PDF DOWNLOAD WACKER NEUSON 5001 DUMPER SERVICE MANUAL 1000159455
Service Manual
Dumper
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Documentation
Description
Order no.
Operator's Manual from AB45091D to AC45157D1000103792
Operator's Manual from AD51001D1000190334
Spare parts catalogue from AB45091D to AB45297D1000128894
Spare parts catalogue from AC45002D to AC45157D1000161144
Spare parts catalogue from AD51001D1000189931
Service manual1000159455
Copyright – 2009 Wacker Neuson Linz GmbH, Linz-Leonding Printed in Austria
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.
Wacker Neuson Linz GmbH
Haidfeldstr. 37
A-4060 Linz-Leonding
Document:SERV-HB 5001 EN Order no.:1000159455
Edition: 2.0
diagram A3 (from AC45039D to AC45157D) ...........................................
Wiring harness legend 1000115009 main wiring harness (up to AB45291D) 10-29 Wiring harness 1000115009: main wiring harness (up to AB45291D)
Wiring harness 1000181595 main wiring harness (from AD51001D) ............ 10-31 Main wiring harness legend 1000181595A (from AD51001D) ............................ 10-32
Wiring harness 1000181595A main wiring harness (from AD51001D) ............... 10-33
Wiring harness 1000115414 engine wiring harness (up to AB45291D)
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Operation
1Operation
1.1Important information on this service manual
This service manual contains important information on how to service your machine safely, correctly and economically. Therefore, it aims not only at new operators, but it also serves as a reference 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 service manual.
Careful and prudent working is the best way to avoid accidents!
Operational safety and readiness of the machine do not only depend on your skill, but also on maintenance and servicing of the machine.
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. will be pleased to answer any further questions regarding the machine or the service manual.
Your Wacker Neuson dealer.
Abbreviations/symbols
• This symbol stands for a list
• Subdivision within lists or an activity. Follow the steps in the recommended sequence
☞ This symbol requires you to carry out the activity described
➥ Description of the effects or results of an activity
n. s. = not shown
“Option” = optional equipment
Stated whenever controls or other components of the machine are installed as an option.
A combination of digits, or a combination of digits and letters, e.g. 40/18 or 40/A used for identifying the control elements, means:
Figure no. 40/control element no. 18 or position A in figure no. 40
Figures carry no numbers if they are placed to the left of the text.
1.2Identification of warnings and dangers
Important indications regarding the safety of the staff and the machine are identified in this Operator's Manual with the following terms and symbols:
Danger!
Failure to observe the instructions identified by this symbol can result in personal injury or death for the operator or other persons.
☞ Measures for avoiding danger
Caution!
Failure to observe the instructions identified by this symbol can result in damage to the machine.
☞ Measures for avoiding danger for the machine
Notice!
This symbol identifies instructions for a more efficient and economical use of the machine.
Environment!
Failure to observe the instructions identified by this symbol can result in damage to the environment. The environment is in danger if environmentally hazardous material (e.g. waste oil) is not subject to proper use or disposal.
1.3Designated use and ex emption from liability
• The machine is intended for:
• transporting the usual bulk material and concrete on construction sites
• Every other application is regarded as not designated for the use of the machine. Wacker Neuson will not be liable for damage resulting from use other than mentioned above. The user alone will bear the risk. Designated use also includes observing the instructions set forth in the Operator's Manual and observing the maintenance and service conditions.
• The safety of the machine can be negatively affected by carrying out machine modifications without proper authority and by using spare parts, equipment, attachments and optional equipment which have not been checked and released by Wacker Neuson GmbH. Wacker Neuson GmbH will not be liable for damage resulting from this
• Wacker Neuson Linz GmbH shall not be liable for personal injury and/or damage to property caused by failure to observe the safety instructions and the Operator's Manual, and by the negligence of the duty to exercise due care when:
• handling
• operating
• servicing and carrying out maintenance work and
• repairing the machine. This is also applicable in those cases in which special attention has not been drawn to the duty to exercise due care, in the safety instructions, the Operator's Manuals and maintenance manuals (machine/engine).
• Read and understand the Operator's Manual before starting up, servicing or repairing the machine. Observe the safety instructions!
1.4Type labels and component numbers
Serial number
The serial number is stamped on the machine chassis next to the right-hand side front tyre. It is also located on the type label. The type label is located on the engine cover.
Type label information (example)
Machine model: 5001
Year of construction:2004
Serial no.: BB 000000
Output: 38.6 kW (51.0 hp)
Dead weight: 3060 kg (6746 lbs.)
