working system
The line scheme of the hydraulic working, braking, and steering systems is
shown in the line diagram.
The pressure is checked at the measuring point M1. The measuring point is
located at the control block.
13.1 Checking the oil level

Fig. 13.2/1
Place the machine horizontally. All operate cylinder bring in. Have the en-
gine operate in idle run.
With cold oil, and the engine in idle run, the oil level shall fill the oil-level
eye. The dipstick is accessible from the left engine compartment.
13.2 Refilling with oil

Fig. 13.2/1
Switch off the engine. Clean the cover area. Oil is topped up through the
return filter (F). To do so, remove the screw from the cover of the return
filter (F), and top up oil through the bore.
Put on the cover again, and screw in the screw plug.
Ensure that the correct type of oil is used. Do not

Fig. 13.2/1
remove the filter cartridge when filling up with oil.
13.3 Changing the oil

Fig. 13.3/1
Place the machine horizontally. Move all working devices into their highest
position, i.e. all cylinders are drawn in.
Discharge the oil in hot state. Before that, screw off the oil dip-stick. Con-
sider the note above!
The tank which is located below the Diesel engine, is equipped with a drain
plug (A) having a self-closing valve so that no oil leaks into the environ-
ment. Screw on the oil drain hose. Collect the drained oil in a container
(analogous procedure as for the exchange of engine oil with the same facil-
ity).
Close the drain facilities after the drainage of the oil again.
Fill in oil according to chapters 13.1 and 13.2.
Start the engine. Carry out all cylinder movements. Check the oil level once Fig. 13.3/1
more, and refill if required (sections 13. and 13.2).
Only use prescribed hydraulic-oil brands. See table

”Fuels and lubricants”
Ensure that the correct type of oil is used.
13
13.1
13.2
13.3
13.4 Replacement of the hydraulic filter
Stop the diesel engine before starting maintenance

work, or before a filter change.
13.4.1 Replacement of the filter cartridge of the backflow filter

Fig. 13.4/1 and Fig. 13.4.1/1
When the control lamp (3A) indicates that the filter is

contaminated the filter element must be urgently
replaced.
Make sure during the replacement of the filter element that no contamina-
tion can reach into the opened filter or tank during assembly. Fig. 13.4/1
Take off the filter cover of the filter (fig. 13.4.1/1) after the fixing nuts have
been screws off.
1. Take out the pressure spring together with the complete set of inserts.
2. Screw off the bypass spring package (1), and take the filter element (2)
from the support (3).
3. Clean the magnet column (4).
4. Mount the new filter element.
5. The assembly is carried out in reciprocal order
6. Turn the bypass spring package to the stop so that the prescribed bypass
opening pressure is adjusted.
Check the gaskets and O-rings for damages.

Care for an even seating of the filter element at the
support.
Carefully install the complete set of inserts into the
tank so that the gasket of the support is not dam-
aged.
Fig. 13.4.1/1
13.4.2 High-pressure filter cleaning

Fig. 13.4.2/1
The filter (1) belongs to the steering system. Clean this filter as specified in
the maintenance and inspection schedule. Unscrew the filter pot (T) and
replace the filter cartridge. Before unscrewing the pot, again clean the parts
in its vicinity. After changing the filter, screw the filter pot back on tightly, and
then unscrew it 1/16th of a turn.
Do not damage the gaskets. Make a trial run and

brake and steering test after any work on the braking
and steering system.
Fig. 13.4.2/1
13.4
13.4.2.1 Replace the filter cartridge of the high-pressure filter

Fig. 13.4/1 and Fig. 13.4.2.1/1
When the control lamp (3B) indicates that the filter is

contaminated the filter element must be urgently
replaced.
Disassemble and replace the filter element (6) as follows:

