Repair Manual Kramer 850

Service Manual
Wheel loaders
Machine model 346-03/346-04

Starting serial no. 346 03 0001/346 04 0001
Edition 1.0
Order number 1000183988 EN
Documentation
Title Order no.
Service manual 1000183988 EN
Operation manual Model 346-03

1000181153 EN
Model 346-04
Spare parts catalogue Model 346-03 1000181183

Model 346-04 1000181182
Legend
Edition Issued
1.0 02/08
Copyright - 2008 Kramer-Werke GmbH, Überlingen

Printed in Germany
All rights reserved
No part of this publication may be reproduced, translated or used in any form or by any means - graphic, electronic
or mechanical including photocopying, recording, taping or information storage or retrieval systems - without prior
permission in writing from the manufacturer.
The cover features the machine with possible optional equipment.
Kramer-Werke GmbH
Postfach 10 15 63
D-88 645 Überlingen
E-mail [email protected]
www.neusonkramer.com
Document: Serv-HB 34603_04 En
Order no.: 1000183988 EN
Edition: 1.0
Table of contents
Table of contents
Table of contents
Cab overview, labels, operation 1
Inside of cab: overview ............................................................................................ 1-1
Instrument panel, multifunctional lever and drive lever: overview ........................... 1-2
Overview of exterior of machine .............................................................................. 1-3
Important information on this manual ...................................................................... 1-4
Abbreviations/symbols ....................................................................................... 1-4
Models and trade names: overview ......................................................................... 1-5
Brief description of the wheel loader ........................................................................ 1-5
Hydrostatic drive ................................................................................................ 1-6
Work hydraulics and 4 wheel steering ............................................................... 1-6
Cooling system .................................................................................................. 1-6
Fields of application and using the wheel loader with an attachment ...................... 1-7
Attachments with certified material densities ..................................................... 1-7
Regulations .............................................................................................................. 1-9
Driving licence ................................................................................................... 1-9
Licence .............................................................................................................. 1-9
Equipment ......................................................................................................... 1-9
Machine inspections ........................................................................................ 1-10
Documents ...................................................................................................... 1-10
Machine warning identification (option) ........................................................... 1-10
Type labels and component numbers .................................................................... 1-11
Serial number .................................................................................................. 1-11
Cab number ..................................................................................................... 1-11
Engine number ................................................................................................ 1-11
Hydraulic pump number .................................................................................. 1-12
Hydraulic motor number .................................................................................. 1-12
Rear axle number ............................................................................................ 1-12
Front axle number ........................................................................................... 1-12
Signs and symbols ................................................................................................. 1-13
Labels on the outside of the machine .............................................................. 1-13
Labels inside the cab ....................................................................................... 1-14
Telltales and warning lights: description ................................................................ 1-16
Telltales and warning lights - instrument panel ............................................... 1-16
Drive interlock with code input (option) .................................................................. 1-18
Keyboard for entering codes: overview ........................................................... 1-18
Entering/changing the personal code .............................................................. 1-19
Enabling the drive interlock ............................................................................. 1-19
Disabling the drive interlock ............................................................................. 1-20
Taking the drive interlock out of service .......................................................... 1-21
Putting the drive interlock back into service again ........................................... 1-21
Interruption of drive interlock power ................................................................ 1-21
Drive interlock maintenance ............................................................................ 1-21
Key-based drive interlock (option) ......................................................................... 1-22
Key-based drive interlock: scope of delivery ................................................... 1-22
Coding (“training”) new ignition keys ............................................................... 1-22
Enabling (locking) the drive interlock ............................................................... 1-23
Disabling (releasing) the drive interlock ........................................................... 1-23
Deleting coded keys ........................................................................................ 1-23
Safety functions ............................................................................................... 1-23
Battery master switch (option) ............................................................................... 1-24
Interrupting power supply ................................................................................ 1-24
Switching on power supply: ............................................................................. 1-24
Oil and fuel preheater (option) ............................................................................... 1-24
Oil preheater operation .................................................................................... 1-24
Fuel preheater operation ................................................................................. 1-24
Serv-HB 34603_04 En - Edition 1.0 * 34603_04s10_enIVZ.fm I-1

Table of contents
Jump-starting the engine (external battery) ........................................................... 1-25

Safety instructions regarding external starting aids ......................................... 1-25
Providing external starting aid ......................................................................... 1-25
Backup warning system (option) ............................................................................ 1-26
Manual throttle (option) .......................................................................................... 1-26
Low-speed control (option) .................................................................................... 1-27
Electric connection - front socket (option) .............................................................. 1-27
Working lights ........................................................................................................ 1-28
Interior light ...................................................................................................... 1-28
Rotating beacon (option) ........................................................................................ 1-29
Signalling system ................................................................................................... 1-29
Additional control circuit for attachments (option) .................................................. 1-30
“Hose burst valve” safety feature (option) .............................................................. 1-31
Towing and transporting the machine .................................................................... 1-32
Safety instructions ........................................................................................... 1-32
Getting ready for towing ................................................................................... 1-32
Specifications 2
Models and trade names: overview ......................................................................... 2-1
Frame ....................................................................................................................... 2-1
Engine ...................................................................................................................... 2-1
Power train ............................................................................................................... 2-2
Variable displacement pump ............................................................................. 2-2
Boost pump ........................................................................................................ 2-2
Variable displacement motor ............................................................................. 2-2
Axles ........................................................................................................................ 2-3
Brakes ...................................................................................................................... 2-3
Service brake ..................................................................................................... 2-3
Parking brake ..................................................................................................... 2-3
Steering system ....................................................................................................... 2-4
Work hydraulics ....................................................................................................... 2-4
Hydraulic pump, control valve, lift and tilt rams ................................................. 2-4
Electric system ......................................................................................................... 2-5
Electric units ...................................................................................................... 2-5
Fuse box ............................................................................................................ 2-5
Main fuse box with relays .................................................................................. 2-6
Switching relays ................................................................................................. 2-6
Tyres ........................................................................................................................ 2-7
Tyres for wheel loader model 346-03 (750) ....................................................... 2-7
Tyres for wheel loader model 346-04 (850) ....................................................... 2-7
Weights .................................................................................................................... 2-7
Noise levels ............................................................................................................. 2-8
Vibration .................................................................................................................. 2-8
Coolant compound table .......................................................................................... 2-8
Tightening torques, conversion tables ..................................................................... 2-9
General tightening torques ................................................................................ 2-9
Specific tightening torques ................................................................................. 2-9
Conversion table: DIN standard - USA standard ............................................. 2-10
Payloads ................................................................................................................ 2-11
Loader unit with bucket .................................................................................... 2-11
Loader unit with pallet forks ............................................................................. 2-11
Loader unit with pallet forks (foldable fork arms option) .................................. 2-12
Loader unit with load hook (option) .................................................................. 2-12
Wheel loader dimensions with bucket (model 346-03) .......................................... 2-13
Wheel loader dimensions with bucket (model 346-04) .......................................... 2-14
Wheel loader dimensions with pallet forks (models 346-03/346-04) ..................... 2-15
I-2 Serv-HB 34603_04 En - Edition 1.0 * 34603_04s10_enIVZ.fm

Table of contents
Maintenance and service work 3

Explanation of symbols on the maintenance label ................................................... 3-1
Maintenance label .................................................................................................... 3-2
Fluids and lubricants ............................................................................................... 3-3
Maintenance plan .................................................................................................... 3-4
Important information on maintenance and service work ........................................ 3-7
Important information on maintenance and service work .................................. 3-7
Repair work on separate components ............................................................... 3-7
Fuel system ............................................................................................................. 3-8
General safety instructions for refuelling ........................................................... 3-8
Diesel fuel specification ..................................................................................... 3-8
Stationary fuel pumps ........................................................................................ 3-8
Refuelling ........................................................................................................... 3-9
Bleeding the fuel system ................................................................................... 3-9
Replacing the fuel filter .......................................................................................... 3-10
Cleaning the fuel pump screen filter ...................................................................... 3-11
Bleeding the fuel system ........................................................................................ 3-12
Checking/filling up the engine oil ........................................................................... 3-13
Changing engine oil ............................................................................................... 3-14
Replacing the engine oil filter cartridge .................................................................. 3-15
Cleaning the radiator fins of the oil/water radiator ................................................. 3-16
Checking the coolant level ..................................................................................... 3-17
Draining coolant ..................................................................................................... 3-18
Filling up coolant .................................................................................................... 3-19
Hydraulic system ................................................................................................... 3-20
Specific safety instructions .............................................................................. 3-20
Checking hydraulic pressure lines ......................................................................... 3-21
Monitoring the hydraulic oil reflux filter .................................................................. 3-22
Important information for the use of biodegradable oil .................................... 3-22
Maintenance of the hydraulic oil reflux filter ........................................................... 3-23
Changing the filter insert .................................................................................. 3-23
Checking the hydraulic oil level ............................................................................. 3-24
Filling up hydraulic oil ............................................................................................ 3-24
Replacing hydraulic oil ........................................................................................... 3-25
Oil levels: rear axle transfer gearbox ..................................................................... 3-26
Oil levels: front and rear axle differentials .............................................................. 3-27
Oil levels: front and rear axle planetary drives ....................................................... 3-28
Air filter maintenance ............................................................................................. 3-29
Checking the air filter for dirt ............................................................................ 3-29
Replacing the air filter cartridge ............................................................................. 3-30
Maintenance of the diesel engine V-belts .............................................................. 3-31
Checking V-belt tension ................................................................................... 3-31
Retightening the V-belts .................................................................................. 3-31
General lubrication work ........................................................................................ 3-32
Lubricating the rear axle oscillation-type bearing ............................................ 3-32
Lubricating the front and rear axle planetary drive bearings ........................... 3-32
Lubricating the loader unit ..................................................................................... 3-33
Maintenance of attachments .................................................................................. 3-33
Lubricating with the central lubrication system (option) ......................................... 3-34
General functional description of the central lubrication system ..................... 3-34
Tip switch for intermediate lubrication ............................................................. 3-34
Setting the lubrication and break times ........................................................... 3-35
Filling the central lubrication system ................................................................ 3-35

Table of contents
Brake system maintenance .................................................................................... 3-36

Checking/filling up the brake fluid level ............................................................ 3-36
Repair work on the brake system .................................................................... 3-36
Tyre maintenance .................................................................................................. 3-37
Daily tyre checks .............................................................................................. 3-37
Changing wheels ................................................................................................... 3-38
Maintenance of cab heating and fresh air filter ...................................................... 3-39
Cleaning the dust filter of the heating system .................................................. 3-39
Air conditioning (option): maintenance ................................................................... 3-40
General instructions regarding the air conditioning system ............................. 3-40
Daily functional and visual checks of the air conditioning ................................ 3-41
Maintenance of the electric system ........................................................................ 3-42
Service and maintenance work at regular intervals ......................................... 3-42
Electric lines, bulbs, ignition lock, relays and fuses ......................................... 3-43
Alternator ......................................................................................................... 3-43
Battery maintenance .............................................................................................. 3-44
General maintenance work .................................................................................... 3-45
When using washing solvents ......................................................................... 3-45
When using compressed air ............................................................................ 3-45
When using a high-pressure cleaner or steam jet ........................................... 3-45
When using volatile and flammable anticorrosion agents and sprays ............. 3-45
Cleaning inside the cab .......................................................................................... 3-46
Cleaning the seat belt ............................................................................................ 3-46
Cleaning the exterior of the machine ..................................................................... 3-46
Cleaning the engine compartment ......................................................................... 3-47
Screw connections, hinges .................................................................................... 3-47
Maintenance work “Aggressive Media” (option) ..................................................... 3-48
Anticorrosion protection applied in the factory ................................................. 3-48
Components coated with anticorrosive wax .................................................... 3-48
Measures for maintaining anticorrosive protection .......................................... 3-49
Applying the protective anticorrosion coating .................................................. 3-50
Treatment of oxidised surfaces ........................................................................ 3-50
Engine 4
Engine designation .................................................................................................. 4-1
Fuel specification ..................................................................................................... 4-1
Coolant specification ................................................................................................ 4-1
Diesel engine D 2011 L04 W overview .................................................................... 4-2
Engine oil cooling ..................................................................................................... 4-3
Belt drive with cooling ports ..................................................................................... 4-4
Fuel system .............................................................................................................. 4-5
Checking and adjusting valve tip clearance ............................................................. 4-6
Replacing the fuel injection pump ............................................................................ 4-7
Switching off minus compensation ......................................................................... 4-12
Heating connection ................................................................................................ 4-12
Removing/mounting the cylinder head ................................................................... 4-13
Sealing the bleed valve .......................................................................................... 4-16
Sealing the intake/exhaust manifold ...................................................................... 4-16
Engine trouble ....................................................................................................... 4-17
Power train 5
Variable displacement pump test ports .................................................................... 5-1
Variable displacement pump .................................................................................... 5-2
Variable displacement motor ................................................................................... 5-3
Inching valve overview ............................................................................................. 5-4

Table of contents
Inching valve circuit ................................................................................................. 5-5

Inching valve diagram .............................................................................................. 5-6
Drive circuit .............................................................................................................. 5-7
Drive diagram .......................................................................................................... 5-8
Towing and transporting the machine ...................................................................... 5-9
Safety instructions ............................................................................................. 5-9
Getting ready for towing .................................................................................... 5-9
Test report: 20 kph power train .............................................................................. 5-10
Test report: 30 kph power train .............................................................................. 5-11
Adjusting boost pressure ....................................................................................... 5-12
Tools required .................................................................................................. 5-12
Adjusting starting revs/control pressure ................................................................. 5-12
Setting high pressure/drive pressure ..................................................................... 5-13
Setting the secondary valves for forwards/reverse driving .................................... 5-14
Checking/setting the hydraulic resistance (characterisic curve) of the pump ........ 5-14
Check engine droop ............................................................................................... 5-15
Setting control initiation on the hydraulic motor ..................................................... 5-15
Setting the wheel revs ........................................................................................... 5-16
Axles 6
Axle overview ........................................................................................................... 6-1
Front axle screw connections .................................................................................. 6-2
Sealing work (joint housing/axle carrier) .................................................................. 6-3
Sealing the bevel gear shaft .................................................................................. 6-14
Removing ........................................................................................................ 6-14
Mounting .......................................................................................................... 6-14
Differential cage/differential lock screw connections ............................................. 6-15
Overview of differential lock and differential cage ................................................. 6-16
Removing the differential cage with the differential lock ........................................ 6-17
Removing the differential lock ................................................................................ 6-18
Assembling the differential lock ............................................................................. 6-19
Removing the gearbox ........................................................................................... 6-20
Input shaft version 1 sealing: overview .................................................................. 6-26
Assembling the gearbox ........................................................................................ 6-27
Brakes 7
Brake circuit ............................................................................................................. 7-1
Brake diagram ......................................................................................................... 7-2
Parking brake circuit ................................................................................................ 7-3
20 kph inching valve circuit ...................................................................................... 7-4
Service brake ........................................................................................................... 7-5
Important information on the brake system ....................................................... 7-5
Brake calliper maintenance ............................................................................... 7-5
Steering system 8
Steering circuit ......................................................................................................... 8-1
Steering circuit ......................................................................................................... 8-2
Steering system adjustment .................................................................................... 8-3
Function ............................................................................................................. 8-3
Hydraulic ports on servostat .................................................................................... 8-3
Pressure relief valve: adjustment ............................................................................. 8-3
Sealing steering rams .............................................................................................. 8-4
Checking a steering ram .......................................................................................... 8-5
Overview of steering ram setting ............................................................................. 8-5
Necessary tools ................................................................................................. 8-5
How to check/set the steering rams ......................................................................... 8-6
Checking the track setting (1) .................................................................................. 8-7
Correcting the track setting (2) ................................................................................ 8-7
Setting the steering limit (3) ..................................................................................... 8-8

Table of contents
Checking steering synchronisation (4) ..................................................................... 8-9

Checking the bypass ......................................................................................... 8-9
Bleeding the steering rams .............................................................................. 8-10
Setting steering synchronisation (5) ....................................................................... 8-11
Final check/test run .......................................................................................... 8-11
Hydraulic system 9
Work hydraulics test report ...................................................................................... 9-1
Work hydraulics oil supply ....................................................................................... 9-2
Control valve ports ................................................................................................... 9-3
Priority valve ports ................................................................................................... 9-3
Priority valve diagram .............................................................................................. 9-4
Load stabiliser ports ................................................................................................. 9-4
Load stabiliser circuit ............................................................................................... 9-5
Load stabiliser diagram ............................................................................................ 9-5
Lift ram: sealing work ............................................................................................... 9-6
Tilt ram: sealing work ............................................................................................... 9-7
Control ram (quickhitch frame): sealing work ........................................................... 9-8
Work hydraulics diagram ....................................................................................... 9-10
Hose burst valve hydraulics diagram (option) ....................................................... 9-11
Electric system 10
Ohm's Law (current, voltage, resistance); power ................................................... 10-1
Measuring equipment, measuring methods ........................................................... 10-1
Terminal description ............................................................................................... 10-2
Colour coding of electric lines ................................................................................ 10-6
Extract from DIN 72551, sheet 4 ..................................................................... 10-6
Other colour codes (identical to IEC 757) ........................................................ 10-8
Switching relay function ......................................................................................... 10-8
Use, mode of function ...................................................................................... 10-8
Terminal description on relay .......................................................................... 10-8
Starter, battery, alternator ..................................................................................... 10-9
Fuse box ................................................................................................................ 10-9
Main fuse box with relays ..................................................................................... 10-10
Switching relays ................................................................................................... 10-10
Description of blocking diodes ............................................................................. 10-11
Blocking diodes V8, V9 .................................................................................. 10-11
Blocking diode V10 ........................................................................................ 10-11
Blocking diode V11 ........................................................................................ 10-11
Blocking diodes V16, V17 .............................................................................. 10-11
Blocking diodes V20, V21 .............................................................................. 10-11
Overview of switch assignment ............................................................................ 10-12
Retrofitting a rotating beacon ............................................................................... 10-13
Retrofitting the backup warning system ............................................................... 10-13
Retrofitting 2 front working lights .......................................................................... 10-14
Retrofitting 2 front working lights and 1 rear working light ................................... 10-14
Retrofitting 2 front working lights and 2 rear working lights ................................. 10-15
Electric diagram legend ....................................................................................... 10-16
Electric diagram sheet 1 ...................................................................................... 10-17
Electric diagram sheet 2 ...................................................................................... 10-18

Cab overview, Overview of cab interior
labels, operation
Cab overview, labels, operation

2 5 35 1 2
1 Cab overview, labels, operation
3
1.1 Inside of cab: overview
4
Roof console
1 Sun visor
5
2 Air conditioning vent (option)
3 Interior light
6 Cab
4 Wiper motor (front)
7 5 Air vent - leg room
6 Accelerator pedal
34 7 Instrument panel
8 8 Lock - side window
33 9 Control lever (joystick)
9 10 Control lever - 3rd control circuit
11 Arrester - left-hand side cab door/right-hand side window
32
12 Switch panel - speed range
10 13 Lever - horizontal seat adjustment
31 14 Parking brake lever
11 15 Switch panel
30 16 Fuse box
I0
17 Instrument panel
11 12 18 Prepared installation for radio (option)
19 Wiper motor (rear)
13 20 Bracket - left-hand side cab door arrester/right-hand side window
29
21 Storage net for Operator's Manual
22 Lever - backrest adjustment - seat
28 14 23 Seat
24 Storage compartment1/air conditioning (option)
27
15 25 Air conditioning rotary switch (option)
26 Fixture1 - first-aid kit
26 27 Seat belt
16
28 Lever - weight adjustment
25 29 Steering wheel
17 30 Multifunctional lever
24 31 Outer door handle
32 Service brake pedal (hydrostatic)/inching
18
33 Tank - washer system
23
34 Brake fluid tank
19 35 Front window defroster vents
22
1. Not installed if equipped with air conditioning option
20
20
21
1-1 1-1 Serv-HB 34603_04 En - Edition 1.0 * 34603_04s111.fm

39 40 41 42 43
1.2 Instrument panel, multifunctional lever and drive lever: overview
Instrument panel
38 44 36 Telltale (red) - coolant level
37 Telltale (green) - right/left turn indicators for rear attachments
38 Telltale (green) - right/left turn indicators
39 Telltale (red) - hydraulic oil filter
37 1
45
40 Telltale (red) - hydraulic oil temperature
41 Telltale (red) - alternator charge function
42 Telltale (red) - parking brake
36 46 43 Telltale (red) - engine oil pressure
44 Diesel engine temperature indicator
45 Telltale (blue) - high beam
47 48 52 46 Hose burst valve telltale (yellow) 1 (option)
47 Fuel level indicator
49 50 51 48 Hour meter
53
Multifunctional lever
49 Horn tip switch
54
50 Tip switch - front/rear washer system
51 Rotary switch - front wiper
55
I 0
Switches and control lever (side console)

52 Control lever with lock - loader unit
53 Control lever with lock - 3rd control circuit
54 Switch - speed range selection
60 55 Central lubrication system tip switch (option)
56 Preheating start switch (engine start)
61
57 Hazard warning switch
62 58 Socket/cigarette lighter
59 Rotary switch - heating (warm/cold)
63 60 Telltale (green) - forwards driving direction
61 Switch - driving direction selection
62 Telltale (green) - reverse driving direction
63 Tip switch - neutral speed range
64 Lights switch
65 Not assigned
16 66 Not assigned
67 Heater fan switch
64 65 66 67 68 56 68 Rear working light tip switch (option)
69 Switch - load stabiliser (option)
57 70 Working light switch
71 Switch - rotating beacon (option)
58
72 Not assigned
73 Switch - front socket (option)
59
1. Hose burst valve is not functional with the load stabiliser switched on (telltale comes on)
69 70 71 72 73
Serv-HB 34603_04 En - Edition 1.0 * 34603_04s111.fm 1-2

Cab overview, labels, operation Cab overview, labels, operation
1.3 Overview of exterior of machine
1 2 3 4 5
18 7
10
17 16 15 14 13 12 11
Fig. 1: Machine outside views
Pos. Description Pos. Description

1 Service flap (fuses, relays, recirculated air filter) 11 Door handle
2 Rearview mirror 12 Lights with turn indicators
3 Handle 13 Access
4 Working lights 14 Wheel chock
5 Eye hook 1 (for removing the cab) 15 Loader unit
6 Brake, rear and turn indicator lights 16 Tilt ram
7 Door arrester Front eye hook for loading/strapping down the
17
machine
8 Towing facility
18 Lift ram
9 Reflectors
Rear eye hook for loading/strapping down the 1. Eye hooks are for removing the cab only, and may not be used for crane handling the
10 machine
machine

1.4 Important information on this manual

This manual contains important information on how to service your machine safely, cor-
rectly and economically. Therefore, it aims not only at new staff, but it also serves as a ref-
erence for experienced ones. It helps to avoid dangerous situations and reduce repair
costs and downtimes. Furthermore, the reliability and the service life of the machine will be
increased by following the instructions in the Operator's Manual.
Careful and prudent working is the best way to avoid accidents!
Insist on using original spare parts when carrying out maintenance and repair work. This
ensures operational safety and readiness of your machine, and maintains its value.
Your KramerAllrad dealer will be pleased to answer any further questions regarding the
machine or the service manual.
Abbreviations/symbols
☞ This symbol requires you to carry out the activity described
☞ Subdivision within lists or an activity. Follow the steps in the recommended sequence
• This symbol stands for a list
• Subdivision within lists or an activity. Follow the steps in the recommended sequence
➥ Description of the effects or results of an activity
“Option” = optional equipment

Stated whenever controls or other components of the machine are installed as an option.
Driving direction in drawings or figures.

1.5 Models and trade names: overview

Wheel loader model Trade name
346-03 750
346-04 850
1.6 Brief description of the wheel loader

The wheel loader is a self-propelled work machine according to German traffic regulations.
Get informed on and follow the legal regulations of your country.
This machine is a versatile and powerful helper for moving earth, gravel and debris on con-
struction sites and elsewhere.
The wide range of attachments accounts for the numerous applications of the machine: as
a fork lift, a snow plough, a spreader for grit, salt etc., a sweeper or a tree replanter.
See chapter Attachments with certified material densities on page 1-7 for further applica-
tions. Retrofit the machine with appropriate safety features when using it in lifting gear
operation (see section “Applications with lifting gear” in chapter Safety Instructions).
The main components of the machine are:
• ROPS/FOPS tested closed cab
Check number: ROPS 04139-CE (cab without protective screen)
Check number: FOPS 04140-CE (cab with optional protective screen)
• Water-cooled Deutz four-cylinder in-line engine, exhaust emissions according to
EC standard 2004/26 EC
• Sturdy steel sheet frame; rubber-mounted engine
• Automotive drive, infinitely variable hydrostatic axial-piston gearbox;
maximum speed 20 kph (30 kph option)
• Hydraulic four-wheel power steering with emergency steering features
• Front and rear planetary steering axles, rear axle with oscillation
➥ Service brake (mechanical and hydrostatic), mechanical disc-type parking brake
1-5 Serv-HB 34603_04 En - Edition 1.0 * 34603_04s110.fm

Hydrostatic drive
The diesel engine permanently drives a hydraulic pump (variable displacement pump),
whose oil flow is sent to a hydraulic motor flanged on the gearbox. The force of the hydrau-
lic motor is transmitted to the rear axle via the transfer gearbox. At the same time, the front
axle is driven by the cardan shaft, ensuring permanent 4 wheel drive.
Work hydraulics and 4 wheel steering

The diesel engine also drives the joint gear pump for work hydraulics and hydrostatic
4 wheel steering. The oil flow of this pump depends on the diesel engine revs only.
When the machine is in operation, the entire diesel engine output can be transmitted to the
gear pump for work hydraulics and steering. This is made possible by a so-called inching
valve which responds as soon as the service brake is used, reducing or cutting off power
input of the drive. Therefore, engine output is fully available for the loader unit by pressing
the accelerator pedal and the brake pedal at the same time.
Cooling system
A combined oil/water radiator (for the diesel engine and the hydraulic oil) is located at the
rear of the machine.
The telltales on the instrument panel of the machine ensure constant monitoring of the
coolant temperature and level, and of the hydraulic oil temperature.

