Wacker Neuson 1101c/1101cp Compact loaders Operator’s Manual - PDF DOWNLOAD

Service Manual Compact loaders

/

Machine models

1101c/cp

Edition

1.0

Language

English

Article number

1000188516

Documentation Description

Order no.

Operator's Manual

1000185550

Service manual

1000188516

Spare parts list

1000187759

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: Order no.: Edition:

SERV-HB 1101c cp EN 1000188516 1.0

table of contents

table of contents Table of contents Operation Important information on this service manual .......................................................... 1-1 Identification of warnings and dangers .................................................................... 1-2 Designated use and exemption from liability ........................................................... 1-3 Type labels and component numbers ...................................................................... 1-4 Machine overview .................................................................................................... 1-6 Cab overview ........................................................................................................... 1-7 Cab (legend) ............................................................................................................ 1-8 Round indicating instrument overview .................................................................... 1-9 Round indicating instrument (legend) .................................................................... 1-10 Maintenance accesses .......................................................................................... 1-11 Engine compartment overview .............................................................................. 1-12 Radiator cover overview ........................................................................................ 1-13 Chassis overview ................................................................................................... 1-14 Tilting the cab ........................................................................................................ 1-15 Towing the machine ............................................................................................... 1-17 Towing the loader ............................................................................................ 1-17 Towing ............................................................................................................. 1-17 Specifications Chassis .................................................................................................................... 2-1 Engine ...................................................................................................................... 2-1 Fuel injection pump ........................................................................................... 2-2 Capacity ............................................................................................................. 2-2 Tightening torque ............................................................................................... 2-2 Travelling drive ........................................................................................................ 2-3 Brakes ...................................................................................................................... 2-3 Work hydraulics ....................................................................................................... 2-4 Pilot control .............................................................................................................. 2-4 Additional “Power Flow” control circuit (cp) ............................................................. 2-4 Electric units ............................................................................................................ 2-5 Fuse box behind the seat on the left ................................................................. 2-5 Main fuse box with relays .................................................................................. 2-5 Relay box at rear left of cab ............................................................................... 2-6 Tracks ...................................................................................................................... 2-6 Noise levels ............................................................................................................. 2-6 Vibration ................................................................................................................... 2-7 Coolant compound table .......................................................................................... 2-7 Dimensions .............................................................................................................. 2-8 Model-specific tightening torques ............................................................................ 2-9 General tightening torques ...................................................................................... 2-9 Tightening torques for hydraulic screw connections (dry assembly) ................. 2-9 Tightening torques for high-resistance screw connections .............................. 2-11 Fluids and lubricants ................................................................................................ 3-1 Additional oil change and filter replacement (hydraulics) .................................. 3-2 Maintenance label .................................................................................................... 3-3 Explanation of symbols on the maintenance label ............................................ 3-3 Maintenance plan (overview) ................................................................................... 3-5 Introduction .............................................................................................................. 3-9 Fuel system ........................................................................................................... 3-10 Specific safety instructions .............................................................................. 3-10 Refuelling ......................................................................................................... 3-10 Stationary fuel pumps ...................................................................................... 3-11 Diesel fuel specification ................................................................................... 3-11 Bleeding the fuel system ................................................................................. 3-11

SERV-HB 1101c cp EN - Edition 1.0 *Sh1101en1_0IVZ.fm

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table of contents Emptying the fuel tank ..................................................................................... 3-12 Fuel filter with water separator ......................................................................... 3-12 Replacing the fuel filter .................................................................................... 3-13 Engine lubrication system ...................................................................................... 3-14 Checking the oil level ....................................................................................... 3-14 Filling up engine oil .......................................................................................... 3-15 Changing engine oil ......................................................................................... 3-16 Replacing the engine oil filter cartridge ............................................................ 3-16 Cooling system ...................................................................................................... 3-18 Specific safety instructions .............................................................................. 3-18 Checking/filling up coolant ............................................................................... 3-19 Draining coolant ............................................................................................... 3-20 Air filter ................................................................................................................... 3-21 Replacing the filter ........................................................................................... 3-22 Functional check once a week of the dust valve ............................................. 3-23 V-belts .................................................................................................................... 3-24 Checking V-belt tension ................................................................................... 3-24 Retightening V-belts ........................................................................................ 3-25 Checking the V-belt of the air conditioning system (option) ............................. 3-26 Tightening the V-belt of the air conditioning system (option) ........................... 3-26 Pressure check ...................................................................................................... 3-27 General ............................................................................................................ 3-27 Standard micro ports ....................................................................................... 3-27 Variable displacement pump measuring points ............................................... 3-28 Preparatory work ............................................................................................. 3-30 Main pressure check (P1 & P2) ....................................................................... 3-30 Boost pressure check of pump and pilot control pressure check of work hydraulics ......................................................................................................... 3-31 Work hydraulics pressure check ...................................................................... 3-32 Checking the pilot control pressure of the drive hydraulics ............................. 3-33 Checking the parking brake release pressure ................................................. 3-33 Checking the DA control pressure ................................................................... 3-34 Checking the pressure of the 3rd control circuit (Power Flow option 1101cp) . 3-34 Test report 1101c ................................................................................................... 3-35 Test report 1101cp ................................................................................................. 3-37 Hydraulic system .................................................................................................... 3-39 Specific safety instructions .............................................................................. 3-39 Checking the hydraulic oil level ....................................................................... 3-40 Bleeding the hydraulic pump housing .............................................................. 3-41 Filling up hydraulic oil ...................................................................................... 3-41 After changing the hydraulic oil ........................................................................ 3-42 Changing hydraulic oil ..................................................................................... 3-42 Monitoring the hydraulic oil reflux filter ............................................................ 3-43 Replacing the reflux filter ................................................................................. 3-43 Checking hydraulic pressure lines ................................................................... 3-44 Undercarriage maintenance ................................................................................... 3-45 Tracks .................................................................................................................... 3-46 Checking track tension .................................................................................... 3-46 Adjusting track tension ..................................................................................... 3-47 Replacing tracks .................................................................................................... 3-48 Travelling drive ....................................................................................................... 3-48 Checking the oil level and filling up oil ............................................................. 3-48 Draining oil ....................................................................................................... 3-49 Lubrication work ..................................................................................................... 3-49 Loader unit ....................................................................................................... 3-49 Lubrication points on the bucket ...................................................................... 3-49 Maintenance of attachments ............................................................................ 3-49 I-2

SERV-HB 1101c cp EN - Edition 1.0 *Sh1101en1_0IVZ.fm

table of contents Electrical system .................................................................................................... 3-50 Specific safety instructions .............................................................................. 3-50 Service and maintenance work at regular intervals ......................................... 3-50 Instructions concerning specific components .................................................. 3-51 Alternator ......................................................................................................... 3-51 Battery ............................................................................................................. 3-52 Jump-starting the engine ................................................................................. 3-52 General maintenance work .................................................................................... 3-53 Cleaning .......................................................................................................... 3-53 General instructions for all areas of the machine ............................................ 3-53 Inside the cab .................................................................................................. 3-54 Under the cab .................................................................................................. 3-54 Exterior of the machine .................................................................................... 3-54 Engine compartment ....................................................................................... 3-54 Rear window .................................................................................................... 3-54 Screw connections and attachments ............................................................... 3-55 Pivots and hinges ............................................................................................ 3-55 Maintenance of attachments ........................................................................... 3-55 Maintenance strut of loader unit ...................................................................... 3-56 Engine ...................................................................................................................... 4-1 TD2011 L04W ................................................................................................... 4-1 Fuel system ............................................................................................................. 4-3 Checking and adjusting valve clearance ................................................................. 4-4 Checking and adjusting the fuel injectors ................................................................ 4-5 Replacing the injection pump/setting fuel injection time .......................................... 4-7 Adjusting engine revs ............................................................................................ 4-11 Compression pressure ........................................................................................... 4-12 Removing/mounting the cylinder head .................................................................. 4-13 Sealing the breather valve ..................................................................................... 4-16 Sealing the intake/exhaust manifold ...................................................................... 4-16 Oil pressure switch ................................................................................................ 4-16 Switching off minus compensation ........................................................................ 4-17 Turbocharger ......................................................................................................... 4-18 Hydraulic system Rexroth AA20 VG45 hydraulic pump ....................................................................... 5-1 Pump unit: exploded view .................................................................................. 5-3 Pump distribution ............................................................................................... 5-4 Main valve block ...................................................................................................... 5-5 Ports and valves ................................................................................................ 5-5 Legend ............................................................................................................... 5-5 Main valve block diagram .................................................................................. 5-6 Hydraulic control ...................................................................................................... 5-7 Control lever ...................................................................................................... 5-7 Float position ..................................................................................................... 5-7 Joystick (left) ...................................................................................................... 5-8 Joystick (right) ................................................................................................. 5-11 Auxiliary hydraulics control .............................................................................. 5-14 Function ........................................................................................................... 5-14 Adjustment ....................................................................................................... 5-14 Travelling drive ...................................................................................................... 5-15 Function ........................................................................................................... 5-15 Travelling drive ................................................................................................ 5-16 Travelling drive layout ...................................................................................... 5-17 Valves .................................................................................................................... 5-18 Auxiliary hydraulics pilot valve ......................................................................... 5-18 Distributing block with brake (brake valve) ...................................................... 5-19

SERV-HB 1101c cp EN - Edition 1.0 *Sh1101en1_0IVZ.fm

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table of contents 3/2 directional valve ......................................................................................... 5-19 Single parallel bucket lift (switched for upwards movement) ........................... 5-20 Breather filter ......................................................................................................... 5-23 Auxiliary hydraulics connections ............................................................................ 5-23 Quickhitch system .................................................................................................. 5-24 Emergency lowering .............................................................................................. 5-24 Troubleshooting in the hydraulic system ................................................................ 5-24 Hydraulics diagram ISO standard (1101c) ............................................................. 5-25 Hydraulics diagram – legend (1101c) .............................................................. 5-26 Hydraulics diagram ISO standard (1101cp) ........................................................... 5-27 Hydraulics diagram – legend (1101cp) ............................................................ 5-28 Hydraulics diagram H controls with options (1101c) .............................................. 5-29 Hydraulics diagram H controls with options (1101c): legend ........................... 5-30 Hydraulics diagram H controls with options (1101cp) ............................................ 5-31 Hydraulics diagram H controls with options (1101cp): legend ......................... 5-32 Hydraulics diagram ISO standard (1101c) ............................................................. 5-34 Hydraulics diagram ISO standard (1101cp) ........................................................... 5-35 Hydraulics diagram H controls with options (1101c) .............................................. 5-36 Hydraulics diagram H controls with options (1101cp) ............................................ 5-37 Hydraulics diagram ISO controls with options (1101c) .......................................... 5-38 Hydraulics diagram ISO controls with options (1101cp) ........................................ 5-39 Electrical system Ohm's Law (current, voltage, resistance); power ..................................................... 6-1 Measuring equipment, measuring methods ............................................................. 6-1 Cable colour coding ................................................................................................. 6-3 Relays ...................................................................................................................... 6-3 Use, mode of function ........................................................................................ 6-3 Electric units ............................................................................................................. 6-4 Fuse box behind the seat on the left .................................................................. 6-4 Main fuse box with relays .................................................................................. 6-4 Relay box at rear left of cab ............................................................................... 6-5 Round indicating instrument overview ..................................................................... 6-6 Switches: overview .................................................................................................. 6-7 Alternator ................................................................................................................. 6-8 Starter ...................................................................................................................... 6-8 Wiring diagram (legend) ......................................................................................... 6-10 Wiring diagram (1) ................................................................................................. 6-11 1101c engine – chassis wiring harness 1000169726 (legend) .............................. 6-13 1101c engine – chassis wiring harness 1000169726 ............................................ 6-14 1101cp engine – chassis wiring harness 1000175467 (option) ............................. 6-15 1101c cab wiring harness 1000169725 (legend) ................................................... 6-16 1101c cab wiring harness 1000169725 ................................................................. 6-17 1101cp cab (option) wiring harness 1000175466 (legend) .................................... 6-18 1101cp cab wiring harness 1000175466 (option) .................................................. 6-19 Front lights wiring harness and legend 1000169728 ............................................. 6-20 Wiring harnesses 1000175462: StVO Austrian road traffic regulations + 1000175463: cab StVO Austrian road traffic regulations (legends) .................... 6-21

I-4

SERV-HB 1101c cp EN - Edition 1.0 *Sh1101en1_0IVZ.fm

table of contents Wiring harnesses 1000175462: StVO Austrian road traffic regulations and 1000175463: cab ................................................................................................... 6-22 Wiring harness 1000171481: attachment control (option) ..................................... 6-23 Cab door (option) legend and wiring harness 1000175468 ................................... 6-24 Rear cab (option) legend and wiring harness 1000175464 ................................... 6-25 Wiring diagram (legend) ........................................................................................ 6-27 Wiring diagram (1) ................................................................................................. 6-28 Wiring diagram (2) ................................................................................................. 6-29 1101c engine – chassis wiring harness 1000169726 (legend) .............................. 6-30 1101c engine – chassis wiring harness 1000169726 ............................................ 6-31 1101cp engine – chassis wiring harness 1000175467 (option) ............................. 6-32 1101c cab wiring harness 1000169725 (legend) ................................................... 6-33 1101c cab wiring harness 1000169725 ................................................................. 6-34 1101cp cab (option) wiring harness 1000169725 (legend) .................................... 6-35 1101cp cab wiring harness 1000175466 (option) .................................................. 6-36 Front lights wiring harness and legend 1000169728 ............................................. 6-37 Wiring harnesses 1000175462: StVO Austrian road traffic regulations + 1000175463: cab StVO Austrian road traffic regulations (legends) .................... 6-38 Wiring harnesses 1000175462: StVO Austrian road traffic regulations and 1000175463: cab ................................................................................................... 6-39 Attachment control (option) wiring harness 1000171481 ...................................... 6-40 Cab door (option) legend and wiring harness 1000175468 ................................... 6-41 Rear cab (option) legend and wiring harness 1000175464 ................................... 6-42 Options Rear working light .................................................................................................... 7-1 Wiring harness ................................................................................................... 7-1 Ports .................................................................................................................. 7-1 BP – Biohyd SE 46 .................................................................................................. 7-2 Properties .......................................................................................................... 7-2 Biodegradable oil Panolin ........................................................................................ 7-2 Properties .......................................................................................................... 7-2 Rearview mirror package ......................................................................................... 7-2 Extra weight ............................................................................................................. 7-2 Drive interlock (antitheft protection) ......................................................................... 7-3 Disabling the drive interlock ............................................................................... 7-3 Enabling the drive interlock ............................................................................... 7-3 Programming ..................................................................................................... 7-3 Rotating beacon ....................................................................................................... 7-5 Wiring harness ................................................................................................... 7-5 Ports .................................................................................................................. 7-5 Crane-handling bracket ........................................................................................... 7-6 Dual parallel bucket lift (switched on for up and down movements) ........................ 7-7 8/2 directional valve – H controls (work hydraulics lock) ......................................... 7-9 Hydraulic quickhitch system (HQS) option .............................................................. 7-9 Power Flow valve (1101cp) ................................................................................... 7-10 Power Flow ports ................................................................................................... 7-10 Speed Control valve (1101cp) ............................................................................... 7-11 Load stabiliser valve .............................................................................................. 7-14 Attachment controls ............................................................................................... 7-15 Backup warning system ......................................................................................... 7-16 Function ........................................................................................................... 7-16 Position ............................................................................................................ 7-16 Side window ........................................................................................................... 7-17 Fixture: ............................................................................................................. 7-17 Road travel certification ......................................................................................... 7-18

SERV-HB 1101c cp EN - Edition 1.0 *Sh1101en1_0IVZ.fm

I-5

Index I

Index A

S

Abbreviations .........................................................................................1-1 Air filter .................................................................................................3-21

Safety instructions Identification ................................................................................... 1-2 Specifications ........................................................................................ 6-1 Additional control circuit ................................................................. 2-4 Brakes ............................................................................................ 2-4 Coolant compound table ................................................................ 2-7 Dimensions ..................................................................................... 2-8 Engine ............................................................................................ 2-3 Noise levels .................................................................................... 2-6 Pilot control ..................................................................................... 2-1 Travelling drive ............................................................................... 2-3 Work hydraulics .............................................................................. 2-4

C Checking track tension ........................................................................3-46

E Electrical system Starter .............................................................................................6-8

F Fluids and lubricants ..............................................................................3-1 Functional check Dust valve .....................................................................................3-23

I Important information On this service manual ...................................................................1-1

T Tilting the cab ...................................................................................... 1-15

M Machine Overview .........................................................................................1-6 Maintenance Bleeding the fuel system ...............................................................3-11 Changing engine oil ......................................................................3-16 Checking the engine oil level ........................................................3-14 Checking the hydraulic oil level ....................................................3-40 Cleaning ........................................................................................3-53 Electrical system ...........................................................................3-50 Engine and hydraulics cooling system ..........................................3-18 Engine lubrication system .............................................................3-14 Filling in engine oil ........................................................................3-15 Filling up coolant ...........................................................................3-19 Fluids and lubricants .......................................................................3-1 Fuel system ..................................................................................3-10 General maintenance work ...........................................................3-53 Hydraulic pressure lines ...............................................................3-44 Hydraulic system ..........................................................................3-39 Instructions concerning specific components ...............................3-51 Pivots and hinges .........................................................................3-55 Replacing the engine oil filter cartridge .........................................3-16 Replacing the fuel filter .................................................................3-13 Screw connections ........................................................................3-55 Service and maintenance work at regular intervals ......................3-50 V-belts ...........................................................................................3-24

O Operation Cab overview ..................................................................................1-7 Round indicating instrument overview ............................................1-9

R Refuelling .............................................................................................3-10 Round indicating instrument overview ......................................... 1-9, 1-10

S-1

SERV-HB 1101c cp EN - Edition 1.0 *Sh1101en1_0SIX.fm

Operation

Operation

Operation

1 1.1

Operation Important 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. Your knowledge and skills will help to avoid dangerous situations and reduce repair costs and downtimes, and will increase the reliability and the service life of the machine.

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.

Your Wacker Neuson After-Sales Service will be pleased to answer any further questions regarding the machine or the service manual.

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.

1-1

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp110.fm

Operation 1.2

Identification of warnings and dangers Important indications regarding the safety of the staff and the machine are identified in this service 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.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp110.fm

1-2

Operation 1.3

Designated use and exemption from liability The machine is intended for: moving earth, gravel, coarse gravel or ballast and rubble as well as for working with the attachments mentioned in chapter Fields of application.

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!

The machine may not be used for transport jobs on public roads

1-3

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp110.fm

Operation 1.4

Type labels and component numbers Serial number The serial number is stamped on the machine chassis. It is also located on the type label.

The type label is located at the rear right of the chassis.

Type label information (example): Fig. 1:

Fig. 2:

Type label: location

Type label

Model:

1101c

Year:

2008

PIN:

DC00814

Power:

50 kW (67 hp)

Mass:

3000 kg (6614 lbs.)

Load:

910 kg (2006 lbs.)

Max. gross load:

---------------

Max. front axle load:

---------------

Max. rear axle load:

---------------

Information on new type label (example): Machine model 1101cp Model year: 2009 Serial no.: DC01024 Output: 63.0 kW (84.48 hp) Max. payload 1150 kg (2535 lbs.)

Service weight: 4450 kg (9811 lbs.)

Other information – see Specifications on page 2-1

Fig. 3:

New type label

Cab number The cab number is stamped on the side in the sheet metal. The type label is also located in the cab, on the left beside the seat.

Fig. 3:

Cab number

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp110.fm

1-4

Operation Engine number The type label (arrow) is located on the valve cover (engine).

Example:

Fig. 4:

Deutz D2011 L04W

Diesel engine number

Hydraulic pump number The type label (arrow) is located on the hydraulic pump housing.

Fig. 5:

Hydraulic pump type label

Travelling drive number The type label (arrow) is located on the travelling drive.

Fig. 6:

1-5

Travelling drive type label

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp110.fm

Operation 1.5

Machine overview 1

2 3 4

5 6

1 Rotating beacon (option) 2

Front working light Rear working light (option)

3 Left and right outside rearview mirrors (option) 4 Front headlights (option) 5 Handles

7 8

Track drive

9

Exhaust pipe

10 Numberplate bracket (option) 11 Type label

6 Standard bucket

12 Radiator cover

7 Loader unit

2

9 10 8

11 12

Fig. 7:

Machine outside views

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp110.fm

1-6

Operation 1.6

Cab overview 1

2

3

4

5

23

6 7 22

8 9 10

21

11

20

12

13 19

14

18

15

17 1-7

16

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp110.fm

Operation 1.7

Cab (legend) Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp110.fm

Description Work hydraulics lock (H controls option) Auxiliary hydraulics pedal Seat – horizontal adjustment Accelerator pedal Round indicating instrument Water tank for washer system Cigarette lighter Control lever (right) Weight adjustment on seat Accelerator lever Switch panel (right-hand side control lever console) Preheating ignition lock Seat belt latch Right-hand side safety bar Seat Rear air vents Document storage bin Fuses Seat belt buckle Left-hand side safety bar Switch panel (left-hand side control lever console) Control lever (left) Front air vents

1-8

Operation 1.8

Round indicating instrument overview 31

30

32

29

33

28

34

27

35

!

36

26

37

25

24

38 39

40 49

41

42

43

44

45

46

47

48

50

51

52

53

54

Option

1-9

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp110.fm

Operation 1.9

Round indicating instrument (legend) Pos. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp110.fm

Description Turn indicator telltale (green) Hour meter Fuel level indicator 2nd speed telltale (green) Cold starter telltale (yellow) Parking brake telltale (red) Engine oil pressure telltale (red) Telltale (red) – alternator charge function Coolant temperature telltale (red) Air filter telltale (red) Hydraulic oil filter telltale (red) Not assigned Coolant temperature Boost pressure telltale (red) Safety electrics/safety bar telltale (red) Load stabiliser telltale (blue) Air conditioning (option) Fan (option) Rotating beacon (option) Rear working light (option) 3rd control circuit (Power Flow) Speed Control (option) – continuously adjustable low-speed control Parallel bucket lift Work hydraulics lock (ISO controls) Parking brake Wiper/washer system switch (option) Stabilisers (option) Hydraulic quickhitch system (HQS) option Lights (option) Hazard warning system (option) Left/right turn indicators (option)

1-10

Operation 1.10 Maintenance accesses

B C

D A

1-11

Pos. A

Description

B

Maintenance strut

C

Engine cover

D

Radiator cover

Engine/hydraulics/electrical system maintenance

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp110.fm

Operation 1.1

Engine compartment overview

55

Pos. 55 56 57 58 59 60 61

56

57

Description Fuel filler inlet Suction lance Fuel filter with water separator Air filter Expansion tank Diesel engine Silencer

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp110.fm

58

59

60

61

For more information see page 3-10 3-12 3-12 3-21 3-19 4-1

1-12

Operation 1.2

Radiator cover overview

62

Pos. 62 63 64 65 66

1-13

63

Description Combined radiator Expansion tank Hydraulic oil filler inlet Type label Radiator cover

64

65

66

For more information see page 3-19 3-41 1-4

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp110.fm

Operation 1.3

Chassis overview

67

71 72 73 69

68

69

74 70

75

Pos. 67 68 69 70 71 72 73 74 75

Description Silencer Main fuse box Diesel engine Power Flow valve (option) Dehumidifier (option) Fuel filter with water separator Air intake hose Double variable displacement pump Twin gear pump

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp110.fm

For more information see page 2-5/6-4 4-1 7-10 3-12 5-1 5-1

1-14

Operation 1.4

Tilting the cab Danger!

Careful when tilting the cab –

E

Danger of accidents! ☞ Always tighten lock screws B when driving and working with the machine! ☞ Place the machine on level ground! ☞ Close the door (option)! ☞ Loader unit strut A may only be installed by a second person! ☞ When tilting the cab make sure no-one is underneath the cab! ☞ Loader unit strut A and cab strut C must always be secured with split pin D!

D A

A

Tilting the cab: D E

B

☞ Remove the attachment ☞ Raise the loader unit and have a second person secure it ☞ Remove split pin D from pin E ☞ Remove pin E ☞ Raise the loader unit until strut A makes contact with the piston rod ☞ Put pin E back into place ☞ Secure pin E with split pin D ☞ Switch off the engine ☞ Lower the loader unit down to loader unit strut A ☞ Remove the ignition key ☞ Fold up the safety bars ☞ Remove securing screws B on either side with a suitable tool ☞ Tilt the cab forwards with the handles ☞ Secure the cab with split pin F

F

C Fig. 8:

1-15

Tilting the cab

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp110.fm

Operation Lowering the cab

Danger!

Incorrect lowering of the cab –

Danger of accidents and of crushing! ☞ Make sure no-one is underneath the cab ☞ Remove the tools! ☞ Before lowering the cab all the way down, make sure no limbs or equipment are squeezed

☞ Remove cab strut C ☞ Lower the cab with both hands on the handles ☞ Make sure no-one is underneath the cab ☞ Before lowering the cab all the way down, make sure no limbs or equipment are squeezed

☞ Firmly retighten lock screws B once the cab is fully lowered

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp110.fm

1-16

Operation 1.5

Towing the machine

Towing the loader Safety instructions:

• • • • • •

Make sure the loader can be towed safely.

Use towing bracket B for towing the machine Use the towing bracket only for towing the machine Use a shackle pin with a lock pin Move off slowly.

Make sure no-one is close to the towing equipment (towing bar, cable)

Towing

Danger!

Keep out of the danger area of the machine –

Danger of accidents!

Make sure no-one is dangerously close to the loader.

Caution!

The maximum admissible load of the towing bracket is 65 kN (14613 lbf).

Caution!

The travelling drive can be damaged when towing the machine.

Switch off the engine.

Tow away the machine only over the shortest possible distance from the loading position.

The machine cannot be steered, cornering is not possible.

Tow away the machine as follows: Switch off the engine!

User the front or rear towing brackets B. Secure shackle C with the shackle pin and a lock pin B

C

Mount a towing bar or cable of adequate size to the towing bore Pull the machine slowly

Notice!

Follow the following instructions under all circumstances: • The manufacturer's warranty shall not apply to accidents or damage caused by towing the excavator.

• No towing away other machines with towing bracket B. B Fig. 9:

1-17

Towing bore

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp110.fm

Specifications

Technische Daten

Specifications

2 2.1

Specifications Chassis Sturdy steel sheet chassis, rubber-mounted engine

2.2

Engine Engine

Models 1101c/1101cp

Product

Deutz diesel engine

Type

TD2011 L04W (turbocharged engine)

Design

Water-cooled 4 stroke diesel engine

No. of cylinders Fuel injection system Aspiration Cooling system Charge air cooler/temperature Lubrication system Displacement

4 in line Direct fuel injection Exhaust turbocharger Thermostatically controlled None Forced feed lubrication system with internal-gear rotor oil pump 3619 cm³ (220.8 cu. in.)

Nominal bore and stroke

96 x 125 mm (3.78 x 4.92”)

Output

63 kW (84.5 hp) at 2500 rpm

Max. torque Max. engine speed without load Idling speed Valve clearance (intake/outlet) 1st cylinder Compression

270 Nm (199.1 ft. lbs.) at 1600 rpm 2700 ± 50 rpm 1400 ± 50 rpm 0.3+0.1/0.5+0.1 mm (0.012/0.02”) (cold) Flywheel side 19 : 1

Compression: specified value

30 bar (435 psi) at 250 rpm

Compression: threshold value

25 bar (363 psi) at 250 rpm

Charge-air pressure

0.9 bar (13 psi) ± 10 %

Engine oil pressure

1.5 bar (21.8 psi)

Pressure switch for engine oil pump

0.5 ± 0.1 bar (7.3 ± 1.5 psi)

Thermostat opening temperature

88 – 92 °C (190 – 198 °F)

Thermal switch Firing order Direction of rotation Starting aid Max. inclined position (engine no longer supplied with oil):

107 – 113 °C (224.6 – 235.4 °F)

1–3–4–2 Counterclockwise (as seen from the flywheel) Preheater (preheating time 10 – 15 s) 30 ° in all directions Observe the machine's tilting limit (20° laterally)!