1. Unscrew the filter bowl (5) from the filter head (2). Use a spanner with 30
mm width across flats, and apply it to the hexagon at the bowl bottom. To
unscrew, turn counterclockwise (as seen from below). It is important to
ensure that not load is applied to the bowl from the sides during unscrew-
ing. Fig. 13.4/1
2. Remove and dispose of the filter element (6). The filter element cannot be
cleaned.
3. Inspect filter head (2) and bypass valve (3) for any possible damage or
malfunction. Replace any damaged parts. Clean any accumulated dirt,
and make certain that no dirt reaches the filter's clean side through the
outlet. Do not start the system unless a filter element is installed.
Inspect the O-ring (4) in the filter bowl (5) for damages. Use a filter ele-
ment (6) with a designation as indicated on the type plate.
4. Wetten the O-ring (4) in the element using clean system fluid, slide the
element (6) with the open end straight onto the nipple in the filter head (2).
Apply a slight amount of clean system fluid to wetten the filter bowl (5)
thread, and use a torque spanner to tighten the bowl to a torque of 100
Nm at the hexagon.
Do not overtighten the bowl as this will not improve the ring’s sealing ef-
fect.
Fig. 13.4.2.1/1
13.4
13.5 Equipment list for the working hydraulics circuit diagram
Circuit diagram No.: 4240461
Status: 09/2007
Pos. Description Part NO. additional information QTY.
1 axial piston pump 5050104 1
2 gear pump 5060004 for steering, feeding, cross scavenging 1
3 way valve block 5067790 1
4 control block 9347068 1
5 compact brake valve 989341156 LT13 1
5.1 pressure switch 9442226 5 bar 1
5.2 pressure switch 9442256 100 bar 1
6 hydraulic accumulator 437706007 1,0 l 4
7 double load lock valve 5067797 1
8 steering aggregate 5070014 1
9 lowering brake valve 506779508 5
10 high pressure filter 5074200051 for steering, feeding, cross scavenging 2
10.1 indication to contaminate 9432502191 2
11 return line filter 507418005 for working hydraulic 1
507418010
11.1 pressure switch oder 1,2 bar 1
943250219
12 breather filter 480502007 1
13 oil cooler 487510005 1
14 temperaturcontroller 6380060011 1
15 membrane accumulator 9306167 1
13.5
13.6 Equipment list for the drive hydraulics circuit diagram
Circuit diagram No.: 4240459
Status: 09/2007
Pos. Description Part NO. additional information QTY.
2 wheel hub motor 9303127 counter-clockwise rotation 1
3 wheel hub motor 9303126 clockwise rotation 1
standby pressure: 24 bar

working pressure: 240 bar
5 valve block 5070002 1
6 pressure sensor 5074160 2
7 gear pump 5060006 for steering, feeding, controlling 1
8 temperaturcontroller 6380060011 1
9 oil-air cooler 9345017 1
10 high pressure filter 5074200051 for steering, feeding, controlling 2
11 brake valve 989341156 LT13 1
12 steering aggregate 5070014 1
13 hydraulic accumulator 1,0 l 1
13.6
Key to symbols
Identifier on components
y13 (MY) Flows: oil leak at : Driving forwards
At pos. 2 and 3 At pos. 5

A Feed AL Feed left engine B; A from pump P1
R Return AR Feed right engine PS from P4 (control / feed)
Y 2. Cubic capacity RL Return left engine T Return pos. 5 to tank
1 Leakage-fuel connection RR Return right engine T1; T2 Leakage oil pos. 2 and 3
13.6
Maintenance instructions 14/15/16
14 Articulated frame joint and articulated steering cylinder

Fig. 14/1
The articulated joint and the cylinder bearings have to be regularly lubri-
cated in accordance with the inspection schedule.
- 6 lubrication points -
Thoroughly clean the grease nipples before the grease gun is attached.
After a long-time operation with the articulated steering locked, the borings
of the supporting fish-plate (H) may be widened. If the deviation from the
nominal boring is > 3 mm the supporting fish-plate has to be replaced.
Fig. 14/1
15 Lubrication of the grading plate

Fig. 15/1
Suspension of the hydraulic cylinder

Piston rod end of the hydraulic cylinder
Fig. 15/1
16 Rear Ripper
Fig. 16/1
Heads of the piston rods of the right and left cylinders.
Fig. 16/1
14
15
16
17 Changing the tyres
The wheels must be removed from the machine in order to change the tyres. To do this, the machine must be raised so
that the relevant wheel is clear of the ground. Loosen the wheel nuts one or two turns before lifting the grader. The grader
can be lifted on one side with the aid of the hydraulics.
To change the rear wheels, set the tip of the blade down on the ground in front of the rear wheel on the side to be lifted,
and lift the grader up with the lifting cylinder until the wheels are clear of the ground. The front wheels can be raised with
the levelling blade or with the blade, the end of which is then placed on the ground behind the front wheel that is to be
raised.
Never have the machine supported by the hydraulic system during the replacement of tyres. Sup-
port the machine by solid backings.
Unscrew the wheel nuts in crosswise order, and lift off the wheel.
Take care not to damage the threads of the wheel bolts when removing or changing the wheels.
Discharge the air from the tyre completely. Only after the air has been discharged completely the tyre may be disassem-
bled. The tyres have to be levered out of the rim well.
Tyres should only be replaced in workshops specifically equipped for this purpose.
After the tyre has been attached to the rim pump in air to the prescribed pressure.
Table of air pressure:
Tyres - type 17,5-25 14.00-24 17,5 R25

Front wheels 2,5 bar 2,75 bar 3,0 bar
Rear wheels 2,5 bar 2,75 bar 3,0 bar
Screw the complete wheel to the machine.