1.7 Fields of application and using the wheel loader with an attachment
The attachments will decide in the first place how the machine is used.
Note that not all attachments listed in the table comply with local traffic regulations.
The attachments complying with local traffic regulations and the applicable provisions are
listed in the machine documentation!
The legislation of your country may require specific permits, certifications, registrations etc.
for the use of attachments that are not certified or not listed in the machine documentation!
Caution!
In order to avoid damage to the machine, only the attachments listed below
have been certified for installation on the machine.
☞ See Attachments with certified material densities
Attachments with certified material densities

Possible equipment and authorised material densities.
Description of attachment Wheel loader Part no. (model) Dimensions Use
1000102344 1750 mm/with teeth

346-03 1000102345 1750 mm/without teeth
Standard bucket - normal 10001606481 1750 mm/without teeth Loosening, picking up, transporting and load-
ing loose or solid material
material 1000096388 1850 mm/with teeth (material density ≤ p = 1.8 t/m³)
346-04 1000096389 1850 mm/without teeth
1000137538 1850 mm/without teeth
346-03 1000096389 1850 mm/without teeth Picking up, transporting and loading very light-
Standard bucket - light-
weight material
weight material2 346-04 1000096393 2050 mm/without teeth (material density ≤ p = 1.3 t/m³)
Standard bucket - super- 346-03 1000096394 Picking up, transporting and loading light-
2150 mm/without teeth
lightweight material2 346-04 1000096397 weight material (material density p = 0.9 t/m³)
1000113244 1750 mm/with teeth

346-03 1000113492 1750 mm/without teeth Grading, removing and scraping vegetation, for
Multipurpose bucket 3 1000168415 1750 mm/without teeth example; picking up and evenly spreading
material; grabbing bulky material; loading
1000050770 1850 mm/with teeth trucks (material density ≤ p = 1.8 t/m³)
346-04
346-03 1000175757 1744 mm/without teeth As standard bucket, however with benefits for
Side swing bucket2, 3 filling and backfilling material
346-04 1000176121 1844 mm/without teeth (material density ≤ p = 1.8 t/m³)

346-03
1000108803 1850 mm/without teeth As standard bucket, however with a 80 - 100
High-tilt bucket3, 4, 5 cm higher dump height
1000156433
346-04 1850 mm/without teeth (material density ≤ p = 1.8 t/m³)
1000154475

Description of attachment Wheel loader Part no. (model) Dimensions Use
Heavy duty bucket with 346-03 1000111090 1850 mm Picking up and transporting e.g. bulky recycling
hydraulic clamp3, 4, 5 346-04 1000111053 2050 mm material (material density ≤ p = 1.3 t/m³)
Heavy duty forks with Picking up and transporting e.g. bulky and
346-03
hydraulic clamp 1000128262 1800 mm fibrous recycling material (e.g. grass, manure,
346-04
(silage bucket)3, 4 brushwood; material density ≤ p = 1.3 t/m³)
346-03 1000101820 1000 mm

Pallet forks3, 4, 6 Picking up and transporting pallets
346-04 1000101822 1200 mm
Pallet forks with foldable

346-04 1000147393 1200 mm Picking up and transporting pallets
fork arms3, 6, 7
346-03
Material pusher3, 4 1000050660 3000 mm For moving loose bulk material
346-04
346-03 Picking up and transporting e.g. grass,

Manure forks with grab 1000178474 1800 mm
346-04 manure, brushwood and straw
346-03
Hydraulic round bale clamp 1000177701 800 - 1800 mm Picking up and transporting round bales
346-04
346-03
Tree replanter3, 4 1000100840 - Digging and transporting nursery trees
346-02
346-03 Scarifying dense soil,

Front scarifier3, 4 1000100841 -
346-04 loosening humus soil
346-03 For repair, assembly, disassembly, mainte-

Work platform8 1000109953 -
346-04 nance and inspection work above ground
346-03
Rotary broom 1000139717 - Cleaning roads or facilities
346-04
346-03
Snow plough2, 3, 4, 9 1000142915 - Winter service
346-04
1. Bucket with screwed-on exchangeable blade

2. Only in connection with additional lights order no. 1000105002 and mounting kit order no. 1000137629 when driving on public roads
3. See the Operator's Manual of the attachment for taking the attachment into service and using it
4. Not certified for driving on public roads (individual certification may be possible depending on your country's legislation)
5. Only in connection with restrictor unit order no. 1000114139
6. Only in connection with load diagrams for model 346-03 (order no. 1000138363) and for model 346-04 (order no. 1000143064)
7. Get informed on the legal regulations of your country which may require specific permits, certifications, registrations etc. for use on public roads!
8. Model 346-03: only in connection with assembly 1000169659
Model 346-04: only in connection with assembly 1000169660
9. Only in connection with rotating beacon order no. 1000133985
Get informed on the legal regulations of your country for further information on mounting attachments

1.8 Regulations
Driving licence
Earth moving machinery may be driven on public roads only if the driver has a driving
licence for the machine, as defined by national traffic regulations.
German traffic regulations require the following driving licences for driving the machine:
Version (20 kph): Driving licence category 5 (old)
Driving licence category L (new, European Union)
Version (up to 40 kph): Driving licence category 3 (old)
Driving licence category C1 (new, European Union)
Licence
The legal regulations of your country may require you to fit a numberplate
and to affix your name and address on your machine.
Equipment
German traffic regulations require to equip the machine with:
• 1 warning triangle with design certification
• 1 warning light with design certification
• 1 first-aid kit in accordance with the legal regulations of your country

Machine inspections
Follow the safety regulations of your country regarding accident prevention when operat-
ing the wheel loader.
The employer must follow the legal regulations of his country regarding occupational
health and safety, which may require him to get informed on type, scope and intervals
required for checking and testing the work equipment.
Documents
German traffic regulations require to have the following documentation on board, e.g.:
• General certification
• Driving licence
• Test report according to legal regulations
• Operator's Manual
Machine warning identification (option)

Local regulations may require that machines operating on roads for
• road construction
• road maintenance
• cleaning roads or facilities
have some type of warning identification (e.g. red and white identification in combination
with an optional yellow rotating beacon).

1.9 Type labels and component numbers

Serial number
The serial number is stamped on the machine frame A (next to the cab attachment, on the
A right in driving direction). It is also located on the type label B.
The type label B is located on the machine frame, at the front right in driving direction (on
one side of the loader unit bulkhead).
Type label information

Example:
Machine model: 346

B Version: 346 03
Serial no.: 346 03 55
Model year: 2006
Front gross axle weight rating: 3600 kg
Rear gross axle weight rating: 4000 kg
Gross weight rating: 5500 kg
Output: 45 kW
Other information - see chapter 2 “Specifications” on page 2-1
Fig. 2: Type label: location
Cab number
The type label (arrow) is located in the cab, at the top right in driving direction.
Fig. 3: Cab type label
Engine number
The type label (arrow) is located on the cylinder-head cover (engine).
Example: Deutz D2011 L04 W
Fig. 4: Diesel engine number

Hydraulic pump number

The type label (arrow) is located on the hydraulic pump housing (next to where the pump is
installed on the diesel engine)
Fig. 5: Hydraulic pump type label
Hydraulic motor number

The type label (arrow) is located on the hydraulic motor, on the right in driving direction.
Fig. 6: Hydraulic motor type label
Rear axle number

The type label (arrow) is located on the upper side of the differential housing, at the rear.
Fig. 7: Rear axle and gearbox type label
Front axle number

The type label (arrow) is located on the upper side of the differential housing, at the front.
Fig. 8: Front axle type label

1.10 Signs and symbols

Labels on the outside of the machine
Label: cab eye hooks
The eye hooks on the cab are for removing the cab only and may not be used for crane-
lifting the machine.
Location
Cab roof (4x)
Fig. 9: Eye hook label
Slinging points for strapping down the machine

Points for strapping down the machine.
The eye hooks are used for strapping down the machine during loading and transport.
Location
On the left and right of the machine frame above the front axle attachment, and at the rear
Fig. 10: Label for points used for strapping down the
underneath the engine
machine
Noise level label

Noise levels produced by the machine.
LWA = sound power level
Other information - see chapter 2 “Noise levels” on page 2-8
XX Location
Rear window
Fig. 11: Noise level label
Label: max. design-specific speed

Design-specific max. machine speed 20 kph (30 kph option)
20 30 Location
At the rear and on the left/right of the counterweight.
Fig. 12: Speed label
General indication of danger

This label warns persons standing or working near the machine of an existing danger
within the area of increased danger around the machine.
Location
Front left and right of machine frame, and at rear of machine.
Fig. 13: Danger label
CE mark
The CE mark means that the machine meets the requirements of the Machine Directive
and that the conformity procedure has been carried out. The machine meets all the health
and safety requirements of the Machine Directive.
Location
ce.ai
On the rear window.
Fig. 14: CE mark
Label: do not open the engine cover

Do not open engine cover before engine is at a standstill!
Do not touch any moving or turning parts!
Location
On the engine cover of the machine.
Fig. 15: Prohibitory label

Labels inside the cab

Load diagram for pallet forks and tyre pressure table
The framed numbers state the maximum authorised load on the fork arms for industrial
and offroad applications. The maximum load varies according to the distance from the load
centre.
Example:
• Off-road operation ➝ S = 1.67 (safety factor)
Load distance = 500 mm
• The maximum load amounts to e.g. 465 kg!
Tyre pressure table
400
600
500
List of authorised types of tyres with prescribed tyre inflation pressures.

Other information - see chapter 2 “Tyres” on page 2-7
Location
Inside the cab, on left side of front window
Important!
The load diagram is valid only for applications with certified pallet forks.
• - see Attachments on page 1-7
• Observe the specific load diagrams of other attachments used, e.g. rotary crane
Typ jib!
model
modèle
30100b1370.eps
Fig. 16: Load diagram
Brake fluid label

Use only LHM brake fluids.
➥ - see chapter 3 “Brake system maintenance” on page 3-36
➥ - see chapter 3 “Fluids and lubricants” on page 3-3
Location
Fig. 17: Brake fluid label
On the brake-fluid tank
Label: control lever (joystick) operation
A B C • A = driving direction: (F) forwards/(R) reverse and (N) neutral position
• B = control lever (joystick) unlocked/locked for road travel
• C = control lever (3rd control circuit for attachments) unlocked/locked
D • D = loader unit operation: raise, lower, dump in/out
E • E = 3rd control circuit operation. Pick up/set down attachment
• F = loader unit operation: raise, lower with float position, dump in/out
Location
On the lower right on the side window
Fig. 18: Label: control lever operation (overview)

Label: avoiding danger in general

Label for avoiding danger of serious injuries or of injuries resulting in death!
Danger!
Read and understand the Operator's Manual under all circumstances before
taking the machine into service!
Location
Inside the cab on the right on the pillar
Fig. 19: Label: avoiding danger
Requires you to fasten your seat belt

Never drive or work without having fastened the seat belt - danger of injury!
Buckle up before moving or working with the machine!
Location
Inside the cab on the right on the pillar
Fig. 20: Seat belt label
Label: biodegradable lubricants (option)

Biodegradable lubricants (biodegradable oil) are used on the machine
➥ - see chapter 3 “Important information for the use of biodegradable oil” on page 3-22
Location
Inside the cab
Fig. 21: Label: biodegradable oil
Load diagram for load hook (option)

Example: Maximum load for model 346-03 (750)
34 6-01
• A Extended loader unit and quickhitch tilted in

➥ Max N => 1900 kg
B A • B Extended loader unit and quickhitch
N = 1400kg N = 1900kg
1000149082
➥ Max N => 1400 kg
Fig. 22: Load diagram for load hook
Location
➥ Inside the cab, on left side of front window

1.11 Telltales and warning lights: description

Telltales and warning lights - instrument panel
Unfold pages 1-1 and 1-2 for a better overview!
Telltale (red) - engine oil pressure
Comes on if the engine oil pressure is too low. In this case:
43 ☞ Stop the machine
☞ Switch off the engine immediately and check the oil level
The telltale comes on when the ignition is turned on and goes out as soon as the engine
runs.
Diesel engine temperature indicator

Indicates the engine oil temperature detected by a sensor.
44
Caution!
Danger of engine breakdown if the telltale comes on with the engine running!
☞ Stop engine immediately
☞ Check the engine oil
• - see chapter 3 “Checking/filling up the engine oil” on page 3-13
☞ Check the cooling system
• - see chapter 3 “Cleaning the radiator fins of the oil/water radiator” on
page 3-16
Telltale (red) - coolant level

Indicates that the coolant level in the radiator is too low:
36 ☞ Check the coolant system for leaks, have possible damage repaired by an authorised
workshop.
☞ Fill up coolant
Telltale (red) - alternator charge function

The telltale comes on when the ignition is turned on and goes out as soon as the engine
41 runs.
The V-belt or the charging circuit of the alternator is faulty if the telltale comes on with the
engine running. The battery is no longer charged.
Telltale (green) - right/left turn indicators

Flashes intermittently when the turn indicators are used
38
Telltale (green) - right/left turn indicators on rear attachment

Flashes intermittently when the turn indicators are used and a front or rear attachment is
38 connected electrically.
Telltale (blue) - high beam

Comes on if high beam is switched on, or during headlight flashing.
45

Parking brake telltale (red)

Comes on when the parking brake is applied.
42
P The electric driving interlock prevents starting the engine with the parking brake applied.
Telltale (red) - hydraulic oil temperature

Comes on if hydraulic oil temperature exceeds 95 °C.
40
Caution!
Danger of hydraulic damage as soon as the telltale comes on!
☞ Release the pressure on the work and drive hydraulics. To do this:
• Stop the machine in a suitable place
• Move the control lever of the loader unit to neutral
• Move the drive lever to neutral
• Run the engine at increased revs until telltale 40 goes out
Telltale (red) - hydraulic oil filter

Indicates inadmissibly high pressure in the hydraulic reflux line to the tank. In this case:
39 ☞ Have the hydraulic oil reflux filter checked and, if necessary, replaced by an authorised
workshop
Telltale (yellow) - hose burst valve (option)

Indicates that the hose burst valve is switched on. This avoids lowering or dumping out the
36 loader unit without any resistance in the event of a burst hose or line.

1.12 Drive interlock with code input (option)

Keyboard for entering codes: overview
The drive interlock is enabled or disabled with “personal” codes entered via the keypad.
Two codes are available:
• The existing unchangeable six-digit main code for disabling the drive interlock, for
entering a personal code or for changing the personal code
• The four, five or six-digit personal code is used for disabling the drive interlock and is
entered by the driver
Caution!
We recommend using the personal code for disabling the system.
LED ☞ Keep the main code in a safe place.
Fig. 23: Drive interlock (code input option)
The keypad consists of:
• 10 numeric key for entering the codes
• A (*) key for confirming the code that has been entered
• An LED (red telltale)
• An internal acoustic signal for signalling specific procedures
➥ Example: a signal sounds to confirm a key has been pressed
The keypad comes on:
• When pressing any key
• The keypad flashes to indicate specific system statuses

Entering/changing the personal code

In order to enter or change the personal code:
☞ Disable the drive interlock by entering the main code (6 digits) and pressing the (*) key
☞ Turn the ignition key to position “Ignition ON” as soon as the LED goes out
☞ The LED comes on for 2 seconds
☞ Enter the 4, 5 or 6-digit new personal code and confirm with the (*) key within 20 sec-
onds after the LED has gone out
☞ Enter the new personal code again and confirm it with the (*) key after a short flashing
of the LED
➥ Confirmation: LED flashes twice briefly, then comes on for 2 seconds
☞ Turn the ignition key to the OFF position and remove it as soon as the LED goes out
➥ The new personal code is now set and can be used for disabling the drive interlock.
Caution!
The personal code must be entered correctly twice consecutively otherwise an
error is indicated by means of a single flashing of the LED:
☞ Codes consisting of 3 and less, or of more than 6 digits are ignored by the
system
☞ Simple codes (with identical or consecutive digits, e.g. 1, 2, 3, 4) are
rejected by the system with four short acoustic signals
☞ Entering a new personal codes replaces the previous code. A code can be
changed any time if the main code is known
Enabling the drive interlock

☞ Switch off the engine and remove the ignition key
➥ The drive interlock is automatically enabled
➥ Flashing LED (on the keypad)

Disabling the drive interlock

☞ Enter the personal code or main code (6 digits).
☞ Press the (*) key.
➥ Confirmation: 2 long acoustic signals and long LED flashing
➥ LED OFF = drive interlock is disabled
➥ Diesel engine can be started
The diesel engine will not start if a wrong code has been entered
➥ Confirmation: 4 short acoustic signals, flashing LED = wrong code
➥ Re-enter the code
☞ Turn the ignition key and switch on the engine before the LED flashes again
(30 seconds)
Caution!
The keypad is blocked for 5 minutes and no codes can be entered if the wrong
code is entered four times consecutively.
☞ Enter the code after 5 minutes
• The keypad does not come on as long as it is blocked. It comes on briefly
every 4 seconds and an acoustic signal sounds
☞ Press the (*) key after every code
☞ The LED comes on briefly when turning the ignition key to the engine start
position

Taking the drive interlock out of service
We recommend taking the drive interlock out of service if the machine has to stay in a
workshop, for instance, or if the machine does not require any protection. This avoids hav-
ing to communicate the code.
1 Disable the system by entering the personal or main code and by confirming with the
(*) key
2 Turn the ignition key to position “ON” as soon as the LED goes out
3 The LED comes on for 2 seconds
4 As soon as the LED goes out, press the (*) key for about 2 seconds until a short
acoustic signal, followed by two further signals, sounds (within 20 seconds after the
LED has gone out)
5 The LED now flashes very slowly, and the keypad is disabled
6 Turn the ignition key to the OFF position and remove it
7 The engine can be started without entering the code. The system is out of service
even if electric power is interrupted.
Caution!
With the system out of service,
☞ the LED flashes slowly even if the ignition key is in position ON
☞ Entering the personal or main code does not have the effect of putting the
system back into service again (the acoustic signals for confirmation are
still given). See the following procedure (“Putting the drive interlock back
into service again”) to leave the out-of-service status again.
Putting the drive interlock back into service again

☞ Press the (*) key for 2 seconds (ignition key in position OFF) until two short acoustic
signals are given for confirmation
➥ The system is enabled again. The code must be entered to start the engine.
Interruption of drive interlock power

If the drive interlock was enabled before electric power was interrupted, short acoustic sig-
nals are given upon switching on the keypad (similar to those that are given when entering
the wrong code four times). In this case, wait until the acoustic signals are no longer given.
Then disable the drive interlock with the personal or main code.
The LED still does not come on if the drive interlock was disabled. The engine can be
started before the LED starts flashing again.
If the drive interlock was out of service, this status remains unchanged and the LED
flashes slowly.
Drive interlock maintenance
The MED 310.1T drive interlock does not require any maintenance.
Protect the keypad and the control unit from heat and humidity

1.13 Key-based drive interlock (option)

Key-based drive interlock: scope of delivery
The drive interlock is integrated in the ignition lock and can be enabled only with the blue
ignition keys!
Scope of delivery:
• Drive interlock installed in the machine
• 2 x blue keys (coded)
• 1 x red master key (for training the blue keys)
Coding (“training”) new ignition keys

New personal keys are coded with the master key (red). This is why it must be carefully
stored outside the machine.
Caution!
Each drive interlock has only one master key!
☞ The drive interlock must be replaced if the master key is lost
• The master is only used for coding new keys, and cannot be used for disabling the
drive interlock
• Coding is carried out by inserting the master key in the ignition lock and by turning it to
position '1' for a maximum 5 seconds. After the master key has been returned to
position '0' and removed, you have 15 seconds for inserting a key that requires coding.
It must be inserted in the ignition lock and turned to position '1' in order to be registered
as a valid key.
• Coding is automatically stopped if no key requiring coding is detected within 15
seconds.
• Several keys requiring coding can be inserted one after another in the ignition lock
• Each key must remain at least 1 second in position '1'.
• Coding can be carried out for a maximum 10 keys

Enabling (locking) the drive interlock

☞ Apply the parking brake
☞ Switch off the engine
☞ Remove the ignition key (blue)
➥ The drive interlock is enabled in 30 seconds
Caution!
The drive interlock remains disabled if the ignition key (blue) is not removed
from the ignition lock!
Disabling (releasing) the drive interlock

Start and switch off the engine exactly as described in the Operator's Manual.
☞ The system is enabled 5 seconds after the ignition key is inserted in the ignition lock
☞ Start the engine
➥ The drive interlock is disabled as long as the engine runs
Deleting coded keys

Deleting coded keys is necessary whenever a coded key is lost
• All coded keys are deleted during deletion
• After deletion has been carried out, all existing keys can be recoded
• Deletion is carried out by inserting the master key in the ignition lock and by turning it to
position '1' for a minimum 20 seconds.
• All coded keys are then deleted, and all existing keys can be recoded
• The master key code is not deleted during deletion
Safety functions
The drive interlock remains enabled for 15 minutes and does not accept any valid keys if
more than 5 keys with different invalid codes are inserted and turned in the ignition lock
within 1 minute. This function avoids 'finding' the correct key by chance by trying different
keys. It is only available if the control valve relay is connected in addition with terminal 30.
The drive interlock remains enabled for 15 minutes and does not accept any valid keys if
several invalid keys have been detected without having set the ignition lock to position '0'.
Valid keys are accepted only after 15 minutes and after the position '0' of the ignition lock
has been detected. This avoids testing keys without actuating the mechanical ignition lock,
e.g. by moving the ignition lock to position '1' by force.
Interruptions of the supply line or other control lines do not disable the drive interlock or
delete data (e.g. data codes). All important data is saved in a non-volatile memory.

1.14 Battery master switch (option)

Interrupting power supply
The battery master switch is located in the engine compartment next to the battery
☞ Turn and remove the key of the battery master switch (notched position)
Switching on power supply:

☞ Insert the key in the battery master switch
☞ Turn the key to the notched position
1.15 Oil and fuel preheater (option)

This equipment is for cold-starting at temperatures below -5 °C.
Oil preheater operation

The engine and hydraulic oil is heated by means of heating elements with a capacity of 750
W in the engine oil pan and in the hydraulic oil tank, according to the gravity principle (warm
oil rises and is replaced by cold oil). The oil can only be thoroughly warmed up to service
temperature if the oil preheater is connected over a longer period of time - preferably over
night.
A ☞ Connect the oil preheater as follows:
• Park the machine near a 220 V socket
• First connect special cable A with machine socket B, then
• Insert the plug into the 220 V socket
☞ Before starting the engine:
Fig. 24: Oil preheater
• Remove the plug from the 220 V socket
• Unplug special cable A from machine socket B
• Close the engine cover
Fuel preheater operation

The fuel preheater prevents paraffin crystals forming, which otherwise clog the fuel filter at
low temperatures.
A temperature switch automatically switches on a heating element in the fuel line between
the tank and the fuel prefilter when ignition is switched on at temperatures below + 10 °C.

1.16 Jump-starting the engine (external battery)

Safety instructions regarding external starting aids
Danger!
Jump-starting the engine with a frozen battery -
Danger of explosion!
☞ Replace the battery by a new one!
If the jump-starting vehicle touches the wheel loader -
Danger of short circuit and sparks!
☞ The jump lead connected to the positive (+) terminal of the starting battery
must never be brought into connection with electrically conductive vehicle
parts
☞ The external power source must deliver 12 V; higher supply voltages will
damage the electric system of the vehicles!
☞ Use only authorised jump leads which conform to the safety requirements
and which are in perfect condition!
☞ Route the jump leads so they cannot catch on rotating components in the
engine compartment!
Providing external starting aid

☞ Drive the jump-starting vehicle close enough to the loader so that the jump leads can
reach to connect the two batteries
☞ Let the engine of the jump-starting vehicle run
☞ First connect one end of the red jump lead (+) to the + terminal of the flat battery, then
Flat battery connect the other end to the + terminal of the starting battery
☞ Connect one end of the black jump lead (-) to the - terminal of the starting battery
12 V ☞ Connect the other end of the black jump lead (-) onto a solid metal component fimly
mounted on the engine block or onto the engine block itself. Do not connect it to the
negative terminal of the flat battery, as otherwise explosive gas emerging from the bat-
tery may ignite if sparks are formed!
☞ Start the engine of the machine with the flat battery
Once the engine has started:

12 V ☞ With the engine running, disconnect both jump leads in exactly the reverse order (first
remove the - terminal, then the + terminal) - this prevents sparking in the vicinity of the
Starting battery battery!
Fig. 25: Starting aid with jump leads

34001b710_05.eps

1.17 Backup warning system (option)
Danger!
When backing up with the machine -
Danger of accidents!
☞ Make sure nobody is within the danger area of the machine when changing
the driving direction!
☞ Do not rely exclusively on the backup warning system (option)!
Important!
A
In certain countries, a backup warning system is mandatory.
The backup warning system consists of a signal transmitter A, fitted on the inside
of the cover over the towing device. The signal transmitter generates an acoustic
signal when shifting into reverse. The acoustic level is about 103 dB (A) at a dis-
tance of 1 m and at a frequency of 2800 Hz.
Fig. 26: Backup warning system (option)
1.18 Manual throttle (option)

The manual throttle is located on the right of the side console
A Danger!
B
Do not actuate the manual throttle lever G when driving on public roads -
☞ Use the manual throttle G during work operation only!
G ☞ Before driving on public roads:
Fig. 27: Manual throttle (option) • Move the manual throttle lever G to idling speed position A
• Set the engine revs with the accelerator pedal only
Function
Permanent setting of engine revs for work operation
Position Engine revs
A Idling speed = minimum revs
B Full throttle = maximum revs
Important!
This function is especially useful for operating hydraulic attachments which need a
continuous supply of hydraulic oil. Drive speed must be set with the brake/inching
pedal or with the low-speed control (option).

1.19 Low-speed control (option)

The control lever is located on the right of the side console
Function
Wheel loader speed can be set more precisely and independently of the engine revs with
control lever H.
This function corresponds to inching with the brake/inching pedal.
Maximum speed depends on the speed range selected.
☞ Select the driving direction
☞ Select a speed range
A B ☞ Set constant engine revs with the accelerator pedal or the manual throttle (option)
☞ Select the required drive speed
➥ Move control lever H towards A
☞ Stop the wheel loader
H ➥ Move control lever H to limit B
Position Drive speed

Fig. 28: Low-speed control (option) A Maximum speed
B Machine at a standstill
1.20 Electric connection - front socket (option)

The machine can be equipped with a 4 pole front socket. Switch 73 on the right on the
instrument panel switches electric power supply on or off for electrically operated attach-
ments such as a spray water pump for a rotary broom.
73
Power supply for front attachments (option)
☞ Press switch 73 to position B ➥ Power supply at the socket is switched
A on
ON
➥ Telltale in switch comes on
B
☞ Press switch 73 to position A ➥ Power supply is switched OFF
OFF
Fig. 29: Backup warning system (option) ➥ Telltale goes out

1.21 Working lights
Danger!
The working light can dazzle motorists on public roads.
☞ Do not switch on the working light when driving on public roads. When
operating the machine, only switch the working light on when no-one can
be dazzled by it!
Front and/or rear working lights (option)

ON ☞ Press switch 70 to position B ➥ Telltale in switch comes on
OFF ☞ Press switch 70 to position A ➥ Telltale in switch goes out
2 front working lights (option)
70 68 OFF ☞ Press switch 70 to position A ➥ Telltale in switch goes out
2 rear working lights (option)
ON ☞ Press tip switch 68 briefly ➥ Telltale in tip switch comes on
OFF ☞ Press tip switch 68 briefly ➥ Telltale in tip switch goes out
Fig. 30: Switch for working lights
Interior light
Interior light
ON ☞ Press switch 3 to the left or right
OFF ☞ Move switch 3 to centre position
Fig. 31: Switch for interior light

1.22 Rotating beacon (option)
Rotating beacon (option)

OFF ☞ Press switch 71 to position A ➥ Telltale in switch goes out
71
Important!
Legal regulations of your country may require you not to switch on the rotating
beacon on public roads unless the road is within the machine's working range and
A the machine represents an obstruction to the normal flow of traffic when the
machine is in work operation.
B Get informed on and follow the legal regulations of your country.
Fig. 32: Switch for rotating beacon
1.23 Signalling system
38 Turn indicators
RIGHT ☞ Push lever 30 forwards R ➥ Telltale 38 flashes
37 ☞ Pull lever 30 to the rear L ➥ Telltale 38 flashes
LEFT
➥ Telltale 37 flashes during trailer operation
Caution!
The turn indicator system is not in order if telltale 38 flashes about twice as fast
R as normally!
☞ Check the front and rear turn indicators immediately
➥ Have the turn indicator system repaired if necessary
34200b0313.eps
L
30
Fig. 33: Turn indicators
57
Fig. 34: Switch for hazard warning system

1.24 Additional control circuit for attachments (option)
Danger!
Working with attachments!
Unintentionally actuating the lever (3rd control circuit) unlocks the quickhitch -
Danger of personal injury!
☞ Secure control lever 10 (3rd control circuit) when working with an attach-
ment
The machine can be equipped with an additional front/rear control circuit (option) for the
operation of hydraulic attachments.
Operation:
The additional control circuit is switched on and off by means of a solenoid valve and
switch 72 on the right in the console.
72
Operation of the additional control circuit (option)
☞ Press switch 72 to position B ➥ 4th control circuit is switched on
ON
A ➥ Telltale comes on
☞ Press switch 72 to position A ➥ 4th control circuit is switched off
OFF
B ➥ Telltale goes out
Fig. 35: Operation of 4th control circuit (option)

1.25 “Hose burst valve” safety feature (option)
Important!
The “Hose burst valve” safety feature prevents the loader unit from being lowered
or dumped out without being braked, in the event of a bursting hose or pipe.
Caution!
Switching on the load stabiliser automatically switches off the hose burst valve!
☞ Switch off the load stabiliser to make sure the the hose burst valve works
correctly during work!
Danger!
The “Hose burst valve” safety feature is activated as soon as a hose or a pipe
bursts -
☞ Have damage to the hydraulic system and to the hose burst valve immedi-
ately repaired and checked by technical staff with appropriate training
In the event of damage, proceed as follows:
☞ Stop the machine immediately

☞ If possible:
☞ Carefully lower the loader unit to transport position
☞ Drive the machine out of the danger area with the loader unit lowered
☞ Switch off the engine
☞ Remove the ignition key and lock the cab
☞ Secure the machine and the attachment
Environment!
Collect the drained hydraulic oil in a suitable container.
☞ Dispose of drained hydraulic oil by an ecologically safe method
☞ Always contact the relevant authorities or commercial establishments in charge of oil
disposal before disposing of biodegradable oil.
☞ Have the hose burst valve immediately repaired by an authorised workshop

1.26 Towing and transporting the machine

Safety instructions
• The machine may only be towed using suitable towing equipment (towing bar or cable)
in connection with suitable towing facilities, such as a towing coupling, hooks and eyes!
• Move off slowly!
Make sure no-one is dangerously close to the towing bar
• The machine may only be towed with a cable if the service brakes and steering are fully
operational!
Getting ready for towing
C B
Danger!
A
Turning the steering wheel requires greater effort if the diesel engine breaks
down. Take this into account especially when towing the machine!
☞ Use a towing bar!
A
B
Caution!
The hydrostatic power train can be damaged when towing the machine!
C
☞ Switch off the engine!
☞ Short-circuit the hydraulic circuit before towing (see below)
Fig. 36: 20 kph hydraulic pump
☞ Do not tow the machine for more than 100 meters and do not tow it
faster than 3 - 4 kph!
D
F ☞ Tow away the machine as follows:
• Fit an adequately sized towing bar to the towing facilities
20 kph hydraulic pump
☞ Switch over the HP pressure relief valves A on the hydraulic pump. To do this:
E • Slacken hexagon lock nuts B on both HP valves A
• Screw in hexagon socket head screws C on both HP valves A until they are flush with
lock nuts B
• Secure hexagon socket head screws C on both HP valves A with lock nuts B
Fig. 37: 30 kph hydraulic pump (option) 30 kph hydraulic pump (option)
☞ Mount hose D between test ports E and F
➥ The hose is included in the tool kit
☞ If possible, run the engine at idling speed when towing the machine
Once towing is over ...