Max. payload 5000 kg (11023 lbs.)
Gross weight rating:---------------
Gross axle weight rating:---------------
Other information – see chapter 2 Specifications on page 2-1
Engine number
The type label (arrow) is located on the valve cover (engine).
Example: Yanmar 46557
H ydraulic pump number
The type label (arrow) is located on the hydraulic pump housing
Fig. 1:Type label: location
Fig. 2:Type label
Fig. 3:Diesel engine number
Fig. 4:Number of variable displacement pump
Operation
Spool number
The type label (arrow) is located on the spool housing
Rollbar number
The type label is located on the rollbar
Axle number
The type label (arrow) is located on the upper side of the axle housing.
Fig. 5:Hydraulic pump type label
Fig. 6:Rollbar type label
Fig. 7:Axle type label
Pos. Description
1Seat
2Control stand
3Engine cover
4Rear chassis
5Rollbar
6Articulated joint
7Steering ram
8Swivel centring
9Mudguard
10Offset ram
11Front chassis
12Swivelling console
Model 5001 from AD51001D
Model 5001 from AB45091 to AB45291D Model 5001from AC45002D to AC45157D
Fig. 8:Machine outside views
1.6Control elements from AB45091D to AC45157D (overview)
1.7Control elements from AD51001D (overview)
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1.8Maintenance strut
Danger!
Crushing or striking hazard. An improperly supported skip can fall unexpectedly during maintenance work.
☞ Fold down the maintenance strut before you carry out maintenance work with the skip raised.
Proceed as follows (AB450191D – AC45157D):
☞ Raise the skip
☞ Remove the spring plug from pin B
☞ Remove the pin from guide C
☞ Fold down maintenance strut A
The maintenance strut shows downwards vertically and is automatically positioned on support D in case the skip should be lowered.
Proceed as follows (from AD51001D):
☞ Raise the skip
☞ Remove hinged split pin C
☞ Fold down maintenance strut A
☞ Lower the skip until maintenance strut A rests on support D
Danger!
Persons can be struck or crushed by a skip that is being lowered too quickly
☞ Lower the skip slowly and carefully, align the maintenance strut with support D
Notice!
Fasten the maintenance strut on the skip again (in the reverse order) once maintenance work is over.
Fig. 9:Maintenance strut
Fig. 10:Maintenance strut (from AD51001D)
Centre pivot strut
Danger!
Secure the steering ram with the red centre pivot strut when crane handling the machine.
The centre pivot strut secures the steering ram to prevent steering movements (via the articulated joint) when crane handling the dumper.
Proceed as follows (AB450191D – AC45157D):
☞ Remove the hinged split pin from pin B
☞ Rotate articulated steering locking bar A towards rear chassis C
☞ Secure centre pivot strut A with the spring plug on pin B
Proceed as follows (from AD51001D):
☞ Remove the hinged split pin from pin B
☞ Rotate articulated steering locking bar A towards rear chassis C
☞ Secure centre pivot strut A with the spring plug on pin B
Notice!
Before putting the machine into operation again, mount the centre pivot strut back onto the front chassis again by means of pin B
Fig. 11:Centre pivot strut AB45091D to AC45157D
Fig. 12:Centre pivot strut AB45091D to AC45157D
Fig. 13:Centre pivot strut from AD51001D
2Specifications
2.1Chassis
2.2Engine
Engine
Sturdy steel sheet chassis, rubber-mounted engine
Model 5001 up to AB45291D Model 5001 up to AC45157D Model 5001 from AD51001D
Forced feed lubrication system (with internal-gear rotor oil pump)
Intake valve lash 0.15 – 0.25 mm (0.006 – 0.010”) 0.3 mm ± 0.05 (0.012” ± 0.002)
Exhaust valve lash
Injection pressure 216 – 226 bar (3133 – 3278
bar (355 psi) ± 0.1 bar (1.45 psi)
Engine oil pressure
mm ± 0.05 (0.020” ± 0.002)
mm (± 0.05) (0.016” ± 0.002)
mm (± 0.05) (0.024” ± 0.002)
(2843 – 2988
(377 – 479
3.5 bar (51 psi) ± 0.5 bar (7 psi) at rated speed 1.4 bar (20 psi) at 900 rpm = low idling speed 1.5 bar (22 psi) at 900 rpm = low idling speed, warm engine (minimum) 2.2 bar (32 psi) at 1800 rpm 3 bar (44 psi) at max. 2800 rpm
Pressure switch for engine oil pump 0.5 bar (7 psi) ± 0.1 bar (1.45 psi) 0.5 bar (7 psi) ± 0.1 bar (1.45 psi) 0.5 bar (7 psi) ± 0.1 bar (1.45 psi)