Max. engine droop

2000 ± 50 rpm

Specific fuel consumption

238 g/kWh (0.391 lbs./hph) 97/68/EC – stage III A

Exhaust values according to

EPA Tier 3 ECE – R24

2-1

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp210.fm

Technische Daten Fuel injection pump Pump type Design Injection pressure Engine speed control Lubrication system

Mechanical unit pump Model 1101c

Model 1101cp Unit pump

210 – 218 bar (3046 – 3162 psi) Mechanical Engine oil lubrication

Capacity Capacities Fuel tank Engine oil (total/min – max) Coolant (without radiator)

Model 1101c

Model 1101cp 72 l (19 gal)

10 l/3.4 l (2.6 gal/0.9 gal) 2.9 l (0.77 gal)

Radiator

5.6 l (1.5 gal)

Expansion tank

2.5 l (0.66 gal)

Tightening torque Tightening torques

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp210.fm

Model 1101c/cp (Nm/ft. lbs.)

Cylinder-head bolt 1st pass 2nd pass

41.1 – 46.9 (lubricated) 85.3 – 91.1 (lubricated)/63 – 67.2

Connecting rod bearing screw

44.1 – 49 (lubricated)/32.5 – 36.1

Main bearing screw

93.2 – 98.1 (lubricated)/68.7 – 72.4

Flywheel screw

83.3 – 88.2 (lubricated)/61.4 – 65.1

2-2

Technische Daten 2.3

Travelling drive Variable displacement pump Design Displacement

Model 1101c/model 1101cp AA20VG45 Infinitey variable axial-piston variable displacement pump with speed-sensitive control 2 x 45 cm³/rev (2.75 cu. in./rev) = 2 x 120 l/min (31.7 gal/min) at 2800 rpm

Max. system operating pressure

365 bar (5294 psi)

Starting RPMs

1200 rpm at 50 bar (725 psi) HP

Boost pump

Model 1101c/model 1101cp Gear (external)

Design

19.0 cm³/rev (1.16 cu. in./rev)

Displacement

26 bar (377 psi)

Charging/boost pressure

Max. capacity 1

Model 1101c/model 1101cp Axial piston motors with reduction gear and integrated multi-disc brake; 50.9 cm³/rev (3.11 cu. in./rev)

Max. capacity 2

30.3 cm³/rev (1.85 cu. in./rev)

Hydraulic motor Design

7/12 kph (4.35/7.46 mph)

Drive speed Flushed with flush valve

15 l/min (4 gal/min) at 26 bar (377 psi) 26.8

Gear reduction

2.4

Brakes Service brake

Model 1101cp

Design

Hydrostatic

Location

Travelling drive Service brake via hydrostatic closed circuit by means of neutral position of pump Model 1101c Model 1101cp

Effect Parking brake Design

Manual, negative-action electrohydraulic disc brake

Location

On either side of hydraulic motor

Effect

2-3

Model 1101c

Hydraulic release; braked if no pressure

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp210.fm

Technische Daten 2.5

Work hydraulics Models 1101c/1101cp

Hydraulic pump (gear pump)

34 cm³/rev (2.1 cu. in./rev) = 85 l/min (22.45 gal/min) at 2500 rpm 3 sections

Displacement Control valve

210 bar (3046 psi)

Max. operating pressure

2.6

Secondary protection bucket ram

Base/rod 275 bar (3989 psi)

Secondary protection for loader unit ram

Base side 275 bar (3989 psi)

Filter

Reflux filter

Hydraulic oil tank

35 l (9.2 gal)

Pilot control Model 1101c

Pilot control

19 cm³/rev (1.16 cu. in./rev)

Displacement

26 bar (377 psi)

Charging/boost pressure

Model 1101c Model 1101cp Hydraulic pressure sensor for driving and working (loader unit, bucket) Electric Lock for unintentional operation

Pilot control unit Joystick Safety bars

2.7

Model 1101cp

Additional “Power Flow” control circuit (cp) Additional control circuit Hydraulic pump displacement Max. operating pressure Operation Power Flow Hydraulic pump displacement Power Flow capacity Max. operating pressure Operation

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp210.fm

Model 1101c 34 cm³/rev (2.1 cu. in./rev) = 85 l/min (22.45 gal/min) at 2500 rpm 210 bar (3046 psi) Hydraulic pilot-controlled pedal Model 1101cp 34 cm³/rev + 19 cm³/rev (2.1 cu. in./rev + 1.16 cu. in./rev) 135 l/min (35.7 gal/min) at 2500 rpm 135 l/min (35.7 gal/min) 210 bar (3046 psi) Electric (ON/OFF) + change of direction

2-4

Technische Daten 2.8

Electric units Units Alternator

12 V 95 Ah

Starter

12 V 2.3 kW (3.1 hp)

Battery

12 V 88 Ah

Socket

E.g. for cigarette lighter; 15 A max.

Fuse box behind the seat on the left

Fuse no.

F3 F4 F5 F6 F7 F8 F9 F10 Fig. 1:

Fuse box

Rated current (A)

Protected circuit

F3

10 A

– Indicating instruments, alternator, starting relay

F4

15A

– Valves

F5

15A

– Working lights

F6

15A

– Lights according to STVO Austrian road traffic regulations

F7

15A

– Turn indicators 12 V/15

F8

15A

– Hazard warning system

F9

15A

– Cigarette lighter

F10

10 A

– Rotating beacon

F11

10 A

– Valves option

F12

15A

– Attachment controls 1

F13

15A

– Attachment controls 2

F14

15A

– Attachment controls 3

F15

10 A

– Heating

F16

15A

– Air conditioning

F17

10 A

– Wiper

F18

10 A

– Not assigned

Standard machine

F11 F12 F13 F14 F15 F16 F17 F18

Main fuse box with relays The main fuse box is located under the cab.

F1

Fuse no.

Rated current (A)

Protected circuit

F2

F1, F2

80 A

– Main fuse

Relay no.

N3 Fig. 2:

2-5

Main fuse box

K5

K7

K5

– Preheating relay

K7

– Start high current relay

N3

– Glow control unit

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp210.fm

Technische Daten Relay box at rear left of cab

K18

K17

Fig. 3:

2.9

K16

K11 K34

K36

K10

RELAIS BOX

Switching relay no.

Protected circuit

K 18

– Attachment controls 3 (option)

K 17

– Attachment controls 2 (option)

K 16

– Attachment controls 1 (option)

K 11

– Air conditioning (option)

K 34

– Load stabiliser (option)

K 36

– 2nd drive range

K 10

– Turn indicator relay (option)

Tracks Width Standard tracks

450 mm

Narrow tracks

320 mm 5

No. of track rollers on either side

2.10 Noise levels Sound power level

Model 1101c

Model 1101cp

Sound power level (LWA)

101.2 dB (A)

100.4 dB (A)

89 dB (A)

90 dB (A)

Sound pressure level (LPA)

Notice!

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.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp210.fm

2-6

Technische Daten 2.11 Vibration Vibration Effective acceleration value for the upper extremities of the body *

< 2.5

m -----s2

(<8.2 ft/s2)

Effective acceleration value for the body *

< 0.5

m -----s2

(<1.6 ft/s2)

*

Measured according to 2002/44/EC. Machine and attachment operation and maintenance as per Operator's Manual.

2.12 Coolant compound table Outside temperature Up to °C (°F) -37 (-34.6)

Coolant: Halvoline XLC (based on ethylene glycol) Eurolub SF D12 coolant (based on ethylene glycol) Water Anticorrosion agent Antifreeze agent cm³/l % by % by volume % by volume volume (in3/gal) 50 10 (2.6) 1 50

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.

• See “Coolant” label in the engine compartment for information on the coolant used

2-7

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp210.fm

Technische Daten 2.13 Dimensions q

p m a

s

t

b k c n

u

l

v r d

o

e

f

g

Fig. 4:

h

Machine dimensions

i

Main data a

Maximum height

3945 mm (155.3”)

b

Height below bucket joint

3120 mm (122.8”)

c

Cab height

2065 mm (81.3”)

d

Ground clearance

250 mm (9.84”)

e

Rear projection (rear axle onwards)

810 mm (31.9”)

f

Wheelbase

1150 mm (45.3”)

g

Overall length without attachment

2860 mm (112.6”)

H

Overall length with standard bucket

3535 mm (139.2”)

I

Maximum length of machine

3925 mm (154.5”)

K

Topmost bucket position

2890 mm (113.8”)

L

Maximum dump height

2380 mm (93.7”)

m

Reach

625 mm (24.6”)

n

Maximum reach (horizontal loader unit position)

1370 mm (53.9”)

o

Dump-in angle

31°

P

Dump-out angle

42°

q

Dump-in angle

86°

R

Departure angle

29°

s

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp210.fm

Model 1101

Machine width (with standard tracks b = 450 mm)

1980 mm (78”)

Machine width (with narrow tracks b = 320 mm)

1850 mm (72.8”)

t

Bucket width

2030 mm (79.9”)

u

Rear turning radius

1540 mm (60.6”)

v

Front turning radius

2250 mm (88.6”)

2-8

Technische Daten 2.14 Model-specific tightening torques 1101s/sp Component

Thread

Travelling drive Angled engine bracket Engine bearing Pump base Pump

M14 12.9 M10 8.8 M12 8.8 M10 8.8 M12 10.9

Tightening torque Nm (ft. lbs.)

180 50 85 50 150

*) All connections with an * must be glued with Loctite S2420 or VaryBond 12-43.

2.15 General tightening torques Tightening torques for hydraulic screw connections (dry assembly) Metric hose fittings for hydraulic applications (light execution, DKOL) Tightening torque Nominal Ø Outer Ø Thread Wrench size Nm (ft. lbs.)

05 6L M12X1.5 WS 14 15 (11) 06 8L M14X1.5 WS 17 20 (15) 08 10L M16X1.5 WS 19 40 (30) 10 12L M18X1.5 WS 22 50 (37) 12 15L M22X1.5 WS 27 75 (55) 16 18L M26X1.5 WS 32 85 (63) 20 22L M30X2 WS 36 100 (74) 25 28L M36X2 WS 41 180 (133) 32 35L M45X2 WS 55 220 (162) Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 % Values determined empirically and to be applied as approximate figures.

Metric hose fittings for hydraulic applications (heavy execution, DKOL) Tightening torque Nominal Ø Outer Ø Thread Wrench size Nm (ft. lbs.)

05 8S M16X1.5 WS 19 40 (30) 06 10S M18X1.5 WS 22 50 (37) 08 12S M20X1.5 WS 24 60 (44) 10 14S M22X1.5 WS 27 75 (55) 12 16S M24X1.5 WS 30 90 (66) 16 20S M30X2 WS 36 100 (74) 20 25S M36X2 WS 41 180 (133) 25 30S M42X2 WS 50 270 (199) 32 38S M52X2 WS 60 400 (295) Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 % Values determined empirically and to be applied as approximate figures.

2-9

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp210.fm

Technische Daten Screw connections with various seals for hydraulic applications (light execution)

Thread

M10X1.0 M12X1.5 M14X1.5 M16X1.5 M18X1.5 M22X1.5 M27X2.0 M33X2.0 M42X2.0 M48X2.0 G1/8A G1/4A G3/8A G1/2A G3/4A G1A G1 1/4A G1 1/2A

Straight pipe fitting with thread and Non-return screwed plug valve with elastic Sealing Elastic O-ring seal washer seal Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

9 (7) 18 (13) 15 (11) 18 (13) 20 (15) 25 (18) 25 (18) 25 (18) 35 (26) 45 (33) 35 (26) 35 (26) 45 (33) 55 (41) 40 (30) 50 (37) 55 (41) 70 (52) 45 (33) 70 (52) 65 (48) 125 (92) 60 (44) 125 (92) 90 (66) 180 (133) 100 (74) 145 (107) 150 (111) 310 (229) 160 (118) 210 (155) 240 (177) 450 (332) 210 (155) 360 (266) 290 (214) 540 (398) 260 (192) 540 (398) 9 (7) 18 (13) 15 (11) 18 (13) 35 (26) 35 (26) 30 (22) 35 (26) 45 (33) 70 (52) 45 (33) 50 (37) 65 (48) 90 (66) 55 (41) 65 (48) 90 (66) 180 (133) 100 (74) 140 (103) 150 (111) 310 (229) 160 (118) 190 (140) 240 (177) 450 (332) 210 (155) 360 (266) 290 (214) 540 (398) 260 (192) 540 (398)

Identification aid outside Ø mm (”) 10 (0.4) 12 (0.5) 14 (0.55) 16 (0.6) 18 (0.7) 22 (0.9) 27 (1.0) 33 (1.3) 42 (1.7) 48 (1.9) 9.73 (0.38) 13.16 (0.52) 16.66 (0.66) 20.96 (0.83) 26.44 (1.04) 33.25 (1.31) 41.91 (1.65) 47.80 (1.88)

Torque tolerance: – 10 %; countermaterial: steel/aluminium

Screw connections with various seals for hydraulic applications (heavy execution) Straight pipe fitting with thread and Non-return screwed plug Identification valve with aid outside Ø elastic Sealing Elastic Thread O-ring seal washer seal Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) mm (”) M12X1.5 20 (15) 35 (26) 35 (26) 35 (26) 12 (0.5) M14X1.5 35 (26) 55 (41) 45 (33) 45 (33) 14 (0.55) M16X1.5 45 (33) 70 (52) 55 (41) 55 (41) 16 (0.6) M18X1.5 55 (41) 90 (66) 70 (52) 70 (52) 18 (0.7) M20X1.5 55 (41) 125 (92) 80 (59) 100 (74) 22 (0.9) M22X1.5 65 (48) 135 (100) 100 (74) 125 (92) 27 (1.0) M27X2.0 90 (66) 180 (133) 170 (126) 135 (100) 12 (0.5) M33X2.0 150 (111) 310 (229) 310 (229) 210 (155) 33 (1.3) M42X2.0 240 (177) 450 (332) 330 (243) 360 (266) 42 (1.7) M48X2.0 290 (214) 540 (398) 420 (310) 540 (398) 48 (1.9) G1/8A 35 (26) 55 (41) 45 (33) 45 (33) 13.16 (0.52) G1/4A 45 (33) 80 (59) 60 (44) 60 (44) 16.66 (0.66) G3/8A 65 (48) 115 (85) 75 (55) 100 (74) 20.96 (0.83) G1/2A 90 (66) 180 (133) 170 (125) 145 (107) 26.44 (1.04) G3/4A 150 (111) 310 (229) 310 (229) 260 (192) 33.25 (1.31) G1A 240 (177) 450 (332) 330 (243) 360 (266) 41.91 (1.65) G1 1/4A 290 (214) 540 (398) 420 (310) 540 (398) 47.80 (1.88) Torque tolerance: – 10 %; countermaterial: steel/aluminium

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp210.fm

2-10

Technische Daten Tightening torques for high-resistance screw connections

Thread M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30

With coarse-pitch thread Screws according to DIN 912, DIN Screws according to 931, DIN 933 etc.

DIN 7984 8.8 10.9 12.9 8.8 10.9 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

Nm (ft. lbs.)

5.5 (4) 8 (6) 10 (7) 5 (4) 7 (5) 10 (7) 14 (10) 17 (13) 8.5 (6) 12 (9) 25 (18) 35 (26) 42 (31) 20 (15) 30 (22) 45 (33) 65 (48) 80 (59) 40 (30) 59 (44) 87 (64) 110 (81) 147 (108) 69 (51) 100 (74) 135 (100) 180 (133) 230 (170) 110 (81) 160 (118) 210 (155) 275 (203) 350 (258) 170 (125) 250 (184) 280 (207) 410 (302) 480 (354) 245 (181) 345 (254) 410 (302) 570 (420) 690 (509) 340 (251) 490 (361) 550 (406) 780 (575) 930 (686) 460 (339) 660 (487) 710 (524) 1000 (738) 1190 (878) 590 (435) 840 (620) 1040 (767) 1480 (1092) 1770 (1305) 870 (642) 1250 (922) 1420 (1047) 2010 (1482) 2400 (1770) 1200 (885) 1700 (1254)

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.

With fine-pitch thread Screws according to DIN 912, DIN Screws according to 931, DIN 933 etc.

DIN 7984 Thread 8.8 10.9 12.9 8.8 10.9 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

Nm (ft. lbs.)

M8X1.0 25 (18) 37 (28) 43 (32) 22 (16) 32 (24) M10X1.0 50 (37) 75 (55) 88 (65) 43 (32) 65 (48) M10X1.25 49 (36) 71 (52) 83 (61) 42 (31) 62 (46) M12X1.25 87 (64) 130 (96) 150 (111) 75 (55) 110 (81) M12X1.5 83 (61) 125 (92) 145 (107) 72 (53) 105 (77) M14X1.5 135 (100) 200 (148) 235 (173) 120 (89) 175 (129) M16X1.5 210 (155) 310 (229) 360 (266) 180 (133) 265 (195) M18X1.5 315 (232) 450 (332) 530 (391) 270 (1991) 385 (284) M20X1.5 440 (325) 630 (465) 730 (538) 375 (277) 530 (391) M22X1.5 590 (435) 840 (620) 980 (723) 500 (369) 710 (524) M24X2.0 740 (546) 1070 (789) 1250 (922) 630 (465) 900 (664) M27X2.0 1100 (811) 1550 (1143) 1800 (1328) 920 (679) 1300 (959) M30X2.0 1500 (1106) 2150 (1586) 2500 (1844) 1300 (959) 1850 (1364) 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.

2-11

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp210.fm

Maintenance

Maintenance

Maintenance 3.1

Fluids and lubricants Component/ application

Maintenance

Engine/machine fluid

Specification SAE 10W

Diesel engine

SAE 20W20

Engine oil

SAE 30

Hydraulic motor gearbox

Gearbox oil

Hydraulic oil tank

Engine oil

Grease nipples

Multipurpose grease

Battery terminals

Acid-proof grease3

2

Season/temperature Below -5 °C (23 °F) -10 to +10 °C (14 to 50 °F) 5 to 30 °C (41 to 86 °F)

SAE 10W40

Year-round

SAE 75W-90 (API GL4, GL5)

Year-round

Capacities1

10 l (2.6 gal)

1.3 l (0.34 gal) for each gearbox

SAE 5W40

Below -25 °C (-13 °F)

SAE 10W40

Year-round

KF2K-25 lithium soap

Year-round

As required

FINA Marson L2

Year-round

As required

Summer or winter diesel depending on outside temperatures

72 l (19 gal)

Year-round

5.6 l (1.5 gal)

Year-round

2 l (0.5 gal)

35 l (9.2 gal)

2-D ASTM D975-94 (USA) 1-D ASTM D975-94 (USA) Fuel tank

Diesel fuel

EN 590:96 (EU) ISO 8217 DMX (International) BS 2869-A1 (GB) BS 2869-A2 (GB) Soft water + antifreeze ASTM D4985

Radiator

Coolant

(ethylene glycol coolant) Distilled water + antifreeze ASTM D4985

Washer system 1.

2.

3.

3-1

Cleaning agent

Water + antifreeze

The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level Capacities indicated are no system fills KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive Standard acid-proof grease

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp310.fm

Maintenance Oil grades for the diesel engine, depending on temperature Engine oil grade

Ambient temperature (C°) °C

-20

-15

-10

-5

0

5

10

15

20

25

30

35

40

95

104

SAE 10W SAE 20W SAE 10W-30 SAE 10W-40 DPI, CD, Cf, CF-4, Ci-4

SAE 15W-40

ACEA A3,B3,E3 ACEA E3, E4, E5 SAE 20 SAE 30 SAE 40 °F

-4

5

14

23

32

41

50

59

68

77

86

Additional oil change and filter replacement (hydraulics)

Caution!

An additional oil change and filter replacement can be required depending on how the machine is used. Failure to observe these replacement intervals can cause damage to hydraulic components.

☞ Observe the following intervals.

Application Normal work (loading work) Percentage of hammer work

20 % 40 % 60 % Over 80 %

Hydraulic oil

Hydraulic oil filter insert

Every 1000 s/h Every 800 s/h Every 400 s/h Every 300 s/h Every 200 s/h

Replace the first time after 50 s/h, then every 500 s/h 300 s/h 100 s/h

Notice!

See – see Maintenance plan (overview) on page 3-5 for other maintenance work.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp310.fm

3-2

Maintenance 3.2

Maintenance label

Explanation of symbols on the maintenance label Symbol

3-3

Assembly

Explanation

General

Visual check

General

Grease instructions

Fuel system

Drain condensation water

Fuel system

Replace the fuel filter, clean the fuel prefilter

Radiator

Check the coolant level

Radiator

Drain and fill in new coolant

Engine

Check valve clearance. Adjust if necessary

Engine

Check the engine oil level

Engine

Change engine oil

Engine

Replace the oil filter

Engine

Check V-belt tension

Travelling drive

Change oil

Travelling drive

Check oil

Hydraulic system

Check oil level

Hydraulic system

Change hydraulic oil

Hydraulic system

Replace the hydraulic oil filter, replace the breather filter

SERV-HB 1101c cp EN – Edition 1.0 * *1101c_cp310.fm

Maintenance Symbol

Assembly

Explanation

Radiator fins

Clean

Battery

Check battery fluid and fill up if necessary

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp310.fm

3-4

Wartung

Maintenance plan (overview)

3

Fuel filter Air filter element as indicated by telltale Coolant (or replace every 2 years) Water separator Hydraulic oil filter insert 4 Hydraulic oil Hydraulic oil tank breather Gearbox oil Track case oil

●

●

●

●

●

●

●

●

● ●

●

●

●

●

●

●

● ●

● ●

●

●

●

●

●

●

●

):

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp311.fm

Check the following material. Refill if necessary: • Engine oil • Engine coolant • Hydraulic oil • Gearbox oil5

●

●

●

●

●

● ●

●

Clean water ducts 6

●

●

Check engine/hydraulic oil radiator and air conditioning for contamination. Clean if necessary

●

●

Check cooling systems, heating and hoses for leaks and damage (visual check)

●

●

Replace the cab filter for heating or air conditioning (air conditioning system option)

●

●

Air filter (damage)

●

●

Fuel filter with water separator: drain water

●

●

Authorised

workshop

Customer

Every 3000 s/h

or 5 years max.

Every 1500 s/h

Every 1000 s/h once a year

Engine oil filter2

Inspection work (

Every 500 s/h

):

Carry out the following oil and filter changes (check oil levels after test run): • Engine oil1 • • • • • • • • • •

Every 250 s/h

Fluid and filter changes (

Every 50 s/h

For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the attachment manufacturer as well.

Maintenance plan/service hours (s/h) Service work (daily)

Work description

Wartung

3-5

3.3

Maintenance plan (overview)

● ●

●

● ●

Exhaust gas turbocharger: clean compressor outlet

●

●

Check valve clearance, adjust if necessary

●

●

Check the fuel injection pump

●

●

Check the injection pressure

●

●

Check the injection nozzles 7

●

●

Replace fuel injectors

●

●

Empty the diesel fuel tank (to avoid condensation water)

●

Check battery fluid, fill up with distilled water if necessary, check for leaks, visual check

●

Check alternator, starter and electric connections, bearing play and function8

●

●

Preheating system, electric connections 9(replace heater plugs every 2 years)

●

●

● ●

Check wheels/tracks for cracks, cuts, check profile and air pressure

●

●

Check wheel nuts

●

●

Check track tension. Retighten if necessary

●

●

Check bearing play of tread rollers, track carrier rollers, front idlers Check piston rods for damage

●

●

●

Check screws for tightness

● ●

●

●

Pin lock

●

●

Attachment of lines (replace clamps if damaged)

●

●

Engine and engine suspension (replace suspension if damaged)

●

Check telltales for correct function

●

●

●

Tilt lock and gas strut of cab

●

●

●

Authorised

workshop

Customer

Every 3000 s/h

●

Replace toothed belt Check exhaust system for damage and condition

or 5 years max.

Every 1500 s/h

Every 1000 s/h once a year

Every 500 s/h

Check V-belt condition and tension (retighten if necessary or replace every 2 years)

Every 250 s/h

For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the attachment manufacturer as well.

Every 50 s/h

Work description

Maintenance plan/service hours (s/h) Service work (daily)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp311.fm

3.3

3-6

3-7

3.3

Maintenance plan (overview)

●

Check insulating mats in the engine compartment for damage/attachment

●

●

●

Adhesive labels and Operator's Manual

●

●

●

Engine cover gas strut

●

Pressure check of work and drive hydraulics Lubrication service (

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

):

Check the function of the following assemblies/components. Rectify if necessary: • Lights, signalling system, acoustic warning system • Check function of safety bars, check for damage • Check emergency lowering • Safety device: maintenance strut of loader unit Leakage check (

●

):

Lubricate the following assemblies/components: • Quickhitch • Mobile parts of lock mechanism • Attachments Functional check (

●

):

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp311.fm

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 and heating circuit ● ☞ Travelling drive ●

● ● ● ●

Authorised

workshop

Customer

Every 3000 s/h

or 5 years max.

●

Every 1500 s/h

Every 1000 s/h once a year

Every 500 s/h

Every 250 s/h

Couplings, dirt pile-up on hydraulic system dust caps

Every 50 s/h

For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the attachment manufacturer as well.

Service work (daily)

Work description

Maintenance plan/service hours (s/h)

Maintenance plan (overview)

Air conditioning: Check the function of the air conditioning, repair if necessary: ☞ Air conditioning function ☞ Replace the cab filter ☞ Check dehumidifier for corrosion, condensation and air bubbles ☞ Replace dehumidifier ☞ Compressor oil (replace the compressor oil every other 1500 s/h servicing) 1.

2.

3.

4.

5.

6.

7.

8.

9.

Drain engine oil the first time after 50 s/h, then every 500 s/h Replace the engine oil filter the first time after 50 s/h, then every 500 s/h Replace the fuel filter the first time after 50 s/h, then every 500 s/h Replace the hydraulic oil filter insert the first time after 50 s/h, then every 500 s/h Check gearbox oil once a week/every 50 s/h Clean the water ducts every other 1000 s/h servicing Check the injection nozzles and the valves every other 1500 s/h servicing First check of alternator and starter at 50 s/h, then every 500 s/h First check of preheating system at 50 s/h, then every 500 s/h

●

●

●

●

●

●

● ●

●

●

●

Authorised

workshop

Customer

Every 3000 s/h

or 5 years max.

Every 1500 s/h

Every 1000 s/h once a year

Every 500 s/h

Every 250 s/h

For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the attachment manufacturer as well.

Every 50 s/h

Work description

Maintenance plan/service hours (s/h) Service work (daily)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp311.fm

3.3

3-8

Maintenance

Maintenance 3.4

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.

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 3-5).

3-9

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Maintenance 3.5

Fuel 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, switch off 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 in the engine compartment, on the left in driving direction. The lock on the filler inlet can be opened with the key of the machine.

Danger!

All work involving fuel carries an increased

Danger of fire and poisoning!

A

☞ Do not refuel in closed rooms. ☞ Never carry out work on the fuel system in the vicinity of naked flames or sparks.

☞ No smoking, no fire.

Fig. 1:

Fuel filler inlet

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 3-11.

Notice!

Fill up the tank with the correct fuel type at the end of each working day to prevent the formation of condensation water in the fuel tank (condensation water damages the injection pump). Do not fill the tank completely but leave some space for the fuel to expand.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

3-10

Maintenance 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

wrong

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.

right

Immerse it down to a max. 15 cm (6”) above the floor of the barrel.

Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter.

Fig. 2:

Keep all refuelling containers clean at all times.

Refuelling from a barrel

Diesel fuel specification

Use only high-grade fuels.