☞ ... reset the HP valves A on the 20 kph hydraulic pump! To this effect, unscrew each of
hexagon socket screws C as far as they will go and secure them with locknuts B, or
☞ On the 30 kph hydraulic pump, remove hose D and protect it with protective caps


Specifications
Specifications
Specifications
2 Specifications
2.1 Models and trade names: overview
Wheel loader model Trade name
346-03 750
346-04 850
2.2 Frame
Sturdy steel sheet frame, rubber-mounted engine
2.3 Engine
Engine Wheel loader models 346-03/346-04

Product Deutz diesel engine
Type D 2011 L04 W
Design In line
No. of cylinders 4
Displacement 3620 cm³
Bore and stroke 96 x 125 mm
Compression ratio 1:19
45 kW
Output (as per ISO 14396)
at 2300 rpm
Max. torque 210 Nm at 1700 rpm
Minimum idling speed 900 rpm
Specific minimum fuel consumption 220 g/kWh
Fuel injection system Direct fuel injection
Firing order 1-3-4-2
Starting aid Glow plug
30° in all directions
Max. inclined position (engine no
Observe the tilting limit of the machine!
longer supplied with oil):
(20° laterally)
Oil pressure 3.0 - 4.5 bar at 2300 rpm
Exhaust emissions according to
97/68 EC
EC standard

Specifications
2.4 Power train

Variable displacement pump
Variable displacement pump Wheel loader models 346-03/346-04

Automotive, infinitely variable hydrostatic
Design
axial-piston gearbox
Displacement
0 - 45 cm³/rev
20 kph
Displacement
0 - 56 cm³/rev
30 kph (option)
Max. operating pressure 340 bar
Starting revs 1250 - 1300 rpm at 50 bar HP
Droop 2150±50 rpm at 250 bar HP
Boost pump
Boost pump Wheel loader models 346-03/346-04

Design Internal gear pump
Displacement 11.6 cm³/rev
Charging/boost pressure 30 bar at 1500 rpm
Speed-sensitive, hydraulic displacement adjustment
Control
with pressure cutoff
Driving direction Electrohydraulic control
Inching Inching valve
Variable displacement motor
Variable displacement motor Wheel loader models 346-03/346-04

Axial piston motor
Design
(swash plate design)
Capacity 20.0 to 80.7 cm³/rev
1st speed range: 0 - 6 kph, forwards and reverse
Drive speed
2nd speed range: 0 - 20 kph, forwards and reverse
Pushing power 34.5 kN

Specifications
2.5 Axles
Front axle Wheel loader models 346-03/346-04
Planetary steering and drive axle, rigid screw connection with
Design
frame
Differential lock Self-locking differential 45 %
King-pin inclination 0°
Camber 0°
Steering angle 40°
Toe-in 0 mm
Track width 1400 mm
Rear axle Wheel loader models 346-03/346-04
Design Oscillating planetary steering and drive axle
Differential lock Self-locking differential 45 %
King-pin inclination 0°
Camber 0°
1
Total oscillation angle +/- 11°
Steering angle 40°
Toe-in 0 mm
Track width 1400 mm
1. Model 346-01 with tyres 12.5-18

Model 346-02 with tyres 12.5-20
2.6 Brakes
Service brake
Service brake Wheel loader models 346-03/346-04

Design Foot-operated hydraulic disc brake
Location Front axle input
Effect On both axles via cardan shaft
Brake fluid - see chapter 3 “Fluids and lubricants” on page 3-3
Parking brake
Parking brake Wheel loader models 346-03/346-04

Design Manual mechanical disc brake
Location Front axle input

Specifications
2.7 Steering system

Steering system Wheel loader model 346-03 Wheel loader model 346-04
Hydrostatic 4 wheel steering
Design
with emergency steering features
Steering mode 4 wheel steering
Hydraulic pump, steering unit with priority valve, steering rams
Assemblies
with automatic synchronisation in left and right final positions
Max. pressure of hydraulic
175 - 180 bar
lines
Hydraulic pump Displacement Displacement
(gear pump) 22.5 cm³/rev 32 cm³/rev
Maximum steering angle ±40°
2.8 Work hydraulics

Hydraulic pump, control valve, lift and tilt rams
Description Wheel loader model 346-03 Wheel loader model 346-04

Hydraulic pump Gear pump
22.5 cm³/rev 32 cm³/rev
Displacement
50 l/min at 2300 rpm 71 l/min at 2300 rpm
Control valve 3 sections (control circuits)
Four-way lever - control of lift and tilt rams with mechanical lock
Control lever (joystick) against unintentional actuation, with electric control for driving
direction and neutral position
3rd control circuit control Operation - quickhitch or hydraulic attachments with mechani-
lever cal lock against unintentional actuation
Max. service pressure 210 bar
Secondary protection tilt Rod side 240 bar
ram Base side 120 bar
Secondary protection Base side 300 bar
lift ram
Filter Suction reflux filter

Specifications
2.9 Electric system

Electric units
Electric system
Alternator 14 V/50 A
Starter 12 V/2.3 kW
Battery 12 V/88 Ah
Fuse box
Rated
No. Protected circuit
current
F1 7.5 High beam (left)
F2 7.5 High beam (right)
F3 5 Left side marker and rear lights, front socket
Switch assignment: front/rear working lights, front attachments
(option), rotating beacon (option)
F4 5 Switch lights: lights, heating S5, load stabiliser S8, 3rd control
circuit
Right side marker and rear lights, front socket (option)
High current relay - preheating and starting, high current relay,
F5 7.5 interior light, relays - minus compensation, preheating telltale,
hazard warning light
F6 25 Cigarette lighter, rotating beacon (option), front/rear working light
F7 25 All lights
F8 7.5 Low beam (left)
F7 F6 F5 F4 F3 F2 F1 F9 7.5 Low beam (right)
Switching relay - front attachment (option), instrument panel, cut-
F10 5
off solenoid, sensor (coolant level indication)
F16 F15 F14 F13 F12 F11 F10 F9 F8
Washer pump, rear wiper, relays - wiper,
F11 15
front wiper, horn
Fig. 36: Fuse box
F12 7.5 Solenoid valve 1st/2nd speed range, load stabiliser
Relays - forwards/reverse, solenoid valve - forwards/reverse,
F13 7.5
backup warning system
F14 20 Front attachment (option), heating fan
Relay - turn indicators, brake lights, solenoid valve (exhaust gas
F15 7.5
recirculation)
F16 5 Radio (option)

Specifications
Main fuse box with relays

The main fuse box with the power relays and the preheating time control unit is located in
F18 the engine compartment on the left underneath the battery.
F17
K5
Fuse no. Rated current (A) Protected circuit
K7 F17 80 A Main fuse (machine)

F19
F18 40 A Preheating (air-intake preheating)
K29
F19 10 A Minus compensation
Fig. 37: Main fuse box

Relay no. Protected circuit
K5 Preheating: power relay
K7 Start: starter relay
K29 Minus compensation
Switching relays
The switching relays are located underneath the switch panel on the right in the side con-
sole (accessed via the maintenance flap on the right on the outside of the cab).
Switching relay no. Protected circuit

K10
K1 High current relay
K3 Reverse driving switching relay
K4 Forwards driving switching relay

K3
K10 Switching relay - turn indicators
K4 K16 Switching relay - front socket (option)
K23 Wiper switching relay
K16
K23
K1
Fig. 38: Relays

Specifications
2.10 Tyres
Tyres for wheel loader model 346-03 (750)
Tyre pressure1 Wheel rims

Tyre size
Front Rear Wheel rim Wheel offset
12.5-18 MPT 04 10 PR 128B 2.3 2.0
340/80 R18 XMCL
335/80 R18 XZLS 151 A2 11 x 18

0 mm
365/70 R18 SPT9 132B 2.5 2.0
365/70 R18 EM01 132B
375/70 R 20 MPT AC70G 11 x 20
1. Increase front tyre pressure by 0.5 bar during pallet forks operation!
Tyres for wheel loader model 346-04 (850)
Tyre pressure1 Wheel rims

Tyre size
Front Rear Wheel rim Wheel offset
12.5-20 MPT 04 10 PR
335/80 R20 SPT9 136B

11 x 20
375/70 R20 MPT AC70G 132B
2.5 2.0
335/80 R20 MPT81
0 mm
365/70 R18 EM SPT9 132B
11 x 18
365/70 R18 EM-01 135 B
405/70 R18 EM01 141B

3.0 2.5 13 x 18
405/70 R18 EM SPT9
1. Increase front tyre pressure by 0.5 bar during pallet forks operation!
2.11 Weights
Wheel loader model Wheel loader model

Weight
346-03 346-04
Kerb weight1 4200 kg 4500 kg
Gross weight rating 5500 kg 6000 kg
Front axle weight rating
3600 kg 4000
Rear axle weight rating
Max. authorised load for towing facility None
1. With standard bucket, driver and full fuel tank

Specifications
2.12 Noise levels

Sound power level, wheel loader models 346-03/346-04 dB(A)
Measured value 99.8
Guaranteed value 101
Noise level in the cab 78
Important!
Measurement of sound power level according to EC Directive 2000/14 EC. Noise
level at the driver's ear measured according to EC Directives 84/532/EEC, 89/514/
EEC and 95/27/EEC. Measurements carried out on asphalted surface.
2.13 Vibration
Vibration
Effective acceleration value for the m
< 2.5 -----
-
upper extremities of the body s2
Effective acceleration value for the m

< 0.5 -----
-
body s2
2.14 Coolant compound table

Outside temperature Water 1 Antifreeze2
Up to °C % by volume % by volume
4 99 -
- 10 79 20
- 20 65 34
- 25 59 40
- 30 55 45
- 42 50 50
1. Water quality at 20 °C = 6.5 - 8.5 ph/overall hardness 3 - 20 °dGH
2. SeeFluids and lubricants on page 3-3

Specifications
2.15 Tightening torques, conversion tables

General tightening torques
Tightening torques in Nm1

Screw dimensions
8.8 10.9 12.9
M4 3 4 5
M5 5.5 8 10
M6 10 14 16
M8 23 34 40
M10 46 67 79
M12 79 115 135
M14 125 185 220
M16 195 290 340
M18 280 400 470
M20 395 560 660
M22 540 760 890
M24 680 970 1150
M27 1000 1450 1700
M30 1350 1950 2300
1. These values are valid for screws with untreated, non-lubricated surfaces
Specific tightening torques
Description Tightening torque

Wheel nut 390 ±10 Nm
Track-rod end (steering ram) 280±10 Nm
Piston rod (steering ram/track rod) 260±10 Nm

Specifications
Conversion table: DIN standard - USA standard

All indications made without engagement.
Volumes
1 litre = 2.1 pts (pints)
1 litre = 1.06 qts (quarts)
1 litre = 0.26 gals (gallons)
1 cm³ (cubic zentimeter) = 0.0611 cu in (cubic inches)
Lengths
1 mm (millimetre) = 0.03937 in (inches)
1 m (metre) = 3.281 feet
1 m (metre) = 1.0936 yards
1 km (kilometre) = 0.622 miles
Weight
1 kp/cm² (kilopond/cm²) = 2.2 lbs
1 kg (kilogram) = 2.205 lbs (pounds)
1 g (gram) = 0.035 oz (ounces)
Torques
1 Nm (Newton metre) = 0.737 ft/lbs (foot-pounds)
1 Nm (Newton metre) = 0.102 kp/cm² (kilopond/cm²)
1 Nm (Newton metre) = 0.102 mkg (metre/kilogram)
Pressures
1 kp/cm² (kilopond/cm²) = 14.22 psi
1 bar = 14.29 psi
Forces
1 N (Newton) = 0.225 lbs (pounds)
1 hp (horse power) = 0.735 kW (kilowatt)
1 kW (kilowatt) = 1.36 hp (horse power)
1 hp (horse power) = 0.985 hp (horse power)

Specifications
2.16 Payloads
Loader unit with bucket

Bucket 1, 2
346-03 346-04
Bucket capacity 0.75 m³ according to ISO 0.85 m³ according to ISO
Tipping load 3000 kg 3200 kg
Payload 1350 kg 1530 kg
Breakout force (lift ram) 31 kN 40 kN
Breakout force (tilt ram) 29 kN 35 kN
Scraping depth 50 mm 60 mm
1. Model 346-01 with tyres 12.5-18
Model 346-02 with tyres 12.5-20
2. Model 346-01 with standard bucket 1000102344
Model 346-02 with standard bucket 1000096388
Loader unit with pallet forks

500 mm load distance
346-03 346-04
Payload,
1900 kg 2000 kg
safety factor 1.25
Payload,
1430 kg 1500 kg
safety factor 1.67
Transport position:
movable payload, 2300 kg 2350 kg
safety factor 1.25
Transport position:
safety factor 1.67
Lift height 2800 mm 3000 mm

Specifications
Loader unit with pallet forks (foldable fork arms option)

500 mm load distance
346-03 346-04
Payload,
1900 kg 2000 kg
safety factor 1.25
Payload,
1430 kg 1500 kg
safety factor 1.67
Transport position:
safety factor 1.25
Transport position:
safety factor 1.67
Lift height 2800 mm 3000 mm
Loader unit with load hook (option)

Payload1
346-03 346-04
Payload with extended loader
1900 kg 1700 kg
unit and quickhitch tilted in
Payload with extended loader
1400 kg 1350 kg
unit and quickhitch
1. Payloads apply with lifting gear (chains, cables, suspension devices)

Specifications
2.17 Wheel loader dimensions with bucket (model 346-03)
45°
750
3065
2915
2400
2480
2680
200
50° 300
1570 1920 1350 1400
4840 1750
Fig. 39: Machine dimensions model 346-01
Dimensions
Overall length1 4840 mm
2
Overall height 2480 mm
2
Overall height with rotating beacon 2680 mm
3
Overall width without bucket 1720 mm
Overall width1 1750 mm
Ground clearance in transport position of loader unit 200 mm
2
Ground clearance below rear axle gearbox 300 mm
Pin height 3065 mm
Load-over height 2915 mm
Dump height 2400 mm
Dump reach 750 mm
Dump-in angle 50°
Dump-out angle 45 °
Track width, front/rear 1400 mm
Wheelbase (front/rear axles) 1920 mm
4
Turning radius 2550 mm
1. With standard bucket order no. 1000102344
2. With tyres 12.5-18
3. With outside mirrors folded in
4. Measured at outer edge of wheel

Specifications
2.18 Wheel loader dimensions with bucket (model 346-04)
45°
660
3250
3100
2500
2510
2710
200
50° 300
1770 1920 1350 1400
5040 1850
Fig. 40: Machine dimensions model 346-02
Dimensions
Overall length1 5040 mm
2
Overall height 2510 mm
2
Overall height with rotating beacon 2710 mm
3
Overall width without bucket 1720 mm
Overall width1 1850 mm
Ground clearance in transport position of loader unit 200 mm
2
Ground clearance below rear axle gearbox 300 mm
Pin height 3250 mm
Load-over height 3100 mm
Dump height 2500 mm
Dump reach 660 mm
Dump-in angle 50°
Dump-out angle 45 °
Track width, front/rear 1400 mm
Wheelbase (front/rear axles) 1920 mm
4
Turning radius 2550 mm
1. With standard bucket order no. 1000096388
3. With outside mirrors folded in
4. Measured at outer edge of wheel

Specifications
2.19 Wheel loader dimensions with pallet forks (models 346-03/346-04)
d
b
a
Fig. 41: Machine dimensions with pallet forks
Wheel loader model 346-03 346-04

1
a Pin height 3065 mm 3250 mm2
b Pallet height 2800 mm1 3000 mm2
c Dump-in angle in transport position3 17°
3
d Dump-out angle 85°
3. With pallet forks order no. 1000101820 (1000 mm)
Other dimensions
➥ - see Wheel loader dimensions with bucket (model 346-03) on page 2-13
➥ - see Wheel loader dimensions with bucket (model 346-04) on page 2-14

Maintenance and service work

3 Maintenance and service work

3.1 Explanation of symbols on the maintenance label
Symbol Explanation
Before starting maintenance work, follow the safety instructions in the Operator's Manual!
Before starting maintenance work, read the “Maintenance” chapter in the Operator's Manual!
Carry out a functional check of the light system!
Check tyres for damage, pressure and tread depth!
Carry out a functional check and synchronise the steering system!
Carry out a functional check of the brake system!
Check hydraulic oil level. Fill up if necessary!
Check engine oil level. Fill up if necessary!
Compress the dust valve
Check radiator for engine coolant and hydraulic oil for contamination. Clean if necessary!
Check condition and initial tension of V-belts. Retighten or replace if necessary!
Leakage check:
Check for tightness, leaks and chafing: pipes, flexible lines and screw connections. Rectify if necessary!
Leakage check:
Check the fuel/water separator. Drain water if necessary!
Lubrication service:
Lubricate the assemblies concerned!

3.2 Maintenance label

Location: inside the cab on the rear window
100 010 40 14
Täglich
10 h Daily
Tous les jours
50 h
342 00 343 01 346 03 347 02
342 01 346 01 346 04 347 03
343 00 346 02 347 01 347 04

3.3 Fluids and lubricants

Engine/ Season/
Component/application SAE grade Specification Capacities1
machine fluid temperature
SAE 10W; EO103 Below -5 °C
3
SAE 20W20; EO20 -10 to +10 °C
2
Engine oil with oil
Diesel engine SAE 30; EO303 5 to 30 °C About 10.5 l
filter
3
HD-C 10W-40; EO1040B
Year-round
HD-C 15W-40; EO1540B3
Gearbox 0.8 l
Front and rear axle differentials 85 W 90 API GL5 or 4.0 l
Gearbox oil4 Year-round
SAE 90 LS (hypoid gear oil)
Planetary drives - left and right,
0.9 l each
front and rear axles
SAE 5 W/30 Up to -25 °C
3
SAE 5 W/40; EO 0540B
Engine oil2
SAE 10 W/40; EO 0540B3 Up to -15 °C
3
Hydraulic oil tank SAE 15 W/40; EO 1540B Up to -10 °C About 50 l
5 3
Hydraulic oil HVLPD 46 (HYD0530 )
AVILUB Syntofluid 46 Year-round
Biodegradable oil
PANOLIN HLP Synth 46
Lithium-saponified brand-name
Grease nipples, loader unit/axles Multipurpose grease Year-round As required
grease MPG-A3
Battery terminals Acid-proof grease SP-B3 Year-round As required
Anticorrosion
Aggressive media (option) Anticorit BW 3666 Year-round As required
protection
Optimoly paste “TA”7 White-
Mounting of pins, shafts Special grease Year-round As required
Paste
Grade no. 2-D Over 4 °C
Fuel tank Diesel fuel8 About 60 l
Grade no. 1-D Below 4 °C
Brake system Brake fluid9 Agip LHM Super/Shell LHM Year-round -
Water
10, 11, 12 Year-round 5.2 l (45 %)
Engine cooling Antifreeze MS Frostschutz HAVOLINE XLC
-31 °C Antifreeze
4.3 l (55 %)
Water
11 Year-round 1.3 l (67 %)
Washer system Cleaning agent Water + antifreeze
-20 °C Antifreeze
0.7 l (33 %)
1. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
2. MIL-L-2104C; API CD/CE/CH4; CCMC-D4
3. Abbreviation for lubricants (Hauptverband der Deutschen Bauindustrie e. V. - German construction engineering association)
4. MIL-L-2105B; API-GL5
5. DIN 51 524
6. TI 8030-015/K 19/MIL-C-16 173 C-Grade 4
7. 250 gr tube, order no.: 1000030311
8. DIN EN 590
9. Standard: B 71 2710
10. SeeCoolant compound table on page 2-8
11. See manufacturer's indications on the packaging and bear in mind the antifreeze compound table
12. Replace the coolant every 2 years!

Maintenance plan/service hours (s/h)
3.4 Maintenance plan
Work description
“A”
“B”
“C”
work
For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the
Delivery
at 100 s/h
inspection
attachment manufacturer as well.
once a year
every 50 s/h
(once a day)
once a week
Maintenance
every 500 s/h2
every 1500 s/h
2nd Inspection
1st Inspection1
Oil and filter changes ( ):
Carry out the following oil and filter changes (check oil levels after test run):
• Engine oil ● ● ●
• Engine oil filter ● ● ●
Serv-HB 34603_04 En - Edition 1.0 * 34603_04s520.fm

• Fuel filter, fuel prefilter ● ● ●
• Air filter insert 3,4 replace safety cartridge every 3rd time the air filter insert is replaced ● ●
• Gearbox oil in front and rear axle differentials and in rear axle gearbox ● ●
• Gearbox oil in front and rear axle planetary drives (left and right) ● ●
• Hydraulic oil5 ●
• Microfilter (line filter in drive) ● ●
• Hydraulic oil filter insert ● ●
• Hydraulic oil tank breather filter 4 ●
• Heating: fine-dust filter6 ● ●
Inspection work ( ):
Check the following material. Refill if necessary:
• Engine oil ● ● ●
• Hydraulic oil ● ● ● ● ● ●
• Engine coolant 7(also check antifreeze in autumn/winter and at temperatures below 4 °C!) ● ● ● ● ● ●
• Gearbox oil in front and rear axle differentials and in rear axle gearbox ● ● ● ●
• Gearbox oil in front and rear axle planetary drives (left and right) ● ● ● ●
• Brake fluid8 ● ● ● ● ● ●
• Check radiator for engine and hydraulic oil for contamination. Clean if necessary9 ● ● ● ● ●
5 ● ●
• When using biodegradable oil: drain the condensation water in the hydraulic oil tank
• Clean dust valve on air filter housing ● ● ● ● ● ●
• V-belts: check condition and pre-tension. Retighten or replace if necessary10 ● ● ● ● ● ●
• Check the fuel/water separator. Drain water if necessary ● ● ● ●
• Clean filter insert on fuel pump, replace if necessary ● ● ● ●
• Check valve tip clearance (engine timing). Set if necessary ●
3-4
3-5
Work description
“A”
“B”
“C”
work
Delivery
at 100 s/h
inspection
once a year
every 50 s/h
(once a day)
once a week
Maintenance
every 500 s/h2
every 1500 s/h
1st Inspection1
2nd Inspection
Other inspection work ( ):
• Battery: check charge condition ● ●
• Heating: clean the fine-dust filter ●
• Check and set service and parking brake pads. Replace if necessary ● ● ●
• Tyre check (damage, air pressure, tread depth) ● ● ● ● ● ●
• Aggressive media (option): check anticorrosion protection, renew if necessary11 ● ● ● ●
Check screws and nuts or screw connections for tightness on the following assemblies/components. Retighten if necessary
• Engine and engine bearing ● ● ●
• Steering system ● ● ●
• Hydraulic system ● ● ●
• Loader unit (pin locking) ● ● ●
• Axle mounting, axle suspension ● ● ●
• Counterweight (attachment) ● ● ●
• Fastening screws of cardan shafts ● ● ●
• Fastening screws of cab ● ● ●
• Wheel nuts ● ● ● ●
Electric system: check electric and earth connections, chafing on wiring harness, battery terminals ● ● ● ●
Lubrication service ( ):12
Lubricate the following assemblies/components:
• Hinges, joints and fittings (e.g. door arrester) ● ● ● ● ●
• Rear axle oscillating bearing ● ● ● ● ●
• Front and rear axle planetary drive bearings (left and right) ● ● ● ● ●
• Loader unit
• Lift frame bearing ● ● ● ● ● ●
• Tilt rod bearing ● ● ● ● ● ●
• Tilt lever bearing ● ● ● ● ● ●
• Lift ram bearing ● ● ● ● ●
• Tilt ram bearing ● ● ● ● ●
• Quickhitch: bearing on lift frame ● ● ● ● ● ●

Work description
“A”
“B”
“C”
work
Delivery
at 100 s/h
inspection
once a year
every 50 s/h
(once a day)
once a week
Maintenance
every 500 s/h2
every 1500 s/h
2nd Inspection
1st Inspection1
Functional check ( ):
Check the function of the following assemblies/components. Rectify if necessary:
• Service and parking brake ● ● ● ● ● ●
• Steering system ● ● ● ● ● ●

• Lights and electric system ● ● ● ● ● ●
• Air conditioning (option) ● ● ● ● ● ●
Leakage check ( ):
Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary:
• Air intake line (air filter - engine) ● ● ● ● ● ●
• Engine lubrication (engine - filter) ● ● ● ● ● ●
• Fuel lines13 ● ● ● ● ● ●
• Cooling system (engine - hydraulic oil) ● ● ● ● ● ●
• Steering system (flexible lines and rams) ● ● ● ● ● ●
• Hydraulic system/loader unit (flexible lines14 and rams) ● ● ● ● ● ●
• Brake system (flexible lines and cylinders) ● ● ● ● ● ●
• Air conditioning flexible lines (option) ● ● ● ● ● ●
1. Work to be carried out once after the first 100 s/h. This work must be carried out by an authorised workshop for warranty claims to be acknowledged.
2. Work after the first 500 s/h (2nd Inspection) must be carried out by an authorised workshop for warranty claims to be acknowledged
3. Replace filter insert as indicated by the telltale on the air filter housing, however at least every 12 months or 1500 s/h.
4. When working in an acidic environment, replace the filter every 300 s/h!
5. When using biodegradable oil: drain the condensation water in the hydraulic oil tank every 500 s/h, in any case before the cold season.
6. Depending on operation and dust conditions, it may be necessary to replace the fine-dust filter more frequently
7. Replace the engine coolant every other year!
8. Replace every 2 years
9. Depending on operation and dust conditions, it may be necessary to clean the radiator more frequently
10. Replace the toothed belt every 3000 s/h or after 5 years at the latest (toothed belt must be replaced by authorised staff)
11. See maintenance instructions for aggressive media, order no. 1000108296
12. Lubricate attachment according to manufacturer's instructions!
13. Replace flexible fuel leak oil lines every 2 years
14. Replace flexible lines every 6 years (UVV, DIN 20066 part 5)
3-6
3.5 Important information on maintenance and service work
Danger!
Do not carry out assembly and maintenance work if the loader unit is raised
and not secured -
Danger of crushing and injury!
☞ Secure the loader unit with an appropriate prop or support to prevent it from
being lowered unintentionally
☞ Also follow the instructions given in chapter 2 “SAFETY INSTRUCTIONS”
of this Operator's Manual
☞ Also follow the instructions given in the Operator's Manuals of the attach-
ments
Operational readiness and the service life of machines are heavily dependent on mainte-
nance.
It is therefore in the interest of the machine owner to carry out the prescribed maintenance
work.
Before carrying out service and maintenance work, always read, understand and follow
the instructions given in
• chapter 2 “SAFETY INSTRUCTIONS” of this Operator's Manual
• the Operator's Manuals of the attachments.
Important information on maintenance and service work

The maintenance plans indicate when the maintenance work mentioned below must
be carried out.
➥ - see Maintenance plan on page 3-4.
Repair work on separate components

- see chapter 4 “Engine” on page 4-1
- see chapter 5 “Power train” on page 5-1
- see chapter 6 “Axles” on page 6-1
- see chapter 7 “Brakes” on page 7-1
- see chapter 8 “Steering system” on page 8-1
- see chapter 9 “Hydraulic system” on page 9-1
- see chapter 10 “Electric system” on page 10-1

3.6 Fuel system

General safety instructions for refuelling
• Extreme caution is essential when handling fuel - high risk of fire!
• Never carry out work on the fuel system in the vicinity of naked flames or sparks!
• Do not smoke when working on the fuel system or when refuelling!
• Before refuelling, switch off the engine and remove the ignition key!
• Do not refuel in closed rooms!
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner! Keep the machine clean to reduce the risk of
fire and wipe away fuel spills immediately!
Diesel fuel specification

Use only high-grade fuels
Grade Cetane number Use
No. 2-D according to EN 590 For normal outside temperatures
Min. 45 For outside temperatures below 4 °C or
No. 1-D according to EN 590
for operation above 1500 m altitude
Stationary fuel pumps

General
Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually contaminated.
Even the smallest particles of dirt can cause
• Increased engine wear
• Malfunctions in the fuel system and
• Reduced effectiveness of the fuel filters
Refuelling from barrels
If refuelling from barrels cannot be avoided, note the following points:
wrong ✗ • Barrels must neither be rolled nor tilted before refuelling
• Protect the suction pipe opening of the barrel pump with a fine-mesh strainer
• Immerse it down to a max. 15 cm above the floor of the barrel
• Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter
right ✓ • Keep all refuelling containers clean at all times
Fig. 42: Refuelling from a barrel

Refuelling
The filler inlet of the fuel tank is located on the left-hand side of the machine
Danger!
All work involving fuel carries an increased
Danger of fire and poisoning!
☞ Do not refuel in closed rooms
☞ Never carry out work on the fuel system in the vicinity of naked flames or
sparks
Fig. 43: Fuel filler inlet
Bleeding the fuel system
Danger!
If the fuel, as it drains, comes into contact with hot engine parts or the exhaust
system, there is an increased
Danger of burns!
A ☞ Never bleed the fuel system if the engine is hot!
Environment!
environmentally friendly manner!
Bleed the fuel system in the following cases:

• After removing and fitting the fuel filter, prefilter or the fuel lines back on again
• After running the fuel tank empty
B
• After running the engine again, after it has been out of service for a longer period of
time
☞ Bleed the fuel system as follows:
1 Place the container under the engine
Fig. 44: Bleeding the fuel system
2 Fill the fuel tank
3 Slacken bleed screw A on the injection pump by a few turns
4 Press button B on the fuel pump with your hand (pumping movement) until the fuel
comes out free of air from the slackened bleed screw
5 Tighten bleed screw A
6 Start the engine
If the engine runs smoothly for a while, and then stops; or if it does not run smoothly:
7 Switch off the engine
8 Check once again if there is any air in the fuel system
9 Bleed the fuel system again as described above

3.7 Replacing the fuel filter
B Danger!
A Danger of burns!
☞ Never change the fuel filter if the engine is hot!
Fig. 45: Fuel filter position
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an environmen-
tally friendly manner!
☞ Change fuel filter 45/A as follows:

1 Pinch off fuel feed line 45/B with a suitable tool
2 Thoroughly clean the outside surfaces of fuel filter 45/A
3 Slacken and unscrew fuel filter cartridge using a commercially available tool
4 Collect the fuel as it drains
Fig. 46: Unscrewing the fuel filter
5 Clean the sealing surface of the filter carrier if it is fouled

6 Lightly oil the rubber gasket of the new filter cartridge or apply a thin coat of clean
diesel fuel to it
7 Screw on the cartridge by hand until the gasket makes contact
Fig. 47: Cleaning the sealing surface and oiling the

gasket
8 Tighten the fuel filter cartridge by turning it a further half revolution

9 Remove the tool which has been used to pinch off the fuel feed line 45/B
10 Make a test run - and check for tightness!
11 Dispose of the old fuel filter cartridge by an ecologically safe method
12 Bleed the fuel system - see page 3-12
Fig. 48: Tightening the fuel filter

3.8 Cleaning the fuel pump screen filter
Danger!
Danger of burns!
☞ Never clean screen the filter when the engine is hot!
☞ Proceed as follows:
1 Pinch off fuel feed line 45/B with a suitable tool
2 Slacken and unscrew hexagon head screw A
3 Remove fuel screen B (cover and screen come out together)
B C
4 Clean fuel screen B with fuel, replace if necessary
5 Position sealing rings C
6 Fit fuel screen B (cover with screen) back on
A 7 Tighten hexagon head screw A
8 Remove the tool which has been used to pinch off the fuel feed line 45/B
9 Bleed the fuel system - see page 3-12
Fig. 49: Removing the screen filter
10 Make a test run - and check for tightness!