Thermostat opening temperature Start 71 °C (160 °F), fully open 85 °C (185 °F) ~ 93 °C (199 °F)
Start 88 °C (190 °F), fully open at 92 °C (198 °F)
Thermal switch 110 °C (230 °F) ± 3 °C (37 °F) 130 °C (266 °F) 110 °C (230 °F) ± 3 °C (37 °F)
Firing order
1 – 3 – 4 – 2 (1st cylinder on fan wheel side) 1 – 3 – 4 – 2 (1st cylinder on flywheel side)
Direction of rotation Left (counterclockwise) as seen onto the flywheel
Starting aid
Preheater (preheating time 15 seconds) Intake manifold preheating by means of glow plug
Max. inclined position (engine no longer supplied with oil):
30° in all directions
30° in all directions
Exhaust values according to 97/68/EC tier 2 EPA tier 2, ECE R24 97/68/EC tier II EPA tier II, ECE-R24 97/68/EC level 3A, EPA tier3, ECE-R24
Engine capacities
Capacities
Engine tightening torques
Tightening torques
rod bearing screw
Model 5001 from AB45091 to AB45291D Model 5001 from AC45002D to AC45157D Model 5001 from AD51001D
1. Mark on oil dipstick alone is relevant Overview of capacities – see Fluids and lubricants on page 3-1:
Safe authorised inclination 25 % in all directions
2.9Vibration
Vibration
Effective acceleration value for the upper extremities of the body *
Effective acceleration value for the body *
< Trigger value (< 2.5 m/s2)
< Trigger value (< 0.5 m/s2)
*Measured according to 2002/44/EC. Machine and attachment operation and maintenance as per Operator's Manual. Uncertainty of measurement: measurements as per EN 12096:1997
2.10Electrical system
Electrical system
5001 up to AC45157D
5001 from AD51001D
Fuse box on the instrument panel from AB45091 to AC45157D
Fuse box in relay box from AD51001D
F3 10 A
Hazard warning system 30 F4 10 A
Parking light F5 10 A
Low beam F6 15A
High beam F7 10 A
Rotating beacon F8 10 A
1st/2nd speed, parking brake F9 10 A
F10 20 A
Buzzer for engine oil temperature, air filter, hydraulic oil filter and coolant temperature
Spare F11 10 A – Cutoff solenoid, fuel pump F12 10 A
Horn, brake lights
F13 10 A – Displays, turn indicators
Fig. 1:Fuse box
Fig. 2:Fuse box
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Relays (from AB45091D to AB45291D)
The relays are located in the relay box under the floor panel of the control stand
Relays (from AC45039D to AC45157D)
The relays are located in the relay box under the floor panel of the control stand
Relays (from AD51001D)
The relays are located in the relay box under the engine cover
Fig. 3:Relays
Fig. 4:Relays
Fig. 5:Relays
2.11Tyres
2.12 Axle mounting
Fastening screws
Wheel nuts
Danger!
Tightening torques
Front axle
Rear axle
Cardan shaft
Retighten the fastening screws every 50 s/h, otherwise –
Danger of accidents!
2.13Noise levels
Sound power level
Sound power level (LWA)
Notice!
2.14Coolant compound table
dB (A)
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.
Use the 1:1 concentration for warm outside temperatures, too:
• Protection against corrosion, cavitation and deposits
Do not mix the coolant with other coolants.
Coolant with specified features is filled in the machine at the factory.
2.15General tightening torques
Tightening torques for hydraulic screw connections (dry assembly)
Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 % Values determined empirically and to be applied as approximate figures.
Tightening torques for high- resistance screw connections
DIN 912 – hexagon socket head cap screw; DIN 931/DIN 933 – hexagon head screw with/without shaft; DIN 7984 – hexagon socket head cap screw with short head All values subject to a
DIN 912 – hexagon socket head cap screw; DIN 931/DIN 933 – hexagon head screw with/without shaft; DIN 7984 – hexagon socket head cap screw with short head All values subject to a friction coefficient of µ = 0.12 and are to be used as approximate figures.
Tightening torques for Nordlock lock washers
Dimensions with larger outside diameters
Fig. 6:Nordlock dimensions
Fig. 7:Nordlock
2.16Dimensions model 5001 AB45091D to AC45157D
8:Machine dimensions (model 5001)
Main data
Dead weight 3060 kg (6746 lbs.)