Grade • 2-D ASTM D975 – 94 • 1-D ASTM D975 – 94 • EN 590: 96

Use

• ISO 8217 DMX • BS 2869 – A1 • BS 2869 – A2

International

USA EU England

Bleeding the fuel system Bleed the fuel system in the following cases:

A

Fig. 3:

Refuelling from a barrel

After removing and fitting the fuel filter and the fuel lines back on again, or After running the fuel tank empty After running the engine again, after it has been out of service for a longer period of time. ☞ Bleed the fuel system as follows: • Raise the cab – see chapter 1.4 Tilting the cab on page 1-15 • Pump with manual pump A until 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: • Switch off the engine.

• Bleed the fuel system again as described above.

• Have this checked by authorised staff if necessary.

3-11

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Maintenance Emptying the fuel tank The fuel tank is fully emptied by removing the fuel with suction lance A.

A

Fig. 4:

Fuel tank suction lance

Fuel filter with water separator Check the fuel filter as follows: unscrew thread A.

➥ The water drains. ➥ Wait until fuel starts flowing (visual check). ☞ Screw thread A back on again.

Environment!

Thread A is fitted with a hose. Collect the water as it drains with a suitable container and dispose of it in an environmentally friendly manner.

A Fig. 5:

Fuel filter with water separator

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

3-12

Maintenance Replacing the fuel filter Fuel filter A is fastened separately on the chassis.

Danger!

A

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 change the fuel filter if the engine is hot.

Fig. 6:

Fuel filter position

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner.

☞ Change fuel filter 6/A as follows:

• • • • •

A

Fig. 7:

Close the fuel feed line with the stop cock on the fuel filter.

Thoroughly clean the outside surfaces of fuel filter 6/A. Place a suitable container under the filter.

Slacken and unscrew fuel filter cartridge using a commercially available tool.

Collect the fuel as it drains.

Unscrewing the fuel filter

• Clean sealing surface B of the filter carrier.

• Lightly oil the rubber gasket of the new filter cartridge or apply a thin coat of clean diesel fuel to it.

B

Fig. 8:

Cleaning the sealing surface and oiling the gasket

A

Fig. 9:

3-13

• Screw on the cartridge by hand until the gasket makes contact.

• • • •

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

Bleed the fuel system – see Bleeding the fuel system on page 3-11.

Make a test run – and check for tightness.

Dispose of the old fuel filter cartridge by an ecologically safe method.

Tightening the fuel filter

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Maintenance 3.6

Engine lubrication system Caution!

If the engine oil level is too low or if an oil change is overdue, this can cause

Engine damage or loss of output! ☞ Have the oil changed by an authorised workshop – see Maintenance plan (overview) on page 3-5.

Checking the oil level

Notice!

Check the oil level once a day. We recommend checking it before starting the engine. After switching off a warm engine, wait at least 5 minutes before checking.

Checking the oil level

☞ Proceed as follows: max min

A

• Park the machine on level ground.

• Switch off the engine.

• Fold up the safety bars.

• Let the engine cool down.

• Open the engine cover.

• Clean the area around the oil dipstick with a lint-free cloth.

• Oil dipstick A: Pull it out,

Fig. 10: Checking the oil level

Wipe it with a lint-free cloth.

Push it back in as far as possible.

Withdraw it and read off the oil level.

However if necessary, fill up oil up to the MAX mark at the latest when the oil reaches the MIN mark on the oil dipstick A.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

3-14

Maintenance Filling up engine oil

Caution!

Too much or incorrect engine oil can result in engine damage! For this reason: Do not add engine oil above the MAX mark of oil dipstick 11/A. Use only the specified engine oil.

Use engine oils of the same brand and grade => never mix different oils.

Environment!

Use a suitable container to collect the engine oil as it drains and dispose of it in an environmentally friendly manner.

B

Proceed as follows: OIL

Clean the area around oil filler cap B with a lint-free cloth.

Open filler cap B. Raise oil dipstick A slightly to allow any trapped air to escape.

A

Fill in engine oil.

Wait about 3 minutes until all the oil has run into the oil sump.

Check the oil level – see Checking the oil level on page 3-14.

Fill up if necessary and check the oil level again.

Fig. 11: Oil dipstick and oil filler cap

Close filler cap B. Push oil dipstick A back in as far as possible.

Completely remove all oil spills from the engine.

3-15

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Maintenance Changing engine oil

Danger!

Caution when draining hot engine oil –

Danger of burns!

+ 80 °C +176 °F

Wear protective gloves.

Use suitable tools.

OIL Fig. 12: Optimum engine oil temperature

Environment!

Use a suitable container to collect the engine oil as it drains and dispose of it in an environmentally friendly manner.

Change the engine oil as follows: Run the engine warm (oil temperature > 80 °C/> 176 °F) Park the machine on level ground.

Switch off the engine.

B

Place a container under the opening to collect the oil as it drains.

Pull out oil drain hose B. Completely drain the oil.

Screw the oil drain hose back on again.

Fill in engine oil – see chapter Filling up engine oil on page 3-15.

Start the engine and let it run briefly at low revs.

Switch off the engine.

Wait a moment until all the oil has run into the oil sump.

Fig. 13: Oil drain plug

Check the oil level again.

Fill up if necessary and check again.

Completely remove all oil spills from the engine.

Replacing the engine oil filter cartridge

Danger!

Caution when draining hot engine oil – A

Danger of burns!

Wear protective gloves.

Fig. 14: 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.

Tilt the cab to replace engine oil filter A Chapter “Maintenance accesses” on page 1-11.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

3-16

Maintenance Change the filter as follows: Switch off the engine.

Place a suitable container underneath the oil filter to collect the oil as it drains.

A

Slowly slacken oil filter cartridge A using a commercially available tool.

Let the oil drain into the container.

Remove the filter cartridge once the oil is completely drained.

Make sure the thread adapter is correctly placed in the filter head.

Fig. 15: Unscrewing the fuel filter

Clean the inside of the filter head.

Apply a thin coat of fresh engine oil to rubber seal B of the new oil filter cartridge.

Tighten the new filter cartridge by hand until the gasket makes contact.

B

Fig. 16: Cleaning the sealing surface and oiling the gasket

Tighten oil filter cartridge A by hand by about a further half revolution.

A

Make sure the oil level is correct.

Let the engine run briefly.

Switch off the engine.

Check the seal of oil filter cartridge A and retighten by hand.

Check the oil level and fill in engine oil if necessary.

Completely remove all oil spills from the engine.

Fig. 17: Tightening the fuel filter

Screw the maintenance flap back on again.

Dispose of the used oil filter in an environmentally friendly manner.

3-17

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Maintenance 3.7

Cooling system The combined radiator is located in the engine compartment, behind the engine.

The hydraulic oil cooler is located at the right, and the radiator at the left.

The expansion tank for the coolant is also located in the engine compartment on the combined radiator. The combined radiator is filled up via the expansion tank pre-tensioned to 1 bar (14.5 psi). The water tank can filled only after the thermostat opens at 88 – 92°C (190 – 198°F).

Specific safety instructions

• Dirt on the radiator fins reduces the cooler's heat dissipation capacity! To avoid this: Clean the outside of the radiator at regular intervals. Use oil-free compressed air (2 bar/29 psi max.) to clean. Maintain a certain distance from the radiator to avoid damage to the radiator fins. Refer to the maintenance plans in the appendix for the cleaning intervals.

In dusty or dirty work conditions, clean more frequently than indicated in the maintenance plans.

• An insufficient coolant level reduces the heat dissipation capacity as well and can lead to engine damage. Therefore: Check the coolant level at regular intervals. Refer to the maintenance plans in the appendix for the intervals.

If coolant must be added frequently, check the cooling system for leaks and/or contact your dealer.

Never fill in cold water/coolant if the engine is warm.

After filling the expansion tank, make a test run with the engine and check the coolant level again after switching off the engine.

• The use of the wrong coolant can destroy the engine and the cooler. Therefore: Add enough antifreeze compound to the coolant – but never more than 50 %. If possible use brand-name antifreeze compounds with anticorrosion additives.

Observe the coolant compound table – see Coolant compound table on page 2-7.

Do not use cooler cleaning compounds if an antifreeze compound has been added to the coolant – otherwise this causes sludge to form, which can damage the engine.

• Once you have filled the expansion tank: Test run the engine until reaching operating temperature or until the thermostat opens.

Switch off the engine.

Let the engine cool down.

Check the coolant level again.

Environment!

Use a suitable container to collect the coolant as it drains and dispose of it in an environmentally friendly manner.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

3-18

Maintenance Checking/filling up coolant

Danger!

Never open the coolant tank and never drain coolant if the engine is warm since the cooling system is under high pressure –

Danger of burns!

Wait at least 15 minutes after switching off the engine.

Wear protective gloves and clothing.

Carefully unscrew filler cap 18/B and release the pressure.

Make sure the coolant temperature is sufficiently low so you can touch the radiator plug with your hands.

Danger!

Antifreeze is flammable and poisonous –

Danger of accidents!

Keep away from flames.

Avoid eye contact with antifreeze.

• If antifreeze comes into contact with the eyes: immediately rinse with clean water and seek medical assistance.

Checking the coolant level Proceed as follows: FULL

• Park the machine on level ground.

LOW

• Switch off the engine.

B A

• Fold up the safety bars.

• Remove the key and carry it with you.

• Allow the engine and the coolant to cool down for about 15 minutes.

• Open the engine cover.

• Check the coolant level in the transparent expansion tank A.

Fig. 18: Expansion tank for coolant

If the coolant level is below seam LOW of the expansion tank: • Fill up coolant.

Notice!

Check the coolant level once a day. We recommend checking it before starting the engine.

The coolant level must always be between the LOW and FULL marks of the expansion tank. Fill up to the FULL mark if necessary.

3-19

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Maintenance Filling up coolant Expansion tank 18/A is pre-tensioned to 1 bar (14.5 psi). The coolant tank is filled only after the thermostat opens (at 88 °C/190 °F).

After the engine has cooled down: Release overpressure in the radiator.

Carefully unscrew filler cap 18/B and release the pressure completely.

Open filler cap 18/B. Fill up coolant up to the lower edge of the FULL seam.

Close filler cap 18/B. Start the engine and let it warm up for about 5 – 10 minutes Switch off the engine.

Remove the key and carry it with you.

Let the engine cool down.

Check the coolant level again.

The coolant level must be between the LOW and FULL tank seams.

If necessary, fill up coolant and repeat the procedure until the coolant level remains constant.

Notice!

Check the antifreeze every year before the cold season sets in.

Draining coolant

Danger!

Never open the coolant tank and never drain coolant if the engine is warm 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.

Carefully unscrew filler cap 18/B and release the pressure.

After the engine has cooled down: Release overpressure in the radiator.

Carefully unscrew filler cap 18/B. Allow the pressure to fully escape.

Open filler cap 18/B. Open the drain plug of the radiator and drain the coolant into a suitable container.

Close the drain plug again.

Fill up the radiator with suitable coolant – see Fluids and lubricants on page 3-1.

Fig. 19: Radiator drain plug

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Check the coolant level – see Checking the coolant level on page 3-19.

3-20

Maintenance 3.8

Air filter Caution!

The filter cartridge is damaged if it is washed or brushed out.

Bear in mind the following to avoid premature engine wear: 33

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.

Telltale 33 on the round indicating instrument monitors the air filter cartridge. This telltale is triggered by maintenance switch A on the air filter.

Replace outside filter B and inside filter C: • If telltale 33 in the round indicating instrument comes on.

• If the red range of the maintenance display is fully visible.

• According to the maintenance plan.

Notice!

For applications in especially dusty environment, the air filter is fitted with an extra inside filter C. Do not clean inside filter C.

A

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.

Replace outside filter B and inside filter C at the latest after the first 50 service hours.

General instructions for air filter maintenance:

• Store filters in their original packaging and in a dry place.

• Do not knock the filter against other objects as you install it.

• Check air filter attachments, air intake hoses and air filters for damage, and B

C

immediately repair or replace if necessary.

• Check the screws at the induction manifold and the clamps for tightness.

• Check the function of the dust valve, replace if necessary.

• Press the reset button of the maintenance display once maintenance work is over. The maintenance display is operational again.

Fig. 20: Air filter

3-21

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Maintenance Replacing the filter

• Replace outside filter A as follows:

D

Switch off the engine.

Remove the key and carry it with you.

Let the engine cool down.

Open the engine cover.

E

Remove dirt and dust from the air filter and the area around the air filter.

Fold bow clips D on filter cover E outwards.

Remove filter cover E. Fig. 21: Removing the lower housing section

Carefully remove outside filter B with slightly turning movements.

B

Make sure all dirt (dust) inside the upper and lower housing sections, including the dust valve, has been removed.

Clean the parts with a clean lint-free cloth, do not use compressed air.

Check the air filter cartridges for damage, only install intact filters.

Carefully insert new outside filter B in the upper housing section.

Position filter cover E (make sure it is properly seated).

Close bow clips D.

Fig. 22: Removing the filter element

• Replace inside filter C as follows: Switch off the engine.

Fold up the safety bars.

Remove the key and carry it with you.

Let the engine cool down.

Open the engine cover.

C

Remove dirt and dust from the air filter and the area around the air filter.

Fold bow clips D on filter cover E outwards.

Remove filter cover E.

Fig. 21: Replacing the inside filter

Carefully remove outside filter B with slightly turning movements.

Carefully remove inside filter C. Cover the air supply at the end of the filter with a clean lint-free cloth to prevent dust from entering the engine.

Clean the parts with a clean lint-free cloth, do not use compressed air.

Remove the cloth from the air supply.

Check the air filter cartridges for damage, only install intact filters.

Carefully insert the new inside filter C. Carefully insert outside filter B in the upper housing section.

Position filter cover E (make sure it is properly seated).

Close bow clips D.

Notice!

Make sure dust valve 23/F shows downwards once it is installed!

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

3-22

Maintenance Functional check once a week of the dust valve The air filter is located in the engine compartment, on the left side of the machine.

Proceed as follows: • Switch off the engine.

• Apply the parking brake.

• Empty dust valve F by squeezing the discharge slot.

• Remove hardened dust by squeezing the upper area of the valve.

Clean the discharge slot.

F Fig. 22: Replacing the inside filter

3-23

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Maintenance 3.9

V-belts Danger!

Only check or retighten/replace the V-belts when the engine is switched off –

Danger of personal injury!

S

Switch off the engine before carrying out inspection work in the engine compartment.

Disconnect the battery or the battery master switch.

Let the engine cool down.

Caution!

Fig. 23: Tensioner

Cracked and stretched V-belts cause engine damage.

Have the V-belts replaced by an authorised workshop.

Check the V-belts once a day or every 10 service hours and retighten if necessary (with tensioner Fig. 23/S).

Retighten new V-belts after about 15 minutes of running time.

Checking V-belt tension

• Check as follows: 1

Switch off the engine.

Fold up the safety bars.

Remove the key and carry it with you.

Disconnect the battery or the battery master switch.

Let the engine cool down.

Open the engine cover.

Carefully check V-belt 1 for damage, cracks or cuts.

Replace the V-belt if it touches the base of the V-belt groove or the discs of the pulley.

Fig. 24: Checking V-belt tension

• If the V-belt is damaged: Have the V-belt replaced by authorised staff.

Press with your thumb to check the deflection of the V-belt between the crankshaft disc and the fan wheel position C. A new V-belt should have a deflection of 6 to 8 mm (0.2” – 0.3”), a used V-belt (after about 5 minutes running time) should have a deflection of 7 to 9 mm (0.3” – 0.35”) Retighten the V-belt if necessary.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

3-24

Maintenance Retightening V-belts

Caution!

Overtightening the V-belts can damage the V-belts, the V-belt guide and the water pump bearing. Avoid contact of oil, grease or similar substances with the V-belts.

Check V-belt tension – see Checking V-belt tension on page 3-24.

• Proceed as follows before retightening: Switch off the engine.

Fold up the safety bars.

Remove the key and carry it with you.

Disconnect the battery or the battery master switch.

Let the engine cool down.

Open the engine cover.

Alternator

• Retighten as follows: Slacken fastening screws 2 and 3 of alternator L

2

Turn alternator L in the direction of the arrow with a suitable tool until the correct V-belt tension is reached.

3

Retighten fastening screws 2 and 3 firmly.

Check V-belt tension again and adjust it if necessary.

Connect the battery or the battery master switch.

Close the engine cover.

L

Fig. 25: Alternator

Water pump

• Retighten as follows: Slacken fastening screws 4 of the tensioner (Fig. 23/S).

Turn water pump K towards A until you reach the correct V-belt tension.

4

Firmly tighten fastening screws 4 again Check V-belt tension again and adjust it if necessary.

Connect the battery or the battery master switch.

K

Close the engine cover.

A

Fig. 26: Coolant and fuel pump

3-25

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Maintenance Checking the V-belt of the air conditioning system (option)

Caution!

Excessive or insufficient tension of the V-belt can cause damage to the V-belt or to the compressor of the air conditioning system.

Always make sure the V-belt has the correct tension.

Replace V-belts with damage, cracks, cuts etc.

Avoid contact of oil, grease or similar substances with the V-belts.

• Check as follows: Switch off the engine.

Fold up the safety bars.

Remove the key and carry it with you.

2

Disconnect the battery or the battery master switch.

Let the engine cool down.

Open the engine cover.

About 8 mm

Carefully check V-belt 1 for damage, cracks or cuts.

1

Fig. 28: Checking the V-belt tension of the air conditioning system

Replace the V-belt if it touches the base of the V-belt groove or the discs of the pulley.

• If the V-belt is damaged: Have the V-belt replaced by authorised staff.

Press with your thumb to check the deflection of the V-belt. A new V-belt should have a deflection of 7 to 9 mm (0.3” – 0.35”), a used V-belt (after about 5 minutes running time) should have a deflection of 9 to 11 mm (0.35” – 0.4”), see 2.

Retighten the V-belt if necessary.

Tightening the V-belt of the air conditioning system (option)

• Retighten as follows: Switch off the engine.

4

5

Fold up the safety bars.

Remove the key and carry it with you.

Disconnect the battery or the battery master switch.

3 A

Let the engine cool down.

Open the engine cover.

Slacken fastening screw 3.

Slacken lock nut 4 and turn it upwards a little.

Fig. 29: Retightening the V-belt of the air conditioning system

Screw the belt tensioner with nut 5 in the direction of arrow A, until you reach the correct V-belt tension.

Firmly tighten lock nut 4 again.

Tighten fastening screw 3.

Check V-belt tension again and adjust it if necessary.

Connect the battery or the battery master switch.

Close the engine cover.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

3-26

Maintenance 3.10 Pressure check General

• Run the machine warm before checking the pressure. Hydraulic oil temperature: 50 °C/ 122 °F min. (operating temperature).

• Set the primary pressure limiting valves (PPLV) at maximum engine revs.

• Bleed the hydraulic pump whenever you reconnect or reroute hydraulic hoses – see chapter Bleeding the hydraulic pump housing on page 3-41.

• Pressure measurements may be carried out by trained staff only.

• Ensure utmost cleanliness of all measuring points and ports, micro measuring lines and pressure gauges that are connected for checking pressure => even the slightest traces of dirt, e.g. a grain of sand, can impair tightness and cause leaks!

• Pressure settings: – see Work hydraulics on page 2-4 and – see Test report 1101cp on page 3-37 – see Test report 1101c on page 3-35 Standard micro ports

Main valve block Brake valve 1

3

2

Pos. 1 2 3

3-27

Description Measuring port MP 1 Measuring port MP 2 Measuring port MP 3

Boost pressure Brake release pressure Work hydraulics pressure

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Maintenance Variable displacement pump measuring points 4

5 Pos. 4

Description Measuring port Y

5

Measuring port G1

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Speed-sensitive pilot control pressure for driving Boost pressure/work hydraulics pilot control pressure

3-28

Maintenance

7

6

8

Pos. 6 7 8 9

3-29

Description Measuring port Mb2 Measuring port Mb1 Measuring port Ma2 (on lower side of pump) Measuring port Ma1 (on lower side of pump)

9

To front right hydraulic motor To front left hydraulic motor To rear right hydraulic motor To rear left hydraulic motor

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Maintenance Preparatory work

☞ Carefully open the cap of the hydraulic tank to the first notch and fully release the pressure

☞ Open the cap of the hydraulic tank. ☞ Install the micro ports at the specific test points. ☞ Connect the measuring instrument. ☞ Bleed the hydraulic pump – see chapter Bleeding the hydraulic pump housing on page 3-41.

☞ Close the cap of the hydraulic tank. ☞ Run the machine warm. ➥ Hydraulic oil temperature: 50 °C/122 °F min. (operating temperature). ☞ You can then carry out the measurements.

Main pressure check (P1 & P2) Checking main pressure 7

☞ Tilt the cab – see Tilting the cab on page 1-15. ☞ Unscrew the plugs of the variable displacement pump. ☞ Screw in the micro measuring device (1000015578) with screw connection (1000085130) into measuring ports Ma1 27/9, Ma2 27/8, Mb1 27/7 and Mb2 27/6 and connect it with the measuring instrument.

6

➥ The inside threads of the pump micro ports are 9/16 UNF threads. ☞ Make sure no wires or cables can be damaged. ☞ Lower the cab. ☞ Start the engine. ☞ Check and make a note of the pressure value.

• Rated pressure: Measure the pressure at maximum revs.

• Measurements Keep the machine in a firm position so that the wheels cannot turn with the joystick in final position (e.g. drive against an earth mound).

8

Drive forwards 9

Keep the machine in a firm position so that the wheels cannot turn with the joystick in final position (e.g. drive against an earth mound).

Drive backwards

Fig. 30: Measuring ports Ma1, Ma2, Mb1, Mb2

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

3-30

Maintenance Boost pressure check of pump and pilot control pressure check of work hydraulics Checking boost pressure

• The boost pressure is monitored by pressure switch A on the distributing block.

• If the boost pressure drops below 8.0 bar (116 psi), the pump can be damaged by cavitation.

The pressure switch activates telltale 31/37 “pump pressure”.

5

Tilt the cab upwards – see Tilting the cab on page 1-15 Remove the hoses on port G1 (fig. 31/5), of the variable displacement pump.

Install a T-fitting with a micro measuring device and connect it with the measuring instrument.

Make sure no wires or cables can be damaged.

Install the hoses again.

Start the engine – leave the cab in the tilted position.

A

Check and make a note of the pressure value.

Measure the pressure at idling speed.

Measure the pressure at maximum revs.

• Measurement Machine at a standstill (joystick not actuated).

• The boost pressure is monitored by pressure switch PS1 on the distributing block.

• If the boost pressure drops below 8.0 bar (116 psi), the pump can be damaged by cavitation:

Fig. 31: Pressure switch PS1 (A)

Caution!

Switch off the engine immediately The pressure switch activates telltale 31/37 “pump pressure”.

37

3-31

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Maintenance Work hydraulics pressure check Checking the work hydraulics pressure Tilt the cab – see Tilting the cab on page 1-15.

Connect the measuring instrument with micro measuring device MA 3 32/3.

3

Make sure no wires or cables can be damaged.

Lower the cab.

Start the engine.

Check and make a note of the pressure value.

• Rated pressure:

Fig. 32: Measuring port MA3

Measure the pressure at idling speed.

Measure the pressure at maximum revs.

• Measurements Extend/retract (base/rode side) the bucket ram as far as it will go.

Extend/retract (base/rode side) the loader unit ram as far as it will go.

Actuate the auxiliary hydraulics fully in both directions.

When checking by extending/retracting (base/rode side) the loader unit ram:

Danger!

Checking the pressure or adjusting with the loader unit function –

Danger of personal injury!

Adjusting the work hydraulics pressure Adjust the pressure at the pressure limiting valve (PLV 1) 33/B on the control valve.

Slacken the locknut of the pressure limiting valve.

Unscrew the pressure limiting valve until you can read off a pressure drop on the measuring instrument.

B

The valve seat can be stuck and must be slackened first.

Adjust the pressure limiting valve and tighten the locknut.

Adjustment value see – see Work hydraulics on page 2-4 – see Test report 1101c on page 3-35 – see Test report 1101cp on page 3-37

Fig. 33: Work hydraulics pressure limiting valve

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Check the pressure limiting valve PLV1 and the pressure drop again once adjustment is over.

3-32

Maintenance Checking the pilot control pressure of the drive hydraulics Checking the drive hydraulics pressure (left-hand side joystick) Tilt the cab upwards – see Tilting the cab on page 1-15 Remove the hoses on port Y (fig. 34/4), of the variable displacement pump.

Install a T-fitting with a micro measuring device and connect it with the measuring instrument.

4

Make sure no wires or cables can be damaged.

Install the hoses again.

Lower the cab.

Fig. 34: Measuring port Y

Start the engine.

Check and make a note of the pressure value.

Measure the pressure at idling speed.

Measure the pressure at maximum revs.

• Measurement Machine at a standstill (joystick not actuated).

Checking the parking brake release pressure Tilt the cab – see Tilting the cab on page 1-15.

Connect the measuring instrument with micro measuring device MA 2 35/2.

Make sure no wires or cables can be damaged.

Start the engine – leave the cab in the tilted position.

Check and make a note of the pressure value.

Measure the pressure at idling speed.

Measure the pressure at maximum revs.

• Measurement Machine at a standstill (joystick not actuated).

2 Fig. 35: Measuring port MA2

3-33

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

Maintenance Checking the DA control pressure Checking the DA control pressure Tilt the cab – see Tilting the cab on page 1-15.

Remove the hoses on port Y (fig. 36/4), of the variable displacement pump.

Install a T-fitting with a micro measuring device and connect it with the measuring instrument.

4

Make sure no wires or cables can be damaged.

Install the hoses again.

Lower the cab.

Fig. 36: Measuring port Y

Start the engine.

Check and make a note of the pressure value.

Measure the pressure at idling speed.

Measure the pressure at maximum revs.

• Measurement Straight-ahead driving with the joystick fully actuated.

Engine droop Install a tachometer in addition.

Check and make a note of the pressure value and of the revs.

Measure the pressure and the revs at maximum revs.

• Measurement Keep the machine in a firm position so that the wheels cannot turn with the joystick in final position (e.g. drive against an earth mound).

Checking the pressure of the 3rd control circuit (Power Flow option 1101cp) Checking the Power Flow pressure 3

Tilt the cab – see Tilting the cab on page 1-15.

Connect the measuring instrument with micro measuring device MA 3 37/3.

Make sure no wires or cables can be damaged.

Lower the cab.

Start the engine.

44

Enable Power Flow 37/44.

Check and make a note of the pressure value.

Measure the pressure at maximum revs.

• Measurement Enable the 3rd control circuit (Power Flow) with switch 37/44.

Fig. 37: Measuring port MA3

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp312.fm

3-34

Maintenance

3-35

Maintenance

3.11 Test report 1101c Boost pressure Specified values

Oil supply by P5 (19 cm³/rev / 1.16 cu. in./rev)

G1 measuring port

Engine speed

Min. revs Max. revs

Rated value Rated value

Pressure in bar (psi) 26 ±1 (377 ±14.5)

Measured value 1

Measured value 2

Measured value 1

Measured value 2

Measured value 1

Measured value 2

26 ±1 (377 ±14.5)

Work hydraulics Oil supply by P3 (34 cm³/rev / 2.1 cu. in./rev) Function

Movement

Pressure limiting valve

Measuring port

DUMP OUT Bucket DUMP IN UP Loader unit DOWN

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp313.fm

Auxiliary hydraulics

Pressure limiting valve Measuring port MP 3 (control valve)

A B

Specified values

max.

Min. max.

Min. max.

Min. max.

Min. max.

Min. max.

Min.