3.9 Bleeding the fuel system
Danger!
Danger of burns!
A ☞ Never bleed the fuel system if the engine is hot!
Environment!
environmentally friendly manner!
Bleed the fuel system in the following cases:

• After removing and fitting the fuel filter, prefilter or the fuel lines back on again
• After running the fuel tank empty
B
• After running the engine again, after it has been out of service for a longer period of
time
☞ Bleed the fuel system as follows:
1 Place the container under the engine
Fig. 50: Bleeding the fuel system
2 Fill the fuel tank
3 Slacken bleed screw A on the injection pump by a few turns
4 Press button B on the fuel pump with your hand (pumping movement) until the fuel
comes out free of air from the slackened bleed screw
5 Tighten bleed screw A
6 Start the engine
If the engine runs smoothly for a while, and then stops; or if it does not run smoothly:
8 Check once again if there is any air in the fuel system
9 Bleed the fuel system again as described above

3.10 Checking/filling up the engine oil
Caution!
If the engine oil level is too high or too low, or if an oil change is overdue, this
may cause engine damage or loss of output!
☞ Use only the specified engine oil
- see Fluids and lubricants on page 3-3
Important!
Check the oil level every 10 service hours or once a day.
After switching off a warm engine, wait at least 5 minutes before checking.
1 Park the machine on level ground
2 Switch off the engine!
max 3 Apply the parking brake
min
4 Open the engine cover
5 Pull out oil dipstick A
6 Wipe it with a lint-free cloth
7 Push it back in as far as possible
A
8 Withdraw it and read off the oil level
9 However if necessary, fill up the oil at the latest when the oil reaches the MIN mark
Fig. 51: Checking the oil level on the oil dipstick A
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in an environ-
mentally friendly manner!
1 Clean the area around oil filler cap B with a lint-free cloth
OIL 2 Open filler cap B
3 Raise oil dipstick A slightly to allow any trapped air to escape
B 4 Fill in engine oil
5 Wait a moment until all the oil has run into the oil sump
A 6 Check the oil level
7 Fill up if necessary and check the oil level again
8 Close filler cap B
Fig. 52: Oil dipstick and oil filler cap
9 Push oil dipstick A back in as far as possible
10 Completely remove all oil spills from the engine

3.11 Changing engine oil
Danger!
Caution when draining hot engine oil -
+ 80 °C Danger of burns!
☞ Wear protective gloves
☞ Use suitable tools
OIL
Fig. 53: Optimum engine oil temperature
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in an environ-
mentally friendly manner!
☞ Change the engine oil as follows:

B C
2 Let the engine run until reaching service temperature (oil temperature
about 80 °C)
A 4 Place a container (about 12 l capacity) under the opening to collect the oil as it
drains
5 Remove the cover from the frame
Fig. 54: Drain plug at rear end of machine
6 Unscrew cap A of oil drain valve B
7 Screw in drain coupling C with a sufficiently long hose D, making sure the end of
the hose is in oil drip tray E
8 Completely drain the oil
9 Unscrew drain coupling C
10 Screw filler cap A of the oil drain valve with a new seal
B
11 Fill in engine oil
12 Start the engine and let it run briefly at low revs
C 13 Switch off the engine
14 Wait a moment until all the oil has run into the oil sump
D
E 15 Check the oil level again
16 Fill up if necessary and check again
Fig. 55: Drain coupling with hose

3.12 Replacing the engine oil filter cartridge
Danger!
Caution when handling hot engine oil -
A
Danger of burns!
Fig. 56: Engine oil filter position

Environment!
Collect the drained engine oil in a suitable container.
Dispose of used oil and filters in an environmentally friendly manner!

2 Place a suitable container underneath the oil filter to collect the oil as it drains
3 Slacken and unscrew oil filter cartridge A with an oil filter strap wrench
4 Make sure the thread adapter is correctly placed in the filter head
A
Fig. 57: Unscrewing the engine oil filter
5 Clean inside the filter head (arrow)

6 Apply a thin coat of engine oil to the rubber seal (fig. 58/B) of the new oil filter car-
tridge
7 Tighten the new filter cartridge by hand until the gasket makes contact
Fig. 58: Cleaning the filter head and oiling the gasket
8 Tighten oil filter cartridge A by hand by about a further ½ revolution or tighten it

with an oil filter strap wrench to 15 Nm (strap wrenches for torque wrenches are
A commercially available)
9 Check the engine oil level. Fill up if necessary
11 Let the engine run briefly
13 Check the seal of oil filter cartridge A
Fig. 59: Tightening the filter cartridge
14 Check the oil level and fill in engine oil if necessary
15 Dispose of the used oil filter in an environmentally friendly manner

3.13 Cleaning the radiator fins of the oil/water radiator
Danger!
Careful when carrying out maintenance work on a hot engine and radiator -
Danger of burns!
☞ Wait at least 10 minutes after switching off the engine
☞ Wear protective gloves and clothing during maintenance work
Caution!
Dirt on the radiator fins reduces the radiator's heat dissipation capacity and
can cause damage to the engine and the hydraulic system!
In order to ensure the radiator's optimal cooling capacity, do not damage the
radiator fins as you clean them with a compressed-air gun!
☞ Check the radiator once a day for dirt and clean it if necessary
☞ Clean the radiator more frequently in dusty or dirty work conditions
1 Park the wheel loader on level ground

2 Lower the loader unit fully
3 Apply the parking brake with the switch on the instrument panel
4 Switch off the engine and let it cool down
5 Switch off the ignition and remove the ignition key
7 Clean the radiator fins by blowing compressed air outwards from the engine side
Fig. 60: Cleaning the oil cooler

3.14 Checking the coolant level
Danger!
Never open the filler cap of the coolant tank and never drain coolant on a warm
engine since the cooling system is under high pressure -
Danger of burns!
☞ Wait at least 10 minutes after switching off the engine!
☞ Wear protective gloves and clothing
☞ Always actuate the safety valve first on the filler cap of the expansion tank.
To do this:
☞ Open the cap to the first notch and release the pressure
Important!
Check the coolant level every 10 service hours or once a day.
Check before starting the engine.
☞ Check the coolant level as follows:

A 1 Park the machine on level ground
3 Apply the parking brake
MAX
MIN
7 Check the coolant level in the expansion tank A
If the coolant level is below the MIN mark of the expansion tank:
Fig. 61: Expansion tank for coolant 8 Fill up coolant to the MAX mark
9 Check the coolant quality (antifreeze) with suitable testing equipment (antifreeze
tester) - see Coolant compound table on page 2-8 or Fluids and lubricants on
page 3-3

3.15 Draining coolant

☞ Drain/replace the coolant as follows:
E 5 Switch off the ignition and remove the ignition key
6 Set the heating temperature controller to max. temperature in order to drain the
coolant from the heating circuit as well.
8 Allow the engine/coolant to cool down
9 Place a suitable container underneath the outlet of the radiator to collect the cool-
ant as it drains
10 Release the overpressure in the coolant expansion tank A. To do this:
11 Open cap A to the first notch and release the pressure
12 Open filler cap A fully
13 Remove the coolant hose below on the radiator E and drain the coolant
A ☞ Fill up coolant as follows:
1 Fasten the coolant hose back onto radiator E below
2 Fill up coolant up to about 30 mm below filler cap A of the expansion tank. Check
MAX the coolant quality (antifreeze) with suitable testing equipment (antifreeze tester) -
MIN see Coolant compound table on page 2-8 or Fluids and lubricants on page 3-3
3 Close filler cap A fully
4 Open the heating circuit fully
5 Start and warm up the engine until the thermostat opens
7 Check the cooling system and the heating water circuit for leaks
8 Check the coolant (MAX mark)
9 If necessary, fill in coolant and repeat the procedure until reaching the correct
coolant level

3.16 Filling up coolant
Danger!
Never open the coolant tank and never drain coolant if the warm engine is
running since the cooling system is under high pressure -
Danger of burns!
☞ Wait at least 10 minutes after switching off the engine!
☞ Wear protective gloves and clothing
☞ Always actuate the safety valve first on the filler cap of the expansion tank.
To do this:
☞ Open the cap to the first notch and release the pressure
☞ Fill up coolant as follows:

A
2 Lower the loader unit
MAX 5 Allow the engine/cooling system to cool down
MIN ☞ Release the overpressure in the coolant expansion tank. To do this:
1 Open cap A to the first notch and release the pressure
2 Open filler cap A fully
3 Fill up coolant to the MAX mark
Fig. 62: Filling up coolant in the expansion tank
4 Use brand-name antifreeze compounds with anticorrosion additives. Check the
coolant quality (antifreeze) with suitable testing equipment (antifreeze tester) -
see Coolant compound table on page 2-8 or Fluids and lubricants on page 3-3
5 Close filler cap A
6 Start and warm up the engine, as you do so:
7 Open the heating circuit fully
9 Check the cooling system and the heating water circuit for leaks
10 Check the coolant level again
11 If necessary, fill in coolant and repeat the procedure until reaching the correct
coolant level

3.17 Hydraulic system

Specific safety instructions
• Release the pressure in all lines carrying hydraulic oil prior to any maintenance and
repair work. To do this:
• Lower all hydraulically controlled attachments to the ground
• Move all control levers of the hydraulic control valves several times
• Apply the parking brake to prevent the machine from rolling away before you carry out
service and maintenance work
• Hydraulic oil escaping under high pressure can penetrate the skin and cause serious
injuries. Always consult a doctor immediately even if the wound seems insignificant -
otherwise serious infections could set in!
• If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has
penetrated the hydraulic system. This may cause damage to the hydraulic pump!
☞ Contact your KRAMER ALLRAD dealer immediately
Caution!
Contaminated hydraulic oil, lack of oil or wrong hydraulic oil -
Danger of severe damage to the hydraulic system!
☞ Take care to avoid contamination when working!
☞ Always fill in hydraulic oil using the filling screen!
☞ Only use authorised oils of the same type - see Fluids and lubricants on
page 3-3
☞ Always fill in hydraulic oil before the level gets too low
☞ If the hydraulic system is filled with biodegradable oil, then only use biode-
gradable oil of the same type for filling up - observe the sticker on the
hydraulic oil tank!
☞ Contact customer service if the hydraulic system filter is contaminated with
metal chippings. Otherwise, follow-on damage may result!
Environment!
Collect drained hydraulic oil and biodegradable oil in a suitable container! Dispose of
drained oil and used filters by an ecologically safe method.
Always contact the relevant authorities or commercial establishments in charge of oil dis-
posal before disposing of biodegradable oil.

3.18 Checking hydraulic pressure lines

Danger!
Caution when checking hydraulic lines, especially when searching for leaks.
Hydraulic oil escaping under high pressure can penetrate the skin and cause
serious injuries.
☞ Always consult a doctor immediately, even if the wound seems insignificant
- otherwise serious infections could set in!
☞ Always observe the following instructions:
• Retighten leaking screwed fittings and hose connections only when the
system is not under pressure; i.e. release the pressure before working
on pressurised lines!
• Never weld or solder damaged or leaking pressure lines and screw con-
nections. Replace damaged parts with new ones!
• Never search for leaks with your bare hands, but wear protective gloves!
• Use paper or wood to check for minor leaks. Never use an unprotected
light or naked flame!
• Have damaged flexible lines replaced by authorised workshops only!
• Leaks and damaged pressure lines must be immediately repaired or replaced by an

authorised workshop or after-sales staff.
This not only increases the operating safety of your machine but also helps to protect
the environment
• Replace hydraulic hoses every 6 years from the date of manufacture, even if they do
not seem to be damaged
In this respect, we recommend that you observe all the relevant safety regulations for
hydraulic lines, as well as the safety regulations regarding accident prevention and occu-
pational health and safety in your country. Also observe DIN 20066, part 5.
The date of manufacture (month or quarter and year) is indicated on the flexible line.
1 Q/08 Example:
The indication “1 Q/08” means manufactured in the 1st quarter of 2008.

3.19 Monitoring the hydraulic oil reflux filter

On the instrument panel, the red telltale 39 monitors reflux pressure and the reflux filter,
40
and telltale 40 monitors oil temperature.
39 ☞ If telltale 39 comes on
➥ the reflux pressure in the filter is too high or
1
☞ if telltale 40 comes on
➥ the hydraulic oil temperature is too high
☞ At the latest after 1500 service hours (once a year)
Telltale 39 on the instrument panel can come on in cold weather immediately after starting
the engine. This is caused by increased oil viscosity. In this case:
☞ Set engine revs so that telltale 39 on the instrument panel goes out
Fig. 63: Preheating start switch
☞ Bear in mind the instructions concerning warmup
Important information for the use of biodegradable oil

• Use only the biodegradable hydraulic fluids which have been tested and approved by
Kramer-Werke GmbH Fluids and lubricants on page 3-3. Always contact Kramer-
Werke GmbH for the use of other products which have not been recommended. In
addition, ask the oil supplier for a written declaration of guarantee. This guarantee is
applicable to damage occurring on the hydraulic components, which can be proved to
be due to the hydraulic fluid
• Use only biodegradable oil of the same type for filling up. In order to avoid misunder-
standings, a label providing clear information is located on the hydraulic oil tank (next to
the filler inlet) regarding the type of oil currently used! Replace missing labels!
The joint use of two different biodegradable oils can affect the quality of one of the oil
types. Therefore, make sure the remaining amount of initial hydraulic fluid in the
hydraulic system does not exceed 8 % when changing biodegradable oil (manufacturer
indications)
• Do not fill up with mineral oil - the content of mineral oil should not exceed 2 % in order
to avoid foaming problems and to ensure biological degradability
• When running the machine with biodegradable oil, the same oil and filter replacement
intervals are valid as for mineral oil - see maintenance plans in the appendix
• Have the condensation water in the hydraulic oil tank drained by an authorised
workshop every 500 service hours, in any case before the cold season. The water
content must not exceed 0.1 % by weight
• The instructions in this Operator's Manual concerning environmental protection are also
valid for the use of biodegradable oil
• If additional hydraulic attachments are mounted or operated, use the same type of
biodegradable oil for these attachments to avoid mixtures in the hydraulic system.
Subsequent change from mineral oil to biodegradable oil must be carried out by
an authorised workshop or by your KRAMER-ALLRAD dealer

3.20 Maintenance of the hydraulic oil reflux filter

The red telltale on the instrument panel monitors the filter. Replace the filter insert:
• If the telltale comes on when the hydraulic oil is at operating temperature
• At the latest after 1500 service hours (once a year)
In cold weather the telltale can come on immediately when the engine is started. This is
caused by increased oil viscosity. In this case:
☞ Set engine speed so that the telltale goes out
☞ Bear in mind the instructions concerning warmup (see Operator's Manual, chapter 3)
Changing the filter insert
Caution!
Contamination may cause
Severe damage on the hydraulic system!
☞ Take care to avoid contamination when working!
A
3 Open breather filter A of the hydraulic oil tank
4 Slacken cap F and 65/1 of the filter by about 2 turns and wait for the oil level in the
filter housing to drop to the oil level of the hydraulic oil tank
5 Unscrew cap F and 65/1 of the filter completely and remove it
F
Fig. 64: Location of hydraulic oil reflux filter
6 Pull out filler pipe 2 with filter insert 3, turning them slightly
7 Remove filter insert 3 from filler pipe 2 and dispose of it
1 4
8 Check that flat gasket 4 on filter cover 1 and O-ring 5 on the filler pipe are in per-
2 fect condition
5
3 2 9 Fit new O-rings if the old ones are damaged
10 Slide filler pipe 2 onto the new filter insert 3 and insert it into the filter
308b1100.eps
11 Tighten cap 64/F and 1 by hand (tightening moment 20 Nm)
12 Tighten breather filter 64/A by hand
Fig. 65: Exploded view of hydraulic oil reflux filter 13 Carry out a test run of the hydraulic system
With the engine switched off:
14 Check the filter for leaks

3.21 Checking the hydraulic oil level

2 Retract all hydraulic rams
✓ A 3 Switch off the engine
6 Check the hydraulic oil level in sight glass A
If the oil level is visible in the lower half of the oil level sight glass
➥ OK
If the oil level is not visible in the oil level sight glass (not enough oil)
Fig. 66: Oil level sight glass on the hydraulic oil tank
➥ Fill up the hydraulic oil
Caution!
Any excess quantity of hydraulic oil in the tank escapes via the breather as
soon as the temperature rises!
If the oil level is no longer visible in the upper half of the oil level sight glass
☞ Drain the hydraulic oil
3.22 Filling up hydraulic oil

Do not fill up the hydraulic oil unless the engine is switched off. Otherwise, hydraulic oil will
run out of the filler opening on the hydraulic tank.
☞ Fill up as follows:
B 1 Park the machine on level ground
2 Retract all hydraulic rams
6 Clean the area around the filler and breather filter B with a cloth
7 Place a container to collect the oil as it drains
8 Open breather filter B by hand
Fig. 67: Hydraulic oil tank
With the filter insert in place
9 Fill up the hydraulic oil
10 Check the hydraulic oil level in the oil level sight glass (fig. 66/A)
11 Fill up if necessary and check again
12 Firmly close breather filter B by hand

3.23 Replacing hydraulic oil
Danger!
Caution when draining hot hydraulic oil and removing the filter element -
Danger of burns!
☞ Use an oil drain coupling with a sufficiently long hose
2 Lower the loader unit completely. To do this: push the lever forwards
3 Tilt in the bucket completely. To do this: push the lever to the left
4 Switch off the engine and prevent the machine from rolling away
6 Unscrew cap 67/B from the hydraulic oil tank
Under the rear end of the machine:
D
7 Place a suitable container of a minimum capacity of 55 l to collect the oil as it
E drains
8 Remove cap C of the oil drain valve
9 Screw oil drain coupling D onto the oil drain valve with a sufficiently long hose,
C making sure the end of the hose is in the oil drip tray
10 Oil drain valve E opens and the oil runs into the container
11 Rinse the hydraulic oil tank with a little hydraulic oil
Fig. 68: Oil drain valve with cap 12 Unscrew oil drain coupling D from oil drain valve E
13 Screw cap C of the oil drain valve back on again
14 Replace the hydraulic oil reflux filter - see Maintenance of the hydraulic oil reflux
filter on page 3-23
15 Check whether the filling screen is installed and not damaged
Caution!
Contaminated hydraulic oil -
Danger of severe damage to the hydraulic system!
☞ Always fill in hydraulic oil using the filling screen!
16 Fill in fresh hydraulic oil up to the middle 66/A of the oil level sight glass
17 Screw cap 67/B back onto the hydraulic oil tank
18 Start the engine
With the engine running at low speed:
19 Fully extend the lift and tilt rams on the loader unit
20 Turn the steering wheel to the left and right several times, from lock to lock
21 Retract all the hydraulic rams again
23 Check the hydraulic oil level again and fill up if necessary

3.24 Oil levels: rear axle transfer gearbox
Important!
Only use new sealing rings for oil filler and drain plugs. Drain oil only after running
the machine for a longer period of time!
Checking the oil level

1 Park the machine on level ground when the gearbox is at operating temperature
A
2 Clean and unscrew plug A on the transfer gearbox
If the oil level is below the opening or if the oil level cannot be seen at all:
3 Fill up the oil
If the oil level is correct:
4 Tighten plug A with a new sealing ring to make an oil-tight seal
Filling up oil
Fig. 69: Transfer gearbox oil level
3 Fill in oil until it runs out of the filler opening
If the oil level in the gearbox remains constant:
Changing the oil
Danger!
Careful when draining hot gearbox oil -
Danger of burns!
☞ Use suitable tools, e.g. for unscrewing the oil drain plug
2 Place a sufficiently large container under the transfer gearbox to collect the oil
A
4 Unscrew screw B on the transfer gearbox
5 Completely drain the old gearbox oil
6 Tighten plug B with a new sealing ring to make an oil-tight seal
B If the oil level in the gearbox remains constant:
Fig. 70: Transfer gearbox oil level
Run the machine warm
9 Check the oil level again after about 5 minutes, and fill up if necessary

3.25 Oil levels: front and rear axle differentials
Environment!
Use a suitable container to collect the gearbox oil as it drains and dispose of it in an envi-
ronmentally friendly manner!
Important!
Only use new sealing rings for oil filler and drain plugs. Drain oil only after running
the machine for a longer period of time!
Checking the oil level

Rear axle
2 Clean and unscrew plugs A
3 If the oil level is below the opening or if the oil level cannot be seen at all:
4 Fill up the oil
If the oil level is correct:
5 Tighten plugs A with new sealing rings to make oil-tight seals
Filling up oil
A
2 Clean and unscrew plug A
Front axle
Changing the oil

1 Park the machine on level ground when it is at operating temperature
2 Place a container under plug B to collect the oil
3 Clean and unscrew plug A (axle tube)
4 Clean and unscrew plug B
5 Completely drain the old oil
6 Tighten plug B with a new sealing ring to make an oil-tight seal
7 Fill in fresh oil through opening A (axle tube) until it runs out of the filler opening
8 Tighten plug A (axle tube) with a new sealing ring to make an oil-tight seal
B
Run the machine warm
9 Check the oil level again after about 5 minutes, and fill up if necessary
Fig. 71: Checking the oil level/draining the oil in the axle

3.26 Oil levels: front and rear axle planetary drives

Checking and filling up the oil level
Important!
Fit new sealing rings! Drain oil only after running the machine for a longer period of
A time!
Fig. 72: Oil filler and inspection plug on planetary drive 1 Park the machine on level ground and secure it against rolling away
2 Place plug A in the position shown in fig. 72 (plug must be at the top)
3 Clean and unscrew plug A (to release possible overpressure)
4 Place plug A in the position shown in fig. 73 (plug must be in horizontal position)
5 Remove plug A
If the oil level is below the opening or if the oil level cannot be seen at all:
6 Fill in fresh oil through opening 73/A until it runs out of the filler opening
A 7 Tighten plug 73/A with a new sealing ring to make an oil-tight seal
Fig. 73: Oil filler and inspection plug on planetary drive
Changing the oil

1 Park the machine at operating temperature on level ground and secure it against
rolling away
A 2 Place a suitable container under drain plug A
3 Place plug A in the position shown in fig. 74 (plug must be at the top)
4 Clean and unscrew plug A (to release possible overpressure)
Fig. 74: Oil drain plug on planetary drive Never raise the machine on one side only for the following work!
5 Turn the planetary drive downwards (plug must be at the bottom)
6 Remove plug A
7 Completely drain the old oil
8 Place opening A in the position shown in fig. 75 (plug must be in horizontal
position)
9 Fill in fresh oil through opening A until it runs out of the filler opening
Fig. 75: Oil filler and inspection plug on planetary drive

3.27 Air filter maintenance
Caution!
The filter cartridge will be damaged if it is washed or brushed out!
Bear in mind the following to avoid premature engine wear!
☞ Do not clean the filter cartridge
☞ Replace the filter cartridge when the telltale comes on
☞ Never reuse a damaged filter cartridge
☞ Ensure cleanliness when replacing the filter cartridge!
Checking the air filter for dirt

Maintenance display B on the filter housing monitors the filter cartridge. The dust is
removed by squeezing discharge slot E of the dust valve.
☞ Checking the dust valve E
2 Remove the ignition key
4 Squeeze the discharge slot of dust valve E
5 Remove hardened dust by compressing the upper area of the valve
E 6 Clean the discharge slot if necessary
☞ Filter cartridge D must be replaced if:
• If the red mark C in maintenance display B is visible
A B C • At the latest after 1500 service hours (however once a year)
- see Replacing the air filter cartridge on page 3-30
Important!
For applications in dusty environment, the air filter is fitted with an extra safety
cartridge F (standard). Do not clean the safety cartridge. Replace the safety car-
tridge every third time maintenance work is carried out!
Caution!
Filter cartridges degrade prematurely when in service in acidic air for longer
periods of time. This risk is present for example in acid production facilities,
steel and aluminium mills, chemical plants and other nonferrous-metal plants.
34001b520_02.iso
☞ Replace filter cartridge D and safety cartridge F at the latest after
E F 500 service hours!
Fig. 76: Air filter with safety cartridge ☞ - see Replacing the air filter cartridge on page 3-30

3.28 Replacing the air filter cartridge

☞ Change the filter cartridge as follows:
H 1 Switch off the engine
2 Prevent the machine from rolling away and remove the ignition key
G
K 4 Fold both bow hooks G to the outside, off the notch of the upper housing section H
5 Remove the lower housing section K
6 Carefully remove filter cartridge D with slightly turning movements
307b0700.ai 7 In addition, every 3rd time the filter is replaced, carefully remove the safety car-
Fig. 77: Removing the lower housing section tridge fig. 76/F with slightly turning movements
Caution!
H D
Bear in mind the following to avoid premature engine wear!
☞ Make sure all contamination (dust) inside the upper and lower housing sec-
tions has been removed
307b0710.ai
☞ Carefully insert new safety cartridge 76/F into the upper housing section H
☞ Carefully insert new filter cartridge D into the upper housing section H
Fig. 78: Removing the filter element
☞ Clean the dust valve fig. 76/E
☞ Position lower housing section K (make sure it is properly seated)
☞ Fold and close both bow hooks G on the notch of the upper housing
section H
☞ After replacing the filter:

A B C 1 Reset the red mark C in the inspection window of indicator B
2 Press reset button A
Fig. 79: Air filter with maintenance display

3.29 Maintenance of the diesel engine V-belts
Danger!
Only check or retighten/replace the V-belts when the engine is switched off -
☞ Switch off the engine before carrying out inspection work in the engine
compartment!
Caution!
Cracked and stretched V-belts cause engine damage
☞ Replace the V-belts every 2 years at the latest
☞ Have the V-belts replaced by an authorised workshop
Checking V-belt tension

Check the V-belts once a day or every 10 service hours, and retighten if necessary!
Retighten new V-belts after about 15 minutes of running time.
☞ Check as follows:
About 10 mm 2 Prevent the machine from rolling away and remove the ignition key
1 3 Carefully inspect V-belt 1 for damage
4 Press with your thumb to check whether the V-belt can be deflected between the
pulleys by no more than about 10 mm
5 Retighten the V-belt if necessary
Fig. 80: Checking V-belt tension
Retightening the V-belts

☞ Retighten as follows:
4 1 Switch off the engine
2 Prevent the machine from rolling away and remove the ignition key
3 Slacken fastening screws 3 of alternator 4
A
4 Use a suitable tool to push the alternator in the direction of arrow A until the correct
V-belt tension is obtained (fig. 80)
5 Keep the alternator in this position, and at the same time retighten fastening
3
screws 3
6 Check V-belt tension (fig. 80) again
Fig. 81: Retightening the V-belts

3.30 General lubrication work

Lubricate all lubrication points mentioned below with lithium-saponified brand-name
grease - see Fluids and lubricants on page 3-3
Lubricating the rear axle oscillation-type bearing
Important!
The machine has an oscillation-type rear axle. Grease the bearing at the latest
after every 50 service hours or once a week.
A ☞ Lubricate grease nipple A of the oscillation-type bearing
Fig. 82: Grease nipples for oscillation-type bearing
Lubricating the front and rear axle planetary drive bearings

☞ Lubricate grease nipples B (2x) on each planetary drive bearing every 50 service
hours or once a week
Fig. 83: Grease nipples on planetary drive bearings

3.31 Lubricating the loader unit

Lubricate the following lubrication points on the loader unit of the machine:
C
☞ Lubricate grease nipple C on the tilt ram bearing on the frame with grease every
50 service hours (or once a week). Lubricate more frequently when in heavy-duty
operation (once a day)
D ☞ Lubricate grease nipple D on the loader unit bearing every 50 service hours (or once
a week). Lubricate more frequently when in heavy-duty operation (once a day)
☞ Lubricate grease nipple E on the lift ram bearing on the frame every 50 service hours
E (or once a week). Lubricate more frequently when in heavy-duty operation (once a day)
Fig. 84: Lubrication points on frame
☞ Lubricate grease nipple F on the tilt rod bearing every 10 service hours (or once a
week). Lubricate more frequently when in heavy-duty operation (once a day)
F ☞ Lubricate grease nipple G on the tilt ram bearing every 50 service hours (or once a
L G ☞ Lubricate grease nipple H on the lift ram bearing every 50 service hours (or once a
☞ Lubricate grease nipple I on the tilt lever bearing every 10 service hours (or once a
☞ Lubricate grease nipples K on the quickhitch bearing every 10 service hours (or once
a week). Lubricate more frequently when in heavy-duty operation (once a day)
☞ Lubricate grease nipples L on the tilt lever bearing every 10 service hours (or once a
K I H
Fig. 85: Lubrication points for lift and tilt ram bearings
3.32 Maintenance of attachments
Important!
Correct maintenance and service is absolutely necessary for smooth and continu-
ous operation, and for an increased service life of the attachments. Please
observe the lubrication and maintenance instructions in the Operator's Manuals of
the attachments!