Tightening torque for wheel nuts: 500 Nm - 550 Nm.
Tighten the wheel nuts in crosswise order.
Check the wheel nut for their straight seat after 5 operating hours, and retighten them if required.
Afterwards do this in compliance with the "Maintenance and inspection schedule", chapter 25.
The retightening is necessary as the bolts and nuts need some time for setting.
Use a torque wrench to tighten, check, and retighten wheel nuts. The tightening torque applies to
metallic-bright threads (black or phosphated). The thread must not be oiled.
17
18 Electrical system
18.1 Electrical system on the machine
Before you start any work at the electrical system of the machine, put the system out of operation. For this purpose, dis-
connect the negative and afterwards the positive cables from the battery. When you reattach the cables, start with the
positive cable and then fix the negative cable.
Do not start the engine if the batteries are not properly connected to the machine’s system.
Never disconnect the batteries, and never turn off the master switch when the engine is running.
The non-compliance with the above rules will lead to destruction of electrical and electronic components.
During each maintenance work, urgently check the cables for loose or contaminated contacts, for damages of the insula-
tion or cable breaks.
Before the beginning of possible required welding activities at the machine urgently disconnect the dynamo.
Do not mix up the polarity of the auxiliary batteries in case of an external start.
Fuse allocation
Fig. 18.1/1
F2.8 fuse 5 A (58) F1.8 fuse 15 A (30)

park light, right working head lamps
F2.7 fuse 5 A (58) F1.7 fuse 7,5 A (30)

park light, left, horn, internal lamp, rotating
instrument lighting flashing beacon, stop light,
flash light, socket, indicating
F2.6 fuse 5 A (56b) instrument
dipped light, right
F1.6 fuse 7,5 A (30)
F2.5 fuse 5 A (56b) warning flasher device
dipped light, left
F1.5 fuse 7,5 A (30)
F2.4 fuse 5 A (56a) power shift gear, engine-
distance light, right control
F2.3 fuse 5 A (56a) F1.4 fuse 5 A (15)

distance light, left control lamps, indicating
instr., locking slide
F2.2 fuse 15 A (15)
front-drive control F1.3 fuse 15 A (15)
cabin heating
F2.1 fuse 5 A (15)
Reserve F1.2 fuse 7,5 A (15)
windscreen wiper, direction
Fig. 18.1/1 ind. lamps
F1.1 fuse 7,5 A (15)

power shift gear
Flat plug fuses are used which can be reached after the cover of the fuse box has been removed.
18
18.1
18.2 Electrical symbols
A1 Microcontroller SC-EASY Microcontroller SD-EASY

A3 Diagnosestecker Vorderachse Diagnose plug front axle
A4 Getriebe 6 WG 160 Transmission 6 WG 160
A5 Stecker Motorsteuerung Plug motor control
A6 Fußgas Foot gas
A7 Handgas Hand gas
A8 Stecker Motorsteuerung Plug motor control
A9 Diagnosestecker Motor Diagnose plug engine
A10 Schaltautomatik Hauptschalter Main switch for automatic switching
B1.1 Horn Horn

B2 Druckschalter Bremsfehler Push button switch brake error
B3 Druckschalter Parkbremse Push button switch parking brake
B4 Druckschalter Stopplicht Push button switch stop light
B6 Druckschalter Luftfilter Push button switch Air Cleaner
B8.1 Druckschalter Rücklauffilter Push button switch reflux filter
B8.2 Druckschalter Druckfilter Push button switch pressure filter
B8.3 Druckschalter Druckfilter Push button switch pressure filter
B11 Temperatur Geber Hydrauliköl Temperature transmitter coolant
B13 Füllstand Kühlmittel Cooling fluid level
B14 Dieseltankgeber Diesel tank giver
B21 Drucksensor Vorderachse vorwärts Pressure sensor front axle forward
B22 Drucksensor Vorderachse rückwärts Pressure sensor front axle backward
B23 Wegsensor Pumpe Proximity sensor pump
E1 Arbeitsscheinwerfer, vorn links Work slip thrower in front left

E2 Arbeitsscheinwerfer, vorn rechts Work slip thrower in front right
E3.1 Arbeitsscheinwerfer, hinten links Work slip thrower at the rear left
E3.2 Arbeitsscheinwerfer, hinten rechts Work slip thrower at the rear right
E4 Rückfahrscheinwerfer Back-up light
E5 Fernlicht links High beam left
E6 Abblendlicht links Headlight low beam left
E7 Standlicht links Parking light left
E8 Fernlicht rechts High beam right
E9 Abblendlicht rechts Headlight low beam right
E10 Standlicht rechts Parking light right
E11 Blinklicht, vorn links Signal light in front left
E12 Blinklicht, vorn rechts Signal light in front right
E13 Blinklicht, Mitte links Signal light center left
18.2
E14 Blinklicht, Mitte rechts Signal light center right