210 ±3 (3046 ±43.5) 190 ±3 (2756 ±43.5) 210 ±3 (3046 ±43.5) 190 ±3 (2756 ±43.5) 210 ±3 (3046 ±43.5) 190 ±3 (2756 ±43.5) 210 ±3 (3046 ±43.5) 190 ±3 (2756 ±43.5) 210 ±3 (3046 ±43.5) 190 ±3 (2756 ±43.5) 210 ±3 (3046 ±43.5) 190 ±3 (2756 ±43.5)

Brake release pressure = boost pressure Oil supply by P5 (19 cm³/rev / 1.16 cu. in./rev)

Measuring port MP 2

Specified values

Min. revs Max. revs

Rated value Rated value

26 ±1 (377 ±14.5) 26 ±1 (377 ±14.5)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp313.fm

3.11 Test report 1101c Drive pilot control pressure Specified values

Oil supply by P5 (19 cm³/rev / 1.16 cu. in./rev)

Engine speed

Min. revs Max. revs

Y measuring port

Rated value Rated value

Pressure in bar (psi) 13 ±1 (189 ±14.5)

Measured value 1

Measured value 2

Measured value 1

Measured value 2

Measured value 1

Measured value 2

26 ±1 (377 ±14.5)

DA control + drive pilot control pressure (driving forwards without load) Oil supply by P5 (19 cm³/rev / 1.16 cu. in./rev)

Y measuring port

Specified values

Min. revs Max. revs Max. engine droop

Rated value Rated value Rated value

13 ±1 (189 ±14.5) at 1200±50rpm 26 ±1 (377 ±14.5) at 2995±50rpm 17 ±2 (247 ±29) at 2100±100rpm

Main pressure (P1 and P2) Oil supply by variable displacement pump P1 and P2 (38.5 cm³/rev / 2.35 cu. in./rev) Function

Engine speed

Forwards

Max. revs

Reverse

Max. revs

Measuring port

Ma1 Ma2 Mb1 Mb2 Ma1 Ma2 Mb1 Mb2

Specified values

Rated value Rated value Rated value Rated value Rated value Rated value Rated value Rated value

22 ±5 (319 ±72.5) 22 ±5 (319 ±72.5) 365 ±10 (5294 ±145) 365 ±10 (5294 ±145) 365 ±10 (5294 ±145) 365 ±10 (5294 ±145) 22 ±5 (319 ±72.5) 22 ±5 (319 ±72.5)

Maintenance

3-36

Boost pressure Oil supply by P5 (19 cm³/rev / 1.16 cu. in./rev)

G1 measuring port

Engine speed

Min. revs Max. revs

Rated value Rated value

Specified values Pressure in bar (psi) 26 ±1 (377 ±14.5)

Measured value 1

Measured value 2

Measured value 1

Measured value 2

Measured value 1

Measured value 2

26 ±1 (377 ±14.5)

Work hydraulics Oil supply by P3 (34 cm³/rev / 2.1 cu. in./rev) Pressure limiting Movement Measuring port valve

Function

DUMP OUT Bucket DUMP IN UP Loader unit DOWN

Pressure limiting Measuring port MP 3 valve (control valve)

A Auxiliary hydraulics B

Specified values

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp313.fm

max.

Min. max.

Min. max.

Min. max.

Min. max.

Min. max.

Min.

210 ±3 (3046 ±43.5) 190 ±3 (2756 ±43.5) 210 ±3 (3046 ±43.5) 190 ±3 (2756 ±43.5) 210 ±3 (3046 ±43.5) 190 ±3 (2756 ±43.5) 210 ±3 (3046 ±43.5) 190 ±3 (2756 ±43.5) 210 ±3 (3046 ±43.5) 190 ±3 (2756 ±43.5) 210 ±3 (3046 ±43.5) 190 ±3 (2756 ±43.5)

Brake release pressure = boost pressure Oil supply by P5 (19 cm³/rev / 1.16 cu. in./rev)

Measuring port MP 2

Specified values

Min. revs Max. revs

Rated value Rated value

26 ±1 (377 ±14.5) 26 ±1 (377 ±14.5)

Maintenance

3-37

3.12 Test report 1101cp

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp313.fm

3.12 Test report 1101cp Drive pilot control pressure Oil supply by P5 (19 cm³/rev / 1.16 cu. in./rev)

Specified values

Min. revs Max. revs

Y measuring port

Rated value Rated value

13 ±1 (189 ±14.5) 26 ±1 (377 ±14.5)

Engine speed

Specified values Pressure in bar (psi) ±1 13 (189 ±14.5) at 1200±50rpm

Measured value 1

Measured value 2

Measured value 1

Measured value 2

Measured value 1

Measured value 2

Measured value 1

Measured value 2

DA control Oil supply by P5 (19 cm³/rev / 1.16 cu. in./rev)

Y measuring port

Min. revs Max. revs Max. engine droop

Rated value Rated value Rated value

26 ±1 (377 ±14.5) at 2995±50rpm 17 ±2 (247 ±29) at 2100±100rpm

Power Flow (3rd control circuit) Oil supply by P5 (19 cm³/rev / 1.16 cu. in./rev) + P3 (34 cm³/rev / 2.1 cu. in./rev)

Measuring port MP 2 Main pressure (P1 and P2)

Max. revs

Specified values

Rated value

210 ±3 (3046 ±43.5)

Oil supply by variable displacement pump P1 and P2 (38.5 cm³/rev / 2.35 cu. in./rev) Function

Engine speed

Forwards

Max. revs

Reverse

Max. revs

Measuring port

Rated value Rated value Rated value Rated value Rated value Rated value Rated value Rated value

22 ±5 (319 ±72.5) 22 ±5 (319 ±72.5) 365 ±10 (5294 ±145) 365 ±10 (5294 ±145) 365 ±10 (5294 ±145) 365 ±10 (5294 ±145) 22 ±5 (319 ±72.5) 22 ±5 (319 ±72.5)

3-38

Maintenance

Ma1 Ma2 Mb1 Mb2 Ma1 Ma2 Mb1 Mb2

Specified values

Maintenance

Maintenance 3.13 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 with the safety bars closed and ignition switched on.

• Fold the control lever base up.

• Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries. Therefore always consult a doctor immediately, even in the case of minor wounds – 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 can cause damage to the hydraulic pump.

• Oil or fuel flowing out of high pressure lines can cause fire or malfunctions, and severe injuries or damage to property. Interrupt work immediately if slackened nuts and damaged hoses and lines are detected.

☞ Contact your Wacker Neuson dealer immediately.

Caution!

Dirty hydraulic oil, lack of oil or wrong hydraulic oil –

Danger of severe damage to the hydraulic system! ☞ Take care to avoid dirt when working. ☞ Always use the filling screen when refilling hydraulic oil. ☞ Only use authorised oils of the same type – see Fluids and lubricants on page 3-1.

☞ Always fill up hydraulic oil before the level gets too low – see Filling up hydraulic oil on page 3-41.

☞ If the hydraulic system is filled with biodegradable oil, then only use biodegradable 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 dirty and contains metal chippings. Otherwise, follow-on damage can 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 disposal before disposing of biodegradable oil.

3-39

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

Maintenance Checking the hydraulic oil level

Caution!

Do not fill up oil if the oil level is above the FULL mark, otherwise the hydraulic system can be damaged and escaping oil can cause serious injuries.

☞ Check the hydraulic oil level each time the machine is put into operation or once a day.

If the attachment is not positioned as shown:

☞ Start the engine and let it run at idling speed ☞ Retract the loader unit ram, lower the bucket to the ground. ☞ Switch off the engine again.

Fig. 38: Parking the loader

B

☞ Proceed as follows: Park the machine on level ground.

FULL

Retract the rams of the loader unit, lower the bucket to the ground.

LOW

Switch off the engine.

Fold up the safety bars.

B

Sight glass B is located on hydraulic oil tank A. FULL

Check the oil level on sight glass B. The oil level must be at the FULL level.

A

• A gauge element in sight glass B indicates the oil level.

If the oil level is lower, Fill up hydraulic oil.

LOW

The oil level varies according to the machine's operating temperature: Machine condition Before putting into operation

Fig. 39: Oil level indicator on the hydraulic oil tank

Normal operation

Hydraulic oil temperature

Oil level

Between 10 and 30 °C (50 and 86 °F)

LOW mark

Between 50 and 90 °C (122 and 194 °F)

FULL mark

Notice!

Measure the oil level of the hydraulic system only after the machine reaches its operating temperature.

1

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

3-40

Maintenance Bleeding the hydraulic pump housing

Caution!

S

Bleed the hydraulic pump whenever you reconnect or reroute hydraulic hoses, otherwise the pump can be damaged.

Proceed as follows: Park the machine on level ground.

Retract the rams of the loader unit, lower the bucket to the ground.

Switch off the engine.

Fold up the safety bars.

Fig. 40: Bleeding the hydraulic pump housing

Let the engine cool down.

Tilt the cab – see Tilting the cab on page 1-15.

Unscrew both plugs 40/S on the upper side of the variable displacement pump until a little oil escapes.

Screw plug 40/S back on again.

Lower the cab and secure it with the screws.

Filling up hydraulic oil

Danger!

C

Removing the breather filter can cause oil to escape suddenly and at high pressure –

Danger of accidents!

Carefully unscrew the filter to slowly reduce the pressure inside the tank.

Do not fill up the hydraulic oil unless the engine is switched off. Otherwise, hydraulic oil will overflow at the filler opening on the hydraulic tank.

Fill up as follows: Park the machine on level ground.

Retract the rams of the loader unit, lower the bucket to the ground.

Switch off the engine.

Fig. 41: Breather filter

Fold up the safety bars.

Remove the key and carry it with you.

Let the engine cool down.

Slowly open cover C. Fill up the hydraulic oil (screen is integrated).

Check the hydraulic oil level on sight glass 39/B. Fill up if necessary and check again.

Firmly retighten cover C.

Notice!

Breather filter C can be locked with a padlock.

3-41

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

Maintenance After changing the hydraulic oil

Caution!

Never start the engine if the oil tank is empty otherwise the pump is damaged.

Bleed the hydraulic pump – see chapter Bleeding the hydraulic pump housing on page 3-41.

Make sure all control levers are in neutral position Let the engine run at idling speed for 2 to 3 minutes.

Actuate the attachment.

Move all pistons several times to remove air in the system.

Check the oil level and fill up oil if necessary.

Changing hydraulic oil

Notice!

Only change the hydraulic oil if it is warm (about 50 °C/122 °F). Retract all hydraulic rams before changing the oil.

B

Open the breather filter to release pressure.

Open drain plug B and let the oil drain into a container.

Check the hydraulic oil tank for dirt and clean if necessary.

Replace the filter according to the maintenance specifications.

Screw the drain plug back in correctly.

Fill in clean hydraulic oil through the screen – see Filling up hydraulic oil on page 3-41.

Close the hydraulic oil tank correctly.

Fig. 42: Hydraulic oil drain plug

Bleed the hydraulic pump – see chapter Bleeding the hydraulic pump housing on page 3-41.

Let the machine run at idling speed without load for some minutes.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

3-42

Maintenance Monitoring the hydraulic oil reflux filter

34

The red telltale 34 on the round indicating instrument monitors the reflux filter. This telltale is triggered by pressure switch 44/A. The control pressure is set at 5 bar (72.5 psi).

Replace the filter element: If telltale 34 comes on when the hydraulic oil is at operating temperature. at the latest after 1000 service hours (once every year).

In cold weather telltale 34 can come on immediately when the engine is started. This is caused by increased oil viscosity. In this case: Set engine speed so that telltale 34 goes out.

Fig. 43: Telltale for reflux filter

Replacing the reflux filter

Environment!

C

Use a suitable container to collect the hydraulic oil as it drains and dispose of it in an environmentally friendly manner.

A

Replace the reflux filter as follows: Thoroughly clean the outside of the reflux filter.

Place a suitable container under the filter.

Slacken and unscrew screws B (4 off).

B

Remove cover C. Collect the hydraulic oil as it drains.

Fig. 44: Reflux filter pressure switch

Remove the old reflux filter and replace it by a new one D. Remove dirt from sealing surface E of cover C if necessary.

Fit cover C back on again.

D

Screw in screws B by hand until cover C is seated correctly.

Tighten screws B. Make a test run – and check for tightness.

Dispose of the replaced reflux filter in an environmentally friendly manner.

E

3-43

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

Maintenance Checking hydraulic pressure lines

Specific safety instructions

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.

Danger of personal injury!

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 connections. Replace damaged parts with new ones.

• Never search for leaks with your hands.

• 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 occupational health and safety in your country. Also observe DIN 20 066.

1 Q/08

The date of manufacture (month or quarter and year) is indicated on the flexible line.

Example: The indication “1 Q/08” means manufactured in the 1st quarter of 2008.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

3-44

Maintenance 3.14 Undercarriage maintenance Danger!

Improper undercarriage repairs –

Danger of accidents!

All repair work on tracks, tyres and rims may only be carried out by authorised workshops.

Notice!

Regular inspections of the tyres • Improve operating safety • Increase the service life of the tyres.

• Reduce machine downtimes. Refer to chapter – see Tracks on page 2-6 for the authorised tyre types and the correct tyre pressures.

Carry out the following maintenance work once a day: • Check tyre pressure.

• Check tracks and track rollers/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.

• Check tyres for wear and measure tread depth.

• Remove foreign bodies or accumulation of earth.

3-45

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

Maintenance 3.15 Tracks Danger!

Use of wrong tracks –

Danger of accidents!

Use only tracks that have been released for your machine.

Check for tightness every time the tracks are changed.

Track wear can vary according to work and ground conditions.

We recommend checking track wear and tension once a day.

Park the machine on firm and level ground to check and carry out maintenance.

Checking track tension

Danger!

Working under the machine with the tracks off the ground and only supported by the attachment is extremely dangerous.

Caution, danger!

Firmly support the machine with chocks or suitable brackets.

Check track tension as follows:

• The rubber track has a mark B as shown in Fig. 45.

Place the loader so that mark B of the rubber track is between drive pinion C and track tension roller D. B C B

D Fig. 45: Rubber track mark

• Standard play between the sliding block's shoulder and the contact area of the centre support roller of the drive pinion is 20 – 25 mm (0.8 – 1”).

20 – 25 mm 0.8-1"

Set the tension as follows if it is not in accordance with the rated value.

Fig. 46: Measuring distance

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

3-46

Maintenance Adjusting track tension

Danger!

The lubricating valve can be squeezed out due to the high grease pressure in the hydraulic ram.

Danger of personal injury!

Do not slacken and unscrew the lubricating valve by more than one turn.

Slacken no other component except the lubricating valve.

Keep your face away from the lubricating valve connection.

➥ Contact your Wacker Neuson dealer if this does not reduce the tension of the rubber sliding block.

Caution!

Excessive tension of the tracks causes severe damage to the ram and the track.

☞ Tighten the tracks only up to the prescribed measuring distance.

Tightening the tracks

☞ Inject grease with the pump through lubricating valve A. ☞ Check the tension is correct by starting the engine, letting it run at idling speed and slowly moving the machine forwards and reverse and switching it off again.

☞ Check the tension of the tracks again. ➥ If it is not correct: ☞ Adjust again. ☞ Should the track still be slack after injecting more grease, replace the track or the seal A Fig. 47: Tightening the tracks

in the ram. Contact a Wacker Neuson dealer in this case.

Reducing track tension

• Draining grease in a way different from the one described below is very dangerous.

Also bear in mind the safety instructions on this page.

☞ Slowly open the lubricating valve A by 1 turn to allow the grease to flow out. ☞ Place a suitable container underneath to collect the grease. ➥ The grease flows out of the groove of the lubricating valve. ☞ Retighten the lubricating valve A. ☞ Check the tension is correct by starting the engine, letting it run at idling speed and A Fig. 48: Reducing track tension

slowly moving the machine forwards and reverse and switching it off again.

☞ Check the tension of the tracks again. ➥ If it is not correct: ☞ Adjust again.

Environment!

Use a suitable container to collect the grease as it flows out and dispose of it in an environmentally friendly manner.

3-47

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

Maintenance 3.16 Replacing tracks Proceed as follows:

☞ Raise and jack up the machine. ☞ Reduce track tension – see chapter Reducing track tension on page 3-47. ☞ Replace the track. ☞ Further procedure in the reverse order. ☞ Check track tension – see chapter Checking track tension on page 3-46

3.17 Travelling drive Danger!

Immediately after switching off the engine, the engine's components and the oil are very hot. This can cause burns.

If the inside of the drive gear is under pressure, the oil or the plug can be squeezed out.

Danger of injury and scalding!

Fig. 49: Travelling drive

☞ Wait until the engine has cooled down before taking up work. ☞ Slowly open the plug to reduce the pressure inside.

Checking the oil level and filling up oil A B

Fig. 50: Checking the oil level

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

☞ Park the machine on firm and horizontal ground. ☞ Place the machine so that filler plug A is at the top. ☞ Switch off the engine. ☞ Let the engine cool down. ☞ Fold up the safety bars. ☞ Unscrew screws A + B with a suitable tool. ☞ A small quantity of oil must flow out of opening B. ➥ If the oil does not flow out of opening B, fill up oil: ☞ Fill in oil through opening A, ➥ until a small quantity of oil flows out of opening B. ☞ Screw screws A and B back in again. ☞ Move the machine a few metres. ☞ Check the oil level again. ➥ If the oil level is not correct: ☞ Repeat the procedure.

3-48

Maintenance Draining oil A B

Fig. 51: Draining oil

☞ Park the machine on firm and horizontal ground. ☞ Place the machine so that filler plug B is at the bottom. ☞ Switch off the engine. ☞ Let the engine cool down. ☞ Fold up the safety bars. ☞ Unscrew screws A and B with a suitable tool. ➥ The oil now flows out of opening B. ☞ Use a suitable container to collect the oil as it drains.

Environment!

Collect the oil with a suitable container and dispose of it in an environmentally friendly manner.

3.18 Lubrication work Apply multipurpose lithium grease with an MoS² additive to all lubrication points indicated.

Loader unit

☞ Apply grease to lubrication points O.

• The grease nipples are located on the pins on the inside of the chassis.

Lubricate a total of 8 pins.

Notice!

Lubricate every 500 service hours or according to the maintenance plan.

Fig. 52: Loader unit lubrication points

Lubrication points on the bucket Apply grease to lubrication points O.

Fig. 53: Lubrication points on the bucket

Maintenance of attachments

Notice!

Correct maintenance and service is absolutely necessary for smooth and continuous 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.

3-49

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

Maintenance 3.19 Electrical system Specific safety instructions

• 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 is spilt: Thoroughly rinse all affected surfaces immediately with plenty of water.

Thoroughly wash any part of the body touched by the sulphuric 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 explode.

Replace the battery immediately.

• Avoid naked flames and sparks and do not smoke in the vicinity of open battery cells – otherwise the gas produced during normal battery operation can 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 electrical 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 Fuse box behind the seat on the left on page 2-5.

• Cable and earth connections.

• Battery charge condition – see Battery on page 3-52.

• Condition of battery terminals.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

3-50

Maintenance Instructions concerning specific components

Cables, bulbs. and fuses Always observe the following instructions:

• Defective components of the electrical 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 electrical system, pay particular attention to ensuring good contact in leads and fuses.

• Blown fuses indicate overloading or short circuits. The electrical system must therefore be checked before installing the new fuse.

• Only use fuses with the specified load capacity (amperage) – see Fuse box behind the seat on the left on page 2-5.

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.

3-51

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

Maintenance Battery

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 acid is spilt: Thoroughly rinse all affected surfaces immediately with plenty of water.

Thoroughly wash any part of the body touched by the sulphuric 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!

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.

• Replace the battery immediately.

Always disconnect the negative terminal (–) from the battery before starting repair work on the electrical system.

The battery is located in the legroom area underneath the footrest plate. The battery is “maintenance-free”. However check the battery at regular intervals to make sure the electrolyte level is between the MIN and MAX marks.

Checking the battery requires it to be removed and must be carried out by an authorised workshop.

Always follow the specific battery safety instructions.

Notice!

Do not disconnect the battery while the engine is running.

Jump-starting the engine

Connect the plus lead of the starting aid with the plus lead on the battery of the machine requiring jump-start (always connect with the flat battery first).

Connect the earthing lead of the starting aid to a bare part of the chassis of the machine requiring jump-start (always connect with the flat battery first).

Charge the flat battery for a few minutes (let the engine run).

Start the engine.

Remove the earthing lead of the starting aid from the chassis.

Remove the plus lead of the starting aid from the battery of the machine requiring jump-start.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

3-52

Maintenance 3.20 General maintenance work Cleaning

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. It is therefore essential to observe the following instructions.

General instructions for all areas of the machine Cleaning with washing solvents

• Ensure adequate room ventilation.

• Wear suitable protective clothing.

• Do not use flammable liquids, such as petrol or diesel.

Cleaning with 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.

Cleaning with 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.

Cleaning with volatile and easily flammable anticorrosion agents and sprays:

• Ensure adequate room ventilation.

• Do not use unprotected lights or naked flames.

• Do not smoke.

3-53

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

Maintenance 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 electrical 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 Moist cloth Bristle brush Water with mild soap solution

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 can destroy the fabric.

Under the cab – see Tilting the cab on page 1-15

Caution!

When cleaning under the cab, open the dirt openings in the floor of the chassis first, otherwise the hydraulic hoses can be damaged if they are immersed in water or if the water freezes in winter, reducing the elasticity of the hoses.

Exterior of the machine

The following articles are generally suitable:

• High-pressure cleaner • Steam jet Engine compartment

Danger!

Clean the engine at engine standstill only –

Danger of personal injury!

Switch off the engine before cleaning.

Caution!

When cleaning the engine with a water or steam jet The engine must be cold and do not point the jet directly at electric sensors such as the oil pressure switch.

The humidity penetrating any such sensors causes them to fail and leads to engine damage.

Rear window

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

3-54

Maintenance Danger!

A dirty or foggy rear window offers limited visibility to the rear –

Danger of accidents!

Clean the rear window if it is dirty or foggy.

Screw connections and attachments All screw connections must be checked regularly for tightness, even if they are not listed in the maintenance schedules: Engine fastening screws Fastening screws on the hydraulic system Line and pin fastenings on the attachment Retighten loose connections immediately. Contact an authorised workshop if necessary.

Pivots and hinges 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.

Maintenance of attachments

Notice!

Correct maintenance and service is absolutely necessary for smooth and continuous 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.

3-55

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

Maintenance Maintenance strut of loader unit

Danger!

Failure to use loader unit strut A for maintenance work on the loader unit, or for maintenance work that requires raising the loader unit –

Danger of accidents!

Always use the loader unit strut A when carrying out maintenance work on the (raised) loader unit.

Loader unit strut A may only be installed by a second person.

Always secure loader unit strut A with split pin D. Mount the loader unit strut as follows: Remove the attachment.

Raise the loader unit and have a second person secure it.

E

Remove split pin D from pin E. Remove pin E.

D

Raise the loader unit until strut A makes contact with the piston rod.

Put pin E back into place.

A

Secure pin E with split pin D. Switch off the engine.

Lower the loader unit down to loader unit strut A. Remove the ignition key.

A

Fold up the safety bars.

D E Fig. 54: Loader unit strut

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

3-56

Maintenance

3-57

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp314.fm

Engine

4-1

Fan blade

V-belt

V-belt pulleys

Temperature sensor

Tensioning pulley

Tensioner

Bracket

V-belt

Water pump

Starter

Exhaust gas turbocharger

Exhaust manifold

Charge-air line

4.1

Valve cover

Oil filler neck

Engine

Engine

Engine

TD2011 L04W

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

Engine oil filter

Engine oil cooler

Oil dipstick

Fuel pump

Oil pressure switch

Oil filler neck

Fuel injection pump

Alternator with voltage regulator

Fuel injector

Engine

4-2

Tank

Fuel filter with water separator (external)

Ve nt

4-3 Feed line

Fuel feed pump

4.2

Tank

Fuel injection pump

Engine

Fuel system

Reflux

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

Engine 4.3

Checking and adjusting valve clearance Standard setting of valve 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 (176 °F)

Notice!

Increase valve clearance by 0.1 mm (0.04”) every time the cylinder-head gasket is replaced. Set the standard valve clearance after 1500 s/h.

Fig. 1:

Turn the engine

With the cylinder-head cover removed Turn the engine until the valves on cylinder no. 1 overlap.

Notice!

Valve overlapping means that the exhaust valve is not closed yet and the intake valve starts to open. Both push rods cannot be rotated.

Fig. 2:

Valve overlapping

Set valve clearance on the cylinder with a feeler gauge.

Inlet valve clearance:

0.3 mm (0.012”)

Exhaust valve clearance:0.5 mm (0.02”) Tighten the locknut.

Tightening torque: 20 ± 2 Nm (14.8 ± 1.5 ft. lbs.)

Check the setting again with the feeler gauge.

Fig. 3:

Setting valve clearance

Carry out the settings for each cylinder.

Put the gasket in place.

Fig. 4:

Put the valve cover gasket in place

Slide the new rubber hoses onto the overflow line and fuel injectors as far as they will go.

Install the valve cover and the overflow line.

Tighten the screws.

Tightening torque: 8.5 Nm (6.3 ft. lbs.)

Fig. 5:

Mounting the valve cover

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

4-4

Engine 4.4

Checking and adjusting the fuel injectors Notice!

Ensure utmost cleanliness when working on the fuel injection system. Use only pure calibrating oil as per ISO 4113 or clean diesel fuel for checking the fuel injectors.

Caution!

Keep your hands away from the nozzle jet. Otherwise the fuel penetrates deeply into your flesh and can cause blood poisoning.

Mount the fuel injector onto the nozzle tester

Fig. 6:

Compression

Checking opening pressure Slowly press down the lever of the nozzle tester with the pressure gauge switched on.

The opening pressure is the pressure at which the needle remains or suddenly drops.

Opening pressure for new setting: 210 + 8 bar (3046 + 116 psi) Adjusting opening pressure Unscrew the union nut.

Remove all parts.

Order in which the parts are removed: 1. Union nut 2. Fuel injector 3. Intermediate piece 4. Thrust pin 5. Tension spring 6. Shim

Fig. 7:

4-5

Fuel injector

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

Engine The pressure is set by selecting the correct shim.

Thicker shim = higher opening pressure Thinner shim = lower opening pressure Re-assemble the fuel injector.

Tighten the union nut.

Tightening torque: 45 ± 5 Nm (33.2 ± 0.7 ft. lbs.)

Check the injection nozzle again with the nozzle tester.

Checking for leaks Dry the nozzle holder and the fuel injector with air.

Slowly press down the manual lever of the nozzle tester until reaching about 20 bar (about 290 psi) less than the opening pressure read before.

The fuel injector is tight if there are no drops within 10 seconds.

If there is a drop, dismantle and clean the fuel injector. Replace the injection nozzle if this does not lead to any satisfactory results.

No rework is allowed!

Clatter check and spray pattern Switch of the pressure gauge of the nozzle tester.

Checking clatter allows you to audibly check whether the nozzle needle moves freely and easily in the nozzle body. New fuel injectors have a different clatter behaviour with regard to used fuel injectors.

Wear in the area of the needle seat causes clatter behaviour to degrade. Replace an injection nozzle by a new one if it does not clatter in spite of having been cleaned.

At rapid lever activity, a used fuel injector must clatter audibly and eject the fuel in a fine spray. The injection pattern can differ significantly from that of a new injection nozzle.

Fig. 8:

Compression

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

4-6

Engine 4.5

Replacing the injection pump/setting fuel injection time Unscrew the crankcase screw plug.

Fig. 9:

Crankcase screw plug

Move the control rack to centre position.

Screw in the adjusting pin for the control rack into the crankcase as far as it will go.

Adjusting pin

Fig. 10: Setting the control rack

Turn the camshaft until the tappet stroke of a specific cylinder is at BDC.

Fig. 11: Camshaft

Mount the injection pump tappets.

Notice!

Use a flexible magnetic lifter.

Fig. 12: Mounting the tappets

4-7

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

Engine Determine the compensation gasket

Fig. 13: Determining the compensation gasket

Measure depth “A” from the crankcase contact surface to the spring seat contact surface on the tappet.