3.33 Lubricating with the central lubrication system (option)

General functional description of the central lubrication system
The central lubrication system allows you to lubricate all lubrication points of the wheel
loader in one single step.
• The yellow LED or the green telltale in the cab (option) comes on for 1.5 seconds upon
switching on ignition to indicate functional readiness of the controls (switch-on check). It
stays lit during the entire lubrication procedure.
• The integrated electronic control unit has a data memory for saving the times that have
been set or that have elapsed. The time is taken and saved if ignition is switched off
during lubrication or during a break. The remaining lubrication time or break time is
read from the memory upon switching ignition on again, and lubrication is resumed
where it was interrupted.
Time control
Break and lubrication times can be set with the time-dependent control of the central lubri-
cation system. Break times are the periods between two lubrication times - see Setting the
lubrication and break times on page 3-35.
Tip switch for intermediate lubrication

☞ Press the tip switch to position B
➥ The machine is being lubricated
➥ Lubrication time is controlled by means of the integrated controls in the lubrication
system - see Setting the lubrication and break times on page 3-35
☞ Release the tip switch
➥ Lubrication is stopped
A
Important!
B
Pressing the tip switch starts intermediate lubrication at any given time if ignition is
switched on. This also serves as a functional check. The pump then immediately
starts with a lubrication cycle. The lubrication or break time that has elapsed so far
55 or that has been saved is reset and starts over again.
A lubrication system malfunction can also be reset by pressing the tip switch, and
the pump restarts lubrication.
Fig. 86: Switch for hazard warning system

Setting the lubrication and break times

Break times and lubrication times are set with the notched switches S and P in the window
of the controls.
Break time ☞ Remove the red frame on the protective motor housing of the pump with a flat screw-
driver to set the time
Lubrication time
☞ Slacken the four cross-slotted screws and remove the transparent cover
☞ Set the break time P and the lubrication time S with a flat screwdriver
Lubrication times (S)
➥ 1 to 16 minutes (16 notches, each 1 minute)
➥ 2 to 32 minutes (16 notches, each 2 minutes)
Break time (P):
➥ 0.5 to 8 h (16 notches, each 0.5 h)
S P L Yellow LED (L)
➥ (B) lubrication system in operation
B ➥ (A) lubrication under progress: 0.5 seconds LED ON/0.5 seconds LED OFF
☞ Install the transparent cover (window) once the settings are carried out
A
Fig. 87: Setting the lubrication times Caution!
Water can penetrate into the controls and damage them if the cover is not
fitted and closed correctly!
Filling the central lubrication system

The lubrication system is filled via conical grease nipple 1 or a fill coupling with a manual or
pneumatic grease gun.
1
Caution!
Use only commercially available greases up to NLGI-Kl. 2 to avoid damage to
the lubrication system and the lubrication points!
☞ - see Fluids and lubricants on page 3-3
Fig. 88: Filling the central lubrication system

3.34 Brake system maintenance

Brakes are crucial to safety. Incorrect work may cause brake failure. Therefore all mainte-
nance and repair work on the brakes must be carried out by trained staff. An exception to
this is the following work which must be carried out by the driver of the machine:
☞ Daily check of the level in the brake fluid tank!
Danger!
Damaged brake lines or hoses -
☞ Replace damaged brake lines or hoses immediately
Checking/filling up the brake fluid level

The brake fluid tank is located at the front left in the cab (next to the brake/inching pedal)
A
Danger!
An incorrect brake fluid grade or an insufficient brake fluid level may impair the
safety of the brake system -
MAX
MIN ☞ Check the brake fluid in the tank at regular intervals
☞ Fill up brake fluid up to the upper edge of the sight glass
☞ The brake fluid must comply with the LHM SAE specification
Fig. 89: Checking the brake fluid level in the tank - see Fluids and lubricants on page 3-3
☞ The brake fluid must be replaced every 2 years by an authorised workshop
☞ If the brake system loses too much brake fluid, have the brake system
checked and repaired by an authorised workshop
If the level is below the upper edge of the sight glass:

☞ Clean the area around the opening with a clean cloth
☞ Open tank cover A
☞ Fill up brake fluid up to the upper edge of the sight glass MAX
☞ Close tank cover A
Repair work on the brake system

- see chapter 7 “Brakes” on page 7-1

3.35 Tyre maintenance
Danger!
Improper tyre repairs -
☞ All repair work on tyres and rims may only be carried out by authorised
workshops
Important!
Regular inspections of the tyres
• Improve operating safety
• Increase the service life of the tyres
• Reduce machine downtimes
• Refer to the table in chapter “Specifications” on page 2-7 for the authorised tyre
types and the correct tyre pressures. A tyre table sticker is also affixed on the
front window of the machine.
Daily tyre checks

☞ Carry out the following maintenance work once a day:
• Check tyre pressure
- see chapter “Specifications” on page 2-7
• Check tyres and rims for damage (cracks, ageing etc.) - also on the inside
• Remove foreign bodies from the tyre tread
• Remove traces of oil and grease from the tyres

3.36 Changing wheels
Danger!
Use of wrong tyres or wheels -
☞ Use only wheels and tyres authorised for your machine - see page
➥ - see chapter “Specifications” on page 2-7
☞ Check the wheel nuts for tightness after every wheel or tyre change
➥ - see chapter 2 “Specific tightening torques” on page 2-9
Caution!
The wheels are heavy and can damage the threads on the wheel studs if they
are handled incorrectly!
☞ Use suitable assembly tools, such as covering sleeves for the studs,
a jack etc.
Removing the wheels

1 Park the machine on level and firm ground and prevent it from rolling away
2 Slightly loosen the wheel nuts of the wheel you want to remove
3 Place a jack under the axle beam, making sure it is standing firmly
4 Raise the side of the axle from which you want to remove the wheel
5 Check the machine is standing firmly
6 Completely remove the wheel nuts
7 Remove the wheel
Fitting the wheels
1 Place the wheel onto the wheel studs
2 Tighten all wheel nuts part-way
3 Lower the raised axle
4 Tighten the wheel nuts to the prescribed tightening torque
- see chapter 2 “Specific tightening torques” on page 2-9

3.37 Maintenance of cab heating and fresh air filter

The heating system of the machine is equipped with a fine-dust filter (EU4, option) which
must be cleaned at regular intervals and replaced once a year, as appropriate.
➥ - see Maintenance plan on page 3-4
The fine-dust filter is located behind the maintenance flap on the right on the outside of the
cab.
Cleaning the dust filter of the heating system

A fine-dust filter cleans the air taken in by the heater. The volume of warm air flowing out of
the air vents decreases as filter contamination increases.
☞ Clean the filter as follows:
1 Open maintenance flap A
2 Remove dust filter B
A 3 Clean dust filter B with compressed air, replace if necessary
4 Close maintenance flap A
Fig. 90: Replacing the dust filter of the heating system

3.38 Air conditioning (option): maintenance

General instructions regarding the air conditioning system
For your own safety, please bear the following instructions in mind:
• Maintenance and repair work may only be carried out by trained staff or by an
authorised workshop.
• Careful when carrying out maintenance and repair work - sharp-edged fins on the
condensor and the heat exchanger.
• Wear protective equipment (protective gloves and goggles) during maintenance and
repair work.
• Do not carry out maintenance work unless the heating and air conditioning systems are
switched off.
• Bear in mind the pertinent regulations relevant to accident prevention, other generally
acknowledged regulations regarding safety and occupational medicine.
Danger!
Lines and hoses containing refrigerants and cooling fluids are under pressure
and can be hot!
Danger of burns!
☞ Avoid touching parts containing refrigerants.
☞ Switch off the air conditioning during checks and when carrying out mainte-
nance work.
Soldering and welding work on the closed system -
☞ Have repair work carried out by an authorised workshop with trained staff
only

Daily functional and visual checks of the air conditioning

The driver must carry out visual checks once a day
Danger!
Careful when carrying out maintenance work on a hot engine and radiator -
Danger of burns!
☞ Wait at least 10 minutes after switching off the engine
☞ Wear protective gloves and clothing during maintenance work

B 4 Check for damage of the refrigerating and heating lines
5 Check the hoses for tightness, leaks and chafing
6 Check the electric connections for correct condition and tightness
☞ Clean the dirty condenser A
A 7 Remove fastening screws B
8 Fold away condenser A
9 Clean the condenser with compressed air or with a water jet (do not use
high-pressure cleaners)
C
Caution!
Do not damage the fins as you clean the condenser!
10 Mount condenser A once cleaning is over

11 Press with your thumb to check whether the V-belt can be deflected between the
pulleys by no more than about 10 mm (arrow)
12 Replace a damaged V-belt
Caution!
The air conditioning system must be checked and serviced twice a year by
trained staff in an authorised workshop! Replace dehumidifier D every 2 years!
D
Fig. 91: Air conditioning: evaporator, dehumidifier

3.39 Maintenance of the electric system

The battery contains sulphuric acid!
• This acid must not be allowed to come into contact with the skin, the eyes, clothing or
the machine. Therefore when recharging or working near the battery: always wear
goggles and protective clothing with long sleeves
• If acid has been spilt: immediately rinse all affected surfaces thoroughly with water.
• Thoroughly wash any part of the body touched by the acid immediately with
plenty of water and seek medical attention at once!
• Especially when charging batteries, as well as during normal operation of batteries, an
oxyhydrogen mixture is formed in the battery cells - danger of explosion!
• Do not attempt to jump-start the machine if the battery is frozen or if the acid level is
low. The battery can rupture or explode!
• Avoid naked flames and sparks and do not smoke in the vicinity of open battery cells -
otherwise the gas produced during normal battery operation may ignite!
• Use only 12 V power sources. Higher voltages will damage the electric components
• When connecting the battery leads, make sure the poles +/- are not inverted, otherwise
sensitive electric components will be damaged
• Do not interrupt voltage-carrying circuits at the battery terminals because of the danger
of sparking!
• Never place tools or other conductive articles on the battery - danger of short circuit!
• Disconnect the negative (-) battery terminal from the battery before starting repair work
on the electric system
• Dispose of used batteries properly
Service and maintenance work at regular intervals

Before driving the machine
☞ Check every time before driving the machine:
• Is the light system OK?
• Is the signalling and warning system OK?
Every week
☞ Check once a week:
• Electric fuses - see chapter 2 “Fuse box” on page 2-5 and “Main fuse box with relays”
on page 2-6
• Cable and earth connections
• Charge condition of battery
• Condition of battery terminals

Electric lines, bulbs, ignition lock, relays and fuses

Always observe the following instructions:
• Defective components of the electric system must always be replaced by an authorised
expert. Bulbs and fuses may be changed by unqualified persons
• When carrying out maintenance work on the electric system, pay particular attention to
ensuring good contact in leads and fuses
• Blown fuses indicate overloading or short circuits. The electric system must therefore
be checked before installing the new fuse
• Only use fuses with the specified load capacity (amperage)
➥ - see chapter 2 “Fuse box” on page 2-5
➥ - see chapter 2 “Main fuse box with relays” on page 2-6
Alternator
Always observe the following instructions:
• Only test run the engine with the battery connected
• When connecting the battery, make sure the poles (+/-) are not inverted
• Always disconnect the battery before carrying out welding work or connecting a quick
battery charger
• Replace defective charge telltales immediately

3.40 Battery maintenance
Danger!
Battery acid is highly caustic!
Danger of caustic injury!
Therefore when recharging and/or working near the battery:
☞ Always wear goggles and protective clothing with long sleeves
If battery acid is spilt:
☞ Thoroughly rinse all affected surfaces immediately with plenty of water
☞ Thoroughly wash any part of the body touched by the battery acid immedi-
ately with plenty of water and seek medical attention at once!
Especially when charging batteries, as well as during normal operation of
batteries, an oxyhydrogen mixture is formed in the battery cells -
☞ Avoid naked lights and sparks in the vicinity of the battery and do not
smoke!
☞ Do not attempt to jump-start the machine if the battery is frozen or if the
acid level is low. The battery can rupture or explode!
☞ Always disconnect the negative terminal (-) from the battery before starting
repair work on the electric system!
Battery A is located in the engine compartment, on the left next to the hydraulic oil tank.
- + The battery is low in maintenance and no fluid needs to be refilled under normal operating
conditions. However have the battery checked at regular intervals.
Always follow the specific battery safety instructions!
A
Important!
As an option, the machine can be fitted with a battery master switch.
Fig. 92: Battery

3.41 General maintenance work

Cleaning the machine is divided into 3 separate areas:
• Inside the cab
• Exterior of the machine
• Engine compartment
The wrong choice of cleaning equipment and agents can impair the operating safety of the
machine on the one hand, and on the other undermine the health of the persons in charge
of cleaning the machine. Therefore always observe the following instructions.
When using washing solvents

• Ensure adequate room ventilation
• Wear suitable protective clothing
• Do not use flammable liquids, such as petrol or diesel
When using compressed air

• Work carefully
• Wear goggles and protective clothing
• Do not aim the compressed air at the skin or at other people
• Do not use compressed air for cleaning your clothing
When using a high-pressure cleaner or steam jet

• Electric components and damping material must be covered and not directly exposed
to the jet
• Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.
• Protect the following components from moisture:
• Engine
• Electric components such as the alternator etc.
• Control devices and seals
• Air intake filters etc.
• Door and engine cover locks
When using volatile and flammable anticorrosion agents and sprays

• Ensure adequate room ventilation
• Do not use unprotected lights or naked flames
• Do not smoke!

3.42 Cleaning inside the cab
Caution!
Never use high-pressure cleaners, steam jets or high-pressure water to clean
inside the cab. Water under high pressure can
• penetrate into the electric system and cause short circuits and
• damage seals and disable the controls!
We recommend using the following aids to clean the cab:

• Broom
• Vacuum cleaner
• Damp cloth
• Bristle brush
• Water with mild soap solution
3.43 Cleaning the seat belt

Clean the seat belt (which remains fitted in the machine) only with a mild soap solution; do
not use chemical agents as they may destroy the fabric!
Danger!
Soiled automatic seat belts may affect and impair winding -
☞ Only wind the seat belt when it is dry!
3.44 Cleaning the exterior of the machine

The following articles are generally suitable:
• High-pressure cleaner
• Steam jet

3.45 Cleaning the engine compartment
Danger!
Clean the engine at engine standstill only -
☞ Switch off the engine before cleaning
☞ Remove the ignition key
☞ Switch off the ignition and remove the ignition key
Caution!
The humidity penetrating the electronics causes it to fail and leads to engine
damage!
When cleaning the engine with a water or steam jet
☞ The engine must be cold
☞ Do not point the jet directly at any of the electric sensors such as tempera-
ture and oil pressure switches or control valves.
☞ Protect all electric parts, such as the alternator, connectors etc. from
humidity
☞ If the water jet is unintentionally pointed at electric components, dry them
with compressed air and apply contact spray to them.
3.46 Screw connections, hinges

All screw connections must be checked regularly, even if they are not listed in the mainte-
nance plans.
Tighten loose connections immediately. Refer to chapter “Specifications” for the tightening
torques.
All mechanical pivot points on the machine (e.g. door hinges, joints) and fittings (e.g. door
arresters) must be lubricated regularly, even if they are not listed in the lubrication plan.

3.47 Maintenance work “Aggressive Media” (option)

Your machine is specially protected against corrosion for work in aggressive media (e.g. a
saline environment).
However, this anticorrosion protection is affected by external factors e.g. dirt, cleaning etc.
This is why it only has ongoing effect if checked at regular intervals and renewed or reap-
plied as required.
If no anticorrosion protection is applied to your machine, for instance for work in a saline
environment, we recommend retrofitting your machine with the “Aggressive Media” option
by your sales partner.
Anticorrosion protection applied in the factory

The following anticorrosive wax has been used in the factory:
Designation: ANTICORIT BW 366
Manufacturer: FUCHS MINERALOELWERKE GmbH/Mannheim (Germany)
Complies with
specification: TI 8030-015/K 19
MIL-C-16 173 C - grade 4
Components coated with anticorrosive wax
Component Remarks
Before applying the wax:
• Apply contact spray to contact surfaces and
connect the plug and socket connections
All electric plug-and-socket, earthing
again
and crimp connections
• Apply a particularly thick anticorrosion layer
to the connecting parts of the fuel level trans-
mitter
Except:
• Piston rods (chromium layer)
• Cab, cab bearings
• Engine cover, engine mounting
All parts of the machine, e.g. • Air filter
Axles, gearbox, trim panels, servicing • Counterweight
lids, loader unit, quickhitch • Fastening surfaces for mounting parts on
frame
• Radiator and insulating mats
• Mudguards, rubber and plastic parts
• Light elements
Flange surfaces E.g. axles, engine and
cab bearing:
• Seal gaps with anticorrosion wax after
assembly
Serv-HB 34603_04 En - Edition 1.0 * Aggressive Medien.fm 3-48

Measures for maintaining anticorrosive protection

Safety instructions
• When handling chemical substances of any kind, such as solvents, wax etc., observe
the specific product-related safety regulations (safety data sheet)!
• When using volatile and easily flammable anticorrosive agents and solvents:
• Ensure adequate room ventilation!
• Do not use unprotected lights or naked flames!
• Do not smoke!
• Corrosion on electric connections or components can lead to dangerous operating
malfunctions. Therefore check the electric functions of the machine with special care.
Immediately take the machine out of service if you detect any defects and have defects
rectified immediately.
• Carry out work on the electric system only with the battery disconnected and the engine
switched off!
Cleaning
• If the machine is used in corrosive environment over a longer period of time, we
recommend removing the floor mat in the cab to avoid collecting corrosive humidity.
• Thoroughly clean machines that are taken out of service over a longer period of time.
• Clean the machine at least once a week. In particular, remove corrosive deposits (such
as salt crusts) as fast as possible.
• Clean the machine with cold running water preferably.
Caution!
Contrary to the instructions given in Chapter "General maintenance work" in
the Operator's Manual of the machine, neither clean the machine with a bristle
brush nor with a steam jet or a high-pressure cleaner. Otherwise the anticor-
rosive protection will be heavily affected.
☞ If cleaning the machine with these means cannot be avoided, check the
wax coating very carefully and have it renewed or reapplied as required.
If you replace components, check whether they are classified as in Compo-
nents coated with anticorrosive wax on page 3-48 and whether they are
subject to special treatment before assembly.
3-49 Serv-HB 34603_04 En - Edition 1.0 * Aggressive Medien.fm

Applying the protective anticorrosion coating

Bear in mind the following instructions as you apply the anticorrosive wax:
Caution!
Carefully cover all fastening surfaces and elements to which the anticor-
rosive protection may not be applied - see Components coated with
anticorrosive wax on page 3-48
• ANTICORIT BW 366 can be applied with a brush, by means of immersion or with all
commercially available spray guns.
• ANTICORIT BW 366 protective coating can be removed with petrol, RENOCLEAN E/K
or FUCHS MULTICLEAN as required.
• ANTICORIT BW 366 spots are difficult to remove on clothing.
• Affix a “Wet paint!” or a similar sign to newly coated machines.
Treatment of oxidised surfaces

If in spite of all precautionary measures some components should be affected by corrosion
(oxidised), proceed as follows depending on the affected component:
Electric connections
☞ Remove the remaining protective wax in the oxidised area with petrol,
RENOCLEAN E/K or FUCHS MULTICLEAN
☞ Treat all affected parts with an oxide solvent, such as KONTAKT 60
☞ Rinse the area with e.g. KONTAKT WL
☞ Treat the contact surfaces of the connection with e.g. KONTAKTSPRAY WD 40
☞ Establish the connection
☞ Apply/spray anticorrosion wax onto the electric connection from all sides
Sheet-metal parts
☞ Remove the remaining protective wax in the oxidised area with petrol,
RENOCLEAN E/K or FUCHS MULTICLEAN
☞ Remove all remaining corrosion and paint coating from the affected area down to the
bare material, otherwise the paint coating will not adhere properly!
☞ Clean the affected part with a cleaning solvent
☞ Apply a 2-component prime coating to the affected area and then a 2-component paint
coating
☞ Preserve the area with anticorrosion wax
Serv-HB 34603_04 En - Edition 1.0 * Aggressive Medien.fm 3-50

3-51 Serv-HB 34603_04 En - Edition 1.0 * Aggressive Medien.fm

Engine
Engine
Engine
4 Engine
4.1 Engine designation
Engine designation Type

D 2011 L04 W (45 kW) 346-03 (750), 346-04 (850)
4.2 Fuel specification
Fuel specification Country

No. 2-D, no. 1-D, ASTM D975-94 USA
DIN EN 590 European Union
ISO 8217 DMX International
BS 2869-A1 or A2 United Kingdom
GB252 China
4.3 Coolant specification

Specification Country
ASTM D6210, D4985 USA
SAE J814C, J1941, J1034 or J2036 International

Engine
4.4 Diesel engine D 2011 L04 W overview
Alternator
Cutoff solenoid
Temperature switch S3
Glow plug
Oil pressure switch S 2
Starter
Fuel injector (separate)
Engine oil filter

Oil dipstick
Engine oil cooler
Fuel filter
Oil drain valve
Elastic clutch Fuel pump with manual

(replacement as a whole unit only) pump for bleeding

4-3
4.5
Hydraulic oil cooling
Engine
Coolant expan- Cooling air intake from
sion tank outside
Engine oil cooling
Engine cooling
(water)
Reflux
Air guidance plate
Caution!
Check engine cover seals!
☞ Replace defective seals
Feed
Important!
Warm air outlet is over the engine to the left side of
the machine
Temperature switch

Engine
4.6 Belt drive with cooling ports
Coolant outlet to radiator
Port to heating
Coolant intake from radi-

ator
Expansion tank
Port from heating

4-5
4.7
Injection line
Engine
(identical for cylinders 1 - 4)
Fuel leak line

(pump/nozzle)
To tank Fuel system
Bleeding the fuel system

Slacken the banjo bolt
Bleed with the manual pump on the fuel
Injection nozzle
pump
Fuel injection pump

(separate)
Tappet
Caution!
Bear in mind the seal size as you
replace a fuel injection pump
Fuel pump
Maintenance can be carried out
Manual pump for bleeding
Fuel filter
34300s410_03.iso

Engine
4.8 Checking and adjusting valve tip clearance

☞ Standard setting of valve tip clearance is possible:
➥ On a cold engine, or on a warm engine after it has cooled down for at least 0.5 h.
➥ Oil temperature = 80 °C
Important!
Increase valve tip clearance by 0.1 mm every time you replace the cylinder head
gasket. Set the standard valve tip clearance after 1500 s/h.
Fig. 93: Turning the engine
The cylinder-head cover has been removed

☞ Turn the engine until reaching valve overlap, cylinder no. 1
Important!
Valve overlap means the exhaust valve is not yet closed and the intake valve
begins to open. Both push rods cannot be turned
Fig. 94: Valve overlap
☞ Set valve tip clearance at each cylinder with the feeler gauge.
➥ Inlet valve tip clearance: 0.3 mm
➥ Exhaust valve tip clearance:0.5 mm
☞ Tighten the locknut.
➥ Tightening torque: 20 ± 2 Nm
➥ Check the setting again with the feeler gauge.
Fig. 95: Setting valve tip clearance
☞ Place the gasket.
Fig. 96: Placing the cylinder-head cover gasket
☞ Slide new rubber hoses onto the overflow line and the fuel injectors as far as
they will go.
☞ Mount the cylinder-head cover and the overflow line.
☞ Tighten the screws.
➥ Tightening torque: 8.5 Nm
Fig. 97: Mounting the cylinder-head cover

Engine
4.9 Replacing the fuel injection pump

☞ Unscrew the screw plug on the crankcase
Fig. 98: Crankcase screw plug
☞ Set the adjusting lever to centre position.

☞ Screw in the adjusting pin for the adjusting lever into the crankcase as far as it will go
Fig. 99: Setting the adjusting lever
☞ Turn the camshaft until the tappet stroke of the cylinder is at lower dead centre
Fig. 100: Camshaft
☞ Mount the injection pump tappet
Important!
Use a flexible magnetic tool.
Fig. 101: Mounting the tappets

Engine
☞ Determine the compensation gasket
Fig. 102: Determining the compensation gasket
☞ Measure dimension “A” from the crankcase base to the tappet base.
Fig. 103: Measuring the tappet base
☞ Dimension “X” of fuel injection pump = 60 mm
Important!
Dimension “X” is used for calculating the compensation gasket and cannot be
measured with the fuel injection pump removed.
☞ Determine the difference between dimensions “X” and “A”.