E15 Begrenzungslicht, vorn links Boundary light in front left
E16 Begrenzungslicht, vorn rechts Boundary light in front right
E17 Schlusslicht, hinten links Tail light at the rear left
E18 Stopplicht, hinten links Stop light at the rear left
E19 Blinklicht, hinten links Signal light at the rear left
E20 Schlusslicht, hinten rechts Tail light at the rear right
E21 Stopplicht, hinten rechts Stop light at the rear right
E22 Blinklicht, hinten rechts Signal light at the rear right
E25 Rundumkennleuchte Rotary beacon
E26 Kabinenbeleuchtung Passenger lighting
E29 Umrissleuchte, links Outlining light left
E30 Umrissleuchte, rechts Outlining light right
E31 Arbeitsscheinwerfer, vorn oben Work slip thrower in front above
E32 Arbeitsscheinwerfer, vorn oben Work slip thrower in front above
E35 Nummernschildbeleuchtung, links Licence plate light left
E36 Nummernschildbeleuchtung, rechts Licence plate light right
G1 Drehstromlichtmaschine Three-phase generator

G2/G3 Batterie Battery
H1 Kontrollleuchte Blinker Control light turn signal

H2 Kontrollleuchte Fernlicht Control light high beam
H3 Kontrollleuchte Batterieladung Control light battery charge
H4 Kontrollleuchte Bremsfehler Control light brake error
H5 Kontrollleuchte Parkbremse Control light parking brake
H6 Kontrollleuchte Luftfilter Control light air cleaner
H9.1 Kontrollleuchte Rücklauffilter Control light reflux filter
H9.2 Kontrollleuchte Druckfilter Control light pressure filter
H10 Kontrollleuchte Motorfehler Control light engine error
H11 Kontrollleuchte Motordiagnose Control light engine diagnosis
K1 Anlassrelais Starting relay

K2 Relais Anlasssperre Relay starter barrier
K4 Relais Arbeitsscheinwerfer vorn Relay work slip thrower in front
K5 Relais Arbeitsscheinwerfer hinten Relay work slip thrower at the back
K6 Relais Standlicht Relay parking light
K7 Relais Rückfahrscheinwerfer Relay back-up light
K8 Relais Riegelsteuerung Relay latch plate price increase
K11 Relais Handbremse Relay hand brake
18.2
K12 Relais Sperre 6. Gang Relay barrier 6. course

K16 Relais Vorwärmung Relay preliminary heating
K20 Relais Vorderachse zuschalten Switch relay front axle
K21 Relais Motor Vg halbe Relay engine Vg half
K22 Relais Differentialsperre Vorderachse Relay differential lock front axle
K23 Relais VA aktive Relay front axle active
K24 Relais Fußbremse Relay service brake
M1 Anlasser Starter
M2 Heizungsmotor Heater engine
M4 Frontscheibenwischermotor Windshield wiper engine
M5 Scheibenwaschpumpe Disk washer pump
M6 Heckscheibenwischermotor Rear windshield wiper engine
M7 Wischer unten links Wiper down left
M8 Wischer unten rechts Wiper down right
P5 Boardcomputer MERLIN On-board computer MERLIN

P6 Fahrtenschreiber Travel writer
R1 Vorwärmung Preliminary heating

R10 Potentiometer Zugkraft Vorderachse Potentiometer traction power front axle
S1 Zündschloss Starter lock

S2 Lichtdrehschalter Light spindle switch
S3 Schalter Scheibenwischer Switch windshield wiper
S4 Impulsgeber Pulse generator
S5 Schalter Scheibenwischer, hinten Switch windshield wiper at the back
S6 Warnblinkschalter Warning light switch
S7 Blinkgeber Flasher
S8 Kombischalter Lenksäule Combination switch steering column
S10 Schalter Rundumkennleuchte Switch rotary beacon
S11 Schalter Leuchtentest Switch light test
S12.1 Schalter Arbeitsscheinwerfer, vorn Switch work slip thrower in front
S12.2 Schalter Arbeitsscheinwerfer, hinten Switch work slip thrower at the back
S15 Schalter Waschanlage Switch washing plant
S18 Schalter Riegel Drehbrücke Switch latch plate swing bridge
S27 Schalter Allrad Switch all wheel
S31 Schalter Notfahrbetrieb (Option) Switch emergency driving (option)
S32 Schalter Arbeitsscheinwerfer, oben Switch work slip thrower above
S33 Hauptschalter Main switch
18.2
S35 Schalter Wischer unten links Switch wiper down left

S36 Schalter Wischer unten rechts Switch wiper down right
S37 Schalter Differentialsprerre Switch differential lock
S40 Schalter Parkbremse Switch parking brake
S41 Batterie-Trennschalter Battery disconnector
V1 Diodenblock Leuchtentest Diode block light test
X Steckverbinder Plug connector
Y4 Magnetventil Parkbremse Single solenoid valve parking brake