Fig. 14: Measuring the spring contact surface on the tappet

Assembly dimension “X” of injection pump = 60 mm (2.36”)

Notice!

The assembly dimension “X” is used for calculating the compensation gasket and cannot be measured on an injection pump that has been removed.

Determine the difference between assembly dimension “X” and depth “A”.

Fig. 15: Injection pump assembly dimension

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

Example: Assembly dimension “X” = 60.00 mm (2.36”) Depth “A” = 59.35 mm (2.34”) Difference = 0.65 mm (0.02”)

4-8

Engine Select a compensation gasket according to the table and the mark.

Difference determined (mm/”)

Mark size (mm/”)

Up to 0.4/0.016

9 ,0/0.35

0.401 – 0.5/0.016 – 0.020

12.0 / 0.47

0.501 – 0.6/0.020 – 0.024

15.0 / 0.59

0.601 – 0.7 / 0.024 – 0.028

18.0/0.71

0.701 – 0.8 / 0.028 – 0.031

21.0 / 0.83

0.801 – 0.9 / 0.031 – 0.035

24.0 / 0.94

0.901 – 1.0 / 0.035 – 0.039

27.0 / 1.06

Fig. 16: Compensation gaskets

Place a matching compensation gasket.

Notice!

Bear in mind the installation position.

Fig. 17: Placing the compensation gaskets

Remove the plug pin from the injection pump.

Fig. 18: Plug pin

4-9

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

Engine Before mounting the injection pump, make sure lock wire has locked into place into the control-sleeve lever.

Fig. 19: Lock wire

Mount the injection pump.

Press down the injection pump centrically as far as it will go.

Tighten the nuts.

Tightening torque: 21 Nm (15.5 ft. lbs.)

Fig. 20: Mounting the injection pump

Pull out the lock wire.

Fig. 21: Pulling out the lock wire

Close the hole with the plug pin.

Fig. 22: Hole with plug pin

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

4-10

Engine Remove the adjusting pin for the control rack.

Fig. 23: Control rack adjusting pin

Tighten the screw plug with a new copper sealing ring.

Tightening torque: 18 Nm (13.3 ft. lbs.)

Fig. 24: Screw plug

4.6

Adjusting engine revs Notice!

A

Maximum engine revs are sealed in the factory and may not be modified.

Adjust engine revs without load Run the diesel engine until it reaches operating temperature.

Check idling speed A and maximum revs B with all attachment functions in neutral.

Idling speed: 1400 ± 50 rpm Max. revs: 2700 ± 50 rpm Adjust according to Fig. 25 if values differ.

B

Fig. 25: Adjusting engine revs

4-11

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

Engine 4.7

Compression pressure Checking and adjusting Switch off the engine.

Remove the ignition key and carry it with you.

The fuel injectors have been removed, the valve clearance has been checked.

Remove the connector from the cutoff solenoid.

Use a special tool (so-called “Connecting piece”) with a special seal.

Put a clamping clip in place.

Tighten the screw.

Screw on an adapter for the connecting piece if necessary.

Connect the compression pressure tester.

Turn the engine with the starter.

Compression pressure: 25 – 30 bar (363 – 435 psi)

The compression pressure depends on the starting revs during measurement and on the geographical altitude, see Fig. 26.

This is why threshold values cannot be exactly specified.

We recommend regarding the compression pressure measurement only as a comparative measurement of all cylinders of one single engine. In case of deviations of over 15 %, remove the affected cylinder unit to determine the cause.

Plug the connector back onto the cutoff solenoid.

Notice!

Mount and tighten the fuel injectors with new special seals.

Tightening torque: 21 Nm (15.5 ft. lbs.)

Mount and tighten the fuel injection lines.

Tightening torque: 25 ± 2.5 Nm (18.4 ± 1.8 ft. lbs.)

Fig. 26: Compression

Slide the new rubber hoses onto the overflow line and fuel injectors as far as they will go.

Mount the overflow line.

Tightening torque: 8.5 Nm (6.3 ft. lbs.)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

4-12

Engine 4.8

Removing/mounting the cylinder head Determine the cylinder-head gasket mark (see circle) Piston projection (mm/”)

Mark (notch)

0.530 – 0.690 / 0.021 – 0.027

1 notch

0.691 – 0.760 / 0.027 – 0.03

2 notches

0.761 – 0.830 / 0.03 – 0.033

3 notches

Fig. 27: Determining the cylinder-head gasket

Remove the valve cover.

Fig. 28: Removing the valve cover

Remove the rocker arm brackets.

Fig. 29: Removing the rocker arm bracket

Remove the valve tappets.

Fig. 30: Removing the valve tappets

4-13

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

Engine Carefully raise the cylinder head off the engine block.

Fig. 31: Removing the cylinder head

Make sure no straight pins are missing.

Fig. Fig.32: 32: Straight Straightpins pins

Place the cylinder-head gasket.

Caution!

The sealing surfaces must be oil-free.

Fig. 33: Putting the cylinder-head gasket in place

Check the length of the cylinder-head bolts.

150 ± 0.8 mm (5.9” ± 0.03”) Mount the cylinder head.

Apply a thin coat of oil to the cylinder-head bolts.

Fig. 34: Putting the cylinder-head gasket in place

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

4-14

Engine Mount the cylinder-head bolts.

Tightening torques: • 1st pass 30 Nm (22 ft. lbs.)

• 2nd pass

80 Nm (59 ft. lbs.)

• 3rd pass

160 Nm (118 ft. lbs.)

• Retightening angle: 90°

8 10

6

4 5 Manifold side 3 1 2

9 7

Caution!

Bear in the mind the order for tightening the cylinder-head bolts.

See figure

Fig. 35: Mounting the cylinder-head bolts

Insert the push rods.

Fig. 36: Inserting the push rods

Insert the rocker arm bracket and align it with the push rods.

Tightening torque: Set valve clearance.

21 Nm (15.5 ft. lbs.)

Fig. 37: Mounting the rocker arm bracket

Place the valve cover gasket.

Mount the valve cover Tightening torque:

8.5 Nm (6.3 ft. lbs.)

Fig. 38: Mounting the valve cover

4-15

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

Engine 4.9

Sealing the breather valve Remove the cover.

Clean the breather valve.

Install a new O-ring.

Install the cover.

Tightening torque:

8.5 Nm (6.3 ft. lbs.)

Fig. 39: Bleeder valve

4.10 Sealing the intake/exhaust manifold Mount the new gaskets.

Mount the intake/exhaust manifold.

Tightening torque Intake manifold: Exhaust pipe

21 Nm (15.5 ft. lbs.)

55 Nm (40.6 ft. lbs.)

Fig. 40: Intake manifold gaskets

4.11 Oil pressure switch Remove the cable connection from the oil pressure switch Start the engine, check for correct idling speed Measurement prod

Measure the resistance of the oil pressure switch as shown by means of an ohmmeter.

Oil pressure switch OK: infinite resistance The oil pressure switch is defective if the oil can pass

Fig. 41: Oil pressure switch

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

4-16

Engine 4.12 Switching off minus compensation

Switching off minus compensation Fig. 42: Minus compensation

4-17

During the starting phase, the engine receives more fuel by means of the start quantity spring.

In order to prevent minus compensation from counteracting, and hence cancelling, the additional start quantity, minus compensation is switched off with a solenoid (terminal 50).

This is achieved with the help of the solenoid that separates the reversing lever from the compensating lever.

In some injection systems, the fuel increase is too strong as revs drop. This means that the engine receives more fuel than fresh air.

The engine smokes The fuel quantity must be reduced Function of minus compensation The reversing lever is loosely connected with the compensating lever. If the engine runs under load, revs drop and the compensating lever moves towards a higher quantity.

This movement is reversed by the reversing lever, and the control rod is moved towards a lower quantity.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

Engine 4.13 Turbocharger

Pos.

Description

Charge-air pressure: 0.9 bar (13 psi) ± 10 %

Pos.

Description

1

Exhaust turbocharger

2

Stud

3

Seal

4

Flange

5

Hexagon nut

6

Banjo bolt

7

Sealing ring

8

Lubrication line

9

Sealing ring

10

Connection piece

11

O-ring

12

Reflux line

13

Sealing ring

14

Hexagon head screw

15

Seal

16

Clamp

17

Rubber sleeve

18

Manifold

19

Hexagon head screw

20

Seal

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

4-18

Engine Engine trouble Problem

Possible causes Wrong SAE viscosity/oil grade of engine lubrication oil Fuel grade does not comply with specifications Defective or flat battery Loose or oxidised cable connections to starter Defective starter, or pinion does not engage Wrong valve clearance Defective fuel injector Defective starting relay

Engine does not start or is not easy to start

Defective preheating system Defective solenoid switch Battery master switch switched off Dirty fuel filter Very dirty air filter/defective exhaust gas turbocharger Cutoff solenoid does not attract Cutoff solenoid without current High pressure created immediately in the hydraulic system Air in fuel system Fuel grade does not comply with specifications Wrong valve clearance Injection line leaks

Engine starts, but does not run smoothly or faultless

Defective fuel injector Dirty fuel filter Very dirty air filter Air in fuel system Lube oil level too low Lube oil level too high Dirty air filter/defective exhaust gas turbocharger Dirty cooler fins

Engine overheats. Temperature warning system responds.

Defective fan, torn or loose V-belts Resistance in cooling system too high, flow capacity too low Defective fuel injector Not enough coolant Defective coolant pump

4-19

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

Engine Problem

Possible causes Lube oil level too high or too low Fuel grade does not comply with specifications Dirty fuel filter Dirty air filter/defective exhaust gas turbocharger

Insufficient engine output

Wrong valve clearance Injection line leaks Defective fuel injector Air in fuel system Injection line leaks

Engine does not run on all cylinders

Defective fuel injector/injection pump Lube oil level too low

Insufficient or no engine oil pressure

Engine inclination too high Wrong SAE viscosity/oil grade of engine lubrication oil Lube oil level too high Engine inclination too high

Engine oil consumption too high

Wrong SAE viscosity/oil grade of engine lubrication oil Worn oil scraper rings Lube oil level too high Blue

Engine inclination too high Engine oil combustion (defective cylinder-head gasket) Worn oil scraper rings Engine starting temperature too low Fuel grade does not comply with specifications

Engine smoke

White

Defective fuel injector Exteme misalignment of injection time Coolant combustion (defective cylinder-head gasket) Dirty air filter/defective exhaust gas turbocharger Defective fuel injector (drips)

Black

Wrong fuel injection pump setting Wrong valve clearance Dirty injection nozzle

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

4-20

Engine

4-21

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp410.fm

Hydraulic system

Hydraulic system

Hydraulic system

5

Hydraulic system The drive hydraulics system is a closed system. The work hydraulics systeme is an open circuit.

5.1

Rexroth AA20 VG45 hydraulic pump Double variable displacement pump + twin gear pump

7 6 10 3

8

4

5 12

3

11

2

9

1 1

Variable displacement pump unit Pos. 1 2 3 4 5 6 7 8 9 10 11 12

5-1

Gear pump unit

Description Tank suction side Pilot control port – right, forwards driving Swash plate stroke limitation Right-hand side hydraulic motor (port B) Right-hand side hydraulic motor (port A) Left-hand side hydraulic motor (port A) Left-hand side hydraulic motor (port B) Boost pump supply Y = P supply drive (left-hand side joystick) with ISO controls Pilot control port – left, forwards driving Gear pump output – Power Flow supply (1101cp) Gear pump output – work hydraulics supply (1101c) Gear pump output – work hydraulics supply/3rd control circuit supply (1101cp)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system

Pump 1 G

G

Pump 2 A

F

C B

B

E H

Pos.

E

E D E

Description

A

Pilot control port X4

B

Mechanical zero-position setting

C

Speed-sensitive control valve

D

P supply (right-hand side joystick)

E

High pressure limiting valve

F

Pilot control port X4

G

Housing vent

H

Boost pressure valve

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

5-2

Hydraulic system Pump unit: exploded view

3

4

1 6 5

2

5

Pos.

5-3

5

Description

1

Drive unit (rotation to the left)

2

Drive unit (rotation to the right)

3

Control disc (rotation to the left)

4

Control disc (rotation to the right)

5

Pressure limiting valve

6

DA adjusting cartridge

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system Pump distribution Model 1101c

Model 1101cp

Variable displacement pump Drive section

Drive section

Pump 1

Supply of left-hand side hydraulic motors

Supply of left-hand side hydraulic motors

Pump 2

Supply of right-hand side hydraulic motors

Supply of right-hand side hydraulic motors

Pump 3

Main valve block supply

Main valve block supply

Pump 4

Boost pump

Section 3rd control circuit Power Flow

Pump 5

-----

Boost pump supply

Variable displacement pump Pump 1

Pump 2

Pump 3

Variable displacement pump Pump 1 (45 cm3/2.75 cu. in.)

Pump 2 (45 cm3/2.75 cu. in.)

Supply of left-hand side hydraulic motors

Supply of right-hand side hydraulic motors

Pump 4

Pump 3 (34 cm3/2.1 cu. in.)

Pump 4 (19 cm3/1.16 cu. in.)

Control valve supply

Boost pump/supply of 3rd control circuit Power Flow (1101cp)

Pump 5 (1101cp option)

A Pump 5 (19 cm3/1.16 cu. in.) (1101cp option) Boost pump supply A...position of SP pump

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

5-4

Hydraulic system 5.2

Main valve block

Ports and valves

P Pressure limiting valve

1 B1

A1

2

Loader unit

1 B2

Bucket

A2 4

1

Auxiliary hydraulics

A3

B3

T

C

Legend

Control lines Port

Legend

Oil supply by (ISO)

A1

Controls loader unit raising

Right-hand side joystick (backwards)

B1

Controls loader unit lowering

Right-hand side joystick (forwards)

A2

Bucket ram control (extend)

Right-hand side joystick (to the right)

B2

Bucket ram control (retract)

Right-hand side joystick (to the left)

A3

Auxiliary hydraulics control (left)

Auxiliary hydraulics pedal

B3

Auxiliary hydraulics control (right)

Auxiliary hydraulics pedal

Pump/tank lines

5-5

Port

Legend

P

Gear pump port

T

Tank line via pressure filter to boost pressure port of pump

C

Additional pressure line for Power Flow (option) SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system Main valve block diagram

A

Pressure limiting valve 1 3 Loader unit 2

1

4

Bucket 1 3

Auxiliary hydraulics

B

Pos.

Description

A

Gear pump input

B

Output via reflux filter to tank/boost pump port

Valves Description

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

1

Non-return valve (direct-controlled load retaining valve)

2

Non-return valve (anticavitation valve)

3

Pressure limiting valve (secondary, antishock)

4

Pressure limiting/anticavitation valve

5-6

Hydraulic system 5.3

Hydraulic control

Control lever

• F1 drive control • F2 work hydraulics control

F2

F1

Left-hand side control lever F1, right-hand side control lever F2

ISO controls

H controls option

Actuation of left-hand side lever (F1)

Reaction

Reaction

Control lever (left)

Machine turns to the left

Lowers the loader unit

Control lever (right)

Machine turns to the right

Raises the loader unit

Control lever forwards

Machine moves forwards

Travelling drive to the front left

Control lever backwards

Machine reverses

Travelling drive to the rear left

Control lever fully to the front left into the engaged position Actuation of right-hand side lever (F2) Control lever (left) Control lever (right) Control lever forwards

Reaction

Reaction

Dumps out the attachment Tilts in the attachment Lowers the loader unit

Tilts in the attachment Dumps out the attachment

Control lever backwards

Raises the loader unit

Control lever fully to the front right into the engaged position

Lowers the loader unit to float position

Travelling drive to the rear right -

Float position

5-7

Lowers the loader unit to float position

Travelling drive to the front right

In float position, the loader unit rams are short-circuited on the rod and base sides. This allows attachments to follow the profile of the ground and to remain flat on the ground at all times.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system Joystick (left)

1-a 1 MA = 50 Nm

76

87 6 10

24 3

610

MA = 1,5 Nm Loctite 262 MA = 40 Nm

2 1

3-a 4

3-d 5

3 4

19 9

MA = 50 Nm

6 21 11

10 20

MA = 18 Nm

Pos. 1 3 5 7 9 11

o

Description Handle Stud Hexagon nut M12 Universal joint Sealing kit Shuttle valve plate sealing kit (ISO only)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Pos. 2 4 6 8 10

Description Rubber collar Curved lever Tappet Retaining plate Shuttle valve plate (ISO only)

5-8

Hydraulic system

ISO characteristic curves (left-hand side joystick):

Ports:

Pressure (bar) Ports 1 – 3 22.4±2.3

17±1.7

Joystick angle (°)

7.6±0.75 18°15' ±2°

Pressure (bar) Ports 2 – 4 22.7

±3

Joystick angle (°) 5±0.75

Port

5-9

Description

Port

Controlled via port

1

Reverse driving (ports E and F)

1

E and F

2

Turn to the left (ports C und F)

2

C and F

3

Forwards driving (ports C and D)

3

C and D

4

Turn to the right (ports D and E)

4

D and E

P

Pilot control pressure

T

Tank line

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system

Characteristic curve of H controls option (left-hand side joystick): Pressure (bar)

Ports:

Joystick angle (°)

Joystick angle (°) X

22.4±2.3 17±1.7

Joystick angle (°)

7.6±0.75 18°15' ±2°

x...angle from which the float position is active

Port

Description

Port

Controlled via port

1

Raise loader unit

1

1

2

Travelling drive to the front left

2

2

3

Lower loader unit or float position

3

3

4

Travelling drive to the rear left

4

4

P

Pilot control pressure

T

Tank line

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

5-10

Hydraulic system Joystick (right)

MA = 40 Nm

1 67 MA = 50 Nm

2 8 7 3 6 10 MA = 1,5 Nm

6 10 Loctite 262 MA = 40 Nm

17-r 9 2 1

3 4

4 3-a

3-d 5

10

11 MA = 18 Nm

12 19

MA = 50 Nm

6 Pos. 1 3 5 7 9 11 5-11

Description Handle Stud Hexagon nut M12 Universal joint with notch Solenoid Screw M4 x 8

Pos. 2 4 6 8 10 12

Description Rubber collar Curved lever Tappet Retaining plate 2-pin connector Sealing kit

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system

ISO characteristic curves (right-hand side joystick):

Ports:

Pressure (bar) Ports 1 – 2 – 4

Joystick angle (°)

Pressure (bar) Port 3

Joystick angle (°)

x

x...angle from which the float position is active

Port

Description

Port

Controlled via port

1

Raises the loader unit

1

1

2

Tilts in the attachment

2

2

3

Lowers the loader unit/lowers it to float position

3

3

4

Dumps out the attachment

4

4

P

Pilot control pressure

T

Tank line

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

5-12

Hydraulic system

Characteristic curve of H controls option (right-hand side joystick): Pressure (bar)

Ports:

Joystick angle (°)

22.4±2.3 17±1.7

Joystick angle (°)

7.6±0.75

18°15' ±2°

Port

5-13

Description

Port

Controlled via port

1

Travelling drive to the rear right

1

1

2

Tilts in the attachment

2

2

3

Travelling drive to the front right

3

3

4

Dumps out the attachment

4

4

P

Pilot control pressure

T

Tank line

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system Auxiliary hydraulics control

• Control valve (rocker pedal version)

4

6

3 2 6

Additional controls (exploded view)

1 Pos. 1 2 3 4 5 6

Description Pilot control unit Pedal Shift lever Lock console Set of tappets Lock/cover

Function Main valve block segment (A) is actuated by means of a control linkage (2) mounted on control pedal (4). Pressing the pedal forwards or backwards actuates the auxiliary hydraulics segment on the main valve block.

Danger!

Unintentional actuation of the auxiliary hydraulics pedal – A Additional hydraulic segment

Danger of accidents! ☞ Always lock the pedal if it is not needed.

Fold up cover 6 to actuate the auxiliary hydraulics pedal. Auxiliary hydraulics pedal 2 can then be pressed to the left or right.

Adjustment

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

The control pedal is set by means of the control linkage threads. At maximum actuation in either direction, the pedal must have its maximum control effect on the main valve block segment.

5-14

Hydraulic system 5.4

Travelling drive

Function

The hydraulically pilot-controlled travelling drive features the well-known standard load limit sensing control (integrated in the tandem pump) that creates an ideal balance between the required hydraulic output and the available maximum engine output at any give time. Engine output is therefore always in the optimal speed range, the engine cannot be stalled and therefore runs without any unnecessary strain or loads.

General The diesel engine permanently drives two axial-piston variable displacement pumps whose oil flow is sent to the right and left-hand side hydraulic motors.

Driving: Actuating the control lever causes the swash plate of the pump to swivel.

Swash plate swivel creates high pressure at outputs A or B (depends on the direction in which the control lever is actuated).

This pressure drop has its effect on the motor, and drives the motor via the oil flow (forwards or reverse, depending on the direction in which the control lever is actuated).

Brakes: Moving the control levers to neutral interrupts the oil flow. There is no pressure drop at the motors. This creates a generator effect, i.e. the motor tries to keep on turning and brakes itself in doing so (hydrostatic brake).

Parking brake: The gear pump 19 cm3 (1.16 cu. in.) doubles up as the boost pump for the double variable displacement pump (tandem pump). Boost pressure is 27 bar (392 psi). This pressure also opens the brake discs in the gearbox. Switching off the diesel engine causes this pressure to drop and to enable the brake. If the engine is running, the brake lever must be actuated for fully intentional braking as usual.

5-15

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system Travelling drive

Pos. 1 2, 3, 4

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Description Travelling drive Screw connections

5

Hydraulic motor

6

Seal

7

O-ring

8

Plug

9

Circlip

10

Sealing ring

11

Control spool

12

Valve set

13

Engine brake set

14

Hydraulic motor sealing kit

5-16

5-17

4

work.

2

☞ Always allow the oil to cool down before carrying out (repair)

Danger of burns!

These components and the oil are very hot after switching off the engine.

Danger!

2 3 4 5 6

Pos. 1

3

Description Axial piston variable displacement pump Hydraulic oil tank Travelling drive (right) Travelling drive (left) Joystick 3/2 directional valve 5

1

6

Hydraulic system

Travelling drive layout

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system 5.5

Valves

Auxiliary hydraulics pilot valve Hydraulic diagram

Characteristic curve

Pressure (bar)

28

2,5

6 0,95

1°30' à 2°30'

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

4,95

9°35' à 11°

5,8

Tappet stroke (mm)

11°30' à 12°30'

Pedal

5-18

Hydraulic system Distributing block with brake (brake valve) Hydraulic diagram

CT1 TP1

A PS1 PS1

TP1 PS2

IN OUT

B

TP2

PS2 CT1

TP2 3/2 directional valve

ISO controls (with Power Flow)

Pos.

1

3

2

Description

1

2nd speed

2

Working

3

Driving

↓

Driving direction

H controls (without Power Flow)

1

5-19

2

3

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system Single parallel bucket lift (switched for upwards movement) Function Actuating parallel bucket lift keeps the bucket at the preset angle with respect to the ground. The bucket does not need to be corrected manually when raising the loader unit, it always remains parallel to the ground as it is raised. This is especially beneficial when using pallet forks.

Bucket ram action is always automatically corrected in order to maintain the correct angle.

Lowering the bucket deactivates the parallel lift.

Hydraulic diagram B C A D

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Port

Legend

A

Loader unit (rod)

B

Control valve 1st segment (port B)

C

Bucket ram (rod)

D

Bucket ram (base)

5-20

1

2

3

5-21 Parallel lift valve

2

4

Loader unit ram

Left-hand side H controls joystick (option)

Right-hand side ISO joystick

Main valve block

1

3

Legend

Port

4

Hydraulic system Loader unit control layout

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system

2

3

1

4

Bucket actuation layout

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Port

Legend

1

Main valve block

2

Parallel lift valve

3

Joystick (right)

4

Bucket ram

5-22

Hydraulic system 5.6

Breather filter The breather filter is in charge of:

• Air intake and outlet for pressure compensation in the hydraulic oil tank (varying oil level) – prevents the oil tank from inflating.

• Pre-tension of the oil tank to the specified overpressure -> supports the variable displacement pump's suction.

• Filtering the intake air.

• Opens at 0.4 bar (5.8 psi).

The breather filter is located under the engine cover.

Replace the breather filter according to the instructions in the maintenance plan – see Maintenance plan (overview) on page 3-5.

Notice!

The breather filter must be replaced at 1000 s/h under all circumstances.

Fig. 1:

Breather filter position

Pos. 1 2

Description Filter fabric Bleeder valve

1 2 Fig. 2:

5.7

Breather filter

Auxiliary hydraulics connections Ports A and B of the auxiliary hydraulics are both pressure and reflux lines. Both ports can be connected depending on the desired function of the auxiliary hydraulics pedal.

C

Socket C for attachment control is installed as an option.

A

5-23

B

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system 5.8

Quickhitch system Attachments are fitted and removed from the loader unit by means of the quickhitch. If you are fitting or removing attachments with their own hydraulic functions – e.g. rotary broom or auger – you must follow the special information given in the Operator's Manual of the attachment. Also refer to the Operator's Manual of the attachment for the procedure to follow for fitting an attachment onto a quickhitch. Chapter 3.40 “Re-equipping the loader unit” in the Operator's Manual describes how attachments are fitted and removed from the loader unit.

5.9

Emergency lowering At engine standstill, or if there is a defect in the hydraulic system, the loader unit is lowered by means of emergency lowering. This works only if the safety bar is closed

5.10 Troubleshooting in the hydraulic system Problem

Possible causes Hydraulic oil level too low Defective pressure limiting valve on main valve block

Hydraulic system without function

Spool is stuck.

Hose rupture (work hoses) Defective connection on solenoid valve

Driving without actuating the control levers, more propulsion on Misalignment of neutral position – slackened fastening nut one side Brake is released.

Defective brake valve Quickhitch couplings not connected correctly

Hydraulic hammer does not work correctly.