Example:
Dimension “X” = 60.00 mm
Fig. 104: Fuel injection pump - dimension Dimension “A” = 59.35 mm
Difference = 0.65 mm

Engine
☞ Select a compensation gasket according to the table and the identification
Difference (mm) Mark size (mm)

Up to 0.4 9.0
0.401 - 0.5 12.0
0.501 - 0.6 15.0
0.601 - 0.7 18.0
0.701 - 0.8 21.0
0.801 - 0.9 24.0
0.901 - 1.0 27.0
Fig. 105: Compensation gaskets
☞ Place the compensation gaskets as needed
Important!
Make sure they are placed in the correct position.
Fig. 106: Placing the compensation gaskets
☞ Remove the lock pin from the fuel injection pump
Fig. 107: Lock pin

Engine
☞ Make sure the lock wire is locked in the pivot lever before mounting the fuel injection
pump
Fig. 108: Lock wire
☞ Mount the fuel injection pump

☞ Press the fuel injection pump in evenly as far as it will go
☞ Tighten the nuts
➥ Tightening torque: 21 Nm
Fig. 109: Mounting the injection pump
☞ Pull out the lock wire
Fig. 110: Pulling out the lock wire
☞ Lock the bore with the lock pin
Fig. 111: Bore with lock pin

Engine
☞ Remove the adjusting pin for the adjusting lever
Fig. 112: Adjusting pin - adjusting lever
☞ Tighten the screw plug with a new copper sealing ring

Tightening torque: 18 Nm
Fig. 113: Screw plug

Engine
4.10 Switching off minus compensation

The engine receives more fuel during the start procedure, with the help of the start quantity
spring.
In order to keep minus compensation from counteracting and neutralising the additional
start quantity, minus compensation is switched off with a solenoid (terminal 50).
In order to do so, the solenoid separates the reversing lever from the compensation lever.
Some injection systems receive too much fuel as engine revs drop, i.e. the engine
receives more fuel than fresh air.
Minus compensa- ➥ The engine smokes
tion switch-off
☞ The fuel quantity must be reduced
Minus compensation - function
Fig. 114: Minus compensation
The reversing lever is loosely connected to the compensation lever. If the engine runs
under load, engine revs drop and the compensation lever moves towards extra volume.
The reversing lever inverts this movement and the adjusting lever is moved towards less
volume.
4.11 Heating connection
Feed
Reflux
Fig. 115: Heating connection

Engine
4.12 Removing/mounting the cylinder head

☞ Determine the cylinder-head gasket's identification (see circle)
Piston projection (mm) Identification (slot)

0.530 - 0.690 1 slot
0.691 - 0.760 2 slots
0.761 - 0.830 3 slots
Fig. 116: Determing the cylinder-head gasket
☞ Remove the cylinder-head cover
Fig. 117: Removing the cylinder-head cover
☞ Remove the rocker arm brackets
Fig. 118: Removing the rocker arm bracket
☞ Remove the valve tappets
Fig. 119: Removing the valve tappets

Engine
☞ Carefully raise the cylinder head from the engine block
Fig. 120: Removing the cylinder head
☞ Make sure the straight pins are in their positions.
Fig. 121: Straight pins
☞ Place the cylinder-head gasket
Caution!
The sealing surfaces must be clean and free of oil
Fig. 122: Placing the cylinder-head gasket
☞ Check the length of the cylinder-head bolts

➥ 150 ± 0.8 mm
☞ Mount the cylinder head
➥ Apply a thin coat of oil to the cylinder-head bolts
Fig. 123: Placing the cylinder-head gasket

Engine
☞ Mount the cylinder-head bolts

➥ Tightening torque:
• 1st pass 30 Nm
• 2nd pass 80 Nm
• 3rd pass 160 Nm
• Angle for retightening: 90°
Caution!
8 6 4 5 9 Bear in the mind the order for tightening the cylinder-head bolts!
Manifold side ☞ See figure
10 3 1 2 7
Fig. 124: Mounting the cylinder-head bolts
☞ Insert the push rods
Fig. 125: Inserting the push rods
☞ Mount the rocker arm bracket and align it with the push rods
➥ Tightening torque: 21 Nm
☞ Set the valve tip clearance
Fig. 126: Mounting the rocker arm bracket
☞ Place the gasket for the cylinder-head cover

☞ Mount the cylinder-head cover
Fig. 127: Mounting the cylinder-head cover

Engine
4.13 Sealing the bleed valve

☞ Remove the cover
☞ Clean the bleed valve
☞ Mount a new O-ring
☞ Mount the cover
Fig. 128: Bleed valve
4.14 Sealing the intake/exhaust manifold

☞ Mount new gaskets
☞ Mount the intake/exhaust manifold
Tightening torque
➥ Intake manifold: 21 Nm
➥ Exhaust manifold 55 Nm
Fig. 129: Intake manifold seals

Engine
4.15 Engine trouble

Problem Possible causes
Parking brake not applied
Steering-column control lever not in neutral
Engine starting temperature too low
Wrong SAE grade of engine lubrication oil
Fuel grade does not comply with specifications
Engine does not start or is not easy to start
Defective or flat battery
Loose or oxidised cable connections in starter circuit
Defective starter, or pinion does not engage
Wrong valve tip clearance
Defective fuel injector
Engine starts, but does not run smoothly or faultless
Injection line leaks
Oil level too low
Oil level too high
Dirty air filter
Defective air filter maintenance switch or gauge
Engine overheats. Temperature warning system
Dirty oil radiator fins
responds
Defective fan, torn or loose V-belt
Cooling air heats up
Resistance in cooling system too high, flow capacity too low
Oil level too high
Dirty air filter
Insufficient engine output Defective air filter maintenance switch or gauge
Engine does not run on all cylinders
Oil level too low
Insufficient or no engine oil pressure Engine inclination too high
Wrong SAE grade of engine lubrication oil

Engine
Problem Possible causes

Oil level too high
Engine oil consumption too high
Engine inclination too high
Oil level too high
Blue
Engine inclination too high
Engine starting temperature too low
White
Engine smoke
Dirty air filter
Defective air filter maintenance switch or gauge
Black

Engine

Power train
Power train
Power train
5 Power train
5.1 Variable displacement pump test ports
Y 4 = forwards driving (green/violet cable colour)

Y 5 = reverse driving (white/violet cable colour)
Test port HP/forwards driving Test port HP/reverse driving Control pressure test port
HP/forwards driving Y5/reverse driving
HP/reverse driving X2
X1
Y4/forwards driving
Boost pressure test port

Power train
5.2 Variable displacement pump
Control cartridge
(starting revs)
Boost pressure valve Transposition plug
High-pressure cartridge set screws

(towing function)
Set screw for mechani-

cal zero position
High-pressure cartridge set screws

(towing function)

Power train
5.3 Variable displacement motor
Control initiation test Large capacity Q-max Leak oil to

port cooler
Control initiation
set screw allen key
3 / w/f 10
Leak oil to non-

return valve 1.5 bar
Small capacity Q-min
Y 10 solenoid valve Y 2 solenoid valve 1st - 2nd speed

Driving direction identification 1st speed energised
Reverse driving energised Cable colour GY/GN
Cable colour GN/VT

Power train
5.4 Inching valve overview

P - control pressure
Bleed valve for brake system
Y - control line (master brake cylinder)
Caution!
No bleed valve,
☞ used for venting/bleeding the piston
T - reflux line
Description of inching valve

Actuating the brake pedal applies pressure to the inching valve and the service
brake.
The machine is first braked by means of the hydraulic drive, and then with the
service brake.
Functional description
Actuating the master brake cylinder applies control pressure to port Y of the
inching valve, which in turn controls the control spool in the inching valve and
establishes a connection between port P and port T.
The control pressure of the variable displacement pump is reduced, and hence
the flow rate of the variable displacement pump is reduced.
The machine slows down. At the same time, the brakes become active, propor-
tionally to the brake pressure.
Danger!
The inching valve is a safety component! Do not carry out any

modifications!

Power train
5.5 Inching valve circuit
Control line to variable

displacement motor
displacement pump
Bleed hose
Caution!
Flexible line must be closed when

P measuring output with the brakes
Y
T
Bleed valve
P from the brake Ventilation and bleeding Reflux line

5.6
Inching valve
From the hydraulic pump

To tank

From the hydraulic motor
Inching valve diagram
S 9 brake light switch Brake cylinder
Brake calliper
Brake pedal unit
Brake fluid tank

Power train
5-6
5-7
5.7
Breather filter Non-return valve Radiator Hydraulic oil
1.5 bar exit radiator
Reflux suc-
tion filter
Power train
Engine coolant
radiator Drive circuit
High pressure lines (HP)
Radiator
entry
Control line
Reflux/control Leak oil

pressure
Suction line
Control initia-
tion test port Inching valve PS
Reflux line
Control line 1000144359_s.iso

In this case: 20 kph brake circuit

5.8
Control cartridge
To the inching Pressure controller Solenoid valve 1st - 2nd speed
valve Forwards/reverse driv- To the priority valve Control initiation setting ➥ 1st speed energised
ing directional valve
➥ 2nd speed de-energised
Drive diagram

Oil-to-water-cooler
Work hydraulics
steering
Reflux suction filter
Pressure switch
Vent filter
HP valves
Servo cylinder
Boost pressure valve Pressure cutoff

Control initiation
test port
Driving direction identification

Valve 1.5 bar
➥ Reverse driving energised (small oil circuit)
➥ Forwards driving de-energised
Power train
5-8
Power train
5.9 Towing and transporting the machine

Safety instructions
• The machine may only be towed using suitable towing equipment (towing bar or cable)
in connection with suitable towing facilities, such as a towing coupling, hooks and eyes!
• Move off slowly!
Make sure no-one is dangerously close to the towing bar
• The machine may only be towed with a cable if the service brakes and steering are fully
operational!
Getting ready for towing
C B
Danger!
A
Turning the steering wheel requires greater effort if the diesel engine breaks
down. Take this into account especially when towing the machine!
☞ Use a towing bar!
A
B
Caution!
The hydrostatic power train can be damaged when towing the machine!
C
☞ Switch off the engine!
☞ Short-circuit the hydraulic circuit before towing (see below)
Fig. 130: 20 kph hydraulic pump
☞ Do not tow the machine for more than 100 meters and do not tow it faster
than 3 - 4 kph!
D
F ☞ Tow away the machine as follows:
• Fit an adequately sized towing bar to the towing facilities
20 kph hydraulic pump
☞ Switch over the HP pressure relief valves A on the hydraulic pump. To do this:
E • Slacken hexagon lock nuts B on both HP valves A
• Screw in hexagon socket head screws C on both HP valves A until they are flush with
lock nuts B
• Secure hexagon socket head screws C on both HP valves A with lock nuts B
Fig. 131: 30 kph hydraulic pump (option) 30 kph hydraulic pump (option)
☞ Mount hose D between test ports E and F
➥ The hose is included in the tool kit
☞ If possible, run the engine at idling speed when towing the machine
Once towing is over ...
☞ ... reset the HP valves A on the 20 kph hydraulic pump! To this effect, unscrew each of
hexagon socket screws C as far as they will go and secure them with locknuts B, or
☞ Remove hose D in the case of the 30 kph hydraulic pump

Power train
5.10 Test report: 20 kph power train
Model: Prod. no. variable displacement pump Prod. no. variable displacement motor Serial no.
______________ ____________________ ____________________ _________________
Test conditions: Rated oil temperature: 50 - 60 °C

Rated driving direction: forwards
See Test features: Notes: Actual value:

page: (rpm)
Min. idling speed Measured on the fan wheel 920 - 980 rpm
Max. idling speed Measured on the fan wheel 2430 - 2470 rpm
Min. idling speed Measured on the fan wheel 1012 - 1078

With air conditioning
(option)
Max. idling speed Measured on the fan wheel 2673 - 2717

(option)
5-12 Boost pressure Max. engine revs 28 - 35 bar
5-12 Control pressure Max. engine revs About 25 - 30 bar

min. engine revs About 5 bar
5-12 Starting revs Measured on the fan wheel 1150 - 1250 rpm
Starting revs with air con- Measured on the fan wheel 1265 - 1375
ditioning (option)
5-13 High pressure 2nd speed braked max. engine 370 - 380 bar
5-14 Drive pressure revs
5-14 Hydraulic resistance curve 1st speed range braked at Over

Hydraulic resistance curve 1800 rpm 320 bar
with air conditioning 1st speed range braked at
(option) 1980 rpm
5-15 Engine droop Measured on the fan wheel, 1st 2100 - 2200 rpm
Engine droop with air con- speed range braked at max. revs 2310 - 2420 rpm
ditioning (option) HP/forwards driving 250 - 260 bar
Hydraulic motor settings
Driving direction identifi- Check solenoid valve electric Reverse

cation supply
5-15 Control piston pressure/ 2nd speed after braking 230 - 260 bar
control initiation
5-16 Wheel speed Max. engine revs

Model 346-03 (750) 105 - 115 rpm
Model 346-04 (850) 102 - 109 rpm

Power train
5.11 Test report: 30 kph power train
Model: Prod. no. variable displacement pump Prod. no. variable displacement motor Serial no.
______________ ____________________ ____________________ _________________

Rated driving direction: forwards
See Test features: Notes: Actual value:

page: (rpm)
Max. idling speed Measured on the fan wheel 2430 - 2470 rpm
Min. idling speed Measured on the fan wheel 1012 - 1078

(option)
Max. idling speed Measured on the fan wheel 2673 - 2717

(option)
5-12 Boost pressure Max. engine revs 28 - 35 bar
5-12 Control pressure Max. engine revs About 25 - 30 bar

min. engine revs About 5 bar
5-12 Starting revs Measured on the fan wheel 1150 - 1250 rpm
Starting revs with air con- Measured on the fan wheel 1265 - 1375
ditioning (option)
5-13 High pressure 2nd speed braked 465 - 480 bar
5-14 Drive pressure max. engine revs
5-14 Hydraulic resistance curve 1st speed range braked at Over

Hydraulic resistance curve 2000 rpm 400 bar
with air conditioning 1st speed range braked at
(option) 2200 rpm
5-15 Engine droop Measured on the fan wheel, 1st 2100 - 2200 rpm
Engine droop with air con- speed range braked at max. revs 2310 - 2420 rpm
ditioning (option) HP/forwards driving 220 - 230 bar
Hydraulic motor settings
Driving direction identifi- Check solenoid valve electric Reverse

cation supply
5-15 Control piston pressure/ 2nd speed after braking 210 - 240 bar
control initiation
5-16 Wheel speed Max. engine revs

Model 750 170 - 174 rpm
Model 850 160 - 165 rpm

Power train
5.12 Adjusting boost pressure
Important!
Run the machine warm before taking the measurement so the hydraulic system
reaches its optimum operating temperature of 60 °C!
Brake the machine with the service brake when taking the measurement. Conse-
quently, unscrew the brake-inching line from the hydraulic pump and fit a dummy
cover! Only set the valves if the pressure has been released!
Tools required
• High pressure gauge (600 bar, 2 off)
• Pressure gauge (60 bar, 2 off)
• Tachometer
Boost pressure valve Boost pressure test port Boost pressure test port Boost pressure valve
20 kph 30 kph
Set the control cartridge w/f 13 - allen key 4 Set the control cartridge w/f 13 - allen key 4
The boost pressure valve can only be set by means of washers in the boost pres-
sure valve
☞ Remove the complete valve
☞ Set the pressure to 28 - 35 bar by adding or removing washers
5.13 Adjusting starting revs/control pressure

Without air conditioning = 50 bar high pressure, 1150 - 1250 rpm
With air conditioning (option) = 50 bar high pressure, 1265 - 1375 rpm
☞ Jack up the machine
☞ Select a driving direction
☞ Slowly increase the revs
Set the starting revs/control pressure at the control cartridge:
➥ Control pressure at idling speed about 5.5 - 6.5 bar
☞ Screw in the control cartridge:
➥ Starts later
☞ Unscrew the control cartridge
➥ Starts sooner

Power train
5.14 Setting high pressure/drive pressure
Test port for high pressure forwards driving Test port for high pressure reverse driving
Connect pressure gauge (600 bar) Connect pressure gauge (600 bar)
High pressure valve reverse
Pressure cutoff
Important!
The pressure cutoff corresponds to the hydraulic pressure measured at the for-
wards and reverse driving HP test ports
☞ Select the 2nd speed range

☞ Drive the machine against “hydraulic resistance” (wheels not allowed to spin at full
thrust)
☞ Read off the pressure on the forwards driving HP gauge
Set the pressure at the pressure cutoff (w/f 13 - allen key 4)
☞ Screw in the pressure cutoff
➥ Pressure increase
☞ Unscrew the pressure cutoff
➥ Pressure reduction for 20 kph machine = 370 - 380 bar
➥ Pressure reduction for 30 kph machine = 465 - 480 bar

Power train
5.15 Setting the secondary valves for forwards/reverse driving

Slacken hexagon
socket screw 3 Important!
Pressure setting of secondary valves: about 10 % higher than pressure cutoff!

Apply tension to
spring cap
☞ Set pressure cutoff to "hydraulic resistance"
☞ Connect the forwards - reverse driving HP gauges
☞ Drive the machine against hydraulic resistance
Set w/f 8 here ☞ Setting: see instructions on the left
1 turn corresponds ☞ Reset the pressure cutoff once the measurement is over
to about 40 bar ➥ - see Test report: 20 kph power train on page 5-10
302S2214.ai ➥ - see Test report: 30 kph power train on page 5-11
Remove valve completely (w/f 32) ➥ w/f 13 - allen key 4
5.16 Checking/setting the hydraulic resistance (characterisic curve) of the pump

High pressure Transposition screw
forwards w/f 17 - allen key 5 Caution!
We recommend you to contact Kramer customer service before modifying the

hydraulic resistance curve!
Important!
Transposition screw is set to 9 o'clock (position indicated by slot in the screw)!

Correct the hydraulic resistance curve as required by turning the transposition
screw!
Connect 600 bar pressure gauge
Connect the tachometer Measurement
Hydraulic resistance
curve set on test rig ☞ Pinch off brake inching
☞ Select a driving direction
Hydraulic resist- ☞ Increase the revs and drive against the hydraulic resistance
ance curve (bar) 6 o'clock ➥ At 2000 rpm, minimum high pressure (forwards) is:
➥ 320 bar (20 kph machine)
500 ➥ 400 bar (30 kph machine)
450
9 o'clock Example:
400
☞ Set the transposition screw to 12 o'clock:
300
➥ Curve becomes flatter (= machine reacts more smoothly)
☞ Set the transposition screw to 6 o'clock:
12 o'clock
200 ➥ Curve becomes steeper (= machine reacts more abruptly)
100
Control pressure
1000 1500 2000 2500

Speed [rpm]

Power train
5.17 Check engine droop

High pressure test port ☞ Jack up the machine
➥ - Connect pressure gauge HP/ ☞ Pinch off brake inching
forwards driving 600 bar ☞ Forwards driving direction, select 1st speed
➥ - Connect a tachometer (diesel ☞ Run the diesel engine to full revs
engine) ☞ 20 kph machine: brake to 250 - 260 bar high pressure
Control cartridge ☞ 30 kph machine: brake to 220 - 230 bar high pressure
➥ Droop revs without air conditioning 2100 - 2250 rpm
➥ Droop revs with air conditioning 2310 - 2420 rpm
If the engine droop is excessive:
☞ Check the diesel engine
☞ Check the control cartridge
Setting: w/f 13/allen key 4
5.18 Setting control initiation on the hydraulic motor

600 bar pressure gauge
High pressure test port connect (control piston)
➥ - Connect pressure gauge
HP/forwards driving 600 bar
302s2215.ai
High pressure gauge forwards driving Adjust control initiation w/f 10 - allen key 3
600 bar - Screw in = pressure increase
- Unscrew = pressure reduction
☞ Pinch off brake inching
☞ High-pressure gauge 600 bar on HP forwards driving and on the control piston of the
variable displacement motor
☞ Forwards driving direction, select 2nd speed
☞ Run the diesel engine to full revs
☞ Slowly brake the machine with the service brake
➥ Pressure on pressure gauge (forwards driving high pressure) and control piston
slowly rises
Important!
When the pressure in the control piston drops rapidly, high pressure (forwards
driving) is
• About 230 - 260 bar (20 kph machine)
• About 210 - 240 bar (30 kph machine)

Power train
5.19 Setting the wheel revs

Measurement and adjustment values
Label (measure-
➥ - see Test report: 20 kph power train on page 5-10
ment point)
➥ - see Test report: 30 kph power train on page 5-11
☞ Forwards driving direction, select 2nd speed
☞ Run the diesel engine to full revs
☞ Read off the wheel revs with a tachometer
Revs are adjusted at the hydraulic motor
☞ Unscrew the set screw
Set screw for wheel revs ➥ Wheel revs are increased
☞ Screw in the set screw
➥ Wheel revs are reduced

Power train

Axles
Axles
Axles
6 Axles
6.1 Axle overview

Axles
6.2 Front axle screw connections

Axles
6.3 Sealing work (joint housing/axle carrier)

☞ Unscrew fastening screws 23 from planetary cover 25 (allen key 8 mm)
23
25
☞ Remove planetary cover 25 from the joint housing by applying pressure with a screw-
driver
41
➥ Both parts 25 and 41 of the housing are sealed with an O-ring
25
☞ Remove the complete planetary cover

➥ There are three planetary gears in each planetary drive
➥ 28 rollers per wheel are used for the planetary gear bearing
☞ Remove circlip 30
30
☞ Unscrew fastening nuts 32 (w/f 19)

32
☞ Remove thrust washer 31

31

Axles
☞ Remove tab washer 33

33
☞ Remove internal-geared wheel 35 by applying pressure with an extractor or a mounting

35 lever
☞ Remove the internal-geared wheel
☞ Remove wheel hub 41 with a plastic hammer

41
☞ Remove inner ring 38 from the bearing

38
☞ Remove wheel hub 41

41

Axles
☞ Remove cassette ring 44 with a mounting lever

44
☞ Make a note of the measure of the screw restricting the steering angle
☞ Slacken the locknut and screw in the stop screw

➥ in order to be able to slacken the fastening nut of the track rod
☞ Unscrew fastening nut (w/f 30) of the track rod
☞ Remove the track rod from joint housing 14 by applying pressure with an extractor
14
☞ Unscrew fastening screws 19 from the lower planetary drive bearing (w/f 15)
19

Axles
☞ Remove bearing pin 20

20 ➥ Lower pin with ball half
☞ Unscrew fastening screw 13 from the upper bearing pin (w/f 15)
13
☞ Remove bearing pin 10 by applying pressure with two mounting levers

13 ☞ Remove sealing ring 8
☞ Remove the complete joint housing 14

14
☞ Remove sealing ring 5

5
☞ Joint housing 5 and axle carrier 3 sealing

Axles
☞ Remove the double cardan shaft

➥ There is no risk of anything falling into the differential
☞ Remove sealing rings 8 and 18 from the pin

8 18
Caution!
Make sure they are placed in the correct position
☞ Remove sealing ring 3 from the axle carrier
3l

Axles
Tightening torques - joint housing/axle carrier assembly

☞ Even rolling resistance of 7 - 20 Nm (without planetary gears)
☞ Initial stress of bearing pins
➥ Torque about 40 - 80 Nm

Axles
Bushing 6 is not slotted

☞ Use an adapter to mount the bushing
☞ Mount sealing ring 5 and cassette ring 44 in the joint housing with an adapter
Caution!
Insert cassette ring 44 without grease!
44
☞ Mount sealing rings 8 and 18

➥ Larger diameter upwards

Axles
☞ Mount sealing ring 3 in the axle carrier with an adapter
☞ Insert double cardan shaft 4 into axle carrier 1
☞ Carefully place joint housing 14 onto the axle carrier
Caution!
Do not damage the sealing ring!
4 14
☞ Place 0.4 - 0.7 mm spacers on the upper pin
☞ Mount the upper pin with a sealing ring

➥ Larger diameter downwards
☞ Mount the lower pin with a sealing ring

Axles
☞ Tighten the fastening screws of the upper and lower bearing pins
➥ 90 - 100 Nm
☞ Check vertical play with a mounting lever and a dial gauge

➥ No play allowed!
☞ Check the tightening moment of the planetary drive bearing

➥ The tightening moment must be 40 - 80 Nm
☞ Hook the track rod of the steering ram into the joint housing and tighten it
➥ Tightening moment 270 - 300 Nm
☞ Adjust the steering angle with the stop screw to the measure taken before

Axles
☞ Mount the bearing and the wheel hub
☞ Mount the internal-geared wheel
☞ Mount the internal-geared wheel onto the seat of the planetary carrier with a plastic
hammer
☞ Mount the lock washer
☞ Put the fastening nuts in place with Loctite 242 and

☞ tighten them in 2 steps with a torque wrench (w/f 19)
➥ 1st pass = 90 Nm
➥ 2nd pass = 100 Nm

Axles
☞ Mount thrust washer 31

31
☞ Mount the circlip
☞ Check the rolling resistance of the wheel bearings

➥ Check without the planetary gears
➥ 7 - 20 Nm
☞ Mount the O-ring
☞ Mount the planetary cover
☞ Mount and tighten the fastening screws

➥ Allen key 8 mm
☞ Fil in oil
☞ Carry out a test run and check for leaks

Axles
6.4 Sealing the bevel gear shaft
Removing
☞ Remove the left and right-hand side axle halves from the differential housing
☞ Remove the differential cage from the differential housing with the crown wheel
☞ Remove the transfer gearbox from the differiential housing (nut 5)
☞ Remove ball bearing 3
☞ Remove slotted nut 11 with a special tool (spare part no. 910.01.4066)
☞ Remove pinion shaft B, spacer ring 12 and spacers 13 and 23 from the differential
housing towards the inside of the housing with a plastic hammer
Mounting
☞ Mount a new sealing ring with an adapter (spare part no. 910.04.4217)
☞ Mount pinion shaft B in the differential housing with the inside bearing ring
☞ Fit spacer ring 12 and spacers 13 and 23 from the outside
☞ Heat the inner ring of the taper roller bearing to 100 °C and mount it on the pinion shaft
☞ Screw threaded ring 11 onto the pinion shaft with Loctite 270
☞ Tighten threaded ring 11 with a special tool to 400 - 500 Nm
(spare part no. 910.04.4066)
☞ Mount ball bearing 3
☞ Flange the transfer gearbox onto the differential housing
☞ Mount the left and right-hand side axle halves

Axles
6.5 Differential cage/differential lock screw connections
26,2 Nm
Side brake shim
Side crown shim 0.75 mm
78 - 86 Nm

Axles
6.6 Overview of differential lock and differential cage
(O-ring)
Seals
Return spring
Sliding sleeve

Axles
6.7 Removing the differential cage with the differential lock

☞ Completely remove the axle tube (on the left in driving direction)
☞ Completely remove the differential cage with the differential lock
☞ Remove the taper roller bearing with an extractor
Caution!
The sliding sleeve can be ejected upwards when slackening the hexagon head
screws!
☞ Press the sliding sleeve downwards and
☞ Remove the hexagon head screws
☞ Remove the sliding sleeve and the spring from the differential cage

Axles
6.8 Removing the differential lock

• Pos. 1: piston
• Pos. 2: stop screw
• Pos. 3 + 4: seals (O-rings)
☞ Remove the fastening screws
☞ Remove the piston

Axles
6.9 Assembling the differential lock

☞ Guide groove A on the sliding sleeve and ball B on the differential cage must be
aligned during assembly
☞ Insert the hexagon head screws of the sliding sleeve with Loctite 242 and
☞ tighten them to a torque of 26.2 Nm
☞ Preheat the taper roller bearing to 100 °C and

☞ mount it with an adapter
☞ Insert the piston of the lock and

A ☞ tighten fastening screws 2 to a torque of 30 Nm
☞ Clean the flange surface on the differential housing
☞ Carefully insert the differential cage with the lock in the piston
☞ Clean the flange surface on the axle tube and

☞ Mount the complete axle tube

Axles
6.10 Removing the gearbox

Tightening torque 120 Nm
Loctite 510
Loctite 270
Tightening moment 270 Nm
Loctite 510
Loctite 510 Tightening torque

90 Nm
Loctite 242
Loctite 510
☞ Unscrew fastening screws 33 from the gearbox
33

Axles
☞ Remove the gearbox from the axle
☞ Unscrew drain plug 20
20
☞ Unscrew screws 21 and 23 from cover 24

21 23
☞ Remove cover 24
24
☞ Remove nut 11 from flange 13

11 13

Axles
☞ Remove nut 11 and O-ring 12

11
13
☞ Remove the flange
☞ Remove fastening screws 15 from cover 14

15
14
☞ Remove cover 14
14
☞ Remove spacers 18
18
17

Axles
☞ Remove shaft 26
26
☞ Remove the oil baffle
☞ Oil baffle
☞ Remove gear 31
31
☞ Remove washer 31 and bearing 19
32
19
☞ Remove bearing shell 19
19

Axles
☞ Unscrew screws 27 from cover 29 and remove the cover

29
27
☞ Remove spacers S2
S2
☞ Unscrew fastening screws 9 from the adapter housing and remove the adapter housing
9
☞ Extract bearing 4 from the adapter housing with an extractor
4
☞ Remove upper shaft 3
☞ Remove outer ring 19 of the bearing
19

Axles
☞ Remove shaft 3 from the bearing with a press
☞ Remove gear 30 and bearing 19

19
30
☞ Remove bearing 4 by applying pressure

4

Axles
6.11 Input shaft version 1 sealing: overview
129 - 143 Nm
86 - 89 Nm
260 - 280 Nm
Loctite 242
S1
S2
35 - 50 Nm
129 - 143 Nm
Loctite 242
25 - 28 Nm