Y6 Magnetventil Riegel Single solenoid valve latch plate
Y13 Proportional-Ventil Pumpe Vorderachse vorwärts Proportional-valve pump front axle, forward
Y14 Proportional-Ventil Pumpe Vorderachse rückwärts Proportional-valve pump front axle, backward
Y17 Magnetnventil Motor Vg halbe Solenoid valve Engine Vg half
Y24 Magnetventil Vorderachse zuschalten switch on magnetic valve front axle
Y25 Magnetventil Vorderachse aktiv magnetic valve front axle active
Y26 Magnetventil Differentialsperre Vorderachse Single solenoid valve differential lock front axle
Y30 Magnetventil Differentialsperre Hinterachse Single solenoid valve differential lock rear axle
18.2
19 Lubricants, fuels, filling quantities
lubricants, quantity in litres lubricants, fuels temperature limits Viscosity classes

fuels, (USgal) (international specifica- in °C (°F)
filling quantities tion)*
hydraulic system approx. 200 H-LP 46 10° - 50° ( 50° - 120°) ISO VG 100
(52,8) DIN 51524 Part 2 -10° - 30° ( 14° - 86°) ISO VG 68
15° - 20° ( 5° - 68°) ISO VG 46 +
-30° - 0° (-22° - 32°) ISO VG 22
Rear axle:
- wheel hubs approx. 4 x 4
(4 x 1)
- axle gear approx. 13,5 SAE 90 LS +

(3,5) MIL-L-2105D/LS SAE 80 W 90 LS
API-GL5 SAE 85 W 90 LS
- Tandems approx. 2 x 21 SAE 85 W 140 LS
(2 x 5,5)
- rotary mechanism approx. 6

(1,6)
fuel tank approx. 386 diesel fuel acc. to see ”diesel fuels
(102) DIN 51601
cooling system approx. 33 long-term coolant see ”Long-term coolants”

(8,7)
grease nipples and multi-purpose grease, K2K to DIN 51825 Part 1

lubrication points addition of lithium or
KP2K to DIN 51825 Part 3
Load shift gear approx.34 API-CH4 15° - 40° (50° - 104°) SAE 10W30
ZP-6 WG 160 (1) (8,9) -10° - 50° (14° - 120°) SAE 15W40 +
-30° - -10° (-22° - 14°) (TYP A Suffix)
Engine: approx. 18 API-CH4 10° - 50° ( 50° - 120°) SAE 40 +

CUMMINS (4,7) 0° - 40° ( 32° - 104°) SAE 30
-5° - 50° ( 23° - 120°) SAE 20W50
-15° - 40° ( -5° - 104°) SAE 10W30
-10° - 50° ( 14° - 120°) SAE 15W40 +
-25° - 20° (-13° - 68°) SAE 5W20
The indicated filling quantities are for orientation only, the test devices are binding. The choice of the viscosity classes is
determined by the outside temperature prevailing over long periods. The temperature limits shall be considered as
orientation permitting a short-time exceeding or dropping below.
+ factory filling
* API = American Petroleum Institute
MIL = US - Military Specification
SAE = Society of Automotiv Engineers
(1)
For the corresponding lubricants and viscosity grades, please refer to the manufacturer's lubricant list. To find this, go
to www.zf.com/schmierstoffe (German) or www.zf.com/interoele (English).
19
20 Lubricants
Only use lubricants which fulfil the specifications mentioned below and which are internationally known.
Do not mix engine, gear and hydraulic oils!
The viscosity limits (viscosity classes) mentioned in the table “”Lubricants, fuels and quantities”, e.g. ISO VG 46I corre-
spond to the codes DIN 51 519 and ISO 3448.
Engine oils (specifications)

API-CH4
Hydraulic systems (specifications)

The hydraulic high-duty drive requires the use of oil according to the a.m. specifications for the hydraulic system.
Gear oils for wet brakes (specifications)

MIL-L-2105 D/LS
API-GL5 LS
Gear oils (specifications)

MIL-L-2105 D
API-GL5
Lubricating grease
lithium-saponified, drop point > 170 °C (338 °F)
walk penetration 275/295
under the addition of molybdenum (IV)-sulphide
NLGI class 2 (DIN 518 18)
Viscosity classes
The viscosity classes can be seen from the table ”Lubricants, fuels and quantities”. Their choice is determined by the
outside temperature prevailing over long periods. The temperature limits shall be considered as orientation permitting a
short-time exceeding or dropping below.
20
21 Diesel fuels
The engine will generate the specified power and show the required running properties only if high-quality fuel is used.
The fuel recommended to be used with Cummins engines shall have the following characteristics:
Cetane number min. 45