Hydraulic oil quantity too high/too low Hydraulic oil pressure too high/too low

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

5-24

Hydraulic system 5.11 Hydraulics diagram ISO standard (1101c)

Right-hand side hydraulic motor

Left-hand side hydraulic motor

5-25

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system Hydraulics diagram – legend (1101c) Pos. 2 3 4 5 6 15 17 20 22 23 26 29 30 31 32 33 34 35 38 39 42 43 44 45 47 48 49

Pressure accumulator

Tank line

Spring-loaded solenoid valve

Measuring port

Stop cock

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Pressure limiting valve

Non-return valve

Description Diesel engine Double variable displacement pump Twin gear pump Right-hand side joystick (ISO controls, hydraulics unit only) Left-hand side joystick (ISO controls, hydraulics unit only) Work hydraulics main valve block (standard without Carry Over) Internal throttle valve Parallel bucket lift valve Auxiliary hydraulics pilot valve (auxiliary hydraulics pedal) 3/2 directional valve cartridges with housings (safety valves) Bladder type accumulator (accumulator boost pressure) Distributing block with brake (brake valve) Distributing block Breather filter with screen Temperature switch Radiator Fan blade Oil filter Pressure switch (brake valve ON/OFF) Pressure switch Pressure switch Left + right-hand side loader unit rams Right-hand side bucket ram Left-hand side bucket ram Left and right-hand side hydraulic motors Pilot control filter Non-return valve

Fixed displacement motor

Throttle orifice

Variable displacement Fixed displacement Double variable motor pump displacement pump

Oil cooler

Filter

Double-acting ram

5-26

Hydraulic system 5.12 Hydraulics diagram ISO standard (1101cp)

Right-hand side hydraulic motor

Left-hand side hydraulic motor

5-27

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system Hydraulics diagram – legend (1101cp) Pos. 2 3 4 5 6 7 16 17 18 20 22 23 26 29 30 31 32 33 34 35 36 38 39 42 43 44 45 47 48 49

Pressure accumulator

Tank line

Spring-loaded solenoid valve

Pressure limiting valve

Measuring Stop cock port

Non-return valve

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Description Diesel engine Double variable displacement pump Twin gear pump Boost pump Right-hand side joystick (ISO controls, hydraulics unit only) Left-hand side joystick (ISO controls, hydraulics unit only) Work hydraulics main valve block (Power Flow with Carry Over) Internal throttle valve Electric Power Flow valve Parallel bucket lift valve Auxiliary hydraulics pilot valve (auxiliary hydraulics pedal) 3/2 directional valve cartridges with housings (safety valves) Bladder type accumulator (accumulator boost pressure) Distributing block with brake (brake valve) Distributing block Breather filter with screen Temperature switch Radiator Fan blade Oil filter Speed Control valve Pressure switch (brake valve ON/OFF) Pressure switch Pressure switch Left + right-hand side loader unit rams Right-hand side bucket ram Left-hand side bucket ram Left and right-hand side hydraulic motors Pilot control filter Non-return valve 8 PL

Fixed displacement motor

Throttle orifice

Variable displacement Fixed displacement Double variable motor pump displacement pump

Oil cooler

Filter

Double-acting ram

5-28

Hydraulic system 5.13 Hydraulics diagram H controls with options (1101c) Joystick (left) Joystick (right)

Right-hand side hydraulic motor

Left-hand side hydraulic motor

5-29

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system Hydraulics diagram H controls with options (1101c): legend Pos. 1

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Description Diesel engine

3

Double variable displacement pump

4

Twin gear pump

9

Right-hand side joystick (H controls, hydraulics unit only)

Option

10

Left-hand side joystick (H controls, hydraulics unit only)

Option

15

Work hydraulics main valve block (standard without Carry Over)

17

Internal throttle valve

19

Changeover valve (work hydraulics lock)

Option

21

Dual parallel bucket lift valve

Option

22

Auxiliary hydraulics pilot valve (auxiliary hydraulics pedal)

23

3/2 directional valve cartridges with housings (safety valves)

24

Solenoid valve (load stabiliser valve; load stabiliser)

Option

25

Option

26

Pressure accumulator (bladder type accumulator for load stabiliser) Bladder type accumulator (accumulator boost pressure)

27

Stabiliser valve

Option

28

Stabiliser distributor valve

Option

29

Distributing block with brake (brake valve)

30

Distributing block

31

Breather filter with screen

32

Temperature switch

33

Radiator

34

Fan blade

35

Oil filter

37

Hydraulic quickhitch system (HQS) option

38

Pressure switch (brake valve ON/OFF)

39

Pressure switch

40

Pressure switch

42

Pressure switch

43

Left + right-hand side loader unit rams

44

Right-hand side bucket ram

45

Left-hand side bucket ram

46

Control ram (HQS)

47

Left and right-hand side hydraulic motors

48

Pilot control filter

49

Non-return valve

Option

Option

Option

5-30

Hydraulic system 5.14 Hydraulics diagram H controls with options (1101cp)

Joystick (right)

Joystick (left)

Right-hand side hydraulic motor

Left-hand side hydraulic motor

5-31

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system Hydraulics diagram H controls with options (1101cp): legend Pos.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

2

Description Diesel engine

3

Double variable displacement pump

4

Twin gear pump

5

Boost pump

9

Right-hand side joystick (H controls, hydraulics unit only)

Option

10

Left-hand side joystick (H controls, hydraulics unit only)

Option

16

Work hydraulics main valve block (Power Flow with Carry Over)

17

Internal throttle valve

18

Electric Power Flow valve

19

Changeover valve (work hydraulics lock)

Option

21

Dual parallel bucket lift valve

Option

22

Auxiliary hydraulics pilot valve (auxiliary hydraulics pedal)

23

3/2 directional valve cartridges with housings (safety valves)

24

Solenoid valve (load stabiliser valve; load stabiliser)

Option

25

Option

26

Pressure accumulator (bladder type accumulator for load stabiliser) Bladder type accumulator (accumulator boost pressure)

27

Stabiliser valve

Option

28

Stabiliser distributor valve

Option

29

Distributing block with brake (brake valve)

30

Distributing block

31

Breather filter with screen

32

Temperature switch

33

Radiator

34

Fan blade

35

Oil filter

36

Speed Control valve

37

Hydraulic quickhitch system (HQS) option

38

Pressure switch (brake valve ON/OFF)

39

Pressure switch

40

Pressure switch

42

Pressure switch

43

Left + right-hand side loader unit rams

44

Right-hand side bucket ram

45

Left-hand side bucket ram

46

Control ram (HQS)

47

Left and right-hand side hydraulic motors

48

Pilot control filter

49

Non-return valve

Option

Option

Option

5-32

Hydraulic system

5-33

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp510.fm

Hydraulic system

Hydraulic system 5.13 Hydraulics diagram ISO standard (1101c)

Left-hand side hydraulic motor

Pos. 1 3 4 6 7 8 15 17 20 22 23 26 29 30 31 32 33 34 35 38 39 42 43 44 45 48 49

Description Diesel engine D2011L04W Double variable displacement pump Twin gear pump 34 cm³/rev (2.1 cu. in./rev) + 19 cm³/rev (1.16 cu. in./rev) Hydraulic motors Right-hand side joystick (ISO controls, hydraulics unit only) Left-hand side joystick (ISO controls, hydraulics unit only) Work hydraulics main valve block (standard without Carry Over) Internal throttle valve Parallel bucket lift valve Auxiliary hydraulics pilot valve (auxiliary hydraulics pedal) 3/2 directional valve cartridges with housings (safety valves) Bladder type accumulator (accumulator boost pressure) Distributing block with brake (brake valve) Distributing block Breather filter with screen Temperature switch 100 °C (212 °F) Radiator Fan blade Oil filter Pressure switch 1 – 10 bar/14.5 – 145 psi (brake valve ON/OFF) Pressure switch 8 bar/116 psi

Right-hand side hydraulic motor

Pressure switch 2 ±0.5 bar/29 ±7 psi Left + right-hand side loader unit rams Right-hand side bucket ram Left-hand side bucket ram Pilot control filter Non-return valve 8 PL

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp511.fm

5-34

Hydraulic system 5.14 Hydraulics diagram ISO standard (1101cp)

Left-hand side hydraulic motor

5-35

Pos. 2 3 4 5 6 7 8 16 17 18 20 22 23 26 29 30 31 32 33 34 35 36 38 39

Description Diesel engine TD2011L04W Double variable displacement pump Twin gear pump 34 cm³/rev (2.1 cu. in./rev) + 19 cm³/rev (1.16 cu. in./rev) Boost pump 19 cm³/rev (1.16 cu. in./rev) Hydraulic motors Right-hand side joystick (ISO controls, hydraulics unit only) Left-hand side joystick (ISO controls, hydraulics unit only) Work hydraulics main valve block (Power Flow with Carry Over) Internal throttle valve Electric Power Flow valve Parallel bucket lift valve Auxiliary hydraulics pilot valve (auxiliary hydraulics pedal) 3/2 directional valve cartridges with housings (safety valves) Bladder type accumulator (accumulator boost pressure) Distributing block with brake (brake valve) Distributing block Breather filter with screen Temperature switch 100 °C (212 °F) Radiator Fan blade Oil filter Speed Control valve Pressure switch 1 – 10 bar/14.5 – 145 psi (brake valve ON/OFF) Pressure switch 8 bar/116 psi

42 43 44 45 48 49

Pressure switch 2 ±0.5 bar/29 ±7 psi Left + right-hand side loader unit rams Right-hand side bucket ram Left-hand side bucket ram Pilot control filter Non-return valve 8 PL

Right-hand side hydraulic motor

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp511.fm

Hydraulic system 5.15 Hydraulics diagram H controls with options (1101c)

Pos. 1

Description Diesel engine D2011L04W

3

Double variable displacement pump

4

Twin gear pump 34 cm³/rev (2.1 cu. in./rev) + 19 cm³/rev (1.16 cu. in./rev) Hydraulic motors

6 9

Joystick (left) Left-hand side hydraulic motor

17

Right-hand side joystick (H controls, hydraulics unit Option only) Left-hand side joystick (H controls, hydraulics unit Option only) Work hydraulics main valve block (standard without Carry Over) Internal throttle valve

19

Changeover valve (work hydraulics lock)

Option

21

Dual parallel bucket lift valve

Option

22

27

Auxiliary hydraulics pilot valve (auxiliary hydraulics pedal) 3/2 directional valve cartridges with housings (safety valves) Solenoid valve (load stabiliser valve; load stabiliser) Option Pressure accumulator (bladder type accumulator for Option load stabiliser) Bladder type accumulator (accumulator boost pressure) Stabiliser valve Option

28

Stabiliser distributor valve

29

Distributing block with brake (brake valve)

30

Distributing block

31

Breather filter with screen

32

Temperature switch 100 °C (212 °F)

33

Radiator

10 15

23 24 25 26

34

Fan blade

35

Oil filter

37

Hydraulic quickhitch system (HQS) option

38 39

Pressure switch 1 – 10 bar/14.5 – 145 psi (brake valve ON/OFF) Pressure switch 8 bar/116 psi

40

Pressure switch 2 ±0.5 bar/29 ±7 psi

42 43

Pressure switch 2 ±0.5 bar/29 ±7 psi Left + right-hand side loader unit rams

44

Right-hand side bucket ram

45

Left-hand side bucket ram

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp511.fm

Option

Right-hand side

Joystick (right) Option

Option

5-36

Hydraulic system 5.16 Hydraulics diagram H controls with options (1101cp) Pos. 2

Joystick (left)

3

Double variable displacement pump

4 5

Twin gear pump 34 cm³/rev (2.1 cu. in./rev) + 19 cm³/rev (1.16 cu. in./rev) Boost pump 19 cm³/rev (1.16 cu. in./rev)

6

Hydraulic motors

9

17

Right-hand side joystick (H controls, hydraulics unit Option only) Left-hand side joystick (H controls, hydraulics unit only) Option Work hydraulics main valve block (Power Flow with Carry Over) Internal throttle valve

18

Electric Power Flow valve

10 16

Left-hand side hydraulic motor

19

Changeover valve (work hydraulics lock)

Option

21

Dual parallel bucket lift valve

Option

22

Auxiliary hydraulics pilot valve (auxiliary hydraulics pedal) 3/2 directional valve cartridges with housings (safety valves) Solenoid valve (load stabiliser valve; load stabiliser)

Option

23 24 25

Option

27

Pressure accumulator (bladder type accumulator for load stabiliser) Bladder type accumulator (accumulator boost pressure) Stabiliser valve

28

Stabiliser distributor valve

Option

29

Distributing block with brake (brake valve)

30

Distributing block

31

Breather filter with screen

32

Temperature switch 100 °C (212 °F)

33

Radiator

34

Fan blade

35

Oil filter

36

Speed Control valve

37

Hydraulic quickhitch system (HQS) option

38 39

Pressure switch 1 – 10 bar/14.5 – 145 psi (brake valve ON/OFF) Pressure switch 8 bar/116 psi

40

Pressure switch 2 ±0.5 bar/29 ±7 psi

26

5-37

Description Diesel engine TD2011L04W

Option

Right-hand side hydraulic motor

±0.5

Option

Joystick (right)

Option

±7

42 43

bar/29 psi Pressure switch 2 Left + right-hand side loader unit rams

44

Right-hand side bucket ram

45

Left-hand side bucket ram

46

Control ram (HQS)

48

Pilot control filter

49

Non-return valve

Option

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp511.fm

Hydraulic system 5.17 Hydraulics diagram ISO controls with options (1101c)

Pos. 1

Description Diesel engine D2011L04W

3

Double variable displacement pump

4

Twin gear pump 34 cm³/rev (2.1 cu. in./rev) + 19 cm³/rev (1.16 cu. in./rev) Hydraulic motors

6 9

Left-hand side hydraulic motor

17

Right-hand side joystick (H controls, hydraulics unit Option only) Left-hand side joystick (H controls, hydraulics unit Option only) Work hydraulics main valve block (standard without Carry Over) Internal throttle valve

19

Changeover valve (work hydraulics lock)

Option

21

Dual parallel bucket lift valve

Option

22

27

Auxiliary hydraulics pilot valve (auxiliary hydraulics pedal) 3/2 directional valve cartridges with housings (safety valves) Solenoid valve (load stabiliser valve; load stabiliser) Option Pressure accumulator (bladder type accumulator for Option load stabiliser) Bladder type accumulator (accumulator boost pressure) Stabiliser valve Option

28

Stabiliser distributor valve

29

Distributing block with brake (brake valve)

30

Distributing block

10 15

23 24 25 26

Option

31

Breather filter with screen

32

Temperature switch 100 °C (212 °F)

33

Radiator

34

Fan blade

35

Oil filter

37

Hydraulic quickhitch system (HQS) option

38 39

Pressure switch 1 – 10 bar/14.5 – 145 psi (brake valve ON/OFF) Pressure switch 8 bar/116 psi

40

Pressure switch 2 ±0.5 bar/29 ±7 psi ±0.5

Option

Option

±7

42 43

bar/29 psi Pressure switch 2 Left + right-hand side loader unit rams

44

Right-hand side bucket ram

45

Left-hand side bucket ram

46

Control ram (HQS)

48

Pilot control filter

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp511.fm

Right-hand side hydraulic motor

Option

5-38

Hydraulic system 5.18 Hydraulics diagram ISO controls with options (1101cp) Pos. 2 3 4 5 6 9 10 16 17 18 19 21 22 23 24 25

39

Pressure accumulator (bladder type accumulator for load stabiliser) Bladder type accumulator (accumulator boost pressure) Stabiliser valve Stabiliser distributor valve Distributing block with brake (brake valve) Distributing block Breather filter with screen Temperature switch 100 °C (212 °F) Radiator Fan blade Oil filter Speed Control valve Hydraulic quickhitch system (HQS) option Pressure switch 1 – 10 bar/14.5 – 145 psi (brake valve ON/OFF) Pressure switch 8 bar/116 psi

40

Pressure switch 2 ±0.5 bar/29 ±7 psi

42 43 44 45 46 48

±0.5 bar/29 ±7 psi

Pressure switch 2 Left + right-hand side loader unit rams Right-hand side bucket ram Left-hand side bucket ram Control ram (HQS) Pilot control filter

49

Non-return valve

26 27 28 29 30 31 32 33 34 35 36 37 38

5-39

Description Diesel engine TD2011L04W Double variable displacement pump Twin gear pump 34 cm³/rev (2.1 cu. in./rev) + 19 cm³/ rev (1.16 cu. in./rev) Boost pump 19 cm³/rev (1.16 cu. in./rev) Hydraulic motors Right-hand side joystick (H controls, hydraulics unit only) Left-hand side joystick (H controls, hydraulics unit only) Work hydraulics main valve block (Power Flow with Carry Over) Internal throttle valve Electric Power Flow valve Changeover valve (work hydraulics lock) Dual parallel bucket lift valve Auxiliary hydraulics pilot valve (auxiliary hydraulics pedal) 3/2 directional valve cartridges with housings (safety valves) Solenoid valve (load stabiliser valve; load stabiliser)

Left-hand side hydraulic motor Option Option

Option Option

Option Option

Option Option

Right-hand side hydraulic motor Option

Option

Option

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp511.fm

Electrical system

Electrical system

Electrical system

6 6.1

Electrical system 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 (ΩW)

Mnemonic:

U R

I

Output Power “P” – Watt (W) P = U x I = R x I² = U²/R

6.2

Measuring equipment, measuring methods Multifunction measuring device

• Measurements of values (U, R, I, f) • Continuity test • Diode test Calculate the 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 electrical system and of wiring harnesses

6-1

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp610.fm

Electrical system Measuring method – 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): • Black cable in COM socket (earth), • red cable in V socket; • connect in parallel to consumer.

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

Test lamp The test lamp is used to test lines and functions with the ignition switched on.

• Line test (testing voltage): Connect test lamp between test point (live cable) and machine earth or between test point (earth line) and a live cable.

• Functional check (testing current): Connect test lamp between a connection on the consumer to be tested and the connection line.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp610.fm

6-2

Electrical system 6.3

Cable colour coding Colour Black Brown Red Orange Yellow Green Blue Violet Grey White Pink

6.4

Code blk brn red org yel grn blu vio gry wht pnk

Relays

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 microelectronics or microswitches (e.g. touchpad keyboards, sensors). The switch contacts can be makecontact, break-contact or changeover switches. These undertake the actual switching function.

Zero-centre relay

86

30

86 = Start of coil

(control line)

85 = End of coil

(earth)

30 = Input

(load line)

87 = Make-contact switch output (load line) 85

87 87a

87 a= Break-contact switch output (load line)

Terminal description on relay

6-3

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp610.fm

Electrical system 6.5

Electric units Units Alternator

12 V 95 Ah

Starter

12 V 2.3 kW (3.1 hp)

Battery

12 V 88 Ah

Socket

E.g. for cigarette lighter; 15 A max.

Fuse box behind the seat on the left

Fuse no.

F3 F4 F5 F6 F7 F8 F9 F10 Fig. 1:

Fuse box

Rated current (A)

Protected circuit

F3

10 A

– Indicating instruments, alternator, starting relay

F4

15A

– Valves

F5

15A

– Working lights

F6

15A

– Lights according to STVO Austrian road traffic regulations

F7

15A

– Turn indicators 12 V/15

F8

15A

– Hazard warning system

F9

15A

– Cigarette lighter

F10

10 A

– Rotating beacon

F11

10 A

– Valves option

F12

15A

– Attachment controls 1

F13

15A

– Attachment controls 2

F14

15A

– Attachment controls 3

F15

10 A

– Heating

F16

15A

– Air conditioning

F17

10 A

– Wiper

F18

10 A

– Not assigned

Standard machine

F11 F12 F13 F14 F15 F16 F17 F18

Main fuse box with relays The main fuse box is located under the cab.

F1

Fuse no.

Rated current (A)

Protected circuit

F2

F1, F2

80 A

– Main fuse

Relay no.

N3 Fig. 2:

K5

K7

Main fuse box

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp610.fm

K5

– Preheating relay

K7

– Start high current relay

N3

– Glow control unit

6-4

Electrical system Relay box at rear left of cab

K18

K17

Fig. 3:

6-5

K16

K11

RELAIS BOX

K34

K36

K10

Switching relay no.

Protected circuit

K 18

– Attachment controls 3 (option)

K 17

– Attachment controls 2 (option)

K 16

– Attachment controls 1 (option)

K 11

– Air conditioning (option)

K 34

– Load stabiliser (option)

K 36

– 2nd drive range

K 10

– Turn indicator relay (option)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp610.fm

Electrical system 6.6

Round indicating instrument overview

8 7

0

6

2

8 7

4 5

Pos. 1 3 5 7 9 11 13 15 17 19

Description Round indicating instrument Preheating start switch Ignition lock cover Heating symbol Working light symbol Speed Control symbol Work hydraulics lock symbol Light bulb Quickhitch symbol Hazard warning system symbol

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp610.fm

Pos. 2 4 6 8 10 12 14 16 18 20

Description Cigarette lighter Ignition key Air conditioning symbol Rotating beacon symbol Power Flow symbol Parallel bucket lift symbol Parking brake symbol Stabiliser symbol Lights symbol (option) Driving direction symbol

6-6

Electrical system 6.7

Switches: overview

40

41

42

43

49

44

45

46

47

48

50

51

52

53

54

Option

Pos. 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

6-7

Description Air conditioning (option) Fan (option) Rotating beacon (option) Front/rear working lights (option) 3rd control circuit (Power Flow option) Speed Control (option) – continuously adjustable low-speed control Parallel bucket lift Work hydraulics lock (ISO controls only) Parking brake Wiper/washer system switch (option) Stabilisers (option) Hydraulic quickhitch system (HQS) option Lights (option) Hazard warning system (option) Left/right turn indicators (option)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp610.fm

Electrical system 6.8

Alternator The alternator charges the battery and supplies direct current to electric consumers.

Pos. 1 2

1 2 3

Description Connection B (battery) Port D (alternator charge function telltale) Port W (revs signal)

3

Fig. 4:

6.9

Alternator

Starter 2

1

Pos. 1 2

Fig. 5:

Description Connection S starting relay Connection B battery

Alternator

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp610.fm

6-8

Electrical system

Electrical system

Wiring diagrams and wiring harnesses include all options.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

6-26

Electrical system 6.25 Wiring diagram (legend) No.

6-27

B1

Fuel level indicator

Description

Section E8 (1)

M4

No. Heating

Section E11 (2)

No. Y55

Description Rear outrigger valve

Section E7 (2)

B2

Horn

C2 (2)

M5

Washer pump

D13 (2)

Y60

Charge air pressure valve (turbocharger)

E3 (1)

B3

Backup warning system

E8/9 (1)

M12

Air conditioning fan

E13 (2)

B15

Coolant level

E6 (1)

N3

Preheating time control unit

C1/2 (1)

Y61

EGR valve

E3 (1)

Y76

Parallel lift magnet

B18

Diodes (warning buzzer unit)

B/C 5/6 (1)

R1

Glow plug

E10 (1)

E2 (1)

Y77

Parallel lift magnet

B19

Quickhitch warning buzzer

B6 (2)

R8

E11 (1)

Glow plug

E2 (1)

U1

Amplifier

E1

Front right parking light

D2/3 (2)

S1

C5/6 (1)

Preheating start switch

A/B1/2 (1)

E2

Rear right light

D5 (2)

E3

Front left parking light

E2/3 (2)

S2

Engine oil pressure switch

E5 (1)

S3

Engine temperature switch

E4

Rear left light

E5 (1)

E5 (2)

S4

Air filter pressure switch

E5

Low beam (right)

D6/7 (1)

D2/3 (2)

S5

Hydraulic oil pressure switch

E7 (1)

S6

Hydraulic oil temperature switch

E7 (1)

S8

Battery master switch

E1 (1) E8 (1)

Option

Description

E6

Low beam (left)

E2/3 (2)

E7

Rear working lights

C1 (2)

E9

Front working light

C1 (2)

S11

Parking brake pressure switch

E10

Front working light

C1 (2)

S12

Turn indicator switch

E4/5 (2)

E14

Interior light

C3 (2)

S14

Light switch

B3/4 (2)

E15

Cigarette lighter

B3 (1)

S15

Heating switch

A/B11 (2)

E16

Numberplate light

D5 (2)

S16

Working light switch

A/B1 (2)

F1

Main fuse

D1 (1)

S18

Rotating beacon switch

A/B2 (2)

F2

Main fuse

D1 (1)

S19

Hazard warning switch

B4/5 (2)

Option

F3

Indicating instruments, alternator, starting relay

A3 (1)

S20

Wiper switch

C13/14 (2)

F4

Valves

A8

S21

2nd speed tip switch

C13 (1) E5 (1)

Option Option

Option Option

F5

Working lights

A1 (1)

S26

Boost pump pressure switch

F6

A3 (1)

S28

Work hydraulics circuit breaker

B9 (1)

F7

Lights according to STVO Austrian road traffic regulations Turn indicators

S29

Safety switch

B8 (1)

F8

Hazard warning system

A4 (1)

S30

Attachment controls 1 tip switch

B8 (2)

Option

F9

Cigarette lighter

A3 (1)

S31

Attachment controls 2 tip switch

B9 (2)

Option

F10

Rotating beacon

A2 (2)

Option

S32

Parallel lift switch

B10 (1)

F11

Valves option

A6 (2)

Option

S33

Power Flow switch

B12 (1)

F12

Attachments 1

A9 (2)

Option

S34

Attachment controls 3 tip switch

B10 (2)

Option

F13

Attachments 2

A10 (2)

Option

S36

Rear outrigger switch

B7 (2)

Option

F14

Attachments 3

A10 (2)

Option

S40

Quickhitch switch

B6 (2)

F15

Heating

A11 (2)

Option

S43

Backup warning system switch

D8/9 (1)

Option

F16

Air conditioning

A13 (2)

Option

S44

Load stabiliser tip switch

B7/8 (2)

Option

F17

Wiper

A13 (2)

F18

Spare

G1

Alternator

E4 (1)

G2

Battery

E1 (1)

H24

Front right turn indicator

D3 (2)

H25

Rear right turn indicator

D5 (2)

H26

Front left turn indicator

E3 (2)

H27

Rear left turn indicator

E5 (2)

H28

Rotating beacon

C2 (2)

K5

Preheating relay

E1/2 (1)

K7

Start high current relay

D2 (1)

K10

Turn indicator relay

C5 (2)

K11

Air conditioning relay

C12 (2)

Option

K16

Attachment control 1 relay

C8 (2)

Option

K17

Attachment control 2 relay

C9 (2)

Option

K18

Attachment control 3 relay

C10 (2)

Option

K34

Load stabiliser relay

C7/8 (2)

Option

K36

2nd speed relay

B13/14 (1)

A4/5 (1)

M1

Starter

E2 (1)

M2

Wiper

D14 (2)

Option

Option

Option

S51

Air conditioning switch

A/B12 (2)

Option

S52

Air conditioning pressure switch

E12 (2)

Option

S54

Air conditioning thermostat

D12 (2)

Option

S55

Horn tip switch

C13/14 (1)

S65

Parking brake switch

B11 (1)

S78

Accumulator pressure switch (H controls)

C/D9 (1)

S83

Speed Control valve switch

B10/11 (1)

Y1

Cutoff solenoid

E4 (1)

Y2

Speed Control valve

C10/11 (1)

Y3

2nd speed valve

E14 (1)

Y13

Drive safety valve

E9 (1)

Y13.1

Work safety valve

E10 (1)

Y20

Load stabiliser valve

E8 (2)

Option

Y21

Load stabiliser valve

E8 (2)

Option

Y25

Quickhitch valve

E6 (2)

Option

Y30

Minus compensation

E3 (1)

Y31

Electro-magnetic clutch compressor

E12 (2)

Y33

Power Flow I valve

E12 (1)

Y34

Power Flow II valve

E12 (1)

Y43

Parking brake magnet

E11 (1)

Option

Wiring diagram (legend)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

Electrical system 6.26 Wiring diagram (1)

Round indicating instrument

Preheating time control unit

2nd speed

Power Flow

Parking brake

Parallel lift

Work safety valve

Drive safety valve

Backup warning system

Parking brake telltale

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

6-28

Electrical system

6.27 Wiring diagram (2)

Wiper

Washer pump

Air conditioning

Air conditioning

Heating

Attachment controls

Load stabiliser

Rear outriggers

Quickhitch

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

6-29

Electrical system 6.28 1101c engine – chassis wiring harness 1000169726 (legend) No. 1 2 3 4 5 6 7 8 9 12 13 14 16 17 18 21 22 24 25 26 28 30 32 33 34 35 36 37 44 45 47 51 64 68 69 70 71 72 73 77 78 79 80 81 102 103 104 105 106 110 111 112 113 114 115

From M1 starter M1 starter M1 starter F2 main fuse F1 main fuse F2 main fuse F2 main fuse F1 main fuse F1 main fuse K7/87 start high current relay K7/87 start high current relay Y30 minus compensation K5/87 preheating relay N3/H glow control unit N3/H glow control unit K7/86 start high current relay K7/86 start high current relay N3/TK glow control unit N3/L glow control unit G1.1 alternator S2 engine oil pressure S3/1 engine temperature switch S3/2 engine temperature sensor B15/1 coolant level S4 air filter pressure switch S6 oil filter contamination S6 oil filter contamination B1/1 fuel sensor N3/15 glow control unit N3/15 EGR sensor Y1 cutoff solenoid S43 backup warning system switch Y13/1 drive safety valve S78/1 accumulator pressure switch (H controls) XS78/1 work safety valve Y13.1/1 work safety valve