Axles
6.12 Assembling the gearbox

☞ Mount bearing 4 on shaft 3
4
☞ Mount gear 30 on shaft 3

30
☞ Mount bearing 19
19
☞ Mount the complete shaft in the housing
☞ Press seal 4 into the adapter housing

Axles
☞ Mount adapter housing 5

5
☞ Tighten fastening screws 9 to 140 Nm

9
☞ Mount bearing shell 19

19
☞ Determine the bearing projection and make a note of it

➥ The dimension of the projection is referred to as Y
☞ Determine dimension X
➥ Dimension X results from the distance between the contact surface and the upper
X
edge of the bearing
☞ Measure both dimensions X and Y to determine the thickness of the spacers

➥ S1 = X - Y (0.02 +- 0.05) = 0.95 - 0.05 = 0.90 = S
S1

Axles
☞ Mount cover 29 with screws 27 and Loctite 510

29
27
☞ Tighten screws 27 to 50 Nm
27
☞ Drive in the input shaft as far as it will go
☞ Place the dial gauge on the housing
☞ Measure the bearing play with a mounting lever

➥ Bearing play 0.02 - 0.05 mm
☞ Mount gear 31
31

Axles
☞ Mount shaft 26 with a plastic hammer

26
☞ Mount the oil driving ring
Caution!
Cut-out side upwards!
To the inside
☞ Mount bearing 19
19
☞ Mount the bearing with a plastic hammer as far as it will go
☞ Mount spacer ring 32
32
☞ Mount inner ring 19 on the shaft
19

Axles
☞ Mount outer ring
19
☞ Mount cover 14 with washers
14
☞ Tighten screws15
15
☞ Mount the gearbox on the axle
☞ Tighten fastening screws 33 to 75 Nm
☞ Unscrew fastening screws 15
15

Axles
☞ Remove washers 18 and cover 14
14
18
☞ Drive in the bearing again
☞ Determine the bearing projection

➥ The dimension is referred to as Y
☞ Measure the dimension on the cover between the contact surface and the upper edge
of the bearing
X ➥ Determine the spacers
➥ X -Y - 0.05 mm (initial stress) = thickness of spacers
☞ Mount washers 18 and cover 14
14
18
☞ Tighten screws 15 to 90 Nm
15

Axles
☞ Mount the spacer washer and the flange
☞ Mount O-ring 12 and nut 11
12
11
☞ Tighten the flange to 280 Nm
☞ Mount cover 24 with Loctite 510
24
☞ Tighten fastening screws 21 and 23 to 28 Nm
21
23

Brakes
Brakes
7
7-1
7.1
Brake-fluid tank
Brakes
• Agip LHM Super
• Shell LHM
Brakes
Brake circuit
2 mm clearance to pedal
Pressure line
Master brake cylinder
Brake light switch (S 16)
Inching up to 8 bar
Inching valve
1000144475_s.iso

Brakes
7.2 Brake diagram
Brake pedal unit
Master brake cylinder

To tank
Inching valve
Brake light switch Brake-fluid tank

• Agip LHM Super
• Shell LHM
Brake (front axle)

Control pressure line
20 kph port

7-3
7.3
Brakes
Setting on cable pull Parking brake lever
Parking brake circuit
Parking brake switch with starting

Setting on cable pull
interlock
➥ Port S 11
➥ Signal (1st/2nd notch)
1000144477_s.iso

Brakes
7.4 20 kph inching valve circuit

displacement motor
displacement pump
Bleed hose
Caution!
Flexible line must be closed when

P measuring output with the brakes
Y
T
Bleed valve
P from the brake Ventilation and bleeding Reflux line

Brakes
7.5 Service brake

Important information on the brake system
Caution!
For reasons of safety, the brake/inching valve, the pressure accumulator and
the brake calliper may be dismantled and repaired by authorised specialist
staff only. Otherwise replace the complete unit.
In order to avoid damage to the seals in the brake system:
☞ Use brake fluid Agip LHM Super or Shell LHM
☞ Make sure old brake fluid in the bleed equipment is fully replaced by the
brake fluid specified above - no mixtures!
Brake calliper maintenance
Caution!
Make sure under all circumstances that no grease with metallic components is
used for maintenance work (e.g. copper paste).
• In connection with copper and salt water, aluminium-alloy brake callipers turn into
galvanic elements producing electric tension. This in turn produces corrosion, and the
components “seize”.
• Use only PLASTILUBE or similar lubricants.
Danger!
Do not dismantle the brake piston in the

brake calliper.
☞ Replace the complete brake calliper
in case of leaks!
Replacing the brake linings

☞ Remove the safety pin
☞ Extract the bearing pin
☞ Remove the cable pull on the brake calliper
Safety pin ☞ Fold the brake calliper up
☞ Remove the brake linings
Bearing pin ☞ Turn the brake cylinder piston to reset it apply-
ing pressure
☞ Insert new brake linings and mount the brake
calliper in the reverse order

Steering system
Steering system
8
8-1
8.1
Check block
Valve 0.5 and 10.0 bar
(in left-hand side access) Pressure relief valve 175 - 180 bar
Steering system
P Steering circuit
Steering system
T
R
Tank
B2 L
Front axle
LS
B1
A1
A2
From the pump
750 52 l
850 71 l
To control valve Rear axle
LS line
Priority valve
Test port and P line to steering
system
1000144594_s.iso Steering ram with final position synchronisation

Steering system
8.2 Steering circuit
Pressure relief valve

(adjustable to 175 - 185 bar)
To control valve
X From the pump
)(
L P T LS R
P to steering system X
CF EF
A1 A2
)(
LS
)(
)(
10 bar 0,5 bar 0,5 bar 10 bar P
B1 B2 34200s810_02.iso
Valve block
(
(
(
Tank
(
((
(
Front axle Rear axle
Steering rams Final position synchronisation

Steering system
8.3 Steering system adjustment

Function
Steering is carried out by means of 2 steering rams. Both steering rams are connected
together on one side of the chamber, the steering valve and the check block are located in
between. Each of these components has a certain amount of leakage which means
hydraulic oil escapes between the front and rear steering rams. This oil is no longer replen-
ished whilst steering since pressure is applied to only one side of the front or rear steering
ram when steering to the left or right. This is why synchronising several times a day is nor-
mal, depending on the use the machine is put to.
8.4 Hydraulic ports on servostat

23 Nm
40 Nm L
P=
L
pressure Hydraulic pump =>priority
18 Nm T valve => servostat
LD =
LD priority valve => servostat
23 Nm
L=
R left servostat => rear axle steering ram
40 Nm
R
P R=
right servostat => front axle steering
T 23 Nm ram
T=
reflux servostat => hydraulic oil tank
T LD
P
8.5 Pressure relief valve: adjustment

Proceed as follows:
Pressure relief valve
☞ Remove the leg room cover
Steering pressure
☞ Remove the side cover on the steering console
☞ Slacken the servostat (4 screws M10) and slide downwards
☞ Adjust the steering pressure with an allen key
➥ 175 bar
Secondary valve

Steering system
8.6 Sealing steering rams
3
34001e2303,eps
7
8
2
6
• Remove lock nut 1 on track rod joint 2
• Remove track rod joint 2 from the planetary carrier
• Determine the setting value between the end of the piston rod and the track rod joint
➥ e.g. determine the revolutions as you remove track rod joint 2
• Remove track rod joint 2 from piston rod 3
• Remove threaded pipe fitting 4
• Remove the complete steering ram from the axle carrier
➥ 3 screws 5
• Fasten the steering ram in a vice with aluminium clamps
• Remove circlip 6
• Slide guide bushing 7 to the inside
• Remove circlip 8
• Pull out piston rod 3 with guide bushing 7
• Replace the seals and cuffs 9
• Assembly in the reverse order

Steering system
8.7 Checking a steering ram

• Apply pressure to the steering ram in centre position, i.e. block one side with a sleeve.
• Remove the hydraulic lines. The connecting piece to the manual pump must have a
micro port and a stop cock
• Raise pressure to 150 bar; pressure is allowed to drop to about 20 bar in 10 minutes
• Then carry out a low-pressure test at 10 bar; no pressure drop in the process!
8.8 Overview of steering ram setting

Readjust the steering system when carrying out repair work on the axles or in case of com-
plaints:
• After replacing/repairing the track rods or the track-rod ends C
• After carrying out repair work on the joint housings or stop screws E
• After carrying out repair work on the steering ram, e.g. replacing the piston rod or ram
cylinder.
The steering requires no setting in case of sealing work during which locknut B on
track-rod end C has not been slackened.
A/ Contact surface for fork spanner Steering rams Track rod

D/ Joint Joint housing
B/ Locknut
C/ Track-rod end
E/ Stop screw
Necessary tools
1 measuring staff, about 3 m
1 track measurement rod
1 screw connection G 10-L (order no. 1000020767)
Standard tools

Steering system
8.9 How to check/set the steering rams

The diagram shows how to follow the separate steps.
1. Check track setting

Specified value = 0 (max. 1 mm toe-in)?
No
2. Correct track setting

OK Specified value = 0 (max. 1 mm toe-in)?
3. Set the steering angle or stop!
4. Check synchronisation
Identical resistance on either side of
No
the steering wheel?
5. Set synchronisation
OK Centre the piston rod (bypass)
1. Check track setting

Specified value = 0 (max. 1 mm toe-in)?
No
OK 6. Test run END

Steering system
8.10 Checking the track setting (1)

Check the track as follows:
A ☞ Jack up the machine and prop it safely. Make sure there is enough space for steering at
the full steering angles for the front and rear axles.
Front axle ☞ Set the steering to straight ahead. Check with the measuring staff
☞ Determine dimension A and dimension B. To this effect, measure with the track
B measurement rod on the inside on the rim flange at the centre of the wheel
➥ Rated dimension B - A = 0, max. + 1 mm
Measuring staff
Rim flange ➥ I.e. dimension A may be a max. 1 mm smaller than dimension B on the same axle
Caution!
A Check and set the tracks of front and rear axles separately!
The front and rear axle dimensions may differ slightly due to production toler-
Rear axle ances.
8.11 Correcting the track setting (2)
A/ Contact surface for fork spanner
C/ Track-rod end B/ Locknut
If the track setting does not correspond to the specified value 0 (max. 1 mm toe-in), set
the track as follows:
☞ Slacken locknut B on either side
☞ Slightly and evenly screw in or unscrew the threaded rod in track-rod end C on either
side.
➥ Make sure dimension X is approximately identical on either side.
☞ Check the track setting again
☞ Repeat this procedure until the track setting corresponds to the specified value.
☞ Counter locknut B
☞ Check dimension X again on either side of the steering ram

Steering system
8.12 Setting the steering limit (3)
F/ Locknut
E/ Stop screw
Specified value: steering angle = 40 ° (front and rear axles)

The steering synchronisation will not run correctly unless the steering angles of all wheels
are exactly the same.
The exact setting of the steering angles and stops has been carried out in the plant.
Proceed as follows if no measurement equipment is available.
Proceed as follows:
☞ Slacken locknuts F on stop screws E
☞ Fully unscrew all stop screws E on either side of the front and rear axles
☞ Actuate the steering ram to the left as far as it will go
➥ Stop screw E is not allowed to touch the limit stop on the axle
☞ Turn stop screw E against the limit stop by hand, then unscrew it again 1.5 revolutions
and counter it with locknut F
☞ Actuate the steering ram to the right as far as it will go
➥ Stop screw E is not allowed to touch the limit stop on the axle
☞ Turn stop screw E against the limit stop by hand, then unscrew it again 1.5 revolutions
and counter it with locknut F
Important!
Carry out these basic settings on both joint housings of the front and rear axles.
Limiting the maximum steering angle ensures steering angles of about 40°.

Steering system
8.13 Checking steering synchronisation (4)

The axles are synchronised by means of a bypass in the final positions of the steering
rams. In the final position of the piston, oil flows from one side of the cylinder to the other.
Bypass
In the axle that reaches the steering limit first, the oil flows through a bypass in the steering
ram and on to the other side if the wheels do not run synchronously.
If the steering wheel is turned further, the steering ram of the other axle moves on as far as
it will go. The wheels on the inside curve have the same steering angle in this case. The
wheels (or the axles) are hence synchronous.
R If the steering is set to straight ahead again, the wheels (or the axles) run in the same
track.
L However, this only works optimally if the bypass position with regard to the left and right of
the piston (and with regard to the front and rear axles) is symmetrical in the limit positions.
This is the case if the same resistance can be felt at the steering limits on the left and right
when evenly turning the steering wheel at the same speed.
➥ The force required to turn the steering wheel at the limit stops on the left and right must
be identical.
The steering rams (or the bypasses) of the front and rear axles must be centred separately
as follows to ensure this.
Checking the bypass

When checking the front axle
☞ Remove both flexible lines from the rear axle steering ram and connect them with an
intermediate screw connection G 10-L (order no. 1000020767)
When checking the rear axle
☞ Remove both flexible lines from the front axle steering ram and connect them with an
intermediate screw connection G 10-L (order no. 1000020767)
Caution!
Make sure there is no air in the steering circuit otherwise synchronisation

cannot be checked or set correctly!
☞ Bleed the steering system after repairing the steering rams - see Bleeding
the steering rams on page 8-10!

Steering system
Bleeding the steering rams

☞ Start the engine
Front
☞ Turn the steering wheel to the left until a resistance can be felt
axle ☞ Continue turning the steering wheel 5 to 10 revolutions until the resistance no longer
changes
☞ Turn the steering wheel to the right until a resistance can be felt
Bypass ☞ Continue turning the steering wheel 5 to 10 revolutions until the resistance no longer
changes
If there is no more air in the steering circuit, then ...
☞ Turn the wheels to the left as far as they will go
☞ Continue turning the steering wheel against the limit
➥ You must be able to feel a certain resistance (oil flows through the bypass)
☞ Turn the wheels to the right as far as they will go
Front ☞ Continue turning the steering wheel against the limit
axle ➥ You must be able to feel the same resistance here, too, as on the other side
➥ If the resistance is stronger (at the same speed with which the steering wheel is
turned), move the piston of the piston rod to the left until reaching the same
Bypass resistance
☞ See “Setting steering synchronisation (5)” on page 8-11
Caution!
The steering rams of the front and rear axles are checked in the same way!

Steering system
8.14 Setting steering synchronisation (5)
A/ Contact surface for fork spanner
C/ Track-rod end B/ Locknut
Caution!
Basically, always move the piston in the direction with the stronger resistance!
Proceed as follows:
☞ Set the steering system to straight-ahead position
☞ Switch off the engine and the ignition
☞ Slacken locknut B on either side, counter on contact surface A with a fork spanner
☞ Move the piston gradually (half revolutions) until the resistance you can feel on the
steering wheel is identical. To this effect:
☞ Unscrew the threaded rod half a revolution on track-rod end C on the left
☞ Screw in the threaded rod the same number of revolutions on track-rod end C on the
right
☞ Tighten locknut B on either side, counter on contact surface A with a fork spanner as
you do so
☞ Check the track again as soon as the piston rod is centred. Dimension X is of no
importance now since it is no longer identical on the left and right.
☞ Remove the intermediate screw connection G 10-L (order no. 1000020767) between
the flexible lines on the steering ram and mount the flexible lines correctly onto the
steering ram connections
Caution!
The steering rams of the front and rear axles are set in the same way!
Final check/test run

☞ Tighten all flexible lines and screw connections oil-tight
☞ Put the machine back onto its wheels
☞ Carry out a test run. Turn the steering wheel to the left and right as far as it will go to
check the synchronous position of the wheels

Hydraulic system
Hydraulic system
Hydraulic system
9 Hydraulic system
9.1 Work hydraulics test report
Model: Serial no.
_______________________________ ____________________________________

Rated driving direction:
Test features: Notes: Actual value:

(rpm)
Max. idling speed 2430 - 2470 rpm
Lower idling revs with air condi- Measured on the fan wheel 1012 - 1078 rpm
tioning 2673 - 2717 rpm
Upper idling revs with air condi-
tioning
Work hydraulics Measured on the hydraulic pump

3rd control circuit (max. engine revs)
Model 346-03 (750) 205 - 225 bar
Model 346-04 (850) 220 - 240 bar
Work hydraulics
Lift ram (secondary) 240 bar
Work hydraulics
Tilt ram (dump out) 115 - 135 bar
Min. idling speed
(secondary)
Work hydraulics
Tilt ram (dump in) 240 bar
(secondary)
Load stabiliser Measured on the hydraulic pump 140 bar
Steering pressure At maximum engine revs 175 - 195
Loader unit lowered T oil = 50 °C Lift ram max. 11.5 mm

Model 346-03 (750) P cylinder = 100 bar/t = 10 min Tilt ram max. 14 mm
Loader unit lowered T oil = 50 °C Lift ram max. 15 mm

Model 346-04 (850) P cylinder = 100 bar/t = 10 min Tilt ram max. 17 mm

9.2
Suction and reflux
filter

Work hydraulics oil supply
Control valve
system test port

Steering1000144734_s.iso
Work hydraulics:
Priority valve • Model 750 = 52 l/min
Work hydraulics • Model 850 = 71 l/min
test port
9-2
Hydraulic system
Hydraulic system
9.3 Control valve ports
115 - 135 bar Primary 210 bar

Plug
35 Nm
B 1 = tilt in
B3 B2 B1
B 2 = lower
B 3 = unlock
A3 A2 A1
A 1 = dump out
T
A 2 = raise
A 3 = lock P
240 bar 240 bar
9.4 Priority valve ports

Control line from the steering system
LS
P from the pump
P CF
Steering system test port

175 - 195 bar
EF
Work hydraulics test port
Model 750 = 205 - 225 bar
Model 850 = 220 - 240 bar

Hydraulic system
9.5 Priority valve diagram
To control valve
To the steering system
Control line from the steering system
From the pump
9.6 Load stabiliser ports
Pressure accumulator 20 bar

(pre-tensioning pressure)
Pressure relief valve 140 bar
Y 20 Y21
Y 20/Y 21
Both energised

Hydraulic system
9.7 Load stabiliser circuit
A2
T
B2
To the pressure accumulator Valve block
Y21
Pressure relief valve 140 bar

Y 20
9.8 Load stabiliser diagram
Lift ram Solenoid valve Pressure accumulator
Control valve

Hydraulic system
9.9 Lift ram: sealing work
Seals (included in sealing kit)
Joint bearing 34300s910_11.iso
Cylinder head/400 Nm Piston/600 Nm
Disassembly/assembly
☞ Unscrew cylinder head with special key
☞ Pull out piston rod
☞ Remove threaded pin on piston
☞ Unscrew piston from piston rod
☞ Replace complete sealing kit
➥ Sealing kit includes all seals, sleeves and threaded pins
➥ Calibrate the piston seal when replacing it
☞ Assembly in the reverse order
➥ Bear in mind the tightening torques
Caution!
Special tools required for sealing the ram

Hydraulic system
9.10 Tilt ram: sealing work
Seals (included in sealing kit)
Joint bearing 34300s910_12.iso
Cylinder head/400 Nm Piston/600 Nm
☞ Unscrew cylinder head with special key
☞ Pull out piston rod
☞ Remove threaded pin on piston
☞ Unscrew piston from piston rod
☞ Replace complete sealing kit
➥ Sealing kit includes all seals, sleeves and threaded pins
➥ Calibrate the piston seal when replacing it
➥ Bear in mind the tightening torques
Caution!

Hydraulic system
9.11 Control ram (quickhitch frame): sealing work
Piston seal
Rod seal
Circlip
Seal between ram cylinder and guide 36eh3610.iso
bushing
☞ Release the pressure in the quickhitch ram control circuit
☞ Remove the circlip
☞ Drive out the piston with an impact extractor M 8
☞ Renew the seal between piston rod and guide bushing
➥ Replace complete sealing kit
Caution!

Hydraulic system

Hydraulic system
Hydraulic system
9.12 Work hydraulics diagram
7 8 9
Pressure line from priority valve EF
Reflux from case flushing 10

(variable displacement pump)
Reflux from hydraulic motor T 2
Reflux from hydraulic motor T
Ref.
Reflux (varia-
ble displace- 1 Reflux suction filter
ment pump S) 2 Pressure switch
2 3 Oil-to-water-cooler
4 Vent filter
5 Non-return valve 1.5 bar
1 6 Hydraulic oil tank
4
7 Tilt ram
8 Lift ram
5 9 Control ram
(3rd control circuit)
10 Quick couplers
6 (3rd control circuit)
11
11 Control valve (3-fold)
Reflux from inching

valve, steering system
Work hydraulics diagram
Reflux from control valve
Serv-HB 34603_04 En - Edition 1.0* 34603_04s911.fm 9-10

Hydraulic system
9.13 Hose burst valve hydraulics diagram (option)
1 2
3 3
Ref.
1 Lift ram
2 Tilt ram
3 Hose burst valve
4 Control valve (3-fold)

Electric system
Electric system
Electric system
10 Electric system
10.1 Ohm's Law (current, voltage, resistance); power
It describes the interrelation between current, voltage and resistance.
Current “I” - Ampere (A)

Voltage “U” - Volt (V)
Resistance “R” - Ohm (Ω)
Mnemonic: R
U
I
Output
Power "P" - Watt (W)
P = U x I = R x I² = U²/R
10.2 Measuring equipment, measuring methods

Multifunction measuring device
• Measurements of values (U, R, I, f)
• Continuity test
• Diode test
Calculate measuring range using known data (P, U, R, I)
and set before measuring!
Observe AC/DC basic setting.
➥ AC = alternating current/voltage;
➥ DC = direct current/voltage
Test device with acoustic and optical signal output
• Continuity test in de-energised machine electric system and of wiring harnesses
Measuring methods - multifunction measuring device
• Measuring current (ignition switched on):
• Black cable in COM socket (earth),
• red cable in A socket or mA socket; connect in series to consumer.
• Measuring voltage (ignition switched on):

• red cable in V socket;
• connect in parallel to consumer.
• Measuring resistance (ignition switched off):
• red cable in Ω socket;
• connect in parallel to consumer (see measuring voltage).

Electric system
10.3 Terminal description

Terminal descriptions and cable descriptions are not identical because equipment with dif-
ferent terminal descriptions can be connected to both ends of a cable.
If there are not enough terminal descriptions (multiple connectors), the terminals are
marked with continuous number or letter codes without any standardised function assign-
ment.
Terminal Meaning
Ignition coil, ignition distributor
1 Low voltage
Ignition distributor with two separate electric circuits
1a
to ignition contact breaker I
1b
to ignition contact breaker II
Short-circuit terminal
2
(magneto ignition)
Ignition coil, ignition distributor
4
High voltage
Ignition distributor with two separate electric circuits
4a from ignition coil I, terminal 4
4b from ignition coil II, terminal 4
15 Switched plus behind battery (output ignition [drive] switch)
15a Output at dropping resistor to ignition coil and starter
Preheating start switch
17 Start
19 Preheating
Battery
30 Input from + battery terminal, direct
12/24 V battery changeover relay
30a Input from + terminal of battery II
Return line to battery
31 Minus terminal or earth, direct
Return line to battery
31b Minus terminal or earth, via switch or relay (switched negative)
12/24 V battery changeover relay
31a Return line to minus terminal of battery II
31c Return line to minus terminal of battery I
Electric motors
32 Return line1)
33 Main terminal connection1)
33a Self-parking switch-off
33b Shunt field
33f For second lower speed range
33g For third lower speed range
33h For fourth lower speed range
33L Counterclockwise rotation
33R Clockwise rotation
Starter
45 Separate starter relay, output; Starter, input (main current)

Electric system
Terminal Meaning
Two-starter parallel operation
Starting relay for engagement current
45a Output starter I,
Input starters I and II
45b Output starter II
48 Terminal on starter and on start-repeating relay (to monitor starting)
Turn indicator unit (pulse generator)
49 Input
49a Output
49b Output, 2nd turn indicator circuit
49c Output, 3rd turn indicator circuit
Starter
50 Starter control (direct)
Battery changeover relay
50a Output for starter control
Starter control
50b with parallel operation of 2 starters with sequential control
Starting relay for sequential control of the engagement current during parallel
operation of 2 starters
50c
Input at starting relay for starter I
50d
Input at starting relay for starter II
Start locking relay
50e Input
50f Output
Start repeat relay
50g Input
50 h Output
AC alternator
51 Direct current voltage at rectifier
51e Direct current voltage at rectifier with choke coil for daytime driving
Trailer signals
52 Signals from trailer to towing machine
53 Wiper motor, input (+)
53a Wiper (+), self-parking switch-off
53b Wiper (shunt winding)
53c Electric window washer pump
53e Wiper (brake winding)
53i Wiper motor with permanent magnet and third brush (for higher speed)
Trailer signal
54 For lamp combinations and trailer plug connections
Brake lights
54g Pneumatic valve for additional retarding brake, electromagnetically actuated
55 Fog lights
56 Headlight
56a High beam and high beam telltale
56b Low beam
56d Headlight flasher contact

Electric system
Terminal Meaning
57 Side marker light for motorcycles (also for cars, trucks etc. in other countries)
57a Parking light
57L Parking light, left
57R Parking light, right
Side marker, rear, numberplate and instrument panel lights
58
Rear light changeover for single-axle tractors
58b
Trailer plug-and-receptacle assembly for single-conductor rear light cable with
58c
fuse in trailer
58d
Variable-intensity instrument panel lights, side marker and rear light
58L
Left
58R
Right, numberplate light
AC alternator (magneto alternator)
59 Alternating voltage, output, rectifier, input
59a Charging armature, output
59b Rear light armature, output
59c Brake light armature, output
61 Alternator charge telltale
Tone sequence control device
71 Input
71a Output to horns 1 + 2 low
71b Output to horns 1 + 2 high
72 Alarm switch (rotating beacon)
75 Radio, cigarette lighter
76 Loudspeaker
77 Door valve control
Switches (break contact and changeover switches)

Input
81
1st output, break side
81a
2nd output, break side
81b
Make-contact switch
Input
82
1st output
82a
2nd output
82b
1st input
82z
2nd input
82y
Multiple position switch
Input
83
Output, position 1
83a
Output, position 2
83b
Output, left-hand side position
83L
Output, right-hand side position
83R
Current relay
84 84a 84b
Input, actuator and relay contact
84a
Output, actuator
84b
Output, relay contact 84

Electric system
Terminal Meaning
Switching relay - output, actuator (end of winding negative or earth)

Input, actuator
85
Start of winding
Start of winding or 1st winding
Winding tap or 2nd winding
86
86 87a 88a 87a 88a 87a 88a
86a 88b
86b
85 87 88 87 87
Relay contact for break and changeover contacts

87
Input
87a
1st output (break side)
87b
2nd output
87c
3rd output
87z
1st input
87y
2nd input
87x
3rd input
Relay contact for make-contact
88 Input
Relay point for make-contact and changeover contacts (make side)
88a 1st output
88b 2nd output
88c 3rd output
Relay contact for make-contact
88z 1st input
88y 2nd input
88x 3rd input
Alternator and governor

B+ Battery positive
B- Battery negative
D+ Dynamo positive
D- Dynamo negative
DF Dynamo field
DF 1 Dynamo field 1
DF 2 Dynamo field 2
U, V, W Three-phase alternator - three-phase terminals
Turn indicators (turn indicator unit)
First telltale
C
Main terminal connection for separate indicator circuits actuated by the turn
C0
indicator switch
C2
Second telltale
C3
Third telltale (e.g. when towing two trailers)
L
Turn indicators (left)
R
Turn indicators (right)

Electric system
10.4 Colour coding of electric lines

The cables are colour-coded according to DIN 72551 Part 4. Refer to the 21 pin cab/frame
interface or the explanation in the wiring harness drawings for other colours not listed in
this DIN standard.
Extract from DIN 72551, sheet 4
Line Identification
Basic colour
From to colour
Ignition coil I Ignition distributor (low-voltage ignition lead) Green -
Ignition coil II Ignition distributor (low-voltage ignition lead) Green Red
Battery Starter Black -
Battery Earth (if bare earth lead is not used) Black -
Starter Alternator Red -
Starter Control panel (30) Red -
Light switch (30) Ignition switch (30) Red -
Control panel (30) or light switch (30) Fuse Red -
Fuse Hand lamp, radio, clock etc. Red -
Heater plug and starter switch; heater-plug tell-
Control panel (15/54) Black -
tale
Heater plug and starter switch; heater-plug tell-
Glow plugs Black -
tale
Ignition switch (15/54) Ignition coil Black -
Ignition switch or control panel (54/15/61a) Telltales Black -
Control panel or ignition switch (15/54) Fuse Black -
Fuse box Brake light Black Red
Fuse box Turn indicator switch Black White-green
Turn indicator switch Turn indicators, left Black White
Turn indicator switch Turn indicators, right Black Green
Telltale Turn indicators Light blue -
Fuse Cigarette lighter Black -
Fuse Heated window Black Yellow-red
Fuse 1st horn Black Yellow
Fuse 2nd and 3rd horn Black Yellow-light blue
Horns 1 pole horn pushbutton (earth) Brown -
Fuse Wipers Black Purple
Terminal 61 of alternator or reverse current cut-
Battery charge telltale Light blue -
out
Fuse Main beam telltale Light blue White
Oil pressure gauge (indicator) Oil pressure switch Light blue Green
Fuel level indicator Fuel tank Light blue Black
Tyre-pressure warning device Tyre-pressure drop indicator Light blue Yellow
Control panel bzw. Lichtschalter Low beam switch White Black
Low beam switch (a) Fuse White -