Viscosity 2.5/4.5 cSt at 40 °C (104 °F)
Density 0.835 to 0.855 kg/l
Sulphur content max. 0.5 %
Boiling point curve 85 % at 350 °C (662 °F)
Cetane number
This number determines the ignition performance.
A low-cetane fuel may cause starting problems and affect combustion.
Viscosity
Viscosity is the flowability of the fuel and can affect - if outside the specified range - the running properties of the engine.
Density
A low density will reduce the engine power, a high density increases the engine power and exhaust gas turbidity.
Sulphur
A high sulphur content (normally not found in Europe, North America and Australasia) may result in increased engine
wear. Where only fuel with a high sulphur content is available, either a high-grade oil must be used or the oil must be
changed frequently.
Boiling point curve

Refers to the mixture of different hydrocarbons in the fuel. A high ratio can have an influence on the combustion charac-
teristics.
The frost resistance of diesel fuels is an important prerequisite for trouble-free operation in winter. When the tempera-
tures drop to a point where paraffin precipitates in the diesel fuel, the filterability and flowability are hampered; the fuel
filter and fuel lines are clogged.
The European mineral oil industry offers a diesel fuel for summer operation and one for winter operation (both in compli-
ance with DIN 51 601).
Operation from - to Frost resistant to

Summer diesel fuel mid-March to mid-October to 0 °C (32 °F)
Winter diesel fuel mid-October to mid-March to -20 °C (-4 °F)
ESSO POLAR FUEL in cold areas in winter below -20 °C (-4 °F)
In general, winter diesel fuels are frost resistant to a temperature of -20 °C (-4 °F). If frost occurs in transient periods or
the winter temperatures are below -20 °C (-4 °F), special diesel fuels with an improved frost resistance have to be used
(see table above).
21
22 Long-term coolants
The cooling system is factory-filled with a long-term coolant which is a mixture of water, antifreeze and anti-corrosive
agents. For moderate climate territories, its frost resistance is set at -37 °C (-35 °F).
A tag on the radiator informs on the use of an antifreeze. For corrosion protection reasons and to prevent furring, the
cooling system should have an antifreeze content of 50 % vol. (corresponds to a frost resistance to -37 °C (-35 °F) also in
summer.
Change the coolant every 2 years. Check its condition once a year.
Antifreeze and anti-corrosive agents of renowned international mineral oil producers, e.g. ESSO, SHELL, BP, MOBIL,
TEXACO, DEA, AGIP, ARAL, TOTAL and HAERTOL (Frostox), are permitted to be used.
The coolant quality has a great influence on the effectiveness and service life of the cooling system. The below-
mentioned recommendations contribute to the protection of the cooling system against frost and corrosion.
If the required measures are not taken, the manufacturer cannot be held responsible for damage caused by frost or cor-
rosion.
Use clean, soft water for the cooling system.
When replacing coolant, make certain that you are using coolant made on an ethylene glycol basis with an anti-corrosion
agent.
The anti-corrosive agent you use should be based on nitric or benzoic sodium.
The mixture should ensure sufficient cooling at all ambient temperatures and protect against corrosion. It must meet the
following standards:
UK: BS.6580:1985: „Specification for corrosion inhibiting engineering concentrate (antifreeze)“.

USA: ASTM D3306-74: „Ethylene glycol based engine coolant“.
Australia: AS 2108-1977: „Antifreeze compounds and corrosion inhibitors for engine cooling systems“.
Antifreeze mixtures which may be required but deviate from those filled in by the manufacturer can be taken from the
following table.
Frost resistance to Required antifreeze percentage