Overall height 2800 mm (110”)
Overall height with rollbar folded down 2010 mm (79”)
Overall height without rollbar
Overall width
Ground clearance
Wheelbase
mm (79”)
mm (76”)
mm (15”)
mm (83”)
Outside turning radius 4425 mm (174”)
Hill climbing ability 50 % theoretically
Safe authorised inclination 25 % in all drive positions left/right
Fig.
2.17Dimensions model 5001 from AD51001D
Main data
Dead weight
Model 5001
3250 kg (7165 lbs.)
Overall height 2830 mm (111”)
Overall height with rollbar folded down 2030 mm (80”)
Overall height without rollbar 2030 mm (80”)
Overall width 1990 mm (78”)
Ground clearance 290 mm (11”)
Wheelbase 2110 mm (83”)
Outside turning radius 4425 mm (174”)
Hill climbing ability 50 % theoretically
Safe authorised inclination 25 % in all drive positions left/right
Fig. 9:Machine dimensions (model 5001)
Maintenance
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3Maintenance
3.1Fluids and lubricants
Component/ application
Diesel engine
4TNV84T-KNSV
Hydraulic oil tank
All lubrication points
Battery terminals
Fuel tank
Engine oil API CD, CF, CF-4, CI-4
Hydraulic oil2 HVLP463
Biodegradable oil5
PANOLIN HLP Synth 46
FINA BIOHYDRAN SE 46
BP BIOHYD SE-46
FINA Energrease L21M
Mobilgrease CM-P As required
Acid-proof grease6 FINA Marson L2 As required
Diesel fuel No. 2-D, DIN 51601 grade
No. 1-D, DIN 51601 grade
Brake system Brake oil HVLP463 200 Hydraulic
Radiator Coolant Water + antifreeze; SP-C Year-round
Axles Differential housing Gearbox oil SAE85W90LS
1.The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
2.Standard system fill ex works
3.According to DIN 51524 section 3
4.Depending on local conditions – see Hydraulics oil grade on page 3-2
5.Hydraulic ester oils (HEES)
6.Standard acid-proof grease
API: CD, CF, CF-4, CI-4
SAE1 E3, E4, E5
1.According to DIN 51511
Oil grades for the diesel engine, depending on temperature
1.According to DIN 51524 section 3
Oil grades for the hydraulic system, depending on temperature
3.2Maintenance plan (overview)
Work description
For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the attachment manufacturer as well.
Fluid and filter changes ():
Carry out the following oil and filter changes (check oil levels after test run):
•Engine oil (first replacement after 50 s/h, then every 500 s/h)
•Engine oil filter (first replacement after 50 s/h, then every 500 s/h)
•Fuel filter (first replacement after 50 s/h, then every 500 s/h)
•Air filter element
•Coolant
•Differential housing oil (first replacement after 50 s/h, then once a year or every 1000 s/h)
•Planetary housing oil (first replacement after 50 s/h, then every 1000 s/h)
•Transfer gearbox oil (first replacement after 50 s/h, then every 1000 s/h)
•Brake oil
•Hydraulic oil filter insert (first replacement after 50 s/h, then every 1000 s/h)
•Hydraulic oil (first replacement after 500 s/h, then every 1000 s/h)
Inspection work ():
Check the following material. Refill if necessary:
•Engine oil
•Engine coolant
•Hydraulic oil
Clean the water ducts (clean the water ducts every other 1000 s/h servicing)
Check radiator for engine and hydraulic oil for dirt. Clean if necessary
Check cooling systems, heating and hoses for leaks and pressure (visual check)
Air filter (damage)
Check the air filter, clean if necessary
Prefilter with water separator: drain water
3.2Maintenance plan (overview)
Work description
For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the attachment manufacturer as well.
Clean the fuel screen filter insert (diesel engine D2011 L04w from AD51001D)
Check V-belt condition and tension
Check exhaust system for damage and condition
Check valve lash. Adjust if necessary
Check injection nozzles and valves (every other 1500 s/h servicing)
Empty diesel fuel tank
Check battery electrolyte. Fill up with distilled water if necessary
Check brake oil, fill up if necessary
Check oil level in axles (differential, semiaxle, transfer gearbox)
check (damage, air pressure, tread depth)
nuts
Check alternator, starter and electric connections, bearing play and function
system, electric connections
Check pressure of primary pressure limiting valve (first
Check screws for tightness (first
telltales for correct function
and Operator's Manual (first check at
3.2Maintenance plan (overview)
Work description
For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the attachment manufacturer as well.