Electric system
Line Identification
Basic colour
From to colour
Fuse Main headlight, left White -
Fuse Main headlight, right White -
Low beam switch (b) Fuse Yellow -
Fuse Low beam, left Yellow -
Fuse Low beam, right Yellow -
Control panel or light switch (58) Fuse Grey -
Fuse Rear light, side light and side marker lights left Grey Black
Fuse Numberplate light (combined with rear left light) Grey Black
Fuse Rear light, side light and side marker lights, right Grey Red
Numberplate light (combined with rear right
Fuse Grey Red
light)
Fuse Numberplate light (only if special line is laid) Grey -
Fuse Dome light Red -
Control panel (57) Fuse Grey Green
Control panel bzw. Lichtschalter Instrument panel light Grey Red
All consumers except the battery earth lead if
Earth Brown -
the use of bare lines is not possible
Battery changeover switch (50)/starter pushbut-
Starter Black -
ton or heater plug and starter switch

Electric system
Other colour codes (identical to IEC 757)
Abbreviation Abbreviation
Colour
Old New
Black sw BK
Brown br BN
Red rt RD
Orange or OG
Yellow ge YE
Green gn GN
Blue bl BU
Violet vi VT
Grey gr GY
White ws WH
Pink rs PK
Gold - GD
Turquoise tk TQ
Silver - SR
10.5 Switching relay function

Use, mode of function
Relays are used for switching electric loads (high currents) whereby the control power of
the relay coil is relatively low. Relays can therefore be controlled by micro electronics or
micro switches (e.g. touchpad keyboards, sensors). The switch contacts can be make-
contact, break-contact or changeover switches. These undertake the actual switching
function.
Terminal description on relay
Zero-centre relay
86 = Start of coil (control line)
85 = End of coil (earth)
30 = Input (load line)
87 = Make-contact switch output (load line)
87 a= Break-contact switch output (load line)

Electric system
10.6 Starter, battery, alternator

Electric system
Alternator 12 V 95 A
Starter 12 V 2.3 kW
Battery 12 V 88 Ah
10.7 Fuse box

The fuse box is located on the instrument panel to the right of the parking brake lever.
Rated
No. Protected circuit
current
F1 7.5 High beam (left)
F2 7.5 High beam (right)
F3 5 Left side marker and rear lights, front socket
Switch assignment: front/rear working lights, front attachments
(option), rotating beacon (option)
F4 5 Switch lights: lights, heating S5, load stabiliser S8, 3rd control
circuit
Right side marker and rear lights, front socket (option)
High current relay - preheating and starting, high current relay,
F5 7.5 interior light, relays - minus compensation, preheating telltale,
hazard warning light
F6 25 Cigarette lighter, rotating beacon (option), front/rear working light
F7 25 All lights
F8 7.5 Low beam (left)
F7 F6 F5 F4 F3 F2 F1
F9 7.5 Low beam (right)
Switching relay - front attachment (option), instrument panel, cut-
F10 5
F16 F15 F14 F13 F12 F11 F10 F9 F8 off solenoid, sensor (coolant level indication)
Washer pump, rear wiper, relays - wiper,
F11 15
Fig. 130: Fuse box
front wiper, horn
F12 7.5 Solenoid valve 1st/2nd speed range, load stabiliser
Relays - forwards/reverse, solenoid valve - forwards/reverse,
F13 7.5
backup warning system
F14 20 Front attachment (option), heating fan
Relay - turn indicators, brake lights, solenoid valve (exhaust gas
F15 7.5
recirculation)
F16 5 Radio (option)

Electric system
10.8 Main fuse box with relays

The main fuse box with the power relays and the preheating time control unit is located in
F18 the engine compartment on the left underneath the battery
.
F17 Fuse no. Rated current (A) Protected circuit

K5
F17 80 A Main fuse
K7
F19 F18 40 A Preheating/start fuse (starter)
K29 F19 10 A Minus compensation
Fig. 131: Main fuse box Relay no. Protected circuit
K5 Preheating: power relay
K7 Start: starter relay
K29 Minus compensation
10.9 Switching relays

The switching relays are located underneath the switch panel (board) on the right in the
side console (accessed via the maintenance flap on the right on the outside of the cab).
Switching relay no. Protected circuit

K10
K1 High current relay 70 A
K3 Reverse driving switching relay 40/60 A

X7
K3 K4 Forwards driving switching relay 40/60 A
X2 X4 X1 K10 Switching relay - turn indicators
K4 K16 Switching relay - front socket (option)
K23 Wiper switching relay

K16 X1
X2
X6 X3
X4 Plug socket
V10 K23 X5
X6
X3
K1 X7
X5 V10

Electric system
10.10 Description of blocking diodes

Blocking diodes V8, V9
Function
• V9 has no function in the 50 series
• V8 only for the differential lock function (100 % switchable)
Location
• On the board
Blocking diode V10

Function
• V10 has no function in the 50 series
Location
• On the board
Blocking diode V11

Function
• V11 has the function of preventing the engine from starting with the parking brake
released.
➥ Relay K7 is earthed via the telltale if V11 is defective
Location
• On X1

Function
• V16/V17 for the lights (S15 switch for fan)
➥ Switch S15 is not lit if V16/V17 are defective
Location
• On the board

Function
• V20, V21 are used for the float position with hose burst valve and load stabiliser
• V20 is used for the load stabiliser
➥ The hose burst valve is not switched if V20 is defective
• V21 is used for the float position with hose burst valve
➥ The hose burst valve does not open if V21 is defective
Location
• On the board

Electric system
10.11 Overview of switch assignment
1 2 3 4 5
Caution!
Mount the switches as shown and affix symbols on

them to avoid damage due to malfunctions!
☞ Remove the dummy cover
☞ Insert the switch (tip switch) in the board
6 7 8 9 10
Switch position 1 2 3 4 5
Abbreviation S 14 Not assigned Not assigned S 15 S 17
Switch order no. 1000051958 - - 1000051967 1000051971
Symbol order no. 1000115420 - - 1000052358 1000096654
Only with 2 rear working

Function Lights - - Heating/fan
lights
Switch position 6 7 8 9 10
Abbreviation S 44 S 16 S 18 S 56 S 27
Switch order no. 1000052377 1000051959 1000051959 1000116428 1000051959
Symbol order no. 1000051962 1000052361 1000052356 1000052354
Rotating 4th control

Function Load stabiliser Working light Front socket
beacon circuit

Electric system
10.12 Retrofitting a rotating beacon

☞ Mount bracket A for the rotating beacon at the rear left of the cab
A OG ☞ The cable for the rotating beacon is located at the rear left in the cab frame
➥ Cable colours OG (orange) for power and
BK (black) for earth
☞ Insert the switch with the symbol in switch console S 18
➥ - see Overview of switch assignment on page 10-12
☞ Check the electric system
OG
BK
10.13 Retrofitting the backup warning system

☞ Mount backup warning system B on the bracket at the rear left of the cab
B ☞ The cable for the rotating beacon is located at the rear left in the cab frame
➥ Cable colours WH/VT (violet/white) for power and
BK (black) for earth
WH/VT
BK

Electric system
10.14 Retrofitting 2 front working lights

☞ Mount the working lights on the brackets at the front left and right
☞ The cables for the front working lights are located in the wiring harnesses at the
upper left and right in the cab frame
➥ GN/VT (green/violet) for power and BK (black) for earth
☞ Insert the switch in switch console S 16
➥ - see Overview of switch assignment on page 10-12
☞ Connect both cables GN/VT (green/violet with white connectors)
GN/VT ➥ The cables are located underneath the board and are accessed via the outside
maintenance flap on the right
➥ Check the electric system
10.15 Retrofitting 2 front working lights and 1 rear working light

☞ Mount the front working lights (see description above)
☞ Mount the working light on the bracket at the rear right and connect it with the cable for
the rear working light
➥ The cables for the rear working light are located in the wiring harness at the upper
right in the cab frame
➥ GN/VT (green/violet) for power and BK (black) for earth
☞ Insert the switch in switch console S 16
Cable connection
(white connector) ➥ - see Overview of switch assignment on page 10-12
☞ Connect the plug and socket connection (white connector and green/violet cable)
Caution!
Only 3 additional lights can be operated with switch S16

☞ A new switch is required in the switch panel when mounting a 4th working
light
☞ - see Retrofitting 2 front working lights and 2 rear working lights on
page 10-15

Electric system
10.16 Retrofitting 2 front working lights and 2 rear working lights

☞ Mount the front working lights
➥ - see Retrofitting 2 front working lights on page 10-14
☞ Mount the working lights on the brackets at the rear left and right, and
☞ connect them with the cables for the rear working lights
☞ The cables are located:
K 31 ➥ at the upper right in the cab frame GN/VT (green/violet) for power and BK (black)
for earth
➥ at the upper left under the roof lining GN/VT (green/violet) for power and BK (black)
for earth
Replace 20 A fuse ☞ Insert tip switch 1000051971 in switch console S 17
with 30 A fuse ➥ - see Overview of switch assignment on page 10-12
☞ Insert relay 1000051953 in slot K 31 (see figure for board)
☞ Replace 20 A fuse with a 30 A fuse
➥ - see Fuse box on page 10-9 (slot F14)
If front working lights are already installed ...

Remove the cable connec-
☞ Remove the plug and socket connection (white connector and green/violet cable), and
tion (white connector)
☞ Connect the cable with the white connector, with the cable with the red connector
(see figure)
➥ Cable colours: green/violet
If no working lights are installed at the front ...
☞ Connect the cable with the white connector, with the cable with the red connector
(see figure)
➥ Cable colours: green/violet
➥ The cables are located underneath the board
Cable connection (red and
➥ Access: via outside maintenance flap on the right
white connector)
Additional parts for the 4th working light (rear)
Pos. Description Order no. Qty

1 Tip switch 1000051971 1
2 Symbol 1000096654 1
3 Relay 1000051935 1
4 Working lights 1000051955 1 (2)
5 Flat fuse (30 A) 1000052491 1
6 Screw 1000085390 2
7 Hexagon nut 1000013022 2
8 Washer 1000015431 2

Electric system
Electric system
10.17 Electric diagram legend
Location Location Location

Equipment Consumer Remarks Equipment Consumer Remarks Equipment Consumer Remarks
(section) (section) (section)
A1 Radio X6/2 Option K23 Wiper speed 1 40/60A X5/1 X2 Drive input connector
B1 Fuel level sensor X1/2 K27 Time lag relay 5 min X2/1 Option (natural
X3 Lights connector
B2 Horn X3/2 M1 Starter 2 coloured)
B3 Backup warning system X3/2 Option M2 Front wiper motor X6/2 X4 Instrument panel connector
B8 Safe load indicator sensor X6/2 M3 Rear wiper motor X6/2 X5 Power supply connector
B11 Loudspeaker X6/2 Option M4 Engine fan X5/2 X6 Roof connector
B12 Loudspeaker X6/2 Option M5 Washer pump X6/2 X7 Min. 13 pole drive interlock connector
E1 Front right side marker light X3/2 P1 Hour meter X4/2 X8 Control lever connector (drive) X2/2
E2 Rear right light X3/2 P2 Fuel level indication X4/2 X9 Control lever connector (auxiliary hydraulics) X2/2
E3 Front left side marker light X3/2 P6 Safe load indicator X6/2 Tele X10 12 pole steering column connector (left)
E4 Rear left light X3/2 R1 Glow plug 2 X11 Front socket X3/2 Option
E5 High, low beam (right) X3/2 R2 Heated rear window X6/2 Option X12 Rear socket X3/2 Option
E6 High, low beam (left) X3/2 S1 Preheating start switch X4/2 X13 Radio connection grey X5/2
E7 Rear working light X6/2 Option S2 Engine oil pressure switch X1/2 X14 Radio connection brown X5/2
E8 Rear working light X6/2 Option S3 Engine temperature switch X1/2 X15 Instrument panel connection X4/2
E9 Front working light X6/2 Option S5 Hydraulic oil pressure switch X1/2 X16 Front wiper connection X6/2
E10 Front working light X6/2 Option S6 Hydraulic oil temperature switch X1/2 X17 Clearance lights connection X4/2
E14 Interior light with switch X6/2 S9 Brake light switch X5/2 X18 Safe load indicator sensor connection X6/2 Tele
E15 Cigarette lighter with light X5/2 S11 Parking brake switch X2/2 Y10 Cutoff solenoid X1/2
F1..F16 Fuses S12 Steering-column control lever (left) X2/2 Y2 1st/2nd speed solenoid valve X1/2
F17 Main fuse S14 Light switch X6/1 Y4 Reverse driving solenoid valve X1/2
F18 Preheating/start fuse S15 Heating switch X5/1 Y5 Forwards driving solenoid valve X1/2
G1 Alternator 2 S16 Working light switch X6/1 Option Y10 Driving direction identification solenoid valve X1/2
G2 Battery 2 S18 Rotating beacon switch X6/1 Option Y20 Load stabiliser solenoid valve X1/2 Option
H1 High beam telltale X4/2 S 19 Hazard warning switch X2/2 Y21 Load stabiliser solenoid valve X1/2 Option
H3 Engine temperature telltale X4/2 S21 1st/2nd speed switch X2/2 Y23 “Retract telescopic boom” solenoid valve X1/2 Tele
H4 Engine oil pressure telltale X4/2 S27 Front socket switch X2/1 Option Y24 “Extend telescopic boom” solenoid valve X1/2 Tele
H5 Alternator charge telltale X4/2 S30 “Unlock” tip switch X2/2 Option Y22 Hose burst valve solenoid (OFF) X1/2 Option
H7 Hydraulic oil filter telltale X4/2 S31 “Lock” tip switch X2/2 Option Y25 Quickhitch lock solenoid valve X5/2 Tele
H8 Hydraulic oil temperature telltale X4/2 S32 3rd control circuit switch X1/1 Option Y26 Tilt ram lock solenoid valve X5/2 Option
H10 Hose burst valve telltale X2/2 Option S33 3rd control circuit switch X1/1 Option Y27 Tilt ram lock solenoid valve X5/2 Option
H11 3rd control circuit telltale X4/2 S34 Forwards driving switch X2/2 Y30 Minus compensation valve (motor II) 2
H18 Parking brake telltale X4/2 S35 Reverse driving switch X2/2 Y33 Solenoid valve 4th control circuit X1/2 Option
H20 Brake lights X5/2 S40 Quickhitch lock tip switch X5/2 Tele Y34 Solenoid valve 4th control circuit X1/2 Option
H21 Brake lights X5/2 S44 Load stabiliser switch X1/1 Option
H22 Machine turn indicator telltale X2/2 S47 Tilt ram lock key-operated switch X5/2 Option
H23 Rear attachment turn indicator telltale X4/2 S56 4th control circuit switch X1/1 Option Electric diagram legend
H24 Front right turn indicator X3/2 S59 Heated rear window switch X2/1 Option
H25 Rear right turn indicator X3/2 S63 Float position/hose burst valve switch X2/2 Option
H26 Front left turn indicator X3/2 V1..V7 Suppressor diode X1/2
H27 Rear left turn indicator X3/2 V8,V9 Blocking diode X1/1
H28 Rotating beacon X6/2 Option V10 Blocking diode X6/1
K1 High current relay 70 A 1 V11 Blocking diode X1/2
K3 Reverse driving 40/60 A X1/1 V13.V15 Suppressor diode X1/2
K4 Forwards driving 40/60 A X1/1 V16,V17 Blocking diode X5/1
K5 High current relay preheating 2 V18,V19 Suppressor diode X5/2
K7 Start high current relay 2 V20,V21 Blocking diode X2/2 Option
K10 Turn indicator relay X2/1 V22 Suppressor diode X5/2 Tele
K16 Front socket 40/60 A X3/1 Option W1 Radio aerial X6/2
K17 Unlock 40/60 A X1/1 Option (natural
X1 Connector engine/valves
K18 Lock 40/60 A X1/1 Option coloured)
Serv-HB 34603_04 En - Edition1.0* 34603_04s1020.fm 10-16

Electric system Electric system
10.18 Electric diagram sheet 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1
A A 2
F14 F11 F12 F13 F15
1 20A 15A 5A 7,5A 7,5A
3
4
5
6
5
B S32 B
2 6 30 86 30 86 15(86) 30 7
9 10
K4 K3 86 30
8
1 87 85 87 85 K27 K16 9
F4 F3 F2 F8
85 87
31(85) 87 5A 5A 7,5A F1 F9 7,5A
7,5A 7,5A 10
11
12
Board
C C
13
14
S44
9
5 15
10
16
2 6
B
17
1
18
19
D D 20
9 1 B
9
1
31 R2 21
B G 22
S27 S59 R K10 23
5
S56 10 10 10
+ C 24
K1 5 3
25
B 9
5
26
V8 1
S33 27
10
V9 9 B 28
1
E E 29
86 30 30 86
30
K18 K17
85 87 87 85 31
32
X1 X2 X3
1 2 14 4 3 6 16 10 8 9 7 12 11 13 5 15 17 18 4 9 11 13 6 12 2 8 14 7 5 3 1 10 1 6 18 3 4 5 2 8 9 10 7 20 13 11 15 21 12 16 14 19 17 22
WH1,5
YE 1,5
BU/WH1,0
BU/GY 1,0
BK/WH1,5
BN 1,0
RD/BK 1,0
GY/RD1,0
GY/GN1,0
BU/GN1,0
VT/BU1,0
BN/YE 1,0
BN/BK 1,0
RD/YE 1,0
RD/BK 1,5
BN/VT 1,0
GY/BK 1,0
RD/YE 1,5
GY/RD1,0
GY/RD 1,0
GY/RD1,0
WH/BK 1,5
YE/BK 1,5
BK/WH1,0
BK/WH1,0
BK/WH1,0
BK/GN1,0
BN/YE 1,0
BN/BK 1,0
BU/BK 1,0
BU/YE 1,0
BU/RD 1,0
RD/GN1,0
GY/GN1,0
WH/BU1,0
WH/GN 1,0
GY/BK 1,0
GY/BK 1,0
GY/BK 1,0
BN/YE 1,5
WH/VT 1,0
BK/GN 1,0
BK/GN 1,0
WH/VT 1,0
WH/RD1,0
WH/VT 1,0
GN/VT1,0
BK/RD/YE 1,0
GN/VT1,0
WH/RD1,0
F F
PINK 1,0
BK 1,0
BU 1,0
BK/WH/GN1,0
2 V20
V21
1
S63
S9
2 33
3
34
35
S2 E1 E3 B2 E5 E6 H25 H27
RD 10,0
RD1,0
S5 B1
BK 10,0
P
P
G Q
G
BK 1,0
BK 1,0
BK 1,0
BK 1,0
BK 1,0
BK 1,0
BK 1,0
BK 1,0
56a 56b 56a 56b
Y1 V14
S6 S3 H24 H26
Wiring harness
V4 V5 V1 V18 V2 V3 V6 V7 V13 V15 3 1 H20 E2 E4 B3

Y24 Y23 Y5 Y10 Y4 Y2 Y34
T T
Y20 Y22
Y33 Y21 2 H21
BK/WH/GN 1,0
BK/WH/RD1,0
S11
BK 1,0
BK 1,0
BK 1,5
BK 1,0
BK 1,0
BK 1,0
BK 1,0
BK 1,0
BK 1,0
BK 1,0
BK 1,5
BK 1,0
BK 1,0
BK 1,0
BK 1,5
BK 1,5
BK 1,0
F17
80A 36
H H
RD6,0
RD6,0
RD6,0
BK 1,5
BK 1,0
RD10,0
F18 S19 49 49a X11 X12
WH/VT1,0
40A 31 58L 54 58R 5/58R 7/58L 3/31 4/R 1/L
RD 6,0
RD 1,0 1 7 R L
15 30
V11
RD/BK 1,5
F19 10 B
S21 37
BK/GN1,0
BK/WH1,0
RD/YE 1,5
10A
9
30 86 30 86 30 86 5
K5 K7 K29
J J
BN/YE 1,0
BN/BK 1,0
87 85 87 85 87 85 BN/BK 1,0
38
RD/BK 4,0
RD/BK 1,0
X9 B C A 2 3 4 1 X8
39
W H/BK 1,0
GN/WH1,0
BU 6,0
GN1,0
YE 1,0
Y30 S30 S35
BK 1,0
BU 1,0
40
BU/YE 1,0
D+
K RD 10,0 B+ K
3G
G1 S31
BK 50
50
B-
S34
30
+
M
M1 41
G2 R1
BK 50
-
BK 50
Electric diagram (sheet 1)

L L
M 1000133956_d_li.iso M
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Electric system
10.19 Electric diagram sheet 2
14 15 16 17 18 19 20 21 22 23 24
1
2 A
F16 F10 F7 F6 F5
1 5A 5A 25A 25A 7,5A
3
4
5
6
3 6
B 10 B
7 2
8 9
K23
9 1 86 30
S14
85 87
10
Board
11
12
C
13
14
15
16
17 9
5
3 S16
18 10 9
19 S15
10 B
20 B 1
21 5 D
9
22 1 5
23 S18
24 V16 B 10
V10
1
25
V17
26
27
BK/WH 1,0
28 4
29 3 E
X7
30 2
1
BU/BK 1,0
31
32
X4 X5 X6
2 9 16 8 7 4 3 18 5 6 12 1 10 11 15 14 17 13 2 3 6 8 11 10 12 16 14 21 22 7 5 1 13 19 20 17 15 4 9 18 2 3 10 9
nc nc 12 6 1 11 13 14 4 5nc 7nc 8
RD/WH2,5
VT 1, 0
BU1,0
OG 1,0
WH/BK 1,0
GY/GN1,5
RD/BK 1,5
GN/BK 1,0
BU/GN1,0
BU 1,5
BK/WH/BU 1,0
RD/YE2,5
RD 1,5
YE 1,5
RD/YE1,5
GY/RD1,0
WH1,5
RD 1,0
BK/BU 1,5
GN/BK 1,5
OG 1,0
GY 1,0
BU /BK1,0
GY/BK 1,0
BU/GN 1,0
WH1,0
BU/YE 1,0
BK/GN1,0
BN/YE 1,5
BU/GN1,0
RD/BK 1,0
BU/GY 1,0
RD/BK 1,0
BK/BU 1,0
VT/BU 1,0
BN/WH1,0
BU/WH1,0
BU/RD1,0
BK/WH1,0
RD/BK 1,0
VT/GN1,5
F
GN1,0
50a
19 30
2 15
S1
33
34
GN1,0
VT/GN 1,0
35 X17
VT/GN 1,5
VT/GN1,5
X15 M3 M4
M M E14 G
5 3 13 2 11 8 4 15 9 12 14 10 7 6 1 E8 E7
E15 X16 3 4 2 1
E10
BK 2,5
BK 1,0
H11 H23 H1 H18 H22 H3 H4 H8 H7

Wiring harness
H10 H5 P1 P2
h Q 53a 53 31b 31
BK 1,5
M M
S47 E9 H28
M5 M2
P6
BK 1,5
BK 1,5
BK 1,5
BK 1,0
BK 1,0
BK 1,0
to
36 18 15 22 6 H
RD1,0
BU1,0
RD/GN1,0
1
BK 1,0
BK 1,0
9 10
S40
W1
B
3
RD/GN 1,0
37 V18 V19
BU1,0
Y26 Y27
X13
V22 8 7 2 1 J
Y25 A1 X18
38
2 1
3 4 5 6 X14
39
BN
BU
to
B8
40
B4 B5 K
41
Electric diagram (sheet 2)

11 8 7 2 6 9 10 5 3 4 1 X10
H 53c 53 31b L R 56b 56a
L
S2
15 49 30 56
1000133956_d_re.iso M
14 15 16 17 18 19 20 21 22 23 24
Serv-HB 34603_04 En - Edition1.0* 34603_04s1020.fm 10-18

Electric system
Notes:

KRAMER-WERKE GmbH keep abreast of the latest technical developments and constantly
improve their products. For this reason, we may from time to time need to make changes to
diagrams and descriptions in this documentation which do not reflect products which have
already been delivered and which will not be implemented on these machines.
Technical data, dimensions and weights are given as an indication only. Responsibility for
errors or omissions not accepted.
No reproduction or translation of this publication, in whole or part, without the written con-
sent of KRAMER-WERKE GmbH.
All rights under the provision of the Copyright Act are reserved.
KRAMER-WERKE GmbH
Nussdorfer Str. 50
D-88662 Überlingen
Germany
Kramer-Werke GmbH
Nussdorfer Str. 50
D-88662 Überlingen
Tel. +49 (0) 7551 802-0
Fax +49 (0) 7551 802-260
Neuson Baumaschinen GmbH

Haidfeldstr. 37
A-4060 Linz-Leonding
Tel. +43 (0) 732 90590-0
Fax +43 (0) 732 90590-200
Neuson Ltd.
Crown Business Park
Dukestown, Tredegar
Gwent. NP22 4EF
United Kingdom
Tel. +44 (0) 1495 723083
Fax +44 (0) 1495 713941
Order no. 1000183988 EN

Repair Manual Kramer 850

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Service Manual

Machine model 346-03/346-04

Title Order no.

Service manual 1000183988 EN

Operation manual Model 346-03

Spare parts catalogue Model 346-03 1000181183

Copyright - 2008 Kramer-Werke GmbH, Überlingen

Serv-HB 34603_04 En - Edition 1.0 * 34603_04s10_enIVZ.fm I-1

Jump-starting the engine (external battery) ........................................................... 1-25

I-2 Serv-HB 34603_04 En - Edition 1.0 * 34603_04s10_enIVZ.fm

Maintenance and service work 3

Serv-HB 34603_04 En - Edition 1.0 * 34603_04s10_enIVZ.fm I-3

Brake system maintenance .................................................................................... 3-36

I-4 Serv-HB 34603_04 En - Edition 1.0 * 34603_04s10_enIVZ.fm

Inching valve circuit ................................................................................................. 5-5

Serv-HB 34603_04 En - Edition 1.0 * 34603_04s10_enIVZ.fm I-5

Checking steering synchronisation (4) ..................................................................... 8-9

I-6 Serv-HB 34603_04 En - Edition 1.0 * 34603_04s10_enIVZ.fm

Cab overview, labels, operation

1-1 1-1 Serv-HB 34603_04 En - Edition 1.0 * 34603_04s111.fm

Switches and control lever (side console)

Serv-HB 34603_04 En - Edition 1.0 * 34603_04s111.fm 1-2

1.3 Overview of exterior of machine

Fig. 1: Machine outside views

Pos. Description Pos. Description

1-3 1-3 Serv-HB 34603_04 En - Edition 1.0 * 34603_04s111.fm

1.4 Important information on this manual

“Option” = optional equipment

Driving direction in drawings or figures.

Serv-HB 34603_04 En - Edition 1.0 * 34603_04s110.fm 1-4

1.5 Models and trade names: overview

1.6 Brief description of the wheel loader

1-5 Serv-HB 34603_04 En - Edition 1.0 * 34603_04s110.fm

Work hydraulics and 4 wheel steering

Serv-HB 34603_04 En - Edition 1.0 * 34603_04s110.fm 1-6

Attachments with certified material densities

Description of attachment Wheel loader Part no. (model) Dimensions Use

1000102344 1750 mm/with teeth

1000113244 1750 mm/with teeth

1000156433 1850 mm/without teeth

1-7 Serv-HB 34603_04 En - Edition 1.0 * 34603_04s110.fm

Description of attachment Wheel loader Part no. (model) Dimensions Use

346-03 1000101820 1000 mm

Pallet forks with foldable

346-03 Picking up and transporting e.g. grass,

346-03 Scarifying dense soil,

346-03 For repair, assembly, disassembly, mainte-

1. Bucket with screwed-on exchangeable blade

Serv-HB 34603_04 En - Edition 1.0 * 34603_04s110.fm 1-8

1-9 Serv-HB 34603_04 En - Edition 1.0 * 34603_04s110.fm

Machine warning identification (option)

Serv-HB 34603_04 En - Edition 1.0 * 34603_04s110.fm 1-10

1.9 Type labels and component numbers

Type label information

Machine model: 346

Fig. 2: Type label: location

Fig. 3: Cab type label

Example: Deutz D2011 L04 W

Fig. 4: Diesel engine number

1-11 Serv-HB 34603_04 En - Edition 1.0 * 34603_04s110.fm