-20 °C (-4° F) 35 Vol. %
-25 °C (-13 °F) 40 Vol. %
-31 °C (-23 °F) 45 Vol. %
-38 °C (-36 °F) 50 Vol. % (factory-filled)
-46 °C (-50 °F) 55 Vol. %
In any case, the mixture ratio given by the antifreeze producer is binding.
The coolant should be an antifreeze mixture consisting of 50% water and 50% antifreeze agent. Avoid a higher percent-
age of antifreeze as this would affect the cooling capacity.
Caution!
Overconcentration of antifreeze or use of high silicate antifreeze can cause damage to the engine.
Even if there is no danger of frost, an antifreeze is recommended to be used because it provides corrosion protection and
improves the cooling capacity.
22
In tropical regions where the air temperature lies above +35 °C (95 °F), the low thermal conductivity of the long-term
coolant may lead to an overheating of the engine. In this case, use water instead of the long-term coolant, and add a
corrosion inhibitor to the water to prevent corrosion and furring. Use the mixture ratio specified by the maker.
Change the water/corrosion inhibitor mixture every 6 months; in case of doubt, ask the supplier.
Add the antifreeze and/or corrosion inhibitor to a bucket-full of water (tap water) and mix. It is not sufficient just to pour
the water and antifreeze successively into the radiator as thorough mixing in the cooling system would take too much
time.
The cooling system features only little evaporation losses. The losses can be compensated by adding clean water with a
low lime content.
Do not fill in too much coolant because it might overflow when it heats up. Moreover, if water is added too often, the con-
centrate would be impermissibly diluted (see Section „Changing the coolant“ in these instructions).
In emergency cases, also normal clean water may serve as coolant. However, it should be replaced as soon as possible
with the required long-term coolant.
Check the latter for frost resistance before the cold season.
22
23 Winter operation
So as to ensure that the machine can be operated without any problems also in winter, a few precautionary measures
must be taken before the cold season begins.
Cooling system The cooling system must be sufficiently resistant to the low temperatures occurring in your
region. If necessary, add antifreeze or replace the coolant with a frost-resistant coolant.
Check the coolant regulator and the radiator cap valves for proper functioning.
Oil Use an oil grade that is suitable for operation at the low temperatures occurring in your
region and has the required viscosity (see „Lubricants, consumables, quantities“).
Fuel Use diesel fuel for winter service. At low temperatures, paraffin may precipitate and clog the
filters and fuel lines (see „Diesel fuels“).
Injection system, batter- Proper condition of the injection system, starter, batteries and alternator ensure easy start-
ies, starter, alternator ing and trouble-free operation of the engine also at very low temperatures. Have these
important components checked by an authorized workshop before the cold season begins.
Compression Insufficient compression pressure affects the starting behaviour of the engine, in particular
pressure at low temperatures. Measure the pressure.
Starter in case of very Actuate the starter for not longer than 30 s. If the engine does not start, wait 30 s and try
low temperatures again.
Engine warm-up Before using the machine, let the engine idle for a few minutes at increased speed. During
warm-up, actuate the unloaded hydraulic equipment several times.
Cutting the engine off In order to prevent components from sticking due to the cold, knock off any soil sticking
after working them to after work, especially from the chassis.
Windscreen washer Add conventional antifreeze to the water. If antifreeze is not available, add 25 % vol. alcohol
(spirit) to the water.
Service brake If the machine is shut down, do not switch on the parking brake. Rather, lay wedges to the
wheels.
23
24 Shutting the machine down for a longer period
1. Drain the engine oil when it is still warm and fill up with the following slushing oil:
a) Engines which are not supercharged (aspirating engines)
- Slushing oil for piston engines, MIL-L 21 260, type 1 or type 2
- SAE class 10 W for preservation in winter
- SAE class 30 for preservation in summer
b) Supercharged engines
- Slushing oil for piston engines, MIL-L 21 260, type 2
- SAE class 10 W for preservation in winter
- SAE class 30 for preservation in summer
2. Add 4 to 6 % of the same slushing oil to the diesel fuel and mix thoroughly. To reduce the formation of condensation
water, fill the fuel tank to the top.
3. Check the long-term coolant for frost resistance; add a sufficient amount of anti freeze, if necessary. If there is no
antifreeze in the cooling system for climatic reasons, add an increased amount (5 % vol.) of corrosion inhibitor (see
„Long-term coolant“).
4. Start the engine and let it idle for at least 15 minutes at various speeds. If gear or hydraulic oil is changed before shut-
down, let the units concerned run for a while (till they are at operating temperature) in order to preserve them with the
fresh oil.
5. Close the air intake of the air cleaner system and the exhaust pipe. Recommended is the use of sturdy plastic caps
which cannot be sucked in.
6. Remove the starter battery and store it - filled and charged - in a dry room free from frost also in winter. Recharge the
batteries at intervals of about one month. Follow the instructions of the battery manufacturer.
7.Protect the machine against moisture and dirt.
8. Apply a thick film of grease to all sliding faces (circle, moldboard) and lubricate all nipples, in particular the swivel
system on the frame.
9. If the ground is uneven, and if it will be a long period of standstill, place the machine on trestles, reduce the air pres-
sure in the tyres to approx. 50 %. Cover the tyres against sun radiation.
10. Fill the tank (with an admixture of anti-corrosion oil at a quantity of 10 % of the filling).
Depending on the climatic conditions, machines preserved in this way can be laid up for a maximum of one year. After a
quarter of a year, however, all units should be activated and idle for approx. 15 minutes, and all nipples should be
greased.
When the machine must be moved during the shutdown period, e.g. when it is intended to be brought to another place,
the engine must not run for more than a total of 10 hours with the slushing oil. Make an oil change if this time is ex-
ceeded.
The machine must not be operated under load during the shutdown period.
When putting the machine into operation again, take all measures and make all tests required to ensure proper opera-
tion. After a shutdown period of one year, also the gear and hydraulic oil must be changed.
24
25 Maintenance and inspection plan
For the first time after the following operating hours