Up to G1 alternator F1 main fuse F2 main fuse K7/30 start high current relay K5/30 preheating relay N3/30 glow control unit X1/B X1/D X1/E M1.1 starter Y60 charge air pressure valve (turbocharger) Y60 charge air pressure valve (turbocharger) R1 glow plug R8 glow plug K5/86 preheating relay X1/A N3/50 glow control unit X1/C X1/F X1/H X1/J X1/K X1/L X1/M X1/N S5 hydraulic oil pressure switch X1/P X1/R X1/S Y61/1 X1/T X2/2 12 V valves 1 X1/T X1/V XS78/2 work safety valve S78/2 work safety valve

Colour red red red red red red red red red wht wht wht brn brn brn wht-blk wht-blk brn-wht gry-red pnk wht-grn grn-blk grn-wht blk/grn gry-blu org-wht org-wht vio-blk blu blu blu-red gry brn-wht brn/wht brn/wht brn/wht

10 10 10 4 6 6 4 4 4 4 1.5 1.5 6 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

XY parallel lift XY parallel lift XY parallel lift Y3/1 2nd speed S43/1 parking brake Y33/1 Power Flow I S11 parking brake telltale S26 boost pressure S43 backup warning system S4 backup warning system S43 backup warning system B3 backup warning system Y34/1 Power Flow II GND earth GND earth GND earth GND earth GND earth S11 earth

X2/1 Y76/1 parallel lift magnet Y77/1 parallel lift magnet X2/4 2nd speed X2/5 X2/6 X1/W X1/X S43.1 S43.1 S43.1 S43.1 X2/3 X1/G Y13/2 Y13.1/2 Y3/2 S26 S26

vio/blk vio/blk vio/blk brn-blk blk-red blu/blk blk/red vio-blu gry gry gry/blk gry/blk org/blu blk blk blk blk blk blk

1 1 1 1 1 1 1 1 1 1 1 1 1 2.5 1 1 1 1 1

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

mm²

No. 116 117 118 119 120 121 122 123 124 125 126 127 128 129

From GND earth GND earth GND earth GND earth GND earth GND earth GND earth GND earth GND earth GND earth K7/85 earth K7/85 earth GND earth GND earth

Up to Y43/2 Y1/2 B1/2 Y61/2 B3 Y77/2 Y76/2 S5 Y33/2 N3/31 N3/31 K5/85 Y34/2 B15/2

Colour blk blk blk blk blk blk blk blk blk blk blk blk blk blk

mm² 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Engine – chassis wiring harness 1000169726 (legend)

6-30

Electrical system 6.29 1101c engine – chassis wiring harness 1000169726 Glow plugs

Hydraulic oil pressure switch

Engine temperature switch

Work safety Drive safety valve valve

2nd speed valve

Coolant level Starter

Parking brake magnet

Emergency lowering

Parking brake pressure switch Boost pump pressure switch EGR valve

Hydraulic oil temperature switch

Power Flow II

Minus compensation

Engine oil pressure switch

Main fuses

Backup warning system switch

Cutoff solenoid

Fuel sensor

Power Flow I

Parallel lift magnet

Charge air pressure valve (turbocharger) Alternator Start high current relay Preheating relay Glow control unit

6-31

Backup warning system

Air filter pressure switch

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

Electrical system 6.30 1101cp engine – chassis wiring harness 1000175467 (option)

Rear outrigger valve

Electro-magnetic clutch compressor

Air conditioning fan

Air conditioning pressure switch

Quickhitch valve

Load stabiliser valves

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

No. 9 10 11 12 13 35 36 37 54 55 56 57 58

From X3/1 Y20/1 Y21/1 X3/2 X3/3 X3/4 Y31 X3/5 GND GND GND GND GND

Up to XY20 load stabiliser XY20 load stabiliser XY20 load stabiliser Y55/1 rear hydraulics Y25/1 quickhitch S52/1 air conditioning S52/2 air conditioning M12 air conditioning fan Y25/2 earth Y20/2 earth Y21/2 earth Y55/2 earth M12 earth

Colour gry-yel gry-yel gry-yel grn brn org-blk org org blk blk blk blk blk

mm² 1 1 1 1 1 1 1 1 1 1 1 1 1

6-32

Electrical system 6.31 1101c cab wiring harness 1000169725 (legend) No. 7 8 9 10 11 19 20 21 23 24 25 26 27 28 29 29A 30 31 32 33 34 36 37 39 40 41 42 43 43A 44 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 68A 71 74 75 76 77 78 79 80

6-33

From X1/B 12 V/30 X1/D 12 V/30 X1/E 12 V/30 S1/5 12 V/15 S1/6 12 V/15 X4/4 X5/4 X1/A S1/3 preheating X1/C X1/F X1/H X10/1 X1/J X10/14 X10/5 X1/K B18/9 X1/L X1/M X1/N X1/P X1/R X4/5 X4/5 U1 amplifier U1 amplifier X10/11 X10/6 X1/S X5/5 X1/T S33/9 S33/9 F4/2 F4/2 F4/2 S65/9 S65/9 S32/1 S32/1 S83/1 S83/1 S33/3 S33/3 F4/2 S29 safety valve X5/6 safety valve X1/U drive safety valve S28/1 safety valve S28/1 safety valve X9/2 work safety valve X1/V work safety valve X9/2 work safety valve X2/1 parallel lift S83/5 Speed Control valve X7/2 2nd speed tip switch X10/16 2nd speed X2/4 2nd speed X2/5 parking brake X2/6 X1/W parking brake telltale

To F9/G 12 V/30 S1/2 12 V/30 S1/1 12 V/30 F4/B 12 V/15 F14/E 12 V/15 S1/7 preheating start switch X5/8 preheating start switch X4/8 preheating start switch S1/9 preheating S1/8 preheating X10/15 preheating telltale B18/5 alternator charge telltale B18/5 alternator charge telltale B18/8 engine oil pressure B18/2 engine oil pressure B18/2 engine oil pressure U1 engine temperature switch U1 engine temperature switch X10/20 engine temperature sensor U1 coolant level X10/2 air filter contamination X10/3 oil filter contamination X10/19 fuel sensor F3/1 12 V telltales, engine X4/7 12 V telltales, engine X4/7 12 V telltales, engine E15 12 V telltales, engine E15 12 V telltales, engine E15 12 V telltales, engine F3/1 12 V telltales, engine X5/9 cutoff solenoid X4/9 cutoff solenoid S33/5 12 V valves 1 X7/1 12 V valves 1 S29 12 V valves 1 X2/2 12 V valves 1 S65/7 12 V valves 1 S65/7 12 V valves 1 S28/9 12 V valves 1 S28/9 12 V valves 1 S32/9 12 V valves 1 S32/9 12 V valves 1 S83/9 12 V valves 1 S83/9 12 V valves 1 S33/5 12 V valves 1 K36/85 12 V valves 1 X4/1 X5/1 X4/6 X4/6 X9/1 S28/5 work safety valve S28/5 work safety valve X10/9 work safety valve S32/5 parallel lift Y2/1 Speed Control valve K36/30 2nd speed tip switch K36/87 2nd speed K36/87 2nd speed S65/5 parking brake S33/1 Power Flow I X10/13 parking brake telltale

Colour red red red blu blu wht-blk wht-blk wht-blk brn-wht brn-wht gry-red pnk pnk wht-grn wht-grn wht-grn grn-blk grn-blk grn-wht blk/grn gry-blu org-wht vio-blk blu blu blu blu blu blu blu blu-red blu-red gry gry gry gry gry gry gry gry gry gry gry gry gry gry brn-wht brn-wht brn-wht brn-wht brn-wht brn/wht brn/wht brn/wht vio/blk brn-grn brn/blk brn-blk brn-blk blk-red blu/blk blk/red

No. 4 4 4 2.5 2.5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

81 82 83 84 85 86 87 88 89 90 91 92 93 94 96 97 98 99 100 106 107 108 110 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149

From X1/X B18/1 boost pressure X14 load stabiliser telltale F5/3 12 V working light S16/2 12 V working light S16/2 12 V working light S18/9 12 V working light S16/6 front working light S16/3 rear working light F6/4 interior light F6/4 12 V lights according to STVO Austrian road traffic regulations F7/5 12 V turn indicators F8/6 hazard warning system X10/8 turn indicator telltale F9/7 cigarette lighter F10/8 12 V rotating beacon F10/8 drive interlock S18/5 rotating beacon X7/3 horn X2/3 X18/1 float position X18/2 earth X1/G earth X12/5 earth X12/6 earth K36/85 earth S18/10 earth S18/10 earth S83/10 earth S83/10 earth S28/10 earth S28/10 earth X7/4 earth S33/10 earth GND2 GND2 GND2 GND2 U1 earth GND2 GND2 XF1/1 12 V/15 XF1/2 12 V/15

To B18/6 boost pressure X10/7 X10/10 load stabiliser telltale S16/1 12 V working light F5/3 12 V working light S16/9 12 V working light S16/9 12 V working light X12/1 X12/2 rear working light X12/9 interior light X8/1 12 V lights according to STVO Austrian road traffic regulations

Colour vio-blu vio-blu gry-grn grn grn grn grn grn-red grn/blu blu blu

1 1.5

X8/2 12 V turn indicators X8/3 hazard warning system X8/4 E15 cigarette lighter S18/1 12 V rotating beacon X4/2 X12/3 X12/4 horn S33/7 Power Flow II X4/1 float position GND2 GND1 GND1 GND1 GND1 GND1 S16/10 earth S33/10 earth S32/10 earth S32/10 earth S65/10 earth S65/10 earth S16/10 earth GND1 Y2/2 earth X8/6 earth X4/3 earth X4/3 earth E15 earth X10/12 earth F4/B 12 V/15 F6/D 12 V/15

yel red red/blk red-blk red red vio org org/blu brn-wht blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blu blu

1 1 1 1 1 1 1 1 1 1 1 2.5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2.5 2.5

1 1 1 1 1 1 1 1

Cab wiring harness 1000169725 (legend)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

Electrical system 6.32 1101c cab wiring harness 1000169725

Cigarette lighter

Safety switch

Speed Control

Display

Ignition lock

Joystick

2nd speed Parking Work Parallel Speed brake hydraulics lift Control lock

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

Power Flow

Working light Rotating beacon

6-34

Electrical system 6.33 1101cp cab (option) wiring harness 1000169725 (legend)

No. 1 2 3 4 5 6 7 8 9 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 37 38 39 40 41

6-35

From F11/1 12 V valves 2 F11/1 12 V valves 2 S40/9 12 V valves 2 S40/9 12 V valves 2 S36/9 12 V valves 2 S36/9 12 V valves 2 X6/2 K34/87 load stabiliser K34/87 load stabiliser S36/5 rear hydraulics S40/5 quickhitch S40/5 quickhitch X6/3 X6/4 S6/5 F12/2 F12/2 K16/87 F13/3 K17/87 F14/4 K18/87 F15/5 S15/2 S15/2 S51/9 S15/6 S15/6 S15/3 S51/5 F16/6 S54/1 S54/2 K11/87 F17/7 X11/1 GND X11/2

To Colour K34/85 12 V valves 2 gry S40/1 12 V valves 2 gry S40/1 12 V valves 2 gry S36/1 12 V valves 2 gry S36/1 12 V valves 2 gry X6/1 12 V valves 2 gry K34/30 load stabiliser relay gry-blk X14 gry-yel X3/1 gry-yel X3/2 grn X3/3 brn B19/1 brn K16/86 auxiliary electric circuit 1 relay wht K17/86 auxiliary electric circuit 2 relay wht-blk K18/86 auxiliary electric circuit 3 relay wht-blu X15/1 auxiliary electric circuit 1 wht K16/30 12 V auxiliary electric circuit wht X15/2 auxiliary electric circuit 1 vio K17/30 auxiliary electric circuit 2 wht-blk X15/3 auxiliary electric circuit 2 wht-blk K18/30 auxiliary electric circuit 3 wht-blu X15/4 auxiliary electric circuit 3 wht-blu S15/1 12 V heating yel S15/1 12 V heating yel S15/9 12 V heating yel S15/9 12 V heating yel S51/1 heating speed I yel-blk M4/2 heating speed I yel-blk M4/3 heating speed II yel-blu K11/86 air conditioning yel-red K11/30 air conditioning org K11/87 air conditioning org X3/4 air conditioning org-blk X3/5 air conditioning fan org X10/1 12 V wiper blu X10/3 washer pump gry X10/2 earth blk X10/2 earth blk

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

No. 42 43 44 45 46 47 48 49 50 51 52 53 60 61

From GND S51/10 GND K11/85 K11/85 K17/85 K17/85 GND GND S40/10 S40/10 X6/6 XF1/1 XF1/2

To S15/10 earth S15/10 earth K34/86 earth K34/86 earth K16/85 earth K16/85 earth K18/85 earth M4/1 earth S36/10 earth S36/10 earth B19/2 earth B19/2 earth F12/B 12 V/15 F17/G 12 V/15

Colour blk blk blk blk blk blk blk blk blk blk blk blk blu blu

1 1 1 1 1 1 1 1 1 1 1 1 2.5 2.5

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

Electrical system 6.34 1101cp cab wiring harness 1000175466 (option) Rear outriggers

Quickhitch

Heating

Air conditioning

Joystick

Heating

Air conditioning

Auxiliary electric circuit 3

Load stabiliser Air conditioning

Auxiliary electric circuit 2

Auxiliary electric circuit 1

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

6-36

Electrical system 6.35 Front lights wiring harness and legend 1000169728

Horn

Interior light

Working light (right)

Working light (left)

No.

6-37

mm2

Colour

Function

1

X12

EX

1

grn-red

Front working light

2

E10/1

EX

1

grn-red

Front working light

3

E9/1

EX

1

grn-red

Front working light

4

X12

B2

1

org

Horn

5

X12

GND

1

blk

Earth

6

E10/2

GND

1

blk

Earth

7

B2

GND

1

blk

Earth

8

E9/2

GND

1

blk

Earth

9

X12

E14

1

blu

Interior light

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

Electrical system 6.36 Wiring harnesses 1000175462: StVO Austrian road traffic regulations + 1000175463: cab StVO Austrian road traffic regulations (legends)

StVO Austrian road traffic regulations (legend) No. 4 5 6 7 8 9 10 11 12 13 14 29 30 31 34 35 36 47 48 49 50 51

From X5/1 PosR PosR PosR PosL PosL PosL PosL X5/2 E1/2 E3/2 X5/3 E4/1 E3/5 X5/4 E2/1 E1/5 GND GND GND GND GND

To Pos clearance light Pos clearance light E2/2 clearance light E1/4 clearance light Pos clearance light E16 clearance light E4/2 clearance light E3/4 clearance light Abbl low beam Abbl low beam Abbl low beam BIL turn indicator (left) BIL turn indicator (left) BlL turn indicator (left) BIR turn indicator (right) BIR turn indicator (right) BIR turn indicator (right) E16 earth E4/3 earth E3/6 earth E2/3 earth E1/5 earth

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

Cab StVO Austrian road traffic regulations (legend) Colour yel/blk 1 yel/blk 1 yel/blk 1 yel/blk 1 yel/blk 1 yel/blk 1 yel/blk 1 yel/blk 1 yel/grn 1 yel/grn 1 yel/grn 1 grn/blk 1 grn/blk 1 grn/blk 1 grn/red 1 grn/red 1 grn/red 1 blk 1 blk 1 blk 1 blk 1 blk 1

No.

From

1

X8/1

2

S14/2

3

S14/2

4 12 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 32 33 34 40 41 42 43 44

S14/6 S14/3 X8/2 X8/2 S19/7 S19/7 X8/3 S19/4 K10/86 S12/3 S19/1 S19/1 X9/4 K10/87 S12/1 X9/5 X9/5 S12/7 X9/6 X9/6 X8/6 S14/10 S14/10 X8/6 X9/3

To Colour S14/1 12 V lights according to STVO blu Austrian road traffic regulations S14/1 12 V lights according to STVO blu Austrian road traffic regulations S14/9 12 V lights according to STVO blu Austrian road traffic regulations X5/1 clearance light yel/blk X5/2 low beam yel/grn X9/1 12 V turn indicators yel S19/8 12 V turn indicators yel S19/8 12 V turn indicators yel S12/9 12 V turn indicators yel S19/2 12 V hazard warning system red S19/6 turn indicators + yel/red S19/6 turn indicators + yel/red S12/5 turn indicators CL brn/yel S12/5 turn indicators CL brn/yel K10/85 turn indicators CL brn/yel K10/85 turn indicators CL brn/yel X8/4 turn indicator telltale red/blk S19/3 turn indicators (left) grn/blk S19/3 turn indicators (left) grn/blk X5/3 turn indicators (left) grn/blk S19/5 turn indicators (right) grn/red S19/5 turn indicators (right) grn/red X5/4 turn indicators (right) grn/red S12/10 earth blk S12/10 earth blk S19/10 earth blk K10/87A earth blk K10/87A earth blk

1.5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

6-38

Electrical system 6.37 Wiring harnesses 1000175462: StVO Austrian road traffic regulations and 1000175463: cab

Rear right light

Front right parking light

Numberplate light

Front left parking light

Turn indicators

Rear left light

Hazard warning system Lights according to StVO Austrian road traffic regulations

Turn indicators

6-39

Turn indicator relay

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

Electrical system 6.38 Attachment control (option) wiring harness 1000171481

No.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

mm2

Colour

Function

1

X15/1

X16/B

1.5

wht

12 V auxiliary electric circuit

2

X15/2

X16/D

1.5

vio

Auxiliary electric circuit 1

3

X15/3

X16/F

1.5

wht-blk

Auxiliary electric circuit 2

4

X15/4

X16/C

1.5

wht-blu

Auxiliary electric circuit 3

5

GND

X16/A

1.5

blk

Earth

6

GND

X16/E

1.5

blk

Earth

6-40

Electrical system 6.39 Cab door (option) legend and wiring harness 1000175468

No.

6-41

mm2

Colour

Function

No.

mm2

Colour

Function

1

XM1

S20/2

1

blu

12 V wiper

7

S20/3

XM/2

1

brn

Washer pump

2

S20/10

S20/2

1

blu

12 V wiper

8

XM/3

M2/2

1

blk

Earth

3

XM/1

M2/1

1

blu

12 V wiper

9

XM/3

S20/9

1

blk

Earth

4

S20/6

S20/7

1

wht

Wiper

10

X17/1

X16

1

gry

Washer pump

5

S20/6

M2/3

1

wht

Wiper

11

X17/2

X16

1

blk

Earth

6

S20/5

M2/4

1

gry

Reset

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

Electrical system 6.40 Rear cab (option) legend and wiring harness 1000175464

Rotating beacon

Working light (left)

1 2 3

X12 E8/1 E7/1

EX EX EX

mm2 1 1 1

4 5 6 7 8

X12 X12 E8/2 H28 E7/2

H28 GND GND GND GND

1 1 1 1 1

No.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp612.fm

Colour

Function

grn/blu grn/blu grn/blu

Front working light Front working light Front working light

vio blk blk blk blk

Rotating beacon Earth Earth Earth Earth

Working light (right)

6-42

Elektrische Anlage

6-9

Elektrische Anlage

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

Wiring diagrams and wiring harnesses include all options.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

6.10 Wiring diagram (legend) No. B1

Description Fuel level indicator

Section E8 (1)

B2

Horn

C2 (2)

B3

Backup warning system

E8/9 (1)

B15

Coolant level

B18

Diodes (warning buzzer unit)

B19

Quickhitch warning buzzer

No. H24

Description Front right turn indicator

Section D3 (2)

No. S26

Description Boost pump pressure switch

Section E5 (1)

H25

Rear right turn indicator

D5 (2)

S28

Work hydraulics circuit breaker

B9 (1)

H26

Front left turn indicator

E3 (2)

S29

Safety switch

B8 (1)

E6 (1)

H27

Rear left turn indicator

E5 (2)

S30

Attachment controls 1 tip switch

B8 (2)

Option

B/C 5/6 (1)

H28

Rotating beacon

C2 (2)

S31

Attachment controls 2 tip switch

B9 (2)

Option

B6 (2)

K5

Preheating relay

E1/2 (1)

S32

Parallel lift switch

B10 (1)

Option

Option

Option

Front right parking light

D2/3 (2)

K7

Start high current relay

D2 (1)

S33

Power Flow switch

B12 (1)

E2

Rear right light

D5 (2)

K10

Turn indicator relay

C5 (2)

S34

Attachment controls 3 tip switch

B10 (2)

Option

E3

Front left parking light

E2/3 (2)

K11

Air conditioning relay

C12 (2)

Option

S36

Rear outrigger switch

B7 (2)

Option

E4

Rear left light

E5 (2)

K16

Attachment control 1 relay

C8 (2)

Option

S40

Quickhitch switch

B6 (2)

E5

Low beam (right)

D2/3 (2)

K17

Attachment control 2 relay

C9 (2)

Option

S43

Backup warning system switch

D8/9 (1)

Option

E6

Low beam (left)

E2/3 (2)

K18

Attachment control 3 relay

C10 (2)

Option

S44

Load stabiliser tip switch

B7/8 (2)

Option

E7

Rear working lights

C1 (2)

K34

Load stabiliser relay

C7/8 (2)

Option

S51

Air conditioning switch

A/B12 (2)

Option

E9

Front working light

C1 (2)

K36

2nd speed relay

B13/14 (1)

S52

Air conditioning pressure switch

E12 (2)

Option

E10

Front working light

C1 (2)

M1

Starter

E2 (1)

S54

Air conditioning thermostat

D12 (2)

Option

E14

Interior light

C3 (2)

M2

Wiper

D14 (2)

S55

Horn tip switch

C13/14 (1)

E15

Cigarette lighter

B3 (1)

M4

Heating

E11 (2)

E16

Numberplate light

D5 (2)

M5

Washer pump

D13 (2)

F1

Main fuse

D1 (1)

M12

Air conditioning fan

E13 (2)

F2

Main fuse

D1 (1)

N3

Preheating time control unit

F3

Indicating instruments, alternator, starting relay A3 (1)

R1

Glow plug

F4

Valves

A8

R8

F5

Working lights

A1 (1)

S1

F6

A3 (1)

S2

Engine oil pressure switch

F7

Lights according to STVO Austrian road traffic regulations Turn indicators

S3

F8

Hazard warning system

A4 (1)

S4

F9

Cigarette lighter

A3 (1)

F10

Rotating beacon

A2 (2)

Option

F11

Valves option

A6 (2)

Option

F12

Attachments 1

A9 (2)

Option

F13

Attachments 2

A10 (2)

Option

F14

Attachments 3

A10 (2)

Option

F15

Heating

A11 (2)

Option

F16

Air conditioning

A13 (2)

Option

F17

Wiper

A13 (2)

F18

Spare

G1

Alternator

E4 (1)

G2

Battery

E1 (1)

Option

A4/5 (1)

Option

S65

Parking brake switch

B11 (1)

S78

Accumulator pressure switch (H controls)

C/D9 (1)

S83

Speed Control valve switch

B10/11 (1)

C1/2 (1)

Y1

Cutoff solenoid

E4 (1)

E2 (1)

Y2

Speed Control valve

C10/11 (1)

Glow plug

E2 (1)

Y3

2nd speed valve

E14 (1)

Preheating start switch

A/B1/2 (1)

Y13

Drive safety valve

E9 (1)

E5 (1)

Y13.1

Work safety valve

E10 (1)

Engine temperature switch

E5 (1)

Y20

Load stabiliser valve

E8 (2)

Air filter pressure switch

D6/7 (1)

Y21

Load stabiliser valve

E8 (2)

Option

S5

Hydraulic oil pressure switch

E7 (1)

Y25

Quickhitch valve

E6 (2)

Option

S6

Hydraulic oil temperature switch

E7 (1)

Y30

Minus compensation

E3 (1)

S8

Battery master switch

E1 (1)

Y31

Electro-magnetic clutch compressor

E12 (2)

S11

Parking brake pressure switch

E8 (1)

Y33

Power Flow I valve

E12 (1)

S12

Turn indicator switch

E4/5 (2)

Y34

Power Flow II valve

E12 (1)

Y43

Parking brake magnet

E11 (1)

Y55

Rear outrigger valve

E7 (2)

Y60

Charge air pressure valve (turbocharger)

E3 (1)

Option

S14

Light switch

B3/4 (2)

S15

Heating switch

A/B11 (2)

S16

Working light switch

A/B1 (2)

S18

Rotating beacon switch

A/B2 (2)

Y61

EGR valve

E3 (1)

S19

Hazard warning switch

B4/5 (2)

Y76

Parallel lift magnet

E10 (1)

S20

Wiper switch

C13/14 (2)

Y77

Parallel lift magnet

E11 (1)

S21

2nd speed tip switch

C13 (1)

U1

Amplifier

C5/6 (1)

Option Option

Option

Option

Option

Elektrische Anlage

6-10

E1

Elektrische Anlage

6-11

6.11 Wiring diagram (1)

Round indicating instrument

Preheating time control unit

2nd speed

Power Flow Parking brake Parallel lift Work safety valve Drive safety valve Backup warning system Parking brake telltale

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

Wiring diagram (2)

Elektrische Anlage

Wiper Washer pump Air conditioning

Air conditioning Heating

Attachment controls

Load stabiliser

Rear outriggers Quickhitch

6-12

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

No. 1 2 3 4 5 6 7 8 9 12 13

From M1 starter M1 starter M1 starter F2 main fuse F1 main fuse F2 main fuse F2 main fuse F1 main fuse F1 main fuse K7/87 start high current relay K7/87 start high current relay

14

Y30 minus compensation

16 17 18 21 22 24 25 26 28 30 32 33 34 35 36 37 44 45 47 51 64 68

K5/87 preheating relay N3/H glow control unit N3/H glow control unit K7/86 start high current relay K7/86 start high current relay N3/TK glow control unit N3/L glow control unit G1.1 alternator S2 engine oil pressure S3/1 engine temperature switch S3/2 engine temperature sensor B15/1 coolant level S4 air filter pressure switch S6 oil filter contamination S6 oil filter contamination B1/1 fuel sensor N3/15 glow control unit N3/15 EGR sensor Y1 cutoff solenoid S43 backup warning system switch Y13/1 drive safety valve S78/1 accumulator pressure switch (H controls)

Up to G1 alternator F1 main fuse F2 main fuse K7/30 start high current relay K5/30 preheating relay N3/30 glow control unit X1/B X1/D X1/E M1.1 starter Y60 charge air pressure valve (turbocharger) Y60 charge air pressure valve (turbocharger) R1 glow plug R8 glow plug K5/86 preheating relay X1/A N3/50 glow control unit X1/C X1/F X1/H X1/J X1/K X1/L X1/M X1/N S5 hydraulic oil pressure switch X1/P X1/R X1/S Y61/1 X1/T X2/2 12 V valves 1 X1/T X1/V

Colour red red red red red red red red red wht wht

mm² 10 10 10 4 6 6 4 4 4 4 1.5

wht

1.5

brn brn brn wht-blk wht-blk brn-wht gry-red pnk wht-grn grn-blk grn-wht blk/grn gry-blu org-wht org-wht vio-blk blu blu blu-red gry brn-wht brn/wht

6 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

No. From 69 XS78/1 work safety valve 70 Y13.1/1 work safety valve

Up to XS78/2 work safety valve S78/2 work safety valve

Colour mm² brn/wht 1 brn/wht 1

71 72 73 77 78 79 80 81 102 103 104 105 106 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129

X2/1 Y76/1 parallel lift magnet Y77/1 parallel lift magnet X2/4 2nd speed X2/5 X2/6 X1/W X1/X S43.1 S43.1 S43.1 S43.1 X2/3 X1/G Y13/2 Y13.1/2 Y3/2 S26 S26 Y43/2 Y1/2 B1/2 Y61/2 B3 Y77/2 Y76/2 S5 Y33/2 N3/31 N3/31 K5/85 Y34/2 B15/2

vio/blk vio/blk vio/blk brn-blk blk-red blu/blk blk/red vio-blu gry gry gry/blk gry/blk org/blu blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk

XY parallel lift XY parallel lift XY parallel lift Y3/1 2nd speed S43/1 parking brake Y33/1 Power Flow I S11 parking brake telltale S26 boost pressure S43 backup warning system S4 backup warning system S43 backup warning system B3 backup warning system Y34/1 Power Flow II GND earth GND earth GND earth GND earth GND earth S11 earth GND earth GND earth GND earth GND earth GND earth GND earth GND earth GND earth GND earth GND earth K7/85 earth K7/85 earth GND earth GND earth

1 1 1 1 1 1 1 1 1 1 1 1 1 2.5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Elektrische Anlage

6-13

6.12 1101c engine – chassis wiring harness 1000169726 (legend)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

6.13 1101c engine – chassis wiring harness 1000169726 Hydraulic oil Glow plugs pressure switch

Engine temperature switch Drive safety valve

Work safety valve

2nd speed valve

Coolant level Starter

Parking brake magnet

Emergency lowering

Parking brake pressure switch

Boost pump pressure switch

Cutoff solenoid

Power Power Flow I Flow II

Fuel level indicator

EGR valve

Hydraulic oil temperature switch Parallel lift magnet

Preheating relay Glow control unit

Backup warning system

Air filter pressure switch

Alternator

6-14

Elektrische Anlage

Start high current relay

Minus compensation

Engine oil pressure switch

Backup warning system switch

Main fuses

Charge air pressure valve (turbocharger)

Electro-magnetic clutch compressor

Rear outrigger valve

Elektrische Anlage

6-15

6.14 1101cp engine – chassis wiring harness 1000175467 (option) Air conditioning fan

Air conditioning pressure switch

Quickhitch valve

Load stabiliser valves

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

No. 9 10 11 12 13 35 36 37 54 55 56 57 58

From X3/1 Y20/1 Y21/1 X3/2 X3/3 X3/4 Y31 X3/5 GND GND GND GND GND

Up to XY20 load stabiliser XY20 load stabiliser XY20 load stabiliser Y55/1 rear hydraulics Y25/1 quickhitch S52/1 air conditioning S52/2 air conditioning M12 air conditioning fan Y25/2 earth Y20/2 earth Y21/2 earth Y55/2 earth M12 earth

Colour gry-yel gry-yel gry-yel grn brn org-blk org org blk blk blk blk blk

mm² 1 1 1 1 1 1 1 1 1 1 1 1 1

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

6.15 1101c cab wiring harness 1000169725 (legend) From X1/B 12 V/30 X1/D 12 V/30 X1/E 12 V/30 S1/5 12 V/15 S1/6 12 V/15 X4/4 X5/4 X1/A S1/3 preheating X1/C X1/F X1/H X10/1 X1/J X10/14 X10/5 X1/K B18/9 X1/L X1/M X1/N X1/P X1/R X4/5 X4/5 U1 amplifier U1 amplifier X10/11 X10/6 X1/S X5/5 X1/T S33/9 S33/9 F4/2 F4/2 F4/2

To Colour F9/G 12 V/30 red S1/2 12 V/30 red S1/1 12 V/30 red F4/B 12 V/15 blu F14/E 12 V/15 blu S1/7 preheating start switch wht-blk X5/8 preheating start switch wht-blk X4/8 preheating start switch wht-blk S1/9 preheating brn-wht S1/8 preheating brn-wht X10/15 preheating telltale gry-red B18/5 alternator charge telltale pnk B18/5 alternator charge telltale pnk B18/8 engine oil pressure wht-grn B18/2 engine oil pressure wht-grn B18/2 engine oil pressure wht-grn U1 engine temperature switch grn-blk U1 engine temperature switch grn-blk X10/20 engine temperature sensor grn-wht U1 coolant level blk/grn X10/2 air filter contamination gry-blu X10/3 oil filter contamination org-wht X10/19 fuel sensor vio-blk F3/1 12 V telltales, engine blu X4/7 12 V telltales, engine blu X4/7 12 V telltales, engine blu E15 12 V telltales, engine blu E15 12 V telltales, engine blu E15 12 V telltales, engine blu F3/1 12 V telltales, engine blu X5/9 cutoff solenoid blu-red X4/9 cutoff solenoid blu-red S33/5 12 V valves 1 gry X7/1 12 V valves 1 gry S29 12 V valves 1 gry X2/2 12 V valves 1 gry S65/7 12 V valves 1 gry

4 4 4 2.5 2.5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

No. 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 68A 71 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90

From S65/9 S65/9 S32/1 S32/1 S83/1 S83/1 S33/3 S33/3 F4/2 S29 safety valve X5/6 safety valve X1/U drive safety valve S28/1 safety valve S28/1 safety valve X9/2 work safety valve X1/V work safety valve X9/2 work safety valve X2/1 parallel lift S83/5 Speed Control valve X7/2 2nd speed tip switch X10/16 2nd speed X2/4 2nd speed X2/5 parking brake X2/6 X1/W parking brake telltale X1/X B18/1 boost pressure X14 load stabiliser telltale F5/3 12 V working light S16/2 12 V working light S16/2 12 V working light S18/9 12 V working light S16/6 front working light S16/3 rear working light F6/4 interior light

To S65/7 12 V valves 1 S28/9 12 V valves 1 S28/9 12 V valves 1 S32/9 12 V valves 1 S32/9 12 V valves 1 S83/9 12 V valves 1 S83/9 12 V valves 1 S33/5 12 V valves 1 K36/85 12 V valves 1 X4/1 X5/1 X4/6 X4/6 X9/1 S28/5 work safety valve S28/5 work safety valve X10/9 work safety valve S32/5 parallel lift Y2/1 Speed Control valve K36/30 2nd speed tip switch K36/87 2nd speed K36/87 2nd speed S65/5 parking brake S33/1 Power Flow I X10/13 parking brake telltale B18/6 boost pressure X10/7 X10/10 load stabiliser telltale S16/1 12 V working light F5/3 12 V working light S16/9 12 V working light S16/9 12 V working light X12/1 X12/2 rear working light X12/9 interior light

Colour gry gry gry gry gry gry gry gry gry brn-wht brn-wht brn-wht brn-wht brn-wht brn/wht brn/wht brn/wht vio/blk brn-grn brn/blk brn-blk brn-blk blk-red blu/blk blk/red vio-blu vio-blu gry-grn grn grn grn grn grn-red grn/blu blu

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

No. From 91 F6/4 12 V lights according to STVO Austrian road traffic regulations 92 F7/5 12 V turn indicators 93 F8/6 hazard warning system 94 X10/8 turn indicator telltale 96 F9/7 cigarette lighter 97 F10/8 12 V rotating beacon 98 F10/8 drive interlock 99 S18/5 rotating beacon 100 X7/3 horn 106 X2/3 107 X18/1 float position 108 X18/2 earth 110 X1/G earth 130 X12/5 earth 131 X12/6 earth 132 K36/85 earth 133 S18/10 earth 134 S18/10 earth 135 S83/10 earth 136 S83/10 earth 137 S28/10 earth 138 S28/10 earth 139 X7/4 earth 140 S33/10 earth 141 GND2 142 GND2 143 GND2 144 GND2 145 U1 earth 146 GND2 147 GND2 148 XF1/1 12 V/15 149 XF1/2 12 V/15

To X8/1 12 V lights according to STVO Austrian road traffic regulations X8/2 12 V turn indicators X8/3 hazard warning system

Colour blu 1.5 yel red

1 1

X8/4 E15 cigarette lighter S18/1 12 V rotating beacon X4/2 X12/3 X12/4 horn S33/7 Power Flow II X4/1 float position GND2 GND1 GND1 GND1 GND1 GND1 S16/10 earth S33/10 earth S32/10 earth S32/10 earth S65/10 earth S65/10 earth S16/10 earth GND1 Y2/2 earth X8/6 earth X4/3 earth X4/3 earth E15 earth X10/12 earth F4/B 12 V/15 F6/D 12 V/15

red/blk red-blk red red vio org org/blu brn-wht blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blk blu blu

1 1 1 1 1 1 1 1 1 2.5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2.5 2.5

6-16

Elektrische Anlage

No. 7 8 9 10 11 19 20 21 23 24 25 26 27 28 29 29A 30 31 32 33 34 36 37 39 40 41 42 43 43A 44 46 47 48 49 50 51 52

Cigarette lighter

Elektrische Anlage

6-17

6.16 1101c cab wiring harness 1000169725

Safety switch

Speed Control

Display

Ignition lock

Joystick

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

Parking brake

2nd speed Work Parallel Speed Power hydraulics lift Control Flow lock

Working Rotating beacon light

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

6.17 1101cp cab (option) wiring harness 1000175466 (legend) No. 1 2 3 4 5 6 7 8 9 12 13 14 15

From F11/1 12 V valves 2 F11/1 12 V valves 2 S40/9 12 V valves 2 S40/9 12 V valves 2 S36/9 12 V valves 2 S36/9 12 V valves 2 X6/2 K34/87 load stabiliser K34/87 load stabiliser S36/5 rear hydraulics S40/5 quickhitch S40/5 quickhitch X6/3

16

X6/4

17

S6/5

18 19

F12/2 F12/2

20 21 22 23 24 25 26

K16/87 F13/3 K17/87 F14/4 K18/87 F15/5 S15/2

To K34/85 12 V valves 2 S40/1 12 V valves 2 S40/1 12 V valves 2 S36/1 12 V valves 2 S36/1 12 V valves 2 X6/1 12 V valves 2 K34/30 load stabiliser relay X14 X3/1 X3/2 X3/3 B19/1 K16/86 auxiliary electric circuit 1 relay K17/86 auxiliary electric circuit 2 relay K18/86 auxiliary electric circuit 3 relay X15/1 auxiliary electric circuit 1 K16/30 12 V auxiliary electric circuit X15/2 auxiliary electric circuit 1 K17/30 auxiliary electric circuit 2 X15/3 auxiliary electric circuit 2 K18/30 auxiliary electric circuit 3 X15/4 auxiliary electric circuit 3 S15/1 12 V heating S15/1 12 V heating

Colour gry gry gry gry gry gry gry-blk gry-yel gry-yel grn brn brn wht

1 1 1 1 1 1 1 1 1 1 1 1 1

wht-blk

1

wht-blu 1 wht wht

1.5 1.5

vio wht-blk wht-blk wht-blu wht-blu yel yel

1.5 1.5 1.5 1.5 1.5 1 1

No. 27 28 29 30 31 32 33 34 35 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 60 61

From S15/2 S51/9 S15/6 S15/6 S15/3 S51/5 F16/6 S54/1 S54/2 K11/87 F17/7 X11/1 GND X11/2 GND S51/10 GND K11/85 K11/85 K17/85 K17/85 GND GND S40/10 S40/10 X6/6 XF1/1 XF1/2

To S15/9 12 V heating S15/9 12 V heating S51/1 heating speed I M4/2 heating speed I M4/3 heating speed II K11/86 air conditioning K11/30 air conditioning K11/87 air conditioning X3/4 air conditioning X3/5 air conditioning fan X10/1 12 V wiper X10/3 washer pump X10/2 earth X10/2 earth S15/10 earth S15/10 earth K34/86 earth K34/86 earth K16/85 earth K16/85 earth K18/85 earth M4/1 earth S36/10 earth S36/10 earth B19/2 earth B19/2 earth F12/B 12 V/15 F17/G 12 V/15

Colour yel yel yel-blk yel-blk yel-blu yel-red org org org-blk org blu gry blk blk blk blk blk blk blk blk blk blk blk blk blk blk blu blu

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2.5 2.5

Elektrische Anlage

6-18

Rear outriggers

Quickhitch

Heating Air conditioning

Joystick

Heating Air conditioning

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

Auxiliary electric circuit 3

Load stabiliser Air conditioning Auxiliary electric circuit 1

Auxiliary electric circuit 2

Elektrische Anlage

6-19

6.18 1101cp cab wiring harness 1000175466 (option)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

6.19 Front lights wiring harness and legend 1000169728

Horn

Interior light

Working light (left)

No.

mm2

Colour

Function

X12

EX

1

grn-red

Front working light

2

E10/1

EX

1

grn-red

Front working light

3

E9/1

EX

1

grn-red

Front working light

4

X12

B2

1

org

Horn

5

X12

GND

1

blk

Earth

6

E10/2

GND

1

blk

Earth

7

B2

GND

1

blk

Earth

8

E9/2

GND

1

blk

Earth

9

X12

E14

1

blu

Interior light

6-20

Elektrische Anlage

1

Working light (right)

StVO Austrian road traffic regulations (legend) No. 4 5 6 7 8 9 10 11 12 13 14 29 30 31 34 35 36 47 48 49 50 51

From X5/1 PosR PosR PosR PosL PosL PosL PosL X5/2 E1/2 E3/2 X5/3 E4/1 E3/5 X5/4 E2/1 E1/5 GND GND GND GND GND

To Pos clearance light Pos clearance light E2/2 clearance light E1/4 clearance light Pos clearance light E16 clearance light E4/2 clearance light E3/4 clearance light Abbl low beam Abbl low beam Abbl low beam BIL turn indicator (left) BIL turn indicator (left) BlL turn indicator (left) BIR turn indicator (right) BIR turn indicator (right) BIR turn indicator (right) E16 earth E4/3 earth E3/6 earth E2/3 earth E1/5 earth

Cab StVO Austrian road traffic regulations (legend) Colour yel/blk yel/blk yel/blk yel/blk yel/blk yel/blk yel/blk yel/blk yel/grn yel/grn yel/grn grn/blk grn/blk grn/blk grn/red grn/red grn/red blk blk blk blk blk

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

No. 1 X8/1

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

2

S14/2

3

S14/2

4 12 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 32 33 34 40 41 42 43 44

S14/6 S14/3 X8/2 X8/2 S19/7 S19/7 X8/3 S19/4 K10/86 S12/3 S19/1 S19/1 X9/4 K10/87 S12/1 X9/5 X9/5 S12/7 X9/6 X9/6 X8/6 S14/10 S14/10 X8/6 X9/3

From

To S14/1 12 V lights according to STVO Austrian road traffic regulations S14/1 12 V lights according to STVO Austrian road traffic regulations S14/9 12 V lights according to STVO Austrian road traffic regulations X5/1 clearance light X5/2 low beam X9/1 12 V turn indicators S19/8 12 V turn indicators S19/8 12 V turn indicators S12/9 12 V turn indicators S19/2 12 V hazard warning system S19/6 turn indicators + S19/6 turn indicators + S12/5 turn indicators CL S12/5 turn indicators CL K10/85 turn indicators CL K10/85 turn indicators CL X8/4 turn indicator telltale S19/3 turn indicators (left) S19/3 turn indicators (left) X5/3 turn indicators (left) S19/5 turn indicators (right) S19/5 turn indicators (right) X5/4 turn indicators (right) S12/10 earth S12/10 earth S19/10 earth K10/87A earth K10/87A earth

Colour blu 1.5 blu

1

blu

1

yel/blk yel/grn yel yel yel yel red yel/red yel/red brn/yel brn/yel brn/yel brn/yel red/blk grn/blk grn/blk grn/blk grn/red grn/red grn/red blk blk blk blk blk

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Elektrische Anlage

6-21

6.20 Wiring harnesses 1000175462: StVO Austrian road traffic regulations + 1000175463: cab StVO Austrian road traffic regulations (legends)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

6.21 Wiring harnesses 1000175462: StVO Austrian road traffic regulations and 1000175463: cab Rear right light

Front right parking light

Numberplate light

Front left parking light

Turn indicators

Rear left light

Hazard warning system

6-22

Lights according to StVO Austrian road traffic regulations

Turn indicator relay

Elektrische Anlage

Turn indicators

No.

Elektrische Anlage

6-23

6.22 Wiring harness 1000171481: attachment control (option)

mm2

Colour

Function

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

1

X15/1

X16/B

1.5

wht

12 V auxiliary electric circuit

2

X15/2

X16/D

1.5

vio

Auxiliary electric circuit 1

3

X15/3

X16/F

1.5

wht-blk

Auxiliary electric circuit 2

4

X15/4

X16/C

1.5

wht-blu

Auxiliary electric circuit 3

5

GND

X16/A

1.5

blk

Earth

6

GND

X16/E

1.5

blk

Earth

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

6.23 Cab door (option) legend and wiring harness 1000175468

Wiper

No.

mm2

Colour

Function

No.

mm2

Colour

Function

XM1

S20/2

1

blu

12 V wiper

7

S20/3

XM/2

1

brn

Washer pump

2

S20/10

S20/2

1

blu

12 V wiper

8

XM/3

M2/2

1

blk

Earth

3

XM/1

M2/1

1

blu

12 V wiper

9

XM/3

S20/9

1

blk

Earth

4

S20/6

S20/7

1

wht

Wiper

10

X17/1

X16

1

gry

Washer pump

5

S20/6

M2/3

1

wht

Wiper

11

X17/2

X16

1

blk

Earth

6

S20/5

M2/4

1

gry

Reset

6-24

Elektrische Anlage

1

Elektrische Anlage

6-25

6.24 Rear cab (option) legend and wiring harness 1000175464

Rotating beacon

Working light (left)

No.

mm2

Colour

Function

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp611.fm

1

X12

EX

1

grn/blu

Front working light

2

E8/1

EX

1

grn/blu

Front working light

3

E7/1

EX

1

grn/blu

Front working light

4

X12

H28

1

vio

Rotating beacon

5

X12

GND

1

blk

Earth

6

E8/2

GND

1

blk

Earth

7

H28

GND

1

blk

Earth

8

E7/2

GND

1

blk

Earth

Working light (right)

Options

Options

7 7.1

Options Rear working light

Working lights

Working light

Wiring harness

Ports No.

7-1

mm2

Colour

Function

1

X12

EX

1

grn/blu

Front working light

2

E8/1

EX

1

grn/blu

Front working light

3

E7/1

EX

1

grn/blu

Front working light

4

X12

H28

1

vio

Rotating beacon

5

X12

GND

1

blk

Earth

6

E8/2

GND

1

blk

Earth

7

H28

GND

1

blk

Earth

8

E7/2

GND

1

blk

Earth

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

Options 7.2

BP – Biohyd SE 46

Properties

Hydraulic ester oil (HEES) BP Biohyd SE-S is a pressure medium based on saturated synthetic esters and synthetic hydrocarbons It can be used in all hydraulic systems!

7.3

Viscosity at 100 °C (212 °F)

46 cSt

9 cSt

Biodegradable oil Panolin

Properties

7.4

Viscosity at 40 °C (104 °F)

This is a fully synthetic, environmentally compatible high-performance hydraulic oil based on saturated esters. A combination of special additives and high-performance base oils greatly reduces the formation of ageing products, deposits and gumming at high operating temperatures Viscosity at 40 °C (104 °F)

Viscosity at 100 °C (212 °F)

48.7 cSt

8.7 cSt

Rearview mirror package Notice!

Depending on the legal regulations of your country, the mirror package can be available with the road travel option – see Road travel certification on page 7-18.

Parts of this package can be ordered separately in case of damage.

7.5

Extra weight Maximum payload can be increased with the extra weights.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

7-2

Options 7.6

Drive interlock (antitheft protection) 1

Pos. 1 2

Description Transponder receiver surface Red LED

2

Fig. 1:

Drive interlock

Disabling the drive interlock

☞ Approach the transponder to 2 cm (0.8”) to the transponder receiver surface. ➥ The red LED goes out. ☞ Insert the ignition key into the ignition lock within 30 seconds and turn it at least to position 1.

➥ The drive interlock remains disabled.

Enabling the drive interlock

☞ Remove or turn the ignition key to position 0. ➥ The drive interlock is enabled after 30 seconds. ➥ The blinking red LED indicates the drive interlock is enabled.

Programming

Coding transponder keys The so-called main or master key is required for coding a new or uncoded key, or a key with different coding, for the drive interlock.

☞ Disable the drive interlock with the master key and in addition, keep it close to the transponder receiver surface for 30 – 45 seconds – see Disabling the drive interlock on page 7-3.

➥ The LED changes to a steady green light. ➥ The system is in programming mode now (coding mode). ☞ Remove the master key from the transponder receiver surface. ➥ The LED changes to a rapidly blinking green light. ☞ Hold the key to be programmed against the transponder receiver surface. ➥ The key is coded once the diode comes on slowly three times. ☞ Hold further keys next to the transmitter/receiver surface to code them as mentioned above.

The drive interlock is no longer in programming mode as soon as there is no key contact for 30 seconds.

➥ Blinking red light

7-3

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

Options Deleting programming/coding

☞ Disable the drive interlock with the master key and in addition, keep it close to the transponder receiver surface for 30 – 45 seconds – see Disabling the drive interlock on page 7-3.

➥ The LED changes to a steady green light. ➥ The system is in programming mode now (coding mode). ☞ Hold the master key against the transponder receiver surface for a further 30 seconds. ➥ The LED changes to a steady red light. ➥ The system is in delete mode now (coding mode). ☞ Remove the master key ➥ The LED changes to a rapidly blinking red light. ☞ You have 30 seconds to hold the master key again to the transponder receiver surface to confirm deletion.

➥ The system is deleted once the diode comes on slowly three times.

Caution!

Deletion deletes all “normal“ transponders and the master!

• Reason: once a key is lost, you can no longer delete it.

• Therefore, the entire system is deleted for safety reasons and can be completely recoded with the remaining (or newly ordered) keys.

Configuration of the deleted system Once deletion is over, the system recognises any TREBE transponder key, i.e. the system can be disabled with any key.

The first transponder key to be recoded for the system is automatically the new master and can be used for coding the “normal” transponder keys – see Programming on page 7-3.

Notice!

The following applies both to the coding and programming mode: the system leaves the coding and programming modes and is disabled as soon as the ignition key is inserted in the ignition lock and turned to the first position.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

7-4

Options 7.7

Rotating beacon It is located at the rear on the roof.

Wiring harness

Ports No.

mm2

Colour

Function

1

X12

EX

1

grn/blu

Front working light

2

E8/1

EX

1

grn/blu

Front working light

3

E7/1

EX

1

grn/blu

Front working light

4

X12

H28

1

vio

Rotating beacon

5

X12

GND

1

blk

Earth

6

E8/2

GND

1

blk

Earth

7

H28

GND

1

blk

Earth

8

E7/2

GND

1

blk

Earth

Notice!

Observe the legal regulations of your country for operating the rotating beacons.

7-5

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

Options 7.8

Crane-handling bracket Fixture for raising the complete skid steer loader.

The crane-handling bracket is screwed together as shown below and is then installed on the cab (figure on the left).

Pos .

Description

Pos .

Description

1

Attachment plate

8

Hexagon nut M12-8 A2C

2

Shackle

9

Hexagon nut M12-8 A2C

3

Hexagon head screw M20x130

10

Cheese-head screw

4

Washer 21

11

Schnorr lock S12

5

Hexagon nut M20-8 A2C

12

Washer 13

6

Damping element

13

Label

7

Hexagon head screw M12x30-10.9 A2C

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

7-6

Options 7.9

Dual parallel bucket lift (switched on for up and down movements) Function C

E

B

Actuating dual parallel bucket lift keeps the bucket at the preset angle with respect to the ground. The bucket does not need to be corrected manually when raising/lowering the loader unit Bucket ram action is always automatically corrected in order to maintain the correct angle.

D F

7-7

A

Hydraulic diagram

Port

Legend

A

Loader unit (rod) and load stabiliser (T port)

B

Control valve 1st segment (port A)

C

Loader unit (base) and load stabiliser

D

Control valve 1st segment (port B)

E

Bucket (base)

F

Bucket (rod)

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

2

1

3

3

4

Main valve block Parallel lift valve Work hydraulics pressure limiting valve Dual parallel lift retrofit kit

2 3 4

Legend

1

Port

Options

Layout

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

7-8

Options 7.10 8/2 directional valve – H controls (work hydraulics lock) Function The loader unit can be locked with this valve when driving from one site to another.

H C F A

Fig. 2:

D

The machine can be driven only.

G

Hydraulic diagram

B E

Locking the work hydraulics

7.11 Hydraulic quickhitch system (HQS) option Attachments can be changed faster with the hydraulic quickhitch. Press switch 51 to this effect.

Danger!

The keys of the quickhitch must be inserted in the opening of the attachment.

The attachment can be released if the lock levers are not secured – 51

Danger of accidents and injury! ☞ Always make sure the attachment is safely locked.

7-9

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

Options 7.12 Power Flow valve (1101cp) Function The valve is controlled electrically. The direction of the oil flow can be changed.

Hydraulic diagram

7.13 Power Flow ports Quick couplers: Port A B C

Description Pressure line/tank line (depending on switch position) Tank line/tank line (depending on switch position) Leak oil line

Couplings according to ISO 16028

C Fig. 3:

A

B

Power Flow ports

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

7-10

Options 7.14 Speed Control valve (1101cp) Function When working with heavy attachments, the Speed Control valve S controls drive speed progressively. This makes it possible to maintain minimum drive speeds over longer distances without tiring.

B

Hydraulic diagram T

P OUT

P IN

B

A

A

45

A S B

7-11

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

Options ISO controls layout

Pilot valve for auxiliary hydraulics

3/2 directional valve Speed Control valve

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

7-12

Power Flow

H controls

Speed Control valve

7-13 3/2 directional valve

Pilot valve for auxiliary hydraulics

Options H controls layout

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

Options 7.15 Load stabiliser valve Function This option achieves excellent handling. A load stabiliser in the loader unit minimises the pitching movements of the attachment.

Hydraulic diagram

Layout (single parallel bucket lift)

Main valve block

Load stabiliser valve

Tank

Single parallel bucket lift Pressure accumulator

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

7-14

Options Dual parallel bucket lift layout Dual parallel bucket lift

Load stabiliser valve

Tank

Pressure accumulator

7.16 Attachment controls A

D

D

G

A

-

Use the right-hand side joystick with 3 buttons if an electrohydraulic multifunctional attachment is installed on the machine.

Each push button is assigned to an electric line: press and hold the button to enable the electric contact, and release it to disable it.

+ G

7-15

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

Options 7.17 Backup warning system Function

Emits a signal when reversing A pressure switch is actuated and a signal is emitted upon pulling back the steering lever.

It is installed in the engine compartment on the left A

Position

A

Pos.

Description

1

Signal transmitter

2

Hexagon head screw M8 x 20-8.8

3

Schnorr lock

4

Washer B8.4-140HV A2C

5

Screw connection

6

Screw connection

7

Screw connection

8

Sealing ring

9

Pressure switch 2 bar ±0.5 (29 psi ±7)

Position

Engine compartment

Double variable displacement pump – see Rexroth AA20 VG45 hydraulic pump on page 5-1

Wiring harness – see 1101c engine – chassis wiring harness 1000169726 on page 6-15

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

7-16

Options 7.18 Side window Protection against weather.

A

A

Fixture:

7-17

Pos.

Description

1

Sliding window

2

Sliding window

3

Side window

4

Fastening angle

5

Window pane bracket 6.4

6

Hexagon nut M6-8 A2C

7

Washer

8

Side window retrofit kit

The side windows are screwed with 8 brackets each onto the fastening points A.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

Options 7.19 Road travel certification Notice!

Main headlight (left)

Rearview mirrors

Main headlight (right)

Numberplate bracket

Numberplate light

Turn indicator/brake/rear light

Tracks

Shackle

Protective plate

Protective plate

1

2

3

4

5

6

7

8

9

10

2

7

5

6

4

6

2

8

9

8

3

10

Pos. Description

Depending on the legal regulations of your country, only specifically certified machines can be allowed to travel on public roads.

SERV-HB 1101c cp EN – Edition 1.0 *1101c_cp710.fm

7-18

Wacker Neuson Linz 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 consent of Wacker Neuson Linz GmbH. All rights under the provision of the Copyright Act are reserved.

Wacker Neuson Linz GmbH Haidfeldstr. 37 A-4060 Linz-Leonding Austria

Wacker Neuson Linz GmbH Haidfeldstr. 37 A-4060 Linz/Leonding Telephone +43 (0) 732/90590-0 Fax +43 (0) 732/90590-200 E-mail: office@wackerneuson.com www.wackerneuson.com