Lubrication service ():
Lubricate the following assemblies/components – see Lubrication points on page 3-29: •Steering ram
ram – offset ram
joint
console
Functional check ():
Check the function of the following assemblies/components. Rectify if necessary:
•Lights, signalling system, acoustic warning system
•Parking brake function
•Steering function
Leakage check ():
Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary: •Visual check
Engine and hydraulic system
Cooling circuit
Travelling drive
Adjustment work and replacement of wear parts on diesel engine D2011 L04w from AD51001D ():
Replace and/or adjust the following wear parts:
Adjust the V-belt (replace every 2 years)
Replace the toothed belt (after 3000 s/h or after 5 years max.)
Adjust the brakes and the parking brake (first check at 50 s/h, then every 500 s/h)
Introduction
Operational readiness and the service life of machines are heavily dependent on maintenance.
Before carrying out service and maintenance work, always read, understand and follow the instructions given in
• Chapter 2 “SAFETY INSTRUCTIONS” in the Operator's Manual
•The Operator's Manuals of the attachments.
Secure open (engine) covers appropriately. Do not open (engine) covers on slopes or in strong wind. Do not open (engine) covers on slopes or in strong wind.
Dirt can be blown away and cause severe injuries when using compressed air. Always wear protective goggles, masks and clothing.
Daily service and maintenance work, and maintenance according to maintenance plan “A” must be carried out by a specifically trained driver. All other maintenance work must be carried out by trained and qualified staff only.
The maintenance plans indicate when the maintenance work mentioned below must be carried out (– see Maintenance plan (overview) on page 3-3).
3.2Fuel system
Specific safety instructions
•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, stop the engine and remove the ignition key!
•Do not refuel in closed rooms!
•Wipe away fuel spills immediately!
•Keep the machine clean to reduce the risk of fire!
Refuelling
Filler inlet A for the fuel tank is located under the engine cover, on the left in driving direction.
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
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!
Notice!
Do not run the fuel tank completely dry. Otherwise, air is drawn into the fuel system. This requires bleeding the fuel system – see Bleeding the fuel system on page 3-8
Notice!
Fill up the tank with the correct fuel type at the end of each working day. This prevents condensation water from forming in the fuel tank over night. Do not fill the tank completely but leave some space for the fuel to expand.
Fig. 1:Fuel filler inlet
Fig. 2:Fuel filler inlet from AD51001D
Stationary fuel pumps
General
Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually dirty.
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 (see fig. 2):
•Barrels must neither be rolled nor tilted before refuelling
•Protect the suction pipe opening of the barrel pump with a fine-mesh screen
•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
•Keep all refuelling containers clean at all times
Diesel fuel specification
Bleeding the fuel system
Use only high-grade fuels
•No. 2-D according to DIN 51601
•No. 1-D according to DIN 51601
Min. 45
For normal outside temperatures
For outside temperatures below 4 °C or for operation above 1500 m altitude
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!
☞ Never bleed the fuel system if the engine is hot!
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
•After running the engine again, after it has been out of service for a longer period of time
Fig. 3:Refuelling from a barrel
Maintenance
Bleeding automatically (Yanmar engine)
Bleed the fuel system as follows:
☞ Fill the fuel tank
☞ Turn the ignition key to the first position
☞ Wait about 5 minutes while the fuel system bleeds itself automatically
☞ Start the engine
If the engine runs smoothly for a while and then stops, or if it does not run smoothly:
☞ Stop the engine
☞ Bleed the fuel system again as described above
☞ Have this checked by authorised staff if necessary
Bleeding with a manual pump (Deutz engine)
Cleaning the filter screen insert
Bleed the fuel system as follows:
• Open the engine cover
• Fill the fuel tank
• Pump in the direction of the arrow with manual pump A
➥ Pressure rises (strong resistance is felt)
• The reflux line must be full (fuel comes out of the reflux line)
• Start the engine.
If the engine runs smoothly for a while and then stops, or if it does not run smoothly:
• Stop the engine.
• Bleed the fuel system again as described above.
Have this checked by authorised staff if necessary.
☞ Close the fuel stop cock
☞ Remove fuel filter hose 4/C
➥ Use a suitable container to collect the fuel as it drains
☞ Unscrew screw 4/B
☞ Remove the fuel screen (the cover and the filter form one unit)
☞ Pick up and clean the sealing ring, replace it if it is damaged
☞ Clean the fuel screen, replace it if necessary
☞ Place the sealing ring back again
☞ Mount the fuel screen again with screw 4/B
☞ Connect fuel filter hose 4/C again
☞ Open the fuel stop cock again
☞ Start the engine and let it run at idling speed
☞ Check for leaks
Fig. 4:Manual pump
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