Daily or every 10 operating hours or if required
Every 50 operating hours
Every 2000 operating hours or annually
Every 4000 operating hours or max. 2,5 years
Pos.
Rear axle:
z Check the oil level in the wheel hubs, tandems, axle gears 9
z Lubricate the self-aligning bearings 10
z Replacement of oil in the wheel hubs, axle gears 11
z Replacement of oil in the tandems 12
5 z Re-tighten the wheel nut 13
Powershift transmission and cardan shafts:
z Check the oil level 14
100 z Replacement of oil and oil filter 15
z Lubricate the joints of cardan shafts 16
Cooling system and air filter:
z Check the coolant level 17
Front axle (driven):
z Lubricate joints 19
5 z Re-tighten the wheel nuts 21
Front axle (not driven):
z Lubricate joints 19
z Replace the grease in the wheel bearings 20
5 z Re-tighten the wheel nuts 21
Blade system, grading plate, ripper, articulated frame joint, articulating cylinder:
10 z Lubricate slewing gear, guidance, bridge joint, cylinder joints 22
10 z Lubricate grading plate, ripper joints, articulated frame joint, articulating cylinder 23
z Lubricate the ball of the draw rod 24
z Check the clearance of the slewing gear and blade guidance 25
z Check the oil level in the rotary mechanism 26
z Replace the oil in the rotary mechanism; retighten the fixing screws 27
z Check the safety coupling in the rotary mechanism for proper functioning 28
Operating and parking brake:
z Check the parking brake for lining wear 29
z Check the hoses and lines for leaks
z Check the wear in the multiple brake disks 32
z Check the oil level in the brake system 33
Hydraulic system:
z Check the oil level; replacement of oil every 3000 hours or max. every 2,5 years 34
z Check the hoses, lines and screw connections for leaks
50 z Clean the oil filter and replace the insert; if the signal lamp lights or all 1000 operating hours 36
z Check the pressures of both circuits 37
Around the machine:
z Remove leaks; retighten screw and line connections, fixing components
z Check the control lamps for proper functioning
z Check the tyre air pressures
Under extreme use conditions and at a high dust load, shorten the maintenance intervals. Maintain the machine always in
a state that it complies with the regulations of operation, traffic and labour safety.
The maintenance and inspection schedule for the diesel engine is in chapter 4.
25
Fig. 25
25

Maintenance Instructions: BG 190TA-4

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B A U M A S C H I N E N

Air filter system 6

Replacement of safety cartridge 6.1.4

Front axle (not driven) 10

Hydraulic working system 13

Articulated frame joint and articulated steering cylinder 14

Lubrication of the grading plate 15

Changing the tyres 17

Lubricants, fuels, filling quantities 19

Shutting the machine down for a longer period 24

Maintenance and inspection plan 25

Keep out of the machine’s danger zone!

Do not stand under the lifted and unsecured grading equipment!

Original HBM-NOBAS parts are especially designed for HBM-NOBAS machines.

Daily or Refuelling - Maintenance Check (3) Section 4.1

Every 250 hours or 3 months - Maintenance Check (3) Section 4.2

Every 500 hours or 6 month - Maintenance Check (1, 2, 3) Section 4.3

Every 1000 hours or 1 year - Maintenance Check (3) Section 4.4

Every 2000 hours, or 2 years - Maintenance Check (2, 3) Section 4.5

Oil Drain Intervals

Date km [Miles], hours Actual km [Miles] Maintenance Check Per- Comments

4.1 Daily Maintenance Procedures

Engine Operation Report

Report to the maintenance department any of the following conditions:

Unusual Engine Noise

4.1.2 Crankcase Breather Tube

4.1.3 Fuel-Water Separator Fig. 4.1.2/1

Drain the water and sediment from the separator daily.

4.1.4 Lubricating Oil Level

4.1.5 Coolant Level

Caution! Fig. 4.1.5/1

The coolant level must be checked daily.

Coolant recommendations and specification details on correct mixing of

4.1.6 Drive Belts

Belt damage can be caused by:

4.2 Maintenance Procedures at 250 hours or 3 months

4.2.2 Charge-Air Cooler

4.2.3 Charge-Air Piping

4.2.4 Radiator Hoses

4.2.5 Air Intake Piping

Replace damaged pipes, and tighten loose clamps, as necessary, to pre-

Torque Value: 8 Nm [72 in-lb] Fig. 4.2.5/1

4.2.6 Fan, Cooling

Inspect for Reuse

4.3 Maintenance Procedures at 500 hours or 6 months

Maintenance Check - coolant

4.3.2 Fuel Filter (Spin-On Type)

Lubricate the o-ring seal with clean lubricating oil.

Torque Value: 34 Nm [25 ft-lb]

Prime fuel system after fuel filter installation.

Note: It is not necessary to pre-fill the on-engine fuel filter.

Operate the engine and check for leaks.

4.3.3 Lubricating Oil and Filters

Drain Fig. 4.3.2/3

Use the oil filter wrench to remove the filter.

Clean the gasket surface of the filter head.

Note: Do not prefill the oil filter. Fig. 4.3.3/4

4.4 Maintenance Procedures at 1000 hours or 1 year

Note: Maximum pulley misalignment is 3 degrees.